2., 5 Mm2, 4 Mm2 Or 6 Mm2 Aluminum Wires With Separate Butt Connectors, Repairing: Procedure

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-- Install the corresponding crimp insert, crimp stamp and contact positioner for the wire cross-section with the contact cross bar as follows on the crimping tool.

-- Open the crimping tool from the :VAS631 001  .

-- Remove the locking pin -1- all the way in the direction of -arrow A-.

-- Open the mount -2- in the direction of -arrow B-.

-- Insert the crimp insert -1- in the crimping tool so that the crimp insert -1- is flush with the front of the clamps.

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-- Tighten the crimp insert with the pins -2- in direction of -arrow A- and the knurled screw hand tight.

-- Insert the crimp stamp -3- that fits the crimp insert in the mount.

-- Secure the crimp stamp with the pin -4- in direction of -arrow B- and the knurled screw hand-tight.

-- Close the adapter -1- in the direction of -arrow A-.

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-- Push the locking pin -2- in the direction of -arrow- all the way.

-- Insert the contact cross bar -1- in the contact positioner -2-.

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-- Position the contact positioner with the contact cross bar on the crimping tool -5- at the same time push the holes in the contact positioner -2- over the knurled screw -4-.

-- Install the knurled bolt -3- and tighten hand-tight.

-- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

-- If necessary, removing the wiring harness wrapping.

-- Cut the damaged section of the wire with wire stripper from the :VAS631 001  .

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-- Insert the wire end from the front all the way in to the wire cross-section corresponding mount in the jaws of the pliers.

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-- Push the pliers completely together.

-- Open pliers again and remove the stripped wire end.

• The insolation must be cut cleanly and remove from the wires.
• No insolation can remain on bare wires.
• The single wires must not be damaged.

-- For the repair remove the corresponding butt connection with a heat-shrinkable tube from the :VAS631 001  .

-- Push the heat-shrinkable tube on one of the wires.

-- Place the butt connection -1- in the contact positioner -2-.

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• The butt connection -1- must be flush with the contact positioner -2- -arrow A-.

-- Push the contact cross bar -3- all the way in the direction of the -arrow B- and secure it with the butt clamp -1-.

• The tab -4- on the butt connection -1- must engage in the groove -5- on the contact cross bar -3-.

-- Insert the wire -2- with the bare wire end all the way in the butt connection -1- -arrow-.

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• All single wires must be pushed into the butt connection.
• The insolation end can at a maximum be flush with the front edge of the insolation crimps.

-- Close the crimping tool completely until it reopens by itself.

-- Push the contact cross bar -2- all the way in the direction of -arrow-.

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-- Remove the butt connection -1- from the contact positioner -3-.

-- Turn the crimping tool for the second crimping.

-- Repeat the wire crimping on the other side as described.

-- Remove the securing pin -1- in the direction of -arrow A- until it stops.

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-- Open the mount -2- in the direction of -arrow B-.

-- Remove the crimped butt connectors.

Correct Crimping Results 

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• The wire ends must project 0.1 mm to 1.0 mm on the front edge of the wire crimps, dimension -a-
• The insolation end must not be crimped in the wire crimps.
• The insolation end can at a maximum be flush with the front edge of the insolation crimps -arrows-.

After crimping the heat-shrinkable tube must positioned over the butt connection and heat-shrunk with a hot air gun, to prevent moisture from entering.

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-- Insert the :VAS1978/15A  on the :VAS1978/14A  .

-- Position the heat-shrinkable tube -1- centered over the butt connection -2-.

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• The dimension -a- must be approximately the same on both sides

-- Heat the heat-shrinkable tube using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

• The completed repair location -3- must look like so.