Tool - Terminal Repair Kit
CATEGORY Tools
SECTION 1
ISSUE 02/97-0734
PAGE 60
CODE 100
Subject: New Essential Special Tool:
Terminal Repair Kit
Application: 1994- 900 and 9000 Models
To ensure the quality of repairs to wiring harnesses, particularly on OBD II cars, a special terminal repair kit has been developed. This new Essential Special Tool contains all terminals currently in use, the appropriate crimping tools for these terminals and a stripping tool.
Use of the right terminal and the right tool is absolutely essential when carrying out repairs. Therefore, the terminals are packed in color-coded boxes indicating a content list. The content list also indicates the jaw position on the crimping tool which should be used for a particular cable cross-section area. There is also a set of crimping tools, color- coded to the corresponding terminal box.
Important
It is extremely important to use the crimping tools only on terminals from the box having the same color as the tool and that that right jaw position on the tool is used. See the contents list on the box. This is important because a hundredth of an inch can make all the difference between a good crimp and a bad one.
In addition to these boxes and tools, the case also contains two external storage compartments. One of these compartments can be use for storing pin removal tool, P/N 85 80 110, for instance. The other compartment can be used for any other suitable equipment.
Parts:
Terminal Repair kit 86 12 079
Price: $1052.00
The Terminal Repair Kit was shipped automatically to all dealers by Kent-Moore in the beginning of February, 1997. Additional terminals can be ordered directly from Kent-Moore by dialing their order desk at 1-800-345-2233.
Action:
5. Set the stripping tool supplied with the kit at 6mm and strip the cable. Check that no strands in the cable are damaged when it was stripped. If any strands have been broken off or damaged, the end of the cable should be cut off and the cable stripped again.
6. Look in the spare parts microfiche for the connector in question to find the part number of the terminal that is to be used.
7. Select the correct terminal and crimping tool having the same color as the box from which you selected the terminal.
Important
It is absolutely essential to use the right terminal with the right crimping tool to ensure proper repair. It is also extremely important to ensure that the crimping tools are used only on terminals from the box having the same color as the tool.
8. Check the cross-section area of the cable to be sure of selecting the right jaw position on the crimping tool. See the contents list in the box which indicates the jaw position of the tool which should be used for the cross-section of the cable in question.
Important
It is extremely important to use the right jaw position on the crimping tool.
9. Place the terminal in the crimping tool. as shown in Figure 3, and squeeze the handles of the tool together just hard enough to hold the terminal in position.
Important
Each jaw position on the tool has two sizes: the large one is for insulation strain relief and the
small one for the conductor strands.
10. Insert the cable into the terminal from the left (the labeled side of the tool). See Figure 4.
11. Crimp the terminal. Note that the crimping tool must be squeezed to its end position before the terminal can be removed.
12. After crimping, the strands of the cable should be visible on both sides of the terminal's contact area.
List of terminals and the boxes holding them: