AH00.19-P-1000-04SM Repair Methods For Wiring Harnesses
AH00.19-P-1000-04SM Repair Methods For Wiring Harnesses
Overview of approved repair methods
The following methods are approved by Daimler AG for the repair of wiring harnesses or the installation of repair wiring harnesses. Of all these methods, crimping should be the preferred one.
Repair method
^ Crimping (cable connectors)
^ Solder connection (Raychem)
^ Axial solder connection (Raychem)
^ Soldering
^ Rapid connection technology
^ Flat conductor pliers
The following wiring harnesses must not be repaired with the solder connector (Raychem) repair method:
^ Shielded lines
^ Twisted lines
^ Wiring harness repairs with more than 3 individual lines damaged
^ Installing repair wiring harnesses
Application
Each individual case must be carefully evaluated in order to determine which repair method can or may be used for a given wiring harness.
Repairs of wiring harnesses should only be performed according to instructions from Daimler and using repair methods approved by Daimler AG.
Lines which must never be repaired:
^ Lines and connectors in the antilock brake system
^ Connectors in the engine wiring harness
^ Shielded lines
^ Lines and connectors in the supplemental restraint system (SRS). This concerns airbag/sidebag/emergency tensioning retractor scopes
Permissible repairs:
^ Individual, separated lines may be repaired with one of the approved repair methods provided that the installation situation and the remaining lengths of the lines will permit this to be done properly. Repairs in visible areas should be avoided wherever possible, but if this is still necessary, the repair point must be wrapped with blue fabric tape.
^ Plugs that have been torn off from the main wiring harness are repaired with Daimler repair wiring harnesses. These repair wiring harnesses are also installed with one of the approved repair methods. In this case as well, repairs in areas that are visible should be avoided wherever possible.
Crimping repair method
When crimping, the line which has already been stripped to the dimension (a) is pinched on the contact (pin) using preformed die sets in special pliers. Crimping is performed quickly and with ease. A special crimper is required.
Only lines up to 4 mm2 shall be crimped.
Raychem repair method
With this method, special solder connectors are used. The solder connections contain the solder and they also feature insulation and a seal. A special hot air blower provides the heat required for soldering and shrinking the insulation. A special reflector is fitted to the hot air blower.
The temperature for this repair method is 400 °C.
Raychem is the manufacturer of the solder connections that are required for this method. The Raychem repair method is mainly used for integrating repair wiring harnesses (cable tails).
Soldering repair method
The strands of the cable (2) are soldered in the solder contact (axial or radial version) (1) using a soldering iron. Commercially available solder is used for the soldered connection. This method is only used for repairing connectors.
Repair method using rapid connection technology
This method uses special rapid-connection wire connector blocks. Mercedes-Benz permits the 2-, 4-, and 6-pin versions. They contain tin-plated rapid connection contacts, which are pressed together to touch the wires of the cables using pliers. The lines do not have to be separated or stripped.
This method can be used for connection to cables with a cross section of 0.35 to 0.75 mm2 and for wire end connections.
The rapid connection method must only be used inside the vehicle or in the trunk because the connection is not watertight. It is not permissible for Controller Area Network (data bus/CAN bus) (CAN) lines.
Flat conductor cable repair method
Select crimp contacts in the wiring harness repair kit and insert into the tool head of the open manual crimp pliers (2). The flat conductor cable (7) must make contact with the tool head, and the correct edge of the flat conductor cable (7) must make contact with the adjusting stop (3). The optical adjusting device (4) in the manual crimp pliers (2) must be fully visible between 2 conductor tracks. Press the manual crimp pliers (2) together all the way. After it has been pressed down all the way, it can be opened again. Remove the finished crimp connection.
