Cable Repair

IMPACT 4.07.
110 17/07/2021
Chassis ID Path
D 203569 371/Repair//Cable repair
Model Identity
FH (4) 144507631
Publish date ID/Operation

01/02/2019
Cable repair
Contents
This service information contains design and function, specification and cable repair, example.
Information about the insulator and cable terminal part numbers, family, size, area and material can be searched for
using Impact.
In this version it is also easier to find the right tool corresponding to Impact News version 4.01.
If there is a connection (Relation) between the part number for the terminal, housing and the corresponding tools for
removing and crimping, this will be shown in Impact for standard parts with a new icon.
Cable repairs, design and function
Cable repairs, definitions
Cable repairs, definitions
Conductors
General
Connectors, terminals and housings
Connectors, terminals and housings

Cable terminal
Housings, function
Housings, function
Single wire seals, plugs and splices
Single wire seals and cavity plugs
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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Splices
Splices
Removal and crimping tools
Removal tools, remove terminals from housings

Crimping tools, terminals and splices
Wiring, data communication
Cables for data communication
Terminals
Grounding points
Battery, Fuse Box, DESS (GIC60 and Grounding Cable) and ADR Relay
Cable terminals, cavity plug/single-wire seal (SWS), tool
Power cabling, cable terminals, cables
Cable repairs, specifications
Contact pressing tool and disassembly tool kit

Crimping and stripping tools
Power cable; crimping tools and cable shears
Removal tools
Using the removal tool, example
Cable repairs, example
Connector block
Disconnect the electrical connector

Opening the secondary locking
Free the terminal's primary locking
Cable terminal
Prepare the wire for connection of terminals

Connect the terminal to the wire
Refit the terminal in the connector
Repair of cables
Repair of cables
Repair of power cable
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Clamping and routing
Wire harness bundling
Wiring harness bundling
The following section describes the components and tools involved in cable repairs.
See IE: Cable repairs, definitions
Conductors
General
Introduction
It is important that the wires in a vehicle are dimensioned for the purpose, and installed in a correct manner. It is also
important that it should be easy to distinguish separate wires by means of colours etc. to facilitate identification and
fault-finding of conductors. Important points to consider when a conductor is changed or extended are as follows:
That the conductor area is correct.

That the interference protection on cables which transmit signals, such as between control units, is intact.
That the wire colours are maintained.
That the wires are installed in a way which protects the insulation from mechanical damage.
The electrical wiring diagrams are a considerable help when you change or repair any wires, please refer to the
service information in group 37.
Note: When you replace any wire, always use the

same type of wire as the original, i.e. the correct
length, insulation, conductor area and preferably the
same colour.
Conductor area
It is important that the conductor area is at least as large after a repair as before, since the current carrying capacity of
the conductor depends on the area.
If the wiring diagram books can not give you any information about the area, it can be estimated by measuring the
diameter of the stripped section with a calliper gauge.
Then read the table to get an approximate estimation of the conductor area.
Note: The conductor cross sectional area always

refer to the metallic conductor in a wire.
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Conductor area measurements
Diameter (mm) Conductor area (mm²)

0,6 0,3
0,8 0,5
1,0 0,75
1,1 1,0
1,4 1,5
1,8 2,5
2,3 4,0
Signal transfer cables

Cables for signal transfer are frequently protected against interference by being arranged as a twisted pair, or they
have a protective shield. It is very important that the interference protection of a cable is put back after replacement or
repair.
A twisted pair must be twisted with the same pitch as the original cable to maintain interference protection. For further
information please refer to Cables for data communication.
On a shielded conductor, it is important that the shield does not come into contact with the conductor it protects, that it
is intact for the entire length of the conductor, and that the shield is terminated at the same place and in the same way
as the replaced cable.
1. Twisted signal conductor

2. Shielded signal conductor
Wire colour
Choose the same colour as the original wire. Different colours must only be used in exceptional cases.
The wiring diagrams often contain the colour codes for each wire.
Please refer to the table, to interpret the colour codes.
Two-coloured wires
If the colour code for a wire consists of two colours, it is designated as follows:
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YE / Shall be read as YELLOW/RED. This means that the wire has a YELLOW insulation outer casing with a RED
RD stripe.
Colour Abbreviation
Black BK
Brown BN
Red RD
Orange OG
Yellow YE
Green GN
Blue BU
Violet (Purple) VT
Grey GY
White WH
Pink PK
Cables
Preparation of a wiring harness
All wires and wiring harnesses must be protected either by taping or by a smooth or ringed sheath. This protection
serves to avoid problems due to vibration and friction that may cause malfunctioning of the wiring, short-circuits and
breaks in electrical continuity.
Installation of taping or a sheath
Before installing adhesive tape or a sheath, it is recommended to pre-form the strand of conductors and twist it slightly
so that it can be bent without causing excessive pulling on the contacts located on the periphery of the connectors.
Installation of the wires protection should not begin flush with the connectors. It is essential to leave a free distance of
A (100 mm) so as to maintain some play at the contacts and enable easy extraction of a contact from a pocket.
1. Connector
2. Sheath or adhesive tape
3. Recommended free distance
4. Connector coupling face
Cable runs
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When a wire is installed, the original wire run shall be followed, and the wire shall be fixed in the same way. The wire
shall be installed in such a way that there is no risk of mechanical damage. No sharp ends must be left projecting
outside the tie wraps.
The wire must be at least as long as the original wire.
Cables for data communication

The information link (SAE J1587/SAE J1708) and control link (SAE J1939) are data communication cables. Both types
of cables have twisted pairs as interference protection.
When information or control links are repaired, the same twisting pitch must be maintained. Repairs shall be done in
the same way as other cables, in other respects.
The cables can be lengthened, but must not exceed a total length of 40 metres. The new cables must be of the same
type, and the cables must have the same twist pitch as the old ones.
Note: It is important that the twist pitch is maintained

when data communication wires are joined.
Note: Use wires with the same type of conductor

area, colour and grade as the originals.
Note: The cables can be lengthened, but must not

exceed a total length of 40 metres.
Information link
SAE J1587/SAE J1708, is used for diagnosis in the vehicle and transmits data at a base speed of 9600 bps.
The wires are wound at a pitch of 30 turns/metre.
Note: SAE J1587/SAE J1708 has a twist pitch of 30

turns/metre.
Lengthening of SAE J1587/SAE J1708 cables can be done at any point along the length.
Control link
SAE J1939 is mainly used when the vehicle is driven, and transmits data at a base speed of 250,000 bps.
The wires are wound at a pitch of 40 turns/metre.
There is a resistor at each end of the control link, either on the cables themselves, or built into the connected control
unit.
Note: SAE J1939 is twisted with a twist pitch of 40

turns/metre.
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SAE J1939 cables must be lengthened at one end of the cable harness, and the resistors located there must be
moved to the end of the extension.
It is possible to join new control units onto the control link. There must be a distance of 0.3 metre between each joint
(stub) and the length of each stub must not exceed 1 metre. It is NOT permissible to join one stub onto another stub. A
stub must always be connected to the original cable harness.
Note: A joint on the control link must always be

connected to the original cable harness. It is NOT
permissible to join one stub onto another stub.
See IE: Connectors, terminals and housings
Single wire seals and cavity plugs
SWS for terminals in housings
Note: Always use a SWS of the correct size for the

wire.
Note: Always use the correct sized plug in unused

cavities in the housing.
SWS are used in places where the housings are exposed to corrosive environments, which means that there is a risk
of water ingress into the housing cavities.
The rubber-based seals prevent corrosion and maintain their sealing properties even when subjected to strong
vibration and temperature cycling.
The SWS are crimped around the wire by the insulation strain relief, and seal against the cavity in the housing.
SWS
If there is a hole in the insulation strain relief, a SWS must be used.
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If there is a hole, a SWS must be used
SWS are found in various colours and sizes.
Plug
Plugs are used to block empty (unpopulated) cavities in a moisture-proof housing.
The plug should be inserted to its end position, or if there is no end position, about 3-5 millimetres.
A plug is more or less the same as a SWS, but without a hole for the wire.
Plugs are found in various colours and sizes.
Plug
Splices
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Butt splices have the function of mechanically joining conductor ends together, in the same way as terminals. The
difference is that it is not possible to undo the joint made by the butt splice. Splices are crimped onto the ends of the
conductors, please refer to Repair of cables for descriptions of the methods.
Splice
A splice consists of two sections:
Crimping section (1), the electrical link with the stripped section of the wire (copper conductor).
Centre stop (2), counterhold for the stripped wire to rest on.
An insulated splice also has an insulating outer casing (3) which protects the splice from unwanted electrical contact.
The outer casing is shrunk onto the wire insulation using a hot air gun.
The crimped section of the splice is formed in the contact pressing tool. It is very important that the crimping process is
done correctly, please refer to Crimping tools, terminals and splices.
Splice
1. Crimping section
2. Centre stop
3. Insulating outer casing
No more than two wires can be connected to each end of a splice.
splice with three conductors connected
Removal tools, remove terminals from housings
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It is important to use the correct removal tools for removal of terminals from housings. The most common tools are
included in the repair kit.
The function of the removal tools is to hold down the primary locking (lock tongue) of the terminal or housing, so that
the terminal can be pulled out.
Each housing demands special disassembly tools. To select the correct tool, first check the appearance of the housing
with regard to the removal groove. See Using the removal tool, example in order to determine which disassembly tool
is appropriate. Then refer to section Remove the terminals from the connector for the method to be used.
Function of removal tools
1. Housing
2. Terminal
3. Lock tongue
4. Removal tools
Crimping tools, terminals and splices
General
Crimping is a method for creating electrical connections. The crimping section of the terminal is pressed around the
conductor with such pressure that it becomes homogenous with the metal in the conductor.
Using the correct tools, it is a quick and easy task to fix a terminal onto a conductor, and makes a more reliable and
stronger joint than a soldered joint, for example.
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Crimping of terminals
Do not use the simple type of tool shown in this illustration. The tool does not provide the force needed for reliable
crimping.
Note: Do NOT use so-called hobby pliers or terminal

pliers!
Design
A crimping tool is designed to suit various types of terminal, by means of both the design of its press jaws and the
press force it generates.
Each cutout on the press jaws has a letter or colour marking, and the tool handle is uniquely colour coded to suit the
part number. Tools with exchangeable jaws only have the markings on the jaws.
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A quick reference manual for these crimping tools is in the case in which the tool is supplied.
Crimping
The goal of using crimping tools is to create cold flow between the terminal and the conductor. Crimping has to be
carried out under extremely high pressure to generate cold flow. For this reason, it is extremely important that the
correct crimping tool is used for each terminal.
Cold flow between terminals and conductor.
Correct crimping of terminals

The wire must be stripped and inserted into the terminal in the correct manner, to give a correct crimp:
1. Only the stripped length of the wire shall be compressed in the crimping section of the terminal. It must not project too
far in front of, or behind the crimping section.
2. The insulated section of the wire should only be compressed under the strain relief section of the terminal. It must not
project too far in front of, or be displaced backwards in the strain relief section.
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Correctly connected terminals
1. Crimping section
2. Strain relief
Examples of poor crimping
Incorrect dimension of crimping section on the terminal

A terminal with a crimping section which is too small cannot surround the copper conductor in the wire.
A terminal with a crimping section which is too large cannot compress the copper conductor sufficiently to cause cold
flow.
Problems occur when crimping has been done incorrectly:
A terminal of incorrect size for the conductor area has been used.
The terminal has been crimped in the wrong cutout in the press tool jaws.
An incorrect tool has been used.
Note: Incorrect crimping causes poor contact, which

can cause contact failure, an open circuit, or
intermittent (irregular) faults which can be difficult to
localize and discover.
Crimping section which surrounds:
1. too large conductor area.

2. too small conductor area.
Twisted copper conductors

Do not twist the stripped end of a wire before crimping. When a copper conductor is twisted, it increases in thickness.
In other words, it assumes a greater conductor area in the twisted section. As time passes, there is a risk that the
copper conductors could be twisted straight again, and the conductor area would fall again. This would lead in its turn
to a loss of crimping force and a contact fault could occur.
Note: Do not twist a copper conductor before

crimping.
Incorrect matching of conductor to terminals

1 Conductor not inserted far enough.
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The conductor is not inserted far enough to ensure current transfer and strain relief.
2 Stripped end of conductor is too short.
In this case, the stripped end of the wire is too short to ensure current transfer, at the same time as part of the
insulation is trapped beneath the crimping section.
3 Cable too far back.
If the stripped section of the wire is too long, and the conductor is correctly aligned in relation to the crimping section,
the strain relief will not surround enough of the wire.
4 Cable too far forwards.
If the stripped section of the wire is too long, and the conductor is correctly aligned in relation to the strain relief
section, the copper conductor will project past the end of the crimping section.
5 Projecting copper conductor.
Projecting copper conductors can lead to short circuits with adjacent conductors.
Terminal with :
1. insufficiently inserted conductor.

2. stripped section of conductor too short.
3. conductor too far back.
4. conductor too far forwards.
5. projecting copper conductor.
Grounding points
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The grounding points are very important components in the electrical system of a vehicle, since all the voltage levels in
the sub-systems are referred to the grounding points as 0 Volt. If there is an grounding point with suspect contact, the
electrical system will be adversely affected.
Several wires are frequently joined together at the same grounding point, which means that several functions and
systems will be affected by the quality of the grounding point.
It is thus very important that the electrical connection at each grounding point is correct, which means that:
there is no paint or dirt on the contact surface between the terminal and the grounding point.
there is no corrosion on the contact surface between the terminal and the grounding point.
the connected terminals are correctly crimped.
nuts and bolts are correctly tightened.
A faulty grounding point can lead to effects in systems and functions which would not at first appear to be related to
grounding faults. These faults can be very difficult to find.
Creating a new chassis point
(A) Drill a hole using a 14 mm (0.55 inches) drill.

(B) Expand the hole using a reamer to 15.3 mm (0.602 inches).
Note: Gives a good contact surface.
Screw the ring terminal in place.
Example of a bolted grounding point.
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Note: In each grounding point, it is very important

that:
there is no paint or dirt on the contact surface

between the terminal and the grounding point.
there is no corrosion on the contact surface between
the terminal and the grounding point.
the connected terminals are correctly crimped.
nuts and bolts are correctly tightened.
Assembly to electrical grounding points diameter 11 mm on chassis:
1. Cleared surface, diameter 30 mm

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2. Flat stainless steel washer, diameter 10 mm

3. Stainless steel nut HM 10x150
4. Grounding terminal or braid
5. Side member
6. Stainless steel screw M 10x150
Tightening torque: 45 +- –9 Nm /
Fixing of grounding terminal or braid to cab:
Fastening of cab grounding lug or braid:
1. Front face panel

2. Flat stainless steel washer, diameter 6 mm
3. Stainless steel stud M6, front face panel
4. Stainless steel nut FIH M6
Note: A protective cap is used when the ground is fastened to the outside of the cab.
Tightening torque for nut (4): 7.4 +- –1.5 Nm /

Fastening to inside of cab:
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1. Front face panel

2. Stainless steel stud M6, front face panel
3. Stainless steel blind nut M6
Warning
The maximum number of connections per grounding point is 3.
Warning
A fault at an grounding connection may cause trouble in systems and functions that seems to have nothing to do
with the grounding connection. Such faults are very difficult to pinpoint.
Battery, Fuse Box, DESS (GIC60 and Grounding Cable) and ADR Relay
It is important to protect terminals in exposed areas from corrosion, as far as possible. Therefore, a thin layer of
corrosion protectant needs to be applied on certain components. Failure to do so may cause these connections to
deteriorate. On cables with high loads it can, in worst cases, cause the contacts to be destroyed.
Some components (battery, fuse box, DESS (GIC60 and Grounding Cable) and ADR relay) have been identified as
particularly vulnerable.
When performing work on these components, the corrosion protection (a thin waxy layer) should always be inspected,
and if necessary, applied / reapplied.
Before reassembly, the terminals should be checked for corrosion damage and cleaned with white spirit or degreaser.
Corroded terminals should be replaced. After reassembly, apply protectant to cable terminals.
Note: Use recommended anti-corrosion spray.

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Cable terminals are purchased separately.
The range can be extended or changed as required. For each change there is also an update to the part number.
Each table also includes the cable area which the terminal suits, and the SWS, if used, which suits the terminal.
Where the terminals require a SWS, there is also a corresponding plug. These plugs shall be used in the cavities in
housings which are not occupied by terminals.
For each terminal, there is a note of the crimping tool used, in certain cases the type of jaw, and the cut-out in the
press jaw which suits the terminal.
In the tables which cross reference terminals with crimping tools, there are terminals which can wrap around conductor
areas of different sizes. In some of these cases, crimping has to be done in different cut-outs, with larger cable areas
in larger cut-outs.
Conductors with small conducting area shall be pressed in cut-out 1, and conductors with greater area in cut-out 2,
unless otherwise noted in the specification.
Contact pressing tool, see Contact pressing tool and disassembly tool kit
*) For conductors with extra thin insulation
Cable terminal, battery cable
The table below shows approved cable terminals for battery cables.
Connecting Area (mm²) Battery Part

angle terminal size number
0° 70 19,2/17,5 977780
STD 1052847 70 17,6/15,9 977781
Cable terminal, power supply cable
The table below shows approved cable terminals for power supply cables.
Connecting Area Bolt Part number

angle (mm²) diameter
45°, STD 70 M10 984932
1058593
45°, STD 95 M10 990409
1058673
90°, STD 25 M8 980082
1052120
Power supply cables
The table below shows the power supply cables, PEX-PVC type, approved .
Cable type Drawing Description

PEX-PVC 1058473
PEX-PVC 1058675 more flexible (soft)
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PEX-PVC 1059023 +125°C
A single-insulated PVC cable, type PVC-Soft 1058547, can be used for wiring in the cab.
Cable type Drawing Description

PVC 1052501
PVC 1058547 more flexible (soft)
PVC 1058585 +115°C
Contact pressing tool and disassembly tool kit

Box 88890240 (space for 36 jaws), contact pressing tool 88890003 and jaws for the contact pressing tool are ordered
separately.
The disassembly tool set 88890037 is also shown below.
88890037
88890240
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88890003
Note: Each tool in the disassembly tool kit can also be ordered separately.
Crimping and stripping tools
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88890003 Contact pressing

tool
88890066 Stripping tool
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Power cable; crimping tools and cable shears

The below tools must be used for crimping power cable.
9812520 Hexagonal crimping tool
9812532 Cable shears
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Removal tools
Complete disassembly tool set 88890037 and individual tools can be ordered using the specified part numbers.
88890036 Removal tools 88890098 Removal tools

88890028 Removal tools 88890037 Kit with removal tool
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88890224 Removal tools 9812479 Spare points for 9812481

9808644 Removal tools 9812476 Half open point for insertion
Matches 9812482
9808647 Spare points for 9808646
Using the removal tool, example
Note: Removal tools can also fit housings and

terminals which are not noted as examples here.
Note: The housings noted here as examples are

available in several sizes and different codes.
In most housings the terminals are attached with the aid of a locking tab, a primary lock. In these cases a tool is
required to prise out the terminal. Prising the terminal out is done with the aid of a removal tool by means of the cavity
opening. The cavity opening has an easily identifiable shape on the contact side, but can have several different
designs.
Round removal groove

Simple removal groove
Semi-open removal groove
Double removal groove
Three-prong removal groove
Four-way removal groove
Square removal groove
The following section contains examples of terminals, housings and removal tools which fit together.
It is important to see the principle for how housings, terminals and cutouts go together, to be able to use the method of
prizing terminals apart in a more general context.
Primary locking in housing
Note: The primary lock is located in the cavity in the

housing. Removing of terminals requires a special
procedure, please refer to Primary locking in the
housing cavity.
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Note: It is important that the secondary lock is open

before the removal of cable terminals, see Opening
the secondary locking
Square removal groove JAE/Radio

Disassembly tool 9808649
Engine connection
Disassembly tool 88890029, 88890028
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Fuse holder
Deutsch connectors
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Disassembly tool 88890038, 9812482,

9812476
Round removal groove

Disassembly tool 9808646 and tool 9809774
with three-way removal groove.
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Assembly tool 9812476 The tool is used for both assembly and removal of the terminals in the
housing.
Disassembly tool 9812482 Deutsch connector block
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Single removal groove or half-open removal groove

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Double removal groove

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Disassembly tools 88890028 and 88890001
Four-way removal groove

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Disassembly tool 88890223,88890224
Note: The illustration shows disassembly

tool 88890223.
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1. Press in the cable terminal.

2. Insert the tool and release the lock.
3. Remove the cable terminal.
The following section describes the components and tools involved in cable repairs.
Cable repairs, example

The various sub-tasks involved in work with wire and cable repairs are described in the following method examples.
The method examples shown are expressed in general terms so that they can be used in most cases.
Note: Original spare parts must always be used for replacement of terminals in housings. The tasks described must
always be carried out during removal, crimping and assembly of terminals.
Note: Keep track of news, as methods and tools are continually being updated to maintain high quality.
Remove the terminals from the connector

Removal of the terminals from the housing is described under this heading.
Disconnect the electrical connector

This section covers handling of two general types of locking methods between connector halves, active and passive,
and how the connector on the engine control unit is disconnected.
Removal of connector with passive locking

Note: If the locking function between the two connector halves is not intact, the housing must be replaced.
1
Disconnect the power supply to the vehicle by turning off the main switch.
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Example of passive locking

Check that the connector really does have passive locking between the connector halves.
3
Pull the connector halves apart.
Removal of connector with active locking

Note: If the locking function between the two connector halves is not intact, the housing must be replaced.
1
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Identify the type of locking.
3
Free the lock and pull the connector halves apart.
Removal of connector for engine control unit

Note: If the locking function between the two connector halves is not intact, the casing must be replaced.
1
Release the connector from the control unit by pressing in the latch and pushing forward the locking clip.
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Move the lock brace forwards so that the metal hooks rest on the rubber pads.
4
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Insert a small screwdriver between one of the metal hooks and its fastening, and carefully prise the joint apart. Slide
the metal hook away to free the fastener from the hole in the hook.
5
Do the same operation on the other three hooks (X4).
6
Remove the locking brace.
7
Unscrew the carrier housing and remove the connector inserts.
Note: Be careful to note the order in which the connectors are located in the housing.
Removal of connectors with slide locking

1
Note: Note: If the locking function is not intact, the housing must be replaced.
Disconnect the power supply to the vehicle by turning off the main switch
Loosen the connector from the control unit by pressing the catch in and moving the lock brace to the side.
Then slide the cover forwards and lift up to access the conductor side of the housing.
Opening the secondary locking

There are many different types of secondary locking. Refer to the illustrated examples as a guide. Certain illustrations
also show the associated removal tools.
Mechanical secondary locking

1
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Below are examples of how the secondary lock is opened with disassembly tool 88890038.
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Use 88890038 and carefully bend up the lock.
1
Use a small screwdriver and prise out the plastic locks on both sides.
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1
Use a small screwdriver and prise out the plastic lock on the side.
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Use a small screwdriver and prise the lock open.
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1
Use a small screwdriver and turn the coloured lock so that it points to the arrow moulded into the connector housing.
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Use a small, narrow screwdriver and carefully prise the lock open.
There is also coding in this secondary lock.
Strain relief
1
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Open the strain relief on the rear of the housing to free the secondary locking.
Extraction of terminals
Warning
To extract the terminals, it is absolutely essential to use correct tool part N° .
Offer up the clip(s)-holder module tool until contact is made.
2
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Extraction tool (A)

Clip(s)-holder (B)
Pull the wire and withdraw the contacts.
Primary locking on the terminal
Press in the terminal from the conductor side of the housing.
Slide in the removal tool into the removal groove and press in the removal tool so that the lock tongue or lock tongues
are pressed down.
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In some cases, the removal tool can be slid into two spaces in each terminal, although only one of them is correct. The
place where the removal tool should be inserted depends on how the terminal is inserted. Test to find the correct place.
Pull out the terminal by pulling the wires from the conductor side.
If you slide the removal tool into the cavity, without pressing the terminal forwards first, the lock tongue can be
destroyed. This can make the terminal difficult to take out.
Free the terminal's primary locking
Primary locking in the housing cavity

1
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Press in the terminal from the conductor side of the housing.
Note: If you slide the removal tool into the cavity, without pressing the terminal forwards first, the lock tongue can be
destroyed and the housing becomes useless.
2
Insert the removal tool into the removal groove and carefully pry up the locking tab, so that the terminal is released.
3
Pull out the terminal by pulling the wire from the conductor side.
Prepare the wire for connection of terminals

Under this heading, there is a description of how to prepare a wire for connection of a terminal or a splice.
Inspection
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Assembly of a wiring harness on-vehicle

Before assembling any wiring harness on the vehicle, the following points must be checked:
Adhesive tape or sheath: Check that the wires keep a certain amount of play and that the free distance between the
protection and the conductors is adhered to.
Locking of the contacts: Check that the locking of the contacts in the pockets of the connectors is effective. To do this,
gently pull each wire.
Integrity of the connector: Check for any irregularities, deformation and visible cracks on the surface of junction boxes
and contacts. Check the appearance, the presence of the various elements and their colour code and/or any
mechanical code.
Integrity of the counterpart: Check that the support face of the counterpart is clean, free from damage and deformation
that might impair the seal of the link.
Note: When assembling any wiring harness on the vehicle, care must be taken to fasten it in accordance with the
Manufacturer's specifications.
Cut the wire at the terminal

1
Check that the wire length will be sufficient once the terminal has been removed.
If the wire is long enough, cut off the wire at the terminal.
If there is a risk that the conductor could become too short when the terminal is replaced, cut off the terminal between
the crimping section and the insulation strain relief section.
4
If the wire is too short, despite this, a new piece must be joined or it must be replaced.
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Check the conductor

1
Check the insulation of the conductor. Check whether there is:
Visible mechanical wear or abrasion damage.

Visible melting damage because of electrical overheating.
2
If there is any damage, cut the damaged section away.
3
Check that sufficient wire remains. If the wire is too short, it must be joined or it must be replaced.
For further checks on the wiring, please refer to separate service information under group 371.
Prepare for damp-proof connections

For a damp-proof connection, the SWS must always be slid over the wire before it is stripped. If the SWS is slid on a
wire which is already stripped, the copper strands in the conductor and the SWS could be damaged.
Always use a SWS of the correct size for the wire.
1
Check that the correct SWS is used, considering the conductor area, terminal and housing.
Slide the SWS about 5 cm onto the wire, with the narrow end facing the end of the wire.
3
After the insulation is stripped, slide the SWS up to the same height as the end of the insulation.
Stripping the wire

Note: Always use the correct stripping length to suit the terminal.
Note: Do not twist the stripped wires
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Check the conductor area, please refer toGeneral.
Use stripping pliers 88890066, checking that the correct stripping length is set.
Part number: 88890066
The stripped section of the wire should be slightly longer than the crimping section.
A common dimension for the stripped length is 4 to 5 mm.
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Specifications:
4-5 mm
Connect the terminal to the wire

This heading contains a description of how the terminal is joined to the conductor.
Crimping
1
Always make your first choice a terminal of a suitable size for the conductor area.
If the only terminal available is for a larger conductor area than the conductor in question, strip the wire to twice the
normal length and fold it double. This gives a well-sealed and secure crimp.
If two conductors are to be crimped into the same terminal:

Select a terminal with sufficiently large conductor area to surround both conductors.
Put the two conductors on top of each other.
If they are of different areas, put the smaller conductor underneath.
4
Select the correct crimping tool to suit the terminal and check the cutout to be used.
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Place the terminal in the cutout in the press jaws.

The terminal must not be inverted, incorrectly aligned, or displaced in the press jaws.
Carefully close the tool, so that the terminal is held in the tool.
7
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Put the conductor in the terminal. The conductor strands should not be twisted.
Put the stripped section of the wire, the copper conductor, in the crimping section (1). The insulation of the wire must
be in the strain relief section (2).
Note: Only one wire is to be mounted per SWS and per damp-sealed terminal.
Note: The insulation of the wire must not be slid into the crimping section.
Note: For moisture-proof joints: Slide the SWS in as far as possible against the terminal, so that the narrow section is
surrounded by the strain relief section of the terminal.
Check that the wire is in the correct position in the terminal and press the crimping tool together.
Do not stop crimping until the tool has become completely compressed and has reached its end position. Only at this
point has correct crimping been achieved and the tool opens.
10
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Certain types of terminals have two cutouts given for crimping. This means that the larger conductor areas specified
for the terminal should be crimped in the larger cutouts.
11
Check that the crimp looks correct, and pull the wire to check that it is securely fixed.
Check the result of the crimping operation

1
Pull the wire to check whether it is correctly fastened.
2
Make a visual check of the crimp, to ensure that there are no cracks in the material of the terminal, and that the
crimping section surrounds the conductor in the correct manner.
Correctly fastened terminals
1. Crimping section.
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2. Strain relief.
Refit the terminal in the connector

This heading contains a description of how to put a terminal back into the housing.
Insert the terminal in the housing

Remember the following:
Check that the terminal lock tongue or lock tongues are not pressed in or damaged in some way.
The secondary locking device must always be open.
Check the wiring diagram to ensure that it is the correct cavity and position number.
The terminal is most often slid into the housing from the conductor side.
Some terminals must be turned the right way around during insertion. Compare it with the existing terminals in the
housing.
Slide in the terminal so far that the lock tongue, the primary locking device, locks the terminal in place. A click is
frequently heard when the terminal locks in place.
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Check that the terminal is correctly located by pulling the wire.
If the housing is of the damp-proof type, any empty spaces for terminals must be plugged. The illustration shows an
example of plugging damp-proof connectors. Other damp-proof housings occurs.
The plug should be located 3 - 5 millimetres down in the cavity, if there is no counterhold for the plug.
Note: Plug empty cavities on damp-proof connectors!
Specifications:
3 - 5 mm
Insertion of contacts
Note: The secondary lock must be open or removed to allow the terminal to be taken out.
Identify the correct type of removal tool for the housing and the removal tool which matches the terminal. Be careful to
distinguish whether the primary locking device is located on the terminal or the housing.
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Place the locking tab of the contact in the "up" position. Insert the contacts in the top row.
Place the locking tab of the contact in the "down" position.
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Insert the contacts in the bottom row.
Close the secondary lock

There are a large number of secondary locking devices, so a few examples of procedures are included.
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Press the heels of the secondary lock together carefully with your thumb.
2
If it is not possible to close the secondary lock, it could be that the terminals are not pressed together sufficiently.
Use a screwdriver to press the plastic catch in on each side of the connector.
2
Make sure that the catches click properly. If it is not possible to close the secondary lock, it could be that the terminals
are not pressed together sufficiently.
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Poke the plastic catch into its groove on the side of the connector.
2
Make sure that the catch clicks properly. If it is not possible to close the secondary lock, it could be that the terminals
are not pressed together sufficiently.
The secondary lock consists of a loose sheet of plastic which is added to the connector from the contact side.
2
Make sure you insert the plastic sheet into its grooves.
3
Press the plastic sheet in until it snaps in place.
4
5
Re-insert the connectors in their housing.
Note: Be careful to ensure that the terminals are inserted into the housing in the same order as before. Check with the
connector on the engine control unit.
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Use a small screwdriver to turn the coloured arrow anticlockwise until it clicks. The arrow should now point to the
arrow moulded into the connector body.
2
Strain relief
1
The secondary lock is activated by closing the strain relief on the rear of the housing.
2
Check connector
1
Pull the wire to check whether it is correctly fastened.
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2
Check that the lock between the connector halves is intact.
3
Check that the terminals are in the correct locations, in the correct cavity. Check with the service information, Wiring
diagram manuals , Group 37.
4
Check that the secondary lock is closed and correctly aligned.
Repair of cables
Note: Water intrusion
If the conductors in a stranded cable are exposed to water, the water can penetrate and travel inside the cable via
capillary action. The sign of water damage on a cable is normally oxidizing. On the connector and the wire strands
outside the insulating sheath a green layer. Inside the cable, the oxidized copper is black. If a cable is damaged by
water, the whole cable shall be replaced up to the next interface. Check the cables connected at the interface for water
damage. If water has bridged the interface and traveled into other cables, change them as well.
Splicing of cables
This heading contains information about joining wires with permanent splices.
Uninsulated splice
If there is major damage the complete cabling must be replaced. Individual damaged wires can be joined.
Note: If you join wires, always connect wires with the same colour(s). Cables of different colours must NOT be joined
together under any circumstances.
Note: If a new wire is joined to the old one, it must be of the same type and have the same colour and conductor area
as the old one.
1
Always make your first choice a splice of correct size for the relevant conductor area.
If two conductors are to be crimped in the same side of a splice:

Select a splice with sufficient conductor area to surround both conductors.
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If only a splice for a larger conductor is available, strip off twice the amount of wire insulation and fold it double.
4
Strip and check the wire.
For each separate joint:

Thread the shrink tubing with adhesive over the end of one of the wires.
The shrink tubing should have a length of 63 mm and diameter of 10.5 - 1.7 mm.
Specifications:
l=63 mm
Φ=10.5 - 1.7 mm
Joining several conductors:

If there are several conductors which are joined at the same place, a piece of shrink tubing with adhesive and an
adhesive cross which covers all the joints shall be threaded over the butt splices.
A kit of shrink tubing with adhesive and an adhesive cross has part number 3090963.
Part number: 3090963
7
Select the correct crimping tool to suit the splice and conductor area, and check the cutouts to be used.
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Put the splice in the cutout and carefully squeeze the tool together so that the terminal remains in the cutout.
Check that the splice is correctly aligned in the crimping tool.
9
Slide in the stripped end of the wire into the side of the splice which the tool is holding.
Note: The insulation of the wire must not be slid into the crimping section of the splice
Note: Do not twist the stripped wires
10
Press the crimping tool handles together.
11
Carry out steps 8to10on the end of the other conductor.
12
Check that the crimp looks correct, and pull on the wire to check that it is securely seated.
13
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Slide the shrink tubing over each separate splice and shrink it with a hot air gun. Make sure that the shrink tubing
seals correctly around the wire insulation.
Note: Make sure that the entire butt splice is covered by shrink tubing.
Note: Avoid breathing the vapours given off during shrinking.
Note: Use a hot air pistol when crimping, not an open flame, since this can cause cracking.
14
If several wires are joined at the same place, shall step 8 to13 for each wire.
15
Slide the larger shrink tubing over all joints and slide the adhesive cross in underneath the shrink tubing at each end.
Shrink the hose with a hot air gun.
Caution
Use ONLY a hot air pistol for heating!
16
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Check on the shrinking. If the tubing has been properly shrunk, the adhesive should have seeped out at the ends of
the splice.
Insulated splice
If there is major damage the complete cabling must be replaced. Individual damaged wires can be joined.
Note: If you join wires, always connect wires with the same colour(s). Cables of different colours must NOT be joined
together under any circumstances.
Note: If a new wire is joined to the old one, it must be of the same type and have the same colour and conductor area
as the old one.
1
Always make your first choice a splice of correct size for the relevant conductor area.
If two conductors are to be crimped in the same side of a splice:

Select a splice with sufficient conductor area to surround both conductors.
If only a splice for a larger conductor area is available, strip off twice the amount of wire insulation and fold it double.
4
Strip and check the wire.
5
Select the correct crimping tool to suit the splice and conductor area, and check the cutouts to be used.
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Put the splice in the cutout and carefully squeeze the tool together so that the terminal remains in the cutout.
Check that the splice is correctly aligned in the crimping tool.
7
Slide in the stripped end of the wire into the side of the splice which the tool is holding.
Note: The insulation of the wire must not be pushed into the crimping section of the splice.
Note: Do not twist the stripped wires.
8
Press the crimping tool handles together.
9
Repeat steps 6to8on the end of the other conductor.
10
Check that the crimp looks correct, and pull on the wire to check that it is securely seated.
11
Shrink the insulated section of the butt splice with a hot air gun.
12
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Check on the shrinking. If the tubing has been properly shrunk, the adhesive should have seeped out at the ends of
the butt splice.
Joining data communication cables

When data communication cables are joined, the twisting pitch must be maintained intact to retain immunity from
interference. Joining takes place in exactly the same way as for other cables, in all other respects.
Note: Check the conditions relating to joining data communication cables in Cables for data communication.
Cut off the wire pairs, allowing 40 mm between the centres of the joints.
2
At the joints, a twisted pair data communication cable may only be untwisted for a length of up to 60 mm, and the total
untwisted length after joining must not exceed 100 mm.
Note: After a twisted pair data communication cable has been joined, the total untwisted length after joining must not
exceed 100 mm.
3
Continue to make joints in accordance with what is described in section Splicing of cables or Insulated splice,
depending on the type of splice being used.
Replacement of wire
Note: If you replace wires, you should choose wires of the same type, length, preferably the same colour and at least
the same conductor area.
Note: When data communication cables are replaced, it is important that the twist pitch of the wires is maintained and
their maximum length is not exceeded. See Cables for data communication.
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1
Measure the length of the original wire.
2
Measure and estimate the area of the original wire. Always select a wire with the same area or, if this area is not
available, the next higher dimension.
3
Preferably choose a wire of the same colour as the original, please refer to the colour code table General.
4
Follow the original wire run and fix the wire in the same way, with tie wraps etc.
Note: No sharp ends must be left projecting outside the cable ties.
Please refer to separate service information under group 371 to check the cables.
Repair of power cable

The following demands must be met when repairing power cable:
No loose conductor strands

No insulation on the connection surface
No burnt conductor strands
No signs of damage to the insulation such as cuts, cracks or clamping damage.
No solder on the conductor strands
Cable strands must not be twisted.
Note: All cable terminals must be fitted in their original condition. Modification of cable terminals is not permitted.
The table below shows the relationships between cable terminals, conductor areas and stripping lengths.
Terminal Area Stripping length

(mm²) (mm)
0° 95 27
M12-M6 70 26
50 21
35 20
25 16
45° 70 29
M10-M8
90° 95 29
M12-M6 70 30
50 19
25 16
Cable terminal, 95 24
battery 70 24
50 24
Crimping of power cable

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The following demands must be met when crimping power cable:
Only use contact pressing tool 9812520.

For good crimping it is important to have the correct combination of cable and terminal sizes; see below.
The cable must be inserted in the cable terminal so that the strands can be clearly seen through the inspection hole;
see figure below.
Crimping must be done so that an obvious cylindrical flange is formed; see figure below.
Apply the crimping about 2 mm from the edge of the cable terminal; see figure below.
Cable strands must not be twisted.
The below table shows the setting that must be used on crimping tool 9812520 in relation to the cable area and the
number of crimps required.
Note: Information in the crimping tool instruction book applies if the information below is contradictory.
Area (mm²) Tool settings Number of crimps

10 8 1
16 9 1
25 11 1
35 13 1
50 14,5 1
70 17 2
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95 20 2
Crimping of a large cross-section wire (10 mm).

1
Use tool 9812520.
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The selection of crimping die is indicated on the terminal.
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Turn the locking button to the open position (yellow) (1) and lift tool handle (2).
Set the crimping dies on tool 9812520.
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Place terminal in tool 2520.

Ensure that the end of the terminal is approximately 2 mm from the jaw of tool 0066. B = 2 mm.
Turn the lock clockwise until jaws touch terminal.
Insert conductor in terminal.
Note: The cable insulation should not be driven into the crimping part of the terminal.
Move levers several times until the wire is crimped sufficiently.
Cutting off the crimped section of a wide cross-section wire (10 mm²).
1
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To cut off a crimped section: Press trigger (1).

Lift lever (2) fully.
Turn lock (3) anti-clockwise.
To check the crimping of a large cross-section wire (10 mm²).

1
Pull the wire to ensure it is secured properly. Visually check that the crimping is correct, that there are no cracks in the
terminal material and that the crimping part correctly surrounds the conductor. Ensure that there is a space between
insulation and terminal of approximately 2 mm.

This section covers general clamping and routing guidelines and recommendations for different situations, which need
to be considered when repairing or adding W/H in the vehicles.
Aim of correct clamping
It is important to clamp the W/H in such a way that it cannot be damaged or damage surrounding components:
The W/H routing and clamping brackets and fixation points provided in the vehicle should always be used as intended.
Clamping locations that are specified on the W/H (e.g. by tape marking) must agree with intended placement in the
vehicle. Any repairs, or added W/H, deviating from the factory installation should follow this recommendation:
Maximum distance between two fixation points in the chassis is 400 mm

Maximum 300 mm for vehicle EATS applications (fixated on vehicle parts)
Maximum 150 mm for engine, transmission, and EATS applications (fixated on mufflers etc.).
W/H or power cables, routed beside or close to the power train shall have a sufficient clearance to avoid contact
W/H or power cables, routed along or through abrasive surfaces, shall be prevented to touch these surfaces, e.g.
sharp edges, bolt threads, and rough edges. This can be achieved by securing with additional clamping or any other
protective device, so that the W/H is not damaged.
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Clamping at the same vibration reference

In order to avoid fretting corrosion and damaged wire strands, connectors and W/H must be properly fixed. This
applies to both sides of a connector. Clamping the W/H on two different parts with different vibration levels, e.g. on the
gearbox on one side and on the frame on the other side, is not allowed.
A-Frame
B- Inline connector
C- Gearbox
Illustration of how the wiring harness branch that comes out of the inline connector misses fixation to the same
vibration reference as the connector, before going to the frame.
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1. Wiring harness
2. Inline connector
3. Wiring harness
4. Tie strap
5. P-clamp
Example of a correct (A) and an incorrect (B)clamping for a wiring harness bundle between two different vibration
areas.
Clamping at breakouts
At a breakout from the wiring harness main branch, fit a cable tie at the break point A to keep the main branch bundle
together. If needed, add a cable tie on the outlet branch, see point B. Also, be sure to fit a cable tie and/or fastener
where the outlet branch is clamped together after the breakout, see point C.
How to properly strap/fixate the different bundles at an outlet point.
Clamping distance to connector

The maximal length between the rear of a connector and the first clamping point must be maintained as intended. If
the first clamping point is missing, terminals in the connector will receive a lot of stress due to movement between the
W/H and the component. This can cause fretting corrosion, possible micro cuts, and damage conductor/strands.
Maximum distance recommended: (A) 100 mm
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Power cable routing

Power cables that are routed along or through abrasive surfaces must not come in contact with these surfaces, e.g.
sharp edges, rough edges, bolt threads, or braided hoses. If routing in the frame is used, routing through cross
members is prohibited. Fasteners must ensure that no contact with the frame is possible and that the cables are
secured from chafing on sharp edges. Power cables should normally be routed on top of brackets.
Routing and clamping the wiring harness.

Clamping with cable ties.
When using cable ties to clamp a wiring harness with earlier made bundles, it is highly recommended to replace the
earlier clamp by a new one that clamps the entire bundle. This is due to difficulties in reaching the correct clamping
force on the cable ties, which causes a risk of either relative movement or deformed hoses. When relative movement
occurs, the inner cable ties can break. See figures below for illustration.
Improper clamping of added wiring harness bundles. The original cable tie should be replaced by a new one
embracing all of the wiring harness bundles.
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A number of wiring harness bundles fixated together and three bundles (corrugated hoses) not yet fixated.
Improper clamping with cable ties. Note that the cable tie does not embrace all of the wiring harness bundles.
Correct multi bundle clamping. Note that the original cable ties are completely replaced by new ones embracing all of
the wiring harness bundles.
Clamping force
Clamping force is individual to each installation situation. Generally, no relative movement is allowed between the
bundles and the force shall not exceed a level that harms the single wires inside the hose
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The left illustration shows a properly tightened wiring harness bundle and the illustration to the right shows an
improperly tightened wiring harness bundle since the tightening force is too small.
After tightening of the clamp is performed, no sharp edges caused by excessive tightening force are allowed on the
corrugated hose. If the deformation of the hose is too big, there is a risk of damaging the single wires inside the hose
A cable tie with anchorage fastened to a wiring harness bundle (corrugated hose) with proper tightening force.
A cable tie with anchorage fastened to a wiring harness bundle (corrugated hose) with too large tightening force.
Note: It is highly recommended to use an appropriate cable tie tool with adjustable tension setting to tighten the cable
ties. Maximum force applied must not exceed the cable tie requirements or damage the wiring bundle (corrugated
hose).
Clamping over length chassis wiring harness bundles

Excess cable must fold back on itself only once and be placed in the frame, in a location where the excess will be able
to be used, or in a solid point due to e.g. vibrations. Do not wind in a coil.
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Proper clamping of over length.
Bending
To avoid damaging the wires or the corrugated hoses when bending, make sure to have sufficient bend radius.
Correct bending radius.
Incorrect bending radius.
Breakouts
When clamping a manifold breakout to a corrugated hose, it is important not to make the loop too short before the first
clamping point is made.
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Illustration of the difference between a proper loop of a wiring harness bundle outlet and a loop with too small bending
radius.
Routing and clamping inside cab/body

Connectors that are not in use and over length W/H must be clamped or taped with assembly tape, cable ties, or equal
to prevent noise and chafe. Over length W/H should be kept to a minimum, but shall be properly secured and properly
protected, if needed, not to be harmed by or harm surrounding components. Fixate and/or apply noise reducing
devices (e.g. textile tape, foam, and shields) to avoid rattling noises.
When clamping the W/H, it is important that it is not in contact or can come in contact (due to movement and/or
vibration) with sharp edges and that it is clamped in a fixed position. It is not recommended to remove pre-assembled
cable ties without replacing them by new ones. All pre-defined clamping points shall be used as well as the pre-
assembled cable clips and cable channels mounted on the wiring harness.
Wiring harness bundling

In order to keep the wires bundled together and to protect the wiring harnesses from water, temperature, vibration and
dirt they should be covered with some form of cable protection such as tape and/or corrugated hose.
The following instructions show how to bundle wiring harnesses.
Bundling wires, general
Wiring harness bundling is done using two different types of tape; wide, dual layer tape with adhesive on both sides,
and narrow, single layer tape with adhesive on one side.
The wide tape is used for covering most of the wiring harness. The narrow tape is used to complement the wide tape
in different ways, described throughout the instructions.
the Volvo Group
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IMPACT 4.07.110 17/07/2021
For tape details and part numbers see the chemicals document “Glue, tape, sealant and locking fluid” found in the
parts catalogue in Impact.
See “Woven adhesive tape, polyester coated” for the narrow tape.
See “Woven adhesive tape, dual layer polyester coated” for the wide tape.
Note: Make sure that the wiring harness is clean and dry before applying new material.
While wrapping, overlap the tape so that no adhesive is visible on the outside of the wiring harness.
Note: Any visible adhesive on the finished bundle must be covered with narrow tape.
This extra layer of tape may not be applied on more than 10% of the wiring harness total length.
the Volvo Group
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IMPACT 4.07.110 17/07/2021
Start wrapping at a 90 degree angle for 1.5 turns.

Continue at a 45 degree angle and finish by wrapping at a 90 degree angle for 1.5 turns.
Cover the end with narrow tape.
Bundling around connectors
Cover the wires with tape.

the Volvo Group
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IMPACT 4.07.110 17/07/2021
Note: Make sure that the wires aren’t stretched inside the connector. End the wrapping approximately 10 mm from the
edge of the connector, or far enough to allow the wires to bend in a natural way.
Install the corrugated hose.
Note: There must be a layer of tape between the wires and the edge of the corrugated hose to prevent chafing.
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IMPACT 4.07.110 17/07/2021
Seal the overlap with narrow tape.
Clamp the bundled wires with a cable tie.
Bundling with corrugated hose
Note: Corrugated hose should only be used on wiring harnesses located on the outside of the frames.
Caution
Be careful when installing or removing the corrugated hose. The edges are very sharp and can damage the
wiring harness.
the Volvo Group
93 / 96
IMPACT 4.07.110 17/07/2021
Cover the wires with tape.

Cover the bundled wires with corrugated hose.
Note: There must be a layer of tape between the wires and the edge of the corrugated hose to prevent chafing.
Seal the overlaps with narrow tape.
Bundling a repaired wiring harness
the Volvo Group
94 / 96
IMPACT 4.07.110 17/07/2021
Cover the repaired wires with the old bundling.

Cover the old bundling with tape.
Seal the overlaps with narrow tape.
Bundling around cable branches
the Volvo Group
95 / 96
IMPACT 4.07.110 17/07/2021
First apply a layer of narrow tape around the branch. Continue wrapping the wires.
Finish by covering the branch with another layer of narrow tape to seal the overlaps.
the Volvo Group
96 / 96

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IMPACT 4.07.

Publish date ID/Operation

Cable repairs, design and function

Cable repairs, definitions

Cable repairs, definitions

Connectors, terminals and housings

Connectors, terminals and housings

Single wire seals, plugs and splices

Single wire seals and cavity plugs

Removal and crimping tools

Removal tools, remove terminals from housings

Wiring, data communication

Cables for data communication

Cable terminals, cavity plug/single-wire seal (SWS), tool

Cable terminals, cavity plug/single-wire seal (SWS), tool

Power cabling, cable terminals, cables

Power cabling, cable terminals, cables

Cable repairs, specifications

Contact pressing tool and disassembly tool kit

Cable repairs, example

Disconnect the electrical connector

Prepare the wire for connection of terminals

Clamping and routing

Clamping and routing

Wire harness bundling

Wiring harness bundling

See IE: Cable repairs, definitions

That the conductor area is correct.

Note: When you replace any wire, always use the

Note: The conductor cross sectional area always

Conductor area measurements

Diameter (mm) Conductor area (mm²)

Signal transfer cables

1. Twisted signal conductor

Preparation of a wiring harness

Installation of taping or a sheath

The wire must be at least as long as the original wire.

Cables for data communication

Note: It is important that the twist pitch is maintained

Note: Use wires with the same type of conductor

Note: The cables can be lengthened, but must not

The wires are wound at a pitch of 30 turns/metre.

Note: SAE J1587/SAE J1708 has a twist pitch of 30

The wires are wound at a pitch of 40 turns/metre.

Note: SAE J1939 is twisted with a twist pitch of 40

Note: A joint on the control link must always be

See IE: Connectors, terminals and housings

Single wire seals and cavity plugs

SWS for terminals in housings

Note: Always use a SWS of the correct size for the

Note: Always use the correct sized plug in unused

If there is a hole in the insulation strain relief, a SWS must be used.

If there is a hole, a SWS must be used

SWS are found in various colours and sizes.

Plugs are found in various colours and sizes.

A splice consists of two sections:

No more than two wires can be connected to each end of a splice.

splice with three conductors connected

Removal tools, remove terminals from housings