General repair methods for wiring harness

AR00.19-D-0100A

General repair methods for wiring harness

14.01.2020

Model

all (Heavy transporter, Light transporter)

 Caution

Risk of injury caused by burns to skin and eyes, risk of poisoning caused by inhaling fumes during soldering.

Wear protective gloves, protective clothing and safety glasses. Ensure that the work area is adequately ventilated. Secure power supply cables. Avoid sources of fire in working area.

AS00.19-Z-0002-01A

 Caution

Risk of injury caused by burns to skin and eyes. Risk of poisoning caused by inhaling fumes when working with heat-shrinkable tubing.

Work in well ventilated rooms only. Wear safety glasses with side protection and protective gloves.

AS00.19-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Notes on replacement of safety-relevant and special components

AH00.19-P-1000-08A

Repair wiring harness

1

Expose repair point

 Remove insulating tubing, corrugated hose or fabric tape. Disassemble electrical connector and remove contact if necessary.

2.1

Repair wiring harness using connector sleeve

Where several lines are connected.

AR00.19-D-0100-09A

 Adapter

*220589019942

 Reflector

*220589019941

 Wire stripper

*220589019940

 Welding bead catcher

*129589019800

2.2

Repair wiring harness by means of axial solder connectors

When replacing or inserting line sections.

AR54.18-D-0100-06A

 Adapter

*220589019942

 Reflector

*220589019941

 Wire stripper

*220589019940

 Welding bead catcher

*129589019800

2.3

Repair wiring harness by crimping

For example, for damaged or oxidized contacts.

AR00.19-D-0100-03A

   JPT crimping set listed representative for all   crimping sets.

 JPT crimping set

*220589019905

 Crimping set overview

*220589049901

 Wire stripper

*220589019940

 Crimp pliers

*220589019910

 Crimp set overview

*000589139901

 New passenger car wiring harness repair kit

*220589049900

 Wiring harness repair kit, basic

*000589139900

2.4

Repair wiring harness by crimping with watertight connections

For damaged or oxidized contacts in wet environments.

AR00.19-D-0100-04A

   JPT crimping set listed representative for all   crimping sets.

 JPT crimping set

*220589019905

 Crimping set overview

*220589049901

 New passenger car wiring harness repair kit

*220589049900

 Wire stripper

*220589019940

 Crimp pliers

*220589019910

 Crimp set overview

*000589139901

 Wiring harness repair kit, basic

*000589139900

2.5

Repairing cable harness by soldering

When using soldering eyes.

AR00.19-D-0100-05A

 Wire stripper

*220589019940

 Welding bead catcher

*129589019800

3

Protect repair area after cable repairs

AR00.19-D-0100-08A

 If necessary.

4

Checking wiring harness

AR54.18-D-0600-01A

 Electrical connection kit

*220589009900

5

Connect diagnostic system; read out fault memory



Model 909

AD00.00-D-2000-04F



Model 900
Model 906

AD00.00-D-2000-04SD



Model 907
Model 910

AD00.00-D-2000-06TS

6

Perform system test in accordance with diagnosis specifications.