Cable Repair

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Cable repair
Contents
Cable repairs, specifications
Oddments boxes
Crimping tools and removal tools, sets
Crimping and stripping tools
Power cabling, cable terminals, cables
Power cable; crimping tools and cable shears
Removal tools
Changes to removal tool, example
Cable repairs, design and function
Cable repairs, definitions

Conductors
Cable terminal
Insulators
Cables for data communication
Seals and plugs
Splices
Earthing points
Removal tools, remove terminals from insulators
Crimping tools, terminals and slices
Soldered joints
Cable repairs, example

The various sub-tasks involved in work with 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: Volvo original spare parts must always be used for replacement of terminals in insulators. 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.
Disconnect the electrical connector

Opening the secondary locking
Free the terminal's primary locking
Prepare the cable for connection of terminals
Connect the terminal to the cable
Refit the terminal in the connector
Repair of data communication cables
Repair of power cable
Oddments boxes
A selection of terminals and accessories is available in the following assortment boxes 88890031, 88890032, 88890033 and 88890035.
The terminals can also be purchased separately.
The range will be expanded or altered as necessary. At each change there will be an update of the part number.
This section presents the terminals and plugs that are included in the four assortment boxes.
Each table also includes the cable area which the terminal suits, and the seal, if used, which suits the terminal.
Where the terminals require a seal, there is also a corresponding plug. These plugs shall be used in the cavities in insulators 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.
The boxes are shown here with illustrations and associated tables.
http://127.0.0.1:9905/impact3/application/staticdb/lang/enGB/sman49201_node1187.xhtm 2/20/2015
Assortment box 88890031
Terminal Area mm² Seal/ Plug Earlier crimping tool version New crimping tool version
Colour of handle Cut-out Jaw Cut-out
949212 4,0-6,0 — ORANGE B C — —
8397490 — — — — — 88890005 C
949489 1,1-2,5 — ORANGE A — 88890005 B
973118 1,1-2,5 — ORANGE A B 88890005 C
949400 0,5-1,0 — RED B C 88890005 B
979003 2,6-4,0 — ORANGE B C — —
979002 1,1-2,5 — ORANGE A B 88890005 B
979001 0,5-1,0 — RED A B 88890005 B
970777 1,0-2,5 — ORANGE A — — —
949404 1,1-2,5 — RED C — 88890005 C
968374 1,1-2,5 — ORANGE A B 88890005 C
970776 0,5-1,0 — RED B — 88890005 B
969780 0,5-1,0 — RED B C 88890005 B
969781* 1,1-2,5 — ORANGE A — 88890005 C
*) For conductors with extra thin insulation
88890032
965825 2,5-4,0 — BLUE C — — —
965823 2,5-4,0 — BLUE C — — —
965824 1,0-2,5 — BLUE A B — —
965822 1,0-2,5 — BLUE A B — —
3963047 1,0-2,5 3986691/ 970771 BLUE/GREEN D — 88890004 C
3944652 0,5-1,0 3944654/ 970771 RED C — 88890004 C
3944653 1,5-2,5 3944655/ 970771 RED C — 88890004 C
3963046 0,5-1,0 3963410/ 970771 BLUE/ORANGE B – – —
8155901 88890004 C
8155903 88890004 C
984945 88890004 B
984846 0,5-1,0 3963410/ 970771 BLUE/GREEN B C 88890004 C
984847 1,0-2,5970771 3986691/ 970771 BLUE/ORANGE B — 88890004 C
9130476 — — — — 88890007 C
6781769 — — — — 88890007 B
3986252 0,5-1,0 977538/ 977540 YELLOW B — —
14370862 — — — — 88890007 B
14370860 — — — — 88890007 B
11709652 — — — — 88890007 A
3963409 0,5-1,0 970772/ 970771 BLUE/GREEN B C — —
14370863 — — — — 88890007 B
14370861 — — — — 88890007 B
11709648 — — — — 88890007 A
978924 0,5-1,5 — RED C — 88890005 B
88890033
881497 2,5-6,0 — YELLOW/BLUE B C 88890010 B
8140576 0,75-1,5 — ORANGE C B — —
881494 1,1-2,5 — YELLOW/BLUE A — 88890010 A
85107489 1– 2.5 — — — — 88890006 —
8154542 — — — — 88890010 A
8154513 — — — — 88890010 A
6781769 0,5-1,5 — RED/ BLUE 88890058 RED
9130476 1,0-2,5 — RED/ BLUE 88890058 BLUE
978304 0.35–0.8 — — — — 88890008 1
977539 0,5-1,5 977538/ 977540 ORANGE/ BLACK B 88890004 A
9130230 1,5-2,5 — RED B — 88890004 B
9130228 0,3-1,0 — RED A — 88890004 B
983020 0.5– 1 — — — — 88890004 C
984523 1.5– 2.5 — — — — 88890004 C
984975 — — — — 88890004 B
984522 0.5– 1 — — — — 88890004 B
20375160 0.5 — — — — 88890005 A
984524 0.5– 1 — — — — 88890004 B
983014 0.5– 1 — — — — 88890028 A
20375162 1.5– 2.5 — — — — 88890005 C
1Markings on this tool may vary. For terminal 978304, use the small hole.
88890035
Seal/ Plug Area mm²
8155900
3963410 0.5−1
8155899
970771 Plug
3986691 1.0−2.5
20393958 Plug
3963410 0.5−1.0
977540 Plug
3944654 0.5−1.0
970772 0.5−1.0
3986691 1.0−2.5
970771 Plug
3944655 1.0−2.5
8397660 Plug
3987745 Plug
11113439 Plug
Other cable terminals (not in assortment box)
11039671 0,5-2,5 — BLUE/GREEN D — — —
20375161 0,2–0,5 88890005
Splice
Terminal Area mm² Seal/ Plug Crimping tools
Colour of handle Cut-

out
6781769 0,5-1,5 — RED/ BLUE RED
9130476 1,0-2,5 — RED/ BLUE BLUE
Splice with hot melt adhesive; see instructions Insulated slice.
DIN, 7/15 - pole trailer connector
Note: Terminals and crimping tools are NOT included in the repair kit.
Terminal Area mm² Pin/Socket Crimping tools
20367456 1,5 Socket
20367457 2,5 Socket
3171184 2,5 Socket
3171182 1,5 Pin
3171183 2,5 Pin
7/15 —pole trailer hitch, 21231906. 21231907. 21189673. 21189676
Terminal Area mm² Pin/Socket Seal/ Plug Area mm² Crimping tools
Jaw Ejector
21231910 0,5-1,0 Pin 25371149 0.5–1.0 88890096 88890098
21231909 1,0-2,5 Pin 25371150 1.0–2.5 88890096 88890098
21231911 3,0-6.0 Pin 25371152 3.0–6.0 88890096 88890098
21303456 1,5-2,5 Pin 21303466 1.5–2.5 88890096 88890098
21303460 1,5-2,5 Pin 21303466 1.5–2.5 88890096 88890098
21303462 1,5-2,5 Socket 21303466 1.5–2.5 88890096 88890098
— — — 25371151 — — —
Power cabling, cable terminals, cables

Cable terminal, battery cable
The table below shows the Volvo approved cable terminals for battery cables.
Connecting angle Area (mm²) Battery terminal Part number

size
0° 70 19,2/17,5 977780
STD 1052847 70 17,6/15,9 977781
Cable terminal, power supply cable

The table below shows the Volvo approved cable terminals for power supply cables.
Connecting angle Area (mm²) Bolt diameter Part number
45°, STD 1058593 70 M10 984932
45°, STD 1058673 95 M10 990409
90°, STD 1052120 25 M8 980082
Power supply cables

The table below shows the Volvo approved power supply cables. They are all of type PEX-PVC STD 1058473
Cable type Area (mm²)/Colour Part number
PEX-PVC 25 /red 984437

STD 1058473
25/black 984436
35/red 984439
35/black 984438
50/red 984441
50/black 984440
70/red 984443
70/black 984442
95/red 980404
95/black 980405
Single insulated PVC cable type PVC-Soft STD 1058547 may be used in the cab.
Cable type Area (mm²)/Colour Part number
PVC, Soft 70/red 984671

STD 1058547
70/black 991105
PVC, +115° C 95/black 991121

STD 1058585
Crimping tools and removal tools, sets

The new crimping tool 88890003 is used for fitting terminals onto cables. The crimping tool is supplied in a case with space for 16 jaw sets. The removal tool set 88890037 is also shown
below.
Note: Each tool can be ordered separately.
Crimping and stripping tools
88890003 Crimping tools

88890004 Jaw for crimping tool


Note: All the old crimping tools will be replaced by new jaws. The old part numbers
still apply but equivalent jaws will probably be supplied against orders, instead of
the old ones.
Translation between crimping tool part number and handle colour
Part number Colour
9512648 RED
9512649 ORANGE
9512652 YELLOW
9512653 BLUE
9512772 BLUE/ORANGE
9512773 BLUE/GREEN
9808641 YELLOW/BLUE
9808642 ORANGE/ BLACK
9808643 RED/ BLUE
88890003 Crimping tools
88890066 Stripping tool
Power cable; crimping tools and cable shears

The below tools must be used for crimping power cable.
9812520 Hexagonal crimping tool
9812532 Cable shears
Removal tools
Complete removal tool set 88890037 and individual tools can be ordered from Volvo Parts AB using the specified part numbers.
88890036 Removal tools 9812481 Removal tools

88890028 Removal tools 9812479 Spare points for 9812481
88890056 Removal tools 9812476 Half open point for insertion
Matches 9812482
88890098 Removal tools
88890037 Kit with removal tool
Changes to removal tool, example
Note: Removal tools can also fit insulators and terminals which are not noted as
examples here.
Note: The insulators noted here as examples are available in several sizes and
different codes.
In most insulators 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, insulators and removal tools which fit together.
It is important to see the principle for how insulators, terminals and cutouts go together, to be able to use the method of prizing terminals apart in a more general context.
Round removal groove
Removal tool 9812480
Removal tool 9808646 and tool 9809774 with three-way removal

groove.
Removal tool 9812482 The tool is used for both assembly and removal of the terminals in the insulator.
Assembly tool 9812476
Removal tool 9812482 Deutsch connector block
Single removal groove or half-open removal groove
Double removal groove
Removal tools 88890028 and 88890001
Four-way removal groove
Primary locking in insulator
Note: Primary locking is located in the cavity in the insulator. Removing of

terminals requires a special procedure, please refer to Primary locking in the
insulator cavity.
Square removal groove JAE/Radio
Engine control unit
Engine connection
Control unit (SAAB/AMP-don)
Removal tools 9812475, 88890028
Fuse holder
Deutsch connectors
Removal tools 11709649, 11709655, 11709666
The following section describes the components and tools involved in cable repairs.
See IE: Cable repairs, definitions
Connectors, terminals and insulators

A connector is a detachable joint between two cable harnesses. The connector consists of two connector halves, which are joined together and locked to each other. A connector half
consists in its turn of an insulator and terminals. One connector half contains pin terminals and the other half contains mating socket terminals. Each terminal is connected to a cable,
generally by crimping, to the purpose of transfering electricity in the best possible manner.
The purpose of the insulator is to protect the terminal from unwanted electrical contact, ensure that the correct terminals are joined together, and that the halves of the connector stay
together.
Cable terminal
There are many different designs of terminals, such as tab and pin; this is a general description of cable terminals.
Structure
Mating section, crimping section and insulation strain relief

Most terminals consist of three sections:
Mating section (1), ensures electrical contact between the terminals.
Crimping section (2) is the electrical joint between the stripped section of the conductor (copper conductor) and the terminal.
Insulation strain relief (3), relieves the crimping section from mechanical stress. The insulation strain relief is placed over the insulating, outer casing of the conductor. This is normally found
on terminals of the open, un-insulated type.
The crimping section of the terminal and the insulation strain relief are formed on the terminal by the crimping tool at the same time. It is very important that the crimping process is correctly
done.
1. Mating section
2. Crimping section
3. Insulation strain relief
Appearance of the crimping section

There are two designs of crimping section for terminals, tubular with or without insulation, and open un-insulated.
Insulated and un-insulated closed terminals
In the closed design, the terminal has a soldered, tubular neck into which the conductor can be inserted.
The insulation on insulated terminals is colour coded for different cable areas.
Strain relief is not normally found on this type of terminal.
Un-insulated open terminals
The open type of terminal has a U-shaped neck in which the conductor can be put.
Strain relief is normally found on this type of terminal.
Size
The size of a terminal either refers to the conductor area which the terminal is intended for, or the size of the mating section between pin and socket.
The size of the mating section is specified as the width or diameter of the tab section and the socket part.
The designation for a terminal is written with the size first, such as 2.8 Tab.
For eyelet terminals, it is the diameter of the hole which is the size. The size of the hole should suit the bolt which the terminal will be fixed to.
Size of terminals
1. Conductor area
2. Size, mating section
Lock tongue, primary locking

Most terminals have one or two tongues which serve as locking devices and hold the terminal in place in the insulator.
The locking device is referred to as the primary locking device and, where fitted, is individual for each terminal. In exceptional cases, primary locking is located on the insulator, please refer
to Insulators for a more detailed description.
It is important that the lock tongue is correctly angled outwards, so that the terminal seats securely in the insulator.
Lock tongue
Single primary locking means terminals with one lock tongue.

Double primary locking means terminals with two lock tongues.
In some cases, there is also a secondary locking device located on the insulator to provide further security in retaining the terminals, please refer to Insulators.
Both primary and secondary locking devices must be opened when the terminal is replaced.
For removal of terminals, please refer to Remove the terminals from the connector for descriptions of the methods.
1. Single primary locking

2. Double primary locking
Embossing
Some tab terminals and tab terminal sockets can be provided with an embossed dimple.
The function of the dimple is to hold the mating sections of the terminals together, through mechanical locking between the tab and the socket.
Terminals with dimples
Insulators
General
When the tab and socket insulators are connected together, they are referred to as connector halves.
The task of the insulator is to protect the terminal from unwanted contact and environmental effect and, in most cases, ensure that the correct terminals are connected together and to ensure
that the connector halves remain together.
An insulator for a tab is referred to as a tab insulator, and an insulator for a socket is referred to as a socket insulator.
Coding
The connector halves are frequently coded to ensure that they only fit each other, to ensure that the correct cables are linked together at each joint. This can be done through coloration
and/or through mechanical coding.
Example of mechanical coding
Locking between connector halves
Insulators can often be locked against each other or against components.
There are two types of locking: active locking and passive locking.
1. Active locking means that the lock must be actively released before the connector halves can be divided.
2. Passive locking means that the connector halves must be pulled apart with a certain amount of force.
When connector halves are divided, tab and socket insulators, the locking device must be freed.
1. Example of active locking

2. Example of passive locking
Contact sides and conductor sides of insulators
The contact side is the side of the insulator which is joined together with the mating insulator. The contact side is also referred to as the front of the insulator.
The conductor side is the side where the conductors or cables go into the insulator. This is also referred to as the rear of the insulator.
1. Contact side
2. Conductor side
Insulator cavities and position numbers
Cavities are the hollow spaces in the insulator where the terminal is located, and where a removal tool can be inserted. The cavity openings on the contact sides of the insulators have easily
identifiable shapes, which are each designed to suit different types of terminals.
Each cavity is numbered, and this number (pin number) is found on the wiring diagram as the position number.
Example: designation SW3 means position 3 in connector SW.
In some isolators there are cavities that are only intended as removal grooves. There are cavities with as many as four removal grooves.
1. Cavity
2. Position number
Reinforced moisture protection
Some insulators can have reinforced moisture protection, by means of gaskets, rubber outer casings on cables, plugs in empty cavities and seals around the crimped sections of the
insulation strain relief on the terminals.
Note: All cavities must either be used or plugged.
Example of moisture-proof joint
1. DIN insulator
2. Volvo's moisture-proof joint
Locking of terminal in insulator
The terminals are retained inside the insulator by various kinds of locking device, to prevent the terminals from being pressed out backwards during connection.
The locking system can consist of primary locking and/or secondary locking devices.
Primary locking: Generally, primary locking is located in the terminal, please refer to Cable terminal for a more detailed description. In exceptional cases, primary locking can be provided on
the insulator.
Primary locking on insulator
Secondary locking: If secondary locking devices are provided, they are always installed on the insulator and lock several terminals at once. Secondary locking protects, provides strain relief
and maintains the terminals in place.
There are many different secondary locking variants. The illustrations show some examples of secondary locking.
Secondary locking by means of a cover
Secondary locking, cavity
Secondary locking by means of the insulators' strain relief
Secondary locking
Both primary and secondary locking devices must be opened when the terminal is replaced.
For terminal removal please refer to Remove the terminals from the connector.
Seals and plugs

Seals for terminals in insulators
Note: Always use a seal of the correct size for the conductor.
Note: Always use the correct sized plug in unused cavities in the insulator.
Seals are used in places where the insulators are exposed to corrosive environments, which means that there is a risk of water ingress into the insulator cavities.
The rubber-based seals prevent corrosion and maintain their sealing properties even when subjected to strong vibration and temperature cycling.
The seals are crimped around the conductor by the insulation strain relief, and seal against the cavity in the insulator.
Seal
If there is a hole in the insulation strain relief, a seal must be used.
If there is a hole, a seal must be used
Seals are found in various colours and sizes.
Plug
Plugs are used to block empty (unpopulated) cavities in a moisture-proof insulator.
The plug should be inserted to its end position, or if there is no end position, about 3-5 millimeter.
A plug is more or less the same as a seal, but without a hole for the conductor.
Plugs are found in various colours and sizes.
Plug
Splices
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 data communication cables for descriptions of the methods.
Splice
A slice consists of two sections:
Crimping section (1), the electrical link with the stripped section of the conductor (copper cable).
Centre stop (2), counterhold for the stripped conductors to rest on.
An insulated slice also has an insulating outer casing (3) which protects the slice from unwanted electrical contact. The outer casing is shrunk onto the conductor insulation using a hot air
gun.
Note: Avoid breathing the vapours given off during shrinking.
The crimped section of the splice is formed in the press tool. It is very important that the crimping process is done correctly, please refer to Crimping tools, terminals and slices.
Splice
1. Crimping section
2. Centre stop
3. Insulating outer casing
No more than two conductors can be connected to each end of a slice.
slice with three conductors connected
Removal tools, remove terminals from insulators

It is important to use the correct removal tools for removal of terminals from insulators. 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 insulator, so that the terminal can be pulled out.
Each insulator demands special removal tools. To select the correct tool, first check the appearance of the insulator with respect to the removal groove, see Changes to removal tool,
example to identify which removal tool is suitable. Then refer to section Remove the terminals from the connector for the method to be used.
Function of removal tools
1. Insulator
2. Terminal
3. Lock tongue
4. Removal tools
Crimping tools, terminals and slices
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.
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.
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 cable. 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 conductor must be stripped and inserted into the terminal in the correct manner, to give a correct crimp:
1. Only the stripped length of the conductor 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 conductor 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.
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 cable.
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 cable before crimping. When a copper cable is twisted, it increases in thickness. In other words, it assumes a greater cable area in the twisted section. As
time passes, there is a risk that the copper cables could be twisted straight again, and the cable 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 cable before crimping.
Incorrect matching of conductor to terminals

1 Conductor not inserted far enough.
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 cable 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 cable is too long, and the conductor is correctly aligned in relation to the crimping section, the strain relief will not surround enough of the cable.
4 Cable too far forwards.
If the stripped section of the cable 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.
Conductors
General
Introduction
It is important that the cables 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 cables 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 conductor colours are maintained.
That the conductors are installed in a way which protects the conductors from mechanical damage.
The electrical wiring diagrams are a considerable help when you change or repair any conductors, please refer to the service information in group 37.
Note: When you replace any conductor, always use the same type of cable 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 area and diameter always refer to the metallic conductor in a
cable.
Conductor diameter 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 conductors, 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
Conductor colour
Choose the same colour as the original conductor. Different colours must only be used in exceptional cases.
The wiring diagrams often contain the colour codes for each conductor.
Please refer to the table, to interpret the colour codes.
Two-tone conductors
If the colour code for a conductor consists of two colours, it is designated as follows:
Y/R Shall be read as YELLOW/RED. This means that the conductor has a YELLOW insulation outer casing with a RED stripe.
Colour Abbreviation
Black SB
Brown BN
Red R
Orange OR
Yellow Y
Green GN
Blue BL
Violet VO
Grey GR
White W
Pink P
Light brown LBN
Cable runs
When a conductor is installed, the original cable run shall be followed, and the conductor shall be fixed in the same way. The conductor 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 conductor must be at least as long as the original conductor.
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
cables are joined.
Note: Use cables with the same type of cable 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.
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.
Earthing points
The earthing 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 earthing points as 0 Volt. If there is
an earthing point with suspect contact, the electrical system will be adversely affected.
Several conductors are frequently joined together at the same earthing point, which means that several functions and systems will be affected by the quality of the earthing point.
It is thus very important that the electrical connection at each earthing point is correct, which means that:
there is no paint or dirt on the contact surface between the terminal and the earthing point.
there is no corrosion on the contact surface between the terminal and the earthing point.
the connected terminals are correctly crimped.
nuts and bolts are correctly tightened.
A faulty earthing point can lead to effects in systems and functions which would not at first appear to be related to earthing 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 cable terminal in place.
Example of a bolted earthing point.
Note: In each earthing point, it is very important that:
there is no paint or dirt on the contact surface between the terminal and the
earthing point.
there is no corrosion on the contact surface between the terminal and the
earthing point.
the connected terminals are correctly crimped.
nuts and bolts are correctly tightened.
Soldered joints
General notes about soldering
Soldering is a relatively easy method to use. No expensive equipment is needed and the conductor area is not so critical.
The disadvantage of soldering is uneven quality. Poor results can be obtained because of contamination at the contact points.
If soldering is to give good contact and durability, it is important that the contact point is completely free of dirt, oxidation, grease, paint etc.
Note: Because of its uneven quality, soldering should only be done where other
alternatives are difficult to implement.
Note: Avoid soldering at points where there is considerable current density.
Soldering quality
The factors affecting the quality of a soldered joint are the choice of solder, flux and soldering tool, and how the joint is located and made.
It is common for the conductor to be heated so much that the insulation is damaged and melts. In addition, the solder can flow too far up the conductor. If this happens, the conductor
becomes hard and brittle, and the risk of cable breakage increases.
Even though the conductor must not be heated up too much, it must be warm enough at the soldering point to avoid creating a dry joint. If a dry joint is created, the electrical and mechanical
contact will be very poor, causing contact failure, open contact or intermittent faults. These faults can be very difficult to discover and localise, since the soldered joint will be covered by
insulating shrink tubing afterwards.
Note: A dry joint means a poor electrical joint, causing contact failure, open contact
or intermittent faults, which can be difficult be very difficult to discover and localize.
Soldering tools
There are various kinds of soldering tools. The most common is the temperature regulated soldering station, which allows the power and temperature of the soldering iron to be regulated.
Solder wire
It is very important to use solder wire containing a good quality, non-corrosive flux.
Note: Do not use solder with aggressive (acid-based) flux. This can cause
oxidation and contact problems.
Finishing
It is important that the soldered joint is insulated and protected from unwanted electrical contact and mechanical damage once it is finished.
Cable repairs, example
Remove the terminals from the connector

Removal of the terminals from the insulator 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 insulator must be replaced.
1
Disconnect the power supply to the vehicle by turning off the main switch.
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 insulator must be replaced.
1
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.
Move the lock brace forwards so that the metal hooks rest on the rubber pads.
4
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 insulator housing and remove the connectors.
Note: Be careful to note the order in which the connectors are located in the housing.
Removal of connectors of type SAAB/AMP

Note: If the locking function is not intact, the insulator must be replaced.
1
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 insulator.
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
Use 88890038 and carefully bend up the lock.
1
Use a small screwdriver and prise out the plastic locks on both sides.
1
Use a small screwdriver and prise out the plastic lock on the side.
Use a small screwdriver and prise the lock open.
1
Use a small screwdriver and prise the plastic lock open.
1
Use a small screwdriver and turn the coloured lock so that it points to the arrow moulded into the connector housing.
Use a small, narrow screwdriver and carefully prise the lock open.
There is also coding in this secondary lock.
Strain relief
1
Open the strain relief on the rear of the insulator to free the secondary locking.
Free the terminal's primary locking

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 insulator and the removal tool which matches the terminal. Be careful to distinguish whether the primary locking device is located on the
terminal or the insulator.
Primary locking on the terminal

1
Press in the terminal from the conductor side of the insulator.
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.
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 cables 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.
Primary locking in the insulator cavity
Press in the terminal from the conductor side of the insulator.
Note: If you slide the removal tool into the cavity, without pressing the terminal forwards first, the lock tongue can be destroyed and the insulator 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 cables from the conductor side.
Prepare the cable for connection of terminals

Under this heading, there is a description of how to prepare a conductor for connection of a terminal or a slice.
Cut the cable at the terminal

1
Check that the cable length will be sufficient once the terminal has been removed.
If the conductor is long enough, cut off the conductor 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 cable is too short, despite this, a new piece must be joined or it must be replaced.
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 cable remains. If the cable 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 seal must always be slid over the conductor before it is stripped. If the seal is slid on a conductor which is already stripped, the copper wires in the
conductor and the seal could be damaged.
Always use a seal of the correct size for the conductor.
1
Check that the correct seal is used, considering the cable area, terminal and insulator.
Slide the seal about 5 cm onto the conductor, with the narrow end facing the end of the conductor.
3
After the insulation is stripped, slide the seal up to the same height as the end of the insulation.
Stripping the conductor

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

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 cable area.
If the only terminal available is for a larger conductor area than the conductor in question, strip the conductor 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.
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
Put the conductor in the terminal. The conductor wires should not be twisted.
Put the stripped section of the conductor, the copper conductor, in the crimping section (1). The insulation of the conductor must be in the strain relief section (2).
Note: Only one conductor is to be mounted per seal and per damp-sealed terminal.
Note: The insulation of the conductor must not be slid into the crimping section.
Note: For moisture-proof joints: Slide the seal 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 cable 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
Certain types of terminals have two cutouts given for crimping. This means that the larger cable areas specified for the terminal should be crimped in the larger cutouts.
11
Check that the crimp looks correct, and pull the conductor to check that it is securely fixed.
Check the result of the crimping operation

1
Pull the conductor to check whether it is correctly fastened.
Correctly fastened terminals
1. Crimping section.
2. Strain relief.
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.
Refit the terminal in the connector

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

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 insulator from the conductor side.
Some terminals must be turned the right way around during insertion. Compare it with the existing terminals in the insulator.
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.
Check that the terminal is correctly located by pulling the conductor.
If the insulator is of the damp-proof type, any empty spaces for terminals must be plugged. The illustration shows an example of plugging of Volvo's damp-proof connectors. Other damp-
proof insulators occur.
The plug should be located 3 - 5 millimeter down in the cavity, if there is no counterhold for the plug.
Note: Plug empty cavities on damp-proof connectors!
Specifications:
3 - 5 mm
Close the secondary lock

There are a large number of secondary locking devices, so a few examples of procedures are included.
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.
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.
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 insulator.
2
Check connector
1
Pull the conductor to check whether it is correctly fastened.
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 data communication cables

This heading contains information about joining cables with permanent splices.
Uninsulated slice
If there is major damage the complete cabling must be replaced. Individual damaged cables can be joined.
Note: If you join cables, always connect conductors with the same colour(s). Cables of different colours must NOT be joined together under any circumstances.
Note: If a new cable 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 cable area.
If two conductors are to be crimped in the same side of a slice:

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

Thread the shrink tubing with adhesive over the end of one of the cables.
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 slice and conductor area, and check the cutouts to be used.
Put the slice in the cutout and carefully squeeze the tool together so that the terminal remains in the cutout.
Check that the slice is correctly aligned in the crimping tool.
9
Slide in the stripped end of the conductor into the side of the slice which the tool is holding.
Note: The insulation of the conductor must not be slid into the crimping section of the slice
Note: Do not twist the stripped wires
10
Press the crimping tool handles together.
11
Carry out steps8to10on the end of the other conductor.
12
Check that the crimp looks correct, and pull on the conductor to check that it is securely seated.
13
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 conductor insulation.
Note: Make sure that the entire butt splice is covered by shrink tubing.
Note: Use a hot air pistol when crimping, not an open flame, since this can cause cracking.
14
If several conductors are joined at the same place, shall step8to13for each conductor.
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
Check on the shrinking. If the tubing has been properly shrunk, the adhesive should have seeped out at the ends of the slice.
Insulated slice
If there is major damage the complete cabling must be replaced. Individual damaged cables can be joined.
Note: If you join cables, always connect conductors with the same colour(s). Cables of different colours must NOT be joined together under any circumstances.
Note: If a new cable 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 cable area.
If two conductors are to be crimped in the same side of a slice:

Select a slice with sufficient conductor area to surround both conductors.
If only a slice for a larger conductor is available, strip off twice the amount of cable and fold it double.
4
Strip and check the cable.
5
Select the correct crimping tool to suit the slice and conductor area, and check the cutouts to be used.
Put the slice in the cutout and carefully squeeze the tool together so that the terminal remains in the cutout.
Check that the slice is correctly aligned in the crimping tool.
7
Slide in the stripped end of the conductor into the side of the slice which the tool is holding.
Note: The insulation of the conductor must not be pushed into the crimping section of the slice.
Note: Do not twist the stripped wires.
8
Press the crimping tool handles together.
9
Repeat steps6to8on the end of the other conductor.
10
Check that the crimp looks correct, and pull on the conductor to check that it is securely seated.
11
Shrink the insulated section of the butt splice with a hot air gun.
12
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 conductor 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 Uninsulated slice or Insulated slice, depending on the type of splice being used.
Replacement of conductor
Note: If you replace cables, you should choose conductors 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 conductors is maintained and their maximum length is not exceeded. See Cables for data
communication.
1
Measure the length of the original cable.
2
Measure and estimate the area of the original cable. Always select a cable with the same area or, if this area is not available, the next higher dimension.
3
Preferably choose a conductor of the same colour as the original, please refer to the colour code table Conductors.
4
Follow the original cable run and fix the conductor 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 cable strands

No insulation on the connection surface
No burnt cable strands
No signs of damage to the insulation such as cuts, cracks or clamping damage.
No solder on the cable 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, cable areas and stripping lengths.
Terminal Area (mm²) Stripping length (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, battery 95 24
70 24
50 24
Crimping of power cable

The following demands must be met when crimping power cable:
Only use crimping 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
95 20 2

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sman49201_node1187 Page 1 of 56

Cable repairs, design and function

Cable repairs, definitions

Cable repairs, example

Disconnect the electrical connector

The terminals can also be purchased separately.

Assortment box 88890031

Colour of handle Cut-out Jaw Cut-out

949212 4,0-6,0 — ORANGE B C — —

949489 1,1-2,5 — ORANGE A — 88890005 B

973118 1,1-2,5 — ORANGE A B 88890005 C

949400 0,5-1,0 — RED B C 88890005 B

979003 2,6-4,0 — ORANGE B C — —

979002 1,1-2,5 — ORANGE A B 88890005 B

979001 0,5-1,0 — RED A B 88890005 B

970777 1,0-2,5 — ORANGE A — — —

949404 1,1-2,5 — RED C — 88890005 C

968374 1,1-2,5 — ORANGE A B 88890005 C

970776 0,5-1,0 — RED B — 88890005 B

969780 0,5-1,0 — RED B C 88890005 B

969781* 1,1-2,5 — ORANGE A — 88890005 C

*) For conductors with extra thin insulation

Colour of handle Cut-out Jaw Cut-out

965825 2,5-4,0 — BLUE C — — —

965823 2,5-4,0 — BLUE C — — —

965824 1,0-2,5 — BLUE A B — —

965822 1,0-2,5 — BLUE A B — —

3963047 1,0-2,5 3986691/ 970771 BLUE/GREEN D — 88890004 C

3944652 0,5-1,0 3944654/ 970771 RED C — 88890004 C

3944653 1,5-2,5 3944655/ 970771 RED C — 88890004 C

3963046 0,5-1,0 3963410/ 970771 BLUE/ORANGE B – – —

984846 0,5-1,0 3963410/ 970771 BLUE/GREEN B C 88890004 C

984847 1,0-2,5970771 3986691/ 970771 BLUE/ORANGE B — 88890004 C

3986252 0,5-1,0 977538/ 977540 YELLOW B — —

3963409 0,5-1,0 970772/ 970771 BLUE/GREEN B C — —

978924 0,5-1,5 — RED C — 88890005 B

Colour of handle Cut-out Jaw Cut-out

881497 2,5-6,0 — YELLOW/BLUE B C 88890010 B

8140576 0,75-1,5 — ORANGE C B — —

881494 1,1-2,5 — YELLOW/BLUE A — 88890010 A

85107489 1– 2.5 — — — — 88890006 —

6781769 0,5-1,5 — RED/ BLUE 88890058 RED

9130476 1,0-2,5 — RED/ BLUE 88890058 BLUE

978304 0.35–0.8 — — — — 88890008 1

977539 0,5-1,5 977538/ 977540 ORANGE/ BLACK B 88890004 A

9130230 1,5-2,5 — RED B — 88890004 B

9130228 0,3-1,0 — RED A — 88890004 B

983020 0.5– 1 — — — — 88890004 C

984523 1.5– 2.5 — — — — 88890004 C

984522 0.5– 1 — — — — 88890004 B

20375160 0.5 — — — — 88890005 A

984524 0.5– 1 — — — — 88890004 B

983014 0.5– 1 — — — — 88890028 A

20375162 1.5– 2.5 — — — — 88890005 C

Seal/ Plug Area mm²

Other cable terminals (not in assortment box)

Colour of handle Cut-out Jaw Cut-out

11039671 0,5-2,5 — BLUE/GREEN D — — —

20375161 0,2–0,5 88890005

Terminal Area mm² Seal/ Plug Crimping tools