Crimping a Cable Terminal
Crimping a cable terminal
Caution! An incorrectly crimped terminal means poor electrical contact, which can cause defective operation or intermittent faults. These problems can be difficult to detect and localize during subsequent fault tracing.
Use a Volvo crimp tool
The crimp tools from the repair kit p/n 981 4235 Replaced by 9512644 981 4235 Replaced by 951 2644 will give a reliable result when used correctly.
Contact crimp tool, inhibitor function
The contact crimp tool has a ratchet which normally prevents a crimping operation from being aborted before the tool is at its final position (and the crimping operation correctly completed). The tool will then open automatically.
To abort a crimping operation when using the contact crimp tool see To abort a terminal crimping operation.
Note! Do NOT use this type of tool!
Do not use this type of simple direct-acting crimping pliers which are intended for the home repairs and hobby market. The tool does not supply the necessary force required or meet Volvo quality standards to ensure reliable terminal crimping.
Place the cable terminal in the tool
- Select the crimping insert for the cable terminal type. See Choice of crimp tool Choice of Crimp Tool
- Locate the cable terminal correctly in the crimping insert.
Check that the cable terminal deformation sections (1) and (2) are in contact with the crimp tool support section (3) and (4). The cable terminal must not be at an angle or lie to far forwards or to the rear in the crimp tool insert.
- Carefully apply pressure to the crimp tool until the jaws hold the cable terminal in place without applying sufficient pressure to deform it.
Check the cable terminal is correctly located in the crimp tool jaws
If the cable terminal is not correctly located
If the cable terminal has turned, moved forward or backwards, or is in the wrong cable area profile section, abort the crimping operation.
If the cable terminal is located correctly
- Proceed to Locate cable in the cable terminal.
To abort a terminal crimping operation
The crimp tools have a ratchet in the grip section. See illustration.
- Use a screwdriver to lift and release the ratchet.
- Reposition the cable terminal correctly in the insert and proceed with operation Locate cable in the cable terminal.
If the cable terminal is damaged
If the cable terminal has already been deformed replace with a new cable terminal and start again from operation Place the cable terminal in the tool.
Locate cable in the cable terminal
The cable terminal should be in the crimp tool as described in Place the cable terminal in the tool.
- Insert the cable end in the cable terminal.
The stripped section of copper conductor is located in the core wings ( 1 ) and the insulated cable section in the insulation wings ( 2 ).
If a seal is required on the cable it should be located as shown in the illustration.
If the cable area is to small for the cable terminal
Always select a cable terminal intended for the cable area of the cable.
If on the other hand the correct cable terminal for the cable area is not available and only one cable terminal is available and it is for a larger cable area than is required:
- Strip the cable to double the normal stripping length and bend it double. In this way the conductor will make a tight and reliable connection in the terminal crimping operation.
Two cables crimped in one cable terminal
Always use a cable terminal that is large enough to take both the cables.
- Insert the cables one on top of the other
If the cables are of different areas always insert the larger cable on top.
Crimp the cable terminal
Check that the cable is still in the correct position in the cable terminal.
- Apply pressure to the grip of the crimp tool
Do not release the pressure on the tool until it is at the final position. Only when the crimping operation is completed will the tool open.
Proceed
Inspect the crimped terminal
Always inspect the crimped cable terminal as described in Examples of correct terminal crimping Examples of Correct Terminal Crimping Examples of incorrect crimping Examples of Incorrect Crimping.
After checking the cable terminal
- To insert the cable terminal in the housing, continue to When cable terminal is to be inserted in a housing When Cable Terminal Is to Be Inserted In A Housing Closing the housing Closing the Housing.