Cables And Fuses - General Information

• Checking The Result Of The Crimping Operation (2000-2004)
  • Examples of correct terminal crimping
    • Checking crimping results
    • Check the position of the cable
    • Check the cable terminal locking tabs
    • Poor results after crimping
  • Examples of incorrect crimping
    • Notes
    • Core too large for the core wings
    • Core is too small for the core wings
    • Reason
    • Incorrect location of cable/cable terminal
      • The stripped cable is not located correctly
      • The stripped core is too short
      • The stripped core is too long
      • The stripped core is incorrectly crimped
      • Reason
• Connectors, Some Examples Of Methods (2000-2004)
  • Example 1
    • Notes
    • Replacement of cable terminals
      • Remove housing
      • Open the housing
      • For a combined pin housing do the following:
      • Extract the cable terminal
      • Crimp new cable terminal
      • Insert new cable terminal
      • Close the housing
      • Reassemble the connector
  • Example 2A
    • Notes
    • Replacement of cable terminal in socket housing
    • Separate the connector pin and socket housings
    • Extract socket housing
    • Open socket housing
    • Extract the cable terminal
    • Crimp new cable terminal
    • Insert new cable terminal in housing
    • Close socket housing
    • Reassemble the connector
  • Example 2B
    • Notes
    • Replacement of cable terminals in pin housing
    • Separate the pin and socket housings of the connector
    • Open the connector
    • Open the pin housing
    • Extract the cable terminal
    • Crimp new cable terminal
    • Insert the new cable terminal in housing
    • Close socket housings
    • Reassemble the connector
  • Example 3
    • Notes
    • Replacement of cable terminals
      • Remove the connector cover
      • Open the housing
      • Extract the cable terminal
      • Crimp new cable terminal
      • Insert the new cable terminal in the housing
      • Close the housing
      • Reassemble the connector
  • Example 4
    • Notes
    • Replacement of cable terminals
      • Open the housing
      • Extract the cable terminal
      • Crimp new cable terminal
      • Insert the new cable terminal in the housing
      • Close the housing
• Extracting The Cable Terminal From The Housing (2000-2004)
  • Cable terminals, different types
    • Notes
    • Cable terminals are divided up into the following main groups
    • Moisture proof cable terminals
    • Ring cable terminal (and forked cable terminal)
    • Receptacle terminals
    • Tab
    • Tab sws (Single Wire Seal)
    • Tab steel sws
    • Timer
    • 2.8 Timer sws
    • 0.64 Socket
    • Pin terminals
    • Socket terminals
  • Cavity opening with one extraction groove
    • Terminal removal tool, p/n 9814229
    • Choose the terminal removal tool with the correct width
  • Housing with half-open contact side
    • (When the cable terminals are partly exposed with the locking tabs visible in the cavities)
  • Housings with round cavity opening
    • Cable terminals that are extracted without using a terminal removal tool
      • 1.6 Pin/Pin sockets
      • 3.5 Moisture proof Pin/Pin sockets
    • Cable terminals that are extracted with terminal removal tools
      • 2.1 Pin/Pin sockets and 3.5 Pin/Pin sockets
  • Housings with square cavity openings
    • Terminal removal tool
    • Single or double cavity row
    • Single cavity row
    • Double cavity row
    • Proceed to
  • Primary locking in general
    • Notes
    • Primary locking in cavities
    • Primary locking on cable terminals
    • Without primary locking
    • Release primary locking
  • Single terminal housings
    • Cable terminals without locking tab
    • Miscellaneous, exceptions
  • Using terminal removal tools
    • Choosing the correct tool
      • General
      • Cavity opening and cable terminal profiles
      • Using terminal removal tools
    • Removing cable terminals with locking tabs
      • Notes
      • Release the locking tab for the cable terminal as follows
      • What NOT to do
  • When the cavity opening has two extraction grooves
    • Terminal removal tool, P/N 9814228
    • Choose the terminal removal tool with the correct width
• Glossary (2000-2004)
  • Glossary for connector/housings
  • Terms used for cable terminals
• Ground Points And Oxidation (2000-2004)
  • Ground points and oxidation
    • Environmental factors
    • Surface oxides
    • Ground points
• Inserting A Cable Terminal In A Housing (2000-2004)
  • Closing the housing
    • Keep in mind the following
    • After completing the repair work
  • When cable terminal is to be inserted in a housing
    • Keep in mind the following
    • Proceed
• Open The Connector (2000-2004)
  • Secondary locking
    • Notes
    • Secondary locking
    • Housing with secondary locking
    • Tools
  • Secondary locking - socket type
    • Open the secondary locking as shown if it is of the socket/housing retainer type
      • General instructions
      • Release socket/housing retainer
      • Remove
      • Proceed
  • Separate the connector
    • Notes
    • General instructions
    • Types of catches and locks
    • Reconnecting
  • When secondary locking is of the cavity cover type
    • To open a housing secondary locking when it is of the cavity cover/locking plate type, proceed as follows
      • General instructions
      • Open cavity cover/locking plate
      • Other examples of cavity cover/locking plates
      • Proceed
  • When secondary locking is of the lid type
    • To open a housing secondary locking of the locking lid/catch type proceed as follows
      • General instructions
      • Open locking lid/catch
      • Proceed
• Operating Procedures For Repairs (2000-2004)
  • Proceed as follows
    • The following information is arranged as follows
    • Basic procedures for repair operations
      • Opening a connector
      • Open the housing
      • Select terminal removal tool
      • Select a new cable terminal
      • Sws (Single Wire Seal)
      • Strip the cable
      • Select a suitable crimp tool for the cable terminal
      • Crimp the cable terminal
      • Checking crimping of a cable terminal
      • Insert the cable terminal in the housing
      • Close the housing
    • Repair work
      • Volvo special tools and Volvo original spare parts
    • Important
• Replacing A Cable Terminal (2000-2004)
  • New cable terminal
    • Notes
    • Identify the cable terminal
    • If no similar cable terminal is available in the cable terminal assortment
  • Seal sws and plug
    • Seal sws for cable terminals
    • Plug
• Soldering, General (2000-2004)
  • Soldering, general
    • Notes
    • Cable Terminals Kit, p/n 9814234
    • Cable Terminals box, p/n 9814232
    • Special tools, in repair kit p/n 9814235
      • Terminal removal tool
      • Crimp tool
    • Cable Terminals Kit, p/n 9814233
    • Repair kit, p/n 9814235
    • Other tools
• Stripping A Cable (2000-2004)
  • Cutting and checking a cable
    • Cutting a cable
    • Inspect the cable insulation
  • Stripping the cable
    • Stripping the cable for a cable terminal
    • Length of the stripped section of cable
• Terminal Crimping (2000-2004)
  • Cable terminals - crimping core wings
    • Insulated cable terminals
      • Crimping core wings, shape
    • Uninsulated cable terminals
      • Notes
      • Enclosed type
      • Open type
    • Core wings and insulation wings
      • Notes
      • Core crimp - electrical efficiency
      • Core crimp - mechanical efficiency
  • Choice of crimp tool
    • Notes
    • Correct choice of crimp tool for a cable terminal
      • Notes
      • Crimp tool (black), p/n 9814223
      • Crimp tool (red), p/n 9814224
      • Crimp tool (yellow), p/n 9814225
      • Crimp tool (green), p/n 9814226
      • Crimp tool (blue), p/n 9814227
  • Crimping a cable terminal
    • Notes
    • Use a Volvo crimp tool
    • Place the cable terminal in the tool
    • Check the cable terminal is correctly located in the crimp tool jaws
    • To abort a terminal crimping operation
    • Locate cable in the cable terminal
    • Crimp the cable terminal
    • Proceed
  • Terminal crimping in general
    • Advantages of terminal crimping
    • Terminal crimping, method and tools
• Cables (2000-2004)
  • Cable terminals surface treatment
    • General information