Harness and Wire Repair Manual – Hexagon Agility

DSM.0036 Ver 1.0
October 26, 2021
Harness and Wire Repair Manual
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 2 of 13
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Table of Contents
Overview
3
Warning Statements Used in this Manual
3
Required Tools
3
Required Materials
3
Preliminary Instructions
4
General Instructions
4
On-vehicle Heat Shrink and Soldering Precautions
4
Splice Procedure
5
Termination Procedure
A. Sealed Connectors
8
B. Unsealed Connectors
11
Contact Information
13
Proprietary Statement
13
Trademark Notice
13
Hexagon Agility Inc. © 2021. All rights reserved
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Overview
This document provides instruction on approved components, materials, tools, and methods to repair damaged fuel system harnesses and associated wire circuits, terminals, and connectors.
Warning Statements Used in this Manual
NOTICE is used to address practices not related to physical injury, such as best practices or tips to help an operation or procedure go smoothly and prevent equipment damage.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Required Tools (most repairs*)
Item
Purpose
side cutters
cut wires
wire strippers
remove insulation from wires
soldering iron
tin over terminal connections
heat gun with reflector
(Steinel® HL 1910E/HL 2010E or equivalent)
melt heat shrink tubing and splice connector adhesive
insulated terminal crimper
(Raychem® AD-1522 or equivalent)
crimp splice connectors and terminals
thermal blanket or other appropriate heat shielding
protect fuel system components when using soldering iron or heat gun
sewing seam ripper
remove harness wrap or loom to access wire splices
*Some repairs may require a specific OEM crimping tool or die; please refer to individual connectors for details.
Required Materials
Item
Purpose
splice sleeve, 18-22 AWG (red)
approved method for wire splice repairs
splice sleeve, 14-16 AWG (blue)
approved method for wire splice repairs
splice sleeve, 10-12 AWG (yellow)
approved method for wire splice repairs
wire loom (braided, mesh or split corrugated tubing)
cover repaired portions of wire harness
electrical tape
(3M® Scotch® Super 33+ or equivalent)
secure wire loom to harness
dielectric grease
prevent corrosion on electrical contacts
wire terminals and seals
(Refer to OEM specifications)
replace damaged terminals; prevent water/debris intrusion and corrosion
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Preliminary Instructions
Secure Vehicle
General Instructions
1. Only use OEM specified tools for depinning and crimping connector terminals.
2. When extending or replacing a section of wire, the replacement section of wire should be the same gauge or larger than the original section.
3. Corroded components must be repaired by replacing the affected connector assembly—terminals, seals, and connector body—or with an OEM pigtail assembly designed for the repair.
4. If reusing a connector, always verify new seals are properly installed, all plugs (if applicable) are in place, and all terminals are completely seated and locked.
5. When required apply a small amount of dielectric grease to all connector junctions when reconnecting harnesses and components.
On-Vehicle Soldering and Heat Shrink Precautions
Only perform work on fueled vehicles in well-ventilated facilities designed for the specific vehicle fuel type or in safe spaces outdoors in accordance with all jurisdictional and industry regulations.
Always disconnect negative battery cable when repairing electrical components installed on the vehicle.
1.Verify vehicle is leak-free. Refer to DSM.0037 Leak Check procedure.
2.Refer to ENP-422 Welding and Hot Work Precautions Near CNG and LNG Vehicles to determine whether vehicle must be depressurized or defueled prior to beginning any repair procedure requiring heat, sparks, flame, or other thermal activity.
3.Always cover fuel system plumbing and cylinders with a thermal blanket or other appropriate heat shielding when applying solder or working with a heat gun.
4.Never use a torch or other open flame to apply heat to heat shrink tubing.
Wear approved personal protective equipment (PPE) including safety glasses.
Set emergency brake and place wheel chocks in front of and behind vehicle tires.
When performing service or repairs on any portion of the fuel system, install proper lockout/tagout (LOTO) device(s) and observe all LOTO practices.
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Splice Procedure
Step 11
 Identify the harness location where the splice connector is to be installed.
Step 21
 Use a sewing seam ripper to open harnesses protected by layers of electrical tape, heat shrink material, wire loom, etc. to allow unobstructed access to the wire(s).
Step 31
 Use side cutters to cut the suspect/damaged wire harness circuit.
Step 41
 Use wire strippers to remove approximately 5/16-in (8 mm) of insulation from the wire end and twist the wire stands together.
When performing multiple splices in a harness, plan to offset splice locations to minimize the possibility of creating a bulge or ridged section in the harness.
splice
splice
wire loom
Sewing seam ripper
harness
electrical tape
Remove electrical tape first and leave as much wire loom intact as possible.
Leave as much wire intact as possible.
wire
insulation
5/16-in
(8 mm)
Do not cut or damage any wire strands during this process.
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Step 51
 Select correct splice sleeve size and crimping die based on wire gauge size listed in Table 1:
TABLE 1: Splice Sleeve by Wire Size, Sleeve Color, and Die Size
Wire Size (AWG)
Splice Color
Crimping Die
18 – 22
red
red
14 – 16
blue
blue
10 – 12
yellow
yellow
Step 61
 Verify crimping die corresponding to the splice sleeve is installed in crimping tool jaws; install correct die if necessary. Refer to manufacturer instructions.
Step 71
 Insert splice sleeve into crimping tool jaws rest slightly on the terminal near the middle of the crimping area.
jaws
blue die
yellow die
red die
splice sleeve
crimping tool
jaw
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Step 81
 Slide one end of wire to be repaired into splice sleeve until the wire strands are inserted fully into the metal portion of the sleeve (the wire should bottom out).
Step 91
 Squeeze crimping tool until the handles are fully compressed the to fully secure the splice sleeve to the wire. NOTE: When fully compressed, crimping tool will ratchet back to the neutral position. Refer to manufacturer instructions.
Step 101
 Gently tug on wire to verify a proper crimp.
Step 111
 Repeat Step 3 through Step 10 for other wire end.
Step 121
Step 131
 Use a heat gun with a reflector to gently apply heat to splice sleeve starting from the middle and working outwards.
 When tubing has shrunk, a small amount of sealant should extend out from the ends of the splice sleeve to insure a complete seal.
Step 141
 If wire loom material was removed to access wires, install new wire mesh loom or split corrugated tubing over splice area and secure to harness with electrical tape.
splice sleeve
wire end
wire end
wire end
splice sleeve
Cover fuel system plumbing and cylinders with a thermal blanket or other appropriate heat shielding.
sealant
sealant
splice sleeve
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Termination Procedure
A. Sealed Connectors
Step 11
 Use a sewing seam ripper to open harnesses protected by layers of electrical tape, heat shrink material, wire loom, etc. to allow unobstructed access to the wire(s).
Step 21
 Use side cutters to cut the suspect/damaged wire harness circuit.
Step 31
 Select the appropriate size seal for the wire gauge and slide it approximately 1-in (25 mm) from the wire end.
Step 41
 Use wire strippers to remove approximately 3/8-in (9.5 mm) of insulation from the wire end and twist the wire strands together.
wire loom
Sewing seam ripper
harness
electrical tape
Remove electrical tape first and leave as much wire loom intact as possible.
Leave as much wire intact as possible.
seal
wire
1-in
(25 mm)
wire
insulation
3/8-in
(9.5 mm)
Do not cut or damage any wire strands during this process.
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Step 51
 Slide seal so face of the crimp end of the seal is even with the edge of the insultation at the wire end.
Step 61
 Insert wire and seal into terminal as follows:
a) center seal tangs on seal body
b) stripped wire should not extend past wire tangs
Step 71
 Use appropriate crimping tool and die to crimp terminal wire tangs. Note: Some crimping tools secure the wire tools and the seal tangs simultaneously.
Step 81
 If required: Use appropriate crimping tool and die to crimp terminal seal tangs.
Step 91
seal
wire end
insulation
seal
wire tangs
terminal
seal tangs
stripped wire
wire tangs
terminal
wire tangs
terminal
seal tangs
seal
Cover fuel system plumbing and cylinders with a thermal blanket or other appropriate heat shielding.
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Step 101
 Use a soldering iron and rosin core solder to secure terminal to the wire.
Step 111
 If wire loom material was removed to access wires, install new wire mesh loom or split corrugated tubing over splice area and secure to harness with electrical tape.
solder
terminal
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B. Unsealed Connectors
Step 11
 Use a sewing seam ripper to open harnesses protected by layers of electrical tape, heat shrink material, wire loom, etc. to allow unobstructed access to the wire(s).
Step 21
 Use side cutters to cut the suspect/damaged wire harness circuit.
Step 31
 Select the appropriate size terminal for the wire gauge.
Step 41
 Use wire strippers to remove approximately 3/8-in (9.5 mm) of insulation from the wire end and twist the wire strands together.
wire loom
Sewing seam ripper
harness
electrical tape
Remove electrical tape first and leave as much wire loom intact as possible.
Leave as much wire intact as possible.
insulation
wire
3/8-in
(9.5 mm)
Do not cut or damage any wire strands during this process.
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Step 51
 Insert wire into terminal as follows:
a) insulation tangs should rest on wire insulation
b) wire tangs should rest evenly on the stripped wire end
c) stripped wire should not extend beyond the tangs
Step 61
 Use appropriate crimping tool and die to crimp all terminal tangs.
Step 71
Step 81
 Use a soldering iron and rosin core solder to secure the terminal to the wire.
Step 91
 If wire loom material was removed to access wires, install new wire mesh loom or split corrugated tubing over splice area and secure to harness with electrical tape.
insulation tangs
stripped wire
terminal
wire tang
wire tang
terminal
crimped wire tangs
crimped insulator tangs
Cover fuel system plumbing and cylinders with a thermal blanket or other appropriate heat shielding.
solder
terminal
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Hexagon Agility® Customer Care and Technical Services
Fuel system warranty or non-warranty product support may be obtained by calling or emailing Hexagon Agility® Customer Care and Technical Services (CCTS).
Please provide your name, phone number, email address, and complete vehicle information: VIN, year, make, model, mileage, unit number vehicle owner, and current vehicle location. A service advisor will contact you to arrange vehicle repair or ship a part.
833-4-HEX-CARE
(toll-free, U.S. and Canada)
+1 949 267 7745
Support
[email protected]
Parts Orders
[email protected]
Proprietary Statement
The information provided within this document is proprietary and confidential. All prior versions, including updates and revisions forwarded separately, are proprietary. The information provided by Hexagon Agility® to its customers and clients is solely for the use of those customers and clients. No portion of this publication may be reproduced or distributed without express written consent of Hexagon Agility®. Hexagon Agility® reserves the right to utilize the intellectual property contained within this publication as content for any other publication produced by Hexagon Agility®.
Trademark Notice
Hexagon® is a registered trademark of Hexagon Technology AS. Agility® is a registered trademark of Agility Fuel Solutions LLC. Trademarks of other manufacturers are the property of their respective companies.
Hexagon Agility® 3335 Susan Street, Suite 100 Costa Mesa, CA 92626 USA www.hexagonagility.com