NHTSA ID Number: 10203563
Manufacturer Communication Number: DSM.0036
Summary
This Wire and Harness Repair Manual provides instruction on approved components, materials, tools, and methods to repair damaged fuel system harnesses and associated wire circuits, terminals, and connectors.
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
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.
SEOCONTENT-START
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
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 3 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 4 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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.
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 5 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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.
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 6 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 7 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 8 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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.
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 9 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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.
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 10 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 11 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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.
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 12 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
DSM.0036 Ver 1.0 Harness and Wire Repair Manual 13 of 13
October 26, 2021 PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED
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
support@hexagonagility.com
Parts Orders
parts@hexagonagility.com
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
SEOCONTENT-END
1 Affected Product
Equipment
BRAND | PART NO. | PRODUCTION DATES |
AGILITY FUEL SYSTEMS | AGILITY FUEL SYSTEMS |
1 Associated Document
Manufacturer Communications
DSM.0036 Ver 1.0
October 26, 2021
https://www.nhtsa.gov/recalls?nhtsaId=10203563
MC-10203563-9999.pdf 677.528KB
MC-10203563-9999
- Crimps insulated termils onto 10-22 AWG stranded copper wire
- Adjustable compound action design puts more crimping power into each squeeze
- Three crimping cavities in one tool: 22–16 AWG (Red), 16–14 AWG (Blue) and 12–10 AWG (Yellow) termils
- Built-in ratchet ensures full-cycle crimping for a uniform crimp every time
- Unique cavity design provides consistent crimp from either side of the tool
- CRIMPS 22-10 AWG non-insulated terminals
- 8 in. high leverage design and a NON-SLIP COMFORT GRIP HANDLE
- EASILY CUT copper and aluminum wire
- TAPERED NOSE for cutting in tight locations
- Made with DROP FORGED STEEL for longevity and durability
- Crimper crimps 10 to 22 AWG insulated and non-insulated terminals
- Cutting and Crimping Tool has specially hardened wire cutter in nose
- Tapered nose design for working in confined spaces
- Crimping die marked for insulated and non-insulated solderless terminals and connectors
- Made in USA
- This wire crimper tool works best with heat shrink connectors.this hand crimper has efficient ratcheting mechanism and High-precision jaw which is color coded. Crimping is accurate and never damage the terminal,crimping is in one step.
- Ergonomic handle provides maximum comfort and reduced hand fatigue.Non-slip design to ensure strong grips in any condition,provides maximum leverage and increased comfort making the grip self adjusting.
- This wire crimper is made of premium industrial grade high strength carbon steel which is treated with black oxidation,rust and corrosion resistance.Qibaok professional insulated wire terminals connectors ratcheting crimper tool is designed for 20-10AWG.
- This terminal crimper has a star wheel that you can adjust the handle crimp strength by adjusting the roulette to ensure uniform crimping each time.Heavy Duty Full-Cycle ratcheting terminal crimper with labor saving system help to a easier operation.The ratcheting function allows to secure a wire connector while you can insert the wires into the crimp.
- Wire Crimper can be used for home appliance repair, home circuit repair, vehicle circuit connection, and everything about circuit connection.
- 【Product upgrade】NEW 「 HX-50BI 」with 6 dies in AWG: 8,6,4,2,1,1/0,NOT IN METRIC
- 【Precise dies】Hexagonal rotating dies are processed with Wire EDM Cutting, more accurate than normal casting dies.
- 【Comfortable operation】Comfortable grip with antislip surface saves strength and improves user's experience.
- 【Solid construction】Made of high quality carbon steel which can offer long service life.
- 【Versatilel】Compatiable with copper&aluminum cable lug,non-welding and standard electrical connection.
- PROFESSIONAL CRIMPING TOOL - this hand crimper has efficient ratcheting mechanism and professional grade crimping die for proper rock-solid crimps every time. This crimping tool works best with insulated nylon electrical terminals
- PRECISE RATCHETING MECHANISM – wire connectors are crimped by squeezing the handle through a complete ratcheting cycle until the handle releases automatically. The ratcheting function allows to secure a wire connector while you can insert the wires into the crimp
- ADJUSTABLE CRIMPING FORCE - The tool has a star wheel that allows to adjust crimping height to ensure the right amount of crimping force depending on your crimping project. A designated quick release lever allows to open the crimper jaws in any position
- ERGONOMIC COMFORTABLE HANDLES - The ergonomic, cushioned, non-slippery handles were designed to ensure strong grips in any condition. These handles have enough leverage to comfortably crimp AWG 22-10 splices
- LIFETIME WARRANTY - Wirefy stands behind the quality of our products. We offer lifetime warranty for our crimping tools. If you have any issues during the lifetime of your crimper, just let us know. Our customer experience team is always here to help
- [VERSATILE]: Strips and removes insulation. Crimp insulated and bare wires. gripping nose works to pull, hold, twist, and bend wire ends.
- [COMPACT]: Thin cable cutter design combines 4 separate functions into one compact 7” tool, ideal for common wire connectors and repairs.
- [DURABLE]: Solid forged alloy steel construction with a protective black finish stands up to extensive everyday carry and daily use.
- [PRECISE]: Blades and teeth are heat treated CNC machined for precision accurate, and clean smooth cuts on copper, aluminum, cables, automotive wires, and soft steel wires.
- [SIZES]: Cut, grip, twist, pull, crimp, and strip wires and cables in gauges from 12, 14, 16, 18 & 20 AWG in one small handheld tool.
- PROFESSIONAL CRIMPING TOOL-This wire crimper tool works best with heat shrink connectors.this hand crimper has efficient ratcheting mechanism and High-precision jaw which is color coded. Ratcheting crimper tool is designed for 20-10AWG.
- PRECISE RATCHETING MECHANISM-Wire connectors are crimped by squeezing the handle through a complete ratcheting cycle until the handle releases automatically. The ratcheting function allows to secure a wire connector while you can insert the wires into the crimp.
- ADJUSTABLE CRIMPING FORCE-The tool has a star wheel that allows to adjust crimping height to ensure the right amount of crimping force depending on your crimping project. A designated quick release lever allows to open the crimper jaws in any position.
- WIDE APPLICATION-Connectors Crimping Tool Kit can be used for home appliance repair, home circuit repair, vehicle circuit connection, and everything about circuit connection.
- PACKAGE INCLUDED-200PCS Heat Shrink Butt Connectors (90PCS×RED.90PCS×BLUE.20PCS×Yellow) and a Crimping Tool For Heat Shrink Connectors. Tubings of different colors with the mark of wire gauge are easy to recognize.
- Hydraulic crimping tool specification: Crimping range 12 AWG-2/0 AWG, Stroke 5.6Inch
- Hydraulic crimping tool 9 pairs of dies: 12.10.8.6.4.2.1/0. 2/0 AWG and 1/8 "for stainless steel wire rope
- 【Wide Application】 The crimper tool is great for battery and welding cables , power Wires , and electrical cables ,even can be rotated 180° freely for narrow space working
- 【Comfortable grip】 The vinyl-dipped grip is very comfortable and easy to use and Wont slip
- 【Easy operation】The mold can be easily replaced by one-way fixed latch
- UPGRADED HANDLES: The upgraded, cushioned and non-slippery handles are optimized for strong grips in any condition. These handles have enough leverage to crimp AWG 22-10 splice connectors comfortably
- ONE KIT FOR ALL: The crimper combokit comes with a connector crimpeing too, a two in one wire striper and cutter and five wire crimping jaws. The tool kit works on all heat shrink/non-heat shrink connectors and ferrule terminals from TICONN and other brands. An ideal tool kit for electricians, DIYer, mechanics and so on.
- PROFESSIONAL CRIMPING TOOL: The wire crimper tool has efficient ratcheting mechanism and professional grade crimping die for proper rock-solid crimps every time. This crimping tool works best with TICONN connectors
- ADJUSTABLE CRIMPING FORCE: The terminal crimper has a star wheel that allows to adjust crimping height to ensure the right amount of crimping force depending on your crimping project. A designated quick release lever allows to open the crimper jaws in any position
- PRECISE RATCHETING MECHANISM: The ratcheting function allows to secure a wire connector while you can insert the wires into the crimp. The wire connectors are crimped by squeezing the handle through a complete ratcheting cycle until the handle releases automatically.
Last update on 2023-03-16 / Affiliate links / Images from Amazon Product Advertising API
This product was presentation was made with AAWP plugin.