VAS 631 001
Operating Instructions
VW LITEALUM Repair Kit
Operating manual No.:
PN operating manual:
Language:

411-18579-1, Rev. A1
744017-8
en (translation of the German original version)

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VW LITEALUM Repair Kit

The information provided is for the purpose of product descriptions only. Users must carry out their own
assessments and tests. It should be noted that our products are subject to natural wear and ageing processes.

© TE Connectivity Ltd. All right reserved, including applications for industrial property rights.
We reserve all rights of disposal such as copying and transfer rights.

The front page show a sample configuration.
The supplied product may vary from that shown.

The original operating instructions were written in German.

2/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

1

General Specifications............................................................................................... 4

1.1

Copyrights, industrial property rights...................................................................................................... 4

2

Using these Operating Instructions............................................................................ 5

2.1

Abbreviations used ................................................................................................................................. 5

3

General Safety Instructions ....................................................................................... 6

3.1

Intended use........................................................................................................................................... 6

3.2

Improper use .......................................................................................................................................... 7

3.3

Reasonably foreseeable misuse ............................................................................................................ 7

3.4

Warnings in these instructions ............................................................................................................... 7
3.4.1

General information .............................................................................................................. 7

3.4.2

When working with the repair kit ........................................................................................... 7

3.4.3

Disposal ................................................................................................................................ 8

3.5

User obligations...................................................................................................................................... 8

4

Scope of Delivery ...................................................................................................... 9

5

Terminals and Conductors to be used ..................................................................... 10

6

Description of Repair Kit .......................................................................................... 12

7

Stripping process ..................................................................................................... 14

8

Die change .............................................................................................................. 15

9

Crimping procedure ................................................................................................. 17

10

Early Release .......................................................................................................... 19

11

Maintenance and Servicing ..................................................................................... 20

11.1

Daily maintenance ................................................................................................................................ 20

11.2

Periodic inspection ............................................................................................................................... 20

12

Disposal................................................................................................................... 21

13

Appendix ................................................................................................................. 22

13.1

Customer support address ................................................................................................................... 22
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©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

1 General Specifications
1.1 Copyrights, industrial property rights

The copyright to these operating instructions is held by TE Connectivity Ltd.
These operating instructions are only intended for users of the VW LITEALUM Repair Kit,
TE PN 6-1579010-3.

The relevant supplementary operating instructions include descriptions, technical drawings, specifications and instructions, no part of which may be reproduced, circulated, disclosed or used for the purpose
of competition without permission.

Should third parties endeavour to gain access to these operating instructions, the same fairness is expected from you as you would expect from your customers in such cases.

All rights reserved in particular including the granting of patents or other registrations. Subject to
technical changes.

4/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

2 Using these Operating Instructions

These operating instructions contain important information about using the repair kit safely and properly.

Read these instructions in full, in particular section 3 "General Safety Instructions", before working with
the repair kit.

TE Connectivity Ltd. accepts no liability for any loss or damage attributed to failure to follow the operating instructions.

These operating instructions must be supplemented by the repair kit user with instructions based on
existing national regulations for the prevention of accidents and environmental protection.

The generally applicable, statutory and other binding regulations of European and national law as well as
the regulations for the prevention of accidents and environmental protection applicable in the country of
use must also be observed.

2.1 Abbreviations used
Abbreviation

Meaning

PN

Part Number

RoHS

Restriction of (the use of certain) hazardous substances;

5/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

3 General Safety Instructions
The repair kit has been manufactured in accordance with the generally accepted codes of practice. Nonetheless, there is a risk of personal injury and material damage if the following general safety instructions and the
warnings preceding the individual operating instructions are not followed.

Read these instructions carefully and in full before working with the repair kit.

Keep these instructions in a place where they are accessible to all users at all times.

These operating instructions must accompany the repair kit if it is passed on to a third party.

RoHS information
Information on the presence and location of substances subject to RoHS guidelines (Restriction on Hazardous Substances) can be found on the following website:

http://www.tycoelectronics.com/customersupport/rohssupportcenter/

Select "Find Compliance Status…" on the website and enter the appropriate part number.

3.1 Intended use
The repair kit is used for stripping aluminium and copper wires with the cross-sections 2.5 /4.0/ 6.0 mm² and
crimping LITEALUM butt splice according to TE processing specification 114-94287.
The repair kit may only be used for repair purposes or for making samples, not for series production.

The repair kit is not a product in the sense of the EU Machinery Directive 2006/42/EC.

Intended use also includes reading and understanding the entire contents of this manual, in particular section 3"General Safety Instructions".
Notification regarding use:

Cumulative trauma complaints may result from prolonged use of hand tools. TE Connectivity hand
tools are intended for occasional use with low part counts. TE Connectivity offers a wide selection
of tools to meet increased demand or for production.

6/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

3.2 Improper use
Use of the repair kit for any other purpose than that described in Section 3.1 "Intended use" is considered
improper use.

3.3 Reasonably foreseeable misuse
An attempt to work with terminals other than those specified in Section 5 constitutes reasonably foreseeable
misuse. Furthermore, the repair kit may only be used for its intended purpose (Section 3.1 "Intended use").
Work with the repair kit must only be carried out by instructed persons or specialists.
A specialist can assess the work assigned to him, recognise potential dangers and take appropriate safety
measures based on his technical training, knowledge and experience as well as being familiar with the pertinent regulations. A specialist must comply with the relevant technical regulations.

3.4 Warnings in these instructions
3.4.1 General information

Observe the regulations for the prevention of accidents and environmental protection in the country
of use and at the workplace.

Only use the repair kit when it is in technically perfect condition.

Inspect the repair kit for any visible defects, such as missing components or parts or components in
poor condition.

The repair kit must not be altered or modified in any way and/or parts replaced with unsuitable
components.

Only use the repair kit for the applications indicated in these operating instructions.

Persons using the repair kit must not be under the influence of alcohol, drugs or medicines liable to
influence the ability to react.

Prior to use, ensure that all components belonging to the repair kit are present and in a perfect
condition. If in doubt, do not use the repair kit or its components.

If there are any visible defects or damage or if the repair kit no longer functions properly, the repair
kit must be sent in.

The warranty applies exclusively to the configuration provided.
The warranty is voided in the event of use other than as intended or improper use.

3.4.2 When working with the repair kit
Only instructed personnel may work with the repair kit within the scope of the intended purpose.

7/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

3.4.3 Disposal
Dispose of the repair kit in compliance with the environmental rules described in Section 11 "Disposal“.

3.5 User obligations
The user of the repair kit from TE Connectivity Ltd. must train their personnel on the following matters:

Following and using the operating instructions and observing statutory provisions.

Intended use of the repair kit.

8/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

4 Scope of Delivery
The scope of delivery comprises the following:

1 CS33-SDE BASIC HAND TOOL

TE PN 3-1579000-5

1 SDE DIE SET LITEALUM BUTT SPLICE 2.5 mm²

TE PN 2-1579017-1

1 SDE DIE SET LITEALUM BUTT SPLICE 4.0 mm²

TE PN 2-1579017-2

1 SDE DIE SET LITEALUM BUTT SPLICE 6.0 mm²

TE PN 2-1579017-3

1 stripping tool

TE PN 6-1579002-2

1 tool case with accessories

TE PN 8-1579010-3

1 operating manual

TE PN 744017-8

9/22
©2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

Operating Instructions
744017-8
Rev A

VW LITEALUM Repair Kit

5 Terminals and Conductors to be used

Terminal

TE PN terminal
set

VW PN terminal
set

TE Application
Specification