2.5 mm²

LITEALUM

2236734-1

000 998 910

144-94287

4.0 mm²

LITEALUM

2236736-1

000 998 911

144-94287

6.0 mm²

The following LITEALUM terminals are processed using the repair kit:

LITEALUM

2236738-1

000 998 912

144-94287

Corresponding terminal material, heat-shrink tubing and aluminium and copper wires are not part of the
scope of delivery of the repair kit. Terminal sets consisting of the terminal and the corresponding heat-shrink
tube can be ordered under the following Volkswagen part numbers:

10/22
©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

Stripping length of the
conductor

TE Application
Specification

2.5 mm²

5.8 +/- 0.3 mm

144-94287

4.0 mm²

6.2 +/- 0.3 mm

144-94287

6.0 mm²

The following aluminium and copper wires are stripped using the repair kit:

6.6 +/- 0.3 mm

144-94287

11/22
©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

6 Description of Repair Kit
The basic hand tool essentially consists of a closed frame to house the SDE DIE SETS, two moveable handles, a ratchet mechanism, two fixing screws for the use of the dies, a locking bolt for opening the frame, and
a positioner with locking lever.
The LITEALUM SDE DIE SETS are equipped with a crimping profile and can be quickly inserted into the
basic hand tool without the use of tools.

5

1
2

6

4

7
3

Fig. 1: Hand tool components

1
2
3
4

Frame
Fixing screws
Release screw (emergency)
Locking pin

8

Fig. 2: Hand tool components

5 Die
6 Adjustor
7 Positioner
8 Knurled screw

12/22
©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

The stripping tool can be used to strip aluminium and copper wires with the cross-sections 2.5 /4.0 /6.0 mm².
The stripping tool is fitted with a positioner that indicates the correct strip lengths for the respective crosssectional ranges.

1

3

2

Fig. 3: Stripping tool

1 Cutting function
2 Positioner
2 Stripping blade for 2.5 /4.0 /6.0 aluminium and copper wire

Fig. 4: Positioner for correct strip length

Fig. 5: Stripping positions

13/22
©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

7 Stripping process

Insert cable up to stop point on positioner.

Close tool until it automatically opens again.

Fig. 6: Insert cable

Fig. 7: Close tool

Remove properly stripped wire.

Fig. 8: Strip wire

Fig. 9: Stripped wire

14/22
©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

8 Die change
Based on the wire cross-section and the relevant processing specification, determine the right SDE DIE SET
for the terminal to be processed. Proceed as follows to change the die:

Close the handles until the ratchet of the ratchet mechanism releases and allows you to fully open
the handles.

Note: The die parts must be assembled so that the coloured points on both components are on the same
side. The anvil cross-sectional marking must be in the direction of the fixing screws during assembly. This is
the only way to prevent damage from occurring to the dies.

Fig. 10: SDE DIE SET 2.5 front view

Fig. 11: SDE DIE SET 2.5 rear view

Note: The ratchet mechanism of the hand tool makes audible clicks when you close the handles. It releases after the last click.

Pull out locking pin (1) to open frame. Turn screw (2/3) anticlockwise, pull out and fasten screw
with a further anticlockwise turn.

2

3
1

Fig. 12: Open frame

15/22
©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

Remove upper and lower die parts to adapt different die set as required.

Turn screw (2/3) clockwise, release from fixing, insert and tighten as far as it will go. Insert locking
pin (1) again to close frame.
2

3
1

Fig. 13: Remove insert

Fig. 14: Close frame

Affix positioner including adjuster to the back of the tool by tightening the knurled screw.

Fig. 15: Back of the tool

Fig. 16: Positioner including adjustor and knurled screw

Fig. 17: Back of tool with assembled positioner

16/22
©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

9 Crimping procedure
Based on the wire cross-section and the relevant processing specification, determine the right SDE DIE SET
for the terminal to be processed. Proceed as follows to crimp the terminal:

Close the handles until the ratchet of the ratchet mechanism releases and allows you to fully open
the handles.

Note: The ratchet mechanism of the hand tool makes audible clicks when you close the handles. It releases after the last click.

Insert terminal into positioner and align with the recess of the adjustor.

Move locking lever of the positioner to the left in order to securely fix terminal.

Fig. 18: Insert terminal into positioner

Fig. 19: Terminal fastened

Now feed the wire, stripped according to the application specification, into the terminal crimp barrel
up to the stop.

Hold the wire against the stop and press the handles together until the ratchet mechanism releases. Let the crimping tool open fully.

Move locking lever of the positioner to the right in order to release terminal locking mechanism. Pull
out locking pin to open frame.

17/22
©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

Fig. 20: Insert cable

Fig. 21: Remove terminal

Remove terminal and perform crimping operation again for the terminal's other crimping zone.

Check the crimp height of the crimped terminal. Refer to the information in the TE Connectivity
processing specification 114-94287.

18/22
©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

10 Early Release
The hand tool can be released in case of inaccurate execution of the crimp process at any time.

Press the handles of the hand tool together slightly.

Turn the unlocking screw (1) anticlockwise using a suitable screwdriver.

The tool opens on its own.

1

Fig. 22: Release unlocking screw

19/22
©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

11 Maintenance and Servicing
11.1 Daily maintenance
The following daily maintenance tasks should be performed by the responsible operator:

Using a soft, clean brush or a lint-free cloth, remove dirt, dust, moisture and other residue from the tool.
Do not use any hard or abrasive tools or materials that could damage the tool.

Ensure that all fixing pins are firmly seated.

Coat all pins, pivot points and bearing surfaces with a film of sewing machine oil. Do not lubricate excessively.

If the individual components of the repair kit are not required, ensure that they are clean and dry and
then store in the tool case provided.

11.2 Periodic inspection

The repair kit should be inspected periodically by suitably qualified staff according to the level of use,
and the inspections should be documented.

Ensure that all fixing pins are firmly seated.

Close the handles until the ratchet mechanism releases and the handles open. Ensure that the tool handles open freely.

Check the stripping tool and hand tool for wear and damage, particularly on the stripping blade, crimping
nest areas and pivot points.

20/22
©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

12 Disposal
The components of the repair kit must be returned to the address stated in Section 12.1 "Customer support
address" to ensure environmentally sound disposal.

21/22
©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

13 Appendix
13.1 Customer support address
TE Connectivity
c/o Schenck Technologie- und Industriepark GmbH
Landwehrstr. 55/Gebäude 83
64293 Darmstadt
Field Service [email protected]
GATD Customer Service Hotline: +49-6151-607-1518

22/22
©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