Page 1993 of 2490
Insulation Stripper
The moving jaw has an adjuster wheel which has a series of holes in it. Turning the wheel and placing the cable in the
matching size hole will automatically adjust the jaw to the correct pressure. Note that some wiring harness(s) may have a
harder insulation and slight adjustment of the wheel may be needed to make a clean strip but exercise care not to damage
the wire.
Insulation Stripper
Page 1994 of 2490
By pressing the outer edges of the wiring harness cable length stop together the adjuster can be slid up or down the jaw.
This decreases or increases the length by which the wiring harn ess cable insulation will be stripped from the pre-terminated
wiring harness or wiring harness wire. The adjuster has a position indicator to align with a graduated scale and this sets the
correct length in millimet res, of insulation to be strippe d. The amount of insulation to be stripped is shown in the
Relationship Table.
The illustration shows the insulation stri pper tool and a wiring harness correctly gripped in the jaws. A wire cutter is
provided on the outer side of the fixed jaw.
Cable Correctly Grippe d in Stripper Blades
Crimping Pliers
Crimping Pliers
Page 1995 of 2490

The crimping pliers have a moving jaw and a stationary jaw, with three different sized crimping enclosures. Each of the
enclosures is identified by a red, blue or yellow coloured dot which correspon ds to the three colours of the pre-terminated
wiring harness(s) and butt splice connector colors.
List of Parts
DescriptionPart NumberQuantity
Wiring Harness Repair Kit 418-S0651
Pre-Terminated Wiring Harness(s)418-066 to 418-103
inclusive 10 each
Glue Lined Heat Shrink Pack – small diameter418-10425 per
pack
Glue Lined Heat Shrink Pack – larger diameter418-10510 per pack
Case Assembly Comprising – carry case, li d, inner lid, base, insert, trays foam
spacers418-1061
Butt Splice Connector – Red 418-10750 per pack
Butt Splice Connector – Blue 418-10850 per
pack
Butt Splice Connector – Yellow 418-10920 per pack
Extraction Tool Handle 418-1101
Extraction Tip Pack consists of 2 spare screws plus 418-S1111
Tip A418-1181
Tip B418-1191
Tip C418-1201
Tip D418-1211
Tip E418-1221
Tip F418-1231
Page 1996 of 2490

Items can be ordered from:
SPX United Kingdom Limited
Ironstone Way
Brixworth
Northants
NN6 9UD
United Kingdom
Telephone: +44 (0) 1327 704461
Fax: +44 (0) 1327 706632
Repair Methods
CAUTION: Several different types and sizes of terminal may be found in a single electrical connector
housing.
It is necessary to identify:
The conductor (wire) size of the affected wiring harness The electrical connector range from which the damaged wiring harness is to be removed The terminal type
Use of the approved diagnostic tool will greatly assist in th e quick identification of electrical connectors and faulty pin
terminal(s).
Reference can also be made to the vehicle Electrical Guides, he ld by Dealers, to identify wiring harness(s) and electrical
connector(s).
By using the Relationship Table, the wiring harness conductor (wire) size can be related to a suitable pre-terminated wiring
harness by the color of the insulation. Also , the correct length of insulation to be stripped from the wiring harness lead is
identified.
Relationship Table
Electrical Connector Terminal Extraction
Tip G418-1241
Tip H418-1251
Tip I418-1261
Tip J418-1271
Tip K418-1281
Sleeve Identification Pa ck – for Red insulation418-112500
Sleeve Identification Pack – for Blue insulation 418-113500
Sleeve Identification Pack – for Yellow insulation 418-114500
Instruction Manual JTP 5931
Crimping Pliers YRW5000101
Wire Stripping Tool 418-1171
CABLE RANGE SPLICE STRIP LENGTH
0.35 mm² to 1.50 mm²RED6.00 to 7.00 mm
1.00 mm² to 2.50 mm²BLUE6.00 to 7.00 mm
4.00 mm² to 6.00 mm²YELLOW9.00 to 9.50 mm
Page 1997 of 2490

It must be noted that some electrical connector(s) have anti-backout devices which prevent the terminals from being
removed from the electrical connector. Some examples of thes e are shown in following illustrations. The anti-backout device must be released before attempting to remove the terminal from the electrical connector. Some anti-backout devices
require a special tip to release the device and these have been included in the kit. Most can be released by carefully using a
suitable small screwdriver.
Various types of electrical connector have seals installed intern ally or externally to prevent moisture ingress. These normally
do not have to be removed but make sure that they are installed when the electrical connectors are connected.
The illustrations show examples of each tip used on different types of electrical connector(s). There are a large number of
different types of electrical connector us ed on vehicles therefore only one example using each tip is shown. Technicians
experience and judgement will dictate whic h type of tip should be used for those electrical connector(s) which are not
shown. Care should be exercised to av oid further damage when removing the te rminals from the electrical connector.
• NOTE: Examples of the extraction tips and anti-backout tips.
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