Mercedes-Benz ML320. Manual — part 570

Fig. 373: Aligning Single-Strand Insulation With Line

5. Select crimping set (1, 2)

for crimp pliers (3)

.

Select crimping set(1, 2)

according to the crimp contact type and single-strand insulation used. See

table.

6. Insert crimping set (1, 2)

into crimp pliers (3)

.

Fig. 374: Identifying Crimping Kit And Crimp Pliers

7.

1. Screw positioner onto crimp pliers

(arrow).

2. Fit positioner with quick-release fitting on crimp pliers

.

Positioners with screw fitting can be exchanged for positioners with quick-release fitting.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

Fig. 375: Locating Screw Positioner Onto Crimp Pliers

8. Insert crimp contact (1) all the way into crimp nest (2) and into positioner (3) of die sets (4, 5).

Select crimp nest (2) according to cable cross section. Crimp contact (1) must be vertical between the

die sets (4, 5).

Fig. 376: Identifying Crimp Contact

9. Close crimp pliers until crimp contact (2) is fixed in crimp nest (3).

Make sure that the crimp contact (2) is inserted correctly in the positioner (5).

Do not yet deform the crimp contact (2), as otherwise the line (1) cannot be inserted correctly into the

crimp contact (2).

10. Guide cable (1) with single-strand insulation (4) into inserted crimp contact (2) (arrow).

Fig. 377: Identifying Guide Cable And Crimp Contact

11. Squeeze crimp pliers

until stop is reached remove crimped connection.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

The crimp pliers

must be squeezed until stop is reached before they will open again.

Fig. 378: Squeezing Crimp Pliers

12. Check crimped connection for deformation and ensure that the wires fill the crimp tab correctly (cross-

section of enclosed wires).

Correct crimped connection (A):

The strands of the cable are evenly enclosed. The crimp tab is evenly shaped.

Incorrect crimped connections (B, C, D)

The crimp shackle has the wrong cross-section. The crimp tab is not filled properly. Individual wire
strands are outside the crimp shackle. The crimp tab is too full. The crimp claws touch the bottom of the
crimped fitting. The crimp tab is too full. The crimp tab is deformed incorrectly and therefore damaged.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

Fig. 379: Cross-Section Of Enclosed Wires - Correct And Incorrect

13. Check crimped connection to ensure that all wires are enclosed correctly.

Insulation and single-strand insulation must be positioned in the center and enclosed completely by the

crimp tab and they must be able to take up tensile force.

Single-strand insulation must not be pinched otherwise galvanic corrosion can occur if the connection

is penetrated by water.

Correct crimped connection (A):

Wire strands are enclosed correctly by the shackle. Insulation and single-strand insulation are enclosed
correctly by the large tab. All parts can withstand the required tensile force.

Incorrect crimped connections (B, C):

The single-strand insulation is not enclosed by the shackle because it was inserted incorrectly during the
crimping procedure.

The crimped area of the single-strand insulation is damaged because the wrong die set or wrong single-
strand insulation was used.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me