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KL-0080-1.. /-2..
Wiring Harness Repair Kit
GEDORE Automotive GmbH
Breslauer Straße 41
78166 - Donaueschingen
Postfach 1329
78154 Donaueschingen - GERMANY
+49 (0) 771 / 8 32 23-0
+49 (0) 771 / 8 32 23-90
info.gam@gedore.com
www.gedore-automotive.com
Worldwide GEDORE service centers and offices are listed on the Internet at: www.gedore.com
www.gedore-automotive.com
www.gedore-automotive.com
Operating instructions
EN
12/2023
KL-0080-1K_-2K(EN231138).indd
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Summary of Contents for Gedore KL-0080-1 Series
- Page 1 78166 - Donaueschingen Postfach 1329 78154 Donaueschingen - GERMANY +49 (0) 771 / 8 32 23-0 +49 (0) 771 / 8 32 23-90 www.gedore-automotive.com www.gedore-automotive.com 12/2023 info.gam@gedore.com www.gedore-automotive.com KL-0080-1K_-2K(EN231138).indd Worldwide GEDORE service centers and offices are listed on the Internet at: www.gedore.com...
- Page 2 Instructions for use and safety are not binding. They never substitute for any legal or trade association regulations. We do not accept any liability for printing errors. Any reproduction, in whole or in part, requires the prior written consent of GEDORE Automotive GmbH. All rights reserved worldwide.
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Page 3: Table Of Contents
2.1 Wiring harness repair kits + supplements ..........................6 2.2 Scope of delivery / spare parts overview ........................... 9 2.3 Component overview ................................... 16 3. USE - QUICK REFERENCE ....................................4. EXAMPLE OF USE ......................................... © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd... -
Page 4: Read And Understand For Your Safety
GEDORE Automotive genuine spare parts and accessories! may only be used in the way described in these operating instructions! Any other use can result in DEATH or SEVERE INJURIES ! 1.4 Reasonably foreseeable misuse... -
Page 5: Labelling Of The Warnings
Always work with the repair tool in accordance with the basic regulations on work safety, accident prevention and environmental protection! Always use the repair tool as intended. GEDORE Automotive GmbH accepts no liability or warranty or guarantee claims for injuries and damage resulting from improper use or failure to observe the safety regulations. -
Page 6: Product Description
Defective, oxidised, or provisionally repaired wire/terminal connections can lead to serious system failures on the vehicle. Especially for this purpose, the GEDORE wiring harness repair kits for professionals offer a comprehensive and robust range for the quick and professional repair of almost all common cable/plug connections on the vehicle. - Page 7 Operating instructions (Translation of the operating instructions) KL-0080-10 K Wiring harness repair kit KL-0080-104 K Contact assortment case KL-0080-1090-5 GEDORE i-BOXX Rack © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 8 Scope of delivery: See Chapter 2.2 - Scope of delivery / overview of the single parts... Necessary accessories KL-0080-1011 - Handle crimping tool KL-0080-1031 - Handle crimping tool KL-0080-102 - Wire stripper © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
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Page 9: Scope Of Delivery / Spare Parts Overview
Operating instructions (Translation of the operating instructions) 2.2 Scope of delivery / overview of the single parts Crimping tool Crimping tool Item Item © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd... - Page 10 Operating instructions (Translation of the operating instructions) Wire stripper Wire stripper Item Item Ejection tool Ejection tool Item Item 10 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 11 0,2 - 0,35 mm 1,5 - 2,5 mm 0,5 - 1,0 mm KL-0080-1046 KL-0080-1047 KL-0080-1048 0,2 - 0,35 mm 1,5 - 2,5 mm 0,5 - 1,0 mm KL-0080-1050 KL-0080-1051 KL-0080-1052 - 11 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 12 0,35 - 0,5 mm 0,35 - 0,5 mm 1,5 - 2,5 mm 1,5 - 2,5 mm 0,75 - 1,5 mm 0,75 - 1,5 mm KL-0080-1067 KL-0080-1068 KL-0080-1069 KL-0080-1070 KL-0080-1071 KL-0080-1072 12 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 13 0,5 -1,3 mm 0,5 -1,3 mm KL-0080-1078 KL-0080-1079 KL-0080-1080 KL-0080-1081 Crimping contacts: Micro 64 Crimping contacts: Micro 64 Item Item Micro 64 Micro 64 0,35 mm 0,5-0,8 mm KL-0080-1211 KL-0080-1212 - 13 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 14 Item Item MCP 1.5K MCP 1.5K 0,2-0,35 mm 0,5-1,0 mm KL-0080-1312 KL-0080-1313 MCP 1.5K ELA MCP 1.5K ELA MCP 1.5K ELA 0,2-0,35 mm 0,5-1,0 mm 1,0-1,5 mm KL-0080-1314 KL-0080-1315 KL-0080-1316 14 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 15 KL-0080-1290-1 - Foam insert KL-0080-1290-2 - Plastic box 47x40mm KL-4990-9274 - Plastic case KL-0080-1090-5 - GEDORE i-BOXX Rack 1100 L - GEDORE L-BOXX 136 1101 L - GEDORE i-BOXX 72 Small parts case - 15 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
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Page 16: Component Overview
1. Loosen the knurled nut by hand 2. Insert the required ejector blade Handle piece 3. Tighten the knurled nut again hand-tight Basic tool for holding the different ejector blades 16 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd... - Page 17 3. Now take the 1st blade out laterally and replace it 4. Relieve the stripper, remove changing aid 5. Repeat this process for the 2nd blade Changing aid 2. Blade 1. Blade Changing aid - 17 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 18 Handle piece Basic tool for holding the different crimping attachments Interlock guarantees complete crimping and the crimper can only be opened again after it had been fully compressed once 18 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
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Page 19: Use - Quick Reference
Properly insert the wire at the female or male contact and crimp with the crimping tool. Re-insert and lock the female or male contact on the wire terminal or housing. - 19 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd... - Page 20 3: Use the wire stripper [B] and cut the wire properly and straightly. 3. Use the cutter and cut the wire at the wire stripper [B] properly and straightly. Result on the wire 20 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 21 6. Strip the insulation from the wire using the wire stripper [B]. Insert the wire on the stripper until it is in contact with the positioner. Result on the wire - 21 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 22 [A] and secure it with the two locking bolts. If necessary, the handle [ A1 ] can also be opened via the emergency release, as described in chapter 2.3. 22 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 23 [A..], depending on the wire cross-section (mm²). Folding positioners facilitate the insertion of particularly small female or male contacts. Typical application: MQS, MCP, JPT, Superseal, ... (with and without ELA) - 23 © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
- Page 24 11. Insert the female or male contact in the correct position on the terminal or housing until the primary lock engages. Lock any possible secondary locks on the terminal or housing. Result on the wire Primary lock Secondary lock 24 - © Copyright by GEDORE Automotive GmbH, Germany KL-0080-1K_-2K(EN231138).indd...
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