Splicing Copper Wire Using Crimp and Seal Splice Sleeves
^ Used on all types of insulation except tefzel and coaxial.^ Used for special requirements such as moisture sealing.
^ Crimp and seal splice sleeves are included in the J 38125 terminal repair kit.
^ If only wire insulation is damaged, find and correct cause of damage.
- If damage is minor, tape over wire.
- If damage is more extensive, replace faulty wire as follows:
1. Open harness
- If harness is taped, remove tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open harness (available from sewing supply stores).
- If harness has a black plastic conduit, pull out desired wires.
2. Cut wire
- Cut off as little wire as possible. Extra length may be needed to change location of a splice to assure that each splice is at least 40mm (1.5 in.) away from other splices, harness branches, or connectors.
Splicing Copper Wire Using Crimp And Seal Splice Sleeves:
3. Strip Insulation
- When replacing a wire, use a wire of equal or larger size than the original. Schematics show wire sizes in metric units. Use the following table to convert metric units to commercial (AWG) wire sizes (each AWG size is equal to or larger than the equivalent metric size).
- If a wire Size is not known, start with the largest opening of a wire stripper and work down until a clean strip of insulation is removed.
- If Wire is nicked or Cut, repeat procedure on new section of Wire. The two wire ends to be spliced should be of equal length.
Splicing Copper Wire Using Crimp And Seal Splice Sleeves:
4. Select proper splice sleeve according to wire size.
- Splice sleeves and tool nests are color coded; (use following table).
Splicing Copper Wire Using Crimp And Seal Splice Sleeves:
- Using the J 38125-8 splice crimp tool, position splice in the proper color nest so the crimp falls midway between the end of the barrel and the stop.
Splicing Copper Wire Using Crimp And Seal Splice Sleeves:
5. Insert wire into sleeve until it hits the barrel stop and close handles tightly until handles open when released.
- Repeat on opposite end of splice sleeve.
Splicing Copper Wire Using Crimp And Seal Splice Sleeves:
6. Using a heat torch, apply heat where barrel is crimped, and gradually move toward end of tubing.
- Tubing is completely shrunk when a small amount of sealant comes out of end of tubing.