SIR Wire Repair
Crimp And Seal Splice Table:
Tools Required
J 38125-A Terminal Repair Kit.
IMPORTANT: Refer to Wiring Repairs in Wiring Systems in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from J 38125-A Terminal Repair Kit. Use the following wiring repair procedures to ensure the integrity of the sealed splice.
IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the Harness.
^ Open the harness by removing any tape.
^ To avoid wire insulation damage, use a sewing seam ripper (available from sewing supply stores) to cut open the harness.
^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial.
^ Do not use the crimp and sealed splice sleeve to form a splice with more than two wires coming together.
2. Cut the Wire.
^ Cut as little wire off the harness as possible. You may need the extra length of wire to change the location of a splice.
^ Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.
3. Strip the Insulation.
^ When adding a length of wire to the existing harness, be certain to use the same size wire as the original wire.
^ To find the correct wire size do one of the following:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gauge.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.
^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
^ Be careful to avoid nicking or cutting any of the strands. Check the stripped wire for nicks or cut strands.
^ If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select and Position the Splice Sleeve.
^ Select the proper sealed splice sleeve according to wire size.
^ See the following table for color coding of the splice sleeves, and the crimp tool nests.
Description:
^ Use the Splice Crimp Tool from J 38125-A Terminal Repair Kit to position the splice sleeve in the proper color nest of the Splice Crimp Tool.
^ Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) to prevent the wire (1) from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest.
5. Insert wires into splice sleeve and crimp.
^ Insert the wire into the splice sleeve barrel until it hits the barrel stop.
^ Close the handles of the crimp tool tightly until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
6. Shrink the insulation around the splice.
^ Using the heat torch, apply beat to the crimped area of the barrel.
^ Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.