SIR Wire Repair

Figure 32:

Figure 33:

TOOL REQUIRED
J 38125-A Terminal Repair Kit.

If any wire except the pigtail is damaged, the wire should he repaired by splicing in a new section of wire of the same gauge size (.5, .8, 1.0, etc.). The sealed splices and splice crimping tool from Terminal Repair Kit J 38125-A must be used for these repairs. The following wiring repair procedures must be used to ensure the integrity of the sealed splice application.

Step One: Open the Harness

If the harness is taped, remove the tape. To avoid wire insulation damage use a sewing "seam ripper" (available from sewing supply stores) to cut open the harness. The crimp and sealed splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one-to-one splice.

Step Two: Cut the Wire

Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 inch) away from other splices, harness branches, or connectors.

Step Three: Strip the Insulation

NOTICE: The following procedures must be followed in the order listed. If wire strands are damaged, the procedure must be repeated until a clean strip with all wire strands intact is obtained.

If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. To find the correct wire size, either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gauge.

If unsure about 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 (5/16 inch) 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.

Step Four: Select and Position the Splice Sleeve

Select the proper sealed splice sleeve according to wire size. The splice sleeves and tool nests are color coded (see following chart).

Using J 38125-A Splice Crimp Tool (Figure 32), position the splice sleeve in the proper color nest of the hand 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 (Figure 33). Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest.

Step Five: Insert Wires Into Splice Sleeve and Crimp

Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimp tool tightly until the crimper handles open when released (Figure 33). The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat "Step Four" and "Step Five" for opposite end of the splice.

Step Six: Shrink the Insulation Around the Splice

Using the heat torch, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing 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 (Figure 33).