WIRE REPAIR Chapter 4

TROUBLESHOOTING STEPS Confirm the Complaint Study the electrical schematic Locate and repair the fault Test the repair

WIRE REPAIR Pg L84 Type of Repair required Ease of Access Type of conductor Size of wire Circuit requirements Manufacturer's recommendations

WIRE SIZE Less resistance in stranded wire Larger gauge number means Page C85-87 Less resistance in stranded wire Larger gauge number means smaller wire Copper wire is flexible and inexpensive

AWG to METRIC Wire Sizes Page C87

WIRE MARKINGS

HEAT SINK When soldering electronics use heat sink

Page L91 SOLDER JOINT

“W” CRIMP Page L87

Page L90 SOLDER LUG

FUSIBLE LINK REPAIR Page L93 1. Remove damaged fusible link 2. Prepare cut wire end for new fusible link 3. Install crimp style lug 4. Install new fusible link by crimping link to lug 5. Solder link to lug also 6. Apply Heat Shrink to connection

HEAT SHRINK Cut Wire Insulation and Strip off Install Crimp terminal Prepare Heat Shrink Install Heat Shrink Apply heat to Heat Shrink tube

SHEILDED CABLE REPAIR Page L93 Cut out damaged section of wire Remove 1 inch out outer insulation Unwrap Mylar tape Splice Cut wires Wrap Mylar tape Splice Drain Wire

SOLDERING OF TERMINAL Strip Wire as normal Form wire terminal around insulation Form wire strands on terminal Solder Strands to terminal

TERMINAL TYPES Page L85 Crimp Style Non-crimp Style Different wire gauge sizes. Color codes Quality

CONNECTORS Page C88 & L98 TYPES ALL USE SOME TYPE OF TERMINAL LOCK MOLDED MUTIPLE WIRE BULKHEAD WEATHER-PACK METRI-PACK ALL USE SOME TYPE OF TERMINAL LOCK Page C88 & L98

TERMINAL TOOLS Page C89 & L97 Bullet Style Spade Style Must use to unlock terminal locks Use push-to-seat and pull-to-seat

PRINTED CIRCUIT BOARDS Page C91 Used on Instrument Panels Made of thin phenolic or fiberglass board Conductive metal is etched to make circuits. Must use care when servicing printed circuit board. Tears, oil off fingers, etc.

TYPICAL PRINTED CIRCUIT BOARD

That’s All folks!