 WARNING!
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Risks of reparing wiring harness.
No repair to ORC circuits.
| • | No repair of twisted or shielded circuits in looms.
| | • | No repair to looms which have been electrically or environmentally damaged; meaning burnt, oil contamination, water ingress etc.
| | • | Maximum of 5 repairs to loom circuits.
| | • | Up to 10 pins per connector
| | • | Repairs made by joining pre-terminated leads to existing loom using butt splice connectors and heat shrink carried out using commercially available strippers and crimping pliers.
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Review harness repair requirements
| 1. | It is recommended that the following types of crimping pliers (1) are used.
| | | 2. | Components required to perform the basic type of repairs are as follows:
| | | 3. | Pre-terminated leads (of different sizes and types).
| | | 4. | Butt splice connectors (different sizes).
| | | 5. | Heat shrink sleeve (different sizes).
| | | 6. | Tape (type as required).
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| | | Care Point: | Butt splice connectors are supplied with red, blue or yellow coverings which indicate the applicable size.
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| | | 7. | Choose the butt splice connector (A, B or C).
APPLICABLE
| SPLICE
| STRIP LENGTH
| HEAT shrink tube
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Up to 1.00 mm2
| RED ©)
| 6.00 to 7.00 mm
| RBK-ILS-125-NR1
| Up to 1.00 mm2 to 2.00 mm2
| BLUE (B)
| 6.00 to 7.00 mm
| RBK-ILS-125-NR2
| Up to 3.00 mm2 to 6.00 mm2
| YELLOW (A)
| 9.00 to 9.50 mm
| RBK-ILS-125-NR3
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| | | Care Point: | Make sure that the window indentation in the butt connector is resting over the guide bar on the lower jaw.
The butt connector has to match the aperture and the butt splice connector colour.
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| | | 8. | Place the selected butt splice connector in the crimping tool (1).
| | | 9. | Inset the stripped pre-terminated lead or wire (3) into the butt connector and make sure that the wire (3) is against the wire stop.
| | | | | Care Point: | When the handles are completely closed the butt connector will be freed from the tool as the handles are released.
If the handles have not been completely closed, the jaws will hold the butt connector and it cannot be removed from the tool until the crimp is fully made by closing the handles completely.
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| | | 10. | Close the grip firmly, crimping the lead to the butt connector.
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| | | Care Point: | If more than one splice is needed, the butt connections must not be crimped to the harness at the same distance from the connector. Splices/joints should be staggered (A1 - A3) to prevent a bulk of splices in the same area of the harness.
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| | | 11. | Make sure that the harness cable has been squarely cut and the correct length of insulation removed.
| | | | | Care Point: | It is preferable to cover butt splices with heat shrink sleeve. Glue lined heat shrink sleeve is essential where the splice/joint is located in a designated wet area. Where heat shrink is used, the correct diameter sleeve must be placed onto the affected harness cable or pre-terminated lead before crimping the butt splice to the harness.
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| | | 12. | Cover butt splices with heat shrink sleeve.
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| | | Care Point: | Make sure that the cable harness wire is against the stop in the butt splice.
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| | | 13. | Place the harness cable (4) into the butt splice with the splice window over the guide bar.
| | | 14. | Crimp the butt splice connector to the harness.
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| 15. | Gently pull the cables (3, 4) either side of the butt splice to make sure that a secure joint has been made.
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