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TM 9-4110-257-14
4-20.
WIRES, CABLES, AND HARNESSES TESTING, REPAIR, AND REPLACEMENT. - Continued
b. Repair. Repairs can be performed to replace terminal ends or to splice wire when cut.
WARNING
Solder and flux contain materials which are hazardous to health. Avoid breathing vapors or
fumes from soldering operations. Perform operations only in well ventilated areas. Wash
hands with soap and water after handling solder and flux. Wear thermal gloves and
protective goggles or face shield to protect against burns.
(1) Soldering Connections. Wire connections must be made mechanically sound before they are soldered; solder
alone does not provide sufficient strength to prevent breakage. Joining surfaces of connections to be soldered
must be clean and bright. Flux should be brushed onto the joint before soldering. Wires should always be heated
to the point at which the solder will melt completely and flow into all parts of the joint. Excessive build up of
solder "gobs" on the joint should be avoided or removed.
(2) Insulating Joints. The preferred method of insulating electrical joints is by the use of heat-shrink tubing. To
apply, cut a piece of heat-shrink tubing of suitable diameter to a length of 1 inch (2.5 cm) for covering joints at
terminals or connectors, or to a length about 1/2 inch (1.3 cm) longer than the joint to be insulated. Slide the
tubing over the wire before making the joint. After the joint is made, slide the tubing so that it covers the joint and
shrink in place with moderate heat.
(3) Splicing Wire. To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced. Solder and apply insulation as described above.
(4) Crimping Terminals. To install a terminal on the end of a wire, strip 1/4-1/2 inch (0.6-1.3 cm) of insulation from
the end of the wire and apply a one inch (2.4 cm) piece of heat shrink tubing (if the terminals are of the
uninsulated type). Insert wire-end into the shank of the terminal. Crimp the shank and install heat-shrink tubing, if
necessary.
NOTE
Preferred repair methods consist of replacing wires, terminals, connectors, etc., rather than
splicing wires, bending ends to form terminals, and other make shift procedures, although
the latter may be appropriate for emergency field repairs.
(5) Wire Size and Length. Determine the proper size and length of the wire, or terminal, or connector to be used for
replacement by referring to the wire list (table 4-4), and to the wiring diagram (fig. 1-4).
4-50
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