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WIRE REPAIR

WIRE REPAIR. Chapter 4. TROUBLESHOOTING STEPS. Confirm the Complaint Study the electrical schematic Locate and repair the fault Test the repair. Pg L84. WIRE REPAIR. Type of Repair required Ease of Access Type of conductor Size of wire Circuit requirements

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WIRE REPAIR

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  1. WIRE REPAIR Chapter 4

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

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

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

  5. AWG to METRIC Wire Sizes Page C87

  6. WIRE MARKINGS

  7. HEAT SINK When soldering electronics use heat sink

  8. Page L91 SOLDER JOINT

  9. “W” CRIMP Page L87

  10. Page L90 SOLDER LUG

  11. 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

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

  13. 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

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

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

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

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

  18. 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.

  19. TYPICAL PRINTED CIRCUIT BOARD

  20. That’s All folks!

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