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Elecktric
Cable repair
The following section describes the components and tools involved in cable repairs.
This section is sub-divided as follows:
Terminals
There are several designs of terminals, such as blades, bullet terminal and timer, please refer to
Terminals and crimping tools for the most common types. A general description of terminals is
given in this manual.
Construction
Mating section, crimping section and insulation strain relief
Most terminals consist of three sections:
Mating section (1), ensures electrical contact between the terminals.
Crimping section (2) is the electrical joint between the stripped section of the conductor (copper
conductor) and the terminal.
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Insulation strain relief (3), relieves the crimping section from mechanical stress. The insulation
strain relief is placed over the insulating sheath of the conductor. This is normally found on
terminals of the open, un-insulated type.
The crimping section of the terminal and the insulation strain relief are formed on the terminal by
the crimping tool at the same time. It is very important that the crimping process is correctly done,
please refer to Crimping tools, terminals and butt splices.
1. Mating section
2. Crimping section
3. Insulation strain relief
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The open type of terminal has a U-shaped neck in which the conductor can be put.
Strain relief is normally found on this type of terminal
Size
The size of a terminal either refers to the conductor area which the terminal is intended for, or the
size of the mating section between pin and terminal.
The size of the mating section is specified as the width or diameter of the blade section and the
receptacle.
The designation for a terminal is written with the size first, such as 2.8 blade terminal.
For eyelet terminals, it is the diameter of the hole which is the size. The size of the hole should suit
the screw which the terminal will be fixed to.
Size of terminals
1. Conductor area
2. Size, mating section
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It is important that the lock tongue is correctly angled outwards, so that the terminal seats
securely in the insulator.
Lock tongue
In some cases, there is a secondary locking device located on the insulator to give further security
in retaining the terminals, please refer to Insulators.
Both primary and secondary locking devices must be opened when the terminal is changed.
Please refer to Cable repair, example for the procedure for dis-assembling terminals.
Embossing
Some blade terminals and blade terminal receptacles can be provided with an embossed dimple.
The function of the dimple is to hold the mating sections of the terminals together, through
mechanical locking between the blade and the receptacle.
Receptacles with a dimple, but without a lock tongue, are intended to connect individual
conductors together, without an insulator.
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Insulators
General
When the blade and receptacle insulators are connected together, they are referred to as
connector halves.
The task of the insulator is to protect the terminal from unwanted contact and environmental
action and, in most cases, ensure that the correct terminals are connected together and to ensure
that the connector halves remain together.
An insulator for a blade is referred to as a blade insulator, and an insulator for a terminal is
referred to as a terminal insulator.
Coding
The connector halves are frequently coded to ensure that they only fit each other, to ensure that
the correct conductors are linked together at each joint. This can be done through coloration and
through mechanical coding.
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1. Active locking means that the lock must be actively released before the connector halves
can be divided.
2. Passive locking means that the connector halves must be pulled apart with a certain
amount of force.
When connector halves are divided, blade and receptacle insulators, the locking device must be
freed.
1. Contact side
2. Conductor side
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Each cavity is numbered, and this number (pin number) is found on the wiring diagram as the
position number.
Example: designation SW3 means position 3 in connector SW.
In some insulators, there are cavity openings which are only intended to be used as disassembly
grooves. Cavity openings are found with up to four disassembly grooves.
1. Cavity
2. Position number
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The terminals are retained inside the insulator by various kinds of locking device, to prevent the
terminals from being pressed out backwards during connection.
The locking system can consist of primary locking or secondary locking devices
Primary locking: Primary locking devices are generally installed on the terminal, please refer to
Terminals for a more detailed description. In exceptional cases, primary locking can be provided on
the insulator.
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Seals are used in places where the insulators are exposed to corrosive environments, which means
that there is a risk of water ingress into the insulator cavities.
The rubber-based seals prevent corrosion and maintain their sealing properties even when
subjected to strong vibration and temperature cycling.
The seals are crimped around the conductor by the insulation strain relief, and seal against the
cavity in the insulator.
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Seal
If there is a hole in the insulation strain relief, a seal should be used.
Plugs
Plugs are used to block empty (unpopulated) cavities in a moisture-proof insulator.
The plug should be inserted to its end position, or if there is no end position, about 3-5 millimeter.
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A plug is more or less the same as a seal, but without a hole for the conductor.
Plugs are found in various colours and sizes. Please refer to Terminals and crimping tools, to see
which seal fits where.
Plug
Butt splices
Butt splices have the function of mechanically joining conductor ends together, in the same way as
terminals. The difference is that it is not possible to undo the joint made by the butt splice. Butt
splices are crimped onto the end of the conductor, please refer to Cable repair, example for the
procedure.
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Butt splice
A butt splice consists of two sections:
Crimped section (1), the electrical link with the stripped section of the conductor (copper cable).
Centre stop (2), counterhold for the stripped conductors to rest on.
An insulated butt splice also has an insulating sheath (3) which protects the butt splice from
unwanted electrical contact. The sheath is shrunk onto the conductor insulation by means of a hot
air gun.
The crimped section of the butt splice is formed in the press tool. It is very important that crimping
is correctly done, please refer to Crimping tools, terminals and butt splices.
Butt splice
1. Crimped section
2. Centre stop
3. Insulating sheath
No more than two conductors can be connected to each end of a butt splice.
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Insulator
Terminal
Lock tongue
Disassembly tool
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Crimping is a method for creating electrical connections. The crimping section of the terminal is
pressed around the conductor with such pressure that it forms a homogenous (gas-tight) seal with
the metal in the conductor.
Using the correct tools, it is a quick and easy task to fix a terminal onto a conductor, and makes a
more reliable and stronger joint than a soldered joint, for example.
Crimping of terminals
Do not use the simple type of tool shown in this illustration. The tool does not give provide the
force needed for reliable crimping.
Design
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A crimping tool is adjusted to suit each terminal, by means of both the design of its press jaws and
the press force it generates.
Each cutout on the press jaws has a letter or colour marking and the tool handle is uniquely colour
coded to suit the part number.
Terminals and crimping tools contains cross references between crimping tools, cutouts and
terminals.
Crimping tools
1.
2.
3.
4.
Press jaws
Cutout/Cutout marking
Coloured handle
Part number
The tools have a ratchet function, which means that crimping must be fully completed before the
tool can be opened again, in order to ensure correct crimping.
If crimping has to be interrupted for some reason, this can be done by lifting the brace upwards
and forwards, to release the ratchet.
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Crimping
The goal of using crimping tools is to create cold flow between the terminal and the conductor.
Crimping has to be carried out under extremely high pressure to generate cold flow. For this
reason, it is extremely important that the correct crimping tool is used for each terminal, please
refer to the Terminals and crimping tools section.
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A terminal of incorrect size for the conductor area has been used.
The terminal has been crimped in the wrong cutout in the press tool jaws.
An incorrect tool has been used.
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Terminal with:
1.
2.
3.
4.
5.
Conductors
General
Introduction
It is important that the cables in a vehicle are dimensioned for the purpose, and installed in a
correct manner. It is also important that it should be easy to distinguish separate cables by means
of colours etc. to facilitate identification and fault-finding of conductors. Important points to
consider when a conductor is changed or extended are as follows:
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That the conductors are installed in a way which protects the conductors from mechanical
damage.
The electrical wiring diagrams are a considerable help when you change or repair any conductor,
please refer to the service information in group 37.
Conductor area
It is important that the conductor area is at least as large after a repair as before, since the current
carrying capacity of the conductor depends on the area.
If the wiring diagram books can not give you any information about the area, it can be estimated
by measuring the diameter of the stripped section with a calliper gauge.
Then read the table to get an approximate estimation of the conductor area.
0.6
0.3
0.8
0.5
1.0
0.75
1.1
1.0
1.4
1.5
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1.8
2.5
2.3
4.0
Conductor colour
Choose the same colour as the original conductor. Different colours must only be used in
exceptional cases.
The wiring schedules frequently contain the colour codes for each conductor.
Please refer to the table, to interpret the colour codes.
Two-tone conductors
If the colour code for a conductor consists of two colours, it is designated as follows
Y/R
Shall be read as YELLOW/RED. This means that the conductor has a YELLOW insulation sheath
with RED stripe.
Colour / Colour
Abbreviation
SVART / Black
SB
BRUN / Brown
BN
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RD / Red
ORANGE / Orange
OR
GUL / Yellow
GRN / Green
GN
BL / Blue
BL
VIOLETT / Violet
VO
GR / Grey
GR
VIT / White
ROSA / Pink
BENVIT / Ivory
LBL
LBN
Cable runs
When a conductor is installed, the original cable run shall be followed, and the conductor shall be
fixed in the same way. The conductor shall be installed in such a way that there is no risk of
mechanical damage. No sharp ends must be left projecting outside the tie wraps.
The conductor must be at least as long as the original conductor.
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Information link
SAE J1587/SAE J1708, is used for diagnosis in the vehicle and transmits data at 9600 bps.
The cables are twisted with a twist pitch of 30 turns/metre.
Lengthening of SAE J1587/SAE J1708 cables can be done at any point along the length.
Control link
SAE J1939 is mainly used when the vehicle is driven, and transmits data at 250 000 bps.
The cables are twisted with a twist pitch of 40 turns/metre
There is a resistor at each end of the control link, either on the cables themselves, or built into the
connected control unit.
SAE J1939 cables must be lengthened at one end of the cable harness, and the resistors located
there must be moved to the end of the extension.
It is possible to join new control units onto the control link. There must be a distance of 0.3 metre
between each joint (stub) and the length of each stub must not exceed 1 metre. It is NOT
permissible to join one stub onto another stub. A stub must always be connected to the original
cable harness.
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Earthing points
The earthing points are very important components in the electrical system of a vehicle, since all
the voltage levels in the sub-systems are referred to the earthing points, as 0 Volt. If there is an
earthing point with suspect contact, the electrical system will be adversely affected.
Several conductors are frequently joined together at the same earthing point, which means that
several functions and systems will be affected by the quality of the earthing point.
It is thus very important that the electrical connection at each earthing point is correct, which
means that:
there is no paint or dirt on the contact surface between the terminal and the earthing point.
there is no corrosion on the contact surface between the terminal and the earthing point.
the connected terminals are correctly crimped.
nuts and screws are correctly tightened.
A faulty earthing point can lead to effects in systems and functions which would not at first appear
to be related to earthing faults. These faults can be very difficult to find.
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Soldered joints
General notes about soldering
Soldering is a method which is relatively easy to do. No expensive equipment is needed and the
conductor area is not so critical.
The disadvantage of soldering is uneven quality. Poor results can be obtained because of
contamination at the contact points.
If soldering is to give good contact and durability, it is important that the contact point is
completely free of dirt, oxidation, grease, paint etc.
Soldering quality
The factors affecting the quality of a soldered joint are the choice of solder, flux and soldering tool,
and how the joint is located and made.
It is common for the conductor to be heated so much that the insulation is damaged and melts. In
addition, the solder can flow too far up the conductor. If this happens, the conductor becomes hard
and brittle, and the risk of cable breakage increases.
At the same time as the conductor must not be heated up too much, it must be warm enough at
the soldering point to avoid creating a dry joint. If a dry joint is created, the electrical and
mechanical contact will be very poor, causing contact failure, open contact or intermittent faults.
These faults can be very difficult to discover and localize, since the soldered joint will be covered
by insulating shrink tubing afterwards.
Note: A dry joint means a poor electrical joint, causing contact failure, open contact or intermittent
faults, which can be difficult be very difficult to discover and localize.
Soldering tools
There are various kinds of soldering tools. The most common is the temperature regulated
soldering station, which allows the power and temperature of the soldering iron to be regulated.
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Solder wire
It is very important to use solder wire containing a good quality flux preparation.
Finishing
It is important that the soldered joint is insulated and protected from unwanted electrical contact
and mechanical damage once it is finished.
Use shrink tubing with part number 1095431
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