5. Repair procedures

5. Repair procedures

5.1. Method for checking a wire

The aim of the wire checking method is to determine whether the repair can be carried out directly on the damaged wire or whether part of the wire must be replaced.

A wire is declared unusable in the following cases :

• The wire is not of sufficient length to permit repair without causing traction stresses which could alter the sealing of the connection or breakage over time (too taut)
• The wire is stripped, pulled out or crushed over a considerable length
• The wire is burnt
• In the case of a wire leaving an overmoulded connector, if the remaining usable length of wire is less than 30 mm

N.B. : In other cases, the wire is declared usable.

5.2. Method for selecting a wire

If a wire is unusable, the choice of the new wire to be used to carry out the repair must conform to the following characteristics :

• Cross-section of the wire
• Colour of the sleeve

ESSENTIAL : The cross-section of the wire must be equal to or larger than the initial cross-section, but never smaller.

N.B. : Depending on certain factors, a larger wire cross-section may cause interference or even a reduction in current.

It is compulsory for an earth cable to be green and yellow.
The other supply or information cables can be of a different colour.

N.B. : Favour the use of a cable of the same colour for the repair.

5.3. Method for stripping a wire

After cutting the wire, strip it without cutting the strands using approved wire strippers and observing the following lengths :

• 2,0 ± 0,5 mm for crimping of a clip or MQS tab
• 5 ± 1 mm for crimping of a clip or MQS tab
• 8 ± 1 mm for crimping a sleeve
• 15 ± 1 mm for an insertion in a sleeve

5.4. Method for tin soldering

The strengthening of a faulty crimp (electrical resistance too high) by tin soldering is permitted, observing the following procedure.

Tools required :

• Soldering iron with clean bit
• Tin 0,7 mm (60% tin 40% lead) with soldering flux without halogen

Method of operation :

• Melt a little tin on the iron bit
• Apply the iron bit under the crimp, the crimp wings must be visible
• Apply the tin wire to the copper strands at the end of the crimp (Soldering consumption approximately 3 mm)