TM 9-4310-394-13
4-25. WIRE ASSEMBLIES REPAIR AND REPLACEMENT.
This task covers:
a.
Removal
b.
Test
c.
Repair
d.
Installation
INITIAL SETUP:
Tools Required
Tool Kit, General Mechanic's (Appendix B, Item 1)
Multimeter (Appendix B, Item 2)
Material's/Parts Required
None
Equipment Condition
Air compressor unit shut down and cool.
a.
Removal.
Tag and disconnect any wires suspected of being defective.
b.
Test.
Use a multimeter to check wiring for continuity. Repair or replace any wire that indicates a shorted circuit.
c.
Repair. 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. Determine the proper size and length of wire, or the terminal, or connector to be used for replacement before
repair. General repair of wires is accomplished by wire splicing or by terminal replacement in accordance with the
following procedures.
(1) Splicing Wires. To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced. A commercial butt splice can be crimped onto the end to join them, or a: Western Union wire splice can be
made. The latter is made by stripping 1/4 to 1/2 inch (0.6 to 1.3 c, ) of insulation from the wire ends, holding the ends
parallel and facing opposite directions, then twisting each end around the other wire at least three turns. Solder and
apply insulation as described above.
(2) Crimping Terminals. To install a terminal on the end of a wire, strip 1/4 to 1/2 inch (0.6 to 1.3 cm) of insulation
from the end of the wire, apply a one-inch piece of heat-shrink tubing (if the terminals are of the uninsulated type), and
insert wire end into the shank of the terminal. Crimp the shank, and install heat-shrink tubing, if necessary.
(3) 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. If a separate flux is used, it should conform to soldering flux (Appendix E, item 9) and should be
brushed onto the joint before soldering. If an uncored solder is used, it should be a lead-tin solder, (Appendix E, item
10). 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 solder "gobs" on the joint should be avoided or removed.
4-52
