4.16 ELECTRICAL SYSTEM GENERAL REPAIR - CONTINUED.
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
(10) 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 with a soldering iron to the point at which the solder will melt completely when
touched to joint and flow into all parts of the joint. Excessive build up of solder on the joint should be
avoided or removed.
(11) Splicing Wire. To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced by using a crimped splice installed per (9) above or by wrapping the stripped wire lead ends onto
themselves then soldering and insulating per (8) and (10) above.
(12) Select appropriate wire lead, cable, or harness then route as noted during removal being sure to pass it
through any grommets or strain relief fittings as necessary.
(13) Tighten any strain relief fittings that were loosened for removal.
(14) Connect wire lead, cable, or harness ends per tags and wiring diagram figure 4-14. Remove tags.
(a) Connect wire leads to components.
(b) Solder and insulate leads to components per (8) and (10) above.
(c) Install connector pins per (9) above and tab housings then connect cable or harness.
(d) Install splice or crimp as appropriate per (9) above.
(15) Secure wires, cables, or harnesses with tiedown straps as necessary. Cut to remove excess tiedown strap
(16) Install any components that were removed for access.
(17) Install any covers and panels that were removed for access.