Wiring Repair

WIRING REPAIR




REFERENCE SERVICE TOOLS




Wiring Repair Kit

REWORK PROCEDURE

1. Use of Wire stripper set (TRK001)







1. Disconnect the battery cable.
2. Choose the correct clamping slot for the wire and strip off the wire coat.
- If the incorrect crimping slot is used, the terminal may be damaged and may not fit into the connector.

2. Use of Remover tool set (TRK002)
- Flat tip type: Removal of single locking male/female terminal from the connector.




1. Remove the front or rear retainer (holder, stopper) of the connector.




2. Ensure that the tip of the tool is inserted into the gap between the elastic arm of key and terminal.
3. Remove the terminal and check the terminal condition, if there is a damaged, replace it with a new terminal.




- Double tip type: Removal of double locking male/female terminal from the connector.

3. Use of Terminal tension gauge set (TRK003)




1. Select the tension gauge that matches the female terminal to be checked.




2. Insert a tension gauge into the female terminal and check the terminal condition. (as shown in the photograph)




- It the tension of female terminal is not tight enough, remove it and replace the terminal and wire assembly (including seal).

4. Use of Ring terminal (TRK012-4)




1. Strip off about 5 mm of the wire coat at the end of the wire.




2. Joint the stripped wire with ring terminal and crimp using wire Stripper.




3. Put the shrink tube over the connection area and shrink the tube using electrical hot gun.

5. Use of Inline solder (TRK012-5) and Shrink tube set (TRK005)




1. Strip off about 5 mm of the wire coat at the end of the wires.




2. Insert each wire into the opposite ends of the inline solder and crimp using wire stripper.




3. Put the shrink tube over the connection area and shrink the tube using electrical hot gun.




- Shrink tube should be securely wrapped around the inline solder area.

6. Use of Terminal with lead wire kit (TRK011)




1. Remove the damaged connector and terminal using remover tool.




2. Select the right wire, which is fitted with the terminal specification from terminal with lead wire box and cut of the end of wire using wire stripper.




3. Put the end of each cut oft wire in the middle of the splice joint terminal and compress using wire stripper.




4. Put the shrink tube over the connection area and shrink the tube using electrical hot gun.




5. Insert the terminal with lead wire into the connector.