Service Information

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Splicing/changing cable 300 Service Information 12/21/2020
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Cables and connectors, general

Splicing/changing cable
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Cables and connectors, general

Uninsulated splice socket

In case of major damage, change the entire cable harness. Single damaged cables can be spliced.
NOTE!
When splicing, always connect cables with the same colour or colour combination. Cables with different colours may NOT be
connected under any circumstances.

NOTE!
If a new cable is spliced onto the old cable, it should be of the same type, same colour and same conductor area as the previous
one.

For functional description, see Splice sockets.

1. As a first choice, always select a splice socket for the conductor area in question.
2. If two cables are to be contact-pressed on the same side in a splice socket: Select a splice socket with sufficient
conductor area to enclose both wires. Place the wires on top of each other.

Figure 1

3. If the only available splice socket is intended for a greater conductor area than the cable's, strip the cable to the double
length and fold it double.
 Figure 2

4. Strip and check the cable according to Preparing cable for connection of cable terminal.
5. For each separate splice:
Fit a shrink hose with adhesive on one cable end.

Figure 3

6. Splicing several cables:

If several cables are to be spliced at the same point, a shrink hose with adhesive, covering all splices, should also be
fitted over the splice sockets.
7. Choose the correct contact-press tool based on splice socket and conductor area, and check which slots should be
used, see Dismantling tools and connector types.
8. Place the splice socket in the slot and carefully close the pliers so that the cable terminal remains in the slot. Check that
the splice socket is positioned correctly in the press tool.

Figure 4

9. Push in the stripped cable end on the side of the splice socket that the tool clamps down on.
NOTE!
The cable's insulation may not be pushed into the splice socket's contact-press part.

NOTE!
The copper wires should not be twisted.

10. Compress the contact-press tool. Do not stop contact-pressing before the tool is closed to the end position. Only then
is complete contact-pressing obtained, and the tool opens.
If contact-pressing has to be stopped, see Connecting cable terminal to cable.
 Figure 5

11. Repeat steps 8 to 10 for the other cable end.

12. Check that the contact-press looks correct, and pull on the cable to check that it's adequately secured.
NOTE!
When connecting more than one cable, more adhesive should be added to the splice socket to ensure a moisture-proof
joint.

Figure 6

13. Push the shrink hose over each separate splice socket and shrink it using a hot-air gun. Make sure that the shrink hose
seals tightly around the cable's insulation.
NOTE!
Make sure that the entire splice socket is covered by the shrink hose.

NOTICE
Ensure there is adequate ventilation when heat shrinking. Fumes may cause eye, skin and throat irritation.

14. If several cables are spliced at the same point, then steps 8 to 13 should be repeated for all cables.
15. Fit the bigger shrink hose over all splices. Shrink the hose using a hot-air gun.

NOTICE
Ensure there is adequate ventilation when heat shrinking. Fumes may cause eye, skin and throat irritation.

16. Check the shrinking. If acceptable shrinking has been obtained, the adhesive should have been forced out at the ends
of the splice socket.
 Figure 7

Insulated splice socket

In case of major damage, change the entire cable harness. Single damaged cables can be spliced.
NOTE!
When splicing, always connect cables with the same colour or colour combination. Cables with different colours may NOT be
connected under any circumstances.

NOTE!
If a new cable is spliced onto the old cable, it should be of the same type, same colour and same conductor area as the previous
one.

For functional description, see Splice sockets.

1. As a first choice, always select a splice socket for the conductor area in question.
2. If two cables are to be contact-pressed on the same side in a splice socket:
Select a splice socket with sufficient conductor area to enclose both wires.
Place the wires on top of each other.

Figure 8

3. If the only available splice socket is intended for a greater conductor area than the cable's, strip the cable to the double
length and fold it double.
4. Strip and check the cable according to Preparing cable for connection of cable terminal.

Figure 9

5. Choose the correct contact-press tool based on splice socket and conductor area, and check which slots should be
used.
6. Place the splice socket in the slot and carefully close the pliers so that the cable terminal remains in the slot.
7. Push in the stripped cable end on the side of the splice socket that the tool clamps down on.
 Figure 10

NOTE!
The cable's insulation may not be pushed into the splice socket's contact-press part.

NOTE!
The copper wires should not be twisted.

8. Compress the contact-press tool. Do not stop contact-pressing before the tool is closed to the end position. Only then
is complete contact-pressing obtained, and the tool opens.
If contact-pressing has to be stopped, see Connecting cable terminal to cable.

Figure 11

9. Repeat steps 6 to 8 for the other cable end.

10. Check that the contact-press looks correct, and pull on the cable to check that it's adequately secured.
NOTE!
When connecting more than one cable, more adhesive should be added to the splice socket to ensure a moisture-proof
joint.
 Figure 12

11. Shrink the insulating part of the splice socket using a hot-air gun.

NOTICE
Ensure there is adequate ventilation when heat shrinking. Fumes may cause eye, skin and throat irritation.

12. Check the shrinking. If acceptable shrinking has been obtained, the adhesive should have been forced out at the ends
of the splice socket.

Insulated, reusable splice socket

Installing:

1. Press on the cable terminals (a female and male) on the cable ends that are to be spliced according to Connecting cable
terminal to cable.

Figure 13

2. Insert the cables with cable terminals in the splice socket.

Figure 14

3. Check that the cables are locked in the splice socket by pulling lightly on the cables.
 Figure 15

Removing:

1. Insert the dismantling tool until it stops.

Figure 16

2. Pull out the cable together with the dismantling tool.

Figure 17

Splicing cable harness data communication

When splicing a cable harness for data communication, it requires that the same winding tightness (closeness) is intact in order
to retain the protection against interference. Otherwise, splices are performed in the same way as for any other cables.
NOTE!
Check the conditions for splicing of the data communication cable harness in Cables.

1. Cut the cable pair so that there is 40 mm between the splice centres.

Figure 18

2. At the splice, a pair-twisted data communication cable harness may only be untwisted 60 mm. After splicing, total
untwisting of the cable harness may be max. 100 mm.
3. Continue splicing according to what is described in section Splice sockets, depending on which type of splice socket is
used.

Changing cable
When changing a cable, always use a cable of the same type, length, same colour and with at least the same conductor area.
NOTE!
When changing a cable harness for data communication, it's important that the cable's winding tightness (closeness) is retained
and that max. length is not exceeded. See Cables.

For functional description, see Cables.

1. Measure the length of the original cable.

2. Measure and calculate the original cable's area, see Cables. Always use a cable with the same area or, if that area isn't
available, the next bigger dimension.
3. Preferably, choose a cable with the same colour as the original one, see colour code table Cables.
4. Follow the routing for the original cable and secure the cable in the same way, with cable ties or similar.
NOTE!
Make sure to not leave sharp cable tie edges protruding.

5. For checking the cable, see wiring diagram, service manual, section 3.