5 REPAIRING WIRING Removal and installation XF 95 series 2.3 FITTING CONTACTS TO ELECTRICAL WIRES The increasing application of electronics in vehicles means a much broader range of connectors, contacts and wiring is being used. The result of this is that more attention has to be paid to making and repairing connections. The following criteria should be taken into account: 1. Wires with a reduced insulation thickness, with retention of the mechanical properties, for use with core sections from 0.5 to 2.5 mm 2 . 3 2. Wires with a normal insulation thickness, for use with core sections from 4 to 120 mm 2 . 3. Wires for various temperature ranges: T1:
from --40 C to +70 C (in cab and chassis) and T2: from --40 C to +100 C (in engine compartment and gearbox) Note: In view of the mechanical strength required, the minimum permissible core section is 1 mm 2 , with the exception of cab wiring. At certain points this may be 0.5 mm 2 . To ensure the reliability of systems and connections, the following points should be observed when repairs or extensions are made to the wiring: A. Always choose the following: - the correct type of contact - the correct wire diameter for the contact used - the correct type of contact material (tin-plated, silver-plated or gold-plated) B. Use the right tool for the job.
Wire ends are always clamped to a contact. Special crimping tools have been developed for this purpose. Note: Connections will only be reliable if these crimping tools are used and the contact is fitted in the correct hole. 2-10 200303