Wiring Harness Damage.

TM 5-4120-394-BD

4-8. Wiring Harness Damage. Wire harness repairs are generally a series of single wire repairs. Establishing circuit

continuity in a bundle of wires is difficult because individual wires are not color coded. Wires must be identified before the y

are connected. Most essential electrical functions can be rapidly restored by using jumper wires. An alphanumeric code is

imprinted onto the outer insulating jacket of each wire. A point to point run of each wire can be determined from the

troubleshooting diagram plate and the alphanumeric code.

a. General Information.

(1) Limitations.

None.

(2) Personnel/time required.

1 Soldier/1-2 hours

(3) Materials/tools.

Electrical tape (Appendix C, Item 10))

Solder, rosin-core (Appendix C)

Soldering iron (Appendix B)

Plastic ties (Appendix C, Item 11)

b. Procedural Steps.

(1) Option 1: Wire bundle repairs. (See figure 4-1.)

(a) Repair the first wire and tape. Leave the tape hanging from the repair.

(b) Repair the next wire, lay it on top of the first repair.

(c) Continue wrapping with insulation tape.

(d) Repeat these steps as often as necessary to repair the wire bundle without cutting or breaking the

tape until the repair has been completed.

Figure 4-1. Wire Bundle Repair of Wiring Harness.

4-4