Electrical RepairElectrical RepairSoldering and Crimping Soldering and Crimping

By Fernando Martinez

And Rudy

Things You Will Need Things You Will Need

Wire Cutter and Stripper

Wire

Wire Terminals Solder

Solder Gun

Solder StationSolder Station

You can always use a solder station or solder pencil instead of a solder gun.

Soldering StationSoldering Station

• Offers adjustable temperature rangeOffers adjustable temperature range• Wet the sponge to clean the tipWet the sponge to clean the tip

Solder GunsSolder Guns

SolderingSoldering

• If solder gun does not work do these three If solder gun does not work do these three thingsthings

• 1. Tighten the nuts, the screw or allen set 1. Tighten the nuts, the screw or allen set screw on the soldering tip. (do not over screw on the soldering tip. (do not over tighten as it gets hot then cold it will tighten as it gets hot then cold it will expand then contract these will always expand then contract these will always come lose)come lose)

• 2. Clean tip on a wet sponge or use a 2. Clean tip on a wet sponge or use a solder flux or paste. Last resort, sand the solder flux or paste. Last resort, sand the tip of the solder gun or replace it.tip of the solder gun or replace it.

• 3. Tin the tip of the solder gun3. Tin the tip of the solder gun

Tighten the nutsTighten the nuts

Solder GunsSolder Guns

OlderStyle solder guns

Types of SolderTypes of Solder

• Rosin coreRosin core – electrical work - wiring – electrical work - wiring– The rosin is flux, which cleans as you solder.The rosin is flux, which cleans as you solder.– 50/50 50% tin 50% Lead melts at 425 degs50/50 50% tin 50% Lead melts at 425 degs– 60/40 60% tin 40% Lead melts at 371 degs60/40 60% tin 40% Lead melts at 371 degs– 63/37 63% tin 37% Lead melts at 361 degs63/37 63% tin 37% Lead melts at 361 degs

• Acid core - radiatorsAcid core - radiators

TipsTips

• The soldering tip is hot it will burn you and The soldering tip is hot it will burn you and melt the insulation on the cord.melt the insulation on the cord.

• Melted solder flows towards heat. Melted solder flows towards heat. • Most beginning students tend to use too much Most beginning students tend to use too much

solder and heat the joint for too long. solder and heat the joint for too long. • Don't move the joint until the solder has Don't move the joint until the solder has

cooled. cooled. • Keep your iron tip clean. Keep your iron tip clean. • Use the proper type of iron and tip size. Use the proper type of iron and tip size. • Use the proper size and type of solderUse the proper size and type of solder

Crimping Wire Crimping Wire

Insert wire into the terminal and crimp one side

Insert the other side and crimp tightly

Be sure to use the right side on the wire stripper !!!!

22 gauge for small wire crimping to 14

Yellow for gauges 10 to 12

End Results End Results

Nice clean crimp job!!!!

The end result

Crimping wire terminalsCrimping wire terminals

Insert wire into hole of the terminal.

Crimp tightly wire the wire striper.

Twist Wires together

First steps in soldering

Cross the wires

Twist the wires together

SolderingSoldering

Step 1: Touch the soldering gun to one of the sides of the wire and Hold the gun on the wire until it gets hot

Step : Touch the solder to the hot wire. The heat of the wire should melt the the solder. Don’t allow to much solder to melt. It will look bad and be a waste of materials.

The parts that are welded should look like different color wire

End Results

Watch out the wire, gun Watch out the wire, gun and the solder are hot and the solder are hot don’t touch, it will burn don’t touch, it will burn

you. Wait 1 to 2 you. Wait 1 to 2 minutes.minutes.

• To Solder on Terminals, Strip the To Solder on Terminals, Strip the wire then crimp it enough to hold wire then crimp it enough to hold the wire in place.the wire in place.

Soldering Terminals

Soldering Terminals

• Put the solder pencil tip on the Put the solder pencil tip on the barrel of the terminal and touch barrel of the terminal and touch the solder to the wire.the solder to the wire.

Crimping the terminal a little can help hold the wire still

The gun tip should not touch the wire. It should be placed on the terminal to heat it hot enough to melt the solder.

Soldering Terminals

The solder will go towardsthe heat so if you do it like this the solder will go the wrong direction

Put the gun tip on top of the barrel it will draw the solder into the wire.

The wire should not be out this far. Also noticed the burned insulation. Leave a little space between the terminal and the insulation of the wire so you can see the solder flow.

Soldering Terminals

Terminal was to close to the wire so it melts the insulation.

1st Place wire on metal holder 2nd Hold the splice together with hand

3rd Use pliers to crimp down the splice

Good Job!!!

T-Tap

Self stripping fuse holder

Insert wires into the self stripping fuse holder

Crimp it

End results

Inserting the fuse into the fuse holder

Used for a quick connectionIt is for temporary repairsIf used on the onside of a car or on a trailer expected live is less then 5 yearsI recommend do the job right the first time.

Quick Splice Quick Splice

The wire in this hole doesn’t go all the way it stops half way

Wire goes all the way threw

White wire goes all the way to the other side

Red wire stops half way

1st Step Crimping it properly

Quick Splice Quick Splice

2nd Step Make sure metal end is in all the way

Quick Splice Quick Splice

3rd Step close and lock into place

Quick Splice Quick Splice

Quick SpliceQuick Splice

• Make sure that a quick splice Make sure that a quick splice is not used out side of the is not used out side of the car. Weather and salt will car. Weather and salt will destroy the connection very destroy the connection very quickly. Best for temporary quickly. Best for temporary use anyway.use anyway.

Bad ends What’s WrongBad ends What’s Wrong

The End for nowThe End for now