Diagnosis and Repair: Fencing Body Cord

ID: 149622

Description: A popular source of error in reporting...

Steps:

1. First locate the fault location. To do this, connect one wire of the cable to a multimeter (continuity tester) as shown in the picture and bend the cable slightly near a plug.

2. Start bending at the connectors, slowly working your way down the length of the cable. Repeat for each conductor. If a cable break is found, mark the damaged area and the affected wire.
3. Unscrew the connector where the fault is.

4. If only one wire has slipped out of the bunched connector, continue with step 10. Otherwise mark wire no. 1 (see photo!) at least 1 cm behind the faulty spot (seen from the plug).

5. Cut the cable 1 cm before the marking (seen from the plug) with side cutters.

6. Remove the bunch plugs from the wires. It may be that the screws are secured with a small amount of varnish, which breaks when unscrewed.

7. Now the cores of the rest of the body cable must be separated from each other. To do this, cut the cable between the wires over a length of 30-35 mm using the cutter knife on the cut-resistant surface.
8. Warning: Make sure you really only cut between the individual wires and don't damage the wires!
9. Caution: the cables usually have a tough silicone jacket, cutting them is a bit difficult!
10. Alternatively - with stronger cables - only 5 mm can be cut at the end between two wires. The wires can then be pulled apart by hand.

11. Strip the cores over a length of 8 mm. Then twist the bare strands a bit.
12. Warning: stripping is difficult because of the silicone coating, with automatic pliers it may not be possible at all!

13. Use crimping pliers to press the ferrules (1 mm²) onto the strands.

14. Screw the bunched plugs back onto the wires. Tighten the screws. Caution: do not use too much force, otherwise the drive of the screws can break out!
15. The screws can be secured against unscrewing under light loads with a small amount of low-strength locking varnish (e.g. LocTite 222).

16. Insert the bunch plugs into one half of the cable plug. Make sure that the marked wire is in position 1 (see photo).
17. The screws in the bunched plugs must point to the side, otherwise the plug cannot be screwed on properly.
18. A bell connector can be used as an alignment aid (see photo).

19. Screw the cable connector together.
20. Tip: Only then pull off the bell connector.

21. Reconnect the multimeter as shown in the photo. Again check all wires for continuity, bending them slightly.