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Created November 2021
by loosening the two large nuts on the terminal cable end.
DO NOT COMPLETELY REMOVE
EITHER OF THE NUTS!
Repairing a Cut or Damaged Cable
Following are various methods to repair cables that have been cut or damaged:
Method 1 – Splicing the Cable
Splicing the cable may be necessary if a cable is cut or damaged during an impact. The length
of the cable must be 50’-0” [15 m] or longer to make the splice.
1. Re-cut the ends of the cable to ensure the ends are clean and smooth.
2. Refer to the
“Cable Splices
” Section when making a cable splice connection.
3. If an accurate length of cable is used for the splice section, two cable splice connectors
will be required to connect the cables together.
4. Connect one end of the splice cable to one end of the cut cable with a connector.
5. Apply another connector to the other end of the splice cable and the end of the
cut cable.
6. Assemble the cable splice connector using a backhoe or other mechanical means.
7. Check the tension on the cable with the tension meter and adjust the turnbuckles to bring
the cable to the correct tension based on the infrared thermometer cable temperature
reading and the values on CASS
®
S4(29) Temperature/Tension Chart.
Note:
If the cable splice has been cut accurately, the tension may be obtained by turning the
turnbuckles at each side of the cut.
If the tension cannot be obtained at the turnbuckles at each side of the splice, it may be necessary
to follow the procedures in the
“Tension and Tension Meter
” Section. Some assemblies may
have field splices at all locations. If this is the case, the measuring, cutting, and re-connecting can
be done at any location.
Method 2 – 5’-0” [1.5 m] Section (Factory Applied Fittings)
A second method to reconnect the cables is to use a 5’-0” [1.5 m] Cable Field Repair Section
(PN-5840G) of cable with a factory applied fitting on each end. This method will also require two
turnbuckles and a left-hand and right-hand threaded fitting to complete the connection.
1. Remove approximately 9’-8” [2.9 m] of cable from the damaged cable.
2. Connect the threaded fittings and the cable ends connections per the
“Factory Applied
Fittings with Turnbuckle”
Section.
Method 3 – Other Than 5’-0” [1.5 m] Cable (Factory or Field Applied Fittings)
When using a cable length other than 5’-0” [1.5 m], the amount of cable removed from the
damaged cable is to be adjusted based on the cable length removed.
1. To determine the amount of cable to be removed, after the threaded fittings are placed on
the piece of splice cable, take a measurement from end-of-fitting to end-of fitting. Take
this measurement and add 4’-6” [1.3 m] and this will be the amount of cable to be removed
from the damaged cable.
2. If the length of cable used is less than 5’-0” [1.5 m], remove less than 9’-8” [2.9 m] of cable
from the damaged cable.
3. If more than 5’-0” [1.5 m] of cable is used, remove more than 9’-8” [2.9 m] of cable from
the damaged cable.
