3
Heating Cable Repair
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Heat the end cap body and cable sheath with a large
flame. When the area to be brazed is up to temperature,
deposit a large bead of silver braze on the top part of
the area to be joined. Apply heat to both the end cap
body and the cable and move the flame slowly around
the circumference of the end cap body (Figure 68). This
will cause the braze to wick its way around the joining
area and also draw the braze inside the end cap body
making a stronger braze (Figure 68). Add more braze
as needed. Ensure that the braze flows to the bottom of
the end cap body to ensure a continuous braze around
the end cap body.
Large flame
Figure 68: braze end cap body to cable
Note: While brazing, it is important to avoid
using excess heat on the portion to be brazed.
Direct flame contact can oxidize the metal surface,
preventing the braze from adhering to the metal.
Care must also be taken not to overheat the end cap
body, which can cause the conductor joint (junction)
to melt.
Reposition end cap body facing upwards. Assemble
powder filled syringe by unscrewing plastic tip cap and
replace with 1-1/4 in (3.2 cm) long steel needle, keeping
syringe facing upwards until ready to use. Do not remove
red cap.
While the end cap body is still hot, fill end cap body to
approximately 3/16 in (5 mm) below the opening. Use
an engraving tool or other vibration method to pack the
powder. If using an engraving tool, reverse the engraving
bit so that the blunt end is visible and place the bit
