NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 TABLE OF CONTENTS Tae 1 [IVFRODUCTION Source of Information Arrangement of Material Revisions 11, General 15. Purpose of Manual 17. 19. Scope 112, Intended Use 16. ba TH [WIRE AND CABLE PREPARATION M1. Introduction 24, — Reference Specifications and Drawings 25° Definitions 246. Cutting Wire and Cable 213, Identifying Wise and Cable 236. Strpping Wire and Cable 2.47. Tinning Copper Wire and Cable 255) ielded Cable Verminating S m NLRAL PURPOSE CONNECTORS 375. 376. 589. 3.93, 399. 3-104, x Introduction Reference Specifications Drawings, and Documents Description General Practices Soldering Crimp Contacts Shielded Connections AN/MS Connectors Disassembly, Reassenibly, and Installation of Connectors... Installation of MS30S7 Series Connector Cable Clamps Interchangeability of US/AN and UK/BMS Connectors Miniature MS Connectors MIL-C-81511 Connectors MIL-C-83723 Connectors MIL-C-38999 Connectors MIL-C-81659 Connectors Special Purpose Connectors v ONNECTORS AND CABLING Introduction Reference Specifications and Drawings Description General Precautions and Procedures Soldering Coaxial Cable to RE Connectors BNC Seties Connectors © Series Connectors Page Section 361 361 34 3-80. 3.84 3.90 3-106 vil 44 44 at 46 47 4it Tie 4-22. TIN Series Connectors 426. _N Series Connectors 4:30. Pulse Series Connectors 434. TNC Series Connectors 437. $C Connectors ‘ 4.38, Miniature RF Connectors 441, Subminiature RF Connectors ‘SOLDERLESS TERMINATIONS AND SPLICES $1. Introduction 5.4. Reference Specifications, Drawings, and Documents $5. Description 5-7. Types and Styles of Terminals 5.8, Terminating Small Copper Wires (Sizes No. 26 through No. 10) with Preinsulated Terminal Lugs 5.18, Terminating Large Copper Wires (Sizes No.8 through No. 4/0). 5.32. High Temperature Terminal Lugs 542. Terminating Aluminum Wire 50, Splicing Sinall Copper Wires (izes No. 26 through No. 10) 5.54. Splicing Large Copper Wires (Sires No. 8 through No. 4/0) 5.62. Inspection of Crimped Connections ‘TAPER PIN TERMINATIONS ot 65. 6-10. 614 6-17 Introduction Taper Pin Tools Crimping Procedures Insertion of Taper Pins Extraction of Taper Pins ‘THERMOCOUPLE WIRE SOLDERING AND INSTALLATION 7-1. Introduction 75. Reference Specifications and Drawings 7.6. Description 7-10. Definitions TAL. Thermocouple Wire Preparation 715, Hard Soldering Thermocouple Wire 728. Soft Soldering Thermocouple Wire 7-31. Thermocouple Wiring Installation. Page 413 416 419 4.24 4.26 426 428 s4 5.5 5.24 5.27 5.29 532 5.35NAVAIR 01-14-5605 (USAF) T.0. 1-18-14 Table of Contents Section Tite VIIL_ BONDING AND GROUNDING XL xl 841. Introduction 84. Reference Specifications’ 85. Definitions .... 86. General Precautions and Procedures 8-7. Selection of Hardware . 8-13. Preparation of Bonding or Grounding Surfaces 8:17. Methods of Bonding or Grounding . 8.23. Bonding and Grounding Jumpers 8:26. Testing Bonds and Grounds 8.29. Refinishing SOLDERING 941, Introduction 9.5. Reference Specifications. and Standards... 2.0.0. ceecceee 9.6. Definitions and Descriptions 9-14, Heat Application Methods 919. Preparation and Maintenance of Soldering Iron ........... 9-24. Soldering Operation ~ General Precautions and Procedures... 941. Inspecting a Finished Solder Joint ELECTRIC CONNECTOR SEALING 10-1. Introduction 104) Reference Speciation 105. Description . 5 106. General Precautions... 0.12.1 10-10. Preparation of Sealing Compound 10-45. Storage of Sealing Compound 10-19. Preparation of Fluorocarbon Insulated Wire for Potting 10-20. Special Instructions for Use of MIL-M-24041 Molding and Potting Compound CONDUIT FABRICATION I-L. Introduction 11.5, Reference Specifications and Drawings 116. Metallic Conduit 11-19. Nonmetallic Conduit - 11-22. Use of Heat Shrinkable Tubing SPECIAL ELECTRICAL WIRING HARNESSES 124. Introduction 124. Reference Specifications 125. Molded Hard Harness 12-16. Compact Wire Bundles 12.49. Rework and Repair of ‘Compact Wire Bundles = 108 au xv - 104 101 2 tod 104 102 104 107 na id Dae 2 18 19 xvi 513s 128 ii Section Tite INSTALLATION OF BUSBARS, CONDUIT, JUNCTION BOXES, PROTECTIVE DEVICES, AND TERMINAL BOARDS IL, Introduction... ees eee eee Reference Specifications and Drawings. Preparation and Installation of Busbars Installation of Conduit Installation of Junction Boxes |. Installation of Protective Devices Installation of Terminal Boards Ba. ELECTRICAL WIRING INSTALLATION 141. Introduction... 143. Reference Specifications and Drawings 144. Definitions - ‘i 145. Wire Types 146. Wire Groups and Bundles .. 14.15, Routing and Installation 14:35. Connections to Terminal Boards and Busbars ... 14-53, Installation of Wires in Conduit 1457. Installation of Connectors ce 14.64, Installation of Wites in Junction Boxes 14.68. Terminal Junction System LACING AND TYING 15-1. Introduction 15-4, Reference Specifications and Drawings 155. Definitions ........ 15-6. Materials... 159. General Precautions . 15-10, Lacing 15-14. Tying 15.20, Self-Clinching Cable Straps 15:22, Lacing and Tying in High Temperature Areas WIRING; LOCK, SHEAR, AND SEAL 16-1. Introduction ..)........ . 16-4, Reference Specifications and Drawings 165. Definitions ...... 169. General Procedures for Lock, Shear, and Seal Wiring 16-16. Specific Procedures for Lock, Shear, and Seal Wiring... LAMPS USED IN AIRCRAFT ELECTRICAL SYSTEMS 17-41. Introduction 0 174. Reference Specifications 17-5. Lamp Types 174, Abbreviations 17-7. General Precautions Be 131 B3 4 136 B8 . 14d i 141 141 are 144 1441 1 1448 fae 1@ 15-1 151 15a ears 2 152 15-2 15-4 185 157 1641 161 161 161 162 174 14 14 i 174Section an NAVAIR _01-1A-505 (USAF) T.0. 1-18-14 'e of Contents FUSES USED IN AIRCRAFT ELECTRICAL SYSTEMS 18-1, Introduction... 18-4. Reference Specifications and Dra 185. _ Definitions and Descriptions 188, Identification 189. General Precautions Poge Section 184 184 1841 181 1841 Tie XIX_ EMERGENCY REPAIRS 19-4, Introduction 19-4. Reference Specifications 19-5, Repairing Broken or Damaged Wires 19-12. Repairing Shielded Cable 19-45. Repairing Coaxial Cable 19-16, Repairing Damaged MS Connectors 19-20. Replacement of Connectors 19-23. Replacing Terminal Board Covers LIST OF ILLUSTRATIONS Figure Title 24 Wites Commonly Used in Airoraft 22 Cables Commonly Used in Aircraft 23 Wires After Cutting 24 — Wire Cutting Tools Examples of Wite Identification Coding Spacing of Identification Stamping ‘on Wire and Cable Location of Identification Sleeve Multi:Conductor Cable Identification Coaxial Cable Identification Wire Identification at Terminal Board Wire Marking Machines ~ Automatic Marking Machines ~ Hand Electric Oven for Heat Setting Identification Marking Marking on Sleeves 2 2415 Marking Machine for Sleeving 216 Identification of Wire Bundles and Harnesses 217 Typical Wire Stripping Tools 218 Stripping Wire in a Hot Blade Stripper 3419 Substitute Hot Blade Stripper 220 Inside View of Rotary Wire Stripper 2.21 Stripping Wire With Hand Stripper 222 Knife Stripping 2.23 Dip-Tinning in Solder Pot 2.24 Alternative Dip Tinning Method 2.25. Tinning Wire With a Soldering Iron 2.26 Stripping Outer Jacket Froin Shielded Cable 227 TwoPiece Grounding Connection for Terminating Shielded Wire 2.28 Alternative Procedure for Two-Piece Grounding Sheath Connector i 22 23 26 27 29 Figure 229 230 231 232 233 Pigtail Termination tos Shielded Wire Alternative Pigtail Termination for Shielded Wire Coinb for Combing Out Shield Dead-Ending Shield With Tape Wrap Dead-Lnding Shield With Permanent Splice Solder Sleeve Shield Termination Solder Sleeve Floating Shield Termination Insulating Sleeving Installed ‘Over Solder Cup - Soldering Iron Tip Shapes Resistance Soldering Pliers for Large Contacts Resistance Soldering Pencil for ‘Small Contacts Torch Soldering Large Contact Soldering Large Size Contacts Soldering Small Size Contacts Soldering Medium Size Contacts Soldering Iron in Safety Sereen Connector Assembly Tool (M3480, MS3481, MS3482) Connector Soldering Sequence Insulating Sleove Bottomed Against Insert Tying Sleeves and Preshaping Wines Crimping Too! M22520/1-01 With M22520/1-02 Turret Head Crimping Too! M2520/2-01 With 'M22520/2-02 Positioner Crimping Tools MS3191-! and MS3181-3 Crimping Tool MS27828¢USAK) With MS27828-2 Universal Head Gaging MIL-C-22520 Crimping Tools Ww 1941 19-1 194 19 197) 198 193) DM 234 baa ite 25 337 238NAVAIR _01-1A-605 (USAF) T.0. 1-10-14 List of Illustrations 3.23 324 3.25 3.26 3a7 3.28 3.29 330 331 332 333 334 3.35 336 337 338 339 3.40 341 342 Tale Gaging MS3191-1 Crimping Tool - ‘Typical M2520 Positioner and "Turset Head M2520 Crimping Tools Contact Insertion in 'M22520 Crimping Tool .. Assembling Wites to Crimp-Type Contacts, ‘Terminating Shielded Wire at MS Connector ... . Grounding Shields Outside Connector ‘Terminating Shielded Wires at Potted Connector ...-- Installing AN3111 Bonding Ring Terminating Two Wires at One Contact Permanent Splice for Terminating ‘Two Wites at One Contact Reducing Wire Size at MS Connector ‘Multimeter for Continuity Test (1S 352 B/U) . ‘Typical Protective Connector Caps. Typical AN(MS) Connectors. AN(MS) Connector Marking Insert Arrangements — AN Type ‘Connectors, MIL-C-5015 .. Altemative Positions of Connector Inserts MS3057 Connector Cable Clamp Types - ‘Typical Manufacturer’s Variations in "AN/MS Connectors tee Potting Connectors Removal of Solid Back Shell... Removal of Cannon Split Back Shell Class E Connector ~ Cannon (Exploded View)... ‘Typical Class R Connectors Class R Connector ~ Bendix (Exploded View) Installation of Amphenol Class A Connector... Location of End of Retaining Ring Installation of Amphenol ‘Class B Connector ...- +++ Safety Wiring Class B Connector Installation of Amphenol (Class C Connector «22602205 Installation of Amphenol Fireproof Connector . Spare Wires for Potting Connector Cleaning Connector Prior to Potting Filling and Curing Potting Connector Installation of O-Ring on. Potted Connector Installation of Bendix ‘Class A and C Connector 321 321 3.21 322 323 338 3.38 339 3.40 341 3.42 342 343 344 Figure 356 37 358 3.59 3.60 361 362 343 364 3.65 366 3.67 348 3469 370 an 372 3B 374 3.82 3.83 3.84 3.85 3.86 387 3.88 3.898 3-896 3.89¢ Tie Reinstalling Contact in Bendix Resilient Insert...» Installation of Bendix Class E Connector Installation of Bendix Class R Connector Bendix Fireproof Connector Partial Disassembly . . Installation of Bendix Fireproof Connector . Torque Wrench Used on Bendix’ Fireproof Connector . Installation of Cannon Clast B Connector Installation of Cannon Class C Connector Installation of Cannon Class E Connector . : Cannon Class E Connector ~ Grommet Installation . Installation of Cannon. Fireproof Connector 5 Removal of Cannon Clip-Held Contacts Removal of Amphenol Insert Assembly... Amphenol Contact and Insert Assembly ~ Exploded View Removal of Solder Contacts from Resilient Insert - 1MS3057 Connector Cable Clamp Types Exploded View ..- Installation of MS3057 Cable Clamp Installation of MS3057A Cable Clamp... Installation of MS3057B Cable Clamp Lubrication of MS3057B Cable Clamp “Typical MS Connectors ~ Miniature... MS Connector Plug — Exploded View . .. MS Connector Receptacle — Exploded View Insert Arrangements — MS Miniature Connectors, MIL-C-26482.... Insert Arrangements — MS Miniature ‘Connectors, MIL-C-26500.... Insertion and Extraction Tools for Front-Release Crimp-Type Contacts Insertion and Extraction Tool for ‘Rear Release Crimp-Type Contacts .. ‘Assembling Wired Contacts Into Connector Removing Crimp: Type Contacts, From Connector Insert Arrangement Summary Be Color Marking for Individual Release MIL-C.0081511 Connectors . MIL-C-83723 Contact Arrangements ‘Typical MIL-C-38999 Connector MIL-C.38999 insert Arrangements MIL-C-38999 Insert Arrangements MIL-C-38999 Insert Arrangements . 3.45 346 3.47 348, 3.49 350 3.50 351 352 353 354 355 3465 361 369 3:70 an 373 397 3.19 3.82 3-86 387 3-88 389Figure 390 391 392 393 394 395 3.96 397 3.98 3.99 3-100 34101 3.102 3.103 3.104 34105 3106 3.107 3-108 3109 34110 Bl 312 3-113 3d NAVAIR 01-14-5605 (USAF) T.0. 1-14-14 List of illustrations Title Typical MIL-C-81659 Duplex Connector .. Assembly of MIL-C-81659 Connectors With Standard Contacts Assembly of MIL-C-81659 Connector Polarization (Keying) Posts and Inserts Assembly of MIL-C-81659 Connectors With Coaxial Contacts Insertion of Standard Contacts in MIL-C-81659 Connectors Removal of Standard Contacts From MIL-C-81659 Connectors Installation of Sealing Boot and Ferrule on Coaxial Cable Before Crimping Contacts Stripping Dimensions for Coaxial Cable in Table 3-27 Crimping Center Contacts With the MIL-C-22520/2-01 Crimping Tool Crimping Center Contacts With the ‘AMP 220015-1 Crimping Tool Contact Assembly Using Seal Ring Crimped Center Contact of Braided Coaxial Cable Inserted in Contact Body . Contact-Ferrule Assembly in Ferrule Crimping Die of Crimping Tool AMP 220015-1 Ready for Crimping AMP 220066-1 Ferrule Crimping Tool Showing the Three Crimping Dies Contact-Ferrule Assembly in Crimping Die of AMP 220066:1 Ferrule Crimping Tool Ready for Crimpit Crimped Center Contact of ‘Semi-Rigid Coaxial Cable Inserted in Contact Body Semi-Rigid Cable-Contact Assembly in Crimping Die of AMP 220066-1 Ferrule Crimping Tool Ready for Backshell Crimping Insertion of Rear-Release Coaxial Contacts in MIL-C-81659 Connectors Removal of Rear-Release Coaxial Contacts from MIL-C-81659 Connectors ‘Subminiature Connectors Rectangular Shell Connectors Miniature Rectangular Connectors Rectangular Shell Connector ~ Cannon DPD (Exploded View) Installation of Cannon DPD Connector Soldering Coaxial Cable to Contacts for DPD Connector ‘Subminiature Connector ~ Exploded View Page 393 3.96 397 3.97 3.99 34101 3101 3-102 3102 3-103 3.103 3-103 3-108 3404 3104 3-104 3.105 3105 34106 34107 3107 3109 3-110 3a 312 Figure 41 42 43 44 4s 46 47 48 49 4:10 41 412 413 414 45 416 447 418 419 420 421 422 423 424 428 426 427 428 429 430 431 432 433 434 435 436 Title Typical BNC Connectors Typical HN Connectors Typical N Connectors Typical C Connectors Typical Pulse Connectors Typical TNC Connectors Typical Coaxial Cables Stripping Outer Jacket From Coaxial Cable Improvised Dielectric Stripper Tinning Center Conductor Tinning Inside of Contact Soldering Contact to Coaxial Cable . ‘Tightening Nut Into Plug or Jack Body Correct Shape for Soldering Iron Tip Improved BNC Connectors — Exploded View BNC Connectors With Captivated Contacts ~ Exploded View Attaching Improved BNC Connectors to Coaxial Cable... Attaching BNC Connectors With Captivated Contacts to Coaxial Cable € Connectors ~ Exploded View ‘Attaching C Connectors to Coaxial Cable Improved HN Connectors Exploded View HN Connectors With Captivated Contacts ~ Exploded View ‘Attaching Improved HN Connectors 10 Coaxial Cable ‘Attaching HN Connectors With Captivated Contacts to Coaxial Cable Improved N Connectors ~ Exploded View N Connectors With Captivated Contacts ~ Exploded View Altaching Improved N Connectors to Coaxial Cable Attaching N Connectors With Captivated Contacts to Coaxial Cable Pulse Connector ~ Ceramic'Insert Pulse Connector ~ Rubber Insert Assembly of Ceramic Insert Pulse Connector Assembly of Rubber Insert alse Connector . ‘TNC Connectors ~ Exploded View Attaching TNC Connectors t0 Coaxial Cable MB Connectors ~ Exploded View Attaching MB Connectors, to Coaxial Cable Page 42 42 42 43 43 44 45 45 46 46 46 a7 416 417 418 419 420 420 422 428 4.26 4aa7NAVAIR _01-18-505 (USAF) T.0. 1-18-14 List of Illustrations 339 440 441 4a 443 444 sa 32 53a 53 53¢ 34 55 56 37 5.5 516 5.7 S18 Title Subminiature RF Connector — Exploded View Attaching Subminiature RF Connectors to Coaxial Cable . Crimping Subminiature RF Connectors Attaching Avien 163-088 and 163-089 Connectors to Coaxial Cable... Attaching Avien 163-07 and 163-027 Connectors to Unshielded Wire Attaching Liquidometer 9100 Series Connectors to Coaxial Cable . . Attaching Nu-Line 1200 Series. Connectors to Coaxial Cable Attaching Liquidometer 8.62 and $63 Connectors to Coaxial Cable ‘Solderless Terminal Lugs and Splices Preinsulated Terminal Lug — Cut-Away Tool MS90413 for Hand Crimping. Preinulated Copper Terminal Lugs (Fully Open Position) ....--..++ Too! MS90413 for Hand Crimping Preinsulated Copper Terminal Lugs (Fully Closed Position) ‘Tool MS90413 for Hand Crimping Preinsulated Copper Terminal Lugs (Wire Side Fully Closed) Tools for Power Crimping Small Preinsulated Copper Terminal Lugs... . 1MS90413 Crimping Too! With Terminal Lug Inserted ceo MS3316 Hand Crimping Tool. Proper Insertion of Stripped Wire in Insulated Terminal Lag for Crimping Insulating Sleeves Tools ~ Hand Crimping Large Copper ‘Terminal Lugs Tools ~ Power Crimping Large Copper” Terminal Lugs - Positioning Flag-Type Terminal Lugs "AMP Crimping Tool for High-Temperature Terminal Lugs Positioning Aluminum Tern Ls in Die Nests Single Crimp on Aluminum Terminal Lugs . - Reducing Wire Size With Permanent Splice ..... Special Splices ....-. Locating MS25181 Splice in 1MS90413-2 Crimping Tool Insulating Sleeves for Splices ‘Size 8 and Larger Pace 429 430 430 431 431 432 433 33 54 56 5.26 $29 5.29 5.29 330 531 532 Figure 5.19 520 521 61 62 63 65 66 TH 12 14 15 16 1 19 740 TAL 742 Tite Positioning Aluminum Splice in Die Nest Indent Inspection Modifying Hand Micrometer for Indent Inspection Crimping Tools for Taper Pins Insertion and Extraction Tools for Taper Pins AMP Combination insertion-Extraction Tool No. 380565 Crimping Tool Insulation Adjustment Positioning Taper Pin in ‘AMP Crimping Tool Pull Test Tool (Bundy TR) ‘Thermocouple Wire ‘Thermocouple Terminals. . ‘Thermocouple Connector Assembly (ANSS37) Stripping Thermocouple Wire for ‘Terminal and for ANSS37 Connector Installation Stripping Thermocouple Wire for Splice Installation Stripping Thermocouple Wire for” MS Connector Installation... Torch Tinning Thermocouple Wire Dip Tinning Thermocouple Wire in Silver Solder Resistance Heating to Tin Wire Resistance Tinning of Terminal Saver Soldering Thermocouple Wire to Terminal - o Modified Crimping Tool for ‘Thermocouple Terminals... Reinforcing Solder on ANS539 Terminals . Serving Thermocouple Wire . Torch Soldering Thermocouple Wire to MS Connector Contact... - ‘Connecting Thermocouple Splices Distributing Slack in Thermocouple Wire - ‘Stud Bonding or Grounding to Flat Surface... Plate Nut Bonding or Grounding to Flat Surface . Bolt and Nut Bonding or Grounding to Flat Surface... Gs Steel Wire Brush With Pilot for ‘Cleaning Aluminum Surfaces Bonding Tab Riveted to Structure 1 1 18 19 19 19 7:10 742 742 713 83 84 85 86 86List of Illustrations Figure 86 a7 104 102 1033 10-3b 103 104 Wa n2 13 14 1s, 19 1110 HAL 112 has nag nas 1146 HAT 1118 Mag 1120 Tithe Aluminum Jumper Connection to Tubular Structure Copper Jumper Connection to Tubular Structure... .. Bonding Conduit to Structure . Special Milliohmmeter and Clip Leads for Testing Bond Resistance ‘Types of Hand Soldering Irons Resistance Soldering Soldering Iron Tip Before and After Cleaning ‘inning Soldering Iron Tip Soldering tron Tip Shapes Correct Solder Application Soldering Iron Holder Good and Bad Soldered Connections Handmixing Potting Compound Mixing Paddle for Potting Compound Machine for Mixing Potting Compound Machine for Mixing Potting Compound Machine for Mixing Potting Compound ‘Tube Dispenser for Potting Compound Capacity Limits for Conduit Bending Rigid Metallic Conduit Good and Bad Conduit Bends Cutting Rigid Metallic Conduit Installing Nut and Ferrule on Rigid Metallic Conduit Flaring Rigid Metallic Conduit Cutting Flexible Conduit ‘Trimming Frayed Ends of Flexible Conduit Stripping Rubber Cover From Flexible Conduit Mandrel and Collet for ‘Amphenol Machine . . Retracting Mandrel Shaft Installing Mandrel and Lower Half Collet Locking Mandrel in Place Bare Flexible Conduit Ready for Swaging Rubber-Covered Flexible Conduit Ready for Swaging Placing Conduit Assembly in Machine Crimping Ferrule Good Crimped Ferrule Breeze Ferrule Swaging Machine Rubber-Covered Conduit Prepared for Breeze Machine NAVAIR _01-1A-505 (USAF) T.0. 1-18-14 107 12 113 4 4 ns ns 16 1s 16 1g HAL Mat at maz waz 113 113 M3 114 1146 135 136 Ba 38 Bg Title Final Position of Collar on Rubber Covered Conduit Soldering Ferrule to Brass Conduit Installing Two-Piece Ferrule on ‘Nonmetallic Conduit ..... ‘Typical Electric Hot-Air Gun Shop Air Heater .. Example of Harness Usage Chart ‘Typical Molded Hard Harness Assembly ‘Typical Rigid Section Typical Cross Section ‘Typical Wire Identification Number... ‘Typical Dimensional Layout, Dimensional Layout Symbols .... Heat Shrinkable Boot Installation Fabricating Boot From Silicone Tape Braid Repair. -..0.2.e sees Use of Heat Shrinking Tool . Connector Location and Wire Trimming... Parallel Connector Crimping Shrinkable End Caps and Sleeve Installation Shielded Stub Splice Stub Splice Area...” 5 Construction of Parallel Butt Spices Modifying SelF-Sealing End Cap Construction of Alternative Parallel But Spices Shielded Wire Stripping Bonding Jumper Shielded Wire Termination Use of Ferrale Crimping Tool Termination of Ungrounded (Floating) Shield ... Adding Wite to Spare Wire Pigtail), Existing Wire, and Splice Construction ‘Adding Shielded Wire Damaged Wire Repair Scratch Brushing Unplated ‘Aluminum Alloy Busbars Mounting Busbars to Structure Installation of Supporting Clamps for Conduit Spacing Clamps for Rigid Metallic Conduit Attaching Junction Box to Structure . ‘Attaching Cover to Junction Box Wire Entry Holes in Junction Box Mounting Protective Devices ‘Typical Mounting Hardware for Protective Devices Pose 1148 118 1119 1120 11-20 122 123 124 124 125 126 127 128 1242 12413 1244 12416 1217 1247 1248 1218 1221 1222 1223 1224 1224 12:25 12.26 1227 1229 1230 1233 132 Ba 133 . BS 138 135 136 137 137NAVAIR 01-1A-605 (USAF) T.0. 1-10-14 tt ans e Frou Tit Page Figure Tite Pane 1310 Determining Screw Length for 14.332 Feedthrough Terminal Junction Modules... 14-23 Mounting Into Blind Holes . 138 14.33b Feedthrough Terminal Junction Assembly 13-11 Mounting of Terminal Board . 139 (Exploded View) ..... 14.28 1312. Alternative Mounting of Terminal Board... 139 1433¢ Feedthrough Terminal Junction Assembly .. 14:24 13.13 Insulation of Terminal Board wee, 139 1434 Removable Contact Wire Splices 2 142s 13-44 Identification of Terminal Boacd ......... 13-10 14:35 Components of Terminal Tunetion System . 2. e+. 14.26 141 Group and Bundle Ties . ce. 142-1436. M8372331 Contact Insertion — 14.2 Comb for Straightening Wires in Bundles... 14-2 Extraction Tools seceeeees 1427 143 Staggered Splices in Wire Bundle 1431437 Contact Insertion in Removable 14-4 Slack Between Supports... i143 Contact Wire Spices «..2.-2.e..s.04. 1428 145 Routing Bundles . {144 14.38. Contact Removal From Removable 14.6 Cable Clamp at Bulkhead Hole i146 Contact Wire Splices 1428 14-7 Cable Clamp and Grommet at Bulkhead Hole 146 15:1 Single Cord Lacing ee a2 148 Drainage Hole in Low Point of Tubing .... 14-7 15-2 Double Cord Lacing........ 2153 149 Separation of Wires From Plumbing Lines |. 14-7 153 Lacing a Branch-Off SI isa 14.10 Preferred Angle for Cable Clamps 148 154 Making Ties no RT isa 14-11 Typical Mounting Hardware for 155 Securing With Tape nus 15S MS21919 Cable Clamps... 149 15-6 Installing SelfClinching Plastic 14-12. Attaching Cable Clamp to Structure ...... 149 Cable Straps... ceseees 156 [413 Tool forstaling Cable Clamp =---s..... 1410 15:7 MS90387 Adjustable Hand Tool 14-14 Installing Cable Clamps to for Installing Self-Clinching Plastic Tubular Structure ......60eeeeeeeees MIO Tie-Down Straps ‘ 156 e Split Grommet .....0-.0cseeceeee 1411 14-16 Cutting Caterpillar Grommet... TL 111 1641 Double Twist Lock Wiring ....... 162 1417 Connecting Terminals to 162 Single Wire Method moe 162 Terminal Board «..- ses M11 163. Use of Wire Twister NIE 163 14.18. Hardware for Wiing Terminal Boards | 16-4 Wiring AN Type Connector « 2S 163 With Copper Terminals... 14-13 165 Drilling Hole in Coupling Nuts. -........ 163 14.19 Hardware for Wiring Terminal Boards 166 Lock Witing Connector to Structure . 164 With Aluminum Terminals .... 1413 16-7. Wiring Spit Shell Assembly Screws 2 164 14.20. Hardware for Wiring Terminal Boards | 168 Seal Wiring Switch Guard... 2 16s With Combination of Terminals ....... 14-14 14.21 Connecting Aluminum Terminal to 17-1 Lamps Used in Aircraft ‘Aluminum Busbar ... eas Electrical Systems iis 14-22. Connecting Copper Terminal to 17.2 Aireraft Lamps Sealed Beam Type... 174 ‘Aluminum Busbar . 14.16 14.23 Connecting Aluminum Terminal to 18.1 Basic Construction, Views A,B,and C .... 183 Copper Busbar 1416 182 Typical Aircraft Fuses . 2 184 14:24 Connecting Copper Terminal to 183 Typical Fuse Holders . SO 184 Copper Busbar_.. . 14:16 18-4 Military Fuse Designations, 14-25 Connecting Two Terminals to Views A,B,C,and D ... ces 1842 ‘Same Point on Busbar .........20c06. M417 14.26. Vinyl Tubing Around Busbar...-.- 1418 19-1 Permanent Splice Repair of Wine ......... 19-2 14.27 Conduit Capacity ... = 1418 19-2 Terminal Lug Bartel Repair of Wire ....... 193 14.28 Leader for Conduit... TI 1419 19.3 Repairing Broken Wire by 14.29. Support for Wire at Conduit End ......... 14:19 Soldering and Potting ........0.2.++. 193 1430 Installing Conduit on 19-4 Bolted Terminal Lug Repair of Connector Back Shell ceeees 1420 Large Wire ceceee 194 1431 Support Inside Junction Box . 11421 19-5 Insulation Repair With Sleeving 194 14.32a Feedback Terminal Junction Assembly .... 14.22 19-6 Repair of Shielded Wire ws @& 14.326 Feedback Terminal Junction Assembly .... 14-22 19-7 Alternative Method for 1432¢ Feedback Terminal Junction Assembly 14.23 Repair of Shielded Wire... . 196ble 24 22 23 24 25 27 29 NAVAIR 01-1A-505 (USAF) T.0. rie Wire Used in Aircraft Blectrical Installations ee Function and Designation Letters Sizes of Identification Sleeving Recommended Sizes of Marking Type Recommended Marking Temperatures Speed Settings for Heat Setting, Electric Oven... Wire Strippers for Use on Copper Wire Allowable Nicked or Broken Strands . ‘Approximate Soldering Iron Sizes for Tinning Shielded Wire Terminations ~ Inner Sleeves age Shielded Wire Terminations ~ Uninsulated Outer Sleeves and Installing Tools Shielded Wire Terminations — Insulated Outer Sleeves and Installing Tools .... Stripping Lengths for Solder Connections - Insulating Sleeving Material Insulating Sleeving Sizes Installation Tools for Wire-to-Contact Adapters MIL-C-5015 Connector Classes : ‘Amphenol Fireproof Connector Fittings (O-Ring Sizes for AN Type Connectors Wire End Caps and Crimping Tools Contact Removal Tool Diameter ‘Sizes of Grommet Sealing Plugs Torque Value for Fireproof Connectors Telescoping Bushings Miniature MS Connector Type and Class Availability Contacts and Their Wire Size Range Connectors With Crimp-Type Contacts and Assembly Tools ‘Tools for Unwired Contacts MIL-C81511 Connectors MIL-C-81511 Contact Insertion and Removal Tools MIL-C-83723 Connectors Availability of MIL-C-38999 Connectors Special Tools . MIL.C-81659 Connectors Contact Insert Arrangements for MIL-C-81659 Connectors Insert Arrangements, MILC-81659 Blectric Connector. Series 1 and 2 Polarization (Keying) Positions Tools for MIL-C-81659 Standard Contacts, 1A-14 LIST OF TABLES Page 24 240 215 217 217 232 32 33 33 3.24 3.26 3.40 3.43 3.44 345 347 3.49 3.59 3462 3.468 3-68 3-70 3.75 378 381 385 3.90 391 392 3.94 3.95 3.98 327 3.28 3.29 330 331 441 43 44 45 46 47 48 49 410 53 54 38 536 57 Tite Stripping Lengths, Crimping Tools, Contacts, and Cables for MIL-C-81659 Coaxial Connectors... +++ Installation Tools for Crimp-Type Contacts — Amphenol #69 Series . Crimping Tools for Crimp-Type Contacts Bendix #10-214000 Series : Installation Tools for Crimp-Type Contacts — Bendix CE Series Stripping Dimer BNC Series Connectors With Associated Cables € Series Connectors Wit ‘Associated Cables Assembly Dimensions for C Series Connectors HN Series Connectors With Associated Cables N Series Connectors With ‘Associated Cables Pulse Series Connectors With Associated Cables TNC Series Connectors With Associated Cables MB Series Connectors With Associated Cables Stripping Dimensions for Coaxial Cable Assembled to MB Connectors ‘Stripping Dimensions and Crimping Tool Positions for Subminiature RF Connectors ‘Stripping Dimensions for Coaxial Cable ‘Assembled to Liquidometer $62 and $63 Series Connectors, Military Standard Solderless Terminals for Aircraft Use Color Coding of Copper ‘Terminal Lug Insulation Nonstandard (Class 2) Crimping Tools for ‘Small Copper Terminal Lugs Gaging Dimensions for AMP Nonstandard Crimping Tools for Small Terminals Gaging Dimensions for T&B Nonstandard Crimping Tools for Small Terminals Wire Stripping Lengths for ‘Small Copper Terminal Lugs . Copper Terminal Lugs (Large) and Crimping Tools i for Coaxial Cable... Page 3100 3108 3-108 3-108 341 412 413 4.16 421 428 4.26 428 4.29 434 52 54 58 say saa 516NAVAIR 01-1A-505 (USAF) T.0. 1-14-14 List of Tables Table Tile 58 Dies and Gages for Military Standard Power Tool MS25441 5.9 Indentors and Nests for T&B Hand Too! WT-117 510 Dies for AMP Power Tools 69061 and 69066 2... eevee S11 _ Die Sets for Burndy Power Tools Y29B and Y29NSC ......2....2+ 5.12. Die Sets for Bundy Power Tools ¥29B anc Y29BUC for Preinsulated Copper Terminal Lugs 5.13 Die Sets for T&B Power Tools 13586A and 13597 5.14 Gaging Dimensions for AMP Tools 5:15 “G" Dimensions for Burndy Power Tools $:16 High-Temperature Terminal Lugs and Crimping Tools... 5:17 Digs Used on Miltary Standard Power Tool for Crimping Aluminum Terminal Lugs 5-18 Gages for MS25442 Crimping Dies 5.19 Stripping Lengths for Aluminum Win 5.20 Stripping Length for Small Copper Splices 521 Length of Insulating Sleeves 2... +++ 5.22 _ Die Sets Used on Burndy Tools 'Y29B and Y29NC for Crimping Large Copper Splices 5.23. Die Sets Used on T&B Head 13642 for Crimping Large Copper Splices 5.24 Wire Stripping Lengths for Large Copper Spices... : 5.25 Wire Size Combinations (Per Splice End) for Mult-Splices «2-222. e seve 5.26 “T” Dimensions for Burndy Uninsulated Copper Splices and Straight and Right-Angle Terminal Lugs 5.27. “T" Dimensions for MS25189 Copper (Flag) Terminal Lugs 6-1 Susipping Lengths for Taper Pin Terminations... 62 Taper Pin Tooling — AMP ‘Standard 53 Series, Noninsulated 63 Taper Pin Tooling — AMP Standard 53 Series, Preinsulated ...... 6-4 Taper in Tooling ~ Burndy 0.053 Series 65 Taper Pin Tooling — Special AMP $3 Series... sess 7-1 Thermocouple System 7-2 Thermocouple Terminals 73 Coding for Thermocouple Contacts in MS Connectors 74 Code for Markings on ANSS37 Pave 517 sa7 519 5.20 5.20 521 521 S21 $24 5.27 5.28 5.28 530 5.32 $32 $32 533 534 $36 536 64 64 64 65 66 74 742 Table a4 82 83 na ns ns 7 us 9 1410 ull 124 122 123 124 125 126 134 132 B3 141 142 143 144 145 vin Hardware for Stud Bonding or Grounding to Flat Surface Hardware for Plate Nut Bonding or Grounding to Flat Surface ....... Hardware for Bolt and Nut Bonding ‘or Grounding to Flat Surface Bend Radii for Rigid Conduit . . [AN Fittings for Rigid Conduit Stripping Length for RubberCovered Flexible Conduit Collars for Rubber-Covered Flexible ‘Aluminum Conduit Used With Breoze Swaging Machine . .. AN Fittings for Bare Aluminum (Type I) Flexible Metallic Conduit AN Fittings for Rubber Covered Aluminum (Type II) Flexible Metallic Conduit ‘Accessories for Breeze Swaging Machine Ferrule Diameter After Swaging Collar Punches and Dies for Breeze Swaging Machine Fittings for Flexible Brass Conduit ‘Sizes of Heat Shrinkable Tubing Special Tools and Test Equipment Boot-Connector Combination Splices, Caps, and Sleeving of Wires of Same Gage Splices, Caps, and Sleeving of Wires of Mixed Gage Splices and Self-Sealing End Caps... Ferrule-Wire Combination Support Clamps for Rubber-Covered Flexible Aluminum or Brass Conduit, ‘Minimum Bending Radii for Flexible ‘Aluminum or Brass Conduit ....... Wire Types... ‘Twists Per Foot . Grommets — Temperature Limitations of Material ..... ‘i 1MS27212 Terminal Boards and Covers... ‘Washers for Use With ‘Aluminum Terminal Lugs... +++ 383 84 85 - na 4 116 - 7 19 1140 MAS MAS 1116 17 119 129 Paty 245 121s 12416 12.26 + 133 133 B4 142 2143 4 1412 14-12List of Tables Table Tie 146 Installation Torques for Copper Terminals 14.7 Installation Torques for ‘Aluminum Terminals 148 Wire Range Accommodations 14.9. Module Identification ..... 14-10 Crimping Tools for TJS Terminals 14-11 Insertion-Extraction Tool Designations 151 Cable Strap Colors 15> Self-Clinching Plastic Cable ‘Straps and Installation Tools NAVAIR _01-1A-505 (USAF) T.O, 1-18-14 Poge Table 161 4 172, 184 182 183 184 157185 Tile Safety Wire Size, Material and Color Code Lamps Used in Aircraft Lighting — Exterior .. Lamps Used in Aircraft Lighting ~ Interior Military Fuse Blow-Time Characteristics Fuses Used in Aircraft Electrical Systems 7 Cross Reference of Military and ‘Commercial Fuse Designations Voltage Code (Old) Cursent Code (Old) Poe loa 72, 172 182 185 187, 1813 183‘Subject Paragraph Adapters, Wire Well, 337 Bonding and Grounding, 8-5 Hardware, 8-7 Jumpers, 8:23 Methods, 8-17 Procedures, 8-6 Surface Preparation, 813 Surface Refinishing, 8.29 Testing, 8-26 Bundles, Wire, Compact, 12-16 ‘Types of Rework, 12-19 Busbars Installation, 13-12, 13-14 Preparation, 13-7, 13-11 Protection, 14:50 Wiring Connection to, 14-35 Cable, 25b (See Also Wire and Cable) Coaxial, 4-7 Caps, Protective, Connector, 3-41 Caps, Wire End, 3.586 Clamps, Cable, 14-29, 14.33, Clamps, Cable, Connector, 3-45 Installation, 3-70 Compound, Potting, 10-5 Dispensers for, 10-18 High Temperature, 10-6 Preparation, 10-10 Storage, 10-15 Conduit, 114 Installation, 13-15 Metallic, 11-6 Nonmetallic, 1-19 NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 132 134,132 14:17 141 344 148, 14-10 331 337 104 10-7 104 10.2 104 iw 133) Md 1118 INDEX SubjectParapraph Connections, Multiple, 336 Connectors, General Purpose, 3-1 t0 3-110 AN/MS Connectors, 3.6, 3-42 Cable Clamp, Connector, 3-45, 3-70 t0 3-74 Contact-Crimping Tools, 3-25 10 3.30 Contact Installation and Removal, 3-79 to 3.85 Continuity Testing, 3-38 to 3-40 Crimp-Contact Connectors, 3-24 Crimp Contacts, Installation, 3-78 Crimp Contacts. Removal, 3.79 Disassembly, 3-48 to 3.68 Grounding Shields, 3.35 Identification, 3-43 Installation, 3-48, 14.57 Interchangeability With UK/BMS Connectors, 3-75 Manufacturers’ Variations in MS Connectors, 3-46 Marking, 3-44 MIL-C-5015 Connectors, 3-43 MIL-C-38999 Connectors, 3.99 10 3-103 MIL-C-81511 Connectors, 3.89 10 3:92 MIL-C-81659 Connectors, 34104 to 3-110 MIL-C-83723 Connectors, 3.93 10 3.98 Miniature MS Connectors, 3-76 to 3-103 Miniature Rectangular Connectors, 3-120 Multiple Connections, 3-36 Nonstandard Connectors With Removable Crimp Contacts, 3-113 to 3-118 Potting Connectors, 3.47, 3.58 Protection of Connectors, 3-81 Reassembly, 3-48 Reducing Wire Size, 3-37 Shield Connections, 3-32 Soldering, 38 to 3.23 Special Purpose. 3-11) Subminiature, 3-119 UK/BMS, Interchangeubility, 3-75 Page 3.22 3-1 to 3-105 32,325 331,357 10 3.60 3.910 320 3.67 103-71 323 10 3:25 39 3.67 103-71 3.67 103-71 3.32 03.54 3.22 325 332, 14.19 361 331 3.28 3.25 3.84 10 3.90 3-74 to 3.80 3.90 5.195 3.8010 93 Bolt? 2 Bz 108 to 3-109 32,341 Index 1Subject/Parapraph Connectors, RF, 4-6 BNC, 4-15 C419 Fuel Quantity Indicating, 4-45 HN, 4.22 Miniature, 4-38, N,4-26 Procedures for, 48 Pulse, 4.30 SC,4:37 Soldering, 4-11 Subminiature, 4-41 TNC, 434 Crimping Connector Contacts, 3-24 Eyesight, 331 Splices, 5-5, 557 Taper Pins, 6-10 Terminal Lugs, 514, 5-17, 5-26, 5-31 Tools (see Tools) Ferrules, Grounding OnoPiece, 2-60 ‘TwoPiece, 258 Fuzes, 18:5 Identification, 18-8 Installation, 13-33, 18.9 Grounding ‘See Bonding and Grounding Grommets, 14-34 Harnesses, Molded Rigid, 12-5 ‘Compact Wire Bundles, 12-19 Repair, 12-14, 12-15 Junction Boxes Installation, 13-23 Lacing and Tying, 15-5 High Temperature Areas, 15-22 Lacing Procedure, 15-10 Materials, 15-6 Self-Clinching Cable Straps, 15-20 Tying Procedure, 15-14 Index 2 NAVAIR 01-1A-505 (USAF) T.O. 1-1A-14 234 229, 1841 18-11 136, 18.11 14-11 124 128 Rs 34 1541 157 152 15-1 155 184 SubjectParagrach Lamps, 17-5 Identification, 17-6 Replacement, 17-7 Lugs, Terminal, Solderles, 5-5 ‘Aluminum, 544 Copper, Small, $8 Copper, Large, 5-18 High Temperature, 5-32 Inspection of Crimp, 5-62 Plugs, Grommet Sealing, 361m Potting ‘MILM-24041 Compound, 10-20 to 10-26 MIL-S-8516 Compound, 10-5 to 10-19 MILS-23586 Compound, 105 to 10-19) Preparation of TRE Wire for, 10-19 Procedure, Connectors, 3-58 Protective Devices, 13-33 (Gee Also Fuzes) Identification, 13-44 Installation, 13.33 Repairs, Emergency ‘Coaxial Cable, 19-15 Connectors, 19-16 Shielded Cable, 19-12 Terminal Board Covers, 19-23 Wire, 19-5 Safety Wiring, 16-5 Lock Wire, 166 Procedures, 16-9, 16-16 Seal Wire, 16-8, 16-22 Shear Wite, 16-7, Sealing, Electric Connector (Gee Potting) ‘Shielded Wire and Cable ‘Dead-Ending, 2-62 to 2-65 Grounding Connections, 3-32, 3-38 Terminating, 2-55 Sleeving Heat-Shrinkable, 11-22 Identification, 2-25 Insulating, 3-12, 5-20 108 10 109 1041 to 10-7 10-1 to 10-7 107 341 Bs e 38 Bs 197 197 194 198 194 1641 161 16-1, 16-2 165 235 320,322 229 We e 213 32,5415‘Subject/Parngraph Solder Hard Solder, 9-11 Soft Solder, 9-9 Soldering, 9-6 Connectors, Electric, 3-15 Connectors, RF, 4-11 Inspection of, 9-41 Methods, 9-14 Procedures, 9-24 ‘Thermocouple Wiring, 7-15, 7-25 Soldering Iron, 9-15 Preparation and Maintenance, 9-19 Selection of, 9-29 Splices Aluminum, 5-59 Copper, 5:50, 5.54 High Temperature, 5-58 MultiSplices, 5-60 Strap, Cable, SelClinching, 15.20, 15-21 Wdentification, 235b ‘Taper Pins, 6-4 ‘Crimping, 6-10 Extracting, 6-17 Inserting, 6-14 Tools, 6-5, 6.20 Terminal Boards Connecting Wires to, 14:35 Covers, 13-52, 14:36 Installation, 13-45 ‘Terminal Junction System (MILT-81714), 14-68 Wdentification, 14.71 ‘Module Installation and Removal, 14-72 Pin Terminals, Insertion and Extraction of, 14-74 ‘Terminal Crimping, 14-73 NAVAIR 01-1A-605 (USAF) T.0. 1-14-14 5.33 5.29, 5:32 5.33 533 155, 15.6 249 141 13-10, 14.11 Ba 1421 14.26 1426 14.27 14.27 ‘Subject Paragraph Terminals ‘Aluminum Wire, 542 High Temps Inspection, Preinsulated, for Large Copper Wires (Wire sizes 8 Through 4/0), 5-18 Preinsulated, for Small Copper Wires (Wire sizes 26 Through 10), 5-8 ‘Thermocouple, 7-8 ‘Types and Styles, 5-7 Tools Cable Clamp, 14:32 Crimping, Connectors, 3-24 Crimping, Taper Pins, 6-6 Crimping, Terminal Lugs, 5.9, 5-21, 5:52, 5.56 Extraction, 3.81, 3-82, 68,69 Insertion, 3-80, 3-82, 6-7,69 Soldering, 9-15, 9-17 Wire Stripping, 2-40 Tubing (See Sleeving) Wire and Cable, 2.5, 14-15 (Gee Also Cable) Cutting, 26 Marking, 2-13 Reducing Size of, 337 Stripping, 2-36 Thermocouple, 7-6 Tinning, 2-47 Wire Groups and Bundles, 14-6 Wiring, Flectrical, 14-4 Installation in Conduit, 14-53 Installation in Junction Box, 14-64 Protection, 14-19 to 14-26 Routing, 14-15 Safety, 16-5 Thermocouple Wiring Installation, 7-31 ‘U8 GOVERNMENT FANETING OFPICE:1672-114 Sas s4 73 52 14.10 39 61 54, 5416, 530, 5:32, 3.48, 3-70, 3-67, 3-70, 6-1 93 221 22,144 23 26 323 221 1" 227 4a 44 1418 1421 145 to 14-7 144 16-1 712 Index 3NAVAIR _01-1A-505 (USAF) T.0. 1-10-14 SECTION | INTRODUCTION 1-1, GENERAL 1.2, This is one of a series of manuals prepared to assist rilitary personnel engaged in the general maintenance and repair of aircraft. The area covered by this manual is that of the aircraft electrical system. Since many airbome missiles remain with their aircraft for long periods of time and ate subjected to the same environment and stresses as the aircraft, itis recommended thatthe coverage of this mental be extended to airborne missle electrical systems. 13, The satisfactory performance of present-day aircraft depends to a very great extent on the continuing reliability, of its electrical system. Improperly or carelessly installed wiring can be a source of both immediate and potential danger, and many malfunctions and failures ofthe electrical system can be traced to this cause. The performance of the system depends on the quality of the design, plus the workmanship used in making the installation. The con tinued proper performance of the system depends on the “know-how” of the men who do the inspection, repair, and maintenance. 1-4, It is highly important therefore that maintenance and repair operations, as well as the original installation, be made in accordance with the best available techniques in ‘order to eliminate possible failures or at least to minimize them, 1-5. PURPOSE OF MANUAL. 1.6. The purposes for which this menual was written are as follows: a, To gather together under one cover the recom- mended practices and techniques to be used for installing, repairing, and maintaining aircraft electrical wiring, b. To standardize these techniques and methods so that electrical installations will be done in a uniform manner. ¢. To indoctrinate all personnel with the importance ‘of good workmanship. 4. To point up the failures which may result from poor workmanship. e. To promote safety by pointing out and prohibiting unsafe practices. 1-7. SOURCE OF INFORMATION 1.8. ‘The information contained in this manual represents the best current knowledge and practice in the aircraft electrical field. It has been compiled with the cooperation and assistance of the country’s leading airframe manufac: turers, airline operators, and military overhaul and repair ‘bases. Many of the illustrations have been provided by the ‘manufacturers of electrical accessories used in aircraft 1.9. SCOPE 110. This manual covers all general purpose wiring and wiring devices used forthe interconnection of equipment in aircraft, It also includes thermocouple systems and coaxial cabling installed in aircraft 1.11, The manual is not concerned in any way with design problems, or with the selection of wire, cable, connections, etc. However, in some cases, materials are noted as meeting specific temperature or environmental requirements. 4-12, INTENDED USE 1.13, This manual is intended primarily for use by personnel engaged in maintenance and repair under govern- ment contract or at military bases. Its use is mandatory for such personnel, except where any procedure contained in it conflicts with any government specification or document, in which case the government specification or document shall take precedence and a report describing the conflict shall be submitted. The manual will also be available to contractors, other than in connection with maintenance and repair, as a guide and as recommended practice, but its use by these contractors is not mandatory. However, the practices used by the contractor should always be compat ible with those of this publication so that modern tech- rniques may be used to maintain the aircraft regardless of the manufacturer. 1-14, The proceduses described in this manual are compat- ible with those currently used by airframe manufacturers. Repair and maintenance accomplished in accordance with this book should result ina quality equivalent to that in the original installation. 1"NAVAIR 01-1A-505 (USAF) T.O. 1-10-14 1.15, For specific installation, this manual is intended to be used in conjunction with the applicable handbook of maintenance instructions. (It supplements but does not supersede the handbook of maintenance instructions.) Cepies of government specifications and other official documents referenced herein may be obtained upon appli- cation to the Commanding Officer, Naval Supply Depot, ‘5801 Tabor Avenue, Philadelphia, Pa. 19120. Copies of the Department of Defense Index of Specifications and Stan- dards may be obtained by directing requests as follows: For Department of the Navy — to the Commanding Officer, U. S. Naval Supply Depot, 5801 Tabor Avenue, Philadelphia, Pa. 19120. For Department of the Air Force ~ to the Commander, WrightPatterson Air Force Base, USAF Engineering Specification and Drawing Branch, Administrative Services Office, Attn: EWB, Wright-Patterson Air Force Base, Ohio. For other than official use — to the Superintendent of Documents, U, S. Government Printing Office, Washington, D.C. 20402. 1-16, ARRANGEMENT OF MATERIAL 1.17, The material comprising the manual is divided into sections. Each section describes and illustrates the recom- ‘mended procedure for a single operation, or for a series of related operations. 1.18, The first six sections contain procedures for prepar- ing and identifying wire, and for assembling it to connec- tors, terminals splices, and taper pins. Later sections deal with procedures for ‘thermocouple wiring, bonding and grounding, soldering, potting, routing and support of wire ‘bundles, and preparation and installation of conduit, ‘busses, terminal blocks, junction boxes, lamps, and protec- tive devices. Directions for emergency repairs are found in the final section. 12 1.19. The material in each section is arranged as far as possible in the general order in which the operations are performed. Illustrations and tables are located as near as possible to the related text. Each section is headed by an introduction containing a short description of the subject and its function in the aircraft electrical system. Where necessary for clarity, alist of definitions is included. 1.20. Also included in the introduction of each section is a listing of applicable government specifications for the various materials required, and design procedures on which these installation techniques are based. The latest applicable revision of the listed specifications will apply 1-21, REVISIONS 1.22. Revisions and additions will be made from time to time to insure that the material in the manual will always reflect the best current techniques and keep abreast of the new developments in the field. Suggestions for correcting ‘and improving this manual are invited and should be sent to: By Naval activities: ‘Commander, Naval Air Systems Command Department of the Navy Washington, D.C. 20360 By Air Force activities: ‘Headquarters, San Antonio Air Material Area/MMST U.S. Air Force Kelly Air Force Base San Antonio, Texas 78241NAVAIR 01-1A-505 (USAF) T.O, 1-14-14 SECTION It WIRE AND CABLE PREPARATION 21, INTRODUCTION 22. GENERALIn order to make installation, mainte: nance, and repair easier, runs of electric wire and cable in aircraft are broken at specified locations by junctions such ‘as connectors, terminal blocks, busses, etc. Before assembly to these junctions, wires and cables must be cut to length, identified, stipped, and if required, tinned. 23. SCOPE, This section describes and illusirates the recommended procedures for preparing wire and cable for attachment to junctions, and for terminating shielded cable, 2-4, REFERENCE SPECIFICATIONS AND DRAWINGS . 00-725 ‘ape, Electrical Wire, Flexible Insulating Sleeving, Marking Machine, (Foil, Wire Identification Marking) 008571 Solder: Lead Alloy, Tin Lead Alloy, and Tin Alloy MILI-631 Insulation, Flectrical, Synthetic-Resin Composition, Non-Rigid MILT-713 Twine and Tape, Lacing and Tying, for Use in Electrical and Electronic Equip. ment MIL-C-1140 Glass Fiber; Yarn, Cordage, Sleeving, Cloth and Tape MIL43158 Insulation Tape, Electrical. Glass-Fiber (Resin Filled); and Cord, Fibrous Glass MIL1-3190 Insulation, Electrical, Sleeving, Flexible, Treated MIL.W-5086 Wire, Electric, Hook-Up and Intercon: necting, PVC Insulation MIL-W-5088 Wiring, Aircraft, Installation of MIL-A6091 Alcohol; Ethyl, Specially Denatured, Aireraft MILS.6872 Soldering Process, General Specification for MIL.W-7072B Wire, Electrical, 600 Volts, Aluminum, Genéral Specification for MIL-C-7078 Cable, Power, Electrical, 600. volts, Shielded MILW-7139B MILA-7444 MILW8777C MIL--15126 Wire, Electrical, Polytetrafluoro- ethylene-Insulated, Copper, 600V Insulation Sleeving, Electrical, Flexible Wire, Electrical, Silicone-Insulated Copper, 600V, 200°C Insulation Tape, Electrical, Pressure Sen- sitive Adhesive WARNING MILI-15126 insulation tape (including the glass fabric type) is highly flammable and should not be used in a high-temperature environment. MIL-1-23594 insulation tape i designed for high temperature operation (suitable for continuous oper SOO'E) and thould be used forall hightemperature environments. MILA-23594 MIL-W-16878D MIL-F-21608, MIL.W22759C MIL-1.23083 MIL-C-25038 MIL--22910 MIL.W-810444, MIL-W.81381 Ms 18114 MS 21986 Insulation Tape, Electrical, High Tem perature, Polytetrafluoroethylene, Pres- sure Sensitive Wire, Electrical, Insulated, High Temper- ature (Navy) Ferrule, Shield Grounding, Insulated, Crimp Style Wire, Electric, Fluorocarbon-Insulated, Copper or Copper Alloy Insulation Sleeving, Electrical, Flexible, Heat Shrinkable Wire, Electrical, High Temperature and Fire Resistant, Aircraft Tools, Crimping, Hand, for CrimpStyle Electric Terminals and Shield Fesrules Wire, Electric, Crosslinked Polyalkene Insulated, Copper Wire, Electric, Polymide-Insulated, Copper and Copper Alloy Wire, Electric, Extruded TFE Fluoro- carbon-Insulated, Nickel-Coated Copper, 1000 volts Wire, Electric, Extruded TRE Fluoro- carbon Insulated, Nickel-Coated Copper, {600 volts 24NAVAIR 01-1A-505 (USAF) T.0. 1-1A-14 2.5, DEFINITIONS ‘a. Insulated Wire. For purposes of electric and elec- tronic installation in aircraft, an insulated wire consists of a metal conductor covered with a dielectric or insulating material (see figure 2-1). Insulated wire is usually referred to as “wire” and will be so designated in this manual. Wires used in aireraft contain stranded conductors for flexibility. Insulations may consist of several materials and layers to provide dielectric insulation, thermal protection, abrasion resistance, moisture resistance, and fluid resistance, Wires ‘commonly used in aircraft are described in table 2-1. b. Cable (see figure 2-2). The term “cable,” as used in aircraft electrical installations, includes the following: 1, Two or more insulated conductors, contained in ‘a common covering, or twisted together without a common covering (multi-conductor cable). 2. One or more insulated conductors with an overall shield, or with an overall shield and a jacket over the shield (shielded cable), 3. Two conductors twisted together (twisted pair). 4. A. single insulated center conductor with a metallic braided outer conductor (coaxial cable). The concentricity of center and outer conductor is carefully controlled during manufacture to insure that they are coaxial SS © ® oO TYPE 1 a © ®® O ® oO (TYPES & AND EE) @® wMsi7411, ms17412, $1800, MS18001 @ a= ©O® oO es MILOHA7199 co MIL- 5086 ercedl 1§MS25190_| ysigto4, MS18105, MS21985 WI bb. IL=W-7072 wms2stot | f MIL-W-22759 Ms17410, MS90294 7 oo MIL=W75038 ———— © © ® O 4. MIL-W8777 ms2s471,_MS27110 s21986 he MiL.w.22789) si8i14 Primery Insulotion ‘Tope, Supported and/or Unsupported Gloss Fiber Brold © Finsrer ® Insulation, Impra we 21. 22 Wires Commonly Used In AircraftNAVAIR 01-14-6505 (USAF) T.O. 1-18-14 (SS& © © 2 UNSHIELDED MULTICONDUCTOR CABLE e. SHIELOED MULTICONDUCTOR CABLE Ba SS S=S_ NOTE: MAKE AS REQUIRED BY TWISTING SINGLE CONDUCTORS 4, TWISTED PAIR (2 Primory insulation CB) wn ste Figure 2:2. Cables Commonly Used In Aircraft Cables commonly used in aircraft are: MS 25313. Single or multiple conductor using MS25190 wire, shielded with thin copper braid and covered with a nylon jacket, MIL-C-27500 Single or multiple conductor, using any wire in table 2-1, shielded with tinned, silver-coated, or nickeloated copper braid as appropriate and covered with appropri- ate jacket, MIL-C-S756 Single or multiple conductor, rubber insu- lated conductor, rubber jacket. MIL-C:17 Coaxial cable. NOTE Instructions for coaxial cable are in section IV. c. Soft Solder. For use in aircraft electrical installa- tions, soft solder is a mixture of 60% tin and 40% lead, SN 60, as described in Federal Specification QQ-S-571. It may be in bar form to be melted for tinning, or in the form of rosin core wire solder for use with soldering iron. 4. Flux, For use with soft solder, flux is water-white rosin, dissolved to pastelike consistency in denatured alcohol 2.6, CUTTING WIRE AND CABLE 2-7, GENERAL. Cut all wires and cables to lengths given ‘on drawings or wiring diagrams. Cut wire and cable so that cut is clean and square and wire is not deformed. (See figure 2-3.) After cutting, reshape large diameter wire with pliers, if necessary. CAUTION Make sure that blades of cutting tools are sharp and free from nicks. A dull blade will deform and extrude wire ends, 23Applicable Specification MIL-W-5086 MIL-W-7072B MILW-7139B MILW-8777C MIL-W-16878D MIL-W-22759C MIL-W-25038 MIL-W-810444, MIL-W-81381 24 NAVAIR 01-14-5605 (USAF) T.O, 1-14-14 Table 2-1. Wires Used in raft Electrical Installations Title/Description Wire, Electric, Hook-Up and Interconnecting, PVC Insulation. TTin, copper, or copper alloy conductors with polyvinyl chloride insulation and nylon or glass braid and nylon jacket, 105°C temperature rating. Wire, Electric, Aluminum, Aircraft, General Specification for ‘Aluminum conductor, PVC, glass braid, nylon braid jacket, 600V insulation, 105°C temperature rating. Wire, Electrical, Polytetrafluoroethylene-Insulated, Copper, 600V Silver of nickel coated copper conductors, TFE fluorocarbon and glass insulation, high temperature interconnecting, self extinguishing, 200°C and 260°C, respectively. Wire, Electrica, Silicone-Insulated, Copper, 600V, 200°C Silver coated copper conductors, slicone rubber insulation, glass braid, polyester braid or FEP fluorocarbon jacket. Wire, Electrical, Insulated, High Temperature (Navy) Silver of nickel coated copper conductors, extruded TFE insulation, 600 ‘and 1000V, 200°C or 260°C. Wire, Electric, Fluorocarbon-Insulated, Copper or Copper Alloy Silver and nickel coated copper conductors with TFE and FEP insulation jn various types for: general hookup, abrasion, and fluid resistance; silver coated conductors, 200°C maximum temperature; nickel coated conduc: tors, 260°C maximum temperature. Wire, Electrical, High Temperature and Fire Resistant, Aircraft Nickel clad copper (27 percent nickel), asbestos, glass, TFE insulation, 600V, 260°C Wire, Electric, Crosslinked Polyalkene Insulated, Copper General purpose wire with tin coated or silverplated copper, or silverplated high-strength copper alloy conductors. Maximum operating temperatures: 125°C and 150°C. Wire, Electric, Polyimide-Insulated, Copper and Copper Alloy General purpose wire for use in high voltage applications. Insulation is tape wrapped of polyimide, or polyimide-fluorocarbon films. Conductors are silver or nickel plated copper or high-strength copper alloy.NAVAIR 01-1A-505 (USAF) T.O. 1-1A-14 ble 2-1. Wires Used In Aircraft Electrical Installations (continued) NOTES: (Paragraph 1-11 applies) Conductor ~ Stranded conductor wire is used for Mexibility in installation and service. Wite sizes approximate ‘AWG sages, but vary sufficiently 20 that itis improper to refer to gzeraft wire as "AWG" In low temperature ‘ie, stands are Ganed (0 facilitate soldering. In wire rated at 200°C conductor temperature, ser is used to ‘coat strands to protect copper from oxidation and to faclitate soldering. Wires for high temperatures use rickel-couting to! prevent oxidation, Nickel-coated wire is more dificult to solder than slvr-coated wire, but makes satisfactory solder connections with proper techniques. Nickel-coated wire has less tendency to wick folder and become brittle than silver coated wie Ineuation: Primary Insulation PVC (Polyvinyl Chloride) — PVC is a common wite insulation. I has good insulation properties and is selfextingulshing after fame. Silicone Rubber — Siicone rubber is rated at 200°C Its highly Nlexble. It is sel-extinguishing aftr flame ‘except in vertical runs. The ash is nonconducting. “TRE-Fiuococarbon (polytetrafuoroethylene) — TFE is widely used as high-temperature insulation. It will ‘not burn but will vaporize in flame, It will not melt at soldering emperatues. TFE is resistant to most ‘uid, PEP-Fivorocarbon (Fluorinated ethylene propylene) ~ FEP is rated at 200°C, but will melt at higher temperatures. PEP has properties similar to TFE, but is meltextrudable. it will melt at soldering temperatures. ‘Thermal and Abrasion Resistant Materials Used in Intermediate and Outside Layers: Gass Braid — Widaly used to provide thermal resistance and cut-through resistance, However, it may bord moisture and its use is Becoming less prevalent. ‘Asbestos ~ Asbestos and other mineral fibers are used to provide high temperatures and flame resistance, ‘Moisture absorption is high, but scone rubber, TFE, or other safurants se used [Nylon — Widely wed in low temperature wits for abraion resistance and fluid resistance. Polyimide — A new material with excellent thermal, abrasion, and cut-through resistance characteristics, Jackets — Extruded nylon, nylon brad, polyester braid, FEP-luorocarbon, and TFE-impregnated gla braids are used as jackets for fluid and abrasion resistance. Smooth extruded jackets are preferred on wires {to be used with grommetseal connectors Hookup Wire — Hook-up wire is normally uted for wire in chasis and other enclosed areas. This wire may be used for interconnection ‘viring in compact wire harnessos when protected by molded or braided Coverings, The term "hook-up" ie sometimes used to include interconnecting wire, and the term “chasis wvite" ip then used to distinguish non-abrasion resistant inslated wie from interconnecting wires. Interconnecting Wire ~ Interconnecting wire is designed to withstand all normal aircraft environment (including limited scuffing) without sleving, jacketing, oF other protection, However, no wire insulation Wwil withstand continuous scuffing or abrasion and must be installed to minimize sich abuse Mediumabrasionesistant wire sich as MS18000 and MS18001 must be installed with extra care. Fire Resistance ~ MIL-W-25038 wite is used in circuits such as fre detection and fie extinguishing circults ‘where insulation properties during flame are required, This wire may also te used in areas where Intermittent temperatures above 260°C are encountered. It wil withstand 400°C (750°F) for periods ing which ime i will gradually lose moisture resistance. Its continuous duty 28NAVAIR _01-1A-505 (USAF) T.O. 1-18-14 NEEDS RESHAPING Figure 2:3. Wires After Cutting 28. CUTTING COPPER WIRE AND CABLE. To cut a large number of heavy wires or cables, use a circular saw with a cable cutting blade. A cable cutting blade is similar to-a meat slicing blade (no teeth). (See figure 2-4a.) WARNING Do not use a circular saw without an adequate guard over the blade. Heavy or light copper wires can also be cut with bench shears such as shown in figure 2-4b. 29. To cut a few heavy gage copper wires or cables, use a fine tooth hack saw. A fine tooth hack saw has 20 or more teeth per inch. See figure 2-4c for use of hack saw and saw vise which protects heavy wire during cutting. 2.10, To cut a few light gage copper wires, use diagonal pliers as shown in figure 2-4e, Do not attempt to cut wires larger than AN-8 with diagonal pliers. 21. CUTTING ALUMINUM WIRE. Be careful when cutting aluminum wire to avoid deforming the conductors. ‘Aluminum wire is more brittle than copper, and if deformed, aluminum wire should be reshaped carefully. Never cut aluminum wire with tools which have reciprocating motion, such as a hack saw. Reciprocat- ing cutting action “work hardens” aluminum. This will lead to broken and torn strands. 26 242, To cut a large number of aluminum wires, use a power circular saw with cable cutting blade as shown in figure 2-4a, Do not use toothed blade for cutting aluminum If cutting tool has been used for other metal, wipe blades clean before cutting aluminum. Copper or steel chips will cause aluminum to corrode. Special cable shears with concave cutting edges such as pruning or dehorning shears may also be safely used to cut ‘aluminum wire. A cable shear of this type is illustrated in figure 2-44. 2:13, IDENTIFYING WIRE AND CABLE 2.14, GENERAL. To make maintenance easier, each interconnecting wire and cable installed in aircraft is marked with a combination of letters and numbers which identify the wire, the circuit it belongs to, its gage size, and other information necessary to relate the wire to a wiring iagram. This marking is called the cable identification code. Details of the code are given in Military Specification MIL-W-5088. Some general information is given in 2-15 and 2.16. Wire received from the manufacturer is printed with ‘the manufacturer's code designation in a light green color at intervals of one to five feet, the MS number and dash number of the wire, and a one-, two, or three-digit number indicating the color of the basic wire insulation and the color of the stripes (if present). The color code is as follows: Black 0 Blue 6 Brown 1 Violet 7 Red 2 Gry 8 Orange 3 White 9 Yellow 4 {includes also Green 5 ‘uncolored insulations) For example, a wire printed with number MS25190A20913, would designate a wire constructed in accordance with Military Standard drawing MS25190, Type 1, size 20, having white insulation (9), a first stripe of brown (1), and ‘a second stripe of orange (3)- NOTE When marking wire with the identification code described in 2-15 and 2-16, it is permissible to overstamp the manufacturer's printing.NAVAIR 01-14-5605 (USAF) T.0, 1-14-14 GUARD CABLE CUTTING BLADE cuarD (NO TEETH) & CIRCULAR SAW FOR CUTTING WIRE ‘AND CABLE ADJUSTABLE STOP 70 FOOT PEDAL Yo. b. BENCH CABLE SHEAR TWENTY OR MORE TEETH PER INCH HACK SAW WITH SAW VISE con a CAVE BLADES CABLE SHEARS ~ PRUNING TYPE O ‘@ DIAGONAL CUTTING PLIERS igure 24. Wire Cutting Tools 27NAVAIR 01-1A-505 (USAF) T.0, 1-14-14 2.415, WIRE IDENTIFICATION CODE (BASIC). The basic wire identification code used for all circuits except those having the citcuit function letters R, S, T, or Y (see figure 2-5a) is as follows, reading from left to right: 4. Unit number: Whete two or more identical items of equipment are installed in the same aircraft, the unit numbers "I", “2", 3", “4”, etc., may be prefixed to differentiate between wires and cables when it is desired that the equipment have the same basic cable identification To facilitate interchengeability requirements, identical wiring located in left and right wings, nacelles, and major interchangeable structural assemblies ‘may have identical cable identification and the unit number is not required. ‘The unit number for circuit functions “R™, “S", “T", and “Y", ate used only where duplicate complete equipments ate installed, and do not apply to duplicate components within a single complete equipment such as duplicate indicator or control boxes. b. Circuit function letter (except R, S, T, and Y): The circuit function letter is used to identify the circuit function specified in table 2-2. Where a wire or cable is used for more than one circuit function, the circuit function letter of that circuit which is functionally predominant applies. When functional predominance is questionable, the circuit function letter for the wire or cable having the owest wire number is used. cc. Wire number: The wire number consisting of one oF more digits is used to differentiate between wires in a iruit. A different number shall be used for wire not ng a common terminal or connection hi 1. Wires with the same circuit function having a ‘common terminal connection or junction have the same ‘wire number but different segment letters. 2. Numbers 2,000 to 4,999, inclusive, are reserved for use by the procuring activity to identify wires installed by service modifications, except for those wires with circuit function letters of R, ST, and Y. 3, Beginning with the lowest number, a number is assigned to each wire in numerical sequence, insofar as practicable, d, Wire segment letter: A wire segment is a conductor between two terminals or connections. The wire segment letter is used to differentiate between conductor segments in a particular circuit. A different letter is used for wire segments having a common terminal or connection. Wire segments are lettered in alphabetical sequence. The letter “A identifies the first segment of each circuit starting at the power source. If a circuit contains only one wire segment, the wire segment is marked “A”. The letters “I” and “O" are not used as segment letters. Double letters “AA”, “AB”, “AC”, ete., are used when more than 24 segments are required. Two permanently spliced wires do ‘not require separate segment letters if the splice is used for ‘modification or repair. e, Wire size number: The wire size number is used to identify the size of the wire or cable. For coaxial cables and thermocouple wires, the wire size number is not included. For thermocouple wires, a dash (-) is used in lieu of the wire size number, £. Ground, phase, or thermocouple letter(s): 1. Ground cable letter “N” is used as a suffix to the ‘wire identification code to identify any wire or cable that ‘completes the circuit to the ground network. Such wires and cables shall be capable of being connected to the ground network of aircraft electrical systems without causing malfunctioning of any circuit. For critical and sensitive electronic systems which have interconnecting “ground” leads, but only one segment actually grounded to structure, only the segment actually grounded to structure is identified with the "N” suffix. 2. Phase letter “A”, “B”, or “C” shall be used as a suffix on the wire identification code to identify the phase ‘of wires that isin the three-phase power distribution wiring of AC systems. The phase sequence shall be “A-B-C” 3. Phase letter “V" shall be used as a suffix on the cable identification code to identify the ungrounded wire fr cable that is ina single-phase system, 4, For thermocouple shall be used as applicable: , the following suffixes CHROM ~ Chromel ALML ~ Alumel TRON ~ Iron CONS ~ Constantan COP — Copper a. For aluminum wire, ALUMINUM or ALUM shall be added as a suffix to the wite identification code.NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 ALTERNATE e — SUFFIX | GROUND, PHASE, OR THERMOCOUPLE LETTER| O WIRE SIZE NUMBER A WIRE SEGMENT LETTER 4 WIRE NUMBER N CIRCUIT FUNCTION LETTER A a-----+------ UNIT NUMBER a L AW AS APPLIED TO ALL CIRCUIT FUNCTIONS EXCEPT R,S,T, ANDY ¢ LL Grouno, PHASE, OR THERMOCOUPLE LETTER WIRE SIZE NUMBER WIRE SEGMENT LETTER WIRE NUMBER EQUIPMENT IDENTIFICATION ------------- UNIT NUMBER DY Figure 2.5. Examples of Wire Identification Coding 29NAVAIR _01-1A-505 {USAF) T.0, 1-18-14 ‘Table 2:2. Function and Designation Letters!/ Circuit Circuit Function Function Tete Cesta Tener Cheuis A ARMAMENT: ENGINE INSTRUMENT: Bomb suspension and release Carburetor sc pressure Torpedo Bearing emperture Depth charge Talpipe temperature Guns Crtutetoranticing Oui quantity Gun heater Foe mixture Chemical Torque meter Rocket Brake mean effective pressure Sit Feel ow Taree Fel quantity Waning al eapacity External pylon and stores Cylinder head temperature Seton fet tanks Olt temperature Coolant temperature 3B muoTocRAmne oes Gun canen Manfold pressure fapping camera Fact presture ao Propeller anthicing fuid quantity Camera doors Engine oil quantity Camera heaters eee a Synehroscope ning Waning © CONTROL SURFACE: ‘Automatic pilot Booster Contol tabs FLIGHT INSTRUMENT: Diving brakes Bank and tum right Rate of climb Horizontal sabuicer Diretonl gy Landing laps ie po Watersudder position Ground potion Tin abe Compas inching fx gate and Wa fps ‘other sublized compass) Waning Gyrohotzon INSTRUMENT (other than ight eemete engine istrments) ‘Altimeter Oitap postion ‘Aemeromems Cowtfap postion Protstatic tbe heater Coclantup position Waring Air presure Free air temperature Landing gear position Hydraulic pressure LANDING GEAR, WING FOLDING: Cabin presure ‘Actuator Carton monoxide Retrction Landing flap postion Wheel bakes Propeller pitch postion Down lock Tastrumet vcaum pump Wing folding Horzonal-stblizer postion Ground safety “Teim-ab position ‘Arresting hook Water pressure Wheel steering Voltmeter Upleck Glock Wheel spinning Warning Waning 1U/ Cucuit function and circuit designation letters of electrical and electronic wires and cables shall as specified herein. Typical circuits are listed under their respective circuit functions, e 2 Unassigned circuit function or eivuit designation letters shall not be used until formally assigned by Joint action of the Ais Force and the Navy 240NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 ‘Teble 2:2. Function and Designation Letters (continued)! Cireuit Circuit Fonction Function Letter Cirovits Letter HEATING, VENTILATING, AND DE:CING: L “Anticing (general) Battery heater Cabin heater (Cigarette lighter Deeicng (genera Heated fying suits Formation Gallery Cargo Windshield defroster Intron Windshield defogger instrument Windshield deer Section (fuselage) Heater blanket Landing (Oil immersion heater Exterior Refrigeration Running. position, navigation Cabin supercharger Pasting Ventiation Search Water heater Tas Oxygen heater ‘nchon Warning Waring 1 In order to avoid confusion with the numeral one, the letter "I shall not be used for MISCELLANEOUS ELECTRIC tireuit or cable identification. Distributor Electronic et assist takeoft Magneto ground wiring Warning K —_ ENGINE CONTROL: ‘Carburetor air lap Blower ratio Cowl fap, ar shutter Intercooler flap Oi cooler shutter Propeller feathering Propeller synchronizer Propele pitch Supercharger regulator Starter Waring 1 Circuit func Windshield spray Bilge pump Cargo door Water distiation Windshield wiper Holst Enclosure operation Positioner; sat, pedal Special test equipment Winches; target, lider UNASSIGNED?! {In order to avoid confusion with the numeral 2410, the letter "O" shall not Be used for ‘Grout or cable identification, DC POWER: Wing in the DC power or powerconteol system, slall be identified by the citcuit function letter and eicuit designation leer of electrical and electronic wires and cables shall be as specified herein. Typical cizcuits are listed under thelr respective circuit functions. Ay Unassigned elruitfunetion or clreult designation letters shall not be used until formally assigned by joint action of the Ai Force and the NavyNAVAIR 01-1A-605, (USAF) T.0. 1-14-14 ‘Table 2-2. Function and Designation Letters (continued) / e Circuit Gest Punetion Fonction etter Crests Tester Circuta © FUELANDOn: TG - GM honing Fudlvaes TH — Infrared Fuel Booster pump motor TK ~ Telemetering Mixture contol TL Attiude indeator On diuton Ta — Chaff dspenser Engine primer TN - Navigation FFucksanfer-pump motor an contol ‘TP — Beacon (rash and locator) FveHioading pump motor ‘TQ — Tranamites and secetert Olt-sansfrpump motor and contol TR — Recevers Otbooster pump TS — Antisubmarne (ASW) Oitscavenger pump TT ~Trananiters ‘Thyotte contol ‘TU Reconnaissance Fuetpump motor TW Weather devices Oltdverer TX — Televison tranamiters Oitvales TY — Televison seekers Water inction Te — Bombing devices Waring U_ MISCELLANEOUS ELECTRONIC: R_—_-RADIO (navigation and communication recuonic wiring for which no "R","S", or “T™ RA ~ Instrument landing designation hasbeen aged by the procuring RC — Command fctity shall have the ett fenton letter 0 IRD — Radio direction finding Assigned Examples of wing for which the eeu RE — VHP ison Tunetion eter "U" wil be sued are common RIL — Homing lead oeectoni equipments and systems RL — Liston interconnection wsing Such a antenna or power RM ~ Marker beacon Sirus common to more than one equipment or sytem, EN “Ns e RP ~ Speci systems VDC POWER and de contol bles for AC systems shall RS ~ SRE command te identified by the ecu function eter" Ar ~ Rats pe W-_ WARNING AND EMERGENCY (in io o os Iisted under other circuit functions: RY ~ VHP command [Enclosure release and locks RX ~ Recorder 2 — Interphone, headphone pees Submersion actuator S RADA Bailout alarm SA Altimeter Seat ctor SF — Interoept Fie detector SG ~ Gunleying Oxygen detector SM — Mapping Noumoking sign SN — Navigation Fastenbelts in 80 homing Interrew burr of Ught SS ~ Seah x acrowER: eer ‘sng inthe AC power syste shall be eng SEE NC eee mentale. SX = Recognition (FF) Y ARMAMENT SPECIAL SYSTEMS: ‘Yea Air toait T SPECIAL ELECTRONIC: YB — Arto surface TA Adaptor YC ~ Muitimode Radar cont Misalegudance Te Radio conto yer Tuner TD ~ Airborne announcing * Armament special systems number TE ~ Electronic countermeasures hi ‘TF ~ Repeat back Z ‘UNASSIGNED2/ 11 Cet ton nd ah pation tof ene nd lew cn a rd ee aaa ay Gamage er ee fee echo en ase al a os e nay esi PoeNAVAIR 01-1A-505 (USAF) T.0, 1-14-14 2:16. WIRE IDENTIFICATION CODE (R, S, T, and Y CIRCUITS). The wire identification code for wires and cables having function letters “R”, “S”, “T, and “Y" is assigned by the equipment contractor as follows and as illustrated in figure 2-Sb. The wire identification code is derived by utilizing that portion of the military type designation (AN nomenclature) following the /, but exclud- ing the hyphen and any suffix letters. The block of wire numbers for each equipment shall start with 1 and continue for as many numbers as are needed to identify all wires. For example, wires of the AN/APS-45 would be identified APS45-1A20 — APS45.975C22, those of the AN/ARC-524. would be ARC52-1A22 ~ ARCS29C22, and the MX-94 would be the MX.94-1A20, etc. For equipment for which a type designation (AN nomenclature) will not be assigned, such as commercial equipment, a block of numbers is obtained from the procuring activity. 2417, IDENTIFICATION METHODS. The identification code may be stamped on wires either horizontally or vertically, as shown in figures 2-Sa and 2-5b. The preferred method of identification is to stamp the identification marking directly on the wire or cable with a hot foil stamping machine. Use this method wherever possible. If the wire insulation or outer covering will not stamp easily, lengths of insulating tubing (sleeves) are stamped with the identification marking and installed on the wire or cable. ‘The following types of wire are usually identified by means of sleeves: ‘8, Unjacketed shielded wire b. Thermocouple wires ©. Multiconductor cable 4d, High temperature wire with insulation difficult to mark (such as asbestos, TFE, fiberglass, et.) Do not use metallic markers or bands for identifica tion, Do not use any method of marking that will damage or deform the wite or cable Use sleeves only if wire cannot be marked directly. With care, some wires previously thought to be unsuitable for direct marking can be stamped with a standard marking machine using special foils. 218, MARKING OBJECTIVES. Whatever method of ‘marking is used, be sure marking is legible, and that color of stamping contrasts with the wire insulation or sleeve. Use black stamping for light colored backgrounds. Use white on dark colored backgrounds. Make sure that markings are dry so they do not smear. 2.19. SPACING OF STAMPED MARKS. Stamp wires and cables at intervals of not more than 15 inches along theit entire lengths. (See figure 2-6.) In addition, stamp wires within three inches of each junction (except permanent splices), and at each terminating point. Stamp wires which ‘are three to seven inches long in the center. Wires less than three inches long need not be stamped, ROTATE 180° BETWEEN IMPRESSIONS IF PRACTICABLE Figure 2.6. Spacing of Identification ‘Stamping on Wire and Cable 243NAVAIR 01-18-6505 (USAF) T.0. 1-14-14 2.20 LOCATION OF SLEEVE MARKING. When wire or cable cannot be stamped directly, install a plastic sleeve ‘marked with the identification number over the outer ‘covering at each terminating end (see figure 2-7). For Air Force planes, also install marked sleeves at not more than six foot intervals on the entire length of such wire or cable. Do not use sleeves to change identification of wire or cable which has already been marked, except in the case of spare wires in potted connectors. FOR AIR FORCE ONLY EXTRA SLEEVES EVERY 6 FEET Pe PT Figure 2-7. Location of Identification Sleeve 221, MULTICONDUCTOR CABLE IDENTIFICATION. Identify multiconductor cables with marked sleeves installed as described in 2-20 (see figure 2-8). Stamp sleeves with identification marking of each wire in the cable. Immediately following the identification code, stamp letters indicating the conductor color, using the following abbreviations: BLK — Black ORN ~ Orange BLU — Blue PR ~ Purple BRN — Brown RED ~ Red GY — Gry WHT ~ White GRN — Green YEL - Yellow ‘At each terminating end, strip back outer covering as far as, necessary and stamp color code letters on insulation of each conductor. 214 Figure 2-8. Multi-Conductor Cable Identification 2.22. COAXIAL CABLE IDENTIFICATION. Identify ‘coaxial cable by direct stamping on the cable (see figure 2.9) of with sleoves. If sleeves are required, install them as indicated in 2-20. In addition, mark coaxial cable on the ‘end terminating in a piece of equipment to match marking on equipment terminal When marking coaxial cable, take care not to flatten the cable as this may change the electrical characteris- tes of the cable. ” 15"*-abe 15" MAX MAX | MAX MATCH TO MARKING ON MATING RECEPTACLE Figure 2.9, Coaxial Cable Identification 2.23, THERMOCOUPLE WIRE IDENTIFICATION. ‘Thermocouple wire which is usually duplexed (two insu- lated conductors laid side by side) is difficult to mark legibly. Sleeves are installed as described in 2-20. The wire size of the identification code is replaced by a dash. The ‘material designation shall be as follows: CHROM - chromel;, ALML - Alumel; IRON - iron; CONST - constantan; COP « copper. 2.24, IDENTIFICATION AT TERMINAL BOARDS AND ENCLOSURES. If possible, mark wires attached to ter rminal boards and equipment terminals between termination and point where wire is brought into wire bundle (see figure 2-10). Identify wires terminating in an enclosure inside enclosure if space permitsNAVAIR _01-1A-605 (USAF) T.O. 1-1A-14 Figure 2-10. Wire Identification at Terminal Board 2.25. SELECTION OF IDENTIFICATION SLEEVING. For general purpose wiring use flexible vinyl sieving, ether clear or white opaque. For high temperature applications (over 100 degrees C) use silicone rubber or silicone fiberglass sleeving. Where resistance to synthetic hydraulic fluids or other solvents is necessary, use nylon sleeving, either clear or white opaque. Select size of sleving from table 2:3. Heat shrinkable polyethylene tubing may also be used to identify wire which cannot be marked directly. Available sizes are given in section XI, table 11-11 226, IDENTIFICATION MARKING MACHINES. See figures 2-11 and 2-12 for typical marking machines. For stamping a large number of long wires, use an automatic wire marking machine, In machines of this type (figure 2-11), wite sizes No. 26 through No. 14 are fed through and stamped automatically. Wires larger than No. 14 are fed ‘through by hand, but stamped automatically. For short wires, on tepait or maintenance work, a hand-operated wire ‘marking machine is more convenient and economical (figure 2-12). In this type of machine, the desired amount Of wire is fed through by hand, and siamped by operating the handle for each marking. Wire guide holders in sizes to fit wires, and slot holders to hold appropriate size type, are furnished to fit the machines. Type is supplied in thre sizes to mark wire No. 26 through No. 0000, as shown in table 24. Marking foil is available in black or white (and other colors if needed for special applications). NOTE Store foils at approximately 70°F and 60% relative humidity. Table 2-3. Sizes of Identification Sleeving Wire Size MIL-W-5086 MIL~ Types I and I Type Il AN AN #22 #720 #22 #8 #20 6 ae aa #16 #2 a4 #10 #2 #8 #10 #6 #8 #4 46 2 4 a 2 0 a #00 +0 7000 00 #70000 +9000 0000 Sleeving Size MIL-W-7072 aa Nominal AL Ne LD (Inches) u 095 10 1106 9 -l1 8 1133; iu 48. 6 1166 4 "208 2 1263 8 0 +330 ¥6 3/8 375 4 v2 +500 #2 1/2 +500 a 5/8 625 #0 5/8 625 #00 3/4 750 000 3/4 750 0000 1/8 875NAVAIR 01-1A-505 (USAF) T.O, 1-18-14 TYPE HOLOER eile \ Figure 2-11, Wire Marking Machines — AutomaticNAVAIR 01-1A-505 (USAF) T.O, 1-1A-14 Figure 2-12, Marking Machines — Hand 2.27. SET-UP OF MARKING MACHINES. FOR WIRE STAMPING, After selecting the proper machine for the job, set it up for the marking procedure as follows (refer to figures 2-11 and 2-12): ‘a, Select from table 24 the type of correct size for wire to be marked. Make up required identification code ‘and insert into type holder, centering type in holder. Use spacers to prevent crowding letters and numbers. Select marking foil of correct width for length of marking. Use black foil for light colored insulation, and white foil for dark insulation. cc, Select wire guide holder with wire hole to fit wire, and having a slot of same length as sot in type holder. Teble 2-4, Recommended Sizes of Marking Type Wire Size Height of Letters inches) 126 & #22 v/16 20 thru #14 5/64 #12 thru #0000 & Coaxial Cable 7/64 Use smallest guide into which wire will fit. If guide is too large, wire will not be held firmly and will be off-centered. 4, Install wire guide and roll of marking foil on machine. Slide type holder into slot provided for it. 2.28, PROCEDURE FOR WIRE STAMPING BY MACH- INE. The procedure for stamping wire by machine is as follows: NOTE Good marking is obtained only by the proper ‘combination of temperature and pressure, and is arrived at by trial. ‘Avoid excessive heat or pressure as it may damage the wire insulation. ‘Tum heat to high, then regulate downward to required temperature. See table 2-5 for recommended temperatures. Table 2.5. Recommended Marking Temperatures ‘Insulation Material Recommended Temperature Kel-F 300 eo 325°F Vinyl 400 to 425°F *TFE 425°F Nylon 400 to 450°F **Silicone 400 to 450°F Polyester 50°F *FEP 550 to 600°F ‘Using special foil jotective coating and shortheat cure after marking recommended. . _ Insert piece of sample or scrap wire into wire guide, and adjust pressure control until mark is sharp and clear. Impression should be just deep enough to sink slightly below surface of insulation, but should not cut into it. The Pressure adjustment also controls the length of dwell in automatic machines. 247NAVAIR 01-1A-505, (USAF) T.0. 1-1A-14 c. When a satisfactory marking has been made, remove sample wire, and insert wire to be marked into wire guide far enough so that first marking will be made about three inches from end. 4. Operate foot pedal or hand lever to make mark, fe. It is desirable (but not mandatory) to rotate wire 180 degrees and mark again on opposite side. {, Mark remaining wire length. If marks are to be spaced at intervals of eight inches or less, operate machine automatically. If intervals are greater than eight inches, orif wite is lager than size No. 8 (regardless of spacing), pull wire through by hand and operate machine at desired spacing. If practicable, rotate wire back and forth at each ‘mark through 180 degrees to mark on opposite side. During ‘marking’ procedure, check permanence of mark from time to time by rubbing with a clean dry cloth. If mark smears or becomes hard to read, adjust machine to correct condition and remark wire. 229. SPECIAL INSTRUCTIONS FOR MARKING TFE- INSULATED WIRE. Because of the chemical nature of TFE, it is difficul to make a permanent marking on ‘TFE insulated wire. Marking machines as described in 2-26 will stamp a legible marking on TFE, but this has a tendency to rub off. The marking may be set permanently by passing the marked wire through an electrically heated oven set at a specified speed and temperature. (See figure 213) 230, PROCEDURE FOR HEATSETTING IDENTIFICA- TION MARKING ON TFE. The procedure for heat-setting {identification marking on TFE-insulated wire is as follows: a. Turn the temperature control to HIGH and allow ‘oven to heat until temperature reaches 1900°F (approx: imately 30 to 45 minutes) b. Tum the motor switch ON and set speed to the desired rate; elect speed from table 2-6. cc. Insert the wire through the guide tube into the forward rollers. As the first part of the wire passes through the oven, depress the rear (exit) roller manually to allow free entry of the wire into the rear guide tube; this will prevent the wire from buckling. The rest of the wire length will pass automatically through the oven. Provide a suitable exhaust hood over the oven to carry off fumes. Make sure there is adequate ventila- tion in the area where the oven is used. Figure 2-13. Electric Oven for Heat Setting Identification Marking 248NAVAIR _01-1A-505 (USAF) T.0. 1-18-14 ‘Table 2-6. Speed Settings for Heat Setting Electric Oven Wire Specification Wire OD, Recommended Speed (Feet per minute) MIL-W-7139 070 + .090 15 t0 20 -090 = -125 10 0 15 MIL-W-16878 .030-.070 1510 20 2070-09012 15 2090+ .125 100 15 2.31, SET-UP OF MARKING MACHINE FOR SLEEVE STAMPING. For stamping identification mark on tubing that has an OD of 1/4 inch or smaller, use the same machine that is used for stamping wire. Set up machine as follows: ‘4. Select type size and wire guide to suit OD of tubing. b. Select mandrel (metal rod) of a diameter that will fit snugly inside tubing. Insert mandrel into tubing, and both into wire guide. If mandrel of proper size is not available, use piece of insulated wire of suitable diameter and length. Prepare type as described in 2-27, step a 4, Select foil and install wire guide, foil, and type holder on machine as described in 2-27, steps b,c, and d. 232, PROCEDURE FOR STAMPING SLEEVES BY MACHINE, To mark tubing, follow procedure for marking wire as described in 2-28, steps a through ¢. After first ‘mark, mark remaining tubing at intervals that will leave ‘about one inch between marks (see figure 2-14). Rotate at ‘each marking to mark again on opposite side. & FSO a Figure 2-14, Merking on Sleeves 2,33. MACHINE STAMPING FOR LARGE SLEEVING. To mark tubing that has OD larger than 1/4 inch, use 2 special machine that marks tubing fat, if it is available (see figure 2-15), Flat type rather than curved type is used on this machine, Otherwise, machine set-up and marking procedure is same as that described in 2-31 and 2.32. 234, INSTALLING IDENTIFICATION SLEEVES ON WIRING, Cut marked tubing into lengths so that marking is approximately centered (refer to figure 2-14). Install cut lengths of tubing over wire or cable at desired spacing, and tie at each end with clove hitch and square knot. See section XV for method of tying and knotting. When heat-shrinkable tubing is used, ties are not required. Before installing heat-shrinkable tubing on the wire, make sure that the wires are clean. Instructions for installation are given in section XI, paragraph 11-22. 235. IDENTIFICATION OF WIRE BUNDLES AND HARNESSES. Identify wire bundles and hamesses (see figure 2-16) by one of the following methods: 1a. If bundle is not too large, select sleeving of proper size to fit snugly over wire bundle. Stamp with identifica- tion marking as described in 2-33 and install on bundle approximately 12 inches from each terminating end. Tie securely at both ends. NOTE Sleeving must be installed on bundle before soldering wires to connectors. Heat shrinkable tubing, marked with the identification code, may also be used, installed as described in section XI, ‘paragraph 11-22. b. Wire bundles up to 4 inches in diameter may be Identified by means of an MS3368 cable identification strap which has a marking tab as part of it. (See figure 2-16.) The procedure is as follows 1. Stamp the wire identification code on the smarking tab as described in 2-33. 2. Pass the strap around the bundle with the ribbed of the strap inside. 3. Insert the pointed end of the strap through the eye, and pull the strap snugly around the bundle. 249NAVAIR 01-1A-505 (USAF) T.O. 1-18-14 Figure 2-16. Marking Machine for Sleeving 4. Feed the tail of the strap through MS30387-1 tool, and slide tool up to eye of the cable identification step. 5. Squeeze tool handles until strap is snug on vundle 6. Close tool handles all the way to cut off the excess strap. NOTE Use of self-clinching adjustable plastic cable straps and installing tools is illustrated and described in section XV. 220 TERE wae TIED IN PLACE Figure 2-16, Identification of Wire Bundles ‘and HarnessesNAVAIR 01-1A-605 (USAF) T.O, 1-18-14 2.36. STRIPPING WIRE AND CABLE 2.37. GENERAL. Before wire can be assembled to con- rectors, terminals, splices, etc., the insulation must be stripped from connecting ends to expose the bare conduc- tor. For attachment to soldertype connectors, enough insulation is stripped so that conductor will bottom in solder cup and leave a small gap between the top of the solder cup and cut end of insulation. Stripping dimensions for MS connectors will be found in section III, for RF connectors in section IV, and for terminals in section V. See figure 2-17 for typical tools used in wire stripping. 2.38, STRIPPING METHODS FOR COPPER WIRE. Copper wire may be stripped in a number of ways depending on size and insulation. See table 2-7 for a summary of wire strippers. ‘Table 2.7. Wire Strippers for Use on Copper Wire Secipper AN Gage No. Insulations Hot Blade 926-4 All excepr asbestos and glass braid Rotary, electric 926-84 All Bench #20-#6 All Hand Pliers #26-#8 All, except as noted* Knife #2- #0000 All Details of each method are given in 2~42 thru 2-46. 239, STRIPPING METHODS FOR ALUMINUM WIRE. ‘Strip aluminum wires with a knife as described in 245. Strip aluminum wire very carefully. Take extreme care not to nick aluminum wire as strands break very easily when nicked. 240. GENERAL STRIPPING INSTRUCTIONS. When stripping wire with any of the tools mentioned in 2:38 and 2.39, observe the following precautions. a. When using hot blade stripper, make sure blades are clean. Clean blades with brass wire brush as necessary The hot blade stripper will not strip wire with gla braid or asbestos insulation. b. Make sure all stripping blades are sharp and free from nicks, dents, ete c. When using any type of wire stripper, hold wire perpendicular to cutting blades. 4. Adjust automatic stripping tools carefully; follow manufacturer's instructions to avoid nicking, cutting, or otherwise damaging any strands. This is especially impor tant for all aluminum wires and for copper wires smaller thin No 10. Examine stripped wires for damage and adjust tool as necessary. Cut off and restrip (if length is sufficient); or reject and replace any wires with more than the allowable number of nicked or broken strands given in table 28. NOTE Longitudinal scratches in copper wire arc not con- sidered cause for rejection or rework. fe. Make sure insulation is clean-cut with no frayed or ragged edges. Trim if necessary. f Make sure all insulation is removed from stripped area. Some types of wites are supplied with a transparent layer between conductor and primary insulation. If this is ‘present, remove it g. When using hand plier strippers to remove lengths of insulation longer than 3/4 inch, itis easier to do in two ‘or more operations. hh. Retwist copper strands by hand or with pliers if necessary to restore natural lay and tightness of strands. Table 2.8, Allowable Nicked or Broken Strands Wire Nicked or Broken Stands Copper AN #22 #12 None #10 2 HB 4 4 #2 - #0 2 Aluminum, all sizes None 221NAVAIR. 01-18-505 (USAF) T.0. 1-18-14 © HOT BLADE WIRE STRIPPER ©. HAND WIRE STRIPPER » LIGHT DUTY Figure 2-17. Typical Wire Stripping Tools 222NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 241, PROCEDURE FOR STRIPPING WIRE WITH HOT BLADE STRIPPER. The procedure for stripping the wire with hot-blade stripper is as follows: a, Adjust blades to correct opening for size of wire to be stripped (see figure 2-18). b. Adjust stop by means of knurled brass nut on top ‘of hood for desired stripping length between 1/4 inch and 1-1/2 inches. c. Adjust each blade to proper heat by trying on sample pieces of wire, Use minimum heat that will remove insulation satisfactorily without damaging strands. WIRE GAGE ADJUSTMENT HEAT ADJUSTMENTS WATER FILLED PAN | 4, Insert wire until it butts against stop. fe, Press foot pedal to bring heated blades against insulation. {Twist wite with lay of strands about 90 degrees and pull out Make sure adequate ventilation is provided when a hot-blade stripper is used to strip TFE-insulated wire. KEEP BLADES CLEAN Figure 2-18, Stripping Wire in a Hot Blade Stripper 242, SUBSTITUTE HOT-BLADE STRIPPER. Where a hot-blade wire stripper is not avaiable, a substitute can be ‘made and used as follows (see figure 2-19): a. In the end of a piece of copper strip, cut a sharp edged "V", At the bottom of the “V" make a wire slot of suitable diameter. b. Fasten the copper strip around the heating element ofan electric soldering iron as shown in figure 2-19. c. Lay wite or cable to be stripped in the “V"";a clean ‘channel will be melted in the insulation. 4. Remove insulation with slight pull 223NAVAIR _01-1A-505 (USAF) T.O. 1-18-14 oO APROXIMATE /16" THICK HARD DRAWN COPPER STRIP Figure 2-19, Substitute Hot Blade Stripper 243, PROCEDURE FOR STRIPPING WIRE WITH POWER ROTARY STRIPPER. The procedure for stripping wire or cable with a rotary stripper is as follows (refer to figure 220) 4. Select and install bushing of proper size for wire to bbe stripped. Bushings are available in 1/8, 1/4, and 3/8 inch sizes. b. Set butt for length of strip desired from 1/4 inch to 1.3/4 inches. ¢. Make adjustment for wire gage. 4, Set switch for clockwise or counterclockwise rota tion according to lay of strands. ¢, Insert wire through bushing until end of wire is stopped against butt. 224 £, Step on foot pedal to close blades on wire. ‘& Pull sharply on wires to remove insulation, 1h. Examine wire to be sure all insulation is removed and also that strands are not nicked or cut. Reset wire gage adjustment (step c) if necessary. 244, PROCEDURE FOR STRIPPING WIRE WITH HAND STRIPPER. The procedure for stripping wire with pliertype hand strippers is as follows (refer to figure 2-21): a. Insert wite into exact center of correct cutting slot for wire size to be stripped. (Each slot is marked with wire size). . Close handles together as far as they will go. c. Release handles, allowing wire holder to retum to open position 4. Remove stripped wire. NOTE Jaws will not snap back until wire is removed. 2.45, PROCEDURE FOR STRIPPING WIRE WITH A KNIFE. The procedure for stripping wire with a knife is as follows (see figure 2-22): Take care not to nick or cut strands, a. Make cut around wire at desired strip length. Do not cut completely through the insulation 'b. Make second cut lengthwise along stripping length. Do not cut completely through insulation. NOTE When a wire has two or more layers of insulation, cut through outer layers and only score innermost. cc. Peel off insulation, following lay of strands.NAVAIR _01-1A-505 (USAF) T.0, 1-14-14 SET SCREW FOR ADJUSTMENT OWL HOLE OF BUTT PLATE POSITION BUTT PLATE SET FOR STRIPPING LENGTH STRIPPING HOLE IN SPINNER LOCKING SCREW FOR ADJUSTMENT WIRE GUIDE BUSHING FOR WIRE GAGE STOP KEEP RODS CLEAN DO NOT OIL COVER PLATE REMOVE TO CLEAN OR SHARPEN BLADES Figure 2:20, Inside View of Rotary Wire Stripper 228NAVAIR 01-1A-605 (USAF) T.0. 1-14-14 SELECT CORRECT HOLE TO MATCH WIRE GAGE STEP 0 BLADES REMAIN OPEN UNTIL WIRE IS REMOVED BE CAREFUL NOT TO NICK OR CUT STRANDS STEP b STEP « CUTTING AROUND INSULATION BE CAREFUL NOT TO NICK OR CUT STRANDS STEP 0 SLITTING INSULATION STEP b PEELING INSULATION STEP ¢ Figure 2:21. Stripping Wire With Hand Stripper 226 Figure 2:22. Knife StrippingNAVAIR 01-1A-605 (USAF) T.0. 1-18-14 246. STRIPPING DIMENSIONS FOR ASSEMBLY TO CONNECTORS. Stripped length on wires which are to be attached to solder-type connectors should be such that ‘when stripped conductor bottoms in solder cup there will be a gap of approximately 1/32 inch between the end of the cup and the end of the insulation, for inspection purposes 2.47, TINNING COPPER WIRE AND CABLE 2.48, GENERAL. Before copper wires are soldered to connectors, the ends exposed by stripping are tinned to hold the strands solidly together. The tinning operation is considered satisfactory when the ends and sides of the wire strands are fused together with a coat of solder. Do not tin ‘wires which are to be crimped to Class K (fireproof) connectors, wires which are to be attached to solderless terminals or splices, or wires which are to be crimped to removable crimp-style connector contacts. 249, TINNING METHODS. Copper wires are usually tinned by dipping into flux and then into a solder bath. In the field, copper wires can be tinned with a soldering iron and rosin core solder. 2.80, EXTENT OF TINNING. Tin conductor for about half its exposed length. This is enough to take advantage of closed part of solder cup. Tinning or solder on wire above cup causes wire to be stiff at point where flexing takes place, This will result in wire breakage 251, PREPARATION OF FLUX AND SOLDER. The flux used to tin copper wire is a mixture of denatured alcohol and freshly ground waterwhite rosin in the proportion of eight ounces of alcohol to one ounce of rosin, mixed together thoroughly and well shaken. During ‘use, the alcohol will evaporate and should be replaced. The solder used is a mixture of 60% tin and 40% lead. Maintain temperature of the solder pot between 450 and 500 degrees F; this will Keep solder in a liquid state. Skim surface of solder pot as necessary with a metal spoon or blade to keep solder clean and free from oxides, drt, etc. Do not use any other flux or solder for tinning. ‘copper wires for use in aircraft electrical systems, 2.82. DIP-TINNING PROCEDURE. Dip-tin wires smaller ‘than No. 8 about eight or ten at a time, Dip-tin wires size No. 8 and larger individually. (See figure 2-23.) During tinning operation, take care not to melt, scorch, or burn the insulation ‘The procedure for dip-tinning is as follows: a. Prepare flux and solder as described in 2-51. 'b. Make sure that exposed end of wire is clean and free from oil, grease, and dirt, Strands should be straight and parallel, Birty wite should be restripped. ¢. Grasp wire firmly and dip into dish of prepared flux. toa depth of about 1/8 inch. d, Remove wire and shake off excess flux. ¢. Immediately dip into molten solder. Dip only half of stripped conductor length into solder. f. Manipulate wire slowly in solder bath until it is thoroughly tinned, Watch the solder fuse to wire. Do not keep wire in bath longer than necessary g. Remove wire and shake off excess solder. NOTE ‘The thickness of the solder coat depends on the speed with which the wires are handled and shaken, and the temperature of the solder bath. 227NAVAIR _01-14-505 (USAF) T.0. 1-18-14 ~ DIP ver DEEP ONLY ROSIN-ALCOHOL PASTE FLUX STEP o DIP AND HOLD IN MOLTEN SOLDER To V2 OF STRIPPED LENGTH SPRINKLE POWDERED ‘BORAX ON SURFACE TO RETARD ‘OXIDATION Figure 2-23. Dip-Tinning in Solder Pot 2.83 ALTERNATIVE DIP-TINNING PROCEDURE. If an electrically heated solder pot is not available, a small umber of wires may be tinned by means of the following procedure (see figure 2-24): a. Cut off beveled section of tip of a discarded soldering iron tip. 228 . _ Drill hole (1/4 to 3/8 inch diameter) in cylindrical part of tip, about two-thirds through, c. Heat up iron and melt rosin-core solder into hole. 4. Tin wires by dipping into motten solder one at a time. fe. Keep adding fresh rosin-core solder as the flux ‘burns away. 5/6" DIA. OR LARGER SOLDERING TIP CUT OFF OLD PITTED TIP ORILL 3/8" HOLE 3/8" DEEP FILL WITH 60/40 TINLEAD SOLDER Figure 2.24, Alternative Dip-Tinning MethodNAVAIR _01-1A-505 (USAF) T.0, 1-18-14 2.84, PROCEDURE FOR SOLDERING IRON TINNING. In the field, wires smaller than size No. 10 may be tinned with a soldering iron and rosin-core solder as follows (see figure 2.25) a. Select a soldering iron having suitable heat capacity for wire size from table 2.9. Make sure that iron is clean ‘and well tinned. b. Prime by holding iron tip and solder together on ‘wire until solder begins to flow. ‘c. Move soldering iron to opposite side of wire and tin half of the exposed length of conductor. 60/40 ROSIN CORE SOLDER Figure 2-25. Tinning Wire With a Soldering Iron ‘Table 2.9. Approximate Soldering Iron Sizes for Tinning Wire Size Soldering Iron Size (AN Gage) (Heat Capacity) #20 - #16 65 Warts #14 & #12 100 Watts #10 & #8 200 Wares 2.55, TERMINATING SHIELDED CABLE 2.56. GENERAL, Shielded cable has a metalic braid over the insulation to provide a bartier against electrostatic interference. To obtain satisfactory result from shielded cable, the shield must be unbroken and must extend to @ point as near the end of the conductor as practicable. Shielded cable is either grounded or dead-ended at each end as required by the individual installation. The following paragraphs describe these procedures. 2.57. STRIPPING JACKET ON SHIELDED CABLE. Some shielded cable has a thin extruded plastic coating over the shielding braid. Strip this off as far as necessary with a hot blade stripper, as described in 2-41 or 2-42. Length of, strip depends on method of shield termination and type of wire connection. Strip outer jacket back far enough for ease in working. If no hot-blade stripper is available, use plier type hand strippers for sizes No. 22 through No. 10, and a knife for sizes larger than No. 10. Be careful not to damage shielding braid. Extruded jacket of shielded twisted wires can also be stripped by holding a soldering iron, with tip removed, against jacket, and pulling off jacket with long nose pliers as iron melts jacket. (See figure 2-26.) NYLON OUTER JACKET Figure 2-26. Stripping Outer Jacket From Shielded Cable 2.88, TWO-PIECE GROUNDING SHEATH CONNECTOR METHOD OF SHIELD TERMINATION. The metallic braid of shielded cable can also be terminated with a two-piece grounding sheath connector, by crimping it, with or ‘without a ground wire as required, between two ferrules (or sleeves). (See figure 2-27.) Use the standard MS inner and outer ferrules listed in tables 2-10, 2-11, and 2-12, and the tools listed in the tables. The procedure is as follows: a. Strip off shielding braid (and outer jacket if present) with hand strippers or scissors. Length to be stripped is determined by length of unshielded conductor necessary for making connection. te. Strip outer jacket (if present) 1/2 to 3/4 inch. Measure OD of insulation directly under shield. 229NAVAIR 01-1A-505 (USAF) T.0. 1-14-14 d. Add 0.005 inch minimum to OD obtained in step c, ‘and select inner sleeve having the nearest larger ID from table 2-10. e. Note OD of inner sleeve selected in step d, and add 0.025 inch minimum to it to allow for thickness of shielding braid. Add an extra 0.030 to 0.040 to allow clearance for a No, 20 or No. 18 ground wire if required From tables 2-11 or 2-12 select an uninsulated or insulated ‘outer sleeve as requited, with the above dimensions as ‘minimum 1D. f, Slide outer sleeve back over insulation and braid. Rotate cable with circular motion to flare out braid. 1h. Slip inner sleeve under braid so that about 1/16 inch of sleeve sticks out beyond braid. i, If required, insert stripped ground wire under outer sleeve and slide both forward over braid and inner sleeve until only 1/32 to 1/16 inch of inner sleeve and braid protrude, (See figure 2-27.) Ground wire may extend from front or back of outer sleeve as requited Examine assembly to make sure that shield br ‘ground wire come through under the outer sleeve. and j. Crimp with hand tool selected from tables 2-11 or 212. Table 2-10. Shielded Wire Terminations — Inner Sleeves Color Part Number Code MS21981 - 046 Tin +058 Yellow +063 Red +071 Green = 080 Blue +090 Orange + 096 Purple = 101 Yellow + 109 Red +s Tin +124 Green +128 Tin = 134 Orange 149) Blue +156 Red +165 Tin 175 Green - 187 Yellow +194 Blue = 205 Orange +219 Tia 25 Yellow +B Red +250 Green +261 Blue + 266 Tin 275 Orange = 281 ellow +287 2297 312 Puple +375 Blue 230 Inner Sleeve Insulation OD (nominal) Under Shield » oD 2031 + .041 046.070 1043 - .053 2058 083, 2048 - .058 2063-088 1056 - .066 O71 096 1065 - .075 2080-104 2075 ~ .085 c090 14 081 - .091 1096-19 2091 + .096 101124 1096 ~ -104 09 «131 2104+ -110 cs 146 ‘10 = 1119 més #110 + 6123 1128152 1123 + 129 Bd 156 1129 = 144 19.179 2145 + 151 156.192 S151 +160 11654194 1160 - £170 T7525 1175 = 1182 m7 1227 1182 - -189 “194.225 1189 + .200 (205.245 1200 + .214 219.248 1214 + .220 ims ce) 256) 1220 = .227 12321263, (250.281 227 + .255 1261297 2261.27 1266-297 1255 + .270 1275306 1270 ~ .276 :281 331 1276 + .282 287327 1282 - .292 12972336 292 + .367 (312.362, 1370 = 380 375.406NAVAIR 01-1A-605 (USAF) T.0, 1-18-14 ‘Toble 2-11, Shislded Wire Terminations — Uninsulated Outer Sleeves and Installing Toolt Sleeve ID (Inches) Installing Tools Part Number Color Code Nominal ‘Thomas & Betts) MS21980 + 101, Tin 101 wr- 219 - 128 Blue +126 = 200 +149 Purple 49 +201 + 156 Yellow 2156 +202 +175 Blue “175 +203 +187 Orange “187 + 206 +194 Red 2194 + 206 +199 Tin -199 = 206 = 205 Yellow 206 = 208 +219 Green 2219 +208 25 Purple 225 + 209 +232 ‘Orange 233 = 210 = 261 Yellow 261 + 2m 275 Tin 275 72 - 281 Purple 281 2214 - 287 Blue 287 -24 = 299 Green 299 +24 312 Yellow Bit +215 +327 Tin 2327 +216 +346 Orange 346 227 +389) Purple 359 = 221 +375 Yellow 2375 +222 = 405 Red 405 +218 415 Blue Als +218 + 460 Tin 460 +20 + 500 Green 500 +223 231NAVAIR _01-1A-605 (USAF) T.O, 1-14-14 ‘Table 2-12, Shielded Wire Terminations Ingulated Outer Sleeves and Installing Tools Unches) instaling Tools an Number color case ‘Nona ot bes) wsisi2t- 101 Tin 1 wr 210 NB Pu 18 633315 “ise alow “i E26 ifs blue ts ins ne Orange 1 iho “ibe Ral “a lho “i tn “be Lhe Ls Yalow Re cal Lhe Gren 2B eit UB Pure B eH ee Orange Be Tht ea Yaloe ta ite Uh Tia s err eH Purple Sa cht e un bie i an a Gree ‘er ca Bn alow Sa eo le Tin a th 2 Orage Ste 6331014 38 Pani 39 wr 6 3 Yalow ea 331-1 3 fed “ts a3 o3tial= 1 3 be 3 Gas 9a te tin “te Ges ssid -2 “0 Gren “oo G33 3NAVAIR 01-1A-605 (USAF) T.0, 1-14-14 “METALLIC SHIELDING BRAID Teas a ouTer INSULATION JACKET OUTER FERRULE INNER FERRULE ROTATE WIRE TO SPREAD SHIELDING BRAID INNER FERRULE PARTIALLY INSERTED eS INSERT. GROUND LEAD BETWEEN OUTER FERRULE AND_ SHIELD. INNER FERRULE FLUSH WITH OUTER PRIMARY CRIMP GROUND INSULATION Wike 2.89. The above procedure may be modified by sliding the inner ferrule over the braid, and folding the braid neatly back over the inner ferrule (see figure 2-28). I this is to be done, add an additional 0.025 inch to the dimension obtained in 2-58, step d, for the extra braid thickness. NER FERRULE = OVER INNER FERRULE So crime Figure 2-28, Alternative Procedure for Two-Piece Grounding Sheath Connector 233NAVAIR 01-1A-605 (USAF) T.O, 1-18-14 260, PIGTAIL METHOD OF SHIELD TERMINATION. ‘When grounding sheath connectors and tools are not available, terminate shield for grounding by making a pigtail as follows (see figure 2-29): Take extreme care not to damage shielding or insulated conductor while forming pigtail Determine and mark point at which shielding is to terminate. This depends on the individual instalation. b. Push back shielding to form a bubble at the termination point. Insert an awl or other pointed tool into shielding braid at termination point and work an open circular area in the shield. Be careful not to cut into wire insulation, 4, Bend cable, insert tool between shielding and wire, and pull insulated conductor through hole formed by tool. e. Pull empty part of shield taut and tin last inch to prevent fraying. f. On unjacketed shielded cable, spot tie shielding on cable with clove hitch and square knot. This ‘is not necessary if cable has extruded plastic jacket over shield. LOOSENED SHIELD PULL THROUGH a TWIST AND TIN ee THIS AREA 261, ALTERNATIVE PIGTAIL METHOD. Some shield- ing braids may be too stiff for the method described in 2.60. In this case, cut shielding wtth scissors approximately 1-1/2 inches forward of termination point. (See figure 2.30.) Comb out strands with comb (see figure 2-31) or pointed bakelite rod. Twist strands into pigtail, or separate strands into three parts; twist each part, and braid together. Tie with cord as described in 2-60, step f. ‘COMB OUT STRANDS, CORD SERVING: TWISTED, AND TINNED Figure 2-30, Alternative Pigtail Termination for Shielded Wire STEEL WIRE CLOTH TAKEN FROM FILE BRUSH : é MAKE FROM 1 INCH Woop DOWEL <&." Figure 2.29. Pigtail Termination for Shielded Wire 234 Figure 2:31. Comb for Combing Out ShieldNAVAIR _01-1A-505 (USAF) T.O. 1-18-14 2.62. DEAD-ENDING SHIELDED CABLE. When the shielding is not to be grounded, itis dead-ended so as to gather all loose shield ends together to prevent them from Puncturing insulation, 263. DEAD-ENDING WITH GROUNDING SHEATH CONNECTOR. When equipment is available, dead-end shielded cable with grounding sheath connector as described in 2-58, omitting ground wire. Refer to figure 2.27. Omit clearance allowed for ground wire when selecting outer sleeve. 2464. DEAD-ENDING WITH TAPE WRAP. When ground- ing sheath connector and tools are not available, dead-end shielding as follows (see figure 2-32): ‘8, Cut shielding braid with scissors about 3/4 inch forward of termination point. b. Loosen braid and turn back on itself 3/4 inch. c. Wrap with two or three tums of plastic tape, ‘making sure that all braid ends are covered. 4. Tie loose end of tape with clove hitch and square knot, or heat seal end of tape with untinned side of soldering iron, A plastic wire strap or tie, as described in section XV, may be used instead of tying cord to secure the loose end of the tape. FOLD SHIELD. BACK ON ITSELF THE WITH TWINE VINYL TAPE Figure 2:32. Dead-Ending Shield With Tape Wrap 2.465. ALTERNATIVE METHODS OF DEAD-ENDING. ‘As an alternative to method described in 2.63, make pigtail 's described in 2.60 or 2.61 and trim pigtail so itis 3/4 inch long. Crimp trimmed pigtail into one end of preinsulated permanent splice of suitable size, and tie back on shielded part of cable. (See figuie 2-33.) If permanent splice is not available, cut tongue off solderiess terminal of suitable size and crimp pigtail into it. Protect with sleeve and tie back on Wire, similar to tie used with permanent spice. .MS25181, PRE-INSULATED PERMAWENT SPLICE TIE WITH TWINE Shield With Permanent Splice 2.66. GROUNDED SHIELD TERMINATION PROCE- DURE. 4. Strip the shielded wire and the ground lead as shown in figure 234. b. Comb out the exposed shielding and fold back over the jacket. c. Position the stripped end of the ground lead against and parallel to the exposed shielding. NOTE Make sure that the ground wire strands and shield braid strands are flat and smooth. d. Select the size solder sleeve that will fit freely but will not be excessively loose over the folded back shielding. ‘and ground lead combination. €. Position the solder sleeve over the assembly so that the solder ring is centered over the folded back shielding as shown in figure 2:34. f, Hold the assembly horizontal and position the sleeve in the heat shield. NOTE The heat gun must have a thermal shield and must develop 550°F at the heat shield nozzle.NAVAIR 01-1A-505 (USAF) T.0. 1-18-14 fg. Rotate the assembly while heating to achieve proper solder penetration and uniform sleeve shrinkage. About 10 to 30 seconds are required for the complete solder melt and flow. NOTE The solder band collapse does not indicate solder flow. Continue to apply heat until solder brightens and starts to flow toward thermoplastic inserts at either end of sleeve. hh. As soon as the solder flow is observed, withdraw the heat. i. When the solder joint has been made, hold the work firmly in place until the joint has set. Disturbing the finished work will result in a joint mechanically weak, and with high electrical resistance. Allow solder joints to cool naturally. Do not use liquids or air blasts. Conventional hot-air guns (see figure 11-24) must not be used on fueled aircraft because of exposed heating elements, exposed brushes of motor, and the fact that air from’ the immediate work area is passed over the heating element. Raychem CV-4504 (sec figure 11-25) or explosion-proof equivalent is superior because the heated air comes from an external source and there are no moving parts. Therefore, only this type of hot-air gun is authorized for use on aircraft other than those defueled and purged for extensive maintenance, IRAN, or major modification. 2.67. UNGROUNDED (FLOATING) SHIELD TERMINA- TION. 1. Strip the shielded wire as shown in figure 2-35. 1b. Comb out the exposed shielding and fold back over the jacket as shown in figure 2-35. ¢. Select the size solder sleeve that will fit freely but will not be excessively loose over the folded back shielding, 2368 4. Make sure that the shield strands are flat and smooth. ¢. Position the solder sleeve over the assembly so that the solder ring is centered over the folded back shielding, f, Hold assembly horizontal and position sleeve in heat shield. NOTE ‘The heat gun must have a thermal heat shield and must develop 550°F at the heat shield nozzle g. Rotate assembly while heating to achieve proper solder penetration and uniform sleeve shrinkage. About 10 to 30 seconds are required for complete solder melt and flow. NOTE The solder band collapse does not indicate solder flow, Continue to apply heat until solder brightens and starts to flow toward thermoplastic inserts at either end of sleeve. hh, As soon as the solder flow is observed, withdraw the heat i. When the solder joint has been made, hold the work firmly in place until the joint has set, Disturbing the finished work will result in a joint mechanically weak, and with high electrical resistance. Allow solder joints to cool naturally. Do not use liquids or air blasts. Conventional hot-air guns (see figure 11-24) must not be used on fueled aircraft because of exposed heating elements, exposed brushes of motor, and the fact that air from the immediate work area is passed over the heating element. Raychem CV-4504 (see figure 11-25) or explosion-proof equivalent is. superior because the heated air comes from an external source and there are no moving parts. Therefore, only this type of hot-air gun is authorized for use on aircraft other than those defueled and purged for extensive maintenance, IRAN, or major modification,NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 238 smup OMENHON 0.1810 0.28 mesos sowen sutve soe aD SFY a Pap rrennorasic wae Figure 28, Solder Sleeve Floating Shield TerminationNAVAIR _01-1A-505 (USAF) T.0. 1-18-14 SECTION III GENERAL PURPOSE CONNECTORS 3-1, INTRODUCTION 3:2. GENERAL. Connectors provide means of quickly connecting and disconnecting wires to simplify installation and maintenance of electric and electronic equipment. 33. SCOPE. This section describes and illustrates the types and classes of Military Standard connectors and the recommended procedures for attaching wires to connector contacts. AN type connectors were formerly designated with the prefix “AN”, and older connectors may still be found with this prefix. The superseding connector has the same part number except that the “AN” has been replaced by "MS". Other connectors commonly used in aircraft, similar to MS connectors, are also described and illustrated in this section, RF connectors are treated separately in section IV. 34, REFERENCE SPECIFICATIONS, DRAWINGS, AND DOCUMENTS we236 Petrolatum, Technical QQ8571 Solder, Lead Alloy, Tin Lead Alloy and Tin Alloy MILI-631 Insulation, Electrical, Synthetic-Resin Composition, Non-Rigid MIL-T-113 ‘Twine, Lacing and Tying, Electrical and Electronic Equipment MIL-CS015 Connectors, Electrical, AN Type MIL-W.5088 Wiring, Aircraft, Installation of MIL-C-5649 Cord, Cotton, Braided, Pre-Waxed MIL-A-6091 Alcohol, Ethyl, Specially Denatured, Aircraft MIL-$.6872 Soldering Process, General Specifica- tion for MIL-D-6998 Dichloromethane, Technical MILIL7444 Insulation Sleeving, Electrical, Flex- ible MILS.8516 Sealing Compound, Synthetic Rubber, Electric Connectors and Electric Systems, Accelerator Required MIL1-18057 Insulation Sleeving, Electrical, Flex- ible, Glass Fiber, Silicone Rubber Treated Crimping Tools, Contact, Electric, Hand, General Specification for MIL-€-22520 MIL-C-23216 Contacts, Crimp Type, Electric Con- rector, General Specification for MIL-C-26482 Connectors, Electric, Circular, Mini ture, Quick Disconnect Connectors, General Purpose, Electri- cal, Miniature, Circular, Environment Resisting, 200°C Ambient Contacts, Crimp Type, for Electrical Connectors MIL-C-26500 MIL-€-26636 MIL-C.:38999 Connectors, Electrical, Circular, Mini- ature, High Density, “Quick Discon- nect, Environmental Resisting, Removable Crimp Type Contact, Rel ability Assurance Program Contacts, Electric, General Specifica- tion for MIL-C39029 MIL-C-81511 Connectors, Electrical, Circular, High Density, Quick Disconnect, Environ- ment Resisting MIL-C-81582(Navy) Connectors, Electric, Bayonet Cou- pling, RFI Shielded and Non-Shielded, Umbilical, General Specification for MILC-81659 Connectors, Electrical, Rectangular, Environment Resistant, Crimp Con: tacts MIL-C-81703(Navy) Connectors, Electric, Circular, Minia- ‘ture, Rack and Panel or Push-Pull Coupling, Environment Resisting MILC-83723 Connectors, Electrical, Circular, Envi- ronment Resisting MIL-C-0026482F Connectors, Electric, Circular, Mini (Navy) ture, Quick Disconnect, Environment Resisting, General Specification for MIL-C-0081511D Connectors, Electrical, Circul (Navy) Density, Quick Disconnect, Em ‘ment Resisting; and Accessories Navy-BuWeps _Electric Connector Sealing EMC No. 89-55 34NAVAIR 01-14-5605 (USAF) T.O, 1-18-14 3.5. DESCRIPTION 36. GENERAL DESCRIPTION OF AN-MS CONNEC- TORS. Each complete connector consists of two parts: a plug assembly and a receptacle assembly coupled by means ‘of a coupling device which is part of the plug assembly. Standard connectors are coupled with a threaded coupling ring except for MS3107, which has a friction coupling Miniature connectors are ‘coupled by means of a threaded ring. a bayonet lock, or a push-pull coupling. The receptacle is usually the “fixed” part of the connector, attached to a wall, bulkhead, or equipment case. ‘The plug is the removable’ part of the connector and includes the coupling device. When the two parts are joined, the electric circuit is made by pin-and-socket contacts inside the connector. The “live” or “hot” side of the circuit should have socket (female) contacts. The contacts are held in place and insulated from each other and from the shell by a dielectric insert. Insert and contacts are housed in a metal shell. Connectors may be grouped into types, classes, ‘and series depending on their manufacture, assembly, end application. ‘The class is determined by the environment or applica- tion of the connector. All classes except Classes H and K have aluminum alloy shells. Class H (hermetic) and Class K (fire resistant) connectors use steel shells. Connectors manufactured in accordance with military specifications are designated in one of two ways. In specifications MIL-C- 5015, MIL-C-26482, and MIL-C-26500, the connector is designated by an “MS” number, such as MS3101. In specifications MIL-C-81511, MIL-C-83723, and later speci- fications, the connector is designated by the specification number followed by a slash and the connector number, such as MIL-C-81511/3, Descriptions of the various connec: tors ate given in the sections dealing with the particular specifications, 3-7, GENERAL PRACTICES 38. SOLDERING 3-9. SOLDERS. Solders and other fastening means are ‘matched to the wire type and (o the installation as follows: a, Soft solder ~ 60/40 tindead (Federal Specification Q0-5.571, composition Sn 60) is used for tin-coated copper wire and for coaxial cable. b. Soft solder — Ieadilver (Federal Specification 005-571, composition Ag 2.5 or Ag 5.5) is used for silvercoated copper wire 32 c. Crimp connections are used for nickel-clad copper ‘wire, and tin, silver, or nickel coated copper wire. 4. Thermocouple wires require special procedures which are detailed in section VII. 3:10, SOLDER CONTACTS. Solder cup contacts are silver ‘or gold plated to provide low contact resistance. Silver- plated contacts have pretinned solder cups. Goldplated contacts are not pretinned because the gold prevents oxidation and is therefore always easy to solder. 3-11. PREPARATION OF WIRES BEFORE ASSEMBLY. ‘The preparation of wires before assembly is as follows (see section I): a, Cut wire to prescribed length. b. Identify wire with proper coding. . Strip ends to the dimensions in table 3-1 4, Tin wires which are to be soldered to contacts. Table 3-1. Stripping Lengths for Solder Connections Contact Stripped Length Size (inches) 20 /8 16 v4 2 5/16 8 5/8 4 5/8 ° 3/4 3:12, INSULATING SLEEVES. Insulating sleeves are used over soldered connections to help protect the connection ‘agninst vibration and to lengthen the arc-over path between contacts, Insulating sleeves are not used under the following conditions: 1, Insulating sleeves ate not used when connectors are to be moisture-proofed by potting b. Insulating sleeves are not_used in miniature MS connectors, nor in AN type Class E or Class R connectors, fs the sealing grommets cover the soldered connection. Class E connectors made by Bendix need insulating sleeves, as the grommets do not cover the soldered connection. The insulating sleeve should not extend into the grommet,NAVAIR 01-1A-505 (USAF) T.0. 1-18-14 3.13, Selection of Insulating Sleeves. Select insulating Sleeving from the materials listed in table 3-2 to suit the temperature conditions in the area where the connector will be installed, Select the proper size from table 3-3 so that the inside diameter of the sleeving will fit snugly over the solder cup. 3-14, Installation of Insulating Sleeves. Cut the sleeving into lengths, as given in table 3-3, to cover the soldered connection completely from the insert to a little over the wire insulation. (See figure 3-1.) Slip insulating sleeve of correct size, material, and length over each prepared wire, far enough back from the stripped end to avoid heat from soldering operation (about one inch). 3:15, SOLDERING PROCEDURE. Wires are soldered to ‘contacts in electrical connectors by means of a soldering iron, resistance heating, or @ torch. Safe connections are the result of clean parts carefully soldered together. See section IX for a description of soldering methods and procedures. ‘When soldering wires to electrical connectors, observe the following precautions: a. Make sure that the wire and the contact are clean and properly tinned. b. Use a soldering iron, or other heating method, of a heat capacity sufficient for the work to be soldered. Resistance soldering is recommended for sizes 8 through 0. AA soldering iron is recommended for sizes 12 through 20; resistance soldering may also be used. Table 3.2. Insulating Sleeving Material ‘Temperature Range Material MIL Specs, Up to 160°F Vinyl, transparent MIL 1-744 or MIL-1-631 Nylon, transparent 160°F-400°F Silicone-impreg- MIL—1-3190 nated fiberglass Silicone-rubber MIL-118087 fiberglass TFE-impee nated fib Table 3.3. Insulating Sleeving Sizes AN Insulating Sleeving Size Number JD Length ee jin inches) Weld 7 2148 3/4 2 5 1186 3/4 10 3 234 3/4 8 1 401 6 o 13300 M/A 4 6 438 M/A 2 V2 1500 1/4 ° 5/8 1625/4 Extruded TFE, = erglass NYLON THe AT END OF SLEEVING VINYL __TIED ON VINYL BEHIND CONTACT Insulating Sleeving Installed Over Solder Cup Figure 3-1 33NAVAIR 01-1A-505 (USAF) T.0. 1-14-14 c. Make sure that the iron has a smooth, well tinned tip. See section IX for detailed instructions on the care and ‘maintenance of the soldering iron. 4d. Keep electric resistance pliers clean and free from flux and solder splatter. Use a brass wire hand brush to clean contacting surfaces. fe. Select a soldering iron tip of a shape to provide good heat transfer. A large contact area touching the solder cut will help to produce a good connection quickly. See figure 3-2 for suitable soldering iron tips. f. Use only rosin of rosin-alcohol as flux for soldering, wires to connector contacts. Do not use any corrosive flux for soldering in an electric connector, . Do not hold the hot iron against the solder cup longer than necessary; this will force solder up into the conductor and stiffen the wire. Stiff wires will break under vibration. hh. Avoid having solder run on the outside of solder ‘cup or drip into insert face. Do not move the soldered ‘connection until the solder has hardened, i. Solder has little mechanical strength. Do not depend on solder to keep a wire from pulling out of a contact. Use t eable clamp, grommet seal, or potting to give mechanical strength. FOR SMALL ‘CONTACTS FOR MEDIUM CONTACTS: FOR #8 AND LARGER CONTACTS 3:16, Electrical Resistance Soldering. Resistance soldering ‘will yield excellent results for both very large and very small contacts. 1a, Large contacts are soldered to wires by the use of resistance soldering pliers. (See figure 3-3.) The contact, Femoved from insert, is held in the jaws of the pliers and Current is applied until the solder in the solder well has melted. Then the pre-tinned wire is inserted slowly into the solder cup while current is still being applied. After the wire is fully inserted, continue heating until the solder flows to form smooth fillet. Allow joint to cool and harden without movement. 4 SOLDER Figure 3:2. Soldering Iron Tip Shapes 34 Figure 3-3. Resistance Soldering Pliers for Large Contacts 'b. Small contacts are heated for soldering by use of pencil type resistance soldering tool shown in figure 3-4 The two electrodes of the tool are placed in contact with the side of the solder cup so that the heating current will pass through the wall of the cup. When the solder in the Cup flows, insert the pre-tinned wire. Continue to apply hhest to connection until solder flows to form smooth fillet, then stop current and allow joint to cool without ‘movernent. ELECTRODES CONTACT BACK OF SOLDER CUP Figure 3-4, Resistance Soldering Pencil for ‘Small ContactsNAVAIR 01-14-6505 (USAF) T. Torch Soldering. A torch can be used to solder wire into a large contact which has been removed from its insert (Gee figure 3-5.) The contact is held in a non-metallic block to avoid heat loss, and the torch is played over the solder cup area until the solder melts. Do not overheat. Excessive heat will destroy the plating and soften the contact When the solder in the cup has melted, insert the wire slowly into the cup and add more composition Sn 60 solder if necessary. Continue to heat the connection until the solder flows into a smooth fillet, then remove the flame. Allow the joint to cool without movement. COMPOSITION SN6O SOLDER NON-METALLIC: Lock PREFERABLY NOT wood. { / Figure 3-5. Torch Soldering Large Contact 318. Soldering Iron Procedure, Soldering with an electri cally heated iron is the most common procedure. For convenience, either the iron or the connector is fastened t0 the bench as described in 3-19. Soldering is accomplished as, follows a. Large contacts which have been removed from ingerts ate held in a non-metallic block and soldered by first heating the solder cup with the specially shaped tip as shown in figure 3-6. Then, while heat is still applied, the ‘pre-tinned wire is slowly inserted into the solder cup until it bottoms. Extra composition Sn 60 solder is added to the solder cup if necessary. Hold the hot iron to the solder cup until the solder has flowed into a smooth fillet, then allow to cool. 110-14 COMPOSITION SN6O SOLDER NON-METALLIC BLOCK PREFERABLY FORMED NOT wooD TIP Figure 3-6, Soldering Large Size Contacts b. Contacts which have not been removed from inserts are soldered as shown in figures 3-7 and 3.8. The solder is flowed by placing the iron alongside the solder cup as the wire is being inserted into it. Medium size contacts such as No. 8 and No, 12 will solder more easily if the iron is held at the point where the wire touches the cutaway of the solder cup as shown in figure 3-8. Adding a small quantity fof composition Sn 60 solder at this point will aid in carrying the heat into the joint. Do not allow solder to collect outside of the solder cup. This will reduce the arc-over distance between contacts and can result in connector failure. 35NAVAIR _01-1A-505 (USAF) T.0. 1-1A-14 IRON TOUCHES SIDE OF SOLDER CUP ‘Not! WIRES ARE PRE-TINNED Figure 3-7. Soldering Small Size Contacts composition Neo SOLDER S IRON TOUCHES JUNCTION BETWEEN SOLDER AND WIRE THEN IS MOVED TO CONTACT SIDE OF CUP Figure 3-8. Soldering Medium Size Contacts 349. Holding Connectors for Soldering. To facilitate soldering wires to contacts which have not been removed from connector, itis helpful to either work to a fixed soldering iron of to fasten the connector into a holding fixture. Ifthe iron is fastened to the bench, secure it into a safety screen as shown in figure 3.9. The screen is made from expanding or perforated steel, painted to retard corrosion. To solder connectors with a fixed iron, itis necessary to hand-hold the connector. If the connector is to be fastened to the bench, a steel bracket bent to a 60° to 75° angle is very useful. The connector assembly tools MS3480 (for MIL-C-S015 connectors), MS3481 (for MIL-C- 26482 connectors), and MS3482 (For MIL-C-81511 connec- tors) are used to hold the connectors while soldering wires to the terminals. Ths assembly tool is ilustrated in figure 3.10, Figure 3-9. Soldering tron in Safety SereenNAVAIR 01-1A-505 (USAF) T.0. 1-18-14 Figure 3-10. Connector Assembly Tool (MS3480, MS3481, MiS3482) 37NAVAIR 01-1A-505 (USAF) T.0. 1-14-14 3-20. SOLDERING SEQUENCE. Follow a rigid sequence 1m soldering wites to a connector. This helps avoid errors in wiring and alse: prevents burning or scorching the insulation of wires alteady soldered, Two useful sequences are shown in fyure 3-11 a, The soldering of the connector in figure 3-118 i started at the right or left lower edge, epending on whether the mechanic is lef. or right-handed, and follows the bottom row across. The row above is nexi and is done in the same direction as the bottom row. This will permit, the insert to coo! between soldering operations. The ‘operation is repeated for each row in sequence until all contacts are soldered NOTE 1 wines ave being soldered to a connector with a large funier of vontacts, plan the work to allow a conlinpofl period after eacls series ol twenty contacts in order to paevent heat build-up b. The sequence for the connector shown in figure 3-110 alse starts with the botton row trom the right or Toft. Th step is to solder to the center contacts ‘working out to each edge. The final operation ts ti solder ‘ites to the top row of contacts. The above two sequences ure suggested procedures that work well in many aiteraft plants. They are not mandatory. ‘but it is important for the mechanic to develop fixed sequence and then not to deviate from that sequence. 321, CLEANING SOLDERED CONNECTIONS. After alt connections have been made. examine the connector for excess solder, eold joints, and flux residues. Take following corrective measures if any of the above are found: a. Remove excess solder by using a soldering iron which was carefully wiped clean with w heuyy clean cloth b. Disassemble cold joints. Shake out all old solder and remake the connections using new 60/40 rosin-core solder, cc. Remove Mux residues with denatured ethyl alcohol or approved proprietary solutions applied with a bustle brush, Blow the connector dry “vith compressed ait 38 Figure 3:11. Connector Soldering Sequence —— warning | Use only approved military standard cleaning oom pounds and approved procedures t@ clean srcial! electsic components. The use of ordinary cleaning compounds or the failure to follow proper pymevderes nay cause fives 04 explosions 322. INSULATING SLEEVE POSITIONING. Ali connie tors except Cass RE, F, P, and those specified ws -12 have tulating sleeves installed over the individual wites Prior tu assembly’ to solder cups. After the connections are cleaned, push the insulating sleeves down over the contact aunail they bottom against the inserts ay shown on figure 3.12. Tie the insulating deeves in position w'th wlou beaut to prevent sliding back on the wires. Tie nylan sleove individually because of nylon’s stiffness Tre all othe: sleeves int groups or as a complete bundle, Make sure fa ‘ue will not intertere with the MS30S? cable clrNAVAIR 01-1A-505 (USAF) T.O. 1-18-14 INSULATING SLEEVE MUST BOTTOM AGAINST INSERT Figure 3-12, Insulating Sleeve Bottomed Against Insert 3:23. PRESHAPING WIRES. Preshape large diameter wires (No. 14 and larger) before soldering to contacts. This, will avoid strain on soldered connection when MS30S7 cable clamp is installed. See figure 3-13, Preshaping is a necessity for connectors using resilient inserts. Side strain on the contacts will cause contact splaying and prevent proper mating of pin and socket contacts 3-24, CRIMP CONTACTS. Removable crimp-type contacts conforming to specifica- tions MIL-C-23216, MIL-C-26636, or MIL-C-39029 are used with the connector types indicated in paragraph 3-4, The method of crimping wires to these contacts essentially the same throughout the entire group of connectors, and standard military crimping tools conform- ing to MIL-C-22520 are employed. 3.28. HAND CRIMPING TOOLS FOR CONNECTOR CONTACTS, Crimping tools used for crimping removable contacts to wire conductors for use in electrical connectors, terminal junction systems, and other electrical or electronic TIE SHOULO BE INSIDE FINAL ASSEMALY PRESHAPE 70 PREVENT STRAIN ON CONTACTS Figur ‘and Preshaping Wires ‘components should conform to MIL-C-22520. These tools are capable of crimping a range of contact wire barrel sizes 12 to 28 or a range of wire sizes 12 to 32. MIL-C-22520 hand operated tools, cycle controlled by means of a ratchet which will not release until the crimping cycle has been completed, supersedes MS-3191, MS-3198, MS-27828 (USAF), and MS-27831(USAF). A brief description of each of these tools is given below: a, MIL-C-22520/1 Crimping Tool. This tool, shown in ‘igure 3-14, consists of a basic crimping tool, M22520/1-01, which is used with turret head M22520/1-02, to crimp size 12, 16, and 20 contacts. This combination of tools can be ‘used to crimp the following contacts: MS3192, MS3193, MS18134, MS18136, MS24254, MS24255, MS9029/01-12- 12, MS9029/01-14-16, MS9029/01-16-20, MS3723/33, and MS3723/34. Other contacts can be crimped with M2220) 1-01 used with other turret heads. (See MIL-C-22520/1.) b, _MIL-C-22520/2 Crimping Tool. This tool, shown in figure 3-15, consists of a basic crimping tool, M22520/2.01, which is used with positioner M22520/2.02 to crimp size 20 contacts, and with positioner M22520/2.03 to crimp size 22 to 28 contacts. M22520/2-01 plus M22520/2-02 can bbe used to crimp MS3192.20, MS3193-20, MS24254-20P, 'MS24255-20S, MS18134-20, and MS18136-20 contacts. 'M22520/2-01 ‘plus M22520/2-03 can be used to crimp 1MS3343.23-22, MS3343-23-28, MS90460-23.22, MS90460- 23-28, MS90461-23-22, and _MS90461-23-28 contacts. Other’ contacts can be crimped with M22520/2-01 used with other positioners. (See MIL-C-22520/2.) 39NAVAIR 01-18-5605 (USAF) T.O. 1-14-14 c. MS3191-1 Crimping Tool. (Superseded by MIL-C- 22520/1.) This tool, shown in figure 3-16a, has one contact positioner installed in the tool, and the other two stored in 4 cavity in the tool handle. This tool will handle contact, sizes 20, 16, and 12, and has the contact sizes, wire sizes, and color codes on a data plate on the face of the tool. The contact size and color code are given below: #20 Red #16 Blue #12 Yellow Do not disassemble this tool. Do not tighten or loosen nuts on back of tool 4. MS3191-3 Crimping Tool. (Superseded by MIL-C. 22520/1.) In this tool, the color coded positioners are fixed in a rotating turret contained in the tool head. (See figure 3-16b.) Wie sizes are marked on a selector plate on the face fof the tool. Correct indentor closure for wire size being used is set by moving thumb button pointer to desired wire NOTE Either MS3191-1 or MS3191-3 may be used to crimp contacts shown on Military Standard drawings MS-3190, MS.3192, MS-3193, MS-24254, MS-24255, MS-18134, and MS-18136, Do not disassemble this tool. Do not tighten or Toosen nuts on back of tool. e. MS3198-1 Crimping Tool. (Superseded by MIL-C- 2520/2.) This tool is similar to the MS3191 tools described above, except that itis used for the smaller #22 and #28 size contacts in the miniature MS connectors. f. MS27828(USAF) Crimping Tool. (Superseded by MIL-C.22520/1-01.) This tool is interchangeable with M22520/1-01 and is used with turret head MS27828-1 ot M22520/1-02 to crimp MS contacts from size 12 to 20 as listed under 3-2Sa above or in table 3-15 below. (See figure 317) g.__MS27831(USAF) Crimping Tool. (Superseded by MIL-C-22520/2-01,) This tool is interchangeable with M22520/2-01 and is used with positioner MS27831-1 or M22520/2-02 to crimp size 20 MS contacts as listed under 3-25b above or in table 3-15. MS27831(USAF) is also used 340 with positioner MS27831-2 or M22520/2-03 to crimp size 22 to 28 MS contacts as listed in 3-25b or table 3-15, h. MS27828(USAF) or M22520/1-01 Crimping Tools. These tools may be used with MS27282-2 or M22520/1-05 universal heads, shown in figure 3-17, to crimp all of the contacts covered in 3.25f and 3-25g above and also to crimp nonmilitary standard contacts. NOTE ‘The USAF crimping tools and positioners described above can be obtained in a kit (MS27426), which also contains all insertion and removal tools for the connectors listed in table 3-15. 326. TOOL INSPECTION. The standard MIL-C-22520 crimping tools are checked for proper adjustment of the crimping jaws by means of the MIL-C-22520/3 inspection sage. The crimping tools should be checked before each series of crimping operations. NOTE If tool fails to gage properly, or if the ratchet bbecomes inoperative, return the tol for repair. a. Inspection of MIL-C-22520 and USAF Crimping Tools. These tools are gaged with the MIL-C-22520/3 (or MS27832) gage. The procedure is as follows: 1. When gaging M22520/1. (or MS27828USAF) crimp tool, set crimp tool wire selector knob on No. 4 wire setting 2. When gaging M22520/2 (or MS27831USAF) crimp tool, set crimp tool wire selector knob on No. 8 wire setting 3. For any of these tools, close handles completely and hold. 4. The GO gage (green) should pass freely between the indentors (see figure 3-18). 5. The NO GO gage (red) should not enter between the indentors (see figure 3-18). 6. If NO GO gage (ted) will enter between the indentors, return the tool for repair Do not crimp down on the gage pin as this will prevent the tool from cycling to ratchet release position.NAVAIR _01-1A-505 (USAF) T.0. 1-14-14 CONTACT INSERTED THIS SIOE COLOR-CODED POSITIONERS. ROTATING TURRET SHOWN IN RELEASED POSITION WIRE SIZE SELECTOR KNOB. M2252011-02 _§ TURRET M22520/1-02 REMOVED Figure 3-14. Crimping Tool M22520/1-01 With M22520/1-02 Turret Head ant342 NAVAIR 01-18-5605 (USAF) T.0. 1-14-14 M225 20/2-02 posiTIONER {SHOWN REMOVED) INDENTOR SELECTOR KNOB CONTACT INSERTED THIS SIDE Figure 3-18. Crimping Tor’ M22620/2.01 With M22620/2-02 PositionerNAVAIR 01-1A-505 (USAF) T.0. 1-18-14 ALTERNATE SIZE POSITIONERS (@) STORED IN HANDLE INDENTOR OPENING COLOR-CODED DATA PLATE REMOVABLE CONTACT POSITIONER POSITIONER LATCH "ASSEMBLY AND rane LOCK SCREW POSITIONER RELEASE 2: CRIMPING TOOL MS3I9I-1 CONTACT, INSERTED THIS SIDE ROTATING TURRET (SHOWN IN RELEASED POSITION) TURRET LATCH coLor-coped POSITIONERS THUMB. BUTTON WIRE SIZE SELECTER PLATE TURRET REMOVED FOR EYESIGHT CRINPING. Figure 3-16. MS3191-1 and MS3191-3 Crimping Tools 343NAVAIR 01-14-5605 (USAF) T.O. 1-18-14 ADJUSTMENT SCREW MS27626-2(M22520/1-05) UNIVERSAL HEAD ws27628 (M22520/-01) ‘CRIMP TOOL WIRE SIZE SELECTOR KNOB CONTACT INSERTED THIS SIDE Figure 3-17. Crimping Tool MS27828(USAF) With MS27828-2 Universal Head anaNAVAIR _01-1A-505 (USAF) T.O, 1-1A-14 oneen ao SS5" Gace once a NS "G0" GAGING "NO GO" GAGING e Figure 3:8, Gaung Mil, © 22820 Crimping TootNAVAIR _01-1A-505 (USAF) T.0. 1-18-14 >, Inspecting MS3191-1 Crimping Tool. This tool is ‘gaged separately for each positioner. The procedure is as, follows: 1, Make sure the positioner is locked in place. 2. Select the proper MS31963 gage for the positioner being used. 3. With the tool fully closed, insert the GO gage through the positioner and into the crimping dies. The GO ‘age should enter the positioner and dies freely so that the ‘gage handle seats firmly on the top of the positioner (see figure 3-19). 4. The NO GO gage should not be able to enter into the crimping dies, and the gage handle should not seat ‘on the positioner, CAUTION, Do not crimp down on the gage pin as this will prevent the tool from cycling to ratchet release position, GO GAGE SEATED ‘ON POSITIONER NOGO GAGE NOT SEATED ON POSITIONER ame | cS Figure 3-19. Gaging MS3191-1, . Inspecting MS3191-3 Crimping Tool. Only the No. 20 wire size indentor setting is gaged for this tool. The procedure i as follows: 1, Slide the thumb button until the pointer is in line with the No, 20 wire size on the selector plate. (See figure 3-16.) 2. Close the tool handles to fully closed position. a6 3. The GO pin of MS3196.20 gage should pass freely through the indentor tips. 4. The NO GO gage pin should not pass between indentor tips. Do not crimp down on the gage pin as this will ‘damage the indentors. 3.27. CRIMPING PROCEDURE FOR MIL-C.22520 (AND USAF) CRIMPING TOOLS. The procedure for crimping ‘wires to contacts using the MIL-C-22520 and the USAF hand crimping tools is as follows: 1, Using the M22520/1.01 (MS27828USAF) crimping tool with the M22520/1-02 (MS27828-1) turret head: NOTE The tool handles must be fully opened when inserting the turret head, and when changing the selector position. 1, To install the turret head, depress the turret ‘tigger to release it to the indexing position as shown in figure 3-20. 2. Position the turret head over the retaining ring fon the back of the tool. Make certain the turret head is seated on the tool; then secure the 9/64 socket head screws with an Allen wrench. 3. The turret has three positioners which are color coded and marked with the applicable contact size (12, 16, ‘or 20). Select the positioner for the contact size that you are crimping. Rotate the turtet until the correct positioner is lined up with the index mark on the turret head. (See figure 3.20.) 4. Push the turret into the turret head until it snaps. {nto the locked position. (See figure 3-20.) $, Lift and turn the wire size selector knob to the correct wire size setting and release (see figure 3-21). The proper wire size selector number is determined from the chart on the side of the turret head. 6. Strip wire as described in 3-28¢.NAVAIR _01-1A-505 (USAF) T.0, 1-14-14 CONTACT NUMBERS (wrcsrec) sELector Position [root HANDLE) runnet EXTENDED PosiTionER a (rreicaty posrTionER Basic HAND TOOL, (azasz0/2-01) SELECTOR tocator PIN sELectoR (ru our AND TURN) Back OF Foot POsITIONER {coLor cooeD) (INDEXING POSITION)(rrrcac) CONTACT size {covor coven) contact NUMBERS (an-srecy wine SIZE SELECTOR POSITION Troon HANDLE) Figure 3-20. Typical M2620 Positioner and Turret Head yunrer MEAD AsIC HAND TOOL, sELecToR (rut our SELECTOR truce ov LOCATOR PIN NO TURN) ruasric rokaric e cura HAND Figure 3:21. M22520 Crimping Tools 347NAVAIR 01-1A-605 (USAF) T.0. 1-14-14 Insert the stripped wire into the contact until cad of wire can be seen through the inspection hole. Turn the tool around so the front is facing you. Then insert the ‘ive and contact through the indentors until it bottoms in the positioner. (See figure 3-22.) NOTE When crimping size 20 contacts, make sure that the wire insulation extends into the insulation support of the vontact. 8. Hold the wire in place and squeeze the tool ‘wens until the ratchet releases and the tool opens. 9. Remove the crimped contact and inspect. Make ‘we the wire strands are visible through the inapection hole an the contact bb. Using the M22520/2.01 (MS27831USAF) crimping ‘ool with the M22520/2-02 (MS27831-1) positioner or the M22520/2.03 (MS2783 1-2) positioner (see table 3-15): NOTE The tool handles must be fully opened when inserting ‘he positioner, and when changing the selector 1. Select the correct positioner for the contact you are crimping (bee 3-25b or g) and insert the positioner into the retaining ring in the back of the tool. The positioner is spring-loaded ahd must be pushed in and then rotated 90° gt 5 BE NAVAI 01-1A-505 (USAF) T.0. 1-18-14 1MS3106, MS3406, MS3456 STRAIGHT PLUG 'AN(MS) Connectors 3.33. TypicalNAVAIR 01-1A-605 (USAF) T.0. 1-1A-14 3.44, AN/MS CONNECTOR MARKING. Each AN/MS ‘connector is marked on the shell or coupling ring with a code of letters and numbers giving all the information necessary to identify the connector. (See figure 3-34.) A typical code is as follows: MS3106F-12:10 PW Shell Insert Insert ‘MS Number Class Size Arrangement Style Position a. The letters “MS” indicate that the connector has been made according to government standards. b. Numbers such as 3106 indicate type of shell, and whether plug or receptacle. (Refer to table 3-5.) ¢. Class letter indicates design of shell, and for what purpose connector is normally used. (Refer to table 3-5.) 4. Numbers following class letter indicate shell size by ‘outside diameter of mating part of receptacle in one sixteenth inch increments, or by the diameter of the coupling thread in sixteenths of an inch. For example, size 12 has an outside diameter or a coupling thread of 3/4 inch. STANDARD TYPE NUMBER LASS. Size INSERT ARRANGEMENT NUMBER 1 conTacT STYLE INSERT ROTATION Figure 3:34. AN/MS Connector Marking e. Numbers following hyphen indicate insert arrange- ‘ment. This number does not indicate the number of contacts. Military Standard drawings cover contact arrange- ‘ments approved for service use. See figure 3:35 for illustrations of insert arrangements. f, First letter following number indicates style of contact.NAVAIR 01-14-5605 (USAF) T.0. 1-14-14 ‘1 Contact ‘4 Contact | 5 Contact | 6 Contact os @ A @| @| &. 2 ~|s\6 2 @|2| 2 2 -|@|@ 6 @ | 2%. 2 @ ~|@|e a i @\|= |= we e me e @ 3 8. ° Fi a\* | 2. 8 3 ‘° @:® 0:0 @:3:0:0 70 i 0:0 0: ee . @:0 :@:@: 7@r@ * § zt 8 6:0 0: @: ae F@re@ * °° By @:@:e:e 2 ® e| @: 6:@ @ usa wane | oe ms 2K INDICATES AIR STANDARDS COORDINATING COMMITTEE PREFERRED. NOTE: FACE VIEW OF PIN INSERTS. ALL INSERTS SHOWN IN NORMAL POSITION T Contact 3 * @ :0:@:@:@'@ :@:3'0:8 m0 Figure 3-36. Insert Arrangements — AN Type Connectors, MIL-C-5015 (Sheet 1) 320NAVAIR _01-18-505 (USAF) T.0. 1-18-14 8 Contact | 9 Contact 11 Contact 14 Contact 16 Contact 23 Contact | 30 Contact @:8:9:0 @:@:6:6 Bi8:8:8 ee :@:@ iS @@ ® mn ® 12 Contact @@:@ @ 3 * @@28 @ 17 Contact 5 Cor & @ cm 9 Contact 8:8 * 78:8 a 31 Contact 7 Contact 52 Contact @ 37 Contact ma ® ll od rss cont | Gonna Tome] se [etme @ CODE OF CONTACT SIZES weed 3:30 Figure 3-95. Insert Arrangements — AN Type Connectors, MIL-C-5015 (Shest 2)NAVAIR 01-14-505 (USAF) T.0. 1-14-14 'g. Second letter indicates alternative insert position. Insert position letters W, X, Y, or Z indicate that the connector insert has been rotated with respect to the shell a specified number of degrees from the normal position Alternative positions are specified to prevent mismating when connectors of identical size and contact arrangement are installed adjacent to each other. These alternative positions are shown on governing military standard draw- ings. If no letter appears, the insert is in the normal position. On connectors with multiple keyways, the degree Of rotation is measured from the widest keyway. See figure 3.36 for typical alternative position arrangements. TH MULTIPL EKEYWAY CONNECTORS: REFERENCE IS TO WIDEST KEYWAY D, =a o 6] NO oO “8, NORMAL = W POSITION ruorwat x. POSITION & ) i ° ae 0 ¥ POSITION 2. POSITION FRONT VIEW SOCKET INSERT (PIN INSERT OPPOSITE) EQUALS DEGREES OF ROTATION Figure 3-36. Alternative Positions of Connector Inserts 345. MS CONNECTOR CABLE CLAMPS. Connector ‘cable clamps are used at the back end of MS connectors, except potted connectors, to support wiring and to prevent twisting or pulling on soldered connections. There are three types of MS cable clamps as shown in figure 5-37. These are as follows: a. MS30S7 — consists of a clamp body, two washers, and a clamp saddle held on the clamp body by two screws and lockwashers b. _MS3057A.— consists of a clamp body and two saddles held on by screws and lockwashers. Used with 'AN3420 telescoping bushing, c. _MS3057B — one piece clamp with no separate cap or saddles. Used with MS3420A bushings. REMOVABLE SADDLE 1Ms3057 REMOVABLE SADDLES M3057 GROUNDING SCREWS Ms20878, Figure 3-37. MS3057 Connector Cable Clamp Types 3.46, MANUFACTURERS’ VARIATIONS IN MS CON- NECTORS. Standard AN-MS plugs and receptacles made to the requirements of a Military Specification may show differences in appearance between one manufacturer and another. (See figure 3-38.) Also minor changes in dis- ‘assembly and installation instructions may be required. The text and illustrations to follow will show differences in detailNAVAIR 01-1A-505 (USAF) T.0. 1-18-14 AMPHENOL BENDIX CANNON Figure 3.38. Typical Manufacturer's Variations in AN-MS Connectors 3.47. MS POTTING CONNECTORS. These connectors are used only where potting is required. They are similar to other standard types, except that they have a shorter body shell and include a potting boot. MS potting connectors are available in the following types (see figure 3-39): 1MS3103 ~ a receptacle with flange for mounting to a wall ‘or bulkhead. ‘MS25183 — a straight plug used at the end of a wire or wire bundle 1MS25183A ~ similar to MS25183, with the addition of a ‘rounding screw. 3-48, DISASSEMBLY, REASSEMBLY, AND INSTALLATION OF CONNECTORS 3.49. GENERAL. Solder type contacts size 8 and smaller ‘are usually not removed for assembly purposes. Large solder contacts (size 4 and larger) are removed from connectors with hard inserts to protect the insert against the greater amount of heat necessary to properly solder wires to the larger contacts. Large solder contacts may be s2s183 removed from connectors with resilient inserts provided the connector is not a pressurized assembly with the contacts bonded into the insert Figure 3-39. Potting Connectors 332NAVAIR 01-1A-505 3.60. REMOVAL OF BACK SHELLS. Remove back shells, if present, from all connectors before attaching wires. Solid back shells of Classes A, C, and K are removed by unscrewing from the front shell as shown in figure 3-40. Split back shells of Class B connectors are held together either by an assembly ring or by captive screws, See figure 3.41 for details of disassembly, STRAP WRENCH SOLID BACK SHELL LEAD JAW PADS TO PROTECT CONNECTOR Figure 3.40. Removal of Solid Back Shell CONNECTOR BODY Se COUPLING NUT SPLIT. SHELL ON CONNECTOR Bopy SHELL ‘ASSEMBLY NUT COUPLING ASSEMBLED nee CONNECTOR sHZLL ASSEMBLY NUT Figure 3.41. Removal of Cannon Split Back Shell (USAF) T.0. 1-18-14 Class E and Class R connectors requir a special disassembly technique which is described in later paragraphs. KK 31. DISASSEMBLY INSTRUCTIONS FOR ANMS E ‘AND F CONNECTORS. Class E and F (environment-resist- ing) connectors are made in two forms. Those made by Bendix have a separate cable clamp similar to MS3057B. ‘Those made by Cannon use a cable clamp which is part of the back shell and similar to MS3057A. (See figure 3-42.) a, Disassembly of a Bendix Class E or F connector is accomplished as follows: 1. Unscrew cable clamp from back shell, using strap wrench or padded jaw connector pliers if necessary 2. Remove tapered grommet compression sleeve and grommet from back shell 3. Unscrew back shell from body assembly using. strap wrench or padded jaw pliers if necessary. 4, Remove contacts size 8 and larger as described in 3.49, NOTE Avoid removing contacts from Class E and F receptacles. . Disassemble Class E connectors made by Cannon as follows: 1. Remove cable clamp saddle by removing two screws, Unscrew cable clamp if MS3108E. 2. Unscrew back shell from body assembly using strap wrench if necessary. 3. Remove MS3420 telescoping bushing(s). 4. Remove grommet follower (grommet retainer) and grommet. - Do not remove inserts of moisture-proof connectors, Removal will destroy the moisture-proofing. Do not remove contacts smaller than size 8 except for replacement. 333NAVAIR 01-1A-605 (USAF) T.0. 1-14-14 GROMMET Msa420 TELESCOPING BUSHINGS 9 BODY ASSEMBLY GROMMET ‘FOLLOWER BACK “SHELL. Figure 3-42. Class E Connector — Cannon — Exploded View 334NAVAIR 01-1A-505 (USAF) T.0. 1-1A-14 3-52. MS CLASS R CONNECTOR DISASSEMBLY. These new lightweight environment-resisting connectors differ in appearance from Class F connectors. (See figure 3-43.) Class R connectors have no separate cable clamp. A ‘grommet, grommet compression nut, and ring are preassem- bled as a single unit, which is disengaged from the shell assembly before wiring contacts. The cable clamp has been replaced with a back nut and compression sleeve. The nut backs the grommet away from the contacts when removed. To disassemble, remove compression sleeve and grommet and unscrew back nut from body assembly. (See figure 3.44.) The cable clamp has been retained on the MS3108R langle plug which is identical with MS3108E except for ‘improved sealing. Otherwise, disassembly instructions for Class R connectors are the same as for the Class E connectors. To effect a satisfactory seal, the grommet must seat against the rear face of the insert. 3.53. AMPHENOL AND CANNON MS CLASS A CON- NECTORS. Amphenol and Cannon connectors are installed as follows (se figure 343) a. Remove back shell by unscrewing from body assembly. If the back shell is too tight to be loosened by hand, attach connector to mating connector shell held in fixture as illustrated in figure 3-40, and use strap wrench to Joosen back shell. Do not remove coupling nut from body. Never use pliers to disassemble or reassemble connec: tors. Use strap wrench. b. If all contacts are size 12 or smaller, no further disassembly is required. For removal of larger contacts, see 349. cc. Install the following items on wire bundle in listed order: 1, Cable clamp without saddle 2. Rubber bushing 3. Metal or plastic washer 4, Back shell 5. Retaining ring if removed in step b. 4, Slide insulating sleeves over each wire in bundle. Sleeves should be placed one inch back from wire ends to avoid burning during soldering operation. See 3-13 for data about insulating sleeves. AMPHENOL BENDIX CANNON 3:96NAVAIR _01-14-505 (USAF) T.0. 1-18-14 ‘COUPLING NUT PLUG SHELL, ae COMPRESSION ‘SCREWS cowpressiOn SLEEVE ef Figure 3-44, Class R Connector — Bendix — Exploded View 336 BODY ASSEMBLY CONTACTS INSULATING SLEEVES SADDLE RuaaeR BUSHING InseRT BACK SHELL METAL oR PLASTIC WASHER ABLE CLAMP Figure 3-45. Installation of Amphenol Class A ConnectorNAVAIR 01-1A-505 (USAF) T.O, 1-1A-14 NOTE ‘Steps € through h apply only if large contacts were removed in step b. fe. Solder wires to large contacts removed in step b. See 3-15 through 3-20 for soldering instructions. £, Reinstall large contacts by threading through rear insert and inserting contacts into front insert. Reassemble inserts and contacts into body assem- bly. Be careful to align keyway with key. Do not force the assembly because a damaged keyway will ruin a connector. 1h. Replace retaining ring so that end of ring is about 1/4 inch from removal slot as shown in figure 3-46. This ‘will simplify future disassembly. i. Solder wires to remaining contacts using methods described in 3-15 through 3.20. j. Clean soldered connections and slide insulating sleeves over contacts until they bottom against insert. k. Tie sleeves to wires using nylon braid as shown in figure 3-13. 1. Slide back shell down over wire bundle and hand tighten to body assembly. Use strap wrench to tighten back shell 1/8 turn beyond hand tight. ‘m, Install cable clamp as described in 3-72 or 3-73 RETAINING RING Figure 3-46. Location of End of Retaining Ring 3-54. AMPHENOL MS CLASS B CONNECTORS. ‘Amphenol Class B connectors are installed as follows (see figure 347): ‘a. Remove back shell by loosening captive assembly screws, Do not remove coupling nut from body. b. If all contacts are size 12 or smaller, no further disassembly is required. For larger contacts, see 3-69 ¢. Install the following items on wire bundle in listed order: 1, Cable clamp without saddle 2. Rubber bushing 3. Metal or plastic washer 4. Back shell 5. Retaining ring, if removed in step b. 4d. Slide insulating sleeves over each wire in bundle. Sleeves should be placed one inch back from wire ends to avoid buming during soldering operation. See 3-13 for data about insulating sleeves. NOTE Steps e through apply only if large contacts were removed in step b. fe. Solder wires to large contacts removed in step b. See 3-15 through 3-20 for soldering instructions. {Reinstall large contacts by threading through rear insert and inserting contacts into front insert. Reassemble inserts and contacts into body assem- bly. Be careful to align keyway with key. Do not force the assembly because a damaged keyway will ruin a connector. hh. Replace retaining ring so that end of ring is about 1/4 inch from removal slot as shown in figure 3-46. This, ‘will simplify future disassembly. i. Solder wires to remaining contacts using methods described in 3.15 through 3-20. Clean connections and slide insulating sleeves over contacts until they bottom against insert. 337NAVAIR 01-1A-505 (USAF) T.O. 1-18-14 BODY ASSEMBLY COUPLING RING SPLIT BACK SHELL HAL 4 @ METAL OR PLASTIC WASHER SADDLE a) CONTACTS INSULATING SLEEVES RUBBER SPLIT BACK SHELL HALE BUSHING Figure 3.47. Installation of Amphenol Class B Connector k. Tie sleeves to wires using nylon braid as shown in figure 3-13 1, Reassemble split shell. Be careful not to pinch wires. NOTE [Angle back shell can be assembled at 45° angles. See ‘engineering drawing for proper setting for each installation. m, Install cable clamp as described in 3-72. le Foloenp ioe ttoc WIRE BACK TO rn. Safety wire the split back shell holding screws, if required by engineering, by passing the wire through screw hncads (see figure 3-48), crossing it and completing with a twist. Figure 3.48, Safety Wiring Class B Connector PROTECT PERSONNEL 3.38NAVAIR 01-14-5605 (USAF) T.0. 1-1A-14 3-55. AMPHENOL MS CLASS C CONNECTORS. ‘Amphenol Class C connectors are installed as follows (see figure 3-49): a, Remove back shell by unscrewing from body. If the back shell is too tight to be loosened by hand, attach connector to mating connector shell held in fixture as iMustrated in figure 3-40, and use strap wrench to loosen back shell. Do not remove coupling nut from plug body. Never use unpadded pliers to disassemble or reassem- ble connectors. b. Large contacts (8, 4, and 0) are threaded into insert. Unscrew the contact for soldering. Do not twist or attempt to remove small contacts. Do not remove Class C inserts. These connectors are pressurized and insert removal will break the pressure seals. cc. Install the following items on wire bundle in listed order: 1. Cable clamp without saddle Rubber bushing Metal or plastic washer Back shell 4, Slide insulating sleeves over each wire in bundle. Sleeves should be placed one inch back from wire ends to avoid burning during soldering operation. See 3-13 for data about insulating sleves. ¢. Reinstall large contacts. Tighten contact until itis seated firmly against lead pressure washer. Use curved long nose pliers if necessary. f. Solder wires to remaining contacts using methods described in 3-15 through 3-20. 8. Clean connections and slide insulating sleeves over contacts until they butt against the insert hh. Tie sleeves to wires using nylon braid as shown in ‘igure 3-13. BODY AND INSERT ASSEMBLY METAL OR PLASTIC WASHER NOTE: 0 NOT REMOVE INSERT RUBBER BUSHING SOLID BACK SHELL SADOLE CABLE CLAMP Figure 3.49, Installation of Amphenol Class C Connector 339NAVAIR 01-1A-505 (UsAF) T. |. Slide back shell dewn over wire bundle and hand tiphten to body assembly. Use strap wrench to tighten back. shull 1/8 tum beyond hand tight i. Install cable clamp as deseribed in 3-72. 3.56. AMPHENOL CLASS E, F, AND R CONNECTORS. Amphenol Class E, F. and R connectors are installed as, follows: 2. Disengage the grommet compression nut assembly om the shel b. Thread pretinned wires through the proper holes in the grommet. <. Solder wires to contacts using the procedures described in 3-15 through 3-20. 1 Work the grommet compression nut assembly back uup the wire bundle and engage nut with shell assembly, siohung sue that the grommet is drawn up flush with the s. Fill all unused grommet holes with grommet sealing phigs . 1-TA-14 a. Use spanner wrench to remove spanner nut. (See figure 3-50.) b. Tap body assembly lightly in palm of hand to remove and separate contact and insert assembly. cc. Install the following items on wire bundle in listed order: 1. Conduit with coupling nut or other required fittings NOTE Fitting threads are not identical with standard MS connectors of same size. Use fitting sizes listed in table 346, 2. Spanner nut 3. Ceramic rear insert 4, Silicone rubber gaskets Table 3-6. Amphenol Fireproof Connector Fittings Connector Fitting Size Theead 357. AMPHENOL FIREPROOF CONNECTORS. 18 2 13/16 - 18 Aniphenol fireproof connectors have crimp type contacts 2 16 17/16 - 18 ‘1 withstand high temperature operating, requirements 32 4 2B Iisallation is as follows: 36 28 2/4 - 16 CONDUIT COUPLING NUT SPANNER NUT CERAMIC REAR INSERT SILICONE RUBBER GASKET FRONT, INSERT BODY AND x BACK SHELL ROTATE CONTACT 90” WHEN INSTALLING INFRONT INSERT Figure 3-50, 3.40 Installation of Amphenol Fireproof ConnectorNAVAIR 01-1A-505 (USAF) T.0. 1-14-14 4. Crimp wires into contacts using any of the methods described in section V. ¢. Reassemble by: (1) sliding contacts into ceramic front insert; (2) pushing silicone rubber gasket down over contacts; and (3) sliding ceramic rear insert over contacts f. Examine contact and insert assembly to see that parts butt, and then slide assembly into body. Tighten spanner nut into place until lush with rear of body shel. Tighten conduit coupling nut or other required fitting over body assembly. Use strap wrench to tighten 1/8 turn beyond hand tight 358, POTTING CONNECTORS a. Potting connectors are supplied with a plastic potting mold. Installation is as follows: 1. Slide the plastic mold over the wire bundle. 2. Solder wires to contacts, See 3-16 through 3-20, for soldering instructions, Do not install insulating sleeves over individual wires Potting compound will not cure properly in contact, with vinyl sleeving. 3, Install spare wires on all unused pins. Use largest gage wire that would normally be attached to each contact. Spare wires are approximately 9 inches long. (See figure 351) 4. Clean the complete connector assembly by scraping off rosin and then brush vigorously in new unused Stoddard’s Solvent, followed by second rinse in clean Stoddard’s Solvent. (See figure 3-52.) 5. _ Rinse area to be potted with methylene chloride applied from hand operated laboratory wash bottle or similar device. CAUTION Do not breathe methylene chloride fumes. Use only in well ventilated areas. FILL ALL SPARE CONTACTS WITH MAXIMUM SIZE WIRES IDENTIFY SPARE WIRES WITH CODE LETTER TO CORRESPOND TO CONTACT 341NAVAIR 01-1A-505 (USAF) T. 1-10-14 METHYLENE CHLORIDE IN WASH BOTTLE @RISTLE BRUSH SAFETY CAN With STODDARD’S SOLVENT Figure 352. Cleaning Connector Prior to Potting NOTE Complete potting within two hours after cleaning, 6. Slide plastic mold into position. Mate connectors before potting either part to avoid splaying contacts during the potting operation. 7. Insert potting compound prepared in accordance ‘with ditections given in section X. Fill back of connector by inserting nozzle down between wires until it almost touches back of insert (see figure 3-53). Fill slowly while ‘moving nozzle back from insert and watch compound to be sure no air bubbles are trapped. Fill to top of mold. Tamp down the compound, if necessary, with a wooden or metal 1/8 inch dowel. Tap connector assembly on a resilient surface or vibrate mechanically to help flow the compound into all spaces and to release trapped air. 8. Insulate the ends of all spare wires. (See figure 3-51.) The preferred method of insulating a spare wire is to crimp it into an MS25274 wire end cap with tool MS25037-1A. Nonstandard end caps are also available for either stripped or unstripped wire 342 POTTING COMPOUND DISPENSER FILLING CONNECTOR POTTING MOLD @ FILLING WITH COMPOUND BRACKET FOR CURING be CURING Figure 3.53. Filling and Curing Potting ConnectorNAVAIR 01-18-605 (USAF) T.O. 1-14-14 9. Immediately after filling each connector, tie the ‘wires together loosely about 6 inches back from connector. ‘Make sure that wires are centrally located in the connector so that each wire is completely surrounded by potting compound. Suspend the assembly by placing the tie over a nail so that the potting material remains level, as shown in figure 3-53, and allow to air cure for atleast 1-1/2 hours at 75°F without any movement. Make sure that the tie is applied after potting. WARNING ‘The accelerator contains a toxic lead compound. Avoid excessive skin contact. Clean hands thoroughly after using. Use gloves. 10. Carefully place assembly, still suspended from to drying oven for 3 10 4 hours at 100°F, or air cure at 75°F for 24 hours, NOTE Full cure with maximum electrical characteristics is not achieved until 24 hours after potting. Do not perform any electrical insulation resistance tests until this period has passed. 11, Apply a light film of lubrication oil to all exterior metal surfaces after potting compound is com- pletely cured. 12. If the plug does not have an O-ring or gasket seal on the barrel, as shown in figure 3-54, then install an 1MS29513 O-ring selected from table 3-7. Roll O-ring tightly against shoulder of plug inside coupling ring. Plug barrel and O-ring must be clean and dry before assembly. Do not use two rings. The added thickness of a second ring will prevent proper mating of contacts. POTTING COMPOUND O-RING COUPLING NUT Figure 3-54. Installation of O-Ring on Potted Connector ‘Table 3-7. O-Ring Sizes for AN Type Connectors Plug Si O-Ring Thickness 8S .070 inches 10S & 10SL. :070 inches 12 & Ls 070 M&S, 1070 16 & 165 2070 18 2070 20 070 22 1070 4 1070 28 070 32 070 36 +103 40 +103, 4 +103, 48 103, Ms29513 O-Ring ID Dash Nos. 312 inches 364 489, 489. 614 739 864 989 14 1.364 1.364 1.737 1.987 “136 2.237 -140 2.487 “144 343NAVAIR _01-1A-605 (USAF) T.0. 1-18-14 b. The procedure for crimping wire end caps with standard tool MS25037-1A is as follows: 1. Select an end cap of the correct size for the wire to be insulated (see table 3-8), and crimp it to the wire with the MS25037 tool 2. Make sure the locator is properly positioned behind the lower nest. Position the wire end cap in the conect die nest (color of cap insulation matches color coding on tool handle) with the closed end of the cap resting against the locator. 3. Insert the stripped wire so that the end of the stripped wire is seated against the closed end of the cap, and the insulation against the metal sleeve of the cap. 4. Close tool handles to crimp end cap to wire, until ratchet releases and the tool opens. Remove the crimped assembly. ble 38. Wire End Caps and Crimping Tools MS Number Color, Wire Size MS252761 Yellow = 26-24 MS2527402 Red 18 MS25274-3 Blue 16-14 MS25274-4 Yellow = 12-10 3.59. BENDIXSCINTILLA MS CLASS A CONNEC- TORS. Bendix Class A connectors are installed as follows (ee figure 3-55): a. Remove back shell by unscrewing from body. Ifthe back shell is too tight to be loosened by hand, attach the connector to mating connector shell attached to fixture (as ‘lustrated in figure 3-40) and use a strap wrench or padded jaw pliers to loosen back shell Do not remove coupling nut from plug body [Never use pliers with unpadded jaws to disassemble or reassemble connectors. b. If all contacts are size 12 or smaller, no further disassembly is required. Larger contacts such as size 8,4, oF ‘O may be removed by applying pressure on solder well end by means of steel or bakelite rod slightly smaller in diameter than the solder well. See figure 3-70 for arbor press fixture suitable for this operation. Table 3-9 lists diameter of rods for removing contacts. S BODY ASSEMBLY INSULATING SLEEVES THis FACE Do NOT LUBRICATE: LUBRICATE THESE FACES COUPLING NUT (00 NOT REMOVE FROM BODY ASSEMBLY) BACK SHELL GLAND TAPERED SLEEVE CABLE CLAMP, Figure 3-55, Installation of Bendix Class A and C ConnectorsNAVAIR 01-1A-605 (USAF) T.0, 1-18-14 Table 3.9. Contact Removal Too! Diameter Contact Rod Diameter Size (inches) ° 450 4 312 8 187 Hold the connector so that pressure is applied in a straight line with contacts. Pushing at an angle may ‘damage the contacts. Bent contacts must be replaced. Do not attempt to straighten damaged contacts. cc. Install MS3057B cable clamp as described in 3-74 4. Slide insulating sleeves over each wire in bundle. Sleeves should be placed one inch back from wire ends to avoid buming during soldering operation. See table 3-3 for sleeving sizes. fe. Solder wires to larger contacts removed in step b. See 3-16 through 3-20 for soldering instructions. f, Reinstall large contacts by pushing them through rear of insert until seated. Use ethyl alcohol as lubricant, if necessary. Install each contact, when cool, before proceeding to solder next contact, This will help avoid terrors. Use a bakelite screwdriver to aid in seating contacts. (Gee figure 3-56.) Use care not to fold thin lip of rubber into hole with contact. Solder wire to remaining smaller contacts using one of the methods described in 3-15 through 3-20. hh. Slide insulating sleeves over cooled connections ‘until they bottom against insert. i. Slide back shell down over wire bundle and hand tighten to body. Use strap wrench or padded jew pliers to tighten back shell until it bottoms. j. Slide telescoping sleeves, if required, through gland until flush with inside edge. Hold telescoping sleeves in back of cable clamping nut while engaging threads. Do not release telescoping sleeves until gland seats on back shel. DO NOT FOLD RUBBER LIP INTO HOLE Figure 3-56, Reinstalling Contact in Bendix Resiliont Insert k, Tighten cable clamp with strap wrench or padded jaw pliers until it bottoms. Mate connector with mating shell in fixture while tightening cable clamp. Keep all parts free of dirt and foreign materi Clean dirty parts with ethyl alcohol and relubis. ste all threads with Military Specification MIL-G327% grease. Relubricate the indicated parts of gland an! tapered sleeve, as shown in figure 3-75, with petrolatum. 3.60. BENDIXSCINTILLA MS CLASS C CONNFC TORS. Bendix Class C connectors are pressurized and cat must be given to avoid breaking the pressure seal. Insal!: tion procedure for Bendix Class C connectors is the same « for Bendix Class A connectors. (See figure 3-S5.) [Never remove insert or contacts from Class C connec tor as this would break the pressure seal incorporated in the unit at the time of factory assembly.NAVAIR _01-1A-505 (USAF) T.0. 1-14-14 3461. BENDIXSCINTILLA MS CLASS E CONNEC: TORS. Bendix Class E connectors are installed as follows: a. Remove cable clamp by unscrewing from back shell. Slide cable clamp over wire bundle. b. Check tapered sleeve and grommet for thin film petrolatum lubricant on indicated surfaces. (See figure 357) c. Slide tapered sleeve over wire bundle. 4. Insert pretinned wires through proper holes in grommet. NOTE Grommet is coded to match insert coding. Use alcohol as a lubricant if necessary. After wires are threaded through grommet, use air blast to dry alcohol. fe. Unscrew back shell from body assembly and slide ‘over wire bundle. If coupling nut is removed, push nut back ‘on wire bundle with threaded end forward. Install insulating sleeves on wires. Solder wires to contacts as described for Bendix- Scintilla Class A connectors in 3-59. Do. not remove contacts from receptacles for soldering, hh. Slide insulating sleeves over cooled connections until dhey bottom against insert i, Slide back shell down over wire bundle and hand tighten to body shell. |. _ Examine insulating sleeves. They should not project over shoulder in back shell k. Use strap wrench or padded jaw pliers to tighten back shell until it bottoms. 1. Carefully push grommet down over wire until it is seated in shoulder of back shell. Do not allow wires to fold inside back shell m. Fill all unused holes with MS25251_ grommet sealing plugs. Sizes are listed in table 3-10. tn, Slide tapered sleeve and cable clamp over grommet and hand tighten, BODY ASSEMBLY INSULATING SLEEVES THIS FACE DO NOT LUBRICATE LUBRICATE THESE FACES COUPLING NUT (00 NOT RENOVE FROM BODY ASSEMBLY) BACK, SHELL GROMMET TAPERED SLEEVE CABLE CLAMP Figure 3-57. Installation of Bendix Class E Connectors 3.46NAVAIR 01-1A-505 (USAF) T.0. 1-18-14 Tighten cable clamp with strap wrench or padded 3.62. BENDIXSCINTILLA MS CLASS R_CONNEC- jaw pliers until it bottoms. TORS. Bendix Class R connectors are installed as follows (see figure 3-58): CAUTION 1, Remove compression sleeve from back nut by When tightening cable clamp, insure that tapered unscrewing the two compression screws, and slide sleeve sleeve and grommet do not rotate with cable clamp. over wire bundle, ‘This will cause tension and possible breakage of wire cecerared b. Insert pretinned wires through the proper holes in ‘grommet and slide along the wire bundle Table 3-10. Sizes of Grommet Sealing Plugs Wire Size MS Part Ne NOTE 22-16 MS25251-16 ae Pecan ‘grommet as a guide in threading wires. Align letters 0-8 MS25251- 8 ‘with corresponding letters on rear face of the insert. PLUG SHELL COUPLING NUT BACK NUT GROMMET INSULATING SLEEVES COMPRESSION SCREWS COMPRESSION SLEEVE OY Figure 3.58. Installation of Bendix Class R Connector 347NAVAIR 01-14-5605 (USAF) T.0, 1-18-14 c. Unscrew the back nut from the body assembly and slide it over the wire bundle. If coupling nut is removed, make sure it is pushed back on the wire bundle with the threaded end forward. d. Solder wires to contacts using the procedures for Bendix Class A connectors as described in 3-59. ©. Mate connector with its mating piece and slide back ‘nut down over wire bundle and hand tighten to shell. Use a strap wrench or padded jaw connector pliers to tighten back nut until it bottoms, f. Push grommet carefully down over wires until it is seated in shoulder of back nut. & Fill all unused grommet holes with MS25251 ‘grommet sealing plugs; sizes are listed in table 3-10. hh. Slide the grommet compression sleeve down over the wire bundle and tighten the two compression screws until they bottom. 3.63. BENDIXSCINTILLA FIREPROOF _CONNEC- TORS. Bendix fireproof connectors have crimp-on type contacts to withstand high temperature operating require- ‘ments. Installation is as follows (see figures 3-59 and 3-60): a, Remove back shell by unscrewing from body. b. Remove threaded insert retaining ring with fingers. If necessary, use spanner wrench (Bendix 11-4045). c. Remove insert assembly by pushing on front insert toward rear of the connector. 4. Remove front insert from contacts. Revolve con: tacts 90° and remove from rear insert and sealing insert. NOTE Use care to prevent tearing or cutting sealing insert. 3.48 fe. Strip wires. f. Attach wires to contacts by silver soldering or crimping with appropriate tool. 8. _ Install the following on the wire bundle in the order sven: 1. Elbow and adapter or other fittings as required. 2. Threaded insert retaining ring. h. To install contacts with wires attached, rotate contacts 90° and insert contacts through proper holes of rear insert NOTE Smallest outside diameter of rear insert must face wires. i. Push sealing insert over contacts until it butts ‘against front face of rear insert. COUPLING NUT ON BODY AND INSERT ASSEMBLY SPANNER NUT BACK SHELL Figure 3-59. Bendix Fireproof Connector Partial DisassemblyNAVAIR 01-1A-605 (USAF) T.0. 1-1A-14 BACK SHELL COUPLING NUT CONNECTOR COUPLING NUT {00 NOT REMOVE FROM BODY) SPANNER NUT SEALING INSERT FRONT, INSERT Booy CRIMPED CONTACTS REAR INSERT 12 3460. Installation of Bendix Fireproof Connector j. Align Keyway of front insert with keyway of rear 1. Start spanner nut into connector body by hand and insert and slide front insert (largest diameter first) over tighten with spanner wrench (see table 3-11), using stan- contacts down to sealing insert. dard torque wrench handle (1/4-inch drive), as shown in figure 3-61. Tighten to torque values in table 3-11. Kk. Align keyway of assembled inserts with keyway in body. Carefully push assembly into back of body. If sealing m. Tighten back shell, or elbow if used, to body. Use insert catches on key, depress insert with a dull instrument strap wrench or padded jaw pliers to tighten until back shell while it passes under the key. is bottomed, Table 3-11. Torque Value for Fireproof Connectors Connector Size Spanner Wrench (Bendix) 10s 11-4045-10 1S & 12 “2 MS & 4 od 16S & 16 “16 18 “18 20 -20 2 2 4 26 28 28 32 232 349NAVAIR 01-1A-505 (USAF) T.0. 1-1A-14 TORQUE WRENCH SPANNER WRENCH SPANNER NUT INSERT AND CONTACT ASSEMBLY BoDy MATING RECEPTACLE IN HOLDING FIXTURE Figure 3.61. Torque Wrench Used on Bendix Fireproof Connector 3464. CANNON MS CLASS B CONNECTORS. Cannon Class B connectors are supplied with a split shell held together by a shell assembly nut as shown in figure 3-62. Cannon Class B connectors are installed as follows: a. Remove split shell by loosening shell assembly nut. Do not remove coupling nut from plug body. b. If all contacts are size 12 or smaller, no further disassembly is requited. For removal of larger contacts, see 3.69. 350 ‘c. Install the following items on wire bundle in listed order as shown in figure 3-62: 1, Cable clamp with loosened saddle. 2, MS3420 telescoping bushing (at least one extra telescoping section is added, if necessary). 4. Slide insulating sleeves over each wire in bundle. Sleeves should be placed one inch back from wire ends to avoid burning during soldering operation. See 3-13 for data about insulating sleeves. COUPLING NUT ON BODY AND INSERT ASSEMBLY INSULATING SLEEVES SPLIT SHELL COUPLING. NUT ASSEMBLY NUT ABLE, ‘CLAMP sa420 TELESCOPING TELESCOPING. BUSHING. SADDLE & CABLE CLAMP Figure 3.62. Installation of Cannon Class 8 ConnectorNAVAIR 01-1A-505 (USAF) T.0. 1-18-14 e. Solder wires to contacts using procedures described 3.65. CANNON MS CLASS C CONNECTORS. Cannon in 3-15 through 3.20. MS Class C connectors are supplied only as receptacles ‘MS3100C and MS3102C. f. Clean connections and slide insulating sleeves over contacts until they bottom against insert. CAUTION ' ' Do not remove Class C inserts or contacts. Removal Tie sleeves to wires using nylon braid as shown in vvll break the pressure seal. figure 3-13. hh, Reassemble split shell. Be careful not to pinch Install Cannon MS3100C as follows (see figure 3-63) wires. Rotate and lock angle back shell in proper po a. Remove back shell by unscrewing from body. Slide 1MS3057A cable clamp, M3420 telescoping bushing, and i, Install cable clamp as described in 3-73, back shell on the wire bundle in that order. BODY AND INSERT ASSEMBLY INSULATING SLEEVES SOLID BACK SHELL MS3420 TELESCOPING BUSHING NOTE: DO NOT REMOVE INSERT % SADDLES Figure 3-63. Installation of Cannon Class C Connector 381NAVAIR 01-14-6505 (USAF) T.0. 1-18-14 b. Slide insulating sleeves over each wire in bundle. Sleeves should be placed one inch back from wire ends to avoid burning during soldering operation. See 3-13 for data about insulating sleeves, Solder wires to contacts using methods described in 3.15 through 3-20, 4. Clean connections and slide insulating sleeves over contacts until they butt against the insert, fe. Tie sleeves to wires using nylon braid as shown in figure 3-13, £, Slide back shell down over wire bundle and tighten to body. Use strap wrench to tighten back shell 1/8 turn ‘beyond hand tight. {Install cable clamp as described in 3-73. Install Cannon MS3102C in the same manner as Cannon MS3100C except omit steps a and f. 3.66. CANNON MS CLASS E CONNECTORS. install ‘Cannon Class E connectors as follows (see figure 3-64) a. Unsetew back shell. Do not pull MS3420 bushings ‘out of back shell. Loosen saddles but do not remove them from back shell b. Slide back shell and bushing assembly over wire bundle, ‘c. Thread pretinned wires through grommet follower and through grommet. Note relationship of grommet follower and grommet in figure 3-64, BODY AND INSERT ASSEMBLY GROMMET NOTE: DO. NOT USE INSULATING SLEEVES GROMMET FOLLOWER BACK SHELL “AND CLAMP Msa4z0 TELESCOPING BUSHINGS % Figure 3-64, Installation of Cannon Class E Connector 362NAVAIR 01-1A-605 (USAF) T.0, 1-18-14 Insert proper wires in holes of grommet and grommet, follower. These are coded to match markings on back of insert. Use alcohol as a lubricant if necessary. After wires are threaded through grommet, use air blast to dry alcohol. NOTE Do not install insulating sleeves on wires. 4d. Solder wires to contacts as described in 3-15 through 3-20. If contacts are larger than number 12 size, they ate removed as described in 3-69. ¢. Reinstall large contacts by pushing them through rear of insert until seated. (See figure 3-56.) Use alcohol as lubricant, if necessary. Install each contact, when cool, before proceeding to solder next contact. This will help avoid errors. Use a bakelite screwdriver to aid in seating contacts, {. Slide grommet down over wire bundle. Pull lightly on each wire as grommet is seated to prevent wires folding between insert and grommet. & _ Slide grommet follower down over wire bundle. Use ‘same caution as instep f. (See figure 3-65.) h, Slide back shell and bushing assembly over wire bundle and hand tighten to body. Use strap wrench to tighten back shell until it bottoms. i, Tighten saddle screws until 1/16.inch clearance remains between each saddle and mounting tab of back shell WIRES FOLDED BETWEEN GROMMET AND INSERT, KEEP WIRES TAUT coop USE SCREWDRIVER TO MOVE GROMMET INTO POSITION Figure 3-65. Connon Class E Connector — Grommet Installation 353NAVAIR 01-1A-605 (USAF) T.O. 1-18-14 3.67. CANNON MS CLASS R CONNECTORS. The instal lation of Cannon Class R connectors isthe same as that for Cannon Class E connectors. 3.68. CANNON FIREPROOF CONNECTORS. Cannon fireproof connectors have crimp type contacts to withstand high temperature operating requirements. Installation is as follows (see figure 3-66) a. Release back shell by removing four holding screws. Do not remove coupling nut from plug body. 'b. Use retaining ring pliers to remove internal retaining ring. c. Tap connector body in palm of hand to remove inserts. Separate inserts to release contacts. 4. Carefully pull retaining clips from contacts. Do not lose clips. ce. Install the following items on wire bundle in listed order: 1, Back shell, with conduit if required. 2. Retaining ring. £, Silver solder, or crimp wires into contacts using any of the methods described in section V. '& Slide contacts through rear insert. Be careful to get each contact into its proper location by observing the identification letters on the insert. th. Reinstall the retaining clips to lock contacts into Inserts. i. Push front insert over contacts. Observe identifice- tion letters to assure proper location of contacts. Examine contact and insert assembly to see that insert halves butt, and then slide assembly into body. k. Reinstall retaining ring. 1. Tighten back shell by replacing four holding screws. m, Tighten conduit coupling nut or other required fitting. Use strap wrench to tighten 1/8 turn beyond hand tight. 354 HOLDING SCREWS BACK SHELL RETAINING RING REAR INSERT CONTACTS CRIMP ED. ~ To WIRES RETAINING CLIPS. FRONT INSERT COUPLING NUT ‘ON BODY Figure 3-66. Installation of Cannon Fireproof ConnectorNAVAIR 01-1A-505 (USAF) T.0, 1-14-14 3469. REMOVAL OF CONTACTS. Solder-type contacts ‘izes 4 and 0 are removed before soldering provided they ‘are not bonded in the connector. Amphenol Class C pin ‘contacts sizes 4 and O are threaded into the insert and can be removed safely. Size 8 contacts (if not bonded in the connector), may be removed if close spacing makes soldering difficult. ‘Avoid removing contacts from Class C, Class E, and. Cass R connectors. Never remove inserts from Class C\E,F,and R connectors. Solderless contacts such as supplied in Class K must be removed in order to crimp wire into contacts. Contacts are removed by the following procedures: PRYING OFF RETAINING CLIP ROTATE 90° BEFORE RETRACTING RETAINING ‘CLIP REMOVING CONTACT a. Cannon spring clip contacts (see figure 3-67) are removed by prying off the clip with a small screwdriver or scriber. Rotate contact 90° and lift out. b. Amphenol two piece inserts have contacts which are held in place by the insert halves. (See figures 3-68 and 3469.) Pry out retaining ring which holds insert in place with small screwdriver. Remove inserts and separate them. ‘This will free contacts c. Some Bendix and Cannon connectors have resilient inserts. Contacts are removed from these resilient inserts by pushing against the solder cup end with a round phenolic rod a little smaller in diameter than the solder cup. An arbor press, as shown in figure 3-70, is helpful in removing large size contacts. [Never use pliers to remove contacts. This will damage the contact. PRYING OUT RETAINING RING Figure 3-67. Removal of Cannon Clip-Held Contacts Figure 3-68. Removal of Amphenol Insert Assembly 356NAVAIR _01-1A-605 (USAF) T.0. 1-14-14 ARBOR PRESS BODY SHELL RETAINING RING DRILL ROD SMALLER IN DIAMETE! eee THAN. CONTACT SOLDER CUP. FRONT INSERT SOCKET CONTACTS CLEARANCE HOLE IN ANVIL OF PRESS Figure 3-69, Amphenol Contact and Insert ‘Assembly — Exploded View Figure 3.70. Removal of Solder Contacts From Resilient Insert 356NAVAIR 01-1A-605 (USAF) T.O. 1-1A-14 3-70. INSTALLATION OF MS3057 SERIES CONNECTOR CABLE CLAMPS 3-71, MS30S7 CABLE CLAMP TYPES. As described in 3-45, there are three types of MS3057 connector cable clamps. (See figure 3-71.) 2, MS3057 has a single saddle held by two screws. It contains a metal or plastic washer and a flat rubber bushing. For shipping, to prevent loss of metal or plastic washer, itis placed inside the clamp and held in place by the rubber bushing. Before using, reverse position to that shown in figure 3-7la, so that metal or plastic washer will contact back shell of connector. b._ MS3057A has two saddles separated by a centering boar. This cable clamp is supplied with MS3420 bushing to protect wire bundle under clamp. Add extra bushings if ‘necessary. cc. MS30S7B has a gland and tapered sleeve. The gland is squeezed around the wire bundle when the cable clamp is screwed to the connector back shell, Before installing MS3057 cable clamps onto connec: tors, screw mating part onto connector with coupling ‘ut. This will help to prevent contacts splaying when cable clamp is tightened. METAL OR PLASTIC WASHER ag CONNECTOR BACK SHELL (REF) RUBBER BUSHING wg 2, MS3057 ce MS30578 Ms3420 BUSHING SADDLE CABLE CLAMP b. MS3057A TAPERED SLEEVE GLAND a CABLE CLAMP Figure 3-71, MS3057 Connector Cable Clamp Types — Exploded View 387NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 3-72. INSTALLATION OF MS3057 CABLE CLAMP. The MS30S7 cable clamp is installed as follows (see figure 3.72): Slide MS3420A telescoping bushings on wire bundle if bundle diameter is too small to be effectively gripped by the saddle b. Slide MS3057 cable clamp without saddle on wire bundle followed by rubber bushing and metal or plastic washer. c. Assemble wires to connector and tighten back shell. (Gee other paragraphs for details for each connector class.) 4. Push MS3057 cable clamp toward back shell and hand tighten, Use strap wrench to tighten fully & 7 Af MIRES 4 / NOT CLAMPED BaD CONNECTOR Ms3420A TELESCOPING BACK SHELL BUSHINGS OR VINYL (REF.) TAPE AS REQUIRED Vie" _Gap. WHEN. TIGHT coop Figure 3-72, Installation of MS3057 Cable Clamp fe. Push MS3420A bushings, if required, into cable clamp until past saddle f, Attach saddle with both screws and tighten until 1/16 inch space is left between saddle and body as shown in figure 3-72. MS3420A bushing, if used, should bulge slightly when saddle is tight. NOTE A wrap of vinyl, nylon, or fiberglass tape can be used instead of MS3420A bushings. If tape wrap is used, secure with nylon braid behind saddle. 3-73, INSTALLATION OF MS30S7A CABLE CLAMP. ‘The MS3057A cable clamp is installed as follows (see figure 3-73): a, Slide MS3057A cable clamp without saddles on wire bundle before wires are connected. b. Slide MS3420 telescoping bushing on wire bundle before wires are connected. cc. Assemble wires to connector and tighten back shell (Gee later paragraphs for details for each connector class). . Push MS3057A cable clamp together with inserted 'MS3420 bushing toward back shell and hand tighten, Use strap wrench to tighten fully €. Attach both saddles with supplied screws and lockwashers When replacing saddles, observe that screw heads are placed so that pushing on screws will tighten cable clamp to back shell {Tighten saddles until 1/16 inch remains between cach saddle and the centering bar as shown. Use extra ¥MS3420 telescoping bushings in original assembly if saddles ate not tight with this 1/16 inch opening, See table 3-12 for telescoping dimensions.NAVAIR _01-1A-605 (USAF) T.0. 1-14-14 CONNECTOR BACK SHELL (REF.) MS2057, CABLE CLAMP 16" GAP. WHEN TIGHT 1Msa420 TELESCOPING BUSHINGS Figure 3-73. Installation of MS3057A Cable Clamp Toble 3-12, Telescoping Bushings *GROUP I “GROUP IIL Inside Diameter Connector Bushing Bushing in inches Size Nos Now FREE CLOSED 10 1MS34203A 1MS34203A MS34203A, 2125 000 2 “4A “4A “4A 219 010 M4 “6A “6A “6A 312 +14 16 “8A 438 2222 18 Scan 00go 438 +200 20 +124 “541 £270 24 “164, +750 433 30 “184 1938 +504 32 938 +620 36 1.125 +682 rr) -28A 1.250 816 “Bushings listed in each group will telescope respectively when free. 359NAVAIR _01-1A-505 (USAF) T.O, 1-18-14 3.74, INSTALLATION OF MS30S7B CABLE CLAMP. ‘The MS30S7B cable clamp is installed as follows (see figure 3.74) 44, Slide MS3420A telescoping bushings, if required, on wire bundle before wires are connected. Sec table 3-12 for telescoping dimensions. b. Slide MS30S7B cable clamp assembly on wire bundle before wires are connected, Proper lubrication of gland and tapered sleeve is important for this assembly. In handling parts, keep them clean and free of dirt. Wash away dirt with clean denatured ethyl alcohol and relubricate with petrolatum (Federal Specification VV-P.236) as shown in figure 3-75. Do not apply petrolatum to inside of gland or to serrated face of gland. cc. Assemble wires to connector and tighten back shell (Gee other paragraphs for details for each connector class) d. Push MS3420A bushings, if used, through gland of MS3057B so that end of bushing is flush with serrated face of gland. fe. Slide entire assembly toward back shell and hand tighten. Use strap wrench or padded jaw connector pliers to fully tighten until MS3057B bottoms onto back shell. While tightening, hold wire bundle and telescoping sleeves until land seats on back shell. NOTE Shield braid (and jacket, if present) must end outside ‘of MS3057B cable clamp to retain moisture resistant {qualities of clamp. Ground braid to either grounding screw on cable clamp. CABLE CLAMP Ms2«20a_ TELESCOPING BUSHINGS AS REQUIRED TAPERED SLEEVE DO NOT LUBRICATE THIS SERRATED =ACE GLAND CONNECTOR BACK SHELL (REF.) Figure 3-74, Installation of MS3057B Cable ClampNAVAIR 01-14-6505 (USAF) T.0, 1-1A-14 DO_NOT LUBRICATE THESE FACES GLAND TAPERED SLEEVE LUBRICATE WITH PETROLATUM GROUNDING SCREWS Figure 3-76. Lubrication of MS3057B Cable Clamp 3-75. INTERCHANGEABILITY OF US/AN AND UK/BMS CONNECTORS Through the Air Standards Coordinating Committee, the United States, Australia, Canada, Great Britain, and New Zealand have standardized on the mechanical interchange- ability of the AN type of connectors. The standard insert arrangements are indicated in figure 3-35. If, during an overseas deployment, a standard US/AN connector is not available, the defective or damaged connector may be replaced by a UK/BMS (United Kingdom/British Miltary Standard) connector under the following conditions: a. Replacing a US/AN receptacle with a UK/BMS fixed plug or fixed socket. 1, _If the US item is Class K (fireproof) then a steel shelled (fireproof) UK item must be used. Otherwise, the standard BMS connector can be used to replace AN ‘connectors Classes A, B,C, E, F, and R. 2. Unless the equipment in question is intended to be ventilated freely, it will be necessary to seal or blank off the four screw holes by which the US receptacle was secured. These will not be required forthe UK item. 3. The existing main panel hole will receive the UK fixed item, but because of excessive clearance, it will be impossible to achieve the UK standard of sealing and difficult to achieve the US standard. 4. Contacts of the UK item are intended to be crimped, and US tools can be used with discretion, Alternatively, it is possible to solder the connections, except when replacing US Class K. b. Replacing a US/AN plug by a UK/BMS free plug or free socket. 1. If the US item is Class K, then a steel shelled UK. item must be used. 2. If the US cable carties cable fittings or conduit, it may be possible, because of the sealed cable entry on the UK item, to dispense with the cable fittings OR it may be necessary to change the entry nut already on the cable OR, with certain of the UK designs, to cut off a projecting rubber gland to allow US fittings to seat c. The US standard contacts covered by Specification MIL-C-26636 and MIL--23216 cannot be used in BMS connectors. 3-76, MINIATURE MS CONNECTORS 3.77. GENERAL DESCRIPTION. Military Specifications cover the miniature MS connectors most commonly used in aircraft: MIL-C-26482, MIL-C-26500, MIL-C-0026482, MIL-C-38999, MIL-C-0081511, MIL-C-81703, and MIL-C- 83723. Connectors manufactured to these specifications hhave either solder type or crimp type contacts and cover a range of contact sizes from 12 to 20. The types and classes ‘of miniature MIL-C-0026482 and MIL-C-26500 connectors are listed in table 3-13. Typical miniature MS connectors ‘are illustrated in figure 3-76. Exploded views of plugs and receptacles are shown in figures 3-77 and 3-78. The contact arrangements for MIL-C-26482 connectors are shown in figure 3-79 (Sheets 1 and 2) and the arrangements for ‘MIL-C-26500 connectors are shown in figure 3-80. 361NAVAIR 01-1A-505 (USAF) T.0. 1-14-14 ‘Table 3-13. Miniature MS Connector Type and Ctass Availability Connector Contact Class Type Description ‘Type Series Availability ‘MIL-C-0026482F — Bayonet Coupling M3110 ‘Wall Mounting Receptacle Soler 1 BEI MS3II1 Cable Connecting lug Solder 1 ELF J,P MS3112 ‘Box Mounting Receptacle Soler 1 MS3113, Solder Mounting Receptacle Soler 1H Ms3i14 Single Hole Mounting Receptacle Soler 1 E,F,PLH MS3I15 Dummy Stowage Receptacle Solder MS3116 Straight Plug Soler 1 EFLPLY MS3119 Bulkhead Mounting Receptacle Soler 1 E oMS3120 Wall Mounting Receptacle Gimp 1 EF Ms3121 Cable Connecting Ping imp 1 ELE,P MS3122 ‘Box Mounting Receptacle Gimp 1 E MS3124 Single Hole Mounting Receptacle Gimp 1 ERP MS3126 Straight Plug Gimp 1 EPP Ms3127 Box Mounting Receptacle Gimp 1 MS3128 ‘Wall Mounting Receptacle Gimp 1 EE,P M3440 [Narrow Flange Mounting Receptacle Solder 2H Ms34a2 ‘Wide Flange Mounting Receptacle Soler 2H M3443, Solder Flange Mounting Receptacle Soler 2H Ms3449 Single Hole Mounting Receptacle Solder 2H Ms3470 Narrow Flange Mounting Receptacle Gimp = 2, Ms347t Cable Connecting Receptacle Gimp 2, MS3472 ‘Wide Flange Mounting Receptacle Gimp 2 e MS3474 ‘Rear Mounting Jam Nut Receptacle im = 2B, MS3475, RFI Shielded Pug Gimp 2 EL MS3476 Plog Gimp 2 EL ‘MIL-C-0026482F — Push-Pull Coupling MS3130 Wall Mounting Receptacle Soler 1 ERT MS3132, Box Mounting Receptacle Sot 1 EH MS3134 Single Hole Mounting Receptacle Soler 1 ELPLJ,H MS3135 ‘Wall Mounting Dummy Stowage Receptacle Solder 12 MS3137 Short Pg Solder 1" EAP, M3138, Lanyard Pug Solder 1 EPS M3139 Bulkhead Receptacle Soler 1 E Ms3140 ‘Wall Mounting Receptacle camp 2 ES said Single Hole Mounting Receptacle Gimp 2B Ms147 Straight Pg. Gimp 2 ET Ms3148 Lanyard Plug Gimp 2 ED MS3424 ‘Wall Mounting Flange Receptacle Gimp 3 EL Ms3445 Rack and Panel Plug Gimp = 2 MS3446 ‘Rack and Panel Pug camp 3 EL Ms3463, rermetic Solder Mounting Receptacle Soller 3 M3464 Jam Nut Mounting Receptacle Cimp 3 EL MS3466 Hermetic Box Mounting Receptacle Soler 3H M3467 Phig Gimp 3 BL MS3468 Lanyard Pg camp 3 EL MS3469 Hermetic Jum Nut Mounting Receptacle Soler 3H ‘MIL-C-26500 — Threaded and Bayonet Couplings Ms24266 Stanght Plug Crimp 1MS27562 Flange Mounting Receptacle Crimp 1MS27563 Single Hole Mounting Receptacle Crimp 1MS27566 ‘tonight Plog (Hard Insert) Crimp 3462NAVAIR 01-1A-505 (USAF) T.O, 1-18-14 WALL MOUNTING RECEPTACLE BOX MOUNTING RECEPTACLE JAM_NUT RECEPTACLE SOLDER: S311 & MS3130 ‘SOLDER: MS3112_&"MS3132 SOLDER: MS3114. 8 MS3134 ‘CRIMP: MS3120 & MS3140 CRIMP: MS3122 CRIMP: MS3124 & S314 STRAIGHT PLUG THRU-BULKHEAD RECEPTACLE SHORT PLUG SOLDER: MS3iN6 SOLDER: M3119 & MS3139 SOLDER: MS3137 ‘CRIMP! MS3147 CRIMP: MS3126 CLASS & CLASS CLASS P. class J GROMMET SEAL STRAIN RELIEF POTTING SEAL GLAND SEAL, CLAM ‘e. MINIATURE CONNECTORS MIL-C-26482 - SOLDER AND CRIMP-TYPE CONTACTS FLANGE MOUNTING RECEPTACLE — SINGLE-HOLE MOUNTING STRAIGHT PLUG 1824264 RECEPTACLE 1MS24266 MS24265 b. MINIATURE CONNECTORS MIL-C-26500 - CRIMP-TYPE CONTACTS ONLY Figure 3:76. Typical MS Connectors — Miniature 363NAVAIR _01-1A-605 (USAF) T.O. 1-18-14 1MS31064 PIN REAR PIN. FRONT FRONT SHELL RT PIN Ns CONTACT on, BACK SHELL XN ‘COUPLING RING RETAINING RING/ SOCKET. REAR < socner o INSER’ Figure 3-77, MS Connector Plug — Exploded View = ob ey (@)) = el: Figure 3-78. MS Connector Receptacle ~ Exploded ViewNAVAIR 01-1A-505 (USAF) T.O. 1-18-14 swe it 8 DCONTACTS CONTACTS S CONTACTS. § CONTACTS COWTACTS 1 CONTACTS 11 CONTACTS os " aes ws ies nao wn swe sue RCOMTACTS IS CONTACTS —-ECOMTACTS.-—=—«N CONTACTS CONTACTS, ZS CONTACTS wa 1s m6 was aa 126 swe sine 38 CONTACTS ‘a comracts ‘5 CONTACTS: ‘6 CONTACTS, 028 nou 2s us) NOTE: FACE VIEW OF PIN INSERTS, ALL INSERTS SHOWN IN NORMAL POSITION a. INSERT ARRANGEMENTS FOR MIL-C26482 CONNECTORS WITH BAYONET COUPLING ENGAGEMENT Figure 3-79. Insert Arrangements — MS Miniature Connectors, MIL-C-26482 (Sheet 1)NAVAIR _01-1A-605 (USAF) T.0, 1-14-14 NOTE: FACE VIEW OF PIN INSERTS, ALL INSERTS SHOWN IN NORMAL POSITION CODE OF CONTACT SIZES mo? 6-6 a3 b. INSERT ARRANGEMENTS FOR MIL-C-26482 CONNECTORS WITH PUSH-PULL ENGAGEMENT Figure 3.79. Insert Arrangements — MS Miniature Connectors, MIL-C-26482 (Sheet 2) 3466NAVAIR _01-1A-505 (USAF) T.0, 1-14-14 sna ie | 9 — a raed 75 anowee @) insolation 0.0. Sceontacts | 12 contacts | 15. eee ‘aed 2 ano size 12 contacts: i “aed amo ‘Max: 170 in, Min: 106 in. A contacts Feontacts Tesataets 102 shietted 1 #2 shielded per MIL-C-7078, type It back face of pin insert as shown Figure 3-80, 3.78. MARKING OF CONNECTORS. Marking of minia- ture MS connectors is identical to that described for the 'AN/MS connectors in 3-44, with the following additional provisions: a. MIL-C-26500 connectors have an additional letter to indicate type of coupling between shell size and insert arrangement code numbers. These letters are “T” for threaded coupling and “B” for bayonet coupling; for example, MS24266R18B30P6, where B indicates the type of coupling, ‘On MIL-C-26500 connectors, alternative positions are indicated by numbers 6, 7, 8,9, 10 instead of by letters. Insert Arrangements — MS Mi jure Connectors, MIL-C-26500 3-79, INSTALLING AND REMOVING CONTACTS. 3.80. Insertion Tools for FrontRelease Crimp Type ‘Contacts. The Military Standard tool for inserting contacts into front-telease connector inserts is MS24256A. (See figure 3-812.) There is a separate tool for each contact size. Contact sizes are listed in table 3-14 and tools in table 3-15. Inserting tools for contact sizes 16 and 12 have a hollow lip ‘which fits snugly over the contact crimping barrel. The toot for size 20 contacts fits over the insulation support Contact sizes 16 and 12 do not have insulation support. An indicating band on the working end of the tool determines correct depth of tool insertion. Use this tool to insert contacts in all Military Standard miniature front-release connectors with removable contacts, 367NAVAIR 01-18-505 (USAF) T.0. 1-18-14 3.81. Extraction Tools for Front-Release Crimp Type Contacts. The Military Standard tool for extracting con- tacts from front-release connector inserts is MS242S6R. (Gee figure 3-81.) The sizes for each contact are listed in table 3-14. This tool has a hollow cylindrical probe which fits snugly over the pin or socket end of the contact and releases the insert retention clip when pushed over the contact. Two indicating bands determine correct depth; the band nearest the working end of the tool is for’ pin contacts, the other for socket contacts. The extraction toot has a thrust assist collar (or slide) which is pushed forward ‘0 eject the contact from the insert retention clip by means of an internal plunger. Use this tool to remove contacts from all Military Standard miniature front-telease connec tors with removable contacts. Teble 3-14, Contacts and Their Wire Size Range Contact Size "20 “16 12 8 4 0 “Available in crimp type connectors Table 3-15. Connectors with Crimp-Type Contacts and Astembly Toots Connector and Color Crimping USAF Contact Size Code Tool USAF Positioner MIL-C-26500: 20 Red MS27828 —-MS27828.1 MIL-C.26500: 16 Blue MS27828.-«-MS27828-1 MIL-C-26500; 12 Yellow —-MS27828—-MS27828-1 MIL-C-26500: 20 Red MS27831—- MS27831-1 MIL-C-38300: 20 Red MS27828 —-MS27828-1 MIL-C:38300: 16 Blue MS27828--MS27828.1 MIL-C.38300: 12 Yellow MS27828-MS27828.1 MIL-C-38300: 20 Red MS27831_—-MS27831-1 20 Red MS27828-—-MS27828.1 16 Blue MS27828.«-MS27828-1 MIL-C-26482: 12 Yellow MS27828 —- MS27828-1 MIL-C-26482: 20 Red MS27831—-MS27831-1 MIL-CA8IS11: 2322 Yellow MS27831_-—-MS27831-2 MIL-C.22857: 20 Red MS27828.--MS27828-3. MIL-C-22857: 16 Blue MS27828--MS278283 MIL-C-21097/9:01 Green MS27828—-MS27828-3 MIL-C:38999: 22 Red MS27831—-MS27831-3 MIL-C-38999: 22M Red MS27831—-MS27831.4 MIL-C-38999: 20 Red MS27831—- MS27831.5 MIL-C.38999: 20 Red MS27828 —-MS278284 MIL-C.38999; 16 Blue -MS27828-MS278284 MIL-C-38999: 12 Yellow MS27828 —-MS278284 MIL-C-83723/29T16 Blue MS27828—-MS27828-1 MIL-C-83723/29T12 Yellow MS27828—-MS27828-1 MIL-C-83723/29T08 Red MIL-C-83723/29T04 Blue MIL-C-83723/29T00 Yellow MIL-C.83723/30T16 Blue MS27828-MS77828-1 ‘MIL-C-83723/29T12 Yellow MS27828.—-MS27828-1 MIL-C-83723/29T08 Red. MIL-C-83723/29T04 Blue MIL-C83723/29T00 Yellow 368 Crimping Insertion Extraction Tool Tool Toot MS3191-1 or-3_MS24256A.20 - MS242S6R.20 MS319!-1 or-3_MS24256A-16 - MS24256R-16 @ MS24256A-12 MS24256R-12 MS24256-A20-MS24256-R20 MS24256-A20- MS24256-RH20 MS24256-A16 —-MS24256-RH16 MS24256-A12_-MS24256-R12 1MS24256-A20- MS24256-RH20 MS3191-1 or-3 -MS24256-A20- MS24256-R20 MS3191-1 or-3 _MS24256-A16- MS24256-16 ‘MS3191-1 or-3_MS24256-A12_- MS24256-12 1MS24256-A20-MS242S6-R20 1MS3342.23, 1Ms3323.22 MS3344-23 MS17805 MS17806 MS17805 MS17806 M21097/12-01 —-M21097/12.01 MS27495-A22_-MS27495-R22 1MS27495-A22M —_MS27495-R22M MS27495-A20 MS27495-A20 MS27495-A16 MS27495-A12 M83723/31-16 M83723/31-12 1MS27495-R20 1MS27495-R20 1MS27495-R16 1MS27495-R12 M83723/31-16 M83723/31-12 Not Required M83723/32.08, Not Required M83723/32.04 Not Required M83723/32.00 M83723/31-16 M83723/31-12 M83723/31-16 M83723/31-12 Not Required M83723/32.08, Not Required M83723/32-04 Not Required M83723/32-00NAVAIR _01-1A-505 (USAF) T.0, 1-18-14 ANPHENOL, PYLE NATIONAL BENDIX ——<— DEUTSCH 1 MS24256A INSERTION TOOLS THRUST ASSIST COLLAR BENDIX THRUST ASSIST KNOB “a cata! SPACER SLEEVE SET FOR CONTACT STYLE be. MS24256R EXTRACTION TOOLS Saaahaeanant Figure 3.81. Insertion and Extraction Tools for Front-Release Crimp-Type Contacts 3469NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 382. Insertion and Extraction Tools for Rear-Release For unwired contacts, an additional tool may have to be Crimp Type Contacts. There is a separate tool for each used in conjunction with the extraction tool to push the connector type and contact size. The tools are plastic and _unwired contact from the front after the locking tines have double-ended, resembling the one shown in figure 3-82, been released by the extraction tool in the rear. Some of They are color-coded according to contact size, the these tools are listed in table 3-16. insertion side being colored and the extraction side, white OPENING COLORED END FOR INSERTION Figure 382. Insertion and Extraction Tool for Rear Table 3-16, Tools for Unwired Contacts Tool Color Key Part Number Standard Contact Size Insert Side Extract Side M83723/31-12 NAS 1664-12 2 Yellow White eo M83723/31-16 NAS 1664-16 16 Blue White 1M83723/31-20 NAS 1664-20 20 Red White 370NAVAIR. 01-1A-505 (USAF) T.O. 1-18-14 3.83, Assembling Wired Contacts Into Connector. Insert ‘the crimped contact into the connector as follows (see figure 3-83): a, Slide rear accessories back onto wire bundle. b, Select the correct insertion tool from table 3-15. Insert the crimped end of the contact into the hollow end of the insertion tool, and lay the wire into the slot in the tool hand. c. Guide the contact into the correctly numbered grommet hole in the rear face of the insert, and feed the contact carefully into the hole. 4. Push the tool straight in at right angles to the grommet susface, until the contact is fully seated. As the indicator band on the tool enters the grommet hole, the contact retention clip will snap into place on the contact with a slight audible cick. fe. Withdraw the tocl, keeping it perpendicular to the ‘grommet face. £. Fill all unused holes with sealing plugs of appropri- Do not attempt to reseat a contact once the insertion tool has been removed. Remove contact and start over again with contact barrel properly located in tool. Failure to follow this precaution will cause insertion tool to shear barrel while inside grommet, Sharp edge of sheared material will cut through ‘grommet web and cause short circuit. 384, Alternative Contact Assembly Procedure. If desired, the following procedure may be used to insert wired contacts into the connector: ‘a. Push the wired contact carefully into the correct grommet hole. Do not push all the way in. b, Slide the insertion tool over the contact barrel. ‘When installing 2 size 20 contact, the tool internal shoulder will butt against the rear of the contact insulation support ‘When installing size 16 or 12 contacts, the tool tip will butt against the contact shoulder. cc. Complete the procedure by following steps d, e, and f of 3-83. Observe caution note of 3-83. 3.88. Removing Contacts From Front-Release Connectors. Remove contacts from the connector as follows (see figure 3.84): NOTE ‘This procedure does not apply to rear-release connec: tors, eg., MIL-C-83723. See 3-98. ‘8, Select the correct extraction tool for the contact to be removed from table 3-15. , Slide rear accessories back on the wire bundle. c. Working from the front or mating end of the connector, slip the hollow end of the extraction tool over the contact, with the tool parallel to the contact, and squarely perpendicular to the insert face. NOTE ‘The Pyle-National extraction tool has a spacer sleeve ‘with positions for either male or female contacts. Set to correct position before installing tool on contact. Refer to figure 3-816. 4d. Push the tool toward the rear of the connector with 1 firm steady push until the tool comes to 2 positive stop ‘and bottoms in the insert hole. A slight rotation of the tool may aid the tool insertion. fe, Push the thrust assist collar or slide forward as far as it will go f. Withdraw the tool from the contact, keeping the tool perpendicular to the insert face. Remove the contact from the back of the con- rector. Make sure the extraction tool is always exactly aligned with the contact to avoid damage to the contact or to the insert anNAVAIR _01-1A-505 (USAF) T.0. 1-18-14 TOOL AT RIGHT ANGLE TO INSERT FACE WIRE LAID IN TOOL SLOT Figure 3:83. Assembling Wired Contacts Into ConnectorNAVAIR 01-14-505 (USAF) T.O, 1-10-14 Figure 3.84. Removing Crimp-Type Contacts From ConnectorNAVAIR 01-1A-605 (USAF) T.O, 1-18-14 3.86, INSTALLATION OF MINIATURE MS CONNEC- TORS WITH SOLDER TYPE CONTACTS. Miniature MS connectors Class E and F are installed as follows: a. Remove retaining nut by unscrewing it from the body shell, and slide the nut over the wire bundle. b. Slide tapered sleeve (grommet follower) over wire bundle. c. Thread wires through the proper grommet holes. 4. Strip and tin wires following the procedure outlined in section Il. Strip insulation 1/4 inch for sizes 12 and 16 ‘contacts; strip insulation 1/8 inch for size 20 contacts. ¢. Insert tinned wire into the solder cup of the contact. Apply heat with a resistance soldering unit as shown in figure 3-4. A soldering unit with a foot switch is recommended. Heat until solder is liquified; apply more solder if necessary. When solder is liquid, press the foot switch to tum off the heat, but do not remove the resistance unit probes until the solder has solidified. Do not ‘move the joint until the solder has cooled. f. Slide the grommet forward over the solder cups of the contact against the face of the insert Slide the tapered sleeve (grommet follower) over the end of the grommet. . 1, _ Bring the retaining nut forward and tighten it to the body shell. Do not remove inserts from these connectors 3.87. INSTALLATION OF MINIATURE CLASS P CON NECTORS, Install Class P miniature MS connectors with solder type contacts as follows: a. Remove potting mold and retaining ring from body shell, and slide over wire bundle. b. Prepare wires and solder to contacts as described in 3-86, steps d and e. 376 ¢._ Slide retaining ring and potting mold down wire ‘bundle, and screw to body shell. NOTE ‘Make sure that retaining ring is fully tightened. A loosely coupled ring affects the bayonet action of the coupling rng. 4. Pot connector as described in 3-58. 3.88, INSTALLATION OF MINIATURE CLASS H CON- NECTORS. Class H miniature MS connectors are not disassembled for soldering. Prepare wires and solder to contacts as described in 3-86, steps d and e. 3-89, MIL-C-81511 CONNECTORS 3.90. DESCRIPTION AND AVAILABILITY. These are general-purpose high-density, environment-resisting connec- tors similar to the MS series. The connectors have a uick-disconnect feature, employing bayonet-type locking zing. The types available are indicated in table 3-17. 3.91. MARKING OF MIL-C81511 CONNECTORS. The connector part number consists of the letter “M”, the basic number of the specification sheet, and the applicable characteristics as in the following example (see Notes 2,3, and 4 from table 3-17): a Military Part No. Indicator Basic Part __| Number Class Shell Size Insert Arrangement Contact Designator Key Positions.Specification (M81511/xx) fo 1/02 103 104 Jos 106 pi 2 R38 Ra ps 26 127 128 Bi 12 [3 Ba 138 136 BT 8 iat Haz 44 (45 146 (a7 (48 149 150 151 152 153 134 Iss 156 157 NAVAIR 01-1-505 (USAF) T. 1-10-14 ‘Table 3.17. MIL-C-81511 Connectors (Sheet 1) Plug or Receptacle Receptacle Receptacle Receptacle Receptacle Receptacle Plug Receptacle Receptacle Receptacle Receptacle Receptacle Plug Receptacle Receptacle Receptacle Receptacle Plug Plug Receptacle Receptacle Plug Plug Receptacle Receptacle Receptacle Receptacle Plug Receptacle Receptacle Receptacle Receptacle Receptacle Receptacle Receptacle Receptacle Receptacle Plug Receptacle Mounting Type Square flange Solder flange Single hole Single hole Cable Cable Square flange Solder flange Single hole Single hole Cable Cable Single hole Single hole thru bulkhead Square flange Single hole Cable Cable Square flange Single hole Cable Cable Square flange Solder flange Single hole Cable Solder flange Single hole Single hole Single hole Square flange Solder flange Single hole Single hole Cable Cable Solder flange Series (Note 1) Classes (Note 2) ARE BG.H ALF.E BG.H ARE ARE ARE BGH ARE BG, ARE ARE B,G,H BCH Cand CrP CTP CTP CTP CTP CTP Te AVE,F D D AEP AEF L L AEE L AEF D AEF D A A, L Contacts Crimp Solder (pins only) Crimp Solder (pins only) Crimp Crimp Crimp Solder (pins only) Crimp Solder (pins only) Crimp Crimp Nonremovable Nonremovable Crimp Crimp Crimp Crimp Crimp Crimp Crimp Crimp Crimp Solder (pins only) Solder (pins only) Crimp Crimp Crimp (pins only) Crimp (pins only) Crimp Crimp (pins only) Crimp Solder (pins only) Crimp Solder (pins only) Crimp Crimp Crimp (pins only) 378