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BHT-ELEC-SPM

CHAPTER 4

CONTENTS — GENERAL MAINTENANCE PROCEDURES


Paragraph Chapter Page
Number Title Number Number

4-1 General ........................................................................................ 4-00-00 3


4-2 Wire/cable cutting .................................................................. 4-00-00 3
4-3 Wire/cable stripping ............................................................... 4-00-00 3
4-4 Soldering ...................................................................................... 4-00-00 6
4-5 Solder shield terminations ........................................................... 4-00-00 13
4-6 Shielded cable splices ................................................................. 4-00-00 20
4-7 Contact crimping procedures ...................................................... 4-00-00 27
4-8 Contact insertion/removal ........................................................... 4-00-00 32
4-9 Solderless terminals .................................................................... 4-00-00 38
4-10 Solderless splices ........................................................................ 4-00-00 41
4-11 Connector potting ........................................................................ 4-00-00 47
4-12 Semiconductor maintenance ........................................................ 4-00-00 55

FIGURES

Figure Page
Number Title Number

4-1 Stripping wire with hand stripper ................................................................................... 4


4-2 Soldering iron tip before and after cleaning ................................................................... 7
4-3 Tinning soldering iron tip ................................................................................................ 8
4-4 Tinning wire with a soldering iron ................................................................................. 9
4-5 Properly stripped and tinned conductor ........................................................................ 9
4-6 Soldering iron tip shapes ............................................................................................. 10
4-7 Correct solder application ............................................................................................... 10
4-8 Soldering iron holder ..................................................................................................... 10
4-9 Spade termination ........................................................................................................ 11
4-10 Turret terminal conductor wrap ..................................................................................... 12
4-11 Turret terminal conductor position ............................................................................... 12
4-12 Inserting conductor ...................................................................................................... 12
4-13 Positioning of conductors ............................................................................................. 13
4-14 Insulation sleeving/tubing ............................................................................................. 13
4-15 Solder quantity .............................................................................................................. 13
4-16 M83519/1 termination selection ................................................................................... 16
4-17 M83519/1 termination placement ................................................................................. 16
4-18 Position termination in reflector ..................................................................................... 17
4-19 M83519/2 termination selection ................................................................................... 18
4-20 M83519/2 termination placement ................................................................................. 19
4-21 Terminating multiple shielded cables with solder sleeves ............................................. 20
4-22 Shield termination ........................................................................................................ 21
4-23 Terminating multiple shielded cables using pigtails ...................................................... 22
4-24 Terminating multiple shielded cables ........................................................................... 22
4-25 Example — 3-conductor shielded cable splice .............................................................. 26
4-26 4 Indenture crimp ........................................................................................................ 27
4-27 Octadent crimp ............................................................................................................ 27
4-28 Turret head crimper ..................................................................................................... 29
4-29 Correct crimped connector pin ..................................................................................... 31
4-30 Crimp tool inspection tool guide ................................................................................... 33

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Figure Page
Number Title Number

4-31 Insertion and extraction tools for front release crimp-type contacts ............................. 34
4-32 Installation and removal of crimp contacts ................................................................... 36
4-33 M81969/14 Plastic-type insertion/removal tool .............................................................. 37
4-34 Pre-insulated terminal — cutaway ............................................................................... 38
4-35 AMP Hydraulic hand crimper ........................................................................................ 39
4-36 Hydraulic crimp head ................................................................................................... 40
4-37 Terminal or splice positioning .......................................................................................... 40
4-38 AMP Crimping tool T-head 59250 for high temperature terminals .............................. 42
4-39 M22520 Series die type crimp tool ............................................................................... 43
4-40 Insertion of wire into insulated terminal lug .................................................................. 43
4-41 Crimp tools M22520/5-01 and /10-01 .............................................................................. 44
4-42 Staggered splices in wire bundle ................................................................................. 46
4-43 Locating sealed splice crimp barrel in crimping dies .................................................... 46
4-44 RayChem environmental butt splices .......................................................................... 48
4-45 Locating MS25181 splice in MS90413-2 crimping tool ................................................. 49
4-46 Hand mixing potting compound ................................................................................... 50
4-47 Mixing paddle for potting compound ........................................................................... 51
4-48 Filling and curing of potting .......................................................................................... 52

TABLES

Table Page
Number Title Number

4-1 Allowable scratched, nicked or broken strands in copper wire .................................... 3


4-2 Ring lug and wire splice strip length ............................................................................. 6
4-3 Approximate soldering iron sizes for tinning ................................................................. 9
4-4 Center strip preparation ............................................................................................... 14
4-5 End strip preparation ...................................................................................................... 15
4-6 End strip with braid fold-back preparation .................................................................... 16
4-7 Dimensions from cable jacket to end of conductor ...................................................... 22
4-8 Kits (D-150-XXXX) for 1 to 1 splice ............................................................................. 23
4-9 Kits (D-150-XXXX) for mixed gage splices .................................................................. 23
4-10 Material list ................................................................................................................... 24
4-11 Dimensions of kit material and cross reference of material to kits ............................... 25
4-12 Termination of shield and jacketed filter line cable ........................................................ 28
4-13 Crimp tool inspection gages ........................................................................................ 32
4-14 Contact and wire size range ........................................................................................ 32
4-15 Insertion/removal tool for rear release contacts ........................................................... 35
4-16 Wire stripping for 2 through 8 wire ............................................................................... 39
4-17 Color coding of copper terminal lug insulation ............................................................. 39
4-18 Wire stripping lengths for small copper terminal lugs (insulation restriction) ................. 41
4-19 Environmental splices and associated crimp tools ...................................................... 46
4-20 Stripping lengths — splices .......................................................................................... 47
4-21 Wire end caps .............................................................................................................. 55

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GENERALMAINTENANCE PROCEDURES
4-1. GENERAL. in thewire contact, terminal,etc.The following outlines
the propertoolsand procedures to performthisfunction.
This chapterdetails general maintenance techniques
for cutting, crimping, and soldering electrical wiring and 2. Stripperswith mechanical die-typebladesprovide
RF cables. These techniques provide general precision hand stripping. Bladesof these strippersrely
Chapters 5,
maintenance procedures for Chapters 6, and 7 for
5, 6, on a wedge-shaped cutter blade (dimensioned to the
repairing wiringharnesses, cable assemblies, shielded conductor) in combination with a centerbore
wire, and cables. In addition, general maintenance (dimensioned to the insulation) to precisely center the
for wire for clean, nick free strips. The Ideal Stripmaster
procedures maintaining semiconductors in
electronic equipment is included. stripperor equivalentshall be used for wire insulation.
Figure 4-1
Figure 4-1 lists the stripperpart number and blade part
NOTE numberfor stripping variouswire specifications.
3. Stripper blades may be replaced, however, the
Always refer to theapplicablemaintenance blades(topand bottom) are amatchedset and must not
manual wiring schematics for termination be interchanged with otherbladehalves. The back side
requirements. of each blade half is imprinted with a serial number
which mustmatchthe number on theother blade half.
Whenchanging blade sets,attentionshould bedirected
4-2. WIRE/CABLECUlliNG. to the correct blade set part number and gripper part
number for the rangeof wire size to be stripped.
1. The mannerin whichwire or cable is cut can have
an effect on subsequent stripping and termination 4. WIRE STRENGTH. Refer to table 4-1 for
preparations. Diagonal cutters (where the blades allowablescratched, nicked or broken strands.
contacteach other)are commonly used forwirecutting,
but tend to bite the wire in half. This action distorts the Table 4-1. Allowable scratched, nickedor broken
strands in copperwire
conductor and flattens the ends of the strands. The
result isincreased stripforceandanincreased tendency
WIRE SIZE SCRATCHED
for the strands to splayduring stripping. This does not
NICKED OR BROKEN
produce a precision cut.
24-12 None
2. The preferred typecutter is a shear-type where the
10 2
bladespassby eachother. Thisactioncausesvery little
distortion of the conductor. The recommended cutter is 8-4 3
Ideal 45-123 or equivalent. This cutter handles a wide 2-0 12
range of wire gage sizes and cannot be used for
stripping.

LJ
4-3. WIRE/CABLESTRIPPING. A KNIFE SHALL NOT BE USED FOR
STRIPPING. A KNIFE BLADE CAN
DRASTICALLY NICK WIRE OR CUT
STRANDS.

EXTREME CARE SHOULD BE EXERCISED 5. Use of HandWire Strippers.


SO AS NOT TO DAMAGE WIRE
Figure 4-1
a. Figure 4-1 illustrates the proper use of hand
INSULATIONAND CONDUCTORS DURING
STRIPPING. strippers, blades, and grippers for variouswire types.
b. The stripper handle and grippingjaws must be
1. Before wire can be assembled to connectors,
fully open priorto stripping.
terminals splices, etc., the insulation must be stripped
fromconnecting endstoexposethebareconductor.The c. After wire size has been determined, place it in
proper striplength is determined bythedepthofthehole exactcenter of corresponding size slot in stripper.

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SELECT CORRECT HOLE BE CAREFULNOTTO


TO MATCH WIRE GAGE NICK OR CUT STRANDS

IDEAL
STRIPMASTER

SELECT CORRECT HOLE


TO MATCH WIRE GAGE

BE CAREFULNOTTO
NICK OR CUTSTRANDS

E/SPM-4-1-1

Figure 4-1. Strippingwire with hand stripper(Sheet 1 of 2)

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STRIPPER BLADESET GRIPPER


WIRETYPE GAGE PART NO. PART NO. PART NO.
MIL-W-22759 26 - 30 45 - 178 L -5561 L - 5217
/32and /33 16 - 26 45 - 1 987 45 - 1987 -1
10-14 45-1611 45-1611-1 L-5215
MIL-W-22759/34, 16 - 26 45 - 1 987 45 - 1987 - 1 L -5217
/35,/41,/42,/43 10-14 45-1611 45-1611-1 L-5215
MIL-W-81044 16 - 26 45 - 171 L - 5211 L—521 7

/6and/7 10-14 45-170 L-5210 L-5215


MIL-W-81044 16 - 26 45 - 174 L - 5563 L - 5217
/9 and /10 10 - 14 45 - 173 L - 5562 L - 5215
MIL-W-81 044 26 - 30 45 - 178 L - 5561 L - 5217
/1 2 and /13 16 - 26 45 - 1987 45 - 1987 - 1
10-14 45-1611 45-1611-1 L-5215
MIL-W-81381A 16 - 26 45 - 1654 45 - 1654 - 1
/11,/12, /13, /14, /22 10 - 14 45 - 1608 45 - 1608 -1
8.4MiI Wall
(KAPTON)
MIL-W-81381A 16 - 26 45 - 1551 45 - 1 551 -1

/7,18,19,110,121 10-14 45-1609 45-1609-1


5.8 MD Wall

(KAPTON)
MIL-W-81381A 1 6 - 26 45 - 1 672 45 - 1672 - 1
/17, /18, /19, /20
4.6 MD Wall
(KAPTON)
Wirewrapping 24 - 30 45 - 169 L - 9300
(thin insulation) 30 45 - 179 L - 7625
solid wire

General purpose 26 - 30 45 - 172 L - 5436


stripping of plastic, 16 - 26 45 - 171 L -5211
fiberglass, and other 10 - 14 45 - 170 L - 5210
hard to strip insula-
tion

Wire StripperTool Chart (Ideal Stripmaster)


EISPM-4-1-2

Figure 4-1 . Strippingwire with hand stripper (Sheet 2)

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d. Partiallyclose the handles,allowing wire to center long provides excessive bare conductorand has poor
in slot as wire grippingfeature on stripperapplies pressure. mechanical strength and possiblycould short circuitto
other conductors. Use the following guides when
e. Close handle completelyto stripthe insulation. inspecting strip length:

f. Afterinsulation has been stripped, partially release a. Connector Contacts and Terminal Module Blocks.
pressureon handles.Thejaws will separate.Thisfeature When stripped portion of wire is fully inserted (bottomed
preventsjawsfrom closingand damagingbare conductor. out) in contact crimp barrel, wire can be viewed at
inspection holeand a maximumof0.031 inch (0.79mm) of
g. Removestripped wire. wire is viewed between crimp barrel and wire insulation.

h. Release handles allowing stripper to return to b. Ring Lugsand Wire Splice. Strip length for small
original position. gage terminated in ring lug and wire splice is as shown
table 4-2.
in table 4-2
i. Inspect wire for the following:
c. The Daniels 737 and CMS 20 electrical tool kits
(1) Nicked, scratched, or cut wire strands.Refer provide exact stripped length dimensions for most
to table
table 4-1.
4-1 connectors used in Bell helicopters.

(2) Frayed insulation. NOTE

Nicked or broken wire strands reduce


(3) Frayed wire strands. electrical current capacity and mechanical
NOTE strength of terminated wire.

Ensure hands are clean before touching 4-4. SOLDERING.


conductor.Grease and dirt will affect electrical
conductivityand tensile strengthof crimp joint. 1. GENERAL. Soldered connections are used in
helicopter electrical wiring to form a continuous and
j. Repeat above procedures if above conditions permanent metallic connection having a constant
warrant. Correct frayed strands by firmly twisting electrical value.Thisparagraph describes the materials
conductorin same direction as normal lay of thewire. and equipment used in soldering helicopter
interconnecting wiring. It also describes and illustrates
6. Inspectwire terminationsduring rework to ensure the the preparation and care of equipment, procedures to
wires are correctlystripped. Thetwo most commondefects befollowed, and the soldering techniques necessary to
in strippingare incorrectstrip length and nickedor broken create a properlysolderedjoint.
wire strands.Barecopperstrandsmust neverbeobserved.
Correct strip lengths are referencedin table 4-2. 2. DEFINITIONS AND DESCRIPTIONS.

Table 4-2. Ring lug and wire splicestrip length a. Soldering. Soldering is the process of joining two
or more metals together at a temperature lower than the
WIRE GAGE STRIP LENGTH melting points of the metals. In its motten state, solder
chemicallydissolvespartofthe metal surlacestobejoined.
26-24 0.16 in (3.96mm) Most metals exposedto atmosphereacquire a thin film of
tarnishoroxide; the longerthe exposurethe thickerthe film
10-20 0.19 in (4.76mm) becomes. This film is present even though it is not visible
18 - 14 0.25 in (6.35mm)
and solder alone cannot dissolveit. A soldering flux with a
meltingpoint lowerthan the solder must be used to wet the
12 -10 0.28 in (7.14mm) metalandallowthe soldertopenetrateand removethefilm.
The flux meltsfirst, removingtarnish or metallicoxide and
also preventingfurther oxide fromforming while the metal
7. STRIP LENGTH. Most termination components
is being heated to solder temperature.The solder then
(connector contacts, terminalmodule blocks, ring lugs, melts floating lighter flux and impuritiessuspendedin it to
and wire splices) provide a viewing window for the outer surlace and edges ofthe moltenfillet. Thesolder
inspecting the wire after the termination component is cools and forms an alloy with the metal. Most of the flux is
installed. Wire stripped too short will not make good burnedaway during the soldering processand anyresidue
contact with the termination device.Wire stripped too is removedby appropriatecleaning methods.

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b. Soft Solder. Soft solder is an alloy consisting of soft solder, use Rosin fluxes conforming to MIL-F-14256
various combinations of tin and lead, with silver and type RMA (mildlyactivated),such as solder flux (EC-023).
other additives, which melts at temperatures below Use RMA flux with SN63WS solder when soldering
699°F (371°C). It maybe in bar form to be melted for MIL-W-81381 wire. MIL-W-81381 (KAPTON) is a
tinning, or in the form of rosin-cored solderfor usewith copper-strandedwire with nickel coating.
a soldering iron or other heating methods. Soft solder
usedin helicopter electrical wiring mustconform to the 3. SOLDERING IRON PREPARATION AND
requirements of Federal Specification QQ-S-571 . Acid MAINTENANCE. For successful, effectivesoldering,
or inorganic chloride flux cores solder should not be soldering iron tip mustbe tinnedto provide a completely
used underany circumstances in a Bell helicopter. metallic surface through which heat may flow readily
from the iron tothemetalbeing soldered. If no tinningis
(1) Core Wire Solders. Rosin cored: present, iron will oxidize and heat cannotflow through.
Nonactivated or mildlyactivated plasticconditioned. Copper has a very high rate of heat conductivity, but
copper tips oxidize quickly and must be frequently
(a) For general applicationsat low temperatures cleaned and tinned. If a tip has becomebadly burned
up to 248°F (120°C), usetype SN6OWRAMAP(EC-039) and pitted, as a resultof overheating, replace it.
(59.5 to 61 .5 percent tin, remainder lead) to solder
tin-coatedcopper wire and coaxial cable. Some copper soldering iron tips used in production
soldering are coated with pure iron to help prevent
(b) For applicationwith silver-coatedcopper wire oxidation.A cleandamp clothmay be used to wipe the iron
and silver-platedconnections, use type SN62WRAMAP tip.
(EC-040) (61.5 to 62.5 percent tin, 1 .75 to 2.25 percent
silver, remainderlead). For high temperatureup to 376°F
(191 °C) maximum, useAg2.5 or Ag5.5. Do not confuse AUTION1
hightemperaturesoft solderwith the hard solder described
paragraph 4-4,
in paragraph 4-4, step 2, substep (c). DO NOT FILE SOLDERING IRON TIPS
COATED WITH PURE IRON. FILING WILL
(c) For applicationson printedcircuit boards and RUIN THEPROTECTIVE COATING. IFTHE
semiconductordevices where temperature limitationsare TIP IS PITTED, REPLACE IT.
criticaland for other applicationswhere an extremely short
melting range is required, use type SN63WRAMAP a. With the iron unplugged, file each working
(EC-041) (62.5 to 63.5 percent tin, remainder lead). surface of the tip with a double-cut mill file until it is
smooth and a bright copper color. Referto figure
figure 4-2.
4-2.
(2) Solid Wire Solder. Rosin-base flux is
normally used with solid solder. Use of type W flux will
ensurethe productis non-activated. Following isa list of
solid wire solders (with application), if preferred over
rosin-cored solders:

(a) SN6OWS for general electrical and


electronics applications.

(b) SN62WSfor silver-plated applications.


(C) SN63WS forapplicationson printed circuit
boards and semiconductor devices.
BEFORE AFTER FILING
c. Hard Solder. Hard solder (EC-045), often CLEANING AND RETINNING
called brazing alloy, is a silver alloy which melts at
E/SPM-4-2
temperatures ranging from 68 to 1600°F (360 to
871°C). Hard solder is usedwhen greatermechanical
strengthor exposure tohighertemperatures is required.
Hard solder is commonly used in helicopter electrical
Figure 4-2. Soldering iron tip before and after
systems for soldering thermocouple connections. cleaning
d. Flux. Flux is a chemical reducerused for surface b. Remove copperfilings from dressededgeswith
conditioningbefore and during the soldering process.With a file card.

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c. Plug in the iron. of a damp cleaning sponge. This removes the surface
dross and excess solder fromthe working surface.

I WARNING 1 b. Once a day, remove thetip and clean the black


scale from the inside of iron and from the tip with fine
steel wool. When iron tip is new, coat inside of shank
AVOID ORAL CONTACT WITH HANDS
DURING SOLDERING OPERATIONS AND EC-090
with dryflake graphiteor antiseize compound (EC-090)
to preventfreezing,and ensuremaximum heattransfer.
WASH HANDS IMMEDIATELY AFTER
Whenreplacing tip, makesure itisinsertedthefull depth
SOLDERING OPERATION. THE LEAD
of casing and seatedfirmlyagainsttheheating element.
CONTAINED IN SOLDER CAN BE A
SOURCE OF OXIDE. LEAD OXIDE IS A
5. GENERAL SOLDERING PROCEDURES.
POISONWHICHCANACCUMULATEINTHE
Cleanliness is of the utmost importance in the soldering
BODY OVER THEYEARS RESULTINGIN A
SERIOUS HEALTH PROBLEM. TOUCHING operation. If possible,soldering should be done in an area
that is reasonablyclean and freefromexcessivedust.
SOLDER FOLLOWED BY SMOKING OR
EATING IS A POTENTIAL MEANS OF
a. Parts contaminated with dirt, oil, grime, grease,
INGESTING TRACE AMOUNTS OF LEAD
OXIDE. etc., cannot be successfully soldered. Make sure all
parts are mechanically bright-clean before soldering.
Cleanpartswith a cloth or brush dipped in ethylalcohol
d. Apply cored solder just as dressed copper is
EC-008 or other approved solvent. Badly corroded
(EC-008),
turning to a pigeon-blue, bronze, oxide color. This will parts may be cleaned carefullyby mechanical means,
allowthe flux to wet and cleantip before soldermeltsto such as using fine abrasive paperor a wire brush.
figure 4-3.
form an even bright coating. Referto figure 4-3.
b. Insulatedconductorsshould be strippeda distance
slightly longer than required for solder connection;excess
conductorwill be trimmed off priorto soldering.The outer
ROSIN-CORE• circumferenceof the end of the insulation shall have a
SOLDER
smooth edge. The inner circumference shall have no
insulationprotrusionsaround wires surface. Insulation shall
not show evidenceof nicks or cuts.

NOTE
I WARNING I
TIN WHILE IRON IS HEATING
AVOID ORAL CONTACT WITH HANDS
DURING SOLDERING OPERATIONS AND
E/SPM-4-3
WASH HANDS IMMEDIATELY AFTER
SOLDERING OPERATION. THE LEAD
Figure 4-3. Tinningsoldering iron tip CONTAINED IN SOLDER CAN BE A
SOURCE OF LEAD OXIDE. LEAD OXIDE IS
e. Wipe off excess solderwith a damp sponge or A POISON WHICH CAN ACCUMULATE IN
cloth. THEBODYOVER THEYEARS RESULTING
IN A SERIOUS HEALTH PROBLEM.
4. SOLDERING IRON MAINTENANCE.

OJ
TOUCHING SOLDER FOLLOWED BY
SMOKING OR EATING IS A POTENTIAL
MEANS OFINGESTING TRACE AMOUNTS
OF LEAD OXIDE.

NEVER SHAKE ORWHIP AN IRON TOGET 6. PRETINNING.


RID OF DROSS OR EXCESSIVE SOLDER
DROPLETS. a. Before wires are soldered to connectors, the
endsexposed by stripping aretinnedto holdthestrands
a. During use and just before each application,pass solidly together. The tinning operation is considered
thesolderingirontip (with arotary motion)throughthefolds satisfactory whenthe endsand sidesofthewirestrands

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are fused togetherwith a coatofsolder. Do not tin wires Table 4-3. Approximate soldering iron sizesfor
which are to be attached to solderless terminals or tinning
splices, or wires whichare to be crimpedto removable
crimp-style connectorcontacts. Wire size Soldering Iron Size
(AWG Gage) K (HeatCapacity)
b. Tinning with Soldering Iron. In the field, wires
smallerthan size No. 10 maybe tinned with a soldering 20-16 65Watts
iron and rosincore solderas follows: l4andl2 100 Watts

(1) Select a soldering iron having suitable heat lOand8 200 Watts
capacity for wire size. Make sure that iron is cleanand
well tinned. a. Solderingirons are available in wattage ranges
from 20 to 500 watts. Irons with wattage ratings of 60,
(2) Tin conductorfor about halfthe exposed length, 100, 200 watts are recommended for general use in
figure 4-4.
refer to figure 4-4. This is enough to take advantage of helicopter electrical wiring. Pencil ironswith a rating of
closed part of solder cup. Tinningor solder on wire above 20 to 60 watts are recommended for soldering small
cup causes wire to be stiff at point where flexing takes parts. The soldering iron recommended for printed
figure4-5
place. Thiswill result in wire breakage. Refer to figure 4-5 circuitsoldering is alightweight 55 wattironwith a600°F
for properlystripped and tinned conductor. (316°C) Curie point tip control. This iron has a
three-wire cord to eliminate leakage currents which
coulddamageprinted circuits.
b. Asoldering ironshouldalso besuitedto thetask.
ROSIN-CORE-
SOLDER
Do not select a small pencil iron where a high steady
heat flow is required.
8. SOLDERING TIP SELECTION. Select the tip best
suited for size and shape of workto be soldered. Some
figure 4-6.
common tip shapesare shown in figure 4-6. Solderingiron
tips are available in sizes from 1/16 inch to 2 inches in
E/SPM-4-4 diameter. For general use, a tip of 1/4 inch to 3/8 inch
Figure 4-4. Tinning wire with a soldering iron diameteris recommended.Forprintedcircuitsoldering,use
a long shanktip of 1/16, 1/8, 3/32 or 3/16 inch diameter.
Screwdriver, chisel, and pyramid shapes are
recommended.

I WARNING 1
AVOID ORAL CONTACT WITH HANDS
DURING SOLDERING OPERATIONS AND
WASH HANDS IMMEDIATELY AFTER
SOLDERING OPERATION. THE LEAD
CONTAINED IN SOLDER CAN BE A
SOURCE OF LEAD OXIDE. LEAD OXIDE IS
E/SPM-4-5 A POISON WHICH CAN ACCUMULATE IN
THEBODY OVER THEYEARS RESULTING
IN A SERIOUS HEALTH PROBLEM.
TOUCHING SOLDER FOLLOWED BY
Figure 4-5. Properly strippedand tinned SMOKING OR EATING IS A POTENTIAL
conductor
MEANS OF INGESTINGTRACE AMOUNTS
(3) Move soldering iron to opposite side of wire OF LEAD OXIDE.
and tin halfof theexposed length of conductor. 9. APPLICATION OF HEATAND SOLDER.
7. SOLDERINGIRON SELECTION. Selectasoldering a. Applyflux-coresolderattheexactpointbetween
iron with a thermal capacity high enough so that heat figure 4-7)
themetal and thesolderingiron (figure 4-7 holding iron
transfer is fast and effective.An iron with excessive heat directlyagainstthe assembly. Melt solder on thejoint,
capacity will burn or melt wire insulation, and iron with too not on the iron. Place soldering iron firmly against
littleheatcapacitywill makeacoldjoint inwhich solderdoes junction.If heavyrocking pressureis necessary, either
not alloywiththework. Table 4-3 providesa listof soldering
Table4-3 irondoes nothavesufficient heatcapacity forthejob, or
iron sizes for various size wire. it has not been properlyprepared, or both.

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ED ED ED 0

n
PYRAMID SCREWDRIVER CHISEL WEDGE CONCAVE BENT
E/SPM-4-6

Figure 4-6. Soldering iron tip shapes

SOLDER

SOLDER
CUP SHALL
BE

E/SPM-4-8

Figure 4-8. Soldering iron holder


11. OVERHEATING PROTECTION. Do not allow
E/SPM-4-7 theiron tooverheat. Disconnecttheiron if it is notin use,
between operations, or use a heat-dissipating stand
which will keeptheiron at a constant temperature.
Figure 4-7. Correct solderapplication 12. COOLING. When the solder joint has been
made, hold firmly in place until the joint has set.
b. Do not apply heat to the work any longer than
Disturbing finished work will result in a mechanically
necessaryto melt solderon allparts ofthejoint. Do notuse weakjoint, with highelectrical resistance. Allow solder
any more solder than necessary. Do not pile up solder joint to cool naturally. Do not use liquidsor air blasts.
around the joint; this iswasteful and resultsin joints difficult
13. CLEANING. If the correct amount of solder is
toinspect.Careshould beexercisedwfth silver-coatedwire used and procedure instructions followed carefully,
to prevent wickingduring solder application. there should be little or no excess solder or flux
10. SOLDERING IRON HOLDER. When the remaining on the finishedjoint. Removeexcesssolder
soldering iron is not in actual use during operations, or flux using the followingprocedure:
keep it in a holder. Referto figure
figure 4-8.
4-8. This will protect a. Excess flux may be removed by brushing joint
the operatoragainstburns andtheironagainstdamage. EC-009 or
with astiff brush dipped in isopropyl alcohol(EC-009)

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a similarapproved solvent.Use alcoholsparinglyand (3) The connector wrap shall be 180 degrees
avoid contact between alcoholand insulation. measured from point of contact with turret post and
figure 4-10.
conductortermination. Referto figure 4-10.
b. For cleaning printed circuit connectionsuse a
swab-stick dipped in isopropyl alcoholfor small areas (4) The conductorshall be positioned in contact
and a lint-free clothfor large areas. with turret post and base throughoutconductorwrap.
The conductor shall not overhang the base of the turret
c. Desoldering or removal of excesssoldermaybe figure 4-11.
4-11.
terminal. Referto figure
accomplished with solder wicks or suction-type
desoldering tools. Solder wicksmay be fashioned from
15. SOLDER CUP.
scrapmetalbraid used on shieldedcable or wire.
a. ConductorRemoval From SolderCup.
(1) Touch end of wick to solderedjoint.

(2) Apply heat to the solder wick to draw off (1) Apply antiwickingtweezersto stranded wire
excess solder. conductors.

14. CONDUCTOR TERMINATION. (2) Prior to removing solderfrom the soldercup,


heat thesolder cup to solder melting temperature and
a. Spade Terminal. remove the conductor.

(1) Strip wire insulation. (3) Remove residual solder from the solder cup.
The wicking method is most effective for removing the
(2) Tin wire to be terminated. smaller amountsof residualsolder atthe bottom ofthe cup.

(3) The conductor wrapon the spadetermination b. SolderCup Preparation.


shall be either 90 degrees or 180 degreesfrom pointof
entry onto the terminaland terminated flushwith thetop
or faceof the spadeterminal. In caseswhereminimum I WARNING I
bend radius of the connectorwrap is less than the
conductordiameter, theconductor wrapshall consist of
figure 4-9.
a 90 degree bend. Refer to figure 4-9. ISOPROPYL ALCOHOL IS FLAMMABLE.
DO NOT USE IN THE PRESENCE OF
SPARKS, HEAT OR FLAME.

(1) Cleanthe soldercup priorto soldering. New


solder cups can be cleaned with isopropyl alcohol,
(EC-009) and an acid brush. Used soldercupsthat are
to be reworked can be cleaned by tinning. Very dirtyor
oxidized soldercups may require abrasive methods to
removenonmetallic oxides.

NOTE

Connectortype solder cups require tinning


on the milled face and the corners of the
soldercup.

(2) Prefill the soldercupwith enough solder tofill


E/SPM-4-9 cupwithoutoverflowwhentinnedconductoris inserted.
Figure 4-9. Spade termination The amount of prefilling needed will depend upon
conductorsize and/or number of of conductorsbeing
(4) The conductor will be centered on spade used. As a rule ofthumb,fillthecupwith solderupto the
terminal.
lower lip of thecutoutsection.
b. TurretTerminal. (3) All excesssoldershouldbe removed, leaving
the terminal interior bright and shiny. Avoid spilling
(1) Strip wire insulation. solder into areas not requiring solder. Clean thesolder
cup with isopropyl alcoholand an acid brush after the
(2) Tin wire to be terminated. tinnedsoldercup hascooled.

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BHT-ELEC-SPM

270°

00
POINT OF
CONTACT

90°
E/SPM-4-10

Figure 4-10. Turret terminal conductorwrap

MINIMUM —,
INSULATION
CLEARANCE

CONDUCTOR
CONTACTS
BOTH THE +
BASE AND POST
OF TERMINAL

E/SPM-4-11

Figure 4-11. Turret terminal conductor position


c. Terminating the Conductorin a Solder Cup.
(1) Stripwireinsulation inaccordance withearlier E/SPM-4-12
instructions.
Figure 4-12. Inserting conductor
(2) Tin wire to be terminated in accordance with
step 6. (7) The insulation sleeving/tubing shall extend
beyond wire insulation a minimum oftwowire insulation
(3) Cut a sufficient length of insulation figure 4-14.
diameters. Referto figure 4-14.
sleeving/tubing (EC-073) and slide onto wire.
(8) The insulation sleeving/tubing shall fit snugly
(4) Heat the solder, and insert conductorwhen
solder is molten (allow gases and fluxes to escape). againstthe wire insulation.
figure 4-12.
Fully bottom theconductor. Refer to figure 4-12.
16. INSPECTION. Agood solderjoint will have a bright
(5) The wire shall be centered in the cup and silvery appearance,with smooth fillets and feathered, not
figure 4-13.
enterparallel to axis of soldercup. Referto figure 4-13. sharpedges. Theentirejoint will becovered with a smooth
The wire shall be bottomed and in contactwith rear of even coat of solder and the contour of the joint will be
thesoldercup. figure 4-15.
visible. Refer to figure 4-15. Anyof the followingindicatea
poor solder joint and are cause for rejection:
(6) Insulation clearance shall be a minimum of one
wire diameter and no greater than two wire diameters a. Dull gray,chalky,or granularappearance(evidence
(including insulation)fromthe top edge of solder cup. of a cold joint).

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BHT-ELEC-SPM

MINIMUM
WIRE FILLET MILLED
STRANDS FACE
BARELY BARELY
COVERED COVERED

INSUFFICIENT SOLDER QUANTITY

E/SPM-4-13

MINIMUM ACCEPTABLE
Figure 4-13. Positioning of conductors SOLDER QUANTITY
LARGE
FILLET
ALMOST
CONVEX
INSULATION
TUBING EXTENDS
A MINIMUM OF TWO INSULATION TUBING NO
WIRE INSULATIONS FITS SNUGLY SPILLAGE
OVER INSULATION AGAINST WIRE
OF WIRE INSULATION

MAXIMUM ACCEPTABLE
SOLDER QUANTITY
E/SPM-4-15

Figure 4-15. Solder quantity


E/SPM-4-14 f. Globules, drips, or tails of solder.

Figure 4-14. Insulation sleeving/tubing g. If any of the aboveare present, thejointmustbe


taken apart, parts cleaned, and entire soldering
b. Hair cracks or irregular surface (evidence of a operation repeated using fresh solderand flux.
disturbedjoint).
4-5. SOLDERSHIELD TERMINATIONS.
c. Grayish, wrinkled appearance (evidence of
excessive heat). Thisparagraph describes theauthorized soldersleeves
and installation procedures for terminating shielded
d. Partially exposed joint (evidence of insufficient cableon helicopters. Shielded termination using pigtails
solder). is also discussed.
e. Scorched wire insulation or burned connector 1. SOLDER SLEEVES. Solder sleeves shall conform
inserts. to MIL-S-83519. This specification covers environment

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BHT-ELEC-SPM

resistant, heat-shrinkablesolder type shield terminations. terminations have pre-installed M22759/32 ground
They maybe used on data-bus, RF and shielded cables leads.
in applications where operating temperature does not
exceed 302°F (150°C). Each termination has a colored 2. SOLDER SLEEVE SHIELD TERMINATION FOR
thermal indicator which is designed to disappear when M83519/1 SERIES.
surlaces have reachedwetting temperature.Terminations
aresupplied premarkedwith a specific identificationcode. a. Prepare cable in accordance with applicable
MIL-S-8351 9 shield terminations are available in two 4-5, or 4-6.
procedures in table4-4, 4-5, 4-6.
styles as follows:
b. Prepare groundedlead by stripping one end of
a. M83519/1 series itemizations are used with theapplicable M22759/32-22-9 wire.
MIL-C-27500 jackettypes:05,08,09,10,11, 12,14,15,
17, 18, 23 and their double jacket equivalents and all
MIL-C-7078cables.Theground lead mustbefabricated figure 4-16
c. Using figure 4-16 as a guide, select the proper
from M22759/32 wire. termination for the cableand ground lead being used.

b. M83519/2 seriesterminations are used with the d. Assemble the cable, ground lead, and
same cables as the M8351 9/1 series. These figure 4-17.
terminations as shown in figure 4-17.

Table 4-4. Center strip preparation

Remove 1/4 to 5/16 inch (6.35to 7.94 mm) of cablejacket at the desired termination pointas follows:
a. Score the jacket around thecable in two places, 1/4 to 5/16 inch (6.35to 7.94 mm)apart.

- 1/4to5/16 inch (6.35 to 7.94 mm)

b. Score the jacket between the cuts.

Score here

c. Remove the section of jacket.

5 6

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BHT-ELEC-SPM

Table 4-5. End strip preparation

Thiscable can be stripped according to the followingprocedures designed to leavetheshieldbraid smooth and
flat.The useof finger cots is recommended to preventtransferof skin oil to theshield.
a. Score and remove thejacket.

Sectionwhere
braid is to be
exposed 1/4 to 5/16 inch (6.35to7.94 mm)

h
b. Bunch thebraid.

c. Trimthe braid as close as possible to the jacket.

d. Score the jacket 1/4 to 5/16 inch (6.35to 7.94 mm)from the end of the braid.

Scorehere

1/4 to 5/16inch (6.35 to 7.94mm)


—i...J uuu__

e. Remove sectionof jacket carefully by pulling straight.Thiswill flattenthebraid strand ends.

5IIIIIII1" Pulistraight

f. Inspect thecableto make sure that thebraid strands are lying flat againsttheprimary insulation.

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BHT-ELEC-SPM

Table 4-6. End strip with braidfold-backpreparation

This cablecan be strippedaccording to thefollowing procedures designed to leavetheshield braid smooth and
flat. The use of finger cots is recommended to preventtransfer of skin oil to the shield.

Braidfolded
backand flat 1/4 to 5/16 inch (6.35 to 7.94mm)

CABLE

Part No. MARKING A B C


CODE MAX MIN MIN
M83519/i-i S1O1X 7/64 (2.78 mm) 3/64 (1.19 mm) 1/32 (0.79 mm)
M83519/1-2 Si02X 9/64 (3.57 mm) 5/64 (1.98 mm) 1/32 (0.79 mm)
M835i9/1-3 Si03X 13/64 (5.16 mm) 3/32 (2.38 mm) 3/64 (1.19mm)
M83519/1-4 5104X 1/4 (6.35 mm) 1/8 (3.18mm) 5/64 (1.98mm)
M83519/1-5 Si05X 19/64 (7.54 mm) 5/32 (3.97 mm) 3/32 (2.38mm)

Figure 4-16. M83519/1 termination selection


NOTE
Allow termination to cool before moving.
e. Using heating tool HT-900 or equivalent and
appropriate reflector, directheatatthe middleportion of
GROUND LEAD figure 4-18.
the termination. Refer to figure 4-18. Heat until the
followingis observed:
(1) Sleeveshrinks.

SHIELDED CABLE TERMINATION


I WARN INil
SLEEVE CONVENTIONAL HOT AIR GUNS MUST
E/SPM-4-17 NOT BE USED ON FUELED
HELICOPTERS BECAUSE OF EXPOSED
HEATING ELEMENTS. USE A RAYCHEM
HT-900, OR EQUIVALENT,COMPRESSED
AIR/NITROGEN HEATING TOOL,
QUALIFIED TO MIL-M-8352i/5.
(2) Solder melts and flows into the wire and shield
Figure 4-17. M83519/1 termination placement strands.

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BHT-ELEC-SPM

(3) Sealing rings melt and begin to seep out the


ends of the sleeve.

e. Inspect termination in accordance with


paragraph 4-5,
paragraph 4-5, step 4.

4. SOLDER SLEEVE TERMINATION INSPECTION.

NOTE

The thermal indicator is an installation aid


and evidenceof color change shall not be
used as sole criterion for acceptance of
terminated assemblies.
E/SPM-4-18
a. Underheated terminations shall show definite
Figure 4-18. Position termination in reflector signs of presence of the thermal indicator. The soldered
area shall show traces of the thermal indicator at the
(3) Sealingrings melt and beginto seep out the minimum acceptable level. Thermal indicator will not be
endsof thesleeve. visibleinthesoldered areaatmaximum solderflowlevel.

f. Inspect termination in accordance with b. Visually examine sealing rings to ensure that
paragraph 4-5,
paragraph 4-5, step 4. they have recovered tightly around cable.
3. SOLDER SLEEVE SHIELDTERMINATION FOR c. Minimum solderflow.Acceptif all ofthefollowing
M83519/2 SERIES. conditions are present:

a. Prepare cable in accordance with applicable (1) Solderhas lost all appearance of ring shape.
4-4 4-5
procedures in table4-4, 4-6.
4-5 or 4-6.
(2) Ground lead and shield contoursare visible.
figure 4-19,
b. Using prepared cable, wire, and figure 4-19,
select the propertermination for the cable being used.
(3) There is a definite filet visible along ground
c. Positionapplicable termination oncable.Referto leadand shield interlace.
figure 4-20.
figure 4-20.
d. Maximum solder flow. Accept if all of the
followingconditionsare present:
I WARNING I
(1) Fillet is clearly visible between ground lead
and shield.
CONVENTIONAL HOT AIR GUNS MUST
NOT BE USED ON FUELED HELICOPTERS
BECAUSE OF EXPOSED HEATING (2) Joint area is visible despite browning of
sleeve.
ELEMENTS. USE A RAYCHEM HT-900,
OR EQUIVALENT, COMPRESSED e. Insufficient heat. Reject if any of the following
AIR/NITROGEN HEATING TOOL, conditionsare present:
QUALIFIEDTO MIL-M-83521/5.
(1) Contourof solder preform is visible.
d. Using heating tool HT-900 or equivalent, and
appropriate reflector, directheatatthe middleportion of (2) Contour of ground lead and/or shield is
figure 4-18.
the termination. Refer to figure 4-18. Heat until the obscuredby solder.
following is observed:
f. Overheated. Reject if any of the following
(1) Sleeveshrinks. conditionsare present:

(2) Soldermeltsandflowsintothewireandshield (1) Joint area is not visible because of severe


strands. darkeningof outersleeve.

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BHT-ELEC-SPM

M22759/XX
WIRE

CABLE

PART MARKING GROUND LEAD A B C


NO. CODE WIRE GAGE MAX MIN MIN

M83519/2-1 SO2O1X 20 7/64 1/32 1/64

M8351 9/2-2 S0202X 20 9/64 1/1 6 1/32

M8351 9/2-3 S0203X 20 13/64 5/64 3/64

M83519/2-4 S0204X 20 1/4 3/32 5/64

M83519/2-5 S0205X 20 19/64 9/64 3/32

M83519/2-6 S0206X 22 7/64 1/32 1/64

M83519/2-7 S0207X 22 9/64 1/1 6 1/32

M83519/2-8 S0208X 22 1 3/64 5/64 3/64

M83519/2-9 S0209X 22 1/4 3/32 5/64

M83519/2-1O SO21OX 22 19/64 9/64 3/32

M83519/2-11 SO211X 24 7/64 1/32 1/64

M83519/2-12 S0212X 24 9/64 1/16 1/32

M83519/2-13 S021 3X 24 13/64 5/64 3/64

M83519/2-14 S0214X 24 1/4 3/32 5/64

M83519/2-15 S0215X 24 19/64 9/64 3/32

M83519/2-16 S0216X 26 7/64 1/32 1/64

M83519/2-17 S0217X 26 9/64 1/16 1/32

M83519/2-18 S0218X 26 13/64 5/64 3/64

M83519/2-19 S0219X 26 1/4 3/32 5/64

M83519/2-20 S0220X 26 19/64 9/64 3/32

(DIMENSIONS ARE IN INCHES)

E/SPM-4-19

Figure 4-19. M83519/2 termination selection

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Page 18
BHT-ELEC-SPM

GROUND LEAD (2) Heat solder joint until the solder melts and
then carefullyseparate thecomponents.

b. Reterminate the solderjoint removing as much


solder from the cable shield as possible and then
paragraph 4-4.
installinganewterminator as described inparagraph 4-4.

SHIELDED CABLE 7. INSPECTION OF REWORK. Inspect all


SHIELD TERMINATION paragraph 4-5,
reworked assemblies per paragraph 4-5, step 4.
SLEEVE
E/SPM-4-20
8. TERMINATING MULTIPLE SHIELDED CABLES.
Whenterminating multiple shieldedcables usingsolder
Figure 4-20. M83519/2 termination placement sleevesproceed as follows:

(2) Solder fillet is not visible along ground lead NOTE


and shield interlace.
If four or more shields are to be terminatedat
(3) Wire insulation damaged (slight browning
okay)outsideof sleeve.
a giventerminationpoint, theshieldsshould be
arrangedinto groups.Each groupwill consistof
5. REWORK OF SOLDER SLEEVES. The a maximum of four shields linked from one
insulation sleeve must be replaced if it is misaligned, shield to the other. The last terminationof each
overheated or otherwise damaged. group willthen beterminatedwith a splice cap.
Final termination of splice capto ground, or a
a. Remove sleeve by perlorming the following: connector pin, requires a separate wire. All
splice capswill have a maximumof fourwires.
(1) Score sleeve using a sharp blade. It is not
necessary to cutthroughthe sleeve.Use care notto cut a. Install solder sleeves as outlined previously in
cablejacketor ground lead insulation.
paragraph 4-5.
paragraph 4-5.

(2) Reheat sleeve until it softens and then grasp it


with needle-nosepliers, on the side oppositeof the scored b. Each cable in turn is attachedto the adjacent
cable and the final hookup wire is terminated with a
line, and gently pull the sleeve off of the assembly.
contactand then insertedinto the connector. Referto
figure 4-21.
figure 4-21.
b. If examination of the solder joint after sleeve
removal show that the solder joint is acceptable,
reinsulate the termination using the following 9. SHIELD TERMINATION. When terminating a
shielded cable assemblyusing a pigtail, refer to figure
figure
procedures:
4-22 and proceed as follows:
4-22
(1) Use a terminatorof the correctsize.
a. Determineand markthepointat whichshielding
(2) Remove the solder preform by crushing the is to terminate. This will dependon length of conductor
preform and allowing it to drop out of the sleeve. necessary to maketheconnection, or in somecaseson
length of braid pigtail required to ground shielding.
(3) Center the sleeve over the solder joint and
heat until it recovers onto the assembly. b. Push backtheshielding so as to forma bulge at
this point, insert an awl, or other pointed tool, between
6. SOLDER JOINT REPLACEMENT. The solder thestrands of shielding and work an open circulararea
joint must be remade if it is misaligned or there is intothe shield. Maximum shield strand breakage shall
insufficient solderin thejointbecause of overheating. not exceed 10 percent. If more than 10 percent are
broken, use of an M83159/1 shield terminator is
a. Disassemblejoint using the following procedures: permissible.

(1) Remove sleeve using the procedures in c. Bend the cable,insertthetool between shielding
subparagraph 5, a. and wire and pull conductorthrough.

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BHT-ELEC-SPM

11. ALTERNATEMULTIPLESHIELD TERMINATIONS.


An alternate method employing pigtails may be used if
connectorhasacable clamp. Theprocedure isas follows:

NOTE
In the following steps if all shields will not fit
intoone solderless terminallug,use several
terminallugs and distribute them underboth
screws.
a. Form a pigtail on each shieldedwire and crimp
together in a solderlessterminallug.
b. Attach the terminal lug under the screw on the
figure 4-24.
cableclamp. Referto figure 4-24.

12. FLOATING SHIELD TERMINATIONS. Wiring


installations that do not requirethe shield to be terminated
to a contact or a ground are preparedas follows:
a. Strip the outer insulating jacket to expose a
maximum five-inchlength of shield.
b. Push backand trimshieldleaving1/4to5/16 inch
of bareshield.
c. Fold the shield back over the outer jacket.
Inspect wires to ensure that center conductorwas not
cut duringstripping.
d. Slide a 3/4-inch length of heat shrinkable tubing
(EC-069) over the folded back shield and apply heat.
The heat shrinkable tubing shall be installed before
conductorsare terminated.
E/SPM-4-21 e. The exposed length of conductor should be the
minimum length which is sufficientto accept insertionand
removal of tools, if applicable, but not more than four
inches.

4-6. SHIELDEDCABLE SPLICES.


Figure 4-21. Terminating multipleshielded
cables with soldersleeves This section covers selection and installation
procedures used for making environment resistant
d. Pullthe empty partofshield tautandtin the last 1/4 in-linesplices in shieldedcables.
inch unless crimped-on type terminal is to be attached.
1. TOOLSAND EQUIPMENT.
Crimp terminationis then accomplishedas required.
10. MULTIPLE SHIELD TERMINATIONS. When Tools Required
terminating multiple shielded cables using pigtails
M22520/5-O1 CrimpTool with die sets -101 or -102
proceed as follows: as required
a. Form a pigtail on each shielded cable. Referto RayChem model CV-5300 or HT-900 minigun
step9. heating tool (notto be used on fueledaircraft).
b. Crimp a single wire into one end of a splice then Ruler readable to 0.0625 inch.
insert and crimp pigtails in opposite end. Refer to figure
figure Stripping tools forcable jacketand primarywires.
4-23.
4-23.
Small scissors or diagonal cutters for trimmingcable
c. Solderorcrimpsingle wire in a selectedcontact. braid.

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BHT-ELEC-SPM

LOOSENED SHIELD

//
\

TWIST NOTE
ANDTIN THIS AREA

Do not tin if crimp terminal is to be installed.


EISPM-4-22

Figure 4-22. Shield termination

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BHT-ELEC-SPM
SOLDERLESS
TERMINAL LUG
PREINSULATED PERMANENT
SPLICE

FORM PIGTAILS
OUTSIDEAREA
TO BE

KEEP POTTING
COMPOUND BELOW
THIS LINE

E/SPM-4-24

Figure 4-24. Terminatingmultipleshieldedcables


3. CABLE PREPARATION. References to cablesA
and B are used to denote opposite sides of splice. All
tolerancesare plus or minus 0.0625 inch unless noted
otherwise. Strip cablesas follows:
a. Removecablejacket as follows:
NOTE
POTTING MOLD OMITTED Both Cables
FOR CLARITY Single ConductorCables 2 in. (50.8mm)
TwoConductorCables 3 in. (76.2mm)
ThreeConductorCables 4.25 in. (107.95 mm)
E/SPM-4-23 Four ConductorCables 5.5 in. (139.7mm)
b. Removeall but0.5 in. (12.7 mm)of braid.

c. Stagger cut conductors. Cables A and B are


mirrorimages e.g. longestprimary conductorin cableA
is shortestin cable B. Referto figure
figure 4-25.
4-25.

Figure 4-23. Terminating multiple shielded 4. MULTICONDUCTOR CABLES. Measure from


cables using pigtails figure 4-25.
cablejacket. Referto table4-7 and figure 4-25.
2. INSTALLATION PROCEDURES. Select proper
tables 4-8
splicekit fromtables 4-8 and 4-9. Table 4-7. Dimensionsfromcable jacket to end
of conductor
Example: A mixed gage cable having three 20
gage conductors connected to three 16 gage First Conductor 1.25 in. (31.75 mm)
conductors would require D-150-0260 kit.
Second Conductor 2.5in. (63.5 mm)
table 4-10
a. Refer to table 10 to determine material Third Conductor 3.75 in. (95.25 mm)
contained in each kit. Fourth Conductor 5.0in. (139.7 mm)
table 4-11
b. Refer to table 4-11 for dimensions material and a. Strip all conductor0.25 to 0.313 in. (6.35 to 7.938
a cross reference of material to kit. mm).

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BHT-ELEC-SPM

b. Table 4-10
Table4-10 providesamaterial listforeach kit. lfthe (5) Apply heat ends of sleeve until sealing rings
two cables to be spliced have different size conductors, meltand flow alongwireinsulation.
place items as follows:
6. INSPECTION.

(1) Large cable. Place outer sleeve, larger a. Wirecolorsinoppositesidesofcrimparecorrect.


terminator, and jumper braid. b. Crimpindentations are clearlyvisible.
C. Sealing sleeve is fully recovered and inserts
(2) Small cable. Place smallerterminator. havelost their shape and flowed alongwire.
d. Sealingsleeve is not split
5. SPLICE ASSEMBLY.
7. BRAIDSPLICE.
a. PrimarySplice: . . . ..
a. Slide jumper braid forward so that trailing end is
. at end of cablejacket.
(1) Place one sealing sleeve onto longer leadof
each matching set of conductors of cableA and B. b. Trimbraid and formboth endsofbraid around the
cableshieldsmaking surethat endofjumper braid does
not extend onto cablejacket.
(2) Installa crimp splice on eachconductorof cable
A. C. Position terminators so that solder preform is
locatedapproximately0.25 in. (6.35mm)from cablejacket.
(3) Crimp matching conductors into open end, of •
d. Heat terminatorsuntil solder melts and flows into
splice
braid.

(4) Center sealingsleeves over completed splices e. Inspection. Ensure terminators have been
and apply heat to center of sleeve to lock in position. heatedenoughand there is no unmelted solder.

Table 4-8. Kits (D-150-XXXX) for 1 to 1 splice

Primary Numberof Primaries


Gage
One Two Three Four
22 -0255 -0256 -0257 -0257
20 -0255 -0256 -0257 -0257
18 -0258 -0259 -0260 -0260
16 -0258 -0259 -0260 -0260
14 -0261 -0262 -0262 -0262
12 -0261 -0262 -0262 -0262

Table 4-9. Kits (D-150-XXXX) for mixed gage splices

SPLICE CONFIGURATION

SIDEA SIDEB KIT


2OAWGTWISTED PAIR 16AWG TWISTEDPAIR -0259
2OAWGTRIO 16AWG TRIO -0260
2X22AWG SINGLE 1X2OAWGSINGLE -0255
2X22AWGSINGLE 1X16AWGSINGLE -0258

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BHT-ELEC-SPM

Table 4-10. Material list

D-150-0255 QTY/ D-1 50-0256 QTY/


ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-01 1 1 D-1 50-0255-01-02 1

2 D-150-0255-02-01 1 2 D-1 50-0255-02-01 1

3 D-1 50-0255-03-01 2 3 D-150-0255-03-02 2


4 D-1 50-0255-04-01 1 4 D-1 50-0255-04-01 2
5 D-1 50-0255-05-01 1 5 D-1 50-0255-05-01 2

D-1 50-0257 QTY/ D-1 50-0258 QTY/


ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-02 1 1 D-1 50-0255-01-01 1

2 D-1 50-0255-02-01 1 2 D-1 50-0255-02-01 1

3 D-1 50-0255-03-03 2 3 D-1 50-0255-03-01 2


4 D-1 50-0255-04-01 4 4 D-1 50-0255-04-02 1

5 D-1 50-0255-05-01 4 5 D-1 50-0255-05-02 1

D-150-0259 QTY/ D-1 50-0260 0Th'/


ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-02 1 1 D-1 50-0255-01-02 1

2 D-1 50-0255-02-01 1 2 D-1 50-0255-02-02 1

3 D-1 50-0255-03-03 2 3 D-1 50-0255-03-03 2


4 D-150-0255-04-02 2 4 D-1 50-0255-04-02 4
5 D-150-0255-05-02 2 5 D-1 50-0255-05-02 4

D-150-0261 QTY/ D-1 50-0262 QTY/


ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-02 1 1 D-1 50-0255-01-02 1

2 D-1 50-0255-02-01 1 2 D-1 50-0255-02-01 1

3 D-1 50-0255-03-02 2 3 D-1 50-0255-03-04 2


4 D-150-0255-04-03 1 4 D-1 50-0255-04-03 4
5 D-1 50-0255-05-03 1 5 D-1 50-0255-05-03 4

4-00-00
Page24
BHT-ELEC-SPM

Table 4-11. Dimensions of kit material and cross reference of material to kits
ITEM NO. 1 OUTER SLEEVE

l.D.
LENGTH USED KITS
PART NAME (NOM.) BEFORE AFTER D-150-
D-150-0255-O1-O1 8.0 0.315 0.080 0255 0258
D-150-0255-01-02 8.0 0.470 0.1 20 0256 0257 0259 0260
0261 0262

ITEM NO. 2 JUMPERBRAID

LENGTH l.D. USED IN KITS


PART NAME (NOM.)* MIN.* D-150-
D-150-0255-02-01 3.5 0.230 0255 0256 0257 0258
0259 0261
D-150-0255-02-02 5.5 0.344 0260 0262
*Measured on mandrel equalto I.D. mm.
ITEM NO. 3 TERMINATOR

LENGTH I.D. USED IN KITS


PART NAME (NOM.) MIN. D-150-
D-150-0255-03-01 0.625 0.180 0255 0258
D-1 50-0255-03-02 0.750 0.235 0256 0261
D-1 50-0255-03-03 0.750 0.280 0257 0259 0260
D-1 50-0255-03-04 0.750 0.370 0262

ITEM NO. 4 SEALING SLEEVE

LENGTH USED IN KITS


PART NAME (NOM.) COLOR D-150-
D-1 50-0255-04-01 0.085 RED 0255 0256 0257
D-1 50-0255-04-02 0.1 10 BLUE 0258 0259 0260
D-1 50-0255-04-03 0.170 YELLOW 0261 0262

ITEM NO. 5 CRIMP SPLICE

LENGTH USED IN KITS


PART NAME (NOM.) COLOR D-150-
D-150-0255-05-01 0.045 RED 0255 0256 0257
D-150-0255-05-02 0.064 BLUE 0258 0259 0260
D-150-0255-05-03 0.097 YELLOW 0261 0262

4-00-00
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BHT-ELEC-SPM

JACKET

SHIELD BRAID

CONDUCTOR
(3 EACH SHOWN FOR
A AND B CABLE)

TERMINATOR CRIMP BARREL

SHIELD BRAID
CABLE A.
(THREE 22 GAGE
CONDUCTORS)

SEALING SLEEVE

SLID BACK OVER CABLE

I
____________ HEAT
f SHRINKAB—
OUTER SLEEVE
I.D.

h CABLE B.
(THREE 22 GAGE
CONDUCTORS)
ITEM 1 OUTER SLEEVE

___________ L___________

ttD.
1.10 IN.

I.D.
ITEM

IIIi
SEALING SLEEVE
-f
ITEM 2 JUMPER BRAID

COLOR
CO.II'
2 PLACES
ITEM 5
O.D.
ITEM 3 TERMINATORS SPLICE
E/SPM-4-25

Figure 4-25. Example— 3-conductor shielded cable splice

4-00-00
Page 26
BHT-ELEC-SPM

8. INSULATION OF SPLICE.
a. Centerheat shrinkableoutersleeveovercompleted
splice.

b. Heatoutersleeve, starting incenter, worktoward


one end and then the other. Move splice through heat
slowing enough to keepsleeve recovering.
c. Inspection. Ensure no splitsor tears are presenton
sleeve.
E/SPM-4-27
NOTE
BAS-KIT-OlO (EC-066) contains materialsand
instructionsto make shieldedcable splices.
9. FILTER LINE CABLE TERMINATIONS.
Figure 4-27. Octadent crimp
Procedures for terminating shieldedand jacketedfilter
table 4-12
line cables are shown in table
table 4-12
4-12.
4-12. figure 4-28
4. M22520 CRIMP TOOL. Refer to figure 4-28 for
identification and operation of this tool. The basic
M22520/2-O1 and M2252017-O1 tool use locatingdevices
4-7. CONTACT CRIMPING PROCEDURES. known as positioners. They are individual locaterswith a
data plate attached to the top which specifiesthe contact
1. CRIMPING TOOLS. Crimping may be part number(s) accommodated,and correlates the wire
accomplished with hand tools that are cycle controlled size with the tool selector sethng. MIL-C-22520/7
by a precision ratchetthat releases the handles at the positioners can only be used on the M22520/7-O1 basic
proper crimp depth. Crimp tools have a turret or tool. A typical positioner is shown in figure
figure 4-28.
4-28.
positioner to select the proper crimp depth for a
specified contactand wire size. 5. TURRET HEADS. Turret Heads.These heads have
a turret which hasthree separate POSITIONERSthat are
2. CONTACT CRIMPING. The optimum method of color-coded and marked with the applicable contact size
attachingwire tothecontact is by crimpingthe barrel ofthe accommodated by each individual positioner within the
contactaroundthe wire. Thiscontrolledcompressiongives head. The color and contact size correspond to the
reliable mechanical strength and electrical continuity. informationon thefoil label (data plate)attachedtothe side
Crimping requires exact wire preparationand the proper of the head. The proper positioner is selected for the
tool to maintain manufacturers standards for the contacttypeand sizeto becrimped by referringtothe data
equipment. Each contact has a viewing hole in the barrel plate. A typical turret head is shown in figure
figure 4-28.
4-28.
to ensure proper placementof the wire.
a. The procedures for crimping contacts to wire
3. CRIMPING CONFIGURATIONS. The four indent conductoris as follows:
crimp provides the most uniform displacement of wire
and contact material and is used as the MIL standard. (1) Select proper positioning head to be usedfor
figure 4-26.
Refer to figure 4-26. The impression of the crimp contacts being crimped.
horizontally for MIL standard is the octadentwhich is
figure 4-27.
illustrated in figure 4-27. (2) If the head to be used is a turret head, first
depressthe turret trigger to release the turret to the
figure 4-28.
indexing or extendedposition as shown in figure 4-28.

(3) Place the head over the retaining ring on the


back of thetool (selectorside) and seated against the
tool body; secure the 9/64 socket head screws with an
Allen wrench. If positioning head is single positioner
type, omit steps4. and 5.

(4) If the positioning head is turret type, it has


three separate positioners that are color coded and
marked with applicable contactsize accommodated by
E/SPM-4-26
each individual positioner. Referto data plateto select
Figure 4-26. 4 Indenture crimp proper positioner to be usedforcontactbeingcrimped.

4-00-00
Page 27
BHT-ELEC-SPM

Table 4-12. Termination of shield and jacketed filter line cable

1. Cut slit and remove jacket from end of cable:


CUT SLIT

MINIMUM

2. Bunch, cut, and remove braided shield:

NOTE

Stripping procedures of filter line shielded jacketed cable for


termination intojunctionmodules and otherterminating devices other
paragraph 4-5,
than connectors shall be in accordance with paragraph 4-5, step 3.

3. Cut, slit, and remove jacket:

0.250 IN. (6.35 mm)


—H

1 IN. (25.4 mm) MINIMUM

4. Position soldersleeve termination and heat with hot air:


BRAID STRAP _________SOLDER SLEEVE TERMINATOR
WITH ATTACHED BRAID STRAP

5. Install protective sleeve (EC-069) using hot air:

PROTECTIVE SLEEVE

0.5 IN. (13 mm)

4-00-00
Page28
BHT-ELEC-SPM

M22520/1-O1CRIMP TOOL
9/64 HEXWRENCH

TURRET HEADASSEMBLY

TRIGGER

DATA PLATE

OPEN POSITION

RETAINER

"— TAPPED HOLES


INSERT CONTACT TO BE CRIMPED (THIS SIDE) Instructions for changing Turret head:
1. Press triggerwhich releasesTurret to indexing
position.

r
2. Place selected Turret Head assembly onto
retainer ring with screws lined up with tapped
holes.
TURRET IN TURRETSHOWN IN 3. After Turret Head assembly is seated against
INDEXING ring, tighten socket head screws with 9/64 inch
Allenwrench. Turret should index easilywithout
POSITION177 LOCKIO7 binding.
4. To remove, loosen socket head screws until
threads are disengaged from retainer ring and
removewithastraightlifting motion.
5. Allheads (single position, universalandturret)
are attached by means of two socket head
screws.
COLOR CODED
POSITIONERS Instructions for IndexingTurret Head Assemblies:
1. Press triggerwhich releasesTurret to indexing
position.
2. Selectpositioner desired fromcolorcoded data
plate on side ofTurret Head assembly.
SOCKET 3. IndexTurretuntilcolorcolded positioneris lined
SCREWS up with Index mark on top of Turret Head
assembly,atwhich timethe trigger will position
the Turret.
4. PressTurret until it snaps into locked position.
SELECTOR KNOB
Instructions for Using Indentor Closure Selector:
1. Refer to data plate on Turret Head assembly.
SEL. Below the wire size and opposite the contact
NO. size is listed the correct indentor closure
number.
SPRING CLIP 2. Removethespringcliplockfromselectorknob.
LOCK WIRE 3. Tool must be in open position when using
selector.
4. Raise selector knob and rotate to desired
selector number.
5. Replace thespringclipand toolis readyforuse.
6. Repeat instruction procedures when changing
contact and/or wiresizes.

EISPM-4-28-1

Figure 4-28. Turret head crimper(Sheet 1 of 2)

4-00-00
Page29
BHT-ELEC-SPM

M2252012-01 CRIMP TOOL


DATA PLATE
(TYP)
POSITIONER

INDEXMARK

POSITIONER
LOCKPLATE

Instructions for Changing Positioners


INSERT CONTACT
(THIS SIDE) 1. Select correctpositioner for contact being crimped.
2. Insert positioner into positioner lock plate. Push and
rotate 900 to install.
3. Determinecorrectselector settingfor the wire size
from the data plateon end of positioner.
4. Lift selector knoband rotate until selector number
aligns with Index mark.
5. Tool is nowready for use. Insert contactand complete
crimping cycle.

CRIMPING INSTRUCTIONS

1. Insert contact thru indentor opening into positioner.


2. Insert wire into contact and hold securely to insure
that it bottomsin contact. Close handles until tool
WIRE bottoms and ratchet "Kicks Oft". Releasehandles and
remove crimped contact.

INSERT CONTACT M22520/1-01 CRIMP TOOL


THIS SIDE DANIELS PART NO.AF8

M2252012-01BASIC CRIMP TOOL


DANIELSP/N AFM8
,, WIRE—-1
TURRET IN
LOCKEDPOSITION ___,//

POSITIONER

NOTE: Aftercrimpingcycleis completed, inspectcontact. Make sure the wire is visible thru inspection hole
and thereare no fractures in contact.
E/SPM-4-28-2

Figure 4-28. Turret head crimper(Sheet 2)

4-00-00
Page 30
BHT-ELEC-SPM

(5) Rotate turretuntil correctpositioner is linedup


withtheindexmark onturrethead andpushturretinuntil 0.000 TO 0.031 INCH BETWEEN
it snaps intolocked position. CONTACT AND INSULATION

(6) Refer again to data platefor correctselector


settingforwire size being used. Withhandles fully open,
remove spring clip lockwire from selector knob, lift and
rotate selector knob (or slide the thumb button) to the
figure 4-28.
correctsettingand release. Referto figure 4-28. Install
spring clip lockwire.
WIRE
(7) Determine the proper length of insulation to INSULATION
be stripped. Wire mustbe visible in inspection holeand
thereshould be a 0.000 to 0.031 inch gap between the INDENT CRIMP
figure 4-29.
contactand the wire insulation. See figure 4-29. CONDUCTOR BARREL

NOTE
WIRE SHOULD BE VISIBLE
When crimping contacts with an insulation IN INSPECTION HOLE

support cup, make sure the insulation


extends into it 0.000 to 0.031 inch (0.40 to CRIMPED CONTACT
0.80 mm)from bottom of cup.
E/SPM-4-29
(8) Insert the stripped wire into wire barrel of
contact until the end ofthe wirecan beseenthrough the
inspection hole. Insert wire and contact through
indenters on front side of tool (opposite from selector Figure 4-29. Correct crimped connector pin
side) until it bottomsand fully seats in positioner.
7. CRIMP INSPECTION. Inspect crimpedcontactfor
(9) Hold the wire and contact in place and thefollowing. Referto figure
figure 4-29.
4-29.
squeeze toolhandlesuntil theyfully bottomand ratchet
releases, thus allowing handles to automatically return a. Wire isvisiblethroughinspectionhole inwire barrel.
to the open position. No wire strands shall protrudethrough inspection hole.

(10) Remove the crimped contact and inspect. b. Position of crimp impression is midwayon wire
Referto step7 and figure
figure 4-29.
4-29. barrel. (2 seriesof 4 indents)

6. SINGLE POSITION HEAD (POSITIONER). The c. Insulation gap should be less than 0.031 inch.
procedure for crimping contacts utilizing the positioner d. Contact is not bent or distorted.
is as follows:
a. Select the proper positioner to be used for the e. Wire strandsshall not be nicked or loose.
contact being crimped. f. Contact wire barrel is not cracked and plating is
b. Insert the positioner into the retaining ring on intact.
figure 4-28.
back of tool selector side. Refer to figure 4-28. The
must be pushed in then g. Allwire strands shall be inside contactbarrel and
positioner is spring-loaded and inserted to bottom of barrel.
rotated 90 degrees clockwise until it locksinto position.
Insert spring clip lockwire, if present, through retaining NOTE
ring.
c. Refertothedata plate forcorrectselectorsetting The following instructions in step 8 are to be
for wire size being used. With handles fully open, used as a guideline. Always refer to the tool
remove spring clip lockwire from selectorknob, lift and manufacturers recommended instructions for
rotate selectorknobto correctsettingand release and inspection.
reinstall spring clip lockwire.
paragraph 4-3.
4-3.
8. TOOL INSPECTION GAGING. All crimping tools
d. Strip wire as described in paragraph
can be checked for propercalibrationof the crimpingjaws
e. Insert wire and contact; crimpand inspectas per (indenters)by means of GO/NO-GO inspection gages. If
figure 4-29.
step7 and figure 4-29. the GO gage does not passthrough indenter tips and/or

4-00-00
Page31
BHT-ELEC-SPM

NO-GOgage passes throughthe tips, do not usethe tool on the basic tool only. The tools may be gaged with a
but return it for repair. Thetools should be checked before positioningdevice installed, as long as it does not interfere
each series of crimpingoperations.Proceed as follows: with the gage operation. If the presenceof the positioning
device makes gaging difficult,remove it before inspecting.

b. The inspection procedureis as follows:

DO NOT CRIMP DOWN ON THE GAGE (1) Selecttheproperinspection gage to be used


PINS AS THIS WILL PREVENT THE TOOL from table4-13.
FROM FULLCYCLING TO THE RATCHET
RELEASE POSITION. (2) Set the selectoratthe proper selectornumber
as specified in table4-13.
a. Inspection of the M22520/O1, M22520/2-O1, and
M22520f7-O1 Basic Tool. Inspection gaging is performed (3) Closethe handles completelyand hold.

Table 4-13. Crimp tool inspection gages

Crimping Tool Part Number Inspection GagePart Number SelectorSetting


M2251 0/1-01 M22520/3-1 4
M22520/2-01 M22520/3-1 8

LJ
M22520/7-01 M22520/3-3 8

(4) The GO gage (green end) should passfreely


figure4-30.
through the indenter. Referto figure 4-30

(5) The NO-GO gage (red end) should not enter DO NOT USE TOOLS THAT HAVE BURRS
figure4-30.
through the indenter tips. Referto figure 4-30
OR SHARP EDGES. BURRS OR SHARP
EDGES CAN CUT THROUGH GROMMET
WIRE SEALING WEBS AND DESTROYTHE
4-8. CONTACT INSERTION/REMOVAL.
ENVIRONMENTALSEALING CAPABILITIES
OF A CONNECTOR.
1. INSERTIONTO FRONT RELEASECONNECTORS.
Insertion tools for inserting contacts into front release
figure 4-31
connector inserts are shown in figure 4-31. There is a a. Insert thecrimpedcontact intotheconnectoras
toolfor each contact size. Contact sizes are listed follows:
separate
in table4-14. An indicatingband on theworking end of the
tool determines correct depth of tool insertion. Use these (1) Slide rearaccessoriesbackonto wire bundle.
tools to insert contacts in front release connectors with
removablecontacts.
(2) Selectthecorrect insertion tool and insertthe
crimpedend of the contact into the hollow end of the
Table 4-14. Contact and wire size range insertion tooland laywire in handle. Refertotable4-14.

Contact Size Wire Range Size (3) Guidethecontactintothecorrectlynumbered


grommet hole in the rearface of the insert and feed the
20 24—20 contactcarefullyintothehole.
16 22—16 NOTE
12 14—12
8 10—8 Isopropyl alcoholcan be used as a lubricant.
4 6—4
(4) Pushthe tool straight in at right anglesto the
0 2—0 grommet surface until contact is fully seated.

4-00-00
Page32
BHT-ELEC-SPM

GREEN RED

RED

GREEN

GO
TYPICAL DIE CLOSURE CHECK
E/SPM-4-30

Figure 4-30. Crimp tool inspection tool guide

(5) Withdrawthetool keeping it perpendicular to WILL CAUSE INSERTIONTOOL TO SHEAR


thegrommet face. BARRELWHILE INSIDEGROMMET.SHARP
EDGE OF SHEARED MATERIALWILL CUT
THROUGH THE GROMMET WEB AND
CAUSE A SHORT CIRCUIT.
DO NOTATTEMPTTO RESEATACONTACT
ONCE THE INSERTION TOOL HAS BEEN b. Gently pull on wire to make sure contact is held in
REMOVED. REMOVE CONTACT AND place.
START OVER AGAIN WITH CONTACT
BARREL PROPERLY LOCATED IN TOOL. (1) Fill all unused holes with unwired contacts
FAILURE TO FOLLOW THIS PRECAUTION and sealingplugsof appropriate size.

4-00-00
Page33
BHT-ELEC-SPM

1- __
r
r

MS24256A20
INSERTION TOOLS MS24256A16

THRUSTASSIST COLLAR

THRUST ASSIST
COLLAR—N

MS24256R20
EXTRACTION TOOLS MS24256R16 EISPM-4-31

Figure 4-31. Insertion and extraction tools for frontrelease crimp-type contacts

4-00-00
Page34
BHT-ELEC-SPM

2. REMOVALFROM FRONT RELEASECONNECTOR. stop and bottomsin the insert hole. A slight rotation of
Tools for extractingcontacts from front releaseconnector thetool may aid the tool insertion.
insertsare shown infigure 4-31.Thesizesfor each contact
figure4-31
are listed in table 4-14. Extraction tools have a hollow d. Push thethrust assist collar or slide forwardas
cylindricalprobe whichMssnuglyoverthe pinorsocketend far as it will go.
of the contact and releasesthe insert retentionclip when
e. Withdrawthetool from thecontact, keeping the
pushed over the contact. Two indicatingbands determine
correct depth;the band nearesttheworking end ofthe tool tool perpendicular to the insertface.
is for pin contacts, the other for socket contacts. The f. Remove the contact from the back of the
extractiontool has a thrust assist collar (or slide) which is connector.
pushedforwardto ejectthecontactfromthe insertretention
clip by means of an internalplunger. 3. CONTACT INSERTION FOR REAR RELEASE
CONNECTOR. Insertion tools may be single ended,
a. Selectthe correctextraction tool for the contact or double ended. Each is color-coded to contact size.
to be removed. Referto table 4-15. Connectorrear accessories (cable
clamp, etc.) must be removed prior to installation or
removalof contacts.
NOTE

MAKE SURE THE EXTRACTION TOOL IS Connectorshaving contactswhich are installed


ALWAYS EXACTLY ALIGNED WITH THE and removed from the rear of the connector
have blue color bands around them.
CONTACT TO AVOID DAMAGE TO THE
CONTACT OR INSERT. a. Contactinstallation with singleor double ended
figure4-33.
tool. Referto figure 4-33
b. Working from the front of mating end of the
connector, slipthe hollowend ofthe extractiontool over the (1) Select correct installation tool and place
contact,with the tool parallel to the contact and squarely contact wire in groove of installation tool.
figure4-32.
perpendicularto the insert face. Refer to figure

NOTE

Someextraction tools havea spacersleeve


4-32

CONTACT
L2J
MUST BE INSERTED
PERPENDICULAR TO THE FACE OF THE
with positions for either pin or socket
CONNECTOR. DO NOT TIP, SPREAD, OR
contacts. Set to correct position before ROTATE THE TOOL WHILE IN THE
installing tool on contact. CONNECTOR.
c. Push the tool toward the rear of the connector (2) Slide tool downwire ontocontactcrimp barrel
with a firm steadypushuntilthetool comesto a positive until it butts againstthe contact shoulder.
Table 4-15. Insertion/removal toolfor rear release contacts
OPENING

COLORED ENDFORINSERTION WHITEENDFOREXTRACTION


EISPM TABLE#4-20

Tool Part No. Insertion End Removal End


M81969/14-04 Yellow White
M81969/14-03 Blue White
M81969/14-10
Red White
M81969/14-11
M81969/14-01 Green White

4-00-00
Page35
BHT-ELEC-SPM

TOOL AT RIGHT ANGLE


TO INSERT FACE

TOOLAT RIGHT ANGLE


TO INSERT FACE

WIRE LAID IN
TOOL SLOT

REMOVALTOOL

INSTALLING TOOL

NO INSULATION CUP

/
WIRE
CONTACT RETENTION CLIP

GROMMET HOLE

INSTALLING TOOL TIP


INSULATION CUP

PLUNGER SLIDE RETRACTED


(THRUST ASSIST COLLAR)
CONTACT RETENTION CUP

WIRE

REMOVAL TOOL
E/SPM-4-32

Figure 4-32. Installation and removal of crimp contacts

4-00-00
Page36
BHT-ELEC-SPM

INSTRUCTIONS FOR PLASTIC TOOLS


INSTALLING (COLORED END) REMOVAL (WHITE END)
1. Hold the insertion half of tool 1. Withthe rearofconnector facing
(colored) between the thumb and you,lay thewireofcontact to be
forefinger and lay the wire to be removed along the slot of
inserted along the slot, leaving removal half (White) of the tool,
about 1/2 inch protruding fromthe leaving about1/2 inch from the
end of the tool tothe crimp barrel end ofthe tool to the rear of the
ofthecontact. connector.

2. Squeeze thewire hardintothetool 2. Squeezethe wire hard into the


at the tip, betweenthe thumb and tool between the thumb and
forefinger and at the same time forefinger about 1/2 inch from
quickly pull the protruding wire the tip and at the same time
withtheother hand awayfromthe quicklypull the connector away
tool. fromthe toolwiththe other hand.

3. The wire will now have snapped


into place. Slide the tool down
3. The wire will now have snapped over the wire and into the rear
intoplace.Pullitbackthrough tool seal and push it slowlyinto the
untilthetip seats on thebackend connector until a positive
ofthecrimpbarrel. resistanceisfelt. Atthistime, the
contact retaining clip is in the
unlock position.

4. Holding the connector with the 4. Press the wire of the contact to
be removed against the
rear seal facing you slowly push connections of the plastic tool
the contact straight into the and pull both the tool and the
connector seal. contact-wire assemblyoutofthe
connector.

5. A firm stop will be evident when


the contact positively seats in the
CAJ
connector. DO NOTTIP, SPREAD OR ROTATE
TOOL WHILEIN CONNECTOR.

REARRELEASECONNECTORS
PLASTIC TOOL
IDENTIFICATION
CRIMPED CONTACT
MATED PLUG AND RECEPTACLE INSTALLING TIP
(COLOR CODED)
-RETENTION CLIP

CONNECTOR
(REAR RELEASE)

Connectors having contacts which are installed and


removed from the rear of the connector have BLUE
color bands around them.
E/SPM-4-33

Figure 4-33. M81 969/14Plastic-type insertion/removal tool

4-00-00
Page37
BHT-ELEC-SPM

(3) Griptool,wire,and contact as aunitandguide (2) Slide tool down wire into the connector
contact into connectorthrough sealing grommet and throughthesealinggrommet and intotheinsertuntilthe
insert until contact is firmly seated. tool stops againstcontactshoulder.

(4) Release grip on wire and withdraw tool from (3) Gripwire andtoolas aunitandwithdrawwire,
the connector until it clears the grommet. Hold wire tool, and contactfrom theconnectorsimultaneously.
forwardwhile tool is being removed from wire.

(5) Gentlypull wireto ensurecontact issecurein 4-9. SOLDERLESS TERMINALS.


connector.
1. GENERAL. Electrical copper wires and cables
4. CONTACT REMOVAL FROM REAR RELEASE are terminated with crimp-typetinned copper terminal
CONNECTOR. lugs to provide an easy and reliable method of making
connections and disconnections
NOTE
Crimp-type terminal lugs are tinned copper with the
For unwired contacts, an additional tool may barrel preinsulated or uninsulated depending on
have to be used in conjunction with the application. The insulated types have a tube of
extraction tool to push the unwired contact polytetrafluoroethylene (TFE) or similar material
from the front after the locking tines have permanently affixed to the copperbarrel.
been released by the extraction tool in rear. This paragraph describes recommended methods for
terminatingcopper and aluminum wires, using solderless
a. Remove with tweezer-type installation tool. terminal lugs. It also describesrecommendedmethods for
permanentlyjoining(splicing)wire, usingsolderlesssplices.
(1) Selectcorrect removal tool. Figure 4-34 illustratesa typical solderlessterminal.
Figure 4-34
(2) Compress tweezerhandles to open tips and Hand, portable power, and stationary powertools are
placewire in groove. Reduce pressure on thehandles, available for crimping terminallugs. These tools crimp
allowing tips to close without nicking or cutting the thebarrel totheconductor, and simultaneously formthe
insulation. Slide tool down wire into connector until it insulation supportto the wire insulation. Use standard
stopsto release spring clip. (Class 1) tools; M22520/5-O1 tool with M22520/5-100

ON
dies for sizes 26 through 10 to crimpstandard copper
terminallugs M25036, M7928/1, and M7928/2.

DO NOT EXERT EXCESSIVE FORCE ON


RANGE OF WIRE SIZES
WIRE. IF CONTACT IS NOT EASILY
EXTRACTED, REMOVE TOOL AND TONGUE
REPEAT PROCEDURES. INSULATION
SUPPORT MFR
MARK
(3) To remove contact, pull on wire while
withdrawing tool.
b. Removal with single or double ended contact
removal tool.

(1) Selectcorrectremovaltool and placearound COLOR-CODED


the attached wire to be removed. INSULATION
WIRE
INSULATION STRIPPED
CAUTION WIRE

E/5PM-4-34
TO AVOID DAMAGE TO TOOL AND/OR
CONNECTOR, DO NOTTIP, SPREAD, OR
ROTATE TOOLWHILEIN CONNECTOR. Figure 4-34. Pre-insulated terminal — cutaway

4-00-00
Page 38
BHT-ELEC-SPM

2. TERMINALTYPES. Table 4-17. Color coding of copperterminallug


insulation
a. Copper wire, sizes 26 through 10 are terminated
with crimp preinsulated tinned copper terminal lugs. Figure
Figure Terminal lug Wire sizes
4-34 shows the insulation as a permanent part of the
4-34 insulationcolor usedwith
terminal lug extendingbeyondthe end ofthe barrel so that Yellow 26—24
it covers a portion of the wire insulation. This eliminates
using insulationsleeves. In addition, preinsulatedcopper Red 22—20,18
terminal lugs have a wire insulation grip barrel beneaththe Blue 16—14
insulation sleeve for additional termination mechanical
Yellow 12—10
strength. Pre-insulated crimp-type copper terminal lugs
accommodatemore than one copper wire size therefore
the insulation sleeve is color-coded. This facilitates the
identity of the wire sizes that canbe terminatedby each of
table 4-17
the terminal lugs. Refer to table 4-17 to identify the wire
sizes for each color code.

3. HIGH PRESSURE CRIMPING.

a. Wire sizes 8 through 2 require a power operated


crimp tool for terminations and splices. The following
proceduresare referencedtothe AMP Hydraulichand tool
figure4-35.
59975-1. Refer to figure 4-35 PLUNGER
(Pressure
Release).
(1) For die selection.

(a) Presshead latch and open crimp head as STRIKER


figure 4-36.
illustrated in figure 4-36.
SETSCREW

(b) Pull back die latchand rotate thumb knob


until desired die size appears. CAP

(c) Rotate thumbknobleftor right until die latch


lockswheel in desired position.

(d) Closehead. TRIGGER

Table 4-16. Wire strippingfor 2 through8 wire


RESERVOIR
HANDLE

WIRE WIRESTRIP LENGTH


MOVABLE
SIZE TERMINALS BUTT SPLICES LEVER
AND PARALLEL
SPLICES
(AWG) MIN MAX MIN MAX

8 21/64 23/64 13/32 7/16 E/SPM-4-35


6 25/64 27/64 15/32 1/2
4 29/64 31/64 17/32 9/16
2 33/64 35/64 19/32 5/8 Figure 4-35. AMP Hydraulic hand crimper

4-00-00
Page39
BHT-ELEC-SPM

(a) Centering ofcrimp(crimpmaybe off center


but notoff end of wire barrel).
PRESS HEAD

(b) Wire size being used matches wire range


stampedon die position and terminal.
(c) End of wire is flush with or extendsslightly
beyond end of wire barrel.

(d) Thereare no nicked or missing strands.


KNOB

TERMINAL PARALLELSPLICE BUTTSPLICE


PULL
THENTURNTHUMB

E'0 "B" EQUALS WIRE BARREL

EISPM-4-36

Figure 4-36. Hydraulic crimp head

(2) Crimping procedure. SPLICE WIRE BARREL


ISVISIBLE,
POSITION SEAM
(a) Stripwiretodimensions listed intable4-16. TOWARD MOVING
(Lower) DIE
(b) Insert terminal or splice in upper die as
figure 4-37.
shown in figure 4-37. EISPM-4-37

(c) Pump leveruntil lowerdie gripsterminal or Figure 4-37. Terminal or splicepositioning


splice.
4. HAND CRIMP TOOLS. M22520 hand crimping
toolshaveaself-locking ratchetwhichpreventsthetools
(d) Insert stripped wire into wire barrel of figure 39
fromopening until crimpiscomplete. Refertofigures39,
terminalor splice. 40, and 41 . This mechanism must never be
disassembled since it ensurespropercrimping closure.
(e) Pump leveruntil an audible pop is heardto These tools are checked by means of a gage for
indicate completion of crimp. assuranceof qualitycrimps. For good crimping results,
gaging is done before each series of crimping
operations. The M22520/5-O1 tool with M22520/5-100
(f) Retract movable die by pulling movable die ischeckedwith gage M22520/3-9 forNo. 12 and No.
leverslightlyoutward. Then,whilesqueezing trigger(to
1 0die closure, and M22520/3-1 0forthe No. 26through
actuate striker) compress levers to depress plunger.
No. 14 die closure. Gaging is done with thetools in the
Movable die will now retract.
fully closed position. Return tools which are out of
tolerance for repair. A hand crimping tool for high
(3) Inspectcrimpfor the following criteria: figure4-38.
temperature terminals is shown in figure 4-38.

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Page 40
BHT-ELEC-SPM

LOCATOR'

TERMINALBARREL RESTS AGAINST LOCATOR

TERMINALTONGUE SLIDES UNDER

INSULATION ADJUSTMENT LOCKING SCREW

INSULATION ADJUSTMENT PINS

FINISHEDCRIMP

CRIMPING COLOR

QUICKTAKE-UPTRIGGERS

COLOR CODEDHANDLES

EISPM-4-38

Figure 4-38. AMP Crimping tool T-head59250for hightemperature terminals

4-00-00
Page41
BHT-ELEC-SPM

INSERTED AND CRIMPED IN THE


TERMINALBARREL.

table 4-18.
a. Strip wireinsulation dimension given intable 4-18.

Table 4-18. Wire stripping lengths for small


copperterminallugs (insulation restriction)

Strip length
Wire size (In inches)
26 and 24 5/32 (3.97mm)
22 and 20 3/16 (4.76 mm)
18—14 1/4 (6.35 mm)
12 and 102 9/32 (7.14 mm)

b. Check tool with gage M22520/3-9forNo. 12-10die


closure and M22520/3-10for the No. 26-14 die closure.
Tools out of adjustment must be returned for repairs.

c. Insert terminallug, tonguefirst, into wire side of


tool crimping jaws, until terminal lug barrel buttsflush
againsttool stop on the locator.
d. Squeeze tool handles slowly until tool jaws hold
E/SPM-4-39
terminallug barrel firmly in place,butwithoutdenting it.
e. Insert strippedwire into terminallug barrel until
Figure 4-39. M22520 Series die type crimptool wire insulation butts flush against near end of wire
figure 4-40.
barrel. Referto figure 4-40.

INSULATION
f. Squeeze tool handlesuntil ratchet releases.
BARREL
6. INSPECTION OF CRIMPED CONNECTIONS.
Examinethe crimpedconnectioncarefullyforthe following:

L=J
DONOTUSE ANYCONNECTIONWHICH IS
FOUND DEFECTIVEAS A RESULTOF THE
VISUAL INSPECTION. CUT OFF
INSULATION
DEFECTIVE CONNECTION AND REMAKE
EISPM-4-40 USING A NEW TERMINAL LUG OR SPLICE.

Figure 4-40. Insertion of wire intoinsulated a. Indent centered on terminallug barrel or splice
terminal lug barrels.

LJ
b. Indentin line with barrel; not cracked.
5. CRIMPING PROCEDURE.
c. Terminal lugor splicebarrel notcracked, nicked,
bent or distorted.

d. Terminal lug or spliceinsulation notcracked.


e. Insulation grip crimped.
IF NOT PROPERLY STRIPPED, SOME OF
THE SMALLER GAGE THIN-WALL WIRE f. All wire strands are inside terminal lug conductor
INSULATION CAN BE INADVERTENTLY barrel.

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BHT-ELEC-SPM

DIE INSTALLATION
M22520/5-O1&/1O-O1 CRIMP TOOLS
1. Align groove in diewith key in crimping tool and
push shank of die into hole. See detail A. Close
handle to makesure dies are properly seatedand
locked in place.thetool is now ready for use.

DIE REMOVAL

1. Withcrimping tool handleopen, place dieremoval


tool against end of knock-out pad and tap gently.
Seedetail B.The diewill bereleasedfromthe lock
springandejected approximately1/16inch.It can DETAIL A
now be removedbyhand.

2. Close the crimping tool handle and slide the die


removal tool betweenthe die and tool body. See
detail C. Pull handle open witha snap action. The
die will be releasedfromthe lockspringand can
then be removedby hand.

DETAIL B
DETAIL C

NOTE

DIE REMOVAL TOOLPART NO. HX3-82 CAUTION


FURNISHED WITH CRIMPING TOOL. BEFORE ATTEMPTING TO REMOVE DIES
(IFDIEREMOVAL TOOLISNOTAVAIL- FROM TOOL, ASSURETHAT ALLLOCKPINS
ABLE, A ROD, 3/16 INCH X 1-3/4 HAVE BEEN REMOVED. FAILURE TO DO SO
INCHES (APPROX.) MAY BE USED.) MAY RESULT IN SERIOUS DAMAGETO THE
TOOL.

DIE SET IDENTIFICATION

(M22520/10) AND (M22520/5) DIE SETS

WIRE & CONTACT


CAVITY ACCOMMODATED
DESIGNATIONS

HEX DIE CONTACT DIE TERMINALDIE


1,2, OR 3 CAVITIES CONTACT SIZE12, 10, (SEEINSTRUCTIONS BELOW)
8,4 & 0

ACTUAL
SIZE

HX3 (M2252o11o) HX4 (M22520/5)


DIE SET DIE SET
E/SPM-4-411

Figure 4-41. Crimp tools M22520/5-0land /10-01 (Sheet 1 of 2)

4-00-00
Page43
BHT-ELEC-SPM

DIES FOR CRIMPING


TERMiNALLUGS, SPLICESAND ENDCAPS

1. Withdies open (see detail A), place termi-


nal, splice or end cap in proper cavity.
Sizes are stamped beloweach cavityon
side of die.
2. Locate terminal, splice or end cap with
locator (see detail B). Terminal should
locate with tonguebetween the arms of
the locator. Splice is centeredwith notch
in spliceresting on the locator. End caps
locate against the face of the locator.
TERMINAL Insertwireto properdepth.

OR 3. Close handle oftooluntildiesareclosed


SPLICE
and ratchetreleases. The crimp is now
complete. (see detail C.)
OR

ENDCAP DETAIL A

WIRE

11IIll!tIiIiliiIII!llhIIIffI!I!IIIIff1 END

DETAILB E/SPM-4-41-2

Figure 4-41. Crimptools M22520/5-01 and /10-01 (Sheet 2)

4-00-00
Page44
BHT-ELEC-SPM

4-10. SOLDERLESS SPLICES. b. Checkcrimptoolwith applicable gagefromtable


4-19. Return tools whichare out of tolerancefor repair.
Electrical copper wire may be spliced using C. Strip 5/16 to 11/32 inch of insulation from wires.
environmental or insulated splices. This paragraph
Ensurea gap of 1/32 to 1/16 inch exists between wire
provides the recommended procedures, toolsand parts insulation and crimp barrel.
necessary to performthis operation.
d. Position splicecrimp barrel in applicable die of
1. RESTRICTIONS.
the M22520/5-O1 or M22520/10-01 crimptool, so that
oneend ofcrimpbarrel buttsagainst crimplocator. Lock
a. There shall be not more than one splice in any in place by partially closing handles without denting
onewire segmentbetween anytwo connectors or other crimp barrel.
disconnect points.
e. Insert wire fully into crimp barrel and crimp by
closing handles until ratchetreleases.
b. Splices in bundles must be staggered, and shall
not increase size of bundle so as to prevent bundle from
f. Before completing the splice, slide the sealing
fitting into itsdesignated place orcause congestionwhich sleeveback over one of the wires.
figure 4-42.
will adversely affectmaintenance. Refer to figure 4-42.

g. Reverse the position of crimpbarrel in crimptool


c. Splices shall not be used to salvage scrap die. The attachedwire will extend through slot in crimp
lengths of wire. locator.

d. Splices shall not be used within 12 inches of a h. Lock crimp barrel in place by partially closing
termination device exceptas allowed in stepe. handleswithoutdentingcrimp barrel.

e. Splices may be used within 12 inches of a i. Insert wire fully into crimp barrel and crimp by
terminating devicewhen attaching to pigtail spare lead closing handles until ratchet releases.
ofaconnector, ortosplicemultiplewirestoasinglewire,
or to adjustwire sizes so that they are compatible with
contactcrimp barrel sizes.
I WARNING 1
2. ENVIRONMENTAL RESISTANT SPLICES.
Environmental resistant splicesare permanent splices DO NOT USE HEAT GUNS WITH
having a heat shrinkable insulating sleeve and meltable ELECTRIC MOTORS WHEN WORKING
environmental seals to protect the splice against ON HELICOPTERS THAT HAVE NOT
corrosion, degradation over time, and harsh BEEN DEFUELED AND PURGED FOR
environments. EXTENSIVE MAINTENANCE.

3. CRIMPING PROCEDURES. j. Slide sealingsleeve over crimp barrel, center it,


and shrinkwith hot airheater(HT-900). Heatthe middle
firstto lock sleevein place;then heat ends until sealing
a. Select the correct environmental splice, crimp ringsmelt and ooze out aroundwire. To ensurea good
tool, and die from table4-19. seal, allowspliceto cool beforehandling.

NOTE 4. PRE-INSULATED SPLICES. Pre-insulated


permanent coppersplices are used tojoin small copper
wires,sizes26through 10. Each splicesizecanbe used
Gaging isdonewiththetoolinthefully closed for morethan one wire size. Splicesare color coded in
position. Refer to crimp tool manufacture the same manner as pre-insulated small copper
manual for gaging procedures. terminallugs.

4-00-00
Page45
BHT-ELEC-SPM

E/SPM-4-42

Figure 4-42. Staggered splicesin wire bundle


Table 4-19. Environmental splicesand associated crimp tools

Dies
Color Splice Wire
Code Part No. Sizes M22520/5-01 Tool M22520/10-01 Tool Gauge
Red M81824/1-1 26—20 M22520/5-103 M22520/1 0-104 M22520/3-14
Blue M81824/1-2 20— 16 M22520/5-103 M22520/1 0-104 M22520/3-13
Yellow M81824/1-3 16— 12 M22520/5-102 M22520/1 0-103 M22520/3-12
figure 4-44.
NOTE: Raychem AD-i377 crimp tool mayalso be used. See figure 4-44.

SEALING SLEEVE METALCRIMP SPLICE

WIRE STOP

5. CRIMPING PROCEDURE. Crimp pre-insulated


CRIMP BARREL copper splices in the26 to 14 wire size rangewith the
M590413tool and the 12 and 10 wire sizes with the
M53316tool as follows:
NOTE
Pre-insulated splices may be crimpedwith
the M22520/5 or /10 tool as described
previously.
a. Check tool for correct adjustment. Tools out of
adjustment must be returnedto the manufacturer for
repairs.
table4-20.
b. Strip wire to length givenin table 4-20.
c. Forthe M590413tool, with tool handlesfully open,
setwire size selector knob to the proper position for wire
size being crimped. Slide terminal lug locatordown below
CRIMP LOCATOR CRIMP TOOLJAWS figure4-45.
diesurfaceintofully retractedposition. Referto figure 4-45.
FortheM525181 splice,slidethe MS9041 3-2 splice locator
E/SPM-4-43 back into retracted position, and insert splice into tool so
thatthe locatingshoulderon side of spliceto be crimped is
Figure 4-43. Locating sealed splicecrimp barrel in the space betweenthe two crimpingdies and insulation
in crimping dies barrel on this side of splice protrudesfrom wire side of tool.

4-00-00
Page46
BHT-ELEC-SPM

Forthe M7928/3splice, slide the MS9041 3-2 locator back the locatorgroove in the splice,and the insulationbarrel on
into retracted position, and insert the splice into the the side ofthe splice to be crimped protrudesfrom thewire
stationarydie so thatthe MS90413-2 locatorfinger fits into side of the tool.

Table 4-20. Strippinglengths— splices

Wire Size Stripping Length (Inches)


26—24 5/32
22—14 7/32
12—10 5/16

d. For the M53316 tool, one locator is used for both where the ambient temperature does not exceed 185°F
terminal lugs and M7928/3 splices. For MS25181 splice, (85°C). MIL-S-23586silicone rubbercompound is used to
insert splice intothe tool so that locating shoulder on the seal connectors located in areas where the ambient
side ofspliceto becrimped isinthespace betweenthetwo temperature is 185 to 448°F (85 to 232°C). MIL-24041
crimpingdies.Theinsulationbarrelon this side ofthe splice potting compound is resistantto fuel and oil and can be
used in areas where the ambient temperature is up to
protrudes from wire side of the tool. For M7928/3 splice,
insert splice into the movabledie so that locatoron the tool 258°F (125°C).
fits intothe groove in the splice.Theinsulationbarrelon the 3. GENERAL PRECAUTIONS. Potting compound
side ofthe splice to becrimped protrudesfromwire side of as received fromthemanufacturer isa two-partkit. The
the tool. containers must not be separated until used. The kits
are properlyweighed and require no furtherweighing
e. Squeeze tool handles slowly until tool jaws hold when mixing at least one kit at a time. Follow the
splice barrel firmly in place, but without dentingthe barrel. manufacturer's instructions carefullywhen mixing the
basecompound and accelerator if both are in separate
I. Insert stripped wire into splice barrel which containers. Substitution, partial mixing, or use of
protrudes from wire side of splice until strippedend of incorrectproportions of compound and acceleratormay
wire butts against the stop in the center of the splice. produce a sealantwith inferiorproperties.
This canbe seenthrough the spliceinspection window. a. Makesure that the entire amountof accelerator
is mixed into the entire amountof base. Any changeS in
g. Crimpby closing tool handles. Tool will notopen
until the full crimping cycle has been completed. catalystratiowill effectproperties ofthe sealant and may
also affectpotlife, reversion resistance, and hardness
h. After crimping, checkthat wire end is still visible of the cured compound. Do not mix base compounds
with accelerator componentsofdifferentbatchnumbers
through the inspection window. because substandard electrical properties may result.
i. Reverse position of splice in crimping tool (or b. Small quantitiesof mix (less than 1 kit) must be
location of crimping tool on splice) and repeatsteps b. mixed 100parts(byweight)ofbasematerials to 12parts
through h. to crimpwire intoother side of splice. (by weight) of accelerator.

4-11. CONNECTOR POTTING. I WARNING I


1. GENERAL. Sealingcompound is used to moisture SEALANT CONTAINS SMALL QUANTITIES
proof and reinforcethe wiring, connectedto the backs of OF FLAMMABLE SOLVENTS AND
electrical connectors, against failure caused by vibration RELEASES FLAMMABLE BYPRODUCTS
and lateral pressurewhich fatigue the wire at the solder DURING MIXING AND CURING. OBSERVE
cup. The sealing compound protects electric connectors ADEQUATE VENTILATION AND FIRE
from corrosion, contamination, and arcing by excluding PROTECTION DURING MIXING AND/OR
moisture, metallic particles, and helicopter liquids. This CURING.
section describes the MIL-S-8516C (EC-067) potting
4. PREPARATION OF PARTS.
compound used on helicopter electric connectors, and
gives instructionfor preparingand storingthe compound. a. The surface of the connectors to be protected
2. DESCRIPTION. Sealing compound in accordance with sealermustbe freefrom oil, grease, dirt, etc.Clean
EC-028 Clean
thoroughly with aliphatic naphtha (EC-028).
with military specification MIL-S-8516A is a two-part
surfaces bywipingdrywithaclean,lint-freecotton cloth.
polysuffidesynthetic rubber compound, consisting of a
base and anaccelerator(curingagent),packagedtogether. b. Apply to cleaned area a mixtureof equal parts (by
Thiscompoundis usedtoseal connectorslocatedin areas EC-064 and Tetrahydrofuran(EC-065).
volume)of primer (EC-064) EC-065

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Page47
BHT-ELEC-SPM

DIE 3 (YELLOW)

DIE 2 (BLUE)
DIE I (RED)

SPLICEMUST BUTT AGAINST LOCATOR

CRIMP TOOLAD-l377
(RAYCHEM)

cL
RAYCHEM COLOR
SPLICES

ccc
PARTNO. CODE

cTp D-436-36 RED

cct=c iô
D-436-37 BLUE

ci D43638 YELLOW

D-436-42 BLUE

ct1Z0
( D-436-43 YELLOW

IIO
LO D-436-26 NONE

EISPM-4-44

Figure 4-44. RayChemenvironmental butt splices

4-00-00
Page48
BHT-ELEC-SPM

STATIONARY

2 SPLICE LOCATOR

WIRE SIDE

WIRE TO BE CRIMPED

TERMINALLUG LOCATOR RETRACTED FORIN-LINE SPLICES


M525181

E/SPM-4-45

Figure 4-45. Locating MS25181 splice in MS90413-2 crimpingtool

4-00-00
Page49
BHT-ELEC-SPM

5. PREPARATIONOF SEALANT.
Equipment and Materials Required

Equipment
1. Automatic mixer
2. Pressure gun and accessories
PylesNo. 950 with variouscartridges and tips or Senco No. 250 with various cartridges and tips.
3. Freezercapableof maintaining a temperature of —30°F(—34.4°C)
4. Heatgun that provides heat of up to 120°F (45.9°C)
5. Centrifugecapable of operating at 2000 RPM
Material
1. EC-028
Aliphatic Naphtha (EC-028)
EC-081
2. Methyl-Ethyl-Ketone (MEK) (EC-081)
EC-062
3. Strippable plasticcoating compound (Hot dipping) (EC-062)
4. MIL-S-8516 (PottingCompound) (EC-067)

To preparesealantproceed as follows:

I WARNING 1

THE ACCELERATOR CONTAINS TOXIC


COMPOUNDS. WEAR RUBBER OR
POLYETHYLENEGLOVES TO AVOID SKIN
CONTACT, AND CLEAN HANDS
PRESS AGAINST
THOROUGHLY IF MATERIALS CONTACT SIDETO FULLY
SKIN. DISTRIBUTE
ACCELERATOR
a. Slowly stiracceleratorto asmooth, creamy paste.
b. Agitate the sealer (MIL-S-8516) for at least two
figure 4-46.
minutes by hand stirring. Referto figure 4-46.

C. Weighoutthe desired amountof sealer.


d. Weigh out 12 parts of accelerator for each 100
parts of sealer used.
e. Add the required quantity of accelerator to the
basematerial and thoroughly agitate until no accelerator
streaks or traces of unmixed sealer are visible. This
usually requires approximately five minutes. The sealer
mustassume a uniform pink or tan color.
f. To ensure that material is adequately mixed,
spread a thin film on white paper and examineclosely
for accelerator or sealerstreaks.
E/SPM-4-46
g. The working life of the accelerated sealer is
approximately90 minutes at 36 to 75°F (24 to 27°C).
Longerworking life maybe obtained by cooling the sealer
to 5 to 60°F (5 to 15.5°C) just prior to addition of
accelerator. Figure 4-46. Hand mixingpotting compound

4-00-00
Page50
BHT-ELEC-SPM

h. The accelerated sealer mayalso be stored, for


periods of from 24 to 36 hours, by cooling quickly
immediately after acceleration and keeping at a
temperature of —20°F(—29°C).

i. After storing at low temperature, the accelerated


sealer may be thawed out by blowing compressedair on
the outside of the container.Do not raise the temperature
ofthe sealer by heatingor by blowingairinto thecontainer.

j. If the mixed compound is not to be used


immediately, store it as directedin paragraph
paragraph 7
7.

k. Sealants havingan application time of one hour


or less shall be hand mixed on the job.

6. MECHANICAL MIXING PROCEDURE. Mechanical


mixing should be done at 60°F (15°C) or lowerto prolong
theworking life ofthe sealant.The procedureis as follows:

a. Hand mix the accelerator, or use paint shaker


vibrating machine if available. Shake for five to seven
minutes.

b. If the base material is packaged in a metal can,


cut off the topof thecontainerusing a mechanical can
opener. This should leave a smooth wall without any
burr at thetop of the can.

c. Clamp base material containersecurely to drill


pressgeared to 50 RPM minimum to90RPM maximum.
Insert a mixing paddle fashioned from a drill rod and
figure4-47.
4-47. EISPM-4-47
wire. Referto figure

d. Start drill press motor and slowly lower mixing


paddle intothe basecompound to combine anymaterial
which maysettle out.
Figure 4-47. Mixing paddle for potting compound

e. Scrape all accelerator from its container and 7. STORAGE OF UNMIXED SEALING COMPOUND.
placeit inthebase material. Startdrillpressmotoragain Store base compound and accelerator in a cool place,
and mix slowly for approximately two minutes. Stop preferably under refrigeration. Shelf life for MIL-S-8516
machine, raise paddle, and scrape containerwalls as and MIL-S-23586 compounds is approximately six
clean as possible. Start the drill press and lower the months when stored below 73°F (23°C) and can be
mixing paddle again and continue mixing for an extendedto one year whenstored at45°F (7°C)orbelow.
additional three minutes.

f. Make thin spread of sealant on white paper as


described in paragraph 5 If necessary, continue mixing
paragraph 5.
in two-minutecycles followed by paper test until no DO NOT STORE SEALING COMPOUND
traces of unmixed material are visible. The sealant is AT TEMPERATURESABOVE 26°C. KEEP
then ready for use. BASE COMPOUND AND ACCELERATOR
TOGETHER IN THE CARTON AS
FURNISHED. NOTE MANUFACTURING
g. Ifthemixed compound is notto be usedat once, DATE STAMPED ON CARTON AND USE
store in accordance with instructions in paragraph 8
paragraph 8. OLDEST MATERIALFIRST.

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Page51
BHT-ELEC-SPM

than MIL-S-8516 compounds after quickfreezing.The


CAUTION storage life of quick-frozen MIL-S-23586 potting
compounds is usually less than three weeksat —40° F
(—40°C). In general, extended storageof mixed, frozen
DO NOT USE SEALING COMPOUND
potting compound shortenspot life and cure time after
WHICH HAS EXCEEDED NORMAL SHELF
thawing.The methodto determine whetherthe frozen
LIFE UNLESS IT HAS BEEN TESTED BY
compound is suitablefor use is to thaw the material. If
AN APPROPRIATE LABORATORY TO it isstill pourable and hassufficient potlife remaining for
EVALUATE ITS ACCEPTABILITY FOR
application purposes it can be considered satisfactory.
FURTHER USE. Mixedcompound intubesshouldnotbe storedin dryice
sincethe material will absorbcarbondioxideand cause
8. STORAGE OF MIXED SEALING COMPOUND. sponging or porosity.
Mixed MIL-S-8516 potting compound can be stored in
cartridgetubesfor periods of 30to 60days provided the 9. APPLICATION OF SEALER. Apply the properly
filled tubes are quick-frozen immediately after mixing mixed, accelerated sealerto the connectorshell with a
and are stored at—40°F(—40°C). Quick-freezing of the spatula,putty knifeor flow gun. A flow tip small enough
filled tubes is done by immersing for five minutes in to reach solderedwire connections at base of plug is
O-T-620 trichloroethane cooled with solid BB-C-104 recommended. Applythe accelerated sealerso that no
carbon dioxideto temperatures below—49°F (—45°C). large entrappedair bubblesremain which result in loss
Freezing by slowcoolingair is not recommended since of strengthand electrical properties. The sealingof the
it reduces the mixed storagelife. Mixed MIL-S-23586 connectors must protect the electrical wiring
potting compounds, usually have shorter storage life connections completely, as shown figure 4-48.
in figure 4-48.

POTTING COMPOUND
DISPENSER FILLING
CONNECTOR

POTTING
MOLD

FILLING WITH COMPOUND CURING

E/SPM-4-48

Figure 4-48. Fillingand curingof potting

4-00-00
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BHT-ELEC-SPM

10. CURING OF SEALER. f. Roughen all surfaces of the original sealant


adjacent to the stripped area over at least one inch of
a. Curethe accelerated sealerforat least24 hours their length, usinga micarta scraperor cleanhardwood.
at(22to27° C) beforethe connectors are installed in the Take care nottoscratchthesurrounding metal surfaces.
electrical system. The curing time will be shortened if
temperatures are higher and will be lengthened if 12. CLEANING PRIOR TO RESEALING.
temperatures are lower.

NOTE
I WARNING I
Remove excess sealer from equipment
before it cures, using tolueneTT-T548. TO PREVENT INJURY TO SKIN, HEAVY
RUBBER GLOVES MUSTBE WORN.
b. When a finish,such as primer or lacquer, has been
removedduringstripping, refinish the area aroundthe new
sealantwith the same finish as was used originally. a. Remove all dirt and foreign matter which may
have accumulated duringstripping operations andother
11. REMOVAL OF SEALANT. structuralrepairs.

b. Scrubthe strippedareaand surroundings with a


I WARNING clean cloth dampened with methylene chloride
EC-027 Apply the cloth to only a small
MIL-M-6998 (EC-027).
TO PREVENTINJURY TO HANDS, HEAVY area at a time and change thecloth frequently.
RUBBER GLOVES MUST BE WORN
DURINGTHEFOLLOWINGPROCEDURES. C. Wipe the area thoroughly with a clean cloth
EC-082 Apply the cloth to
dampened with butyl acetate (EC-082).
a. Cut away as much sealant as possible around only a small area at a time, and wipe off with a clean dry
the repairarea, using a sharp micarta scraper. Do not cloth before the butyl acetate dries. Change both cloths
usea tool made of metal. frequently.

b. Mask off the area surrounding the scraped d. Wipe the whole area under repair with a clean dry
sealantwithfabric-backed masking tape, (EC-049) and cloth.
similarlymaskany areas where the ensuing application
of strippermaysplash or drip.
13. PREPARATION OF CONNECTORS.
C. EC-047 to the scraped sealant as
Apply stripper (EC-047)
as
heavily possible without running or dripping. A micarta a. MS31 00, 3106, and 3108 connectors— Assemble
scraper pushed under the sealantwill acceleratethe action the backshell to the connector.Build up the back shell, if
of the stripper.Wipe off immediatelyanystripper that falls EC-068 to a depth of
necessary, withthe cellophanetape (EC-068)
accidentallyon unmaskedsurroundingareas with a clean at least 0.25 inch past the solder pots.
dry cloth, and mark its position for cleaning later, refer to
paragraph
paragraph4-11,
4-11, step 12. b. MS3102connectors— All MS31 02 connectorsshall
have a fittingsleeve ofcellophanetapeoverthebackbarrel
d. At 10 minute intervals, remove the stripperand beforepotting.Tapesleeveshall besufficientheightto allow
any loosened sealant with micarta scraper, and applya pottingto a depth of at least 0.25 inch pastthe solder pots.
fresh quantityof stripper. Do not allowthe stripperto dry Remove tape afterpotting hascured.
out onthesealer. Repeat this cycleofoperations until all
the sealant has been removed. If there is any finish,
such as primeror lacquer, underthesealant, continue c. Other connectors— MS3103, 3110, 3112, 3114,
stripping to bare metal. 3116, and 25183connectorsare supplied with separate
plastic polyethylene molds. They shall be used in
e. Remove all masking tape. accordance with manufacturer's instructions.

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14. PREPARATION OF UNETCHED TEFLON WIRE. d. Allowthe etchant to remain on the wire insulation
until the insulationbecomes dark (normally 15 seconds to
1 minute).

I WARNING I
e. Using a clean cloth saturated with naphtha or
MEKclean etched area.
ETCHANT SOLUTION EC-063
(EC-063) IS
FLAMMABLE AND MUST NOT BE f. Peel strippable plastic coating compound from
EXPOSED TO OPEN FLAME. RUBBER connectorpin end of wire.
GLOVES AND SAFETY GOGGLES MUST
BE WORN. ANY ETCHING SOLUTION g. Place unused etchant in suitablecontainer fro
SPILLED ON SKIN MUST BE IMMEDIATELY disposal.
FLUSHED OFF WITH RUNNING WATER.
ETCHANTISTOXIC IFTAKEN INTERNALLY, 15. APPLICATION OF POTTING COMPOUND.
DUE TO CAUSTIC SODA FORMED ON Potted-type connectors differfrom the standard type by
REACTION WITH MOISTURE. IF having a shorterbodyshell. Thepotting compound is to
ACCIDENTALLYSWALLOWED, DRINK MILK be appliedas follows:
OR WATER. DO NOT INDUCE VOMITING.
OBTAIN IMMEDIATEMEDICALSERVICE.
I WARNINGj
a. Before potting, teflon wires not pre-etched shall SEALANT CONTAINS SMALL QUANTITIES
be treated as follows: OF FLAMMABLE SOLVENTS AND
RELEASES FLAMMABLE BYPRODUCTS
(1) Roughen (very lightly) the area to be etched DURING MIXING AND CURING. OBSERVE
EC-092 Do
using 600 grit sandpaper or Scotchbrite (EC-092). ADEQUATE VENTILATION AND FIRE
notsand through braids on outer insulation. PROTECTION DURING MIXING AND/OR
CURING.
(2) Clean roughened area with aliphatic naphtha NOTE
EC-028 MEK (EC-081).
(EC-028), EC-081 Wipe dry before solvent

LJ
evaporates. Complete potting within two hours after
cleaning.

a. Slide the plastic mold over the wire bundle if


applicable or ensure tape sleeve is in place.

THE ETCHANT CONTAINS INGREDIENTS b. Ensure all wires are soldered or crimped to

LJ
THAT ARE HARMFUL TO METAL connector pins and all connector pins are inserted in
COMPONENTS.THEREFORE CARE MUST connector.
BE TAKEN TO ENSURE ETCHANT DOES
NOT COME IN CONTACT WITH WIRE,
SOLDER, SOLDER PIN, OR CONNECTOR.
ANY ETCHANT SPILLED ON CONNECTOR
MUST BE IMMEDIATELYWIPEDOFF USING POLYTETRAFLUORETHYLENE(TFE) AND
A CLEAN CLOTH SATURATED WITH FLUORINATED ETHYLENE PROPYLENE
EC-028 OR MEK (EC-081).
NAPHTHA(EC-028), EC-081 (FEP) INSULATED WIRES REQUIRE
SPECIAL PREPARATION PRIOR TO
POTTING. REFER TO PARAGRAPH 4-11,
b. Dip wire connecter end into (hot dipping) STEP 14.
EC-062 deep
strippable plastic coating compound (EC-062)
to
enough encapsulate solderpin,solder, and barewire. c. Install spare wires on all unused pins. Use the
largestgage wire that would normallybe attachedto each
EC-063 ontothe
c. Dip, pour, orswabthe etchant(EC-063) contact. Spare wires are approximately9 inches long.
arearequired forpotting.Thisareashall notexceed0.25
inch fromendofinsulation to aminimum of0.75inch and d. Insulate spare wires using MS25274 end caps.
a maximum of 1.5 inch onto insulation. Referto table4-21 to determine end cap part number.

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e. Clean the complete connector assembly by a resilient surface or vibrantmechanicallyto help flow
scraping off rosin and then brush vigorously in new compound into all spaces and to releasetrapped air.
unused trichloroethane.

f. Insert pottinggun nozzle between centerwiresso i. Immediatelyafterfillingconnector,tie wires together


that sealantwill flow around contacts. looselyabout 6in. fromthe connector.Make sure that wires
are centrally located in the connectorso that each wire is
g. Maintaintip ofnozzleslightlybelowswell of material completelysurroundedby pottingcompound.Suspendthe
level while movingthe nozzle up as connectorfills. assembly so that the potting material remains level, as
figure 4-48
shown in figure 4-48 and allow to aircure for at least 1 1/2
h. To prevent air entrapment,pat downcompound, if hours at 75°F (24°C) without any movement. Make sure
necessary, with a 1 inch dowel.Tapconnectorassemblyon that the tie is applied afterpotting.

Table 4-21. Wire end caps

MS NUMBER COLOR WIRESIZE


M25274-1 Yellow 26—24
M25274-1 Red 22—18
M25274-1 Blue 16—14
M25274-1 Yellow 12— 10

4-12. SEMICONDUCTOR MAINTENANCE.


I WARNING I In solid statecircuitsthe impedance's and resistance's
encountered are of much lower values than those
THE ACCELERATORCONTAINS A TOXIC encountered in earlier state of the arts circuitry.
LEAD COMPOUND. AVOID EXCESSIVE Therefore, when measuring values of capacitors an
SKIN CONTACT. CLEAN HANDS instrument accurate in the high ranges must be
THOROUGHLY AFTER USING. WEAR
employed. Capacitorpolarity must be observedwhen
GLOVES.
measuring resistance. Usually more accurate
measurements can be obtained if the semiconductor
are removed from the circuit.
I WARN ING1
1. SEMICONDUCTOR TEST EQUIPMENT. Damage
SEALANT CONTAINS SMALL QUANTITIES to semiconductors by test equipment is usually the
OF FLAMMABLE SOLVENTS AND result of accidentally applying too much current or
RELEASES FLAMMABLE BYPRODUCTS voltage to the elements. Common causes of damage
DURING MIXING AND CURING. OBSERVE from test equipment are discussed in the following
ADEQUATE VENTILATION AND FIRE paragraph.
PROTECTION DURING MIXING AND/OR a. Test equipment with transformerless power
CURING.
supplies is one source of high current. However, this
type of test equipment can be used by employing an
j. Carefully placeassembly, still suspended, intoa isolation transformer in the AC power line.
drying oven for3to4 hours at 100 °F (38°C), or aircure
at 75°F (24°C)for 24 hours. b. It is possible to damage semiconductors from
line current, even though the test equipment has a
NOTE power transformer in the power supply, if the test
equipment is provided with a line filter. This filter may
Full cure with maximum electrical functionas avoltagedividerandapplyhalfvoltage tothe
characteristics is not achieved until 24 hours semiconductor. To eliminatethis condition, connect a
after potting. Do not perform electrical ground wire from the test equipment chassis to the
insulation resistance tests until this period chassisof theequipment undertest beforemaking any
haspassed. other connections.

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BHT-ELEC.SPM

C. Anothercause of semiconductors damage is a TRANSISTOR.IFASHORT CIRCUITEXISTS


multimeter that requires excessive current to provide IN THE CIRCUIT, PUTTING IN ANOTHER
adequate indications. Multimeters with sensitivities of TRANSISTOR WILL MOST LIKELY RESULT
less than 20,000ohms-per-volt should not be used on IN BURNINGOUTTHE NEW COMPONENT.
semiconductors as they could cause damage. If more DO NOT DEPEND UPON FUSES TO
than one milliampere is drawnon any range, this range PROTECTTRANSISTORS.
can not be safely used on small semiconductors.
C. Always check the value of the bias resistors in
d. When using a battery-type powersupply, always series with the various elements. A transistoris very
usefreshbatteriesofthe propervalue.Makecertain that sensitive to improper bias voltage; therefore,a short or
the polarity of the power supply is correct for the open circuit in the bias resistance may damage the
equipmentundertest.Donotusepowersupplieshaving transistor.
poorvoltage regulation
3. REPLACING SEMICONDUCTORS. Neverremove
2. TRANSISTOR TESTING. A transistor checker orreplace asemiconductor with a supply voltageturned
should be used to properly evaluate transistors. If a on. Transients thus produced may damage the
transistor tester is not available, a good multimeter may semiconductor or others remaining in the circuit. If a
be used. Make sure that the multimeter meets the semiconductor is to be evaluated in an external test
requirements outlined in the preceding paragraph. circuit, be sure that no more voltage is applied to the
semiconductor than normallyis used in the circuitfrom
a. To checka PNP transistor, connectthe positive which it came.
lead of the multimeter to the baseof thetransistorand
the negative lead to the emitter. Generally, a resistance a. Use onlyalow heatsoldering iron wheninstalling
or removing soldered-in parts.
reading of 50,000 ohms or more should be obtained.
Reconnect the multimeter with the negative leadto the
base. With positive lead connectedto the emitter or b. When installing or removing a soldered-in
collectora resistance value of 500 ohmsor less should semiconductor grasp the lead to which heat is applied
be obtained. between solder joint and the semiconductor with
long-nosed pliers. This will dissipate someof the heat
that would otherwise conduct into the semiconductor
b. Similartests canbe made on an NPNtransistor.
from the soldering iron. Make certain that all wires
With the negative lead of the multimeterconnected to
the base of the transistor the value of resistance soldered to semiconductor terminals have first been
between the baseand the collectoror emittershouldbe properlytinnedso thatthe necessary connection can be
made quickly. Excessive heat will permanently damage
high. Withthe positive lead ofthe multimeter connected
to the base, the value of resistance between the a semiconductor.
collectoror emittershouldbe low. If theseresults are not
C. In some cases, powertransistorsare mounted
obtained, thetransistoris probablydefective andshould
be replaced. on heat sinks that are designed to dissipate heat away
from them. In some powercircuits, thetransistormust
also be insulated from the ground. This insulating is
A U TION accomplished by means of an insulating washermade
of mica. When replacing transistors mounted in this
manner, be sure that the insulating washers are
IF A TRANSISTOR IS FOUND TO BE replaced in properorder. After thetransistoris mounted,
DEFECTIVE, MAKE CERTAIN THAT THE and before making any connections, check from the
CIRCUIT IS IN GOOD OPERATINGORDER caseof the transistortogroundwith a multimeter to see
BEFORE INSTALLING A REPLACEMENT that the insulation is effective.

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