NAVAIR 01-1A-505 (USAF) T.0, 1-18-14 TABLE OF CONTENTS Tae 1 [IVFRODUCTION Source of Information Arrangement of Material Revisions 11, General 15. Purpose of Manual 17. 19. Scope 112, Intended Use 16. ba TH [WIRE AND CABLE PREPARATION M1. Introduction 24, — Reference Specifications and Drawings 25° Definitions 246. Cutting Wire and Cable 213, Identifying Wise and Cable 236. Strpping Wire and Cable 2.47. Tinning Copper Wire and Cable 255) ielded Cable Verminating S m NLRAL PURPOSE CONNECTORS 375. 376. 589. 3.93, 399. 3-104, x Introduction Reference Specifications Drawings, and Documents Description General Practices Soldering Crimp Contacts Shielded Connections AN/MS Connectors Disassembly, Reassenibly, and Installation of Connectors... Installation of MS30S7 Series Connector Cable Clamps Interchangeability of US/AN and UK/BMS Connectors Miniature MS Connectors MIL-C-81511 Connectors MIL-C-83723 Connectors MIL-C-38999 Connectors MIL-C-81659 Connectors Special Purpose Connectors v ONNECTORS AND CABLING Introduction Reference Specifications and Drawings Description General Precautions and Procedures Soldering Coaxial Cable to RE Connectors BNC Seties Connectors © Series Connectors Page Section 361 361 34 3-80. 3.84 3.90 3-106 vil 44 44 at 46 47 4it Tie 4-22. TIN Series Connectors 426. _N Series Connectors 4:30. Pulse Series Connectors 434. TNC Series Connectors 437. $C Connectors ‘ 4.38, Miniature RF Connectors 441, Subminiature RF Connectors ‘SOLDERLESS TERMINATIONS AND SPLICES $1. Introduction 5.4. Reference Specifications, Drawings, and Documents $5. Description 5-7. Types and Styles of Terminals 5.8, Terminating Small Copper Wires (Sizes No. 26 through No. 10) with Preinsulated Terminal Lugs 5.18, Terminating Large Copper Wires (Sizes No.8 through No. 4/0). 5.32. High Temperature Terminal Lugs 542. Terminating Aluminum Wire 50, Splicing Sinall Copper Wires (izes No. 26 through No. 10) 5.54. Splicing Large Copper Wires (Sires No. 8 through No. 4/0) 5.62. Inspection of Crimped Connections ‘TAPER PIN TERMINATIONS ot 65. 6-10. 614 6-17 Introduction Taper Pin Tools Crimping Procedures Insertion of Taper Pins Extraction of Taper Pins ‘THERMOCOUPLE WIRE SOLDERING AND INSTALLATION 7-1. Introduction 75. Reference Specifications and Drawings 7.6. Description 7-10. Definitions TAL. Thermocouple Wire Preparation 715, Hard Soldering Thermocouple Wire 728. Soft Soldering Thermocouple Wire 7-31. Thermocouple Wiring Installation. Page 413 416 419 4.24 4.26 426 428 s4 5.5 5.24 5.27 5.29 532 5.35NAVAIR 01-14-5605 (USAF) T.0. 1-18-14 Table of Contents Section Tite VIIL_ BONDING AND GROUNDING XL xl 841. Introduction 84. Reference Specifications’ 85. Definitions .... 86. General Precautions and Procedures 8-7. Selection of Hardware . 8-13. Preparation of Bonding or Grounding Surfaces 8:17. Methods of Bonding or Grounding . 8.23. Bonding and Grounding Jumpers 8:26. Testing Bonds and Grounds 8.29. Refinishing SOLDERING 941, Introduction 9.5. Reference Specifications. and Standards... 2.0.0. ceecceee 9.6. Definitions and Descriptions 9-14, Heat Application Methods 919. Preparation and Maintenance of Soldering Iron ........... 9-24. Soldering Operation ~ General Precautions and Procedures... 941. Inspecting a Finished Solder Joint ELECTRIC CONNECTOR SEALING 10-1. Introduction 104) Reference Speciation 105. Description . 5 106. General Precautions... 0.12.1 10-10. Preparation of Sealing Compound 10-45. Storage of Sealing Compound 10-19. Preparation of Fluorocarbon Insulated Wire for Potting 10-20. Special Instructions for Use of MIL-M-24041 Molding and Potting Compound CONDUIT FABRICATION I-L. Introduction 11.5, Reference Specifications and Drawings 116. Metallic Conduit 11-19. Nonmetallic Conduit - 11-22. Use of Heat Shrinkable Tubing SPECIAL ELECTRICAL WIRING HARNESSES 124. Introduction 124. Reference Specifications 125. Molded Hard Harness 12-16. Compact Wire Bundles 12.49. Rework and Repair of ‘Compact Wire Bundles = 108 au xv - 104 101 2 tod 104 102 104 107 na id Dae 2 18 19 xvi 513s 128 ii Section Tite INSTALLATION OF BUSBARS, CONDUIT, JUNCTION BOXES, PROTECTIVE DEVICES, AND TERMINAL BOARDS IL, Introduction... ees eee eee Reference Specifications and Drawings. Preparation and Installation of Busbars Installation of Conduit Installation of Junction Boxes |. Installation of Protective Devices Installation of Terminal Boards Ba. ELECTRICAL WIRING INSTALLATION 141. Introduction... 143. Reference Specifications and Drawings 144. Definitions - ‘i 145. Wire Types 146. Wire Groups and Bundles .. 14.15, Routing and Installation 14:35. Connections to Terminal Boards and Busbars ... 14-53, Installation of Wires in Conduit 1457. Installation of Connectors ce 14.64, Installation of Wites in Junction Boxes 14.68. Terminal Junction System LACING AND TYING 15-1. Introduction 15-4, Reference Specifications and Drawings 155. Definitions ........ 15-6. Materials... 159. General Precautions . 15-10, Lacing 15-14. Tying 15.20, Self-Clinching Cable Straps 15:22, Lacing and Tying in High Temperature Areas WIRING; LOCK, SHEAR, AND SEAL 16-1. Introduction ..)........ . 16-4, Reference Specifications and Drawings 165. Definitions ...... 169. General Procedures for Lock, Shear, and Seal Wiring 16-16. Specific Procedures for Lock, Shear, and Seal Wiring... LAMPS USED IN AIRCRAFT ELECTRICAL SYSTEMS 17-41. Introduction 0 174. Reference Specifications 17-5. Lamp Types 174, Abbreviations 17-7. General Precautions Be 131 B3 4 136 B8 . 14d i 141 141 are 144 1441 1 1448 fae 1@ 15-1 151 15a ears 2 152 15-2 15-4 185 157 1641 161 161 161 162 174 14 14 i 174Section an NAVAIR _01-1A-505 (USAF) T.0. 1-18-14 'e of Contents FUSES USED IN AIRCRAFT ELECTRICAL SYSTEMS 18-1, Introduction... 18-4. Reference Specifications and Dra 185. _ Definitions and Descriptions 188, Identification 189. General Precautions Poge Section 184 184 1841 181 1841 Tie XIX_ EMERGENCY REPAIRS 19-4, Introduction 19-4. Reference Specifications 19-5, Repairing Broken or Damaged Wires 19-12. Repairing Shielded Cable 19-45. Repairing Coaxial Cable 19-16, Repairing Damaged MS Connectors 19-20. Replacement of Connectors 19-23. Replacing Terminal Board Covers LIST OF ILLUSTRATIONS Figure Title 24 Wites Commonly Used in Airoraft 22 Cables Commonly Used in Aircraft 23 Wires After Cutting 24 — Wire Cutting Tools Examples of Wite Identification Coding Spacing of Identification Stamping ‘on Wire and Cable Location of Identification Sleeve Multi:Conductor Cable Identification Coaxial Cable Identification Wire Identification at Terminal Board Wire Marking Machines ~ Automatic Marking Machines ~ Hand Electric Oven for Heat Setting Identification Marking Marking on Sleeves 2 2415 Marking Machine for Sleeving 216 Identification of Wire Bundles and Harnesses 217 Typical Wire Stripping Tools 218 Stripping Wire in a Hot Blade Stripper 3419 Substitute Hot Blade Stripper 220 Inside View of Rotary Wire Stripper 2.21 Stripping Wire With Hand Stripper 222 Knife Stripping 2.23 Dip-Tinning in Solder Pot 2.24 Alternative Dip Tinning Method 2.25. Tinning Wire With a Soldering Iron 2.26 Stripping Outer Jacket Froin Shielded Cable 227 TwoPiece Grounding Connection for Terminating Shielded Wire 2.28 Alternative Procedure for Two-Piece Grounding Sheath Connector i 22 23 26 27 29 Figure 229 230 231 232 233 Pigtail Termination tos Shielded Wire Alternative Pigtail Termination for Shielded Wire Coinb for Combing Out Shield Dead-Ending Shield With Tape Wrap Dead-Lnding Shield With Permanent Splice Solder Sleeve Shield Termination Solder Sleeve Floating Shield Termination Insulating Sleeving Installed ‘Over Solder Cup - Soldering Iron Tip Shapes Resistance Soldering Pliers for Large Contacts Resistance Soldering Pencil for ‘Small Contacts Torch Soldering Large Contact Soldering Large Size Contacts Soldering Small Size Contacts Soldering Medium Size Contacts Soldering Iron in Safety Sereen Connector Assembly Tool (M3480, MS3481, MS3482) Connector Soldering Sequence Insulating Sleove Bottomed Against Insert Tying Sleeves and Preshaping Wines Crimping Too! M22520/1-01 With M22520/1-02 Turret Head Crimping Too! M2520/2-01 With 'M22520/2-02 Positioner Crimping Tools MS3191-! and MS3181-3 Crimping Tool MS27828¢USAK) With MS27828-2 Universal Head Gaging MIL-C-22520 Crimping Tools Ww 1941 19-1 194 19 197) 198 193) DM 234 baa ite 25 337 238