TM 5-3805-248-23-1
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
0018 00
ELECTRICAL SYSTEM COMPONENTS AND WIRING - CONTINUED
9.
Crimping Wires.
a.
Cut off and discard broken, bent or discolored contacts with diagonal cutting pliers. Discard bad contacts. Use
thermal wire stripper to strip insulation off wires.
b.
Position contact crimping tool with color band toward rear. Put bare wire into contact and squeeze crimping tool.
Take crimped contact out of tool and check crimp by looking into inspection hole. You must be able to see end of
bare wire.
Installing Insulation Sleeving.
10.
a.
Insulation sleeving should be twice the diameter of the part over which it will be shrunk. Slide insulation over wire
and terminal. Hold portable heat gun 4-5 inches (10-13 cm) away from insulation and apply heat for 30 seconds.
Take heat gun away as soon as insulation forms to shape of wire and terminal. Let insulation cool for 30 seconds
before handling.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic
material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in
well-ventilated areas. Keep away from open flames and other sources of ignition.
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure
when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning compo-
nents. DO NOT direct compressed air against human skin. Failure to follow this warning may cause
injury or death. Make sure air stream is directed away from user and other personnel in the area. To pre-
vent injury, user must wear protective goggles or face shield.
b.
When replacing wires, cut insulation sleeving off terminals of wire to be replaced. Unsolder wire or cut if crimped.
When soldering wires, hold the bare wire near the soldering point with long, round-nosed pliers. Pliers act as a heat
sink, preventing heat damage to electrical and electronic components. Cut new wire to desired length and slide
new insulation over ends of wire. Use thermal wire stripper to push insulation back and strip insulation off wiring.
Solder or crimp wire to end terminal. Clean soldered joint with acid-swabbing brush and solvent cleaning com-
pound. Slide insulation over connection. Shrink insulation with heat gun.
Applying Preservatives to Electrical Connectors.
11.
WARNING
Water-displacing corrosion-preventive compound vapors can be harmful to eyes and lungs. To avoid injury,
keep the corrosion preventive away from heat, wear protective goggles and use in a well-ventilated area.
CAUTION
There are two types of water-displacing corrosion-preventive compounds. Care must be used to apply the
correct compound. Failure to do so can cause loss of continuity or moisture protection.
a.
Pin contacts: Spray an even, thin coat of compound over male pin area of connector.
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