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ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-67. WIRE HARNESS - Continued.
REPAIR
1.
General. Preferred repair methods consist of replacing wires, terminals, connectors, etc, rather than splicing wires,
bending ends to form terminals, and other makeshift procedures, although the latter may be appropriate for
emergency field repairs. Determine the proper size and length of wire, or terminal, or connector to be used for
replacement.
2.
Soldering Connections. Wire connections must be made mechanically sound before they are soldered. Solder
alone does not provide sufficient strength to prevent breakage. Joining surfaces of connections to be soldered must
be clean and bright. If a separate flux is used, it should conform to Specification MIL-F-14256 rosin base flux, and
should be brushed onto the joint before soldering. Wires should always be heated to the point at which the solder
will melt completely and flow into all parts of the joint. Excessive build up of solder "gobs" on the joint should be
avoided or removed.
3.
Insulating Joints. The preferred method of insulating electrical joints is by the use of heat-shrink tubing. To apply,
cut a piece of heat-shrink tubing of suitable diameter to a one inch length for covering joints at terminals or
connectors, or to a length about 1/2 inch (1. 3cm) longer than the joint to be insulated, and slide the tubing over the
wire before making the joint. After the joint is made, slide the tubing so that it covers the joint, and shrink in place
with moderate heat.
4.
Splicing Wires. To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced. A commercial butt splice can be crimped onto the ends to join them, or a "Western Union" wire splice can
be made. The latter is made by stripping 1/4 1/2 inch (0. 6 1. 3cm) of insulation from the wire ends, holding the
ends parallel and facing opposite directions, then twisting each end around the other wire at least three turns.
Solder and apply insulation as described above.
5.
Crimping Terminals. To install a terminal on the end of a wire, strip 1/4 1/2 inch (0. 6 1. 3cm) of insulation from
the end of wire, apply a one inch piece of heat-shrink tubing (if the terminals are of the uninsulated type), and insert
wire end into the shank of the terminal. Crimp the shank, and install heatshrink tubing, if necessary.
FOLLOW ON PROCEDURES
Install any panels that were removed.
4-130
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