TM 10-8145-222-23
0092
INTRODUCTION CONTINUED
9. Cut leads at solder connections then remove and discard insulation sleeve pieces from wire lead ends and
component.
10. Disconnect wire leads from component.
11. Loosen strain relief fittings as necessary then note routing and remove wire lead, cable, or harness.
12. Insulating Joints. The preferred method of insulating bare electrical joints is by using insulation sleeves. To
apply, slide a piece of insulation sleeve over the wire lead before making the joint. Make the joint then slide the
insulation sleeve over the joint and shrink in place with heat gun.
13. Crimping Terminals. If the terminal is not insulated, refer to step 12 above. To install the terminal, strip 1/4-1/2
inch (0.6-1.3 cm) of insulation from the end of the wire lead, insert bare wire lead end into the shank of the
terminal. Crimp the shank securely onto the wire lead
WARNING
Solder and flux contain materials which are hazardous to health. Avoid breathing
vapors or fumes from soldering operations. Perform operations only in well ventilated
areas. Wash hands with soap and water after handling solder and flux. Wear thermal
gloves and protective goggles or face shield to protect against bums.
14. 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. Flux should be brushed onto the joint before soldering. Wires should always
be heated with a soldering iron to the point at which the solder will melt completely when touched to joint and
flow into all parts of the joint. Excessive build up of solder on the joint should be avoided or removed.
15. Splicing Wire. To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced by using a crimped splice installed per step 13 above or by wrapping the stripped wire lead ends onto
themselves then soldering and insulating per step 12 and step 14 above.
16. Select appropriate wire lead, cable, or harness then route as noted during removal being sure to pass it through
any grommets or strain relief fittings as necessary.
17. Tighten any strain relief fittings that were loosened for removal.
18. Connect wire lead, cable, or harness ends per tags and electrical schematic diagram (FO-1) at the end of the
manual. Remove tags.
19. Connect wire leads to components.
20. Solder and insulate leads to components per step 12 and step 14 above.
21. Install connector pins per step 13 above and tab housings then connect cable or harness.
22. Install splice or crimp as appropriate per step 13 and step 15 above.
23. Secure wires, cables, or harnesses with tie straps as necessary. Cut to remove excess tie strap material.
24. Install any components that were removed for access.
0092-2
