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Page Title:
ELECTRICAL WIRING REPAIR GENERAL |
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 TM5-4120-347-14
Preferred repair methods consist of replacing wires, terminals, connectors, etc., rather than splicing wires.
bending ends to form terminals, and other make-shift procedures, although the latter may be appropriate for
emergency field repairs. Determine the proper size and length of wire, or the terminal, or connector to be used
for replacement by referring to Table 4-3, "Wire List," and to the wiring diagram (figure 4-5).
a. 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-4995,
Type 1, rosin-alcohol flux, and should be brushed onto the joint before soldering. If a flux-core solder is used, it
should always be rosin-core electrical solder. If an uncored solder is used, it should be a lead-tin solder
conforming to Specification QQ-S-571. 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.
b. 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 (1.3 cm) 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.
c. 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 -1.3 cm) 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.
d. Crimping Terminals. To install a terminal on the end of a wire, strip 1/4 - 1/2 inch (0.6 -1.3 cm) of
insulation from the end of the 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 heat-shrink
tubing, if necessary.
IDENT NO,
TERMINATION
AWG
TERMINATION
LENGTH
Wire
(Marking)
FROM
CM.
IN.
TO
Size
TERMINAL TYPE
TERMINAL TYPE
LOOSE WIRES
V1A20
10
S1-12
20
13216E6191-1
MS25036-149
25.4
S3-2
V2A20
S1-11
7
13216E6191-1
S3-1
20
17.8
MS25036-149
X14A16A
S1-2C
7
13216E6191-2
S2-A2
13216E6191-2
16
17.8
X15A16B
S1-2B
9
13216E6191-2
S2-B2
13216E6191-2
16
22.9
X16A16C
8
S1-3C
13216E6191-2
S2-C2
16
20,3
13216E6191-2
5.1
X47A16A
2
S6-4
MS25036-153
S6-2
16
MS25036-153
X48A16A
18
S6-3
16
MS25036-153
TB2-9
13216E6191-2
45.7
X49A16B
18
S6-1
MS25036-153
TB2-8
13216E6191-2
16
45.7
8
X50A16C
S6-2
MS25036-153
TB2-7
16
13216E6191-2
45.7
AUXILIARY POWER CABLE ASSEMBLY
--
X40A12A
--
J11-A
P6-A
10 1.6
12
40
--
X41A12B
--
J11-B
P6-B
10 1.6
12
40
--
X42A12C
--
P6-C
J11-C
10 1.6
12
40
--
X43A12N
--
J11-D
P6-D
10 1.6
12
40
4-40
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