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Page Title: ELECTRICAL WIRING REPAIR GENERAL
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TM  5-4120-377-14 b.    Cleaning (1)  Wash  in  mild  detergent  and  water  solution. (2)  Rinse  thoroughly  in  clear  water. (3)  Shake  out  excess  water  prior  to  installation. c.    Inspection (1) (2) (3) Check  for  punctures,  cuts,  and  other  visible  damage. Check  for  packed  or  mashed  areas  that  would  block  air  flow. Replace  if  found  bad. d.   Installation.   Slide   mist   eliminator   straight   down   into   guides. NOTE Be sure TOP marking is up and air flow arrow points out away from evaporator coil and unit. Follow-on  procedure:  Install  top  panel.  (See  para  4-28.) 4-36.  ELECTRICAL  WIRING  REPAIR  GENERAL 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 4-20). 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-14256, rosin base flux, item 16, Appendix E, 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, item 2, Appendix E, 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  end  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. 4-70

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