ELECTRICAL WIRING REPAIR - TM-9-4120-428-140127

TM 9-4120-428-14

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UNIT MAINTENANCE

AIR CONDITIONER, HORIZONTAL, COMPACT

(NSN 4120-01-502-1319)

ELECTRICAL WIRING REPAIR

INITIAL SETUP:

Materials/Parts

Tools

Wire

Refrigeration Unit Service Tool Kit, WP 0000 00, Item

Insulation Sleeving

Solder, WP 0000 00, Item 2

Soldering Gun Kit, WP 0000 00, Item 2

Flux, WP 0000 00, Item 2

Crimping Tool Kit, WP 0000 00, Item 2

Heat Gun, WP 0000 00, Item 4

REPAIR

1. 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 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.

2. 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 length of 1 inch (2.5 cm) 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. 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.

3. 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 joint 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, and sliding on a piece of insulation

tubing as described above. Hold the ends parallel and facing opposite directions, then twist each end around the

other wire at least three turns. Solder and apply insulation as described above.

4. 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 (2.5 cm) piece of heat-shrink tubing (if the terminals are of the non-insulated type). Insert wire-end

into the shank of the terminal. Crimp the shank and install heat-shrink tubing, if necessary.

NOTE

Preferred repair methods consist of replacing wires, terminals, connectors, ect., rather

than splicing wires, bending ends to form terminals, and other makeshift procedures.

Although some methods may be appropriate for emergency field repairs, determine the

proper size and length of the wire, the terminal, or the connector to be used for

replacement by referring to Table 1, Wire List and to the wiring diagram as shown on

WP 0000 00.

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