Advisory Circular: September 2013 Aircraft Wiring and Bonding

1
AC 21-99(1): Aircraft wiring and bonding
Advisory Circular
AC 21-99(1)
SEPTEMBER 2013
AIRCRAFT WIRING AND BONDING

CONTENTS
1. References
2. Purpose
3. Status of this AC
Section 1
1. Introduction
Section 2
1. Wire and Cable
2. Identifying Wire and Cable
3. Preparing Wire and Cable
4 Electrical Wire Installation
5. Repairing Wire and Cable
6. Solderless Terminations and Splices
7. Soldering
8. Harnesses, Lacing and Tying
9. Wiring: Lock, Shear and Seal
10. General Purpose Connectors
11. Electric Connector Sealing Compound
12. RF Connectors and Cabling
13. Bonding and Grounding
14. Earthing and Bonding of Aircraft and Ground
Support Equipment
15. Installation of Busbars, Junction Boxes,
Protective Devices and Terminal Boards
16. Thermocouple Wire Soldering
and Installation
17. Aged Aircraft Wiring

18. Aircraft Electrical System Inspection
19. Fibre Optics
1.
REFERENCES
21 of the Civil Aviation
Regulations (CASR) 1998.
Safety
Part
RTCA DO-160D: Environmental Conditions and

Test Procedures for Airborne Equipment Section
16 (Power Input).
SAE Aerospace AS50881 Wiring Aerospace
Vehicles.
Federal Aviation Administration (FAA) Advisory
Circular
43.13-1B:
Acceptable
Methods,
Techniques and Practices Aircraft Inspection
and Repair.
2.
PURPOSE
The purpose of this Advisory Circular (AC) is to

provide guidance material for maintenance of aircraft
electrical systems and bonding of aircraft. The AC
highlights the techniques, inspection regimes and
maintenance processes required to ensure that aircraft
wiring systems continue to function with minimum
degradation to their designed service life.
3.
STATUS OF THIS AC
This is the second issue of this Advisory Circular. It has

been amended with further guidance on maintenance of
aged wiring and a section on the use of solder sleeves to
terminate or install shielded cable has been added.
Clearer illustrations of crimping tools and related
wiring maintenance processes have been provided. The
updated Section 2 Chapters are 3, 5, 6, 8, 10, 12 and 17.
Advisory Circulars are intended to provide advice and guidance to illustrate a means, but not necessarily the only
means, of complying with the Regulations, or to explain certain regulatory requirements by providing informative,
interpretative and explanatory material.
Where an AC is referred to in a Note below the regulation, the AC remains as guidance material.
ACs should always be read in conjunction with the referenced regulations.
This AC has been approved for release by the Executive Manager Standards Division .
September 2013
AC 21-99 Aircraft Wiring and Bonding

Table of Contents
TABLE OF CONTENTS
Page No
List of Tables
List of Figures
Para No
vii
xi
SECTION 1
CHAPTER 1
INTRODUCTION
General
Purpose of Manual
Scope
Intended Use
Arrangement of Material
Revisions
1
1
1
1
1
2
1 to 3
4
5
6
7 to 10
11
1
1
1
3
1A-1
1B-1
1C-1
1D-1
1E-1
1F-1
1G-1
1H-1
1 to 2
3
4 to 6
7 to 16
SECTION 2
CHAPTER 1
WIRE AND CABLE

Introduction
Reference Specifications
Definitions
Selection of Aircraft Electrical Wire and Cable
MIL-DTL-16878
SAE-AS-81044
MIL-W-22759
MIL-DTL-25038
MIL-W-7072
NEMA WC 27500
MIL-DTL-81381
MIL-C-85485
Current Ratings of Wire and Maximum
Allowable Nicked or Broken Strands
Wire Gauge Comparison
CHAPTER 2
1I-1
1J-1
IDENTIFYING WIRE AND CABLE

Introduction
Wire Identification Code (Basic)
Wire and Component Identification Codes for
Modification
Identification Methods
Marking Objectives
Spacing of Wire Identification
Location of Sleeve Marking
Multi-conductor Cable Identification
Coaxial Cable Identification
Thermocouple Cable Identification
Wire Identification at Terminal Boards and
Enclosures
Selection of Identification Sleeving
Wire Marking
Set-up of Marking Machine for Wire Stamping
Set-up of Marking Machine for Sleeve Stamping
Installing Identification Sleeves on Wiring
Identification of Wire Bundles and Harnesses
1
1
1 to 2
3 to 26
3
6
6
6
6
6
6
7
27 to 28
29
30
31
32
33 to 34
35
36
7
7
7
7
8
8
8
37
38
39 to 40
41
42
43
44

Table of Contents
CHAPTER 3
PREPARING WIRE AND CABLE

Introduction
Cutting Wire and Cable
Stripping Wire and Cable
Tinning Wire and Cable
Terminating Shielded Cable
CHAPTER 4
1
2
3
4
5 to 14
15 to 32
33 to 34
35 to 39
40
41 to 46
47 to 59
60 to 76
77 to 79
80 to 85
86 to 88
89 to 102
1
1
1
5
10
1
5 to 19
20
21 to 23
24 to 38
SOLDERLESS TERMINATIONS AND

SPLICES
Introduction
Description
Terminating Small Copper Wires with
Pre-insulated Terminal Lugs
Terminating Large Copper Wires
Crimping Procedure for MS25441 Tools
Terminating Aluminium Wire
Splicing Small Copper Wires
Splicing Procedure for M81824 Environmental
Splices
Splicing High Temperature Wires
Splicing Aluminium Wires
Multi-splicing
Environment Resistant Wire Disconnect Splices
Splicing to Reduce Wire Size
Inspection of Crimped Connections
Terminal Junction Systems
Terminations and Tooling
Stud Size and Corresponding Terminal Lug
Dimension Reference Chart
Disconnect Splices and Tooling
Crimp Tool Testing
ii
1
1
2
2
2
5
8
8
9
9
13
18
25
26
28
28
WIRING MAINTENANCE PRACTICES INCLUDING REPAIRING WIRE

AND CABLE
Introduction
Wiring Maintenance Practices
Single Wire Repair
Multi-conductor Repair
MIL-STD-1553 Data Bus Cable Repair
CHAPTER 6
1
2 to 6
7 to 13
14 to 23
24 to 56
ELECTRICAL WIRING INSTALLATION

Introduction
Definitions
Wire Types
Wire Groups and Bundles
Routing and Installation
Conduit
Metallic Conduit
Non-metallic Conduit
Heat-shrinkable Tubing
Cable Clamps
Connections to Terminal Boards and Busbars
Installation of Wires in Conduit
Installation of Connectors
Installation of Wire in Junction Boxes
Terminal Junction System
CHAPTER 5
1
1
2
7
8
1
1
1
1
8
9
9
11
16
16
17
17
17
17
17
18
6A-1
6B-1
6C-1
6D-1
1 to 2
3
4 to 7
8 to 14
15 to 19
20
21 to 25
26 to 37
38
39
40
41
42
43
44
45

Table of Contents
CHAPTER 7
SOLDERING
Introduction
Reference Specifications and Standards
Definitions and Descriptions
Heat Application Methods
Preparation and Maintenance of the Soldering Iron
Soldering Operation
Inspecting a Finished Solder Joint
CHAPTER 8
1
1
1
1
2
3
3
5
5
7
1 to 2
3
4 to 7
8 to 10
11
12 to 15
13 to 24
25 to 29
30 to 30
40
1
1
1
1
3
1 to 2
3
4 to 7
8 to 13
14 to 21
1
1
2
4
5
9
10
10
12
24
24
27
28
36
38
39
39
41
44
50
51
51
55
1 to 3
4
5 to 11
12 to 14
15 to 26
27 to 28
29 to 33
34 to 36
37 to
38
43 to 46
47
48 to 54
55 to 60
61 to 62
63
64 to 66
67
68 to 77
78 to 82
83 to 84
85 to 89
90 to 91
60
61
68
73
76
90
92 to 93
94 to 99
100 to 102
103 MIL-C104 to 113
114
WIRING: LOCK, SHEAR AND SEAL

Introduction
Definitions
General Procedures for Lock, Shear and Seal Wiring
Specific Procedures for Lock, Shear and Seal Wiring
CHAPTER 10
1 to 3
4
5 to 11
12 to 15
16 to 20
21 to 37
38 to 40
HARNESSESS, LACING AND TYING

Introduction
Definitions
Materials
General Precautions
Lacing
Harness Installation
Tying
Self-clinching Cable Straps and Spiral Wrap
Lacing and Tying in High Temperature Areas
CHAPTER 9
1
1
1
3
3
4
6
GENERAL PURPOSE CONNECTORS

Introduction
Description
Insulating Sleeves and Heat-shrinkable Tubing
Soldering Procedure
Crimp Contacts
Hand Crimping Tools for Connector Contacts
Tool Inspection Gauging
Crimp Tool Build Up and Adjustment
Types of Contact Positioning Devices
Crimping Procedures
Crimping Tool Kits
Installing and Removing Crimp Type Contacts
Shield Connections
Continuity Test
Test Leads
Protection of Electrical Connectors
Potting Connectors
Connector Accessories
Boot Repair Procedures
Rectangular Connectors
MIL-DTL-83723 Circular Connectors
MIL-DTL-5015 Connectors
MIL-C-26482, MIL-C-26500 and MIL-C-81703
Connectors
MIL-C-81511 Connectors
M and MS Connector Cable Clamps
81659 Connectors
Multiple Termination Connectors
iii

Table of Contents
CHAPTER 11
ELECTRIC CONNECTOR SEALING COMPOUND

Introduction
Description
General Precautions
Preparation of Sealing Compound
Storage of Sealing Compound
Preparation of Fluorocarbon Insulated Wire
for Potting
PR-1547 (MIL-M-24041) Moulding and Potting
Compound
CHAPTER 12
13 to 18
19 to 24
1
1
1
4
6
7
19
23
26
31
36
38
1 to 2
3
4 to 6
7 to 8
9 to 11
12 to 14
15 to 16
17 to 19
20 to 22
23 to 25
26 to 28
29 to 31
41
32 to 37
44
38 to 40
47
55
41 to 51
52 to 53
1
1
1
1
2
6
6
8
9
10
1 to 2
3
4 to 6
7
8 to 13
14 to 17
18 to 23
24 to 26
27 to 28
29
1
1
1 to 4
5 to 21
4
7
22 to 43
44 to 52
10
11
11
12
18
53 to 62
63 to 66
67 to 77
78 to 86
87 to 91
EARTHING AND BONDING OF AIRCRAFT

AND GROUND SUPPORT EQUIPMENT
Introduction
Electrical Grounding for Aircraft Safety
Electrical Earthing and Bonding Procedures
for Aircraft and GSE
Testing Interconnection Leads
Aircraft Earthing Receptacle Inspection
Procedure
Testing GSE Connection Points
Ground Earthing Points
Testing Ground Earthing Points
Mains Operated GSE
iv
BONDING AND GROUNDING

Introduction
Definitions
General Precautions and Procedures
Selection of Hardware
Preparation of Bonding or Grounding Surfaces
Methods of Bonding or Grounding
Bonding and Grounding Jumpers
Testing Bonds and Grounds
Refinishing
CHAPTER 14
1 to 2
3
4
5 to 6
7 to 9
10 to 12
RF CONNECTORS AND CABLING

Introduction
Description
Soldering Coaxial Cable to RF Connectors
BNC and TNC Series Connectors
C and SC Series Connectors
HN Series Connectors
N Series Connectors
Pulse Series Connectors
Miniature RF Connectors
Sub-miniature RF Connectors
RF Connectors Used in Fuel Quantity Indicating
Systems
Assembly Procedure for Sub-miniature
Connector ONO89558
Assembly Procedure for SMA Termination of
Semi-rigid Cable Using Tool M22520/36
Triaxial Connectors
CHAPTER 13
1
1
1
1
2
3

Table of Contents
CHAPTER 15
INSTALLATION OF BUSBARS, JUNCTION

BOXES, PROTECTIVE DEVICES, AND
TERMINAL BOARDS
Introduction
Preparation and Installation of Busbars
Installation of Junction Boxes
Installation of Protective Devices
Installation of Terminal Boards
CHAPTER 16
1 to 3
4
5 to 8
9
10 to 12
13 to 21
22 to 27
28 to 38
39
40 to 42
1
1
2
2
2
3
1
2 to 6
7
10 to 11
12
13 to 16
17 to 33
34 to 35
AIRCRAFT ELECTRICAL SYSTEM INSPECTION

Introduction
Inspection
CHAPTER 19
1
1
1
3
3
5
9
11
15
15
AGED AIRCRAFT WIRING

Introduction
Definitions
General
Service Difficulty Reporting
Causes of wiring Degradation
Handling Aged Wiring
Recognition of Damaged/Deteriorated Wire
and wire system components
Precautions Should Be Observed when Handling
Electrical Connectors
CHAPTER 18
1 to 2
3
4 to 12
13 to 21
22 to 42
43 to 50
THERMOCOUPLE WIRE SOLDERING

AND INSTALLATION
Introduction
Description
Definitions
Thermocouple Wire Preparation
Hard Soldering Thermocouple Wire
Soft Soldering Thermocouple Wire
Thermocouple Wire Splicing
Mounting AN5537 Connector Assembly
Routing Thermocouple Wiring
CHAPTER 17
1
1
1
2
4
7
1
1
1
2 to 14
Introduction
Information
1
1
1
2 to 13
Alphabetical Index for Section 2 Chapters 1 to 19
FIBRE OPTICS
INDEX

List of Tables
LIST OF TABLES
Table No
Title
Page No
SECTION 2
CHAPTER 1
11
12
1A1
1A2
1A3
1A4
1A5
1B1
1B2
1B3
1C1
1C2
1C3
1D1
1D2
1D3
1E1
1E2
1E3
1F1
1F2
1F3
1F4
1F5
1F6
1F7
1G1
1G2
1G3
1G4
1H1
1H2
1H3
1H4
1H5
1H6
1I1
1I2
1J1
Airframe Wire Used In Aircraft Electrical Installations

Common Aircraft Wire Insulations
Specification Sheets
Part Number Coding
Conductor Size
Conductor Stranding
Colour Code
Part Number Coding
Colour Code
Part Number Coding
Colour Code
Part Number Coding
Colour Code
Part Number Coding
Wire Size
Classification
Cable Part Number Breakdown
Basic Wire Specification
Shield Identification
Jacket Identification
Preferred Cable Identification Method
Optional Cable Identification Method
Part Number Coding
Colour Code
Equivalent Non-Kapton Insulated Wires
Component Wire
Finished Cable
Shielded, Jacketed Cable Construction
Unshielded, Unjacketed Cable Construction
Cable Colour Designation
Current Rating of Wires (SAE AS50881)
Maximum Allowable Nicked or Broken Strands (SAE AS50881)
3
4
1A1
1A2
1A2
1A3
1A3
1B1
1B1
1B2
1C1
1C2
1C2
1D1
1D2
1D2
1E1
1E1
1E2
1F1
1F1
1F2
1F2
1F2
1F3
1F4
1G1
1G2
1G2
1G3
1H1
1H1
1H1
1H2
1H2
1H2
1I1
1I2
1J1
CHAPTER 2
21
22
23
Function and Designation Letters

Marking Foil Identification
Recommended Sizes of Marking Type
4
8
8
vii

List of Tables
CHAPTER 3
31
32
33
34
35

Identification of Precision Stripper and Blades
Approximate Soldering Iron Sizes for Tinning
Heat Shrink Solder Sleeves For Tin and Silver Plated Conductors
(Splice Temperature rating 150C) Maximum
Heat Shrink Tooling
2
4
6
Wire Types
Twists Per Foot
Bend Radii for Rigid Conduit
SAE AMS-DTL-23053/4, Class 2
SAE AMS-DTL-23053/8
SAE AMS-DTL-23053/12
Chloroprene Cushion Clamps
Fluorosilicone Cushion Clamps
Nitrile Cushion Clamps
Cable Clamp Standoff Identification
Grommets - Temperature Limitations of Material
MS27212 Terminal Boards and Covers
Washers for Use with Aluminium Terminal Lugs
Installation Torques for Copper Terminal (Inch Pounds of Torque)
Installation Torques for Aluminium Terminal
(Inch Pounds of Torque)
Component Identification
Wire Range Accommodations
Crimping Tools for TJS Terminals
Insulation Repair Tape
2
3
9
10
10
11
11
14
14
15
17
18
19
22
22
Splice Selection
Splice Selection
Shield Repair Kit Selection
Tooling
Materials
2
4
7
9
10
Colour Coding of Copper Terminal Lug Insulation

Terminal Lugs and Tooling High Temperature Wire
Gauging Tools
Wire Stripping Lengths for Small Copper Terminal Lugs
Dies and Gauges for Power Tool MS25441
Stripping Lengths for Aluminium Wire
Splices and Tooling High Temperature Wire
Circular Mil Area (CMA) of Wires and Splices
MS25036 Terminal Lug, Crimp Style, Copper, Insulated,
Ring Tongue, Bell Mouthed, Type II, Class 1, For 105C
Total Conductor Temperature
SAE AS7928/1 Terminal Lug, Crimp Style, Copper, Insulated,
Ring Tongue, Type II, Class 1, For Thin Wall Wire For 105C
SAE AS7928/4 Terminal Lug, Crimp Style, Copper, Insulated,
Ring Tongue, Bell Mouthed, Type II, Class 1, For 150C
3
3
4
7
8
10
13
13
8
8
CHAPTER 4
41
42
43
44
45
46
47
48
49
410
411
412
413
414
415
416
417
418
419
420
22
33
33
35
37
CHAPTER 5
51
52
53
54
55
CHAPTER 6
61
62
63
64
65
66
67
68
6A1
6A2
6A3
viii
6A1
6A3
6A4

List of Tables
6A4
6A5
6C1
6C2
6D1
6D2
6D3
SAE AS81824/1 Splice, Electric, Permanent Crimp Style,

Copper, Insulated, Environment Resistant, Class 1, For 150C
MS25274 Cap, Electrical, Wire End, Crimp Style, Class 1,
For 105C Total Conductor Temperature
Single Wire In-Line Junctions
Double Wire In-Line Junctions
Copper Terminal Lugs and Splices (SAE AS7928 and
SAE AS81824)
Aluminium Terminal Lugs and Splices (SAE AS70991)
Electrical Connector Contacts (MIL-C-39029)
6A6
6A6
6C1
6C2
6D3
6D4
6D4
CHAPTER 8
81
82
83
Tape Lacing and Tying

Self Clinching Cable Straps and Installation Tools
Selection of Spirap
2
6
8
Safety Wire - Identification
Stripping Lengths for Solder Connections

Insulating Sleeving Material
Heat Shrinkable Tubing Material
Insulating Sleeving/Heat Shrinkable Tubing Sizes
Electrical Contact BIN Code Listing
Specification Replacements
Crimping Tool Inspection Gauges and Selector Settings
Contacts and Their Wire Size Range
Test Leads
Electrostatic Free Dust Caps
Wire End Caps
O-Ring Sizes For AN Type Connectors
Telescoping Bushings (MS3420 XX)
Selecting MS3057 Cable Clamp
MIL-DTL-5015 Connector Classes
Miniature MS Connector Type and Class Availability
MIL-C-81511 Contact Insertion and Removal Tools
Availability of MIL-DTL-38999 Connectors
Installation Torque Values for MIL-C-85049 Circular Electrical
Contact Insert Arrangements for MIL-C-81659 Connectors
Insert Arrangements, MIL-C-81659 Connector, Series 1 and 2
Polarization (Keying) Positions
Tools for MIL-C-81659 Standard Contacts
Stripping Lengths, Crimping Tools, Contacts, and Cables for
MIL-C-81659 Coaxial Connectors
MS27488 Sealing Plugs and Superseded Part Numbers
4
5
5
5
12
21
21
25
36
37
40
40
44
45
50
53
60
62
65
68
CHAPTER 9
91
CHAPTER 10
101
102
103
104
105
106
107
108
109
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
70
75
76
78
79
80
83
87
ix

List of Tables
CHAPTER 11
111
Shrinkable Tubing
CHAPTER 12
121
122
123
124
125
126
127
128
129
1210
1211
1212
1213
BNC & TNC Series M39012 Connectors and Associated Cables

(MIL-C-17)
Series C and SC M39012 Connectors and Associated Cables
(MIL-C-17)
HN Series Connectors (MIL-C-3643) with Associated Cables
Series N M39012 Connectors and Associated Cables (MIL-C-17)
Pulse Series Connectors (MIL-C-3643) with Associated Cables
MB Series Connectors with Associated Cables
Stripping Dimensions for Coaxial Cable Assembled to
MB Connectors
Stripping Dimensions and Crimping Tool Positions for
Subminiature RF Connectors
Stripping Dimensions for Coaxial Cable Assembled to
Liquidometer S62 and S63 Series Connectors
Crimping Tool Details
Crimping Tool Details
Cable, Connector and Tool Component Selection
Bend Segment Selection
12
19
25
28
33
38
38
39
43
44
45
49
52
CHAPTER 13
131
132
133
134
Hardware for Stud Bonding or Grounding to Flat Surface

Hardware for Plate Nut Bonding or Grounding to Flat Surface
Hardware for Bolt and Nut Bonding or Grounding to Flat Surface
Tinned Copper Woven Braid for Fabrication of Electrical Grounding
and Bonding Leads
3
4
5
Parts List For Interconnection Leads
Thermocouple System
Thermocouple Terminals
Coding for Thermocouple Contacts in MS Connectors
Code for Markings on AN5537
2
2
4
11
CHAPTER 14
141
CHAPTER 16
161
162
163
164

List of Figures
LIST OF FIGURES
Figure No
Title
Page No
SECTION 2
CHAPTER 1
11
12
Wires Commonly Used In Aircraft

Cables Commonly Used In Aircraft
2
2
Example of ADF Wire Identification Coding

Spacing of Identification Marking on Wire and Cable
Location of Identification Sleeve
Multi-conductor Cable Identification
Wire Identification at Terminal Board
Marking on Sleeves
Identification of Wire Bundles and Harnesses
2
6
6
7
7
7
8
9
Wires After Cutting

Wire Cutting Tools
Examples to look for when Stripping Multi-Stranded Wire
Stripping Coaxial Cable using a Knife
Stripping the Outer Jacket of the Wire
Peeling away the Outer Jacket
Removal of Excess Braiding
Removal of the Insulation Surrounding the Inner Conductor
Stripping Wire With Hand Stripper
Dip-Tinning in Solder Pot
Tinning Wire With Soldering Iron
Coaxial Cable Strippers
Procedure of Stripping Coaxial Cable
Combined Cable Diameter Measurements
Solder Sleeve Shield Termination
Solder Sleeve Floating Shield Termination
The M83519/1 type of Solder Sleeves
The M83519/2 type of Solder Sleeves
Infrared Heating Tool
Compressed Air/Nitrogen Heating Tool
Turbofan Type Heat Gun
Termination Sleeve Reflector
Miniature Termination Sleeve Reflector
Boot and Tubing Reflector
Needle Point Reflector
Large Boot and Tubing Reflector
Preparation of Centre Stripped Cable
Preparation of End Stripped Cable
Preparation of End Stripped Braided Cable
Installation of the M83519/1 Solder Sleeve
Examples of Solder Sleeve Assembles
1
2
4
4
5
5
5
5
6
7
8
8
9
10
11
12
12
12
13
14
15
16
16
16
16
16
17
18
18
18
19
19
Group and Bundle Ties

Staggered Splices in Wire Bundles
2
3
CHAPTER 2
21
22
23
24
25
26
27
28
CHAPTER 3
31
32
33
34
35
36
37
38
39
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
CHAPTER 4
41
42
xi

List of Figures
43
44
45
46
47
48
49
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
Slack Between Supports

Routing Bundles
Cable Clamp at Bulkhead Hole
Cable Clamp and Grommet at Bulkhead Hole
Drainage Hole in Low Point of Tubing
Separation of Wires From Plumbing Lines
Capacity Limits for Conduit
Preferred Angle for Cable Clamps
Typical Mounting Hardware for MS21919 Cable Clamps
Attaching Cable Clamp to Structure
Tool for Installing Cable Clamp
Installing Cable Clamps to Tubular Structure
Split Grommet
Cutting Caterpillar Grommet
Connecting Terminal Lugs to Terminal Board
Hardware for Wiring Terminal Boards With Copper Terminals
Hardware for Wiring Terminal Boards With Aluminium Terminals
Hardware for Wiring Terminal Boards With Combination of
Terminals
Connecting Aluminium Terminal to Aluminium Busbar
Connecting Copper Terminal to Aluminium Busbar
Connecting Aluminium Terminal to Copper Busbar
Connecting Copper Terminal to Copper Busbar
Connecting Two Terminals to Same Point on Busbar
Insulating Tubing Around Busbar
Conduit Capacity
Leader for Conduit
Support for Wire at Conduit End
Installing Conduit on Connector Back Shell
Self-Locking Connector
Support Inside Junction Box
Feedback Terminal Junction Assembly Series I
Feedback Terminal Junction Assembly Series I
Feedback Terminal Junction Assembly Series II
Grounding Junction Assembly Series II
Feed-Through Terminal Junction Assembly Series I
Removable Contacts and Wire Splices Series I
Removable Contacts and Wire Splices Series II
Installation and Removal of Modules
Components of Terminal Junction System Series I
Components of Terminal Junction System Series II
Contact Insertion in Removable Contact Wire Splices
Contact Removal from Removable Contact Wire Splices
3
4
6
6
8
8
9
15
16
16
17
17
18
18
18
20
20
Damage Assessment
Removing Damaged Area
Sealing Sleeve Placed on One Wire End
Correctly Installed Crimp Barrel
Sealing Sleeve Centred Over Crimp Barrel
Splice Sealing
Completed Splices
Scored Jacket on Multi-Conductor Cable
Damage Assessment
Removing Damaged Area
Sealing Sleeve Placed on One Wire End
Correctly Installed Crimp Barrel
Sealing Sleeve Centred Over Crimp Barrel
Splice Sealing
Completed Splices
Taping Cable Jacket
Scored Jacket
Damaged Multi-conductor Cable
3
3
4
4
4
4
5
5
5
5
6
6
6
6
7
7
8
8
21
23
23
23
24
24
25
25
26
26
28
28
28
29
30
30
31
31
32
32
33
34
34
36
36
CHAPTER 5
51
52
53
54
55
56
57
58
59
510
511
512
513
514
515
516
517
518
xii

List of Figures
519
520
521
522
523
524
525
526
527
528
529
530
Wire With Damaged Section Removed

Undamaged Wires Cut at Staggered Locations
Tubing and Braid Located on Cable End
Jumper Wire Cut to Match Removed Segment
Jacket Removed
Repair Braid Centred Over Repair Area
Heating Repair Braid
Tubing Centred Over Repaired Area
Single Shield Cable Strip Dimensions
Double Shield Cable Strip Dimensions
Single Shield Cable Strip Dimensions for Mini-Seal Crimp
Double Shield Cable Strip Dimensions for Mini-Seal Crimp
8
8
8
9
10
10
10
10
11
13
14
15
CHAPTER 6
61
62
63
64
65
66
67
68
69
610
611
612
613
614
615
616
6C1
6C2
6D1
6D2
6D3
Solderless Terminal Lugs and Splices

Preinsulated Terminal Lug Cut-Away
Crimp Tools and Dies
Proper Insertion of Stripped Wire in Insulated Terminal Lug for
Crimping
Insulating Sleeves
Power Crimping Tools Large Copper Terminal Lugs
Positioning Aluminium Terminal Lugs in Die Nests
Single Crimp on Aluminium Terminal Lugs
Wire Damaged Along Length
Removal of the Damaged section
Procedure for Installing Sealing Sleeve
Insert Crimp Barrel into Correct Cavity of Crimping Tool
Crimping the Wire
Positioning the Sealing Sleeve
Shrinking the Sealing Sleeve
Re-Positioning the Wires within the Loom
Single Wire In-Line Junction Body
Double Wire In-Line Junction Body
Terminal Lug
Splice
Connector Contacts
2
3
5 to 6
8
8
9
11
11
12
12
13
14
14
15
15
16
6C1
6C2
6D2
6D2
6D3
CHAPTER 7
71
72
73
74
75
Soldering Iron Tip Before and After Cleaning

Tinning Soldering Iron Tip
Soldering Iron Tip Shapes
Correct Solder Application
Good and Bad Soldered Connections
3
3
5
6
6
Single Cord Lacing

Double Cord Lacing
Lacing a Branch-off
Making Ties
Strap Configuration
MS90387 Adjustable Hand Tools for Installing Self-Clinching
Plastic Tiedown Straps
2
4
4
5
6
Double Twist Lock Wiring

Single Wire Method
Use of Lock Wire Pliers
Lock Wiring Thread Coupled Connector
Twisting Method
2
3
3
4
4
CHAPTER 8
81
82
83
84
85
86
CHAPTER 9
91
92
93
94
95
xiii

List of Figures
96
97
98
99
910
Drilling Hole in Coupling Nut

Lock Wiring Connector Using Adel Clamp
Lock Wiring Connector to Structure
Wiring Split Shell Assembly Screws
Shear Wiring Switch Guard
4
5
5
6
6
MS Connector Marking
Alternative Positions of Connector Inserts
Typical Circular Connectors
Insulating Sleeving Installed Over Solder Cup
Soldering Iron Tip Shapes
Resistance Soldering Pliers For Large Contacts
Resistance Soldering Pencil For Small Contacts
Torch Soldering Large Contact
Soldering Large Size Contacts
Soldering Small Size Contacts
Soldering Medium Size Contacts
Connector Soldering Sequence
Insulation Sleeve or Heat Shrinkable Tubing Bottomed Against
Insert
Preshaping and Tying Wires
Contact Marking
Go/No Go Gauge
Testing the Crimp tool
Typical M22520 Positioner and Turret Head
M22520 Crimping Tools
Assembling Wires To Crimp Type Contacts
Before and After Crimp views
Cross sectional Views of type 2 crimps
Broken Wire Contact Removal
Insertion and Extraction Tools for Front Release Crimp Type
Contacts
Assembling Wired Contacts Into Connector
Removing Crimp Type Contacts From Front Release Connectors
Insertion and Extraction Tool For Rear Release Crimp Contacts
Tweezer Type Installing Tools
Single or Double Ended Contact Installing Tools
Single or Double Ended Contact Removal Tools
Tweezer Type Removal Tools
Terminating Shielded Wire at MS Connector
Terminating Shielded Wire at Potted Connector
Terminating Two Wires at One Contact on
Non-environmental Resistant Connector
Reducing Wire Size at Connector Using Permanent Environmental
Splice
Installing AN3111 Bonding Ring
Terminating Two Wires to One Contact Using Permanent
Environmental Splice
Typical Protective Connector Caps
Spare Wires for Potting Connector
Filling and Curing Potting Connector
Installation of O-Ring on AN Type Potted Connector Plug
Cable Clamps
MS3057 Connector Cable Clamp Types Exploded View
Installation of MS3057 Cable Clamp
Installation of MS3057A Cable Clamp
2
3
4
6
6
7
7
7
8
8
8
9
CHAPTER 10
101
102
103
104
105
106
107
108
109
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1050
1051
xiv
9
10
10
10
11
11
12
12
13
13
25
26
27
27
27
29
29
30
32
29
33
34
34
35
35
36
36
37
37
38
38
40
41
42
42
46
46
47
48

List of Figures
1052
1053
1054
1055
1056
1057
1058
1059
1060
1061
1062
1063
1064
1065
1066
1067
1068
1069
1070
1071
1072
1073
1074
1075
1076
1077
1078
1079
1080
Installation of MS3057B Cable Clamp

48
Typical AN(MS) Connectors
57
Insert Arrangements - AN Type Connectors, MIL-DTL-5015 and
MIL-DTL-83723, Series II
58 to 59
Typical MS Connectors Miniature
64
Colour Marking for Individual Release MIL-C-81511 Connectors
66
Typical MIL-DTL-38999 Connectors
72
Typical Cable Clamps For MIL-DTL-5015 (MS3400 & MS3450
Series), MIL-C-26482 (Series 2), MIL-C-81703 (Series 3) and
MIL-DTL-83723 (Series I and Series II) Connectors
Typical Cable Clamps For MIL-DTL-38999 Series I, II, III & IV
Connectors
75
Typical MIL-C-81659 Duplex Connector
79
Assembly of MIL-C-81659 Connectors With Standard Contacts
79
Assembly of MIL-C-81659 Connectors Polarization (Keying) Posts
and Inserts
83
Assembly of MIL-C-81659 Connectors with Coaxial Connectors
84
Insertion of Standard Contacts in MIL-C-81659 Connectors
85
Removal of Standard Contacts in MIL-C-81659 Connectors
85
Installation of Sealing Boot and Ferrule on Coaxial Cable Before
Crimping Contacts
85
Stripping Dimensions for Coaxial Cable in Table 1027
85
Crimping Centre Contacts with AMP 220015-1 Crimping Tool
87
Contact Assembly Using Seal Ring
88
Crimped Centre Contact of Braided Coaxial Cable Inserted in
Contact Body
88
Contact-Ferrule Assembly in Ferrule Crimping Die of Crimping
Tool AMP 220015-1 Ready for Crimping
88
AMP 220066-1 Ferrule Crimping Tool Showing the Three
Crimping Dies
88
Contact-Ferrule Assembly in Crimping Die of AMP 220066-1
Ferrule Crimping Tool Ready for Crimping
88
Crimped Centre Contact of Semi-Rigid Coaxial Cable Inserted in
Contact Body
88
Semi-Rigid Cable-Contact Assembly in Crimping Die of AMP
220066-1 Ferrule Crimping Tool Ready for Backshell Crimping
89
Insertion of Rear-Release Coaxial Contacts in MIL-C-81659
Connectors
89
Removal of Rear-Release Coaxial Contacts From MIL-C-81659
Connectors
89
Multiple Termination Connector
91
Inspection Criteria
92
CHAPTER 12
121
122
123
124
125
126
127
128
129
1210
1211
1212
1213
1214
1215
1216
1217
1218
RF Connectors
Typical BNC Connectors
Typical HN Connectors
Typical N Connectors
Typical C Connectors
Typical Pulse Connectors
Typical TNC Connectors
Typical SC Connectors
Typical Coaxial Cables
Tinning Centre Conductor
Tinning Inside of Contact
Soldering Contact to Coaxial Cable
Tightening Braid Clamp Nut into Plug or Jack Body
Correct Shape for Soldering Iron Tip
Attaching BNC & TNC (M39012) Crimp Connectors to Coaxial
Cable
M22520/5-01 Crimping Tool and Hex Dies
M22520/5-01 Crimping Tool and Turret
M22520/5-01 Crimping Tool Turrets
2
3
3
3
3
4
4
4
4
5
5
6
6
6
8
9
10
11
xv

List of Figures
1219
1220
1221
1222
1223
1224
1225
1226
1227
1228
1229
1230
1231
1232
1233
1234
1235
1236
1237
1238
1239
1240
1241
1242
1243
1244
1245
1246
1247
1248
1249
1250
1251
1252
1253
1254
1255
1256
1257
1258
1259
1260
1261
1262
1263
1264
1265
1266
1267
1268
Attaching Improved BNC Connectors to Coaxial Cable

Attaching BNC Connectors With Captivated Contacts to Coaxial
Cable
Attaching Series C and SC Connectors to Coaxial Cable
Cable Crimping Instructions
Improved HN Connectors - Exploded View
HN Connectors with Captivated Contacts - Exploded View
Attaching Improved HN Connectors to Coaxial Cable
Attaching HN Connectors with Captivated Contacts to Coaxial Cable
N Crimp Connectors
Cable Stripping Instructions
Attaching N Connectors with Captivated Contacts to Coaxial Cable
Pulse Connector Ceramic Insert
Pulse Connector Rubber Insert
Assembly of Ceramic Insert Pulse Connector
Assembly of Rubber Insert Pulse Connector
MB Connectors - Exploded View
Attaching MB Connectors to Coaxial Cable
Subminiature RF Connector - Exploded View
Attaching Subminiature RF Connectors to Coaxial Cable
Crimping Subminiature RF Connectors
Attaching Avien 163-088 and 163-089 Connectors to Coaxial Cable
Attaching Avien 163-088 and 163-089 Connectors to Unshielded
Wire
Attaching Liquidometer 9100 Series Connectors to Coaxial Cable
Attaching Nu-Line 1200 Series Connectors to Coaxial Cable
Attaching Liquidometer S62 and S63 Series Connectors to Coaxial
Cable
Stripping Dimensions, Scaling Boot, Ferrule and Contact Before
Crimping the Contact
Final Assembly and Outer Ferrule Crimping
Crimping Tool for Shielded Outer Ferrule
Final Connection Assembly
Stripping Dimensions and Sealing Boot Before Crimping the
Contact
Assembly Before Crimping
Final Assembly and Outer Ferrule Before Crimping Outer Ferrule
Assembly of Dage Type Connectors
SMA Connectors M39012, Category F
Tooling to Prepare Semi-rigid Cable
Pointing the Cable End
Termination Tooling
Locator and Locking Screw
Orientation of Die Chambers
Die Alignment
Plug Termination
Jack Termination
Radii Dimensions for Semi-Rigid Cable Bending
Spacer on Dummy Jack
0.025 Inch Radius Bends on RG-402/U Cable and 0.125 Inch
Radius Bends on RG-405/U Cable
0.125 Inch Radius Bends on RG-402/U Cable
Triaxial Connector Assembly - Exploded View
Attaching Triaxial Connector to Cable
Attaching Gasket to Middle Insulation
Attaching Outer Shell to Gasket
17
Stud Bonding or Grounding to Flat Surface

Plate Nut Bonding or Grounding to Flat Surface
Bolt and Nut Bonding or Grounding to Flat Surface
Stainless Steel Wire Brush With Pilot for Cleaning Aluminium
Surfaces
3
4
5
18
19
23
25
25
26
26
26
27
31
32
32
34
36
37
37
39
40
40
41
41
42
43
44
45
45
46
46
46
47
47
48
49
50
50
51
52
52
52
53
53
54
54
54
55
55
56
56
56
CHAPTER 13
131
132
133
134
xvi

List of Figures
135
136
137
138
Bonding Tab Riveted to Structure

Aluminium Jumper Connection to Tubular Structure
Copper Jumper Connection to Tubular Structure
Bonding Conduit to Structure
7
8
8
8
Mobile (Self Contained) Aircraft External Power Supply

Mobile Rectifier/Frequency Converter Aircraft External Power
Supply
Reticulated Aircraft External Power
Safety Interconnection Lead (Configuration 1)
Suggested Format for Test and Inspection Log
Standard Earth Reference Point
Temporary Earth Reference Point
Earth Reference Point Test Setup for GEOHM Type Testers
Suggested Format for Test and Inspection Log
Helicopter Earthing Pole
3
3
3
7
8
8
8
10
13
14
15
16
17
Scratch Brushing Unplated Aluminium Alloy Busbars

Mounting Busbars to Structure
Attaching Junction Box to Structure
Attaching Cover to Junction Box
Wire Entry Holes in Junction Box
Mounting Protective Devices
Typical Mounting Hardware for Protective Devices
Determining Screw Length for Mounting into Blind Holes
Circuit Breaker Lockout Ring
Mounting of Terminal Board
Alternative Mounting of Terminal Board
Insulation of Terminal Board
Identification of Terminal Board
3
4
4
5
5
6
6
6
7
8
8
8
9
Thermocouple Wire
Thermocouple Connector Assembly (AN5537)
Stripping Thermocouple Wire for Terminal and for AN5537
Connector Installation
Stripping Thermocouple Wire for Splice Installation
Stripping Thermocouple Wire for MS Connector Installation
Torch Tinning Thermocouple Wire
Dip Tinning Thermocouple Wire in Silver Solder
Resistance Heating to Tin Wire
Resistance Tinning of Terminal
Silver Soldering Thermocouple Wire to Terminal
Modified Crimping Tool for Thermocouple Terminals
Reinforcing Solder on AN5539 Terminals
Serving Thermocouple Wire
Torch Soldering Thermocouple Wire to MS Connector Contact
Butt Splicing Procedure
Stub Splicing Procedure
Distributing Slack in Thermocouple Wire
2
3
4
CHAPTER 14
141
142
143
144
145
146
147
148
149
1410
1411
1412
1413
CHAPTER 15
151
152
153
154
155
156
157
158
159
1510
1511
1512
1513
CHAPTER 16
161
162
163
164
165
166
167
168
169
1610
1611
1612
1613
1614
1615
1616
1617
1618
4
4
5
5
6
6
7
7
8
8
9
10
13
14
15
xvii

List of Figures
CHAPTER 17
171
172
173
174
Visible Broken Conductors

Hidden Broken Conductors
Chafed Conductors
Various Connectors
6
6
7
8
Typical Fibre Optic Cable Construction

Loss Due To End Separation
Loss Due To Lateral Displacement
Loss Due To Angular Displacement
1
1
2
2
CHAPTER 19
191
192
193
19-4
xviii

Alphabetical Index
ALPHABETICAL INDEX
FOR SECTION 2 CHAPTERS 1 TO 19
Page No
Page No
Busbars - Protection15-2
Aged Wiring
17-1
Busbars - Protection Against Shorting
4-24
Aged Wiring - Care
17-4
Busbars - Repairing Damaged Plating
15-2
Aged Wiring - Handling
17-2
Aged Wiring - Maintenance
17-4
Airframe Wire
1-3
Aluminium Terminations
1-5
Aluminium Terminal Lugs
6-9
Aluminium Terminal Lugs - Crimping
6-10
Aluminium Terminals - Installation Torques
4-22
Aluminium Wire
1-3, 2-2
Aluminium Wire - Terminating
6-9
Aluminium Wires - Splicing
6-13
Arc Tracking
17-1
Asbestos in Aircraft
4-7
B
Bend Radii
4-4
BNC Connectors
12-17
BNC Connectors with Captivated Contacts
12-18
BNC Fuel-Quantity-Indicating Connectors
12-41
Bonding
13-1
Bonding - Cable Clamp
13-2
Bonding - Cleaning Aluminium Surfaces
13-6
Bonding - Cleaning Magnesium Surfaces
13-6
Bonding - Cleaning Steel Surfaces
13-6
Bonding - Connection to Cylindrical Surfaces
13-7
Bonding - Connection to Flat Surfaces
13-6
Bonding - Connection to Tab Riveted to

Structure
13-7
C
C and SC Series Connectors
12-18
Cable
1-1
Cable Clamps
4-13
Cable Clamps - Chloroprene Cushion
4-13
Cable Clamps - Fluorosilicone Cushion
4-14
Cable Clamps - Installation
4-15
Cable Clamps - Installing on Tubular

Structure
4-17
Cable Clamps - M and MS Connectors
10-70
Cable Clamps - Nitrile Cushion
4-14
Cable Identification Multi-conductor
2-6
Cable Repair - MIL-STD-1553 Data Bus
5-9
Cable Repair - Multi-Conductor
5-3
Cable Strap Installation
8-6
Carbon Arc Tracking
17-1
Circuit Breakers
15-4
Circuit Breaker Maintenance
15-5
Circuit Breaker Resetting
15-5
Circuit Breaker Blanking Plugs
15-7
Circuit Breakers - Inspection of
18-7
Circuit Breaker Lockout/Deactivation
15-7
Circuit Function Letter
2-1
Circular Mil Area (CMA)
1J-1
Circular Mil Area of Wire and Splices
6-13
Cleaning Soldered Connections
10-9
Coaxial Cable
12-3
2-6
Bonding - Hardware13-2
Bonding - Inspection of
18-6
Bonding - Primary Structure
13-1
Combing Wires
4-2
Bonding - Quick-Disconnect Jumpers
13-9
Component Numbering
2-3
Bonding - Refinishing Metal Surfaces
13-10
Conduit - Bend Radii
4-9
Bonding - Resistance Tests
13-9
Conduit - Capacity
4-25
Bonding - Surface Preparation
13-6
Conduit - Damage Limitations
4-8
Bonding - Tightness of Connections
13-7
Conduit - Inspection of
18-6
Bonding and Grounding Jumpers
13-8
Conduit - Installation of Wires
4-25
13-7
Conduit - Non-Metallic
4-9
Bonding or Grounding Methods
13-6
Conduit
4-8
Busbars
4-22
Conduit Size
4-9
Busbars - Connection Hardware
4-22
Connector - Shrinkable Strain Relief Boots
10-46
Busbars - Insulation
15-2
10-41
Busbars - Mounting Hardware
15-2
Connectors - Inspection of
18-5
Busbars - Preparation and Installation
15-1
Connector Boot Installation
10-47
Busbars - Plated Aluminium and Copper
15-2
Connector Boot Rebonding
10-47
Busbars Unplated Aluminium Alloy
15-2
Connector Boot Removal
10-47

Alphabetical Index
Connector Boot Repair Procedures
10-46
Crimping Procedures
Connector Cable Clamps - Installation
10-40
Connector Cable Clamps - Removal
10-46
Crimping Standard Contacts in MIL-C-81659

Connectors
10-77
Connector Contact Positioning Devices
10-22
Crimping Tool Adjustment - MS25441
6-8
Connector Contacts - Crimp
10-10
Crimping Tool Inspection
10-21
10-11
Crimping Tool Inspection Gauging
10-11
Connector Contacts - Removable Solder Type
10-10
Crimping Tool Kits
10-25
Connector Disassembly
10-51
Crimping Tool MIL-DTL-22520/1
10-11
Connector - Resistance Soldering
10-6
10-11
Connector Marking
10-2
10-11
10-34
10-11
Connector Pin - Multiple Shield Connections
10-33
Crimping Tools
6-4, 6-10
Connector Plug - Assembly and Disassembly
10-48
Connector - Soldering Procedure
10-5
Crimping Tools for Sizes 8 thru 4/0

Terminals
6-8
Connector - Soldering Sequence
10-8
Cutting Aluminium Wire
3-1
Connector - Torch Soldering
10-7
Cutting Copper Wire and Cable
3-1
Connector Contacts - Hand Crimping Tools
Connector Pin - Multiple Connections
10-22
Connectors - AN, D, M and MS
10-2
Connectors - Assembly to Receptacles
4-26
Connectors - Attaching Single Shielded Wire
10-33
Databus - Double Shield Cable with Miniseal

Crimp Primary Splice
5-12
Connectors - Circular
10-2
Connectors - Coding
4-27
Databus - Double Shield Cable with Solder

Sleeve Primary Splice
5-10
Connectors - Disassembly from Receptacles
4-27
Connectors - Installation
4-26
Databus - Single Shield Cable with Miniseal

Crimp Primary Splice
5-11
Connectors - Installing Conduit
4-28
Databus Harness Tester
5-9
Connectors - MB Miniature Series
12-36
Databus Repair Inspection
5-14
Connectors - Miniature RF FQI
12-42
Databus Repair Testing
5-14
Databus Splice Kit Mini-Seal Crimp

24-22 AWG Double Shield
5-10
Databus Splice Kit Mini-Seal Crimp

24-22 AWG Single Shield
5-11
Databus Splice Kit Solder Sleeve

24-22 AWG Double Shield
5-10
Databus Splice Kit Solder Sleeve

24-22 AWG Single Shield
5-11
Dip-Tinning Procedure
3-5
Drip Loop
4-5
Connectors - Mounting
4-27
Connectors - Multiple Termination
10-87
Connectors - N Series
12-26
Connectors - N Type Crimp Connectors
12-26
Connectors - N Type Captivated Contacts
12-27
Connectors - Holding for Soldering
10-8
Connectors - Identification and Components
10-48
Connectors MIL-C-26482
10-57
10-57
10-58
10-73
10-57
Connectors MIL-DTL-38999
10-65
Connectors MIL-DTL-5015
10-52
Connectors - MIL-DTL-83723
10-48
Connectors with Resilient Inserts
4-27
Contamination
E
Ground Earthing Points - Testing
14-12
Earthing and Bonding - Aircraft and GSE
14-3
Earthing and Bonding - Hardware
14-6
Earthing and Bonding - Testing GSE

Connection Points
14-11
17-1
Earthing and Bonding - Testing

Interconnection Leads
14-7
Continuity Test
10-35
Earthing Receptacle - Inspection
14-10
Crimp Contacts - Installing and Removing
10-25
Electrical Component Numbers
2-3
Crimp Tool
6-10
EMI Sensitive Wire - Identification
2-3
Crimped Connections - Inspection
6-14
EMI Sensitive Wire - Installation
4-8
End Caps, Splices, Terminal Lugs and Tools
6-1
Extraction Tools for Front Release

Crimp Contacts
10-26
Crimping Coaxial Contacts in MIL-C-81659

Connectors
10-80
Crimping Contacts in MIL-DTL-83723

Connectors
10-51
Crimping Procedure for M22520/5 and

M22520/10 Hand Tools
6-7
Fibre Optic Cable
19-1
Crimping Procedure for MS25441 Tools
6-9
Filter Line Cable
1H-1

Alphabetical Index
Flux and Solder
3-5
Function and Designation Letters
2-4
Kapton Wire
1G-1
Fuses - Inspection
18-4
Kapton Wire Alternatives
1G-3
Grommets - Installation
4 -17
Lacing
Ground, Phase or Thermocouple Letter(s)
2-2
Lacing - Double Cord
8-3
Grounding
Grounding/Bonding Receptacles Inspection
13-1
Lacing - Single Cord
8-3
18-8
Lacing and Tying - High Temperature Areas
8-7
Grounding for Aircraft Safety
14-1
Grounding Shields with Bonding Ring
10-34
GSE - Mains Operated
14-18
8-1, 8-3
Lacing Branch-Offs
8-3
Lacing or Tying in Junction Boxes
4-28
Lock, Shear and Seal Wiring
9-1
Lock Wiring - Double Twist
9-2
Lock Wiring Connectors to Structure
9-5
Hand Tool Inspection
6-4
Heat-Shrinkable Tubing
4-9, 4-13
Lock Wiring Connectors with Threaded

Coupling Rings
9-3
Lock Wiring Connectors and Backshells
9-3
Lock Wiring Solid Shell Angle Plugs
9-5
High Temperature Wires - Splicing
6-12
HN Connectors - Attaching to Coaxial Cable
12-23
HN Connectors with Captivated Contacts
12-24
HN Series Connectors
12-23
Hookup Wire
1-4
Hot Air Gun
5-10
I
Insertion and Extraction Tools for
Rear-Release Crimp Type Contacts
Insertion and Removal of Contacts
10-30
10-52, 10-59
Insertion and Removal - Rear Release

Coaxial Contacts
Lock Wiring Split Shell Assemblies
9-5
Lock Wiring - Single Wire Method
9-2
M
Metallic Seals
9-1
Millivolt Drop and Tensile Strength Test
6-4, 6-8
Multi-splicing
6-13
N
O
10-86
Insertion Tools for Front Release Contacts
10-25
Inspection of Crimped Connections
6-14
Potting Compound - Curing Time
11-6
Insulated Wire
1-1
Potting Compound - Dispensers
11-3
Insulating Sleeves
6-7, 6-10
Potting Compound - Frozen Pre-Mixed
11-2,11-5
Potting Compound - General Precautions
11-1
Potting Compound - Hand Mixing Procedure
11-2
Potting Compound - Mechanical Mixing
11-2
Insulating Sleeves and Heat-Shrinkable

Tubing
10-4, 10-9
J
Junction Box Covers
15-3
Junction Boxes - Bonding or Grounding
15-4
Junction Boxes - Drainage
15-3
Junction Boxes - Identification
15-4
Junction Boxes - Inspection
18-6
Junction Boxes - Installation
15-2
Junction Boxes - Insulation
15-3
Junction Boxes - Mounting Circuit Breakers
15-6
Junction Boxes - Mounting Hardware
15-3
Junction Boxes - Mounting Relays
15-7
Junction Boxes - Mounting Toggle Switches
15-6
Junction Boxes - Protection
15-7
Junction Boxes - Protective Devices
15-4
Junction Boxes - Vapour Tight Boxes
15-3
Junction Boxes - Wire Entry Holes
15-3
Potting Compound - MIL-M-24041
11-5
Potting Compound - Mixing Instructions
11-6
Potting Compound - preparation
11-2
Potting Compound - Storage
11-3
Potting Compound - Storage Life
11-6
Potting Compound - Storage Mixed
11-3
Potting Compound - Storage Unmixed
11-3
Potting Compound - Surface Preparation
11-6
Potting Connectors
10-38
Potting Fluorocarbon Insulated Wire
11-3
Protection Against Battery Acids
4-7
Protection Against Chafing
4-6
Protection Against High Temperature
4-6
Protection Against Overheating
7-6
Protection Against Personnel and Cargo
4-7
Protection Against Solvents and Fluids
4-7
Protection in Wheel Wells and Wing Folds
4-7

Alphabetical Index
Protection of Electrical Connectors
10-36
Soldering - Securing the Joint
7-5
Pulse Connectors - Ceramic Insert
12-31
Soldering - Torch
7-3
Pulse Connectors - Rubber Insert
12-35\1
Soldering Cleanliness
7-4
Pulse Series Connectors
12-31
Soldering Flux
3-5, 7-2
Soldering Iron
7-3, 7-5
Q
R
Rectangular Connectors
10-48
Reducing Wire Size at MS Connector
10-35
Reinstalling Convoluted and Standard Boots
10-47
Soldering Iron Holder
7-6
Soldering Iron Preparation and Maintenance
7-3, 7-4
Soldering Iron Tinning Procedure
3-6
Soldering Operations
7-2, 7-4
Soldering Precautions and Procedures
7-4
Soldering Tips
7-5
Removing Contacts from Connectors
10-26
RF Connectors
12-1
RF Connectors - BNC and TNC Series
12-7
RF Connectors - Miniature
12-36
RF Connectors - Soldering Coaxial Cable
12-6
Splices - Environment Resistant Wire

Disconnects
6-13
RF Connectors Sub-miniature
12-38
Splices - Environmental M81824
6-12
RF Connectors Used in FQI Systems
12-41
Splices - Inspection of
18-5
Routing and Installation
4-5
Splices - Nickel
6-13
Splices - Nickel Plated
6-13
S
Sealing Plugs - Connector
10-62
Solders
10-3
Spiral Wrap
8-7
Spliced Connection in Bundles
4-3
Splicing - Multi-wire
6-13
Splicing Small Copper Wires
6-11
Splicing to Reduce Wire Size
6-13
Stripping Dimensions
3-4
Stripping Instructions General
3-2
Stripping Jacket on Shielded Cable
3-6
Stripping Kapton Wire with a Hand Stripper
3-3
Stripping Methods for Aluminium Wire
3-2
Self-Clinching Cable Straps and Spiral Wrap
8-5
Semi-Rigid Cable - Bending Procedures
12-48
Semi-Rigid Cable - Preparing
12-47
Semi-Rigid Cable - Termination
12-48
Semi-Rigid Cable - Tooling
12-47
Separation from Control Cables
4-8
Separation from Plumbing Lines
4-7
Shear Wiring Emergency Devices
9-6
Shear Wiring of Electrical Components
9-5
Shield Connections
10-33
Shield Termination - Grounded
3-6
Shield Termination - Ungrounded (Floating)
3-10
Sleeving Identification
2-8
Solder and Flux Selection
7-4
Solder Contacts
10-4
Solder Hard
7-2
Terminal Boards - Attaching Busbar
Solder Joint - Acceptable
7-6
Terminal Boards - Hardware for Wiring
4-21
Solder Joint - Cleaning
7-6
Terminal Boards - Identification
15-8
Solder Joint - Cooling the
7-6
Terminal Boards - Installation
15-6
Solder Joint - Inspecting
7-6
Terminal Boards - Insulation
15-7
Solder Joint - Unacceptable
7-6
Terminal Boards - Method of Attachment
15-7
Solder Sleeves
3-8
Terminal Boards - Mounting Hardware
15-6
Solder Soft
7-1
Terminal Boards - Protection
15-8
Soldering
7-1
Terminal Junction System
4-28
Soldering - Amount of Solder
7-5
Terminal Junction System - Crimping
4-35
Soldering - Application of Heat and Solder
7-5
Terminal Junction System - Insertion and
Soldering - Dip
7-3
Soldering - Heat Application Time
7-5
Soldering - Heating Capacity
7-5
Soldering - Pre-Tinning
7-4
Terminal Junction System Components
4-32
Soldering - Resistance
7-3
6-14
Stripping Methods for Copper Wire
3-2
Stripping Wire and Cable
3-2
Stripping Wire with Hot-Blade Stripper
3-3
Sub-miniature Connectors Crimping
12-39
Sub-miniature RF Connectors
12-38
Support
4-5
Switches Inspection of
18-7
Extraction of Terminals
15-8
4-36
Terminal Junction System - Installation and

Removal
4-32

Alphabetical Index
Terminal Lugs - Connecting to Busbars
4-22
Tying Sleeves to Wire Groups or Bundles
8-5
Terminal Lugs - Connecting to Equipment
4-25
Tying Wire Groups into Wire Bundles
8-5
Terminal Lugs - Connecting to Terminal

Boards
4-18
Terminal Lugs - High Temperature
6-3
Unit Number
Terminal Lugs - Pre-Insulated
6-2
Terminals and Terminal Blocks - Inspection
18-5
Terminals - Gold Plated, PIDG, Ring Tongue,

Insulated
6-3
Terminals - Nickel Plated Ring Tongue
6-3
Wire - Airframe
1-3
Terminals - Nickel Ring Tongue Terminals
6-3
Wire - Aluminium
1-3
Terminals, Large Copper - Installation
4-22
Wire - Hookup
1-4
Terminating Large Copper Wires
6-7
Wire - Installation in Junction Boxes
4-28
Terminating Shielded Cable
3-6
Wire - Insulated
1-1
Test Leads
10-36
Wire - Lock
9-1
Thermocouple Contacts in MS Connectors
16-3
Wire - Seal
9-1
Thermocouple Terminals and Connectors
16-1
Wire - Shear
9-1
Thermocouple Wire - Attaching Terminals
16-7
Thermocouple Wire - Cleaning for Soldering
16-3
Wire and Cable - Safety of Flight Critical

EMI Sensitive
2-3
Thermocouple Wire - Cleaning Silver Soldered

Terminal Connections
Wire and Cable - Cutting
3-1
16-8
Wire and Cable Junctions - Inspection of
18-6
Thermocouple Wire - Cutting and Identifying
16-3
Wire and Cable - Stripping
3-2
Thermocouple Wire - Hard Soldering
16-5
Wire and Cable Selection
1-3
Thermocouple Wire - Mounting AN5537

Connector Assembly
16-15
Wire and Component Identification Codes for

Modification
2-4
Thermocouple Wire - Protection
16-15
Wire Bundle
8-1
Thermocouple Wire - Resistance Soldering
16-8
Wire Bundle Size
4-2
Thermocouple Wire - Resistance Tinning
16-6
Wire Bundles and Harnesses - Identification
2-9
16-15
Wire Combing
4-2
10-87
Thermocouple Wire - Routing
2-1
16-9
Wire Connection Procedure
Thermocouple Wire - Slack
16-15
Wire Current Carrying Capacity
1-5, 1I-1
Thermocouple Wire - Soft Soldering
16-9, 16-10
Wire Gauge
1-5, 1J-1
Thermocouple Wire - Serving
Wire Group
8-1
16-11
Wire Groups and Bundles
4-2
Thermocouple Wire - Soldering to MS

Connectors
16-10
Wire Identification at Terminal Boards and

Enclosures
2-7
Thermocouple Wire - Splicing
16-11
Wire Identification Code
2-1, 2-4
Thermocouple Wire - Stripping
16-3
Wire Identification Methods
2-6
Thermocouple Wire - Stub Splicing
16-12
Wire Identification Sleeving
2-8
Thermocouple Wire - Tinning Terminals
16-7, 16-9
Wire Identification Spacing
2-6
Thermocouple Wire - Torch Soldering
16-8
Wire Identification Spare Contacts
2-2
Thermocouple Wire - Torch Tinning
16-5
Wire Insulations
1-5
Thermocouple Wire - Identification
2-7
Wire Insulation Repair
4-36
Thermocouple Wire Leads
16-1
Wire Limitations
1-5
Thermocouple Wire - Preparation
16-3
Wire Marking
2-7
Ties
8-4
Wire Marking Objectives
2-6
Ties - Temporary
8-5
Wire Numbers
2-1, 2-4
Tightness of Wire
9-3
Wire Protection
4-6, 4-7
Tinning Copper Wire and Cable
3-5
Wire Routing and Installation
4-5
Triaxial Connectors
12-55
Wire Support
4-5
Twisting Wires
4-2
Wire Twisting
4-2
Twisting with Pliers
9-2
Wire Types
4-2
Twisting with Special Tools
9-3
Wire Removal Procedure
10-87
Tying
8-1, 8-4
Wire Repair - Single
5-1
Thermocouple Wire - Soldering to AN5537

Firewall Connector

Alphabetical Index
Wire Segment Letter
2-1
Wire Separation
4-2
Wire Size - Minium
1-5
Wire Size - Maximum
1-5
Wire Size Number
2-2
Wire Slack
4-4
Wire Sleeve Marking Location
2-8
Wire Sleeve Stamping
2-8
Wire Specifications
1-4
Wire Stamping
2-8
Wire Support at End of Rigid Conduit
4-25
Wire Support Inside Junction Boxes
4-28
Wire Temperature Ratings
1-5
Wire Types
4-2
Wires - Preparation Prior to Assembly
10-4
Wires - Pre-shaping
10-10
Wires Added at Modification
2-3
Wires Sensitive to EMI
2-3
Wiring - Identification Sleeves
2-8
Wiring Installation
4-1
Wiring Installation - EMI Sensitive
2-3
Wiring Installation Inspection
18-1
Wiring Qualification - EMI Sensitive
2-3
X
XLETFE
Y
Z
1-4

Sect 1 Chap 1
SECTION 1
CHAPTER 1
INTRODUCTION
GENERAL
1.
This AC has been produced to assist personnel
engaged in the installation, maintenance and repair of
aircraft and ground support equipment (GSE) electrical
systems.
2.
The satisfactory performance of present-day
aircraft depends to a very great extent on the continuing
reliability of its electrical system. Improperly or carelessly
installed wiring can be a source of both immediate and
potential danger, and many malfunctions and failures of
an electrical system can be traced to this cause. The
performance of the system depends on the quality of the
design, plus the workmanship used in producing the
installation. The continued proper performance of the
system depends on the know-how of the personnel who
carry out the inspection, repair and maintenance.
3.
It is extremely important therefore, that
maintenance and repair operations, as well as the
original installation, be carried out in accordance with the
best available techniques in order to eliminate possible
failures or at least to minimise them.
PURPOSE
4.
The purposes for which this AC was written are as
follows:
a.
To gather together under one cover the

recommended practices and techniques to be
used for installing, repairing, and maintaining
aircraft and GSE electrical wiring.
b. To standardise these techniques and methods so

that electrical installations will be uniform.
c.
To highlight to all personnel the importance of

good workmanship and the failures which may
result from poor workmanship.
d. To promote safety by pointing out unsafe

practices.
SCOPE
5.
This AC covers all general purpose wiring and
wiring devices used for the interconnection of equipment
in aircraft. It also includes details of thermocouple
systems and coaxial, fibre optics, and data bus cabling

installed in aircraft. This AC is not intended to replace
aircraft manufacturers wiring manuals or recommended
practices.
INTENDED USE
6.
This AC is intended to be used as a separate
manual for general wiring practices, and is primarily
used by personnel engaged in maintenance and repair
of aircraft wiring systems were no other data exists for
repair or maintenance. Its use is recommended for such
personnel, except where any procedure contained in it
conflicts with any aircraft or equipment specific
publication in which case the aircraft or equipment
specific document should take precedence.
ARRANGEMENT OF MATERIAL
7.
The material is divided into chapters. Each
chapter describes and illustrates the recommended
procedure for a single operation, or for a series of
related operations.
8.
The first seven chapters contain procedures for
preparing and identifying wire, and for assembling it to
connectors, terminals and splices. Later chapters deal
with procedures for thermocouple wiring, bonding and
grounding, soldering, potting, routing and support of wire
bundles, and preparation and installation of busses,
terminal blocks, junction boxes, and protective devices.
9.
The material in each chapter is arranged as far as
possible in the general order in which the operations are
performed. Illustrations and tables are located as near
as possible to the related text. Each topic is headed by
an introduction containing a short description of the
subject and its function in the aircraft electrical system.
Where necessary for clarity, a list of definitions is
included.
10. Also included, after the introduction of applicable
chapters, is a listing of applicable specifications for the
various materials required and design procedures on
which these installation techniques are based. The latest
applicable revision of the listed specifications shall
apply.

Sect 1 Chap 1
REVISIONS
11. Amendments will be made from time to time to
ensure that the material in the manual will always reflect
the best current techniques and keep abreast of the new
developments in the field. Suggestions for correcting or
improving this manual are invited and should be
submitted to the Standards Division at CASA,
www.casa.gov.au

Sect 2 Chap 1
SECTION 2
CHAPTER 1
WIRE AND CABLE

INTRODUCTION
1.
In order to make installation, maintenance, and
repair easier, runs of electric wire and cable in aircraft
are broken at specified locations by junctions such as
connectors, terminal blocks, busses, etc. Before
assembly to these junctions, wires and cables must be
cut to length, identified, stripped, and if required, tinned.
2.
This chapter describes a variety of wire and
cables suitable for use in aircraft.
REFERENCE SPECIFICATIONS
3.
The following specifications are applicable to
aircraft wire and cable preparation:
MIL-C-17
Cable, Radio Frequency,

Flexible and Semirigid, General
Specification
MIL-C-5756
Cable and Wire Power, Electric,

Portable
MIL-C-85485
Cable, Electric, Filter Line, Radio

Frequency Absorptive
MIL-DTL-16878
Wire, Electrical, Insulated,

General Specification
MIL-DTL-25038
Wire, Electrical, High

Temperature and Fire Resistant
Aircraft
MIL-DTL-8777
Wire, Electrical Silicone

Insulated Copper, 600 Volts,
200C
MIL-W-22759
Wire, Electric, Fluoropolymer

Insulated, Copper or Copper
Alloy
MIL-W-7072
(Cancelled)
Wire Electric, 600 Volts,

Aluminium, Aircraft
NEMA WC 27500
Cable, Electrical, Shielded and

Unshielded, Aerospace
SAE AS 81044
Wire, Electric, Crosslinked

Polyalkene, Crosslinked Alkaneimide Polymer, or Polyarylene
Alloy
MIL-DTL-81381
Wire, Electric, Polyimide

Insulated, Copper and Copper
Alloy
DEFINITIONS
Insulated Wire
4.
For the purposes of electric and electronic
installation in aircraft, an insulated wire consists of a
metal conductor covered with a dielectric or insulating
material (refer to Figure 11). Insulated wire is usually
referred to as wire and will be so designated in this
manual. Wires used in aircraft contain stranded
conductors for flexibility. Insulations may consist of
several materials and layers to provide dielectric
insulation, thermal protection, abrasion resistance,
moisture resistance, and fluid resistance. Wires
commonly used in aircraft are described in Table 11.
Insulations commonly used in aircraft are described in
Table 12.
Cable
5.
The term cable, as used in aircraft electrical
installations (refer to Figure 12), includes the following:
a.
Two or more insulated conductors, contained in a

common covering, or twisted together without a
common covering (multi-conductor cable).
a.
One or more insulated conductors with an overall

shield, or with an overall shield and a jacket over
the shield (shielded cable).
b. Two insulated conductors twisted together

(twisted pair).
c.
A single insulated centre conductor with a metallic

braided outer conductor (coaxial cable). The
concentricity of centre and outer conductor is
carefully controlled during manufacture to ensure
that they are coaxial.

Sect 2 Chap 1
Figure 1- 1 Wires Commonly Used In Aircraft
6.
Cables commonly used in aircraft include the
following:
Figure 1- 2 Cables Commonly Used In Aircraft
MIL-C-17
Cable, Radio Frequency,

Flexible and Semirigid
(Coaxial)
MIL-C-5756
Single or multiple conductor,

rubber insulated conductor,
rubber jacket.
MIL-C-85485
Cable, Electric, Filter Line,

Radio Frequency Absorptive
NEMA WC 27500
Single or multiple conductor,

using any wire listed in Table
11, shielded, with tin coated,
silver-coated, or nickel-coated
copper braid as appropriate
and covered with appropriate
jacket.

Sect 2 Chap 1
SELECTION OF AIRCRAFT ELECTRICAL

WIRE AND CABLE
General
7.
Wire and cable is to be of a type suitable for the
application. It is to be selected so that the maximum
conductor temperature is not exceeded for any
combination of electrical loading, ambient temperature
and heating effects of bundles, conduits or other
enclosures. Factors to be considered include voltage,
current, ambient temperature, mechanical strength,
abrasion qualities, flexibility and pressure/altitude
requirements.
8.
This AC limits the installation of specific wire
type/gauge in aircraft to replacement of old type wire
with a similar type and appropriate gauge as detailed in
this chapter or applicable aircraft documentation.
NOTE
Installation of wire for modification, design or repair for
devices used in aerospace applications, should conform
to SAE AS 50881, Wiring Aerospace Vehicle.
9.
A standard of wire is MIL-W-22759 and is suitable
for general aircraft use. Annex C to this chapter details
the method of determining the appropriate wire part
number. If the part number is not identified:
a.
Aluminium Wire
10. The use of aluminium wire for aircraft use is quite
limited and whenever replacement of an installed wire is
necessary, it may be advantageous to consider copper
wire with similar electrical/physical characteristics.
Currently there are no appropriate specifications
detailing aluminium wire suitable for use in general
aviation aircraft. Annex E to this chapter provides details
of MIL-W-7072 that was cancelled in 1997. This
information may be useful when determining a suitable
replacement wire.
NOTE
Aluminium wire may be used on new aircraft designs
and manufacturers information should be used to
maintain this type of wire.
Airframe Wire
11. Airframe wire is wire that is specifically designed
for use as component interconnection wire in the
airframe of aerospace vehicles. Airframe wire is usually
classed as normal or medium weight and has two
insulation coverings for protection against abrasions.
This type of wire should be used where a secondary
covering of insulation material is not required. The
M22759/34 (tin plated, 150C) and M22759/43 (silver
plated, 200C) wire is suitable for general airframe wire.
Variants of the original part number may be

required ie colour, stranding or insulation type,
b. Other Military Specification wire types should be

investigated.
Table 11 Airframe Wire Used In Aircraft Electrical Installations

Applicable Specification
Title/Description
MIL-DTL-16878
Wire, Electrical, Insulated, General Specification For
MIL-DTL-25038
Wire, Electrical, High Temperature and Fire Resistant, Aircraft
MIL-DTL-81381
Wire, Electric, Polyimide-Insulated, Copper and Copper Alloy
MIL-DTL-8777
Wire, Electrical, Silicone-Insulated, Copper, 600V, 200C
MIL-W-22759
Wire, Electric, Fluoropolymer Insulated, Copper or Copper Alloy
MIL-W-7072
(Cancelled)
Wire, Electric, 600 Volt, Aluminium, Aircraft, General Specification For
SAE-AS-81044A
Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkane-imide, or Polyarylene Insulated,

Copper or Copper Alloy

Sect 2 Chap 1
Hookup Wire
NOTE
Stranded conductor wire is used for flexibility. In low
temperature wire (150C), copper or copper alloy
strands are tin plated to facilitate soldering. In wire rated
at 200C conductor temperature, silver plating is used to
protect the copper from oxidation and to facilitate
soldering. Wires for high temperatures (260C) are
nickel plated to prevent oxidation. Nickel plated wire is
more difficult to solder, but satisfactory solder
connections can be made with proper techniques. It is
also more difficult to obtain low resistance crimp
terminations on nickel plated wire.
NOTE
Hookup wire is not to be used in the airframe of
aerospace vehicles where the wire or loom is not
covered with a secondary insulation (ie PTFE conduit)
for abrasion protection.
12. Hookup wire is designed for component

interconnection inside a box or as an airframe wire only
where there is a secondary insulation covering for
abrasion protection. Hookup wire is usually classed as
lightweight and has only one insulation covering. Hookup
wire is normally of a smaller overall diameter than the
equivalent gauge airframe wire. M22759/32 (tin plated,
150C) and M22759/33 (silver plated, 200C) wire is
suitable for general hookup wire.
Specifications
13. Annexes to this chapter contain limited details of
each Military Specification wire and cable suitable for
aircraft use.
Table 12 Common Aircraft Wire Insulations
Type
Description
Asbestos
Asbestos is used to provide high temperature and flame resistance.

No longer suitable for use due to health and safety issues.
ETFE (Ethylenetetrafluoroethylene)
ETFE is a fluoropolymer rated up to 260C. It is widely used as aircraft wire insulation.
FEP-Fluorocarbon
(Fluorinated ethylene
propylene)
FEP is rated at 200C, but will melt at higher temperatures. FEP has properties similar to
TFE, but will melt at soldering temperatures.
Glass Braid
Widely used to provide thermal resistance and cut-through resistance. However, it may
absorb moisture and its use is becoming less prevalent.
Polyamide (Nylon)
Widely used in low temperature wires as an outer insulation layer for abrasion resistance
and fluid resistance.
Polyimide (Kapton)
This material has excellent thermal, abrasion, and cut-through resistance characteristics
however due to its susceptibility to arc tracking its use is discouraged in new installations.
PVC (Polyvinyl Chloride)
PVC is a common wire insulation and is fitted in older aircraft. It is no longer approved for
use in manned aerospace applications. It may be used for replacement purposes however
alternate insulations should be considered.
Silicone Rubber
Silicone rubber is rated at 200C. It is highly flexible and self-extinguishing after flame except
in vertical runs. The ash produced is non-conducting.
TFE-Fluorocarbon
(polytetrafluoroethylene)
TFE or PTFE is widely used as a high-temperature insulation. It will not burn but will
vaporise in flame. It will not melt at soldering temperatures. TFE is resistant to most fluids.
XLETFE Crosslinked
Ethylene-tetrafluoroethylene
XLETFE is ETFE that has been irradiated (crosslinked) to produce a tougher insulation.

Sect 2 Chap 1
f.
Limitations
14. Insulation. Except for existing installations, the
use of polyvinyl chloride (PVC) insulated wire and cable
for manned aerospace applications is prohibited.
15. Kapton. Due to the undesirable properties
exhibited by polyimide (Kapton) insulated wiring, its use
in aircraft should be avoided wherever practicable.
Wire Temperature Ratings
16. Generally, aircraft electrical wire must be selected
to perform continuously in a specified temperature range
ie 150C, 200C, 260C or fire resistant. Degradation will
occur if the wire is subjected to continuous operation at
elevated temperatures. Factors to be considered that will
affect the temperature are:
a.
Wire Gauge. The wire should be of a gauge to

ensure adequate current carrying capacity so that
the voltage drops are acceptable.
b. Current Carrying Capacity. The continuous duty

current for each wire gauge is specified in Annex I
to this chapter.
c.
Bundle/Looms or Conduit. Annex I to this chapter

details current ratings for the following:
(1) wires positioned in free air, and
(2) wires in bundles, conduit or confined areas.
NOTE
The ratings listed in Annex I are based upon bundles of

33 or more wires. For further information on current
ratings, refer to SAE AS 50881 or contact the publication
sponsor.
d. Aluminium Wire. The use of aluminium wire shall
be restricted in applications and should not be:
Aluminium
Terminations.
Aluminium
terminations should conform to SAE AS 70991.
Refer to Section 2, Chapter 6 of this publication
for details of aluminium terminals.
g. Minimum Wire Size. The minimum wire sizes are

specified below unless authorised by specific
aircraft publications.
(1) Copper Wire. SAE AS 50881 prohibits the
use of wires smaller than 22 AWG for use in
aircraft, helicopters and lighter than air
vehicles. This restriction is due to
maintenance difficulties, however many
service aircraft have now been
manufactured using 24 AWG and 26 AWG
wire. When required, these wires should be
repaired/replaced with similar gauge wires.
Appropriate precautions should be taken to
prevent failure caused by vibration and
handling and wires should be adequately
supported at each termination. For direct
attachment to engine mounted accessories,
wire size smaller than 18 AWG should not
normally be used, however where 20 AWG
wires are required they may be used,
provided they are grouped, spot tied and
clamped to the connector. If fewer than four
20 AWG wires are used with one connector,
insulated tubing is to be used.
(2) Aluminium Wire Size. Aluminium wire is
restricted to 8 AWG minimum. (Refer to
para 10).
h. Maximum Wire Size. The maximum wire sizes
should be as listed below, unless specifically
authorised
by
the
applicable
aircraft
documentation.
(1) Copper wire - 2 AWG.
(2) Aluminium wire - 0 AWG.
(1) directly attached to engine mounted

accessories or any area of severe vibration,
or
e.
installed where frequent connection/disconnection

is necessary.

Sect 2 Chap 1
Annexes:
A.
MIL-DTL-16878 Wire, Electrical, Insulated,

F.
NEMA WC 27500 Standard For Aerospace and

Industrial Electrical Cable
B.
SAE-AS-81044 Wire, Electrical, Crosslinked

Polyalkene, Crosslinked Alkane-imide Polymer
or Polyarylene Insulated Copper or Copper
Alloy
G.
MIL-DTL-81381 Wire, Electric, PolyimideInsulated, Copper
H.
MIL-C-85485 Cable, Electric, Filter Line, Radio

Frequency Absorptive
C.
MIL-W-22759 Wire, Electric Fluoropolymer

Insulated Copper or Copper Alloy
I.
Current Ratings of Wire and Maximum

D.
MIL-DTL-25038
Wire,
Electrical,
High
Temperature, Fire Resistant and Flight Critical,
J.
E.
MIL-W-7072 Wire, Electric, 600 Volt,

Aluminium, Aircraft, General Specification

Annex A to Sect 2 Chap 1
MIL-DTL-16878 WIRE, ELECTRICAL, INSULATED, GENERAL

SPECIFICATION
Scope
1.
This specification covers unshielded wire for hook-up and lead wiring of electrical and electronic components and
equipment. The temperature rating of wire under this specification ranges from -65C to 260C, with potential rating
from 250Vrms to 5000Vrms.
2.
Specification Sheets are as follows:

Table 1-A-1 Specification Sheets
Description
MIL-W-16878D
MIL-W-16878E
MIL-W-16878F
MIL-DTL-16878G
600 Volt,105C, PVC
TYPE B
M16878/1
M16878/17
M16878/1
M16878/17
M16878/1
M16878/17
1000 Volt,105C, PVC
TYPE C
M16878/2
M16878/18
M16878/2
M16878/18
M16878/2
M16878/18
3000 Volt,105C, PVC
TYPE D
M16878/3
M16878/19
M16878/3
M16878/19
M16878/3
M16878/19
600 Volt, 200C/260C,

PTFE
TYPE E
M16878/4
M16878/21
M16878/25
M16878/26
M16878/4
M16878/21
M16878/25
M16878/26
NEMA HP 3
NEMA HP 3
NEMA HP 3
NEMA HP 3
1000 Volt, 200C/260C,

PTFE
TYPE EE
M16878/5
M16878/22
M16878/27
M16878/28
M16878/34
M16878/35
M16878/5
M16878/22
M16878/27
M16878/28
M16878/34
M16878/35
NEMA HP 3
NEMA HP 3
NEMA HP 3
NEMA HP 3
NEMA HP 3
NEMA HP 3
250 Volt, 200C/260C,

PTFE
TYPE ET
M16878/6
M16878/20
M16878/23
M16878/24
M16878/6
M16878/20
M16878/23
M16878/24
NEMA HP 3
NEMA HP 3
NEMA HP 3
NEMA HP 3
600 Volt, Silicone Rubber
TYPE F
M16878/7
M16878/29
M16878/7
M16878/29
M16878/7
M16878/29
1000 Volt, Silicone Rubber
TYPE FF
M16878/8
M16878/30
M16878/31
M16878/32
M16878/8
M16878/30
M16878/31
M16878/32
M16878/8
M16878/30
M16878/31
M16878/32
PE, 75C
TYPE J
M16878/10
M16878/33
M16878/10
M16878/33
M16878/10
M16878/33
FEP, 600 Volt, 200C
TYPE K
M16878/11
M16878/11
NEMA HP 4
FEP, 1000 Volt, 200C
TYPE KK
M16878/12
M16878/12
NEMA HP 4
FEP, 250 Volt, 200C
TYPE KT
M16878/13
M16878/13
NEMA HP 4
XLPE, 600 Volt, 125C
---
M16878/14
M16878/14
M16878/14
---
M16878/15
M16878/15
M16878/15
---
M16878/16
M16878/16
M16878/16
XLPO, 600 Volt, 105C
---
---
M16878/36
M16878/36
1A1

Table 1-A-1 Specification Sheets (continued)

Description
MIL-W-16878D
MIL-W-16878E
MIL-W-16878F
MIL-DTL-16878G
EPDM, 600 Volt, 125C
---
---
M16878/37
M16878/37
EPDM, 5000 Volt, 125C
---
---
M16878/38
M16878/38
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA HP 3 -
Electrical and Electronic PTFE Insulated High Temperature Hook-Up Wire; Types ET (250 Volts), E (600
Volts) and EE (1000 Volts)
NEMA HP 4 -
Electrical and Electronic FEP Insulated High Temperature Hook-Up Wire; Types KT (250 Volts), K (600
Volts) and KK (1000 Volts).
Part Number
3.
Part numbers under this specification are coded as in the following example:
Table 1-A-2 Part Number Coding

M16878/3
903
Specification Sheet
(para 2)
Conductor Material
(para 4)
Conductor Size
(para 5)
Conductor Stranding
(para 6)
Insulation Colour Code

(para 7)
Conductor Material
4.
Conductor Material is designated by a single letter as follows:

B Coated Copper
C Coated Copper-Clad Steel
D Coated High Strength Copper Alloy
Conductor Size
5.
The conductor American Wire Gauge (AWG) size is designated by a single letter as follows:
Table 1-A-3 Conductor Size
1A2
AWG
Letter
AWG
Letter
32
30
28
26
24
22
20
18
16
14
12
A
B
C
D
E
F
G
H
J
K
L
10
8
6
4
2
1
0
00
000
0000
M
N
P
R
S
T
U
W
Y
Z

Conductor Stranding
6.
The number of strands making up the conductor is designated by a single letter as follows:
Table 1-A-4 Conductor Stranding

Number of Strands
Letter
Number of Strands
Letter
1
7
10
16
19
26
37
41
65
105
A
B
C
D
E
F
G
H
J
K
133
259
427
665
817
1045
1330
1672
2109
L
M
M
P
R
S
T
V
W

7.
The insulation colour code is in accordance with the identification coding of MIL-STD-681 and may be one, two,
or three digits depending on the number of stripes or bands. The first number is the colour of the insulation; the second
number is the colour of the first stripe or band; and the third number is the colour of the second stripe or band. The
colours and their corresponding numbers are as follows:
Table 1-A-5 Colour Code

Colour
Number Designator
Colour
Number Designator
Black
Green
Brown
Blue
Red
Violet (Purple)
Orange
Grey (Slate)
Yellow
White
1A3

Annex B to Sect 2 Chap 1
SAE-AS-81044 WIRE, ELECTRICAL, CROSSLINKED POLYALKENE,

CROSSLINKED ALKANE-IMIDE POLYMER OR POLYARYLENE
INSULATED COPPER OR COPPER ALLOY
Scope
1.
This specification covers single conductor electric wires made as specified in the applicable specification sheet
with tin-coated, silver-coated or nickel-coated copper or copper alloy conductors insulated with crosslinked polyalkene,
crosslinked alkane-imide polymer or polyarylene. The crosslinked polyalkene, crosslinked alkane-imide polymer or
polyarylene may be used alone or in conjunction with other materials as detailed in the specification sheet.
2.
Table 1-B-1 Specification Sheets

Specification No
Title
SAE-AS-81044/5
Wire, Electric, Crosslinked Polyalkene Insulated, Silver-coated Copper, Normal Weight, 600 Volt,
150C.
SAE-AS-81044/6
Wire, Electric, Crosslinked Polyalkene Insulated, Tin-coated Copper, Normal Weight, 600 Volt,
150C.
SAE-AS-81044/7
Wire, Electric, Crosslinked Polyalkene Insulated, Silver-coated Copper, High Strength Copper
Alloy, Normal Weight, 600 Volt, 150C.
SAE-AS-81044/8
Wire, Electric, Crosslinked Polyalkene Insulated, Silver-coated Copper, Medium Weight, 600
Volt, 150C.
SAE-AS-81044/9
Wire, Electric, Crosslinked Polyalkene Insulated, Tin-coated Copper, Medium Weight, 600 Volt,
150C.
SAE-AS-81044/11
Wire, Electric, Crosslinked Polyalkene Insulated, Silver-coated Copper, Light Weight, 600 Volt,
150C.
SAE-AS-81044/12
Wire, Electric, Crosslinked Polyalkene Insulated, Tin-coated Copper, Light Weight, 600 Volt,
150C.
Part Number
3.
Table 1-B-2 Part Number Coding

M81044/5
- 22
-9
Specification Sheet
(para 2)
Conductor Size (AWG)

(para 4)
1B1

Annex B to Sect 2 Chap 1
Colour Chart
4.
The colour coding is as follows:
Table 1-B-3 Colour Code

Colour
1B2
Number Designator
Colour
Number Designator
Black
Green
Brown
Blue
Red
Violet (Purple)
Orange
Grey (Slate)
Yellow
White

Annex C to Sect 2 Chap 1
MIL-W-22759 WIRE, ELECTRIC FLUOROPOLYMER-INSULATED

COPPER OR COPPER ALLOY
Scope
1.
This specification covers fluoropolymer-insulated single conductor electric wires made with tin coated, silver
coated or nickel-coated conductors of copper or copper alloy as specified in the applicable specification sheet. The
fluoropolymer insulation of these wires may be polytetrafluoroethylene (TFE), fluorinated ethylene propylene (FEP),
polyvinylidene fluoride (PVF2), ethylene-tetrafluoroethylene copolymer (ETFE), or other fluoropolymer resin. The
fluoropolymer may be used alone or in combination with other insulation materials.
2.
Table 1-C-1 Specification Sheets

Specification No
Title
MIL-W-22759/1
Wire, Electric, Fluoropolymer-insulated, TFE and TFE Coated Glass, Silver Coated Copper
Conductor, 600 Volt, 200C.
MIL-W-22759/2
Wire, Electric, Fluoropolymer-insulated, TFE and TFE-Coated Glass, Nickel Coated Copper
MIL-W-22759/5
Wire, Electric, Fluoropolymer-insulated, Abrasion Resistant, Extruded TFE, Silver Coated Copper
MIL-W-22759/7
Wire, Electric, Fluoropolymer-insulated, Abrasion Resistant, Extruded TFE, Medium Weight, Silver
Coated Copper Conductor, 600 Volt, 200C.
MIL-W-22759/8
Wire, Electric, Fluoropolymer-insulated, Abrasion Resistant, Extruded TFE, Medium Weight, Nickel
MIL-W-22759/11
Wire, Electric, Fluoropolymer-insulated, Extruded TFE, Silver Coated Copper Conductor, 600 Volt,
200C.
MIL-W-22759/12
Wire, Electric , Fluoropolymer-insulated, Extruded TFE, Nickel Coated Copper Conductor, 600 Volt,
260C.
MIL-W-22759/16
Wire, Electric, Fluoropolymer-insulated, Extruded TFE, Medium Weight, Tin Coated Copper
MIL-W-22759/22
Wire, Electric, Fluoropolymer-insulated, Extruded TFE, Silver Coated, High Strength, Copper Alloy
MIL-W-22759/32
Wire, Electric, Fluoropolymer-insulated, Cross-Linked Modified ETFE, Light Weight, Tin Coated
Copper Conductor, 600 Volt, 150C.
MIL-W-22759/33
Wire, Electric, Fluoropolymer-insulated, Cross-Linked Modified ETFE, Light Weight, Silver Coated,
High Strength, Copper Alloy Conductor, 600 Volt, 200C.
MIL-W-22759/34
Wire, Electric, Fluoropolymer-insulated, Cross-Linked Modified ETFE, Normal Weight, Tin Coated
Copper Conductor, 600 Volt, 150C.
MIL-W-22759/41
Wire, Electric, Fluoropolymer-insulated, Cross-Linked Modified ETFE, Normal Weight, Nickel

MIL-W-22759/43
Wire, Electric, Fluoropolymer-insulated, Cross-Linked Modified ETFE, Normal Weight, SilverCoated Copper Conductor, 600 Volt, 200C.
1C1

Annex C to Sect 2 Chap 1
Part Number
3.
Table 1-C-2 Part Number Coding

M22759/1
- 22
-9
Specification Sheet
(para 2)
Wire Size
(AWG)

(para 4)
Colour Chart
4.
Table 1-C-3 Colour Code

Colour
1C2
Number Designator
Colour
Number Designator
Black
Green
Brown
Blue
Red
Violet (Purple)
Orange
Grey (Slate)
Yellow
White

Annex D to Sect 2 Chap 1
MIL-DTL-25038 WIRE, ELECTRICAL, HIGH TEMPERATURE, FIRE

RESISTANT AND FLIGHT CRITICAL, GENERAL SPECIFICATION
Scope
1.
This specification covers insulated single wire for electrical use in flight critical circuits and under short-time
emergency conditions involving exposure to flames with temperatures up to 1,093C (2,000F). The wire covered by
this specification is predominantly used in the engine compartment of aerospace vehicles.
WARNING
This wire may contain asbestos.
2.
The use of asbestos products in wire insulation designed for high temperature areas is no longer considered
appropriate due to the well documented health problems attributed to this material. Asbestos materials are NOT to be
used in aircraft electrical systems except under circumstances detailed in the following warning.
WARNING
The introduction of new products and equipment containing asbestos
into the environment is not permitted except where it can be
demonstrated clearly that no suitable alternative is available and that
the use of the product will not create a risk to health.
NOTE
Asbestos has been not been permitted in the manufacture of this wire
since 1993 however as it may be impossible to determine the
manufacture date of wire fitted to aircraft or held in stock, all wire of
this type which has no manufacture date, should be treated as
containing asbestos.
3.
Where asbestos materials are identified or suspected in aircraft electrical systems, Environmental Health
personnel should be contacted to provide advice on appropriate handling procedures. Authorised engineering
personnel should then determine the feasibility of replacing the asbestos products with suitable non-asbestos
alternatives or, where no alternatives are available, introducing appropriate risk management procedures.
4.

Table 1-D-1 Specification Sheets
Specification No
MIL-DTL-25038/1
Title
Wire, Electrical, High Temperature, Fire Resistant and Flight Critical, Normal Weight,
260C, 600 Volt.
Wire sizes 22 through 12 are inactive for new design.
For new design use MIL-W-25038/3.
MIL-DTL-25038/3
Wire, Electrical, High Temperature, Fire Resistant and Flight Critical, Light Weight, Small
Diameter, 260C, 600 Volt.
1D1

Annex D to Sect 2 Chap 1
Part Number
5.
Table 1-D-2 Part Number Coding

M25038/3
- 22
-9
Specification Sheet (para 2)
Wire Size
(AWG)

(para 4)
Note:
For M25038/3, add H to the part number for heavier wall construction.
Colour Chart
6.
Table 1-D-3 Colour Code

Colour
1D2
Number
Designator
Colour
Number
Designator
Black
Green
Brown
Blue
Red
Violet (Purple)
Orange
Grey (Slate)
Yellow
White

Annex E to Sect 2 Chap 1
MIL-W-7072 WIRE, ELECTRIC, 600 VOLT, ALUMINIUM, AIRCRAFT,

GENERAL SPECIFICATION
(CANCELLED)
Scope
1.
This specification covers 600 volt insulated single aluminium conductors capable of continuous operation at a
maximum conductor temperature of 105C (221F). This wire is suitable for use in aircraft using any combination of
electrical loading and ambient temperatures providing that the maximum conductor temperature is not exceeded.
NOTE
This specification and specification sheet were cancelled without
replacement in May 1997 and September 1996 respectively. The details
below are retained for information purposes only and may be useful when
selecting replacement copper wire.
Specification Sheet
2.
Specification Sheet is as follows:
Table 1-E-1 Specification Sheet

Specification No
Title
MS25191
Wire, Electric, 600 Volt, Aluminium, Aircraft
Part Number
3.
Table 1-E-2 Part Number Coding

M25191
- 01
Specification Sheet
(para 2)
Wire Size (para 4)
Insulation Material (para 5)
1E1

Annex E to Sect 2 Chap 1
Wire Size
4.
The conductor size is indicated as follows:
Table 1-E-3 Wire Size

Number
Wire Size (AWG)
01
02
00
03
000
04
0000
Insulation Material
5.
B Primary insulation is Polyvinyl Chloride (PVC) with a secondary insulation of Glass Fibre braid impregnated
with Nylon finisher. Outer layer is Nylon Fiber Braid impregnated with Nylon finisher.
1E2

Annex F to Sect 2 Chap 1
NEMA WC 27500 STANDARD FOR AEROSPACE AND INDUSTRIAL

ELECTRICAL CABLE
Scope
1.
This standard contains requirements for finished cables. The component wires are covered by other referenced
standards. These cables are intended for signal and low voltage power applications with defined environment or
temperature conditions found in commercial aircraft and high performance vehicles.
Classification
1.
The cable shall be constructed as follows:
Table 1-F-1 Classification

Type
Description
Unjacketed
2 to 15 colour coded wires, spirally laid without an overall outer jacket.
Jacketed
2 to 15 colour coded wires, spirally laid with an overall outer jacket.
Shielded
A single wire or 2 to 15 colour coded wires spirally laid, with one or two overall shields.
Shielded and Jacketed
A single wire or 2 to 15 colour coded wires spirally laid, with one or two shields and one
or two jackets.
Cable Designation
2.
Cable shall be identified by a combination of digits and letters (not exceeding 16) in accordance with the
following example.
Table 1-F-2 Cable Part Number Breakdown

M27500
22
SD
23
Identification
Number
Identification
method of cable
wire (See Note)
Wire
Size
(AWG)
Basic wire
Specification
(Table 1-F-3)
Numbers of
Wires
Shield
(Table 1-F-4)
Jacket
(Table 1-F-5)
Note:
Refer to NEMA WC 27500.
1F1

Table 1-F-3 Basic Wire Specification

Symbol
Note:
Wire Specification
TE
MIL-W-22759/16
JF
MIL-DTL-25038/3
MH
MIL-W-81044/9
MV
MIL-DTL-81381/10
SB
MIL-W-22759/32
SD
MIL-W-22759/34
SP
MIL-W-22759/43
Refer to NEMA WC 27500
Table 1-F-4 Shield Identification

Symbol
Note:
Shield Material
No Shield
Tin Coated Copper, 150C (single shield)
Silver Coated Copper, 200C (single shield)
Nickel Coated Copper, 260C (single shield)
Tin Coated Copper, 150C (double shield)
Silver Coated Copper, 200C (double shield)
Nickel Coated Copper, 260C (double shield)
Table 1-F-5 Jacket Identification

Symbol
Note:
1F2
Jacket Material
00
No Jacket
02
Extruded Clear Nylon, 105C (single jacket)
05
Extruded Clear FEP, 200C (single jacket)
06
Extruded White PTFE, 260C (single jacket)
23
White, Crosslinked, Extruded ETFE, 200C (single jacket)
52
Extruded Clear Nylon, 105C (double jacket)
55
Extruded Clear FEP, 200C (double jacket)
56
Extruded White PTFE, 260C (double jacket)

Identification of Cable Wire

3.
The insulation color of wires used within the cable shall be as detailed in Table 1-F-6 or Table 1-F-7. Table 1-F-6
details the color coding of wires, ie. White wire with a colored stripe, which is the current preferred method, and would
normally be used when installing a new cable into an aircraft during modification etc. Table 1-F-7 details the optional
color coding of wires, ie. Solid color wires, which is the method used to identify cable wires currently fitted too many
aircraft and should be used when repairing or replacing these existing cables.
Table 1-F-6 Preferred Cable Identification Method

No of Wires in
Cable
Identification Colors for Respective Wires in Cable

Wire Number
10
11
12
13
14
White
White
Blue
White
Blue
Orange
White
Blue
Orange Green
White
Blue
Orange Green
Red
White
Blue
Orange Green
Red
Black
White
Blue
Orange Green
Red
Black
Yellow
White
Blue
Orange Green
Red
Black
Yellow
Violet
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
10
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
Brown
11
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
Brown
Blue/
Blue
12
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
Brown
Blue/
Blue
Orange/
Orange
13
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
Brown
Blue/
Blue
Orange/ Green/
Orange Green
14
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
Brown
Blue/
Blue
Orange/ Green/ Red/

Orange Green Red
15
White
Blue
Orange Green
Red
Black
Yellow
Violet
Gray
Brown
Blue/
Blue
Orange/ Green/ Red/

Orange Green Red
15
Black/
Black
Note: For cables with 2 to 10 conductors, the wire insulation shall be white with a single colored spiral stripe.
For cables with more than 10 conductors, the wire insulation for conductors 11 to 15 shall be white with double spiral stripes.
(Blue/Blue indicates a white base wire with double blue stripes).
1F3

Table 1-F-7 Optional Cable Identification Method

No of Wires
in Cable
Identification Colors for Respective Wires in Cable

Wire Number
White
Red
Blue
Red
Blue
Yellow
Red
Blue
Yellow
Green
Red
Blue
Yellow
Green
White
Red
Blue
Yellow
Green
White
Black
Red
Blue
Yellow
Green
White
Black
Brown
Red
Blue
Yellow
Green
White
Black
Brown Orange
10
11
12
13
14
15
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
10
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
Gray
11
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
Gray
Red/
White
12
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
Gray
Red/
White
Blue/
White
13
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
Gray
Red/
White
Blue/ Yellow/
White White
14
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
Gray
Red/
White
Blue/ Yellow/ Green/

White White White
15
Red
Blue
Yellow
Green
White
Black
Brown Orange Violet
Gray
Red/
White
Blue/ Yellow/ Green/ Black/

White White White White
Note: For cables with 1 to 10 conductors, the wire insulation shall be a solid color.
For cables with more than 10 conductors, the wire insulation for conductors 11 to 15 shall be a solid color with a stripe.
(Red/White solid red insulation with a white stripe).
1F4

Annex G to Sect 2 Chap 1
MIL-DTL-81381 WIRE, ELECTRIC, POLYIMIDE INSULATED,

COPPER OR COPPER ALLOY (KAPTON)
Scope
1.
This specification covers polyimide-insulated single conductor electric wires made with silver coated or nickel
coated conductors of copper or copper alloy, as specified in the applicable specification sheet. The polyimide insulation
may be used alone or in combination with other insulation materials.
2.

Table 1-G-1 Specification Sheets
Specification No
Title
MIL-DTL-81381/7
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Silver Coated Copper, 600 Volt,
200C. Nominal 5.8 Mil Wall.
MIL-DTL-81381/8
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Nickel Coated Copper, 600 Volt,
200C. Nominal 5.8 Mil Wall.
MIL-DTL-81381/9
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Silver Coated High Strength Copper
Conductor, 600 Volt, 200C. Nominal 5.8 Mil Wall.
MIL-DTL-81381/10
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Nickel Coated High Strength Copper
Conductor, 600 Volt, 200C. Nominal 5.8 Mil Wall.
MIL-DTL-81381/11
Wire, Electric, Fluorocarbon/Polyimide Insulated, Medium Weight, Silver Coated Copper Conductor,
600 Volt, 200C. Nominal 8.4 or 15.4 Mil Wall.
MIL-DTL-81381/12
Wire, Electric, Fluorocarbon/Polyimide Insulated, Medium Weight, Nickel Coated Copper Conductor,
MIL-DTL-81381/13
Wire, Electric, Fluorocarbon/Polyimide Insulated, Medium Weight, Silver Coated High Strength
Copper Alloy Conductor, 600 Volt, 200C. Nominal 8.2 or 8.4 Mil Wall.
MIL-DTL-81381/14
Wire, Electric, Fluorocarbon/Polyimide Insulated, Medium Weight, Nickel Coated High Strength
Copper Alloy Conductor, 600 Volt, 200C, Nominal 8.2 or 8.4 Mil Wall.
MIL-DTL-81381/17
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Silver Coated Copper Conductor. 600
Volt, 200C. Nominal 4.6 Mil Wall.
MIL-DTL-81381/18
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Nickel Coated Copper Conductor, 600
MIL-DTL-81381/19
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Silver Coated, High Strength Copper
Alloy Conductor, 600 Volt, 200C. Nominal 4.6 Mil Wall.
MIL-DTL-81381/20
Wire. Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Nickel Coated, High Strength Copper
Alloy Conductor, 600 Volt, 200C. Nominal 4.6 Mil Wall.
MIL-DTL-81381/21
Wire, Electric, Fluorocarbon/Polyimide Insulated, Light Weight, Tin Coated Copper Conductor, 600
MIL-DTL-81381/22
Wire, Electric, Fluorocarbon/Polyimide Insulated, Medium Weight, Tin Coated Copper Conductor,
1G1

NOTE
Polyimide based wiring insulation (commonly known by the Du Pont
trade name KAPTON) exhibits a property known as flashover or arc
tracking. For this phenomenon to occur, damaged insulation, a
conductive path to ground and sufficient voltage and source current
capability to sustain arcing are required. When these conditions exist,
an arc is produced which converts the insulation to a conductive
carbon residue. Additionally, Polyimide insulation is prone to radial
cracking which results from hydrolytic degradation in humid
environments, and also a property known as memory effect where,
after installation, the wire tends to regain its original manufactured lay
(ie coiled on a spool). For these reasons, the use of polyimideinsulated wiring in aircraft should be avoided. (Refer to Table 1-G-4
for alternate wires).
Part Number
3.
Table 1-G-2 Part Number Coding

M81381/7
22
Specification Sheet (para 2)
Wire Size
(AWG)

(para 4)
Colour Chart
4.
Table 1-G-3 Colour Code

Colour
1G2
Number Designator
Colour
Number Designator
Black
Green
Brown
Blue
Red
Violet (Purple)
Orange
Grey (Slate)
Yellow
White

Cross Reference of Kapton to Non-Kapton Insulated Wires

5.
When selecting a replacement wire, consideration must be given to the specific application and end use. Table
1-G-4, below, provides a direct equivalent for a Kapton wire, however this wire may not be the most appropriate or cost
effective option in all applications.
Table 1-G-4. Equivalent Non-Kapton Insulated Wires

KAPTON
NON-KAPTON
M81381/7
M22759/44
M81381/8
M22759/45
M81381/9
M22759/33
M81381/10
M22759/46
M81381/11
M22759/43
M81381/12
M22759/41
M81381/13
M22759/35
M81381/14
M22759/42
M81381/17
M22759/44
M81381/18
M22759/45
M81381/19
M22759/33
M81381/20
M22759/46
M81381/21
M22759/32
M81381/22
M22759/34
1G3

Annex H to Sect 2 Chap 1
MIL-C-85485 CABLE, ELECTRIC, FILTER LINE, RADIO FREQUENCY

ABSORPTIVE
Scope
1.
This specification covers the requirements for radio frequency absorptive component wires and finished cables
that function electrically as distributed low-pass filters.
2.
Table 1-H-1 Specification Sheets

Specification No
Title
MIL-C-85485/5
Cable, Electric, Filter Line, Component Wire, Tin-Coated Copper Conductor, Radio Frequency
Absorptive, 150C, 600 Volt.
MIL-C-85485/6
Cable, Electric, Filter Line, Component Wire, Silver-Coated High Strength Copper Alloy Conductor, Radio
Frequency Absorptive, 150C, 600 Volt.
MIL-C-85485/7
Cable, Electric, Filter Line, Unshielded, Unjacketed, Multiple-Component, Radio Frequency Absorptive,
150C, 600 Volt.
MIL-C-85485/8
Cable, Electric, Filter Line, Shielded, Jacketed, Radio Frequency Absorptive, 150C, 600 Volt.
MIL-C-85485/9
Cable, Electric, Filter Line, Component Wire, Tin-Coated Copper Conductor, Radio Frequency
Absorptive, 150C, 600 Volt.
MIL-C-85485/10
Cable, Electric, Filter Line, Component Wire, Silver-Coated High Strength Copper Alloy Conductor, Radio
Frequency Absorptive, 150C, 600 Volt.
MIL-C-85485/11
Cable, Electric, Filter Line, Unshielded, Unjacketed, Multiple-Component, Radio Frequency Absorptive,
150C, 600 Volt.
MIL-C-85485/12
Cable, Electric, Filter Line, Shielded, Jacketed, Radio Frequency Absorptive, 150C, 600 Volt.
Part Number
3.
Table 1-H-2 Component Wire

M85485
/5
- 22
- 7L
Basic Specification
Specification Sheet
Wire Size
Color Code
Table 1-H-3 Finished Cable

M85485
Basic
Specification
/8
Specification Sheet
(para 2)
- 22
Wire Size
(AWG)
U
Construction
(Tables 1-H-4 & 1-H5)
3
Number of
Component
Wires
A
Color Code
Designator
(Table 1-H-6)
1H1

Annex H to Sect 2 Chap 1
Table 1-H-4 Shielded, Jacketed Cable Construction

Letter Code
Conductor Type
Shield Type
Tin Coated Copper
Tin Coated Copper
Silver Coated Copper
Nickel Coated Copper
Silver Coated High Strength Copper Alloy
Nickel Coated High Strength Copper Alloy
Tin Coated Copper
Note:
Refer to MIL-C-85485 or publication sponsor for full details.
Table 1-H-5 Unshielded, Unjacketed Cable Construction

Letter Code
Note:
Conductor Type
Tin Coated Copper
Colour Chart
4.
The color of the first component wire shall be light violet, designated by 7L. Any additional component wires shall
be light violet with a colored stripe as per Table 1-H-6.
Table 1-H-6 Cable Colour Designation

Component Wire
Number
Wire Insulation
Base Color
Light Violet
Light Violet
Light Violet
Light Violet
Light Violet
Light Violet
Light Violet
Stripe Color
N/A
Blue
Orange
Green
Red
Black
Yellow
Note:
1H2

Annex I to Sect 2 Chap 1
CURRENT RATINGS OF WIRE AND MAXIMUM

ALLOWABLE NICKED OR BROKEN STRANDS
Table 1-I-1 Current Rating Of Wires In Amps (SAE AS 50881)
Conductor
Material
Wires in Bundles, Groups or

Harnesses (Note 1)
Wire in Free Air & Ambient 70C

(Note 2)
Wire Temp Rating
Wire Temp Rating
Wire
Size
105C
150C
200C
105C
150C
200C
Copper or
22
12.5
16
Copper Alloy
20
11
17
21
18
12
15
22.5
28
16
11
14
17
26
33
14
10
14
18
23
35
44
12
13
19
25
31
47
60
10
17
26
32
41
62
78
38
57
71
64
90
125
50
76
97
82
125
68
103
133
110
170
Aluminium
95
141
179
155
113
166
210
185
1/0
128
192
243
210
2/0
147
222
285
240
3/0
172
262
335
276
4/0
204
310
395
340
30
45
40
61
54
82
76
113
90
133
1/0
102
153
2/0
117
178
3/0
138
209
4/0
163
248
Notes:
1
Rating for 70C ambient, 33 or more wires in harness with no more than 20% harness current
capacity being used at operating altitude of 60,000 ft.
Rating of wires in FREE air at ambient temperature of 70C.
1I1

Annex I to Sect 2 Chap 1
Table 1-I-2 Maximum Allowable Nicked Or Broken Strands (SAE AS 50881)

Conductor
Material
Total Allowable Nicked

and Broken Strands
Copper or
19
2 nicked, none broken
Copper Alloy
37
4 nicked, none broken
Above 37
6 nicked or broken
All numbers of strands
None nicked or broken
Aluminium
1I2
Number of Strands
per Conductor

Annex J to Sect 2 Chap 1
WIRE GAUGE COMPARISON
Table 1-J-1 Wire Gauge Comparison

American Wire Gauge
(AWG)
Standard Wire Gauge (UK)

(SWG)
Wire Gauge
Number
ConductorDiameter
(Inches)
[Note 1]
Conductor Area
(Circular Mils)
[Note 2]
Conductor
Diameter (Inches)
[Note 1]
Area
(Circular Mils)
[Note 2]
26
0.020
304
0.018
289
24
0.025
475
0.022
419
22
0.031
754
0.028
661
20
0.039
1216
0.041
1156
18
0.049
1900
0.051
1825
16
0.055
2426
0.060
2645
14
0.069
3831
0.072
3553
12
0.089
5874
0.090
5781
10
0.113
9354
0.113
9120
0.173
16983
0.173
17683
0.217
26818
0.192
26316
0.274
42614
0.268
42642
0.340
65500
0.338
67516
0.425
104500
0.421
103050
00
0.475
133000
0.477
131479
Notes:
1
Wire diameters and areas are listed for the equivalent wire gauge number. The actual diameter and area
of the conductor in an aircraft wire will vary due to the stranding and plating used. Refer to the
appropriate military specification or the publication sponsor for exact dimensions.
A circular mil is the cross-sectional area of a circular conductor having a diameter of 1 mil (0.001 inch).
The circular mil area (CMA) of a conductor is calculated by squaring the diameter (in mils) of the circular
2
conductor. Thus, a wire having a diameter of 4 mils (0.004 inch) has a CMA of 4 , or 16 circular mils. If
the conductor is stranded, the CMA for the conductor is calculated by multiplying the CMA of the strand
by the number of strands.
Details of terminal lugs and splices and associated tooling are contained in Section2, Chapter 6.
1J1

Sect 2 Chap 2
SECTION 2
CHAPTER 2
IDENTIFYING WIRE AND CABLE

INTRODUCTION
1.
To
make
maintenance
easier,
each
interconnecting wire and cable installed in aircraft should
be marked with a combination of letters and numbers
which identify the wire, the circuit it belongs to, its gauge
size, and other information necessary to relate the wire
to a wiring diagram. This marking is called the wire
identification code. Wire, as received from the
manufacturer, is printed with the manufacturers code, in
a contrasting colour, at intervals of one to five feet. This
code consists of the specification or MS number and
slash or dash number of the wire, and a one, two or
three-digit number, indicating the colour of the basic wire
insulation and the colour of the stripes (if present). The
colour code is as follows:
Black
Brown
Red
Orange
Yellow
Green
0
1
2
3
4
5
Blue
6
Violet
7
Gray
8
White
9
(includes also
uncoloured insulations)
2.
For example, a wire printed with number
M22759/34-22-948 would designate a wire constructed
in accordance with MIL-W-22759/34, wire size 22, white
insulation (9), first stripe yellow (4), and a second stripe
of grey (8).
NOTE
When marking wire with the identification code
described in this chapter, it is permissible to overstamp the manufacturers printing.
WIRE IDENTIFICATION CODE (BASIC)

3.
The basic wire identification code used for all
circuits (refer Table 21) is described in the following
paragraphs and Figure 21.
Unit Number
4.
Where two or more identical items of equipment
are installed in the same aircraft, the unit numbers 1,
2, 3, 4, etc., may be prefixed to differentiate
between wires and cables when it is desired that the
equipment have the same basic cable identification. To
facilitate interchangeability requirements, identical wiring

located in left and right wings, nacelles, and major
interchangeable structural assemblies may have
identical cable identification and the unit number is not
required. The unit numbers for circuit functions R, S,
T and Y, are used only where duplicate complete
equipment is installed, and does not apply to duplicate
components within a single complete equipment such as
duplicate indicators or control boxes.
Circuit Function Letter
5.
The circuit function letter is used to identify the
circuit function specified in Table 21. Where a wire or
cable is used for more than one circuit function, the
circuit function that is predominant applies. When
functional predominance is questionable, the circuit
function letter for the wire or cable having the lowest
wire number is used.
Wire Number
6.
The wire number consisting of one or more digits
is used to differentiate between wires in a circuit. A
different number shall be used for wire not having a
common terminal or connection.
7.
Wires with the same circuit function having a
common terminal connection or junction will have the
same wire number but different segment letters.
8.
Beginning with the lowest number, a number is
assigned to each wire in numerical sequence, as far as
practicable.
Wire Segment Letter
9.
A wire segment is a conductor between two
terminals or connections. The wire segment letter is
used to differentiate between conductor segments in a
particular circuit. A different letter is used for wire
segments having a common terminal or connection.
Wire segments are lettered in alphabetical sequence.
The letter A identifies the first segment of each circuit
starting at the power source. If a circuit contains only
one wire segment, the wire segment is marked A. The
letters I and O are not used as segment letters.
Double letters AA, AB, AC, etc., are used when more
than 24 segments are required. Two permanently
spliced wires do not require separate segment letters if
the splice is used for modification or repair.

Sect 2 Chap 2
Figure 21 Example of Wire Identification Coding
Wire Size Number
14. For thermocouple wire, the following suffixes shall

be used as applicable:
10. The wire size number is used to identify the size

(AWG) of the wire. For coaxial cables and thermocouple
wires, a dash (-) is used in lieu of the wire size number.
CHROM Chromel
ALML Alumel
IRON Iron
Ground, Phase or Thermocouple Letter(s)
Aluminium Wire
11. The letter N is used as a suffix to the wire

identification code to identify any wire or cable that
completes the circuit to the ground network (earth). Such
wires and cables shall be capable of being connected to
the ground network of aircraft electrical systems without
causing malfunctioning of any circuit. For critical and
sensitive electronic systems that have interconnecting
ground leads, but only one segment actually grounded
to structure, only the segment actually grounded to
structure is identified with the N suffix.
15. For aluminium wire, ALUMINIUM or ALUM shall

be added as a suffix to the wire identification code.
12. Phase letter A, B or C shall be used as a

suffix on the wire identification code to identify the phase
of wires that are in the three-phase power distribution
wiring of AC systems.
17. When required, each harness shall be identified

with the letter W and a distinct numerical suffix.
Examples W-1, W-2, W-3, etc.
CONS Constantan
COP Copper
Spare Contact Wire Identification

16. Wires attached to spare contacts shall be
identified by the contact designation.
Harness Identification
Wires Added at Modification

13. Phase letter V shall be used as a suffix on the
cable identification code to identify the ungrounded wire
or cable that is in a single-phase system.
18. When additional wires are installed in aircraft

during modification, they should be identified by
including the letter M as a suffix to the wire

Sect 2 Chap 2
Multi-Conductor Cables
19. Wires within multi-conductor cables are identified
with either solid colours or coloured stripe(s) on a white
background. Mark these wires in accordance with
paragraph 34.
Wires Sensitive to Electromagnetic Interference
(EMI)
20. Sensitive wiring is defined as wiring that is
especially susceptible to EMI, and is therefore more
likely to create disruption of the equipment to which it is
connected.
21. A current method for identifying EMI sensitive
wires and cables consists of a suffix to the wire number
that identifies the susceptibility to EMI and indicates that
specific handling instructions are detailed in the aircraft
wiring manual. This suffix shall remain at the end of the
significant wire number regardless of the requirement for
any other suffix. Figure 21 provides an example of a
wire identification number with the EMI identifier
included.
22. The identification of EMI sensitive wiring is
dependent on the following:
a.
level of shielding or protection applied to the wire

(eg. twisted pair, shielded wire etc);
b. electromagnetic susceptibility of the coupled

victim equipment;
c.
physical separation between the subject wiring

and potential electromagnetic sources (including
other wires); and/or
d. the type of grounding/bonding methods utilised.

23. Audio and data signals are often the most
susceptible to EMI. Other typical waveforms that are
more susceptible to EMI have the following
characteristics:
a.
low voltage,
b. low current, and/or

c.
slow rise times.
24. SAE AS 50881 Wiring, Aerospace Vehicle,

requires sensitive wiring to be routed to avoid
electromagnetic interference. SAE AS 50881 Appendix
B allows for, but does not mandate, the identification of
EMI sensitive wires and cables with a category code
added to the significant wire number. In the past, EMI
sensitive wires and cables added during modification of

aircraft have been isolated in accordance with the
specification, however they have not been identified as
EMI sensitive and therefore their integrity may be
compromised during subsequent aircraft modification.
Safety of Flight (SOF) Critical EMI Sensitive Wire and
Cable
25. Where wires and cables are susceptible to EMI
and are identified as critical to the safety of flight (SOF)
of the aircraft, they should be identified with red sleeves.
(This is in addition to the EMI suffix on the wire
identification code). The red sleeves (heat shrink is
appropriate) should be a minimum of 50mm in length
and positioned at intervals no greater than 375mm along
the entire length of the wire or loom, utilising application
methods detailed in this manual. Marking of the sleeving
to further highlight the EMI sensitivity is optional, but
should be consistent with existing aircraft labelling
practices and clearly documented in wiring publications.
26. The sleeving procedure detailed above is also
appropriate for non-SOF systems that are sensitive to
EMI and where interference may affect the airworthiness of the aircraft.
WIRE AND COMPONENT IDENTIFICATION

CODES FOR MODIFICATION
Wire Numbers
27. When additional wires and cables are installed in
aircraft during modification they should be appropriately
identified in accordance with this publication. Wire
numbers in the range 2000 to 4999 inclusive, should be
allocated. All wire numbers allocated to modifications
should be suffixed with the letter M (eg. L2001A20M).
Wires installed within aircraft components and wires less
than six inches long need not be numbered.
Electrical Component Numbers
28. Electrical components such as switches, lights,
circuit breakers etc. which are installed during
modification, should be identified on wiring diagrams
using a code letter and sequential number. As different
aircraft manufacturers use various code letters for
similar components, it is recommended that the coding
convention, used by the manufacturer on original aircraft
wiring diagrams, be retained.

Sect 2 Chap 2
Table 21 Function and Designation Letters

Circuit
Function
Letter
A
UNASSIGNED
PHOTOGRAPHIC
Mapping camera
Camera intervalometer
Camera doors
Camera heaters
Warning
CONTROL SURFACE
Automatic pilot
Booster
Control tabs
Diving brakes
Flight
Horizontal stabilizer
Landing flaps
Water-rudder position
Trim tabs
Wing flaps
Warning
Circuits
INSTRUMENT (other than flight

or engine instruments)
Ammeter
Oil-flap position
Cowl-flap position
Coolant-flap position
Air pressure
Free air temperature
Landing gear position
Hydraulic pressure
Cabin pressure
Carbon monoxide
Landing-flap position
Propeller pitch position
Instrument vacuum pump
Horizontal-stabilizer position
Trim-tab position
Water pressure
Voltmeter
Clock
Cabin heater
Cigarette lighter
De-icing (general)
Heated flying suits
Gallery
Windshield defroster
Windshield defogger
Windshield de-icer
Heater blanket
Oil immersion heater
Refrigeration
Cabin supercharger
Ventilation
Water heater
ENGINE INSTRUMENT
Carburettor air pressure
Bearing temperature
Tailpipe temperature
Carburettor anti-icing fluid quantity
Fuel mixture
Torque meter
Brake mean effective pressure
Fuel flow
Fuel quantity
Circuit
Function
Letter
Circuits
PHOTOGRAPHIC
Oil pressure
Manifold pressure
Fuel pressure
Propeller anti-icing fluid quantity
Engine oil quantity
Tachometer
Synchroscope
Warning
FLIGHT INSTRUMENT
Bank and turn
Rate of climb
Directional gyro
Air position
Ground position
Compass (including flux gate and
other stabilized compasses)
Gyro horizon
Attitude gyro
Driftmeter
Altimeter
Airspeed
Accelerometer
Pitot-static tube heater
Warning
LANDING GEAR, WING FOLDING

Actuator
Retraction
Wheel brakes
Down lock
Ground safety
Wheel steering
Up lock
Wheel spinning
Warning
HEATING, VENTILATING, AND DE-ICING

Anti-icing (general)
Battery heater
UNASSIGNED
IGNITION
Booster
Vibrator
Distributor
Electronic
Magneto ground wiring
Warning
ENGINE CONTROL
Carburettor air flap
Blower ratio
Cowl flap, air shutter
Intercooler flap
Oil cooler shutter
Propeller feathering
Propeller synchronizer
Propeller pitch
Supercharger regulator
Starter
Warning
LIGHTING
Approach

Sect 2 Chap 2
Circuit
Function
Letter
E
Circuits
ENGINE INSTRUMENTS (continued)
Fuel capacity
Cylinder head temperature
Oil temperature
Interior
Instrument
Section (fuselage)
Landing
Exterior
Running, position, navigation
Passing
Search
Taxi
Anchor
Warning
Circuit
Function
Letter
L
Positioner; seat, pedal

UNASSIGNED
TW - Weather devices
TX - Television transmitters
TY - Television receivers
UNASSIGNED
DC POWER
Wiring in the DC power or power-control
system shall be identified by the circuit
function letter "P".
FUEL AND OIL

Fuel valves
Fuel booster-pump motor
Mixture control
Oil dilution
Engine primer
Fuel-transfer-pump motor and control
Fuel-loading-pump motor
Oil-transfer-pump motor and control
Oxygen heater
RADIO (navigation and communication)
RA Instrument landing
RD Radio direction finding
RF - VHF
RH - Homing
RM - Marker beacon
RN - Navigation
RX - Recorder
RZ - Interphone, headphone
RV - VHF command
LIGHTING (continued)
Cockpit
Drift
Cabin
RADAR
SA - Altimeter
SM - Mapping
SN - Navigation
SR - Recorder
SS - Search
SW - Warning
SX Recognition - transponder
SPECIAL ELECTRONIC
TB - Radar control
TC - Radio control
TD - Airborne announcing
TF - Repeat back
TL - Attitude indicator
TN - Navigation
TP - Beacon (crash and locator)
TQ - Transmitters and receivers
TR - Receivers
TT - Transmitters
MISCELLANEOUS ELECTRIC
Windshield spray
Bilge pump
Cargo door
Water distillation
Windshield wiper
Hoist
Circuits
MISCELLANOUES ELECTRONIC
Oil-booster pump
Oil-scavenger pump
Throttle control
Fuel-pump motor
Oil diverter
Oil valves
Water injection
Warning
DC POWER and DC control cables for

AC systems shall be identified by the circuit
function letter V.
Wiring in the AC power system shall be
identified by the circuit function letter X.
WARNING AND EMERGENCY (in addition to

those listed under other circuit functions)
Enclosure release and locks
Fire extinguishers
Flare release
Fire detector
Oxygen detector
No-smoking sign
Fasten-belts sign
Intercrew buzzer or light
AC POWER
power circuits common to more than one
equipment or system.
UNASSIGNED
UNASSIGNED
Circuit function and circuit designation letters of electrical and electronic wires and cables should be as specified
herein. Typical circuits are listed under their respective circuit functions.

Sect 2 Chap 2
IDENTIFICATION METHODS
29. The identification code, as shown in Figure 21
should be applied to wires either horizontally or
vertically. The preferred method of identification is to
apply the identification marking directly on the wire or
cable with a laser wire-marking machine. Use this
method wherever possible. If the wire insulation or outer
covering will not mark clearly, lengths of insulating
tubing (standard or heat shrink) may be laser marked or
hot stamped with the identification code and installed on
the wire or cable. The following types of wire may
require identification by means of sleeves:
a.
Unjacketed shielded wire.
b. Thermocouple wires.
c.
Multi-conductor cable.
In addition, mark wires within 75mm of each junction

(except permanent splices), and at each terminating
point. Wires less than 15cm long need not be marked.
LOCATION OF SLEEVE MARKING

32. When wire or cable cannot be marked directly,
install a sleeve, (refer Figure 23) marked with the
identification number, over the outer covering at each
terminating end and at not more than 90cm intervals
along the entire length of the wire or cable.
NOTE
Do not use sleeves to change the identification of
wire or cable that has already been marked, except in
the case of spare wires in potted connectors.
d. High temperature wire.
CAUTION
75mm
MAX
1m
H215A20
Do not use metallic markers or bands for

identification. Do not use any method of marking that
may damage or deform the wire or cable insulation.
75mm
MAX
1m
H215A20
H215A20
Figure 23 Location of Identification Sleeve

NOTE
Use sleeves only if wire cannot be marked directly.
MARKING OBJECTIVES
30. Which ever method of marking is used, ensure
marking is legible, and that colour of marking contrasts
with the wire insulation or sleeve.
MULTICONDUCTOR CABLE IDENTIFICATION

33. Multi-conductor cables may be identified by
marking directly onto the outer sheath using a laser
marking machine or with pre-marked sleeves (refer
Figure 24) installed as described in paragraph 44.
Immediately following each wire identification number,
indicate the colour of the individual conductor as detailed
in Figure 21 using the following abbreviations:
Black
Brown
Red
Orange
Yellow
Green
- BK
- BR
- RD
OR
- YE
- GN
Blue
Violet
Grey
White
Pink
Purple
- BL
- VT
- GY
- WH
- PK
- PR
34. Individual wires within a cable shall be identified

within 75mm of their termination.
Figure 22 Spacing of Identification Marking on Wire

and Cable
SPACING OF WIRE IDENTIFICATION

31. Mark wires and cables at intervals of not more
than 38cm along their entire lengths (refer Figure 22).
COAXIAL CABLE IDENTIFICATION

35. Coaxial cable should NOT be hot-stamped
directly. The marking pressure and stress (tension and
torsion) applied while the cable moves through the
machine can create electrical changes in cables and
physical damage in miniature cables. When laser
marking is unsuitable for marking coaxial cable, use premarked sleeves (refer Figure 25) as described in
paragraph 43 and 44.
AC 21-99 A
Aircraft Wiring and Bondin
ng
Sect 2 Chap
p2
Figu
ure 24 Multicconductor Cab
ble Identificatio
on
Figure 26
6 Wire Identiffication at Term
minal Board
WIRE
W
MARK
KING
F
Figure
25 Coaxial Cable Identification
I
THERMOCOUPLE WIRE
W
IDENT
TIFICATION
36. Thermocouple wire,
w
which is usually du
uplexed
(two insu
ulated conducctors laid side
e by side), may
m
be
difficult to
o mark legiblyy. Where slee
eves are utilissed, the
wire size in the identificcation code sh
hould be repla
aced by
a dash. The
T material designation sha
all be as follow
ws:
CHROM Chromel
ALML Alumel
A
IRON Irron
CONS
S Constantan
n
COP Copper
WIRE ID
DENTIFICAT
TION AT TER
RMINAL BOARDS
AND EN
NCLOSURES
S
37. If possible,
p
markk wires attache
ed to terminal boards
and equiipment termin
nals between termination and
a
the
point whe
ere wire enterrs the wire bundle (refer Fig
gure 2
6). Identify wires termiinating within an enclosure, inside
osure, if space
e permits.
the enclo
SELECT
TION OF IDE
ENTIFICATIO
ON SLEEVIN
NG
38. For general airfrrame wiring, in
i most appliccations,
heat-shrin
nkable polyetthylene tubing
g should be used
u
to
identify wire
w
that cann
not be marke
ed directly. Avvailable
sizes are given in Secttion 2, Chapter 4.
39.
3
Excimer Laser marking is the reco
ommended wire
marking
m
meth
hod. It is a rapid, non
n-contact, no
onaggressive
a
priinting techniqu
ue that relies on alteration of
the
t
Titanium Dioxide (TiO
O2) pigment present in the
insulation matterial. This wirre marking method produces
a high contrasst, high definitiion, permanen
nt mark on mo
ost
single
s
wire and multi-ccore cables without any
degradation
d
o the insulatio
of
on. Laser marking should be
carried
c
out in
i accordancce with the manufacturers
instructions.
40.
4
Hot stam
mp marking d
directly on to the
t insulation of
aircraft
a
electriical wire and cable is nott recommende
ed
due
d
to the degradation
d
th
hat may be caused to the
insulation and because alte
ernate, improv
ved identificatio
on
methods
m
are available. W
Where hot sta
amp marking is
determined
d
to
o be the most appropriate marking
m
metho
od
(eg
(
large conductors and
d heat shrink
k sleeving) the
details
d
listed in
i Table 22 are provided to assist in the
selection
s
of the approprriate marking
g foil, marking
temperature
t
a dwell time.
and
NO
OTE
Store foils at
a approximate
ely 22C and
d 60% relative
e
humidity.
SET-UP
S
OF MARKING M
MACHINE FO
OR WIRE
STAMPING
S
41.
4
After se
electing the prroper machine
e for the job, set
s
it up for the ma
arking procedure as follows
s:
a.
From Table
T
23, sellect the corre
ect size type for
f
the wirre to be m
marked. Make
e up require
ed
identificcation code a
and insert intto type holde
er,

Sect 2 Chap 2
centring type in holder. Use spacers to prevent

crowding letters and numbers.
CAUTION
Use correct size guide. If guide is too large, wire will
not be held firmly and marking will be off centre.
b. Select marking foil of correct width for length of

identification code.
Table 22 Marking Foil Identification
c.
Foil Part Number
Colour
Insulation Type
KT26
Black
Teflon
210 to 227C
Quick
K-36
Black
PVC, Nylon,
Polyethylene
163 to 260C
Medium
K520
Black
ETFE/ECTFE
150C
Select wire guide into which wire will fit snugly.
d. Install wire guide and roll of marking foil on

machine. Slide type holder into slot provided for it.
Table 23 Recommended Sizes of Marking Type

Wire Size
(AWG)
Marking Temperature
Dwell Time
Quick
and tie at each end with clove hitch and square knot.
Refer to Section 2, Chapter 8 for method of tying and
knotting. When heat shrinkable tubing is used, ties are
not required. Before installing heat shrinkable tubing on
the wire, make sure that the wires are clean. Instructions
for installation of heat shrink sleeving are provided in
Section 2, Chapter 4.
Letter Height
(mm)
26 thru 22
1.6
20 thru 14
2.0
12 thru 0000 & Coaxial Cable
2.8
SET-UP OF MARKING MACHINE FOR SLEEVE

STAMPING
42. For stamping identification mark on tubing that
has an OD of 6.3 mm or smaller, use the same machine
that is used for stamping wire. Set up machine as
follows:
a.
Select type size and wire guide to suit OD of

tubing.
b. Select mandrel (metal rod) of a diameter that will

fit snugly inside tubing. Insert mandrel into tubing,
and both into the wire guide. If a mandrel of
proper size is not available, use a piece of
insulated wire of suitable diameter and length.
c.
Prepare type to provide required wire number.
d. Select foil and install wire guide, foil, and type

holder on machine.
INSTALLING IDENTIFICATION SLEEVES ON

WIRING
43. Cut marked tubing into lengths so that marking is
approximately centred (refer to Figure 27). Install cut
lengths of tubing over wire or cable at desired spacing,
Figure 27 Marking on Sleeves
IDENTIFICATION OF WIRE BUNDLES AND

HARNESSES
44. Identify wire bundles and harnesses (see Figure
28) by one of the following methods:
a.
If bundle is not too large, select sleeving of proper

size to fit snugly over wire bundle. Stamp with
identification marking as described in paragraph
45 and install on bundle approximately 30cm from
each terminating end. Tie securely at both ends.
NOTE
Sleeving must be installed on bundle before attaching

wires to connectors.

Sect 2 Chap 2
b. Heat shrinkable tubing, marked with the

identification code, may also be used, installed as
described in Section 2, Chapter 4.
c.
Wire bundles up to 100mm in diameter may be

identified by means of an MS3368 cable
identification strap that incorporates a marking tab
(refer Figure 28). Install as follows:
NOTE
Use of self clinching adjustable plastic cable straps
and installing tools is described in Section 2, Chapter
8.
(1) Stamp the wire identification code on the

marking tab.
(2) Pass the strap around the bundle with the
ribbed side of the strap inside.
(3) Insert the pointed end of the strap through the
eye, and pull the strap snugly around the
bundle.
(4) Feed the tail of the strap through MS90387-1
tool, and slide the tool up to the eye of the
cable identification strap.
(5) Squeeze tool handles until strap is snug on
the bundle.
(6) Close tool handles all the way to cut off the
excess strap.
Figure 28 Identification of Wire Bundles and

Harnesses

Sect 2 Chap 3
SECTION 2
CHAPTER 3
PREPARING WIRE AND CABLE

INTRODUCTION
Cutting Copper Wire and Cable
1.
Before wire and cable can be installed in aircraft
and connected to components it must be prepared by
cutting to the appropriate lengths and preparing the wire
ends for attachment to connectors, terminal lugs or
solder splices, etc.
3.
To cut heavy gauge copper wires or cables, use a
fine tooth hacksaw. A fine tooth hacksaw has 20 or more
teeth per inch. See Figure 32 Wire Cutting Tools for
use of hack saw and saw vice which protects heavy wire
during cutting. Heavy or light copper wires can also be
cut with bench shears.
CUTTING WIRE AND CABLE
4.
To cut a few light gauge copper wires, use
diagonal pliers as shown in Figure 32. Do not attempt
to cut wires larger than AWG-8 with diagonal pliers.
General
2.
Cut all wires and cables to lengths given on
drawings or wiring diagrams. Cut wire and cable so that
cut is clean and square and wire is not deformed (refer
Figure 31). After cutting, reshape large diameter wire
with pliers, if necessary.
CAUTION
Make sure that blades of cutting tools are sharp and
free from nicks. A dull blade will deform and extrude
wire ends.
Cutting Aluminium Wire

5.
Be careful when cutting aluminium wire to avoid
deforming the conductors. Aluminium wire is more brittle
than copper, and if deformed, aluminium wire should be
reshaped carefully.
CAUTION
Never cut aluminium wire with tools that have
reciprocating motion, such as a hack saw.
Reciprocating cutting action work hardens
aluminium. This will lead to broken and torn strands.
CAUTION
If cutting tool has been used for other metals, wipe
blades clean before cutting aluminium. Copper or
steel chips will cause aluminium to corrode.
6.
Special cable shears with concave cutting edges
such as pruning shears may also be used to cut
aluminium wire.
Figure 3- 1 Wires After Cutting

Sect 2 Chap 3
SHEAR TYPE CUTTING TOOLS
Figure 3- 2 Wire Cutting Tools
STRIPPING WIRE AND CABLE
Stripping Methods for Aluminium Wire
7.
Before wire can be assembled to connectors,
terminals, splices, etc, the insulation must be stripped
from connecting ends to expose the bare conductor. For
attachment to solder type connectors, enough insulation
must be stripped so that the conductor will bottom in the
solder cup and leave a small gap between the top of the
solder cup and cut end of the insulation. Stripping
dimensions for MS connectors are found in Section 2,
Chapter 10, for RF connectors in Section 2, Chapter 12,
and for terminals in Section 2, Chapter 6.
9.
Strip aluminium wires very carefully. Take
extreme care not to nick aluminium wire as strands
break very easily when nicked.
General Stripping Instructions
10. When
precautions:
wire
observe
the
following
a.
When using a hot blade stripper, make sure

blades are clean. Clean blades with a brass wire
brush as necessary. The hot blade stripper will not
strip wire with glass braid or asbestos insulation.
b.
Make sure all stripping blades are sharp and free

from nicks, dents, etc.
c.
When using any type of wire stripper, hold wire

perpendicular to cutting blades.
Stripping Methods for Copper Wire

8.
Copper wire may be stripped in a number of ways
depending on size and insulation.
stripping

Sect 2 Chap 3
d.
Adjust automatic stripping tools carefully. Follow

manufacturers instructions to avoid nicking,
cutting, or otherwise damaging any strands. This
is especially important for all aluminium wires and
for copper wires smaller than No 10. Examine
stripped wires for damage and adjust tool as
necessary. Cut off and restrip (if length is
sufficient); or reject and replace any wires with
more than the allowable number of nicked or
broken strands given in Table 31.
strippers can become loaded with insulating

material in time. This condition causes the wire to
slip in the grippers and results in an unsatisfactory
strip. Clean these gripping surfaces with a stiff
brush as needed.
l.
NOTE
Longitudinal scratches in copper wire are not
considered cause for rejection or rework.
Stripping Wire with Hot-Blade Stripper
Table 31 Allowable Nicked or Broken Strands

Wire Size
(AWG)
Copper
22 12
10
84
20
Aluminium, all sizes
Wire Cutters - Shear type wire cutters (PN 45123 or equivalent) are recommended for cutting
wire prior to stripping. Standard diagonal cutting
pliers will crush and deform the ends of the
conductors and increase the force necessary to
slide the slug of insulation off the wire. Smooth cut
round ends are also easy to insert into the crimp
wells of terminals and contacts.
CAUTION
Nicked or Broken
Strands
Ensure adequate ventilation is provided when a hotblade stripper is used to strip TFE-insulated wire.
None
2
4
12
None
11. The procedure for stripping a wire with a hot-blade

stripper is as follows:
a.
Adjust blades to correct opening for size of wire to

be stripped.
e.
Ensure insulation is clean-cut with no frayed or

ragged edges. Trim if necessary.
b.
f.
Ensure all insulation is removed from stripped

area. Some types of wires are supplied with a
transparent layer between the conductor and
primary insulation. If this is present, remove it.
Adjust stop by means of knurled brass nut on top

of hood for desired stripping length between 6.5
and 38mm.
c.
When using hand plier strippers to remove lengths

of insulation longer than 19mm, it is easier to do in
two or more operations.
Adjust each blade to proper heat by testing on

sample pieces of wire. Use minimum heat that will
remove insulation satisfactorily without damaging
strands.
d.
Insert wire until it butts against stop.
e.
Press foot pedal to bring heated blades against

insulation.
f.
Twist wire with lay of strands about 90 degrees

and pull out.
g.
h.
i.
Retwist copper strands by hand or with pliers if

necessary to restore natural lay and tightness of
strands.
Precision hand pliers have die type blades that
are designed for a specific insulation wall
thickness and type of conductor. Table 32 lists
manufacturers part numbers for one acceptable
model. Equivalent tools may be used.
CAUTION
Due to the differences in the diameter of General
Purpose and Small Diameter conductors, the blade
set used should be the one specified for the wire
being stripped.
j.
k.
Precision Blade Wear - Although these blades

are hardened to provide long life, they will wear in
time. When the blade no longer provides a
satisfactory removal of insulation when used with
the correct size and type of wire, it should be
replaced.
Cleaning Wire Gripping Surfaces of Precision
Tools - Wire gripping surfaces on precision
NOTE
Polytetrafluoroethylene (PTFE) which includes all
teflon based insulation materials is an inert plastic
material that decomposes at approximately 400C.
At this temperature, the Teflon particles become
airborne and, if inhaled, can cause a type of
poisoning known as POLYMER FUME FEVER, which
has influenza like symptoms. The symptoms occur
for several hours after exposure and usually subside
within 24 to 48 hours.
WARNING
Do not smoke in areas where PTFE materials are
used. Do not carry cigarettes or tobacco into PTFE
work areas as contamination of these products may
occur. After working with PTFE material wash hands
thoroughly before smoking. Do not incinerate PTFE
waste.

Sect 2 Chap 3
Stripping Kapton Wire with a Hand Stripper
Inspection after Stripping
12. The procedure for stripping Kapton wire or cable

with a hand stripper is as follows (see Figure 33):
13. When visually inspecting multi-stranded wire,

determine if any of the conditions illustrated in Figure 3-3
exist.
a.
Insert wire into exact centre of correct cutting slot

for wire size to be stripped. (Each slot is marked
with wire size).
b.
Close handles together as far as they will go.
c.
Partially release handles so that the jaws of the

stripper remain open and the blades and gripper
pads also open to permit removal of the wire.
d.
Remove stripped wire.
e.
Continue to release handles so that the jaws snap

closed and the stripper is ready to use again.
14. When one or more of the conditions below exist

but are within tolerance, correct and reshape conductor
strands by twisting the strands in the direction of the
natural lay of the wire. Do not overtwist.
15. When the conditions in Figure 3-3 exist, but are
out of tolerance, cut off the stripped portion and start the
procedure again. If the wire length does not permit,
restart with a new length of wire.
WARNING
Care should be exercised when smoothing insulation
or twisting conductors as nicked, frayed, or broken
strands can cause injury.
Figure 3-3 Examples to look for when Stripping Multi-Stranded Wire

Stripping Coaxial Cable Using A Knife
16. Cut dimensions are detailed in the manufacturers
instructions.
17. The first cut is to remove the desired length of the
outer jacket. After placing the cable on a solid surface,
position the knife blade at the desired strip point and
press gently, using sufficient pressure to score the jacket
without damaging the inner shielding. Cut dimensions
are detailed in the manufacturers instructions or local
instructions.
18. The first cut is to remove the desired length of the
outer jacket. After placing the cable on a solid surface,
position the knife blade at the desired strip point and
press gently, using sufficient pressure to score the jacket
without damaging the inner shielding.
Figure 3-4
illustrates this process.
19. Without damaging the inner shielding, carefully slit
the outer jacket, as shown in Figure 3-5.
Figure 3-4
Striping Coaxial Cable using a Knife

Sect 2 Chap 3
Figure 3-8
Removal of the Insulation Surrounding the
Inner Conductor
Figure 3-5
Slitting the Outer Jacket of the Wire
20. Peel away the outer jacket to expose the shielding
(Figure 3-5).
22. Cut away the excess braiding using side cutters to

expose the insulated inner conductor. Be careful not to
damage the insulation of the inner conductor with the
cutters. Using the knife, repeat step two removing the
insulation surrounding the inner conductor. The finished
cable will appear as depicted in Figure 3-8.
Figure 3-6 Peeling away the Outer Jacket

21. Using the knife, repeat step two removing the
insulation surrounding the inner conductor. The finished
cable will appear as depicted in Figure 3-7
Figure 3-7 Removal of Excess Braiding

Sect 2 Chap 3
Stripping Dimensions for Assembly to Connectors

Table 34
Blades
Identification of Precision Stripper and
Wire Stripper Identification

Wire Type
Gage
Stripper PN
Blade PN
MIL-W-22759
/9,/10
16-26
10-14
45-174
45-173
L5563
L5562
/11,/12,
/22,/23
16-26
10-14
45-1212
45-1611
L5560
L5559
/16,/17,/32,
/33,/34,/35,
/41,/42,/43
16-26
10-14
45-1987
45-1611
45-1987-1
45-1611-1
/18,/19
16-26
10-14
45-1551
45-1608
45-1551-1
45-1608-1
/44,/45,/46
16-26
10-14
45-1513
45-1611
45-1513-1
45-1611-1
MIL-W-81044
/6,/7
16-26
10-14
45-171
45-170
L5211
L5210
/9,/10
16-26
10-14
45-174
45-173
L5563
L5562
/12,/13
28-30
16-26
10-14
45-178
45-1513
45-1611
L5561
45-1513-1
45-1611-1
/16,/17
16-26
10-14
45-1610
45-1611
45-1610-1
45-1611-1
MIL-DTL-81381
/1,/2,/5,/6,
/7,/8,/9,/10
16-26
10-14
45-1551
45-1609
45-1551-1
45-1609-1
/3,/4
16-26
10-14
45-1610
45-1611
L5563
L5562
/11,/12,/13,
/14,/22
16-26
10-14
45-1654
45-1608
45-1654-1
45-1608-1
/17,/18,/19,/20
16-26
45-1672
45-1672-1
/21
16-26
45-1523
45-1523-1
MIL-C-85485
/5,/6,/7,/8,/9,
/10,/11,/12
16-26
10-14
45-1924
45-1925
45-1924-1
45-1925-1
Wire Wrap
Solid Wire
30
24-30
45-179
45-169
L7625
L9300
General
Purpose
26-30
16-26
10-14
45-172
45-171
45-170
L5436
L5211
L5210
23. Stripped length of wires that are to be attached to

solder-type connectors should be such that when
stripped conductor bottoms in solder cup there will be a
gap of approximately 0.76 mm between the end of the
cup and the end of the insulation, for inspection
purposes.
STEP A
STEP B
STEP C
Note: Specification MIL-W-81381A and the various

commercial specifications used for procuring aerospace wire
provide for various wall thickness of insulation. The stripper
part numbers identify the strippers and blades for each
variation.
NOTE
When the handles are partially released, the stripper
jaws remain open so the wire can be removed without
kinking the conductor. (refer to Fig 3-8, step c).
Figure 3-9 Stripping Wire With Hand Stripper

Sect 2 Chap 3
TINNING COPPER WIRE AND CABLE

General
24. Before copper wires are soldered to connectors,
the ends exposed by stripping are tinned to hold the
strands solidly together. The tinning operation is
considered satisfactory when the ends and sides of the
wire strands are fused together with a coat of solder. Do
not tin wires which are to be crimped to Class K
(fireproof) connectors, wires which are to be attached to
solderless terminals or splices, or wires which are to be
crimped to removable crimp-style connector contacts.
Tinning Methods
c.
Grasp wire firmly and dip into dish of prepared flux

to a depth of about 3mm.
d.
Remove wire and wipe off excess flux.
e.
Immediately dip into molten solder. Dip only half

of stripped conductor length into solder.
f.
Manipulate wire slowly in solder bath until it is

thoroughly tinned. Watch the solder fuse to the
wire. Do not keep the wire in bath longer than
necessary.
g.
Remove wire if excess solder is noted and

remove excess with solder sucker or equivalent.
25. Copper wires are usually tinned by dipping into

flux and then into a solder bath. In the field, copper wires
can be tinned with a soldering iron and rosin core solder.
Extent of Tinning
26. Tin conductor for about half its exposed length.
This is enough to take advantage of the closed part of
solder cup. Tinning or solder on wire above the cup
causes wire to be stiff at point where flexing takes place.
This will result in wire breakage.
WARNING
Ensure adequate ventilation and exercise care while
using a solder pot. Solder Fumes are toxic and the
hazard of severe burns exists.
Flux and Solder
27. The solder used is a mixture of 60% tin and 40%
lead. Maintain the temperature of the solder pot between
235C and 260C, this will keep solder in a liquid state.
Skim surface of solder pot as necessary with a metal
spoon or blade to keep the solder clean and free from
oxides, dirt, etc.
CAUTION
Do not use any other flux or solder for tinning copper
wires for use in aircraft electrical systems.
Dip-Tinning Procedure
28. Dip-tin wires smaller than No. 8 about eight or ten
at a time. Dip-tin wires size No. 8 and larger individually.
(See Figure 310).
CAUTION
During tinning operation, take care not to melt, scorch
or burn the insulation.
29.
The procedure for dip tinning is as follows:
a.
Prepare flux and solder as described in paragraph

11.
b.
Ensure that exposed end of wire is clean and free

from oil, grease, and dirt. Strands should be
straight and parallel. Dirty wire should be restripped.
Figure 3-10 Dip-Tinning in Solder Pot

Sect 2 Chap 3
ended at each end as required by the individual

installation.
Stripping Jacket on Shielded Cable
NOTE
The thickness of the solder coat depends on the
speed with which the wires are handled and the
temperature of the solder bath. Never shake or whip
wire(s) to remove excess flux or solder.
Soldering Iron Tinning Procedure
30. In the field, wires smaller than size No. 10 may be
tinned with a soldering iron and rosin-core solder as
follows (see Figure 311):
a.
Select a soldering iron having suitable heat

capacity for wire size as listed in Table 33. Make
sure that the iron is clean and well tinned.
b.
Prime by holding iron tip and solder together on

wire until solder begins to flow.
c.
Move the soldering iron to the opposite side of the

wire and tin half of the exposed length of
conductor.
Table 33 Approximate Soldering Iron Sizes for Tinning

Wire Size
(AWG)
Soldering Iron Size (Heat

Capacity)
20 - 16
14 & 12
65 Watts
100 Watts
32. Most shielded cable has a thin extruded plastic

coating over the shielding braid. Strip this off as far as
necessary with a hot blade stripper, as described in
paragraph 5. The length of the strip depends on the
method of shield termination and type of wire
connection. Strip the outer jacket back far enough for
ease in working. If no hot-blade stripper is available, use
plier type hand strippers for sizes No. 22 through No. 10
and a knife for sizes larger than No. 10. Be careful not to
damage the shielding braid.

33. As their name implies, coaxial cable strippers are
used for preparing coaxial cable. Coaxial cable strippers
are unique in that they have two blades located on each
side of the tool and a round blade attached to the front,
as can be seen in Figure 3-12.
34. There are several types of coaxial cable strippers
available, so, where available, always make sure the
tool instructions are referred to when selecting the
correct tool for cable type.
35. As depicted in Figure 3-12, the two blades located
on each side of the tool may be adjusted individually to
vary the stripping dimension and the depth of the cut.
The axial stripping blade attached to the front of the
stripper is used to slit the cable axially (along the length
of the cable).
Figure 3- 11 Tinning Wire With Soldering Iron
TERMINATING SHIELDED CABLE

General
31. Shielded cable has a metallic braid over the
insulation to provide a barrier against electromagnetic
interference. To obtain a satisfactory result from
shielded cable, the shield must be unbroken and must
extend to a point as near to the end of the conductor as
practicable. Shielded cable is either grounded or dead-
Figure 3-12
36. To strip coaxial cable using coaxial cable
strippers:
a.
Adjust the blades to the applicable stripping

dimensions, ensuring the depth of the blades is

Sect 2 Chap 3
set so that the jacket will be scored without

damage to the inner shielding.
b.
c.
Position the tool on the cable so that an excess

length of cable will be left after the stripping
operation is complete.
Spin the tool around the cable, as demonstrated
in Figure 3-13 until the maximum cutting depth is
obtained.
c.
Ensure that the shield braid strands are flat and

smooth.
NOTE
Solder sleeve terminations consist of a heat
shrinkable insulation sleeve with an integral solder
preformed with flux and thermal indicator, and two
integral rings of sealing material. When the solder
sleeve is placed over a cable and heated, the solder
melts and flows connecting the ground lead to the
shield. The outer sleeve shrinks and the
thermoplastic insert melts, encapsulating the
termination. The result is a soldered, strain relieved,
environmentally protected termination. Solder sleeves
are available with or without preinstalled leads.
WARNING
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft.
Use of nitrogen with hot air gun M83521/5-01 in an
enclosed area can be hazardous. Ensure area is well
ventilated.
Figure 3-13
Procedure For Stripping Co-axial Cable
d.
Slit the cable jacket by simply placing the cable in

the front notch of the tool and pulling it through.
e.
Peel off the jacket.
f.
Steps one to three are repeated to strip the

excess shielding. Be careful not to damage the
inner dielectric.
g.
Remove the excess shielding.
h.
The dielectric may be stripped by hand using a

knife or by repeating steps one to three.
i.
To remove excess dielectric, flex the scored cut to

separate the dielectric. Slide the excess dielectric
off the inner conductor.
CAUTION
Solder sleeves may only be used in areas where the
temperature does not exceed 150C.
NOTE
The heat shrinkable solder sleeves listed in Table 34
are qualified to SAE AS 83519 and are appropriate
for terminating shielded cables, however they should
not to be used in lieu of alternate methods detailed in
specific aircraft maintenance publications, without
prior engineering approval.
d.
Measure the diameters A, B and C as shown in

Figure 314.
e.
Select the appropriate size sleeve from Table 34.
f.
Position the solder sleeve over the assembly so

that the solder ring is centred over the shielding
as shown in Figure 314.
g.
Install solder sleeves using approved tooling listed

in Table 314.
Grounded Shield Termination
h.
Hold assembly horizontal and position sleeve in

heat shield.
38. Grounded shield termination procedure is as

follows:
i.
Rotate assembly while heating to achieve proper

solder penetration and uniform sleeve shrinkage.
About 10 to 30 seconds are required for complete
solder melt and flow.
j.
Continue to apply heat until solder brightens and

starts to flow toward the thermoplastic inserts at
either end of sleeve.
37. Coaxial cable strippers are particularly useful if a

large quantity of cables need to be stripped. However,
they require accurate setting up that can be time
consuming. To strip individual cables, it is often quicker
to use a knife.
a.
Strip the shielded wire.
b.
Comb out the exposed shielding and fold back

over the jacket.

Sect 2 Chap 3
k.
As soon as the solder flow is observed, withdraw

the heat.
l.
When the solder joint has been made, hold the

work firmly in place until the joint has set.
Disturbing the finished work will result in a joint

mechanically weak, and with high electrical
resistance. Allow solder joints to cool naturally. Do
not use liquids or air blasts.
Figure 3-14 Combined Cable Diameter Measurements

Table 34 Heat Shrink Solder Sleeves For Tin and Silver Plated Conductors
(Splice Temperature rating 150C) Maximum
Part Number
Gauge of
Pre-installed
Ground Lead
A Maximum
B Minimum
C Minimum
M83519/1-1
M83519/1-2
M83519/1-3
M83519/1-4
M83519/1-5
2.7
3.7
5.0
6.5
7.6
0.9
1.4
2.2
3.3
4.3
0.5
0.8
1.3
1.8
2.5
M83519/2-1
M83519/2-2
M83519/2-3
M83519/2-4
M83519/2-5
20
20
20
20
20
2.7
3.7
5.0
6.5
7.6
0.9
1.4
2.2
3.3
4.3
0.5
0.8
1.3
1.8
2.5
M83519/2-6
M83519/2-7
M83519/2-8
M83519/2-9
M83519/2-10
22
22
22
22
22
2.7
3.7
5.0
6.5
7.6
0.9
1.4
2.2
3.3
4.3
0.5
0.8
1.3
1.8
2.5
M83519/2-11
M83519/2-12
M83519/2-13
M83519/2-14
M83519/2-15
24
24
24
24
24
2.7
3.7
5.0
6.5
7.6
0.9
1.4
2.2
3.3
4.3
0.5
0.8
1.3
1.8
2.5
M83519/2-16
M83519/2-17
M83519/2-18
M83519/2-19
M83519/2-20
26
26
26
26
26
2.7
3.7
5.0
6.5
7.6
0.9
1.4
2.2
3.3
4.3
0.5
0.8
1.3
1.8
2.5
All dimensions are in mm.
When using a sleeve with a pre-installed lead (M83519/2-*), A is the diameter of the cable only.
C is the minimum diameter on which the sleeve will seal.
Table 35 Heat Shrink Tooling

Part Number
10
Description
Use
M83521/5-01
Heat Gun Electric
Installation of heat shrinkable items on fuelled aircraft.
IR500
Infra-red Heat Gun
Installation of heat shrinkable items in workshops etc.
CV-5302
Hot Air Blower
Installation of heat shrinkable items in workshops etc.
PR13
Heat Reflector
Short lengths of tubing up to 6.4mm diameter and high temperature

solder sleeves.
PR24
Heat Reflector
Smaller molded parts and tubing 25 to 40mm diameter.
PR24A
Heat Reflector
Larger molded parts and tubing over 12mm diameter.

Sect 2 Chap 3
Figure 3-15Solder Sleeve Shield Termination
Ungrounded (Floating) Shield Termination

39. Ungrounded
(floating)
procedure is as follows:
shield
termination
a.
Strip the shielded wire as shown in Figure 314.
b.
Comb out the exposed shielding and fold back

over the jacket.
c.
Select the appropriate size solder sleeve from

Table 34.
d.
Make sure that the shield strands are flat and

smooth.
e.
Position the solder sleeve over the assembly so

that the solder ring is centred over the folded back
shielding.
11

Sect 2 Chap 3
WARNING
g.
Rotate assembly while heating to achieve proper

solder penetration and uniform sleeve shrinkage.
About 10 to 30 seconds are required for complete
solder melt and flow.
h.
Continue to apply heat until solder brightens and

starts to flow toward the thermoplastic inserts at
either end of sleeve.
i.
As soon as the solder flow is observed, withdraw

the heat.
j.
When the solder joint has been made, hold the

work firmly in place until the joint has set.
Disturbing the finished work will result in a joint
mechanically weak, and with high electrical
resistance. Allow solder joints to cool naturally. Do
not use liquids or air blasts.

fuelled aircraft.
ventilated.
CAUTION
Solder sleeves may only be used in areas where the
temperature does not exceed 150C.
f.
Hold assembly horizontal and position sleeve in

heat shield.
Figure 3- 16 Solder Sleeve Floating Shield Termination
Types of Solder Sleeves

40. As with any component used to maintain aircraft,
solder sleeves should conform to a specification. The
Military Spec styles of solder sleeve termination are the
M83519/l, and M83519/2.
Figure 3-17
The M83519/l Type of Solder Sleeves
41. The M83519/l, (shown in Figure 3-16) and the

M83519/2, (shown in Figure 3-17), are identical in
construction, function and use, except that the M83519/2
contains a pre-tinned ground lead.
Figure 3-18
The M83519/2 Type of Solder Sleeves
12

Sect 2 Chap 3
a.
infrared heating tool,
Solder Sleeve Heating Tools
b.
compressed air/nitrogen heating tool, and
42. Proper application of heat is important to produce

a reliable solder connection and sealing of the solder
sleeve. The sleeves are designed to be installed using a
hot air source or alternately an infra-red heating tool.
c.
turbofan type heat gun.
43. The type of tool selected will depend largely on

the work environment; ie whether you are working in a
workshop or on an aircraft. If working on an aircraft, the
tool must be portable and present no risk of igniting fuel
vapour.
44.

45. The infrared heating tool is a self-contained
portable unit. The main components are labelled in
Figure 3-19.
Infrared heat tools offer several
advantages over other methods of heating solder
sleeves including faster shrinking and solder flow. Also
being less complicated, they are easier to set up.
The three heating tools in common use are:
Figure 3-19
46. The compressed air/nitrogen heating tool (illustrated in Figure 3-20) is a portable source of heat for use with
heat-shrinkable tubing and solder sleeves. As the unit is fully enclosed, it is approved for use on fuelled aircraft. To
operate, the heating tool must be connected to an external source of compressed air/nitrogen and power.
13

Sect 2 Chap 3
Figure 3-20
47.
When operating the compressed air/nitrogen heating tool, the following warnings apply:
Warning
The nozzle and output air from the heat gun get very hot. Use extreme care while operating the heat gun to avoid
serious burns.
The use of nitrogen with the heat gun in an enclosed area can be hazardous. Discharge of nitrogen into a poorly
ventilated area can result in asphyxiation.
Do not use electrical power from an aircraft under repair. Aircraft power should be off during repair of aircraft
electrical systems. Use electrical power from a ground power unit.
14

Sect 2 Chap 3
Turbofan Type Heat Gun

48. The Thermogun Mark II heating tool, illustrated in Figure 3-21, is a rugged stand mounted or hand held hot air
tool. The heating tool has been engineered with a turbo fan driven blower and a double jacketed element housing for
heavy duty use. It has features such as adjustable side vents for limited temperature control, and a wide variety of hot
air reflectors. The Thermogun provides precise control when terminating a broad range of heat shrinkable products
including boots and tubing up to 75 mm in diameter.
Figure 3-21 Turbofan Type Heat Gun

49. There are numerous models and variations of the turbofan type heat guns available. The following description of
operation is similar for most turbofan type heat guns.
Pre-operation
50.
a.
b.
c.
Before using the heating tool, carry out the following:

Visually check the reflector for foreign material accumulation.
If accumulation is found, remove the reflector by pulling it straight off the nozzle.
Clean foreign material off reflector surfaces with a soft cloth and isopropyl alcohol.
Warning
Isopropyl alcohol is flammable. Do not use in the presence of sparks, heat or flame.
d. Install the reflector being careful not to touch the reflective surface.
Reflector Selection
51. Heating tool attachments consist of a range of reflectors. These reflectors are attached to the nozzle of the
heating tool and concentrate the heated output around the material. Note, the exact reflectors supplied will vary
according to the make and model of the heating tool. A selection of the various reflectors you may encounter are as
follows:
15

Sect 2 Chap 3
a.
Termination sleeve reflector. Used for heating solder termination sleeves and shrinking small diameter tubing.
Figure 3-22Termination Sleeve Reflector

b.
Miniature termination sleeve reflector. Used for heating small solder termination sleeves and making terminations
in a confined area.
Figure 3-23 Miniature Termination Sleeve Reflector

c.
Boot and tubing reflector. - Used for shrinking tubing and moulded components such as strain-relief boots and
potting caps.
Figure 3-24 Boot and Tubing Reflector

d.
Needle point reflector. Used where a lower, more precise air-flow is required to terminate micro-miniature
connectors, or to repair or modify low temperature insulated wire terminations.
Figure 3-25 Needle Point Reflector

e.
Large boot and tubing reflector. Used for installing large diameter tubing and moulded parts.
Figure 3-26 Large Boot And Tubing Reflector
16

Sect 2 Chap 3
Operation
52.
To operate the heat guns, proceed as follows:
Warning
Do not use heat guns with electric motors when working on aircraft that have not been defueled and purged. Sparks
generated by the electric motors may ignite fuel vapour.
Nozzle and output air of heat guns get very hot. Use extreme care while operating a heat gun to avoid serious
burns.
a.
Select the appropriate reflector for the application.
b.
Install the reflector on the front of the heat gun nozzle by pushing the reflector straight on.
c.
Check the power requirement of the tool being used and plug the cord into the appropriate power supply.
d.
Prepare the assembly to be heated (this will be covered in detail in the next section).
e.
Turn the heating tool on and allow a short warm up period.
f.
Place the assembly into the heating area.
g.
Observe the assembly during the heating process. After the assembly has received sufficient heat, remove the
assembly from the heating area and turn the heat gun off.
h.
Inspect the assembly for correct forming (this will also be covered in detail in the next section).
Post Operation
53.
After using the heating tool, proceed as follows:
a.
Disconnect the power connector from the power source.
b.
Allow a few minutes for the reflector to cool.
c.
Visually check the reflector for foreign material accumulation. If material is found, clean
pre-operation procedure.
as described in the
Cable Preparation
54. Before terminating the shielded wire, the cable needs to be prepared. To prepare the shielded cable, use one of
the following methods applicable to the intended application:
a.
For centre stripped cables rated above 125C, prepare as per dimensions illustrated in Figure 3-27.
STRIP 6.0 to
8.0 mm
Figure 3-27
Preparation of Centre Stripped Cable
b.
For end stripped cables rated above 125C, prepare as per dimensions illustrated in Figure 3-28.
17

Sect 2 Chap 3
STRIP 6.0 to
8.0 mm
Figure 3-28
Preparation of End Stripped Cable
c.
For cables rated between 105C and 125C, or to build up the diameter of small cables, fold back the braid and
prepare as per dimensions illustrated in Figure 3-29.
STRIP 6.0 to
8.0 mm
Figure 3-29 Preparation of End Stripped Braided Cable

d.
To provide proper sealing and connection, the solder sleeve must be selected by size and cable dimensions
Installation of the Mil Spec M83519/1 Solder Sleeve

55. The M83519/1 solder sleeve does not have a pre-installed ground lead so it will be required to prepare a ground
lead prior to installation. The procedure to manufacture a ground lead and install the solder sleeve is as follows:
a.
Select and prepare a ground lead suited to application from a relevant aircraft wiring publication. Strip one end
to the dimension as illustrated in Figure 3-30.
Figure 3-30 Installation of the M83519/1 Solder Sleeve
18

Sect 2 Chap 3
b.
Assemble the cable, ground lead, and solder sleeve ensuring no strands protrude to puncture the sleeve, as
illustrated in Figure 3-31. Note, the ground lead can enter the sleeve from either side.
Figure 3-31 Examples of Solder Sleeve Assembles

c.
Apply heat directly at the solder preform using a suitable heat gun deflector. Remove from heat when the solder
melts
and
wets
to
the
shield
braid
and
ground
lead,
as
illustrated
in
Figure 3-32.
Figure 3-32 Installation of the M83519/1 Solder Sleeve
Note
The collapse of the solder preform does not indicate solder flow. Continue to apply heat until the solder flows and
forms a fillet between the shield and the ground lead.
If necessary, heat each end of the sleeve to complete shrinkage of the tubing and inserts.
Warning
Do not handle the termination when hot as serious burns will result. Allow the termination to cool prior to handling.
56.
a.
Inspect the termination according to the following guidelines:

Unacceptable Termination (Insufficient Heat)
The thermal indicator is clearly visible as a dull red colour.
19

Sect 2 Chap 3
b.
c.
d.
e.
The original shape of the solder preform is clearly visible.
The sealing inserts have not flowed.
The contour of the braid and/or lead is blocked by solder.
Acceptable Termination (Minimum Solder Flow)
The thermal indicator shows slight traces of dull red colour.
The solder has lost all its original shape.
The sealant inserts have melted and flowed along the wires.
The shield and lead contours are visible.
A definite fillet is visible between lead and shield.
Acceptable Termination (Maximum Solder Flow)
The dull red colour has disappeared from the thermal indicator.
A definite fillet is clearly visible between the lead and shield.
The joint area is visible despite the browning sleeve.
Unacceptable Termination (Overheated)
The joint area is not visible because of severe darkening of the outer sleeve.
The solder fillet is not visible along the lead and shield interface.
Wire insulation is damaged outside of the sleeve.
Re-shrink, if necessary, until acceptable conditions exist.
If an overheated condition has occurred, cut out the damaged termination and start the
procedure again.
20
Installation of the M83519/2 solder sleeve is the same as the M83519/1 with the
exception of the ground lead preparation not being required as it is pre-installed.

Sect 2 Chap 4
SECTION 2
CHAPTER 4
ELECTRICAL WIRING INSTALLATION

INTRODUCTION
1.
This chapter describes recommended procedures
for installing electrical wiring and related accessories in
ADF aircraft.
MS25036
MS25274
2.
electrical wiring installation:
AN742
AN936
AN960
MIL-DTL-23053
MIL-DTL-25038
MIL-DTL-5593
MIL-DTL-8777
MIL-DTL-8794
MIL-I-631
MIL-K-81786
MIL-PRF-46846
MIL-PRF-8516
MIL-T-81714
MIL-W-22759
MIL-W-81044
MS18029
MS21919
Clamp, Loop, Plain, Support,

Aircraft
Washer, Tooth Lock
Washer Flat
Insulation, Sleeving, Electrical,
Heat Shrinkable
Wire, Electrical, High-Temperature,
Fire Resistant and Flight Critical
Hose, Aircraft, Low- Pressure,
Flexible
Wire Electrical, Silicone Insulated,
Copper, 600-Volt, 200C
Hose, Elastomeric - Hydraulic
Fluid, Oil and Fuel Resistant
Insulation, Electrical, SyntheticResin Composition, Non-rigid
Kit, Maintenance, ElectricalElectronic, Cable and Cable
Harness
Rubber, Synthetic, Heat Shrinkable
Sealing Compound, Polysulfide
Rubber, Electric Connectors and
Electric Systems, Chemically
Cured
Environment Resistant
Wire, Electric, Fluoropolymer
Insulated, Copper or Copper Alloy
Wire, Electric, Crosslinked
Polyalkene, Crosslinked Alkaneimide Polymer, or Polyarylene
Insulated, Copper or Copper Alloy
Cover Assembly, Electrical, For
MS27212 Terminal Board
Assembly
Clamp. Cushioned, Support, LoopType, Aircraft
MS25435
MS3373
MS35489
MS51957
NAS1070
NASM21042
NASM21266
NASM22529
NASM25440
NASM35338
NASM35649
NASM35650
NASM961
NEMA
WC27500
SAE AS25281
SAE AS27212
SAE AS50881
SAE AS 6136
MIL-I-7444
SAE AS735
Terminal, Lug, Crimp Style,

Copper, Insulated, Ring-Tongue,
Bell Mouthed, Type II, Class 1
Cap, Electrical Wire End, Crimp
Style, Type II, Class 1
Terminal, Lug, Crimp Style,
Straight Type for Aluminium
Aircraft Wire, Class 1
Strip, Mounting, Nut Insulating, for
Grommet, Synthetic and Silicone
Rubber, Hot Oil and Coolant
Resistant
Screw, Machine-Pan Head, CrossRecessed, Corrosion Resisting
Steel, UNC-2A
Washer, Plain, Oversize for
Aluminium Terminals
Nut, Self-Locking, 450F, Reduced
Hexagon, Reduced Height, Ring
Base , Non-corrosion Resistant
Steel
Grommet, Plastic, Edging
Grommet, Edging
Washer For Use with Aircraft.
Aluminium Terminals
Washer, Lock-Spring, Helical,
Regular Medium Series
Nut, Plain, Hexagon Machine
Screw, UNC-2B
Nut, Plain, Hexagon, Machine
Screw, UNF-2B
Washer, Flat, Electrical
Standard for Aerospace and
Industrial Electrical Cable
Clamp, Loop, Plastic, Wire Support
Terminal Board. Assembly,
Moulded-In Stud, Electric
Wiring, Aerospace Vehicle
Conduit, Electrical, Flexible,
Shielded, Aluminium Alloy for
Aircraft Installation
Insulation Sleeving, Electrical,
Flexible
Clamp, Loop-Type, Bonding

Sect 2 Chap 4
DEFINITIONS
Size of Wire Bundle
3.
The following definitions are applicable to electrical
wiring installation:
6.
Wiring specifications generally limit the size of wire
bundles to 5 cm diameter.
a.
Open Wiring. Any wire, wire group, or wire bundle

not enclosed in a covering.
b. Wire Group. Two or more wires tied together to

retain identity of the group.
c.
Wire Bundle. Two or more wire groups, tied

together because they are going in the same
direction at the point where the tie is located.
d. Wire Harness. Wire group or bundle tied together

as a compact unit (open harness) or contained in
an outer jacket (enclosed harness). Wire
harnesses are usually prefabricated and installed
in the aircraft as a single assembly.
Figure 4- 1 Group and Bundle Ties

Identity of Groups Within Bundles
e.
Electrically Protected Wiring. Those wires which

have protection against overloading, through
fuses, circuit breakers, or other current-limiting
devices.
7.
When several wires are grouped at junction boxes,
terminal boards, panels, etc., retain the identity of the
group within a bundle by spot ties, as shown in Figure 4
1.
f.
Electrically Unprotected Wiring. Those wires

(generally from generators to main buss
distribution points) which do not have protection
from fuses, circuit breakers or other currentlimiting devices.
Combing Wires
8.
Comb out all wires, except those listed in
paragraph 9, so that wires will be parallel to each other in
a group or bundle.
Twisting Wires
WIRE TYPES
4.
The wires most commonly used in aircraft
electrical systems are in accordance with the
specifications listed in Table 41. See Section 2, Chapter
1, for details of conductor, insulation, voltage and
temperature.
9.
When specified on applicable engineering
drawings, twist together the following wires:
a.
Wiring in vicinity of magnetic compass or flux

valve.
b. Three-phase distribution wiring.

c.
WIRE GROUPS AND BUNDLES

Wire Separation
5.
Specification SAE AS50881 restricts the grouping
or bundling of certain wires, such as electrically
unprotected power wiring, and wiring to duplicate vital
equipment. Do not add such wires to existing bundles
unless specifically authorised.
Other wires (usually sensitive circuit avionic wiring)

as specified on engineering drawings.
10. Twist wires so they lie snugly against each other,

making approximately the number of twists given in Table
42. Check wire insulation for damage after twisting. If
insulation is torn or frayed, replace the wire.
Table 41 Wire Types

600 Volts or Under
General Purpose
Aluminium
High Temperature
Fire Resistant
MIL-W-22759
N/A
MIL-DTL-8777
*MIL-W-22759
MIL-DTL-25038
Cable, Shielded and Jacketed

NEMA WC27500
*MIL-W-22759 covers wire rated at 600 volts and 1000 volts

Sect 2 Chap 4
Table 42 Twists Per 30cm

Wire Size
#22
#20
#18
#16
#14
#12
#10
#8
#6
#4
2 Wires
10
3 Wires
10
10
7.5
6.5
10
8.5
6.5
5.5
Spliced Connection in Bundles
d. Splices shall not be used within 30cm of a

termination device, except as stated in sub-para e.
11. Locate spliced connections in wire groups or

bundles so that they can be inspected. Stagger splices
as shown in Figure 42 so that the bundle does not
become excessively enlarged. Ensure that all noninsulated splices are covered by shrinkable tubing or by
plastic sleeves securely tied at both ends. Splices are
subject to the restrictions of SAE AS50881. Splices are
subject to the following restrictions:
a.
There shall be no more than one splice in any one

wire segment between any two connectors or
other disconnect points, except as stated in subpara e.
b. Splices in bundles shall be staggered and shall not

increase the size of the bundle, so as to prevent
the bundle from fitting in its designated space or
cause congestion that will adversely affect
maintenance.
c.
Splices shall not be used to salvage scrap lengths

of wire.
e.
Splices may be used within 30cm of a termination

device when attaching to the pigtail spare lead of a
potted termination device, to splice multiple wires
to a single wire, or to adjust the wire sizes so that
they are compatible with the contact crimp barrel
sizes.
f.
Splices may be used to repair manufactured

harnesses or installed wiring when approved by an
appropriate engineering authority.
g. Splices shall not be used on firing or control

circuits associated with ordnance or explosive subsystems.
NOTE
Splices may be used if incorporated in the original
design or authorized by an engineering change.
h. The application of splices shall be under design
control and shall be authorized by engineering
drawings.
Figure 4- 2 Staggered Splices in Wire Bundles
Figure 4- 3 Slack Between Supports

Sect 2 Chap 4
Bend Radii
Slack
12. Do not install single wires or wire bundles with
excessive slack. Slack between support points such as
cable clamps should normally not exceed 12.7mm. (See
Figure 43.) This is the maximum that it should be
possible to deflect the wire with moderate hand force.
This may be exceeded if the wire bundle is thin and the
clamps are far apart but the slack must never be so great
that the wire bundle can touch any surface against which
it may abrade. Allow a sufficient amount of slack near
each end for any or all of the following:
a.
To permit ease of maintenance.
b. To allow replacement of terminals at least twice.

c.
To prevent mechanical strain on the wires, cables,

junctions, and supports.
13. Bend individual wires to a minimum radius of ten

times the outside diameter of the wire, except that at
terminal boards where the wire is suitably supported at
each end of the bend, a minimum radius of three times
the outside diameter of the wire is acceptable. Bend wire
bundles to a minimum radius of ten times the outside
diameter of the largest wire in the bundle.
CAUTION
Never bend coaxial cable to a smaller radius than six
times the outside diameter.
14. When it is not possible to hold the bending radius
of single wires to the above limits, enclose bend in tight
plastic tubing for at least 5cm each side of the bend.
d. To permit free movement of shock-and-vibration

mounted equipment.
e.
To permit shifting of equipment, for purposes of

maintenance, while installed in the aircraft.
Figure 4- 4 Routing Bundles

Sect 2 Chap 4
ROUTING AND INSTALLATION

Drip Loop
15. Where wiring is dressed downward to a connector,
terminal block, panel or junction box, a drip loop shall be
provided in the wiring to prevent fluids or condensation
from running into the components.
General Instructions
16. Install wiring so that it is mechanically and
electrically sound, and neat in appearance. Wherever
practicable, route wires and bundles parallel with, or at
right angles to, the stringers or ribs of the area involved,
NOTE
Route coaxial cable as directly as possible. Avoid
unnecessary bends in coaxial cable. Locate
attachments at each frame rib on runs along the length
of the fuselage, or at each stiffener on runs through the
wings.
General Precautions
17. When installing electrical wiring in aircraft, observe
the following precautions:
a.
Do not permit wire or wire bundles to have moving,

frictional contact with any other object.
b. Do not permit wire or wire bundles to contact

sharp edges of structure, holes, etc. (Refer to
paragraph 20.)
c.
Do not use any installation tools other than those

specifically authorized.
d. Do not damage threads of attaching hardware by

over-tightening or cross-threading.
e.
Do not subject wire bundles to sharp bends during

installation. (Refer to paragraph 13.)
f.
Do not allow dirt, chips, loose hardware, lacing

tape scraps, etc., to accumulate in enclosures or
wire bundles.
g. Do not hang tools or personal belongings on wire

bundles.
k.
Do not stretch wires to mate connectors; allow

sufficient slack to permit easy mating.
l.
Do not paint electrical wires, connectors, switches

or other electrical devices.
Support
18. Bind and support wire and wire bundles to meet
the following requirements:
a.
Prevent chafing of cables.
b. Secure wires and wire bundles routed through

bulkheads and structural members.
c.
Fasten wires in junction boxes, panels, and

bundles for proper routing and grouping.
d. Prevent mechanical strain that would tend to break

the conductors and connections.
e.
Prevent arcing or overheated wires from causing

damage to mechanical control cables.
f.
Facilitate re-assembly to equipment and terminal

boards.
g. Prevent interference between wires and other

equipment.
h. Permit replacement or repair of individual wires
without removing the entire bundle.
i.
Prevent excessive movement in areas of high

vibration.
j.
Use of mounting plate, P/N TC-92, for wire bundle

support is recommended in areas where selfclinching cable straps are used.
Protection
19. Install and route wires and wire bundles to protect
them from the following:
a.
Chafing or abrasion.
b. High temperature.
c.
Use of wire bundles as handholds, footrests, or

steps, or as support for personal belongings and
equipment.
d. Damage by personnel moving within the aircraft.
h. Do not use installed wire bundles or equipment as

footrests, steps, or handholds.
e.
Damage from cargo stowage or shifting.
i.
f.
Damage from battery acid fumes, spray, or

spillage.
j.
Do not compensate for wires that are too long by

folding wire back on itself and hiding such folds
within bundles.
Do not twist or pull wire bundles during assembly
or installation so that pins are pulled from
connectors, or connectors or wires are otherwise
damaged.
g. Damage from solvents and fluids.

h. Abrasion in wheel wells where exposed to rocks,
ice, mud, etc.

Sect 2 Chap 4
Protection Against Chafing
Protection Against High Temperature
20. Install wires and wire groups so they are protected

against chafing or abrasion in locations where contact
with sharp surfaces or other wires would damage the
insulation. Damage to the insulation may result in short
circuits, malfunction, or inadvertent operation of
equipment. Use approved cable clamps to support wire
bundles at each hole through a bulkhead. (See Figure 4
5.) If wires come closer than 6.3mm to edge of hole,
install a suitable grommet in hole as shown in Figure 46.
21. To prevent wire insulation deterioration, keep wires

separate from high temperature equipment such as
resistors, exhaust stacks, heating ducts, etc. The amount
of separation is specified by engineering drawings. If
wires must be run through hot areas, insulate the wires
with high temperature material such as fibreglass, or
PTFE. Additional protection in the form of conduit may be
specified by engineering drawing.
CAUTION
Do not depend on insulating sleeving as protection
against abrasion or chafing, or as a substitute for
good routing practice.
Figure 4- 5 Cable Clamp at Bulkhead Hole
CAUTION
Never use a low temperature insulated wire to
replace a high temperature insulated wire.
22. Many coaxial cables have soft plastic insulation
such as polyethylene. These are especially subject to
deformation and deterioration at elevated temperatures.
Avoid all high temperature areas with these cables.
Figure 4- 6 Cable Clamp and Grommet at Bulkhead

Hole

Sect 2 Chap 4
Use of Asbestos in Aircraft
Protection in Wheel Wells and Wing Folds
23. In the past asbestos products were used to protect

wire insulation in high temperature areas. This is no
longer considered appropriate due to the well
documented health problems attributed to this material.
Asbestos materials are NOT to be used in aircraft
electrical systems.
28. Wires located in wheel wells and wing folds are

subject to many additional hazards such as exposure to
fluids, pinching, and severe flexing in service. Make sure
that all wire bundles are protected by sleeves of flexible
tubing securely held at each end. There should be no
relative movement at the point where flexible tubing is
secured. Inspect these wires and the insulating tubing
carefully at very frequent intervals. Replace wires and/or
tubing at the first sign of wear. There should be no strain
on attachments when parts are fully extended but slack
should not be excessive.
24. Where asbestos materials are identified or

suspected in aircraft electrical systems, Environmental
Health personnel should be contacted to provide advice
on appropriate handling procedures. Authorised
engineering personnel should then determine the
feasibility of replacing the asbestos products with suitable
non-asbestos alternatives or, where no alternatives are
available, introducing appropriate risk management
procedures.
Protection Against Personnel and Cargo
25. Install wire bundles so they are protected by the
structure. Use structure or conduit to prevent pinching
against the airframe by cargo. Locate wire bundles so
that personnel are not tempted to use sections of the wire
runs as handholds or ladder rungs.
Protection Against Battery Acids
26. Never route any wires below a battery. Inspect
wires in battery areas frequently. Replace any wires that
are discoloured by battery fumes.
Protection Against Solvents and Fluids
27. Avoid areas where wires will be subjected to
damage from fluids. Wires and cables installed in aircraft
bilges shall be installed at least 15cm from the aircraft
centreline. If there is a possibility that the wire without a
protective outer jacket may be soaked in any location,
use plastic tubing to protect it. This tubing should extend
past the wet area in both directions and be tied at each
end if the wire has a low point between the tubing ends.
The lowest point of the tubing should have a 3mm
drainage hole as shown in Figure 47. Punch the hole in
the tubing after the installation is complete and the low
point definitely established. Use a hole punch to cut a
half circle. Be careful not to damage any wires inside the
tubing when using the punch. Tape (non-adhesive) used
as a wrap around the wires and cables shall also have
drainage holes at the low points.
Separation from Plumbing Lines

29. When wiring must be routed parallel to
combustible fluid or oxygen lines for short distances,
maintain as much fixed separation as possible, 15cm or
more. Route the wires on a level with, or above, the
plumbing lines. Space clamps so that if a wire is broken
at a clamp it will not contact the line. Where a 15cm
separation is not possible, clamp both the wire bundle
and the plumbing line to the same structure to prevent
any relative motion. If the separation is less than 50mm
but more than 12.7mm, use a nylon sleeve over the wire
bundle to give further protection. Use two cable clamps
back to back, as shown in Figure 48, to maintain a rigid
separation only (not for bundle support).
CAUTION
Do not route any wire so that it can possibly come
closer than 12.7mm to a plumbing line. Factory
installed wiring within 12.7mm of a fluid line should be
moved when possible. If moving the wiring is not
possible, the wiring should be wrapped, tied, and
clamped to maintain separation from the fluid line.
CAUTION
Never support any wire or wire bundle from a
plumbing line carrying flammable fluids or oxygen.
Clamps may be used only to Ensure separation.
CAUTION
If it is necessary to move or repair wires which have a
protective jacket with a drainage hole at the low point,
make sure drainage hole is still at the low point
afterward. If the location of the low point has
changed, punch a new hole in the protective jacket at
the new low point.

Sect 2 Chap 4
between wires, cables and looms classified EMI

sensitive and other equipment, wires, cables and
looms.
c.
Wires, cables and looms that are EMI sensitive

and are required to cross other wires, cables or
looms, should do so at right angles, while
maintaining the maximum clearance; and
d. Appropriate levels of EMI protection (shielding,

double-shielding, twisted pairs etc) should be
applied to wire(s) and looms as required.
32. When aircraft wiring manuals are amended during
the modification process, details of all special handling
instructions for EMI sensitive wires, cables and looms,
including the level of susceptibility, separation and
marking requirements, shall be included.
Figure 4- 7 Drainage Hole in Low Point of Tubing
CONDUIT
Introduction
33. Conduit is used to protect electric wire and cable
from abrasion, corrosive fluids, high temperatures, RF
interference, and damage from cargo handling or
activities of aircraft personnel. Extensive use of conduit is
undesirable because of weight therefore it is used only in
areas where harmful conditions exist, in parts of aircraft
hard to get at for permanent installation, and in short runs
compatible with its protective function.
34. Conduit is available in metallic or non-metallic
(plastic) form. Metallic conduit is either rigid or flexible;
non-metallic conduit is flexible.
Figure 4- 8 Separation of Wires From Plumbing

Lines
METALLIC CONDUIT
Damage Limitations
Separation from Control Cables

30. Route wiring to maintain a minimum clearance of
7.6cm from control cables. If this is not possible, install
mechanical guards to prevent contact of wiring with
control cables.
Installation of EMI Sensitive Wiring
31. Unless engineering justification is provided to
establish alternative procedures, the following
requirements shall be met to reduce the possibility of
EMI:
a.
Wires and cables classified as EMI sensitive may

be grouped together in the same loom, but they
shall not be grouped together with any other wires
and cables.
b. Appropriate clearance (either as far as practical or

as defined by the OEM) shall be maintained
35.
a.
The damage limitations are as follows:

Cuts. Cuts are acceptable provided cut does not
extend into the interior of the conduit.
b. Chafing. Chafing is permissible provided damage

does not extend into the interior of the conduit, and
the conduit is repositioned to prevent further
chafing.
c.
Bends. Bends are acceptable provided bends do

not decrease interior area sufficiently to prevent
freedom of movement of the wire bundle. Bends
that cause the conduit to interfere with other parts
are unacceptable.
d. Dents. Minor dents are acceptable provided they

do not decrease the interior area sufficiently to
prevent freedom of movement of the wire bundle
throughout the length of the conduit.

Sect 2 Chap 4
36. Metallic conduit is either rigid or flexible. Rigid

metal conduit is aluminium or aluminium alloy tubing.
Aluminium flexible conduit conforms to Specification SAE
AS 6136, which covers two types: Type I - bare flexible
conduit, and Type II - rubber-covered flexible conduit.
Brass flexible conduit conforms to SAE AS 25064.
Flexible, aluminium conduit is used only when it is
impracticable to use rigid conduit, such as in areas where
the necessary bends are so complex as to interfere with
installation, or where there is relative motion between the
conduit ends. Flexible brass conduit is used instead of
flexible aluminium in areas where it is necessary to
minimise RF interference, or in areas of high
temperature.
Selection of Conduit Size
37. The protected wire or wire bundle diameter must
not be more than 80% of the inside diameter of the
conduit. (See Figure 49)
NOTE
Rigid metallic conduit is supplied in outside diameter
sizes. Subtract twice the wall thickness to obtain the
inside diameter. Flexible metallic conduit is supplied in
inside diameter sizes; no calculation of diameter is
necessary.
38. Determine conduit length to accommodate length
of wire to be installed in conduit between connections so
that when conduit is installed there is no strain on the
wires or ferrules.
Bending Metallic Conduit
39. Bends in metallic conduit should be kept to a
minium. Table 43 provides details of minimum bend
radii.
Table 43 Bend Radii for Rigid Conduit

Nominal Tube
OD (mm)
Minimum Bend
Radii (mm)
3.175
9.525
4.75
14.275
6.35
19.05
9.525
28.575
12.7
38.1
15.875
47.625
19.05
57.15
12.4
76.2
31.75
95.25
38.1
114.3
44.45
133.35
50.8
152.4
NON-METALLIC CONDUIT
40. Non-metallic conduit is made of flexible plastic
tubing, conforming to Military Specifications MIL-I-631 or
MIL-I-7444. There is no specification for rigid non-metallic
conduit; phenolic tubing is sometimes used.
HEAT-SHRINKABLE TUBING
41. In certain applications heat shrinkable tubing may
be an appropriate alternate to flexible conduit. Details of
various types of heat-shrinkable tubing are listed below.
42. Table 44 provides details of SAE AMS-DTL23053/4 Insulation Sleeving, Electrical, Heat Shrinkable,
Polyolefin, Dual-Wall, Outer Wall Crosslinked, Class 2
(Flame Retardant). This sleeving consists of an outer wall
which shrinks and an inner wall that flows when heated. It
is rated from -55C to 110C and has a dielectric strength
of 500 volts/mil. Heat shrinkable dual wall sleeving is
suitable for one step potting, encapsulating, or moisture
sealing of electrical components.
SAE AMS DTL-23053/5, Class 1
Polyolefin, Flexible, Crosslinked, Class 1 (Flame
Resistant). This sleeving is rated from -55C to 135C
and has a dielectric strength of 500 volts/mil. Heat
shrinkable flexible polyolefin sleeving is suitable for light
duty harness jackets, wire colour coding, marking or
identification.
Figure 4- 9 Capacity Limits for Conduit

Sect 2 Chap 4
SAE AMS-DTL-23053/8
44.
Table 46 provides details of SAE AMS-DTL23053/8 Insulation Sleeving, Electrical, Heat Shrinkable,
Polyvinylidene Fluoride, Semi-Rigid, Crosslinked. This
sleeving is clear and is rated from -55C to 175C. It has
a dielectric strength of 800 volts/mil up to 12.7mm
diameter and 600 volts/mil over 12.7mm diameter. Heat
shrinkable semi-rigid polyvinylidene fluoride sleeving is
suitable for wire or termination strain relief.
Polytetrafluoroethylene. This sleeving is produced in 5
classes (which relate to wall thickness) and is rated from
-67C to 250C. It has a dielectric strength of 800
volts/mil. This sleeving is suitable for use in areas where
resistance to flame and high temperature is required.
Table 44 SAE AMS-DTL-23053/4, Class 2

Part Number
(Note 1)
Minimum Inside
Diameter Expanded
(mm)
After Unrestricted Shrinkage

Minimum Inside Diameter
(mm)
Total Wall Thickness

(mm)
M23053/4-201-*
6.05
3.18
0.74 0.13
M23053/4-202-*
9.02
4.75
0.74 0.13
M23053/4-203-*
12.07
6.35
0.76 0.13
M23053/4-204-*
18.09
9.53
0.89 0.13
M23053/4-205-*
24.13
12.70
1.07 0.13
M23053/4-206-*
36.20
19.05
1.19 0.13
Notes:
1.
* is replaced with appropriate number to indicate colour. (0-Black, 2-Red, 4-Yellow, 9-White, etc.)
Table 45 SAE AMS-DTL-23053/5, Class 1

Part Number
(Note 1)
Minimum Inside
Diameter Expanded
(mm)

(mm)

(mm)
M23053/5-101-*
1.17
0.58
0.41 0.08
M23053/5-102-*
1.60
0.79
0.43 0.08
M23053/5-103-*
2.36
1.17
0.51 0.08
M23053/5-104-*
3.18
1.58
0.51 0.08
M23053/5-105-*
4.75
2.36
0.51 0.08
M23053/5-106-*
6.35
3.18
M23053/5-107-*
9.53
4.75
0.64 0.08
M23053/5-108-*
12.70
6.35
M23053/5-109-*
19.05
9.53
M23053/5-110-*
25.40
12.70
M23053/5-111-*
38.10
19.05
M23053/5-112-*
50.80
25.40
M23053/5-113-*
76.20
38.10
M23053/5-114-*
19.60
50.80
0.64 0.08
0.64 0.08
0.76 0.08
0.89 0.13
1.02 0.15
1.14 0.18
1.27 0.20
1.40 0.23
Notes:
1.
10

Sect 2 Chap 4
Table 46 SAE AMS-DTL-23053/8

Part Number
(Note 1)
Minimum Inside
Diameter Expanded
(mm)

(mm)

(mm)
M23053/8-001-C
1.17
0.58
0.25 0.05
M23053/8-002-C
1.60
0.79
0.25 0.05
M23053/8-003-C
2.36
1.17
0.25 0.05
M23053/8-004-C
3.18
1.58
0.25 0.05
M23053/8-005-C
4.75
2.36
0.25 0.05
M23053/8-006-C
6.35
3.18
M23053/8-007-C
9.53
4.75
0.31 0.08
M23053/8-008-C
12.70
6.35
M23053/8-009-C
19.05
9.53
M23053/8-010-C
25.40
12.70
M23053/8-011-C
38.10
19.05
0.31 0.08
0.31 0.08
0.43 0.08
0.48 0.08
0.51 0.08
Notes:
1.
Table 47 SAE AMS-DTL-23053/12

Part Number
(Note 1)
Minimum Inside
Diameter Expanded
(mm)

(mm)

(mm)
Class 1 - Thick
Wall
M23053/12-101-*
4.22
3.30
M23053/12-102-*
0.76 0.13
6.35
4.90
M23053/12-103-*
0.76 0.13
8.38
6.53
M23053/12-104-*
0.76 0.13
10.54
8.13
M23053/12-105-*
0.76 0.13
12.65
9.73
M23053/12-106-*
0.76 0.13
14.73
11.38
M23053/12-107-*
16.92
12.95
0.76 0.15
M23053/12-108-*
19.00
14.53
M23053/12-109-*
21.08
16.18
M23053/12-110-*
23.24
17.78
M23053/12-111-*
25.4
19.41
M23053/12-112-*
29.72
22.63
M23053/12-113-*
33.78
25.91
0.76 0.15
0.76 0.15
0.76 0.15
0.81 0.15
1.01 0.18
1.14 0.18
1.27 0.20
11

Sect 2 Chap 4

Part Number
(Note 1)
Minimum Inside
Diameter Expanded
(mm)

(mm)

(mm)
Class 2 Standard Wall

M23053/12-201-*
1.27
0.69
M23053/12-203-*
0.30 0.05
1.52
0.99
M23053/12-206*
0.40 0.07
2.16
1.37
M23053/12-208-*
0.40 0.07
3.05
1.83
M23053/12-212-*
0.40 0.07
4.32
2.57
M23053/12-216-*
0.40 0.07
6.10
3.58
M23053/12-220-*
9.40
5.69
0.51 0.10
M23053/12-224-*
11.43
7.90
M23053/12-227-*
11.94
8.54
M23053/12-230-*
19.05
13.31
M23053/12-232-*
28.78
19.96
M23053/12-233-*
33.28
23.14
M23053/12-234-*
38.10
26.31
0.51 0.10
0.51 0.10
0.64 0.15
0.64 0.15
0.90 0.20
0.90 0.20
0.90 0.20
Class 3 - Thin
Wall
0.86
0.38
M23053/12-301-*
0.23 0.05
1.17
0.56
M23053/12-303-*
0.25 0.07
1.52
0.99
M23053/12-306-*
0.30 0.07
1.93
1.24
M23053/12-308-*
0.30 0.07
3.05
1.83
M23053/12-312-*
0.30 0.07
4.82
2.57
M23053/12-316-*
6.10
3.58
0.30 0.07
M23053/12-320-*
9.40
5.69
M23053/12-324-*
10.92
7.06
M23053/12-327-*
11.94
8.81
M23053/12-330-*
0.38 0.10
0.38 0.10
0.38 0.10
0.38 0.10
Class 4 - Very
Thin Wall
12
M23053/12-401-*
1.27
0.64
M23053/12-403-*
0.15 0.05
1.52
0.97
M23053/12-406-*
0.15 0.05
2.16
1.37
M23053/12-408-*
0.15 0.05
2.79
1.60
M23053/12-412-*
0.15 0.05
4.32
2.51
M23053/12-416-*
0.20 0.05
6.10
3.53
M23053/12-420-*
9.40
5.44
0.20 0.05
M23053/12-424-*
11.45
7.65
M23053/12-426-*
11.94
8.81
0.25 0.07
0.25 0.07
0.25 0.07

Sect 2 Chap 4

Part Number
(Note 1)
Minimum Inside
Diameter Expanded
(mm)

(mm)

(mm)
Class 5 - High
Shrink Thin Wall
M23053/12-501-*
1.98
0.64
M23053/12-503-*
0.23 0.05
4.75
1.27
M23053/12-506-*
0.30 0.05
9.53
2.44
M23053/12-508-*
0.30 0.05
12.70
3.66
M23053/12-512-*
0.38 0.10
19.05
5.69
M23053/12-514-*
0.38 0.10
25.40
7.06
M23053/12-516-*
38.10
10.16
0.38 0.10
M23053/12-518-*
50.80
13.20
M23053/12-520-*
63.50
16.51
M23053/12-522-*
76.20
19.69
M23053/12-524-*
88.90
22.86
M23053/12-526-*
101.60
26.04
0.38 0.10
0.51 0.13
0.51 0.13
0.51 0.13
0.51 0.13
0.51 0.13
Notes:
1.
Use of Heat-Shrinkable Tubing

46. Heat-shrinkable tubing conforming to SAE AMSDTL-23053 (except those manufactured from PVC), may
be used to identify, colour code, or strain relieve wires
and wire terminations or for cable jacketing and repair.
The procedure is as follows:
a.
Refer to Table 44, Table 45, Table 46 and

Table 47 and select a tubing type and size that
conforms to the use requirements.
b. Position the tubing as required over the item to be

covered.
d. Remove the heat as soon as the heat-shrinkable

tubing conforms to the component being covered.
Allow to cool for 30 seconds before handling.
CABLE CLAMPS
Chloroprene Cushion Clamps
47. The Chloroprene cushion clamps listed in Table 4
8 are intended for general purpose clamping applications
including electrical wire bundle clamping. A part number
example is listed below:
WARNING
Heat guns with electric Motors are not explosion proof
and are not approved for use in hazardous locations
or where explosion proof equipment is required.
Compressed air/nitrogen heat gun M83521/5-01 or
equivalent are the only heat guns that may be used in
hazardous locations.
WARNING
Heating the heat shrink tubing and Polyurethane
insulated wire or cables above 315C will cause
Polyurethane coatings to release irritating gases.
c.
48. Chloroprene cushion clamps are for general

purpose use in areas exposed to petroleum based
hydraulic fluids and occasional fuel splash. They have
excellent ozone resistance however they are not resistant
to phosphate ester based fluids and are not suitable for
use on titanium tubing. Their colour is black with a blue
stripe on both edges.
Use a hot-air gun or compressed air type heater

as a hot air source. Use the appropriate hot-air
reflector on the nozzle of the heating tool to shrink
the tubing quickly and evenly.
13

Sect 2 Chap 4
Table 48 Chloroprene Cushion Clamps

Fluorosilicone Cushion Clamps
49. The Fluorosilicone cushion clamps listed in Table
49 are intended for clamping applications, including
electrical wire bundle clamping, in elevated temperature,
fluid contaminated areas. A part number example is listed
below:
50. Fluorosilicone cushion clamps are for elevated

temperature usage in areas contaminated with petroleum
based fluids. They are unaffected by ozone however they
are not resistant to phosphate ester based fluids. Their
colour is solid blue.
Nitrile Cushion Clamps
51. The Nitrile cushion clamps listed in Table 410 are
intended for clamping applications, including electrical
wire bundle clamping, in fuel or fuel vapour areas. A part
number example is listed below:
52. Nitrile cushions are for use in fuel immersion and

fuel vapour areas. They have good ozone resistance
however they are not resistant to phosphate ester based
fluids. Not to be used on Titanium tubing. Their colour is
solid yellow.
14
Part
Number
Inside
Diameter
(mm)
Part
Number
Inside
Diameter
(mm)
MS21919WDG2
3.18
MS21919WDG16
25.40
MS21919WDG3
4.75
MS21919WDG17
26.97
MS21919WDG4
6.35
MS21919WDG18
28.58
MS21919WDG5
7.92
MS21919WDG19
30.15
MS21919WDG6
9.53
MS21919WDG20
31.75
MS21919WDG7
11.10
MS21919WDG21
33.32
MS21919WDG8
12.70
MS21919WDG24
38.10
MS21919WDG9
14.27
MS21919WDG26
41.28
MS21919WDG10
15.88
MS21919WDG28
44.45
MS21919WDG11
17.45
MS21919WDG30
47.63
MS21919WDG12
19.05
MS21919WDG32
50.80
MS21919WDG13
20.62
MS21919WDG36
57.15
MS21919WDG14
22.22
MS21919WDG40
63.5
MS21919WDG15
23.08
MS21919WDG48
76.2
Table 49 Fluorosilicone Cushion Clamps

Part
Number
Inside
Diameter
(mm)
Part
Number
Inside
Diameter
(mm)
MS21919WCJ2
3.18
MS21919WCJ16
25.40
MS21919WCJ3
4.75
MS21919WCJ17
26.97
MS21919WCJ4
6.35
MS21919WCJ18
28.58
MS21919WCJ5
7.92
MS21919WCJ19
30.15
MS21919WCJ6
9.53
MS21919WCJ20
31.75
MS21919WCJ7
11.10
MS21919WCJ21
33.32
MS21919WCJ8
12.70
MS21919WCJ24
38.10
MS21919WCJ9
14.27
MS21919WCJ26
41.28
MS21919WCJ10
15.88
MS21919WCJ28
44.45
MS21919WCJ11
17.45
MS21919WCJ30
47.63
MS21919WCJ12
19.05
MS21919WCJ32
50.80
MS21919WCJ13
20.62
MS21919WCJ36
57.15
MS21919WCJ14
22.22
MS21919WCJ40
63.5
MS21919WCJ15
23.08
MS21919WCJ48
76.2
AC 21-99 A
Aircraft Wiring and Bondin
ng
Sect 2 Chap
p4
Installation
I
of Cable Clam
mps
Table 410 Nitrile Cushio

on Clamps
art
Pa
Num
mber
side
Ins
Diam
meter
(m
mm)
Part
P
Nu
umber
nside
In
Dia
ameter
(
(mm)
MS21919
9WDF2
3.18
MS2191
19WDF16
25.40
MS21919
9WDF3
4.75
MS2191
19WDF17
26.97
MS21919
9WDF4
6.35
MS2191
19WDF18
28.58
MS21919
9WDF5
7.92
MS2191
19WDF19
30.15
MS21919
9WDF6
9.53
MS2191
19WDF20
31.75
MS21919
9WDF7
1
11.10
MS2191
19WDF21
33.32
MS21919
9WDF8
1
12.70
MS2191
19WDF24
38.10
MS21919
9WDF9
1
14.27
MS2191
19WDF26
41.28
MS21919
9WDF10
1
15.88
MS2191
19WDF28
44.45
MS21919
9WDF11
1
17.45
MS2191
19WDF30
47.63
MS21919
9WDF12
1
19.05
MS2191
19WDF32
50.80
MS21919
9WDF13
2
20.62
MS2191
19WDF36
57.15
MS21919
9WDF14
2
22.22
MS2191
19WDF40
63.5
MS21919
9WDF15
2
23.08
MS2191
19WDF48
76.2
53.
5
Install MS21919
M
cable
e clamps as sh
hown in Figure
e
410.
4
The mo
ounting screw
w should be above
a
the wire
e
bundle,
b
if posssible. It is also d
desirable that the back of the
e
cable
c
clamp rest against a structural member. Use
e
hardware,
h
as shown in Fig
gure 411, to
o mount cable
e
clamps
c
to struccture. Be careful not to pinch
h wires in cable
e
clamp.
c
If the wire bundle iis smaller tha
an the nearesst
clamp
c
size, or
o if a clamp of the prope
er size is no
ot
available,
a
wra
ap the wire b
bundle with the
t
necessaryy
number
n
of turn
ns of insulating
g tape so that the bundle will
be
b held securrely in the clam
mp. If the clam
mp can not be
e
installed witho
out pinching and/or crushing the wiring
g
harness,
h
repla
ace the clamp
p with the nex
xt larger clamp
p
size
s
that will securely hold the harness in place.
Figure 4- 10 Preferred Ang

gle for Cable Clamps
C
1
15

Sect 2 Chap 4
Figure 4- 11 Typical Mounting Hardware for MS21919 Cable Clamps
NOTE
MS21919 cable clamps are cushioned with insulating
material to prevent abrasion of wires. Never use metal
clamps without cushions to hold wires
54. MS25281 nylon cable clamps may be used to
support wire bundles up to 50mm in diameter in open
wiring, or inside junction boxes and on the back of
instrument panels. When installing nylon cable clamps,
use a large diameter metal washer under the screw head
or nut securing the clamp.
57. A tool to facilitate the installation of cable clamps is

shown in Figure 413; a similar tool manufactured to
Federal Specification GGGP00477 is available. Similar to
conventional multiple slip joint pliers, the tool compresses
and holds the clamp with the securing bolt in place while
a nut is being installed on the bolt. The tool is particularly
useful for installing clamps in restricted areas and for
installing groups of two or three clamps.
WARNING
The plastic strap must be cut flush with the boss
surface in order to eliminate painful cuts and
scratches from protruding strap ends.
CAUTION
Do not use nylon cable clamps where the ambient
temperature may exceed 85C.
NOTE
MS25281 plastic cable clamps, spaced at intervals not
to exceed 60cm, may be used for wire support provided
every fourth clamp is a rubber cushion type
(MS21919W). The use of plastic cable clamps on other
than horizontal runs should be avoided unless the
installation is such that slack cannot accumulate
between clamping points.
55. Mount cable clamps directly to Z members of
structure. Use angle bracket with two mounting screws if
structural member is angled as shown in Figure 412.
56. Where additional clearance is required between
cable and aircraft structure or equipment, a cable clamp
standoff may be used. Suitable standoffs are identified in
Table 411
16
Figure 4- 12 Attaching Cable Clamp to Structure

Sect 2 Chap 4
Figure 4- 13 Tool for Installing Cable Clamp
Installing Cable Clamps to Tubular Structure

58. Use AN735 clamps without cushions for clamping
to tubular structure. The clamps must fit tightly but should
not deform when locked in place. Attach wire bundle in
MS21919 cable clamp to the AN735 clamp with AN
hardware as shown in Figure 414.
Installing Grommets
59. Military Standard grommets are available in
rubber, nylon, and TFE. Select grommet suitable for the
environmental conditions from Table 412. If it is
necessary to cut a nylon grommet in order to install it,
make the cut at an angle of 45 degrees as shown in
Figure 415. Cement the grommet in place with general
purpose cement, with the cut at the top of the hole. When
installing caterpillar grommets, cut the grommet to the
required length, making sure to cut square across the
teeth as shown in Figure 416. Cement the grommet in
place with general purpose cement, with the cut at the
top of the hole.
Figure 4- 14 Installing Cable Clamps to Tubular

Structure
Table 411 Cable Clamp Standoff Identification

Part Number
Standoff Length (mm)
Thread Size
L35064A2B075
19.6
0.1640-32UNJC (8/32)
L35064A2B100
25.4
0.1640-32UNJC (8/32)
L35064A2B125
31.75
0.1640-32UNJC (8/32)
L35064A2B150
38.10
0.1640-32UNJC (8/32)
L35064A2B175
44.45
0.1640-32UNJC (8/32)
L35064A2B200
50.8
0.1640-32UNJC (8/32)
L35064A2C075
19.6
0.1900-32UNJF (10/32)
L35064A2C100
25.4
0.1900-32UNJF (10/32)
L35064A2C125
31.75
0.1900-32UNJF (10/32)
L35064A2C150
38.10
0.1900-32UNJF (10/32)
L35064A2C175
44.45
0.1900-32UNJF (10/32)
L35064A2C200
50.8
0.1900-32UNJF (10/32)
17

Sect 2 Chap 4
Table 412 Grommets - Temperature Limitations of

Material
Upper
Temperature
Limit
Standard
Material
MS35489
Rubber, Hot Oil &

Coolant Resistant
Nylon
120C
TFE
260C
MIL-C-22529 &
MS21266
MIL-C-22529 &
MS21266
85C
CONNECTIONS TO TERMINAL BOARDS AND

BUSBARS
Connecting Terminal Lugs to Terminal Boards
60. Install terminal lugs on MS27212 terminal boards
in such a way that they are locked against movement in
the direction of loosening. (See Figure 417.) See Table
413 for MS27212 terminal board specifications, A
maximum of four lugs or three lugs and one bus shall be
connected to any one stud.
NOTE
MS27212 terminal boards are used as a replacement
for previously used NAS191 and MS25123 terminal
boards.
Figure 4- 15 Split Grommet
TEETH
Figure 4- 17 Connecting Terminal Lugs to Terminal
Board
CUT LINE
Figure 4- 16 Cutting Caterpillar Grommet
18

Sect 2 Chap 4
Table 413 MS27212 Terminal Boards and Covers

Terminal Board MS Part
Number
Stud Thread
Application
Torque Steel
Number of Studs
Cover Part Number
MS27212-1-20
6-32UNC-2A
8-10
20
MS18029 - 1(*) - (N)
MS27212-2-16
10-32UNC-2A
20-29
16
MS18029 - 2(*) - (N)
MS27212-3-8
1/4-28UNF-2A
60-70
MS18029 3(*) - (N)
MS27212-4-8
5/16-24UNF-2A
90-140
MS18029 4(*) - (N)
MS27212-5-8
3/8-24UNF-2A
115-175
MS18029 - 5(*) - (N)
Note: Terminal boards and covers are procured in full lengths with number of studs indicated.
Cut to suit needs at installation.
Cover Assembly Part

Number
Cover Part Number

Type L Type S
Studs
Maximum (N)
Nut Assembly
Dash No.
Threaded Metal
Insert
Retaining
Ring Part
Number
MS18029 - 1(*) - (N)
-11L - (N) - 11S - (N)
20
21
.138-32UNC-2B
MS166241040
MS18029 - 2(*) - (N)
-12L - (N) - 12S - (N)
16
22
.190-32UNC-2B
MS166241040
MS18029 - 3(*) - (N)
-13L - (N) - 13S - (N)
23
.250-28UNF-2B
MS166241062
MS18029 - 4(*) - (N)
-13L - (N) - 13S - (N)
24
.312-24UNF-2B
MS166241062
MS18029 - 5(*) - (N)
-13L - (N) - 13S - (N)
25
.375-24UNF-2B
MS166241062
MS18029 - 6(*) - (N)
-14L - (N) - 14S - (N)
16
26
.164-32UNC-2B
MS166241040
NOTES:
1. (*) Use letter L or S to indicate type cover desired.

(N) Indicates the number of studs in a MS27212 terminal board assembly to be covered.
2. Example of part number:
MS18029-2S-16 indicates a cover assembly for a MS27212 terminal board assembly having 16 studs.
This cover assembly will consist of the following:
1. MS18029-12S-16 type S cover.
2. MS18029-22 nut assemblies.
3. Part number shall be marked on top of cover.
3. Cover assemblies are not to be used in installations where the temperature exceeds 245C.
4. A minimum of three threads must be exposed after terminal stacking on the end studs for cover
installation.
19

Sect 2 Chap 4
Figure 4- 18 Hardware for Wiring Terminal Boards With Copper Terminals
Figure 4- 19 Hardware for Wiring Terminal Boards With Aluminium Terminals
20

Sect 2 Chap 4
Figure 420 Hardware for Wiring Terminal Boards With Combination of Terminals
Hardware for Wiring Terminal Boards

61. MS25123 terminal boards have studs secured in
place with a AN960 or AN960C flat washer and a
MS35649 or MS35650 steel nut. Place copper terminal
lugs directly on top of the MS35649 or MS35650 nut.
Follow with a AN960 or AN960C flat washer, a MS35338
split steel lockwasher, and a MS35649 or MS35650 steel
nut; or a AN960 or AN960C flat washer and a MS21042
self-locking all metal nut.
CAUTION
Do not use AN960D aluminium washers.
62. MS27212 terminal boards have studs moulded in
and therefore do not require hardware for attaching studs
to the terminal board. Use same hardware for installing
terminal lugs for MS25123 terminal boards (refer to
paragraph 56 and Figure 418). Mounting screws are
insulated with MS3373 insulators when using MS27212
terminal boards.
63. Place aluminium terminal lugs over a MS25440 or
NAS1070 plated flat washer of the correct size for
terminal and stud (see Table 414). Follow the terminal
lugs with another MS25440 or NAS1070 flat washer, a
MS35338 split steel lockwasher and either a MS35649 or

MS35650 nut or a MS21042 self-locking all metal nut.
See Figure 419 for details of this assembly.
CAUTION
Do not place any washer in the current path between
two aluminium terminal lugs or between two copper
terminal lugs.
CAUTION
Never place a lockwasher directly against the tongue
or pad of an aluminium terminal or busbar.
64. To join a copper terminal lug to an aluminium
terminal lug, place a MS25440 or NAS1070 flat washer
over the nut that holds the stud in place. Follow with the
aluminium terminal lug, another MS25440 washer, the
copper terminal lug, AN960 or AN960C plain washer,
MS35338 split steel lockwasher, and MS35649 or
MS35650 plain nut or MS21042 self-locking nut. See
Figure 420 for details.
21

Sect 2 Chap 4
Table 414 Washers for Use with Aluminium Terminal Lugs

NAS No.
MS No.
MS25440-3
8, 6, 4,
Stud Size
No. 10
NAS 1070-416
MS25440-4
8, 6, 4, 2, 1, 1/0
6.35mm
NAS 1070-516
MS25440-5
8, 6, 4, 2, 1, 1/0, 2/0
7.92mm
NAS 1070-616
MS25440-6
8, 6, 4, 2, 1, 1/0, 2/0
9.53mm
NAS 1070-716
MS25440-6A
NAS 1070-816
MS25440-8
Do not use AN960D aluminium washers.

Installation Torques for Large Copper Terminals
65. Use a torque wrench to tighten nuts on studs that
have a diameter of 9.5mm or larger. This will provide
appropriate pressure to ensure good electrical contact.
The tightening torques for steel studs are as listed in
Table 415.
Installation Torques for Aluminium Terminals
66. Use a torque wrench to tighten nuts over any
stack-up containing an aluminium terminal lug. The
tightening torques for aluminium studs are listed in Table
416.
Table 415 Installation Torques for Copper
Terminals (Inch Pounds of Torque)
Stud Size
Plain Nuts
Self-locking Nuts
0.375 24
0.500 20
110 120
135 150
115 125
150 170
Table 416 Installation Torques for Aluminium

Terminals (Inch Pounds of Torque)
Stud Size
No. 10
6.35mm
7.92mm
9.53mm
12.70mm
3/0, 4/0
9.53mm
2, 1, 1/0, 2/0
12.70mm
Connecting Terminal Lugs to Busbars
CAUTION
22
Terminal Size
Nut Torque
40
100
135 165
220 250
440 470
67. In order to obtain maximum efficiency in the

transfer of power, the terminal lug and the busbar should
be in direct contact with each other so that the current
does not have to go through any of the attaching parts,
even if these are good current carrying materials. As
illustrated in Figure 421 through Figure 424, the above
applies whether the terminal lugs and the busbar are of
the same or of different materials.
Cleaning Busbars When Making Connections
68. Clean all busbar areas before making new
connections or replacing old connections. See Section 2,
Chapter 15 for procedure to be followed in cleaning
busbars. The cleaned surface of an aluminium busbar is
coated with a petrolatum-zinc dust compound which is
left on the surface while the connection is made.
Hardware for Connection to Busbars
69. Cadmium plated steel hardware is used to secure
terminals to busbars. Use split lockwashers under hex
nuts and under self-locking nuts. Use plated steel plain
washers between lockwashers and copper terminals.
Use flat washers (MS25440) between lockwashers and
aluminium terminals. As shown in Figure 421 through
Figure 424, the head of the screw or bolt can be located
on the terminal side or the busbar side, as required to
simplify the installation.
70. Use a cadmium plated steel split lockwasher
MS35338 under the head of every bolt or screw and also
under the nut, as shown in Figure 421.
71. Use cadmium plated steel flat washers (MS25440)
in contact with aluminium. The washer diameter must be
at least equal to the tongue diameter of the terminal. See
Table 414. Do not select a washer so large that it will
ride on the barrel of the terminal. After tightening
connection, use soft cloth to wipe off excess petrolatumzinc compound left in place in accordance with paragraph
66.

Sect 2 Chap 4
Precautions When Replacing Existing Connections

72. Observe the following precautions when replacing
existing terminal lug connections to busbars:
a.
Check all flat washers. Replace bent washers

Replace washers that have scratched plating or
paint on faying surface.
b. Clean busbar connection areas by approved

methods. (See Section 2, Chapter 15.)
c.
Check plated copper terminal lugs before

connecting to an aluminium busbar. If plating is
scratched, replace terminal lug.
Figure 421 Connecting Aluminium Terminal to Aluminium Busbar
Figure 422 Connecting Copper Terminal to Aluminium Busbar
Figure 423 Connecting Aluminium Terminal to Copper Busbar
23

Sect 2 Chap 4
Figure 424 Connecting Copper Terminal to Copper Busbar
Figure 425 Connecting Two Terminals to Same Point on Busbar
Connecting Two Terminals to Same Point on Busbar
Protection of Busbars Against Accidental Shorting
73. Terminal lugs must always be in direct contact with

busbar. As shown in Figure 425, connect one terminal
lug to top of busbar and the other to bottom.
74. Busbars are usually enclosed in panels or junction

boxes to protect them against accidental shorting. If the
busbars are not enclosed, it is desirable to use some
protective coating. A good protective coating which is
easily applied is MIL-PRF-8516 Sealing Compound. This
is applied thickly with a spatula or short bristled brush to
the cleaned busbar prior to assembly of connections.
Mask all areas where connections will be made. Use
pressure sensitive tape for masking. See detailed
NOTE
Terminal lug offset is positioned so that barrel cannot
contact busbars. This allows proper seating of tongue
on busbar.
24

Sect 2 Chap 4
instructions for applying and curing sealing compound in

Section 2, Chapter 11. Remove masking tape after
sealing compound is cured by cutting into compound next
to tape with a razor blade and peeling tape from the
masked area.
75. Busbars can also be protected by slitting a piece of
insulating tubing and wrapping it around the busbar after
all connections are made. Select insulating tubing which
has large enough diameter to permit a generous overlap
when tying it in place. See Figure 426 for cutting and
tying details.
CAUTION
Do not bend terminal lugs to an angle greater than 90
degrees. Do not subject terminal lugs to more than
one bending operation.
Connecting Terminal Lugs to Equipment
76. When connecting wired terminal lugs to terminals
on switches, relays, and other equipment, the terminal
lugs may be bent at the barrel tongue junction if
necessary to permit installation. When bending is
required, keep the bend radius as large as possible,
while keeping the bend as small as possible. If protection
from adjacent equipment or personnel is necessary,
exposed terminal lugs may be covered with an easily
removable non-corrosive sealant, such as RTV3145 or
equivalent.
CAUTION
No ties or splices are permitted inside a conduit.
Feeding Wires into Conduit
78. Feed wires through a short length of conduit by
taping the end of the bundle together and pushing it
gent1y through. Longer runs of conduit or conduit with
complex bends will require a leader. Make a leader out of
a flannel or other soft cloth patch attached to a string long
enough to pass completely through the conduit. The
patch should fit loosely in conduit. (See Figure 428.)
Use compressed air at no more than 240kPa (35psi) to
blow patch and attached string through the conduit. Tie
wire bundle securely to string and tape over junction to
cover all wire ends. Pull string through conduit while
careful1y feeding wires into other end. After wire is
installed, remove tape and detach string.
Supporting Wires at End of Rigid Conduit
79. Use an MS21919 cable clamp to support wires at
each end of conduit. Place the cable clamp in a direct
line with the conduit end to prevent chafing of wires at
end of conduit. Place cable clamp as close to end of
conduit as practicable, but never more than 25cm away.
(See Figure 429.)
NOTE
Do not leave wire slack inside conduit. Wires should be
free, but not taut, inside conduit.
Figure 426 Insulating Tubing Around Busbar
INSTALLATION OF WIRES IN CONDUIT

Conduit Capacity
Figure 427 Conduit Capacity
77. Measure the bundle wires before installing in

conduit. In accordance with Specification SAE AS50881,
the bundle diameter must not exceed 80% of the internal
diameter of the conduit. (See Figure 427)
25

Sect 2 Chap 4
INSTALLATION OF CONNECTORS
Assembly of Connectors to Receptacles
80.
Assemble connectors to receptacles as follows:
WARNING
Unless otherwise required by specific equipment
technical data, power should be removed from the
affected circuit to avoid shock hazard and possible
arcing of connectors.
CAUTION
Do not use excessive force to mate connectors to
receptacles.
a.
Locate the proper position of the plug in relation to

the receptacle by aligning the key of one part with
the groove or keyway of the other part.
CAUTION
Figure 428 Leader for Conduit
Do not twist wire bundle excessively to achieve

proper matching of plug and receptacle.
b. Start the plug into the receptacle with a light
forward pressure and engage the threads of
coupling ring and receptacle.
c.
Alternately push in the plug and tighten the

coupling ring until the plug is completely seated.
CAUTION
Never use a torque wrench or pliers to lock coupling
rings.
Figure 429 Support for Wire at Conduit End
d. Use a strap wrench or padded conduit pliers to

tighten coupling rings 1/16 to 1/8 turn beyond
finger tight if space around connector is too small
to obtain a good finger grip. Self-locking
connectors are coupled until the moveable
indicator is aligned with index marks on coupling
ring. (See Figure 431.) In fully mated condition
locking indicator shall be aligned within orange
colour band.
NOTE
There shall be no relative movement between body of
connector and coupling ring. This condition represents
a properly seated connector.
26

Sect 2 Chap 4
Disassembly of Connectors from Receptacles

81.
Disassemble connectors as follows:
WARNING
Unless otherwise required by specific equipment
technical data, power should be removed from the
affected circuit to avoid shock hazard and possible
arcing of connectors.
a.
Use a strap wrench or padded pliers to loosen

coupling rings which are too tight to be loosened
by hand.
b. Alternately pull on the plug body and unscrew

coupling ring until connector is separated.
CAUTION
Do not pull on attached wires.
c.
Protect disconnected plugs and receptacles with

caps to keep debris from entering and causing
faults.
make sure that plug is inserted straight into the

receptacle before tightening coupling ring.
b. Avoid, where possible, locating connectors of the
same shell size adjacent to each other, whether
they have different insert arrangements or not.
c.
Locate receptacles where they are clearly visible

and accessible to aid in keying and inserting plug.
This will help to avoid bending receptacle pins
while seeking proper polarization.
d. Position receptacle so large keyway is at top if

mounted vertically or at forward end if mounted
horizontally.
CAUTION
Do not misconnect plugs and receptacles by forcing
pins into the resilient insert, either by misalignment of
properly mating connectors or by joining connectors
with identical shells but differently keyed insert
arrangements.
e.
When mating connectors with bayonet lock

coupling, make sure that all locking rivets of the
coupling are engaged.
Coding of Connectors
82. As a design objective, receptacles whose plugs
are interchangeable are not located in close proximity to
each other. However, when installation requirements are
such that these receptacles are in adjacent locations, use
clamps on the plug wires or assemble plugs and
receptacles so as to use one of the alternate insert
positions, to make it physically impossible to connect a
plug into the wrong receptacle. Also, colour-code the
connector plug body and the flange or mounting area of
the receptacle.
a.
Use one bright colour, such as red, green, or

yellow, for each matching pair.
b. Paint only the shell of plugs - not the coupling

rings.
c.
Paint only the mounting flange of the receptacle.

NOTE
Avoid painting the threaded surfaces or insulators of

plugs or receptacles.
CAUTION
Be careful not to lock the plug while cocked, i.e., two
locking rivets engaged and one not engaged.
Mounting Connectors
84. Before mounting receptacles to the back of a panel
or bulkhead, make sure there is sufficient clearance to
couple the plug to the receptacle. Make sure that
mounting hardware does not interfere with the installation
of the locking ring.
Installing Conduit on Connectors
85. When installing a stepped-down conduit on the
back shell of a connector having large wires (size No. 8
or larger), add an additional back shell to the connector
before installing the conduit. This will allow the wire
bundle to decrease in diameter gradually and prevent
sharp bends in the wires. (See Figure 430)
Special Precautions for Connectors with Resilient

Inserts
83. When assembling or installing miniature MS
connectors with resilient inserts, observe the following
special precautions:
a.
Before mating connectors, check that contacts are

not splayed or bent. When mating connectors,
27

Sect 2 Chap 4
Figure 430 Installing Conduit on Connector Back

Shell
Figure 431 Self-Locking Connector
INSTALLATION OF WIRE IN JUNCTION BOXES

Lacing or Tying in Junction Boxes
86. Wire bundles can be either laced or tied with spot
ties. Lacing and tying procedures are described in
CAUTION
Use nylon cable straps on wire bundles containing
coaxial cable in accordance with Section 2,
CHAPTER 7.
Support Inside Junction Boxes
87. Use MS21919 cable clamps to support wires
across hinged doors so that wires will be twisted and not
bent when the door is opened. See Figure 432 for
correct and incorrect methods of support.
88. Attach wire bundles to walls of junction box to
prevent chafing or abrasion against terminal studs or
other items in box. Tie up slack (required for terminal
rework) to prevent snagging.
28
Figure 432 Support Inside Junction Box
TERMINAL JUNCTION SYSTEM

89. The MIL-T-81714 terminal junction system is
designed to replace the open, screw type terminal blocks
found in older aircraft. There are two systems
designated, MIL-T-81714, Series I, and MIL-T-81714,
Series II. The Series I system utilizes a pin contact on the
wire. The Series II system utilizes a socket contact on the
wire.

Sect 2 Chap 4
90. The components making up the Series I terminal

junction system are as follows:
a.
Terminal junction modules:
91. The components making up the Series II terminal

junction system are as follows:
a.
(1) Feedback type - all connections made to

one side of module. (See Figure 433 and
Figure 434.)
(1) Feedback type - all connections made to

one side of module, non-electronic and
electronic. (See Figure 435.)
(2) Feedthrough type - connection carried

through from one side to the other of the
module. (See Figure 437.)
(2) Distribution type - different size contacts

bussed together.
(3) Grounding type - all connections grounded
to the panel, stud mount and flange mount.
(See Figure 436.)
b. Tracks or frames (holders) for modules. (See

Figure 433 and Figure 437.)
c.
Terminal junction modules:
Wire splices, removable contact. (See Figure 438

and Figure 439.)
b. Wire splices, removable contact, non-electronic

and electronic. (See Figure 438 and Figure 4
39.)
c.
Tracks or frames (holders) for modules. (See

Figure 435.)
Figure 433 Feedback Terminal Junction Assembly Series I
29

Sect 2 Chap 4
Figure 434 Feedback Terminal Junction Assembly Series I
Figure 435 Feedback Terminal Junction Assembly Series II
30

Sect 2 Chap 4
Figure 436 Grounding Junction Assembly Series II
Figure 437 Feed-Through Terminal Junction Assembly Series I
31

Sect 2 Chap 4
TYPICAL
CONTACT
SINGLE SPLICE
DOUBLE SPLICE
Figure 438 Removable Contacts and Wire Splices Series I
Availability of Terminal Junction System

Components
93. The wire terminal contacts are available in five
sizes for Series I and four sizes for Series II, as listed in
Table 418. The tracks are available in two basic types,
feedback and feedthrough, as listed in Table 417. The
modules available are feedback, feedthrough, distribution
and grounding. The splices available are single and
double as listed in Table 417.
Identification
94. The components of the terminal junction system
are identified in Figure 441 for Series I, and Figure 442
for Series II. For actual part number breakdown see MILT-81714 specification sheets.
Installation and Removal of Modules from Tracks
95. Installation and removal of Series I modules from
the tracks is accomplished as follows (See Figure 433 ,
Figure 434 and Figure 437):
a.
Loosen screw in locking clamp and slide clamp to

end of rail containing indexing marks.
b. Insert module into rail next to locking clamp, with

module indexing indicator on same side as rail
indicator.
NOTE
Figure 439 Removable Contacts and Wire Splices
Series II
Classification
92.
Terminal junction modules and spices are class D.

Class D
200C
max
Environmental type, fluid

resistant
All other classes (class A, B and C) are inactive in favour of

class D.
32
Modules can be installed in only one position in rail.

c.
Slide module against fixed stop at opposite end of

rail.
d. Install additional modules as required, sliding them

against last previously installed module.
e.
Slide locking clamp against last module and

tighten screw securely.
96. Removal of modules is accomplished by reversing

the procedures given above.

Sect 2 Chap 4
97. Series II modules are individually installed,

retained and removed. The installation of modules in the
track is accomplished as follows (See Figure 435 and
Figure 440):
a.
To insert, press the module into the track

assembly by hand until a definite stop is felt and
an audible click is heard.
b. To remove, slide the double-sided tool (module

extraction tool M81714/69) down the indents of the
module to the maximum depth to unlock the
retaining clips. Holding tightly, remove both tool
and module.
Table 418 Wire Range Accommodations

Series I
Mating
Size
Wire Barrel
20
22D
28, 26
24, 22
0.76/
1.37
16
22
26, 24
22
0.86/
1.52
16
20
24, 22
20
1.02/
2.11
14
16
20, 18
16
1.65/
2.77
12
12
14, 12
2.46/
3.61
Table 417 Component Identification

Series I
Module
Type
Feedback
Feedthrough
Conductor
Size
Insulation
O.D.
Series II
Mating
Size
Wire Barrel
Conductor
Size
Insulation
O.D.
22
22
26, 24
22
0.76/
1.37
Size
Spec. Sheet
22D
22
20
16
12
M81714/17
M81714/1
M81714/2
M81714/3
M81714/4
20
20
24, 22
20
0.86/
1.52
16
16
20, 18
16
1.02/
2.11
22
20
16
12
M81714/6
M81714/7
M81714/8
M81714/9
12
12
14, 12
1.65/
2.77
Splice
Size
Spec. Sheet
Single
Type
All
M81714/11
Double
All
M81714/12
Size
Spec. Sheet
Track
Type
Feedback
All
M81714/5
Feedthrough
All
M81714/10
Series II
Module Feedback
Type
Size
Spec. Sheet
Non-electrical
All
M81714/60
Distribution
All
M81714/61
Electronic
All
M81714/62
Grounding
All
M81714/63
Size
Spec. Sheet
Single
All
M81714/65
Double
All
M81714/66
Splice
Type
Figure 440 Installation and Removal of Modules
Track
Type
Size
Spec. Sheet
Feedback
All
M81714/67
33

Sect 2 Chap 4
Figure 441 Components of Terminal Junction System Series I
Figure 442 Components of Terminal Junction System Series II
34

Sect 2 Chap 4
Table 419 Crimping Tools for TJS Terminals

Series I
Module
Block
Size
Contact
Crimping Tools
Wire
Barrel
Size
Wire
Size
Range
Contact
Ins/Rem
Tools
Part No.
Bin
Code
Mating
End
Size
Basic
Positioner
or
Turret
22D
M39029/1-507
507
20
22D
22-28
M22520/2-32
M22520/2-32
M81968/14-01
or
MS27534-22D
or
M81969/8-01
and
M81969/8-02
22
M39029/1-100
100
16
22
22-26
M22520/2-01
M22520/2-11
M81969/14-10
or
MS27534-20
20
M39029/1-101
101
16
20
20-24
M22520/2-01
M22520/1-01
M22520/2-11
M22520/1-02
(blue)
M81969/14-10
or
MS27534-20
16
M39029/1-102
102
14
16
16-20
M22520/2-01
M22520/1-02
(blue)
M81969/14-03
or
MS27534-16
12
M39029/1-103
103
12
12
12-14
M22520/2-01
22520/1-02
(yellow)
M81969/14-04
or
MS27534-12
Series I
Module
Block
Size
Contact
Crimping Tools
Wire
Barrel
Size
Wire
Size
Range
Contact
Ins/Rem
Tools
Part No.
Bin
Code
Mating
End
Size
Basic
Positioner
or
Turret
22
M39029/22-191
191
22
22
22-26
M22520/7-01
M22520/7-11
M81968/16-04
20
M39029/22-192
192
20
20
20-24
M22520/1-01
Daniels No.
Th343 (red)
M81969/14-10
16
M39029/22-193
193
16
16
16-20
M22520/1-01
Daniels No.
Th343 (blue)
M81969/14-03
12
M39029/22-605
605
12
12
12-14
M22520/1-01
M22520/1-16
M81969/16-03
Crimping of Terminals
98. The terminals are crimped on the wires, using the
appropriate crimping tool as indicated in Table 419.
Crimping is accomplished as follows:
a.
Burn through the insulation with a hot wire stripper.

Do not remove the insulation at this point. This will
protect the wire from contamination and the
strands from splaying. Recommended wire
stripping
dimensions
are
as
follows:
Series
Contact Size
20 and 22
16 and 12
22,20,16
12
II
Wire Stripping
Dimensions (mm)
3.18 to 3.96
5.54 to 6.35
5.26 + 0.76
5.72 + 0.51
NOTE
Wires may be stripped by any of the methods listed in
35

Sect 2 Chap 4
b. Place the contact into the crimp tool (of the

selected wire size) with the contact crimp barrel
facing up.
c.
Remove the small piece of burnt insulation from

the wire, taking care not to pinch the insulation
with the finger nails.
d. Insert the bare wire into the open end of the

contact barrel. Push the wire in until it bottoms.
Squeeze the crimp tool. (The crimp tool will
release the contact only when the full crimping
cycle has been performed.)
e.
Check that the wire is crimped correctly by looking

at the inspection hole on the side of the contact
crimp barrel. Visibility of the bare wire in the
contact inspection hole indicates that the wire has
been properly inserted.
NOTE
No insertion-extraction tool, whether plastic or metal,
should be subjected to mishandling or left loose among
tools in a toolbox. They should be stored and carried in
a separate container to prevent being damaged. Their
tapered ends in particular shall be protected when the
tool is not in use. The tips of all tools shall be inspected
prior to use. Tools with broken, cracked, or bent tips
shall not be used.
NOTE
All cavities shall be filled with contacts. Sealing plugs
will be inserted in the cavities in the rear of all unwired
contacts.
Insertion and Extraction of Terminals

99. Insertion and extraction of the contacts are
accomplished through use of the applicable tool, see
Table 419. All the tools are of the same basic design but
differ in size and all are colour-coded. The tools, squared
at the middle for strength and ease in handling, have
tapered tubes at each end: one for insertion and one for
removal of the contact.
100. Insertion is accomplished as follows:
a.
Hold the coloured half of the appropriate

insertion/removal tool between the thumb and
forefinger and lay the wire to be inserted along the
slot, leaving about 12.7mm of wire protruding.
Then snap the wire into the tool. (See Figure 4
43)
Figure 443 Contact Insertion in Removable

Contact Wire Splices
b. Pull the wire back through the tool, until the tip of
the tool seats against the shoulder of the contact.
c.
Holding the module block with the cavities facing

you, slowly push the contact straight in to the
cavity.
d. A firm stop will be evident when the contact is

locked in place in the module block. Then let go of
the wire and pull out the tool.
101. Removal is accomplished as follows:
a.
With the module facing you, snap the white end of

the appropriate size double-ended plastic tool over
the wire of the contact to be removed. (See Figure
444.)
b. Slowly slide the tool along the wire into the insert
cavity until it engages the contact rear and a
positive resistance is felt. At this time, the contact
retaining fingers are in the unlocked position.
c.
36
Press the wire of the contact to be removed

against the serrations of the plastic tool and pull
both the tool and the contact wire assembly out.
Figure 444 Contact Removal from Removable

Contact Wire Splices
Insulation Repair
102. Unless otherwise specified by design or official
directive, wire/cable that has insulation damage, and the
centre conductor itself is not damaged, may be repaired if
approved by authorised engineering officer. Damaged
area must not be in excess of 7.6cm in length, and no
more than two damaged areas in a three foot section.

Sect 2 Chap 4
Repair may be made with a non-adhesive backed tape,

such as those listed in Table 420, utilizing the following
procedures:
a.
Wrap tape around the cable for one complete turn,

beginning 5cm from the damaged area.
b. Using the same continuous length of tape, spiral

wrap with a 50% overlap, wrap to a point 5cm past
the damaged area. Terminate by wrapping one
complete turn around the cable then cut the tape.
c.
With nylon lacing string, spot tie both ends to the

tape and at 25mm intervals over the entire length.
Table 420 Insulation Repair Tape

Colour
Adhesive Type
Specification
Black
Self-bonding
MIL-I-46852
Red
Self-bonding
MIL-I-46852
Black
Non-adhesive
MIL-S-1103GE
NOTE
Silicone rubber tapes shall not be used where they will be exposed to fluids such as jet fuels, hydraulic fluids, engine oils, silicone damping
fluid (DC-200), etc. These fluids may cause silicone rubber tapes to swell and/or lose adhesive properties.
37

Sect 2 Chap 5
SECTION 2
CHAPTER 5
WIRING MAINTENANCE PRACTICES INCLUDING REPAIRING

WIRE AND CABLE
INTRODUCTION
1.
All wiring should be maintained so that it is
mechanically and electrically sound and neat in
appearance. It is imperative to prevent or significantly
reduce potential contamination or debris from coming
into contact with the wiring and components during all
maintenance, repairs and modifications. This begins
with an awareness of potential wiring contamination,
and remembering to install appropriate protection
(e.g., plastic sheeting), as necessary, to cover
avionics/electrical wiring and components.
2.
A "clean-as-you-go" process helps to maintain
the integrity of the installation. Care should be taken to
protect wire bundles and connectors during work, and
to ensure that all shavings, debris and contamination
are cleaned up after work is completed.
3.
Aircraft wiring is sometimes damaged during
normal operation and maintenance. This chapter
provides information on general maintenance
techniques and the methods that may be relevant in
repairing various types of wire and cable.
4.
Always follow the manufacturers repair process
but for those aircraft that do not have repair processes
for the wiring installations then an acceptable methods
of maintaining the original electrical and mechanical
integrity are set out in in this document and FAA A.C.
43-13 1B & 2A.
NOTE
Where practicable, damaged wire or cable should
be replaced from one termination to the next.
WIRING MAINTENANCE PRACTICES

5.
Following maintenance, care should be taken to
ensure the routing is in accordance with
manufacturers documentation. The wiring must be
adequately supported throughout its length. A
sufficient number of supports must be provided to
prevent undue vibration of the unsupported lengths. All
wires and wire groups should be maintained and be
routed or installed to protect them from:
a.
Chafing or abrasion
b.
High temperature
c.
Being used as handholds
d.
Damage by personnel moving within the aircraft
e.
Damage from cargo stowage or shifting
f.
Damage from battery acid fumes, spray, or

spillage
g.
Damage from solvents and fluids.
6.
Specific routing and installation procedures are
described in the aircraft maintenance/wiring diagram
manuals. In general terms, the following items can be
considered guidelines when conducting wiring
maintenance:
7.
Protection Against Chafing. Wires and wire
groups should be protected against chafing or
abrasion in those locations where contact with sharp
surfaces or other wires would damage the insulation.
Cable clamps should be used to support wire bundles
and maintain spacing at each hole through a
bulkhead. If wires come closer than 3/8 inch (10mm)
to the edge of the hole, a suitable grommet should be
used in the hole Sometimes it is also necessary to cut
nylon or rubber grommets to facilitate installation. In
these instances, after insertion, the grommet can be
secured in place with general-purpose cement. The
cut should be at the top of the hole, and made at an
angle of 45 degrees to the axis of the wire bundle
hole.
8.
Protection Against High Temperature. To
prevent insulation deterioration, wires should be kept
separate from high-temperature equipment, such as
resistors, exhaust stacks, or pneumatic ducts. The
amount of separation is normally specified by
engineering drawings. Some wires must invariably be
run through hot areas. These wires must be insulated
with high temperature material. A low-temperature
insulation wire should never be used to replace a hightemperature insulation wire. Many coaxial cables have
soft plastic insulation, such as polyethylene, which is
especially subject to deformation and deterioration at
elevated temperatures. All high temperature areas
should be avoided when installing cables insulated
with plastic or polyethylene.
9.
Protection Against Solvents and Fluids. One
frequently encountered hindrance to inspections is dirt
and grime. Consult the manufacturers maintenance
instructions for recommendation on materials suitable
for cleaning electrical connectors and wires. For wire
inspections, a soft cloth, such as a cotton glove, can
be used to clean individual wires. With any cleaning
process, care should be taken not to remove wire
markings and ID tape. In addition, airplanes are often
pressure washed with a general purpose detergent.
Moderate pressure and a general purpose detergent
are not harmful to wiring, but water under high
pressure can penetrate components such as
connectors and splices. Moisture penetration into

Sect 2 Chap 5
components tends to increase with elevated water

temperatures.
10. Engine
and
APU
Wire
Harnesses.
Consideration should be given to the refurbishment of
engine and APU wire harnesses during engine and
APU maintenance visits due to the harsh environment.
11. Protection of Wires in the Wheel Well Area.
Typically, wire bundles in this area should be
mechanically protected. These wires and their
protective devices should be inspected carefully at
frequent intervals. There should be no strain on
attachments when parts are fully extended, slack
should not be excessive.
12. Routing Precautions. When wiring must be
routed parallel to combustible fluid or oxygen lines for
short distances, as much fixed separation as possible
should be maintained. Specific separation standards
should be available in manufacturer documentation.
However, when such information is unavailable, a sixinch minimum separation may be used as a guideline,
and no wire should be routed nearer than inch to a
plumbing line. The wires should be on the level with,
or above, the plumbing lines. Clamps should be
spaced so that if a wire is broken at a clamp, it will not
contact the line. When a specified separation is not
possible, both the wire bundle and the plumbing line
can be clamped to the same structure to prevent any
relative motion. A wire or wire bundle should not be
supported from a plumbing line that carries flammable
fluids or oxygen. Wiring should be routed to maintain a
manufacturer recommended minimum clearance from
control cables. When a manufacturer-specified
clearance is not given, coordinate with the Original
Equipment Manufacturer.
13. Connectors.
A
connector
should
be
disconnected from a receptacle in the following
manner:
a.
Use connector pliers to loosen coupling rings,

which are too tight to be loosened by hand.
b.
Alternately pull on the plug body and unscrew

the coupling ring until the connector is
separated.
c.
Protect disconnected plugs and receptacles to

keep contamination from entering and causing
faults.
d.
Do not use excessive force, and do not pull on

attached wires.
e.
Use only approved contact cleaners do not use

oil based water displacement products unless
the connector is properly cleaned prior to reinstallation
f.
When reconnecting, special care should be

taken to ensure the connector body is fully
seated, the jam nut is fully secured, and no
tension is on the harness.
14. Conduits are used in aircraft installation for

protection of wires and cables. Conduits are available
in metallic and non-metallic material, both in rigid and
flexible form. When selecting conduit size, a general
recommendation is to select the inside diameter of the

conduit to be about 25% larger than the maximum
diameter of the conductor bundle. Conduits are
vulnerable to abrasion at the ends. Suitable fittings are
affixed to the conduit ends in such a manner that a
smooth surface comes in contact with the conductor
within the conduit. When fittings are not used, the
conduit ends should be flared to prevent wire
insulation damage. The conduit should be supported
by clamps along its run. Many of the common conduit
problems can be avoided by proper attention to the
following details:
15.
Do not use a conduit as a handhold or footstep.
16. Ensure drain holes are provided at the lowest

point in a conduit run and are clear. Drilling burrs
should be carefully removed from the drain holes.
17. Ensure that the conduit is supported to prevent
chafing against the structure and to avoid stressing its
end fittings. Damaged conduit sections should be
repaired to prevent damage to the wires or wire
bundle. The minimum acceptable tube bend radii for a
rigid conduit as prescribed by the manufacturers
instructions should be followed. Kinked or wrinkled
bends in a rigid conduit are normally not acceptable.
Transparent adhesive tape is recommended when
cutting flexible tubing with a hacksaw to minimize
fraying of the braid.
18. Cleaning. Care must be taken whenever wiring
is being cleaned, especially as the aircraft and its
wiring age. In general, wire insulation may become
brittle, so displacement or moving of wiring during
cleaning must be kept to the absolute minimum.
Careful identification of the most appropriate cleaning
methodology is very important. Vacuuming, perhaps in
combination with light sweeping of wiring and wire
bundles with soft brushes, to remove dirt and debris
may be preferred. Additionally, significant damage can
be done to wire insulation and other electrical system
components with the inappropriate use of cleaning
solvents.
19. Wire Marking. Some wiring, due to either or
both gauge and wire type is unsuitable for Hot Stamp
marking as defect reporting has identified a significant
number of insulation failures due to damage from this
process. Care must be used and the recommended
temperatures, pressures and dwell time for hot
stamping must be followed. After marking an insulation
test should be carried out to determine the integrity of
the insulation. Preferentially the alternate process of
inkjet and UV laser marking should be used.
SINGLE WIRE REPAIR

20. If an aircraft wire is damaged at a single point
and there is sufficient slack in the wire, the damaged
wire should be repaired with a single splice. If a wire
is damaged along its length, the damaged segment
must be cut out and replaced with a jumper wire and
two splices (Figure 51).

Sect 2 Chap 5
WIRE DAMAGED
AT SINGLE POINT
WIRE DAMAGED
AT ALONG LENGTH
Figure 51 Damage Assessment

2.
e.
If more than one jumper wire is to be installed,

stagger splice positions by varying lengths of
sections that are cut out of the damaged wires.
f.
Determine type and gauge of wire to be

replaced from wire identification code or wiring
diagram.
g.
Cut replacement wire 12.7mm longer than

removed segment.
h.
From Table 51, select applicable splice for wire

being replaced.
Carry out repairs as follows:

a.
Cut cable ties and remove cable clamps as

required to access wire damage.
b.
Work damaged wires to outside of wire bundle.

Pull slack in wire toward damaged area to
prevent strain on splice.
c.
If more than one wire is to be spliced and wires

are not colour coded or otherwise identified, tag
wires before proceeding.
d.
Cut out the segment of wire with conductor or

insulation damage. If a jumper wire is required,
cut out at least 15cm of the damaged wire to
allow room for splicing (Figure 52).
WARNING
Dry cleaning solvent P-D-680, type II is flammable.
Avoid eye and skin contact or breathing of vapours.
Appropriate protective equipment is required.
i.
Clean 50mm of insulation, at wire ends to be

spliced, with dry cleaning solvent.
j.
Strip wire insulation appropriate length for

selected splice.
k.
Slide splice sealing sleeve over one end of

stripped wire (Figure 53).
CUT OUT DAMAGED AREA
CUT MINIMUM 150 mm
Figure 52 Removing Damaged Area

Sect 2 Chap 5
Table 51 Splice Selection

Wire Gauge
Splice Part Number
Colour Band
Crimp Tool
Crimp Die
26, 24, 22, 20
M81824/1-1
Red
M22520/5-01
or
M22520/10-01
M22520/5-103
or
M22520/10-104
20, 18, 16
M81824/1-2
Blue
M22520/5-01
or
M22520/10-01
M22520/5-103
or
M22520/10-104
16, 14, 12
M81824/1-3
Yellow
M22520/5-01
or
M22520/10-01
M22520/5-102
or
M22520/10-103
WARNING
fuelled aircraft
WARNING
Figure 53 Sealing Sleeve placed on One Wire End
l.
Using appropriate crimping tool and die (Table

51) crimp splice to wire ends (Figure 54)

enclosed area can be hazardous. Ensure area is
well ventilated.
n.
Shrink sealing sleeve using hot air gun with

small termination reflector. Shrink middle first
and move heat towards one end until sealant
melts and begins to flow out of sleeve (Figure
56). Repeat for other end. Allow to cool.
Figure 54 Correctly Installed Crimp Barrel

m. Centre sealing sleeve over crimp barrel (Figure
55).
Figure 55 Sealing Sleeve Centred over Crimp

Barrel
Figure 56 Splice Sealing

Sect 2 Chap 5
o.
If installing a jumper wire, repeat steps i to n.
p.
Work repaired wires into the bundle ensuring

splices remain staggered (Figure 57).
Figure 58 Scored Jacket on Multi-Conductor Cable
Figure 57 Completed Splices

q.
Replace cable clamps and cable ties removed

for access.
Figure 59 Damage Assessment
MULTI-CONDUCTOR CABLE REPAIR

e.
If more than one wire is to be spliced and wires

are not colour coded or otherwise identified, tag
wires before proceeding.
f.
Cut out the segment of wire with conductor or

insulation damage. If a jumper wire is required,
cut out at least 15cm of the damaged wire to
allow room for splicing (Figure 510).
21. The following paragraphs provide details of

procedures, components and tooling for the repair of
multi-conductor cables.
NOTE
Where practicable, damaged cable should be
replaced from one termination to the next.
22. Unshielded Cable Repair.
as follows:
a.
Carry out repairs

required to access cable damage.
CAUTION
When scoring cable jacket, ensure conductor
insulation is not damaged.
b.
Using a sharp blade or knife, score cable jacket

around the cable and along the length of the
damaged area (Figure 58).
c.
Flex cable at score marks until jacket separates.
d.
Remove jacket to gain access to damaged

wires (Figure 59).
Figure 510 Removing Damaged Area

g.

h.
Determine type and gauge of wire to be

replaced from wire identification code or wiring
diagram.
i.
Cut replacement wire 12.7 mm longer than

removed segment.
j.
Select applicable splice for wire being replaced

from Table 52.

Sect 2 Chap 5
Table 52 Splice Selection

Wire Gauge
Splice Part Number
Colour Band
Crimp Tool
Crimp Die
26, 24, 22, 20
M81824/1-1
Red
M22520/5-01
M22520/5-103
20, 18, 16
16, 14, 12
M81824/1-2
M81824/1-3
Blue
Yellow
or
or
M22520/10-01
M22520/10-104
M22520/5-01
M22520/5-103
or
or
M22520/10-01
M22520/10-104
M22520/5-01
M22520/5-102
or
or
M22520/10-01
M22520/10-103
WARNING
Dry cleaning solvent P-D-680, Type II is flammable.
avoid eye and skin contact and breathing of
VAPOURS. appropriate Protective equipment is
required.
k.
Using dry cleaning solvent, clean 50 mm of

insulation at wire ends to be spliced.
l.
Strip wire insulation appropriate length for

selected splice.
Figure 513 Sealing Sleeve Centred Over Crimp

Barrel
WARNING
fuelled aircraft.
WARNING
Figure 511 Sealing Sleeve Placed on One Wire
End

well ventilated.
m. Slide splice sealing sleeve over one end of

stripped wire (Figure 511).
n.
Using appropriate crimping tool and die (Table

52) crimp splice to wire ends (Figure 512).
o.
Centre sealing sleeve over crimp barrel (Figure

5-13).
Figure 512 Correctly Installed Crimp Barrel
Figure 514 Splice Sealing

Sect 2 Chap 5
p.
Shrink sealing sleeve using hot air gun with

small termination reflector. Shrink the middle
first and heat towards one end until sealant
melts and begins to flow out of sleeve (Figure
514).
q.
Repeat for other end. Allow to cool. If installing

a jumper wire, repeat steps l. to p.
Figure 515 Completed Splices

r.
Work repaired wires into the bundle ensuring

splices remain staggered (Figure 515).
NOTE
When applying insulating tape, hands should be
free of dirt and oil.
s.
Apply insulating tape starting 12.7 mm before

repaired area. Wrap tape one complete turn
around cable parallel to jacket cut line (Figure
516).
t.
Keeping tape stretched firmly, begin wrapping

around cable in a single layer, spiral wrap, using
a 50% overlap.
u.
Continue wrapping until cable is wrapped

12.7 mm beyond repair area.
v.
Terminate tape by wrapping one complete turn

around cable, keeping tape at a right angle to
axis of bundle.
w. Spot tie both ends of insulating tape (Figure 5

16).
x.
Replace cable clamps and cable ties removed

for access.
Figure 516 Taping Cable Jacket

Sect 2 Chap 5
23. Shielded Cable Repair.

follows:
Carry out repairs as
NOTE
This procedure calls for cutting all conductors in the
cable to allow installation of the repair braid and
insulation tubing.
a.

required to access cable damage.
Figure 519 Wire With Damaged Section Removed
b.
Select shield repair kit according to the outside

diameter of the damaged cable jacket (Table 5
3).
i.
c.
Using a sharp blade, score cable jacket around

the cable and along the length of the damaged
area (Figure 517).
Cut undamaged wires at staggered locations

(Figure 520).
Figure 520 Undamaged Wires Cut at Staggered

Locations
j.
Figure 517 Scored Jacket
d.
Flex cable at score marks until jacket separates.
e.
Remove jacket.
f.
Using small scissors or diagonal cutter, remove

shield, taking care not to damage underlying
wire insulation (Figure 518).
Slide tubing and braid from shield repair kit,

over one cable end (Figure 521). Tape tubing
and braid away from repair area.
Figure 521 Tubing and Braid Located on Cable

End
k.
If damaged sections of wire have been removed

ensure that the removed sections are at least
50 mm long, to allow room for splicing.
l.

Figure 518 Damaged Multi-conductor Cable
g.
If wires are not colour coded or otherwise

identified, tag all wires before proceeding.
h.
Cut wires to remove damage. If a segment of

damaged wire must be cut out, remove at least
50 mm total length. (Figure 519). If damage is
at a single point, damaged wire can be cut at
the point of damage.
m. Determine type and gauge of wire to be

replaced from cable identification code or wiring
diagram.
n.
Cut replacement wire appropriate length to

match removed segment (Figure 522).

Sect 2 Chap 5
Table 53 Shield Repair Kit Selection

Repair Kit
Cable Parameters
Part Number
Number of
Conductors
Conductor
Size Range
Kit Components
Conductor Splice
Part Number
Splice
Quantity
Shield Splice
Part Number
M81824/5-1
D-150-0168
or
26-24-22-20
M81824/1-1
M81824/4-1
M81824/5-2
D-150-0169
or
20-18-16
M81824/1-2
M81824/4-2
M81824/5-3
D-150-0170
or
16-14-12
M81824/1-3
M81824/4-3
M81824/5-4
D-150-0174
or
26-24-22-20
M81824/1-1
M81824/4-4
M81824/5-5
D-150-0175
or
18-16
M81824/1-2
M81824/4-5
M81824/5-6
D-150-0176
or
14
M81824/1-3
M81824/4-6
M81824/5-7
D-150-0177
or
12
M81824/1-3
M81824/4-7
M81824/5-8
D-150-0178
or
3 or 4
26-24
M81824/1-1
M81824/4-4
M81824/5-9
D-150-0179
or
3 or 4
22-20
M81824/1-1
M81824/4-5
M81824/5-10
D-150-0180
or
3 or 4
18-16
M81824/1-2
M81824/4-6
M81824/5-11
D-150-0181
or
3 or 4
14-12
M81824/1-3
M81824/4-7
o.
Carry out wire splicing procedure as detailed in

paragraph 3, steps i to n.
p.
When all wires have been reconnected, remove

12.7 mm of cable jacket at each end by carefully
scoring around cable and along length to be
stripped (Figure 517).
Figure 522 Jumper Wire Cut to Match Removed

Segment

Sect 2 Chap 5
Figure 523 Jacket Removed

q.
Slide repair braid along cable and centre over

repaired area (Figure 524).
Figure 525 Heating Repair Braid
Figure 524 Repair Braid Centred Over Repair Area

Figure 526 Tubing Centred Over Repaired Area
WARNING
fuelled aircraft.
WARNING
well ventilated.
r.
Heat one end of the repair braid using hot air

gun fitted with appropriate size reflector. Apply
heat to the overlapping shield area until the
solder melts and the sleeve shrinks onto the
cable. Continue heating until solder flows into
braid strands. Allow to cool undisturbed until
solder solidifies (Figure 525).
s.
Repeat step r. for opposite end.
t.
Slide heat shrink tubing over repaired area and

centre (Figure 526).
u.
Heat tubing using hot air gun fitted with

appropriate size reflector. Start in the middle
and heat until tubing shrinks moving out to one
end. Repeat for other end.
10
MIL-STD-1553 DATA BUS CABLE REPAIR

24. The following paragraphs provide general
information on MIL-STD-1553 data bus system and
the tooling, materials, and procedures for repair of the
data bus.
25. The 1553B Data Bus is a computerized and
multiplex digital data distribution system for the many
functions of command, control, communications, and
intelligence designed for military aircraft. A twinax
cable of 78 ohms was selected to provide the
transmitted digital information with the required
protection from magnetic and electrostatic interference
including nuclear electromagnetic pulse. Therefore,
complete shielding of the pair along the transmission
path as well as within the multi-pin connector must be
maintained.
NOTE
While the information and procedures contained in
this supplement are appropriate for repairing MILSTD-1553 data bus cables, aircraft specific repair
procedures take precedence.

Sect 2 Chap 5
Single Shield Cable with Solder Sleeve Primary

Splice.
26. Prepare
procedure:
the
cable
using
the
Remove 31mm of cable jacket (Figure 527).
b.
Trim shield to 9mm from cable jacket.
c.
Strip primary conductors 12.7mm and pre-tin.
d.
Trim fillers flush with shield.
a.
b.
Overlap conductors under solder preforms.
d.
Use a holding fixture to hold wires in alignment.
following
a.
27.
c.
WARNING
fuelled aircraft.
WARNING
well ventilated.
Assemble as follows:
Place D-150-0124-01 outer sleeve and
D150-0124-02 shield splice (small end first)
onto one cable.
e.
Heat solder preforms until they melt and form a

fillet along wires.
Insert primary conductors in D-150-0124-03

primary splice assembly.
Figure 527 Single Shield Cable Strip Dimensions
Table 54 Tooling
Name
Part Number
Crimp Tool
AD-1377
or
M22520/10-01
with die
M22520/10-104
Holding Fixture
AD-1319
Hot Air Gun
M83521/5-01
Databus
Harness
Tester
(Aircraft specific test leads
required)
S2476N
11

Sect 2 Chap 5
Table 55 Materials
Name
Part Number
Splice Kit
Solder Sleeve
24-22 AWG
Single Shield
D-150-0124
Splice Kit
Mini-Seal Crimp
24-22 AWG
Double Shield
D-150-0133
Splice Kit
Solder Sleeve
24-22 AWG
Double Shield
D-150-0134
Splice Kit
Mini-Seal Crimp
24-22 AWG
Single Shield
D-150-0167
NOTE
The thermal indicator will lose its colour when
sufficient heat has been applied to make the joint.
f.
Heat ends of sleeves until inserts melt and flow

along wires.
g.
Perform inspection (Paragraph 17).
h.
Centre D-150-0124-02 shield splice sleeve over

splice and exposed cable shields.
i.
Using heat gun, heat centre of sleeve until

solder melts and shield and tube recover.
j.
Move sleeve slowly through heat to one end of

shield to keep sleeve recovering.
k.
Apply additional heat for 5 to 10 seconds to final

12.7mm of sleeve shield to ensure sufficient
heat transfer to the cable to make a good joint.
l.
Apply heat to end of sleeve until ring melts and

flows along cable jacket.
m. Repeat for other end of sleeve.

n.
o.
Centre D-150-0124-01 strain relief sleeve over

completed splice.
12
p.
Apply heat in centre of sleeve and move it

through the heat until it has recovered onto the
assembly.
q.
Double Shield Cable With Solder Sleeve Primary

Splice
28. Prepare
procedure:
the
cable
using
the
following
a.
b.
Trim shield to 18mm from cable jacket, then trim

outer shield to 9mm from cable jacket.
c.
Strip primary conductors 12.7mm and pre-tin

primaries.
d.
Trim fillers flush with shields.
29.
a.
Place D-150-0134-01 outer sleeve and

D150-0134-02 shield splice (small end first)
onto one cable.
b.
Insert primary conductors in D-150-0134-03

primary splice assembly.
c.
Overlap conductors under solder preforms.

Sect 2 Chap 5
d.
Use a holding fixture to hold wire in alignment.
WARNING
fuelled aircraft.
NOTE
f.

along wires
g.
WARNING
h.

well ventilated.

splice and exposed cable shields.
i.
Using heat gun, heat centre of sleeve until

solder melts and shield and tube recover.
j.

e.
Using heat gun, heat solder preforms until

melted and form a fillet along the conductors.
Figure 528 Double Shield Cable Strip Dimensions
k.
l.

12.7mm of sleeve to ensure sufficient heat
transfer to the cable shield to make a good joint.
Apply heat to end of sleeve until rings melt and
flow along cable jacket.
m. Repeat for other end.
q.
Single Shield Cable with Miniseal Crimp Primary

Splice
30. Prepare
procedure:
the
cable
using
the
following
n.
a.
o.

completed splice.
b.
Trim shield to 9mm from cable jacket.
c.
Cut one primary 23mm from cable jacket.
p.
Apply heat in centre of sleeve and move it

through the heat until it has recovered onto the
assembly.
d.
Strip both primaries 7mm.
e.
13

Sect 2 Chap 5
Figure 529
Single Shield Cable Strip Dimensions for Mini-Seal Crimp
h.

splice and exposed cable shield.
a.
Place D-150-0167-04 outer sleeve and D150-0167-01 shield splice (small end first) onto
one of the cables.
i.
Heat centre of sleeve until solder melts and

shield and tube recover.
b.
Place one D-150-0167-03 sealing sleeve onto

longer lead of each cable.
j.

c.
Crimp matching primaries into opposite ends of

D-150-0167-02 crimp splice.
k.
d.
Centre D-150-0167-03 sleeves over splices.

0.5 inch (12.7mm) of sleeve to ensure sufficient
heat transfer to cable shield to make a good
joint.
l.

31.
WARNING
fuelled aircraft.

n.
Perform inspection.
o.

completed splice.
p.
Starting at centre of sleeve, move sleeve

through heat until it has recovered onto
assembly.
q.
Perform inspection.
WARNING
well ventilated.
e.
Using heat gun, apply heat to centre of sleeves

until recovered and then heat ends until sealing
rings melt and flow along wires.
NOTE
f.

along wires.
g.
14
Double Shield Cable with Miniseal Crimp Primary

Splice
32. Prepare
procedure:
the
cable
using
the
following
a.
b.
Trim shield to 19mm from cable jacket, then trim

outer shield to 9mm from cable jacket.
c.
Cut one primary 32mm from cable jacket.
d.
Strip primaries 7mm.
e.

Sect 2 Chap 5
33.
a.
b.
c.
Place D-150-0133-04 outer sleeve and D150-0133-02 shield splice (small end first) onto
one cable.
Crimp matching primaries into opposite end of

D-150-0133-03 crimp splice.
d.
Centre D-150-0133-04 sleeves over splices.
Place one D-150-0133-04 sealing sleeve onto

longer lead of each cable.
Figure 530
Double Shield Cable Strip Dimensions for Mini-Seal Crimp
WARNING

fuelled aircraft.
h.

splice and exposed cable shield.
i.
Apply heat to centre of sleeve until solder melts

and shield and tube recover.
j.

k.

12.7mm of sleeve to ensure sufficient heat
transfer to cable shield to make a good joint.
l.

WARNING
well ventilated.
e.
Using heat gun, apply heat to centre of sleeves

until recovered and then heat ends until sealing
rings melt and flow along wires.
NOTE
f.

along wires.
g.

n.
Perform inspection.
o.

completed splice.
p.
Starting from centre of sleeve, move sleeve

through heat until it has recovered onto
assembly.
q.
Perform inspection.
15

Sect 2 Chap 5
Inspection
34. Solder sleeve splices must be inspected for the
following:
a.
Conductors must be overlapped a minimum

9mm.
36. Shield splices must be inspected for the

following:
a.
Sleeve/shield must be recovered along its entire

length.
b.
Sleeve must be recovered tightly around cable

jacket.
c.
Sealing rings must have flowed along cable

jacket.
b.
Fillet length must be a minimum 6mm.
c.
Sealing rings must have flowed along the wire.
d.
Sleeve must not have discoloured to the degree

that joint cannot be inspected.
d.

that the joint cannot be inspected.
e.
Sleeve must not be cut or split.
e.
f.
Strands of conductor must not be sticking

through the sleeve.
f.
Strands must not be sticking through of sleeve.
35. Mini-Seal splices must be inspected for the

following:
a.
Conductors must be visible at point where they

enter crimp barrel.
b.
Both indentations of crimp, must be on crimp

barrel.
c.
Sealing sleeve inserts must have flowed along

wire insulation.
d.

that crimp barrel cannot be inspected.
e.
16
37. Outer sleeves must be inspected for the

following:
a.
Sleeves must be recovered

assembly along its full length.
tightly
onto
b.
An adhesive bead should be visible at ends of

sleeve.
c.
Testing
38. On completion of the inspection procedure the
data bus should be tested to ensure there are no short
circuits, shorts to shield, open circuits or crossovers,
using test equipment detailed in Table 54, or
equivalent.

Sect 2 Chap 6
SECTION 2
CHAPTER 6
SOLDERLESS TERMINATIONS AND SPLICES

INTRODUCTION
1. Electric wires are terminated with solderless terminal
lugs to permit easy and efficient connection to and
disconnection from terminal boards, busbars, and other
electrical equipment. Solderless splices join electric wires
to form permanent continuous runs.
2. This chapter describes recommended methods for
terminating copper and aluminium wires, using solderless
terminal lugs. It also describes recommended methods for
permanently joining (splicing) wires, using solderless
splices. (Termination of thermocouple wires is covered in
Section 2, Chapter 16.)
3. The following specifications are applicable to
solderless terminations and splices:
MIL-DTL-22520
Crimping Tools, Wire Termination,

General Specification For
MIL-S-81824
Splice, Electric, Permanent, Crimp

Style, Copper, Insulated,
Environment Resistant
MIL-T-81714
Terminal Junction System (TJS),

Environment Resistant General
Specification For
SAE AS70991
Terminals, Lug and Splice, Crimp

Style, Aluminium, for Aluminium
Aircraft Wire
SAE AS7928
Terminals, Lug: Splices, Conductor:

Crimp Style, Copper, General
Specification For
splices. Terminal lugs and splices are crimped to wires by

means of hand or power crimping tools. Power tools may
be portable or stationary (bench-mounted). Typical
crimping tools are illustrated where they are mentioned in
the procedures. Environmental sealed splices (MIL-S81824) are the only permanent splices that should be used
on aircraft. Potted non-environmental splices may be used
as a temporary/emergency repair and shall be replaced as
soon as practicable.
End Caps, Splices, Terminal Lugs and Crimp Tools
6. Only Class I end caps, splices, terminal lugs and
crimping tools qualified to SAE AS 70991, SAE AS 7928,
MIL-S-81824 or MIL-DTL-22520 are recommended for use
on aircraft unless otherwise authorised by an appropriate
engineering authority. Class I terminations are approved
for the replacement of Class II terminations or nonqualified terminations fitted by the manufacturer or
specified in the aircraft/equipment IPB.
7. Terminal Lugs, splices, end caps and tooling are
classified as follows:
a.
b.
c.
DESCRIPTION
d.
4. Solderless terminal lugs and splices are plated copper
or aluminium, and are pre-insulated or uninsulated,
depending on the application. Terminal lugs and splices for
high temperature applications are silver or nickel plated
copper and are insulated with TFE (or a similar material).
e.
Class I Terminal Lugs and Splices and End Caps

Lugs, splices and end caps that conform to all the
requirements of the applicable specification when
installed with the specified crimping tools.
Class I Tools are those which meet all the
requirements of the applicable specification.
Class II Terminal Lugs, Splices and End Caps lugs, splices and end caps that conform to the
material and marking requirements of the
specification and are replaceable by Class I
terminals. They conform to the performance
requirements of the specification when crimped with
a tool having crimping dies and motion conforming
to the terminal manufacturers drawing.
Class II tools, terminal lugs, end caps and splices
should not to be used on aircraft.
The types and styles of terminal lugs, splices and
end caps are listed in Annex A, Table 6A1.
TERMINATING SMALL COPPER WIRES WITH

PRE-INSULATED TERMINAL LUGS
NOTE
Use only copper terminations on copper wire and
aluminium terminations on aluminium wire. Only
environment resistant sealed splices shall be used as
permanent electrical wire splices on aircraft.
5. Terminal lugs are available in four styles: straight, 90
degree upright, angle, and flag, for use under different
applications. Figure 61 shows typical terminal lugs and
8. Small copper wires (sizes No. 26 thru No. 10) are

terminated with solderless pre-insulated straight copper
terminal lugs conforming to SAE AS 7928. (See Annex A,
Table 6A1.) As shown in Figure 62, the insulation is
part of the terminal lug and extends beyond its barrel, so
that it will cover a portion of the wire insulation; this makes
the use of an insulation sleeve unnecessary. In addition,
pre-insulated terminal lugs have an insulation support (a
metal reinforcing sleeve) beneath the insulation for extra

Sect 2 Chap 6
supporting strength on the wire insulation. Most preinsulated terminals accommodate more than one size of
wire. The insulation is colour coded and the range of wire
sizes is marked on the tongue to identify the wire sizes that
can be terminated with each of the terminal lug sizes.
Figure 61 Solderless Terminal Lugs and Splices
CAUTION
Using tin plated terminals on nickel plated wire may not achieve appropriate voltage drop and tensile strength
requirements. Refer to SAE AIR 1263.
High Temperature Terminal Lugs
9. Appropriately rated high temperature terminal lugs shall be used on high temperature wire where the termination is
located in a high temperature area. Where wire termination is in a low temperature area, standard crimp terminals may be
used. Table 62 provides details of tools and terminations that are considered suitable for use on high temperature wire.

Sect 2 Chap 6
Figure 62 Preinsulated Terminal Lug Cut-Away
Colour of Terminal Lug

Installation
To Be Used On Wire
Size(s)
Yellow with Black Stripe
26
Yellow with Blue Stripe
24
Yellow
26 or 24
Red with Green Stripe
22
Red with Red Stripe
20
Red with White Stripe
18
Red
22, 20 or 18
Blue with Blue Stripe
16
Blue with Green Stripe
14
Blue
16 or 14
Yellow with Yellow Stripe
12
Yellow with Brown Stripe
10
Yellow
12 or 10
Table 61 Colour Coding of Copper Terminal Lug
Insulation
Gold Plated PIDG Ring Tongue Insulated Terminals Rated to 260C (500F)
Terminal Part Number
Stud Size
Wire Size
1-332433-0
22-20
332434
22-20
1-332434-0
10
22-20
332453
18-16
332454
18-16
1-332454-0
10
18-16
Tool Part Number (AMP)

69692-1
69693-1
Nickel Plated Ring Tongue Terminals Rated to 343C (650F) Uninsulated with Insulation Support
323151
22-16
323152
22-16
323153
10
22-16
46673
Nickel Ring Tongue Terminals Rated to 649C (1200F) Uninsulated with Insulation Support
321892
22-16
321893
22-16
321894
10
22-16
46673
Crimping Tools
Hand Tool Description
10. Only tools qualified to MIL-DTL-22520 are to be used

for crimping terminal lugs. These tools crimp the barrel to
the conductor, and simultaneously form the insulation
support to the wire insulation.
11. All approved hand crimping tools have a self-locking

ratchet, which prevents the tool from opening until crimp is
complete. This mechanism must never be disassembled
since it ensures proper crimping closure. The M22520/5
and M22520/10 tools are the approved tools to be used in
crimping sizes 26 through 10, end caps, splices and
terminal lugs. The M22520/5-01 and M22520/10-01 crimp
tools have removable dies for crimping 26 through 10
terminal (wire barrel) sizes see Figure 63.
CAUTION
With some of the smaller gauge thin wall wires,
insulation can be inadvertently inserted and crimped in
the terminal barrel.
Hand Tool Inspection

12. Dies and other working parts of crimping tools used
for electrical terminations become worn in service and this
can result in unsatisfactory terminations. An effective
means to ensure a serviceable termination is to monitor
the condition of the tool by regular testing. The standard

Sect 2 Chap 6
tools are checked by means of a GO/NOGO gauge for

assurance of quality crimps. For good crimping results,
gauging should be carried out prior to each series of
crimping operations. Replace or repair hand tools, which
are out of tolerance. The details contained in Table 63
are provided for in-service inspection gauging of
M22520/5-01 and M22520/10-01 tools and dies. Prior to
performing the gauging test, ensure that both the crimping
tool jaws and the shafts of the gauge are clean and free of
damage.
13. When gauging tools are unavailable, testing can be

accomplished by carrying out a millivolt drop and tensile
strength test on a completed crimp (Refer to Annex D).
Table 63 Gauging Tools
Die Part Number
Die Cavity Size
Gauge Part Number
M22520/5-100
12 10
M22520/3-9
M22520/5-100
26 14
M22520/3-10
M22520/5-101
26 20
M22520/3-11
M22520/5-102
16 12
M22520/3-12
M22520/5-103
20 16
M22520/3-13
M22520/5-103
26 20
M22520/3-14
M22520/10-100
12 10
M22520/3-9
M22520/10-101
26 14
M22520/3-10
M22520/10-102
26 20
M22520/3-11
M22520/10-103
16 12
M22520/3-12
M22520/10-104
20 16
M22520/3-13
M22520/10-104
26 20
M22520/3-14

Sect 2 Chap 6
Figure 63 Crimp Tools and Dies (Sheet 1 of 2)

Sect 2 Chap 6
Figure 63 Crimp Tools and Dies (Sheet 2 of 2)

Sect 2 Chap 6
Table 64 Dies and Gauges for Power Tool MS25441

Terminal Lug Size
Die Part Number

(For Head MS25441-1)
MS Gauge Part Number
MS23002-8
MS23003-8
MS23002-6
MS23003-6
MS23002-4
MS23003-4
MS23002-2
MS23003-2
Insulated Terminals
MS23002-1
MS23003-1
1/0
MS23002-01
MS23003-01
2/0
MS23002-02
MS23003-02
3/0
MS23002-03
MS23003-03
4/0
MS23002-04
MS23003-04
MS90485- 8
MS90486-8
MS90485-6
MS90486-6
MS90485-4
MS90486-4
MS90485-2
MS90486-2
MS90485-1
MS90486-1
1/0
MS90485-01
MS90486-01
2/0
MS90485-02
MS90486-02
3/0
MS90485-03
MS90486-03
4/0
MS90485-04
MS90486-04
MS25442-8A
MS25472- 1
MS25442-6A
MS25472-2
MS25442-4A
MS25472-3
MS25442-4A
MS25472-4
MS25442-1A
MS25472-5
1/0
MS25442-01A
MS25472-6
2/0
MS25442-02A
MS25472-7
3/0
MS25442-03A
MS25472-8
4/0
MS25442-04A
MS25472-9
Uninsulated Terminals
Aluminium Terminals

Sect 2 Chap 6
Crimping Procedure for M22520/5 and M22520/10 Hand

Tools
14. Hand crimp pre-insulated copper terminal lugs in the
No. 26 - No. 10 wire size range with M22520/5 or
M22520/10 hand tools as follows:
a.
b.
c.
d.
e.
f.
g.
Strip wire insulation using one of the recommended

stripping procedures detailed in Section 2, Chapter
3. (Stripping lengths are provided in Table 64).
Check tool for correct adjustment in accordance
with paragraph 12. Tools out of adjustment must be
returned to the manufacturer for repair.
Insert terminal lug, tongue first, into wire side of
hand tool barrel crimping jaws, until terminal lug
barrel butts flush against tool stop on the locator.
(See Figure 63 for correct insertion method).
Squeeze tool handles slowly until tool jaws hold
terminal lug barrel firmly in place, but without
denting it.
Insert stripped wire into terminal lug barrel until wire
insulation butts flush against near end of wire barrel.
(See Figure 62 or Figure 64.)
Figure 64 Proper Insertion of Stripped Wire in

Insulated Terminal Lug for Crimping
Squeeze tool handles until ratchet releases.

Remove completed assembly and examine it for
proper crimp in accordance with paragraph 36.
CAUTION
With some of the smaller gauge thin wall wires,
insulation can be inadvertently inserted and crimped in
the terminal wire barrel.
Table 65 Wire Stripping Lengths for Small Copper
Terminal Lugs
Wire Size
Stripping Length (mm)
26 and 24
4.0
22 and 20
4.7
18, 16 and 14
6.4
12 and 10
7.0
TERMINATING LARGE COPPER WIRES

15. Copper terminal lugs of two styles (straight and flag)
are used to terminate copper wires sizes No. 8 through No.
4/0. The style to be used depends on existing space
conditions. These terminal lugs are available uninsulated
in both types and pre-insulated in the straight type. Straight
pre-insulated terminal lugs conform to SAE AS 7928 (see
Annex A, Table 6A1). As shown in Figure 62, preinsulated terminal lugs have the insulation extending
beyond the wire barrel, so that it will cover a portion of the
wire insulation. This makes the use of a separate
insulating sleeve unnecessary. Straight uninsulated
terminal lugs conform to SAE AS 7928 and MS20659. Flag
uninsulated terminal lugs conform to SAE AS 7928 and
MS25189.
Figure 65 Insulating Sleeves

Insulating Sleeves
16. Uninsulated straight flag terminal lugs are insulated
(after assembly to wire) with heat shrinkable tubing (see
Section 2, Chapter 4) or with lengths of transparent tubing.
These methods of insulation provide electrical and
mechanical protection at the connection. When the size of
sleeving used is such that it will fit tightly over the terminal
lug, the sleeving need not be tied; otherwise, it is to be tied
with lacing cord. (See Figure 65.)
Crimping Tools for Sizes 8 through 4/0 Terminals
17. Manual and/or power crimping tools are available for
crimping M7928/4 and MS25036 insulated terminals,
MS20659 uninsulated terminals and MS25189 flag type
terminals. The tools are the MS25441-5 hydraulic pedal
pump and the MS25441-4 electric hydraulic pump used
with the MS25441-1 hydraulic head and the MS25441-3
hose (or an adaption - without the control cable), and the
proper dies.
MS25441 Tool Adjustment
18. The MS25441 tools can be checked for proper
adjustment. For good crimping results, this must be done
before each series of crimping operations. When tool is
adjustable, proper correction must be made; otherwise, the
tool must be returned to manufacturer for repair. Gauge
the dies of the MS25441 tool in the closed position with the
appropriate GO/NO GO gauges listed in Table 65.

Sect 2 Chap 6

19. When gauging tools are unavailable, testing can be
accomplished by carrying out a millivolt drop and tensile
strength test on a completed crimp (Refer to Annex D).
CRIMPING PROCEDURE FOR MS25441 TOOLS

20. Crimp large Military Standard copper terminals as
follows:
a.
Select proper die for terminal and wire size from

Table 65 and install die in tool.
WARNING
ALWAYS disconnect power tool from its pressure
source BEFORE installing or removing dies.
NOTE
Do not use any crimping tool beyond its rated capacity.
b.
Strip wire insulation, using recommended practices

described in Section 2, Chapter 3. Stripping lengths
for copper wire shall be conductor barrel length plus
1.6mm.
c.
Insert stripped wire into terminal barrel until wire

insulation butts flush against end of barrel.
d.
Insert wire and terminal lug assembly into die.
e.
Actuate the crimp tool. Press button on handle for

electrically operated tool. Do not release the button
until the dies open automatically. Actuate handle for
manual hydraulically operated tool.
f.
Remove the crimped assembly, and examine it for

proper crimp, in accordance with paragraph 36.
TERMINATING ALUMINIUM WIRE

21. Aluminium wire is used in aircraft because of its
weight advantage over copper. Aluminium, however, has
the disadvantage of being softer than copper. Further,
bending aluminium wire will cause work hardening of the
metal that makes it more brittle. This will result in failure or
breakage of strands much sooner than in copper wire.
Aluminium also forms a high resistance oxide film
immediately upon exposure to air. To compensate for
these disadvantages it is important to follow carefully the
recommended installation procedures.
Figure 66 Power Crimping Tools Large Copper

Terminal Lugs
Aluminium Terminal Lugs

22. Only aluminium terminal lugs conforming to SAE AS
70991 are used to terminate aluminium wires. See Figure
61 for typical connections. Aluminium terminal lugs are
available in four types; straight (MS25435), 90 degrees
upright (MS25436), left angle (MS25437), and right angle
(MS25438). The barrels of aluminium terminal lugs are
filled with a petroleum-base abrasive compound. This
compound, by a grinding process during the crimping
operation, removes the oxide film from the aluminium. The
compound also prevents oxide from reforming in the
completed connection. All aluminium terminals have an
inspection hole to allow checking the depth of wire
insertion (see Figure 61). This inspection hole is sealed
with a removable plastic plug, which also serves to retain
the oxide-inhibiting compound. Each aluminium terminal
lug is marked with the letters AL indicating it is for use
with aluminium wire, and also with the wire size it will
accommodate.
CAUTION
Do not use any aluminium wire which has nicked or
broken strands. Damaged strands will fail in service.
CAUTION
Do not remove the inspection plug until the crimp has
been completed and the wire insertion is to be
inspected. Replace plug after inspection.

Sect 2 Chap 6
Insulating Sleeves
23. Aluminium terminal lugs are not pre-insulated;
therefore, it is necessary to insulate them, after assembly,
with lengths of transparent flexible tubing or heatshrink
sleeves. The sleeve provides mechanical and electrical
protection at the connection. (See Figure 65).
Crimping Tools
24. Use the MS25441 tool to install MS aluminium
terminal lugs. See paragraph 18 for tool adjustment.
i.
Check visually to see that the correct wire size is

imprinted on the barrel.
j.
Remove the inspection plug and check visually or

with the aid of a probe to see that wire is fully
inserted. Replace the plug after inspection.
k.
Slide insulating sleeve over the terminal lug barrel

and secure in accordance with paragraph 16 and
Figure 65.
Table 66 Stripping Lengths for Aluminium Wire
Wire Size
MS25435, MS25436,
MS25437, MS25438
17.5
20.6
21.5
CAUTION
2.6.0
Use care when stripping wire insulation. do not nick or

damage aluminium wire strands.
26.0
1/0
25.0
2/0
31.0
3/0
32.5
4/0
36.5
Crimping Procedure for Aluminium Terminal Lugs

25. Crimp MS aluminium terminal lugs as follows:
a.
b.
c.
d.
Using MS25441 tool, select proper die for wire size.

Die is stamped with the wire size on both upper and
lower faces and with the letters AL. Install die in tool
head.
Strip wire insulation carefully, using recommended

stripping practices for aluminium wire described in
Section 2, Chapter 3. Stripping lengths are listed in
Table 66.
Install insulating sleeve over wire insulation, well
back from crimping area.
Inspect to see that inner barrel is well coated with
compound.
CAUTION
Do not remove the inspection plug as this keeps the
compound in the barrel. When the wire is inserted to the
full depth of the barrel, the compound is forced between
and around the conductor strands.
e.
Insert wire into terminal barrel.
f.
Wipe off any excess compound squeezed out of

terminal lug barrel with a clean soft cloth.
g.
Insert assembly into the die and position as shown

in Figure 67.
h.
Actuate the crimp tool. On electrically operated tool,

press the button on the control handle. Do not
release the button until the dies open automatically.
Actuate handle for manual hydraulically operated
tool.
NOTE
Wire sizes No. 8 thru No. 2/0 require only one crimp.
Wire sizes No. 3/0 and No. 4/0 require two crimps.
Locate the second crimp centrally on the portion of the
barrel remaining after the first crimp. See Figure 68.
10

Sect 2 Chap 6
SPLICING SMALL COPPER WIRES

26. Environmental permanent splices conforming to MILS-81824 are used to join small copper wire sizes No. 26
through No. 10. Typical splices are shown in Figure 61.
The splice insulation extends over the wire insulation.
Each splice size can be used for more than one wire size.
Splices are colour coded in the same manner as insulated
copper terminal lugs; refer to paragraph 8 and Table 61
for details.
27. Permanent wire splices may be used to assemble
sub-assemblies, to incorporate changes or to facilitate
repairs. The use of permanent splices shall be subject to
the following restrictions:
Figure 67 Positioning Aluminium Terminal Lugs in Die

Nests
a.
There shall not be more than one splice in any one

wire segment between any two connectors or other
disconnect points, except as allowed by sub-paras
e, g and h below.
b.
Installation of splices in bundles shall not increase

the size of the bundle so as to prevent the bundle
from fitting in its designated space or cause
congestion that will adversely affect maintenance.
c.
Splices shall not be used to salvage scrap lengths

of wire.
d.
Splices shall not be used within 30cm of a

termination device, except for sub-para e, below.
e.
Splices may be used within 30cm of a termination

device when attaching to the pigtail spare lead of a
potted termination device, or to splice multiple wires
to a single wire, or to adjust the wire sizes so that
they are compatible with the contact crimp barrel
sizes.
f.
The application of splices shall be under design

control and shall be authorised by engineering
drawings.
g.
Splices may be used to repair manufactured

harnesses or installed wiring when approved by an
appropriate engineering authority.
h.
Splices shall not be used on firing or control circuits

associated with ordnance or explosive sub-systems.
i.
Splices shall not be used on fire resistant wire.
28. When practicality conflicts with the intent of these

restrictions refer to local engineering authority.
Crimping Tools
29. The M22520/5 and M22520/10 crimp tools with
appropriate dies are the approved tools for crimping sizes
26 through 10 splices.
Figure 68 Single Crimp on Aluminium Terminal Lugs
11

Sect 2 Chap 6
Single Conductor Wire Splicing And Repair
Procedure
30. The following text is the repair procedure for a single

conductor, non-shielded copper wire of 6 to 26 AWG.
33. If a wire is damaged at a single point and there is

sufficient slack in the wire, as shown in Figure 6-9, the
damaged wire can be repaired with a single splice.
31. To carry out the repair on a single conductor, a MIL-S81824 splice is used. The splice is a two piece;
environmentally resistant, copper crimp type splice used
on 12 to 26 AWG copper wire. They may be used with tin
plated and silver plated conductors, where the total
temperature of the wire insulation does not exceed 150C.
35. To perform a single conductor wire splicing and repair:
Restrictions
32. The following restrictions apply when carrying out a
repair of a single conductor, non-shielded copper wire of 6
to 26 AWG:
a.
b.
34. If a wire is damaged along its entire length, as shown

at the bottom of Figure 6-10, the damaged segment must
be cut out and replaced with a jumper wire installed using
two splices
Repairs requiring multiple splices must be

staggered. Splices should not increase the size of
the bundle enough to prevent it from fitting into its
designated place or cause congestion that will
adversely affect maintenance.
Splices should not to be used within 300 mm of a
termination device except as follows:
(1) When attaching to the pigtail spare lead of a

potted termination device;
a.
Cut ties and remove support clamps as required to

access wire damage.
b.
Work damaged wires to outside of wire bundle.

Carefully pull slack in wire toward damaged area to
prevent strain on the splice.
c.
If more than one wire is to be spliced, and the wires

are not colour coded or otherwise identified, tag the
wires to be spliced with an identification before
proceeding.
d.
Cut out any wire with damaged conductor or

insulation. If a jumper is required, proceed as
follows:
(2) To splice multiple wires to a single wire; or

(3)To adjust wire sizes so they are compatible with contact
crimp barrel sizes.
Figure 6-9 - Wire Damaged Along Its Entire Length

36. Figure 6-10 illustrates, that at least 130 mm of the damaged wire must be removed to allow room for splicing.
FOR WIRES DAMAGED ALONG LENGTH THAT REQUIRE A JUMPER A

MINIMUM CUT GAP OF 130MM IS REQUIRED
Figure 6-10 Removal of the Damaged Section
12

Sect 2 Chap 6
37. If more than one jumper is to be installed, stagger splice positions by varying lengths of sections that are cut out of
damaged wires. This prevents bunching of the splices, keeping the diameter of the loom to a minimum. Then:
a.
Determine type and gauge of wire being repaired from applicable aircraft wiring data manual.
b.
Select a jumper wire of the same type and gauge, cutting a 12.5mm longer section than removed.
c.
Select applicable splice for gauge of wire being repaired from the Table 6-6.
Wire Gauge
Splice Part No.
Colour Band
20 - 26
M81824/1-1
RED
16 - 18
M81824/1-2
BLUE
12 - 14
M81824/1-3
YELLOW
D-436-0081
N/A
Table 6-6
Warning
Dry cleaning solvent P-D-680, Type 2 is flammable. Avoid eye and skin contact or breathing of vapours. Protective
equipment consisting of goggles and gloves is required.
d.
Clean the last 5 cm of both ends of the wires insulation, to be spliced, with dry cleaning solvent.
e.
Strip wire insulation to dimensions specified in the table shown below.
Splice Part No.
Strip Dimension (mm)

1.5, -0
M81824/1-1
6.0
M81824/1-2
8.0
M81824/1-3
8.0
D-436-0081
11.0
Table 6-7
f.
Slide sealing sleeve over one end of the stripped wire, as shown in Figure 6-11.
Figure 6-11 Procedure for Installing Sealing Sleeve

g.
Choose the corresponding crimping tool, die set, and inspection gauge specified in the table below for the splice
selected. Insert die set into the crimping tool and ensure correct die closure using the specified inspection gauge.
13

Sect 2 Chap 6
Splice Part No.
Strip Dimension (mm)

1.5, -0
Crimp Tool
M81824/1-1
6.0
AD-1377
M81824/1-2
8.0
AD-1377
M81824/1-3
8.0
AD-1377
D-436-0081
11.0
H20
Table 6-8
h.
Insert crimp barrel into correct cavity of crimping tool as shown in Figure 6-12. For wire gages 12 through 26, the
cavity colour code will match the colour of the stripe on the crimp barrel. Ensure that the end of the crimp barrel is
against the of the tool and the inspection hole is visible.
Figure 6-12 Insert Crimp Barrel into Correct Cavity of Crimping Tool
i.
Insert end of wire into end of crimp barrel opposite stop. The wire must be visible through inspection hole. A gap of
0.8 to 1.5 mm for wire gages 10 through 26, or 1.5 to 3.0 mm for wire gages six and eight, must exist between wire
insulation and crimp barrel as illustrated in Figure 6-13. Trim conductor or insulation as required.
1.5 to 3.0 mm MAXIMUM GAP
Figure 6-13 Crimping the Wire

j.
Squeeze handles of the crimping tool through complete crimp cycle.
k.
Reverse crimp barrel in cavity. The attached wire will fit in the slot of the stop. Ensure end of crimp barrel is against
stop of tool and inspection hole is visible.
l.
Repeat the two steps above.
14

Sect 2 Chap 6
m.
Examine crimped connection for the following:
(1) Indent centred on splice barrel,

(2) Indent in line with barrel,
(3) Barrel not cracked,
(4) Wire cannot be pulled out of splice, and
(5) A gap of 0.8 to 1.5 mm for wire gages 10 through 26, or 1.5 to 3.0 mm for wire gages 6 and 8, should exist
between wire insulation and crimp barrel.
n.
Centre the sealing sleeve over crimp barrel as shown in Figure 6-14.
Figure 6-14 Positioning the Sealing Sleeve

o.
Shrink sealing sleeve using a heat gun with a small termination sleeve reflector as shown in Figure 6-15. Start by
shrinking the middle then heat towards each end until sealant melts and begins to flow out of both ends. Allow time
for sleeve to cool before handling.
Figure 6-15
Shrinking the Sealing Sleeve
p.
If installing a jumper, repeat steps six to 17 for the other end.
q.
If wire identification is no longer within 75 mm of a termination the wire will require remarking.
r.
As illustrated by Figure 6-16, position repaired wires into a bundle ensuring the splices remain staggered.
15

Sect 2 Chap 6
Figure 6-16
Re-Positioning the Wires within the Loom
s.
21.
Reinstall any support clamps removed for access.
SPLICING PROCEDURE FOR M81824

ENVIRONMENTAL SPLICES
WARNING
38. Splice in accordance with the following:

ventilated.
a.
Check the M22520/5 or /10 crimp tool for wear in

accordance with paragraph 12. If the tool is worn
out of tolerance, it must be replaced.
b.
Identify the correct size splice
c.
Identify the correct size die that will accommodate

the wire(s) to be crimped and install in M22520/5 or
/10 crimp tool.
d.
Strip 0.79mm to 0.86mm of insulation from wires,

following one of the procedures in Section 2,
Chapter 3.
e.
Position the crimp barrel in the die of the M22520/5

or /10 crimp tool, so that one end of the crimp barrel
butts against the crimp locator. Lock in place by
partially closing the handles without denting the
crimp barrel.
f.
Insert the wire fully into the crimp barrel, and crimp
by closing the handles until the ratchet releases.
g.
Before completing the splice, slide the sealing

sleeve, which will be shrunk later, back over one of
the wires.
h.
Reverse the position of the crimp barrel in the crimp

tool die. The attached wire will extend through the
slot in the crimp locator.
i.
Lock the crimp barrel in place by partially closing the

handles. Insert the other wire(s) and crimp as
before.
WARNING
fuelled aircraft.
16
j.
Slide the sealing sleeve over the crimp barrel,

centre it and heat with hot air to shrink the sleeve.
Heat the middle first to lock the sleeve in place, then
heat the ends until the sealing rings melt and ooze
out around the wire. To ensure a good seal; allow to
cool before handling.
CAUTION
Fire resistant wire shall not be spliced. When fire
resistant wire is damaged or deteriorated replace the
entire length of wire from one permanent termination to
the next.
CAUTION
Fusing tin plated splices on nickel plated wire may not
achieve appropriate voltage drop and tensile strength
requirements. Refer to SAE AIR 1263.
SPLICING HIGH TEMPERATURE WIRES

39. Splices for high temperature applications are available
in the same wire size ranges as terminal lugs. The tools
and crimping procedures are the same for splices as for
terminal lugs. Crimp splice at both ends. Appropriately
rated high temperature splices shall be used on high
temperature wire where the splice is located in a high
temperature area. Where wire splice is in a low
temperature area, standard splices may be used. See
Table 69 for details of splices suitable for use on high
temperature wire.

Sect 2 Chap 6
Table 69 Splices and Tooling High Temperature Wire

Nickel Plated Splices Rated to 343C (650F) Uninsulated with Insulation Support
Splice Pt No
AWG
Tool Pt No.
322823
22-16
46673
322825
16-14
46988
Nickel Splices Rated to 649C (1200F) Uninsulated with Insulation Support

322325
22-16
46673
322346
16-14
46988
Table 610 Circular Mil Area (CMA) of Wires and Splices

Wire AWG
Circular Mils
(Nominal)
Splice Part Number
Circular Mils
(Nominal)
26
304
M81824/1-1
2025
24
475
M81824/1-2
3969
22
754
M81824/1-3
9025
20
1216
18
1900
16
2426
14
3831
12
5874
SPLICING ALUMINIUM WIRES

40. Splice large aluminium wires sizes No. 8 through No.
4/0 with splice MS25439. Use the MS25441 power tool
with the correct dies from MS25442. Follow the same
procedure as for aluminium terminal lugs outlined in
paragraph 25, positioning the splice in the tool. Crimp
splice at both ends.
complying with MS27488 shall be installed in unused

grommet holes. Annex C contains details of SAE
AS81714/11 and SAE AS81714/12 environment proof,
disconnect, wire splices and associated tooling.
SPLICING TO REDUCE WIRE SIZE
NOTE
43. Splices may be used to reduce wire sizes. This is a

special application and may be used only when called for
on the applicable engineering drawing or otherwise
authorised by an appropriate authority.
The sealing properties of environmental splices may be

compromised when multi-splicing.
CAUTION
MULTI-SPLICING
41. Multi-splicing is the crimping together of three or more
wires in a single splice. This is a special application and
may be used only when called for on the applicable
engineering drawing or otherwise authorised by an
appropriate authority. Where more than one wire is to be
crimped into one end of a splice the technician must
ensure that the combined size (circular mil area) of the
conductors is compatible with the selected splice.
Additionally, the wires must fit into the splice insulation
support without altering their insulation. Refer to Table
610 for circular mil area (CMA) of common wires and
splices.
ENVIRONMENT RESISTANT WIRE

DISCONNECT SPLICES
42. When splices are used for inline connections of two or
more wires, where disconnection is required, disconnect
splices complying to SAE AS81714/11 and SAE
AS81714/12 are approved for use. Sealing plugs
Do not use any connection which is found defective as

a result of the visual inspection. Cut off defective
connection and remake using a new terminal lug or
splice.
INSPECTION OF CRIMPED CONNECTIONS

44. Examine the crimped connection carefully for the
following:
a.
b.
c.
d.
e.
f.
g.
h.
Crimp indent centred on terminal lug barrel or splice

barrels
Crimp indent in line with barrel.
Terminal lug or splice barrel not cracked.
Terminal lug or splice insulation not cracked.
Insulation support on lugs crimped.
Spliced wires are butted against the stop.
Splices for correct environmental sealing.
Splices for evidence of overheating.
17

Sect 2 Chap 6
TERMINAL JUNCTION SYSTEMS

45. See Section 2, Chapter 4, Electrical Wiring
Installation, for terminal junction systems.
Annexes:
A. Terminations and Tooling
B. Stud Size and Corresponding Terminal Lug
Dimension Reference Chart
C. Disconnect Splices and Tooling
D. Crimp Tool Testing
18

Sect 2 Chap 7
SECTION 2
CHAPTER 7
SOLDERING
INTRODUCTION
DEFINITIONS AND DESCRIPTIONS
1.
Soldered connections are used in aircraft
electrical wiring to form a continuous and permanent
metallic connection having a constant electrical value.
The importance of establishing and maintaining a high
standard of workmanship for soldering operations
cannot be overemphasised.
2.
This section describes the materials and
equipment used in soldering aircraft interconnecting
wiring. It also describes and illustrates preparation and
care of equipment, procedures to be followed, and the
soldering techniques necessary to make a good
soldered joint.
3.
In addition, special materials, equipment, and
techniques used in soldering printed circuit assemblies
are mentioned where they differ from those used in
general electrical soldering. In the repair of printed circuit
assemblies, soldering is closely associated with repairs
to the insulating base and conductor pattern, and with
replacement of components. These repairs are usually
accomplished at the intermediate or depot level where
other component or black box repairs are made. For
detailed information on printed circuit repairs to a
particular system, the handbook of maintenance
instructions for the particular equipment involved should
be consulted.
REFERENCE SPECIFICATIONS AND

STANDARDS
4.
The following specifications and standards are
applicable to soldering:
ANSI/J-STD-004
Requirements
Fluxes
for
Soldering
ANSI/J-STD-006
Requirements
for
Grade Solder Alloys
Electronic
MIL-HDBK-454
General Guidelines for Electronic

Equipment
0-F-499
Flux, Brazing, Silver Alloy, Low

Melting Point
QQ-B-654
Brazing Alloy, Silver
TT-I-735
Isopropyl Alcohol
Soldering
5.
Soldering is the process of joining two or more
metals together at a temperature lower than the melting
points of the metals. In its molten state, solder
chemically dissolves part of the metal surfaces to be
joined. However, most metals exposed to the
atmosphere acquire a thin film of tarnish or oxide; the
longer the exposure the thicker the film will become.
This film is present even though it is not visible, and
solder alone cannot dissolve it. A soldering flux with a
melting point lower than the solder must be used to wet
the metal and allow the solder to penetrate it and
remove the film. The flux melts first, removing the tarnish
or metallic oxide, and also preventing further oxide from
forming while the metal is being heated to soldering
temperature. The solder then melts, floating the lighter
flux and the impurities suspended in it to the outer
surface and edges of the molten fillet. The solder cools
and forms an alloy with the metal. Most of the flux is
burned away during the soldering process; any residue
is removed by appropriate cleaning methods.
6.
The soldering methods used for general aircraft
wiring are essentially the same for both production
soldering and repair work. For printed circuit assemblies,
production methods and repair methods are different. In
production, a dip soldering method is used, where
several connections are made at the same time.
Soldering repairs, however, are made individually, using
techniques similar to those used for soldering general
wiring - with special precautions to prevent thermal
damage to the heat-sensitive, closely packed circuit
elements.
Soft Solder
7.
Soft solder is an alloy consisting of various
combinations of tin and lead, with silver and other
additives, which melts at temperatures below 370C. It
may be in bar form to be melted for tinning or in the form
of rosin cored wire for use with a soldering iron.

Sect 2 Chap 7
8.
The following soft solders may be used on ADF
aircraft electrical systems:
a.
For general applications at temperatures up to

120C use:
(1) non-activated flux cored solder, 60% tin, 40%
lead, 1.2mm diameter, qualified to BS441.
lead, 0.7mm diameter, qualified to BS441.
b. For applications with silver plated components

use:
silver remainder lead, 0.9mm diameter,
qualified to Federal Specification QQ-S-571.
c.
For high temperature applications (190C) use:

(1) solid wire solder, 97.5% lead, 1% tin, 1.5%
silver 16 SWG, qualified to SAE AMS 4756.
Hard Solder
9.
Hard solders should not be confused with high
temperature soft solders. Hard solder is a silver alloy
and is used when greater mechanical strength or
exposure to higher temperatures, such as thermocouple
connections, is required. When silver soldering electrical
equipment or fittings, use, Brazing Alloy-Silver which is a
cadmium free, flux coated brazing rod qualified to
Federal Specification QQ-B-654.
CAUTION
Use RMA type flux only in those cases where use of
a mildly activated flux is required to obtain a good
solder joint. ensure no flux remains on the solder joint
by Cleaning using the procedure outlined in
paragraph 37. The activating agents in the flux may
cause corrosion if not adequately removed after
soldering.
Flux
10. Flux is a chemical reducer used for surface
conditioning before and during the soldering process.
With soft solder, use only rosin fluxes conforming to
Types R (non-activated) or type RMA (mildly activated)
of ANSI/J-STD-004. With hard solder, use 0-F-499
fluxes, Borax or similar material mixed to a paste with
water. A special solder flux sometimes used in
thermocouple connections is described in Section 2,
Chapter 16.
Typical Soldering Operations
11. Following are examples of typical soft-soldering
operations used in aircraft electrical wiring:
NOTE
Hard-soldering procedures are described in Section
2, Chapter 16.
a.
WARNING
Liquid solder flux, ANSI/J-STD-004, may generate a
flammable vapour. Keep away from open flames and
other sources of ignition.
WARNING
Avoid breathing fumes generated by soldering. Eye
protection is required.
Tinning - wires or cables preparatory to

soldering and to fuse ends; contact pins
inside surfaces of solder cups; shielded
braid, after twisting, to fuse, terminate,
connect.
joint
and
wire
and
b. Soldering - wires and cables, previously tinned,

inserted into solder cups of terminals, or
mechanically wrapped on shaped lugs and post or
hooked terminals; twisted connections, or broken
wire for emergency repair; printed circuit
conductor pattern defects, or component leads
and lugs to conductor pattern terminal areas.
c.
De-soldering - soldered joints prior to re-making;

printed circuit component connections to remove
component for replacement.
WARNING
Soldering may result in the emission of hazardous
metallic fumes and vapours from fluxes used.
personnel should position themselves so as to not
directly inhale the fumes/vapours.

Sect 2 Chap 7
HEAT APPLICATION METHODS

Soldering Iron
12. The most commonly used method of' heat
application for soldering joints in aircraft electrical wiring
is by means of an electrically heated, hand held
soldering iron. In addition to the conventional iron, a
pencil iron is frequently used. Pencil irons, except for
their smaller size, are identical to conventional irons and
are used for precision soldering of small units and
miniature assemblies.
Resistance Soldering
13. Resistance soldering is frequently used in large
volume production where the operation is standardised.
In this method, a low voltage transformer is used and the
metal to be soldered is heated by the resistance to a
flow of electric current. The work is gripped between two
electrodes, completing the circuit and heating the metal
for soldering. In another application, a carbon pencil is
used as one electrode and the metal to be soldered
forms the other electrode. When contact is established
through the carbon pencil, intense heat is generated at
the point of contact. Resistance soldering is well
adapted to the soldering of small parts or for congested
assemblies where it is desired to restrict heat to a small
part of the assembly.
Torch Soldering
14. Torch soldering is used where a high heat is
required - as in silver soldering. This process is also
suitable for soft-soldering large work which is not part of
an assembly or when the part to be soldered can be
removed for soldering. For example, wires may be torchsoldered to large contacts that have been removed from
MS connectors. Torch soldering is not suitable for
soldering small parts.
iron to the metal being soldered. If no tinning is present,

the iron will oxidise and the heat cannot flow through.
Copper has a very high rate of heat conductivity, but
copper tips oxidise quickly and must be frequently
cleaned and re-tinned. If a tip has become badly burned
and pitted as a result of overheating, replace it.
Preparing the Soldering Iron
17. Before using the soldering iron prepare it as
follows:
a.
With the iron shut off, file each working surface of

the soldering iron tip with a double-cut mill file until
it is smooth and a bright copper colour. (See
Figure 71.) Remove copper fuzz from dressed
edges with a file card.
Figure 71 Soldering Iron Tip Before and After

Cleaning
b. Plug in the iron and apply cored solder just as the

bright dressed copper colour is turning to a
pigeon-blue, bronze, oxide colour. This will allow
the flux to wet and clean the working area when
the solder melts to form an even, bright silver
coating on the tip. (See Figure 72.)
Dip Soldering
CAUTION
15. Dip soldering is the process of immersing
connections in molten solder; one or more connections
can be made in a single operation. This process is used
on printed circuits, where the conductor pattern is on
one side of the board and the components on the
opposite side. Joints are mechanically secured, dipped
first into liquid flux, then into molten solder.
Do not allow the iron to reach full temperature before

starting the tinning operation.
PREPARATION AND MAINTENANCE OF THE

SOLDERING IRON
General
16. For successful, effective soldering, the soldering
iron tip must be tinned to provide a completely metallic
surface through which the heat may flow readily from the
Figure 72 Tinning Soldering Iron Tip

Sect 2 Chap 7
c.
Wipe off excess solder with a damp sponge or

cloth.
NOTE
Do not file soldering iron tips coated with pure iron.

Filing will ruin the protective coating. If the tip is
pitted, replace it.
18. Some copper soldering iron tips used in
production soldering are coated with pure iron to help
prevent oxidation. Follow manufacturers instructions for
cleaning such irons. A clean damp cloth may be used to
wipe the iron.
Cleanliness
22. Cleanliness is of the utmost .importance in the
soldering operation. If possible, soldering should be
done in clean dust free environment. Drafty areas should
be avoided so that the soldering iron will not cool. Parts
contaminated with dirt, oil, grime, grease, etc, cannot be
successfully soldered. Ensure that the parts are
mechanically bright-clean before soldering. Clean the
parts with a cloth or brush dipped in alcohol, or other
approved solvent. Badly corroded parts may be cleaned
carefully by mechanical means, such as fine abrasive
paper or a wire brush.
Soldering Iron Maintenance

19. Prior to use, remove the tip from the iron and
clean out the black scale from the inside of the iron and
from the tip with fine steel wool. When the iron or tip is
new, coat the inside of the shank with dry flake graphite
or anti-seize material to prevent freezing, and to ensure
maximum heat transfer. When replacing the tip, make
sure it is inserted to the full depth of the casing and
seated firmly against the heating element.
WARNING
Never shake or whip an iron to get rid of dross or
excess solder droplets.
20. During use and just before each application, pass
the soldering iron tip (with a rotary motion) through the
folds of a damp cleaning sponge or wipe on a wiping
pad. This will remove the surface dross and excess
solder from the working surface.
WARNING
Avoid breathing fumes generated by soldering. Eye
protection is required.
Pre-Tinning
23. Wires to be attached to most electrical connectors
must be pre-tinned. Follow the instructions given in
Selection of Flux and Solder
24. Use the solder and fluxes described in paragraphs
7 through 10.
WARNING
Liquid solder flux, ANSI-J-STD-004, may generate a
flammable VAPOUR WHEN heated. Keep away from
open flames and other sources of ignition.
SOLDERING OPERATION
21. Regardless of the heating method used in the
soldering process, a good connection will result only if
the proper soldering techniques are followed and certain
precautions observed. The following instructions apply
generally to soldering operations. Detailed procedures
are given for soldering wires to MS connectors in
Section 2, Chapter 10, to coaxial connectors in Chapter
12, and for thermocouple connections in Chapter 16.
NOTE
A quality soldered joint can be accomplished only on
a mechanical connection of approved geometry,
dress, and dimensions.
CAUTION
Do not use any corrosive flux on aircraft electrical
wiring.
Heating Capacity
25. Use a soldering iron or other heating method of
sufficient capacity to heat the metal being soldered to
solder-melting temperature.

Sect 2 Chap 7
Selection of Soldering Iron
Soldering Iron
26. The sole purpose of the soldering iron is to heat

the joint to a temperature high enough to melt the solder.
Select a soldering iron with a thermal capacity high
enough so that the heat transfer is fast and effective. An
iron with excessive heat capacity will burn or melt wire
insulation; an iron with too little heat capacity will make a
cold joint in which the solder does not alloy with the
work. Soldering irons are available in wattage ranges
from 20 to 500 watts. Irons with wattage rating of 60,
100, and 200 watts are recommended for general use in
aircraft electrical wiring. Pencil irons with a rating of 20
to 60 watts are recommended for soldering small parts.
The soldering iron recommended for printed circuit
soldering is a lightweight 55 watt iron with a 315C
Curies point tip control. This iron has a three-wire cord to
eliminate leakage currents that could damage the
printed circuits.
29. Before starting the soldering operation, make sure

that the iron tip is clean, smooth, and well tinned. See
paragraphs 15 through 19 for instructions on preparation
and maintenance of soldering iron. When resistance
soldering equipment is to be used, make sure that
probes are clean.
27. A soldering iron should also be suited to the

production rate. Do not select a small pencil iron where
a high steady heat flow is required.
Choice of Soldering Tip
28. Select the tip best suited for the size and shape of
the work being soldered. Some common tip shapes are
shown in Figure 73. Soldering iron tips are available in
sizes from 1.6mm to 50mm in diameter. For general use,
a tip of 6mm to 9mm diameter is recommended. For
printed circuit soldering, use a long shank tip of 1.6mm,
2.4mm, 3mm or 4.8mm diameter. Screwdriver, chisel,
and pyramid shapes are recommended.
Securing the Joint

30. Whenever possible, make sure that the joint is
mechanically secure before soldering. When this is not
possible (as with MS connector contacts), make sure
that the joint is held rigid during the cooling period.
Application of Heat and Solder
31. Apply flux-core solder at the exact point between
the metal and the soldering iron (as shown in Figure 7
4) and hold the iron directly against the assembly. Melt
the solder on the joint, not the iron. Place the soldering
iron firmly against the junction. If heavy rocking
pressure is necessary, either the iron does not have
sufficient heat capacity for the job, or it has not been
properly prepared, or both.
Heat Application Time
32. Do not apply heat to the work any longer than the
time necessary to melt the solder on all parts of the joint.
Figure 73 Soldering Iron Tip Shapes

Sect 2 Chap 7
Amount of Solder
33. Do not use any more solder than necessary. Do
not pile up solder around the joint; this is wasteful and
results in joints difficult to inspect. Care should be
exercised with silver-coated wire to prevent wicking
during solder application.
Soldering Iron Holder
34. When the soldering iron is not in actual use during
operations, keep it in a holder. This will protect the
operator against burns and the iron against damage.
stick for small areas and a lint-free clean cloth for large
areas and board edges.
INSPECTING A FINISHED SOLDER JOINT

Acceptable Solder Joint
38. A good soldered joint will have a bright silvery
appearance, with smooth fillets and feathered nonsharp, edges. The entire joint will be covered with a
smooth even coat of solder, and the contour of the joint
will be visible. (See Figure 75.)
Figure 74 Correct Solder Application
Figure 75 Good and Bad Soldered Connections
Protection Against Overheating
Unacceptable Solder Joint
35. Do not allow the iron to overheat. Disconnect the

iron when it is not in use (between operations), or use a
heat-dissipating stand that will keep the iron at a
constant temperature.
39. Any of the following indicate a poor solder joint

and are cause for rejection:
Cooling the Solder Joint

36. When the solder joint has been made, hold the
work firmly in place until the joint has set. Disturbing the
finished work will result in a mechanically weak joint,
with high electrical resistance. Allow solder joints to cool
naturally. Do not use liquids or air blasts.
Cleaning
37. If the correct amount of solder is used and
procedure instructions followed carefully, there should
be little or no excess flux remaining on the finished joint.
If cleaning is necessary, remove excess flux by brushing
the joint with a stiff brush dipped in methyl alcohol, or a
similar approved solvent. Use alcohol sparingly and
avoid contact between alcohol and wire insulation. For
cleaning printed circuit connections, use a cotton swab-
a.
Dull grey, chalky, or granular appearance evidence of a cold joint.
b. Hair cracks or irregular surface - evidence of a

disturbed joint.
c.
Greyish, wrinkled appearance - evidence of

excessive heat.
d. Partially exposed joint - evidence of insufficient

solder.
e.
Scorched wire insulation or burned connector

inserts.
f.
Globules, drips, or tails of solder.
40. If any of the above are present in a finished solder

joint, the joint should be taken apart, parts cleaned, and
the entire soldering operation repeated, using fresh
solder and flux.

Sect 2 Chap 8
SECTION 2
CHAPTER 8
HARNESSESS, LACING AND TYING

INTRODUCTION
DEFINITIONS
1.
Wire groups and bundles are laced or tied to
provide ease of installation, maintenance, and
inspection.
2.
This chapter describes and illustrates
recommended procedures for harnessing, lacing
tying wire groups or bundles, using knots which will
tightly under all conditions; and for installing
clinching plastic cable straps.
the
and
hold
self-
3.
The following reference
applicable to lacing and tying:
specifications
A-A-52080
Tape Lacing and Tying, Nylon
A-A-52081
Tape Lacing and Tying, Polyester
A-A-52083
Tape Lacing and Tying, Glass
A-A-55809
Insulation Tape, Electrical,

Pressure Sensitive, Adhesive,
Plastic
A-A-59474
are
Insulation Tape, Electrical, High

Temperature, PTFE, Pressure
Sensitive
MIL-I-19166
Insulation Tape, Electrical, High

Temperature, Glass Fibre,
Pressure Sensitive
MIL-I-24391
Insulation Tape, Electrical, Plastic,

Pressure-Sensitive
MIL-T-713
Twine, Fibrous, Impregnated,

Lacing and Tying
MIL-T-81306
Tool, Forming, for Adjustable

Plastic and Meal Cable Straps
MS90387
Tool, Hand, Adjustable, for Plastic

and Metal Tiedown Straps
SAE AS 23190
Strap, Clamps, and Mounting

Hardware, Plastic and Metal for
Cable Harness Tying and Support
SAE AS 33671
Strap, Tiedown, Electrical

Components, Adjustable, SelfClinching, Plastic, Type I, Class 1
SAE AS 33681
Strap, Tiedown, Electrical

Components, Identification,
Adjustable, Self-Clinching, Plastic,
Type 11, Class 1
Tying
4.
Tying is the securing together of a group or
bundle of wires, with individual ties at regular intervals
around the group or bundle.
Lacing
5.
Lacing is the securing together of a group or
bundle of wires, installed inside enclosures, by means of
a continuous cord forming loops at regular intervals
around the group or bundle. Except for enclosures, wire
groups or bundles should not be laced.
Wire Group
6.
A wire group is two or more wires tied or laced
together to give identity to an individual system.
Wire Bundle
7.
A wire bundle is two or more wire groups tied or
laced together because they are going in the same
direction at the point where the tie is located.
MATERIALS
CAUTION
Tape listed in Table 81 shall be used for tying or
lacing bundles containing coaxial cables, with the
exception that plastic Class 1, self-clinching straps in
accordance with MIL-S-23190 installed by MS90387
tool, may be used for tying bundles containing coaxial
cables. When using self-clinching straps, the
MS90387 tool tension must be set to minimum.
Coaxial cables containing air or air foam dielectric
shall not have self-clinching straps used on them.
8.
Use narrow flat tape wherever possible for lacing
and tying. Round cord may also be used, but its use is
not preferred because cord has a tendency to cut into
wire insulation. Use cotton, linen, nylon, or glass fibre
cord or tape according to temperature requirements
(MIL-T-713). Cotton or linen cord or tape must be prewaxed to make it moisture and fungus resisting. Nylon
tape may be waxed or unwaxed. Nylon cord must be
waxed in order to make it hold a knot. Glass fibre cord or
tape is usually not waxed.
9.
Use either vinyl or glass fibre pressure-sensitive
tape, according to temperature requirements. Use
pressure-sensitive tape only when its use is specifically
permitted.
10. Moulded nylon self-clinching cable straps may be
used where the strap temperature does not exceed
85C.

Sect 2 Chap 8
GENERAL PRECAUTIONS
b.
Do not use ties on wire groups or bundles located

inside a conduit.
11. When lacing or tying wire groups or bundles,

observe the following precautions:
c.
When tying wire bundles behind connectors, start

ties far enough back from the connector to avoid
splaying of contacts.
d.
Essential Equipment. Certification basis of the

aircraft requires wiring to each system which must
operate to maintain flight control of the aircraft
under normal or emergency conditions is to be
separately routed from other wiring. Essential
engine circuits are to have their wiring so routed
as to prevent damage to any circuit for one engine
affecting circuits of any other engine. Propeller
circuits are to be routed separately from all other
circuits.
a.
Lace or tie bundles tightly enough to prevent

slipping, but not so tightly that the cord or tape
cuts into or deforms the insulation. Be especially
careful when lacing or tying coaxial cable, which
has a soft dielectric insulation between the inner
and outer conductors.
CAUTION
Do not use round cord for lacing or tying coaxial cable
or bundles THAT contain coaxial cable.
Table 81 Tape Lacing and Tying

Description
General Use (Natural)
(Finish B, Size 4)
A-A-52080-B-4
General Use (Black)

(Finish B, Size 3)
A-A-52080-B-3
Rubber Impregnated Co-axial Cable

(Finish C, Size 3)
A-A-52081-C-3
Temperature Resistant Engine Looms

(Finish D, Size 2)
A-A-52083-D-2
(Seal knot with Glyptal, PN GE1201
Figure 81 Single Cord Lacing
Part Number
AA52083-2-D

Sect 2 Chap 8
HARNESS INSTALLATION
LACING
13. Installation
Objectives.
Wiring/harness
installation is accomplished to conform to the following in
order of precedence:
21. Continuous lacing may be used only on those wire

groups or bundles that are to be installed in panels or
junction boxes. Use double cord lacing on groups or
bundles larger than 25mm in diameter. Use either single
or double cord lacing on groups or bundles 1 inch or less
in diameter. For lacing groups that branch off a main
bundle, see paragraph 15.
a.
Safety of Flight,
b.
Ease of Maintenance, and
c.
Cost Effectiveness.
NOTE
14. Safety of Flight. Safety of flight is always the

prime concern on any accomplished maintenance, and
must not be compromised by anyone for any reason.
15. Ease of Maintenance. Wiring is installed to
achieve the following:
a. maximum reliability,
b. minimum interference and coupling between
systems,
When lacing wire groups or bundles, observe the

precautions listed in paragraph 11.
Single Cord Lacing
22. Lace a wire group or bundle with a single cord as
a.
Start the lacing at the thick end of the wire group

or bundle with a knot consisting of a clove hitch
with an extra loop.
b.
At regular intervals along the wire group or

bundle, and at each point where a wire or wire
group branches off, continue the lacing with half
hitches.
c. accessibility for inspection,

d. accessibility for maintenance, and
e. prevention of damage.
16. Cost Effectiveness. The effectiveness of cost
pertains to the contractor but is also dependent upon
correct maintenance practices.
17. Arrangement of Wiring. Wiring is to be arranged
into groups and bundles to facilitate installation and
maintenance. Individual groups are spot tied and when
these groups are bundled the spot ties are not to be
removed.
18. Bundle and Group Size. As a design objective,
bundles and groups within clamps are to be no more
than 50 mm in diameter. High density harnesses are
exempt from this requirement. Wiring to high density
connectors may be run as a single group, provided all of
the wiring in the group is pertinent to a single item,
equipment, or system.
19. High Density Harness Size. The numbers of
wires in a high density harness are to limited only by
efficient and good design. The use of wire sizes larger
than AWG 16 is discouraged unless there are also
smaller wires in the same harness.
20. Inspection and Maintenance. In open wiring,
groups are to be installed to permit replacement of the
group without the removal of the bundle. High density
harnesses are to be designed so that they are readily
replaceable in sections.
NOTE
Space half hitches so that the group or bundle is neat
and securely held.
c.
End the lacing with a knot consisting of a clove

hitch with an extra loop.
d.
Trim the free ends of the lacing cord to 9.5mm

minimum.
Double Cord Lacing

23. Lace a wire group or bundle with a double cord as
a.
Start the lacing at the thick end of the wire group

or bundle with a bowline on a bight.
b.
At regular intervals along the wire group or

bundle, and at each point where a wire group
branches off, continue the lacing with half hitches,
holding both cords together.
NOTE

and securely held.
c.
End the lacing with a knot consisting of a half

hitch, using one cord clockwise and the other

Sect 2 Chap 8
counter clockwise, and then tying the cord ends

with a square knot with an extra loop (see Figure
82).
d.

minimum.
Lacing Branch-Offs
24. Lace a wire group that branches off the main wire
bundle as follows (see Figure 83):
a.
Start the branch-off lacing with a starting knot

located on the main bundle just past the branchoff point. When single cord lacing is used, make
this starting knot as described in paragraph 13,
step a; when double cord lacing is used, make it
as described in paragraph 14, step a.
b.
Continue the lacing along the branched off wire

group, using regularly spaced half hitches. Where
a double cord is used, both cords are held
together.
NOTE

and securely held.
c.
End the lacing with the regular knot used in single

and double cord lacing, as described in paragraph
13, step c, and paragraph 14, step c, respectively.
d.

minimum.
Figure 82 Double Cord Lacing

Figure 83 Lacing a Brach-Off

Sect 2 Chap 8
TYING
SELF-CLINCHING CABLE STRAPS AND

SPIRAL WRAP
25. Tie all wire groups or bundles where supports are

more than 30cm apart. Space ties 30cm or less apart.
Making Ties
26.
Make ties as follows:
Self-Clinching Cable Straps

30. These are adjustable, lightweight, flat plastic
straps used for tying and supporting cable assemblies
and wire bundles. The strap configuration is shown in.
The straps are of two types:
a.
Wrap cord around wire group or bundle, as shown

in Figure 84.
a.
MS3367 cable securing strap shown by the bold

lines in Fig 85 and;
b.
Make a clove hitch, followed by a square knot with

an extra loop.
b.
c.
Trim free ends of cord to 9.5mm minimum.
MS3368 identification and securing strap

illustrated by the broken lines in Fig 85. These
straps are available either in black or natural
colour.
31. Strap, Tiedown, Black is weather resistant and is

to be used where straps are subjected to direct sunlight.
32. Tool tension settings specified in Table 82 are
for typical wire bundle applications. Settings higher or
lower than those specified may be necessary for specific
applications.
33. Tiedown straps may be used on wire bundles
containing solid dielectric coaxial cables provided that
the tension setting on the installation tool is not greater
than required to prevent axial slippage.
34. Tiedown straps should NOT be used in the
following situations:
a.
b.
c.
Figure 84 Making Ties
Temporary Ties
27. Temporary ties are used to aid in making up and
installing wire groups or bundles. Use coloured cord to
make temporary ties; remove these ties when the
installation is complete.
CAUTION
Cut temporary ties with scissors or diagonal pliers
only. Do not use a knife or other sharp edged
instrument that may damage the insulation.
Tying Wire Groups into Wire Bundles
28. Tie wire groups into bundles as described in
paragraph 17, treating the wire groups as though they
were individual wires.
d.
e.
f.
g.
h.
i.
Where total temperature (ambient plus rise)

exceeds 85 C.
Where failure of the strap would permit movement
of the wiring against parts which could damage
the insulation or foul mechanical linkages.
Where failure would permit the strap to fall into
moving mechanical parts.
In high vibration areas.
Outside the fuselage.
In wheel wells.
Where exposure to ultraviolet light might exist,
unless the straps are resistant to such exposure
ie. black coloured straps.
To tie wire groups or harnesses within bundles.
On coaxial cables or wire bundles containing
coaxial cables which do not have solid dielectrics.
35. Paragraph 25 step f disallows the use of tiedown

straps in wheel well applications. Concession is given to
use black tiedown straps PN MS3367-3-0 and MS33676-0 enclosed in plastic tubing PN G167 or equivalent, to
secure wiring in wheel well applications where all other
avenues to secure the wiring in accordance with this
publication have been exhausted.
36. Tiedown straps conforming to SAE AS23190 can
be supplied with either a metal or plastic locking device.
Both types are suitable for aircraft use.
Tying Sleeves to Wire Groups or Wire Bundles

29. Secure sleeves to wire groups or bundles by
tying.

Sect 2 Chap 8
Figure 85 Strap Configuration

Table 82 Self Clinching Cable Straps and Installation Tools
Description
(Width/Length)
[Inches]
Part Number
Tool
Part Number
Tool
Tension
Setting
MS3367-1-0
Strap, Tiedown, Electrical Components,

Standard, Black (0.190/6.30)
1.587-44.45
(0.0625 1.750)
MS90387-1
6 to 8
MS3367-1-9

Standard, Natural (0.190/6.30)
1.587-44.45
(0.0625 1.750)
MS90387-1
6 to 8
MS3367-2-0

1.587-101.60
(0.0625 4.0)
MS90387-1
6 to 8
MS3367-2-9

1.587-101.60
(0.0625 4.0)
MS90387-1
6 to 8
MS3367-3-0

Heavy, Black (0.310/12.0)
4.763-88.90
(0.1875 3.5)
MS90387-2
5 to 8
MS3367-3-9

Heavy, Natural (0.310/12.0)
4.763-88.90
(0.1875 3.5)
MS90387-2
5 to 8
MS3367-4-0

Miniature, Black (0.100/2.72)
4.763-15.87
(0.1875 0.625)
MS90387-1
1 to 3
MS3367-4-9

Miniature, Natural (0.100/2.72)
4.763-15.87
(0.1875 0.625)
MS90387-1
1 to 3
MS3367-5-0

Intermediate, Black (0.146/4.68)
4.763-31.75
(0.1875 1.25)
MS90387-1
3 to 5
MS3367-5-9

Intermediate, Natural (0.146/4.68)
4.763-31.75
(0.1875 1.25)
MS90387-1
3 to 5
MS3367-6-0

Heavy, Black (0.310/26.25)
4.763-203.20
(0.1875 8.0)
MS90387-2
5 to 8
MS3367-6-9

Heavy, Natural (0.310/26.25)
4.763-203.20
(0.1875 8.0)
MS90387-2
5 to 8
MS3367-7-0

1.587-76.2
(0.0625 3.0)
MS90387-1
6 to 8
MS3367-7-9

1.587-76.2
(0.0625 3.0)
MS90387-1
6 to 8
Cable Strap Installation

37. Using the Military hand tool listed in Table 82
and illustrated in Figure 86, perform the following:
Bundle Diameter
(Min-Max) mm
[Inches]
a.
From Table 82 select a strap size and

appropriate tool for the wire bundle diameter
being secured. (Refer to paragraph 25 for
restrictions on strap usage).

Sect 2 Chap 8
b.
Slip strap tip around the bundle with boss side up.
Spiral Wrap
c.
Thread tip through eye then hand pull strap tight

against the bundle.
d.
Adjust the tool index line to the tension locator

value specified in Table 82. If standard changes
in the tension adjustment knob does not align the
index line with the required tension locator value,
the knob may be pulled out and rotated until
alignment occurs.
38. The use of Tube, Plastic, Spiral Wrap (Spirap) as

an alternative method to prevent chafing of wiring is
discouraged. However, where chafing cannot be
avoided using procedures listed in Section 2, Chapter 4,
the use of Spirap is approved.
e.
Pass the free end of the cable tie through the slot
in the end of the tool, then push tool snugly
against the boss.
f.
While holding strap firmly against side of tool and

tool face squarely against boss, pump handle
several times without fully activating the tool's
cutting knife. Once the strap has been stretched
to its maximum, squeeze handle slowly and firmly
until strap is cut.
WARNING
The strap must be cut flush with the boss surface in
order to eliminate painful cuts and scratches from
protruding strap ends.
g.
Inspect strap end to ensure strap end is flush with

boss surface and trim or replace strap as required
to ensure strap end is flush with boss surface.
h.
Carry out appropriate disposal of all broken straps

and strap ends that were cut off.
39. Listed in Table 83 are identification details for

Spirap for use in various environments.
LACING AND TYING IN HIGH TEMPERATURE

AREAS
40. Use A-A-59474 high temperature insulation tape
to tie all wire groups and cable bundles in areas where
the temperature may go above 85C. Use MIL-I-19166
high temperature insulation tape in areas where the
temperature may exceed 85C and dimensional stability
of the tape is required. (jet turbine engine areas).
WARNING
MIL-I-15126 insulation tape (including the glass fibre
type) is highly flammable and should not be used in a
high temperature environment. A-A-59474 insulation
tape is designed for high-temperature operation
(suitable for continuous operation at 260C) and
should be used in high temperature environments at
or below 260C. MIL-I-19166 glass fibre insulation
tape is designed for jet turbine engine areas where
temperatures may exceed 370C where dimensional
stability and high strength are required.
Figure 86 MS90387 Adjustable Hand Tools for Installing Self-Clinching Plastic Tiedown Straps

Sect 2 Chap 8
Table 83 Selection of Spirap

Part Number
Nomenclature
Description
(Tube Diameter)
B47287-I-1/2
Tube, Plastic, Spiral Wrap

Natural Colour
PTFE (Teflon)
(12.7 mm)
B47287-I-3/8

Natural Colour
PTFE (Teflon)
(9.5 mm)
B47287-I-1/4

Natural Colour
PTFE (Teflon)
(6.35 mm)
B47287-I-1/8

Natural Colour
PTFE (Teflon)
(3.17 mm)
B47287-II-1.00

Black
Polyamide (Nylon)
(25.4 mm)
B47287-II-3/4

Black
Polyamide (Nylon)
(19.0 mm)
B47287-II-1/2

Black
Polyamide (Nylon)
(12.7 mm)
B47287-II-1/4

Black
Polyamide (Nylon)
(6.35 mm)
B47287-II-1/8

Black
Polyamide (Nylon)
(3.17 mm)

Sect 2 Chap 9
SECTION 2
CHAPTER 9
WIRING: LOCK, SHEAR AND SEAL

INTRODUCTION
NOTE
1.
Electric connectors, emergency devices, and
other pieces of electrical equipment in aircraft are
secured with wire when specified on engineering
drawings or specified in the applicable aircraft
maintenance handbook in order to prevent accidental
loosening.
2.
This chapter outlines the recommended
procedures for wiring MS electric connectors and
emergency devices such as switches, switch guards,
and handles which operate ejection seats, emergency
bomb releases, fire extinguishers, etc. General practices
for safety wiring are specified in Military Standard
Drawing MS33540 and wire identification is provided in
Table 9-1.
3.
The following specifications are applicable to Lock
Wire, Shear Wire and Seal Wire:
SAE AS 50881
Wiring Aerospace Vehicle
NASM20995
Wire, Safety or Lock
NASM33540
Safety Wiring and Cotter Pinning,

General Practices for
DEFINITIONS
Lock Wire
4.
Lock wire is normally a single strand steel wire
installed by twisting to double strand. It is used to secure
parts against inadvertent opening or loosening in areas
of high vibration such as the engine compartment.
Electrical connectors are lockwired or safety wired in
such high vibration areas. (Refer SAE AS 50881)
NOTE
Use 0.032 inch lockwire for general purpose
lockwiring. 0.020 inch lockwire may be used on parts
having a nominal hole diameter of less than 0.045
inch or on closely spaced screws and bolts of 0.250
inch (6.35mm) diameter or less.
Connector plugs with self-locking coupling rings are

designed for high vibration environments and do not
have lock wire provisions.
Shear Wire
5.
Shear wire is used where it is necessary to
purposely break or shear the wire to permit operation or
actuation of emergency devices. Shear wire is a thin,
single strand, easily breakable wire used to secure
emergency devices.
NOTE
General purpose shear wire shall be 0.020 inch
diameter.
Seal Wire
6.
Seal wire is the same as shear wire except that
the ends of the wire are sealed with a lead seal. Seal
wire is used to secure emergency devices such as fire
extinguishers, oxygen regulators, etc., to prevent
tampering with or use of these devices without
indication.
Metallic Seals
7.
Metallic seals are not to be used on airborne
components, equipment or systems. When antitampering seals are required for lock wire, a bright gloss
paint system is to be used. The paint is to be applied in
such a manner that will provide a visible indication that
the lock wire has been tampered with.
GENERAL PROCEDURES FOR LOCK, SHEAR

AND SEAL WIRING
WARNING
Eye protection is required when using pliers that cut
or trim and shall be worn while installing or removing
safety wire. Keep fingers away from jaws and cutting
edge.

Sect 2 Chap 9
WARNING
NOTE
Lockwire ends must be bent under to prevent injury.

Care should be taken not to confuse steel with
aluminium wire.
All plugs and sockets that are required to be lock

wired, as specified on an engineering drawing or in
the applicable aircraft maintenance manual, are to be
lock wired using the twisted wire method.
CAUTION
Use only new wire when replacing wired electrical
connectors or emergency devices.
Length
8.
Use wire of the shortest length that will allow
accomplishment of the procedures outlined in Paras 14
through 22.Double Twist Lock Wiring
9.
Use the double twist method of lock wiring as
illustrated in Figure 91 for all equipment in areas of
high vibration and for electrical connectors in areas
which are inaccessible.
Single Wire Method
10. Use the single wire method shown in Figure 92
in all conditions specified for shear and seal wire as
described in Paragraphs 5 and 6. In addition, the single
wire method may be used with locking wire in areas hard
to reach and small screws in a closely spaced or closed
geometrical pattern such as triangles, squares,
rectangles, circles, etc.
Figure 91 Double Twist Lock Wiring
Table 91 Safety Wire Identification

Wire Type
Material
Colour
Size
Identification
Lock Wire
Steel
(Corrosion Resistant)
Silver
0.020 inch
MS20995C20
9505-00-221-2650
0.032 inch
MS20995C32
9505-00-293-4208 or
9505-00-847-1663
0.020 inch
MS20995N20
9505-00-529-9195
0.032 inch
MS20995N32
9505-00-529-0442
0.015 inch
MS20995CY15
9525-01-082-1008
0.020 inch
MS20995CY20
9525-01-047-6455
0.032 inch
MS20995AB32
9525-01-031-1086
Lock Wire
(Above 370C)
Shear or Seal Wire
Lock, Shear or Seal

Wire for Magnesium
Parts
Inconel
Annealed Copper
(Cadmium Plated)
Aluminium Alloy
(Anodized)
Natural
Golden
Yellow
Blue

Sect 2 Chap 9
Twisting with Pliers
a.
11. When wire is twisted by hand, use pliers for the

final twists to apply tension and to secure ends of wire.
Cut off part of wire gripped by pliers to remove rough
edges.
b. Pull knob; spiral rod spins pliers and twists the

wire.
NOTE
Make sure wire does not become kinked or nicked
during twisting operation. If wire is damaged, replace
with new wire.
c.
Grip wire in jaws of wire twister and slide outer

sleeve down with thumb to lock handles.
Squeeze handles together to release wire.
Tightness of Wire
13. Install wire so that the wire will be in tension if the
part loosens. Twist wire together so that it is tight, but do
not overstress wire as it may break under load or
vibration.
Figure 93 Use of Lock Wire Pliers

Figure 92 Single Wire Method
Twisting With Special Tools

12. Twist wire with a wire twister as follows (see
Figure 93):
WARNING
Eye protection shall be worn while installing or
removing safety wire. Keep fingers away from jaws
and cutting edge.
WARNING
When using wire twisters and wire extends 3 inches
(75mm) beyond jaws of twisters, loosely wrap wire
around pliers to prevent whipping and possible injury.
SPECIFIC PROCEDURES FOR LOCK, SHEAR

AND SEAL WIRING
Lock Wiring Electrical Connectors and Backshells
NOTE
Do not install lock wire under the head of a screw or
bolt. Use predrilled fillister head screws or safety
tabs.
14. Secure electrical connectors and back-shells with
lock wire when specified on engineering drawings or
specified in the applicable aircraft maintenance
handbook. Electrical and RF connectors and backshells,
unless of the self-locking type, shall be lock-wired in
engine nacelles, areas of high vibration, locations not
readily accessible for periodic maintenance and external
electronic compartments. Connectors and backshells in
these locations are identified by a painted/affixed red dot
0.50 inch (12.7mm) in diameter on adjacent aircraft
structure.

Sect 2 Chap 9
15. Do not lock wire electric or RF connectors and

backshells which have a mechanical lock, as lock wiring
will act against the locking feature. Backshells on
bayonet coupled connectors shall not be safety wired to
connector coupling ring. Backshells with safety wire
holes shall be safety wired to aircraft structure or to
connector mounting flange when required (see Figure 9
9).
b. Twist wire, under slight tension, approximately 9

to 11 turns per inch, (see Figure 95), by hand or
by special tool, as described in Paras 11 and 12.
Twist wire right handed so it will have a tightening
effect. Twist to within approximately 0.125 inch
(3mm) of each unit.
Lock Wiring Connectors with Threaded Coupling

Rings
16. When specified on engineering drawings or
specified in the applicable aircraft maintenance
handbook, lock wire connectors as follows (see Figure
94):
a.
Thread lock wire through wire hole in coupling

ring.
CAUTION
Figure 95 Twisting Method

c.
When installing new lock wire or replacing

unserviceable existing lock wire, use MS20995, 0.020
inch lock wire only. Larger lock wire can break out the
hole in the coupling ring.
Pull one end of twisted wire through hole in drilled

fillister head screw on mounting flange of
connector. Use a fillister head screw so located as
to allow a 60 or smaller angle of the wire, as
shown in Figure 91.
CAUTION
NOTE
If connector plug to be lock wired does not have a
wire hole, remove coupling nut and drill a #56 (0.046
inch) diameter hole diagonally through the edge of
nut, as shown in Figure 96.
Do not back off or over-torque mounting fillister head

screws, in order to align holes for lock wiring.
d. Form pigtail approximately 0.5 inch (12.7mm) or
3-7 turns.
NOTE
Individual sections of connectors may be lockwired
with a continuous piece of lock wire if appropriate
authorisation is obtained.
Figure 96 Drilling Hole in Coupling Nut

e.
Figure 94 Lock Wiring Thread Coupled Connector
Bend pigtail back towards body of connector to

prevent it from injuring personnel.

Sect 2 Chap 9
f.
Safety wire attached cable clamps/coupling ring to

connector coupling ring if provisions exist. (See
Figure 94.) If necessary, safety wire these parts
to structure (see Figure 98) or to mounting flange
(see Figure 99). Use same procedure as
described in steps a through e.
CAUTION
Electrical connectors shall not be lockwired to any
part of fuel, oil, hydraulic or oxygen systems (lines,
tubes, elbows, flanges, jam nuts etc).
Lock Wiring Split Shell Assemblies

18. Split shell connectors are held together by two
fillister head screws. Secure these screws as follows
(see Figure 99):
a.
Draw wire through hole in one screw.
b. Cross wire from left to right between screws, and

draw through second screw.
c.
Twist wires together with pliers and bend back.
Wiring Solid Shell Angle Plugs

NOTE
Connectors should be lock wired to fillister head
screws, through safety wire tabs or drilled holes in
structure provided for that purpose. If no holes are
provided, connectors may be lockwired to each other,
however, the maximum number of connectors that
can be lock-wired in series is three (3). In those
applications where RF connectors require safety
wiring and physical dimensions preclude drilling
safety wire holes, a cable clamp can be attached t o
the connector for securing the safety wire. Attach the
cable clamp as illustrated in Figure 97.
19. Angle plugs with solid black shells are in two

parts, held together by four screws through mating
flanges. Wire these screws with a single lock wire as
shown in Figure 92. Solid shell angle plugs made by
Bendix and Cannon have back shells held in place by
assembly nuts. Install a double twisted lock wire
between hole in assembly nut and lug on backshell as
shown in Figure 94. If necessary to lock wire the plug
itself install a second double twisted wire between the
assembly nut and the coupling nut or between the
coupling nut and one of the receptacle mounting screws,
Figure 98 Lock Wiring Connector to Structure

Figure 97 Lock Wiring Connector Using Adel Clamp
Shear Wiring of Electrical Components

20.
Lock Wiring Connector to Structure

17. If no fillister head screw or safety wire tab is
available for attaching lock wire, secure wire to drilled
hole in structure not more than 6 inches (15cm) from
connector, as shown in Figure 98. Use same procedure
as described in Para 14.
a.
The purpose of shear wiring is as follows:

Prevent inadvertent operation of a switch, and
b. To highlight the selection or operation of a

particular service or function.

Sect 2 Chap 9
Figure 99 Wiring Split Shell Assembly Screws
Shear Wiring Emergency Devices

21. Use single wire method to secure emergency
devices. (See Figure 910.) Make sure that wire is so
installed that it can easily be broken when required in an
emergency situation.
NOTE
Several sizes of shear wire may be used within
aircraft, however, for applications such as shear
wiring of electrical switches and switch covers
Annealed Copper Wire PN MS20995CY20 (NSN
9525-01-047-6455) is to be used.
Figure 910 Shear Wiring Switch Guard

Sect 2 Chap 10
SECTION 2
CHAPTER 10
GENERAL PURPOSE CONNECTORS

INTRODUCTION
1.
Connectors provide a means of quickly
connecting and disconnecting wires to simplify
installation and maintenance of electric and electronic
equipment. Connectors should be inspected and
cleaned, repaired or replaced as warranted, for any
condition that will impair connector performance, such
as those listed below.
J-STD-006
Requirements for Electronic

Grade Solder Alloys and Fluxed
and Non-Fluxed Solid Solders for
Electronic Soldering Applications
MIL-C-26482
Connectors, Electric, Circular,

Miniature, Quick Disconnect
a.
Dirty and/or contaminated with fluids.
MIL-C-26500
a.
Corroded, worn, bent, recessed, broken or

splayed pin or socket contacts.
Connectors, General Purpose;

Electrical, Miniature, Circular,
Environment Resisting
MIL-C-39029
Contacts, Electric, General

Specification For
b.
Damaged (torn, burned, etc) interfacial grommet

seals, rear wire grommet seals and o-rings or
peripheral seals.
MIL-C-81511
Connectors, Electrical, Circular,

High Density, Quick Disconnect,
c.
Damaged (corroded, broken, bent, worn, missing

bayonet pin, etc) shell or coupling ring.
MIL-C-81659
Connectors, Electrical,
Rectangular, Environment
Resistant, Crimp Contacts
d.
Cracked, chipped or distorted dielectric connector

inserts.
MIL-C-81703
Connectors, Electric, Circular,

Miniature, Rack and Panel or
Push-pull Coupling, Environment
Resisting
MIL-DTL-22520
Crimping Tools, Contact,

Electric, Hand, General
Specification For
MIL-DTL-24308
Connector, Electric Rectangular,

Miniature Polarized Shell, Rack
and Panel General Specification
For
MIL-DTL-28748
Connector, Electrical,
Rectangular, Rack and Panel,
Solder Type and Crimp Type
Contacts General Specification
For
MIL-DTL-38999

Miniature, High Density, Quick
Disconnect, Environmental
Resisting, Removable Crimp
Type Contact, Reliability
Assurance Program
MIL-DTL-83723

2.
A connector with irreparable damage that could
degrade its sealing capability, electrical performance or
mechanical integrity should be replaced.
3.
This chapter describes and illustrates the types
and classes of Military Standard connectors and the
recommended procedures for attaching wires to
connector contacts. AN type connectors were formerly
designated with the prefix AN, and older connectors
may still be found with this prefix. The superseding
connector has the same part number except that the
AN has been replaced by MS. Other connectors
commonly used in aircraft, similar to MS connectors, are
also described and illustrated in this section. RF
connectors are treated separately in Section 2, Chapter
12.
4.
general purpose connectors:
AN3111
Ring-Bonding, Electrical
Connector
J-STD-004
Requirements for Soldering

Fluxes
J-STD-005

Pastes

Sect 2 Chap 10
MIL-DTL-83733
Connector Electrical, Miniature,

Rectangular Type, Rack to
Panel, Environment Resisting
200C Total Continuous
Operating Temperature, General
Specification For
MIL-DTL-5015

Threaded, AN Type
MIL-I-3190

Flexible, Coated
MIL-I-631
Insulation, Electrical, SyntheticResin Composition, Non-Rigid
MIL-I-7444

Flexible
MIL-PRF-46846
Rubber, Synthetic, Heat

Shrinkable
MIL-T-83507
Tool Kit, Electrical Connectors,

Contacts, and Connector and
Cable Accessories General
Specification For
MIL-W-22759
Wire, Electric, Fluoropolymer,

Alloy
MS25274
Cap, Electrical Wire End, Crimp

Style, Type II, Class I
MS3101
Connector, Plug Electric, Cable

Connecting, Solder Contacts
MS3190
Contact Wire Barrel, Crimp Type
SAE AMS-DTL23053

Heat Shrinkable, General
Specification For
6.
The class is determined by the environment or
application of the connector. Connectors manufactured
in accordance with military specifications are designated
in one of two ways. In some specifications such as MILDTL-5015, MIL-C-26482, MIL-C-26500 and MIL-DTL38999 series I and II, the connector is designated by and
MS number, such as MS3101. In specifications MILDTL-38999 series III and IV, MIL-C-81511, MIL-DTL83723, and later specifications, the connector is
designated by a D or M preceding the specification
number followed by a slash and the connector number,
such as D38999/21 or M83723/65.
General Description of Circular Connectors
7.
Military Specifications cover the circular
connectors most commonly used in aircraft: MIL-DTL5015, MIL-C-26482, MIL-C-26500, MIL-DTL-38999, MILC-81511,
MIL-C-81703,
and
MIL-DTL-83723.
Connectors manufactured to these specifications have
either solder type or crimp type contacts and cover a
range of contact sizes from 0 to 22.
Military Connector Marking
8.
Each connector is marked on the shell or
coupling ring with a code of letters and numbers giving
all the information necessary to identify the connector
(see Figure 10-1).
DESCRIPTION
General Description of AN, D, M and MS Connectors
5.
A connector set consists of two parts: a plug
assembly and a receptacle assembly. The receptacle is
usually the fixed part of the connector, attached to a
wall, bulkhead, or equipment case. The plug is the
removable part of the connector usually attached to a
cable. When the two parts are joined, the electric circuit
is made by pin-and-socket contacts inside the
connector. The live or hot side of the circuit should
have socket (female) contacts. The contacts are held in
place and insulated from each other and from the shell
by a dielectric insert. Insert and contacts are housed in a
metal shell. Connectors may be grouped into types,
classes, and series depending on their manufacture,
assembly, and application.
Figure 101 MS Connector Marking

a.
The letters MS indicate that the connector has

been made according to government standards.
b.
Numbers such as 3106 indicate type of shell, and

whether plug or receptacle. (Refer to Figure 10-3).
c.
Class letter indicates design of shell, and for what

purpose connector is normally used.
d.
Numbers following class letter indicate shell size

by outside diameter of mating part of receptacle in
1.6mm increments, or by the diameter of the
coupling thread in 1.6mm. For example, size 12
has an outside diameter or a coupling thread of
1.9mm.

Sect 2 Chap 10
e.
Numbers following a hyphen indicate the insert

arrangement. This number does not indicate the
number of contacts. Military Standard drawings
cover contact arrangements approved for service
use.
f.
First letter following the number indicates style of

contact. Contact style letters will normally be P
for pin contacts and S for socket contacts,
however, some connector specifications call out
A and B to replace the P and S in the
marking (part numbering) system. The A and B
indicate a connector supplied without contacts. A
indicates a connector without pin contacts. B
indicates a connector without socket contacts.
The A and B designators are used only when
other than a standard power contacts are to be
used (example: shielded, coaxial, thermocouple
and wrappost contacts). The required contacts
must be ordered separately when A or B is
shown in the connector part number.
g.
Last letter indicates alternative insert position.

Insert position letters W, X, Y, or Z indicate that
the connector insert has been rotated with respect
to the shell a specified number of degrees from
the normal position. Alternative positions are
specified to prevent mismating when connectors
of identical size and contact arrangement are
installed adjacent to each other. These alternative
positions are shown on military standard
drawings. If no letter appears, the insert is in the
normal position. On connectors with multiple
keyways, the degree of rotation is measured from
the widest keyway. See Figure 10-2 for typical
alternative position arrangements.
NOTE
MIL-C-26500 connectors have an additional letter to

indicate type of coupling between shell size and insert
arrangement code numbers. These letters are T for
threaded coupling and B for bayonet coupling; for
example, MS24266R18B30P6, where B indicates the
type of coupling. On MIL-C-26500 connectors,
alternate positions are indicated by numbers 6, 7, 8,
9, 10 instead of by letters.
Solders
c.
Crimp connections are used for nickel-clad copper

wire, and tin, silver, or nickel plated copper wire.
d.
Thermocouple wires require special procedures

that are detailed in Section 2, Chapter 16.
Figure 102 Alternative Positions of Connector

Inserts
Solder Contacts
10.
Solder cup contacts are silver, tin, or gold plated
to provide low contact resistance. Silver-plated contacts
have pre-tinned solder cups. Gold-plated contacts are
not pre-tinned because the gold prevents oxidation and
is therefore always easy to solder.
Preparation of Wires Prior to Assembly
11.
The preparation of wires before assembly is as
follows:
a.
Cut wire to prescribed length.
b.
Identify wire with proper coding.
c.
Strip ends to the dimensions shown in Table 10

1.
d.
Tin wires that are to be soldered to contacts.
9.
Solders and other fastening means are matched
to the wire type and to the installation as follows:
a.
Soft solder per standard J-STD-006 is used for tin

or silver plated copper conductors and coaxial
cable.
b.
Soft solder per standard J-STD-006 is used for

silver coated copper wire.

Sect 2 Chap 10
Figure 103 Typical Circular Connectors

0
INSULATING SLEEVES AND HEATSHRINKABLE TUBING

12.
Insulating sleeves or heat-shrinkable tubing is
used over soldered connections to help protect the
connection against vibration and to lengthen the arcover path between contacts. Insulating sleeves and heat
shrinkable tubing are not used under the following
conditions:
a.
b.
Selection of Insulating Sleeves and Heat-Shrinkable

Tubing
13.
Select insulating sleeving or heat-shrinkable
tubing from the materials listed in Table 102 or Table
103 to suit the temperature conditions in the area
where the connector will be installed. Select the proper
size from Table 104 so that the inside diameter of the
sleeving or recovered heat-shrinkable tubing will fit
snugly over the solder cup.
when connectors are to be moisture-proofed by

potting; and,
when connectors have rear environmental wire
sealing grommets that cover the soldered
connection.
Table 101 Stripping Lengths for Solder Connections

Contact
Size
Stripped Length
(mm)
20
16
12
8
4
3.0
6.0
8.0
16.0
16.0
19.0
WARNING
Temperatures above 315C used to heatshrink tubing
on Polyurethane insulated wire or cables will cause
Polyurethane to release irritating gases.
Installation of Insulating Sleeves and HeatShrinkable Tubing
14.
Cut the sleeving into lengths, as given in Table
104, to extend from the insert and overlap the wire
insulation, covering the soldered connection completely.
(See Figure 104.) Slip insulating sleeve or tubing of
correct size, material, and length over each prepared
wire, far enough back from the stripped end to avoid
heat from the soldering operation (about 25mm).
Table 102 Insulating Sleeving Material

Temperature Range
Material
MIL Spec.

Sect 2 Chap 10
Up to 70C
Synthetic resin composition transparent
MIL-I-631*
Up to 205C
Silicone impregnated fiberglass
MIL-I-3190
Up to 275C
TFE Resin, Non-rigid
MIL-I-22129
* MIL-I-631, Types E & F are not to be used.
Table 103 Heat Shrinkable Tubing Material

Temperature Range
Material
MIL Spec.
-55 to 135C
Polyolefin
SAE AMS-DTL-23053/5
-55 to 175C
PVF
SAE AMS-DTL-23053/8
-67 to 250C
PTFE
Table 104 Insulating Sleeving/Heat Shrinkable Tubing Sizes

Heat Shrinkable Tubing
Insulating Sleeving
Wire Size
Size
Type
Number
I.D. (mm)
16-14
12
10
8
6
4
2
0
6.4
6.4
9.5
12.7
12.7
19.0
25.4
25.4
CRN
CRN
CRN
CRN
CRN
RNF-100
RNF-100
RNF-100
7
5
3
1
0
0.437
0.500
0.625
3.8
4.7
5.9
7.5
8.4
11.1
12.7
15.9
SOLDERING PROCEDURE
15.
Wires are soldered to contacts in electrical
connectors by means of a soldering iron, resistance
heating, or a torch. Safe connections are the result of
clean parts carefully soldered together. See Section 2,
Chapter 7 for a description of soldering methods and
procedures. When soldering wires to electrical
connectors, observe the following precautions:
a.
Make sure that the wire and the contact are clean
and properly tinned.
recommended for sizes 12 through 20; resistance

soldering may also be used.
c.
Make sure that the iron has a smooth, well tinned

tip. See Section 2, Chapter 7 for detailed
instructions on the care and maintenance of the
soldering iron.
d.
Keep electric resistance pliers clean and free from

flux and solder splatter. Use a brass wire hand
brush to clean contact surfaces.
e.
Select a soldering iron tip of a shape to provide

good heat transfer. A large area touching the
contact will help to produce a good connection
quickly. See Figure 105 for suitable soldering
iron tips.
f.
Use only rosin or rosin-alcohol as flux for

soldering wires to connector contacts.
NOTE
Solder type contacts size 8 and smaller are usually
not removed for assembly purposes. Large solder
contacts (size 4 and larger) are removed from
connectors with hard inserts to protect the insert
against the greater amount of heat necessary to
properly solder wires to the larger contacts. Large
solder contacts may be removed from connectors
with resilient inserts provided the connector is not a
pressurised assembly with the contacts bonded into
the insert.
b.
Use a soldering iron, or other heating method,

with a heat capacity sufficient for the work to be
soldered. Resistance soldering is recommended
for sizes 8 through 0. A soldering iron is
CAUTION
Do not use any corrosive flux for soldering an electric
connector.
g.
Do not hold the hot iron against the solder cup

longer than necessary; this will force solder up

Sect 2 Chap 10
into the conductor and stiffen the wire. Stiff wires

will break under vibration.
h.
i.
Avoid having solder run on the outside of solder

cup of drip into insert face. Do not move the
soldered connection until the solder has
hardened.
Solder has little mechanical strength. Do not
depend on solder to keep a wire from pulling out
of a contact. Use a cable clamp, grommet seal, or
potting to give mechanical strength.
Electrical Resistance Soldering
the wire is fully inserted, continue heating until the

solder flows to form smooth fillet. Allow joint to
cool and harden without movement.
b.
Small contacts are heated for soldering by use of

pencil type resistance soldering tool shown in
Figure 107. The two electrodes of the tool are
placed in contact with the side of the solder cup
so that the heating current will pass through the
wall of the cup. When the solder in the cup flows,
insert the pre-tinned wire. Continue to apply heat
to connection until solder flows to form smooth
fillet, then stop current and allow joint to cool
without movement.
16.
Resistance soldering will yield excellent results
for both very large and very small contacts. Large
contacts are soldered to wires by the use of resistance
soldering pliers, (See Figure 106.) The contact,
removed from insert, is held in the jaws of the pliers and
current is applied until the solder in the solder well has
melted:
Figure 106 Resistance Soldering Pliers For Large

Contacts
Torch Soldering
Figure 104 Insulating Sleeving Installed Over
Solder Cup
17.
A torch can be used to solder wire into a large
contact that has been removed from its insert (See
Figure 108.) The contact is held in a non-metallic block
to avoid heat loss, and the torch is played over the
solder cup area until the solder melts.
Figure 107 Resistance Soldering Pencil For Small

Contacts
Figure 105 Soldering Iron Tip Shapes
a.
Then the pre-tinned wire is inserted slowly into the

solder cup while current is still being applied. After

Sect 2 Chap 10
CAUTION
CAUTION
Do not overheat. Excessive heat will destroy the

plating and soften the contact
Do not allow solder to collect outside of the solder

cup. This will reduce the arc-over distance between
contacts and can result in connector failure.
18.
When the solder in the cup has melted, insert
the wire slowly into the cup and add more solder if
necessary. Continue to heat the connection until the
solder flows into a smooth fillet, then remove the flame.
Allow the joint to cool without movement.
Figure 109 Soldering Large Size Contacts

Figure 108 Torch Soldering Large Contact
Soldering Iron Procedure
19.
Soldering with an electrically heated iron is the
most common procedure. For convenience, either the
iron or the connector is fastened to the bench as
described in paragraph 20. Soldering is accomplished as
follows:
a.
b.
Large contacts which have been removed from

inserts are held in a non-metallic block and
soldered by first heating the solder cup with the
specially shaped tip as shown in Figure 109.
Then, while heat is still applied, the pre-tinned
wire is slowly inserted into the solder cup until it
bottoms. Extra solder is added to the solder cup if
necessary. Hold the hot iron to the solder cup until
the solder has flowed into a smooth fillet, and then
allow to cool.
Figure 1010 Soldering Small Size Contacts
Contacts that have not been removed from inserts

are soldered as shown in Figure 1010 and
Figure 1011. The solder is flowed by placing the
iron alongside the solder cup as the wire-is being
inserted into it. Medium size contacts such as No.
8 and No. 12 will solder more easily if the iron is
held at the point where the wire touches the
cutaway of the solder cup as shown in Figure 10
11. Adding a small quantity of solder at this point
will aid in carrying the heat into the joint.

Sect 2 Chap 10
NOTE
The above two sequences are suggested procedures
that work well. They are not mandatory, but have
proved to be successful.
Figure 1011 Soldering Medium Size Contacts
Holding Connectors for Soldering

20.
To facilitate soldering wires to contacts that
have not been removed from connectors, it is helpful to
either work to a fixed soldering iron or to fasten the
connector into a holding fixture. To solder connectors
with a fixed iron, it is necessary to hand-hold the
connector. If the connector is to be fastened to the
bench, a steel bracket bent to a 60 to 75 angle is very
useful.
Soldering Sequence
21.
Follow a rigid sequence in soldering wires to a
connector. This helps avoid errors in wiring and also
prevents burning or scorching the insulation of wires
already soldered. Two useful sequences are shown in
Figure 1012.
a.
The soldering of the connector in Figure 1012

detail A is started at the right or left lower edge,
depending on whether the technician is left or
right-handed, and follows the bottom row across.
The row above is next and is done in the same
direction as the bottom row. This will permit the
insert to cool between soldering operation. The
operation is repeated for each row in sequence
until all contacts are soldered.
NOTE
If wires are being soldered to a connector with a large

number of contacts, plan the work to allow a cooling
off period after each series of twenty contacts in order
to prevent heat build-up.
b.
The sequence for the connector shown in Figure

1012 detail B also starts with the bottom row
from the right or left. The next step is to solder to
the centre contacts working out to each edge. The
final operation is to solder wires to the top row of
contacts.
Figure 1012 Connector Soldering Sequence

Cleaning Soldered Connections
22.
After all connections have been made, examine
the connector for excess solder, cold joints, and flux
residues. If any of the above are found, take following
corrective measures:
a.
Remove excess solder by using a soldering iron

that has been wiped clean with a heavy, clean
cloth.
b.
Disassemble cold joints by removing all solder

with a de-soldering tool or solder removal tool and
remake the connection using new 60/40 rosincore solder.
WARNING
Use personnel protective equipment (eye goggles
and face shield) when using compressed air.

Sect 2 Chap 10
c.
Remove flux residues with denatured ethyl alcohol

or other approved solutions applied with a bristle
brush. Blow the connector dry with compressed
air.
WARNING
Use correct cleaning compounds and approved
procedures to clean aircraft electric components.
Preshaping Wires
25.
Preshape large diameter wires (No. 14 and
larger) before soldering to contacts. This will avoid strain
on soldered connection when cable clamp is installed.
See Figure 1014.
CAUTION
Preshaping is a necessity for connectors using
resilient inserts. Side strain on the contacts will cause
contact splaying and prevent proper mating of pin and
socket contacts.
WARNING
On fuelled aircraft use only a heat source such as
Compressed air/nitrogen hot air gun M83521/5-01 or
equivalent.
Insulating Sleeving/Heat-Shrinkable Tubing
Positioning
23.
Install sleeves or heat-shrinkable tubing over the
individual wires prior to assembly to solder cups. After
the connections are cleaned, push the insulating sleeves
or sections of heat-shrinkable tubing down over the
contact until they bottom against the inserts as shown in
Figure 1013. Shrink heat-shrinkable tubing around the
solder cups and terminated wire ends with hot-air gun.
24.
Rotate the connector so that the pieces of tubing
are fully and evenly shrunk. Where insulation sleeves
are not a firm fit on the contact and wire, tie in position
with nylon braid to prevent sliding back on the wires.
Ensure that the ties will not interfere with the cable
clamp.
Figure 1014 Preshaping and Tying Wires

Removable Solder Type Shielded Contacts
26.
Damaged removable solder-type shielded
contacts should be replaced with equivalent crimp type
shielded contacts. Procedures for installing shielded
contacts are packaged with the contacts.
CRIMP CONTACTS
27.
Removable crimp-type contacts conforming to
specification MIL-C-39029 are used with the connector
types indicated in paragraph 5. The method of crimping
wires to these contacts is essentially the same
throughout the entire group of connectors. Standard
crimping tools conforming to MIL-DTL-22520 are used to
crimp the contacts. Contacts manufactured after April
1978 will be identified with BIN (basic identification on
number) code colour bands (see Figure 1015). Each
digit of the BIN code will be designated on the contact by
a colour band in accordance with the following:
Figure 1013 Insulation Sleeve or Heat Shrinkable
Tubing Bottomed Against Insert
0 Black
1 Brown
2 Red
3 Orange
4 Yellow
5 Green
6 Blue
7 Violet
8 Grey
9 White

Sect 2 Chap 10
28.
See Table 105 for contact to BIN code cross
reference.
MIL-DTL-22520/1 Crimping Tool

30.
The
basic
crimping
tool,
M22520/l-0l,
accommodates contacts with wire barrel sizes 12
through 20 and has a provision for selecting the proper
depth of crimp depending on the contact/wire
combination being used. The contact is crimped by the
creation of four sets of double impressions caused by
the closure of the four indenters. Appropriate turret or
positioner heads are installed depending on the
application.
31.
The basic crimping tool, M22520/2-01,
through 28, and has a provision for selecting the proper
combination being used. The contact is crimped by the
creation of four sets of double impressions caused by
the closure of the four indenters. Appropriate positioners
are installed depending on the application.
Figure 1015 Contact Marking

HAND CRIMPING TOOLS FOR CONNECTOR

CONTACTS
29.
Crimping tools used for crimping removable
contacts to wire conductors for use in electrical
connectors, terminal junction systems, and other
electrical or electronic components, should conform to
MIL-DTL-22520 and one of its associated specification
sheets. These tools are capable of crimping a range of
contact wire barrel sizes 12 to 28, to a range of wire
sizes 12 to 32. All MIL-DTL-22520 hand operated tools
are cycle controlled by means of a ratchet mechanism
that will not release until the crimping cycle has been
completed. A brief description of each of these tools
follows:
CAUTION
Do not disassemble any crimping tools. Do not
tighten or loosen nuts or otherwise attempt to adjust.
Required adjustments SHOULD be made only by the
manufacturer, or by a calibration laboratory.
32.
The basic tool, MS22520/4-01, is used only with
the M22520/4-02 single positioner head. This tool head
combination is used to crimp outer pin and socket
coaxial contacts to the shielded cables specified for
them. The tool, which is not operator adjustable, creates
a circular crimp around the contact. For specific tool
application, see MIL-DTL-22520/4.
33.
The basic crimping tool, M22520/7-01,
through 22, and has a provision for selecting the proper
combination being used. It is similar to the M22520/2-01
in that it is smaller than the M22520/1-01 and is
therefore easier to handle. It is also similar in
appearance and has the same method of operation.
TOOL INSPECTION GAUGING

34.
Prior to use, the crimp tool must be carefully inspected to determine correct operation. The indenters should
be checked for equal travel and simultaneous movement, as the handles are closed. The indenter closing selector
should also be checked to ensure a positive detent at each selector setting.
35.
To ensure proper crimp dimensions during operation, a suitable Go/No Go gauge is to be used for tool
verification. The inspection gauge, illustrated in Figure 10-16 should be used prior to commencing any crimp operation.
Figure 10 -16 - Go/No Go Gauge
10

Sect 2 Chap 10
CAUTION
Do not crimp down on the gauge pins as this will prevent the tool from full cycling to the ratchet release position.
36.
The gauge ends are colour coded green for Go and red for No Go. The Go end of the gauge should freely
pass through indenters when the tool is in the fully closed position. Conversely, the No Go gauge should not pass
through indenters when the tool is in the fully closed position. When either gauging fails, reject the tool and have it sent
for repair or calibration. The following sequence details the gauging procedure:
a.
Remove the safety pin from the position selector knob located on the tool frame. Pull the wire size selector knob
upwards and rotate knob to setting 4. Reinstall the safety pin.
b.
Close the handles completely and hold in fully closed position.
c.
Axially align the Go end of the gauge (Green) with the indenter opening, as depicted in Figure 10-17.
d.
Slide the gauge into the indenter opening and through the indenters. The gauge should pass freely through the
indenters, as shown in Figure 10-18. If not, the tool should no longer be used until it has been repaired.
Figure 10-17 Testing the Crimp Tool
Figure 10-18 Testing a Crimp Tool

e.
Invert the inspection gauge while continuing to hold the handles in the fully closed position. Insert the No Go
gauge (Red) into the indenter opening, as shown in Figure 10-19. The gauge should not pass between the
indenters. If the No Go gauge does pass through the indenters, have the tool repaired.
11

Sect 2 Chap 10
Figure 10-19 Testing a Crimp Tool

CRIMP TOOL BUILD UP AND ADJUSTMENT
37.
To achieve a mechanically and electrically sound crimp contact, the proper combination of locater and selector
setting is necessary. The selection of an appropriate turret head and fitment to the crimping tool is referred to as tool
build up. Tool build up and adjustment is performed using the following procedure and table:
Contact
Size
Wire Size
Selector
Setting
Turret Bushing
20
20
20
16
16
16
12
12
24
22
20
20
18
16
14
12
2
3
4
4
5
6
7
8
Red
Red
Red
Blue
Blue
Blue
Yellow
Yellow
a.
Remove the safety pin from the position selector knob and rotate the knob to the required setting. Reinstall the
safety pin.
b.
Select the turret to suit the connector pin or socket. Each connector has a complete breakdown of information
such as pin and contactor size, and the crimping tool required. Press the trigger on the turret head to release the
positioner into the extended or indexing position, as illustrated in Figure 10-20.
Figure 10-20 Crimp Tool Build Up and Adjustment

c.
12
Seat the turret head onto the retainer ring on the back of the tool. Align the screws with the tapped holes
ensuring correct orientation of the turret. Tighten the cap screws with an appropriately sized Allen key as shown
in Figure 10-21.

Sect 2 Chap 10

d.
With the positioner extended, rotate, as shown in Figure 10-22 to select the matching colour index mark.

e.
Push the positioner back in until an audible click is heard. The tool is now ready to use.
13

Sect 2 Chap 10
Table 105 Electrical Contact BIN Code Listing

Bin Code
Superseded
Part Number
Pin or
Socket
100
M39029/1-100
M39029/1-16-22
101
M39029/1-101
M39029/1-16-20
102
M39029/1-102
M39029/1-14-16
103
M39029/1-103
M39029/1-12-12
104
M39029/2-104
M39029/2-22-22
105
M39029/2-105
M39029/2-20-20
106
M39029/2-106
M39029/2-16-16
107
M39029/3-107
M39029/3-22-22
108
M39029/3-108
M39029/3-20-20
109
M39029/3-109
M39029/3-16-16
110
M39029/4-110
M39029/4-20-20
M83723-33B20
M39029/4-16-16
M83723-33B16
111
M39029/4-111
112
M39029/4-112
M39029/4-16-20
113
M39029/4-113
M39029/4-12-12
M83723-33B12
114
M39029/4-114
M39029/4-12-16
115
M39029/5-115
M39029/5-20-20
M83723-34B20
M39029/5-16-16
M83723-34B16
116
14
Current
Part Number
M39029/5-116
117
M39029/5-117
M39029/5-16-20
118
M39029/5-118
M39029/5-12-12
M83723-34B12
119
M39029/5-119
M39029/5-12-16
120
M39029/6-120
M39029/6-01
121
M39029/6-121
M39029/6-02
122
M39029/6-122
M39029/6-03
123
M39029/6-123
M39029/6-04
124
M39029/6-124
M39029/6-05
125
M39029/6-125
M39029/6-06
126
M39029/7-126
M39029/7-001
127
M39029/7-127
M39029/7-002
128
M39029/7-128
M39029/7-003
129
M39029/8-129
M39029/8-001
130
M39029/8-130
M39029/8-002
131
M39029/8-131
M39029/8-003
132
M39029/9-132
M39029/9-20-20-C1
133
M39029/9-133
M39029/9-20-20-C2
134
M39029/9-134
M39029/9-20-20-C3
135
M39029/9-135
M39029/9-20-20-C4
136
M39029/9-136
M39029/9-20-20-C5
138
M39029/10-138
M39029/10-20-20-C1
139
M39029/10-139
M39029/10-20-20-C2
140
M39029/10-140
M39029/10-20-20-C3

Sect 2 Chap 10
Table 105 Electrical Contact BIN Code Listing (Continued)

Bin Code
Current
Part Number
Superseded
Part Number
Pin or
Socket
141
M39029/10-141
M39029/10-20-20-C4
142
M39029/10-142
M39029/10-20-20-C5
144
M39029/11-144
M39029/11-22-22
145
M39029/11-145
M39029/11-20-20
146
M39029/11-146
M39029/11-16-16
147
M39029/11-147
M39029/11-12-12
148
M39029/12-148
M39029/12-22-22
149
M39029/12-149
M39029/12-20-20
150
M39029/12-150
M39029/12-16-16
151
M39029/12-151
M39029/12-12-12
152
M39029/13-152
M39029/13-01
153
M39029/13-153
M39029/13-02
154
M39029/13-154
M39029/13-03
155
M39029/13-155
M39029/13-04
156
M39029/13-156
M39029/13-05
157
M39029/13-157
M39029/13-06
158
M39029/14-158
M39029/14-01
159
M39029/14-159
M39029/14-02
160
M39029/14-160
M39029/14-03
161
M39029/14-161
M39029/14-04
162
M39029/14-162
M39029/14-05
163
M39029/14-163
M39029/14-06
166
M39029/16-166
M39029/16-23-28
167
M39029/16-167
M39029/16-23-22
168
M39029/16-168
M39029/16-20-20
169
M39029/16-169
M39029/16-16-16
170
M39029/16-170
M39029/16-12-12
171
M39029/17-171
M39029/17-23-28
172
M39029/17-172
M39029/17-23-22
173
M39029/17-173
M39029/17-20-20
174
M39029/17-174
M39029/17-16-16
175
M39029/17-175
M39029/17-12-12
176
M39029/18-176
M39029/18-23-28
177
M39029/18-177
M39029/18-23-22
178
M39029/18-178
M39029/18-20-20
179
M39029/18-179
M39029/18-16-16
180
M39029/18-180
M39029/18-12-12
181
M39029/19-181
M39029/19-01
182
M39029/19-182
M39029/19-02
183
M39029/19-183
M39029/19-03
184
M39029/20-184
M39029/20-01
185
M39029/20-185
M39029/20-02
186
M39029/20-186
M39029/20-03
187
M39029/21-187
M39029/21-01
188
M39029/21-188
M39029/21-02
15

Sect 2 Chap 10

Bin Code
Superseded
Part Number
Pin or
Socket
189
M39029/21-189
M39029/21-03
190
M39029/22-190
M39029/22-22-28
M39029/15-22-28
191
M39029/22-191
M39029/22-22-22
M39029/15-22-22
192
M39029/22-192
M39029/22-20-20
193
M39029/22-193
M39029/22-16-16
194
M39029/23-194
M39029/23-01
195
M39029/23-195
M39029/23-02
196
M39029/23-196
M39029/23-02
197
M39029/23-197
M39029/23-04
198
M39029/23-198
M39029/23-05
199
M39029/24-199
M39029/24-01
200
M39029/24-200
M39029/24-02
201
M39029/24-201
M39029/24-03
202
M39029/24-202
M39029/24-04
203
M39029/24-203
M39029/24-05
204
M39029/25-204
M39029/25-01
205
M39029/25-205
M39029/25-02
206
M39029/25-206
M39029/25-03
207
M39029/26-207
M39029/26-01
208
M39029/26-208
M39029/26-02
209
M39029/26-209
M39029/26-03
210
M39029/27-210
M39029/27-12A
211
M39029/28-211
M39029/28-12A
212
M39029/29-212
M39029/29-16-16
M83723-29T16
M53162-16-16
M39029/29-12-12
M83723-29T12
M53162-12-12
M39029/29-8-8
M83723-29T8
M53162-8-8
M39029/29-4-4
M83723-29T4
M53162-4-4
M39029/29-0-0
M83723-29T0
M53162-0-0
M39029/30-16S-16
M83723-30T16
M53163-16S-16
M39029/30-16-16
M83723-30T16
M53163-16-16
213
214
215
216
217
218
16
Current
Part Number
M39029/29-213
M39029/29-214
M39029/29-215
M39029/29-216
M39029/30-217
M39029/30-218

Sect 2 Chap 10

Bin Code
219
220
221
222
Current
Part Number
M39029/30-219
M39029/30-220
M39029/30-221
M39029/30-222
Superseded
Part Number
Pin or
Socket
M39029/30-12-12
M83723-30T12
M53163-12-12
M39029/30-8-8
M83723-30T8
M53163-8-8
M39029/30-4-4
M83723-30T4
M53163-4-4
M39029/30-0-0
M83723-30T0
M53163-0-0
223
M39029/31-223
MS3192-20-20A
224
M39029/31-224
MS3192-20-20C4
225
M39029/31-225
MS3192-20-20C1
226
M39029/31-226
MS3192-20-20C2
227
M39029/31-227
MS3192-20-20C3
228
M39029/31-228
MS3192-16-16A
229
M39029/31-229
MS24254-16P
230
M39029/31-230
MS3192-16-16C4
231
M39029/31-231
MS3192-16-16C1
232
M39029/31-232
MS3192-16-16C2
233
M39029/31-233
MS3192-16-16C3
234
M39029/31-234
MS3192-12-12A
235
M39029/31-235
MS24254-12P
236
M39029/31-236
MS3192-12-12C4
237
M39029/31-237
MS3192-12-12C1
238
M39029/31-238
MS3192-12-12C2
239
M39029/31-239
MS3192-12-12C3
240
M39029/31-240
MS3192-A20-20A
241
M39029/31-241
MS24254-20P
242
M39029/32-242
MS3193-20-20A
243
M39029/32-243
MS3193-20-20C4
244
M39029/32-244
MS3193-20-20C1
245
M39029/32-245
MS3193-20-20C2
246
M39029/32-246
MS3193-20-20C3
247
M39029/32-247
MS3193-16-16A
248
M39029/32-248
MS24255-16S
249
M39029/32-249
MS3193-16-16C4
250
M39029/32-250
MS3193-16-16C1
251
M39029/32-251
MS3193-16-16C2
252
M39029/32-252
MS3193-16-16C3
253
M39029/32-253
MS3193-12-12A
254
M39029/32-254
MS24255-12S
255
M39029/32-255
MS3193-12-12C4
256
M39029/32-256
MS3193-12-12C1
17

Sect 2 Chap 10

Bin Code
18
Current
Part Number
Superseded
Part Number
Pin or
Socket
257
M39029/32-257
MS3193-12-12C2
258
M39029/32-258
MS3193-12-12C3
259
M39029/32-259
MS3193-A20-20A
260
M39029/32-260
MS24255-20S
261
M39029/33-261
MS3343A23-28
262
M39029/33-262
MS3343B23-28
263
M39029/33-263
MS3343A23-22
264
M39029/33-264
MS3343B23-22
265
M39029/33-265
MS3343A20-20
266
M39029/33-266
MS3343B20-20
267
M39029/33-267
MS3343A16-16
268
M39029/33-268
MS3343B16-16
269
M39029/33-269
MS3343A12-12
270
M39029/33-270
MS3343B12-12
271
M39029/34-271
MS17803-20-20
272
M39029/34-272
MS17803-16-20
273
M39029/34-273
MS17803-16-16
274
M39029/35-274
MS17804-20-20
275
M39029/35-275
MS17804-16-20
276
M39029/35-276
MS17804-16-16
277
MS39029/36-277
MS17807-16-20
278
MS39029/36-278
MS17807-16-16
279
MS39029/36-279
MS17808-16-20
280
MS39029/37-280
MS17808-16-16
287
MS39029/44-287
MS90453-16-22
288
MS39029/44-288
MS90453-16-16
289
MS39029/44-289
MS90453-12-16
290
MS39029/44-290
MS90453-12-12
291
MS39029/44-291
MS90453-8-8
292
MS39029/44-292
MS90453-4-4
293
MS39029/44-293
MS90453-0-0
294
MS39029/45-294
MS90454-16-22
295
MS39029/45-295
MS90454-16-16
296
MS39029/45-296
MS90454-12-16
297
MS39029/45-297
MS90454-12-12
298
MS39029/45-298
MS90454-8-8
299
MS39029/45-299
MS90454-4-4
300
MS39029/45-300
MS90454-0-0
301
M39029/46-301
MS90460A23-28
302
M39029/46-302
MS90460B23-28
303
M39029/46-303
MS90460A23-22
304
M39029/46-304
MS90460B23-22
305
M39029/46-305
MS90460A20-20
306
M39029/46-306
MS90460B20-20
307
M39029/46-307
MS90460A16-16
308
M39029/46-308
MS90460B16-16
309
M39029/46-309
MS90460A12-12

Sect 2 Chap 10

Bin Code
Current
Part Number
Superseded
Part Number
Pin or
Socket
310
M39029/46-310
MS90460B12-12
311
M39029/47-311
MS90461-A23-28
312
M39029/47-312
MS90461-B23-28
313
M39029/47-313
MS90461-A23-22
314
M39029/47-314
MS90461-B23-22
315
M39029/47-315
MS90461-A20-20
316
M39029/47-316
MS90461-B20-20
317
M39029/48-317
MS90559-11
318
M39029/48-318
MS90559-12
319
M39029/48-319
MS90559-14
320
M39029/48-320
MS90559-8
321
M39029/48-321
MS90559-9
322
M39029/48-322
MS90559-13
323
M39029/48-323
MS90559-5
324
M39029/48-324
MS90559-6
325
M39029/48-325
MS90559-3
326
M39029/48-326
MS90559-4
327
M39029/48-327
MS90559-1
328
M39029/48-328
MS90559-2
329
M39029/49-329
MS90560-7
330
M39029/49-330
MS90560-8
331
M39029/49-331
MS90560-5
332
M39029/49-332
MS90560-9
333
M39029/49-333
MS90560-3
334
M39029/49-334
MS90560-2
335
M39029/49-335
MS90560-1
336
M39029/47-336
MS90461-A16-16
337
M39029/47-337
MS90461-B16-16
338
M39029/47-338
MS90461-A12-12
339
M39029/47-339
MS90461-B12-12
340
M39029/50-340
N83733/13-12
341
M39029/51-341
N83733/14-12
342
M39029/54-342
MS27184-22P
343
M39029/54-343
MS27184-20P
344
M39029/55-344
MS27185-22S
345
M39029/55-345
MS27185-20S
348
M39029/56-348
MS27490-22D
349
M39029/56-349
MS27490-22M
350
M39029/56-350
MS27490-22
351
M39029/56-351
MS27490-20
352
M39029/56-352
MS27490-16
353
M39029/56-353
MS27490-12
354
M39029/57-354
MS27491-22D
355
M39029/57-355
MS27491-22M
356
M39029/57-356
MS27491-22
357
M39029/57-357
MS27491-20
358
M39029/57-358
MS27491-16
19

Sect 2 Chap 10

Bin Code
20
Current
Part Number
Superseded
Part Number
Pin or
Socket
359
M39029/57-359
MS27491-12
360
M39029/58-360
MS27493-22D
361
M39029/58-361
MS27493-22M
362
M39029/58-362
MS27493-22
363
M39029/58-363
MS27493-20
364
M39029/58-364
MS27493-16
365
M39029/58-365
MS27493-12
366
M39029/59-366
MS27535
367
M39029/60-367
MS27536
368
M39029/63-368
MS24308/10-1
369
M39029/64-369
MS24308/11-1
384
M39029/69-384
M39029/69-1
385
M39029/69-385
M39029/69-2
386
M39029/69-386
M39029/69-3
387
M39029/70-387
M39029/70-1
388
M39029/70-388
M39029/70-2
389
M39029/70-389
M39029/70-3
390
M39029/71-390
M39029/71-1
391
M39029/71-391
M39029/71-2
392
M39029/71-392
M39029/71-3
393
M39029/72-393
M39029/72-1
394
M39029/72-394
M39029/72-2
395
M39029/72-395
M39029/72-3
396
M39029/73-396
M39029/73-12A
397
M39029/73-397
M39029/73-12B
398
M39029/73-398
M39029/73-12C
399
M39029/74-399
M39029/74-12A
400
M39029/74-400
M39029/74-12B
401
M39029/74-401
M39029/74-12C
402
M39029/27-402
M39029/27-12B
403
M39029/27-403
M39029/27-12C
404
M39029/27-404
M39029/27-12D
405
M39029/27-405
M39029/27-12E
406
M39029/27-406
M39029/27-12F
407
M39029/27-407
M39029/27-12G
408
M39029/27-408
M39029/27-12H
409
M39029/28-409
M39029/28-12B
410
M39029/28-410
M39029/28-12C
411
M39029/28-411
M39029/28-12D
412
M39029/28-412
M39029/28-12E
413
M39029/28-413
M39029/28-12F
414
M39029/28-414
M39029/28-12G
415
M39029/28-415
M39029/28-12H
416
M39029/75-416
M39029/75-12A
417
M39029/75-417
M39029/75-12B
418
M39029/75-418
M39029/75-12C
419
M39029/75-419
M39029/75-12D

Sect 2 Chap 10

Bin Code
Current
Part Number
Superseded
Part Number
Pin or
Socket
420
M39029/75-420
M39029/75-12E
421
M39029/75-421
M39029/75-12F
422
M39029/75-422
M39029/75-12G
423
M39029/75-423
M39029/75-12H
424
M39029/76-424
M39029/76-16A
425
M39029/76-425
M39029/76-16B
426
M39029/76-426
M39029/76-16C
427
M39029/76-427
M39029/76-16D
428
M39029/77-428
M39029/77-16A
429
M39029/77-429
M39029/77-16B
430
M39029/77-430
M39029/77-16C
431
M39029/77-431
M39029/77-16D
432
M39029/78-432
M39029/78-16A
433
M39029/78-433
M39029/78-16B
434
M39029/78-434
M39029/78-16C
435
M39029/78-435
M39029/78-16D
436
M39029/79-436
M39029/79-16A
437
M39029/79-437
M39029/79-16B
438
M39029/80-438
M39029/80-16A
439
M39029/80-439
M39029/80-16B
440
M39029/34-440
M39029/34-22-22
441
M39029/35-441
M39029/35-22-22
448
M39029/31-448
M39029/31-20-20
449
M39029/32-449
M39029/32-20-20
450
M39029/83-450
M39029/83-20-22
451
M39029/83-451
M39029/83-20-28
452
M39029/84-452
M39029/84-20-22
453
M39029/84-453
M39029/84-20-28
454
M39029/85-454
M39029/85-16-16-C1
455
M39029/85-455
M39029/85-16-16-C2
456
M39029/85-456
M39029/85-16-16-C3
457
M39029/85-457
M39029/85-16-16-C4
458
M39029/85-458
M39029/85-12-12-C1
459
M39029/85-459
M39029/85-12-12-C2
460
M39029/85-460
M39029/85-12-12-C3
461
M39029/85-461
M39029/85-12-12-C4
462
M39029/86-462
M39029/86-16-16-C1
463
M39029/86-463
M39029/86-16-16-C2
464
M39029/86-464
M39029/86-16-16-C3
465
M39029/86-465
M39029/86-16-16-C4
466
M39029/86-466
M39029/86-12-12-C1
467
M39029/86-467
M39029/86-12-12-C2
468
M39029/86-468
M39029/86-12-12-C3
469
M39029/86-469
M39029/86-12-12-C4
470
M39029/87-470
M39029/87-22-22-C1
471
M39029/87-471
M39029/87-22-22-C2
472
M39029/87-472
M39029/87-22-22-C3
21

Sect 2 Chap 10

Bin Code
22
Current
Part Number
Superseded
Part Number
Pin or
Socket
473
M39029/87-473
M39029/87-22-22-C4
474
M39029/87-474
M39029/87-20-20-C1
475
M39029/87-475
M39029/87-20-20-C2
476
M39029/87-476
M39029/87-20-20-C3
477
M39029/87-477
M39029/87-20-20-C4
478
M39029/87-478
M39029/87-16-16-C1
479
M39029/87-479
M39029/87-16-16-C2
480
M39029/87-480
M39029/87-16-16-C3
481
M39029/87-481
M39029/87-16-16-C4
482
M39029/88-482
M39029/88-22-22-C1
483
M39029/88-483
M39029/88-22-22-C2
484
M39029/88-484
M39029/88-22-22-C3
485
M39029/88-485
M39029/88-22-22-C4
486
M39029/88-486
M39029/88-20-20-C1
487
M39029/88-487
M39029/88-20-20-C2
488
M39029/88-488
M39029/88-20-20-C3
489
M39029/88-489
M39029/88-20-20-C4
490
M39029/88-490
M39029/88-16-16-C1
491
M39029/88-491
M39029/88-16-16-C2
492
M39029/88-492
M39029/88-16-16-C3
493
M39029/88-493
M39029/88-16-16-C4
494
M39029/89-494
M39029/89-22-22-C1
495
M39029/89-495
M39029/89-22-22-C2
496
M39029/89-496
M39029/89-22-22-C3
497
M39029/89-497
M39029/89-22-22-C4
498
M39029/89-498
M39029/89-20-20-C1
499
M39029/89-499
M39029/89-20-20-C2
500
M39029/89-500
M39029/89-20-20-C3
501
M39029/89-501
M39029/89-20-20-C4
502
M39029/89-502
M39029/89-16-16-C1
503
M39029/89-503
M39029/89-16-16-C2
504
M39029/89-504
M39029/89-16-16-C3
505
M39029/89-505
M39029/89-16-16-C4
506
M39029/89-506
------
507
M39029/89-507
M39029//-20-22D
508
M39029/83-508
------
509
M39029/84-509
------
528
M39029/58-528
------
529
M39029/90-529
------

Sect 2 Chap 10
Table 106 Specification Replacements

MIL-DTL-83723, Series I are replaced by MIL-C-26482 as shown below
MIL-DTL-83723 Specification Sheet
Superseded By
1 and 2
3 and 4
5 and 6
7 and 8
9 and 10
11 and 12
13 and 14
33
34
36, 37, 38, 39, 40 and 41
42 and 43
44
45
46
48 and 49
MS3470
MS3472
MS3474
MS3471
MS3440
MS3443
MS3476
MIL-C-39029/4
MIL-C-39029/4
No superseding document
MS3475
MS3181
MS3115
MS3180
MIL-DTL-83723, Series II are replaced by MIL-DTL-5015 as shown below

MIL-DTL-83723 Specification Sheet
Superseded By
17 and 18
19 and 20
21 and 22
23 and 24
25
26
27
29
30
35
50
52 and 53
MS3451
MS3450
MS3452
MS3456
MS3141
MS3143
MS3109 or MS3117 and MS3158 or MS3416
MIL-C-29029/29
MIL-C-29029/30
MS3459
Table 107 Crimping Tool Inspection Gauges and Selector Settings

Crimping Tool Part Number
Inspection Gauge Part Number
Selector Setting
M22520/1-01
M22520/3-1
M22520/2-01
M22520/3-1
M22520/4-01
M22520/3-2
Not applicable
M22520/7-01
M22520/3-3
23

Sect 2 Chap 10
Inspection of M22520/1-01, M22520/2-01, M22520/401, M22520/7-01 Basic Tools

38.
Inspection gauging is performed on the basic
tool only. However, the tools may be gauged with a
positioning device installed as long as it does not
interfere with the gauging operation. If the presence of
the positioning device makes gauging difficult, remove it
before inspecting. The inspection procedure is as
follows:
a.
Select the proper inspection gauge to be used

from Table 107.
b.
Set the selector at the proper selector number as

specified in Table 107.
or for which no positioning heads are available.

They are adjusted for each application while
attached to the tool as described below, but have
no data plate with crimping information.
M22520/2-01and M22520/7-01 Basic Tools
41.
These tools use locating devices known as
positioners. They are individual locators with a data plate
attached to the top that specifies the contact part
numbers(s) accommodated, and correlates the wire
sizes.
M22520/4-01 Basic Tool
c.
Close the handles completely and hold.
42.
This is a single purpose tool that only uses the
M22520/4-02 single positioner head that is not operator
adjustable.
d.
The GO gauge (green end) should pass freely

through the indenter tips.
CRIMPING PROCEDURES
e.
The NO GO gauge (red end) should not enter

through the indenter tips.
M22520/1-01 Crimping Tools with Turret Heads and

Single Position Heads
TYPES OF CONTACT POSITIONING DEVICES

39.
All crimping tools have positioning devices
available that are used for locating contacts in the proper
relation to the tool indenters. The following is a brief
description of the types of positioners used for the
various types of tools:
43.
The procedure for crimping contacts to wire
conductors is as follows:
a.
Select the proper positioning head to be used for

the contacts being crimped.
b.
If the head to be used is a turret head, first

depress the turret trigger to release the turret
portion to the indexing or extended position as
shown in Figure 1023.
c.
Place the head over the retaining ring on the back

of too1 (selector side) and seat against the tool
body; secure the 3.5mm socket head screws with
Allen wrench (see Figure 1023). If the positioning
head is the single positioner type, omit steps d.
and e.
d.
If the positioning head is the turret type, it has

three separate positioners that are colour coded
and marked with the applicable contact size
accommodated by each individual positioner. The
colour code and contact size correspond to the
information contained on the data plate. Refer to
the data plate to select the proper positioner to be
used for the contact being crimped.
e.
Rotate the turret until the correct positioner is

lined up with the index mark on the turret head
and push the turret in until it snaps into the locked
position (see Figure 1023).
M22520/1-01 Basic Tools

40.
These tools use turret heads, single positioner
heads and universal heads.
a.
b.
c.
24
Turret Heads. These heads have a turret that has

three separate positioners that are colour coded
and marked with the applicable contact size
accommodated by each individual positioner
within the head. The colour and contact size
correspond to the information on the foil label
(data plate) attached to the side of the head. The
proper positioner is selected for the contact type
and size to be crimped by referring to the data
plate.
Single Position Heads. These heads have only
one positioner and are not adjustable. They also
have data plates which provide crimping
information.
Universal Heads. These heads are used for
locating contacts which are not military standard

Sect 2 Chap 10
Figure 1023 Typical M22520 Positioner and Turret Head

f.
g.
h.
Refer again to the data plate for the correct

selector setting for the wire size being used. With
the handles fully open, remove spring clip lock
wire from selector knob, lift and rotate the selector
knob (or slide the thumb button) to the correct
setting and release and reinstall spring clip lock
wire.
Determine the proper length of insulation to be
removed. Wire must be visible in inspection hole,
insulation must be between 0.4mm and 0.8mm
from end of contact. Strip the insulation from the
conductor by using any of the methods described
in Section 2, Chapter 3.
Insert the stripped wire into the wire barrel of the
contact until the end of the wire can be seen
through the inspection hole. Insert the wire and
contact through the indenters on the front side of
tool (opposite from selector side) until it bottoms

and fully seats in the positioner.
NOTE
When crimping contacts with an insulation support
cup, make sure the insulation extends into it (0.4 to
0.8 mm from bottom of cup).)
i.
Hold the wire and contact in place and squeeze

the tool handles until they fully bottom and the
ratchet releases, allowing the handles to
automatically return the open position.
j.
Remove the crimped contact and inspect, making

sure the wire strands are visible through the
inspection hole in the contact wire barrel (see
Figure 1025).
25

Sect 2 Chap 10
Type 1 crimp tools are those which produce an indent crimp.
Type 1 Crimping Tool (Indent Crimp)
Type 2 crimp tools are used to produce a formed crimp.
Type 2 Crimping Tool (Formed Crimp)
Figure 1024 M22520 Crimping Tools
26

Sect 2 Chap 10
M22520/1-01 Crimping Tools with Universal Heads

45.
The universal head may be used when a turret
or single position head is not available. The procedure is
as follows:
a.
b.
Rotate the lock nut counter clockwise to the

released position and turn adjustment nut counterclockwise until head can be seated on tool.
Place the head over the retaining ring on the back
of the tool (selector side) and seat against the tool
body; secure the 3.5mm socket head screws with
an Allen wrench. With the tool handles fully open,
remove spring clip lock wire from selector knob,
raise and rotate the selector knob (or slide the
thumb button) until the arrow is in line with the
wire size being crimped, release selector knob
and reinstall spring clip lock wire.
CAUTION
The wire sizes are for reference only. They are based
on the use of MIL-W-22759 silver plated wire crimped
in MS3190 wire barrels. Settings must be established
when using other contact/wire combinations.
c.
Figure 1025 Assembling Wires to Crimp Type

Contacts
d.
e.
Turn adjustment screw on head clockwise until it

stops. With the tool opening facing up, insert
contact through indenter opening into positioner
until it bottoms. Begin turning adjustment screw
out until indenters are cantered between
inspection hole and end of wire barrel. If contact
has insulation support cup, centre the indenters
between inspection hole and bottom of cup.
Without turning the adjustment screw, tighten lock
nut against head.
Strip wire, insert wire and contact, crimp and
inspect.
M22520/2-01 and M22520/7-01 Crimping Tools with

Positioners
46.
The procedure for the crimping contacts with
these tools is as follows:
a.
b.
Figure 10-26
44.
Type 2 crimp tools, are used to produce a
formed crimp. The tool can be fitted with a number of
different die sets used to compress the barrel of a crimp
into a variety of shapes. Figure 10-27 shows a cross
sectional view of various formed crimps.
c.
d.
Select the proper positioner to be used for the

contact being crimped.
Insert the positioner into the retaining ring on the
back of the tool (selector side). The positioner is
spring-loaded and must be pushed in and then
rotated 90 clock-wise until it locks into position.
Insert the spring clip lock wire (if present) through
the retaining ring.
Refer to the data plate for the correct selector
setting for the wire size being used. With the
handles fully open, remove spring clip lock wire
from selector knob, lift and rotate the selector
knob to the correct setting and release and
reinstall spring clip lock wire.
Strip wire. Insert wire and contact, crimp and
inspect.
CRIMPING TOOL KITS

47.
There are several crimping tool kits available for
maintenance use.
Figure 10-27 Cross Sectional Views Of Type 2 Crimps
27

Sect 2 Chap 10
INSTALLING AND REMOVING CRIMP TYPE

CONTACTS
Insertion Tools for Front Release Crimp Type
Contacts
48.
Type tools for inserting contacts into front
release connector inserts are shown in Figure 1028.
There is a separate tool for each contact size. Contact
sizes are listed in Table 108. An indicating band on the
working end of the tool determines the correct depth of
tool insertion. Use these tools to insert contacts in front
release connectors with removable contacts.
Table 108 Contacts and Their Wire Size Range
Contact
Size
Wire Size
Range
20
24-20
16
22-16
12
14-12
10-8
6-4
2-0
NOTE
After all contacts and sealing plugs have been
inserted into MIL-C-81511 series 1 and 2 connectors,
tighten the rear nut by turning clockwise until the
locking nut is tight.
CAUTION
Do not attempt to reseat a contact once the insertion
tool has been removed. Remove contact and start
again with contact barrel properly located in tool.
Failure to follow this precaution will cause insertion
tool to shear barrel while inside grommet. Sharp edge
of sheared material will cut through grommet web and
cause short circuit.
Alternative Front Release Contact Assembly
Procedure
50.
If desired, the following procedure may be used
to insert wired contacts into the connector:
a.
b.
Assembling Wired Contacts into Front Release

Connector
c.
49.
Insert the crimped contact into the connector as
follows:
a.
Slide rear accessories back onto wire bundle.

NOTE
Before attempting any insertion of contacts into MILC-81511 series 1 or 2 connectors, determine that the
rear nut assembly is in the unlocked position. A
coloured stripe will appear when the rear nut
assembly is rotated counter clockwise. At this point,
the connector is in position for both insertion and
removal of contacts.
b.
c.
d.
e.
f.
g.
28
Select the correct insertion tool. Insert the crimped

end of the contact into the hollow end of the
insertion tool, and lay along handle (see Figure
1028).
Guide the contact into the correctly numbered
grommet hole in the rear face of the insert and
feed the contact carefully into the hole.
Push the tool straight in at right angles to the
grommet surface, until the contact is fully seated.
Withdraw the tool, keeping it perpendicular to the
grommet face.
Gently pull on wire to make sure contact is held in
place.
Fill all unused holes with unwired contacts and
sealing plugs of appropriate size.
Push the wired contact carefully into the correct

grommet hole. Do not push all the way in.
Slide the insertion tool over the contact barrel.
(See Figure 1021).
Complete the procedure by following steps d, e, f
and g of paragraph 45. Observe caution and note
in paragraph 45.
Extraction Tools for Front Release Crimp Type

Contacts
51.
Typical tools for extracting contacts from frontrelease connector inserts are shown in Figure 1028.
The sizes for each contact are listed in Table 108. This
tool has a hollow cylindrical probe which fits snugly over
the pin or socket end of the contact and releases the
insert retention clip when pushed over the contact. Two
indicating bands determine correct depth; the band
nearest the working end of the tool is for pin contacts,
the other for socket contacts. The extraction tool has a
thrust assist collar (or slide) which is pushed forward to
eject the contact from the insert retention clip by means
of an internal plunger. Use these tools to remove
contacts from front release connectors with removable
contacts.
Removing Contacts from Front Release Connectors
52.
Remove contacts from the connector as follows:
a.
Select the correct extraction tool for the contact to

be removed.
b.
Slide rear accessories back on the wire bundle.

NOTE
On MIL-C-81511 series 1 and 2 connectors, loosen

the rear nut assembly by turning it counter clockwise
when viewed from the wire end. Approximately
1.5mm of axial movement unlocks the contacts. The
coloured stripe will fully appear. The connector is now
in position for removal of contacts.

Sect 2 Chap 10

53.
The removal of a contact from a plug when the wire is broken is as follows:
a.
Using the insertion removal tool, insert the white tip 3.0 mm into rear of connector as shown in
Figure 10-28.
Figure 10-28 Broken Wire Contact Removal

b.
If resistance is felt, withdraw tool slightly and rotate tool 1/6 of a turn and reinsert. Repeat this
step until tool passes the resistance area. Continue until a positive stop is felt.
c.
Exert pressure on the mating end of the contact (from the front of the connector as shown in Figure 1029 with pin or socket.
d.
Use pressure on the mating end of the contact to push the broken contact out of the connector before
disengaging the tool from the connector.
Figure 10-29 Broken Wire Contact Removal
29

Sect 2 Chap 10
Figure 1030 Insertion and Extraction Tools for Front Release Crimp Type Contacts
30

Sect 2 Chap 10
Figure 1031 Assembling Wired Contacts Into Connector
31

Sect 2 Chap 10
Figure 1032 Removing Crimp Type Contacts From Front Release Connectors
32

Sect 2 Chap 10
e.
Series 1 and 2 (gauge release) contacts are

removed from the front of the connector as
follows:
(1) The pin contact removal tool has a hole to

accept the pin contact. The socket removal
tool has a pin tip to insert in the socket.
(2) Grasp the tool by the handle. Locate the

contact to be removed by numbers on the
insert face. (See Figure 1032)
(3) Mate the tool with the contact and, holding the
tool at right angles with the insert face, push
axially against the tip of the contact until the
contact appears at the grommet (rear) end of
the connector. The removal tools are
designed to bottom against the insert face
when the contact is completely released and
pushed out.
(4) The wire and contact can now be removed

from the connector.
f.
Working from the front or mating end of the

connector, slip the hollow end of the extraction
tool over the contact, with the tool parallel to the
contact, and squarely perpendicular to the insert
face. (See Figure 1032)
Insertion and Extraction Tools for Rear-Release

Crimp Type Contacts
54.
There is a separate tool for each contact size,
The tools may be plastic or metal, single or double
ended tools (see Figure 1033) or metal tweezer type
tools (see Figure 1034). See Figure 1035 and Figure
1036 for contact installation instructions. See Figure
1037 and Figure 1038 for contact removal
instructions.
NOTE
Connector rear accessory (cable clamp, etc) must be
removed prior to installation or removal of contacts.
NOTE
Insertion/extraction tools are colour coded according
to contact size; the insertion tool being coloured and
the extraction tool white. For unwired contacts, an
additional tool may have to be used in conjunction
with the extraction tool to push the unwired contact
from the front after the locking tines have been
released by the extraction tool in the rear.
NOTE
Some extraction tools have a spacer sleeve with
positions for either pin or socket contacts. Set to
correct position before installing tool on contact.
g.
Push the tool toward the rear of the connector

with a firm steady push until the tool comes to a
positive stop and bottoms in the insert hole. A
slight rotation of the tool may aid the tool insertion.
h.
Push the thrust assist collar or slide forward as far

as it will go.
i.
Withdraw the tool from the contact, keeping the

tool perpendicular to the insert face.
j.
Remove the contact from the back of the

connector.
Figure 1033 Insertion and Extraction Tool For Rear

Release Crimp Contacts
CAUTION
Ensure the extraction tool is always exactly aligned
with the contact to avoid damage to the contact or
insert.
33

Sect 2 Chap 10
Figure 1034 Tweezers Type Installing Tools
Figure 1035 Single or Double Ended Contact Installing Tools
34

Sect 2 Chap 10
Figure 1036 Single or Double Ended Contact Removal Tools
Figure 1037 Tweezer Type Removal Tools
35

Sect 2 Chap 10
SHIELD CONNECTIONS
Connecting Single Shielded Wire to Connector
terminate shields outside the connector. The procedure

is as follows:
a.
Form pigtail from shield outside connector area

(see Figure 1039).
55.
Terminate shielded wire as described in Section
2, Chapter 3. For connection to non-environmental
resistant connectors, shield must end inside back shell
as shown in Figure 1038. For connection to
environmental resistant connectors with rear wire seal or
potted connectors, shield must end outside seal. Splice
pigtail to short length of wire that is then terminated
inside connector to a contact in the regular manner, as
b.
Solder or crimp each wire to its contact.
NOTE
c.
Crimp pigtails together into one end of permanent

splice (see Figure 1039).
d.
Crimp single wire, doubled if necessary; into other

end of permanent splice (see Figure 1040).
e.
Slide sleeve over splice and tie or heat shrink as

appropriate.
f.
Solder or crimp single wire to proper contact in

connector as shown in Figure 1039.
g.
Complete connector assembly in normal manner.
Connector accessories (backshells) should not be

used to terminate ground wires or shields unless they
were specifically designed for that purpose.
(1) For potted connector, pigtail should start 1

inch (25mm) from end of wire.
(2) For other connectors, pigtail should start far

enough back to remain outside cable clamp.
NOTE
Shield connections currently installed under cable
clamp screws should not be disturbed unless
maintenance is being performed on the connector,
and then shield connections must be installed in
accordance with current requirements.
Figure 1038 Terminating Shielded Wire at MS

Connector
Multiple Shield Connections

56.
Potted connectors that contain shielded wires
and all other connectors that have many shields should
36
Figure 1039 Terminating Shielded Wires at Potted

Connector

Sect 2 Chap 10
Grounding Shields with Bonding Ring

58.
When specified on the applicable engineering
drawing, an AN3111 bonding ring may be used to
ground shields on certain solder type MIL-DTL-5015
connectors.
Figure 1040 Terminating Two Wires at One Contact

on Non-environmental Resistant Connector
a.
Remove washers from the connector cable clamp

and slide clamp back on wire bundle.
b.
Install the AN3111 bonding ring on the wire

bundle between the connector back shell and the
cable clamp, with the bonding ring lug toward the
solder contacts.
c.
Make a hole in one shield and expand it to hold up

to three other shields as shown in Figure 1042.
Tighten the expanded shield around the others
and seat solder together. Repeat as necessary for
number of shields to be grounded.
d.
Pull one of the shields through to form a jumper.

Install a length of insulating sleeving over the
jumper shield.
e.
Clamp the ears of the bonding ring lug around the

jumper(s) and solder. Pull the insulating sleeve
over the soldered connection.
Multiple Connections
CAUTION
Do not connect two wires to one contact in
environmental type connectors; this will cause loss of
environmental sealing.
57.
Connect two wires to one contact by using one
of the following methods:
a.
If both wires can be fitted into contact solder cup,

proceed as with single wire. Slide insulating
sleeve over both wires together and insert them
into solder cup. Make sure all strands are inside
cup before soldering. When solder has cooled,
push insulating sleeve down until it butts against
insert. (See Figure 1040).
b.
If both wires cannot fit into solder cup, use

permanent splice to join both wires to a third wire
that can fit into solder cup or crimp barrel. See
Section 2, Chapter 6 for splicing procedure and
Figure 1041 and Figure 1043 for illustration of
this connection.
Figure 1041 Reducing Wire Size at Connector Using

Permanent Environmental Splice
37

Sect 2 Chap 10
Figure 1042 Installing AN3111 Bonding Ring
Reducing Wire Size at MS Connector
CAUTION
Reduction of wire size needs approval by an
engineering design approval. Current carrying
capacity of smaller wire and contact must not be
exceeded.
59.
Reduction of wire size to enable a larger
diameter wire to be soldered or crimped to a smaller
diameter contact is sometimes required. A safe method
of making the reduction is as follows:
a.
Select a permanent splice or sealed splice that

will accommodate the larger wire. Crimp this
splice to the stripped wire as described in Section
2, Chapter 6.
b.
Select a 15cm length of wire that will fit the wire

barrel of the contact. Strip one end sufficiently
long to be able to double the stripped portion back
on itself as shown in Figure 1043.
Assembly and Disassembly Instructions for

Connectors and Wire Terminations not Covered by
Military Specifications or Standards
60.
Assembly instructions and tool calibration
procedures recommended by the connector and/or tool
manufacturer(s) should be followed in assembling
electrical connectors and wire terminations not covered
by military specifications or standards.
38
Figure 1043 Terminating Two Wires to One Contact

Using Permanent Environmental Splice
CONTINUITY TEST
61.
Test all wires and wire groups as fabricated,
with terminations attached, for short circuits as well as
for continuity between the termination points specified
on the applicable schematic. Continuity test on
unshielded wires and wires less than 15 meters can be
accomplished by using a light or buzzer connected to a
nine volt battery.

Sect 2 Chap 10
Table 109 Test Leads
CAUTION
Do not use lead pencils to count pins in connectors.
points can break off and lodge in the connector,
leading to arcing, shorting, and system malfunction.
Do not use oversize prods in connector sockets
during testing; this may result in splayed or damaged
sockets. Do not puncture wire insulation with a probe,
or attach clamps to wire insulation while continuity
testing or trouble shooting.
62.
Use the ohmmeter section of an approved
multimeter to determine circuit continuity. Continuity for
short runs, where conductor resistance is not a factor, is
defined as zero resistance. The procedure for
determining continuity, using a multimeter is as follows:
a.
b.
c.
Set the function control to OHMS, and the range

control to Rx1. Zero the instrument as directed in
the operating manual for the instrument used.
Attach the test leads to the terminations of the
wire run.
Note reading on the ohms scale. A reading of 0.25
ohms, +0.25 ohms, is considered verification of
circuit continuity.
Item Name
Part No
Test Leads (Black)
Model B-36-0
Test Leads (Red)
Model B-36-2
22 Gauge Sockets (Black)
4690-0
22 Gauge Sockets (Red)
4690-2
22 Gauge Pins (Black)
4691-0
22 Gauge Pins (Red)
4691-2
3560-0
3560-2
3561-0
20 Gauge Pins (Red)
3561-2
3562-0
3562-2
3563-0
18 Gauge Pins (Red)
3563-2
3564-0
3564-2
3565-0
16 Gauge Pins (Red)
3565-2
NOTE
The test lead extremities contacting the terminations
under test must provide adequate constant contact,
and must not damage the termination.
TEST LEADS
63.
For ground points and terminal lugs, use test
leads with alligator clips. For connector pins and
sockets, use a special lead ending in a sleeve-insulated
pin or socket of the same size as that being tested.
PROTECTION OF ELECTRICAL CONNECTORS

64.
Protect all unmated connector plugs and/or
receptacles with protective covers. (See Figure 1044)
Standard protective covers for connectors are listed in
the applicable connector specification. Protective covers
are available with or without an attaching chain. Plastic
dust caps to fit MS plugs and receptacles are also
available. Electrostatic free dust caps for electrical
connectors are listed in Table 1010.
WARNING
Ensure both the plug and receptacle are covered
while not in use. foreign objects can present a hazard
that may damage equipment and harm personnel.
39

Sect 2 Chap 10
CAUTION
Protect ESD susceptible items. Failure to adequately
protect ESD could cause damage to equipment.
65.
All unmated connector plugs and/or receptacles
should be protected. All loose wires/cables should be
secured as detailed in Section 2, Chapter 4.
66.
Unmated connectors can be wrapped with MILI-46852, silicone rubber tapes. Both materials can be
secured with waxed or nylon cord. These are alternative
methods used to protect unmated connectors exposed
to contaminants during repairs or storage when standard
protective covers and plastic caps are not available.
Silicone rubber tapes should not be used where they will
be exposed to fluids, such as jet fuels, hydraulic fluids,
engine oils, silicone damping fluid (DC-200), etc. These
fluids may cause silicone tapes to swell and/or lose
adhesive properties.
Figure 1044 Typical Protective Connector Caps
Table 1010 Electrostatic Free Dust Caps

Dust Cap Internal Diameter
(mm 0.25)
40
Part Number
15.5
MS90376-10RF
16.3
MS90376-12YF
18.3
MS90376-12RF
19.9
MS90376-14YF
21.6
MS90376-14RF
22.7
MS90376-16YF
24.7
MS90376-16RF
26.1
MS90376-18YF
27.8
MS90376-18RF
29.2
MS90376-20YF
31.3
MS90376-20RF
32.3
MS90376-22YF
34.0
MS90376-22RF
35.3
MS90376-24YF
37.2
MS90376-24RF
41.9
MS90376-28YF
43.6
MS90376-28RF
48.0
MS90376-32YF
49.9
MS90376-32RF
Nomenclature
Cap Protective Antistatic

Sect 2 Chap 10
Figure 1045 Spare Wires for Potting Connector
c.
CAUTION
Do not use pressure sensitive tape on connectors as
The residue left after the tape is removed will cause
contaminants to stick to the connectors.
(1) Select an end cap of the correct size for the
POTTING CONNECTORS
wire to be insulated
67.
These connectors are used only where potting is
required. They are similar to other standard types,
except that they have a shorter body shell and include a
potting mould. Potting connectors are supplied with a
plastic potting mould. Installation is as follows:
a.
(2) Make sure the locator is properly positioned

behind the lower nest. Position the wire end
cap in the correct die nest with the closed end
of the cap resting against the locator.
(3) Insert the stripped wire so that the end of the
Slide the plastic mould over the wire bundle.
stripped wire is seated against the closed end

of the cap, and the insulation is against the
metal sleeve of the cap.
CAUTION
Polytetrafluoroethylene
(TFE)
and
fluorinated
polyethylene propylene (FEP) insulated wires require
special preparation prior to potting (see section 2,
chapter 11).
b.
Identify and install wires into contacts.
Insulate the ends of all spare wires. (See Figure

1045). The preferred method of insulating a
spare wire is to crimp it into an MS25274 wire end
cap (Table 1011) with tool as detailed in Section
2, Chapter 6. The procedure for crimping wire end
caps with standard tool is as follows:
(4) Close tool handles until ratchet releases and

the tool opens.
assembly.
Remove
the
crimped
WARNING
Skin, eye, and respiratory protection is required. Do
not breathe fumes, maintain good ventilation.
NOTE
Spare wires should be installed in all unused
contacts. Use the largest gauge wire suitable for each
contact. Spare wires should be approximately 23cm
long. (See Figure 1047.)
d.
Clean the complete connector assembly by

scraping off rosin and then brush vigorously with
suitable cleaning solvent, such as Isopropyl
Alcohol.
41

Sect 2 Chap 10
e.
Rinse area to be potted with suitable cleaning

solvent, such as Isopropyl Alcohol.
NOTE
Complete potting within two hours after cleaning.

f.
Slide plastic mould into position on rear of

connector.
WARNING
The accelerator contains toxic compounds. Use in a
well ventilated area. Avoid eye and skin contact. Use
personal
protective
equipment,
rubber
or
polyethylene gloves and approved eye protection.
Clean hands thoroughly after use.
CAUTION
Mate connectors before potting either part to avoid
splaying contacts during the potting operations.
g.
Apply potting compound prepared in accordance

with directions in Section 2, Chapter 11. Fill back
of connectors by inserting nozzle down between
wires until it almost touches back of insert (see
Figure 1046). Fill slowly while moving nozzle
back from insert and ensure no air bubbles are
trapped. Fill to top of mould. Tamp down the
compound, if necessary, with a wooden or metal
3mm dowel. Tap connector assembly on a
resilient surface or vibrate mechanically to help
flow the compound into all spaces and to release
trapped air.
h.
Immediately after filling each connector, tie the

wires together loosely about 15cm away from the
connector. Ensure that wires are centrally located
in the connector so that each wire is completely
surrounded by potting compound. Suspend the
assembly so that the potting material remains
level, as shown in Figure 1046, and allow to air
cure for at least 1.5 hours at 24C without any
movement. Make sure that the tie is applied after
potting.
i.
Figure 1044 Filling and Curing Potting Connector
Carefully place assembly, still suspended, into

drying oven for 3 to 4 hours at 38C or air cure at
24C for 24 hours.
NOTE
Full cure with maximum electrical characteristics is

not achieved until 24 hours after potting. Do not
perform any electrical insulation resistance tests until
this period has passed.
j.
42
Apply a light film of lubricating oil to all exterior

metal surfaces after potting compound is
completely cured.
Figure 1045 Installation of O-Ring on AN Type Potted

Connector Plug

Sect 2 Chap 10
Table 1011 Wire End Caps

Wire
Gauge
Wire Strip
Length (mm)
Cap
Colour
Cap Part
Number
Crimp Tool
Positioner
26-24
7.6
Yellow
MS25274-1
M22520/5-01
M22520/10-01
M22520/5-100
M22520/10-101
22-18
7.6
Red
MS25274-2
M22520/5-01
M22520/10-01
M22520/5-100
M22520/10-101
16-14
7.6
Blue
MS25274-3
M22520/5-01
M22520/10-01
M22520/5-100
M22520/10-101
12-10
8.9
Yellow
MS25274-4
M22520/5-01
M22520/10-01
M22520/5-100
M22520/10-101
Table 1012 O-Ring Sizes For AN Type Connectors

Plug Size
O-Ring Size
(mm)
O-Ring ID
(mm)
MS29513 Dash
Nos.
8S
1.8
7.9
-10
10 & 10S
1.8
9.2
-12
12 & 12S
1.8
12.4
-14
14 & 14S
1.8
12.4
-14
16 & 16S
1.8
15.6
-16
18
1.8
18.8
-18
20
1.8
21.9
-20
22
1.8
25.1
-22
24
1.8
28.3
-24
28
1.8
34.6
-28
32
1.8
34.6
-28
36
2.6
44.1
-132
40
2.6
50.5
-136
44
2.6
56.8
-140
48
2.6
63.2
-144
43

Sect 2 Chap 10
CONNECTOR ACCESSORIES
68.
Circular electrical connectors should be
provided with accessories. Connector accessories for all
new design and retrofit wiring systems should be in
accordance with SAE AS50881 and this publication.
Installation of Cable Clamp
69.
The cable clamp, is installed as follows (see
Figures 1050, and 1051):
a.
b.
CAUTION
Ensure bushings are not pinched between saddles
and centre bar. Ensure that there is no flexing of the
cable within the tightened saddle bars. Flexing will
cause damage to the connector wiring. Cable
assemblies with connector clamps should not be
disturbed regardless of backshell screw positions
unless authorised repair work is warranted.
Slide cable clamp without saddles on wire bundle

before wires are connected.
NOTE
Slide bushing (if needed) on wire bundle before

wires are connected.
Ensure that the saddle clamp screw heads are placed

so that pushing on screw heads will tighten cable
clamp to backshell. (Some saddle bars have both
screw heads on same side).
NOTE
A wrap of teflon, silicone rubber or glass fibre tape
can be used instead of a bushing. Only teflon tapes,
silicone rubber tapes and glass fibre tapes should be
used to build-up under saddle clamps. MIL-I-23594
teflon, tape, teflon tape part number P440-4IN, A-A59163, Type 1, silicone rubber tapes and MIL-I-19166
glass fibre tapes work satisfactorily as build-up tapes
under saddle clamps. Silicone rubber tapes should
not be used where they will be exposed to fluids,
such as jet fuels, hydraulic fluids, engine oils, silicone
damping fluid (DC-200), etc. These fluids may cause
silicone rubber tapes to swell and/or lose adhesive
properties. Neoprene rubber tapes and vinyl tapes
should be not be used for build-up under the saddle
clamp because of their shrinkage and out-gassing
properties. If tape wrap is used, secure with nylon
braid behind saddle. A bushing or tape build-up is
required where the wire bundle diameter is too small
to be effectively gripped by the saddle bar.
c.
Assemble wires to connector.
d.
Install bushing into cable clamp and attach clamp

to connector. Padded jaw connector pliers may be
used to tighten or loosen a cable clamp or other
backshell accessory if necessary.
f.
Installation of MS3057 Series Connector Cable

Clamps
70.
There are three types of MS3057 connector
cable clamps. (See Figure 1049 and Table 10-14).
a.
MS3057 has a single saddle held by two screws.

It contains a metal or plastic washer and a flat
rubber bushing. For shipping, to prevent loss of
the metal or plastic washer, it is placed inside the
clamp and held in place by the rubber bushing.
Before use, reverse the position to that shown in
Figure 1049 so that the metal or plastic washer
will contact the back shell of the connector.
b.
MS3057A has two saddles separated by a

centring bar. This cable clamp is supplied with
MS3420 bushing to protect the wire bundle under
the clamp. Add extra bushings if necessary.
c.
MS3057B has a gland and tapered sleeve. The

gland is squeezed around the wire bundle when
the cable clamp is screwed to the connector back
shell.
d.
Before installing MS3057 cable clamps onto

connectors, screw the mating part onto the
connector with the coupling nut. This will help to
prevent contacts splaying when the cable clamp is
tightened.
CAUTION
Care should be taken not to bend the coupling ring or
backshell when a strap wrench or padded jaw pliers
are used.
e.
44
Attach saddle bars with supplied screws and

lockwashers.
Attach saddles with both screws and lockwashers

and tighten until cable is secured within the saddle
clamp. There should be no flexing of the cable
within the saddle clamp. Use extra bushings in
original assembly if saddle is not tight.

Sect 2 Chap 10
Installation of MS3057 Cable Clamp

71.
The MS3057 cable clamp is installed as follows
(see Figure 1050):
a.
Slide the MS3420A telescoping bushings on the

wire bundle if the bundle diameter is too small to
be effectively gripped by the saddle.
b.
Slide the MS3057 cable clamp without saddle on

the wire bundle followed by the rubber bushing
and the metal or plastic washer.
c.
Assemble wires to the connector and tighten the

backshell.
d.
Push the MS3057 cable clamp toward the

backshell and hand tighten. Use a strap wrench to
tighten fully.
e.
Push the MS3420A bushings, if required, into the

cable clamp until it is past the saddle.
f.
Attach saddle with both screws and tighten until

1.6mm space is left between the saddle and the
body as shown in Figure 1050. MS3420A
bushing, if used, should bulge slightly when the
saddle is tight.
NOTE

so that pushing on the screw heads will tighten the
cable clamp to backshell. (Some saddle bars have
both screw heads on same side).
c.
Assemble wires to connector and tighten back

shell.
d.
Push MS3057A cable clamp together with

inserted MS3420 bushing toward back shell and
hand tighten. Use plug pliers or a strap wrench to
tighten fully.
e.
Attach both saddles with supplied screws and

lockwashers.
NOTE

so that pushing on screw heads will tighten cable
clamp to backshell. (Some saddle bars have both
screw heads on same side).
CAUTION
cable within the tightened saddle bars, Flexing will
cause damage to the connector wiring.
f.
Tighten saddles until firm against cable, making

sure that the cable is not pinched within the
clamping assembly. If saddles do not prevent
cable from flexing inside the connector, use extra
MS 3420 telescoping bushings in the connector
assembly. See Table 1013 for telescoping
bushing dimensions. The saddle clamps may be
tight against the centring bar as long as the cable
is not pinched within the assembly.
CAUTION
cable within the tightened saddle bars. Flexing will
cause damage to the connector wiring.
Installation of MS3057A Cable Clamp
72.
The MS3057A cable clamp is installed as
a.
Slide MS3057A cable clamp, without saddles, on

to the wire bundle before wires are connected.
b.
Slide MS3420 telescoping bushing on wire bundle

before wires are connected.
45

Sect 2 Chap 10
Figure 1048 Cable Clamps
Figure 1049 MS3057 Connector Cable Clamp Types Exploded View
46

Sect 2 Chap 10
Figure 1050 Installation of MS3057 Cable Clamp
Table 1013 Telescoping Bushings
Bushing
Connector
Size
Bushing
Part No.
Inside Diameter
(mm)
Outside Diameter
(mm)
Length
(mm)
8S, 10S
MS3420-3A
3.3
5.3
73.0
10SL, 12S, 12
MS3420-4A
5.6
7.7
69.8
14, 14S
MS3420-6A
7.9
10.8
66.7
16, 16S
MS3420-8A
11.0
14.0
63.5
18
MS3420-10A
14.2
15.6
60.3
20, 22
MS3420-12A
15.9
18.8
57.1
24, 28
MS3420-16A
19.0
23.5
53.9
32
MS3420-20A
23.8
31.5
50.8
36
MS3420-24A
31.7
34.7
47.6
40
MS3420-28A
34.9
41.0
44.5
44
MS3420-32A
41.2
47.3
41.3
48
MS3420-40A
47.6
60.0
38.1
47

Sect 2 Chap 10
Table 1014 Selecting MS3057 Cable Clamp

Cable Clamp
MS Connector
Shell Size
MS3057-3
8S, 10S
MS3057-4
10SL, 12S, 12
MS3057-6
14, 14S
MS3057-8
16, 16S
MS3057-10
18
MS3057-12
20, 22
MS3057-16
24, 28
MS3057-20
32
MS3057-24
36
MS3057-28
40
MS3057-32
44
MS3057-40
48
MS connector shell sizes are the same for type MS3057 A

or B cable clamps
Figure 1051 Installation of MS3057A Cable Clamp
Figure 1052 Installation of MS3057B Cable Clamp
48

Sect 2 Chap 10
Installation of MS3057B Cable Clamp
Installation of MS3152 and MS3154 Cable Clamp
73.
The MS3057B cable clamp is installed as
74.
The MS3152 and MS3154 cable clamps are
installed as follows (see Figure 1048):
a.
Slide MS3420A telescoping bushings, if required,

on wire bundle before wires are connected. See
Table 1013 for telescoping dimensions.
b.
Slide MS3057B cable clamp assembly on wire

bundle before wires are connected.
a.
Slide cable clamp on wire bundle before wires are

connected.
b.
Assemble wires to connector and tighten back

shell.
c.
Wrap cable using teflon, silicone rubber, or glass

fibre tape at the point where wire will have contact
with saddle bar.
d.
Tie cable wrap at both ends with lacing cord or

self clinching cable straps.
CAUTION
Proper lubrication of gland and tapered sleeve is
important for this assembly. In handling parts, keep
them clean and free of dirt. Wash away dirt with clean
denatured ethyl alcohol and relubricate with
petrolatum (Federal Specification VV-P-236) as
shown in Figure 1052. Do not apply petrolatum to
inside of gland or to serrated face of gland.
e.
WARNING
Perform all solvent cleaning operations in a well
ventilated area. Avoid prolonged breathing of
vapours. Avoid eye and repeated skin contact. Keep
solvents away from sparks and flames.
wires
to
connector
NOTE
Plastic cable straps will not be used on coaxial cables
or bundles containing coaxial cables that do not have
hard dielectrics.
c.
Assemble
backshell.
and
tighten
d.
Push MS3420A bushings, if used, through gland

of MS3057B so that end of bushing is flush with
serrated face of gland.
e.
Slide entire assembly toward back shell and hand

tighten. Use strap wrench or padded jaw
connector pliers to fully tighten until MS3057B
bottoms onto backshell. While tightening, hold
wire bundle and telescoping sleeving until gland
seats on backshell.
Secure cable to saddle bar with lacing cord or self

clinching cable straps (see Figure 1048).
Removal of Cable Clamp

75.
The cable clamp is removed as follows:
a.
Remove screws from saddle bars and remove

saddle bars from clamp.
b.
Unscrew cable clamp from connector. The strap

wrench or padded jaw pliers listed previously may
be used if necessary.
Instructions for Assembly and Disassembly of Plug

Connector
76.
Instructions for assembly and disassembly of
Plug Connector to and from Receptacle Connector are
given in Section 2, Chapter 10.
Heat Shrinkable Strain Relief Boots for Connectors
NOTE
Shield braid (and jacket, if present) should end
outside of MS3057B cable clamp to retain moisture
resistant qualities of clamp. Ground braid in
accordance with standard procedures.
77.
Heat shrinkable strain relief boots are used at
the rear of connectors to support wiring and to prevent
twisting or pulling on crimped or soldered connections.
They are available for a variety of connectors.
NOTE
Protect all unmated connectors with protective
covers.
49

Sect 2 Chap 10
BOOT REPAIR PROCEDURES
c.
Rebonding Boot
78.
The following steps should be followed in
rebonding a boot to a connector or harness assembly:
a.
b.
Clean visible bonding surfaces with lint free cloth

dampened with Standard Oil Company 265
cleaning
solvent
(aliphatic
petroleum
hydrocarbon) or equivalent. Wipe immediately
with clean lint free cloth.
Prepare Raychem Corporation S-1009 adhesive
by thoroughly mixing equal amounts by weight of
components A and B.
NOTE
Pot life of mixed epoxy is 1 hour at 21C 6C.

c.
d.
Apply a thin continuous coat of mixed adhesive on

bonding surfaces. Reassemble boot to connector
and/or cable harness.
Allow adhesive to cure at room temperature for 24
hours.
80.
In some cases the boot may have to be cut off.
When a boot has to be cut off the following procedure
should be used:
a.
Score (cut) the boot lengthwise, taking care not to

cut through the boot into the cable jacket.
b.
Heat the boot with a heat gun until warm to touch.
c.
Peel the boot from the cable jacket and connector

with pliers.
Reinstalling Convoluted and Standard Boots

81.
Heat the boot with a heat gun until warm to
touch, slide backshell and boot up to rear of connector
and tighten backshell coupling ring.
New Boot Installation
82.
The following steps should be followed when
installing a new boot on a connector harness assembly:
a.
Abrade outer jacket on jacketed cable with 320

emery cloth. Clean loose particles from surface
with a clean, dry cloth or paper tissue.
b.
Degrease connector backshell or adapter with

suitable cleaning solvent, such as Isopropyl
Alcohol.
c.
Apply adhesive to cable and connector bonding

areas if required (some boots are pre-coated with
an adhesive in the bonding areas).
d.
Install new boot over end of cable.
CAUTION
Do not bend or stress bonded cable joints during
adhesive cure. Improper bond(s) could result if
bonded joints are bent or stressed during adhesive
cure.
Boot Removal
79.
Remove a boot from a cable assembly as
follows:
a.
Loosen the connector backshell adapter to gain

access to the connector backside.
Standard Boots. Heat the boot with heat gun

until warm to touch, then pull the adapter and boot
back exposing the connector backside with
enough clearance to allow repair.
NOTE
WARNING
fuelled aircraft.
WARNING
ventilated.
b.
50
Convoluted Boots. Heat the boot with heat gun

until warm to touch, and pull the loosened adapter
away from the connector exposing the wire
conductors where they enter the connector. Hold
in the retracted position until cool and the boot
remains retracted.
Boots can be installed over connectors in most cases.

Occasionally, it may be necessary to disassemble a
connector to install the repair boot.
e.
Shrink the boot starting at the connector end and

proceeding to the cable end with a heat gun.
f.
Cure the adhesive according to recommended

curing instructions.

Sect 2 Chap 10
RECTANGULAR CONNECTORS
83.
Environmental resistant and non-environmental
resistant rectangular connectors are used in electrical
and electronic rack and panel applications. These
connectors are available with front release crimp
contacts, rear-release crimp contacts and solder
contacts. Rectangular connectors most commonly used
in aircraft are covered by military specifications such as
MIL-DTL-24308, MIL-DTL-28748, MIL-C-81659 and
MIL-DTL-83733.
Identification of Connectors and Component Parts

86.
For purposes of ordering MIL-DTL-83723
connectors, the part numbers are constructed as follows:
a.
MM83723
01
22 55
Military designator
Specification sheet
Class (Table 4-14)
Assembly and Disassembly of Rectangular

Connectors
Shell size in 0.0625 inch
84.
Assembly and disassembly procedures are the
same as those used for circular connectors. Refer to the
appropriate paragraph in the circular connector
instructions for assembly and disassembly procedures.
MIL-DTL-83723 CIRCULAR CONNECTORS
Connectors.
Insert arrangement
Insert position
b.
Description
85.
The connectors provided by this specification
are miniature environment resisting types with either
bayonet or threaded couplings (See Table 1015). MILDTL-83723, Series I (bayonet coupling) are replaced by
MIL-C-26482, Series II, and MIL-DTL-83723. Series II
(threaded coupling) are replaced by MIL-DTL-5015.
(See Table 106)
Backshell hardware for Series I (bayonet) and

Series III (bayonet and threaded) is shown in
Figure 1054.
MS3417
22
Basic part number

Shell size
Finish
MS34l5 - 45 clamp
MS34l6E - No clamp
MS34l7 - Straight clamp
MS341S - 90 clamp
NOTE
These connectors will be supplied without backshell
hardware (See paragraph 81).
Finish
A - Cadmium
G - Black anodize
(non-conductive)
N - Electroless nickel
CAUTION
Installation and removal of MIL-DTL-83723 contacts
is from the rear of the connectors.
c.
Backshell hardware for Series II (threaded).
M83723
35
22
Military designator
Specification sheet
Backshell type
A - 90 clamp
S - Straight
N - No clamp
Shell size
Finish
R - 200 conductive
G - Stainless steel
A - Black anodized (non-conductive)
51

Sect 2 Chap 10
d.
Series II (threaded) saddle clamp backshell

hardware.
M83723
50
22
f.
Contacts and service tools, Series I and Series III

(rear release contacts).
M39029
Military designator
Military designator
Specification sheet
Specification sheet
/5 socket contact
/4 pin contact
Backshell type
R - Straight strain relief
rotatable arm
A - 90 strain relief
B - 45 strain relief
/4 - 110
Bin code
Shell size
Finish
N - Electroless nickel
A - Anodic coating
e.
For shrink hardware (bayonet and threaded

connector series).
M83723
Military designator
Base specification and
specification sheet
(-16 Series I & III)
(-37 Series II)
Type shrink boot
(A: 90 angle)
(S: Straight)
Shell size (0.0625 inch)
(A: 150C 1000 hr)
(B: 200C shrink hardware)
52
16
22
Bin
Codes
Contact
Size
Contact
Insertion/
Extraction Tool
/4-110, /5115
20-20
M81969/14-02
/4-111, /5116
16-16
M81969/14-03
/4-112, /5117
16-20
M81969/14-03
/4-113, /5118
12-12
M81969/14-04
/4-114, /5119
12-16
M81969/14-04

Sect 2 Chap 10
Table 1015 MIL-DTL-83723 Connectors

Specification
M83723/XX
Series I (Bayonet)
/1
/2
/3
/4
/5
/6
/7
/8
/9
/10
/11
/12
/13
/14
/36
/37
/38
/39
/40
/41
/42
/43
/48
/49
Series II (Threaded)
/17
/18
/19
/20
/21
/22
/23
/24
/25
/26
Plug or Receptacle
Mounting Type
Class
(See Note)
Coupling
Contacts
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Plug
Plug
Plug
Plug
Receptacle
Receptacle
Receptacle
Receptacle
Plug (R.F.I.)
Plug (R.F.I.)
Plug (R.F.I.)
Plug (R.F.I.)
Narrow Flange
Narrow Flange
Wide Flange
Wide Flange
Single Hole
Single Hole
Cable
Cable
Narrow Flange
Wide Flange
Solder Flange
Single Hole
Cable
Cable
Cable
Cable
Narrow Flange
Narrow Flange
Wide Flange
Wide Flange
Cable
Cable
Cable
Cable
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
G, R
G, R
G, R
G, R
G, R
G, R
G, R
G, R
H
H
H
H
G, R
G, R
G, R
G, R
G, R
G, R
G, R
G, R
G, R, A
G, R, A
G, R, A
G, R, A
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Solder Pin
Solder Pin
Solder Pin
Solder Pin
Crimp Socket
Crimp Pin
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Cable
Cable
Wall Mount
Wall Mount
Box Mount
Box Mount
Cable
Cable
Square Flange
Solder Flange
G, R
G, R
G, R
G, R
G, R
G, R
G, R
G, R
H
H
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Solder Pin
Solder Pin
/52
Plug
Cable
Crimp Pin
/53
Plug
Cable
Threaded
Threaded
Threaded
Threaded
Threaded
Threaded
Threaded
Threaded
Threaded
Threaded
Threaded Selflock
Threaded Selflock
Crimp Socket
Receptacle
Receptacle
Receptacle
Receptacle
Plug
Plug
Plug (R.F.I.)
Plug (R.F.I.)
Receptacle
Receptacle
Receptacle
Receptacle
Receptacle
Flange
Flange
Single Hole
Single Hole
Cable
Cable
Cable
Cable
Flange
Solder Flange
Single Hole
Flange
Flange
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Bayonet
Threaded
Threaded
G, R, A
G, R, A
G, R, A
G, R, A
G, R, A
G, R, A
R
R
H
H
H
G, K, R, A
G, K, R, A
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Socket
Crimp Pin
Crimp Pin
Crimp Pin
Crimp Pin
Crimp Socket
Crimp Pin
Series III
/71
/72
/73
/74
/75
/76
/77
/78
/79
/80
/81
/82
/83
53

Sect 2 Chap 10
MIL-DTL-83723 Connectors (Continued)

Specification
M83723/XX
Plug or
Receptacle
Mounting Type
Coupling
Class
(See Note)
Contacts
/84
Receptacle
Single Hole
Bayonet
G, K, R, A
Crimp Socket
/85
Receptacle
Single Hole
Bayonet
G, K, R, A
Crimp Pin
/86
Plug
Cable
Bayonet
G, K, R, A
Crimp Socket
/87
Plug
Cable
Bayonet
G, K, R, A
Crimp Pin
/88
Receptacle
Flange
Bayonet
Solder Pin
/89
Receptacle
Single Hole
Threaded
Solder Pin
/90
Receptacle
Solder Flange
Threaded
Solder Pin
/93
Receptacle
Solder Flange
Bayonet
Straight Pin
/94
Receptacle
Single Hole
Bayonet
Straight Pin
/95
Plug
Cable
Threaded Self-lock
K, R, A
Crimp Socket
/96
Plug
Cable
Threaded Self-lock
K, R, A
Crimp Pin
Note
Classes
g.
200C
Aluminium Shell, Conductive Finish
200C
Steel Shell, Hermetic, Fluid Resistant Insert
200C
Stainless Steel Shell, Passivated, Fluid Resistant Insert
200C
Black Anodize (non-conductive)
200C
Stainless Steel, Passivated, Fluid Resistant Insert (firewall type)
175C
Aluminium Shell, Cadmium Plated Conductive Finish
Contacts and service tools, Series II (rear release

contacts).
M39029 /29 - 212
Disassembly of Connectors
87.
Disassembly of MIL-DTL-83723 connectors is
accomplished as follows:
a.
Plugs. Remove backshell, ferrule, and coupling

nut.
b.
Receptacles. Remove backshell and ferrule.

Since these are environmentally sealed
connectors, the inserts cannot be removed from
the connector shell.
Military designator
Specification sheet
/30 socket contact
/29 pin contact
Bin code
(see paragraph 28)
Crimping of Contacts for MIL-DTL-83723 Connectors
Bin
Codes
Contact
Size
Contact
Insertion/
Extraction
Tool
/30-217
16S-16
M81969/14-03
/29-212, /30-218
16-16
M81969/14-03
/29-213, /30-219
12-12
M81969/14-04
/29-214, /30-220
8-8
M81969/29-02*
/29-215, /30-221
4-4
M81969/29-03*
/29-216, /30-222
0-0
M81969/29-04*
88.
Wires may be crimped in sizes 12, 16 and 20
contacts with M22520/1-01 crimp tool with M22520/1-02
crimp tool turret head assembly. The detail procedures
are given in paragraph 40. To crimp size 0, 4 and 8
contacts, a power crimping tool, M22520/23-01, with
appropriate die set and locator is required. Die set
M22520/23-02 and locator M22520/23-09 are required
for size 8 contacts. Die set M22520/23-04 and locator
M22520/23-11 are required for size 4 contacts. Die set
M22520/23-05 and locator M22530/23-13 are required
for size 0 contacts. Follow crimping procedures provided
with tool. Wire stripping dimensions are as follows:
*Extraction Tool only sizes 8, 4 and 0 contacts can be

installed without the use of an insertion tool.
Contact Size
54

Sect 2 Chap 10
c.
Connectors.
20
4.7mm
16
6.3mm
12
6.3mm
12.7mm
MS number
12.7mm
15.8mm
Class
(see Table 4-16)
MS3456
12 - 10
Shell size
(see paragraph 8)
CAUTION
Insert arrangement
(see Figure 4-43)
If a size 10 wire is used in a size 8-8 contact, a

bushing, MS3348-8-10, must be used to ensure a
good crimp joint. If a size 6 wire is used in a size 4-4
contact, a bushing, MS3348-4-6, must be used. If a
size 2 wire is used in a size 0-0 contact, a bushing,
MS3348-0-2, must be used.
Contact style
(see paragraph 8)
Insert position
(blank for normal position)

89.
The crimp type contacts, which are found in all
but the Class H (hermetic) connectors, are removable.
The procedures for insertion and removal are given
below:
a.
b.
Remove backshell, ferrule, and coupling nut from

plug (backshell and ferrule from receptacle) and
slide back over wire loom.
Follow instructions given in Figures 1022 to
1026 as applicable.
MIL-DTL-5015 CONNECTORS
90.
Description. MIL-DTL-5015 covers circular,
electric connectors with solder or removable crimp
contacts (both front and rear release). These connectors
are for use in electronic, electrical power, and control
circuits. The type designations and class availability are
given in Table 1016.
91.
See Figure 1051 for typical illustrations of
AN/MS type connectors. Refer to Figure 1052 for insert
arrangement. For the purpose of ordering MIL-DTL-5015
connectors, the part numbers of connectors and
component parts are given as follows:
a.
b.
Cable clamps for MIL-DTL-5015 connectors are

described in paragraph 98 and Figure 1053.
Crimping of Contacts: Use same crimping
procedure and tools described for MIL-DTL-83723
connectors (see paragraph 83).
d.
Contacts and service tools for connector series

MS3450 through MS3459 (Rear Release
Contacts).
M39029 /29 - 212

Military designator
Specification sheet
/30 socket contact
/29 pin contact
Bin code
(see paragraph 28)
Bin
Codes
Contact
Size
Contact
Insertion/
Extraction Tool
/30-217
16S-16
M81969/14-03
/29-212, /30-218
16-16
M81969/14-03
/29-213, /30-219
12-12
M81969/14-04
/29-214, /30-220
8-8
M81969/29-02*
/29-215, /30-221
4-4
M81969/29-03*
/29-216, /30-222
0-0
M81969/29-04*
*Extraction Tool only sizes 8, 4 and 0 contacts can be

installed without the use of an insertion tool.
55

Sect 2 Chap 10
e.
Contacts and service tools for connector series

MS3400 through MS3412 (Front Release
Contacts).
Bin Codes
Contact Size
Contact Insertion
Tool
Contact Extraction Tool
/44-287, /45-294
/44-288, /45-295
/44-289, /45-296
/44-290, /45-297
/44-291, /45-298
/44-292, /45-299
/44-293, /45-300
16-22
16-16
12-16
12-12
8-8
4-4
0-0
M81969/17-01
M81969/17-01
M81969/17-02
M81969/17-02
M81969/17-06
M81969/17-07
M81969/17-08
M81969/19-01
M81969/19-01
M81969/19-02
M81969/19-02
M81969/19-03
M81969/19-04
M81969/19-05
Limited
Neoprene
Aluminium
Cadmium, olive
drab
Split shell
Limited
Neoprene
Aluminium
Cadmium, olive
drab
Pressurized
Limited
Neoprene
Aluminium
Cadmium, olive
drab
High impact
shock
Partial
Silicone
Wrought
aluminium
Cadmium, over
nickel
Without clamp
Limited
Neoprene
Aluminium
Cadmium, olive
drab
With clamp
Limited
Neoprene
Aluminium
Cadmium, olive
drab
Hermetic seal
Complete
Silicone
Ferrous
alloy
Electroless
nickel
Gland seal for

jacketed cable
Limited
Neoprene
Aluminium
Cadmium, olive
drab
Firewall
Complete
Silicone
Ferrous
alloy
Electroless
nickel
Fluid resistant
Complete
Silicone
Aluminium
Electroless
nickel
Potting seal
Limited
Neoprene
Aluminium
Cadmium, olive
drab
Grommet seal
without clamp
Limited
Neoprene
Aluminium
Cadmium, olive
drab
High
temperature
Partial
Silicone
Aluminium
Electroless
nickel
Life
Complete
Silicone
Aluminium
Cadmium, olive
drab
Accepts large
wire insulation
O.D.
Partial
Silicone
Aluminium
Cadmium, olive
drab
Class
Shell Finish
Shell Material
Insert Material
Environ.
Resistant
Solid shell
Fluid Resistant
Rear Release
Crimp Contacts
MS3400 Series
Feature
Front Release
Crimp Contacts
MS3400 Series
Solder Contacts
MS3100 Series
Table 1016 MIL-DTL-5015 Connector Classes
1/
1/ MS3450 Series is the preferred replacement for MS3100 Series.
56

Sect 2 Chap 10
Figure 1053 Typical AN(MS) Connectors
57

Sect 2 Chap 10
Figure 1054 Insert Arrangements - AN Type Connectors, MIL-DTL-5015 and MIL-DTL-83723, Series II
(Sheet 1 of 2)
58

Sect 2 Chap 10
Figure 1055 Insert Arrangements - AN Type Connectors, MIL-DTL-5015 and MIL-DTL-83723, Series II
(Sheet 2 of 2)
59

Sect 2 Chap 10
a.
MIL-C-26482, MIL-C-26500 AND MIL-C-81703

CONNECTORS
Contacts and service tools for MIL-C-26482

Series 1, MIL-C-26500 and MIL-C-81703 Series 2
connectors.
Description
M39029 /31 - 224
92.
MIL-C-26482, MIL-C-26500 and MIL-C-81703
cover, electric connectors with solder or removable
crimp contacts. The types and classes of MIL-C-26482,
MIL-C-26500 and MIL-C-81703 connectors are listed in
Table 1017.
Military designator
Specification sheet
/31 pin
/32 socket
93.
Typical connectors are illustrated in Figure 10
53. Refer to paragraph 8 and Figure 101 for typical
connector identification.
Bin Code
Bin code
(see paragraph 28)
Contact
Size
Basic Crimp
Tool
Positioner
or Turret
M22520/1-02
20-20
M22520/1-01
or
M22520/2-01
or
M22520/7-01
M22520/1-02
16-16
M22520/1-01
or
M22520/7-01
/31-223, /31-240
/31-241, /31-448
/32-242, /32-250
/32-260, /32-449
/31-228, /31-229
/32-247, /32-248
/31-243, /31-235
M22520/1-01
12-12
M22520/2-02
M22520/7-03
M22520/1-02

Series 2 and MIL-C-81703 Series 3 connectors.
M39029
Contact
Extraction Tool
M81969/14-02
or
M81969/17-03
M81969/19-07
M22520/7-02
/32-253, /32-254
b.
Contact
Insertion Tool
/4 - 110
c.
M81969/14-03
or
M81969/17-04
M81969/14-04
or
M81969/17-05
M81969/19-08
M81969/19-09
Cable clamps, for MIL-C-26482 Series 1 and MILC-81703 Series 2 connectors, are provided with
the connectors. Cable clamps for MIL-C-26482
series 2 and MIL-C-81703 connectors are
Military designator
Specification sheet
/5 socket contact
/4 pin contact
Bin code
/4-112, /5-117
16-20
/4-113, /5-118
12-12
Basic Crimp
Tool
M22520/1-01
or
M22520/2-01
or
M22520/7-01
M22520/1-01
or
M22520/7-01
M22520/1-01
or
M22520/7-01
M22520/1-01
/4-114, /5-119
12-16
M22520/1-01
Bin Code
/4-110, /5-115
/4-111, /5-116
60
Size
20-20
16-16
Positioner
or Turret
M22520/1-02
M22520/1-02
M22520/2-02
M22520/7-02
M22520/1-02
M22520/7-03
M22520/1-02
or
M22520/7-03
M22520/1-02
Contact Insertion/
Extraction Tool
M81969/14-02
M81969/14-03
M81969/14-03
M81969/14-04
M81969/14-04

Sect 2 Chap 10
a.
MIL-C-81511 CONNECTORS

Series 1 and 2 connectors.
Description
M39029 /33 - 261
94.
MIL-C-81511 connectors are general-purpose
high-density, environment-resisting connectors similar to
the MS series. The connectors have a quick disconnect
feature, employing bayonet-type locking ring. The types
available are indicated in Table 1018.
Military designator
Specification sheet
/33 socket (Series I)
/46 socket (Series 2)
/47 pin (Series 1 & 2)
Marking MIL-C-81511 Connectors

95.
The connector part number consists of the letter
M, the basic number of the specification sheet, and the
applicable characteristics as in the following example
(See Notes 2, 3, and 4 from Table 1018):
Bin code
(see paragraph 28)
b.
M 81511/01 E D 01 P 1
Military part
number indicator
Basic part number

Series 3 and 4 connectors.
M39029 /16 - 166

Military designator
Class
Specification sheet
/18 pin (Series 3 & 4)
Shell size
Insert arrangement
Contact designator
Bin code
(see paragraph 28)
Key positions
Bin Code
Contact
Size
Basic Crimp
Tool
Positioner
or Turret
Contact
Insertion Tool
Contact
Extraction Tool
/33-261, /33-262
23-28
M22520/2-01
M22520/2-03
M81969/2-01
M81969/3-01
/33-263, /33-264
23-22
M22520/2-01
M22520/2-03
M81969/2-01
M81969/3-01
/46-301, /46-302
23-28
M22520/2-01
M22520/2-03
M81969/2-01
M81969/3-01
/46-303, /46-304
23-22
M22520/2-01
M22520/2-03
M81969/2-01
M81969/3-01
/47-311, /47-312
23-28
M22520/2-01
M22520/2-03
M81969/2-01
M81969/3-05
/47-313, /47-314
23-22
M22520/2-01
M22520/2-03
M81969/2-01
M81969/3-05
/33-265, /33-266
20-20
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-02
/46-305, /46-306
20-20
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-02
/47-315, /47-316
20-20
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-06
/33-267, /33-268
16-16
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-03
/46-307, /46-308
16-16
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-03
/47-336, /47-337
16-16
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-07
/33-269, /33-270
12-12
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-04
/46-309, /46-310
12-12
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-04
/47-338, /47-339
12-12
M22520/1-01
M22520/1-08
M81969/2-02
M81969/3-08
61

Sect 2 Chap 10
Bin Code
Contact
Size
Basic Crimp
Tool
Positioner
or Turret
Contact Insertion/
Extraction Tool
Extraction Tool
For Unwired
Contact
/16-166
23-28
M22520/2-01
M22520/2-13
M81969/16-04
M81969/30-01
/16-167
23-22
M22520/2-01
M22520/2-13
M81969/16-04
M81969/30-01
/17-171
23-28
M22520/2-01
M22520/2-16
M81969/16-04
M81969/30-01
/17-172
23-22
M22520/2-01
M22520/2-16
M81969/16-04
M81969/30-01
/18-176
23-28
M22520/2-01
M22520/2-13
M81969/16-04
M81969/30-01
/18-177
23-22
M22520/2-01
M22520/2-13
M81969/16-04
M81969/30-01
/16-168
20-20
M22520/2-01
M22520/2-14
M81969/16-01
M81969/30-02
/17-173
20-20
M22520/2-01
M22520/2-17
M81969/16-01
M81969/30-02
/18-178
20-20
M22520/2-01
M22520/2-14
M81969/16-01
M81969/30-02
/16-169
16-16
M22520/2-01
M22520/2-15
M81969/16-02
M81969/30-03
/17-174
16-16
M22520/2-01
M22520/2-18
M81969/16-02
M81969/30-03
/18-179
16-16
M22520/2-01
M22520/2-15
M81969/16-02
M81969/30-03
/16-170
12-12
M22520/1-01
M22520/1-09
M81969/16-03
M81969/30-04
/17-175
12-12
M22520/1-01
M22520/1-10
M81969/16-03
M81969/30-04
/18-180
12-12
M22520/1-01
M22520/1-09
M81969/16-03
M81969/30-04
consist of nicks or actual voids due to small

portions of the rubber being removed or gouged
out. Larger voids will present a serious sealing
problem, and the connector will require
replacement.
96.
The connector inserts in the MIL-C-81511
connectors are bonded to the connector shells and are
not removable. The insertion and/or removal of contacts
in these connectors is accomplished as follows:
97.
Precautionary Measures. These connectors
are built to withstand successfully the anticipated
conditions common to the application in which they will
be used. However, certain precautionary measures as
listed below must be followed when working with these
connectors.
a.
Do not attempt to remove the inserts from the

shell. These components are permanently bonded
to the shells and cannot be removed without
destroying them. Also, do not attempt to remove
the face seal from the pin insert.
b.
When working with these connectors, always

choose a clean, dry, smooth working surface, to
prevent foreign matter from collecting on the
sealing surfaces and/or the electrical components.
This is necessary also to prevent abrasion of
sealing surfaces. It is also important to avoid
sliding the resilient components along working
surfaces.
c.
62
Occasionally some damage to the wire holes in

the resilient grommet may occur during insertion
of the contacts. This damage may be limited to
small slash or knife-blade type cuts resulting in
cracks that radiate between the wire holes. The
grommet will seal satisfactorily in this case. On
the other hand, the damage around the holes may
98.
Insertion of Contacts. The insertion of contacts
is as follows:
a.
Before attempting any insertion of contacts,

determine if the rear nut assembly is in the
unlocked position. A coloured stripe will appear
when the rear nut assembly is rotated counter
clockwise. At this point, the connector is in
position for both insertion and removal of
contacts. This can also be determined by
checking the space between the rear nut knurled
diameter and the shell. The space should be
between 2.5 to 4 mm.
b.
Place the contact into the desired hole in the rear

of the connector by hand; then, using the
appropriate insertion tool (see Table 1019),
place the crimped contact in the front of the tool.
The mating end should extend out of the tool and
the wire into the tool. The tool is in its proper
position when it grasps the rear of the contact
behind the contact shoulder.
c.
The contact and the tool should be aligned within

the desired hole as straight as possible to avoid
serious damage to the connector.

Sect 2 Chap 10
Table 1017 Miniature MS Connector Type and Class Availability

Connector
Type
Description
Contact
Type
Series
Class
Availability
MIL-C-26482F Bayonet Coupling

MS3110
MS3111
MS3112
MS3113
MS3114
MS3115
MS3116
MS3119
MS3120
MS3121
MS3122
MS3124
MS3126
MS3127
MS3128
MS3440
MS3442
MS3443
MS3449
MS3470
MS3471
MS3472
MS3474
MS3475
MS3476
Wall Mounting Receptacle

Cable Connecting Plug
Box Mounting Receptacle
Solder Mounting Receptacle
Single Hole Mounting Receptacle
Dummy Stowage Receptacle
Straight Plug
Bulkhead Mounting Receptacle
Cable Connecting Plug
Straight Plug
Narrow Flange Mounting Receptacle
Wide Flange Mounting Receptacle
Solder Flange Mounting Receptacle
Narrow Flange Mounting Receptacle
Cable Connecting Receptacle
Wide Flange Mounting Receptacle
Rear Mounting Jam Nut Receptacle
RFI Shielded Plug
Plug
Solder
Solder
Solder
Solder
Solder
Solder
Solder
Solder
Crimp
Crimp
Crimp
Crimp
Crimp
crimp
Crimp
Solder
Solder
Solder
Solder
Crimp
Crimp
Crimp
Crimp
Crimp
Crimp
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
E, F, J
E, F, J, P
E
H
E, F, P, H
Solder
Solder
Solder
Solder
Solder
Solder
Solder
Crimp
Crimp
Crimp
Crimp
Crimp
Crimp
Crimp
Solder
Crimp
Solder
Crimp
Crimp
Solder
1
1
1
1,2
1
1
1
2
2
2
2
3
2
3
3
3
3
3
3
3
E, P, J
E, H
E, P, J, H
E, F, P, J
E
E, F
E, F, P
E
E, F, P
E, F, P
E
E, F, P
H
H
H
H
E, L, W, A
E, L, W, A
E, L, W, A
E, L, W, A
E, L, W
E, L, W, A
MIL-C-81703 Push-Pull Coupling

MS3130
MS3132
MS3134
MS3135
MS3137
MS3138
MS3139
MS3140
MS3144
MS3147
MS3148
MS3424
MS3445
MS3446
MS3463
MS3464
MS3466
MS3467
MS3468
MS3469

Wall Mounting Dummy Stowage Receptacle
Short Plug
Lanyard Plug
Bulkhead Receptacle
Straight Plug
Lanyard Plug
Wall Mounting Flange Receptacle
Rack and Panel Plug
Rack and Panel Plug
Hermetic Solder Mounting Receptacle
Jam Nut Mounting Receptacle
Hermetic Box Mounting Receptacle
Plug
Lanyard Plug
Hermetic Jam Nut Mounting Receptacle
E, P, J
E, P, J
E
E, J
E, J
E, J
E, J
E, L
E
E, L
H
E, L
H
E, L
E, L
H
MIL-C-26500 Threaded and Bayonet Couplings

MS24266
MS27562
MS27563
MS27564
Straight Plug
Flange Mounting Receptacle
Straight Plug (Hard Insert)
Crimp
Crimp
Crimp
Crimp
F. H, R
F, H, R
F, H, R
F, H. R
63

Sect 2 Chap 10
Figure 1056 Typical MS Connectors Miniature

d.
Push the contact into the connector. The shoulder

on the contact provides a positive stop. At this
point, the contact is fully inserted. Slide the tool
back along the wire insulation until it clears the
grommet.
NOTE
For rear-release contacts (series 3 and 4 crimp-type),
tines will lock into place behind the contact shoulder.
A light pull should be exerted on the wire of rearrelease contacts to be sure they are locked into
position.
e.
64
A contact should be inserted in all unwired holes

in the receptacle to provide for proper sealing on

Sect 2 Chap 10
the equipment. Sealing plugs must be placed

behind all unwired contacts.
f.
After all contacts and sealing plugs have been

inserted into the connector, tighten the rear nut by
turning clockwise until the locking nut is tight.
NOTE
To maintain seal, all holes behind unused contacts
must be filled with the proper size sealing plugs.
Table 1018 MIL-C-81511 Connectors

Specification
(M81511/XX)
Plug or
Receptacle
Mounting
Type
Series
(Note 1)
Classes
(Note 2)
Contacts
/01
Receptacle
Square flange
A, F, E
Crimp
/02
Receptacle
Solder flange
B, G, H
Solder (pins only)
/03
Receptacle
Single hole
A, F, E
Crimp
/04
Receptacle
Single hole
B, G, H
Solder (pins only)
/05
Receptacle
Cable
A, F, E
Crimp
/06
Plug
Cable
A, F, E
Crimp
/21
Receptacle
Square flange
A, F, E
Crimp
/22
Receptacle
Solder flange
B, G, H
Solder (pins only)
/23
Receptacle
Single hole
A, F, E
Crimp
/24
Receptacle
Single hole
B, G, H
Solder (pins only)
/25
Receptacle
Cable
A, F, E
Crimp
/26
Plug
Cable
A, F, E
Crimp
/27
Receptacle
Single hole
B, G, H
Non-removable
/28
Receptacle
Single hole
B, G, H
Non-removable
/31
Receptacle
Square flange
C, T, P
Crimp
/32
Receptacle
Single hole
C, T, P
Crimp
/33
Plug
Cable
C, T, P
Crimp
/34
Plug
Cable
C, T, P
Crimp
/35
Receptacle
Square flange
C, T, P
Crimp
/36
Receptacle
Single hole
C, T, P
Crimp
/37
Plug
Cable
C, T, P
Crimp
/38
Plug
Cable
C, T, P
Crimp
/41
Receptacle
Square flange
A, E, F
Crimp
/42
Receptacle
Solder flange
Solder (pins only)
/44
Receptacle
Single hole
Solder (pins only)
/45
Receptacle
Cable
A, E, F
Crimp
/46
Plug
A, E, F
Crimp
/47
Receptacle
Solder flange
Crimp (pins only)
/48
Receptacle
Single hole
Crimp (pins only)
/49
Receptacle
Single hole
A, E, F
Crimp
/50
Receptacle
Single hole
Crimp (pins only)
/51
Receptacle
Square flange
A, E, F
Crimp
/52
Receptacle
Solder flange
Solder (pins only)
/53
Receptacle
Single hole
A, E, F
Crimp
/54
Receptacle
Single hole
Solder (pins only)
/55
Receptacle
Cable
A, E, F
Crimp
/56
Plug
Cable
A, E, F
Crimp
/57
Receptacle
Solder flange
Crimp (pins only)
65

Sect 2 Chap 10
Table 1018 MIL-C-81511 Connectors (Continued)

NOTES
(1) Series are defined as follows:
Series 1 & 3 Long shell
Series 2 & 4 Light weight, short shell
(2) Series defined as follows:
Type
Grommet seal
Hermetic seal
Potting seal
Operating Temperature
150C 175C 200C
E
F
A
H
G
B
P
T
C
(3) The shell size and insert arrangement are identified by a two-part code. The first part consists of a
single letter indicating the shell size in accordance with the following code. The second part should be two
digits indicating the insert arrangement in accordance with the applicable insert arrangement.
Shell Size Code
Shell Size
Code Letter
8 A
10
B
14
D
16
E
18
F
20
G
22
H
24
J
(4) The following designators are used to indicate a full complement of applicable power contacts:
P Pin contacts
S Socket contacts
C Feedthrough contacts
The following designators are used to indicate a connector less contacts. They will be used only when
other than power contacts are to be installed in the connector. Examples of this are shielded,
thermocouple, and coaxial contacts:
A Less pin contacts
B Less socket contacts
Figure 1057 Colour Marking for Individual Release MIL-C-81511 Connectors
66

Sect 2 Chap 10
99.
Connector Disassembly and Removal of
Contacts. Carry out connector disassembly and
removal of contacts as follows:
CAUTION
The newer type MIL-C-81511 (series 3 and 4)
connectors have individual release contacts which
must be removed (and installed) from the rear of the
connector. These connectors are identified by a
special blue band on both front and rear as shown in
Figure 1056.
a.
Remove any adapters from the rear of the

connector.
b.
Loosen the rear nut assembly by turning it counter

clockwise when viewed from the wire end.
Approximately 1.5mm of axial movement unlocks
the contacts. The coloured stripe will fully appear.
The connector is now in position for removal of
contacts.
c.
Select the proper contact removal tool from Table

1019.
d.
Series 1 and 2 (gang release) contacts are

removed from the front of the connector as
follows:
(1) The pin contact removal tool has a hole to

accept the pin contact. The socket removal
tool has a pin tip to insert in the socket.
CAUTION
Good axial alignment should be maintained during
removal of series 1 and 2 contacts. Misalignment can
bend the contact and damage the connector.
e.
Series 3 and 4 (individual release) contacts are

removed from the rear of the connector as follows:
(1) With the rear of the connector facing you, lay

the wire of the contact to be removed along
the slot of the tool. Squeeze the wire firmly
into the tool between the thumb and forefinger
about 1.2mm from the tool tip, and snap the
wire into the tool. (A quick pull on the tool
away from the connector may be necessary
to snap the wire into place).
(2) With the wire in place in the tool, slide the tool
down along the wire and into the rear cavity
and slowly into the connector until a positive
resistance is felt. At this time, the contact
retaining mechanism is in the unlocked
position.
CAUTION
When using minimum diameter wire, the tool may
have a tendency to stop against the rear of the
contact crimp barrel. If this should occur, careful
manipulation of the tool will permit it to ride over the
crimp barrel and into the proper position to unlock the
contact.
(2) Grasp the tool by the handle. Locate the
(3) Press the wire of the contact against the
contact to be removed by the numbers on the

insert face.
serrations of the plastic tool, and pull both the

tool and the wired contact out of the
connector.
(3) Mate the tool with the contact and, holding the
tool at right angles with the insert face, push
axially against the tip of the contact until the
contact appears at the grommet (rear) end of
the connector. The removal tools are
designed to bottom against the insert face
when the contact is completely released and
pushed out.
(4) The wire and contact can now be removed

from the connector.
CAUTION
Individual release contacts are easily removed. The
use of too much force may damage the connector
insert.
f.
Unwired series 3 and 4 (individual release)

contacts are removed from the rear of the
connector as follows:
(1) Remove sealing plug and insert appropriate

size MS3159 tool into rear of cavity. Extended
plunger in MS3159 tool can be used to guide
tool through cavity to rear of contact crimp
barrel.
67

Sect 2 Chap 10
(2) When plunger butts against contact barrel,
(3) When probe bottoms in connector, contact
release plunger and grasp tool using probe

hand grip. Push probe in so that contact
barrel slides into hollow centre of probe and
pushes plunger back. Hollow probe diameter
is slightly less than contact barrel diameter so
contact will stick in probe.
locking tines will be released, and contact

may be pulled out.
(4) Plunger may then be used to push removed

contact from removal tool.
Table 1019 MIL-C-81511 Contact Insertion and Removal Tools

Series 1 & 2 (Gang Release) Contacts
Series 3 & 4 (Individual Release) Contacts
Contact
Size
Insertion
Tool
Pin Removal
Tool
Socket
Removal Tool
Insertion and Removal

Tool
Unwired Contact
Removal Tool
22 & 23
MS3323-23
MS3342-23
MS3344-23
MS3160-22
MS3159-22
20
MS3323-20
MS3342-20
MS3344-20
MS3160-20
MS3159-20
16
MS3323-16
MS3342-16
MS3344-16
MS3160-16
MS3159-16
MS3160-12
MS3159-12
12
b.
MIL-DTL-38999 CONNECTORS
Types:
(1) Plugs:
General Description
100.
Connectors
manufactured
under
this
specification are miniature, high-density, environmentresisting types. They are available with removable crimp
type contacts, except for the hermetic sealing types
which have non-removable solder contacts. The
availability of MIL-DTL-38999 is indicated in Table 10
20. Typical MIL-DTL-38999 connectors are illustrated in
Figure 1057.
(a) Straight.
(b) Straight, Grounded.
(c) Lanyard Release.
(2) Receptacles:
(a) Box Mounting.
Classification
(b) Wall Mounting.
101.
(c) Jam-nut Mounting.
a.
These connectors are classified as follows:

Series:
(d) Solder Mounting.
(1) I Grounded, Scoop-proof; Bayonet
c.
Classes (Series I & II):
Coupling.
(a) E Environment resisting.
(2) II Low Silhouette; Bayonet Coupling.
(b) P For potting; includes potting form.
(3) III Grounded, Scoop-proof; Threaded
(c) T Environment resisting.
Coupling.
Grounded,
Coupling.
(4) IV
Scoop-proof;
NOTE
The series I, II, III and IV connectors are not
interchangeable or intermatable.
68
(d) Y Hermetically sealed.
Breech
d.
Classes (Series III & IV):

(a) C Environment resisting nonconductive
finish.

Sect 2 Chap 10
(b) F Environment resisting conductive

finish.
(c) K Environment resisting firewall barrier.
e.
h.
Cable Clamps for MIL-DTL-38999 connectors are

i.
Contact Styles:
(d) W Environment resisting corrosion

resistant plating.
(a) P Pin.
(e) Y Hermetically Sealed.
(b) S Socket.
Finishes (Series I & II):
M39029 /58 - 360
(a) A Bright cadmium plate.

(b) B Olive-drab cadmium plate.
Military designator
(c) C Anodic.
Specification sheet
/56 socket contact
(Series I, III & IV)
/57 socket contact
(Series II)
/58 pin contact
(Series I, II, III & IV)
(d) D Fused tin plate.

(e) E Stainless steel, unplated.
(f) F Electroless nickel.
f.
Finishes (Series III & IV):
Bin code
(see paragraph 28)
(a) C Anodic.
(b) F Electroless Nickel.
(c) K Corrosion Resistant Steel Shell.
(d) W Olive-drab cadmium plate.
(e) Y Corrosion resistant steel shell.
g.
Shell Size Code Series III & IV only:

Shell
Size
Code
Letter
Shell
Size
Code
Letter
17
11
19
13
21
15
23
25
69

Sect 2 Chap 10
Socket Bin Code

(Series I, III & IV)
Socket Bin
Code (Series
II)
Pin Bin Code

(Series I, II,
III & IV)
Contact
Size
Contact Insertion
Tool*
/56-348
/57-354
/58-360
22-22D
M81969/14-01
or
M81969/8-01
M81969/14-01
or
M81969/8-02
/56-349
/57-355
/58-361
22-22M
M81969/14-01
or
M81969/8-01
M81969/14-01
or
M81969/8-02
/56-350
/57-356
/58-362
22-22
M81969/8-03
M81969/8-04
/56-351
/57-357
/58-363
20-20
M81969/14-02
or
M81969/8-05
M81969/14-02
or
M81969/8-06
/56-352
/57-358
/58-364
16-16
M81969/14-03
or
M81969/8-07
M81969/14-03
or
M81969/8-08
/56-353
/57-359
/58-365
12-12
M81969/14-04
or
M81969/8-09
M81969/14-04
or
M81969/8-10
/56-327
N/A
/58-528
10-10
M81969/14-05
M81969/14-05
* M81969/8-XX is a metal tool.

M81969/14-XX is a double ended plastic insertion/extraction tool.
Bin Code
70
Contact
Extraction
Tool*
Contact Size
Basic Crimp Tool
Positioner or Turret
/56-348, 56/349
and /56-350
22-22D
22-22M
22-22
M22520/2-01
or
M22520/7-01
M22520/2-07
or
M22520/7-05
/56-354, 56/355
and /56-356
22-22D
22-22M
22-22
M22520/2-01
or
M22520/7-01
M22520/2-06
or
M22520/7-06
/56-360, 56/361
and /56-362
22-22D
22-22M
22-22
M22520/2-01
or
M22520/7-01
M22520/2-09
or
M22520/7-07
/56-351, 56/357
and /56-363
20-20
M22520/1-01
or
M22520/2-01
or
M22520/7-01
M22520/1-04
or
M22520/2-10
or
M22520/7-08
/56-352, 56/358
and /56-364
16-16
M22520/1-01
or
M22520/7-01
M22520/1-04
or
M22520/7-04
/56-353, 56/359
and /56-365
12-12
M22520/1-01
M22520/1-04

Sect 2 Chap 10
Table 1020 Availability of MIL-DTL-38999 Connectors

Spec (MSxxxxx)
27466
27467
27468
27469
27470
27471
*27472
*27473
*27475
*27476
*27477
*27478
*27479
*27480
*27481
*27482
*27483
*27484
Type
Mounting
Receptacle
Wall Flange
Plug Straight
Receptacle
Jam Nut
Receptacle
Wall Flange
Receptacle
Jam Nut
Receptacle
Solder
Receptacle
Wall Flange
Plug Straight
Receptacle
Wall Flange
Receptacle
Box Flange
Receptacle
Jam Nut
Receptacle
Solder
Receptacle
Wall Flange
Plug Straight
Receptacle
Jam Nut
Receptacle
Wall Flange
Receptacle
Jam Nut
Plug Straight
Grounding
27496
Receptacle
Box Flange
*27497
Receptacle
Back Panel Wall
*27498
Plug 90 Elbow
*27499
Receptacle
Box Flange
*27500
Receptacle
Box Flange
*27503
Receptacle
Solder
*27504
Receptacle
Box Flange
27505
Receptacle
Box Flange
*27508
Receptacle
Back Panel Box
*27513
Receptacle
Box Flange
*27515
Receptacle
Back Panel Wall
*Inactive for new design. **Class E and P inactive for new design.
Spec (D38999/)
Type
Mounting
20
Receptacle
Wall Mount Flange
21
Receptacle
Box Mount Flange
22
Receptacle
Dummy Stowage
23
Receptacle
Jam Nut
24
Receptacle
Jam Nut
25
Receptacle
Solder
26
Plug (EMI)
Straight
27
Receptacle
Weld
28
Nut
Connector Mounting
29
Plug (Pins)
Lanyard Release
30
Plug (Sockets)
Lanyard Release
31
Plug
Lanyard Release
32
Cover Plug
Protective
33
Cover Receptacle
Protective
34
Receptacle
Breakaway Jam Nut
35
Receptacle
Breakaway Wall Mount
40
Receptacle
Wall Mount Flange
41
Receptacle
Box Mount Flange
42
Receptacle
Box Mount Flange
43
Receptacle
Jam Nut
44
Receptacle
Jam Nut
45
Receptacle
Solder
46
Plug (EMI)
Straight
47
Plug
Breech Coupling
48
Receptacle
Weld Mount
49
Receptacle
Breech Coupling
50
Receptacle
Dummy Stowage
Series
I
I
I
I
I
I
II
II
II
II
II
II
II
II
II
II
II
II
E,P,T
E,P,T
E,P,T
Y
Y
Y
E,P,T
E,P,T
Y
Y
Y
Y
E,P,T
E,P
E,P,T
Y
Y
E,P,T
Class**
I
II
I
II
II
II
II
I
II
II
I
E,P,T
E,P,T
E,P
E
E
Y
E,P,T
E
E,P,T
E
E,P,T
Series
III
III
III
III
III
III
III
III
III, IV
III
III
III
III
III
III
III
IV
IV
IV
IV
IV
IV
IV
IV
IV
IV
IV
Class
F, G, J, K, M, S, W
N, Y
G, J, M, W
N, Y
F, G, J, K, M, S, W
N, Y
F, G, J, K, M, S, W
N, Y
C, F, G, H, J, K, M, W
F, K, S, W
F, K, S, W
W
G, J, M, W
G, J, M, W
W
W
C, F, K, S, W
N, Y
C, F, W
N, Y
C, F, K, S, W
N, Y
F, K, S, W
C, W
N, Y
C, F, W
W
71

Sect 2 Chap 10
Figure 1058 Typical MIL-DTL-38999 Connectors
72

Sect 2 Chap 10
Marking
102.
a.
b.
Series III and IV:
The connectors are marked as follows:
D38999/
Series I and II:
MS27467
13
20
A 35 P
DOD number
prefix
Specification sheet
number
MS number
(see Table 4-20)
Class (see paragraph 96)
Class (see paragraph

96 and see Table 4-22)
Shell size code

(see paragraph 96)
Shell size
Insert arrangement
Finish (see paragraph 96)
Contact style (see paragraph 96)
Insert arrangement
Polarization (Key or Key way location)

(letter N required for normal)
Contact style (see paragraph 96)

Polarization (Key or Key way location)
(no letter required for normal)
M AND MS CONNECTOR CABLE CLAMPS

103.
Connector cable clamps are used on the back
end of M and MS connectors to support wiring and to
prevent twisting or pulling on wire terminations. Standard
cable clamps that fit MIL-DTL-5015 (MS3400 and
MS3450 Series), MIL-C-26482 (Series 2), MIL-C-81703,
(Series 3) and MIL-DTL-83723 (Series I and III) are
shown in Figure 1056. Standard cable clamps for MILDTL-38999 connectors are shown in Figure 1059. See
Table 1021 for connector accessory installation torque
values.
Table 1021 Installation Torque Values For MIL-C-85049 Circular Electrical Connector Accessories
Accessory Thread Torque 5 inch pounds
Shell Sizes
Group 1
MIL-C-85049 Part Numbers:
/17, 27, 29, 30, 32, 33, 34, 35, 36, 37, 41,
42, 45, 46, 47, 49, 56, 57, 61, 62, 63, 64,
65, 76, 77, 82, 83, 84, 85, 86, 87, 88, 89,
90, 91, 92
Group 2
MIL-C-85049 Part Numbers:
/1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 14, 15, 16,
18, 19, 20, 21, 23, 24, 25, 26, 31, 38, 39,
43, 51, 52, 53, 54, 55, 59, 60, 66, 67, 69,
78, 79
70
8, 9, A
40
3, 10, 10SL, 11, B
40
95
7, 12, 12S, 13, C
40
135
14, 14S, 15, D
40
145
16, 16S, 17, E
40
145
18, 19, 27, F
40
145
20, 21, 37, G
80
170
22, 23, H
80
170
24, 25, 61, J
80
170
28, 29
120
185
32, 33
120
185
36
120
185
40
170
205
44
170
205
170
205
48
Note: The above values are recommended.
73

Sect 2 Chap 10
Figure 1059 Typical Cable Clamps For MIL-DTL-5015 (MS3400 & MS3450 Series), MIL-C-26482
(Series 2), MIL-C-81703 (Series 3) and MIL-DTL-83723 (Series I and Series II) Connectors
74

Sect 2 Chap 10
Figure 1060 Typical Cable Clamps For MIL-DTL-38999 Series I, II, III & IV Connectors
75

Sect 2 Chap 10
in single, double, triple, or quadruple plugs or

receptacles. Any combination of insert
arrangements may be used in the multiple plugs
or receptacles. Some of the various
combinations of insert arrangements are listed
in Table 1024 with their corresponding
designation numbers.
MIL-C-81659 CONNECTORS
Description
104.
MIL-C-81659
environment-resistant,
rectangular connectors are used in electrical and
electronic rack and panel applications. These
connectors are available with front release contacts
(Series 1) or rear-release contacts (Series 2). Series 1
and Series 2 connectors are available in two types and
classes. Type I has a short grommet seal and Type II
has a standard grommet seal. Class 1 is built for a
temperature range from -65C to 125C. Class 2 will
operate at a higher temperature, its range being from
-65C to 200C. The connectors are furnished with
standard contacts sizes 22, 20 and 16, and coaxial
contacts sizes 1, 3, 5, 7 and 9. The connectors have
crimp type removable standard contacts and crimp type
coaxial contacts, some of which are rear-releasable
and others non-releasable. Their availability is indicated
in Table 1022.
Marking of MIL-C-81659 Connectors
105.
The connector part number consists of the
letter M, the basic number of the specification sheet,
and the coded numbers or letters as in the following
example:
M81659/29 A 2 - 0002 12
Basic part number
Shell size designator
Series designator
Insert designator
Polarization
(no number required for 01 position)
c.
The
polarization
positions
and
the
corresponding
polarization
numbers
are
explained in Table 1025. Normally the plugs
and receptacles are furnished with 01
polarization, i.e., all plug polarizing posts up and
all receptacle polarizing insert holes up. If the
polarization must be changed to prevent
connection of similar plugs to the wrong
receptacles, the polarization number from Table
1025 must be marked on the connector shell
following the connector part number.
MIL-C-81659 Assembly and Disassembly

106.
The method of assembling and disassembling
MIL-C-81659 connectors with standard contacts or
with rear-release coaxial contacts is shown in Figure
1061. The method of disassembling the polarizing or
keying assembly to change the polarization position is
shown in Figure 1062. The method of assembling
and disassembling MIL-C-81659 connectors with nonreleasable coaxial contacts is shown in Figure 1061.
a.
Installing Non-releasable Coaxial

Contacts. (See Figure 1063).
Socket
(1) Select the plug shell needed for your

application. A double shell is shown in
Figure 1063 to illustrate the possible
combination of a C2 coaxial contact insert
and a standard contact insert.
(2) Insert two socket contacts into the rear

a.
b.
Shells with size designator A have a key stone

shape and a mounting flange width of 50mm.
Shells with size designator B have a rectangular
shape and a mounting flange width of 6.3cm.
The insert arrangements are described in
MS3157. There are fifteen different insert
arrangements shown in MS3157 Sheets 1
through 14. Table 1023 lists the number, size,
and type (standard or coaxial) of contacts in each
insert arrangement. In a given insert, the
contacts may be all pins, in which case they are
housed in a receptacle (See Figure 1058).
The insert arrangements may be housed
insert. Position this assembly on a

horizontal support with the back of the
contacts resting on the support.
(3) Slide the retention springs over the front of

the contacts.
(4) Install the retaining rings by using a suitable

tool to spread each ring and slide it over the
front of the contact. Push the ring down
until it locks behind the shoulder of the
contact. Ensure the ring is properly seated
behind the shoulder.
(5) Slide the retaining plate over the cables.

Then slide the contact ferrules over the
unstripped cables.
76

Sect 2 Chap 10
(6) Strip the cables and crimp the contacts.

(7) Insert the front insert into the back of the
connector as indicated in Figure 1063.
(8) Insert the contacts into the front insert by

hand until the back insert is flush with the
back of the plug shell.
(9) Slide the retainer plate over the cables and

position it on the back of the shell. Secure
the plate with the four screws and washers
supplied with the connector.
b.
Installing Non-releasable Coaxial Pin Contacts.

(See Figure 1063.)
(3) Insert the front insert into the back of the

receptacle shell as shown in Figure 1063.
Make sure the recessed cavities in the front
insert are facing the back of the shell.
(4) Slide the retainer plate over the crimped

contacts and cable.
(5) Insert the contacts by hand into the front

insert. Make sure the contacts seat in the
recessed cavities.
(6) Slide the rear insert over the rear portion of

the contacts. Push the rear insert in until it
is flush with the back of the shell.
(7) Slide the retainer plate over the cables and

(1) Select the receptacle shell that mates with
the plug shell used above.
position the plate on the back of the shell.

Secure the plate with the four screws and
washers supplied with the connector.
(2) Strip and crimp the coaxial cable to the

contacts using the procedure described in
paragraph 40. (Figure 1063 illustrates a
semi-rigid coaxial cable.)
77

Sect 2 Chap 10
Table 1022 MIL-C-81659 Connectors

Specification
(MIL-C-81659/xx)
/1
/2
/3
/4
/5
/6
/7
/8
/9
/10
/11
/12
/21
/22
/23
/24
/25
/26
/27
/28
/29
/30
/31
/32
/33
/34
/35
/36
/37
/38
/39
/40
/41
/42
/43
/44
/45
/46
/47
/48
/49
/50
/51
/52
/53
/54
/55
/56
/57
/58
/59
/60
78
Plug or
Receptacle
Plug
Plug
Receptacle
Receptacle
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Receptacle
Receptacle
Plug
Plug
Plug
Plug
Receptacle
Receptacle
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Plug
Plug
Receptacle
Receptacle
Type
Class
Series
Shell Size
II
II
II
II
I
I
II
II
II
II
I
I
II
II
I
I
II
II
I
I
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
A
A
A
A
A
A
A
A
A
A
A
A
B
B
B
B
B
B
B
B
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Insert Plug
Types
Single
Single
Single
Single
Single
Single
Double
Double
Double
Double
Double
Double
Double
Double
Double
Double
Double
Double
Double
Double
Single
Single
Single
Single
Double
Double
Double
Double
Triple
Triple
Triple
Triple
Quadruple
Quadruple
Quadruple
Quadruple
Single
Single
Single
Single
Double
Double
Double
Double
Triple
Triple
Triple
Triple
Quadruple
Quadruple
Quadruple
Quadruple

Sect 2 Chap 10
Table 1023 Contact Insert Arrangements for MIL-C-81659 Connectors

Position Insert
Arrangement
26
40
45
57
67
106
124
C2
C3
C8
D8
10C3
32C2
33C4
40C1
Total Number of
Contact Positions
26
40
45
57
67
106
124
2
3
8
8
10
32
33
40
Number, Size and Type of Contacts

26 size 16
40 size 20
45 size 20
57 size 20
64 size 20, 3 size 16
106 size 20
124 size 20
2 size 1 coaxial
2 size 7 coaxial, 1 size 3 coaxial
8 size 9 coaxial
4 size 16, 4 size 12
7 size 20, 3 size 11 coaxial
25 size 20, 4 size 16, 4 size 5 coaxial
Shell
Size
A
A
A
A
A
A
B
A
A
A
A
A
A
A
A
MS3157 Sheet
Number
1
2
3
3
4
5
6
7
8
9
10
11
12
13
14
Figure 1061 Typical MIL-C-81659 Duplex Connector
Figure 1062 Assembly of MIL-C-81659 Connectors With Standard Contacts
79

Sect 2 Chap 10
Crimping and Assembly of Standard Contacts in

CAUTION
107.
Crimping of standard contacts and their insertion
and removal in the MIL-C-81659 connectors are
accomplished with the tools listed in Table 1026.
a.
Installation of Rear-Release Standard Pin or

Socket Contacts.
(1) Select
the
insertion
tool
MS3156
corresponding to the size of the contact barrel
(-22, -20, or -16). (See Table 1026) Place
the wire from the contact over the wire slot of
the coloured insertion tip and hold it in this
position with your thumb.
(2) While applying light pressure on the wire,

slide your thumb toward the tip of the tool.
The tip will spread, allowing the wire to enter
the tip.
(3) Position the tool tip against the shoulder of

the contact as shown in Figure 1064. (Note
that the bevelled tip of the insertion tool is
smaller than the outside diameter of the
contact shoulder. This allows the locking tines
in the cavity to grip the shoulder of the
contact.)
(4) Press the wire against the tool handle to hold
Contacts are easily inserted. The use of too much

force may damage the connector insert.
b.
Removal of Rear-Release Standard Pin or Socket

Contacts.
(1) Select
the
extraction
tool
MS3156
corresponding to the size of the contact barrel
(-22, -20, or -16). (See Table 1026) Place
the wire from the contact over the wire slot of
the white extraction tip and hold it in this
position with your thumb.
(2) Apply light pressure on the wire and slide

your thumb toward the tip of the tool. The tip
will spread, allowing the wire to enter the tip.
(3) Insert the tool tip straight into the cavity until it
bottoms. This will release the locking tines.
(4) Hold the wire against the tool handle. Pull the
tool and contact straight out the back of the
connector cavity. (See Figure 1075).
CAUTION
Contacts are easily removed. The use of too much
force may damage the connector insert.
the contact in position.
(5) Align the contact with the cavity and insert the
contact straight into the cavity until it bottoms
and the locking tines in the cavity click into
position behind the contact shoulder.
(6) Remove the tool. Pull back lightly on the wire

to make certain the contact is locked in the
cavity.
NOTE
To remove unwired rear-release contacts, remove
sealing plug, insert the appropriate size removal tool,
MS3156, to grasp the rear of the contact and release
the locking tines. Then push on the front of the
contact with tool MS3344 (or the appropriate size
variation of this tool). After the contact has been
released from the insert, remove the extraction tool,
grasp rear of contact, and pull from the connector.
Table 1024 Insert Arrangements, MIL-C-81659 Connector, Series 1 and 2

Insert
Designation
Number
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012
0013
0014
0015
0016
0017
0018
0019
80
Shell Insert Arrangement

A
26 P
26 S
26 P
26 S
26 P
26 S
26 P
26 S
40 P
40 S
40 P
40 S
40 P
40 S
40 P
40 S
45 P
45 S
45 P
26 P
26 S
26 P
26 S
26 P
26 S
26 P
26 S
26 P
26 S
40 P
40 S
40 P
40 S
40 P
40 S
40 P
40 S
40 P
40 S
45 P
26 P
26 S
40 P
40 S
Insert
Designation
Number
0070
0071
0072
0073
0074
0075
0076
0077
0078
0079
0080
0081
0082
0083
0084
0085
0086
0087
0088
Shell Insert Arrangement

A
C8S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
D8P
D8S
C8P
C8S
106 S
106 P
33 C4S
106 S
106 P
67 P
67 S
67 P
67 S
106 S
106 P
106 S
106 P
67 P
67 S
C8P
C8S
106 S
106 P
33 C4P
33 C4S
67 P
67 S
33 C4P
33 C4S
33 C4P
33 C4S
67 P
67 S
67 P
67 S
C8P
C8S
C8P
C8S

Sect 2 Chap 10
Table 1024 Insert Arrangements, MIL-C-81659 Connector, Series 1 and 2 (Continued)

Insert
Designation
Number
0020
0021
0022
0023
0024
0025
0026
0027
0028
0029
0030
0031
0032
0033
0034
0035
0036
0037
0038
0039
0040
0041
0042
0043
0044
0045
0046
0047
0048
0049
0050
0051
0052
0053
0054
0055
0056
0057
0058
0059
0060
0061
0062
0063
0064
0065
0066
0067
0068
0069
0139
0140
0141
0142
0143
Shell Insert Placement

A
45 S
45 P
45 S
45 P
45 S
57 P
57 S
57 P
57 S
57 P
57 S
57 P
57 S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
106 S
106 P
106 S
106 S
106 P
106 S
106 P
106 S
124 P
124 S
124 P
124 S
124 P
124 S
124 P
124 S
106 S
106 P
26 P
26 S
26 P
26 S
10 C3P
10 C3S
C8P
C8S
C8P
C8S
C8P
32 C2P
32 C2S
40 C1P
40 C1S
67 C3P
45 S
45 P
45 S
45 P
45 S
C
45 P
45 S
45 P
45 S
45 P
45 S
57 P
57 S
57 P
57 S
57 P
57 S
57 P
57 S
57 P
57 S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
67 P
67 S
106 P
106 S
106 S
106 P
106 S
106 P
106 S
106 P
106 S
106 P
106 S
106 P
106 S
124 P
124 S
124 P
124 S
124 P
124 S
124 P
124 S
124 P
124 S
124 P
124 S
26 P
26 S
106 S
106 P
26 P
26 S
10 C3P
10 C3S
C8P
C8S
C8P
C8S
33 C4P
26 P
26 S
C8P
C8S
C8P
C8S
106 S
106 P
57 P
57 S
26 S
26 P
67 P
67 S
Insert
Designation
Number
0089
0090
0091
0092
0093
0094
0095
0096
0097
0098
0099
0100
0101
0102
0103
0104
0105
0106
0107
0108
0109
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
0120
0121
0122
0123
0124
0125
0126
0127
0128
0129
0130
0131
0132
0133
0134
0135
0136
0137
0138
0144
0145
0146
0147
0148
Shell Insert Placement

A
106 S
106 P
106 S
106 P
106 S
106 P
106 S
106 P
106 S
106 P
106 S
106 P
106 S
106 P
33 C4P
33 C4S
33 C4P
33 C4S
33 C4P
33 C4S
C2P
C2S
C2P
C2S
C3P
C3S
C3P
C3S
C8P
C8S
10 C3P
10 C3S
32 C2P
32 C2S
32 C2P
32 C2S
32 C2P
32 C2S
32 C2P
32 C2S
32 C2P
32 C2S
40 C1P
40 C1S
57 P
57 S
C8P
C8S
10 C3P
10 C3S
67 C3S
C8P
C8S
57 P
57 S
67 P
67 S
106 S
106 P
106 S
106 P
C8P
C8S
67 P
67 S
67 P
67 S
106 S
106 P
67 P
67 S
33 C4P
33 C4S
106 S
106 P
106 S
106 P
C8P
C8S
67 P
67 S
106 S
106 P
C8P
C8S
C8P
C8S
67 P
67 S
106 S
106 P
C8P
C8S
40 C1P
40 C1S
57 P
57 S
67 P
67 S
106 S
106 P
106 S
106 P
32 C2P
32 C2S
40 C1P
40 C1S
45 P
45 S
57 P
57 S
67 P
67 S
106 S
106 P
40 C1P
40 C1S
106 S
106 P
57 P
57 S
26 P
26 S
81

Sect 2 Chap 10
Table 1025 Polarization (Keying) Positions
KEY
CODE
#PLUG
KEYING POST
L
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
# L LEFT
82
C
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
KEY
CODE
R
1
1
1
1
1
1
6
6
6
6
6
6
5
5
5
5
5
5
4
4
4
4
4
4
3
3
3
3
3
3
2
2
2
2
2
2
1
1
1
1
1
1
6
6
6
6
6
6
5
C CENTRE
RECEPTACLE
KEYING INSERT
L
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
R RIGHT
4
4
4
4
4
4
5
5
5
5
5
5
6
6
6
6
6
6
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
5
5
5
5
5
5
6
C
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
3
3
3
3
3
3
3
3
3
3
3
3
KEY
CODE
R
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
# PLUG
KEYING POST
L
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
C
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
R
5
5
5
5
5
4
4
4
4
4
4
3
3
3
3
3
3
2
2
2
2
2
2
1
1
1
1
1
1
6
6
6
6
6
6
5
5
5
5
5
5
4
4
4
4
4
4
3
3
3
KEY
CODE
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
RECEPTACLE
KEYING INSERT
L
6
6
6
6
6
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
5
5
5
5
5
5
6
6
6
6
6
6
1
1
1
1
1
1
2
2
2
C
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
R
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
6
6
5
4
3
2
1
6
5
4
3
3

Sect 2 Chap 10
Table 1026 Tools For MIL-C-81659 Standard Contacts

Contact Size
Crimp Tool
Insertion Tool
Removal Tool
Series 1 Front Release

22
MIL-DTL-22520/2
AMP 91039-1
AMP 91040-1
20
MIL-DTL-22520/2 (or /1)
AMP 91039-1
AMP 91040-1
16
MIL-DTL-22520/1
22
MIL-DTL-22520/2
MS 3156-22 (Black End)
MS 3156-22 (White End)
20
MIL-DTL-22520/2 (or /1)
MS 3156-20 (Green End)
16
MIL-DTL-22520/1
MS 3156-16 (Blue End)
MS 90455-1
Series 2 Rear Release
MS 90456-1
Figure 1063 Assembly of MIL-C-81659 Connectors Polarization (Keying) Posts and Inserts
Crimping of Coaxial Contacts in MIL-C-81659
Connectors
108.
Table 1027 lists the type of contact, type of
coaxial cable, crimping tools, selector position setting,
and contact positioner used with inner contact crimping
tool, crimping die opening used with ferrule crimping
tool, and cable stripping lengths for each of the MIL-C81659 coaxial connectors. These connectors are
described in MS drawings 3168 through 3177. Sizes 1, 3
and 7 connector contacts are non-releasable. They can
only be removed by disassembling the connector as
shown in Figure 1063. Size 5 and 9 connectors are

equipped with rear-release contacts that may be
released and removed from the rear of the connector
with the use of special tool MS3178-001.
109.
Centre Contact Crimping Procedure. The
centre contacts of MIL-C-81659 coaxial connectors are
crimped with either the MS22520/2-01 standard crimping
tool or the AMP 220015-1 crimping tool as listed in Table
1027. If the MS22520/2-01 tool is used, a special AMP
contact positioner (also listed in Table 1027) must be
employed.
83

Sect 2 Chap 10
Figure 1064 Assembly of MIL-C-81659 Connectors with Coaxial Connectors
a.
The procedure to be used with the MS22520/2-01

crimping tool is as follows:
(6) Slip sealing boot (when used) over cable. The

end of the sealing boot with the rounded lip
should face the end of the cable.
(1) Select the special AMP positioner to use from

Table 1027.
(2) Open the tool handles. (If not already open.

The tool handles must be fully closed to
release the ratchet).
(3) Install the positioner by inserting it into the

crimping tool retainer ring and turning 90 to
the right until the bayonet pin locks.
(4) Install the safety clip in retainer ring.

(5) Raise selector knob on crimping tool, and
rotate it until selector position number from
Table 1027 is opposite index mark.
84
NOTE
Sealing boots are needed with all size 5 and size 9
coaxial contacts. Sealing rings are needed for all size
3 and size 7 coaxial contacts and for some size 1
contacts. In general, the manufacturer will furnish the
parts needed to seal the connector from the
environment and to keep moisture from getting into
the cable. Make sure all seals furnished with the
contacts are properly installed. (See Figure 1066)

Sect 2 Chap 10
Figure 1065 Insertion of Standard Contacts in MILC-81659 Connectors
Figure 1066 Removal of Standard Contacts in MIL-C81659 Connectors
(4) Insert stripped centre conductor into centre

(1) Slip ferrule (when used) over cable. The
crimp end of the ferrule should face the end of
the cable and the shoulder end of the ferrule
should face away from the end of the cable.
(See Figure 1066).
contact until cable dielectric butts against rim

of wire barrel. Then close crimp tool handles
until ratchet releases. Handles will then return
to open position, allowing crimped contact to
be removed.
NOTE
A crimping ferrule is not used with semi-rigid coaxial
cable.
(2) Strip cable using stripping lengths given in

Table 1027 and illustrated in Figure 1065.
For braided cable, flare braid. (See Figure
1066.)
(3) Insert contact into indentor opening so that
Figure 1067 Installation of Sealing Boot and Ferrule

on Coaxial Cable Before Crimping Contacts
contact rests in positioner and wire barrel is

between indentor jaws.
Figure 1068 Stripping Dimensions for Coaxial Cable

in Table 1027
85

Sect 2 Chap 10
b.
The procedure to be used with AMP 220015-1

NOTE
Sealing boots are needed with all size 5 and size 9
coaxial contacts. Sealing rings are needed for all size
3 and size 7 coaxial contacts and for some size 1
contacts. In general, the manufacturer will furnish the
parts needed to seal the connectors against the
environment and to keep moisture from getting into
the cable. Make sure all seals furnished with the
contacts are properly installed.
(1) Slip sealing boot (when used) over cable. The

end of the sealing boot with the rounded lip
should face the end of the cable. (See Figure
1066)
Table 1027 Stripping Lengths, Crimping Tools, Contacts, and Cables for MIL-C-81659 Coaxial Connectors
Stripping Lengths and Crimping Tools
Stripping Length, mm 0.4
Contact MS
Number
Braid
A
Wire
B
Braid +
Insul.
C
Total
Jacket
D
3168
1.2
4.8
1.2
6.7
3169
3170
12.7
5.5
4.8
3.2
12.7
5.5
17.5
11.0
3171
3172
12.7
5.5
4.8
3.2
12.7
7.9
17.5
11.0
3173
5.5
3.2
7.9
11.0
3174
5.5
3.2
7.9
11.0
3175
5.5
3.2
7.1
10.3
3176
1.2
4.8
1.2
6.7
3177
5.5
3.2
7.9
11.0
Centre Contact
Crimp Tool
M22520/2-01
AMP-1-601966-9
AMP-220015-1
M22520/2-01
AMP-1-601966-8
AMP-220015-1
M22520/2-01
AMP-1-601966-6
M22520/2-01
AMP-1-601966-6
M22520/2-01
AMP-1-601966-7
M22520/2-01
AMP-1-601966-7
M22520/2-01
AMP-1-601966-6
M22520/2-01
AMP-1-601966-6
Selector
Setting
Outer
Contact
Crimp Tool
Die
220066-1
220015-1
220066-1
5
5
220015-1
220066-1
220066-1
220066-1
220066-1
220066-1
220066-1
Contacts and Cables

Contact MS
Number
Outer
Contact Type
Contact Size
Cable Type
Exit Arrangement
Removal Tool
3168
3169
3170
3171
3172
Pin
Socket
Pin
Socket
Pin
1
1
3
3
5
3173
Socket
3174
3175
3176
3177
Pin
Socket
Pin
Socket
7
7
9
9
141S.R.
RG214
RG142
RG214
RG58C
RG223
RG58C
RG223
RG188
RG58C
141S.R.
RG58C
Straight
Straight
Straight or 90
Straight
Straight
Straight
Straight
Straight
Straight or 90
Straight
Straight
Straight
Non-releasable
Non-releasable
Non-releasable
Non-releasable
MS3178-001
MS3178-001
MS3178-001
MS3178-001
Non-releasable
Non-releasable
MS3178-001
MS3178-001
(2) Slip ferrule (when needed) over cable. The

crimp end of the ferrule should face the end of
the cable and the shoulder end of the ferrule
should face away from the end of the cable.
(See Figure 1059)
NOTE
A crimping ferrule is not used with semi-rigid coaxial
cable.
86

Sect 2 Chap 10
(3) Strip cable using stripping lengths given in
(1) Install seal ring (if used) over braid support
Table 1027 and illustrated in Figure 1067.

For braided cable, flare braid. (See Figure
1057.)
section of contact against shoulder on

contact. (See Figure 1069)
(2) Insert crimped centre contact into contact
(4) With crimping tool handles fully open, rotate
body until cable dielectric bottoms against

dielectric inside contact body. Braid should fit
over braid support section of contact. (See
Figure 1070)
contact locator-stop knob (on back of tool

head) to open position. (See Figure 1068)
(5) Insert centre conductor of coaxial cable into

centre contact wire barrel until cable dielectric
butts against rim of wire barrel. Then place
contact in tool head as shown in Figure
1068.
NOTE
When crimped centre contact of size 1 contact is
inserted into the size 1 contact body, an internal
locking feature should engage and hold the centre
contact captive. Pull back lightly on cable to deter
mine if contact is being held captive by the internal
locking feature. This locking feature is not present in
the smaller size contacts.
(3) Position ferrule over braid and against

shoulder on contact.
(4) Place the assembly in crimping die of tool

with shoulder of contact against die. (See
Figure 1071)
(5) Close tool handles until ratchet releases to

form braid crimp.
b.
The procedure for crimping braided coaxial cable

to outer contacts with the AMP 220066-1 tool is as
follows:
(1) Install seal ring (if used) over braid support

section of contact. (See Figure 1069)

dielectric inside contact body. Braid should fit
over braid support section of contact. (See
Figure 1070)
Figure 1069 Crimping Centre Contacts with AMP
220015-1 Crimping Tool
(6) Close tool handles until ratchet releases. Tool

ratchet will not release and handles will not
open until full crimping cycle has been
completed, assuring proper depth of crimp
indent.
110.
Outer Contact Crimping Procedure. The outer
contacts of MIL-C-81659 coaxial connectors are crimped
with either the AMP 220066-1 crimping tool or the AMP
220015-1 crimping tool as listed in Table 1027. The
220015-1 tool has only one outer contact crimping die,
but the 220066-1 tool has three. The correct die to use is
given in Table 1027.
a.
The procedure for crimping braided coaxial cable

to outer contacts, with the AMP 220015-1 tool is
as follows:
NOTE
contact captive. Pull back lightly on cable to
determine if contact is being held captive by internal
(3) Position ferrule over braid and against

shoulder on contact.
(4) Place the contact-ferrule assembly in the

appropriate crimping die (from Table 1027)
of the tool, with the shoulder of the contact
against the tool jaw. (See Figure 1072 and
10-73)

from braid crimp.
87

Sect 2 Chap 10
c.
The procedure for crimping semi-rigid coaxial

cable contacts with the AMP 220066-1 ferrule

dielectric inside contact body. Outer
conductor of cable should slip inside contact
backshell. (See Figure 1074)
NOTE
contact captive. Pull back lightly on cable to
determine if contact is being held captive by internal
Figure 1072 Contact-Ferrule Assembly in Ferrule

Crimping Die of Crimping Tool AMP 220015-1 Ready
for Crimping
(2) Place the cable-contact assembly in the

appropriate crimping die (from Table 1027)
of AMP 220066-1 ferrule crimping tool so that
the contact backshell is in the crimping die
and the shoulder of the contact body
(adjacent to the backshell) butts against the
die. (See Figure 1075)

form backshell crimp.
Figure 1073 AMP 220066-1 Ferrule Crimping Tool
Showing the Three Crimping Dies
Figure 1070 Contact Assembly Using Seal Ring
Figure 1074 Contact-Ferrule Assembly in Crimping

Die of AMP 220066-1 Ferrule Crimping Tool Ready
for Crimping
CONTACT BACKSHELL
Figure 1071 Crimped Centre Contact of Braided

Coaxial Cable Inserted in Contact Body
Figure 1075 Crimped Centre Contact of Semi-Rigid
Coaxial Cable Inserted in Contact Body
88

Sect 2 Chap 10
e.
SHOULDER ON CONTACT
BUTTS AGAINST DIE
Pull the cable and tool out of the contact cavity.
113.
Sealing Plugs. All unused cavities in circular
and rectangular connectors should be filled with unwired
contacts and appropriate MS27488 sealing plugs (see
Table 1028). The unwired contacts and sealing plugs
are required to preserve the environmental sealing
characteristics of the connectors.
PLACE BACKSHELL OF
CONTACT BODY ON
CRIMPING DIE
Figure 1076 Semi-Rigid Cable-Contact Assembly in

Crimping Die of AMP 220066-1 Ferrule Crimping Tool
Ready for Backshell Crimping
Insertion and Removal of Rear Release Coaxial

Contacts in MIL-C-81659 Connectors
111.
Inserting Contacts. An insertion tool is not
required for inserting these contacts. To insert a contact,
align it with the back of the contact cavity and push it
straight into the connector until it bottoms. Pull back
lightly on the cable to make certain the contact is locked
in the cavity. Slide the sealing boot over the cable and
into the contact cavity until the collar of the seal butts
against the insert as shown in Figure 1076. Slight
rotation of the seal will ease insertion.
Figure 1077 Insertion of Rear-Release Coaxial

Contacts in MIL-C-81659 Connectors
112.
Extracting Contacts. Removal tool MS3178001 is designed to remove size 5 and 9 contacts from
MIL-C-81659 connectors. The procedure is as follows:
a.
Slide the sealing boot back over the cable a

minimum distance of 8.2cm before extracting the
contact. Do not cut or otherwise damage the
sealing boot.
b.
Place the cable over the V notch of the

extraction tool handle. Then press the cable into
the notch. The tool handle will spread open and
allow the cable to enter. Make certain the cable is
seated in the full length of the tool as shown in
Figure 1077.
c.
Grip the tool handle firmly and insert the tip to the
contact cavity until it bottoms.
d.
Figure 1078 Removal of Rear-Release Coaxial

Contacts From MIL-C-81659 Connectors
Maintain slight inward pressure on the back of the

tool handle and pull back on the cable to release
the contact.
89

Sect 2 Chap 10
Connector or
Module
Contact Cavity
Size
Superseding
Part Number
Table 1028 MS27488 Sealing Plugs and Superseded Part Numbers
22 & 23
MS27488-22
M81511/39-22
20
MS27488-20
M81511/39-20
M83723/28-20
MS25251-20
MS27186-1
MS27187-3
MS3187-20-2
16
MS27488-16
M81511/39-16
M83723/28-16
MS25251-16
MS27186-2
MS27187-1
MS3187-16-2
12
MS27488-12
M81511/39-12
M83723/28-12
MS25251-12
MS27186-3
MS27187-2
MS3187-12-2
MS27488-8
M83723/28-8
MS25251-8
MS27488-4
M83723/28-4
MS27488-0
M83723/28-0
Superseded Military Specification Part Number
MS27187-4
WARNING
fuelled aircraft.
WARNING
Wire Removal Procedure

115.
The wire removal procedure for MTCs is as
follows:
a.
b.
c.
d.
Insert wafer removal tool in the rear of the MTC

connector and gently pull the cable to release the
wafer from the shell.
Clamp the appropriate wafer holding fixture in a
convenient position and insert wafer into holding
fixture.
If working on installed harnesses, attach the static
grounding bus to the wafer contacts. It attaches
by clipping onto the contacts of either pin or
socket wafers. Do not force the grounding bus
rightly onto the wafer. Very gentle insertion is
sufficient for static grounding.
Isolate the wire and sleeve terminator with the
sleeve isolator on the holding fixture.

ventilated.
e.
Use the M83521/5-01 heater and direct hot air at

the solder joint only. When the solder melts pull
the wire and the sleeve material straight off with
tweezers.
f.
To prevent electrostatic discharge damage to

sensitive electronic components when working on
installed harnesses, the static grounding bus must
be used whenever any solder sleeve terminators
are installed, either on the wafer or anywhere on
the wires.
Wire Connection Procedure

116.
The wire connection procedure for MTCs is as
follows:
a.
90
MS3187-4-2
MS3187-0-2
MULTIPLE TERMINATION CONNECTORS

(MTCS)
114.
MTCs are rectangular, flat and high density
connectors used in making environmentally protected
electrical connections between round wire harnesses
(see Figure 1078).
MS3187-8-2
Clamp appropriate wafer holding fixture in a

convenient position and insert wafer into holding
fixture.

Sect 2 Chap 10
b.
Install a connector solder sleeve terminator back

over the wire flue end first.
c.
Strip wire back 3.8 4.3mm.
d.
Position stripped wire over solder tab and slide

sleeve terminator over wire and tab until it touches
the wafer.
e.
WARNING
ventilated.
f.
Using a M83521/5-01 hot air gun, direct hot air at

the solder until it melts and flows.
Isolate sleeve with the sleeve isolator in holding

fixture.
NOTE
Allow terminator to cool before disturbing.
WARNING
g.
Remove assembly from fixture and inspect in

accordance with Figure 1079.
h.
Insert wafer into rear of MTC shell.

fuelled aircraft.
Figure 1079 Multiple Termination Connector
91

Sect 2 Chap 10
Figure 1080 Inspection Criteria
92

Sect 2 Chap 11
SECTION 2
CHAPTER 11
ELECTRIC CONNECTOR SEALING COMPOUND

INTRODUCTION
NOTE
1.
Sealing compound is used to moisture-proof and
reinforces the wiring connected to the backs of electric
connectors against failure caused by vibration and
lateral pressure which fatigues the wire at the solder
cup. This process is commonly called potting. The
sealing compound protects electric connectors from
corrosion, contamination, and arcing by excluding
moisture, and other contaminants.
2.
This chapter describes the potting compounds
used on aircraft electric connectors, and gives
instructions for preparing and storing the compounds.
Instructions for potting MS electric connectors are
detailed in Section 2, Chapter 10.
3.
electric connector sealing:
MIL-PRF-8516
Sealing Compound, Synthetic

Rubber, Electric Connectors and
Electric Systems, Chemically
Cured
MIL-PRF-23586
Sealing Compound (With

Accelerator), Silicone Rubber,
Electrical
MIL-M-24041
Moulding and Potting

Compound, Chemically Cured,
Polyurethane
SAE AMS-DTL23053

Heat Shrinkable
MIL-M-24041 must be prepared under controlled

conditions as described in Paras 19 to 25. The use of
MIL-PRF-23586 Type II, Class II, Grade A, silicone
potting compound should be restricted to small
connectors used in adequately vented areas. Under
all other conditions, use only the Grade B compound.
Sealing compound is not generally applied to the
following connectors: environment-proof H, K, L
and W connectors, and coaxial connectors.
GENERAL PRECAUTIONS
5.
Potting compounds may be supplied in paired
containers of base compound and accelerator, premixed and frozen and in bulk. Follow the manufacturers
instructions carefully when mixing the base compound
and accelerator if both are supplied in separate
containers. Substitution, partial mixing or use of incorrect
proportions of compound and accelerator may produce a
sealant with inferior properties.
6.
Ensure that the entire amount of accelerator is
mixed into the entire amount of base. Any change in
catalyst ratio will affect the electrical properties of the
sealant and may also affect the pot life, reversion
resistance, and hardness of the cured compound. Do
not mix base compounds and accelerator components of
different batch numbers because substandard electrical
properties may result.
WARNING
The sealants may contain small quantities of
flammable solvents or release flammable by-products
on curing. Observe adequate ventilation and fire
precautions during mixing, curing, and/or storage.
DESCRIPTION
4.
Sealing compound in accordance with military
specification MIL-PRF-8516 is a two-part polysulfide
synthetic rubber compound, consisting of a base and an
accelerator (curing agent), packaged together. This
compound is used to seal connectors located in areas
where the ambient temperature does not exceed 85C.
Sealing compound in accordance with military
specification
MIL-PRF-23586,
silicone
rubber
compound, consists of a base and an accelerator (curing
agent). This compound is used to seal connectors in
areas where the ambient temperature exceeds 85C, but
does not exceed 230C.
WARNING
Elastomeric sealing and potting compounds shall
comply with the requirements of specifications MILPRF-8516 and MIL-PRF-23586. Silicone potting
compound (RTV) containing acetic acid shall not be
used on connectors because acetic acid causes
corrosion.

Sect 2 Chap 11
PREPARATION OF SEALING COMPOUND
e.
Determine if mixing is complete by spreading a

drop of the mixture very thinly on a piece of white
paper with a knife blade or similar instrument.
Close examination should not reveal any specks
or streaks. Do not mix the sealant beyond the
point where tests show the accelerator to be
thoroughly mixed into the base compound.
f.
When the mixing procedure has been completed,

the sealant is ready for use and may be poured
directly into the connector (primed in accordance
with the manufacturer's instructions) to be sealed.
For details of connector sealing, see Section 2,
Chapter 10.
Preparing Frozen Pre-Mixed Sealants

7.
Remove the frozen, pre-mixed sealant from the
deep freeze and bring its temperature to room
temperature before use by warming with compressed air
on the outside of the container. Never use heat to raise
the sealant temperature. Utilise frozen, pre-mixed
sealant as soon as possible after removal from the deep
freeze because of a significant reduction in work life
(approximately 50 percent).
Hand Mixing Procedure
g. If the mixed compound is not to be used

immediately, store it as directed in Paragraph 11.
WARNING
The accelerator contains toxic compounds. Use in a
well ventilated area. Avoid eye and skin contact. Use
personal
protective
equipment,
rubber
or
polyethylene gloves and approved eye protection.
Clean hands thoroughly after use.
8.
Paired containers of base
accelerator shall be mixed as follows:
a.
compound
and
Remove lid from accelerator container and stir

contents slowly into a smooth creamy paste with a
clean spatula, wooden tongue depressor, or putty
knife.
h. Sealants having an application time of one hour or

less shall be hand mixed on the job. Do not freeze
such material.
Mechanical Mixing
9.
Mechanical mixing should be done at 15C or
lower to prolong the working life of the sealant. The
a.
Hand mix the accelerator as described in Para 8.

A paint shaker vibrating machine may be used if
available. Shake for five to seven minutes.
b. Remove top from the base compound container

and stir contents until material has a smooth
texture. This is necessary to recombine material
that may have settled in storage.
b. If the base material is packaged in a metal

container, cut off the top of the container using a
mechanical can opener. This should leave a
smooth wall without any burr at the top of the can.
c.
c.
Combine accelerator and base material and

thoroughly agitate or mix until no accelerator
streaks or traces of unmixed material are visible.
Mix slowly, do not beat or whip; fast mixing may
cause excessive amounts of air to become
trapped in the compound. Mixing normally
requires five to eight minutes. Continued scraping
of the sides and corners of the bottom of the
container will ensure complete mixing.
d. For base compound and accelerator supplied in

bulk, weigh out the desired amount of base
compound and the related specified amount of
accelerator in separate containers. Follow the
manufacturer's instructions carefully. Combine the
accelerator and the base material and thoroughly
agitate or mix in such a manner as to minimise the
entrapment of air until no accelerator streaks or
traces of unmixed material are visible. This
normally requires five to eight minutes. Continued
scraping of the sides and corners of the bottom of
the container will ensure complete mixing.
Clamp base material container securely to drill

press geared to 50 RPM minimum to 90 RPM
maximum. Insert a mixing paddle fashioned from
a drill rod and wire.
d. Start drill press motor and slowly lower mixing

paddle into the base compound to recombine any
material that may have settled.
e.
Scrape all accelerator from its container and place

it in the base material. Start drill press motor again
and mix slowly for approximately two minutes.
Stop machine, raise paddle, and scrape container
walls as clean as possible. Start the drill press
and lower the mixing paddle again and continue
mixing for an additional three minutes.
f.
Make thin spread of sealant on white paper as

described in Paragraph 8, step e. If necessary,
continue mixing in two-minute cycles followed by
paper test until no traces of unmixed material are
visible. The sealant is then ready for use.
g. If the mixed compound is not to be used at once,

store in accordance with instructions in Paragraph
11.

Sect 2 Chap 11
STORAGE OF SEALING COMPOUND
Dispensers for Sealing Compound
Storage of Unmixed Sealing Compound
12. Potting compound once mixed should be

immediately poured into dispenser tubes made of
polyethylene, TFE, or aluminium. If necessary to store
mixed compound in accordance with Paragraph 11, the
compound should first be poured into the final dispenser
tube.
10. Store base compound and accelerator in a cool

place, preferably under refrigeration. Shelf life for MILPRF-8516 and MIL-PRF-23586 compounds is
approximately six months when stored below 24C and
can be extended to one year when stored at 7C or
below.
CAUTION
Do not store sealing compound at temperatures
above 27C. Keep base compound and accelerator
together in the carton as supplied. Note
manufacturing date stamped on carton and use
oldest material first.
NOTE
Do not use sealing compound which has exceeded
normal shelf life unless it has been tested by an
appropriate laboratory to evaluate its acceptability for
further use.
Storage of Mixed Sealing Compound
11. Mixed MIL-PRF-8516 potting compound can be
stored in cartridge tubes for periods of 30 to 60 days
provided the filled tubes are quick-frozen immediately
after mixing and are stored at -40C. Quick-freezing and
thawing of the filled tubes should be done in accordance
with the manufacturers instructions. Freezing by slow
cooling in air is not recommended since it reduces the
mixed storage life. Mixed MIL-PRF-23586 potting
compounds usually have shorter storage life than MILPRF-8516 compounds after quick-freezing; the storage
life of quick-frozen MIL-PRF-23586 potting compounds
is usually less than three weeks at -40C. In general,
extended storage of mixed, frozen potting compound
shortens pot life and cure time after thawing. The
method to determine whether the frozen compound is
suitable for use is to thaw the material; if it is still
pourable and has sufficient pot life remaining for
application purposes, it can be considered satisfactory.
CAUTION
Mixed compound in tubes should not be stored in dry
ice since the material will absorb carbon dioxide and
cause sponging or porosity.
PREPARATION OF FLUOROCARBON
INSULATED WIRE FOR POTTING
13. The following types of insulated wire must be
specially prepared prior to potting regardless of the type
of sealant to be used: polytetrafluoroethylene (PTFE) or
fluorinated polyethylene propylene (FEP). The preferred
method is to etch the insulation with fluorocarbon
compound. (See Paragraph 16)
14. An etching compound currently available is TetraEtch.
15. MIL-PRF-23586 silicone rubber sealant will
require a primer application to all metal surfaces in
addition to the etched fluorocarbon surfaces prior to
potting. When using MIL-PRF-8516 sealant, prime
and/or
pre-coat
when
recommended
in
the
manufacturers instructions.
Etching Method
WARNING
Personnel engaged in cleaning and etching
operations should use appropriate personal protective
equipment.
WARNING
Etching vapours are toxic. Ensure Adequate
ventilation. if etchant solution contacts the skin,
Neutralise with butyl alcohol and flush immediately
with water. Avoid direct contact of the etchant solution
with water, chlorinated hydrocarbons, and carbon
dioxide. Any spillage of etchant solution should first
be neutralised with butyl alcohol before washing with
water. Etchant solution is highly flammable and
should be kept away from open flames.

Sect 2 Chap 11
CAUTION
Sodium in the etchant solution reacts with oxygen,
moisture, and carbon dioxide, and exposure to air
affects the solution strength. Etchant that has
deteriorated badly will appear as a yellow or white
solution. The nominal colour of a fresh solution is
dark bluish-black. etching solution loses its normal
dark colour as its potency reduces.
d. Before any etchant is brought into an aircraft,

cover a sufficient section below the area to be
treated with heavy grade polyethylene and, in
turn, cover this with cloth. Any flowing of etchant
(if spilled) across the polyethylene will be
eliminated.
e.
If etchant is dripped or spilled on material other

than the polyethylene cover, wipe it up
immediately with a soft lint-free cloth.
Shrink Tube Method
CAUTION
Chemical etches should be applied only to TFE and
FEP insulations. Contact with other types of insulation
should be avoided.
16. Etching wire to provide a bondable surface shall
be completed prior to attachment to the connector, as
follows:
a.
Clean the bonding surfaces by scrubbing with

clean safety solvent and immediately wipe with a
clean dry cloth.
b. Dip the ends of the wire, at least 3mm above the

anticipated potted level, in a fresh etchant solution
for ten to thirty seconds. If the wire cannot be
conveniently immersed, fresh solutions may be
brushed on the bonding surfaces to obtain desired
etching.
c.
After dipping, neutralise the solution on the wire

with butyl alcohol and clean off residue by wiping
with a clean cloth wet with acetone.
d. A properly etched surface will have a brown to

deep brown colour.
17.
a.
Carry out a quality control check as follows:

Uniform colour of etched wires is desired.
b. A colour comparison may be used with samples

previously etched to within the acceptable colour
range. The individual wires within the typical
bundle may vary in colour within this range.
c.
Every precaution shall be taken to ensure that

etchant or water does not come in contact with a
connector assembly or pin.
18. An alternate to etching is to use heat shrink tubing

as follows:
a.
Select tubing from Table 111 that has an

unrestricted shrinkage that is at least 20% smaller
than the outside diameter of the wire being used.
b. Shrink a section of the tubing to the portion of

individual wire insulation that is to be encased in
potting compound. Tubing should extend
approximately 9.5mm beyond the anticipated
potting level.
PR-1547 (MIL-M-24041) MOULDING AND

POTTING COMPOUND
NOTE
PR-1547 must be prepared
conditions as described below.
under
controlled
Description
19. PR-1547 sealing compound is a two component
polyether polyurethane system consisting of a
prepolymer and a curing agent, before mixing. These
compounds are flexible cold-flow and cold-resistant
materials with excellent electrical properties and are
intended for use in a sea-water environment. This
compound will adhere to metal, rubber, or
polyvinylchloride, and may be used for sealing and
reinforcing electrical connectors, wiring, and other
electrical apparatus. This compound is used to seal
connectors located in areas where the temperature
range is -62C to 150C.

Sect 2 Chap 11
Table 111 Shrinkable Tubing

Military
Part Number
As Supplied
I.D. Min. (mm)
0.58
0.6 0.05
M23053/8-002C
1.6
0.78
0.6 0.05
M23053/8-003C
2.36
1.17
0.6 0.05
M23053/8-004C
3.18
1.6
0.6 0.05
M23053/8-005C
4.75
2.36
0.6 0.05
M23053/8-006C
6.35
3.18
0.3 0.08
M23053/8-007C
9.52
4.79
0.3 0.08
M23053/8-008C
12.7
6.35
0.3 0.08
M23053/8-009C
19.0
9.53
0.4 0.08
M23053/8-010C
25.4
12.7
0.45 0.08
M23053/8-011C
38.1
19.3
0.5 0.08
Thawing time and temperature must be controlled

closely to obtain the maximum application life.
Application life will be reduced by an increase in
either the thawing time or temperature. An incomplete
thaw will result if thawing time or temperature is
reduced.
Prepare as follows:
Remove cartridge from storage and place upright
in an oven, heating block, or in a dry metal sleeve
in a water bath at 55C for 20 minutes.
b. Remove cartridge from heat and work the pliable

cartridge with hands to distribute temperature
evenly.
c.
Replace cartridge at 55C for 5 minutes.
d. Remove cartridge from heat, bleed any entrapped

air from under the plunger.
e.
Wall Thickness
1.17
CAUTION
a.
I.D. Max
M23053/8-001C
Frozen Pre-Mixed Cartridges
20.
Insert cartridge in sealant gun, attach nozzle, and

apply.
Mixing Instructions
NOTE
The base compound absorbs moisture from the air.
Do not open containers until ready to use.
21. For
dense
void-free
compounds,
it
is
recommended that the material be degassed prior to
application. For small quantities, the material may be
degassed in a standard laboratory dessicator connected
to a vacuum pump. Larger quantities may be degassed
in standard volume equipment. Instructions are as
follows:
a.
Prolonged storage of the base compound below

18C will result in thickening. The base compound
may be liquefied by warming to 82C for
approximately two to three hours and stirring
thoroughly.
b. The accelerator thickens at ambient temperatures.

Warm the accelerator to 94C to 99C. Stir
occasionally until a homogeneous mix results.
WARNING
Avoid inhalation of vapours resulting from heating of
accelerator. Conduct operation only in a well
ventilated area.

Sect 2 Chap 11
c.
Cool the base compound and the accelerator to

21C to 27C. Combine components and mix
thoroughly. A wooden paddle must not be used
due to the high moisture content of wood.
d. Place freshly mixed material in a container

approximately two times the volume of the mixed
material and degas under a vacuum of 3
millimetres of mercury or less for a period of 5 to
15 minutes or until foaming subsides. After this,
the material is ready to use. If smaller quantities
are desired, mix 100 parts base compound with
25 parts accelerator, using procedure outlined in
the above paragraphs. It should be noted that
when the base compound has been exposed to
atmospheric moisture, it may chemically react
and, further, foam and solidify. It is recommended
that a blanket of inert gas be used on all base
compound containers if small quantities are
utilised.
CAUTION
After mixing the base compound and the accelerator,
all subsequent operations should be expedited to
minimise the reduction in application life.
Curing Time
22. PR-1547 may be cured at either room
temperature or at elevated temperatures. PR-1547 cures
to a firm condition in 24 hours at 25C and in 1-1/2 to 2
hours at 82C. PR-1547 reaches ultimate hardness after
five days at 25C or six hours at 82C. When required,
faster curing periods can be obtained by using cure
temperatures of 94C to 99C.
Storage Life
23. When stored at temperatures below 27C in
original unopened containers, the storage life of PR1547, supplied in two-component kit form, is six months.
Pre-mixed frozen PR-1547has a storage life of at least 7
days when stored at -29C and a minimum storage life
of 28 days when stored at -68C.
Surface Preparation
24. Before applying PR-1547 potting compound,
prepare the surface as follows:
a.
Cleaning. To obtain good adhesion, PR-1547

should be applied only to clean, dry surfaces.
Surfaces may be cleaned with an oil-free solvent
using a small brush or a clean, oil-free cloth.
b. Application of Primer. Primers should be used

for optimum adhesion and moisture resistance.
The
following
surface
preparations
are
recommended:
(1) Metal. PR-420-HTC is designed for metal
surfaces. A thin film of primer is applied to the
clean, dry surface.
(2) Neoprene. PR-1523M is designed for
neoprene surfaces. For some neoprene
formulations, buffing with an abrasive is
sufficient. Otherwise, after thoroughly buffing,
apply a coat of PR-1523M to the clean, dry
surface.
(3) Polyvinyl Chloride. PR-1543 is designed for
polyvinyl chloride surfaces. When a primer is
required, apply a thin coat PR-1543 to the
clean, dry surface.

Sect 2 Chap 12
SECTION 2
CHAPTER 12
RF CONNECTORS AND CABLING

INTRODUCTION
1.
Coaxial cable assemblies are used to carry radio
frequency (RF) power from one point to another with a
known rate of loss. An assembly consists of RF
connectors attached to coaxial cable. The coaxial cable
described in this chapter is of the flexible, solid
dielectric type, relatively small to medium size. The
characteristic impedance of most of the cable is 50
ohms, but several of the cables listed have a
characteristic impedance of 48, 53, 75 or 93 ohms.
2.
This chapter describes and illustrates the Military
Standard RF connectors and coaxial cable most
commonly used in aircraft and the recommended
methods for assembling coaxial cable to the
connectors. This section also describes and gives
instructions for assembly of miniature RF connectors to
coaxial cable, and for RF connectors used in fuelquantity-indicating systems. General procedures for
installation of coaxial cable assemblies into aircraft are
given in Section 2, Chapter 4.
MIL-DTL-22520
Crimping Tools, Wire

Termination, General
Specification For
MIL-DTL-25516
Connectors, Electrical,
Miniature, Co-axial, Environment
Resisting Type, General
Specification For
MIL-PRF-39012
Connectors, Coaxial, Radio

Frequency, General
Specification for
DESCRIPTION
RF Connectors
4.
RF connectors are available as pin-contact or
socket-contact plugs. (See Figure 121.) All plugs are
cabled and are for attaching to the ends of coaxial
cables. Receptacles are designed for mounting to
panels or chassis. Receptacles are either cabled or
uncabled. The following categories of RF connectors
are used for replacement purposes, with Category D
being the preferred.
3.
The following specifications are applicable to RF
connectors and cabling:
J-STD-004

Fluxes
J-STD-005

Pastes
J-STD-006
Requirements for Electronic

Grade Solder Alloys and
Fluxed and Non-Fluxed Solid
Solders for Electronic
Soldering Applications.
MIL-C-17
MIL-C-3607
MIL-C-3643
a.
Category A - Braid clamp and solder contact.
b.
Category C - Solder centre pin or socket crimp

ferrule. See Figure 122.
c.
Category D - Crimp centre pin or socket, crimp

ferrule. See Figure 122.
5.
The following series of RF connectors are used:

a.
Cables, Radiofrequency,
Flexible and Semi-rigid, General
Specification For
BNC Series. A small, lightweight, bayonet type,

quick-connect/disconnect connector, used with
small coaxial cables, where peak voltage is not
more than 500 volts. (See Figure 122.)
b.
Connectors, Coaxial,
Radiofrequency, Series Pulse,
HN Series. A high voltage (up to 5,000 volts),

threaded coupling connector used with medium
size coaxial cables. (See Figure 123.)
c.
Connectors, Coaxial,
Radiofrequency, Series HN,
N Series. A general purpose, threaded coupling

connector used with medium size coaxial cables.
(See Figure 124.)
d.
C
Series.
A
bayonet
type,
quickconnect/disconnect connector used with medium
size coaxial cables. It is electrically similar to the
N series. (See Figure 125.)
SAE AS 8660
Silicone Compound NATO Code

Number S-736 FSC 6850
MIL-S-22473
Sealing, Locking and Retaining

Compounds, Single-Component

Sect 2 Chap 12
e.
Pulse Series. A high-voltage connector for pulse

or DC applications. (See Figure 126.) Designed
to be used with rubber dielectric pulse cables but
may be used with equivalent-size cables of other
constructions where high voltage is not required.
With ceramic inserts, peak voltage is 15,000
volts at sea level. With rubber inserts, peak
voltage is 5,000 volts at 50,000 feet, but higher
voltages may be used at lower altitudes.
f.
TNC Series. A small lightweight connector

similar to the BNC series, but having a threaded
coupling, used where a positive coupling under
vibration and a low noise level is desirable. See
Figure 127.)
g.
SC Series. A connector used with medium size

coaxial cables; similar to the C series, but having
a threaded coupling. (See Figure 128.)
Figure 121 RF Connectors

Sect 2 Chap 12
Figure 122 Typical BNC Connectors
Figure 124 Typical N Connectors
Figure 123 Typical HN Connectors
Figure 125 Typical C Connectors
Coaxial Cable
6.
Coaxial cable consists of an inner (centre)
conductor separated from the outer conductor, usually
called a shield, by an insulating dielectric. The cable is
protected against moisture and abrasion by a tough
outer jacket (sometimes called a sheath). See Figure
129 for typical coaxial cables. The inner conductor is
usually copper, either solid or stranded, and may be
bare, tin plated, or silver plated. The outer conductor
(shield) is usually a copper braid, bare, tin plated, or
silver plated, woven over the dielectric. Some coaxial

cables have a double outer conductor (double shield)
to provide extra shielding. The dielectric has two
functions: (1) it provides low loss insulation between
the inner conductor and the outer conductor, and (2) it
maintains the relative position of the inner conductor
inside the outer conductor and therefore keeps the
capacitance between the two at a constant value. The
maximum operating temperature of cables with
polyethylene dielectric is 85C. The maximum
operating temperature of cables with teflon dielectric is

Sect 2 Chap 12
200C. Teflon dielectric coaxial cables can replace

polyethylene dielectric cables of the same physical and
electrical characteristics.
Figure 128 Typical SC Connectors
Figure 126 Typical Pulse Connectors
Figure 129 Typical Coaxial Cables
GENERAL PRECAUTIONS AND PROCEDURES

Figure 127 Typical TNC Connectors
General Precautions
7.
A good connection depends on holding coaxial
cable and connectors to the design dimensions. Any
change in these dimensions will cause added losses to
the RF power being carried, and may also cause
radiation interference. It is important that the assembly
directions given for each connection be followed
carefully to avoid problems. The following precautions

Sect 2 Chap 12
are common to all assemblies of the coaxial cable and

RF connectors:
a.
When working with coaxial cable, never step on

the cable, set anything heavy on it, or bend it
sharply. This will flatten the cable and will
change its electrical characteristics. Handle
coaxial cable carefully at all times. Anything
which damages it, or which might lead to its
being damaged later, reduces the efficiency of
the system.
b.
Do not use pliers to assemble or disassemble

RF connectors.
c.
Pins and sockets for RF connectors are usually

packed unassembled. Do not misplace them.
d.
Use care in starting the braid clamp nut into a

plug or jack body, in order to prevent cross
threading.
e.
Keep soldering iron clean, smooth, and well

tinned at all times. See Section 2, Chapter 7 for
care of soldering iron.
f.
RF connectors should be physically tight on their

coaxial cable. Improperly fitting connectors will
allow movement that degrades the electrical
connection by bending, nicking, and breaking the
braided shield wires. This can cause premature
failure or equipment damage if the cable is used
in a transmitting system. Degraded signal
carrying capability can occur in a receiving or
data transfer system. If any rotational movement
is found between the RF connector and cable,
the connector shall be replaced.
g.
In areas where RF connectors are subject to

mechanical or physical strain that would tend to
break connections or braided shields, strain
relieving cable clamps may be installed to
prevent damage
General Procedures
8.
During the preparation of coaxial cable
assemblies, observe the following general procedures:
a.
Cut coaxial cable to length with long handled

cable cutters or pruning shears, making sure cut
is clean and square.
b.
Identify cable by using the methods described in

c.
Strip outer jacket from cable by first making a cut

carefully around circumference with a sharp
knife. Then make a lengthwise slit, and peel off
jacket. Take care not to nick, cut, or damage
shield.
d.
For connectors using braid clamps comb out the

braid by using a pointed wooden dowel or a
scriber.
CAUTION
Do not damage dielectric or break shield strands.
Figure 1210 Tinning Centre Conductor
WARNING
Failure to ensure that the centre conductor is not
shorted may result in equipment damage, personal
injury or death.
h.
Check assembled coaxial connectors with an

ohm-meter to ensure that the centre conductor is
not shorted to the shield. This can be
accomplished by placing the ohm-meter on its
highest scale, ensuring that the other end of the
coaxial cable is disconnected from the
equipment, then placing the ohm-meter leads on
the centre pin and the connector shell. The
reading should be infinite ohms. An optional
check can be performed using a time domain
reflectometer (TDR).
Figure 1211 Tinning Inside of Contact

Sect 2 Chap 12
e.
To remove dielectric, cut with sharp knife around

circumference, not quite through to centre
conductor, taking care not to nick or cut strands
or otherwise damage conductor. Pull off
dielectric.
f.
For connectors using solder pins or sockets, tin

centre conductor with soldering iron as shown in
Figure 1210.
g.
h.
Tin inside of solder type pins and sockets with a

soldering iron, as shown in Figure 1211. (Use
untinned face of tip to prevent depositing solder
on outside of contact.)
Solder pins and sockets to centre conductor with
clean well tinned soldering iron using solder per
standard J-STD-006.
CAUTION
Contact must butt flush against dielectric before and
after soldering.
i.
When assembling the connector, always start

the clamping nut into the body by hand, then
hold the body assembly in a vice using lead or
neoprene jaw protectors. (See Figure 1213.)
Hold body only on the flats. Do not use
excessive pressure, since the body can be easily
distorted. Tighten nut with end spanner.
SOLDERING COAXIAL CABLE TO RF

CONNECTORS
Preparation of Work
9.
The work to be soldered must be clean and free
from oxides. Remove grease by cleaning with
Stoddards solvent or other approved cleaner. Oxides,
if not too heavy, are removed by the action of the rosin
flux during the soldering operation. Heavily oxidised
wire cannot be cleaned by the rosin flux and should be
discarded.
Selection of Soldering Iron
10. For good soldering, it is important to select a
soldering iron of the proper size and heat capacity. For
soldering coaxial cable to RF connectors, use an iron
with a heating element rated at 65 to 100 watts, and a
tip of about 0.25 inch (6.3mm) in diameter. The
soldering tip should be shaped as shown in Figure 12
14. Maintain this shape by dressing the tip with a mill
smooth file. Make sure the soldering iron is clean,
smooth, and well tinned. See Section 2, Chapter 7 for
detailed instructions on care and maintenance of the
soldering iron.
Figure 1212 Soldering Contact to Coaxial Cable
Figure 1214 Correct Shape for Soldering Iron Tip
NOTE
For soldering coaxial cable to RF connectors, tin only
one face of the tip so that areas adjacent to that being
soldered will not be coated with solder by accident.
Figure 1213 Tightening Braid Clamp Nut into Plug
or Jack Body

Sect 2 Chap 12
Soldering Procedure
BNC AND TNC SERIES CONNECTORS
11. See Section 2, Chapter 7 for general soldering

procedures and precautions. For soldering cable to RF
connectors, use only 60/40 tin-lead solder with a core
of rosin flux. Heat the parts to be joined, and apply the
solder at the junction of the soldering iron tip and the
work as shown in Figure 1212. Do not apply heat
longer than is necessary to melt the solder; excessive
heat will swell the dielectric and make it difficult to
insert into the body shell. Do not allow solder to flow
over the outside of the contact. After the joint has
cooled, remove excess flux by wiping with a clean
cloth, using denatured alcohol as a solvent if
necessary.
BNC and TNC Connector Types

12. There are three versions of connectors, differing
in the method of attaching coaxial cable to the
connector body. (See Figure 1215.)
a.
Crimp Ferrule, Crimp Centre Pin or Socket

consists of connector body, crimp outer ferrule,
and crimp centre pin or socket.
b.
Crimp Ferrule, Solder Centre Pin or Socket

consists of connector body, crimp outer ferrule,
and solder centre pin or socket.
c.
Braid Clamp, Solder Centre Pin or Socket

consists of connector body, nut, gasket clamp,
bushings, and solder centre pin or socket.

Sect 2 Chap 12
Figure 1215 Attaching BNC & TNC (M39012) Crimp Connectors to Coaxial Cable

Sect 2 Chap 12
Figure 1216 M22520/5-01 Crimping Tool and Hex Dies

Sect 2 Chap 12
Figure 1217 M22520/1-01 Crimping Tool and Turret
10

Sect 2 Chap 12
Figure 1218 M22520/1-01 Crimping Tool Turrets
11

Sect 2 Chap 12
Table 121 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17)
Cable
Connector
Centre
or Socket
Pin
Tool
Ferrule
Crimp
Tool
Alternate
BNC (Cabled) Plug, Pin, Contact

RG-58
M39012/16-0504
RG-141
M39012/16-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/16-0013
Solder
RG-223
M39012/16-0014
Solder
RG-142
M39012/16-0503
RG-59
M39012/16-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/16-0015
Solder
RG-140
M39012/16-0015
Solder
RG-210
M39012/16-0015
Solder
RG-122
M39012/16-0501
RG-71
M39012/16-0017
Positioner
M22520/1-12
Solder
RG-302
M39012/16-0020
Solder
RG-400
M39012/16-0503
RG-180
M39012/16-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
B
B
B
A
A
A
A
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
A
A
A
B
A
A
A
A
B
A
A
B
B
BNC (Cabled) Plug, Socket, Contact

RG-58
M39012/17-0504
RG-141
M39012/17-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/17-0013
Solder
RG-223
M39012/17-0014
Solder
RG-142
M39012/17-0503
RG-59
M39012/17-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/17-0015
Solder
RG-140
M39012/17-0015
Solder
RG-210
M39012/17-0015
Solder
RG-122
M39012/17-0501
RG-71
M39012/17-0017
Positioner
M22520/1-12
Solder
RG-302
M39012/17-0020
Solder
12
B
B
B
A
A
A
A
A
B
A
A
A
A
A
B
A
A
A
A
B
A
A

Sect 2 Chap 12
Table 121 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre
or Socket
RG-400
M39012/17-0503
RG-180
M39012/17-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Pin
Tool
Ferrule
Cavity
M22520/5-05
Cavity
M22520/5-05
Crimp
A
B
Tool
Alternate
Cavity
M22520/5-19
Cavity
M22520/5-41
B
B
BNC (Cabled) Receptacle, Socket, Contact, Flange Mounted

RG-58
M39012/18-0504
RG-141
M39012/18-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/18-0013
Solder
RG-223
M39012/18-0014
Solder
RG-142
M39012/18-0503
RG-59
M39012/18-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/18-0015
Solder
RG-140
M39012/18-0015
Solder
RG-210
M39012/18-0015
Solder
RG-122
M39012/18-0501
RG-71
M39012/18-0017
Positioner
M22520/1-12
Solder
RG-302
M39012/18-0020
Solder
RG-400
M39012/18-0503
RG-180
M39012/18-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
B
B
B
A
A
A
A
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
A
A
A
B
A
A
A
A
B
A
A
B
B
BNC (Cabled) Receptacle, Socket, Contact, Jam Nut Mounted

RG-58
M39012/19-0504
RG-141
M39012/19-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/19-0013
Solder
RG-223
M39012/19-0011
Solder
RG-142
M39012/19-0503
RG-59
M39012/19-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/19-0015
Solder
RG-140
M39012/19-0015
Solder
RG-210
M39012/19-0015
Solder
RG-122
M39012/19-0501
Positioner
M22520/1-12
Solder
RG-71
M39012/19-0017
B
B
B
A
A
A
A
A
B
A
A
A
A
B
A
A
A
A
B
A
13

Sect 2 Chap 12
Cable
Connector
Centre
or Socket
RG-302
M39012/19-0020
Solder
RG-400
M39012/19-0503
RG-180
M39012/19-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Pin
Tool
Ferrule
Crimp
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
B
Tool
Alternate
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
B
BNC (Cabled) Plug, Pin, Contact, Right Angle

RG-58
M39012/20-0504
RG-141
M39012/20-0006
Positioner
M22520/1-12
Solder
RG-303
M39012/20-0006
Solder
RG-223
M39012/20-0007
Solder
RG-142
M39012/20-0503
RG-122
M39012/20-0501
RG-302
M39012/20-0010
Positioner
M22520/1-12
Positioner
M22520/1-12
Solder
RG-400
M39012/20-0503
RG-180
M39012/20-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
B
B
B
A
B
A
A
B
A
A
A
B
B
A
B
B
TNC (Cabled) Plug, Pin, Contact

RG-58
M39012/26-0504
RG-316
M39012/26-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/26-0010
Solder
RG-223
M39012/26-0011
Solder
RG-142
M39012/26-0503
RG-59
M39012/26-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/26-0012
Solder
RG-174
M39012/26-0022
Solder
RG-210
M39012/26-0012
Solder
RG-122
M39012/26-0501
RG-71
M39012/26-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/26-0021
Solder
RG-400
M39012/26-0503
RG-180
M39012/26-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
14
B
B
B
A
A
A
B
A
B
A
A
A
B
A
A
A
B
A
A
B
A
B
A
A
B
B

Sect 2 Chap 12
Cable
Connector
Centre
or Socket
Pin
Tool
Ferrule
Crimp
Tool
Alternate
TNC (Cabled) Plug, Socket, Contact

RG-58
M39012/27-0504
RG-316
M39012/27-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/27-0010
Solder
RG-223
M39012/27-0011
Solder
RG-142
M39012/27-0503
RG-59
M39012/27-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/27-0012
Solder
RG-174
M39012/27-0022
Solder
RG-210
M39012/27-0022
Solder
RG-122
M39012/27-0501
RG-71
M39012/27-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/27-0021
Solder
RG-400
M39012/27-0503
RG-180
M39012/27-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
B
B
B
A
A
A
B
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
A
A
B
A
A
B
A
B
A
A
B
B
TNC (Cabled) Receptacle, Socket, Contact, Jam Nut Mounted

RG-58
M39012/28-0504
RG-316
M39012/28-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/28-0010
Solder
RG-223
M39012/28-0011
Solder
RG-142
M39012/28-0503
RG-59
M39012/28-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/28-0012
Solder
RG-174
M39012/28-0022
Solder
RG-210
M39012/28-0012
Solder
RG-122
M39012/28-0501
RG-71
M39012/28-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/28-0021
Solder
RG-400
M39012/28-0503
RG-180
M39012/28-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
B
B
B
A
A
A
A
A
B
A
A
A
B
B
A
A
B
A
A
B
A
B
A
A
B
B
15

Sect 2 Chap 12
Cable
Connector
Centre
or Socket
Pin
Tool
Ferrule
Crimp
Tool
Alternate
TNC (Cabled) Receptacle, Socket, Contact, Flange Mounted

RG-58
M39012/29-0504
RG-316
M39012/29-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/29-0010
Solder
RG-223
M39012/29-0011
Solder
RG-142
M39012/29-0503
RG-59
M39012/29-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/29-0012
Solder
RG-174
M39012/29-0022
Solder
RG-210
M39012/29-0012
Solder
RG-122
M39012/29-0501
RG-71
M39012/29-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/29-0021
Solder
RG-400
M39012/29-0503
RG-180
M39012/29-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
B
B
B
A
A
A
B
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
A
A
B
A
A
B
A
B
A
A
B
B
TNC (Cabled) Plug, Pin, Contact, Right Angle

RG-58
M39012/30-0504
RG-316
M39012/30-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/30-0010
Solder
RG-223
M39012/30-0011
Solder
RG-142
M39012/30-0503
RG-59
M39012/30-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/30-0012
Solder
RG-174
M39012/30-0022
Solder
RG-210
M39012/30-0012
Solder
RG-122
M39012/30-0501
RG-71
M39012/30-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/30-0021
Solder
RG-400
M39012/30-0503
RG-180
M39012/30-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
16
B
B
B
A
A
A
B
A
B
A
A
A
B
B
A
A
B
A
A
B
A
B
A
A
B
B

Sect 2 Chap 12
Attaching Improved BNC Connectors to Coaxial

Cable
13. When attaching improved BNC connectors to
coaxial cable (see Figure 1219), use the following
procedure:
NOTE
i.
Push cable assembly into connector body as far

as it will go. Make sure gasket is properly
seated, with sharp edge of sleeve clamp
entering gasket groove. Slide nut into connector
body and fasten in vice. Start nut by hand and
tighten with end spanner until enough pressure
is applied to make a good seal by splitting the
gasket. (See Figure 1213.)
While attaching connector, observe all general

precautions and procedures listed in paragraphs 7
and 8.
CAUTION
Do not nick or damage shield.
a.
Remove 7.8mm of outer jacket, exposing shield.
b.
Slide nut and gasket (V-groove away from nut),

in that order, onto jacket. Slide sleeve clamp
over tapered shield until inside shoulder of clamp
butts flush against cut end of jacket.
c.
Comb out shield. Use care to prevent breaking

shield strands.
d.
Strip dielectric 4.7mm from edge of jacket to

edge of dielectric exposing centre conductor.
CAUTION
Do not nick or damage centre conductor.
e.
Comb shield back smoothly over sleeve clamp,

and trim to 2.3mm with scissors.
f.
Trim dielectric to 3mm from shield, and cut off

centre conductor to 3mm from edge of dielectric.
g.
Tin centre conductor as shown in Figure 1210.

Tin inside of pin or socket as shown in Figure
1211.
h.
Slip contact over centre conductor so that

contact butts flush against dielectric. For RG62/U and 71/U, add bushing. Solder, using a
clean, well tinned, soldering iron. Contact must
still be flush against dielectric after solder has
cooled; if it is not, remake the joint. (See Figure
1212.)
CAUTION
Ensure that correct contact is used. a male contact
always goes into a plug body, and a female contact
always goes into a jack body.
Figure 1219 Attaching Improved BNC Connectors to

Coaxial Cable
17

Sect 2 Chap 12
Attaching BNC Connectors with Captivated Contacts

to Coaxial Cable
14. When attaching BNC connectors with captivated
contacts to coaxial cable (see Figure 1220), follow
this procedure:
NOTE
and 8.
a.
Remove 9.5mm of outer jacket, exposing shield,

for all except plugs 31-301 and 31-304; strip
jacket for these plugs 10.7mm. Disassemble nut,
grooved gasket, and sleeve clamp from plug or
jack body. Slide nut and grooved gasket (Vgroove away from nut), in that order, over shield
onto jacket.
CAUTION
Do not nick or damage shield.
b.
Comb out shield. Use care to prevent breaking

shield strands.
c.
Cut off cable dielectric to 4.7mm for cables RG55/U, 58/U, 59/U, 140/U, 141/U, and 142/U. Cut
to 0.156 inch (4mm) for cables RG-62/U and
RG-71/U.
CAUTION
Do not nick or damage centre conductor.
d.
Comb shield back smoothly over sleeve clamp

and trim to proper length; form evenly over
clamp. Tin centre conductor as shown in Figure
1210. Slide on contact. These parts must butt
as shown. When attaching to cables RG-62/U
and RG-7l/U, add insulator bushing.
e.
Solder pin or socket to centre conductor (see

Figure 1214). Remove excess flux and solder
from outside of contact.
f.
Slide front insulator over contact and butt against

contact shoulder. Do not reverse direction of
insulator.
g.
Insert cable assembly into connector body. Make

sure that the sharp edge of the clamp seats
properly in the gasket. Tighten the nut, holding
the body stationary. (See Figure 1213.)
18
Figure 1220 Attaching BNC Connectors With

Captivated Contacts to Coaxial Cable

Sect 2 Chap 12
C AND SC SERIES CONNECTORS

15. There are three versions of C and SC
connectors, differing in the method of attaching coaxial
cable to the connector body.
c.
As shown, (see Figure 1222) flare end of cable

braid slightly to facilitate insertion onto inner
ferrule. Do not comb out braid.
d.
Place contact on cable centre conductor so that

it butts against cable dielectric. Centre conductor
should be visible through inspection hole. Crimp
or solder the pin or socket in place as follows:
e.
Crimp Method. Select appropriate tool from

Table 122. Crimp centre pin or socket. (See
Figure 1216.)
f.
Solder Method. Soft solder contact to cable

centre conductor. Do not get any solder on
outside surfaces of contact. Avoid excessive
heat to prevent swelling of dielectric.
g.
Install cable assembly into body assembly so

that inner ferrule portion slides under braid. Push
cable assembly forward until contact snaps into
place in insulator. Slide outer ferrule over braid
and up against connector body. Crimp outer
ferrule using cavity of die set specified in Table
122. (See Figure 1216.)
Attaching Series C and SC Crimp Connectors to

Coaxial Cable
16. When attaching C and SC connectors to coaxial
cable (see Figure 1221), use the following procedure:
a.
Select correct connector for cable. See Table

122.
CAUTION
Do not nick or damage braid, dielectric, or centre
conductor.
b.
Strip cable jacket, braid, and dielectric to

dimensions shown 0.25mm (see Figure 1222).
All cuts are to be sharp and square. Tinning of
centre conductor is not necessary if contact is to
be crimped. For solder method, tin centre
conductor avoiding excessive heat. Slide outer
ferrule onto cable as shown.
Figure 1221 Attaching Series C and SC Connectors to Coaxial Cable
Table 122 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
C (Cabled) Plug, Pin, Contact

RG-212
M39012/06-0027
Solder
RG-304
M39012/06-0027
Solder
RG-213
M39012/06-0028
Solder
RG-214
M39012/06-0029
Solder
RG-165
M39012/06-0028
Solder
RG-225
M39012/06-0030
Solder
RG-11
M39012/06-0031
Solder
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
A
A
A
A
A
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
A
A
A
A
A
A
19

Sect 2 Chap 12
Table 122 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
C (Cabled) Plug, Socket, Contact

RG-212
M39012/07-0014
Solder
RG-304
M39012/07-0014
Solder
RG-213
M39012/07-0011
Solder
RG-214
M39012/07-0012
Solder
RG-165
M39012/07-0011
Solder
RG-225
M39012/07-0013
Solder
RG-11
M39012/07-0015
Solder
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
A
A
A
A
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
A
A
A
A
A
C (Cabled) Receptacle, Socket, Contact, Flange Mounted

RG-212
M39012/08-0013
Solder
RG-304
M39012/08-0013
Solder
RG-213
M39012/08-0010
Solder
RG-214
M39012/08-0011
Solder
RG-165
M39012/08-0010
Solder
RG-225
M39012/08-0012
Solder
A
A
A
A
A
A
A
A
A
A
C (Cabled) Pin, Contact, Right Angle

RG-213
M39012/10-0006
Solder
RG-214
M39012/10-0007
Solder
RG-165
M39012/10-0006
Solder
RG-225
M39012/10-0008
Solder
A
A
A
A
A
A
C (Cabled) Socket, Contact, Receptacle, Jam Nut Rear Mounted

RG-212
M39012/11-0012
Solder
RG-304
M39012/11-0012
Solder
RG-213
M39012/11-0013
Solder
RG-214
M39012/11-0014
Solder
RG-165
M39012/11-0013
Solder
RG-225
M39012/11-0015
Solder
RG-11
M39012/11-0016
Solder
20
A
A
A
A
A
A
A
A
A
A
A
A

Sect 2 Chap 12
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
SC (Cabled) Plug, Pin, Contact

RG-212
M39012/35-0010
Solder
RG-304
M39012/35-0010
Solder
RG-213
M39012/35-0502
M22520/1-14
RG-214
M39012/35-0501
M22520/1-14
RG-165
M39012/35-0011
Solder
RG-225
M39012/35-0501
M22520/1-14
RG-11
M39012/35-0013
Solder
RG-144
M39012/35-0013
Solder
RG-400
M39012/35-0503
M22520/1-14
RG-142
M39012/35-0503
M22520/1-14
RG-393
M39012/35-0501
M22520/1-14
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
SC (Cabled) Plug, Socket, Contact

RG-212
M39012/36-0009
Solder
RG-304
M39012/36-0009
Solder
RG-213
M39012/36-0502
M22520/1-14
RG-214
M39012/36-0501
M22520/1-14
RG-165
M39012/36-0007
Solder
RG-225
M39012/36-0501
M22520/1-14
RG-11
M39012/36-0010
Solder
RG-144
M39012/36-0010
Solder
RG-400
M39012/36-0503
M22520/1-14
RG-142
M39012/36-0503
M22520/1-14
RG-393
M39012/36-0501
M22520/1-14
A
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
A
A
A
21

Sect 2 Chap 12
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
SC (Cabled) Receptacle, Socket, Contact, Flange Mounted Rear

RG-212
M39012/38-0008
Solder
RG-304
M39012/38-0008
Solder
RG-213
M39012/38-0502
M22520/1-14
RG-214
M39012/38-0501
M22520/1-14
RG-165
M39012/38-0006
Solder
RG-225
M39012/38-0501
M22520/1-14
RG-400
M39012/38-0503
M22520/1-14
RG-142
M39012/38-0503
M22520/1-14
RG-393
M39012/38-0501
M22520/1-14
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
A
A
A
A
A
A
A
A
SC (Cabled) Plug, Pin, Contact, Right Angle

RG-213
M39012/39-0502
M22520/1-13
RG-214
M39012/39-0501
M22520/1-13
RG-165
M39012/39-0004
Solder
RG-225
M39012/39-0501
M22520/1-13
RG-400
M39012/39-0503
M22520/1-13
RG-142
M39012/39-0503
M22520/1-13
RG-393
M39012/39-0501
M22520/1-13
A
A
A
B
B
A
A
A
A
A
A
A
SC (Cabled) Receptacle, Socket, Contact, Jam Nut Rear Mounted

RG-212
M39012/40-0014
Solder
RG-304
M39012/40-0014
Solder
RG-213
M39012/40-0502
M22520/1-14
RG-214
M39012/40-0501
M22520/1-14
RG-217
M39012/40-0018
Solder
RG-165
M39012/40-0015
Solder
RG-225
M39012/40-0501
M22520/1-14
RG-11
M39012/40-0021
Solder
RG-144
M39012/40-0021
Solder
RG-216
M39012/40-0017
Solder
RG-400
M39012/40-0503
M22520/1-14
22
A
A
A
A
A
A
A
B
A
A
A
A
A
A
A
A

Sect 2 Chap 12
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
SC (Cabled) Receptacle, Socket, Contact, Jam Nut Rear Mounted (Continued)

RG-142
M39012/40-0503
M22520/1-14
RG-393
M39012/40-0501
M22520/1-14
Cavity
M22520/5-19
Cavity
M22520/5-61
B
A
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
HN SERIES CONNECTORS
HN Connector Types
17. There are two versions of HN connectors with
differing methods of attaching coaxial cable to the
connector body. See Figure 123 for typical examples
of HN connectors. Table 123 lists the more common
connectors in the HN series and shows the coaxial
cables associated with each.
NOTE
The HN series of RF connectors are used for
replacement purposes only.
a.
Improved Version. Consists of a plug or jack

body assembled to coaxial cable with nut,
gasket, and braid clamp (see Figure 1223).
Plug UC-59E/U and jack UG-60E/U are typical of
this version.
b.
Captivated Contact Version Consists of a plug

or jack body assembled to coaxial cable with nut,
gland, gasket, clamp, sleeve, and front and rear
insulators (see Figure 1224). Plug UG-l213/U
and jack UG-l214/U are typical of this version.
Attaching Improved HN Connectors to Coaxial Cable

18. When attaching improved HN connectors to
coaxial cable (see Figure 1225), use the following
procedure:
NOTE
and 8.
a.
b.
Disassemble nut, grooved gasket and braid

clamp from plug or jack body. (See Figure 12
23.)
Remove 17.5mm from outer jacket, exposing
shield. Slide nut and gasket, in that order, over
shield onto jacket. Make sure that groove in
gasket faces away from the nut.
Figure 1222 Cable Crimping Instructions
CAUTION
Do not nick or damage shield or centre conductor
c.
Comb out shield and strip dielectric 6.3mm.
23

Sect 2 Chap 12
d.
Slide clamp over shield until inside shoulder of

clamp butts flush against cut end of jacket.
e.
Fold shield strands back over clamp without

overlaps. Trim strands with scissors, so that all
strands end at end of clamp taper.
f.
Tin centre conductor as shown in Figure 1210.
g.
Tin inside of contact (male or female) as shown

in Figure 1211.
h.
Slip pin or socket over centre conductor so that

contact butts flush against dielectric. Solder,
using a clean, well tinned, soldering iron.
Contact must still be flush against dielectric after
solder has cooled; if not, remake the joint. (See
Figure 1212).
a.
Disassemble nut, gland, gasket, clamp, sleeve,

and front and rear insulators front plug or jack
body. (See Figure 1224.)
b.
Slide nut and gland onto jacket. Make sure that

sharp edge of gland is toward end of cable. Then
slide gasket onto jacket, with "V" groove toward
gland. Remove 4cm from outer jacket, exposing
shield. Slide clamp over the braid until inside
shoulder of clamp butts flush against end of
jacket.
CAUTION
Take care not to nick or damage shield or centre
conductor
c.
Comb out shield and cut off dielectric 23mm

from end of jacket.
d.
Fold shield strands back over clamp without

overlaps. Trim strands with scissors so that all
strands end at end of clamp taper.
e.
Tin centre conductor as shown in Figure 1210,

using minimum amount of heat.
f.
Slide sleeve and rear insulator over cable

dielectric. Slip contact over centre conductor.
Rear insulator must seat against cable dielectric,
and contact shoulder must be flush with insulator
face. Solder contact to centre conductor. (See
Figure 1212.)
g.
For jacks only, install front insulator.
CAUTION
Ensure correct pin or socket is used. a male pin
always goes into a plug body, and a female socket
i.
Push cable assembly into connector body as far

as it will go. Slide gasket into connector body;
make sure gasket is properly seated with sharp
edge of braid clamp entering groove in gasket.
Slide nut into connector body and fasten body in
vice (see Figure 1213). Start nut by hand and
tighten with spanner until moderately tight.
NOTE
Gasket should be cut in half during tightening.
CAUTION
Attaching HN Connectors with Captivated Contacts
to Coaxial Cable
19. When attaching HN connectors with captivated
contacts to coaxial cable (see Figure 1226), use the
following procedure:
NOTE
and 8.
Ensure that correct pin or socket is used. a male pin

always goes into a plug body, and a female socket
h.
Push cable assembly carefully into connector

body as far as it will go. Make sure that sharp
edge of gland remains in the gasket groove,
Tighten nut with spanner, holding body
stationary. (See Figure 1213.)
NOTE
Gasket should be cut in half during tightening.
24

Sect 2 Chap 12
Figure 1223 Improved HN Connectors - Exploded View
Table 123 HN Series Connectors (MIL-C-3643) with Associated Cables

Plug
Jack
Panel Jack
*UG-59E/U
**UG-1213/U
*UG-60E/U
**UG-1214/U
*UG-61E/U
**UG-1215/U
*Improved Version
For Use With

Cable Types
RG8/U,
213/U AND 214/U
9/U,
**Captivated Contact Version
Figure 1224 HN Connectors with Captivated Contacts - Exploded View
25

Sect 2 Chap 12
N SERIES CONNECTORS
N Connector Types
20. There are three versions of N connectors,
differing in method of attaching coaxial cable to the
connector body. Refer to paragraph 4.
Attaching N Type Crimp Connectors, M39012, to
Coaxial Cables
21. N Type Crimp Connectors are attached as
follows:
a.
Figure 1225 Attaching Improved HN Connectors to

Coaxial Cable
Select correct connector for cable Table 124.
Figure 1227 N Crimp Connectors
CAUTION
The 50 ohm N type RF connectors are not compatible
and should not be mated.
NOTE
Some 70 ohm coaxial cables do not have suitable 70
ohm
connectors
and
therefore
equipment
manufacturers may have substituted compatible 50
ohm connectors. This practice is accepted, but
physical matching of male and female connectors is
essential.
Figure 1226 Attaching HN Connectors with

Captivated Contacts to Coaxial Cable
26
b.

dimensions shown (see Figure 1228). All cuts
are to be sharp and square. Important: Do not
nick braid, dielectric, and centre conductor.
Tinning of centre conductor is not necessary if
contact is to be crimped. For solder method, tin
centre conductor avoiding excessive heat.
c.
Slide outer ferrule onto cable as shown. Flare

slightly end of cable braid as shown to facilitate
insertion onto inner ferrule.

Sect 2 Chap 12
h.
Slide outer ferrule over braid and up against

connector body. Crimp outer ferrule using cavity
of Die Set specified in Table 124. (See Figure
1216.)
Attaching N Type Connectors with Captivated

Contacts to Coaxial Cables
22. When attaching captivated contact N Type
connectors to coaxial cable (see Figure 1229), use
the following procedure:
NOTE
and 8.
CAUTION
Do not nick shield or centre conductor.
a.
Remove 9.1mm of outer jacket, exposing shield.
b.
Comb out shield and cut off cable dielectric

3.1mm from end of jacket.
c.
Disassemble nut, gasket, clamp, washer, and

insulator from plug or jack body.
d.
Place contact on cable centre conductor so it

butts against cable dielectric. Centre conductor
should be visible through inspection hole in
contact. Crimp or solder centre pin or socket in
place as follows:
Taper shield toward centre conductor, and wrap

with tape. Slide nut and gasket, in that order,
over tapered shield onto jacket. Make sure
grooved side of gasket faces away from nut.
Then slide clamp over tapered shield and push
back against cable jacket.
e.
Remove tape and fold shield strands back over

clamp taper without overlaps. Trim shield with
scissors so that strands end at end of clamp
taper.
e.
Crimp Method. Select appropriate tool from

Table 124. Crimp centre pin or socket (see
Figure 1216).
f.
Check that exposed dielectric is 1.1mm beyond

shield.
f.
Solder Method. Soft solder contact to cable

centre conductor. Do not get any solder on
outside surface of contact. Avoid excessive heat
to prevent swelling of dielectric.
g.
Tin centre conductor as shown in Figure 1210,

using minimum amount of heat.
h.
Slide on washer, rear insulator, and contact, so

that the counter-bored end of the rear insulator
butts flush against the dielectric, and the pin or
socket shoulder butts flush against the rear
insulator, Solder the contact to centre conductor.
(See Figure 1212.)
Figure 1228 Cable Stripping Instructions
NOTE
Do not comb out braid.
d.
g.
Install cable assembly into body assembly so

inner ferrule portion slides under braid. Push
cable assembly forward until contact snaps into
place in insulator.
27

Sect 2 Chap 12
Table 124 Series N M39012 Connectors and Associated Cables (MIL-C-17)

Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
N (Cabled) Plug, Pin, Contact

RG-212
M39012/01-0016
Solder
RG-222
M39012/01-0016
Solder
RG-213
M39012/01-0502
M22520/1-13
RG-214
M39012/01-0501
M22520/1-13
RG-217
M39012/01-0019
Solder
RG-165
M39012/01-0021
Solder
RG-225
M39012/01-0501
M22520/1-13
RG-11
M39012/01-0023
Solder
RG-144
M39012/01-0023
Solder
RG-216
M39012/01-0024
Solder
RG-6
M39012/01-0027
Solder
RG-400
M39012/01-0503
M22520/1-13
RG-142
M39012/01-0503
M22520/1-13
RG-393
M39012/01-0501
M22520/1-13
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
B
B
B
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
N (Cabled) Plug, Socket, Contact

RG-212
M39012/02-0019
Solder
RG-222
M39012/02-0019
Solder
RG-213
M39012/02-0502
M22520/1-13
RG-214
M39012/02-0501
M22520/1-13
RG-217
M39012/01-0022
Solder
RG-165
M39012/02-0024
Solder
RG-225
M39012/02-0501
M22520/1-13
RG-11
M39012/02-0026
Solder
RG-144
M39012/02-0026
Solder
RG-216
M39012/02-0039
Solder
RG-6
M39012/02-0040
Solder
RG-400
M39012/02-0503
M22520/1-13
RG-142
M39012/02-0503
M22520/1-13
RG-393
M39012/02-0501
M22520/1-13
28
A
A
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
A
A
A
A

Sect 2 Chap 12
Table 124 Series N M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
N (Cabled) Receptacle, Socket, Contact, Flange Mounted

RG-212
M39012/02-0027
Solder
RG-222
M39012/02-0027
Solder
RG-213
M39012/02-0512
M22520/1-13
RG-214
M39012/02-0511
M22520/1-13
RG-165
M39012/02-0041
Solder
RG-225
M39012/02-0511
M22520/1-13
RG-11
M39012/02-0042
Solder
RG-144
M39012/02-0042
Solder
RG-216
M39012/02-0030
Solder
RG-6
M39012/02-0043
Solder
RG-400
M39012/02-0513
M22520/1-13
RG-142
M39012/02-0513
M22520/1-13
RG-393
M39012/02-0511
M22520/1-13
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
A
N (Cabled) Receptacle, Socket, Contact Jam Nut, Mounted

RG-212
M39012/03-0013
Solder
RG-222
M39012/03-0013
Solder
RG-213
M39012/03-0502
M22520/1-14
RG-214
M39012/03-0501
M22520/1-14
RG-217
M39012/03-0016
Solder
RG-165
M39012/03-0018
Solder
RG-225
M39012/03-0501
M22520/1-14
RG-11
M39012/03-0020
Solder
RG-144
M39012/03-0020
Solder
RG-216
M39012/03-0021
Solder
RG-6
M39012/03-0023
Solder
RG-400
M39012/03-0503
M22520/1-14
RG-142
M39012/03-0503
M22520/1-14
RG-393
M39012/03-0501
M22520/1-14
A
A
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
A
A
A
A
29

Sect 2 Chap 12
Table 124 Series N M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
N (Cabled) Plug, Right Angle

RG-212
M39012/05-0016
Solder
RG-222
M39012/05-0016
Solder
RG-213
M39012/05-0502
M22520/1-13
RG-214
M39012/05-0501
M22520/1-13
RG-165
M39012/05-0015
Solder
RG-225
M39012/05-0501
M22520/1-13
RG-11
M39012/05-0014
Solder
RG-144
M39012/05-0014
Solder
RG-216
M39012/05-0017
Solder
RG-6
M39012/05-0013
Solder
RG-400
M39012/05-0503
M22520/1-13
RG-142
M39012/05-0503
M22520/1-13
RG-393
M39012/05-0501
M22520/1-13
30
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
A
A

Sect 2 Chap 12
k.
CAUTION
Ensure that the correct pin or socket is used. a pin
always goes into a plug body, and a socket always
goes into a jack body.
i.
j.
Slide front insulator over pin or socket; make

sure the counter-bored end of the insulator is
toward the mating end of the contact.
Push the cable assembly into the connector
body. Make sure that the sharp edge of the
clamp seats properly in the gasket. Tighten the
nut, holding the body stationary. (See Figure
1213.)
WARNING
fuelled aircraft.
PULSE SERIES CONNECTORS

Pulse Connector Types
23. There are two versions of pulse connectors.
These versions differ in the material of the inserts,
and in the method of attaching the coaxial cable to
the connector body. See Figure 126 for typical
examples of pulse connectors. Table 125 lists the
more common connectors in the pulse series and
shows the coaxial cables associated with each.
a.
WARNING
Use of nitrogen with hot air gun in an enclosed area
can be hazardous. Ensure area is well ventilated.
Cut two lengths of heat shrink, one 7cm and

one 8cm. Slide the 7cm piece of heat shrink
over the connector covering only the back
15.8mm of it. Heat the heat shrink until it is
secure on the cable and connector. Repeat the
same procedure with the 8cm piece of heat
shrink.
Ceramic Insert Version. Consists of a plug or

jack body assembled to coaxial cable with nut,
cable clamp, washer, and corona shield. (See
Figure 1230). Plug UG-174/U is typical of this
version.
Rubber Insert Version consists of a plug or
jack body assembled to coaxial cable with
clamp, washer, gasket, sleeve, and ferrule.
(See Figure 1231). Plug UG-l80A/U and jack
UG-182A/U are typical of this version.
Figure 1229 Attaching N Connectors with Captivated Contacts to Coaxial cable
31

Sect 2 Chap 12
Figure 1230 Pulse Connector - Ceramic Insert
32
Figure 1231 Pulse Connector - Rubber Insert

Sect 2 Chap 12
Table 125 Pulse Series Connectors (MIL-C-3643) with Associated Cables

Plug
Jack
Panel Jack
For Use With

Cable Types
Ceramic Insert:
UG-34/U
UG-174/U
RG-25/U
RG-28/U
Rubber Insert:
UG-180A/U
UG-182A/U
UG-1086/U
UG-181A/U
Attaching Ceramic Insert Pulse Connectors to

Coaxial Cable
NOTE
first shield. Trim shield strands 1.5mm below

diameter of cable clamp flange.
e.
Slide brass washer carefully over second shield

against fanned-out shield. Remove second
shield to 4.7mm from brass washer for RG-281U
cable, and 31mm for RG-25/U cable, exposing
conducting rubber.
f.
Remove layer of conducting rubber to 9.5mm

from face of brass washer for RG-28/U cable
and 4.7mm for RG-25/U cable by making small
slit at end of cable core and removing
conducting rubber with dull knife. Scrape
insulating rubber underneath to remove any
traces of conducting rubber.
The following procedure is for assembling UG-l74/U

plug to RG-28/U cable, and UG-34/U plug to RG-25/U
cable. Both assemblies differ in dimensions. Both
cables have a double shield.
24. When attaching ceramic insert pulse connectors
to coaxial cable (see Figure 1232), use the following
procedure:
NOTE
Observe all general precautions and procedures
listed in paragraphs 7 and 8.
a.
b.
Disassemble nut, cable clamp, washer, and

corona shield from plug or jack body. (See
Figure 1230.)
Slide nut and cable clamp, in that order, onto
cable jacket. Remove 9.2cm of outer jacket of
RG-28/U cable and 7cm of RG-2S/U cable,
exposing first shield.
CAUTION
Do not damage insulating rubber.
g.
Slide corona shield over conducting rubber and

under second shield until straight part of corona
shield enters hole in brass washer approximately
1.5mm.
h.
Solder second shield to brass washer and to

corona shield. Remove excess flux. Remove
insulating rubber and conducting rubber
underneath it to 6.7cm from face of brass
washer for RG-28/U cable and 27mm for RG25/U cable, exposing centre conductor. Taper
rubber down to conductor 9.5mm for RG-28/U or
6.3mm for RG-25/U. Tin centre conductor.
Remove excess flux.
i.
Scrape nickel plating from recess of plug into

which brass washer fits. Remove set screws.
CAUTION
Do not nick shield.
c.
Remove first shield to 0.76mm from cut edge of

outer jacket exposing insulating tape.
d.
Comb out shield and bend at right angles, as

shown. Remove insulating tape even with cut
edge of outer jacket, exposing second shield.
Slide cable clamp forward against fanned-out
RG-25/U, 64/U, 77/U,

78/U & 88/U
33

Sect 2 Chap 12
Figure 1232 Assembly of Ceramic Insert Pulse Connector
34

Sect 2 Chap 12
j.
Slide cable assembly into plug body, allowing

cable clamp to slide back on cable. Solder brass
washer to recess in plug by flowing solder into
space between washer and groove. Remove
excess flux.
k.
Slide cable clamp against washer, and nut onto

plug body. Start nut by hand and tighten with
spanner. Hold plug with strap wrench to prevent
it from turning.
l.
Cut off excess conductor protruding beyond

contact pin. Solder conductor to contact by
flowing solder down into hole. Leave a drop of
solder on end of contact and file smooth.
Remove excess flux.
m. Insert bleeder tube in top hole so it is vertical.

Insert pressure gun in lower hole and fill plug
cavity with SAE AS 8660 compound until
material oozes from bleeder tube. Replace set
screws and stake with prick punch.
Attaching Rubber Insert Pulse Connectors to
Coaxial Cable
e.
NOTE
Cable RG-25A/U, 64A/U, 78/U, and 88A/U have a
thin layer of red insulating rubber over the cable core.
Do not remove this layer. Cables RG-25/U and RG64/U have a thin layer of black conducting rubber
over the cable core. Remove this layer to 1.5mm from
ferrule very carefully with a sharp knife.
f.
25. When attaching rubber insert pulse connectors

to coaxial cable (see Figure 1233), use the following
procedure:
NOTE
and 8.
a.
Disassemble nut, washer, gasket, sleeve, and

ferrule from plug or jack body. (See Figure 12
31.)
Ensure correct pin or socket is used. a pin always

goes into a plug body, and a socket always goes into
a jack body.
g.
Push cable core into plug or jack body as far as

it will go. Insert sleeve and tighten as far as it will
go against ferrule, holding body with spanner so
it will not turn. (See Figure 1213.)
h.
Insert gasket, then washer into sleeve. Install nut

on sleeve and tighten until gasket deforms
around cable to hold it securely.
Do not nick shield or cut cable core.

Slide nut, washer, gasket, and sleeve, in that
order onto cable jacket. Remove 6.7cm of outer
jacket exposing shield.
c.
Cut shield to 9.5mm from cut edge of outer

jacket, exposing cable core.
d.
Push ferrule over cable core and under shield.
Tin inside of pin or socket as shown in Figure

1211. Slip contact over centre conductor so
that contact butts flush against cable cow.
Solder, using a clean well tinned soldering iron.
Pin or socket must still be flush against cable
core after solder has cooled; if it is not, remake
this joint. (See Figure 1212.) Remove excess
flux.
CAUTION
CAUTION
b.
Solder shield carefully to ferrule all around its

circumference. Ensure solder flows through to all
shields. If it is necessary to solder shields
separately, fold back outer shield. Solder inner
shield, then bring forward outer shield and solder
separately on top of inner shield. After solder
has cooled, grasp cable in left hand, ferrule in
right hand, and give several quick pulls to
remove' any slack in shield. Remove excess
flux. Remove cable core with sharp square cut
leaving 28.5mm from ferrule for connection to
UG-180A/U and 25mm from ferrule for
connection to UG-181A or 182A/U. Trim centre
conductor to 4.7mm and tin.
35

Sect 2 Chap 12
connectors consist of a plug or jack body assembled to

coaxial cable with clamp nut, braid clamp, and insulator
bushing. (See Figure 1234.)
Attaching MB Connectors to Coaxial Cable
27. The assembly procedure differs according to the
cable used. For assembly to cables RG-58/U and RG141/U, the procedure is as follows (see Figure 1235):
a.
Remove cable jacket to A dimension given in

Table 127. Insert clamp nut over cable jacket
and braid clamp over braid wire.
b.
Comb out braid wire, fold back over braid clamp,

and trim to length. Cut off cable dielectric to
dimension C in Table 127, and tin exposed
conductor. If solderless contact is used, omit
tinning.
c.
Insert contact over conductor. The end of the

solderless contact with the shortest slot is
inserted over the conductor. If a solder contact is
used, solder it to the conductor, and remove
excess solder from the outside of the contact.
d.
Insert assembly minus clamp nut into body and

rotate slightly to make sure braid clamp is
seated. When assembling straight plugs, insert
insulator over contact before assembly into
body. Thread clamp nut into body and tighten
nut, holding body stationary.
28. For assembly into cables RG-59/U and 62/U, the

a.
Remove cable jacket to dimension A in Table

127. Insert clamp nut over cable so that internal
shoulder seats against end of cable jacket. Insert
braid clamp over wire.
b.
Comb out braid wires, fold back over braid

clamp, and trim to length. Cut off cable dielectric
to dimension C in Table 127, and tin exposed
conductor. If solderless contact is used, omit
tinning.
c.
Insert contact over conductor. The end of the

solderless contact with the shortest slot is
inserted over the conductor. Insert insulator
bushing over contact if cable RG-62/U is being
used. If solder contact is used, solder it to the
conductor, and remove excess solder from the
outside of the contact.
d.
Insert insulator over contact. Insert assembly

minus clamp nut into body and rotate slightly to
make sure braid clamp is seated. Thread clamp
nut into body and tighten nut, holding body
stationary.
Figure 1233 Assembly of Rubber Insert Pulse

Connector
MINIATURE RF CONNECTORS
MB Miniature Connector Series
26. These are small, lightweight, bayonet type, quick
connect/disconnect connectors, used with small RF
cables where peak voltage is not more than 500 volts.
These connectors do not carry a military number. No
soldering is required in the assembly of plugs to solid
centre conductors, such as RG58/U, 59/U, 62/U, 71/U,
and 141/U. All jacks require soldering. Table 126 lists
the more common connectors in the MB series and
shows the coaxial cables associated with each. These
36

Sect 2 Chap 12
e.
Right angle jacks or plugs: Strip cable jacket and

dielectric, install parts, and form braid as
instructed in steps a and b above.
f.
Tin conductor, and insert assembly into body.
g.
With cap removed, solder the conductor in slot of

angle plug contact.
h.
Insert cap, and spot solder or spot stake.
Figure 1234 MB Connectors - Exploded View
Figure 1235 Attaching MB Connectors to Coaxial Cable
37

Sect 2 Chap 12
Table 126 MB Series Connectors with Associated Cables

Plug
Jack
Panel Jack
IPC
King
IPC
King
IPC
King
Cable RG-
79875
79525
KA51-03
KA51-02
79600
79500
KA31-02
KA31-03
79425
79925
KA11-04
KA11-03
55/U,
59/U
58/U
Table 127 Stripping Dimensions for Coaxial Cable Assembled to MB Connectors

Connector
Part (IPC)
RG- /U Cable
A
(mm)
C
(mm)
Plugs
45000
45025
45050
45550
58,
59,
58,
59, 62
141
62
141
161.1
282.0
161.1
282.0
51.0
51.0
51.0
51.0
Jacks
46300
46325
46700
46775
58,
59,
58,
59, 62
141
62
141
161.1
322.6
161.1
322.6
61.0
61.0
61.0
61.0
Angle Plugs
53000
53500
58,
59, 62
141
241.3
241.3
71.0
71.0
SUBMINIATURE RF CONNECTORS
Subminiature RF Connectors (Amphenol #27 Series)
29. These connectors are very small, lightweight
connectors designed for use with RG-l74/U
miniaturized coaxial cable, where peak voltage does
not exceed 500 volts. Coupling is either of the screw
thread type or the push-on type. The connectors
consist of a plug or jack body assembled to coaxial
cable with a sleeve and an insulator. (See Figure 12
36.) The assembly is crimped into the body, and a vinyl
boot shrunk on for cable strain relief. Table 128 lists
types of Amphenol #27 series connectors commonly
used in aircraft.
CAUTION
Do not nick braid.
b.
Trim jacket to dimension A in Table 128.
c.
Slip sleeve over braid against cable jacket. Fold

braid back over the sleeve and comb out so it
lays even without overlapping.
CAUTION
Avoid overheating during soldering, excessive heat
may deform dielectric.
d.
Trim dielectric to dimension B in Table 128. Tin

exposed centre conductor, and clean off excess
solder.
e.
Straight plugs and jacks. Slip contact over

centre conductor so that it butts flush against cut
end of dielectric. Solder contact to conductor,
and remove excess solder from outside of
contact.
f.
Slip cable assembly into body and trim off

excess braid protruding beyond body end. Crimp
the assembly securely (see paragraph 31 for
detailed crimping instructions), and pull boot
over body as shown.
Attaching Subminiature RF Connectors to Coaxial

Cable
30. When attaching subminiature RF connectors to
coaxial cable, follow this procedure (see Figure 1237):
a.
38
Dilate the boot and slip it over the cable. The

boot will remain dilated for approximately five
minutes.

Sect 2 Chap 12
g.
Angle plugs. Unscrew front part of body. Follow

procedure of steps a through d above. Then
thread cable through back part of body as shown
and crimp. Thread female insulator over
conductor and insert into body. Holding the
female insulator in place in the body, pull the
cable as far forward as possible to remove all
slack. Trim conductor to 2.1mm minimum.
a.
Open jaws of tool 227-900 by loosening nut and

pulling down lock screws (see Figure 1238).
Place the connector assembly in jaws, and set
optimum distance between jaws for each
assembly by means of the travel limit screw.
Refer to connector placement Figure 1238, A,
B and C for straight plugs and jacks, and Figure
1238, D for angle plugs.
h.
Slip contact over conductor and butt contact

flush against the female insulator. Solder contact
to conductor, and remove excess solder.
b.
Lock jaws by pulling lock screws up, and tighten

nut.
c.
Squeeze handles to crimp.
i.
Place male insulator over the contact, and screw

the front body part into back body arid tighten
with end spanner.
d.
Release handles to open jaws, and remove

crimped assembly. Trim off any excess braid
protruding beyond end of body.
e.
Slip boot over body end.
Crimping Procedure for Subminiature Connectors

31.
Crimp subminiature connector bodies as follows:
Figure 1236 Subminiature RF Connector - Exploded View
Table 128 Stripping Dimensions and Crimping Tool Positions for Subminiature RF Connectors
A
(mm +0 0.4)
B
(mm Max)
Position in
Tool 27-900
Figure No.
Straight Plug
231.1
40.6
11-38 A
Jack, Push-on
241.3
40.6
11-38 B
Jack, Screw-on
241.3
53.3
11-38 C
Bulkhead Jack
241.3
53.3
11-38 C
Angle Plug
503.0
53.3
11-38 D
Body Type
39

Sect 2 Chap 12
Figure 1237 Attaching Subminiature RF Connectors

to Coaxial Cable
40
Figure 1238 Crimping Subminiature RF

Connectors

Sect 2 Chap 12
RF CONNECTORS USED IN FUEL-QUANTITY

INDICATING SYSTEMS
32. Because of their transmission line efficiency, RF
connectors are often used in aircraft fuel-quantityindicating systems. The connectors most commonly
used for this purpose are of two types. One is similar to
the standard BNC connector; typical of this type are the
163 series made by Avien, and the Liquidometer 9100
series. The second type is the miniature RF connector;
the Nu-Line 1200 series (MIL-DTL-25516) and
Liquidometer S62 and S63 are typical. These
connectors are designed to be used with coaxial cable,
but they are also frequently used with standard
shielded or unshielded wire. They do not carry a
military number.
Assembling BNC Type Fuel-Quantity-Indicating
Connectors
33. For assembly of Avien 163-088 and 163-089
connectors to RG-58A/U coaxial cables, (see Figure
1239), use the following procedures:
a.
Slide nut, washer, and gasket onto cable. Strip

outer jacket 11mm, taking care not to nick the
braid. Slide the clamp over the braid so it rests
flush against the cut end of the jacket.
b.
Comb out braid and fold it back over the clamp,

and trim the braid even with edge of clamp.
c.
Strip dielectric 2.4mm from edge of clamp.
d.
Cut exposed conductor to 2.8mm.
e.
Slide contact onto conductor, and check that

there is no exposed conductor between the
insulation and the contact solder hole. Check
that the distance from the braid to the end of the
contact is 12.7mm, as shown in Figure 1239.
f.
Tin conductor and solder hole, and solder

contact to conductor. Remove any excess
solder.
g.
Push assembly into connector body, screw nut

into body, and tighten.
Figure 1239 Attaching Avien 163-088 and 163-089

Connectors to Coaxial Cable
34. For assembly of Avien 163-07 and 163-027

connectors to AN No. 20 unshielded wire, (see Figure
1240), use the following procedure:
a.
Strip wire to expose 6.3mm of conductor, and tin

the stripped wire. Tin inside of contact.
b.
Slide nut, washer, and gasket over the wire.

Install TFE clamp over the wire so that the inside
shoulder of the clamp butts against the cut
insulation.
Figure 1240 Attaching Avien 163-088 and 163089 Connectors to Unshielded Wire
41

Sect 2 Chap 12
c.
Slide contact over the wire so that it butts

against end of the clamp. While doing this, hold
the insulation firmly in place against the clamp
shoulder.
d.
Solder the contact to the conductor, and remove

any excess solder.
e.
Insert the assembly into the connector body. The

contact end should be flush with the end of the
TFE clamp, but a recess of 0.8mm maximum is
acceptable.
f.
Tighten nut while holding the body stationary.
35. For assembly of Liquidometer 9100 series

connectors to RG-58/U coaxial cable, (see Figure 12
41), use the following procedure:
a.
Slide nut, washer, and gasket over the cable;

strip outer jacket 9.5mm, taking care not to nick
the braid. Slide the large eyelet over the braid so
that it butts against the cut end of the jacket.
b.
Comb out the braid up to the large eyelet, and

slide the smaller eyelet over the dielectric.
c.
Clamp the braid between the two eyelets with

special slotted pliers, as shown in Figure 1243.
Trim off excess braid.
d.
Cut dielectric 3.0mm from the small eyelet, and

cut off the exposed conductor to 3.0mm.
e.
Tin the exposed conductor and the inside hole of

the contact.
f.
Slide the contact onto the conductor and solder.

Remove any excess solder.
g.
Seat contact and eyelets into connector body

and install the gasket firmly against the eyelets.
Insert washer firmly against the gasket.
h.
Screw nut into connector body and tighten,

holding connector body stationary. Tighten to 40
47 Newton metres (Nm) torque.
Figure 1241 Attaching Liquidometer 9100 Series

e.
Slide braid clamp sleeve (large ID toward

gasket) over braid, and trim off excess braid with
scissors. Install O-ring as shown.
f.
Place contact retainer firmly over dielectric, and

strip off dielectric flush with contact retainer,
exposing centre conductor.
g.
Cut off centre conductor 2.0mm from cut end of

dielectric.
Assembling Miniature RF Fuel-Quantity-Indicating

Connectors
36. For assembly of Nu-Line 1200 Series coaxial
connectors to coaxial cable, (see Figure 1242), use
the following procedure:
a.
Remove 12.7mm of outer jacket, exposing

shield.
b.
Slide nut, washer, and gasket, in that order, onto

outer jacket.
c.
Screw threaded braid clamp over jacket as

shown.
d.
Comb out braid, and fold braid back over braid

clamp, without overlap.
42

Sect 2 Chap 12
NOTE
When connector is properly torqued, the gap between
nut and body assembly should not exceed 1.0mm.
37. For assembly of Liquidometer S62 and S63
series connectors to RG-58/U coaxial cable (see
Figure 1243), use the following procedure:
a.
Slide nut and bushing back over cable. Cut outer

jacket to dimension A in Table 129, being
careful not to nick braid.
b.
Place the two halves of the cable clamp over the

cable, lining up front (large) end of clamp with
cut end of outer jacket. Slide bushing over
tapered end of clamp. Compress bushing over
cable clamp with special pliers as far as it will go.
NOTE
Special pliers No. TJF-107 are available from

connector manufacturers.
c.
Comb braid back over clamp and trim braid

around edge of clamp.
NOTE
Omit step (d) when using connectors S624 and S634.
Figure 1242 Attaching Nu-Line 1200 Series

h.
Slide contact, male or female, over centre

conductor so that contact butts flush against
dielectric.
i.
Solder contact to centre conductor; contact must

still be flush against dielectric after soldering.
j.
Slide cable assembly into connector body as far

as it will go. Apply (MIL-S-22473, Grade C,
sealing compound completely around the hex
nut threads. Torque nut to approximately ten
inch pounds.
d.
Slide washer, gasket, and second washer over

dielectric and push up to cable clamp. Cut off
dielectric to expose 2.4mm of conductor, and tin
conductor.
e.
Slide contact over conductor

Remove any excess solder.
f.
Slide assembly into plug or jack body until

contact shoulder seats on insulator. Screw
clamp nut into body, using a torque of 20Nm.
and
solder.
Table 129 Stripping Dimensions for Coaxial Cable

Assembled to Liquidometer S62 and S63 Series
Connectors
Connector
(Liquidometer Number)
Stripping
Dimension A
S62-1 and -4
8.7mm
S62-2 and -3
7.9mm
S63-1 and -4
7.9mm
S63-2 and -3
3.9mm
43

Sect 2 Chap 12
c.
Flair the ends of the wire braid to facilitate

insertion of inner ferrule of body assembly. (See
Figure 1244.) Do not comb out the braid.
d.
Place the stripped centre conductor into the

contact until the cable dielectric butts against it.
End of the wire must show through the
inspection hole. (See Figure 1244.)
e.
Insert the contact into the crimping tool until it is

fully seated in the contact locator. Crimp with
one full stroke. (See Table 1210 for crimping
tool information.)
Table 1210 Crimping Tool Details

Crimp on Centre Contact
Figure 1243 Attaching Liquidometer S62 and S63

Series Connectors to Coaxial Cable
ASSEMBLY PROCEDURE FOR SUBMINIATURE CONNECTOR, ONO89558
b.
44
Install the sealing boot and slide the outer ferrule

onto cable prior to stripping the cable. (See
Figure 1244.)
dimensions indicated. (See Figure 1244.) All
cuts are to be square and sharp. Do not nick
braid, dielectric or centre conductor when
cutting. If the wire ends of the centre conductor
are frayed, twist them to normal lay.
Basic Tool
Setting
Contact Locator
M22520/2-01
No. 5
M22520/2-24
f.
Install the centre contact in the body assembly

while sliding the inner ferrule underneath the
wire braid. (See Figure 1245.) The centre
contact shall be inserted until it is locked into
place in the body assembly. A 1.5 kilogram min
to 2.3 kilogram max pull shall be exerted on the
cable to assure that the contact is securely
locked in place.
g.
Slide the outer ferrule over the wire braid and up

against the body assembly. No slack shall exist
in the wire braid.
h.
Crimp the outer ferrule with M22520/5-01 tool

and M22520/5-10 die. See Figure 1246.
i.
The shielded contact now assembled shall be

inserted into the connector assembly with
insertion tool ONO89564.
j.
Push the sealing boot forward into the grommet

of the connector until the O-ring riser of the boot
has effected its snap-in seal. (See Figure 12
47). The installation of the shielded contact is
complete.
38. For assembly of connector to RG-l95/U coaxial

cable, use the following procedure:
a.
Basic Tool
39. For assembly of connector to twisted pair of 26

or 24 A.W.G. wires, use the following procedure:
a.
Install the sealing boot onto the untwisted wire

prior to stripping the wires. (See Figure 1248.)
b.
Strip the wires to the dimensions indicated. (See

Figure 1248.) All cuts are to be square and
sharp. Do not nick the conductors when stripping
the insulation.

Sect 2 Chap 12
Figure 1244 Stripping Dimensions, Scaling Boot, Ferrule and Contact Before Crimping the Contact
Figure 1245 Final Assembly and Outer Ferrule Crimping
c.
Fold the longer stripped wire to a 5.5mm

dimension. (See Figure 1248.)
d.
Place the insulator and the contact onto the

shorter stripped wire. The wire which is now the
centre conductor must be visible through the
contact inspection hole (See Figure 1249.)
e.
Insert the contact into the crimping tool until it is

fully seated in the contact locator. Crimp with
one full stroke. (See Table 1211 for crimping
tool information.)
Table 1211 Crimping Tool Details
f.
Slide the outer ferrule onto the cable prior to

installing the centre contact in the body
assembly. (See Figure 1250.)
g.
Position the folded wire on top of the inner

ferrule. (See Figure 1250.) The centre contact
shall be inserted until it is locked in place in the
body assembly. A 1.5kg min to 2.3kg maximum
pull shall be exerted on the cable to assure that
the contact is securely locked in place.
h.
Slide the outer ferrule over the folded wire and

against the body assembly. Crimp the outer
ferrule with crimp tool ONO89140.
i.
The shielded contact now assembled shall be

inserted into the connector assembly with
insertion tool ONO89564.
j.
Push the sealing boot forward into the grommet

of the connector until the O-ring riser of the boot
has effected its snap-in seal. (See Figure 12
49). The installation of the shielded contact is
complete.
Crimp on Centre Contact

Basic Tool Setting
Basic
Tool
26 A.W.G.
24 A.W.G.
Contact
Locator
M22520/2-01
No. 6
No. 7
M22520/2-24
45

Sect 2 Chap 12
Figure 1246 Crimping Tool for Shielded Outer Ferrule
b.
Slide cable nut and bushing over cable. Do not

nick, braided shield or conductor.
c.
With a knife cut through and remove 9.5mm of

outer jacket.
d.
Comb out braid and cut inner dielectric 2.5mm

from end of cable.
e.
Place cable clamp in place making sure end of

clamp is flush with end of outer jacket. (See
Figure 1251.)
f.
Slide nut into place to hold cable clamp in

position.
g.
Carefully fold back braid over cable clamp,

position first washer and gasket in place and trim
excess braid flush with washer.
h.
Place second washer in place, tin centre

conductor and contact hole.
i.
Solder contact on centre conductor flush with

inner dielectric. Place insulator in place.
CAUTION
Turn nut only. Do not rotate body of cable.
j.
Insert cable assembly into connector, push firmly

in place and tighten nut until flush with body of
connector.
k.
Place front gasket in place.
Figure 1247 Final Connection Assembly

40. For assembly of Dage Type Connectors, use the
following procedure:
a.
Cut off end of cable even and square.
Figure 1248 Stripping Dimensions and Sealing Boot Before Crimping the Contact
46

Sect 2 Chap 12
c.
Position 2.8mm to 3.3mm thick jewellers saw in

slot of fixture, and carefully cut through cable
shield while rotating cable and maintaining
pressure against fixture.
d.
Remove cable from fixture.
CAUTION
Do NOT nick or score centre conductor with blade.
Figure 1249 Assembly Before Crimping
e.
Using a razor blade, cut and remove dielectric to

expose centre conductor.
f.
Using the trimmer tool, smooth copper shield

and dielectric (Figure 1253). This is
accomplished as follows:
(1) Slip correct end of tool over exposed end of
cable.
(2) Push lightly against cable while slowly
revolving tool clockwise two or three times.
(3) Remove tool and clean any chips from end
of cable.
g.
Re-insert cable into cable dressing fixture for

pointing. Keep pressure against fixture and
rotate cable slowly while filing on 45 surface
(Figure 1254) with a small pillar file or mill file.
Continue filing until conductor offers no
resistance to the file.
h.
Remove cable and brush off any chips.
Figure 1250 Final Assembly and Outer Ferrule

Before Crimping the Outer Ferrule
ASSEMBLY PROCEDURE FOR SMA

TERMINATION OF SEMI-RIGID CABLE USING
HAND TOOL M22520/36
41. SMA connectors, Category F, designed for use
with RG-402/U (3.6mm OD) and RG405/U (2.2mm OD)
semi-rigid cable, consist of a plug (with or without a
centre contact) or jack body. The plug (or jack) is
assembled and terminated to the semi-rigid cable by
means of an integrated grip sleeve. See Figure 1252.
A plug couples to a jack by means of screw threading.
Tooling for Preparing Semi-Rigid Cable
42. Before terminating the SMA connectors to the
semi-rigid cable, the cable must be prepared using the
components of the preparation tooling listed in Figure
1253.
Selection of Cable, Connector, and Tool

Components
44. Refer to Figure 1255, and select the correct
combination of cable, connector, hand tool locator, and
die set from Table 1212.
Tool Setup Procedure
45. Before the connector can be terminated to the
prepared cable the hand tool must be set up with an
appropriate locator and dies as follows:
a.
Having selected the proper locator die set for the

selection chart (see Table 1212), loosen locator
locking screw on tool (see Figure 1256).
b.
Insert locator into cavity of ram, making sure

locator bottoms on top surface of ram.
c.
Re-tighten locking screw.
d.
Position each die of the die set on its respective

tool jaw, orienting chamfer on die as shown in
Figure 1257. Die chamfers positioned
improperly will result in an unacceptable
termination.
Preparing the Semi-Rigid Cable

43.
Prepare both cable ends as follows:
a.
Place cable dressing fixture in vice.
b.
Insert end of cable into cable size-designated

hole (see Figure 1253).
47

Sect 2 Chap 12
e.
Secure, without tightening, the dies to jaws with

the die-holding screws.
f.
Align dies by placing cable inside locator and

squeezing the handles to dose tool. After
ensuring that the dies are aligned with each
other, tighten the die-holding screws (see Figure
1258).
e.
When terminating PANEL JACK to cable, align

sides of panel jack with tool jaws as shown in
Figure 1260.
f.
Support cable connector assembly and close

tool handles until ratchet releases to complete
termination.
Cable Bending Procedures

Cable Termination
46. Refer to Figure 1259 (plug termination) or
Figure 1260 (jack termination), then proceed as
follows:
a.
Slide connector over cable, flange end first.
b.
Place connector and cable inside locator of tool.
c.
Ensure that centre conductor or centre contact

enters hole in locator if applicable.
d.
Ensure that connector is seated squarely on

locator.
47. The 90 bending fixture assembly makes precise

right-angle bends on the cable adjacent to the flange
end of the plug. Refer to Figure 1261 for tangent-ofradius to end-of-connector dimensions. Bends can
have a radius of either 3.1mm on RG-402/U or RG405/U cable, or 6.3mm on RG-402/U cable only. The
spacer shown in Figure 1262 must be positioned
behind the dummy jack when bending the following:
RC-402/U cable to either radius when cable is
terminated with either plug M39012/79-3308 or plug
M39012/79-3208; RG-405/U cable to 3.2mm radius
when cable is terminated with plug M39012/79-3307 or
plug M39012/79-3207. Simply loosen dummy jack to
insert spacer, and retighten jack before proceeding.
Figure 1251 Assembly of Dage Type Connectors
48

Sect 2 Chap 12
Figure 1252 SMA Connectors M39012, Category F
Table 1212 Cable, Connector and Tool Component Selection

Connector Part Number
For RG-402/U
(3.6mm OD.) Cable Using
Dies
M22520/36-02
For RG-405/U
(2.2mm OD.) Cable Using
Dies
M22520/36-03
M39012/79-3308
M39012/79-3307
Plug with centre contact
M22520/36-04
M39012/79-3208
M39012/79-3207
Plug with centre contact, with safety wire

holes
M22520/36-04
M39012/92-3301
Plug without centre contact
M22520/36-06
M39012/92-3201
Plug without centre contact, with safety

wire holes
M22520/36-06
Connector
Description
Locator
Part Number
M39012/81-3208
M39012/81-3207
Jack
M22520/36-05
M39012/82-3208
M39012/82-3207
Panel Jack
M22520/36-05
M39012/83-3208
M39012/83-3207
Bulkhead Jack
M22520/36-05
49

Sect 2 Chap 12
Figure 1253 Tooling to Prepare Semi-rigid Cable

6.3mm Bends on RG-402/U Cable or 3.2mm Bends
on RG-405/U Cable
48.
Refer to Figure 1263, and proceed as follows:
a.
Screw terminated plug onto dummy jack of

holder.
b.
Refer to Table 1213, and slip appropriate bend

segment under cable.
NOTE
Figure 1254 Pointing the Cable End
50
TOP marking is not designated on bend segment

M22520/36-12.

Sect 2 Chap 12
d.
Re-attach plug to dummy jack of holder.
e.
Place conforming block over cable with tongue

of block in slot of holder (see Figure 1264).
0.125-Inch Radius Bends on RG-402/U Cable
f.
Insert limiting pin through hole in conforming

block, and slide block against holder.
49.
g.
Place assembly in a vice with a 7cm opening

and tighten vice to force conforming block into
holder slot. Continue to tighten vice until legs of
holder prevent further movement of vice jaws.
c.
Using finger pressure, bend cable around

segment to desired angle, 90 maximum.
d.
Unscrew plug from dummy jack on holder.
Refer to Figure 1264, and proceed as follows:
a.
Form a 6.3mm radius bend as described in

paragraph 48.
b.
Remove plug from dummy jack on holder.
h.
c.
Replace 6.3mm bend segment with the 3.2mm

segment for RG402/U cable.
Remove assembly from vice, and unscrew plug

from dummy jack on holder.
i.
Remove conforming block and bend segment

from holder.
Figure 1255 Termination Tooling
51

Sect 2 Chap 12
Table 1213 Bend Segment Selection

Cable
Bend
Number
RG-402/U
RG-405/U
Segment
Radii Dimension
Plug Number
M22520/36-12
6.3mm
M39012/79-3308
M22520/36-11
3.2mm
M39012/79-3208
M39012/92-3301
M39012/92-3201
M22520/36-13
3.2mm
M39012/79-3307
M39012/79-3207
Figure 1256 Locator and Locking Screw

Figure 1258 Die Alignment
Figure 1257 Orientation of Die Chambers
52

Sect 2 Chap 12
Daily Maintenance
good SAE No. 20 motor oil. Do NOT oil

excessively.
50. Each operator of the hand tool shall be made

aware of, and responsible for, the following four steps
of daily maintenance.
a.
d.
When tool is not in use, keep handles closed to

prevent objects from becoming lodged in the
dies; store tool in a clean, dry area.
Remove dust, moisture, and other contaminants

with a clean brush, or a soft, lint-free cloth. Do
NOT use objects that could damage the tool.
Periodic Inspection
b.
Make sure proper retaining pins are in place and

secured with proper retaining rings.
51. Regular periodic inspection and testing of hand

crimping tools shall be performed in accordance with
the requirements of Section 2 Chapter 6.
c.
Make certain all pins, pivot points and bearing

surfaces are protected with a THIN coat of any
Figure 1259 Plug Termination
Figure 1260 Jack Termination
53

Sect 2 Chap 12
Figure 1261 Radii Dimensions for Semi-Rigid Cable Bending
Figure 1262 Spacer on Dummy Jack
Figure 1263 0.025 Inch Radius Bends on RG-402/U Cable and 0.125 Inch Radius Bends on RG-405/U Cable
54

Sect 2 Chap 12
Figure 1264 3.2mm Radius Bends on RG-402/U Cable
Figure 1265 Triaxial Connector Assembly - Exploded View
TRIAXIAL CONNECTORS
Assembling Triaxial Cable Connectors
52. MIL-PRF-49142 triaxial connectors and other

such related connectors and fittings are intended for
use with triaxial cable and can be used for radio
frequency application when more shielding is required.
It can be used in video circuits and for serial digital
transfer.
53. When assembling triaxial cable connectors to

wire or cable, refer to Figure 1265 through to Figure
1268.
a.
Remove 12.7mm of outer insulation.
b.
Comb outer shield. Taper the shield over end

middle insulation.
55

Sect 2 Chap 12
c.
Slide nut over outer insulation.
d.
Slide washer A over tapered shield. Press the

washer firmly against outer insulation.
e.
Cut outer shield to dimension shown in Figure

1266.
f.
Flare outer shield. Install washer B firmly against

shield. If necessary, trim shield flush with
circumference of washers A and B.
g.
Install gasket firmly against washer B.
h.
Cut middle insulation to dimension shown in

Figure 1267.
i.
Install teflon washer firmly against gasket.
j.
Install washer C firmly against teflon washer.
k.
Cut middle shield to dimension shown in Figure

1267.
l.
Flare middle shield. Install washer firmly against

shield. If necessary, trim shield flush with
circumference of washers C and D.
Figure 1266 Attaching Triaxial Connector to Cable
m. Cut inner insulation and inner conductor to

dimensions shown in Figure 1268.
n.
Tin inner conductor. Solder contact to inner

conductor (do not over heat). Remove excess
solder.
o.
Install items E, F, G and H. Tighten nut to

14+1 inch-pounds while holding outer shell and
outer
insulation
fixed.
Figure 1267 Attaching Gasket to Middle Insulation
Figure 1268 Attaching Outer Shell to Gasket
56

Sect 2 Chap 13
SECTION 2
CHAPTER 13
BONDING AND GROUNDING

INTRODUCTION
1.
Bonding and grounding connections are made for
the following purposes:
a.
Splice, Conductor, Disconnect,

Crimp Style, Copper, Insulated
Barrel, Type II, Class 1
SAE AMS-M-3171
Magnesium Alloy; Processes

for Pre-treatment and
Prevention of Corrosion
SAE AS 50881
Wiring, Aerospace Vehicle
SAE AS 7928
Terminals, Lug and Splices,

Conductor Crimp Style,
Copper, General Specification
To protect aircraft and personnel against hazards

from lightning discharge.
b. To provide current return paths.

c.
MS27429
To prevent development of RF potentials.
d. To protect personnel from shock hazard.

e.
To provide stability and homogeneity of radio

transmission and reception.
f.
To prevent accumulation of static charge.
g. To provide fault current return paths.

2.
This chapter describes and illustrates the
recommended procedures to be followed in the
preparation and installation of bonding and grounding
connections.
DEFINITIONS
Bonding
4.
The electrical connecting of two or more
conducting objects not otherwise adequately connected.
Grounding
5.
The electrical connecting of conducting object to
primary structure or earth electrode, for return of current.
3.
bonding and grounding connections:
Primary Structure
A-A-857
Thinner, Dope, & Lacquer

(Cellulose-nitrate)
6.
The main frame, fuselage, and wing structure of
the aircraft (commonly referred to as ground).
MIL-C-83413/8
Connectors and Assemblies,

Electrical, Aircraft Grounding:
Type IV Jumper Cable
Assembly, Lead Electrical
MIL-DTL-22520
Crimping Tools, Wire

Termination, General
Specification For
MIL-PRF-23377
Primer Coatings, Epoxy, High

Solids
MIL-PRF-85582
Primer Coatings, Epoxy,

Waterborne
MIL-STD-464
Electromagnetic
Environmental Effects
Requirements for Systems
MIL-T-81714
GENERAL PRECAUTIONS AND PROCEDURES

7.
When making bonding or grounding connections
in aircraft, observe the following general precautions and
procedures:
a.
Bond or ground parts to the primary aircraft

structure where practicable.
b. Make bonding or grounding connections in such a

way as not to weaken any part of the aircraft
structure.
c.
Bond parts individually wherever possible.
d. Make bonding or grounding connections against

smooth, clean surfaces.
Terminal Junction System,

Environment Resistant,

Sect 2 Chap 13
e.
f.
Install bonding or grounding connections so that

vibration, expansion or contraction, or relative
movement incident to normal service use will not
break or loosen the connection.
Locate bonding and grounding connections in
protected areas whenever possible. Locate
connections, whenever possible, near hand holes,
inspection doors, or other accessible areas to
permit easy inspection and replacement.
g. Do not compression-fasten bonding or grounding

connections through any non-metallic material.
h. Inspect the grounding and bonding straps to
ensure that they are free of corrosion which will
adversely affect performance, and are not frayed
or cut more than 25% of the original strap.
i.
No more than four ground wires should be

connected to a common ground stud. Ground
modules in accordance with MIL-T-81714 may be
used for multiple grounds. No more than 16
ground wires should be connected in a ground
module. Each ground for electric power sources
(primary, secondary, emergency) should be
connected to separate ground points. Grounds for
utilisation equipment may be connected to a
common ground point only when supplied from
the same power source, provided this equipment
does not perform duplicate or overlapping
functions.
SELECTION OF HARDWARE
8.
Hardware used to make bonding or grounding
connections is selected on the basis of mechanical
strength, current to be carried, and ease of installation.
Where connection is made by aluminium or copper
jumpers to structure of dissimilar material, a washer of
suitable material should be installed between the
dissimilar materials so that any corrosion which may
occur will occur in the washer, which is expendable,
rather than in the structure.
Hardware Material and Finish

9.
Select hardware material and finish from Table
131, Table 132 or Table 133, depending on material
of structure to which attachment is made, and material of
jumper and terminal specified for the bonding or
grounding connection.
Selection of Stud
10. Use either an AN screw or bolt of the proper size
for the specified jumper terminal. Length of screw or bolt
should be such that when bonding or grounding
connection is fully tightened, approximately 3.7mm of
screw protrudes beyond top of nut.
Selection of Nuts
11. Use AN nuts, either plain or self-locking, where
indicated in Figure 131 and Figure 133. Use an allmetal, self-locking nut if practicable. Always use an allmetal, self-locking nut where current will be present.
Where installation conditions require, use an AN nutplate, riveted to structure.
Selection of Washers
12. Use AN plain washers and split lock washers as
indicated in Figure 131, Figure 132 and Figure 133.
Unless otherwise directed by applicable equipment
technical order, use split lock washers with nuts, either
plain or self-locking. With aluminium terminals, use a
plain washer of at least the diameter of the terminal
tongue, next to the aluminium terminal. If an AN washer
does not meet this requirement, use a washer of the
SAE heavy series, or a special washer made for this
application.
Selection of Cable Clamp
13. For bonding or grounding to cylindrical surfaces,
use an AN735 clamp. Where an AN735 clamp is not
available, or where installation conditions do not allow its
use, a non-cushioned AN742 clamp may be substituted.
NOTE
When repairing or replacing existing bonding or
grounding connections, use the same type of
hardware as used in the original connection.
CAUTION
Do not use cushioned clamps in any bonding or
grounding connection.

Sect 2 Chap 13
Figure 131 Stud Bonding or Grounding to Flat Surface
Table 131 Hardware for Stud Bonding or Grounding to Flat Surface

(Refer to Figure 131)
Aluminium Terminal and Jumper
Structure
Screw or Bolt;
Locknut
Plain Nut
Washer A
Washer B
Washer
C&D
Lockwasher E
Lockwasher F
Aluminium
Alloys
Cadmium
Plated Steel
Tin Plated
Brass
Aluminium
Alloy
Aluminium
Alloy
Cadmium
Plated Steel
or Aluminium
Cadmium
Plated Steel
Cadmium
Plated Steel
Magnesium
Alloys
Cadmium
Plated Steel
Cadmium
Plated
Steel
Magnesium
Alloy
Magnesium
Alloy
Cadmium
Plated Steel
or Aluminium
Cadmium
Plated Steel
Cadmium
Plated Steel
Steel,
Cadmium
Plated
Cadmium
Plated Steel
Cadmium
Plated
Steel
None
None
Cadmium
Plated Steel
or Aluminium
Cadmium
Plated Steel
Cadmium
Plated Steel
Steel,
Corrosion
Resisting
Corrosion
Resisting Steel
Cadmium
Plated
Steel
None
None
Cadmium
Plated Steel
or Aluminium
Corrosion
Resisting Steel
Cadmium
Plated Steel
Lockwasher E
Lockwasher F
Cadmium
Plated Steel
Cadmium
Plated Steel or
Aluminium
Tinned Copper Terminal and Jumper

Structure
Aluminium
Alloys
Screw or Bolt;
Locknut
Cadmium
Plated Steel
Plain Nut
Cadmium
Plated
Steel
Magnesium
Alloys
Washer A
Aluminium
Alloy
Washer B
Aluminium
Alloy
Washer
C&D
Cadmium
Plated Steel
AVOID CONNECTING COPPER TO MAGNESIUM
Steel,
Cadmium
Plated
Cadmium
Plated Steel
Cadmium
Plated
Steel
None
None
Cadmium
Plated Steel
Cadmium
Plated Steel
Cadmium
Plated Steel
Steel,
Corrosion
Resisting
Corrosion
Resisting Steel
Corrosion
Resisting
Steel
None
None
Cadmium
Plated Steel
Corrosion
Resisting Steel
Corrosion
Resisting Steel

Sect 2 Chap 13
Figure 132 Plate Nut Bonding or Grounding to Flat Surface
Table 132 Hardware for Plate Nut Bonding or Grounding to Flat Surface
Structure
Screw or Bolt;
Nut Plate
Rivet
Lockwasher
Washer A
Washer B
Aluminium Alloys
Cadmium Plated
Steel
Aluminium Alloy
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium
None
Magnesium Alloys
Cadmium Plated
Steel
Aluminium Alloy
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium
None or
Magnesium Alloy
Steel, Cadmium
Plated
Cadmium Plated
Steel
Corrosion
Resisting Steel
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium
None
Steel, Corrosion
Resisting
Corrosion
Resisting Steel or
Cadmium Plated
Steel
Corrosion
Resisting Steel
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium
Cadmium Plated
Steel

Structure
Aluminium Alloys
Screw or Bolt;
Nut Plate
Cadmium Plated
Steel
Magnesium Alloys
Rivet
Aluminium Alloy
Lockwasher
Cadmium Plated
Steel
Washer A
Cadmium Plated
Steel
Washer B
Aluminium Alloy
Steel, Cadmium
Plated
Cadmium Plated
Steel
Corrosion
Resisting Steel
Cadmium Plated
Steel
Cadmium Plated
Steel
None
Steel, Corrosion
Resisting
Corrosion
Resisting Steel
Corrosion
Resisting Steel
Cadmium Plated
Steel
Cadmium Plated
Steel
None

Sect 2 Chap 13
Figure 133 Bolt and Nut Bonding or Grounding to Flat Surface
Table 133 Hardware for Bolt and Nut Bonding or Grounding to Flat Surface
Structure
Screw or Bolt;
Locknut
Lockwasher
Washer A
Washer B
Washer C
Aluminium Alloys
Cadmium Plated
Steel
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium
None
Cadmium Plated
Steel or Aluminium
Magnesium Alloys
Cadmium Plated
Steel
Cadmium Plated
Steel
Magnesium Alloy
None or
Magnesium Alloy
Cadmium Plated
Steel or Aluminium
Steel, Cadmium
Plated
Cadmium Plated
Steel
Cadmium Plated
Steel
Cadmium Plated
Steel
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium
Steel, Corrosion
Resisting
Corrosion
Resisting Steel or
Cadmium Plated
Steel
Cadmium Plated
Steel
Corrosion
Resisting Steel
Cadmium Plated
Steel
Cadmium Plated
Steel or Aluminium

Structure
Aluminium Alloys
Screw or Bolt;
Locknut
Lockwasher
Cadmium Plated
Steel
Cadmium Plated
Steel
Magnesium Alloys
Washer A
Cadmium Plated
Steel
Washer B
Aluminium Alloy
Washer C
Cadmium Plated
Steel
Steel, Cadmium
Plated
Cadmium Plated
Steel
Cadmium Plated
Steel
Cadmium Plated
Steel
None
Cadmium Plated
Steel
Steel, Corrosion
Resisting
Corrosion
Resisting Steel or
Cadmium Plated
Steel
Cadmium Plated
Steel
Corrosion
Resisting Steel
None
Cadmium Plated
Steel

Sect 2 Chap 13
PREPARATION OF BONDING OR GROUNDING

SURFACES
14. Clean bonding and grounding surfaces thoroughly
before making the connection. Remove paint, anodic or
conversion coating film and surface corrosion from
planned attachment area with abrasive mat, A-A-58054.
CAUTION
Do not use abrasives such as emery cloth, crocus
cloth, steel wool, etc. These may leave particles
imbedded in the surface or scattered in the area
which may cause corrosive action.
Cleaning Procedure for Steel Surfaces

17. When the surface is corrosion resisting or plated
steel, clean bonding or grounding surface as described
in paragraph 16, steps a and b.
CAUTION
Do not remove zinc or cadmium plate from steel
surfaces.
Cleaning Procedure for Aluminium Surfaces

15. Apply a coating of petrolatum compound to
bonding or grounding surface of aluminium structure and
clean surface thoroughly, using stainless steel wire
brush with pilot as shown in Figure 134. Wipe off the
petrolatum compound with a clean dry cloth.
Cleaning Procedure for Magnesium Alloy Surfaces
16. Prepare magnesium alloy surfaces for bonding or
grounding as follows:
WARNING
Cleaning solvents are toxic to skin, eyes and
respiratory tract. Skin and eye protection is required.
Avoid repeated or prolonged contact. ensure
adequate general ventilation and avoid breathing
fumes generated by solvents.
a.
Remove grease and oil from surface with P-D680, Type III.
Figure 134 Stainless Steel Wire Brush With Pilot for

Cleaning Aluminium Surfaces
WARNING
A-A-857 is flammable and toxic to eyes, skin, and
respiratory tract. Skin and eye protection is required.
Avoid prolonged contact. Use only with adequate
ventilation.
b. If present, remove paint or lacquer from surface
with lacquer thinner, A-A-857.
c.
Brush area liberally with chrome pickle solution,

SAE AMS-M-3171, Type I for one minute, then
rinse within five seconds by brushing with clean
water.
d. Dry thoroughly.
METHODS OF BONDING OR GROUNDING

18. Bonding or grounding connections are made
directly to a flat surface of basic structure, or to a
cylindrical surface of basic structure.
Connection to Flat Surfaces
19. Bonding and grounding of through bolts or
screws, where installation has easy access. There are
three types of bolted connection, as follows:
a.
Stud Connection. In this type of connection, a

bolt or screw is locked securely to structure, thus
becoming, in effect, a stud. (See Figure 131 and
Table 131.) Grounding or bonding jumpers can
be removed or added to the shank of stud without
removing stud from structure. Not more than four
lugs should be connected to any one stud.

Sect 2 Chap 13
b. Nut Plate and Bolt Connection. Nut plates are

used where access to the nut for repairs may be
difficult. Nut plates are riveted or welded to a
clean area of the structure. (See Figure 132 and
Table 132.) Cleaning of structure is done in
accordance with paragraphs 15 through 17 as
applicable.
c.
Nut and Bolt Connection. In this connection the

bolt or screw is not attached permanently to
structure. (See Figure 133 and Table 133.)
When jumpers are to be added or removed, the
entire connection is remade. The table lists
materials and platings that are compatible with the
structure to which they are mounted. These
materials are selected so that corrosion, if it
occurs, will occur in the washers, which are
expendable, rather than in the structure.
Connection to Tab Riveted to Structure

22. Bond aluminium alloy or corrosion-resisting steel
conduit to structure as shown in Figure 138. If
installation conditions require, an AN742 clamp may be
used instead of an AN735 clamp, using same hardware.
Tightness of Connections
23. Make sure that all connections are tight, as
evidenced by the split lockwashers being completely
compressed.
CAUTION
When terminal is under head of screw or bolt (as
shown in Figure 132), it is preferable not to install
more than one terminal. Otherwise, the screw may
loosen and cause improper operation of equipment.
20. For bonding leads carrying high current, (size

AWG 4 or larger), do not make the connection directly to
the structure, but to a tab of suitable size adequately
bonded to the aircraft structure. (See Figure 135.)
When a bonding or grounding connection is made to a
tab riveted to the structure rather than directly to the
structure, clean the bonding or grounding surface and
make the connection exactly as though the connection
were being made to structure. If it is necessary to
remove the tab for any reason, replace rivets with one
size larger. Make sure mating surfaces of structure and
tab are clean and free of anodic film.
Connection to Cylindrical Surfaces
21. Make bonding or grounding connections to
aluminium alloy, magnesium alloy, or corrosion resisting
steel tubular structure as shown in Figure 136 and
Figure 137. Figure 136 shows the arrangement of
hardware for bonding with an aluminium jumper.
Because of the ease with which aluminium is deformed,
it is necessary to distribute screw and nut pressure by
means of plain washers as shown. Figure 137 shows
the arrangement of hardware for bonding with a copper
jumper. No extra washers are used. If installation
conditions require, use an AN742 clamp (noncushioned) instead of an AN735 clamp. Do not change
any other hardware if this substitution is made.
Figure 135 Bonding Tab Riveted to Structure

Sect 2 Chap 13
Figure 136 Aluminium Jumper Connection to Tubular Structure
Figure 137 Copper Jumper Connection to Tubular Structure
Figure 138 Bonding Conduit to Structure
BONDING AND GROUNDING JUMPERS
Fabricating Bonding and Grounding Jumpers
24. To accomplish the purpose of bonding or

grounding, it is necessary to provide a conductive path
where direct electrical contact does not exist. Jumpers
are used for this purpose in such applications as
between moving parts, between shock-mounted
equipment and structure, and between electrically
conducting objects and structure. Keep jumpers as short
as possible; if practical, under 76mm. Do not use two or
more jumpers in series.
25. Jumpers of tinned copper wire are fabricated in

accordance with MIL-C-83413/8. For smaller size wire,
terminate with MS25036 insulated copper terminal lugs
of appropriate size. Use M22520/5-01 tool with
M22520/5-100 for crimping terminals to wire. For larger
wire size, terminate with MS20659 uninsulated copper
terminal lugs, crimped to the wire with M22520/24-10 or
MS25441 tool. The appropriate size copper wire braid
should be selected from Table 134.

Sect 2 Chap 13
Table 134 Tinned Copper Woven Braid for Fabrication of Electrical Grounding and Bonding Leads
Construction
Strand Diameter
Width
Part Number
Lays
Strands
Mil
SWG
mm
Ins
Area
Cir Mils
Current
Rating
Terminal
Lug Size
G154-8-3-.122
0.122
40
1.19
.047
380
26-24
G154-16-3-.122
16
0.122
40
1.58
.063
1000
22-18
G154-24-3-.1226
24
0.122
40
2.78
.110
1900
10
22-18
G154-24-4-.122
24
0.122
40
3.18
.125
2550
13
16-14
G154-24-6-.1228
24
0.122
40
4.76
.187
3800
15
16-14
G154-24-8-.122
24
0.122
40
6.35
.250
5100
20
16-14
G154-24-14-.122
24
14
0.122
40
9.52
.375
7650
30
12-10
G154-32-16-.122
32
16
0.122
40
12.70
.50
10200
40
12-10
G154-32-20-.122
32
20
0.122
40
15.88
.625
12700
50
12-10
G154-48-16-.122
48
16
0.122
40
19.05
.75
14300
60
G154-48-32-.122
48
32
0.122
40
25.40
1.0
21700
80
Note
For RF bonding, a rule of thumb for achieving
minimum bond strap inductance is that the length-towidth ratio of the strap should be 5:1 or less.
bonding of RF components is required, the resistance

should be a maximum 0.0025 ohms (2.5 milliohms)
(Reference MIL-STD-464). Test is made after the
mechanical connection is completed, and consists of a
milli-ohmmeter reading of the overall resistance between
the cleaned areas of the object and the structure.
Quick-Disconnect Jumpers
Resistance Test Procedure
26. Where a quick disconnect jumper is required,

crimp an MS27429 electrical disconnect splice into a
copper wire jumper, fabricated as described in
paragraph
25,
using
M22520/5-01
tool
with
M22520/5-100 die. Note that the disconnect splice is not
centred in the jumper, but is installed so that the coupler
remains on the short end when the jumper is
disconnected.
28. Measurements of the specified resistance value

are made with special calibrated low-range ohmmeters.
The Avtron T477W or functional equivalent meeting UL913 explosion-proof test criteria should be used in
enclosed areas where hazards exist, such as explosive
vapours from fuel systems. The AN/USM-21A can be
used in non-hazardous areas. Proceed as follows,
observing the precautions emphasised in the meter
instruction manual.
TESTING BONDS AND GROUNDS

Resistance Tests After Connection
NOTE
The resistance figures provided below are for general
electrical and RF bonding. Specific requirements
detailed in aircraft or component publications should
take precedence.
27. The resistance across a bonding or grounding
jumper is required to be 0.1 ohms or less for general
electrical bonding whether using bonding jumpers or
where metallic components are directly attached. Where
a.
With the Function Control OFF, set the Range

Control to the 0.1 ohm position.
b. Attach the instrument test clips for good electrical

contact with the cleaned areas immediately
adjacent to the jumper terminal lugs of object and
structure.
c.
Set the Function Control to CALIBRATE, then use

the Calibration Adjustment Control to obtain a 0.1
ohm full scale deflection.
d. Set the Function Control to OHMS position, and

note the bond (only) reading. It should be less
than 0.1 ohm.

Sect 2 Chap 13
REFINISHING
Refinishing Metal Surfaces
WARNING
Appropriate personal protective equipment should be
worn when handling and using cleaning and corrosion
control solutions.
29. Following the connection and successful testing of
bonding or grounding leads, the bare metal surface must
be protected from corrosion.
10

Sect 2 Chap 14
SECTION 2
CHAPTER 14
EARTHING AND BONDING OF AIRCRAFT

AND GROUND SUPPORT EQUIPMENT
INTRODUCTION
1.
Electrical bonding of aircraft to earth has generally
been aimed at protecting aircraft and personnel from the
hazards associated with static electrical discharge.
However, with utilisation of external power sources,
electrical bonding to earth must also protect aircraft and
personnel from the potential hazards associated with the
electrical ground power supplies.
2.
The latter concern has led to an extensive
examination of the hazards and electrical bonding
procedures, and this has resulted in a different approach
to electrical bonding requirements. This approach
emphasises the need to counteract the potential hazards
associated with electrical ground power supplies. If
protection against these is adequate then protection
against the hazards associated with static electrical
build-up and discharge is also adequate.
3.
Increasing utilisation of electrically operated GSE,
primarily mains powered equipment (240V, 50Hz), has
highlighted the need to protect personnel against the
potential hazards associated with this type of equipment.
4.
The purpose of this chapter is to clearly present
the approach that should be adopted in relation to
electrical protection, bonding and earthing and to define
the procedures to be employed. In particular the aims
are:
a.
hazards associated with ground power supplies. The

grounding methods presented make a clear distinction
between static grounding and power grounding. The
following definitions apply:
a.
b. Power Ground. An approved ground point with

an impedance of less than 10 ohms to the power
system neutral.
6.
Static grounding of aircraft is required whenever
the aircraft is parked; including during refuelling, defuelling, hot refuelling, stores loading and whenever
external power is connected.
7.
All aircraft require externally generated electrical
power supplies to facilitate servicing and maintenance.
For safe use of these power supplies the aircraft must
be correctly grounded. This grounding is to provide
protection against the potential hazards of these external
power supplies and is in addition to aircraft static
grounding or earthing procedures.
8.
There are two basic types of power supply
available for supplying electrical power for aircraft
servicing. They are:
a.
To describe the nature of the hazards associated

with static electricity, ground power supplies and
mains operated GSE.
b. To specify the procedures to be used for electrical

protection of personnel, and electrical bonding
and earthing of aircraft and ground support
equipment.
Static Ground. An approved ground point with an

impedance of less than 10,000 ohms referenced
to earth.
Reticulated Power Supplies. These are usually

supplies peculiar to the aircraft or equipment,
reticulated from another source and terminated in
the hangar. From these, the power is fed to the
aircraft. Typical supply values are 115/208V
400Hz AC and 28VDC.
b. Mobile Generating Sets. These may be:

(1) engine driven generating sets;
(2) static rectifiers; and
ELECTRICAL GROUNDING FOR AIRCRAFT

SAFETY
Introduction
5.
The following paragraphs provide maintenance
personnel with the rationale behind the requirements for,
and the detailed information required to carry out
electrical safety grounding of aircraft. This includes
grounding for both static electricity and the potential
(3) frequency changers.

External Power Supply System Characteristics
9.
The use of external power supplies always
involves two basic electrical characteristics:
a.
a voltage (potential) above earth mass potential to

create the electrical pressure necessary to cause
a current flow; and

Sect 2 Chap 14
b. a return path, normally at earth mass potential, to

complete the electrical circuit.
b. an extensive reticulation system is required to

provide electrical power to the aircraft.
10. The electrical cable used in sub para 9a. is

termed the active or positive lead, and in sub para 9b.
the neutral or negative lead.
17. The above characteristics allow for supplementary

return paths, ie earth loops to be established in parallel
with the neutral or negative lead. Current flow will be
proportional to the resistance of the return circuit. Under
normal conditions the current flow is of an acceptably
low value in the earth loops. This is due to the relatively
high resistance between hangar floor earths and the
earth/neutral link at the sub-mains.
11. External power supplies, both mobile and

reticulated, are designed so that the return path from the
aircraft load to the power source is always via the
negative or neutral lead. However, parallel return paths
can be established and it is these that provide the
hazards associated with external power supplies.
12. The current flow in a return path will depend on
the total resistance of the circuit and be in proportion to
the resistance (and therefore currents) of other parallel
paths. Not only may equipment operation be unbalanced
by multiple return paths, but more importantly, personnel
may sustain serious injury by becoming part of a return
path.
13. All efforts are aimed at ensuring that, generally,
only one return path is possible and that adequate safety
measures are taken so that personnel are afforded the
best possible protection from the potential hazards
associated with external electrical power supplies.
Mobile External Power Supplies
14. Mobile aircraft external power supplies are to
have the output AC neutral lead and/or the DC negative
lead connected to the chassis. A return path may be
established if the chassis is bonded to the earth mass,
consequently a general policy should require that the
power source chassis is NOT bonded to the earth mass.
This is illustrated in Figure 141.
15. GSE and safety interconnection leads are not
designed to withstand a high value of continuous current
flowing in the components that could form part of a
parallel return path. In addition, the electrical instability
engendered by multiple return paths, if these are
established, is generally undesirable.
Reticulated Aircraft External Power Supplies
16. Reticulated aircraft external power supplies have
certain characteristics which set them apart from mobile
power supplies, ie:
a.
very effective earthing of the source of the power

at the mains or sub-mains earth/neutral link; and
18. The most acute hazard associated with reticulated

power supplies serving hangar facilities is the possibility
of the aircraft frame being connected to the hanger
structure. In this situation, the earth loop will carry a
greater proportion of the return current. This current flow
will be greater still if the resistance of the power supply
neutral or negative is high or the main return path is
disconnected.
19. If earth loop currents are high, due to either
incorrect earthing or faulty neutral/negative return leads,
the following hazardous situations will exist when power
is applied to the aircraft:
a.
arcing will occur when the safety interconnection

lead is connected or disconnected; and
b. personnel becoming part of this circuit will suffer

electric shock.
20. For the above reasons it is imperative that all
personnel ensure that correct earthing techniques are
always employed.
WARNING
Connection/disconnection of safety interconnection
leads should not be made whilst reticulated external
electrical power is applied to the aircraft.
21. Illustrated in Figure 142 and Figure 143 are the
two static aircraft external power supply situations, and
the correct connections to ensure equipment and
personnel safety.

Sect 2 Chap 14
Figure 141 Mobile (Self Contained) Aircraft External Power Supply
Figure 142 Mobile Rectifier/Frequency Converter Aircraft External Power Supply
Figure 143 Reticulated Aircraft External Power

Sect 2 Chap 14
ELECTRICAL EARTHING AND BONDING

PROCEDURES FOR AIRCRAFT AND GSE
Introduction
22. The following paragraphs contain the procedures
and sequences to be used for electrical earthing and
bonding of aircraft and ground support equipment. The
observance of these procedures is recommended for
personnel involved in aircraft ground handling and
maintenance.
23. Correct
electrical
earthing
and
bonding
procedures are essential to minimise the hazards
associated with static electricity. Safety interconnection
leads, which have been designed to provide this
earthing and bonding for aircraft and equipment, must
be connected correctly and in the proper sequence.
Aircraft Earthing Procedure
24. Unless otherwise directed by the specific aircraft
documentation,
a
safety
interconnection
lead
manufactured to the requirements detailed in this
chapter is to be connected/disconnected using the
following sequence:
a.
The safety interconnection lead clamp is

connected to a known serviceable earth reference
point followed by the connector pin or clamp being
attached to an appropriate location on the aircraft.
The interconnection should exist at all times whilst
the aircraft is parked.
b. Disconnection procedure is the reverse of the

connection sequence ie. the connector pin or
clamp is removed from the aircraft followed by the
lead clamp removal from the earth reference
point.
25. Any one of the configurations detailed in Figure
144, Figure 145, Figure 146 or Figure 147 may be
used to earth the aircraft.
Bonding GSE to Aircraft
CAUTION
External electrical power supply units are NOT to be
connected to an earth reference point, or
interconnected to aircraft earth receptacles.
26. Personnel operating GSE in conjunction with
aircraft are responsible for ensuring the proper
sequence of earthing and bonding is observed and that
the connections are correctly made.
Replenishing or Removing Flammable Fluids

NOTE
Whilst oxygen is classified as non-flammable, the
dangers
involved
during
aircraft
oxygen
replenishment dictate that oxygen should be treated
as a flammable fluid. However, when replenishing
airborne oxygen systems, bonding of the filling
connector to the aircraft is not required.
27. Before replenishing an aircraft with flammable
fluid or removing flammable fluid from an aircraft, the
following bonding procedures and sequences are to be
observed (Refer to the note following Paragraph 23
regarding operating from civilian airports):
a.
Check that a safety interconnection lead is

connected between a serviceable earth reference
point and the aircraft.
b. Connect a safety interconnection lead from the

GSE to the same earth reference point to which
the aircraft is earthed.
c.
Connect a safety interconnection lead from the

GSE to an earth point on the aircraft.
d. Personnel involved in the operation are to touch

an earthed conductor to themselves and their
clothing to discharge any static electricity that they
may have generated.
e.
Before opening the inlet of the replenishment

point, connect the replenishment hose bonding
connector plug or clamp to an earth point adjacent
to the fluid inlet.
28. After the replenishment connections have been

removed at the completion of the operation, disconnect
the bonding leads in the reverse sequence.
Replenishing or Removing Non-Flammable Fluids
29. The sequence for electrical bonding of GSE used
for replenishing or removing non-flammable fluids from
an aircraft is as follows:
a.

point and the aircraft, and;

GSE to the same earth reference point to which
the aircraft is bonded.
NOTE
When operating at airports where earth points are
unavailable, a bonding lead should be connected
from the GSE to the aircraft. The GSE can then be
connected and operated.

Sect 2 Chap 14
Servicing Aircraft with Flammable Fluids from

Drums or Containers
30. Before replenishing an aircraft with flammable
fluid from a drum or other container, or removing
flammable fluids from an aircraft into a drum or other
container, the following earthing and bonding
procedures and sequences should be observed.
a.


fuel servicing unit (FSU) to the same earth
reference point to which the aircraft is earthed.
c.
d. Connect a safety interconnection lead from the

FSU to the aircraft.
e.
Personnel involved in the fuelling operation are to

touch an earthed conductor to themselves and
their clothing to discharge any static electricity that
they may have generated.
f.
Before opening the inlet of the aircraft

replenishment
point,
connect
the
FSU
replenishment hose bonding connector plug or
clamp to an earth point adjacent to the fuel inlet.
b. The drums or containers are to be bonded to each

other with safety interconnection leads, (Leads as
detailed in Figure 147 should be used).
c.
Connect a safety interconnection lead between

the bonded drums or containers and the same
earth reference point to which the aircraft is
earthed.
d. Connect a safety interconnection lead between

the pumping unit (can be a tanker, fuel servicing
unit or wheel or sled mounted centrifugal pumping
unit) and the same earth reference point to which
the aircraft and containers are connected.
e.
f.

the bonded drums or containers and the pumping
unit.
the pumping unit and the aircraft.
g. Personnel involved in the fuelling operation are to

touch an earthed connector to themselves and
their clothing to discharge any static electricity that
they may have generated.
h. Prior to opening the inlet of the aircraft
replenishing point, connect the hose connector
plug or clamp to an earth point adjacent to the
fluid inlet.
31. After the fuelling connections have been removed
at the completion of the replenishment operation,
disconnect the bonding leads in the reverse sequence.
Refuelling Aircraft from Hydrant Systems
32. Before refuelling an aircraft from a hydrant
system, the following bonding procedures and sequence
should be observed:
a.

Before connecting the FSU supply hose to the

hydrant supply point, connect the FSU supply
hose bonding connector or clamp to an earth point
adjacent to the hydrant supply point.
g. After the fuelling connections have been removed

disconnect the bonding leads in the reverse
sequence.
Bonding Procedures to be Observed when
Refuelling GSE
33. The following bonding procedures should be used
when refuelling GSE on aircraft tarmac areas:
a.
Ensure that GSE is inoperative and disconnected

from the aircraft.

refuelling vehicle to the GSE.
c.
Personnel are to touch an earthed conductor to

themselves and their clothing to discharge any
static electricity they may have generated.
d. Prior to opening the inlet of the GSE replenishing

point connect the replenishing hose bonding
connector plug or clamp to an earth point adjacent
to the refuelling inlet.
e.
After the fuelling connections have been removed

disconnect the bonding leads in the reverse
sequence.
Aircraft Other Than Australian Aircraft

34. Aircraft of any nation that are to be serviced or
replenished should to be treated in accordance with the
procedures detailed in this chapter.

Sect 2 Chap 14
AIRCRAFT AND GSE INTERCONNECTION

HARDWARE
Introduction
35. The
following
paragraphs
describe
the
interconnection hardware required to earth aircraft and
GSE used to service aircraft.
Hardware to be Fitted to Aircraft
b. GSE Dispensing Gaseous Oxygen. Gaseous

oxygen carts should be provided with two or more
safety interconnection leads. Whilst gaseous
oxygen is classified as non-flammable, the
dangers involved during aircraft oxygen
replenishment dictate that oxygen should be
treated as a flammable fluid. However, when
replenishing airborne oxygen systems, earthing of
the filling connector to the aircraft is not
necessary.
c.
36. The requirement for aircraft earthing receptacles

is based on the US Military Specification MIL-C-83413
and receptacle location as indicated at Paragraph 39.
37. The recommended earthing receptacle locations
on aircraft are as follows:
a.
one receptacle at each inlet for aircraft fuel;
b. one receptacle at each pylon hard-point or other

attachment point for armament equipment; and
c.
one or more receptacles at points convenient for

an interconnection lead between aircraft and earth
mass.
Fluid Dispensing GSE

38. GSE used for dispensing fluids, (gases and
liquids) except engine and hydraulic oil replenishing
dollies, is to be fitted with interconnection hardware as
detailed in Figure 144, Figure 145, Figure 146 or
Figure 147. Specific interconnection hardware
requirements for GSE dispensing flammable and nonflammable fluids are as follows:
a.
GSE Dispensing Flammable Fluids. GSE such

as AVGAS and AVTUR tankers and underground
fuel supply hydrant carts which dispense
flammable fluids should be provided with two or
more safety interconnection leads. Additionally, a
safety interconnection lead should be provided at
the delivery end of the fuel dispensing hoses, for
connection to the aircraft. This lead should be a
minimum of 122cm in length to allow connection
to earth points that may be located a maximum of
104cm from the refuelling point.
GSE Dispensing Non-Flammable Fluids. GSE

dispensing non-flammable fluids such as hydraulic
rigs, air-conditioning carts, air supply carts and
nitrogen gas replenishment trolleys, should be
fitted with one safety interconnection lead.
GSE Supplying Electrical Power

39. GSE capable of supplying only electrical power to
an aircraft is NOT to be fitted with safety interconnection
leads. At no time is an item of GSE supplying external
electrical power to an aircraft to be bonded to the earth
mass.
CAUTION
The safety interconnection lead on multi-purpose
GSE is to be used when the GSE is supplying
replenishing fluid only. The lead is not to be
connected when the GSE is supplying electrical
power only, or when simultaneously supplying
electrical power and replenishing fluid.
Multi-purpose GSE
40. When an item of GSE is capable of supplying both
non-flammable fluids and electrical power to an aircraft,
it should be fitted with one safety interconnection lead
for bonding to an earth reference point. The GSE safety
interconnection lead is connected to the earth reference
point before dispensing hoses are coupled to the
aircraft. (See caution above).

Sect 2 Chap 14
General Purpose GSE
CAUTION
Work stands used in conjunction with fuel tank
maintenance should comply with the requirements of
paragraph 41.
41. Work stands used in conjunction with fuel tank
maintenance should be fitted with bonding leads to
enable the stand to be connected to an earth point and
bonded to the aircraft. The stand should also be fitted
with a static discharge plate made of copper, zinc or zinc
coated material. The plate should be welded to the
handrail at the entrance to the stand and should be
marked Personnel Static Discharge Plate.
42. Generally,
stands,
jacks,
electronic
test
equipment, vacuum cleaners etc, whether mains power
operated or not, need not be fitted with safety
interconnection leads.
Safety Interconnection Leads
43. Safety interconnection leads used on aircraft and
GSE should to conform to one of the configurations
detailed in Figure 144, Figure 145, Figure 146 and
Figure 147. Four configurations are provided to enable

companies to utilise the type most appropriate for local
requirements. In some cases fitment of streamers to fuel
tanker interconnection leads may not be appropriate.
Accordingly, the fitment of streamers to fuel tanker
safety interconnection leads is left to the discretion of
individual companies.
TESTING INTERCONNECTION LEADS

Introduction
44. The following paragraphs detail the test and
inspection procedures that should be followed when
servicing safety interconnection leads used to provide
electrical bonding between GSE, aircraft and earth
reference points.
Responsibilities and Periodicity
45. The testing of safety interconnection leads should
be carried out by electrical tradesmen at six monthly
intervals.
Figure 144 Safety Interconnection Lead (Configuration 1)

Sect 2 Chap 14

Sect 2 Chap 14
NOTES
(Refer to Figures 94 to 97)
1.
Safety interconnection lead length should be determined by user requirements. (Maximum length
30 meters). Lengths are to be continuous. Splices are prohibited.
2.
The maximum total resistance of the assembled lead should be:

a. For leads less than 15 meters in length - 5 ohms.
b. For safety interconnection leads, as fitted to fuel tankers, 15 to 30 meters - 10 ohms.
3.
The streamer should be red, 50 10 cm long, 8 3 cm wide and have stencilled in white on both
sides REMOVE BEFORE FLIGHT.
4.
The streamer should be no more than 40 cm from the connector plug or grounding clip.
5.
A reel may be used to facilitate storage of the interconnection lead.
6.
Refer to Table 141 for component identification.
Table 141 Parts List For Interconnection Leads

Item No
Description
Connector, Plug
M83413/4-1
Clip, Grounding, Electrical
M83413/7-1
Cable, Grounding, Insulated
B1054-300
Terminal Lug, Crimp Style, Insulated
MS25036-XXX
(Dash number as
appropriate)
Streamer, Rayon or Cotton
Local Manufacture
Sleeve (cut crimp end from terminal

lug)
MS25036-XXX
(Dash number as
appropriate)
Test Equipment
46.
a.
The test equipment to be used is either:

Resistance - Capacitance - Inductance Bridge, PN
250DA,
b. Gossen Earth Tester, PN GEOHM2, 66; or

c.
48. Measure the resistance between the safety

interconnection lead extremities with any of the items
detailed in Paragraph 46. The maximum permissible
resistance end-to-end is:
a.
For leads less than l5m in length, 5 ohms; or
b. For safety interconnection leads, as fitted to fuel

tankers, with lead lengths 15 to 30m 10 ohms.
a low voltage ohmmeter.
49. Leads passing this test may be released for

further use.
Procedure
47. Visually
components.
Part Number
examine
leads
for
deterioration
of
NOTE
The cable, when new, has bright orange PVC
insulation which fades in sunlight. Fading of this
insulation in itself is not cause for replacement.
50. Unserviceable leads fitted with Clip Grounding,

PN M83413/7-1, should be removed from service and
repaired as follows:
a.
Withdraw roll pins and remove the steel jaw.
b. Clean the mating surfaces of the steel jaws and

aluminium handles with a wire brush.

Sect 2 Chap 14
c.
Smear mating surfaces with deoxidising product

PN 50-851, and assemble clips using roll pin PN
MS9048-007.
d. Check serviceability of cable and integrity of all

electrical connections. Replace or repair as
necessary.
e.
Retest the safety interconnection

accordance with Paragraph 51.
leads
in
51. Unserviceable leads not fitted with grounding clips

are to be tested in accordance with Paragraph 53, steps
d and e.
Where the contents of this chapter are at variance with

an aircraft maintenance manual and the maintenance
manual specifies a maximum resistance of less than 0.l
ohm between the earthing receptacles and the aircraft
skin, the maintenance manual should take precedence.
Responsibilities and Periodicities
54. The testing of earthing receptacles should be
carried out by suitable qualified tradesmen. A test
requirement should be incorporated in the aircraft
schedule service.
WARNING
Recording Action
52. Safety interconnection leads should be marked
with a serial number and tests are to be appropriately
recorded. A suggested format for a log sheet is shown at
Figure 148.
When testing bonding connections in enclosed areas

where explosive vapours may be present, use
ohmmeter PN T477W.
Test Equipment
55.
AIRCRAFT EARTHING RECEPTACLE

INSPECTION PROCEDURE
a.
Introduction
53. The following paragraphs detail the testing
procedures for earthing receptacles fitted to aircraft.
The equipment to be used for this test is either:

Ohmmeter PN T477W, or equivalent for areas
where explosive vapours may be present,
b. Milliohmmeter PN BT51, or equivalent for other

areas.
YEAR:
Lead No
Location
Inspection
Date
Date
Resistance
Readings
Rectification and
Remarks
Figure 148 Suggested Format for Test and Inspection Log

Procedures
56. Visual Inspection. Inspect for loosely mounted
receptacles and evidence of corrosion on washers, lugs,
nuts and the aircraft skin.
57. Mechanical. Tests are performed using stainless
steel plug PN M83413/4-1,. The plug is inserted in the
receptacles being tested to ensure that the contact
(spring) is seated in the plug detent.
10
58. Withdrawal Force. The longitudinal force

required to remove the plug from the receptacle is 2.72
to 4.54kg. Less than 2.72kg indicates a weak or
damaged receptacle contact (spring). (Ref. MIL-C83413)

Sect 2 Chap 14
59. Engagement. There should be no free axial

movement of the contact tip in the plug detent due to
clearance between the contact (spring) tip and plug
detent. Free axial movement indicates the contact is not
maintaining connection with the plug.
60. Electrical
Resistance
Tests.
Electrical
resistance measurements to aircraft skin should be at a
point where the aircraft skin is clean and unpainted. The
DC resistance of cables, or test leads, including the plug
used for making a specific resistance test, should be
measured and subtracted from the reading for that
specific test.
61. The DC resistance between earthing receptacles
and the aircraft skin should be less than 0.l ohm. Greater
resistance indicates a defective receptacle contact
(spring), loose receptacle mounting or defective bonding
strap, if used.
62. The DC resistance between earthing receptacles
(electrical interconnection through aircraft frame or skin)
should be less than l ohm. Greater resistance indicates
defective or insufficient bonding.
TESTING GSE CONNECTION POINTS
GROUND EARTHING POINTS

Introduction
67. Ground earthing points are the connection points
between aircraft or GSE and the earth mass. The point
is constructed from a galvanised mild steel stake with a
cast bronze head brazed to it. The assembly is driven
into the ground, and, if the electrical resistance of the
assembly to earth is within limits, it may be used to
electrically bond aircraft and ground support equipment
to earth mass.
68. Ground earthing
configurations, namely:
a.
points
may
be
of
two
standard ground earthing points, which are

permanent installations; and
b. temporary ground earthing points, which are for

use when standard points are not available.
CAUTION
Ground earthing points other than those described
below should not to be used for earthing aircraft.
Introduction
Standard Ground Earthing Points
63. The following paragraphs detail the testing

procedures for terminal connection points of safety
interconnection leads that are fitted to GSE and
refuelling equipment. Testing of safety interconnection
leads is detailed in Paragraph 46.
69. Standard ground earthing points, similar to the

detailed drawing at Figure 149, should be located
adjacent to aircraft parking positions. Ideally, sufficient
points are to be available so that no more than one
aircraft is connected to any one point; however, this
requirement is not mandatory.
Responsibilities and Periodicity

64. The testing of safety interconnection lead terminal
connection points should be carried out by suitably
qualified tradesmen.
Test Equipment
65.
a.
The test equipment to be used is either:

Ohmmeter, PN T477W, or equivalent for areas
where explosive vapours may be present; or
b. Milliohmmeter, PN BT51, or equivalent for other

areas..
Procedure
66. Test and inspection procedures for bonding
connections are contained in Section 2, Chapter 13. The
maximum permissible bonding resistance is 0.1 ohms.
70. The installation of standard ground earthing points

should be coordinated through aerodrome managers.
Appropriate contractors should be made responsible for
the installation and repair requirements. Testing of
installed points should be conducted in accordance with
Paragraph 81.
71. The rod and cap should be assembled by welding
(brazing) with the rod projecting 25mm above the cap.
When the rod has been driven into the earth mass so
that the base of the cap is at the level of the hard-stand,
the rod should then be cut off flush with the top of the
cap.
72. The ground earthing point should be installed in
such a manner that when the base of the cap has been
driven to the level of the hard-stand there should be no
lateral or vertical movement of the ground earthing point
cap.
11

Sect 2 Chap 14
Construction
TESTING GROUND EARTHING POINTS
73. A sample ground earthing point specifications are

detailed in Figure 149 and Figure 1410.
Introduction
Temporary Ground Earthing Points

74. Temporary ground earthing points should be
manufactured using one of the following methods:
a.
Preferred Method. Made in the same form as a

standard ground earthing point, (see Figure 14
9), except the minimum length is 50 cm.
b. Alternate Method. When the standard earth point

shown in Figure 149 is not available, temporary
earth points may be manufactured using a
galvanised mild steel rod with a brass top plate as
78. Manual of Standards Part 139 Aerodromes

section 11.1.16 Ground Earth Points details the
requirements for installation and testing of earthing
points. All standard ground earthing points used for the
earthing of aircraft and GSE are to be regularly, tested
and inspected. The following paragraphs describe the
procedures that are to be used for testing, marking and
recording of test results.
Maintenance of Standard Ground Earthing Points
79. Maintenance Periodicities. The following
periodicities should apply to the maintenance of newly
installed and existing standard ground earthing points:
a.
CAUTION
In all cases where temporary points are to be
installed, the local authority controlling the airfield is
to be contacted to ensure that underground services
will not be interfered with.
75. Temporary earth points should be used when
operating from remote airfields where suitable standard
ground earthing points are not available.
76. Temporary earth points need not be used for intransit stops at civil or remote airfields where standard
ground earthing points are unavailable; however aircraft
and refuelling vehicles (or containers) must still be
appropriately bonded. (Refer Paragraph 22).
77. Installation, maintenance and testing of temporary
ground earthing points should be conducted by
appropriately trained personnel.
Newly Installed Ground

Resistance Measurement:
(1) Immediately after
replacement)
Earthing
installation.
Points
(or
any
(2) Six month after installation, or replacement.

(3) Thereafter as part of Aerodrome Technical
Inspection
b. Physical Inspection - Ground earthing points are
to be physically inspected as part of the quarterly
technical inspection to ensure that:
(1) The ground earthing point is firmly connected
to the earthing rod and seated on the
pavement.
(2) The earthing rod is firmly embedded in the
ground.
(3) The fins used for making the electrical
connections are free from dirt, grease, paint
or any other substances.
(4) No ground earthing points have been buried
or removed.
12

Sect 2 Chap 14
Figure 149 Standard Ground earthing Point
13

Sect 2 Chap 14
Figure 1410 Temporary Ground earthing Point
14

Sect 2 Chap 14
Ground Earthing Check
Testing Temporary Ground earthing Points
80. Several methods may be used to measure the

resistance of ground earthing points depending on the
equipment used. The following method is recommended
when using either a 'Gossen Earth Tester' Part No
GEOHM or Part No GEOHM2:
84. Testing and recording requirements for temporary

ground earthing points are as follows:
a.
Three Electrode Method. This is the preferred

method of measuring the earth resistance of an
ground earthing point. Using three collinear
electrodes, (ie three ground earthing points A, B
and C as shown in Figure 1411), measure the
resistance between each in turn. The resistance
of earth point A is calculated from:
a.
testing procedures are the same as those outlined

in paragraph 80 for standard ground earthing
points, except that either temporary or standard
points may be used in the three electrode method;
RA = RAB + RAC RBC

2
Where:
RA is the resistance of reference point A
RAB is the resistance between points A and B
RAC is the resistance between points A and C
RBC is the resistance between points B and C
Serviceability of Ground Earthing Points
81. A serviceable ground earthing point is one having
a resistance to earth mass of l0,000 ohms or less. Any
point which has a resistance greater than 10,000 ohms
is unserviceable and is to be serviced by authorised
personnel.
Marking of Ground earthing Points
82. Serviceable ground earthing points should have a
15cm diameter circular white disc painted around the
head.
83. Unserviceable ground earthing points that cannot
immediately be repaired or replaced, the head of the
ground earthing point must be either removed or marked
with a 15cm diameter circle, painted red, to show it
cannot be used.
Figure 1411 Ground earthing Point Test Setup for

GEOHM Type Testers
15

Sect 2 Chap 14
Earth Point Number
Location
Six Monthly Inspection

(Include Date)
Biennial Resistance
Reading (Include Date)
Rectification Details or
Remarks
Figure 1412 Suggested Format for Test and Inspection Log
16

Sect 2 Chap 14
b. a point is to be classified serviceable if the

resistance to earth is less than 10,000 ohms; and
c.
points having a resistance in excess of 10,000

ohms are to be relocated and re-tested.
location should also be provided. Log books should be

capable of retaining information for at least six (6)
consecutive years. Figure 1412 is a suggested layout
for a log book.
Helicopter Earthing Poles
NOTE
Unserviceable temporary ground earthing points
should not to be left embedded in the ground under
any circumstances.
Log Books
85. A log book should be maintained in which details
of earthing point locations, identification numbers,
periodical test figures, rectifications and re-tests are
recorded. Inclusion of a plan of ground earthing point
86. Helicopter earthing poles are used to earth

helicopters while in the hover, prior to personnel
contacting the aircraft during cargo hookup etc. Details
of a helicopter earthing pole are shown Figure 1413.
Each earthing pole should be inspected for general
cleanliness, corrosion and fraying or damage to leads.
Carry out a continuity test between the pole tip and the
earthing clip or spike to ensure that the resistance is no
greater than 2 ohms. This inspection and test should be
carried out monthly and recorded in a log.
Figure 1413 Helicopter Earthing Pole
17

Sect 2 Chap 14
MAINS OPERATED GSE
Use of Residual Current Devices
Introduction
89. RCDs are to be connected as close as

possible, and directly to 240V 50Hz reticulated mains
power outlets. This provides maximum protection of
personnel in the event of damage to long trailing or
extension leads.
87. Protection of personnel against electrical hazards

associated with the use of mains powered GSE, ie
soldering irons, drills, vacuum cleaners etc, is a
significant aspect of aircraft earthing considerations.
The mains earthing system will provide protection
against hazards developing from internal faults in the
equipment. However, when mains powered GSE is
used inside aircraft there is a possibility of the aircraft
structure becoming electrically live should the power
lead become partially severed, or by other mischance
the active conductor contacts the aircraft. In this event
there is no guarantee that the protective circuit
breaker/fuse would operate to disconnect the fault,
owing to the possible high resistance to earth mass of
the aircraft earth reference point.
Residual Current Devices, 250V, 50Hz
88. To provide protection for personnel in the event
of a 250V, 50Hz, mains powered GSE equipment
power lead shorting to an aircraft frame, core balanced
residual current devices (RCD) are to be used
wherever the type of GSE listed in paragraph 102, is
operated in or near aircraft. The RCDs are available in
either a 10 amp or 15 amp current rating.
18
Operation of 415V, 50Hz, Three Phase Mains

Powered GSE
90. Protection of personnel using 415V, 50Hz, three
phase mains powered GSE on aircraft would involve
the installation of permanent three phase RCDs on
maintenance facility power distribution boards. On
consideration of the size and types of GSE requiring
415V, three phase power, eg. hydraulic test rigs, large
vacuum cleaners etc, operation of these items
physically in or on an aircraft is extremely unlikely.
Therefore there should be no need to introduce 415V,
three phase RCDs to existing installations unless
warranted by specific circumstances in a particular
area to ensure safety of personnel either using 415V,
three phase equipment, or working in the immediate
area.
91. Operation of 415V, three phase GSE, physically
in or on an aircraft should be avoided. Also trailing
leads supplying three phase power are not to be
routed across aircraft, servicing stands or other GSE.

Sect 2 Chap 15
SECTION 2
CHAPTER 15
INSTALLATION OF BUSBARS, JUNCTION BOXES, PROTECTIVE

DEVICES, AND TERMINAL BOARDS
INTRODUCTION
NASM21044
1.
Procedures for installing equipment in aircraft are
recommended in order to make installation easier, to
standardize the methods used, and to provide the best
possible protection for personnel and equipment.
Nut, Self-Locking, HexagonRegular Height, 250F, 125 KSI

FTU and 60 KSI FTU
NASM21047
Nut, Self-Locking Plate, Two

Lug, Low Height, Steel, 125 KSI
FTU, 450F
NASM35338
Washer, Lock-Spring, Helical,

Regular (medium) Series
NASM35649
Nut, Plain Hexagon, Machine

Screw, UNC-2B
NASM35650
Nut, Plain-Hexagon , Machine

Screw, UNF-2B
SAE AS 27212
Terminal Board Assembly,

Molded-In Stud, Electric
SAE AS 7351
Clamp, Loop Type Bonding
2.
This chapter describes procedures for installing
busbars (including preparation), junction boxes,
protective devices, and terminal boards in aircraft. It also
describes methods of identification and protection and
the correct use of hardware.
3.
busbars, conduit, junction boxes, protective devices, and
terminal boards:
AN3064
Box Connector, Electrical
AN960
Washer, Flat
MIL-C-85049
Connector Accessories,
Electrical
MS18029
Cover Assembly, Electrical, for

Assembly
MS21919
Clamp, Loop-Type, Cushioned

Support
MS25082
Nut, Plain, Hexagon, ElectricalThin
MS3373
Strip, Mounting, Nut Insulating,

for MS27212 Terminal Board
MS35335
Washer, Lock, Flat - External

Tooth
MS51957
Screw, Machine Pan Head,

Cross-recessed, Corrosion
Resistant Steel, UNC-2A
NASM21042
Nut, Self-Locking, 450F,

Reduced Hexagon, Reduced
Height, Ring Base, NonCorrosion Resistant Steel
PREPARATION AND INSTALLATION OF

BUSBARS
General
4.
Busbars are used in aircraft for power distribution.
The most commonly used materials for busbars are bare
aluminium, plated aluminium, or plated copper.
Aluminium used for busbars is EC (electrical) grade.
Preparation of Busbars
5.
Busbars for an aircraft electrical system must be
clean and free from grease, dirt, and oxide. Any of these
at the electrical junction will cause the connection to
heat up and fail. Busbars are cleaned prior to installation
in the aircraft and are also treated to prevent or minimize
oxidation after installation.
WARNING
Use only approved cleaning compounds and
approved procedures to clean aircraft electric
components. The use of inappropriate cleaning
compounds or failure to follow proper procedures
may cause fires or explosions.

Sect 2 Chap 15
WARNING
WARNING

worn when handling and using cleaning solutions.

Preparation of Unplated Aluminium Alloy Busbars

6.
Clean unplated aluminium busbars by immersing
in MIL-PRF-680 (Stoddard's solvent) or by wiping with a
clean, soft cloth saturated with the solvent. Wipe dry with
a clean, soft cloth.
7.
After cleaning, treat all electrical contact surfaces
as follows:
a.
Cover contact surfaces completely with an even

coating of petrolatum-zinc dust compound (50%
petrolatum, 50% fine zinc dust, by weight).
a.
Scratch brush the coated areas, using a rotary

steel wire brush with a pilot as shown in Figure
151. Brush through the compound.
b. Remove most of the compound from busbar by

wiping lightly with a clean, soft cloth.
c.
Examine busbar to make sure that there are no

steel brush bristles lodged in the aluminium.
d. Apply a thin coating of clean petrolatum-zinc

compound to contact surfaces. This compound is
the same as that supplied in MS aluminium
terminal lugs.
NOTE
Allow final coat of compound to remain on busbar
when installed. Excess will be squeezed out of
connections and removed later.
Preparation of Plated Aluminium and Copper

Busbars
8.
Clean plated aluminium and copper busbars
thoroughly by immersing in MIL-PRF-680 (Stoddards
solvent) or by wiping with a clean, soft cloth saturated
with the solvent. Wipe dry with a clean, soft cloth.
Repairing Damaged Plating
9.
Examine contact surfaces of plated aluminium or
copper busbars for damage to plating. Reject damaged
aluminium busbars and return for rework. Repair slight
damage to plated copper busbars by tinning with a
soldering iron. Thoroughly wash and dry repaired areas.
Do not attempt to repair plating on aluminium.
Mounting Hardware
10. When installing a copper busbar, always place
cadmium plated steel plain washer between the busbar
and the lockwasher or self-locking nut. (See Figure 15
2.) When installing an aluminium alloy busbar, place an
aluminium alloy plain washer between the busbar and
the lockwasher or self-locking nut.
Insulation
11. Insulate the busbar from structure, junction box, or
support with a fibreglass, phenolic, or other rigid
insulating stand-off as shown in Figure 152. Do not use
any moisture-absorbing material.
Protection
WARNING
Use only approved cleaning compounds and
approved procedures to clean aircraft electric
components. The use of inappropriate cleaning
compounds or failure to follow proper procedures
may cause fires or explosions.
12. Install busbars inside panels, junction boxes, or in

protected areas when possible. If this cannot be done,
protect the busbar with insulating tubing or other means
of insulation. See Section 2, Chapter 4 for details.
INSTALLATION OF JUNCTION BOXES

General
13. Junction boxes are containers with hinged or
removable covers used in aircraft to provide a protected
area for electrical power distribution equipment such as
busbars and terminal boards. The material of junction
boxes is either metal or hard fibreglass.

Sect 2 Chap 15
Junction Box Covers

16. Junction box covers may be hinged or attached by
means of screws. Screw threads must not extend into
the box in the vicinity of wiring. The sharp threads may
cut wire insulation. If covers are not hinged, secure the
cover to the box with an insulated bead chain, or No. 14
wire, as shown in Figure 154. Make this attachment
outside the box so that when the box is closed the chain
or wire will not interfere with the wiring.
NOTE
If covers are bent during installation or repair,
straighten them before final attachment.
Preparation of Wire Entry Holes
17. Determine the outside diameter of the wire, or
wire bundle, and make sure that the opening is at least
3mm larger in diameter to allow for later enlargement of
the bundle. Use a box connector and cable clamp to
protect wiring if this is indicated on the engineering
drawing.
CAUTION
Deburr the inner surface of box connectors.
Figure 151 Scratch Brushing Unplated Aluminium
Alloy Busbars
Mounting Hardware
14. Use standard AN bolts or screws of the
appropriate size to attach junction boxes to aircraft
structure. (See Figure 153.) Insert screws or bolts so
that the head of the screw or bolt is inside the junction
box. Do not install attaching hardware so that threaded
part of the screw or bolt protrudes inside the junction
box, as the sharp thread edges will damage wire
insulation.
NOTE
When a box connector is not used, protect the edges
of the entry hole with plastic or fibre grommets. (See
Figure 155.)
Drainage of Junction Boxes
18. Provide one or more drainage holes (4.7mm
diameter minimum) at the lowest point of the junction
box when the aircraft is on the ground. After drilling
drainage holes in metal junction boxes, deburr the edges
of the hole with a deburring tool or a file.
CAUTION
Insulation
Do not drill holes in vapour-tight junction boxes.

15. The inside of metallic junction boxes is coated
with white glyptal or similar material to insulate wiring
from the metal, to improve visibility and to make
inspection easier. Non-metallic junction boxes need not
be so insulated. If this coating is damaged during the
installation procedure, repair the damaged parts with,
the same material as used in the original installation.
When a new metallic box is installed, make sure the
insulating coating is present and undamaged.
Vapour Tight Boxes

19. Vapour-tight junction boxes in aircraft are
identified as such on the covers. When doing work of
any kind on vapour-tight boxes, carefully follow the
instructions given in the aircraft manufacturers
handbook of maintenance instructions for the specific
aircraft model.

Sect 2 Chap 15
Figure 152 Mounting Busbars to Structure
Chapter 13. Grounding of equipment in non-metallic

boxes shall be on an individual basis, not in series.
INSTALLATION OF PROTECTIVE DEVICES

General
22. Protective devices are items of electrical
equipment such as circuit breakers, fuses, etc., installed
in aircraft to protect the electrical system against
overloads caused by short circuits or other faults.
Circuit Breakers
23. A circuit breaker is a device designed to open and
close an electric circuit and to open the circuit
automatically at a predetermined overload current,
without damage to itself. The primary purpose of circuit
breakers in aircraft is to provide overcurrent protection
for wire and cable and to minimise the danger of smoke
and fire.
Figure 153 Attaching Junction Box to Structure

Identification
20. If junction boxes, as originally installed, are not
identified, it is not necessary to do so. If the junction box
does have identification marking, make sure marking is
replaced as in original.
Bonding or Grounding Junction Boxes
21. Bond or ground junction boxes to structure by
direct metal-to-metal contact or by means of a bonding
jumper. Test bond or ground as described in Section 2,
24. Correct circuit breaker selection should result in a

protective device with the lowest standard rating that will
not trip inadvertently. It must interrupt the fault or
overload current by disconnecting the faulted line from
the power distribution point before any wire or insulation
damage occurs.
25. The nameplate current rating of circuit breakers is
a nominal rating for identification and the actual useable
rating for a particular application may be considerably
different. Most circuit breakers must carry approximately
115% of their rated current indefinitely. This excess is to
provide a tolerance for the effects of wear, vibration etc.
The instantaneous trip current is usually in the order of
ten times the current rating of the circuit breaker. The
applicable Military Standard (MS) should be reviewed
when determining the actual trip current for a circuit
breaker.

Sect 2 Chap 15
26. When selecting a circuit breaker for a particular

application all the variables should be considered. These
variables include time-current characteristics of the
circuit breaker, start-up surges of equipment, wire type,
size and location (ambient temperature) and the
maximum altitude at which the equipment is likely to
operate. The current carrying capacity of a wire varies
considerably depending on the application and should
be determined using the graphs contained in SAE
AS50881.
27. Both magnetic and thermal type circuit breakers
are available however circuit protection in aircraft is
primarily provided by thermal circuit breakers which are
dependent on temperature rise in the sensing element
for actuation. Operation is achieved by deflection of a bimetal strip that will open the circuit at a pre-determined
temperature. Temperature rise in the sensing element is
caused principally by the load current however this is
affected by ambient temperature which can raise or
lower the actual current at which the circuit breaker will
trip.
28. Trip-free circuit breakers are normally used for all
aircraft applications. Manual resetting of this type of
circuit breaker cannot be effected while an over current
circuit fault remains. Non trip-free circuit breakers are
used when the application requires over-riding of the
tripping mechanism, in an emergency, when the fault still
exists. Both types of circuit breaker can be manually
operated to both ON and OFF positions with power
applied, without damage to the electrical contacts
however circuit breakers should not be used as switches
unless specifically designed for this purpose.
Mounting with Through Bolts or Screws

32. When possible, attach protective devices to
aircraft structure or other support with through bolts or
screws. Install a plain washer under the head of the bolt
or screw, and a plain washer and a split lockwasher
under the nut. (See Figure 156.)
Mounting Into Tapped Hole or Nut Plate
33. When it is necessary to install a protective device
with a screw into a tapped hole or a nut plate, install a
plain washer and a split lockwasher under the screw or
bolt head. (See Figure 157.)
Figure 154 Attaching Cover to Junction Box
29. The trip characteristics of a circuit breaker can

change when the trip mechanism has been dormant for
long periods. This phenomenon is due to the high
internal spring forces which are inherent in most circuit
breakers and which can cause a static type of wear to
the trip mechanism when in the closed position. Test
data suggest that this condition can be prevented by
periodically operating the circuit breaker manually with
no electrical load, however manual operation should be
limited to two or three times a year to avoid excessive
dynamic wear of the tripping mechanism.
30. Where practicable, power in and power out
wires should be physically separated to avoid the
possibility of a short circuit negating the effect of the
circuit breaker.
Mounting Hardware
31. If attaching hardware is furnished with the
protective device, use it. If no attaching hardware is
furnished, mount the protective device with standard AN
cadmium plated steel screws or bolts of the appropriate
size. When replacing a protective device, use hardware
exactly the same as in the original installation except
that a longer screw may be used if necessary.
Figure 155 Wire Entry Holes in Junction Box

Sect 2 Chap 15
b. Insert the screw into the blind tapped hole and

thread it in until it bottoms in the hole. Plain and
lock washers should remain free.
c.
Back out the screw two turns and measure the

length of screw between the under surface of the
head and the top washer.
d. Measure the thickness of the mounting part of the

protective device and subtract it from the
measurement obtained in step c. If the device to
be mounted is thicker than the dimension
obtained in step c, repeat steps a, b, and c, using
a longer screw.
Figure 156 Mounting Protective Devices
e.
Subtract dimension obtained in step d from the

overall length of the screw; this will give the
maximum length that can be used without
bottoming in the tapped hole. If the final length is
not a standard length, use the next shorter
standard screw.
Figure 158 Determining Screw Length for Mounting

into Blind Holes
Mounting Circuit Breakers

Figure 157 Typical Mounting Hardware for Protective
Devices
Mounting Into Blind Hole
34. When a protective device must be attached with a
screw into a blind tapped hole, make sure that the screw
will give maximum thread engagement without
bottoming in the hole. The length is determined as
a.
Select a screw of approximately the correct length

and install a plain washer and lockwasher on it.
NOTE
Do not mount the protective device when determining

screw length.
35. Mount switch circuit breakers so that when the

switch breaker is in the off or open position, the handle
will be down or to the rear.
Mounting Toggle Switches and Switch Guards
36.
a.
Mount switches and switch guards as follows:

Insert toggle switch through the mounting surface.
b. Adjust lower jam nut to obtain approximately 5

threads above the mounting surface.
c.
Place switch guard over the switch and install

upper jam nut.

Sect 2 Chap 15
d. Adjust the switch up or down as required with

upper and lower jam nuts to obtain proper height
of the switch lever.
e.
When switch is adjusted to the proper height, it

can be closed with switch guard and the guard will
not interfere with switch operation (see Section 2,
Chapter 9, Figure 910).
Mounting Relays
37. Mount relays so that foreign particles cannot fall
between the terminals and so that liquid cannot
accumulate inside the cover.
Special Precautions for Bonding or Grounding
Connections
38. When a bond or ground connection is made
through the mating surfaces of structure and mounting
pad, prepare the contacting surfaces as described in
Section 2, Chapter 13, before attaching the device to
structure.
Protection
39. If possible, mount protective devices in junction
boxes or protected areas. If this is not possible, and the
devices are to be installed in locations where they may
be subject to damage or where the terminals may be
dangerous to personnel, provide a cover to go over the
protective device.
Circuit Breaker Lockout/Deactivation
CAUTION
Use only red or white TEFLON devices for
deactivating circuit breakers. Do not use black for this
purpose.
40. When positive lockout/deactivation of an electrical
circuit breaker is required, install circuit breaker collar
PN 12E2081-9. and secure with a self-clinching cable
tie-wrap.
Circuit Breaker Blanking Plugs

41. When a circuit breaker is removed a blanking plug
should be installed in the mounting hole. The following
blanking plugs are suitable for this purpose: Metal Plug,
PN NAS451-43 or Rubber Plug, PN G34.
Identification
42. Make sure that each protective device is identified
by a plate or decal, permanently attached to adjacent
aircraft structure. If the location of a protective device is
changed, make sure that the identification marking is
also relocated and completely visible. Make sure the
new identification marking is exactly the same as the
original.
INSTALLATION OF TERMINAL BOARDS

General
43. Terminal boards are used in aircraft to provide
junction points of good electrical conductivity for circuits
that are not frequently disconnected.
Mounting Hardware
44. Use standard AN cadmium plated steel hardware
of the appropriate size.
Method of Attachment
45. Install mounting screws so that the screw
protrudes through the bottom of the terminal board, as
shown in Figure 1510. The length of the screw should
allow for some protrusion beyond the nut. Pass a steel
scale or other flat piece of metal over the top of the nut.
If it passes over freely, the screw is too short and is to
be replaced with the next longer length. Protrusion of
screw should not exceed two threads.
Alternative Method of Attachment
46. If it is not possible to install the mounting screw
from the top of the terminal board, install it from the
back, as shown in Figure 1511. In this case, the end of
the screw should project just beyond the top of the nut,
but do not use a screw that will extend beyond the level
of the terminal board mounting surface.
Insulation
Figure 159 Circuit Breaker Lockout Ring
47. Place an insulating strip over each mounting

screw, long enough so it will go over the two adjacent
terminal studs. If there is no terminal mounted to the
stud the insulating strip should be secured to the board
under a nut and washers as shown in Figure 1512. The
MS14151 washer is not required if a busbar is installed
on the terminal stud.

Sect 2 Chap 15
Attaching Busbar to Terminal Board

48. When a MS25226 busbar is to be attached to a
MS25123 terminal board, mount the busbar directly on
top of the nut that holds the terminal stud in place. When
MS25226 busbar is to be attached to a MS27212
terminal board, mount the busbar directly on the base of
the moulded-in stud, and above the insulating strip
(MS3373) if used. (See Figure 1512 and Section 2,
Chapter 4, Figure 418).
NOTE
If aluminium busbars are removed and are to be
reinstalled, examine the busbar for deformation
before reinstalling it. If there is any deformation,
discard it and install a new busbar.
Figure 1512 Insulation of Terminal Board
Protection of Terminal Boards
Figure 1510 Mounting of Terminal Board
49. Where possible, mount terminal boards inside

junction boxes or other enclosures. If this is not possible,
and the terminal board is located where it may be
damaged, or may be dangerous to personnel, provide a
cover. Use terminal board cover MS18029 on the
MS27212 terminal board. Attach no more than two
terminal lugs on the stud that is to be used for mounting
the cover to the terminal board. If no cover is available
the terminal board may be protected by a wrapping of
insulating sheeting. Use a piece of insulating sheet large
enough to make a generous lap over the studs. Punch
holes in the insulating sheet, install it over the grounded
studs, and fasten with nuts and washers.
Identification
50. Each terminal board in the aircraft electrical
system is identified by the letters TB, followed by a
number which is the number of the individual board.
Each stud on the terminal board is identified by a
number located adjacent to it, with the lowest number in
the series at the end nearest the terminal board
identification number. (See Figure 1513.) The
identification may be marked on the aircraft structure to
which the terminal board is attached or may be on an
identification strip cemented to the structure under the
terminal board. When a terminal board is replaced, do
not remove the identification marking unless it has been
damaged. In that case replace the identification marking
exactly as in the original, in accordance with the
applicable wiring diagram.
Figure 1511 Alternative Mounting of Terminal Board

Sect 2 Chap 15
Figure 1513 Identification of Terminal Board

Sect 2 Chap 16
SECTION 2
CHAPTER 16
THERMOCOUPLE WIRE SOLDERING AND INSTALLATION

INTRODUCTION
DESCRIPTION
1.
Thermocouples are used in aircraft to detect and
measure temperature changes. They consist of a pair of
dissimilar metallic conductors that detect changes in
temperature and are used to measure that change.
Thermocouples are supplied with short leads that end in
terminals such as AN5548 or AN5539. At installation,
the technician fabricates extension leads to carry the
voltages generated by the thermocouple to the indicating
instruments. The components of a thermocouple system
are designed to have a high degree of accuracy; correct
installation is required to maintain this accuracy.
Thermocouple Wire Leads
2.
This
chapter
describes
and
illustrates
recommended procedures for fabrication and installation
of thermocouple extension leads.
3.
The importance of good workmanship in the
fabrication and installation of thermocouple wires cannot
be over-emphasised.
4.
thermocouple wire soldering and installation:
A-A-54192
Rosins: Gum, Wood, and Tall Oil
AN5537
Connector Assembly Thermocouple

Lead
AN5538
Terminal Thermocouple Lead

Soldering
AN5539
Terminal Thermocouple, Brass
AN5548
Terminal Lug, Thermocouple,

Chrome1 and Alumel
MIL-PRF-680
Degreasing Solvent (Stoddards

Solvent)
MS25036
Terminal, Lug, Crimp Style, Copper,

Insulated, Ring-Tongue, Bell-Mouthed,
Type II, Class 1
O-F-499
Flux, Brazing, Silver Alloy, Low Melting

Point
QQ-B-654
Brazing Alloy, Silver
SAE AS 7928
Terminal, Lug and Splice, Crimp Style,

Copper
TT-I-735
5.
Thermocouple extension wires (see Figure 161)
are paired in a braided jacket and colour-coded as
detailed in Table 161. The material for extension leads
is the same as the thermocouple material. Ironconstantan extensions are used for iron-constantan
thermocouples, chromel-alumel extensions for chromelalumel
thermocouples,
and
copper-constantan
extensions for copper-constantan thermocouples.
Thermocouple Terminals and Connectors
6.
Selection of terminals for thermocouple wiring is
based on location within the airframe, and on
temperature conditions. Hot areas are those subject to
high temperature, such as engine compartment, exhaust
areas, etc. Cool areas are those on the side of the
firewall away from the engine or other heat sources.
Where the temperature does not exceed 120C, use
terminals listed in Table 162. Dash letters after basic
numbers indicate whether terminal is plain or lock type,
except for AN5538, where dash number indicates
change in size only.
NOTE
Solderless terminals and splices may be used on
thermocouple wires in cool areas.
7.
Thermocouple connector AN5537 (shown in
Figure 163) is used to carry thermocouple connections
through firewalls. This is a plug and jack connection,
supplied with an insulating plate for attachment to the
firewall. Plugs and jacks are supplied in chromel-alumel
or iron-constantan combinations. The jack part of the
connector is installed on the cool side of the firewall. The
pin plug part of the connector is installed on the hot side
of the firewall.
Isopropyl Alcohol

Sect 2 Chap 16
Table 161 Thermocouple System

IRON CONSTANTAN SYSTEMS
Conductor
Insulation Colour
Polarity
Iron
Black
Positive (+)
Constantan
Yellow
Negative ()
Type II 8 ohms per 30.5 m.
Type III 8 ohms per 61.0m.
Class A
Class B
Class A
Class B
Light Blue
Light Blue
Light Blue
Light Blue
Tracer Colour
None
One Red
Two Black
Two Red
Temperature Limit of Insulation
120C
230C
120C
230C
Outer Jacket Base Colour
CHROMEL-ALUMEL SYSTEM
Conductor
Insulation Colour
Polarity
Chromel
White
Positive (+)
Alumel
Green
Negative ()
Type II 7 ohms per

7.6m.
Type III 7 ohms per

15.2m
Type IV 7 ohms per 30.5m
Class A
Class A
Class A
White
White
White
One Green
Two Green
Three Green
315C
315C
315C

Tracer Colour
COPPER-CONSTANTAN SYSTEM
Conductor
Insulation Colour
Polarity
Copper
Red
Positive (+)
Yellow
Negative ()
Constantan
Type II 7 ohms per 61.0m.

Tracer Colour
Class A
Class A
Black
Black
One White
Two White
120C
230C
Table 162 Thermocouple Terminals
Figure 161 Thermocouple Wire
Hot Areas (Silver

Soldered)
Cool Areas (TinLead Soldered)
Iron-Constantan
AN5539
AN5538
Chromel-Alumel
AN5548
AN5538

Sect 2 Chap 16
b. Hard Solder. Silver alloy with flow point at

approximately 635C, as specified in QQ-B-654.
c.
Soft Solder Flux. Fluxes shall conform to the

requirements of J-STD-004.
d. Hard Solder Flux. For hard solder, use flux

qualified to Federal Specification O-F-499, mixed
to a paste-like consistency with water.
e.
Soldering and Brazing. For purposes of this

chapter, the term soldering includes soft
soldering, silver (hard) soldering, and brazing.
THERMOCOUPLE WIRE PREPARATION

Cutting and Identifying Thermocouple Wire
10. Cut thermocouple wire with diagonal pliers to
length specified in drawing. Cut so that end is clean and
square. Identify wire with sleeves as described in
Section 2, Chapter 2. If outer covering is removed more
than 76mm from termination, install sleeve just back of
serving at branching point (refer to Paragraph 21).
Stripping Thermocouple Wire
Figure 162
Thermocouple Contacts in MS Connectors

8.
MS type connectors may be supplied with ironconstantan or chromel-alumel contacts in sizes 12, 16,
or 20 in insert arrangements for thermocouple
connections. These contacts are coded to identify the
material. (See Table 163.)
11. Remove outer covering, of thermocouple wire with

a knife by slitting between parallel conductors and
trimming the fabric braid with scissors or diagonal pliers.
The stripping dimensions for each use are shown in
Figure 164, Figure 165 and Figure 166. Note that
longer stripped lengths are required if the wires are to be
resistance tinned. Use a hand stripper, as illustrated in
Section 2, Figure 33, for removing the primary
insulation from each conductor.
Cleaning Wire Prior To Soldering
12.
If necessary, clean stripped conductor as follows:
WARNING
DEFINITIONS
a.
9.
b. Dry with clean lint free cloth.
Definitions are as follows:

a.
Soft Solder. A mixture of 60% tin and 40% lead,

as specified in J-STD-006. It may be in bar form to
be melted for tinning, or in the form of rosin core
solder wire for use with soldering iron.
Remove grease and dirt by brushing or wiping

with MIL-PRF-680 (Stoddards Solvent).
CAUTION
Do not use extra heat and special fluxes as a
substitute for clean soldering surfaces.

Sect 2 Chap 16
Figure 163 Thermocouple Connector Assembly (AN5537)
Table 163 Coding for Thermocouple Contacts in MS Connectors

Code
Manufacturer
Method of
Coding
Iron
Constantan
Chromel
Alumel
Amphenol
Colour
White
Red
Green
Orange
Bendix
Letters
Ir.
Con.
Ch.
Al.
Cannon
Letters
IR
CO
CH
AL
Figure 164 Stripping Thermocouple Wire for

Terminal and for AN5537 Connector Installation
Figure 165 Stripping Thermocouple Wire for Splice

Installation

Sect 2 Chap 16
HARD SOLDERING THERMOCOUPLE WIRE

Torch Tinning with Silver Solder
13. Before wires are soldered to terminals or other
connections, they are tinned. The-inability to obtain a
good tinned surface indicates that the wire was not
clean. The procedure for torch tinning is as follows (see
Figure 167):
WARNING
Open flames shall not be used on or near fuelled
aircraft or in other hazardous locations.
a.
Dip half of exposed, clean conductor into hard

solder flux.
b. Protect wire insulation with notched copper sheet

shield, to prevent scorching.
c.
Apply flame to wire until flux bubbles. Then feed a

small amount of silver solder, in wire form, to
fluxed area while flame is kept there. After the
silver solder has flowed, remove the flame and
allow the wire to cool in the air.
Figure 166 Stripping Thermocouple Wire for MS

Connector Installation
CAUTION
Silver solder will flow and adhere to conductor at
approximately 635C. Avoid greater heat than
necessary. Excess heat will decompose flux and
prevent alloying of silver solder to the wire.
Dip Tinning Wire with Silver Solder
14. Thermocouple wires can be dip-tinned in molten
silver solder if a solder pot capable of maintaining the
required 635C heat is available. The process is similar
to that used in a dip tinning copper wire in soft solder as
described in Section 2, Chapter 7. The procedure for dip
tinning with silver solder is as follows (see Figure 168):
a.
Dip half of exposed, clean conductor into hard

solder flux.
b. Dip fluxed conductor into solder pot. Do not dip

conductor deeper than one-half of exposed area.
NOTE
Powdered borax sprinkled over top of molten solder
will retard oxidation of solder and aid alloying of silver
solder to the wire.
c.
After solder has flowed between strands, remove

the wire and allow it to cool in air.
Figure 167 Torch Tinning Thermocouple Wire

Sect 2 Chap 16
stripping dimensions. The procedure for resistance

tinning is as follows:
a.
Apply hard solder flux to area to be tinned. This is

an area about 3mm long, as shown in Figure 16
9.
b. Grasp end of wire in resistance heating pliers.

Grasp wire only as shown.
c.
Apply current for approximately five seconds and

then touch silver solder wire to area previously
fluxed.
d. After solder has flowed between strands, shut off

the current and allow the wire to cool in air.
CAUTION
Do not overheat the wire by allowing the current to
remain on longer than necessary to flow the silver
solder.
e.
Trim off the holding area of the exposed

conductor. The conductor should be trimmed with
diagonal pliers to the point of tinning.
Figure 168 Dip Tinning Thermocouple Wire in Silver

Solder
WARNING
Resistance soldering shall not be used on or near
fuelled aircraft or in other hazardous locations.
Resistance Tinning Wire with Silver Solder
15. Electrical resistance heat is a good method for
silver soldering thermocouple wires. Use a unit that has
a capacity of 1000 watts (Figure 169). Wire that is to be
tinned by means of electrical resistance should be
stripped 12.7mm longer than wire which is to be diptinned or torch-tinned. The extra 12.7mm provides a
holding area which is removed after tinning is complete.
See Figure 164, Figure 165 and Figure 166 for
Figure 169 Resistance Heating to Tin Wire

Sect 2 Chap 16
The tinned portion of the conductor should then

be inside the wire grip. (See Figure 1611.)
CAUTION
Do not crimp insulation grip until after soldering
operation. The heat of soldering may damage
insulation if insulation grip is tight during soldering.
c.
Crimp wire grip over conductor using modified

crimping tool illustrated in Figure 1612.
Figure 1610 Resistance Tinning of Terminal
WARNING
Soldering may result in the emission of hazardous
metallic fumes and vapours from fluxes used.
Workers should position themselves so as not to
directly inhale the fumes/vapours.
Tinning Terminals with Silver Solder
16. Tin only section of thermocouple terminals inside
wire grip as shown in Figure 1610. Terminals for silver
soldering should not be plated.
CAUTION
Do not allow any flux or solder to get on the insulation
grip or on the ring tongue.
a.
With a brush, apply a small amount of hard solder

flux to the area to be tinned.
b. Using a torch or the resistance heating pliers, melt

a thin coat of silver solder onto inside of wire grip.
See Figure 1610 for use of resistance heating
pliers in this operation.
c.
Allow terminal to cool in air.
Procedure for Attaching Terminals to Thermocouple

Wire
17.
a.
Secure terminal to thermocouple wire as follows:

Flux previously tinned areas of terminal and wire.
b. Install terminal on wire so that insulation is flush

with or protrudes slightly beyond insulation grip.
Figure 1611 Silver Soldering Thermocouple Wire to

Terminal

Sect 2 Chap 16
Torch Soldering Terminals to Thermocouple Wire
c.
18. Secure terminal to thermocouple wire as follows:

(See Figure 1611.)
a.
Use copper shield to protect insulation.
b. Heat joint until flux bubbles and then apply silver

solder wire to joint as shown. Keep flame in
motion to assure uniform heating.
When solder has flowed down into wire grip,

remove flame and allow joint to cool without
disturbing it.
NOTE
AN 5539 terminals require reinforcement with silver

solder at indicated areas. (See Figure 1613).
CAUTION
Do not allow solder to flow onto ring tongue as this
will prevent proper assembly into system.
Resistance Soldering Terminals to Thermocouple
Wire
19.
a.
Secure terminal to thermocouple wire as follows:

Grasp terminal and wire assembly, prepared in
accordance with Paragraph 17, at wire grip area.
The resistance heating pliers are to be in the
position shown in Figure 1610.
b. Apply current until flux bubbles; then apply silver

solder wire to connection from conductor end of
assembly.
c.
Figure 1612 Modified Crimping Tool for
Continue to apply heat and watch for flow of

solder inside wire grip. When solder is visible at
opposite end of wire grip from where it was
applied, turn off current.
d. Allow assembly to solidify before removing from

pliers.
Cleaning and Completing Silver Soldered Terminal
Connections
20. After the silver solder has solidified and cooled,
the junction must be completed as follows:
a.
Remove flux residues with warm water and a

bristle brush, then dry thoroughly.
b. Secure insulation grip on insulation using modified

crimping tool shown in Figure 1612. The final
result is shown in Figure 1611.
NOTE
Insulation grip tabs may be trimmed so they butt.
Figure 1613 Reinforcing Solder on AN5539

Terminals

Sect 2 Chap 16
c.
Examine junction to be sure that silver solder has

alloyed to wire and terminal. Examine also to be
sure that insulation has not been scorched.
Rework any connection that is defective.
Serving Thermocouple Wire

21. After soldering operation has been completed,
and solder has cooled, serve thermocouples at the
branching point as shown in Figure 1614. Use nylon or
waxed cotton cord in cool areas, and fibreglass cord in
hot areas. Coat the serving with clear lacquer. The
serving will prevent unravelling of the outer jacket.
SOFT SOLDERING THERMOCOUPLE WIRE

Soft Soldering Thermocouple Wire
22. Tin thermocouple wire for soft soldering in the
same manner as copper wire as described in Section 2,
Chapter 7. Either dip tinning or soldering iron tinning is
satisfactory. Occasionally, if wires are oxidised, rosinalcohol flux may not do a satisfactory job of tinning. If
this happens, use flux A-A-59142 or equivalent. After
tinning, remove flux and flux residue on the tinned
surface by using a cleaning solution of 50 percent water
and 50 percent isopropyl alcohol, grade A, technical (TTI-735). Dry thoroughly.
Tinning Terminals for Soft Soldering
23. Tin terminal section inside wire grip, using a 200
to 250 watt soldering iron and rosin core solder. Do not
allow flux or solder to get on the insulation grip or on the
ring part of the tongue.
Soft-Soldering Wire to Terminals
24. The procedure for soft-soldering thermocouple
wires to terminals is as follows:
a.
Install terminals on thermocouple wires as

described in Para 17, and illustrated in Figure 16
11.
b. Soft solder, using 200 to 250 watt iron and rosin

core solder. Make sure that solder flows inside
wire grip and forms a smooth fillet.
CAUTION
For soft-soldering, do not use any flux other than
rosin-alcohol, regardless of flux used for tinning.
c.
Remove excess flux by brushing with denatured

alcohol (A-A-51693).
d. Bend insulation grip ears around insulation using

modified crimping tool shown in Figure 1612.
Trim ears so they butt flush around small wires.
(See Figure 1611.)
Figure 1614 Serving Thermocouple Wire

Sect 2 Chap 16
Soldering Wire to MS Connectors

25. Thermocouple contacts in MS series connectors
are not tinned by the manufacturer. Therefore, it is
necessary to properly tin these contacts with soft solder
before thermocouple wire is soft soldered into place. MS
connector contacts must be removed from inserts for
soldering because of the extra heat required to raise
thermocouple wire to solder temperature. Best results
are obtained when electrical resistance heating pliers
are used to tin the contact and also for soldering wire
into contact. The procedure for tinning and soldering is
as follows:
a.
Tin contact by use of resistance heating pliers or

torch. Use rosin-alcohol flux and 60/40 tin-lead
solder or, if necessary, use flux described in
paragraph 22 with the same 60/40 tin-lead solder.
WARNING
b. Remove flux residues by brushing vigorously with
Stoddards solvent (MIL-PRF-680) or with
denatured alcohol (A-A-51693). Lactic acid flux is
removed by brushing in warm water. Dry each
tinned contact thoroughly before proceeding with
next step.
c.
NOTE
For chromel and alumel contacts, material verification
can be made with the aid of a magnet, since a
magnet will attract the alumel contact but not the
chromel contact.
Soft Soldering With Silver Solder Bonding Paste
26. In areas where temperatures do not exceed
120C and a high tensile strength or high electrical
conductivity is required, silver solder bonding paste may
be used as an alternative to the procedures described in
paragraphs 22 to 25, as follows:
a.
For attaching terminals, clean terminals and wire

with isopropyl alcohol. Next, install terminal, apply
bonding paste to wire, and heat with a 140 watt
soldering iron. Wipe clean with isopropyl alcohol.
b. For soldering MS and AN connectors, clean wire

and socket contacts of connector with isopropyl
alcohol. Apply bonding paste to wire and insert
into socket. Heat with a 140 watt soldering iron,
then clean with isopropyl alcohol. Inspect joint to
ensure smooth fillet and that no excess solder is
outside of solder cup or socket. Assemble the
connector.
Check contact coding and wire coding carefully to

avoid mismatch of materials. (See Table 161 and
Table 163.)
CAUTION
It is important that thermocouple materials match.
Ensure that the thermocouple wire is soldered to a
contact of the same material.
d. Insert properly pre-tinned wire into contact and
solder using resistance pliers or torch. Use only
rosin core solder for this operation. (See Figure
1615.)
e.
After solder has flowed and alloyed, allow

connection to cool without motion. Then remove
flux residues with Stoddards solvent (MIL-PRF680) or with denatured alcohol (A-A-51693).
f.
Examine joint to be sure solder has flowed to form

a smooth fillet, and that no solder is left on outside
of solder cup.
g. Reassemble contacts into MS connector as

described in Section 2, Chapter 10. Be careful to
reassemble each contact into the hole from which
it was removed.
10
Figure 1615 Torch Soldering Thermocouple Wire to

MS Connector Contact

Sect 2 Chap 16
Soldering Wire to AN5537 Firewall Connector
THERMOCOUPLE WIRE SPLICING
27. Thermocouple wires are brought through firewalls

by means of AN5537 firewall connectors. To preserve
the integrity of the system, it is necessary to hard solder
wires to the connector on the hot side of the firewall. The
cool side of the firewall may be either hard or soft
soldered. The procedure for attaching wires is as follows
(refer to Figure 163):
Installing Thermocouple Wire Splices on MIL-W5846, Type I, Stranded Conductor, AWG 20 AlumelChromel Thermocouple Cable
CAUTION
Ensure wire leads are connected to mating materials
of connector. Connector plugs and sockets are coded
with letters to indicate materials. Sizes are also
different to aid in quick identification. (SEE Table 16
4 for code.)
a.
Disassemble connector as shown. Slide nuts over

the pre-tinned leads that will be installed on the
hot side of the firewall.
b. Tin the wire grips of the socket assemblies using

hard solder as described in Paragraph 16.
c.
Assemble and hard-solder wires to socket

assemblies as described in Paragraphs 17
through 19.
28. Similar metal terminations are required to make

connections from the thermocouple probe to the circuitry
cable at any point where temperature changes may be
expected. Termination of thermocouple cables in areas
where all components would be at the same
temperature normally would not require similar metal
terminations. Splicing and connections of AlumelChromel thermocouple cables in engine nacelles,
individual cable runs and wire bundles will be made
using Alumel-Chromel Butt Splice with Insulation
Support. These splices are uninsulated and separate
insulation must be installed over the splice at the time of
installation. An additional outer jacket must also be
installed for cable protection and mechanical support.
29. Install thermocouple splices as detailed in Figure
1616.
WARNING
fuelled aircraft.
d. Complete assembly of hot side wires by cleaning

and crimping insulation grips.
e.
Attach plugs to wires on cold side of firewall by

using hard or soft solder, as required on
applicable drawing for the specific installation. The
method of attachment, soldering, cleaning, etc, is
the same as that previously described.
Table 164 Code for Markings on AN5537

Material
Code
Size
Iron
Constantan
Chromel
Alumel
FE
CON
CR
AL
Large
Small
Large
Small
WARNING
ventilated.
30.
a.
Tools and Equipment:

Heat Gun: Raychem Part Nos. AA-400, CV5700
or M83521/5-01 Heat Gun Kit.
b. Crimp Tool: Amp Part No. 46673.

31.
a.
Materials:
Materials Installation Kit: Raychem Part No. D436-0133.
b. MIL-W-5846
(M5846/1E2/20-(AC))
Alumel
Chromel Thermocouple Cable (as required).
c.
12.7mm wide fibreglass tape with thermosetting

adhesive (optional).
11

Sect 2 Chap 16
NOTE
WARNING
The following materials are contained in the Raychem

Part No. D-436-0133 Materials Installation Kit:

fuelled aircraft.
Qty 1 D-436-133-01 Chromel Splice, Colour

Coded Gray.
Qty 1 D-436-133-02 Alumel Splice, Colour

Coded Green.
Qty 2 D-436-133-03 Splice Sealing Sleeves.
Qty 1 D-436-133-04 Overall Insulation Sleeve.
32. Butt Splicing Procedure. Procedures for butt

splicing are shown in Figure 1616.
33.
a.
WARNING
ventilated.
35.
a.
Quality Assurance Summary:

Ensure butt splices have been properly selected
to match colour code of conductors:
(1) ALUMEL (AL) Green
(2) CHROMEL (CH) Gray
Tools and Equipment:

Heat Gun: Raychem Part Nos. AA-400, CV-5700,
M83521/5-01 Heat Gun Kit.
b. Crimp Tool: Amp Part No. 49935 or Raychem Part

No. AD1377.
36.
a.
Materials:
Parallel Connector, 34130 or D-609-04.
b. Ensure butt splices are completely insulated by

D436-133-03 sealing sleeves.
b. Raychem D-300-08 End Cap, Shrinkable, Self

sealing.
c.
c.
Ensure splices have been staggered. See Figure

1616, step 6.
12.7mm Fibreglass Tape, with thermo-setting

adhesive.
Stub Splicing in Stub Splice Areas
37. Stub Splicing Procedure. Procedures for stub

splicing are shown in Figure 1617.
34. In stub splice areas, all components can be

expected to be at the same temperature. Similar metal
connections and terminations are not required.
38.
a.
Quality Assurance Summary:

Ensure like colour-coded wires have been spliced
together.
b. Ensure individual stub

completely insulated.
12
splices
have
been

Sect 2 Chap 16
Figure 1616 Butt Splicing Procedure
13

Sect 2 Chap 16
Figure 1617 Stub Splicing Procedure
14

Sect 2 Chap 16
MOUNTING AN5537 CONNECTOR ASSEMBLY

39. AN5537 firewall connector assemblies
mounted as follows (refer to Figure 163):
a.
are
Attach insulating block to firewall on hot side.

Bosses on block should fit into holes in firewall so
that block face is flush against wall.
b. Push socket assemblies through holes and lock

into place with coupling nuts.
c.
Push plugs into socket assemblies from cold side

of firewall.
ROUTING THERMOCOUPLE WIRING

40. Route thermocouple wiring as described in
Section 2, Chapter 4. In addition, observe the following
special precautions:
a.
Support thermocouple wiring so it will not come

into contact with heat producing surfaces, such as
exhaust pipe or combustion chamber, at any
point.
Slack in Thermocouple Wiring

42. Thermocouple wire installations require the use of
fixed wire lengths to maintain a specified resistance
(See Figure 1618). The slack that results should be
distributed by one of the following methods:
a.
Distribute excess slack evenly between wire

supports, as shown in Figure 1618.
b. If sufficient slack is available, take it up at a

support, in the form of a loop of which the
diameter is at least 20 times the thickness of the
thermocouple wire, as shown in Figure 1618.
CAUTION
Do not bend thermocouple leads to less than a 50mm
radius. When calibration resistors are used in the
circuit to adjust for short lengths, do not allow any
excess slack, except for approximately 76mm at each
end for maintenance.
b. Do not bend thermocouple leads sharply.

c.
Do not splice thermocouple leads except where

specifically indicated, and then only with approved
splices such as shown in Figure 1616.
d. Protect adjacent wiring against abrasion from

thermocouple splices as described in Paragraph
41.
e.
Route thermocouple wiring away from hot spots.
Protection
41. Insulate
thermocouple
spliced
terminal
connections with sleeves to protect the insulation of
adjacent wires from abrasion. Use plastic sleeving in
cool areas and silicon impregnated rubber or glass
sleeving in hot areas. Tie sleeving securely at both ends.
Figure 1618 Distributing Slack in Thermocouple

Wire
CAUTION
Do not use sleeving as a substitute for safe routing.
15

Sect 2 Chap 17
SECTION 2
CHAPTER 17
AGED AIRCRAFT WIRING

INTRODUCTION
1.
A generally accepted belief in the aviation industry, reinforced by several studies, is that poor maintenance
practices are a significant contributor to wiring degradation problems.
2.
Wire degradation has been found to be principally caused by installation, environmental, and maintenance
factors including: drill shavings and other metal debris in bundles (with cut insulation); lint accumulations; chemicals of
various types on wiring (corrosion inhibitor, paint, hydraulic fluid, oil, grease, soft drinks, coffee, lavatory fluid, etc.);
aging and deterioration of materials (cracks in wire insulation, clamp cushions crumbling, crumbled potting in pump
connectors, cracked o-rings, etc.); extensive nicks, cuts, and chafes; workmanship issues; and compromised wiring
segregation.
3.
The damage caused to wiring looms and harnesses is not always immediately evident and may be initiated
through incorrect installations; however, incorrect handling rapidly accelerates any dormant problems.
4.
If maintenance personnel are cognisant of the causes of wiring degradation and adopts a policy of improved
wiring husbandry, inspection processes and correct installation practices the possibility of wiring defects causing
significant problem will be reduced.
5.
This chapter provides information and instructions on the inspection, care and maintenance of aged aircraft
wiring installations that have degraded and become more prone to damage during maintenance activities.
DEFINITIONS
6.
The following definitions have been used in communicating about the subject of aged aircraft wiring:
a.
Aged Wiring. Wiring which has degraded by a noticeable amount from its new condition, through time and/or
environmental conditions.
b.
Arc Tracking (wet). Wet arc tracking occurs when contaminating moisture or aircraft fluids create a short circuit
between an exposed conductor and the aircraft structure or an adjacent exposed conductor at a different
potential. In wires using aromatic polyimide insulating material this can lead to carbon arc tracking.
c.
Arc Tracking (dry). Dry arc tracking occurs in dry conditions when one or more conductors are shorted as a
result of abrasion from the aircraft structure, wire to wire abrasion, installation error or battle damage. In wires
using aromatic polyimide insulating material this can lead to carbon arc tracking.
d.
Carbon Arc Tracking. This failure mode occurs in wires using aromatic polyimide insulating material (Kapton),
where the insulation is converted into a conductor. Micro arcs of only a few milli-amps of leakage current,
occurring due to a breakdown in the insulation, convert the insulation into micro-spots of conducting carbon.
Eventually these micro-spots of conducting carbon join up to complete an electrical path that results in a power
arc with further carbonising occurring. At this stage there is a thermal and electrical avalanche which can lead to
catastrophic failure of entire wire looms and in some cases aircraft structure. Although the avalanche current is
limited by the power source, wiring and the circuit breakers, the duration of the flashover may not be sufficient to
trigger the circuit breaker before serious damage has occurred.
e.
Combustible. The ability of any solid, liquid or gaseous material to cause a fire to be sustained after removal of
the ignition source.
f.
Contamination. With regard to wiring contamination refers to the presence of a foreign material that is likely to
cause degradation of wiring or the presence of a foreign material that is capable of sustaining combustion after
removal of ignition source.
g.
Detailed Visual Inspection. An intensive examination of a specific item, installation or assembly to detect
damage, failure or irregularity. Available lighting is normally supplemented with a direct source of good lighting
at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses or other means may be
necessary. Surface cleaning and elaborate access procedures may be required.
h.
General Visual Inspection. A visual examination of an interior or exterior area, installation or assembly to
detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance
unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the
inspection area. This level of inspection is made under normally available lighting conditions such as daylight,
hangar lighting, flashlight or droplight and may require removal or opening of access panels or doors. Stands,
ladders or platforms may be required to gain proximity to the area being checked.

Sect 2 Chap 17
i.
Maintenance. For the purpose of this chapter, maintenance means inspection, overhaul, repair, preservation,
and the replacement of parts. It also includes preventive maintenance.
j.
Needling. The puncturing of a wires insulation to make contact with the conductor to test for continuity or the
presence of voltage.
k.
Swarf. A term used to describe the metal particles, generated from drilling and machining operations.
l.
Wiring Installation. An electrical connection between two or more points including the associated termination
devices such as connectors, terminal blocks, splices, switches, relays etc, and the necessary means for its
installation and identification.
GENERAL
7.
Many aircraft have been in service for around thirty years and the wiring installations have generally performed
very well, with only one aircraft accident currently attributable to wiring failure. However numerous aircraft accidents
investigated by international agencies implicate deteriorated wiring as a major contributing factor. While varying
amounts of wiring have been replaced in aircraft, all airframes contain a substantial amount of original wire that has
obviously deteriorated to some degree since its installation.
8.
Wire insulation deteriorates through factors such as chronological ageing and temperature cycling over which we
have no control, however we do have control over other factors such as incorrect or inappropriate maintenance
procedures. Wire may appear to be robust and strong, however minor abuse or apparently insignificant damage will
exacerbate deterioration of the insulation with time.
9.
Maintenance activity can vary greatly from aircraft to aircraft. The disruptive effects of maintenance activity can
be more random than the environmental factors that can lead to accelerated wire degradation. Maintenance practices
should focus on maintaining the integrity of the wiring system.
SERVICE DIFFICULTY REPORTING

10. This information is general guidance. Any inspections should be conducted as deemed appropriate by each
Certificate of Registration (CoR) holder, based on aircraft maintenance experience. Discrepancies found should be
repaired per the aircraft maintenance manuals and reported to CASA as part of the Service Difficulty Report (SDR)
process. CoR holders are encouraged to review and incorporate the following guidelines as a part of their current
aircraft maintenance program and wiring practices.
11. CoR holders/operators have a responsibility to provide Service Difficulty Reports (SDRs) to the TC holder, the
equipment manufacturer or the STC/Subpart 21.M holder and a copy to CASA. This enables appropriate investigations
and components/ systems to be modified to improve reliability.
CAUSES OF WIRING DEGRADATION

12. The following items are considered principal causes of wiring degradation and should be used to help focus on
the problem areas and generate appropriate maintenance programs:
a.
Vibration - High vibration areas tend to accelerate degradation over time, resulting in chattering contacts and
intermittent symptoms. High vibration can also cause tie-wraps, or stringties to damage insulation. In addition,
high vibration will exacerbate any existing problem with wire insulation cracking and wiring installed with
inadequate support (loose clamps & tie-wraps) and clearances.
b.
Moisture - High moisture areas generally accelerate corrosion of terminals, pins, sockets, and conductors. It
should be noted that wiring installed in clean, dry areas with moderate temperatures appears to hold up well.
c.
Maintenance - Maintenance activities, if done carelessly and improperly, can contribute to long term problems
and wiring degradation. Repairs made to minimum airworthiness standards may have limited durability and
should be evaluated to ascertain if rework may be necessary. Repairs that conform to manufacturers
recommended maintenance practices are generally considered permanent and should not require rework. e.g.
Metal shavings and debris have been discovered on wire bundles after maintenance or repairs have been
conducted. As a general rule, wiring that is undisturbed will have less degradation than wiring that is reworked.
As wiring and components become more brittle with age, this effect becomes more pronounced.
d.
Indirect Damage - Events such as pneumatic duct ruptures can cause damage that, while not initially evident,
can later cause wiring problems. When such an event has occurred, surrounding wire should be carefully
inspected to ensure no damage is evident.
e.
Chemical Contamination - Chemicals such as hydraulic fluid, battery electrolytes, fuel, corrosion inhibiting
compounds, waste system chemicals, cleaning agents, deicing fluids, paint, and soft drinks can contribute to
degradation of wiring. Insignificant things like spills of medication left in a wiring loom can contribute to wiring
damage. Wiring in the vicinity of these chemicals should be inspected for damage or degradation.
Recommended original equipment manufacturer cleaning instructions should be followed. Hydraulic fluids, for
example, require special consideration. Hydraulic fluid is very damaging to connector grommet and wire bundle

Sect 2 Chap 17
clamps, leading to indirect damage, such as arcing and chafing. Wiring that may have been exposed to hydraulic
fluid should be given special attention during wiring inspections.
f.
Heat - Wiring exposed to high heat can accelerate degradation, insulation dryness, and cracking. Direct contact
with a high heat source can quickly damage insulation. Even low levels of heat can degrade wiring over long
periods of time. This type of degradation is sometimes seen on engines, in galleys, and behind lights.
g.
Cleaning - Overzealous cleaning and use of inappropriate solvents can cause rapid wiring degradation.
HANDLING AGED WIRING

13.
To minimise degradation, wiring should be handled in accordance with the following instructions:
a.
Inspection. General visual inspection is currently considered the most appropriate method of assessing the
condition of aircraft wiring. While visual inspection has inherent limitations, the various technologies to detect
wire degradation currently under development cannot provide a reliable wire analysis for other than hard faults.
b.
Visual inspection is the preferred method for detecting wire degradation however the requirement to inspect aged
wiring must be critically assessed against the potential damage that may be caused by the manipulation of wiring
looms.
c.
The following wire system degradation items are typical of what should be detectable and subsequently
addressed as a result of a visual inspection:
(1) Wire/Wire Harnesses
a) Wire bundle chafing.
b) Wire bundle sagging or improperly secured.
c)
Wires damaged (large scale damage due to mechanical impact, overheat, localised chafing, etc).
d) Lacing tape and/or ties missing/incorrectly installed.

e) Wiring protection sheath/conduit deformity or incorrectly installed.
f)
Grommet missing or damaged.
g) Dust and lint accumulation.

h) Surface contamination by metal shavings/swarf.
i)
Contamination by liquids.
j)
Deterioration of previous repairs.
k)
Inappropriate repairs.
l)
Inappropriate attachments to or separation from fluid lines.
(2) Connectors
a) External corrosion.
b) Backshell/tail broken.
c)
Rubber pad or packing on backshell missing.
d) No backshell clamp.
e) Missing or broken safety wire.
f)
Discolouration/evidence of overheat on terminal lugs/blocks.
g) Torque stripe misalignment.

(3) Ground points
a) Corroded.
(4) Bonding braid/bonding jumper
a) Braid broken or disconnected.
b) Multiple strands broken.
(5) Wiring clamps or brackets
a) Cushion damaged or missing.
b) Corroded.
c)
Broken/missing.
d) Bent or twisted.

Sect 2 Chap 17
(6) Circuit breakers, contactors or relays

a) Signs of overheating.
b) Signs of arcing.
d.
The following installations and areas should always be adequately addressed in maintenance requirements:
(1) Clamping points Wire chafing is aggravated by damaged clamps, clamp cushion migration, or improper
clamp installations. When replacing clamps use those specified by the aircraft manufacturer. Adding new
wire to existing wire bundles may overload the clamps causing wire bundle to sag and wires to chafe.
(2) Connectors Worn environmental seals, loose connectors, missing seal plugs, missing unused contacts, or
lack of strain relief on connector grommets can compromise connector integrity and allow contamination to
enter the connector, leading to corrosion or grommet degradation. Connector pin corrosion can cause
overheating, arcing and pin-to-pin shorting. Drip loops should be maintained when connectors are below the
level of the harness and tight bends at connectors should be avoided or corrected.
(3) Terminations Terminations, such as terminal lugs and terminal blocks, are susceptible to mechanical
damage, corrosion, heat damage and contamination from chemicals, dust and dirt. High current-carrying
feeder cable terminal lugs can over time lose their original torque value due to vibration. One sign of this is
heat discolouration at the terminal end. Proper terminal build-up hardware and nut torque is especially
critical on high current carrying feeder cable lugs. Corrosion on terminal lugs and terminal blocks can cause
high resistance and overheating. Dust, dirt and other debris are combustible and therefore could initiate a
fire if ignited from an overheated or arcing terminal lug. Terminal blocks and terminal strips located in
equipment power centres, avionics compartments and throughout the aircraft need to be kept clean and free
of any combustibles.
(4) Back-shells Wires may break at back-shells, due to excessive flexing, lack of strain relief, or improper
build-up.
(5) Sleeving and Conduits Damage to sleeving and conduits, if not corrected, will often lead to wire damage.
(6) Grounding Points Grounding points should be checked for security, condition of the termination,
cleanliness, and corrosion. Any grounding points that are corroded or have lost their protective coating
should be repaired.
(7) Splices Both sealed and non-sealed splices are susceptible to vibration, mechanical damage, corrosion,
heat damage, chemical contamination, and environmental deterioration. Power feeder cables normally carry
high current levels and are very susceptible to installation error and splice degradation. Splice replacement
shall be with environmental splices.
(8) Wire Raceways and Bundles Adding wires to existing wire raceways may cause undue wear and chafing
of the wire installation and inability to maintain the wire in the raceway. Adding wire to existing bundles may
cause wire to sag against the structure, which can cause chafing.
(9) Wings The wing leading and trailing edges are areas that experience difficult environments for wiring
installations. The wing leading and trailing edge wiring is exposed on some aircraft models whenever the
flaps or slats are extended. Other potential damage sources include slat torque shafts and bleed air ducts.
(10) Engine, Pylon, and Nacelle Area These areas experience high vibration, heat, frequent maintenance,
and are susceptible to chemical contamination.
(11) Auxiliary Power Unit (APU) Like the engine/nacelle area, the APU is susceptible to high vibration, heat,
frequent maintenance, and chemical contamination.
(12) Landing Gear and Wheel Wells This area is exposed to severe external environmental conditions in
addition to vibration and chemical contamination.
(13) Electrical Panels and Line Replaceable Units (LRUs) Due to limited space, panel wiring is particularly
prone to broken wires and damaged insulation when these high density areas are disturbed during
maintenance and modifications.
(14) Batteries Wires in the vicinity of aircraft batteries are susceptible to corrosion, discolouration and damage
from abrasion and excessive bending. Discoloured wires should be inspected for serviceability.
(15) Power Feeders High current wiring and associated connections have the potential to generate intense
heat and should be checked for signs of overheating and security. If any signs of overheating are seen, the
splice or termination should be replaced.
(16) Under Galleys and Lavatories Areas under the galleys, lavatories and other liquid containers are
particularly susceptible to contamination from coffee, food, water, soft drinks, lavatory fluids, etc. Fluid drain
provisions should be periodically inspected and repaired as necessary.
(17) Cargo Bay/Underfloor Damage to wiring in the cargo bay and underfloor area can occur due to cargo
handling and maintenance activities in the area.

Sect 2 Chap 17
(18) Surfaces, Controls, and Doors Wiring that is subject to movement or bending during normal operation or
maintenance access should be inspected regularly.
(19) Access Panels Wiring near access panels may receive accidental damage as a result of repetitive
maintenance access.
(20) Under Cockpit Sliding Windows Areas under cockpit sliding windows are susceptible to water ingress
from rain and snow. Fluid drain provisions should be periodically inspected and repaired.
(21) Areas Difficult to Access Areas where wiring is difficult to access may accumulate excessive dust and
other contaminants as a result of infrequent cleaning. In these areas it may be necessary to remove
components and disassemble other systems to facilitate access to the area.
e.
Care. Wiring located below or adjacent to maintenance activity, including painting, should be appropriately
covered to protect it from damage or contamination.
f.
Individual wires and looms should be handled and moved the minimum amount necessary during maintenance
activity. Ensure minimum bend radii of looms and individual wires and cables are never exceeded. This is
particularly relevant when wiring is moved for access.
g.
Wires and wiring components should be kept clean using appropriate cleaning materials. While all wiring
insulations used in aircraft are resistant to fuels and lubricants, continuous contact with these chemicals will
cause deterioration over time. Additionally, fluids can migrate along looms to connectors and other wiring
components that can suffer degradation.
h.
Any accumulations of combustible materials such as lint, fluff and dust should be removed using appropriate
cleaning methods. These materials can be readily ignited from an electrical arc and then, in turn, ignite less
flammable materials.
i.
Ensure swarf from structural repairs is completely removed and does not become trapped in wiring looms. Metal
shavings left in looms can eventually cut through insulation and cause short circuits.
j.
Maintenance. Non-environmental splices that exhibit signs of discolouration or other degradation should be
replaced with environmentally sealed splices qualified to SAE AS81824.
k.
Wires and looms resting against the aircraft structure should be adequately restrained to achieve appropriate
clearance. Where this is impractical, looms should be wrapped with abrasion resistant material such as teflon
sheet to provide additional protection.
l.
Abrasion of wire insulation can also occur because of differences in hardness between adjacent wires.
Therefore, new wires, added during modification, which have significantly different insulation hardness or
abrasion characteristics to current aircraft wiring, should be routed in separate bundles. This is particularly
important in areas of high vibration.
m. Abrasion of either the insulation or the insulation-facing material of clamps, conduits, or other devices used to
secure or support wires or bundles can also be hazardous. Therefore, during maintenance activity, any rework or
replacement of wires or looms should ensure that the original integrity of the design is maintained. The
insulation-facing material should have hardness compatible with that of the insulation.
n.
Wiring looms should be appropriately clamped to avoid relative movement that can cause fatigue and chafing.
o.
When repairing wire, use serviceable tooling and methods that are appropriate for the wire type being repaired.
p.
The practice of pulling through wires during replacement or modification should be avoided wherever possible. If
cables are laid in then damage to insulation surface by snagging or abrasion will be avoided. Additionally, the
strain placed on the wire being pulled can cause damage to the insulation or conductor.
q.
Piercing of wiring insulation for test purposes is not an acceptable practice.
r.
Ensure there is adequate strain relief for looms particularly where they are located across hinged, movable
panels etc.
14.
Wiring should be replaced under the following circumstances:
a.
Wiring that has been subjected to chafing or fraying, that has been damaged, or where the primary insulation is
suspected of being penetrated.
b.
Wiring on which the outer insulation is brittle when slight flexing causes it to crack.
c.
Wiring that has weather-cracked outer insulation. NOTE: some wire insulation types appear to be wrinkled when
the wire is bent and may not be damaged.
d.
Wiring that is known to have been exposed to electrolyte or on which the insulation appears to be, or is
suspected of being, in an initial stage of deterioration due to the effects of electrolyte.
e.
Wiring where there is visible evidence of insulation damage due to overheating.
f.
Wiring that bears evidence of having been crushed or severely kinked.
g.
Shielded wiring on which the metallic shield is frayed and/or corroded.

Sect 2 Chap 17
h.
15.
Wiring showing evidence of breaks, cracks, dirt, or moisture in the plastic sleeves placed over wire splices or
terminal lugs.
Replacement wires should have the same physical, electrical and shielding characteristics as the original wires.
16. Studies have indicated that through life handling of aircraft wiring has a greater effect on deterioration than age
alone, so the prime requirement when handling aircraft wiring installations is to treat them with the care and attention
appropriate for a vital aircraft system.
RECOGNITION OF DAMAGED/DETERIORATED WIRE AND WIRE SYSTEM COMPONENTS

17. Common Faults. Listed below are some of the more common faults that may encounter in electrical looms,
cables and connectors:
Broken Conductors,
Overheated Conductors and Insulation,
Chafed Insulation,
Contamination,
Cracking, Hardening and Contaminated Insulation, and
Connector Damage.
18. Broken Conductors Broken conductors are probably the most common fault. Causes for broken conductors
are many, ranging from overstressing the cable to damage caused by other maintenance being carried out on the
aircraft (eg. drilling).
19. In its most severe case, a broken conductor can be detected visually. A cable may have suffered a clean cut
through both the insulation and conductor breaking the circuit path as illustrated in Figure 17-1.
Figure 17-1 Visible Broken Conductors

20. Alternatively, the damage may not be visible. The conductor could be broken while the insulation remains intact.
This may occur where the bend radius of the cable has been exceeded as shown in Figure 17-2.
Figure 17-2 Hidden Broken Conductors

21. In both cases, the most reliable method of confirming a broken conductor is to carry out a continuity check. If the
check indicates an open circuit, then repair action will be necessary. In both of these examples, the broken conductors
can be repaired by using an in line splice.
22. Overheated Conductors. Overheating of the conductor can be caused by many factors. The most serious is
where the system suffers a short circuit and the circuit breaker fails to operate in time or not at all. This results in the
excessive current flow heating the conductor. As the temperature of the conductor increases, the insulation of the wire
melts and eventually the conductor also melts.
23. Even if the conductor is not destroyed completely after being subjected to excessive heat for extended periods of
time the insulation may become discoloured indicating heat damage. If this damage is not found this could lead to the
insulation and or conductor becoming hard and brittle and eventually cracking and breaking. The resistance of the wire
will increase possibly affecting the system it connects.

Sect 2 Chap 17
24. Once again, carrying out a continuity check is the best method of detecting where conductor breakdown has
occurred. An open circuit indication will not always be the case. An overheated circuit may still indicate as closed but
will have a higher circuit resistance.
25. When repairing overheated conductors, it is very hard to isolate the damaged portion of the cable. The best
option for repair is to replace the entire cable.
26. Chafed Conductors. Chafing is the result of a cable or harness continually rubbing against another part of the
aircraft. It is usually caused by the incorrect routing of the cable or harness, or insufficient support along its entire
length.
27. Chafing causes the insulation of the cable to be worn away and if not detected early, could lead to eventual
breaking and shorting/arcing of the conductor as shown in Figure 17-3.
Figure 17-3 Chafed Conductors

28. Chafing can be repaired by using an in line splice, however, if the damage is along the entire length of the wire a
jumper lead will be required to bridge the gap. Ensure the loom has sufficient clearance from the cause of the chaffing.
If it is not possible to gain the clearance required then the loom should be wrapped with abrasion resistant material
such as Teflon sheet to provide additional protection.
29. Chafing can also occur due to differences in hardness of insulation material between adjacent wires. Therefore if
a new wire is added to an existing loom it should have the same abrasion characteristics as the existing wires. If a wire
of different abrasion characteristic has to be used then it should be routed in separate bundles.
30. Contamination. Whilst all wiring insulations used in aircraft are resistant to fuels and lubricants, continuous
exposure with these chemicals will cause deterioration over time. Also if the chemicals are not kept off the looms, the
chemicals can migrate to connectors and other wiring components. If contamination occurs, the looms should be
cleaned with appropriate cleaning materials.
31. Ideally looms should be protected from damage/contamination during maintenance being carried out in the
immediate vicinity. If metal shavings are found they should be removed from looms, as the shavings could become
trapped in the looms and cut through the insulation and cause a short-circuit.
32. Connector Damage. Electrical connectors form the link between the component and aircraft system. Whenever
an aircraft component is removed or installed the electrical connector should be inspected. This inspection allows for
the early detection of deteriorating components or even the cause of system failure. Examples of various electrical
connectors are shown in Figure 17-4

Sect 2 Chap 17
Figure 17-4 Various Connectors

33. Whenever disconnecting or reconnecting an electrical connector it must be examined for the following possible
damage:
Pins or sockets pushed back into the insulator;

Pins bent over or shorting other pins;
Moisture, corrosion or contamination (this can cause shorts when power is applied);
The insulator has no cracks or tears and is not perished;
Wire/s loose in the back of the plug (possible causes are: contact not seated; or wire no longer
connected to contact);
Overall physical condition of the connector; and
Burn marks caused by poor connections or shorting.
PRECAUTIONS SHOULD BE OBSERVED WHEN HANDLING ELECTRICAL CONNECTORS:
34. Disconnecting electrical connectors. Prior to disconnecting any electrical connector the following precautions
are to be observed:
Ensure system power has been removed (turned off) before disconnecting any of the systems
electrical connectors;
Always use the correct tool to disconnect an electrical connection (soft jawed multigrips called
plug pliers);
Never use the loom to pull a connector from its receptacle;
When disconnecting a component with multiple plugs, ensure that they are clearly identified to
ensure their correct reconnection; and
Annotate disconnection of electrical connector in appropriate aircraft documentation.
35. Connecting electrical connectors. Prior to connecting any electrical connector, the following precautions are to
be observed:
Ensure system power has been removed (turned off) before connecting any of the systems
electrical connectors;
Never force a connector together; always ensure keyways align before attempting connection;
After connection, ensure that the connector is securely mated (locked in the indent); and
Ensure that if the connection was previously lock wired the lock wiring is replaced.

Sect 2 Chap 18
SECTION 2
CHAPTER 18
AIRCRAFT ELECTRICAL SYSTEM - INSPECTION

(1) Chafing.
INTRODUCTION
(2) Use as handholds, or as support for

personal equipment.
1.
The purpose of this chapter is to provide
instructions for inspecting aircraft electrical system
wiring and interconnecting components and to detail
requirements to be met. Compliance with these
instructions will be effective in minimising electrical
system malfunctions. These instructions should be
complied with, except where any procedure conflicts
with the aircraft maintenance manual, in which case
the aircraft manual shall take precedence.
(3) Damage by personnel moving within the

vehicle.
(4) Damage by stowage or shifting of cargo.
(5) Damage by battery or acid fumes and fluids.
(6) Damage in wheel wells exposed to rocks,
ice, mud, etc.
WARNING
(7) Damage by moving parts.
To avoid the possibility of personal injury or

equipment damage, it is mandatory that all electrical
power be removed from the aircraft prior to
commencing an inspection or maintenance.
INSPECTION
(8) Harsh environments such as SWAMP areas,

high temperatures, or areas susceptible to
significant fluid or fume concentration.
d. Wires and cables are provided with enough
slack to meet the following requirements:
(1) Permit ease of maintenance.
Wiring Installation
(2) Prevent mechanical strain on the wires,

cables, junctions and supports.
2.
Wires and cables should be inspected for
adequacy of support, protection and general condition
throughout. The desirable and undesirable features in
aircraft wiring are outlined below and indicated as
conditions that should or should not exist. Accordingly,
aircraft wiring should be inspected to ascertain that:
a.
(3) Permit free movement of shock and

vibration mounted equipment.
(4) Permit removal and installation of equipment
for maintenance or repair.
Wiring installation conforms to the following

precedence:
(5) When wiring is terminated at a connector

(excluding RF connectors) a minimum of
25mm of slack has been provided to
facilitate complete connector replacement.
(1) Safety of flight.

(2) Ease of maintenance, removal and
replacement of the wiring.
(6) At each end of a wire terminated by a lug, a

minimum length of slack equal to twice the
barrel length of the lug has been provided.
For copper wire AWG 2 and larger, and
aluminum wire, AWG 4 and larger, the
minimum length of slack shall be equal to
one barrel length of the lug.
(3) Cost effective aircraft production or

modification.
b. Wiring has been fabricated and installed so as to
achieve the following:
(1) Maximum reliability.
e.
Wiring is adequately separated from high

temperature equipment such as resistors,
exhaust stacks, heating ducts and deicers to
prevent insulation damage or deterioration.
f.
Conduit, flexible tubing or braided outer jackets,

properly supported, covers all wiring in wheel
wells. When tubing is used, drainage holes shall
be provided at all trap points and at the lowest
points between each set of support clamps.
(2) Minimum interference and coupling between

systems.
(3) Accessibility for inspection and
maintenance.
(4) Prevention of damage.
c.
Wiring has been routed to ensure reliability and

to offer protection from the following hazards:

Sect 2 Chap 18
(4) Support does not restrict the wiring in such a

manner as to interfere with the movement of
shock mounted equipment.
g. Wiring has been supported to meet the following

requirements:
(1) Prevent chafing.
(5) Tape or tying and lacing string has not been

used as primary support.
(2) Secure wiring where routed through

bulkheads and structural members.
(6) Plastic cable straps have not been used in

the following areas:
(3) Properly support and route wiring in junction

boxes, panels and bundles.
a)
Where the total temperature (ambient

plus rise) exceeds 85C (185F).
b)
(5) Prevent arcing or overheated wiring from

causing damage to mechanical control
cables and associated moving equipment.
Where failure of the strap would permit

movement of the wiring against parts
which could damage the insulation or
allow wiring to foul mechanical linkages.
c)
(6) Facilitate reassembly to equipment terminal

boards.
Where failure would permit the strap to

fall into moving parts.
d)
In high vibration areas.
e)
In SWAMP areas such as wheel wells,

near wing flaps, or wing folds.
f)
Where exposed to ultra-violet light

(sunlight) unless the straps are resistant
to such exposure.
g)
To tie wires into groups within a bundle.
(4) Prevent mechanical strain or workhardening

that would tend to break the conductors and
connections.
(7) Prevent interference between wiring and

other equipment.
(8) Prevent excessive movement in areas of
high vibration.
(9) Provide rigid support to wiring routed within
15cm of any flammable liquid, fuel or oxygen
lines.
h. Primary support of wiring has been provided by
cushion clamps at intervals of not more than
60cm, except when contained in troughs, ducts
or conduits. The clamps must be of a suitable
size and type to retain the wiring in place
securely and without damage to the insulation.
Clamps must be compatible with their installation
environment.
Cushion
compounds
are
formulated to meet specific requirements and
are not suitable for all applications.
i.
(7) Moisture-absorbent type material is not used

as "fill" for clamps or adapters.
k.
(1) For single wires individually routed and

supported, the minimum bend radius is ten
times the outside diameter of the wire. At the
point where an individual wire breaks out
from a group, harness or bundle, the
minimum bend radius of the wire is ten times
the outside diameter of the wire, provided
the wire is suitably supported at the
breakout point. If wires used as shield
terminators or jumpers are required to
reverse direction in a harness, the minimum
bend radius of the wire is three times the
diameter at the point of reversal providing
the wire is adequately supported.
Secondary support of wiring (support between

primary supports) has been provided by the
following devices, as detailed in Chapter 8:
(1) Tying and lacing string.
(2) Plastic cable straps.
(2) The minimum bend radius of a group,

bundle, or harness is six times the diameter
of the group, bundle, or harness. In no case
shall the bend radius of the group, bundle or
harness be less than ten times the diameter
of the largest included single wire.
(3) Insulation tape.

j.
Limitations on support:
(1) Continuous lacing has not been used except
in panels and junction boxes where this
practice is optional.
(3) The minimum bend radius of a coaxial cable

will not adversely affect the characteristics of
the cable. For flexible type coaxial cables,
the radius of bend shall not be less than six
times the outside diameter. For semi-rigid
types, the radius shall not be less than ten
times the outside diameter.
(2) The use of insulation tape and sleeving for

the protection of wiring has been kept to a
minimum. Sleeving is preferred when such
protection is necessary.
(3) Wires have not been tied or fastened
together in conduit, covered raceways, or
insulation sleeving. This will facilitate ease of
replacement.
Radius of bend.
l.
Wires and cables routed within 15cm of any

flammable liquid or fuel line are closely and
rigidly supported.

Sect 2 Chap 18
m. A trap or drip loop is provided to prevent fluids or

condensed moisture from running into wires and
cables dressed downward to a connector,
terminal block, panel, or junction box.
n. Drain holes are present in drip loops or lowest
portion of tubing placed over wiring.
o. Wires and cables, installed in bilges and other
locations where fluids may be trapped are routed
as far removed from the lowest point as possible
or protected with vinyl tubing when this is not
possible.
p. Wires and cables attached to assemblies where
relative movement occurs (such as at hinges
and rotating pieces; particularly control sticks,
control wheels, columns and flight control
surfaces) are installed or protected in such
manner as to prevent deterioration of the wires
and cables caused by the relative movement of
the assembly parts.
q. Unused wires are individually dead ended, tied
into a bundle, and secured to a permanent
structure. Each wire is to have strands cut even
with insulation and a pre-insulated end cap, or a
25mm piece of insulating tubing placed over wire
with its end folded back and tied.
Wiring Replacement
g. Wiring that bears evidence of breaks, cracks,

dirt, or moisture in the plastic sleeves placed
over wire splices or terminal lugs.
h. Sections of wire on which in-line splices do not
comply with Chapter 6, Paragraph 27, should be
replaced.
Terminals and Terminal Blocks
4.
Inspect to ensure compliance with the following
installation requirements:
a.
b. Terminal connections are securely attached to

terminal block studs.
c.
Wiring that has been damaged to the extent that

the primary insulation has been breached.
b. Wiring that is known to have been exposed to

battery acid or on which the insulation appears
to be, or is suspected of being, in an initial stage
of deterioration, due to the effects of battery
acid.
c.
Wiring that shows evidence of overheating.
d. Wiring on which the insulation has become

saturated with engine oil, landing gear lubricant,
hydraulic fluid, etc. Saturated wire will be
determined by a visual inspection taking into
consideration wire and circuit intent. If the wire is
saturated, the wire should be replaced. If
spillage has occurred, but the wire does not
appear to be saturated, clean with solvent that
will not deteriorate the insulation.
Insulating tubing is placed over terminals (except

pre-insulated types) to provide electrical
protection and mechanical support; and is
secured to prevent slippage of the tubing from
the terminal.
d. Evidence of overheating and corrosion is not

present on connections to terminal block studs.
e.
A maximum of four terminal lugs or three

terminal lugs and a bus bar have been
connected to any one stud.
f.
Physical damage to studs, stud threads, and

terminal blocks is not evident. Replace cracked
terminal strips and those studs with stripped
threads.
3.
Wiring should be replaced when found to have
any of the following defects:
a.
Terminal blocks are securely mounted.
g. When the terminal lugs attached to a stud vary in

diameter, ensure the largest diameter lug is
placed on the bottom and the smallest diameter
on top.
h. Terminal lugs have been selected with a stud
hole diameter which matches the diameter of the
stud.
i.
Terminal lugs have been positioned so that

bending of the terminal lug is not required to
remove the fastening screw or nut, and
movement of the terminal lugs will tend to tighten
the connection.
j.
The following discrepancies are cause for

replacement of terminal boards:
(1) Crack(s) extending from a terminal to any
threaded insert.
e.
Wiring that bears evidence of having been

crushed or kinked.
(2) Crack(s) extending from a terminal to any

other terminal.
f.
Shielded wiring on which the metallic shield is

frayed and/or corroded. Cleaning agents or
preservatives shall not be used to minimize the
effects of corrosion or deterioration of wire
shields.
(3) Crack(s) extending over 6.35mm in length

from any terminal in any direction.

Sect 2 Chap 18
Fuses and Fuse Holders

5.
i.
Inspect as follows:
a.
For security of mounting of fuse holder.
Spare contacts in potted connectors shall have a

pigtail attached, consisting of a wire of the
largest size that can be accommodated by the
contact and which extends 12.7 to 17.8cm
beyond the potting material. The pigtails shall be
identified and dead ended.
b. For security of connections to fuse holders.

c.
For the presence of corrosion and evidence of

overheating on fuses and fuse holders. Replace
corroded fuses and clean fuse holders. If
evidence of overheating is found, check for
correct rating of fuse.
d. For replenishment of spare fuses used in flight,

ensure fuses possess the same electrical
features including blowtime, current and voltage
rating.
e.
Inspect fuse holder cap to ensure the rubber

grommet is properly installed.
f.
Ensure the fuse holder cap retains the fuse

when either inserting or removing a fuse.
Fuseholder caps which do not securely retain
fuses must be replaced.
NOTE
A bayonet coupled electrical connector is correctly
fastened if all three bayonet pins on the receptacle
are located in the holes on the plug coupling ring. A
click will be heard when the pins locate into the
receptacle ring holes. A threaded coupled electrical
connector is correctly fastened if the plug is fully
seated in the receptacle and cannot be moved in or
out of the receptacle. A slight lateral movement is
permissible due to the difference in size between the
locating keys and keyways.
Splices
7.
Crimp type splices shall comply with the
following:
a.
MS Connectors.
6.
Ensure the following criteria for connectors are
met or that repairs are effected as required:
a.
Inspect connectors for security, evidence of

overheating and for corrosion or cracks. Replace
where necessary.
b. Ensure installation of cable clamp adapters on

all MS connectors except those that are moisture
proof, on which they are optional.
b. The spacing of splices at staggered intervals to

prevent excessive enlargement of the bundle.
Groups of non-staggered splices need not be
replaced, however it may be necessary to use
extra clamps to support the added localized
weight.
c.
c.
Ensure that approved tape is wrapped around

wires in cable clamp adapters so that tightening
of the cable clamp provides sufficient grip on the
wires to keep tension from being applied to the
connector pins.
d. Ensure that unused plugs and receptacles are

appropriately sealed to avoid contamination. The
connectors should then be secured to the aircraft
structure or to other wiring that is properly
anchored.
e.
f.
Ensure that the coupling nut of MS connectors is

secured, by lock wire or other mechanical
locking means, as required by the applicable
aircraft maintenance manual.
Ensure that moisture-absorbent type material is
not used as fill under clamps or adapters.
g. Ensure that there is no evidence of deterioration

of potting compound in potted connectors.
h. When crimp contact connectors are used, the
unused contacts shall be installed. Sealing plugs
should be inserted in unused grommet holes of
environment resistant connectors.
Only environmentally sealed splices should be

used aircraft wiring for new and replacement
applications. Where non-environmental splices
are
currently
fitted,
replacement
with
environmental splices is only required when
original splices display signs of degradation.
Quick disconnect splices, designed for

disconnection without the use of tools, should
not be used.
d. There should not be more than one splice in any

wire segment between any two connectors or
other terminating points.
e.
Splices should not be used to salvage scrap

lengths of wire.
f.
Splices should not be used within 30cm of a

connector or other terminating point.
g. Splices should not be used on firing or control

circuits associated with ordinance or explosive
systems.
Junction Boxes, Panels, Shields and Micro-Switch
Housings.
8.
These housing assemblies should be examined
to ascertain the following:
a.
Suitable hole(s) smaller than 9.5mm diameter,

but not less than 3.1mm diameter, is (are)
provided at the lowest point(s) of the box(es),

Sect 2 Chap 18
except vapour-tight boxes, to allow for drainage

with the airplane on the ground and in level
flight.
b. Vapour-tight or explosion proof boxes are
externally labelled "vapour-tight" or "explosion
proof."
c.
Boxes are securely mounted.
d. Boxes are clean internally and free of foreign

objects.
e.
f.
Safety wiring is installed on all lid fasteners on

J-boxes, panels, shields, or micro-switch
housings which are installed in areas not
accessible for inspection in flight, unless the
fasteners incorporate self-locking devices.
There are no unplugged unused holes (except
drainage holes) in boxes.
Conduit - Rigid Metallic, Flexible Metallic and Rigid

Non-Metallic.
9.
Inspect conduit assemblies to ensure that:

a.
Conduit is installed so that strain and flexing of

ferrules is relieved.
b. Conduit is not collapsed or flattened from

excessive bending.
c.
Conduits are installed so that fluids or

condensed moisture will not be trapped. Suitable
drain holes shall be provided at the low points,
except for metallic flexible conduit.
c.
d. Self-tapping screws have not been used for

bonding purposes. Only standard threaded
screws or bolts of appropriate size should be
used.
e.
Exposed conducting frames or parts of electrical

or electronic equipment have a low resistance
bond of less than 0.1 ohm to structure.
f.
Bonding jumpers have been kept as short,

straight and direct as possible.
g. Bonds have been attached directly to the basic

aircraft structure rather than through other
bonded parts as far as practical.
h. Bonds have been installed to ensure that the
structures of aircraft are electrically stable and
free from the hazards of lightning, static
discharge, electrical shock, etc., and to provide
for the suppression of radio interference
resulting from these hazards.
Wire and Cable Junctions
11. Ensure that only approved devices, such as
solderless type terminals, terminal blocks, connectors,
disconnect splices and permanent splices are used for
wire and cable junctions. Inspect for compliance with
the provisions listed below:
a.
d. Bonding clamps are installed in a manner that

damage to the conduit cannot result.
e.
The diameter of wiring bundles installed in

conduits shall not exceed 80% of the conduits
inner diameter.
Electrical Bonds
10. An electrical bond is defined as any fixed union
existing between two metallic objects that results in
electrical conductivity between them. Such union
results from either physical contact between conductive
surfaces of the objects or from the addition of an
electrical connection between them. Other desirable
features which must be present in order for a good
bond to exist are as follows:
a.
Metallic conduit bonded to the aircraft structure

at each terminating and break point. The
bonding path may be through the equipment at
which the conduit terminates.
b. Bond connections are secure and free from

corrosion.
Bonding jumpers do not interfere in any way with

the operation of movable components of the
aircraft.
Electrical junctions are protected from short

circuits resulting from movement of personnel,
cargo, shell cases, clips, and other loose or
stored materials. Protection shall be provided by
covering the junctions, installing them in junction
boxes, or by locating them in such a manner that
additional protection is not required.
b. Exposed junctions and busses shall be protected

with insulating materials. Junctions and busses
located within enclosed areas containing only
electrical and electronic equipment are not
considered to be exposed.
c.
Electrical junctions shall be mechanically and

electrically secure. They shall not be subject to
mechanical strain or used as a support for
insulating materials, except for insulation on
terminals.
Switches, Toggle
12. In the event the following inspections reveal that
the switches are unserviceable, replace defective
switches with switches of the same type and current
rating. Inspect as follows:
a.
Conduct visual examination for physical damage

and that switches are securely attached to the
mounting panel.

Sect 2 Chap 18
b. Check for loose or deformed electrical

connections or evidence of corrosion of the
terminals, terminal lugs or screws.
c.
Switches that are exposed to direct water spray,

rain or heavy dust concentrations require more
frequent checks for manual operation, corrosion
and continuity.
Circuit Breakers
WARNING
Installed circuit breakers should be selected off and
all electrical power including batteries should be
disconnected prior to proceeding with inspection or
maintenance.
WARNING
Replacement circuit breakers must have equivalent
electrical characteristics
13. When replacement is necessary use circuit
breakers of the same type and current rating. Inspect
as follows:
a.
Ensure that the circuit breaker is firmly secured

to the mounting panel and there is no evidence
of physical damage.
b. Inspect for loose electrical terminations or

evidence of corrosion of the terminals, terminal
lugs and screws.
c.
Ensure positive manual operation by actuating

the push-pull button or toggle several times. This
operation also serves to remove any superficial
contaminates or foreign deposits present on the
surface of the internal electrical contacts.
d. Check for
overheating.
Test for electrical continuity, as measured across

the external breaker terminals. Use an
appropriate ohmmeter to determine that the
maximum electrical resistance does not exceed
one tenth (0.1) of an ohm. Intermittent or
excessive resistance readings normally indicate
that the internal breaker contacts are corroded.
In the event a few additional actuations of the
breaker do not correct this condition, the breaker
should be replaced. Continuity tests of installed
breakers require that the breaker be electrically
isolated from other circuitry to preclude
measurement of low resistance parallel systems.
This can usually be accomplished by opening
the switch or switches on the load side of the
breaker.
f.
Circuit breakers that are exposed to direct water

spray, rain, snow or heavy dust concentrations
require more frequent checks for manual
operation, corrosion, continuity, evidence of
burning or electrical arcing.
Check for manual operation by actuating toggle

lever several times. This also serves to remove
any superficial contamination or foreign deposits
on the internal electrical contacts
d. Test for electrical continuity as measured across

the external terminals by means of an
ohmmeter. Electrical resistance across any set
of closed contacts should not exceed one (1)
ohm. Intermittent or excessive resistance
normally indicates that the internal contacts are
corroded. In the event a few additional
actuations of the switch do not clear up this
condition, replace the switch with like item.
Continuity tests of installed switches require that
the switch be electrically isolated from other
circuitry to preclude measurement of low
resistance parallel systems. This can usually be
accomplished by opening the circuit breaker or
fuse on the line side of the switches.
e.
e.
evidence
of
circuit
breaker
Grounding/Bonding Receptacles
14. Inspect grounding/bonding receptacles for
serviceability in accordance with Section 2, Chapter 14,
Para 56. Replace defective items as required.

Sect 2 Chap 19
SECTION 2
CHAPTER 19
FIBRE OPTICS
INTRODUCTION
1.
This chapter provides general information on
the use, handling, termination and repair of fibre
optic cables.
e.
Destination. The destination equipment utilises

the electrical signal.
INFORMATION
2.
General. Fibre optics is a term describing a
lightwave or optical communication system used to
transfer information. In this type of system electrical
energy is converted to light, transmitted to another
location, and converted back to electrical
information. It consists of the following:
a.
Information Source. The information source

provides an electrical signal for transmission.
b. Transmitter. The transmitter or optical

source converts the electrical signal into an
optical
light
waveform
suitable
for
transmission. A light emitting diode (LED) is
most commonly used as the light source due
to its low drive voltage, small size, excellent
brightness and fast response time. Lasers
are also used as a light source and
appropriate safety precautions should be
observed.
c.
Fibre Optic Cable. The fibre optic cable

(Figure 19-1) provides a suitable medium for
transfer of the lightwave. It consists of an
optical fibre, which is a cylinder or core of
transparent dielectric, usually plastic or
glass, with a high refractive index,
surrounded by a second dielectric with a
lower refractive index, called the cladding.
Due to the fragile nature of these fibres, they
are covered with a protective cover or buffer
and a plastic jacket. A further strength
member of Kevlar or fibreglass and an outer
jacket are often added. The cable must be
interconnected with the least possible loss to
signal transmission. This loss can be caused
by End Separation (Figure 19-2), Lateral
Displacement (Figure 19-3) or Angular
Displacement (Figure 19-4).
d. Receiver. The optical receiver normally

consists of a photo detector, amplifier, filter
and demodulating electronics that are used
to convert the lightwave signal to an
electrical signal.
Figure 191 Typical Fibre Optic Cable

Construction
Figure 192 Loss Due To End Separation
NOTE
Numerical Aperture (NA) of an optical fibre is a
measure of the maximum angle at which light,
entering the fibre, will propagate in the core of the
fibre.

Sect 2 Chap 19
Figure 193 Loss Due To Lateral Displacement
3.
Advantages. The use of fibre optics
overcomes many problems associated with
conventional electrical wiring such as short circuits,
spark and fire hazard, intermittent problems caused
by
dirty
contacts,
and
electromagnetic
environmental effects (E3). By using multiple fibres
bundled together, the information carrying
capability is increased with a significant weight
reduction. Security is also improved as it is much
more difficult to tap into a fibre optic cable and
impossible to use an electromagnetic pickup.
4.
Disadvantages. Fibre optic cable is not as
flexible or robust as copper wire and requires extra
support and protection. Minium bend radius is
critical to avoid fracturing the optic fibre. Coupling
and alignment of fibres is time consuming and
critical as loss factors increase considerably if
these procedures are not carried out correctly.
Safety
5.
Following are the minium safety procedures
to be observed when working with fibre optics:
a.
Hazards to Sight. Radiation emitted from

optical fibre transmission or test equipment is
in the near infra-red (IR) region of the
spectrum and is invisible to the human eye.
Staff working with such equipment should be
aware of the hazards of exposure to radiation
that can result in serious and permanent
impairment of vision.
b. Safety glasses. Safety glasses should be

worn at all times when the bare fibre is being
worked as fibre fragments are small and
extremely sharp and, if mishandled, can
lodge in an eye.
c.
Fibre Off-Cuts. Glass fibre off-cuts or

fragments can be extremely sharp and are
difficult to locate using the unaided eye.
Immediately after cleaving, fibre off-cuts or
fragments should be placed in a specially
marked resealable plastic or glass container.
Figure 194 Loss Due To Angular Displacement
d. Cleaning Solvents. Cleaning solvents used

with optical fibres are volatile and highly
flammable. Use only in well ventilated areas
away from heat sources, flames and sparks.
Avoid contact with skin.
e.
General. Only the correct tools and equipment

should be used when working with optical fibres
or cable. All tools should be kept clean and in
good working order. Care should be exercised
when using cable cutters, cable sheath
strippers and other tools with cutting blades.
Installation Considerations
6.
Fibre optic cables are reasonably rugged and,
when handled by competent tradesmen, pose no
special problems.
7.
The installation should be planned to ensure
that the manufacturers recommended maximum
tensile and crushing forces are not exceeded.
8.
Minium bend radii must be observed at all
times. The tendency to keep it neat by exceeding the
minimum bend radius of the fibre optic cable, to match
installed looms, is to be avoided.
9.
As with copper wires, allowance in the length of
optic cable should be made to facilitate post
installation re-termination of connectors.
10. When using cable clamps
precautions should be observed:
a.
the
following
support clamps should be used as often as

practicable,
b. clamping force should be the minium required

to prevent slippage, and
c.
a small amount of cable slack should be

incorporated between clamps to allow for
temperature variations and vibration.

Sect 2 Chap 19
Connectors
11. The purpose of connectors in a fibre optic
system is to join fibre ends for efficient signal
transfer. Connectors are designed to be used in
applications where there is a requirement for the
fibre optic cable to be disconnected and
reconnected during system repair, maintenance
etc. Several types of fibre optic connectors are
currently available and fitting is to be carried out in
accordance with manufacturers instructions.
Fibre Optic Repairs
12. When damaged or broken, fibre optic cables
should be replaced from one permanent
termination to the next. Where this is impractical,
repairs must be accomplished so as to provide
minium signal loss.
13. Splicing. Splicing is an acceptable method of

repairing fibre optic cables. Splices must provide
precise alignment of the fibre ends when completed.
Several splicing methods are currently available with
the two most common methods being epoxy and
fusion splicing. Epoxy splicing is achieved by aligning
the prepared ends of the fibre with an alignment tool
and joining the fibre ends with epoxy. Index matching
fluid is sometimes used to minimise losses. An
alternate fibre joining method is to use fusion splicing.
With this method, the fibre ends are aligned by
manipulation under a microscope or by monitoring
optical throughputs, and the ends then fused by
electric arc. Splicing is to be carried out in accordance
with manufacturers instructions.

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1

AC 21-99(1): Aircraft wiring and bonding

AIRCRAFT WIRING AND BONDING

17. Aged Aircraft Wiring

RTCA DO-160D: Environmental Conditions and

The purpose of this Advisory Circular (AC) is to

This is the second issue of this Advisory Circular. It has

AC 21-99 Aircraft Wiring and Bonding

WIRE AND CABLE

IDENTIFYING WIRE AND CABLE

AC 21-99 Aircraft Wiring and Bonding

PREPARING WIRE AND CABLE

SOLDERLESS TERMINATIONS AND

WIRING MAINTENANCE PRACTICES INCLUDING REPAIRING WIRE

ELECTRICAL WIRING INSTALLATION

AC 21-99 Aircraft Wiring and Bonding

WIRING: LOCK, SHEAR AND SEAL

HARNESSESS, LACING AND TYING

GENERAL PURPOSE CONNECTORS

AC 21-99 Aircraft Wiring and Bonding

ELECTRIC CONNECTOR SEALING COMPOUND

EARTHING AND BONDING OF AIRCRAFT

BONDING AND GROUNDING

RF CONNECTORS AND CABLING

AC 21-99 Aircraft Wiring and Bonding

INSTALLATION OF BUSBARS, JUNCTION

AIRCRAFT ELECTRICAL SYSTEM INSPECTION

AGED AIRCRAFT WIRING

THERMOCOUPLE WIRE SOLDERING

Alphabetical Index for Section 2 Chapters 1 to 19

AC 21-99 Aircraft Wiring and Bonding

Airframe Wire Used In Aircraft Electrical Installations

Function and Designation Letters

AC 21-99 Aircraft Wiring and Bonding

Allowable Nicked or Broken Strands

Colour Coding of Copper Terminal Lug Insulation

AC 21-99 Aircraft Wiring and Bonding

SAE AS81824/1 Splice, Electric, Permanent Crimp Style,

Tape Lacing and Tying

Safety Wire - Identification

Stripping Lengths for Solder Connections

AC 21-99 Aircraft Wiring and Bonding

BNC & TNC Series M39012 Connectors and Associated Cables

Hardware for Stud Bonding or Grounding to Flat Surface

Parts List For Interconnection Leads

AC 21-99 Aircraft Wiring and Bonding

Wires Commonly Used In Aircraft

Example of ADF Wire Identification Coding

Wires After Cutting

Group and Bundle Ties

AC 21-99 Aircraft Wiring and Bonding

Slack Between Supports

AC 21-99 Aircraft Wiring and Bonding

Wire With Damaged Section Removed

Solderless Terminal Lugs and Splices

Soldering Iron Tip Before and After Cleaning

Single Cord Lacing