BHT-ELEC-SPM

ELECTRICAL STANDARD PRACTICES

MANUAL
FOR ALL BELL HELICOPTER COMMERCIAL PRODUCTS

NOTICE

The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
other directions issued by Bell Helicopter Textron Inc. and Airworthiness Directives (AD) issued by the
applicable regulatory agencies, shall be strictly followed.

COPYRIGHT NOTICE
COPYRIGHT 2012
BELL ® HELICOPTER TEXTRON INC.
AND BELL HELICOPTER TEXTRON
CANADA LTD.
ALL RIGHTS RESERVED

15 NOVEMBER 1996
REVISION 2 — 20 JULY 2012
BHT-ELEC-SPM

PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron Inc. Disclosure,

reproduction, or use of these data for any purpose other than helicopter
operation or maintenance is forbidden without prior written authorization from
Bell Helicopter Textron Inc.

DESTINATION CONTROL STATEMENT

These commodities, technology, or software were exported from the United

States in accordance with the Export Administration Regulations (EAR).
Diversion contrary to U.S. law prohibited. The data contained in this manual are
classified as ECCN EAR99.

Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron Inc.
P. O. Box 482
Fort Worth, Texas 76101-0482

PN Rev. 1 27 MAY 2011

REVISION ONLY BHT-ELEC-SPM

NOTICE

This revision updates the front matter and Chapters 8 and 11.

Chapters 8 and 11 are revised in their entirety so no change bars are shown.

Please incorporate these updates into the manual in accordance with the Log of
Pages attached.

Bell Helicopter Textron would like to thank its customers for providing us with
customer feedback. This information is appreciated and allows us to improve the
quality of our manuals with each revision.

15 NOVEMBER 1996
REVISION 2 — 20 JULY 2012
 BHT-ELEC-SPM

WARNING
THIS MANUAL APPLIES ONLY TO HELICOPTERS AND COMPONENTS
MAINTAINED IN ACCORDANCE WITH BELL HELICOPTER TEXTRON
(BELL) APPROVED PROCEDURES USING BELL APPROVED PARTS.

ALL INSPECTION, REPAIR AND OVERHAUL PROCEDURES PUBLISHED

BY BELL, INCLUDING PART RETIREMENT LIFE, ARE BASED SOLELY ON
THE USE OF BELL PARTS THAT HAVE BEEN MAINTAINED USING BELL
APPROVED DATA. THE DATA PUBLISHED HEREIN OR OTHERWISE
SUPPLIED BY BELL IS NOT APPLICABLE TO NON-BELL PARTS OR
PARTS THAT HAVE BEEN REPAIRED USING DATA AND/OR PROCESSES
NOT APPROVED BY BELL.

BELL IS NOT RESPONSIBLE FOR ANY PART OTHER THAN THOSE THAT
IT HAS APPROVED.

BEFORE PERFORMING ANY PROCEDURE CONTAINED IN THIS MANUAL

YOU MUST INSPECT THE AFFECTED PARTS AND RECORDS FOR
EVIDENCE OF ANY MANUFACTURE, REPAIR, REWORK OR USE OF A
PROCESS NOT APPROVED BY BELL.

IF YOU IDENTIFY OR SUSPECT THE USE OF PARTS NOT AUTHORIZED

BY BELL, EITHER REMOVE THE AFFECTED ITEM FROM THE AIRCRAFT
OR OBTAIN INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FROM
THE MANUFACTURER OR THE ORGANIZATION THAT APPROVED THE
REPAIR.

27 MAY 2011 Rev. 1 Warning

BHT-ELEC-SPM

CUSTOMER SUPPORT AND SERVICES

Flying smart means that no matter where you are, or what time it is, you can make a call
and get additional information, clarification, or advice on a technical or operational issue
concerning your helicopter or information contained in our Technical Publications.
Product Support Engineering (PSE) is just a phone call away and may be contacted as
follows:

Model 206 or 407

Phone: 450-437-2862 or 800-243-6407 (U.S./Canada)
Fax: 450-433-0272
E-mail: pselight@bh.com

Model 222, 230, 427, 429, or 430

Phone: 450-437-2077 or 800-463-3036 (U.S./Canada)
Fax: 450-433-0272
E-mail: pseinter@bh.com

Model 204, 205, 212, or 412

Phone: 450-437-6201 or 800-363-8028 (U.S./Canada)
Fax: 450-433-0272
E-mail: psemedium@bh.com

Model 214, 210, HUEY II and All Bell’s Active and

Surplus Military Medium Helicopter Models
Phone: 817-280-3548
Fax: 817-280-2635
E-mail: mts-medium@bh.com

Model OH-58, TH-67, TH-57, Both Active and Surplus

Military
Phone: 817-280-3548
Fax: 817-280-2635
E-mail: mts-light@bh.com

For additional information on Customer Support and Services as well as Product Support
Engineering (PSE) and your local Customer Service Engineering (CSE) network, please
access http://www.bellhelicopter.com/support.

CSS Rev. 2 20 JUL 2012

 BHT-ELEC-SPM

SPARE PARTS WARRANTY

ONE YEAR/1,000 HOURS PRORATED

WARRANTY AND REMEDY: Seller warrants each new helicopter part or helicopter part reconditioned by seller to be free from defect
in material and workmanship under normal use and service and if installed on Bell model helicopters. Seller’s sole obligation under this
warranty is limited to replacement or repair of parts which are determined to Seller’s reasonable satisfaction to have been defective
with 1,000 hours of operation or one (1) year after installation, whichever occurs first and reimbursement of reasonable freight charges.
After 200 hours of use, there will be a prorated charge to the Purchaser for replacement parts (prorating the hours of total use against
the then applicable part life or 2,000 hours, whichever is the lesser). Defective parts must be reported in writing to the Seller’s Warranty
Administration within 90 days of being found defective. Replacement of parts may be with either new or reconditioned parts, at Seller’s
election. Warranty adjustment is contingent upon the Purchaser complying with the Warranty Remedies as described in the
Commercial Warranty Information brochure and the Seller’s Warranty Administration disposition instructions for defective parts. Failure
to comply with all of the terms of this paragraph may, at Seller’s sole option, void this warranty.

NOTE: Parts, components and assemblies of all new helicopters may have been restored or reworked due to mars, blemishes, dents
or other irregularities during the manufacturing process. Such restoration and/or rework is permitted under Seller’s approved
manufacturing and engineering processes and guidelines. The restoration and/or rework so completed does not render such items
defective in material or workmanship.

THIS WARRANTY IS GIVEN AND ACCEPTED IN PLACE OF (i) ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS OF MERCHANT ABILITY AND
FITNESS FOR A PARTICULAR PURPOSE AND (ii) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACTOR
IN TORT (DELICT), INCLUDING PRODUCT LIABILITIES BASED UPON STRICT LIABILITY, NEGLIGENCE, OR IMPLIED
WARRANTY IN LAW.

This warranty is the only warranty made by Seller. The Purchaser’s sole remedy for a breach of this warranty or any defect in a part is
the repair or replacement of helicopter parts and reimbursement of reasonable freight charges as provided herein. Seller excludes
liability, whether as a result of a breach of contract or warranty, negligence or strict product liability, for incidental or consequential
damages, including without limitation, damage to the helicopter or other property, costs and expenses resulting from required changes
or modifications to helicopter components and assemblies, changes in retirement lives and overhaul periods, local customs fees and
taxes, and costs or expenses for commercial losses or lost profits due to loss of use or grounding of helicopters or otherwise.

Seller makes no warranty and disclaims all liability in contract or in tort (delict), including, without limitation, negligence and strict tort
(delictual) liability, with respect to work performed by third parties at Purchaser’s request and with respect to engines, engine
accessories, batteries, radios, and avionics, except Seller assigns each manufacturer’s warranty to Purchaser to the extent such
manufacturer’s warranty exists and is assignable.

This warranty shall not apply to any helicopter part which has been repaired or altered outside Seller’s factory in any way so as, in
Seller’s judgment, to affect its stability, safety or reliability, or which has been subject to misuse, negligence or accident, or which has
been installed in any aircraft which has been destroyed unless that helicopter has been rebuilt by Bell. A list of destroyed aircraft is
obtainable from Bell Product Support. Repairs and alterations which use or incorporate parts and components other than genuine Bell
parts or parts approved by Bell for direct acquisition from sources other than Bell itself are not warranted by Bell, and this warranty shall
be void to the extent that such repairs and alterations, in Seller’s sole judgment, affect the stability, safety or reliability of the helicopter
or any part thereof, or damage genuine Bell or Bell-approved parts. No person, corporation or organization, including Bell Customer
Service Facilities, is authorized by Seller to assume for it any other liability in connection with the sale of its helicopters and parts.

NO STATEMENT, WHETHER WRITTEN OR ORAL, MADE BY ANY PERSON, CORPORATION OR ORGANIZATION, INCLUDING
BELL CUSTOMER SERVICE FACILITIES MAY BE TAKEN AS A WARRANTY NOR WILL IT BIND SELLER.

Seller makes no warranty and disclaims all liability with respect to components or parts damaged by, or worn due to, corrosion. Seller
makes no warranty and disclaims all liability for consumables (wear items) which are defined as items required for normal and routine
maintenance or replaced at scheduled intervals shorter than the warranty period. “Consumables” include but are not limited to engine
and hydraulic oil, oil filters, packings and o-rings, anti-corrosion and/or sealing compounds, brush plating material, nuts, bolts, washers,
screws, fluids, compounds, and standard aircraft hardware that is readily available to aircraft operators from sources other than Seller.

All legal actions based upon claims or disputes pertaining to or involving this warranty including, but not limited to, Seller’s denial of any
claim or portion thereof under this warranty, must be filed in the courts of general jurisdiction of Tarrant County, Texas or in the United
States District Court for the Northern District of Texas, Ft. Worth Division located in Ft. Worth, Tarrant County, Texas. In the event that
Purchaser files such an action in either of the court systems identified above, and a final judgment in Seller’s favor is rendered by such
court, then Purchaser shall indemnify Seller for all costs, expenses and attorneys’ fees incurred by Seller in defense of such claims. In
the event Purchaser files such a legal action in a court other than those specified, and Seller successfully obtains dismissal of that
action or transfer thereof to the above described court systems, then Purchaser shall indemnify Seller for all costs, expenses and
attorneys’ fees incurred by Seller in obtaining such dismissal or transfer.

January 2007

27 MAY 2011 Rev. 1 Warranty

 BHT-ELEC-SPM

LOG OF REVISIONS

Insert latest revision pages and dispose of superseded ones.

On a revised page, the text and/or illustration affected by the latest revision is shown by a vertical line. A revised
page with only a vertical line next to the page number indicates that text has shifted or that non-technical
correction(s) were made on that page.

Original ........ 0 ........... 15 NOV 96 Revision ...... 1............ 27 MAY 11 Revision .......2 ............ 20 JUL 12

LOG OF PAGES

Page No. Rev No. Page No. Rev No. Page No. Rev No.

Cover .........................................1 5/6.............................................. 1 Chapter 8

Title ............................................2 1 – 38 .........................................2
PN ..............................................1 Chapter 3
Warning......................................1 1/2.............................................. 1 Chapter 9
CSS............................................2 3 – 28......................................... 1 1/2 ..............................................1
A/B .............................................2 29/30.......................................... 1 3 – 22 .........................................1
Help............................................1 23/24 ..........................................1
Customer Feedback...................1 Chapter 4
Helicopter Sales Notice..............1 1 – 56......................................... 0 Chapter 10
Warranty.....................................1
BR ..............................................1 Chapter 5 1/2 ..............................................0
TR ..............................................1 1/2.............................................. 0 3 – 6 ...........................................0
i/ii................................................1 3 – 30......................................... 0
Chapter 11
Chapter 1 Chapter 6 1 – 2 ...........................................2
1/2 ..............................................1 1 – 2........................................... 0 3/4 ..............................................2
3 – 6 ...........................................1 3/4.............................................. 0 5 – 40 .........................................2
5 – 50......................................... 0
Chapter 2 Alphabetical Index
1/2 ..............................................1 Chapter 7 Deleted.......................................1
3 – 4 ...........................................1 1 – 32......................................... 0

20 JUL 2012 Rev. 2 A/B

 H ELF

E VALUATE

L
P
Have you found something wrong with this manual — an
error, an inconsistency, unclear instructions, etc.? Although
we strive for accuracy and clarity, we may make errors on
occasion. If we do and you discover it, we would appreciate
your telling us about it so that we can change whatever is
incorrect or unclear. Please be as specific as possible.

Your complaint or suggestion will be acknowledged and we

will tell you what we intend to do.

You may use the enclosed Customer Feedback form, as

applicable, to inform us where we have erred.

Your assistance is sincerely appreciated.

 CUSTOMER FEEDBACK

RETURN VIA FAX TO PRODUCT SUPPORT ENGINEERING (450) 433-0272

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Manual Number (If assigned): __________________________________________
Date of Issue:
Date of Last Revision: ________________________________________________
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What is the Complaint?_________________________________________________

Now Reads:

Should Read:

Your Name:
Address:

Position:__________________________Telephone No. ____________________

Company: _____________________________ Fax No. ___________________
Reference No. (Your Initials and Date): ___________________________________

(Ifyou choose to mailthis form,fold in thirds, with address exposed, tape and mail.)
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updates to their Bell Helicopter Textron Technical Manuals and Bulletins.

Model of Helicopter Sold or Purchased ___________________________________________

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 BHT-ELEC-SPM

BULLETIN RECORD

This Bulletin Record provides a current listing of applicable bulletins that have been incorporated in this manual.
Subsequent applicable bulletins will be incorporated in future revisions/reissues.

ALERT SERVICE BULLETINS

ASB NUMBER SUBJECT DATE

TECHNICAL BULLETINS

TB NUMBER SUBJECT DATE

27 MAY 2011 Rev. 1 BR

BHT-ELEC-SPM

TEMPORARY REVISION RECORD

This Temporary Revision Record provides a current listing of active Temporary Revisions against the manual.
Temporary Revisions, which have been canceled/incorporated, will only be maintained on the record until the next
revision is issued. If there are no Temporary Revisions shown on the record, this is confirmation that there are no
Temporary Revisions issued against the manual.

TEMP. REV. NO. TITLE DATE ISSUED DATE CANCELED

NOTE: For tracking purposes, Temporary Revisions are now being numbered (Example: TR-1).

TR Rev. 1 27 MAY 2011

 BHT-ELEC-SPM

LIST OF CHAPTERS

Title Chapter

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Circuit, Component, Wire, Cable, and Harness Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Maintenance Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connector Contacts and Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wiring Harnesses and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RF Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bonding and Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Consumable Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Nickel Cadmium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

27 MAY 2011 Rev. 1 i/ii

 BHT-ELEC-SPM

ALPHABETICAL INDEX
Paragraph/Table! Paragraph/Table!
Subject Figure Number Subject Figure Number
A Boot installation F6-37
Boot installation with expandosleeve F6-30
Allowable nicked or broken strands in BNC and INC seriesconnectors 7-5
copperwire T4-1 BNCconnectorstripping and assembly F7-12
Alternate termination method of gross Branchties F6-25
shield T4-15
AMP C
Crimping tool for high temperature
terminals F4-39 C and SC connectors 7-7, F7-14
Hydraulic hand crimper F4-36 Cconnector 7-8
Antichafing rework instructions 6-13 SCconnector 7-9
Harness to component rework 6-14 Cable crimping instruction F7-15
Harness to structure rework 6-15 Cablepreparation F4-18
Harnesstolinerework 6-16 ForTNCconnectors F7-l3
Insulation damage repair 6-17 Cablestripping
Approximate soldering iron sizesfor tinning . . . T4-43 instructions F7-17
Attaching improved N connector F7-18 outerjacket F7-6
ATUM Cabletypes 6-3
Patch F6-16 Cablecrimping instruction F7-l5
Tubingbackshell F6-13 Calibrationofequipment 11-37
Automatic stop after discharge 11 -78 Cell construction Fl 1 -20
Cell fatigue (cellophane barrier) test 11-73
B Cellpuller Fll-21
Cell shorting clips Fll-l8
BandingtoolandbandsA-100 F6-32 Cell shorting clips workaid Fli-lO
Basicseriesof connectors F7-3 Cell voltage balance test duringconstant
or
Batteryacceptance rejection criteria 11 -62 currentcharge Fll-72
Batteryconstruction F11 -2 Center strip preparation T4-4
Batterycontainer F11-1 Chafing 6-7
Batterydata T11-5 Harness to component 6-10
Batteryhistorycard F11-11 Harness to harnesschafing 6-9
Batteryinspection 11-81 Harnesstoline 6-12
Batteryservice record F11 -1 Fl
2, 1-13 Harness to structure 6-11
Batteryservicing procedures Inspection 6-8
Batteryanalysis and acceptance Chargeand overcharge equations Tll-l
criteria 11-61 Charging characteristics 11-17
Operational characteristics 11-57 Charge/discharge techniques 11-19
RF8OHautomatic reflect charger/ Charge techniques 11-20
analyzer 11-56 Charging efficiency 11-18
using model PCA-l 31 seriesto charge Discharge techniques 11-23
and analyzeaircraft nickel-cadmium Charging only 11-74
batteriesautomatically 11-89 Charging the batteries 11-108
using model RF8OH automatic reflex Charging voltage requirement Fll-26
charge/analyzer 11-55 Circuit, component, wire, and cable
Batteryschematic Fl 1-22 harnessdesignations 1-3
Batteryshop safetyprocedures 11-38 Circuitfunctions T3-l
Bonding and grounding 1-8 Circuitidentification F3-2
Bonding of structures Clamping at bulkhead hole F6-ll
by directcontact F8-5 Cleaning procedures prior to bonding F8-4
by direct contact/assembly using fasteners Coaxial cable
or connectors F8-6 cushion clamp insert F6-9

Index1
BHT-ELEC-SPM

ALPHABETICAL INDEX (Cont)

Paragraph/Table! Paragraph/Table/
Subject Figure Number Subject Figure Number

stripperblade set F7-5 Power contactsper MIL-C-39029 5-8

Coaxial RF Relay socketto powercontactto relay
cable assemblies 1-7 cross reference 5-9
connectorcrimping 5-12 Correct crimped connectorpin F4-29
Coaxial, triaxal, and twin axial applications T6-4 Correct shape for soldering tip F7-7
Color coding of copperterminallug Correct solderapplication F4-7
insulation T4-23 Crimpcontacttooling F5-1
Comparison of discharge voltagefor typical Crimptool inspection
lead-acid and nickel-cadmium helicopter gages 14-18
storagebatteries F11-7 tool guide F4-30
Component symbols 3-3, F3-3 Crimptools 5-5
Connecting aluminum Crimptools MS22520/5-01 and 110-01 F4-42
terminal to aluminum busbar F6-48 Cross-sectional view of wire harness F6-34
terminal to copperbusbar F6-50 Cylindrical sealed cell F11-6
Connecting copper
terminal to aluminum busbar F6-49 D
terminalto copperbusbar F6-51
Connecting terminal lugs to terminalboard . . . F6-44 Dageconnectors 7-13

Connections to busbars 6-43 Assembly— dage DM type connector 7-14

Connecting terminallugs to busbars 6-4 Assembly— triax type 7-15
Definitions and descriptions 7-3
Hardware for connecting to busbars 6-45
Dimensions from cable jacketto end of
Connections to terminal boards 6-38
conductor 14-7
Connecting terminalboards 6-39
Dimensions of kit material and cross reference
Hardware for wiring terminalboards 6-40
Connector contactsand tooling 1-5 of material to kits 14-11
4-11 Discharge characteristics 11-16
Connectorpotting
Discharge equations 111-2
Connector powercontactper MIL-C-39029 T5-2
DM connector F7-22
Connectortooling T5-7 —
DM miniature exploded view and
Connectortooling 17-2
Connectors 5-1
installation F7-25
Connectorcontacts 5-2 DM miniature plugs and receptacles F7-24
Pin and socketidentification 5-3 Doublecord lacing F6-22
Connectors and contactsby vendor part E
number 5-10,15-5
Constant current power supplyusedas Eagle-pitcher recommended procedure 11 -102
discharge unit F11-8 Electrical bonding procedures 8-6
Construction 11-2 Electrical inspection 11-83
Cylindrical sealedcell 11-6 Electrolyte adjustment 11-110
Electrolyte 11-7 Electrolyte adjustmentprocedures 11-111
Principal parts and material 11-3 Electrolyte level
Consumable material list 110-1 adjustment Fl1-27
Consumable materials 1-10 and removalsyringe Fll-14
Contact and wire size range 14-19 check 11-68
Contact crimping 5-4 checkduring charge 11-71
Contact crimpingprocedures 4-7 End strip preparation 14-5
Contactinsertion/removal 4-8 End stripwith braid fold-backpreparation 14-6
Crimping solderless terminations 4-9 Entire unitis inserted in cell case and
Crimping splices 4-10 sealed Fll-5
Contactinsertion/removal 5-6 Environmental splices and associated
Connectorpowercontact per crimptools 14-25
MIL-C-39029 5-7 Example — shield cable splice F4-25

Index 2
 BHT-ELEC-SPM

ALPHABETICAL INDEX (Cont)

Paragraph/Table! Paragraph/Table!
Subject Figure Number Subject Figure Number
F

Factorsaffecting servicelife 11-40 Idealcoaxial cable stripper F7-4, T7-1

Adjustment of electrolyte level 11-41 Improved N connector— exploded view F7-19
Electrolyte requirements and Initial assemblyof wire harness F6-33
adjustments 11-52 Initial setting beforeturn on and
General warnings 11-46 adjustments 111-6
Overheated nickel-cadmium batteries . . . . 11-45 lnsertingconductor F4-11
Storage/shipping 11-51 Insertion and extraction tools for front
Temporary loss of capacity 11-47 release crimp-type contacts F4-31
Fillingandcuringofpotting F4-49 Insertion of wire into insulation restriction
Filmtype resistors color code T3-3 terminallug F4-41
Fold of individual shield around backshell . . . . F6-35 Insertion/removal tool for rear release
contacts 14-20
G Inspection and maintenance check 11-94
Inspection, charging, and analysis
General
procedures 11-80
Electrical bonding and grounding 8-1
Generalmaintenance procedures 4-1
Installation and removal of crimpcontacts .... F4-32
Installation of
Safety hazards 2-1
primarysupports F6-7
Wire/cable cutting 4-2 shield terminalband F6-36
Wire/Cable stripping 4-3
harnesses and cable assemblies . . . . 6-1
torquesfor aluminum terminal 16-9
Wiring
Generaldescription torquesfor copperterminal 16-8
wiring nearflammablelines F6-1 9
Circuit, component, wire and cable Installation torques
harnessdesignations 3-1 for aluminum terminals 6-42
Consumable materials 10-1
for copper terminals 6-41
Introduction
RF cableassemblies
1-1
7-2 Installing self-clinching plasticcable straps ... F6-28
Insulation damagerepair F6-20
General maintenance practices 1-4 Insulation sleeving/tubing F4-13
GO/NO-GO decision in discharge cycle 11-66 Internal resistance — typicalvalues 111-3
H
J
Hand mixing potting compound F4-47
Hardware for bolt and nut bonding or grounding
to flat surface F8-2 K
Hardware for nutplate bonding or grounding
to flat surface F8-3 Kits (D-150-XXXX)
Hardware for stud bonding or grounding to for mixedgage splices 14-9
flat surface F8-1 for 1 to 1 splice 14-8
Hardware for wiring terminalboards
with aluminum terminals F6-46 L
with combination of terminals F6-47
with copper terminals 8-3 Lacing 6-22
Hardware selection 8-3 Branch ties 6-27
Harness assemblyto connectoradapter Double cord lacing 6-25
EMI termination F6-31 General 6-23
— band-itinstallation 6-35 Single cord lacing 6-24
— detail instruction 6-36 Spot-ties 6-29
Helicopterelectrical cable F6-1 Tying groupswithin bundles 6-28
Hydrauliccrimphead F4-37 Lacingand tying in high temperature areas 6-32

Index3
BHT-ELEC-SPM

ALPHABETICAL INDEX (Cont)

Paragraph/Table! Paragraph/Table!
Subject Figure Number Subject Figure Number
N
High temperature pressure sensitive
tape 6-33
Nconnector F7-16
Lacing branch-off F6-23
N connectors
Locating MS25181 splice in MS90413-2
F4-46 with captivated contacts F7-21
crimpingtool
with captivated contacts— exploded
Locating sealedsplice crimp barrel in
view F7-20
crimping dies F4-44
N seriesconnectors 7-10
Lockwiring connectorto structure F6-41
Lockwiring electrical connectors 6-37, Improved N connectors 7-11
F6-38, F6-43 Captivated contact N connector 7-12
Nickel-cadmium
Lockwiring of RF connectors F6-39
batterymaintenance 1-11
helicopter storage battery 11-1
M
specialequipmentand tools 111-4

Maintenance 11-105 0
Maintenance and reconditioning schedules . . . . 11-93
Makingties F6-24 Octadent crimp F4-27
Manual selection of discharge mode 11-77 Operating procedureafter powerfailure 11-79
Marathon aircraft battery, model PCA-131/ Operation and maintenance 11-103
PCA-131, 50/60 seriescharger/analyzer . . . . 11-88 Operation of batteryshop 11-29
Marathon model PCA-131/PCA-131, 50/60 Batteryrecords 11-33
seriescharger/analyzer controlsand Separation of lead-acid and alkaline
indications F11-17 batteryfacilities 1 1 -32
Materiallist T4-10 Separation of nickel-cadmium and lead-acid
Materialpreparation 8-4 batteryfacilities 11-31
Mating polarities F7-23 Special equipmentand tools 1 1 -36
MIL- Training of personnel 11-30
0-27500 cablecharacteristics T6-2 Operational characteristics 11 -90
W-22759partnumberbreakdown F6-2 Operations 11-104
W-25038 part number breakdown F6-3 Optional procedures 11-69
W-81044 part number breakdown F6-4
W-81381 part number breakdown F6-5 P
Military standard solderless terminals for
helicopter use 14-21 Pin and socketidentification 15-1
for
Mixing paddle potting compound F4-48 Plastic cable straps 6-30
Modification of terminated harness 14-17 Installation 6-31
MS21919WDG cushionclamp part number Plastic clamp part number to diameter 16-6
to diameter 16-5 Position termination in reflector F4-17
MS27495 tweezer-type insertion/removal Positioning of conductors F4-12
tool F4-33 Powerconnectortorquingguide F11-23
MS90387 adjustable hand tool F6-29 Powercontactsper MIL-C-39029 15-3
M22520 series die-type crimp tool F4-40 Pre-insulated terminal— cutaway F4-35
M81969/14plastic-type insertion/removal Precautions when replacing existing
tool F4-34 connections 6-46
M83519/1 Connecting two terminals to samepoint
termination F4-15 on busbar 6-47
termination placement F4-1 6 Precautions of busbarsagainst
M83519/2 accidental shorting 6-48
termination placement F4-20 Principles of operation 11-8
termination selection F4-19 Capacity 11-12

Index 4
 BHT-ELEC-SPM

ALPHABETICAL INDEX (Cont)

Paragraph/Table! Paragraph/Table!
Subject Figure Number Subject Figure Number
Electrochemical action 11-9 Special wire and cable applications 16-3
Factors affecting capacity 11-13 "Stack-up" is prepared Fl1-3
Procedures 8-2 Staggered splices in wire bundle F4-43
Properly strippedand tinnedconductor F4-5 Standard setup and operation 11-84
Protective boot — with cable clamp 6-34 Storage 11-107
Stowage of electrical wiring and connectors . . . . 6-19
Q General 6-20
Instructions 6-21
R Strap application for wire bundle F6-27
Stripping lengths— splices 14-26
Raychem environmental butt splices F4-45 Stripping wire with hand stripper F4-1
RE type resistance code 13-4 Sub-miniature — DM connectors 7-16
Readingahydrometer F11-15 Surface preparation 8-5
Reconditioning nickel-cadmium batteries 11-98 Syrings needle modification F11-28
Reference designators 3-5, 13-2
Refinishing 8-8 T
Relay socket to power contact to relay cross
reference 15-4 Temperature sensor
RERtype resistance code 13-5 conversion chart F11-25
Resistance of electrical bonds 18-1 test harness Fl1-24
Resistor characteristic codes 3-6 Terminal of splice positioning F4-38
RF cable assemblyprocedures 7-4 Terminals are weldedto "stack-up" F11-4
RF cables and connectors 7-1 Terminating multiple shieldedcables F4-24
RF8OHautomatic reflex charger/analyzer using pigtails F4-23
controls and indicators F11-16 with solder sleeves F4-21
Ring lug and wire splicestrip length 14-2 Termination of
Routing bundles F6-6 bundle shielded and jacketedcable 14-13
grossshield harness(containing primary
S wiresonly) 14-16
grossshieldedharness (containing shielded
Safetyand hazards 1-2 and jacketedcableswith or without
Safetypractices 2-2, 6-2 primarywires) 14-14
Sealing 8-7 shield and jacketedfilter lihe cable 14-12
Semiconductor maintenance 4-12 Test equipment and special tools 1-9
Separation of main wire bundles F6-15 Test of bond resistance 8-9
Service loopantichafing techniques F6-1O Thermocouple contactcrimping 5-11, 15-6
Shield termination F4-22 Tightening braid clampnut in plug of
Singlecord lacing F6-21 jack body F7-11
Solder quantity F4-14 Tinning conductor F7-8
Soldering 4-4 Tinning inside of contact F7-9
Shield cablesplices 4-6 Tinning soldering iron tip F4-3
Soldershield terminations 4-5 Tinning wire with a soldering iron F4-4
Soldering contactto coaxial cable F7-10 INC connector 7-6
Soldering iron Turret head crimper F4-28
holder F4-8 Turretterminal
tip before and aftercleaning F4-2 conductorposition F4-10
tip shapes F4-6 conductorwrap F4-9
Special tools Tying groupswithin bundles F6-26
and test equipment 9-1 Typical coaxial cables F7-1
list 19-1 Typical RF connectors F7-2

Index5
BHT-ELEC-SPM

Subject

Visual inspection

Wire harnessto
.
component chafing
structure chafing
Wire identification code
U

Wire installation across hinge point

Wire split shell assemblyscrews
Wire stripping
for2through8wire
ALPHABETICAL INDEX (Cont)
Paragraph/Table!

lengthsfor small copperterminallugs

Wire types
(insulation restriction)

Applications
Wiring installation
Figure Number

Washers for usewith aluminum terminal lugs

Wire and cable data
Wire end caps
11-82

.. . T6-7
T6-1
14-27

F6-17
F6-18
F3-1
F6-14
F6-42

14-22

14-24
6-4
6-5
6-6
Subject

Wiring AN type connector

Wiring drip loop
Wiring harnesses
and cable assemblies
and cable designation
Wiring identification code
Wiring support

0.5tol.Oohmworkaid
xYz

1.0 ohm, 2 watts resistor

4indenturecrimp
0

4
Paragraph/Table!
Figure Number

F6-40
F6-12

1-6
3-4
3-2
F6-8

F11-9

Fl1-19

F4-26

Index 6
 BHT-ELEC-SPM

CHAPTER 1 — GENERAL INFORMATION

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

1-1 Scope of the Manual.................................................................. 1-00-00 3

1-2 Supplemental Documents .................................................... 1-00-00 3
1-3 Customer Feedback ............................................................. 1-00-00 3
1-4 General Information — Use of the Manual ................................ 1-00-00 3
1-5 Use of the Manual — Document Structure........................... 1-00-00 4
1-6 Use of the Manual — Revision Status and List of
Effective Pages .................................................................... 1-00-00 4
1-7 Use of the Manual — Warnings, Cautions, and Notes ......... 1-00-00 4
1-8 Use of the Manual — Materials Required............................. 1-00-00 5
1-9 Use of the Manual — Special Tools ..................................... 1-00-00 5
1-10 Use of the Manual — Symbols ............................................. 1-00-00 5
1-11 Use of the Manual — Torques.............................................. 1-00-00 5

FIGURES

Figure Page
Number Title Number

1-1 Use of Manual — Symbols ............................................................................. 6

1-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 1/2
 BHT-ELEC-SPM

GENERAL INFORMATION

1-1. SCOPE OF THE MANUAL NOT RESPONSIBLE FOR PARTS OR

PR OC ES SE S O TH ER THAN THO SE
WHICH IT HAS ITSELF DEVELOPED OR
NOTE APPROVED.
An electronic copy of this manual is
available via the Electronic Commercial 1-2. SUPPLEMENTAL DOCUMENTS
Technical Publications Web site at
www.bellhelicopter.net. Technical Bulletins (TB) and Alert Service Bulletins
(ASB) are published when necessary. These
This manual contains information and procedures that documents supplement the Electrical Standard
are common to primary electrical installations in all Practices Manual (BHT-ELEC-SPM) and provide
Bell helicopters. In addition to providing data instructions and data to replace or modify components
concerning safety and hazards, information necessary or systems, and perform maintenance practices on the
to locate, repair, and replace wiring, cables, or helicopter. When a bulletin affects the way the
components to maintain the manufacturers standards helicopter is maintained, it is incorporated in the
of performance and quality is provided. This manual is BHT-ELEC-SPM at the next available opportunity.
not intended for use as a design document. Refer to the bulletin record (page BR) for the list of
bulletins that have been incorporated in the manual.
Electronic systems such as navigation and
communication, or power sources such as alternating Temporary Revisions (TR) are published when
current (AC) inverters or direct current (DC) necessary. TRs supersede the content of the
generators, etc., require the use of maintenance BHT-ELEC-SPM on the applicable page range. Refer
practices and procedures specified by the to the temporary revision record (page TR) for a list of
manufacturer of that equipment. active temporary revisions against the manual.

1-3. CUSTOMER FEEDBACK

WARNING
Bell Helicopter Textron (BHT) strives to provide you,
the customer, accurate and straightforward manuals.
ALL REPAIR AND OVERHAUL Sometimes, we may make mistakes. If you find any
PROCEDURES LIVES PUBLISHED BY mistakes, we would appreciate it if you told us. Your
BELL HELICOPTER TE X T R O N , observation, suggestion, or complaint will be
INCLUDING COMPONENT RETIREMENT acknowledged.
LIFE, ARE BASED SOLELY ON THE USE
OF BELL APPROVED PARTS AND For your convenience, we have included a Customer
PROCESSES. IF PARTS OR Feedback form at the beginning of the Electrical
PROCESSES DEVELOPED OR Standard Practices Manual (BHT-ELEC-SPM). You
APPROVED BY PARTIES OTHER THAN can send it by fax or mail it to us. When you tell us
BELL HELICOPTER ARE USED, THEN about a mistake that is found in the MM, please be as
THE DATA PUBLISHED OR OTHERWISE specific as possible. Your help to make sure that this
SUPPLIED BY BELL HELICOPTER ARE publication is correct is very much appreciated.
NOT APPLICABLE. THE USER IS
WARNED TO NOT RELY ON BELL 1-4. GENERAL INFORMATION — USE OF
HELICOPTER DATA FOR PARTS AND THE MANUAL
PROCESSES NOT APPROVED BY BELL
H E L C I O P T E R. A L L A P P L I C A B L E The instructions provided in the Electrical Standard
INSPECTIONS AND REPAIR METHODS Practices Manual (BHT-ELEC-SPM) and those
MUST BE OBTAINED FROM THE modified either by Alert Service Bulletins (ASB) issued
SUPPLIER OF THE PARTS OR by Bell Helicopter Textron (BHT), or by Airworthiness
PROCESSES NOT APPROVED BY BELL Directives (AD) issued by the local Aviation Authority,
HELICOPTER. BELL HELICOPTER IS shall be strictly followed.

1-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 3
BHT-ELEC-SPM

1-5. USE OF THE MANUAL — DOCUMENT 1-6. USE OF THE MANUAL — REVISION
STRUCTURE STATUS AND LIST OF EFFECTIVE PAGES

The revision status of the manual is provided in the log

NOTE
of revisions at the beginning of the Electrical Standard
A list of all the chapters contained in this Practices Manual (BHT-ELEC-SPM) (page A/B) and
manual is provided at the beginning of the on the title page of the manual. The log of pages
Electrical Standard Practices Manual provides the revision status of every page in the
(BHT-ELEC-SPM) (page i/ii). manual.

The BHT-ELEC-SPM is divided into 11 chapters as

1-7. USE OF THE MANUAL — WARNINGS,
follows:
CAUTIONS, AND NOTES

VOLUME 1 — GENERAL INFORMATION WARNING

Chapter 1 General Information

Chapter 2 Safety and Hazards A MAINTENANCE PROCEDURE,
PRACTICE, ETC. THAT, IF NOT
Chapter 3 Circuit, Component, Wire, Cable, STRICTLY OBSERVED, COULD RESULT
and Harness Designations IN PERSONAL INJURY OR DEATH.
Chapter 4 General MaintenanceTechniques

Chapter 5 Connector Contacts and Tooling

CAUTION
Chapter 6 Wiring Harnessses and Cable
Assemblies
A MAINTENANCE PROCEDURE,
Chapter 7 RF Cable Assemblies
PRACTICE, ETC. THAT, IF NOT
Chapter 8 Bonding and Grounding STRICTLY OBSERVED, COULD RESULT
Chapter 9 Special Tools IN DAMAGE TO EQUIPMENT OR TO THE
HELICOPTER.
Chapter 10 Consumable Materials

Chapter 11 Nickel Cadmium Batteries NOTE

A note provides supplemental data about
the procedure, practice, condition, etc. for
A Table of Contents (TOC) is provided at the beginning the required maintenance task.
of every chapter of the BHT-ELEC-SPM. Each TOC
reflects the breakdown of the chapter into sections and Warnings, cautions, and notes are used throughout
subjects, as applicable, and allows for quick access to the manual to emphasize important and critical
the required information within the chapter. instructions. They normally appear ahead of the
procedure they apply to. Notes used in tables and
Paragraph, figure, and table numbering uses a figures are numbered in sequence, starting at 1. When
combination of the chapter number followed by a the number is highlighted with a symbol (e.g., ), the
sequence number, starting at 1 (e.g., Figure 6-5). note applies to specific data contained in the table or
Page numbering uses a sequence number, starting at figure. When the number is not highlighted, the note
1 at the beginning of each chapter. applies to all of the content.

1-00-00
Page 4 Rev. 1 27 MAY 2011 ECCN EAR99
 BHT-ELEC-SPM

1-8. USE OF THE MANUAL — MATERIALS latest date of issue or revision shows the preferred
REQUIRED material. However, either material may be used for the
maintenance task, unless otherwise specified in the
procedure.
WARNING
1-9. USE OF THE MANUAL — SPECIAL TOOLS

MAKE SURE ALL SAFETY Some maintenance procedures require the use of Bell
PRECAUTIONS ARE FOLLOWED WHEN Helicopter Textron (BHT) special tools, commercial
HANDLING AND USING CONSUMABLE tools, or workaids. All of the necessary tools are listed
MATERIALS. FAILURE TO DO SO CAN in a “Special Tools” table at the beginning of every
CAUSE INJURY OR DEATH. applicable maintenance procedure.

A description and illustration of the BHT special tools

CAUTION are found in the Special Tools Illustrated Parts
Breakdown manual (BHT-SPECTOOL-IPB). Supplier
information for the commercial tools is provided when
HANDLING, STORAGE, AND tools are too specific and may be difficult to find. Other
SAFETY PRECAUTIONS FOR commercial tool brands with equivalent or similar tools
CONSUMABLE MATERIALS SHALL may be used to accomplish the tasks. Dimensions and
BE IN ACCORDANCE WITH materials necessary to make the workaids are shown
MANUFACTURER ’S INSTRUCTIONS, in the applicable figures.
UNLESS OTHERWISE SPECIFIED IN
THIS MANUAL. 1-10. USE OF THE MANUAL — SYMBOLS

NOTE Some illustrations have symbols to highlight common

processes such as the application of sealant, primer,
Until such time that all chapters of the corrosion preventive compound, etc. Other processes
BHT-ELEC-SPM have been updated with include the use of heat, assembly fluid, or unreduced
C-codes (BHT-ALL-SPM, Chapter 13), wet primer. Figure 1-1 shows symbols used in this
EC-codes and reference to Chapter 10 of manual. In addition, always use the consumable
the BHT-ELEC-SPM will be shown in some material (C-XXX) that is called out in the applicable
chapters. text or figure (paragraph 1-8).

Most of the maintenance procedures require the use

1-11. USE OF THE MANUAL — TORQUES
of consumable materials. All of the necessary
consumable materials are listed in a “Materials
Required” table at the beginning of every applicable When a torque value is not shown, the standard
maintenance procedure. The consumable materials torque value for that combination of fasteners shall be
are also called out by nomenclature and c-code used as applicable to fasteners. This will be identified
number in the text (e.g., drycleaning solvent (C-304)). throughout the manual by the term “tighten”. Standard
The c-code number is a unique identification code for torque values for various combinations of fasteners
each material to be referenced in the Standard are found in the Standard Practices Manual
Practices Manual (BHT-ALL-SPM, Chapter 13). (BHT-ALL-SPM, Chapter 2).

On occasion, the materials that are used in In cases where torque values are provided, they are
maintenance tasks will change properties, change highlighted in the applicable figure with a symbol ( T )
suppliers, or be discontinued. Also, new or improved followed by the torque value. The text will show a
materials may become available. If there is ever a symbol ( T ) only alongside the item affected. This
difference between the Electrical Standard Practices shows that this item has a torque value assigned to it
Manual (BHT-ELEC-SPM) and the Standard Practices and the reader should refer to the applicable figure for
Manual (BHT-ALL-SPM), the manual that has the that value.

1-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 5
BHT-ELEC-SPM

ASSEMBLY FLUID

ADHESIVE

CORROSION PREVENTIVE COMPOUND

GREASE

GREASE

GREASE

HEAT APPLICATION

LOCKWIRE

NO ORGANIC FINISH

PRESERVATIVE

SEALANT

SYSTEM LUBRICANT

THERMAL FIT BY COOLING

TIE-WRAP

TORQUE

WET UNREDUCED PRIMER

429_MM_01_0001+

Figure 1-1. Use of Manual — Symbols

1-00-00
Page 6 Rev. 1 27 MAY 2011 ECCN EAR99
 BHT-ELEC-SPM

CHAPTER 2 — SAFETY AND HAZARDS

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

2-1 General Information ................................................................... 2-00-00 3

2-2 Electrical Safety and Hazards ................................................... 2-00-00 3
2-3 Standard Practices — General .................................................. 2-00-00 3
2-4 Standard Practices — Electrical Maintenance or Repairs.... 2-00-00 3
2-5 Standard Practices — Electrical Work in Confined Spaces . 2-00-00 5
2-6 Environmental Safety ................................................................ 2-00-00 5

2-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 1/2
 BHT-ELEC-SPM

SAFETY AND HAZARDS

2-1. GENERAL INFORMATION • Do not touch components that have electrical

power. Direct contact with a high voltage
circuit, or a lower voltage circuit with a high
High voltages in electrical and electronic systems are
current capability, can be fatal.
hazardous to personnel. Serious injury may be caused
by electrical shocks or, in some cases, by rapid
withdrawal from the electrical source in a confined • Proper tools and safety equipment must be
area. Explosion may occur if sparks are generated in available. Use them to ensure the safety of
the presence of flammable vapors. Equipment may be personnel and to make sure the given task is
damaged if metallic objects contact powered electrical done to the specified standards.
conductors or components.
• Do not wear jewelry when you work on a
system that is powered.
2-2. ELECTRICAL SAFETY AND HAZARDS
• Use recommended test equipment or their
equivalents. Follow the equipment operation
WARNING instructions. Additional test equipment, lights,
etc., may be used as desired, provided the
purpose and intent of the specified test is not
OBEY ALL THE SAFETY PRECAUTIONS compromised.
WHEN YOU DO MAINTENANCE ON OR
NEAR ELECTRICAL/ELECTRONIC • The leads and the probes of the test
EQUIPMENT. equipment must be serviceable. They must be
of a sufficient length to put the test equipment
High voltages in the electrical and electronic systems at a proper location. The location of the test
are hazardous to personnel. Electrical shocks may equipment must provide a full view of the
cause serious injuries. The generation of sparks in the indicator. Make sure there is no tension on the
presence of flammable vapors may cause explosions. test leads or the probes.
Metallic objects that come in contact with the powered
electrical conductors or components can cause injury • Give special attention to the WARNINGS,
to personnel and damage to components. CAUTIONS, and NOTES before a
maintenance procedure is initiated. Some
maintenance procedures require the use of
2-3. STANDARD PRACTICES — GENERAL
toxic chemicals, extreme temperatures, and
flammable materials.

WARNING 2-4. STANDARD PRACTICES — ELECTRICAL

MAINTENANCE OR REPAIRS

OBEY ALL THE SAFETY PRECAUTIONS

WHEN YOU DO MAINTENANCE ON OR MATERIALS REQUIRED
NEAR ELECTRICAL/ELECTRONIC
EQUIPMENT. Refer to BHT-ALL-SPM for specifications.

When you do any maintenance or repairs to an NUMBER NOMENCLATURE

electrical system, or to any system that requires
electrical power, follow these precautions: C-136 Caps and/or Plugs

C-156 Caps and/or Plugs

• Personnel must be trained for the specific
task.

2-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 3
BHT-ELEC-SPM

WARNING WARNING

UNLESS POWER IS REQUIRED FOR A WHEN USING ANY CHEMICAL OR

MAINTENANCE PROCEDURE, O T H E R M AT E R I A L S , O B E Y A L L
DISCONNECT THE BATTERY AND THE T H E M A N U FA C T U R E R S S A F E T Y
EXTERNAL POWER. PUT A TAG ON THE RECOMMENDATIONS. REFER TO THE
MANUFACTURERS TECHNICAL DATA
BATTERY SWITCH TO INFORM OTHER
SHEET, MATERIAL SAFETY DATA SHEET
PERSONNEL THAT WORK IS BEING (MSDS), OR ANY OTHER APPLICABLE
PERFORMED. D O C U M E N TAT I O N AVA I L A B L E
THROUGH BELL HELICOPTER
TEXTRON OR THE MANUFACTURER OF
THE PRODUCT.
WARNING
2. Sealing, etching, soldering, and some cleaning
materials used in the maintenance of electrical
INFORM ALL PERSONNEL THAT WORK equipment contain chemicals that may be toxic to the
IS BEING PERFORMED ON THE human body. Observe the manufacturers instructions
HELICOPTER BEFORE YOU SUPPLY carefully.
POWER TO THE ELECTRICAL
SYSTEMS. a. Skin, eye, and respiratory protection is
required.
1. The procedure that follows will help to avoid injury
to personnel and damage to equipment. b. Always wear chemical manufacturers
recommended protective clothing and use safety
equipment.
a. If an electrical connector is to be left
disconnected, install protective caps and/or plugs to c. Compounds should be mixed in a well
protect the contacts from shorts and prevent Foreign ventilated area.
Object Damage (FOD). Use either caps and/or plugs
(C-136) for Electrostatic Discharge Sensitive (ESDS) d. If application is in a closely confined area,
equipment, or caps and/or plugs (C-156) for other utilize an exhaust fan to remove fumes or use
non-ESDS sensitive equipment. personal ventilation equipment as recommended by
manufacturer.

b. If a circuit breaker must remain open until a e. If material is flammable, take all precautions to
maintenance procedure is complete, install a clip or a prevent sparks, arcing, or other sources of ignition.
plastic cable strap under the circuit breaker button. Put
a tag on the circuit breaker to inform other personnel f. Keep skin contact to a minimum and wash
not to set the circuit breaker to the closed position. thoroughly after any use of toxic materials.

c. If a switch must remain open or closed until a

maintenance procedure is complete, put a tag on the WARNING
switch to inform other personnel not to touch the
switch.
DO NOT USE ANY PROCEDURE
CAPABLE OF PRODUCING SPARKS,
d. Inform all personnel that work is being ARCING, OR ANY OTHER SOURCE OF
performed on the helicopter before you supply power IGNITION WHEN EXPLOSIVE FUMES
to the electrical systems. ARE PRESENT.

2-00-00
Page 4 Rev. 1 27 MAY 2011 ECCN EAR99
 BHT-ELEC-SPM

3. The following electrical maintenance procedures • Heat damage to adjacent equipment

require the use of heat capable of inflicting personal
injury and damage to equipment. • Poor quality of workmanship

a. Heat shrink materials are applied to various d. Power to heating tools should be turned off
wiring bundles and connectors for insulation and and the equipment immediately removed from the
reinforcement. Use only an explosion proof heat gun, helicopter upon completion of the maintenance
such as the RayChem HT 900 or equivalent, when procedure.
working on fueled helicopters.
2-5. STANDARD PRACTICES — ELECTRICAL
b. Some connections require soldering. WORK IN CONFINED SPACES
Soldering iron tips may have temperatures in excess
of 600°F (316°C). When not in use during 1. Some equipment installations are in confined
maintenance operations, keep soldering iron in a areas and access to the test points can be difficult.
holder to prevent burns or damage to other equipment. When you do a test on a powered circuit in a confined
area, follow these precautions:

WARNING a. Have the applicable fire safety equipment

available when you do a maintenance procedure.

AVOID ORAL CONTACT WITH HANDS b. Before you start work in a confined area, look
DURING SOLDERING OPERATIONS AND at the schematics or wiring diagrams of the applicable
WASH HANDS IMMEDIATELY AFTER electrical systems and at the location of the equipment
SOLDERING OPERATION. THE LEAD you will test. Make a note of the location of the high
CONTA INE D IN S OL DE R CA N B E A voltage areas near the equipment you will test.
SOURCE OF LEAD OXIDE. LEAD OXIDE
IS A POISON THAT CAN RESULT IN A c. Be careful around any control cable or control
SERIOUS HEALTH PROBLEM. mechanism. Movement of engine or flight controls can
TOUCHING SOLDER FOLLOWED BY cause movement of cables or control rods.
SMOKING OR EATING IS A POTENTIAL
MEANS OF INGESTING TRACE
d. For systems not tested, set the applicable
AMOUNTS OF LEAD OXIDE.
circuit breakers to the open position.
c. Do not use makeshift tools or other
unapproved sources of heat when applying heat shrink 2-6. ENVIRONMENTAL SAFETY
materials or soldering. The adverse effects are as
follows: Refer to local and regional environmental and safety
rules and regulations when performing any
• Fire hazard maintenance activity.

2-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 5/6
 BHT-ELEC-SPM

CHAPTER 3 — CIRCUIT, COMPONENT, WIRE, CABLE, AND HARNESS DESIGNATIONS

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

CIRCUIT, COMPONENT, WIRE, AND CABLE HARNESS DESIGNATIONS

3-1 General Information ................................................................... 3-00-00 3

3-2 Wiring Identification Code.......................................................... 3-00-00 3
3-3 Wiring Harness and Cable Designation..................................... 3-00-00 3
3-4 Component Symbols ................................................................. 3-00-00 5
3-5 Electrical Components and Assemblies —
Reference Designator Assignment ............................................ 3-00-00 17
3-6 Resistor Characteristic Codes ................................................... 3-00-00 24

FIGURES

Figure Page
Number Title Number

3-1 Wire Identification Code ................................................................................. 4

3-2 Circuit Identification ........................................................................................ 6
3-3 Component Symbols — Typical ..................................................................... 7
3-4 Reference Designator..................................................................................... 23
3-5 Typical Film Resistor Color Codes ................................................................. 26

TABLES

Table Page
Number Title Number

3-1 Circuit Functions ............................................................................................. 5

3-2 Reference Designator — System Number and Description (Typical)............. 17
3-3 Reference Designator — Unit Number and Item Number Letter Codes
(Typical) .......................................................................................................... 21
3-4 Electrical and Electronic Components, Reference
Designator/Description/Location — Reference Table (Examples) ................. 22
3-5 Film Type Resistor Color Codes .................................................................... 24
3-6 RE Type Resistance Code ............................................................................. 27
3-7 RER Type Resistance Code........................................................................... 28
3-8 RWR Type Resistance Code.......................................................................... 29

3-00-00
ECCN EAR99 27 MAY 2011 Rev. 1 Page 1/2
 BHT-ELEC-SPM

CIRCUIT, COMPONENT, WIRE, CABLE, AND HARNESS DESIGNATIONS

3-1. GENERAL INFORMATION side system and system number 2 to designate the
same equipment for the pilot or right side system.
This chapter includes information necessary to
understand the identification of the wires, cables,
NOTE
harnesses, components, and circuits. Each wire,
cable, and cable harness is physically marked for Some customizing installations may use
identification on wiring diagrams and schematics. additional codes not listed in Table 3-1.
Wiring diagrams and schematics also use symbols to
identify the type of electrical components within a 2. The next designation is the wire number for a
system or circuit. particular circuit. This number identifies the complete
wire run between two components. Typically, it is
Each electrical component has a reference designator power from a source or bus to the controlling
consisting of a system number, unit number, and an component or a wire from the controlling component to
item number, when applicable, for identification on an actuator, motor, or indicator (Figure 3-2).
schematics and wiring diagrams.
3. Each segment of a wire number is marked
Resistors are employed in some circuits for voltage starting with the letter A at the power or control source.
reduction and/or biasing. Information to identify the Each time that wire number is interrupted by a terminal
value, tolerance, and method of attachment is also board, connector, etc., the wire segment letter is
provided. advanced to the next letter in alphabetical sequence
(Figure 3-2).
3-2. WIRING IDENTIFICATION CODE
4. Wire size number denotes the wire size to
American Wire Gauge (AWG) standards.
NOTE
It is not necessary to mark wires and cables 5. Ground letter notation (N) designates a wire as
that are shorter than 6 inches (15.2 cm) in part of a ground circuit.
length.
3-3. WIRING HARNESS AND CABLE
Each wire is stamped with a coded designation DESIGNATION
approximately 10 inches (25.4 cm) apart along the
entire length (Figure 3-1). The code identifies the Wiring harness and cable assembly identification is
circuit function, wire number of that circuit, the marked by part number on a white teflon sleeve or
segment of a specific wire number, wire size, and if marking label placed within 3 inches (7.6 cm) of the
applicable, ground. terminating connector (Figure 3-2).

1. In most cases, the circuit function is the first letter On some helicopters, each harness is also assigned a
or letters in the code. Refer to Table 3-1 for circuit unique wire harness identification code. This
identification. In the event there are two or more alphanumeric code starts with a W. The wire harness
identical items or equipment installed on the same W-code (e.g., W5A) can be found on the harness
helicopter, a system or unit number is used as a prefix identification label (Figure 3-2). The harness
to the circuit function letter. For example, system identification is installed every 36 to 48 inches (914 to
number 1 can be used to designate the copilot or left 1219 mm) along the harness.

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ECCN EAR99 27 MAY 2011 Rev. 1 Page 3
BHT-ELEC-SPM

L 18 A 20 N

GROUND LETTER
WIRE SIZE NUMBER
WIRE SEGMENT LETTER
WIRE NUMBER
CIRCUIT FUNCTION LETTER

2 A U D 37 A 20 N

GROUND LETTER
WIRE SIZE NUMBER
WIRE SEGMENT LETTER
WIRE NUMBER
CIRCUIT FUNCTION LETTER
SYSTEM (UNIT) NUMBER

ELEC-SPM_ch03_0001

Figure 3-1. Wire Identification Code

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 BHT-ELEC-SPM

Table 3-1. Circuit Functions Table 3-1. Circuit Functions (Cont)

CODE NOMENCLATURE CODE NOMENCLATURE

ADF Automatic Direction Finder Q Fuel and Oil

ALT or Radio (Radar) Altimeter R Radio (navigation and communication)

ALTM RD Direction Finder
ARC UHF Communication RF VHF Liaison
ATC Air Traffic Control RL HF Communication
AUD Interphone RM Marker Beacon
C Control Surfaces RN Navigation
COMM Communication RU UHF Command
D Instruments (other than flight or engine) RV VHF Command
DME Distance Measuring Equipment RZ Interphone and Headphone
E Engine Instruments S Radar
F Flight Instruments SX IFF Transponder
FL Electrical Filter T Special Electronics
G Landing Gear TCS Traffic Collision and Avoidance System
GPS Global Positioning System V DC Power and DC Control Cables for
GYRO Gyromagnetic Compass AC System

H Heating, Ventilating, and De-icing VHF VHF Communication

J Ignition W Warning and Emergency

K Engine Control X AC Power

L Lighting XPDR Transponder

M Miscellaneous Electric

MKR or Marker Beacon

MB 3-4. COMPONENT SYMBOLS
N Ground
Components are identified on schematics and wiring
NAV Navigation diagrams by symbols illustrated in Figure 3-3. These
symbols are typical. Refer to the wiring diagram
P DC Power chapter in the Maintenance Manual for model specific
symbols.

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ECCN EAR99 27 MAY 2011 Rev. 1 Page 5
BHT-ELEC-SPM

CIRCUIT FUNCTION

WIRE NUMBER
WIRE SEGMENT LETTER
WIRE SIZE

REFERENCE DESIGNATOR
COMPONENT SYMBOL

FWD CB PANEL LH AVIONIC BLOWER

LCTN - PEDESTAL LH LCTN - PEDESTAL
3940A1 2150B1
2150B1P1
AVIONIC
BLOWER H014A24 3 FAULT SIGNAL
3940A1J1 3940A1P1
2150CB1 4 HEATER
M
28 VDC ESS 1 2A H004A22 F H004B22 WHT 1 28 VDC
BUS H004B22 BLU 2 GROUND

H017A22N CHASSIS GND 1

2150GC1
429-079-101-XXX CABLE ASSEMBLY H018A22N DC GND 1
2150GD3

GROUND DESIGNATION

HARNESS IDENTIFICATION LABEL 1

CONNECTOR
WIRING ASSEMBLY
IDENTIFICATION (2150B1P1)
EXAMPLE (AVIONIC BLOWER)
HARNESS IDENTIFICATION LABEL
HARNESS IDENTIFICATION
2150B1P1 CODE (W101)
AVIONIC BLOWER
3.0 IN.
(7.6 cm)

OR

2150B1P1 CABLE ASSEMBLY

AVIONIC BLOWER (429-079-101)
NOTE
W101
429-079-101 1 A white shrink sleeve tubing positioned every
36 to 48 inches (91.4 to 121.9 cm) along the
harness may also be utilized.

ELEC-SPM_ch03_0002

Figure 3-2. Circuit Identification

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 BHT-ELEC-SPM

ANTENNAS
LH HALF

RH HALF DME, UHF/VHF AND

ADF LOOP VHF AM VOR TRANSPONDER TRANSPONDER

MARKER BEACON SENSE FM COMM (WHIP) HOMING

RADAR ALTIMETER LOOP ADF SENSE

ANTENNAS (TYPICAL) COUPLER

CONNECTORS

A1 F1 1 BUSSED A F
MA MB B G
B1 G1 POSITIONS MC MD
COAX C H
2 ME MF D J
C1 H1 MG MH E K
3
MODULE
STUD TYPE GROUND MODULE

RESISTOR MODULE HF TERMINAL BOARDS AND BLOCKS

A
A F
B
PERMANENT B G
C
SPLICE TERMINAL CONNECT C H
1J3 1P3
D J
E K
J = JACK (RECEPTACLE)
P = PLUG (CONNECTOR) 1 2

RECEPTACLE QUICK IN LINE CONNECTOR TERMINAL JUNCTION

AND PLUG DISCONNECT (TYPICAL)
ELEC-SPM_ch03_0003a

Figure 3-3. Component Symbols — Typical (Sheet 1 of 10)

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BHT-ELEC-SPM

INSTRUMENTS

A +
A –
IND B B L V
+
C C -

INDICATOR AND CONNECTOR AMMETER (LOADMETER) VOLTMETER HOUR METER

SENSOR PRESS
A
FIRE B

C
D
E
FAIL

FIRE DETECTOR ELEMENT

A A
B
B

TEMP BULB PITOT HEATER

TEMPERATURE
CONTROLLER

STATIC PORT HEATER

A
B
C

CHIP DETECTOR
ELEC-SPM_ch03_0003b

Figure 3-3. Component Symbols — Typical (Sheet 2 of 10)

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 BHT-ELEC-SPM

LIGHTS

C
R L
L L
G

NAVIGATION LIGHT COCKPIT LIGHT PANEL LIGHT

+ 1
+ S-RED
3
W
– ENG OUT
– W 4
2

INCANDESCENT LAMP CHART LIGHT LED ANNUNCIATOR

1
A
2 1
L
2 E
3 3 L

SEARCHLIGHT LANDING LIGHT WARNING LIGHT

C L L
1 L
G B
L
A
2

FIRE PULL HANDLE

PRESS TO TEST AND INDICATOR ANTICOLLISION LIGHT (MAIN & RESERVE)

D 2
W A 4
B
E 1
R
A A
5

LIGHTING
DOME LIGHT POWER SUPPLY MASTER WARNING LIGHT
ELEC-SPM_ch03_0003c

Figure 3-3. Component Symbols — Typical (Sheet 3 of 10)

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BHT-ELEC-SPM

RELAYS

E
X1
K
X2
A1 A2
A
A1
A2 B
A1 A2 B1 B2
X1 F
X1 X2 A3
X2 B1 C
B2 G

B3 D
H

SINGLE POLE/ SINGLE POLE/ DOUBLE POLE/ DOUBLE POLE/

SINGLE THROW DOUBLE THROW DOUBLE THROW DOUBLE THROW (DELAY)

1 2 A1 A2
A3
A2 11 12
A1 13 14
B3
B2
B1 3
X1 H X1
S3
X2 X2 S1
A 5A
S2
5B

PLUG-IN RELAY POWER RELAY RCCB RELAY

BUS
13
14
A1

A2
COIL
CONTROL

CURRENT
TIMER LEVEL AND
SENSE
OVRD
SWITCH SW
RESET RST

BATTERY RELAY

ELEC-SPM_ch03_0003d
Figure 3-3. Component Symbols — Typical (Sheet 4 of 10)

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 BHT-ELEC-SPM

POWER COMPONENTS

PUSH SWITCH

5
A1 A2
- +
PUSH PULL A3
REMOTE CONTROL

CAPACITOR CIRCUIT BREAKER

–
B B
–
+
+
+ C E
+ C E
NPN PNP

EXTERNAL POWER RECEPTACLE TRANSISTOR FUSE BUS BAR

A
E
ARM

E C B D A
A

STARTER GENERATOR

A
B – +
C

GENERATOR REGULATOR
VOLTAGE REGULATOR CONTROL UNIT SHUNT

X1 X2 M

TRANSFORMER CURRENT
(STEP UP OR DOWN) TRANSFORMER INVERTER
ELEC-SPM_ch03_0003e

Figure 3-3. Component Symbols — Typical (Sheet 5 of 10)

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BHT-ELEC-SPM

POWER COMPONENTS

+
–
+
–
+
BATTERY
A
– B
C
D

BATTERY

C
OPEN
M A E
CLOSE
D

INTERCONNECT VALVE VALVE

CLOSE D
B

PMM E
OPEN

A
C

F
G

SHUT-OFF VALVE

ELEC-SPM_ch03_0003f

Figure 3-3. Component Symbols — Typical (Sheet 6 of 10)

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 BHT-ELEC-SPM

SWITCHES

A3
A2
A1

SINGLE POLE/
SINGLE POLE/ SINGLE POLE/ SINGLE THROW
SINGLE THROW DOUBLE THROW (ALTERNATE ACTION) (MOMENTARY ACTION)

PUSH-ON CENTER SINGLE POLE/

PUSH-OFF SWITCH SINGLE THROW RELAY RESET SWITCH FOOT SWITCH

15 INCR DECR

14 16
P A
NC A 13 17
COM B
NO C B NO NO NO
12 11 18 C C
OFF
DOUBLE POLE/
PRESSURE SWITCH SELECTOR SWITCH DOUBLE THROW-INDEPENDENT

EXTEND/ON
UP

LEFT RIGHT
LEFT RIGHT

RETRACT/STOW
DOWN

THERMAL
OVERHEAT SWITCH SWITCH FOUR POSITION SWITCH

NORMALLY OPEN

NORMALLY CLOSED

PUSH BUTTON SWITCH POTENTIOMETER (CONTROLS VOLTAGE) RHEOSTAT (CONTROLS CURRENT)

ELEC-SPM_ch03_0003g

Figure 3-3. Component Symbols — Typical (Sheet 7 of 10)

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BHT-ELEC-SPM

SWITCHES

PTT

NC

NO
NC 2 1
4 3
C

NO

INERTIA SWITCH GOV RPM SWITCH TEST SWITCH MOMENTARY SWITCH

ENG 1 3
1
2 2
5 A 4
OEI TRNG 4 1
NC
6 3
C
7
2 NO
PUSH
ENG 2 8 TO TEST B 4
1
3

MAGNETICALLY HELD SWITCH MOMENTARY PUSH SWITCH NORMALLY CLOSED

TRIM 2
A
ON 3
B 1 2

5 OFF 5 STOP
4 3
6 4 HIGH
OFF 7 5 C1 3 LOW
8 DIM
9 6 2
10 1 INT
11 7 OFF/MANUAL
BRT
12 ENABLE
ON
13
14
15
16

SWITCH/LIGHT ROTARY KNOB ROTARY SWITCH

ELEC-SPM_ch03_0003h

Figure 3-3. Component Symbols — Typical (Sheet 8 of 10)

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 BHT-ELEC-SPM

MISCELLANEOUS

ANODE + CATHODE –

+ –
STRUCTURAL GROUND + –
ZENER DIODE

END CAP DIODE

+ RED

R_ _
– BLUE
HOLDING
PUMP RESISTOR COIL PANEL LIGHT PLUG

FUEL UNIT A A
CELL COUPLER
(TYP) (TYP) B D

FUEL QUANTITY CONNECTORS SOLENOID VALVE

T SHIELDED SINGLE

(TRIPLE) (PAIR) COAXIAL CABLE

ENGINE VIB. METER RECPT SHIELDED WIRES IN CABLE

AIR CORE IRON CORE

HEATED BLANKET
RECEIVER
RECEPTACLE
TRANSMITTER
INDUCTORS THERMOCOUPLE HARNESS CONTROLS

ELEC-SPM_ch03_0003i

Figure 3-3. Component Symbols — Typical (Sheet 9 of 10)

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BHT-ELEC-SPM

MISCELLANEOUS

A A
B B
C

MISCELLANEOUS EQUIPMENT FIRE EXTINGUISHER CARTRIDGE

+
–

HORN OR LOUDSPEAKER HEADSET MICROPHONE

THERMISTOR TEMPERATURE SENSOR

A
B
C

INDICATOR PANEL

ELEC-SPM_ch03_0003j

Figure 3-3. Component Symbols — Typical (Sheet 10 of 10)

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 BHT-ELEC-SPM

3-5. ELECTRICAL COMPONENTS AND item such as a connector, which connects to the
ASSEMBLIES — REFERENCE particular reference designator.
DESIGNATOR ASSIGNMENT
Components are identified by their reference
designator on the electrical schematics, wiring
Each electrical component and assembly is assigned diagrams, and by a decal or label adjacent to their
an alphanumeric code on the wiring diagrams and installed location on the helicopter. Table 3-4 provides
schematics called a reference designator (Figure 3-4). an example of a reference designator listing that may
be provided in some Maintenance Manuals.

The reference designator consists of a system number The Index of Reference Designator listing provided in
(Table 3-2) and unit number (Table 3-3) for Illustrated Parts Breakdown Manuals (IPB) may also
identification. Item numbers (Table 3-3) are also used be used to identify the installed location of the
at the end of the reference designator to identify an component as well as its part number.

Table 3-2. Reference Designator — System Table 3-2. Reference Designator — System
Number and Description (Typical) Number and Description (Typical) (Cont)

SYSTEM SYSTEM
SYSTEM DESCRIPTION SYSTEM DESCRIPTION 1
NUMBER 1 1 NUMBER 1

1 Propulsion and Fuel Systems 2240 Autopilot System Monitor

2 DC Power System, Start and 2300 Communications System —

Ignition System General

4 Instruments Panels and Console 2310 Communications — (HF)

6 Flight Controls 2320 Communications — (VHF)

8 Light Systems 2321 Communications — (ELT)

9 Flight Control Hydraulic System 2330 Communications — Passenger

Address and Entertainment
10 Environmental Control Systems
2340 Communications — Interphone
24 Float, Cargo Hook, and
Miscellaneous Kits 2350 Communications — Audio
Integrating
2100 Air Conditioning — General
2360 Communications — Static
2140 Heating System
Dissipation
2150 Cooling System
2370 Communications — Audio and
2160 Temperature control Video

2200 Autopilot System — General 2400 Electrical Power System —

General
2210 Autopilot System
2420 AC Generation System
2220 Autopilot Speed — Attitude
Correction 2430 DC Generator Power System

2230 Autopilot Auto Throttle 2440 External DC Power System

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BHT-ELEC-SPM

Table 3-2. Reference Designator — System Table 3-2. Reference Designator — System
Number and Description (Typical) (Cont) Number and Description (Typical) (Cont)

SYSTEM SYSTEM
SYSTEM DESCRIPTION 1 SYSTEM DESCRIPTION 1
NUMBER 1 NUMBER 1

2450 Electrical Power — Electrical 2930 Hydraulic Power — Indicating

Load Distribution
3000 Ice and Rain Protection System
2500 Equipment — General — General

2510 Equipment — Flight Compartment 3030 Ice and Rain Protection System
— Pitot and Static
2520 Equipment — Passenger
Compartment 3040 Ice and Rain Protection System
— Windows and Windshield
2560 Equipment — Emergency
3060 Ice and Rain Protection System
2580 Equipment — Cargo Hook
— Rotors and Prop Rotors
2581 Equipment — External Hoist
3080 Ice and Rain Protection System
2600 Fire Protection System — — Detection
General
3100 Indicating/Recording System —
2610 Fire Detection System General
2620 Fire Extinguishing System 3130 Indicating/Recording System —
2700 Flight Control System — General Recorders/Data Acquisition

2701 Flight Control System — Copilot 3140 Indicating/Recording System —

Collective Central Computer

2702 Flight Control System — Pilot 3150 Indicating/Recording System —

Collective Central Warning

2703 Flight Control System — Copilot 3160 Indicating/Recording System —

Cyclic Grip Central Display System

2704 Flight Control System — Pilot 3170 Indicating/Recording System —

Cyclic Grip Aircraft Data Interface Unit (ADIU)

2720 Flight Control System — 3200 Landing Gear System — General

Collective Position Sensor 3210 Landing Gear System — Main
2800 Fuel System — General Gear and Doors

2810 Fuel System — Storage 3220 Landing Gear System — Nose

Gear and Doors
2820 Fuel Balance System — Control/
Distribution 3230 Landing Gear System —
Extension and Retraction
2840 Fuel System — Fuel Gauging/
Indicating 3240 Landing Gear System — Wheels
and Brakes
2900 Hydraulic Power — General
3260 Landing Gear System — Position
2910 Hydraulic Power — Main System and Warning

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 BHT-ELEC-SPM

Table 3-2. Reference Designator — System Table 3-2. Reference Designator — System
Number and Description (Typical) (Cont) Number and Description (Typical) (Cont)

SYSTEM SYSTEM
SYSTEM DESCRIPTION 1 SYSTEM DESCRIPTION 1
NUMBER 1 NUMBER 1

3300 Lighting System — General 3930 Electrical/Electronic Components

— Junction Boxes and Relay
3310 Lighting System — Flight
Panels
Compartment
3940 Electrical/Electronic Panels and
3320 Lighting System — Passenger
Components — Multipurpose
Compartment
Electronics Components
3340 Lighting System — Exterior
3942 Electrical/Electronic Panels and
3347 Lighting System — Searchlight Components — Terminal Module
3380 Lighting System — Emergency 3945 Electrical/Electronic Panels and
3400 Navigation System — General Components — Ground Module

3406 Navigation System — ADF 3950 Electrical/Electronic Panels and

Components — Integrated
3407 Navigation System — ADAHRS Circuits
3410 Navigation System — Flight 3960 Electrical/Electronic Panels and
Environment Data Components — Printed Circuit
3420 Navigation System — Attitude Card Assemblies
and Direction 4296 Integrated Avionics System
3421 Navigation System — Weather 4350 Pilot Headset
Radar
5200 Doors — General
3427 Navigation System —
Transponder, Encoding Altimeter 5270 Door Warning

3440 Navigation System — TCAS 6500 Rotor System — General

3450 Navigation System — GPS 6510 Rotor System — Main Rotor

3460 Navigation System — Display 6520 Rotor System — Anti-torque

Unit Heater Rotor Assembly

3470 Navigation System — Course 6530 Rotor System — Accessory

Heading Flight Director Panel Drives/Gearboxes
(CHFD) 6540 Rotor System — Controlling
3900 Electrical/Electronic Panels and 6550 Rotor System — Braking
Components — General
6560 Rotor System — Indicating
3910 Electrical/Electronic Panels and
7100 Power Plant System — General
Components — Instruments and
Control Panels 7150 Power Plant System — Electrical
Harness
3920 Electrical/Electronic Panels and
Components — Equipment Racks

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ECCN EAR99 27 MAY 2011 Rev. 1 Page 19
BHT-ELEC-SPM

Table 3-2. Reference Designator — System Table 3-2. Reference Designator — System
Number and Description (Typical) (Cont) Number and Description (Typical) (Cont)

SYSTEM SYSTEM
SYSTEM DESCRIPTION 1 SYSTEM DESCRIPTION 1
NUMBER 1 NUMBER 1

7160 Power Plant System — Inlet 7900 Oil — General

Barrier Filter
7930 Oil — Indicating
7200 Engine — General
8000 Engine Start System — General
7300 Engine Fuel and Control System
8010 Engine Start System — Cranking
— General
9500 Crew Escape and Safety —
7320 Engine Fuel and Control System
General
— Controlling
9560 Crew Escape and Safety —
7330 Engine Fuel and Control System
Flotation
— Indicating
9900 Surveillance — Articulated
7400 Ignition — General
Landing Light
7410 Ignition — Electrical Power
NOTE:
Supply

7420 Ignition — Distribution 1 The listing provided is typical and is

primarily based on DOD-STD-863B. Due to
7500 Air — General differing system number and descriptions
7510 Air — Engine Anti-icing used in the past, refer to the specific
helicopter model Maintenance Manual for
7540 Air — Indicating
additional information.
7700 Engine Indicating — General

7710 Engine Indicating — Power

7720 Engine Indicating — Temperature

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 BHT-ELEC-SPM

Table 3-3. Reference Designator — Unit Number Table 3-3. Reference Designator — Unit Number
and Item Number Letter Codes (Typical) and Item Number Letter Codes (Typical) (Cont)

LETTER LETTER
CLASS OF COMPONENT CLASS OF COMPONENT
CODE CODE

A Electronic or Electrical Assembly, LS Speaker, Warning Horn

Control Panel, Fuel Probe M Indicator, Clock
AT Electrical or Electronic Termination MG Starter Generator
B Electrical Driven Pump, Blower, Fan MP Directional Gyroscope
BT Battery, Battery Cell MT Sensor, Transducer
C Capacitor ND Ground Assembly
CB Circuit Breaker P Electrical Connector
CM Computer PS Power Supply
CP Control Panel (avionics), Coupler Q Transistor
Connector, Adapter (electrical)
R Resistor, Shunt
CR Diode, Diode Assembly
RE Receiver (avionics)
CT Course Heading Flight Director Panel
(CHFD) RT Resistive Temperature Bulb

D Light S Switch

DS Light Assembly (electrical), Indicator T Transducer

(avionics), Alarm, Annunciator TB Terminal Block
E Chip Detector (electrical), Fire TC Thermocouple
Detection Element, Temperature
TR Transceiver (avionics), Magnetometer
Probe, Igniter, Antenna (avionics)
TX Transmitter (avionics)
F Fuse
VR Voltage Regulator, Generator
G Pressure Transducer, Accelerometer
Regulator Control Unit (GRCU)
HR Heater
WTB Junction Module
J Electrical Receptacle
WTD Ground Module
K Relay, Contactor
XK Relay Mount Socket
L Solenoid, Searchlight
Z Fuel Signal Conditioner

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BHT-ELEC-SPM

Table 3-4. Electrical and Electronic Components, Reference Designator/Description/Location —

Reference Table (Examples)

REFERENCE FIGURE SHEET

COMPONENT DESCRIPTION LOCATION
DESIGNATOR LOCATION

407 MAINTENANCE MANUAL EXAMPLE

2S1 Switch, BATT Switch Overhead Console Sheet 11

2S2 Switch, GEN RESET Switch Overhead Console Sheet 11

2TB1 Terminal Board (junction block) Overhead Console Sheets 11 and 14

2VR1 Voltage Regulator FS 160.0, LBL 20.0, WL 52.0 Sheets 16 and 20

2VR1P1 Connector, Voltage Regulator FS 160.0, LBL 20.0, WL 52.0 Sheets 16 and 20
2XK4 Relay Socket, Field/Igniter Relay FS 166.0, DC Equipment Panel Sheet 20

3CB1 Toggle Circuit Breaker 30 amps, Overhead Console Sheet 11

OFF AVIONICS MASTER (kit)

3J1 Receptacle, DC Power Panel FS 155.0, WL 60.0, Right Side Sheet 16

3P1 Connector, DC Power Panel FS 155.0, WL 60.0, Right Side Sheet 16

4A1 Switch Box, Collective Collective Sheet 8

412 MAINTENANCE MANUAL EXAMPLE

1A1 Engine and Fuel Control Panel

1A1P1 Connector

1A1P2 Connector

1A1K1 Fuel Crossfeed Relay

1A1S1 Engine 1 Fuel Switch

1A1S2 Engine 2 Fuel Switch

1A1S3 Engine 1 Gov Switch

1A1S4 Engine 2 Gov Switch

1A1S5 Engine 1 Boost Pump Switch

1A1S6 Engine 2 Boost Pump Switch

1A1S7 Fuel Intcon Switch

1A1S8 Fuel Crossfeed Switch

1A1S9 Fuel Intcon/Crossfeed Switch

1A1S12 Engine 1 Fuel Transfer Switch

1A1S13 Engine 1 Fuel Transfer Switch

3-00-00
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 BHT-ELEC-SPM

8DS3J1
ITEM NUMBER
J-CONNECTOR, RECEPTACLE
1-CONNECTOR NO.1
UNIT NUMBER
(CERTAIN UNITS CAN HAVE
DS-LIGHT ASSEMBLY MORE THAN ONE CONNECTOR.
SYSTEM NUMBER 3-3RD ASSEMBLY IN THIS CASE THEY WOULD BE
(LIGHTING) IDENTIFIED J2, J3, ETC.)

ELEC-SPM_ch03_0009

Figure 3-4. Reference Designator

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BHT-ELEC-SPM

3-6. RESISTOR CHARACTERISTIC CODES

For film type resistors Table 3-5 will identify the

resistance in ohms, tolerance and type of attachment.
Refer to Figure 3-5 for typical film resistor color codes.
RE, RER, and RWR type codes are explained in
Table 3-6 through Table 3-8 respectively.

Table 3-5. Film Type Resistor Color Codes

BAND A 2 BAND B 3 BAND C 4 BAND D 5 BAND E 6 BAND F 7

Color Color Color Color Color Color

Solderable Terminal
Second significant

Third significant
First significant

Resistance
Tolerance
(percent)
Multiplier
number

number

number

Silver Silver Silver Silver 10-2 Silver ±10% White

Yes
(x 0.01)
Gold Gold Gold Gold 10-1 Gold ±5% No Band

No
(x 0.1)
Black 0 Black 0 Black 0 Black 1
Brown 1 Brown 1 Brown 1 Brown 10 Brown ±1%
Red 2 Red 2 Red 2 Red 102 Red ±2%

Orange 3 Orange 3 Orange 3 Orange 103

Yellow 4 Yellow 4 Yellow 4 Yellow 104
Green 5 Green 5 Green 5 Green 105 Green ±0.5%

Blue 6 Blue 6 Blue 6 Blue 106 Blue ±0.25%

Violet 7 Violet 7 Violet 7 Violet 107 Violet ±0.10%

Gray 8 Gray 8 Gray 8 Gray 108 Gray ±0.05%

White 9 White 9 White 9 White No ±20%

Color

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 BHT-ELEC-SPM

Table 3-5. Film Type Resistor Color Codes (Cont)

NOTES:

1 Example of color coding 5100 ohms ±1%, solderable leads.

Band A — green; Band B — Brown; Band C — Black; Band D — Brown; Band E — Brown; Band F — White

2 The first significant number of the resistance value.

3 The second significant number of the resistance value.

4 The third significant number of the resistance value. This significant number is only applicable to
resistors with a 5-band coding (Figure 3-5).

5 The multiplier (the multiplier is the factor by which the significant numbers are multiplied to yield the
nominal resistance value).

6 The resistance tolerance.

7 Indicates a solderable terminal and has a white indicator band. This band is approximately 1.5 times the
width of other bands. This band is only applicable to resistors with military specifications. Commercial
resistors may have a band indicating the temperature coefficient or resistor reliability.

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ECCN EAR99 27 MAY 2011 Rev. 1 Page 25
BHT-ELEC-SPM

4 BAND

BAND B BAND E
BAND F (ONLY SHOWN WHEN RESISTOR
BAND A BAND D HAS SOLDERABLE TERMINALS)

TOLERANCE ≥2%

1 2 4 5 6
1 2 3 4 5
TOLERANCE ≤1%

BAND A BAND C BAND E

BAND B BAND D

5 BAND
1. 1st significant figure
2. 2nd significant figure
3. 3rd significant figure
4. Multiplier
5. Resistance tolerance
6. Solderable terminal

FOUR BAND CODE EXAMPLES

Green, blue, red, with silver tolerance band: 56 x 100 = 5.6 ohms, with a tolerance of
10%, white band for solderable terminals.

Red, red, brown, silver tolerance band: 22 x 10 = 220 ohms (220 ohms), with a
tolerance of 10%.

Brown, black, orange, gold tolerance band: 10 x 1000 = 10000 ohms (or 10K ohms),
with a tolerance of 5%.

FIVE BAND CODE EXAMPLES

Red, red, brown, black, with a brown tolerance band: 221 x 1 = 221 ohms, with a
tolerance of 1%, white band for solderable terminals.

Blue, brown, white, brown, green tolerance band: 619 x 10 = 6190 ohms (6.19K ohms),
with a tolerance of 0.5%.

Brown, black, black, red, with a brown tolerance band: 100 x 100 = 10000 ohms
(10.0K), with a tolerance of 1%.

NOTE
1 Refer to Table 3-5 for additionnal information.
ELEC-SPM_ch03_0010

Figure 3-5. Typical Film Resistor Color Codes

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 BHT-ELEC-SPM

Table 3-6. RE Type Resistance Code

RE77 G 1001

Style: The two-letter symbol RE identifies chassis-mounted, power type,

wirewound fixed resistors; the two-digit number identifies the
physical size and power rating.

Characteristics: The single-letter symbol identifies the maximum

continuous operating temperature and type of winding as follows:

G (inductive wound) — +250°C maximum continuous operating temperature

N (non-inductive wound)

Resistance: The four-digit number identifies the nominal resistance value,

expressed in ohms; the first three digits represent significant
figures and the last digit specifies the number of zeros to follow.
For values less than 100 ohms, all digits are significant with the letter "R"
representing the decimal point (see the following examples).

Examples:
R050 = 0.05 ohm
R100 = 0.10 ohm
1R00 = 1.0 ohm
10R0 = 10.0 ohms
1000 = 100 ohms
1001 = 1000 ohms
1002 = 10,000 ohms

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ECCN EAR99 27 MAY 2011 Rev. 1 Page 27
BHT-ELEC-SPM

Table 3-7. RER Type Resistance Code

RER65 F 1001 M

Style: The three-letter symbol RER identifies established reliability,

chassis-mounted, power type, wirewound, fixed resistors; the two-digit
number identifies the physical size and power rating.

Resistance tolerance: The single-letter symbol identifies the

resistance tolerance as follows:

F = ±1.0%

Resistance: The four-digit number identifies the nominal resistance

value, expressed in ohms; the first three digits represent significant
figures and the last digit specifies the number of zeros to follow.
For values less than 100 ohms, all digits are significant with the letter
"R" representing the decimal point (see the following examples).

Examples:
R100 = 0.10 ohm
1R00 = 1.0 ohm
10R0 = 10.0 ohms
1000 = 100 ohms
1001 = 1000 ohms
1002 = 10,000 ohms

Failure rate level: The single-letter symbol identifies the life failure
rate as follows:

M = 1.0%/1000 hours
P = 0.1%/1000 hours
R = 0.01%/1000 hours
S = 0.001%/1000 hours

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 BHT-ELEC-SPM

Table 3-8. RWR Type Resistance Code

RWR74 S 49R9 F M

Style: The three-letter symbol RWR identifies axial-lead, power

type, wirewound, fixed resistors; the two-digit number identifies
the physical size and power rating.

Terminal and winding: Terminal capability and inductive or

noninductive winding designation as follows:

S = Solderable, inductive wound

W = Weldable, inductive wound
N = Solderable, noninductive wound
Z = Weldable, noninductive wound

Resistance: The four-digit number identifies the nominal

resistance value, expressed in ohms; the first three digits
represent significant figures and the last digit specifies the
number of zeros to follow. For values less than 100 ohms, all
digits are significant with the letter "R" representing the decimal
point (see the following examples).

Examples:
R100 to R988 = 0.1 to 0.988 inclusive
1R00 to 9R88 = 1.0 to 9.88 inclusive
10R0 to 98R8 = 10 to 98.8 inclusive
1000 to 9888 = 100 to 988 inclusive
1001 to 9881 = 1000 to 9880 inclusive
1002 to 4022 = 10,000 to 40,200 inclusive

Resistance tolerance: The single-letter symbol identifies the

resistance tolerance as follows:

B = ±0.1%
D = ±0.5%
F = ±1.0%

Failure rate level: The single-letter symbol identifies the failure

rate as follows:

M = 1.0%/1000 hours
P = 0.1%/1000 hours
R = 0.01%/1000 hours
S = 0.001%/1000 hours

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 BHT-ELEC-SPM

CHAPTER 4

CONTENTS — GENERAL MAINTENANCE PROCEDURES

Paragraph Chapter Page
Number Title Number Number

4-1 General ........................................................................................ 4-00-00 3

4-2 Wire/cable cutting .................................................................. 4-00-00 3
4-3 Wire/cable stripping ............................................................... 4-00-00 3
4-4 Soldering ...................................................................................... 4-00-00 6
4-5 Solder shield terminations ........................................................... 4-00-00 13
4-6 Shielded cable splices ................................................................. 4-00-00 20
4-7 Contact crimping procedures ...................................................... 4-00-00 27
4-8 Contact insertion/removal ........................................................... 4-00-00 32
4-9 Solderless terminals .................................................................... 4-00-00 38
4-10 Solderless splices ........................................................................ 4-00-00 41
4-11 Connector potting ........................................................................ 4-00-00 47
4-12 Semiconductor maintenance ........................................................ 4-00-00 55

FIGURES

Figure Page
Number Title Number

4-1 Stripping wire with hand stripper ................................................................................... 4

4-2 Soldering iron tip before and after cleaning ................................................................... 7
4-3 Tinning soldering iron tip ................................................................................................ 8
4-4 Tinning wire with a soldering iron ................................................................................. 9
4-5 Properly stripped and tinned conductor ........................................................................ 9
4-6 Soldering iron tip shapes ............................................................................................. 10
4-7 Correct solder application ............................................................................................... 10
4-8 Soldering iron holder ..................................................................................................... 10
4-9 Spade termination ........................................................................................................ 11
4-10 Turret terminal conductor wrap ..................................................................................... 12
4-11 Turret terminal conductor position ............................................................................... 12
4-12 Inserting conductor ...................................................................................................... 12
4-13 Positioning of conductors ............................................................................................. 13
4-14 Insulation sleeving/tubing ............................................................................................. 13
4-15 Solder quantity .............................................................................................................. 13
4-16 M83519/1 termination selection ................................................................................... 16
4-17 M83519/1 termination placement ................................................................................. 16
4-18 Position termination in reflector ..................................................................................... 17
4-19 M83519/2 termination selection ................................................................................... 18
4-20 M83519/2 termination placement ................................................................................. 19
4-21 Terminating multiple shielded cables with solder sleeves ............................................. 20
4-22 Shield termination ........................................................................................................ 21
4-23 Terminating multiple shielded cables using pigtails ...................................................... 22
4-24 Terminating multiple shielded cables ........................................................................... 22
4-25 Example — 3-conductor shielded cable splice .............................................................. 26
4-26 4 Indenture crimp ........................................................................................................ 27
4-27 Octadent crimp ............................................................................................................ 27
4-28 Turret head crimper ..................................................................................................... 29
4-29 Correct crimped connector pin ..................................................................................... 31
4-30 Crimp tool inspection tool guide ................................................................................... 33

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BHT-ELEC-SPM

Figure Page
Number Title Number

4-31 Insertion and extraction tools for front release crimp-type contacts ............................. 34
4-32 Installation and removal of crimp contacts ................................................................... 36
4-33 M81969/14 Plastic-type insertion/removal tool .............................................................. 37
4-34 Pre-insulated terminal — cutaway ............................................................................... 38
4-35 AMP Hydraulic hand crimper ........................................................................................ 39
4-36 Hydraulic crimp head ................................................................................................... 40
4-37 Terminal or splice positioning .......................................................................................... 40
4-38 AMP Crimping tool T-head 59250 for high temperature terminals .............................. 42
4-39 M22520 Series die type crimp tool ............................................................................... 43
4-40 Insertion of wire into insulated terminal lug .................................................................. 43
4-41 Crimp tools M22520/5-01 and /10-01 .............................................................................. 44
4-42 Staggered splices in wire bundle ................................................................................. 46
4-43 Locating sealed splice crimp barrel in crimping dies .................................................... 46
4-44 RayChem environmental butt splices .......................................................................... 48
4-45 Locating MS25181 splice in MS90413-2 crimping tool ................................................. 49
4-46 Hand mixing potting compound ................................................................................... 50
4-47 Mixing paddle for potting compound ........................................................................... 51
4-48 Filling and curing of potting .......................................................................................... 52

TABLES

Table Page
Number Title Number

4-1 Allowable scratched, nicked or broken strands in copper wire .................................... 3

4-2 Ring lug and wire splice strip length ............................................................................. 6
4-3 Approximate soldering iron sizes for tinning ................................................................. 9
4-4 Center strip preparation ............................................................................................... 14
4-5 End strip preparation ...................................................................................................... 15
4-6 End strip with braid fold-back preparation .................................................................... 16
4-7 Dimensions from cable jacket to end of conductor ...................................................... 22
4-8 Kits (D-150-XXXX) for 1 to 1 splice ............................................................................. 23
4-9 Kits (D-150-XXXX) for mixed gage splices .................................................................. 23
4-10 Material list ................................................................................................................... 24
4-11 Dimensions of kit material and cross reference of material to kits ............................... 25
4-12 Termination of shield and jacketed filter line cable ........................................................ 28
4-13 Crimp tool inspection gages ........................................................................................ 32
4-14 Contact and wire size range ........................................................................................ 32
4-15 Insertion/removal tool for rear release contacts ........................................................... 35
4-16 Wire stripping for 2 through 8 wire ............................................................................... 39
4-17 Color coding of copper terminal lug insulation ............................................................. 39
4-18 Wire stripping lengths for small copper terminal lugs (insulation restriction) ................. 41
4-19 Environmental splices and associated crimp tools ...................................................... 46
4-20 Stripping lengths — splices .......................................................................................... 47
4-21 Wire end caps .............................................................................................................. 55

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 BHT-ELEC-SPM

GENERALMAINTENANCE PROCEDURES
4-1. GENERAL. in thewire contact, terminal,etc.The following outlines
the propertoolsand procedures to performthisfunction.
This chapterdetails general maintenance techniques
for cutting, crimping, and soldering electrical wiring and 2. Stripperswith mechanical die-typebladesprovide
RF cables. These techniques provide general precision hand stripping. Bladesof these strippersrely
maintenance procedures for Chapters 5, 6, and 7 for on a wedge-shaped cutter blade (dimensioned to the
repairing wiringharnesses, cableassemblies, shielded conductor) in combination with a centerbore
wire, and cables. In addition, general maintenance (dimensioned to the insulation) to precisely center the
wire for clean, nick free strips. The Ideal Stripmaster
procedures for maintaining semiconductors in
electronic equipment is included. stripperor equivalentshall be used for wire insulation.
Figure4-1 lists the stripperpart number and blade part
NOTE numberfor stripping variouswire specifications.
3. Stripper blades may be replaced, however, the
Always refer to theapplicablemaintenance blades(topand bottom) are amatchedset and must not
manual wiring schematics for termination be interchanged with otherbladehalves. The back side
requirements. of each blade half is imprinted with a serial number
which mustmatchthe number on theother blade half.
Whenchanging blade sets,attentionshould bedirected
4-2. WIRE/CABLECUlliNG. to the correct blade set part number and gripper part
number for the rangeof wire size to be stripped.
1. The mannerin whichwire or cable is cut can have
an effect on subsequent stripping and termination 4. WIRE STRENGTH. Refer to table 4-1 for
preparations. Diagonal cutters (where the blades allowablescratched, nicked or broken strands.
contacteach other)are commonly used forwirecutting,
but tend to bite the wire in half. This action distorts the Table 4-1. Allowable scratched, nickedor broken
strands in copperwire
conductor and flattens the ends of the strands. The
result isincreased stripforceandanincreased tendency
WIRE SIZE SCRATCHED
for the strands to splayduring stripping. This does not
NICKED OR BROKEN
produce a precision cut.
24-12 None
2. The preferred typecutter is a shear-type where the
10 2
bladespassby eachother. Thisactioncausesvery little
distortion of the conductor. The recommended cutter is 8-4 3
Ideal 45-123 or equivalent. This cutter handles a wide 2-0 12
range of wire gage sizes and cannot be used for
stripping.

LJ
4-3. WIRE/CABLESTRIPPING. A KNIFE SHALL NOT BE USED FOR
STRIPPING. A KNIFE BLADE CAN
DRASTICALLY NICK WIRE OR CUT
STRANDS.

EXTREME CARE SHOULD BE EXERCISED 5. Use of HandWire Strippers.

SO AS NOT TO DAMAGE WIRE
a. Figure 4-1 illustrates the proper use of hand
INSULATIONAND CONDUCTORS DURING
STRIPPING. strippers, blades, and grippers for variouswire types.
b. The stripper handle and grippingjaws must be
1. Before wire can be assembled to connectors,
fully open priorto stripping.
terminals splices, etc., the insulation must be stripped
fromconnecting endstoexposethebareconductor.The c. After wire size has been determined, place it in
proper striplength is determined bythedepthofthehole exactcenter of corresponding size slot in stripper.

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BHT-ELEC-SPM

SELECT CORRECT HOLE BE CAREFULNOTTO

TO MATCH WIRE GAGE NICK OR CUT STRANDS

IDEAL
STRIPMASTER

SELECT CORRECT HOLE

TO MATCH WIRE GAGE

BE CAREFULNOTTO
NICK OR CUTSTRANDS

E/SPM-4-1-1

Figure 4-1. Strippingwire with hand stripper(Sheet 1 of 2)

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 BHT-ELEC-SPM

STRIPPER BLADESET GRIPPER

WIRETYPE GAGE PART NO. PART NO. PART NO.
MIL-W-22759 26 - 30 45 - 178 L -5561 L - 5217
/32and /33 16 - 26 45 - 1 987 45 - 1987 -1
10-14 45-1611 45-1611-1 L-5215
MIL-W-22759/34, 16 - 26 45 - 1 987 45 - 1987 - 1 L -5217
/35,/41,/42,/43 10-14 45-1611 45-1611-1 L-5215
MIL-W-81044 16 - 26 45 - 171 L - 5211 L—521 7

/6and/7 10-14 45-170 L-5210 L-5215

MIL-W-81044 16 - 26 45 - 174 L - 5563 L - 5217
/9 and /10 10 - 14 45 - 173 L - 5562 L - 5215
MIL-W-81 044 26 - 30 45 - 178 L - 5561 L - 5217
/1 2 and /13 16 - 26 45 - 1987 45 - 1987 - 1
10-14 45-1611 45-1611-1 L-5215
MIL-W-81381A 16 - 26 45 - 1654 45 - 1654 - 1
/11,/12, /13, /14, /22 10 - 14 45 - 1608 45 - 1608 -1
8.4MiI Wall
(KAPTON)
MIL-W-81381A 16 - 26 45 - 1551 45 - 1 551 -1

/7,18,19,110,121 10-14 45-1609 45-1609-1

5.8 MD Wall

(KAPTON)
MIL-W-81381A 1 6 - 26 45 - 1 672 45 - 1672 - 1
/17, /18, /19, /20
4.6 MD Wall
(KAPTON)
Wirewrapping 24 - 30 45 - 169 L - 9300
(thin insulation) 30 45 - 179 L - 7625
solid wire

General purpose 26 - 30 45 - 172 L - 5436

stripping of plastic, 16 - 26 45 - 171 L -5211
fiberglass, and other 10 - 14 45 - 170 L - 5210
hard to strip insula-
tion

Wire StripperTool Chart (Ideal Stripmaster)

EISPM-4-1-2

Figure 4-1 . Strippingwire with hand stripper (Sheet 2)

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BHT-ELEC-SPM

d. Partiallyclose the handles,allowing wire to center long provides excessive bare conductorand has poor
in slot as wire grippingfeature on stripperapplies pressure. mechanical strength and possiblycould short circuitto
other conductors. Use the following guides when
e. Close handle completelyto stripthe insulation. inspecting strip length:

f. Afterinsulation has been stripped, partially release a. Connector Contacts and Terminal Module Blocks.
pressureon handles.Thejaws will separate.Thisfeature When stripped portion of wire is fully inserted (bottomed
preventsjawsfrom closingand damagingbare conductor. out) in contact crimp barrel, wire can be viewed at
inspection holeand a maximumof0.031 inch (0.79mm) of
g. Removestripped wire. wire is viewed between crimp barrel and wire insulation.

h. Release handles allowing stripper to return to b. Ring Lugsand Wire Splice. Strip length for small
original position. gage terminated in ring lug and wire splice is as shown
in table 4-2.
i. Inspect wire for the following:
c. The Daniels 737 and CMS 20 electrical tool kits
(1) Nicked, scratched, or cut wire strands.Refer provide exact stripped length dimensions for most
to table4-1. connectors used in Bell helicopters.

(2) Frayed insulation. NOTE

Nicked or broken wire strands reduce

(3) Frayed wire strands. electrical current capacity and mechanical
NOTE strength of terminated wire.

Ensure hands are clean before touching 4-4. SOLDERING.

conductor.Grease and dirt will affect electrical
conductivityand tensile strengthof crimp joint. 1. GENERAL. Soldered connections are used in
helicopter electrical wiring to form a continuous and
j. Repeat above procedures if above conditions permanent metallic connection having a constant
warrant. Correct frayed strands by firmly twisting electrical value.Thisparagraph describes the materials
conductorin same direction as normal lay of thewire. and equipment used in soldering helicopter
interconnecting wiring. It also describes and illustrates
6. Inspectwire terminationsduring rework to ensure the the preparation and care of equipment, procedures to
wires are correctlystripped. Thetwo most commondefects befollowed, and the soldering techniques necessary to
in strippingare incorrectstrip length and nickedor broken create a properlysolderedjoint.
wire strands.Barecopperstrandsmust neverbeobserved.
Correct strip lengths are referencedin table 4-2. 2. DEFINITIONS AND DESCRIPTIONS.

Table 4-2. Ring lug and wire splicestrip length a. Soldering. Soldering is the process of joining two
or more metals together at a temperature lower than the
WIRE GAGE STRIP LENGTH melting points of the metals. In its motten state, solder
chemicallydissolvespartofthe metal surlacestobejoined.
26-24 0.16 in (3.96mm) Most metals exposedto atmosphereacquire a thin film of
tarnishoroxide; the longerthe exposurethe thickerthe film
10-20 0.19 in (4.76mm) becomes. This film is present even though it is not visible
18 - 14 0.25 in (6.35mm)
and solder alone cannot dissolveit. A soldering flux with a
meltingpoint lowerthan the solder must be used to wet the
12 -10 0.28 in (7.14mm) metalandallowthe soldertopenetrateand removethefilm.
The flux meltsfirst, removingtarnish or metallicoxide and
also preventingfurther oxide fromforming while the metal
7. STRIP LENGTH. Most termination components
is being heated to solder temperature.The solder then
(connector contacts, terminalmodule blocks, ring lugs, melts floating lighter flux and impuritiessuspendedin it to
and wire splices) provide a viewing window for the outer surlace and edges ofthe moltenfillet. Thesolder
inspecting the wire after the termination component is cools and forms an alloy with the metal. Most of the flux is
installed. Wire stripped too short will not make good burnedaway during the soldering processand anyresidue
contact with the termination device.Wire stripped too is removedby appropriatecleaning methods.

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 BHT-ELEC-SPM

b. Soft Solder. Soft solder is an alloy consisting of soft solder, use Rosin fluxes conforming to MIL-F-14256
various combinations of tin and lead, with silver and type RMA (mildlyactivated),such as solder flux (EC-023).
other additives, which melts at temperatures below Use RMA flux with SN63WS solder when soldering
699°F (371°C). It maybe in bar form to be melted for MIL-W-81381 wire. MIL-W-81381 (KAPTON) is a
tinning, or in the form of rosin-cored solderfor usewith copper-strandedwire with nickel coating.
a soldering iron or other heating methods. Soft solder
usedin helicopter electrical wiring mustconform to the 3. SOLDERING IRON PREPARATION AND
requirements of Federal Specification QQ-S-571 . Acid MAINTENANCE. For successful, effectivesoldering,
or inorganic chloride flux cores solder should not be soldering iron tip mustbe tinnedto provide a completely
used underany circumstances in a Bell helicopter. metallic surface through which heat may flow readily
from the iron tothemetalbeing soldered. If no tinningis
(1) Core Wire Solders. Rosin cored: present, iron will oxidize and heat cannotflow through.
Nonactivated or mildlyactivated plasticconditioned. Copper has a very high rate of heat conductivity, but
copper tips oxidize quickly and must be frequently
(a) For general applicationsat low temperatures cleaned and tinned. If a tip has becomebadly burned
up to 248°F (120°C), usetype SN6OWRAMAP(EC-039) and pitted, as a resultof overheating, replace it.
(59.5 to 61 .5 percent tin, remainder lead) to solder
tin-coatedcopper wire and coaxial cable. Some copper soldering iron tips used in production
soldering are coated with pure iron to help prevent
(b) For applicationwith silver-coatedcopper wire oxidation.A cleandamp clothmay be used to wipe the iron
and silver-platedconnections, use type SN62WRAMAP tip.
(EC-040) (61.5 to 62.5 percent tin, 1 .75 to 2.25 percent
silver, remainderlead). For high temperatureup to 376°F
(191 °C) maximum, useAg2.5 or Ag5.5. Do not confuse AUTION1
hightemperaturesoft solderwith the hard solder described
in paragraph4-4, step 2, substep (c). DO NOT FILE SOLDERING IRON TIPS
COATED WITH PURE IRON. FILING WILL
(c) For applicationson printedcircuit boards and RUIN THEPROTECTIVE COATING. IFTHE
semiconductordevices where temperature limitationsare TIP IS PITTED, REPLACE IT.
criticaland for other applicationswhere an extremely short
melting range is required, use type SN63WRAMAP a. With the iron unplugged, file each working
(EC-041) (62.5 to 63.5 percent tin, remainder lead). surface of the tip with a double-cut mill file until it is
smooth and a bright copper color. Referto figure 4-2.
(2) Solid Wire Solder. Rosin-base flux is
normally used with solid solder. Use of type W flux will
ensurethe productis non-activated. Following isa list of
solid wire solders (with application), if preferred over
rosin-cored solders:

(a) SN6OWS for general electrical and

electronics applications.

(b) SN62WSfor silver-plated applications.

(C) SN63WS forapplicationson printed circuit
boards and semiconductor devices.
BEFORE AFTER FILING
c. Hard Solder. Hard solder (EC-045), often CLEANING AND RETINNING
called brazing alloy, is a silver alloy which melts at
E/SPM-4-2
temperatures ranging from 68 to 1600°F (360 to
871°C). Hard solder is usedwhen greatermechanical
strengthor exposure tohighertemperatures is required.
Hard solder is commonly used in helicopter electrical
Figure 4-2. Soldering iron tip before and after
systems for soldering thermocouple connections. cleaning
d. Flux. Flux is a chemical reducerused for surface b. Remove copperfilings from dressededgeswith
conditioningbefore and during the soldering process.With a file card.

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BHT-ELEC-SPM

c. Plug in the iron. of a damp cleaning sponge. This removes the surface
dross and excess solder fromthe working surface.

I WARNING 1 b. Once a day, remove thetip and clean the black

scale from the inside of iron and from the tip with fine
steel wool. When iron tip is new, coat inside of shank
AVOID ORAL CONTACT WITH HANDS
with dryflake graphiteor antiseize compound (EC-090)
DURING SOLDERING OPERATIONS AND
to preventfreezing,and ensuremaximum heattransfer.
WASH HANDS IMMEDIATELY AFTER
Whenreplacing tip, makesure itisinsertedthefull depth
SOLDERING OPERATION. THE LEAD
of casing and seatedfirmlyagainsttheheating element.
CONTAINED IN SOLDER CAN BE A
SOURCE OF OXIDE. LEAD OXIDE IS A
5. GENERAL SOLDERING PROCEDURES.
POISONWHICHCANACCUMULATEINTHE
Cleanliness is of the utmost importance in the soldering
BODY OVER THEYEARS RESULTINGIN A
SERIOUS HEALTH PROBLEM. TOUCHING operation. If possible,soldering should be done in an area
that is reasonablyclean and freefromexcessivedust.
SOLDER FOLLOWED BY SMOKING OR
EATING IS A POTENTIAL MEANS OF
a. Parts contaminated with dirt, oil, grime, grease,
INGESTING TRACE AMOUNTS OF LEAD
OXIDE. etc., cannot be successfully soldered. Make sure all
parts are mechanically bright-clean before soldering.
Cleanpartswith a cloth or brush dipped in ethylalcohol
d. Apply cored solder just as dressed copper is
(EC-008), or other approved solvent. Badly corroded
turning to a pigeon-blue, bronze, oxide color. This will parts may be cleaned carefullyby mechanical means,
allowthe flux to wet and cleantip before soldermeltsto such as using fine abrasive paperor a wire brush.
form an even bright coating. Referto figure 4-3.
b. Insulatedconductorsshould be strippeda distance
slightly longer than required for solder connection;excess
conductorwill be trimmed off priorto soldering.The outer
ROSIN-CORE• circumferenceof the end of the insulation shall have a
SOLDER
smooth edge. The inner circumference shall have no
insulationprotrusionsaround wires surface. Insulation shall
not show evidenceof nicks or cuts.

NOTE
I WARNING I
TIN WHILE IRON IS HEATING
AVOID ORAL CONTACT WITH HANDS
DURING SOLDERING OPERATIONS AND
E/SPM-4-3
WASH HANDS IMMEDIATELY AFTER
SOLDERING OPERATION. THE LEAD
Figure 4-3. Tinningsoldering iron tip CONTAINED IN SOLDER CAN BE A
SOURCE OF LEAD OXIDE. LEAD OXIDE IS
e. Wipe off excess solderwith a damp sponge or A POISON WHICH CAN ACCUMULATE IN
cloth. THEBODYOVER THEYEARS RESULTING
IN A SERIOUS HEALTH PROBLEM.
4. SOLDERING IRON MAINTENANCE.

OJ
TOUCHING SOLDER FOLLOWED BY
SMOKING OR EATING IS A POTENTIAL
MEANS OFINGESTING TRACE AMOUNTS
OF LEAD OXIDE.

NEVER SHAKE ORWHIP AN IRON TOGET 6. PRETINNING.

RID OF DROSS OR EXCESSIVE SOLDER
DROPLETS. a. Before wires are soldered to connectors, the
endsexposed by stripping aretinnedto holdthestrands
a. During use and just before each application,pass solidly together. The tinning operation is considered
thesolderingirontip (with arotary motion)throughthefolds satisfactory whenthe endsand sidesofthewirestrands

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 BHT-ELEC-SPM

are fused togetherwith a coatofsolder. Do not tin wires Table 4-3. Approximate soldering iron sizesfor
which are to be attached to solderless terminals or tinning
splices, or wires whichare to be crimpedto removable
crimp-style connectorcontacts. Wire size Soldering Iron Size
(AWG Gage) K (HeatCapacity)
b. Tinning with Soldering Iron. In the field, wires
smallerthan size No. 10 maybe tinned with a soldering 20-16 65Watts
iron and rosincore solderas follows: l4andl2 100 Watts

(1) Select a soldering iron having suitable heat lOand8 200 Watts
capacity for wire size. Make sure that iron is cleanand
well tinned. a. Solderingirons are available in wattage ranges
from 20 to 500 watts. Irons with wattage ratings of 60,
(2) Tin conductorfor about halfthe exposed length, 100, 200 watts are recommended for general use in
refer to figure 4-4. This is enough to take advantage of helicopter electrical wiring. Pencil ironswith a rating of
closed part of solder cup. Tinningor solder on wire above 20 to 60 watts are recommended for soldering small
cup causes wire to be stiff at point where flexing takes parts. The soldering iron recommended for printed
place. Thiswill result in wire breakage. Refer to figure 4-5 circuitsoldering is alightweight 55 wattironwith a600°F
for properlystripped and tinned conductor. (316°C) Curie point tip control. This iron has a
three-wire cord to eliminate leakage currents which
coulddamageprinted circuits.
b. Asoldering ironshouldalso besuitedto thetask.
ROSIN-CORE-
SOLDER
Do not select a small pencil iron where a high steady
heat flow is required.
8. SOLDERING TIP SELECTION. Select the tip best
suited for size and shape of workto be soldered. Some
common tip shapesare shown in figure 4-6. Solderingiron
E/SPM-4-4 tips are available in sizes from 1/16 inch to 2 inches in
diameter. For general use, a tip of 1/4 inch to 3/8 inch
Figure 4-4. Tinning wire with a soldering iron diameteris recommended.Forprintedcircuitsoldering,use
a long shanktip of 1/16, 1/8, 3/32 or 3/16 inch diameter.
Screwdriver, chisel, and pyramid shapes are
recommended.

I WARNING 1
AVOID ORAL CONTACT WITH HANDS
DURING SOLDERING OPERATIONS AND
WASH HANDS IMMEDIATELY AFTER
SOLDERING OPERATION. THE LEAD
CONTAINED IN SOLDER CAN BE A
SOURCE OF LEAD OXIDE. LEAD OXIDE IS
E/SPM-4-5 A POISON WHICH CAN ACCUMULATE IN
THEBODY OVER THEYEARS RESULTING
IN A SERIOUS HEALTH PROBLEM.
TOUCHING SOLDER FOLLOWED BY
Figure 4-5. Properly strippedand tinned SMOKING OR EATING IS A POTENTIAL
conductor
MEANS OF INGESTINGTRACE AMOUNTS
(3) Move soldering iron to opposite side of wire OF LEAD OXIDE.
and tin halfof theexposed length of conductor. 9. APPLICATION OF HEATAND SOLDER.
7. SOLDERINGIRON SELECTION. Selectasoldering a. Applyflux-coresolderattheexactpointbetween
iron with a thermal capacity high enough so that heat themetal and thesolderingiron (figure 4-7) holding iron
transfer is fast and effective.An iron with excessive heat directlyagainstthe assembly. Melt solderon thejoint,
capacity will burn or melt wire insulation, and iron with too not on the iron. Place soldering iron firmly against
littleheatcapacitywill makeacoldjoint inwhich solderdoes junction.If heavyrocking pressureis necessary, either
not alloywiththework. Table4-3providesa listof soldering irondoes nothavesufficient heatcapacity forthejob, or
iron sizes for various size wire. it has not been properlyprepared, or both.

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BHT-ELEC-SPM

ED ED ED 0

n
PYRAMID SCREWDRIVER CHISEL WEDGE CONCAVE BENT
E/SPM-4-6

Figure 4-6. Soldering iron tip shapes

SOLDER

SOLDER
CUP SHALL
BE

E/SPM-4-8

Figure 4-8. Soldering iron holder

11. OVERHEATING PROTECTION. Do not allow
E/SPM-4-7 theiron tooverheat. Disconnecttheiron if it is notin use,
between operations, or use a heat-dissipating stand
which will keeptheiron at a constant temperature.
Figure 4-7. Correct solderapplication 12. COOLING. When the solder joint has been
made, hold firmly in place until the joint has set.
b. Do not apply heat to the work any longer than
Disturbing finished work will result in a mechanically
necessaryto melt solderon allparts ofthejoint. Do notuse weakjoint, with highelectrical resistance. Allow solder
any more solder than necessary. Do not pile up solder joint to cool naturally. Do not use liquidsor air blasts.
around the joint; this iswasteful and resultsin joints difficult
13. CLEANING. If the correct amount of solder is
toinspect.Careshould beexercisedwfth silver-coatedwire used and procedure instructions followed carefully,
to prevent wickingduring solder application. there should be little or no excess solder or flux
10. SOLDERING IRON HOLDER. When the remaining on the finishedjoint. Removeexcesssolder
soldering iron is not in actual use during operations, or flux using the followingprocedure:
keep it in a holder. Referto figure 4-8. This will protect a. Excess flux may be removed by brushing joint
the operatoragainstburns andtheironagainstdamage. with astiff brush dipped in isopropyl alcohol(EC-009) or

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 BHT-ELEC-SPM

a similarapproved solvent.Use alcoholsparinglyand (3) The connector wrap shall be 180 degrees
avoid contact between alcoholand insulation. measured from point of contact with turret post and
conductortermination. Referto figure 4-10.
b. For cleaning printed circuit connectionsuse a
swab-stick dipped in isopropyl alcoholfor small areas (4) The conductorshall be positioned in contact
and a lint-free clothfor large areas. with turret post and base throughoutconductorwrap.
The conductor shall not overhang the base of the turret
c. Desoldering or removal of excesssoldermaybe terminal. Referto figure 4-11.
accomplished with solder wicks or suction-type
desoldering tools. Solder wicksmay be fashioned from
15. SOLDER CUP.
scrapmetalbraid used on shieldedcable or wire.
a. ConductorRemoval From SolderCup.
(1) Touch end of wick to solderedjoint.

(2) Apply heat to the solder wick to draw off (1) Apply antiwickingtweezersto stranded wire
excess solder. conductors.

14. CONDUCTOR TERMINATION. (2) Prior to removing solderfrom the soldercup,

heat thesolder cup to solder melting temperature and
a. Spade Terminal. remove the conductor.

(1) Strip wire insulation. (3) Remove residual solder from the solder cup.
The wicking method is most effective for removing the
(2) Tin wire to be terminated. smaller amountsof residualsolder atthe bottom ofthe cup.

(3) The conductor wrapon the spadetermination b. SolderCup Preparation.

shall be either 90 degrees or 180 degreesfrom pointof
entry onto the terminaland terminated flushwith thetop
or faceof the spadeterminal. In caseswhereminimum I WARNING I
bend radius of the connectorwrap is less than the
conductordiameter, theconductor wrapshall consist of
a 90 degree bend. Refer to figure 4-9. ISOPROPYL ALCOHOL IS FLAMMABLE.
DO NOT USE IN THE PRESENCE OF
SPARKS, HEAT OR FLAME.

(1) Cleanthe soldercup priorto soldering. New

solder cups can be cleaned with isopropyl alcohol,
(EC-009) and an acid brush. Used soldercupsthat are
to be reworked can be cleaned by tinning. Very dirtyor
oxidized soldercups may require abrasive methods to
removenonmetallic oxides.

NOTE

Connectortype solder cups require tinning

on the milled face and the corners of the
soldercup.

(2) Prefill the soldercupwith enough solder tofill

E/SPM-4-9 cupwithoutoverflowwhentinnedconductoris inserted.
Figure 4-9. Spade termination The amount of prefilling needed will depend upon
conductorsize and/or number of of conductorsbeing
(4) The conductor will be centered on spade used. As a rule ofthumb,fillthecupwith solderupto the
terminal.
lower lip of thecutoutsection.
b. TurretTerminal. (3) All excesssoldershouldbe removed, leaving
the terminal interior bright and shiny. Avoid spilling
(1) Strip wire insulation. solder into areas not requiring solder. Clean thesolder
cup with isopropyl alcoholand an acid brush after the
(2) Tin wire to be terminated. tinnedsoldercup hascooled.

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BHT-ELEC-SPM

270°

00
POINT OF
CONTACT

90°
E/SPM-4-10

Figure 4-10. Turret terminal conductorwrap

MINIMUM —,
INSULATION
CLEARANCE

CONDUCTOR
CONTACTS
BOTH THE +
BASE AND POST
OF TERMINAL

E/SPM-4-11

Figure 4-11. Turret terminal conductor position

c. Terminating the Conductorin a Solder Cup.
(1) Stripwireinsulation inaccordance withearlier E/SPM-4-12
instructions.
Figure 4-12. Inserting conductor
(2) Tin wire to be terminated in accordance with
step 6. (7) The insulation sleeving/tubing shall extend
beyond wire insulation a minimum oftwowire insulation
(3) Cut a sufficient length of insulation diameters. Referto figure 4-14.
sleeving/tubing (EC-073) and slide onto wire.
(8) The insulation sleeving/tubing shall fit snugly
(4) Heat the solder, and insert conductorwhen
solder is molten (allow gases and fluxes to escape). againstthe wire insulation.
Fully bottom theconductor. Refer to figure 4-12. 16. INSPECTION. Agood solderjoint will have a bright
(5) The wire shall be centered in the cup and silvery appearance,with smooth fillets and feathered, not
enterparallel to axis of soldercup. Referto figure 4-13. sharpedges. Theentirejoint will becovered with a smooth
The wire shall be bottomed and in contactwith rear of even coat of solder and the contour of the joint will be
thesoldercup. visible. Refer to figure 4-15. Anyof the followingindicatea
poor solder joint and are cause for rejection:
(6) Insulation clearance shall be a minimum of one
wire diameter and no greater than two wire diameters a. Dull gray,chalky,or granularappearance(evidence
(including insulation)fromthe top edge of solder cup. of a cold joint).

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 BHT-ELEC-SPM

MINIMUM
WIRE FILLET MILLED
STRANDS FACE
BARELY BARELY
COVERED COVERED

INSUFFICIENT SOLDER QUANTITY

E/SPM-4-13

MINIMUM ACCEPTABLE
Figure 4-13. Positioning of conductors SOLDER QUANTITY
LARGE
FILLET
ALMOST
CONVEX
INSULATION
TUBING EXTENDS
A MINIMUM OF TWO INSULATION TUBING NO
WIRE INSULATIONS FITS SNUGLY SPILLAGE
OVER INSULATION AGAINST WIRE
OF WIRE INSULATION

MAXIMUM ACCEPTABLE
SOLDER QUANTITY
E/SPM-4-15

Figure 4-15. Solder quantity

E/SPM-4-14 f. Globules, drips, or tails of solder.

Figure 4-14. Insulation sleeving/tubing g. If any of the aboveare present, thejointmustbe

taken apart, parts cleaned, and entire soldering
b. Hair cracks or irregular surface (evidence of a operation repeated using fresh solderand flux.
disturbedjoint).
4-5. SOLDERSHIELD TERMINATIONS.
c. Grayish, wrinkled appearance (evidence of
excessive heat). Thisparagraph describes theauthorized soldersleeves
and installation procedures for terminating shielded
d. Partially exposed joint (evidence of insufficient cableon helicopters. Shielded termination using pigtails
solder). is also discussed.
e. Scorched wire insulation or burned connector 1. SOLDER SLEEVES. Solder sleeves shall conform
inserts. to MIL-S-83519. This specification covers environment

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BHT-ELEC-SPM

resistant, heat-shrinkablesolder type shield terminations. terminations have pre-installed M22759/32 ground
They maybe used on data-bus, RF and shielded cables leads.
in applications where operating temperature does not
exceed 302°F (150°C). Each termination has a colored 2. SOLDER SLEEVE SHIELD TERMINATION FOR
thermal indicator which is designed to disappear when M83519/1 SERIES.
surlaces have reachedwetting temperature.Terminations
aresupplied premarkedwith a specific identificationcode. a. Prepare cable in accordance with applicable
MIL-S-8351 9 shield terminations are available in two procedures in table4-4, 4-5, or 4-6.
styles as follows:
b. Prepare groundedlead by stripping one end of
a. M83519/1 series itemizations are used with theapplicable M22759/32-22-9 wire.
MIL-C-27500 jackettypes:05,08,09,10,11, 12,14,15,
17, 18, 23 and their double jacket equivalents and all
MIL-C-7078cables.Theground lead mustbefabricated c. Using figure 4-16 as a guide, select the proper
from M22759/32 wire. termination for the cableand ground lead being used.

b. M83519/2 seriesterminations are used with the d. Assemble the cable, ground lead, and
same cables as the M8351 9/1 series. These terminations as shown in figure 4-17.

Table 4-4. Center strip preparation

Remove 1/4 to 5/16 inch (6.35to 7.94 mm) of cablejacket at the desired termination pointas follows:
a. Score the jacket around thecable in two places, 1/4 to 5/16 inch (6.35to 7.94 mm)apart.

- 1/4to5/16 inch (6.35 to 7.94 mm)

b. Score the jacket between the cuts.

Score here

c. Remove the section of jacket.

5 6

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 BHT-ELEC-SPM

Table 4-5. End strip preparation

Thiscable can be stripped according to the followingprocedures designed to leavetheshieldbraid smooth and
flat.The useof finger cots is recommended to preventtransferof skin oil to theshield.
a. Score and remove thejacket.

Sectionwhere
braid is to be
exposed 1/4 to 5/16 inch (6.35to7.94 mm)

h
b. Bunch thebraid.

c. Trimthe braid as close as possible to the jacket.

d. Score the jacket 1/4 to 5/16 inch (6.35to 7.94 mm)from the end of the braid.

Scorehere

1/4 to 5/16inch (6.35 to 7.94mm)

—i...J uuu__

e. Remove sectionof jacket carefully by pulling straight.Thiswill flattenthebraid strand ends.

5IIIIIII1" Pulistraight

f. Inspect thecableto make sure that thebraid strands are lying flat againsttheprimary insulation.

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BHT-ELEC-SPM

Table 4-6. End strip with braidfold-backpreparation

This cablecan be strippedaccording to thefollowing procedures designed to leavetheshield braid smooth and
flat. The use of finger cots is recommended to preventtransfer of skin oil to the shield.

Braidfolded
backand flat 1/4 to 5/16 inch (6.35 to 7.94mm)

CABLE

Part No. MARKING A B C

CODE MAX MIN MIN
M83519/i-i S1O1X 7/64 (2.78 mm) 3/64 (1.19 mm) 1/32 (0.79 mm)
M83519/1-2 Si02X 9/64 (3.57 mm) 5/64 (1.98 mm) 1/32 (0.79 mm)
M835i9/1-3 Si03X 13/64 (5.16 mm) 3/32 (2.38 mm) 3/64 (1.19mm)
M83519/1-4 5104X 1/4 (6.35 mm) 1/8 (3.18mm) 5/64 (1.98mm)
M83519/1-5 Si05X 19/64 (7.54 mm) 5/32 (3.97 mm) 3/32 (2.38mm)

Figure 4-16. M83519/1 termination selection

NOTE
Allow termination to cool before moving.
e. Using heating tool HT-900 or equivalent and
appropriate reflector, directheatatthe middleportion of
GROUND LEAD the termination. Refer to figure 4-18. Heat until the
followingis observed:
(1) Sleeveshrinks.

SHIELDED CABLE TERMINATION

I WARN INil
SLEEVE CONVENTIONAL HOT AIR GUNS MUST
E/SPM-4-17 NOT BE USED ON FUELED
HELICOPTERS BECAUSE OF EXPOSED
HEATING ELEMENTS. USE A RAYCHEM
HT-900, OR EQUIVALENT,COMPRESSED
AIR/NITROGEN HEATING TOOL,
QUALIFIED TO MIL-M-8352i/5.
(2) Solder melts and flows into the wire and shield
Figure 4-17. M83519/1 termination placement strands.

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 BHT-ELEC-SPM

(3) Sealing rings melt and begin to seep out the

ends of the sleeve.

e. Inspect termination in accordance with

paragraph 4-5, step 4.

4. SOLDER SLEEVE TERMINATION INSPECTION.

NOTE

The thermal indicator is an installation aid

and evidenceof color change shall not be
used as sole criterion for acceptance of
terminated assemblies.
E/SPM-4-18
a. Underheated terminations shall show definite
Figure 4-18. Position termination in reflector signs of presence of the thermal indicator. The soldered
area shall show traces of the thermal indicator at the
(3) Sealingrings melt and beginto seep out the minimum acceptable level. Thermal indicator will not be
endsof thesleeve. visibleinthesoldered areaatmaximum solderflowlevel.

f. Inspect termination in accordance with b. Visually examine sealing rings to ensure that
paragraph 4-5, step 4. they have recovered tightly around cable.
3. SOLDER SLEEVE SHIELDTERMINATION FOR c. Minimum solderflow.Acceptif all ofthefollowing
M83519/2 SERIES. conditions are present:

a. Prepare cable in accordance with applicable (1) Solderhas lost all appearance of ring shape.
procedures in table4-4, 4-5 or 4-6.
(2) Ground lead and shield contoursare visible.
b. Using prepared cable, wire, and figure 4-19,
select the propertermination for the cable being used.
(3) There is a definite filet visible along ground
c. Positionapplicable termination oncable.Referto leadand shield interlace.
figure 4-20. d. Maximum solder flow. Accept if all of the
followingconditionsare present:
I WARNING I
(1) Fillet is clearly visible between ground lead
and shield.
CONVENTIONAL HOT AIR GUNS MUST
NOT BE USED ON FUELED HELICOPTERS
BECAUSE OF EXPOSED HEATING (2) Joint area is visible despite browning of
sleeve.
ELEMENTS. USE A RAYCHEM HT-900,
OR EQUIVALENT, COMPRESSED e. Insufficient heat. Reject if any of the following
AIR/NITROGEN HEATING TOOL, conditionsare present:
QUALIFIEDTO MIL-M-83521/5.
(1) Contourof solder preform is visible.
d. Using heating tool HT-900 or equivalent, and
appropriate reflector, directheatatthe middleportion of (2) Contour of ground lead and/or shield is
the termination. Refer to figure 4-18. Heat until the obscuredby solder.
following is observed:
f. Overheated. Reject if any of the following
(1) Sleeveshrinks. conditionsare present:

(2) Soldermeltsandflowsintothewireandshield (1) Joint area is not visible because of severe

strands. darkeningof outersleeve.

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BHT-ELEC-SPM

M22759/XX
WIRE

CABLE

PART MARKING GROUND LEAD A B C

NO. CODE WIRE GAGE MAX MIN MIN

M83519/2-1 SO2O1X 20 7/64 1/32 1/64

M8351 9/2-2 S0202X 20 9/64 1/1 6 1/32

M8351 9/2-3 S0203X 20 13/64 5/64 3/64

M83519/2-4 S0204X 20 1/4 3/32 5/64

M83519/2-5 S0205X 20 19/64 9/64 3/32

M83519/2-6 S0206X 22 7/64 1/32 1/64

M83519/2-7 S0207X 22 9/64 1/1 6 1/32

M83519/2-8 S0208X 22 1 3/64 5/64 3/64

M83519/2-9 S0209X 22 1/4 3/32 5/64

M83519/2-1O SO21OX 22 19/64 9/64 3/32

M83519/2-11 SO211X 24 7/64 1/32 1/64

M83519/2-12 S0212X 24 9/64 1/16 1/32

M83519/2-13 S021 3X 24 13/64 5/64 3/64

M83519/2-14 S0214X 24 1/4 3/32 5/64

M83519/2-15 S0215X 24 19/64 9/64 3/32

M83519/2-16 S0216X 26 7/64 1/32 1/64

M83519/2-17 S0217X 26 9/64 1/16 1/32

M83519/2-18 S0218X 26 13/64 5/64 3/64

M83519/2-19 S0219X 26 1/4 3/32 5/64

M83519/2-20 S0220X 26 19/64 9/64 3/32

(DIMENSIONS ARE IN INCHES)

E/SPM-4-19

Figure 4-19. M83519/2 termination selection

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 BHT-ELEC-SPM

GROUND LEAD (2) Heat solder joint until the solder melts and
then carefullyseparate thecomponents.

b. Reterminate the solderjoint removing as much

solder from the cable shield as possible and then
installinganewterminator as described inparagraph 4-4.

SHIELDED CABLE 7. INSPECTION OF REWORK. Inspect all

SHIELD TERMINATION reworked assemblies per paragraph 4-5, step 4.
SLEEVE
E/SPM-4-20
8. TERMINATING MULTIPLE SHIELDED CABLES.
Whenterminating multiple shieldedcables usingsolder
Figure 4-20. M83519/2 termination placement sleevesproceed as follows:

(2) Solder fillet is not visible along ground lead NOTE

and shield interlace.
If four or more shields are to be terminatedat
(3) Wire insulation damaged (slight browning
okay)outsideof sleeve.
a giventerminationpoint, theshieldsshould be
arrangedinto groups.Each groupwill consistof
5. REWORK OF SOLDER SLEEVES. The a maximum of four shields linked from one
insulation sleeve must be replaced if it is misaligned, shield to the other. The last terminationof each
overheated or otherwise damaged. group willthen beterminatedwith a splice cap.
Final termination of splice capto ground, or a
a. Remove sleeve by perlorming the following: connector pin, requires a separate wire. All
splice capswill have a maximumof fourwires.
(1) Score sleeve using a sharp blade. It is not
necessary to cutthroughthe sleeve.Use care notto cut a. Install solder sleeves as outlined previously in
cablejacketor ground lead insulation.
paragraph 4-5.
(2) Reheat sleeve until it softens and then grasp it
with needle-nosepliers, on the side oppositeof the scored b. Each cable in turn is attachedto the adjacent
cable and the final hookup wire is terminated with a
line, and gently pull the sleeve off of the assembly.
contactand then insertedinto the connector. Referto
b. If examination of the solder joint after sleeve figure 4-21.
removal show that the solder joint is acceptable,
reinsulate the termination using the following 9. SHIELD TERMINATION. When terminating a
shielded cable assemblyusing a pigtail, refer to figure
procedures:
4-22 and proceed as follows:
(1) Use a terminatorof the correctsize.
a. Determineand markthepointat whichshielding
(2) Remove the solder preform by crushing the is to terminate. This will dependon length of conductor
preform and allowing it to drop out of the sleeve. necessary to maketheconnection, or in somecaseson
length of braid pigtail required to ground shielding.
(3) Center the sleeve over the solder joint and
heat until it recovers onto the assembly. b. Push backtheshielding so as to forma bulge at
this point, insert an awl, or other pointed tool, between
6. SOLDER JOINT REPLACEMENT. The solder thestrands of shielding and work an open circulararea
joint must be remade if it is misaligned or there is intothe shield. Maximum shield strand breakage shall
insufficient solderin thejointbecause of overheating. not exceed 10 percent. If more than 10 percent are
broken, use of an M83159/1 shield terminator is
a. Disassemblejoint using the following procedures: permissible.

(1) Remove sleeve using the procedures in c. Bend the cable,insertthetool between shielding
subparagraph 5, a. and wire and pull conductorthrough.

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BHT-ELEC-SPM

11. ALTERNATEMULTIPLESHIELD TERMINATIONS.

An alternate method employing pigtails may be used if
connectorhasacable clamp. Theprocedure isas follows:

NOTE
In the following steps if all shields will not fit
intoone solderless terminallug,use several
terminallugs and distribute them underboth
screws.
a. Form a pigtail on each shieldedwire and crimp
together in a solderlessterminallug.
b. Attach the terminal lug under the screw on the
cableclamp. Referto figure 4-24.
12. FLOATING SHIELD TERMINATIONS. Wiring
installations that do not requirethe shield to be terminated
to a contact or a ground are preparedas follows:
a. Strip the outer insulating jacket to expose a
maximum five-inchlength of shield.
b. Push backand trimshieldleaving1/4to5/16 inch
of bareshield.
c. Fold the shield back over the outer jacket.
Inspect wires to ensure that center conductorwas not
cut duringstripping.
d. Slide a 3/4-inch length of heat shrinkable tubing
(EC-069) over the folded back shield and apply heat.
The heat shrinkable tubing shall be installed before
conductorsare terminated.
E/SPM-4-21 e. The exposed length of conductor should be the
minimum length which is sufficientto accept insertionand
removal of tools, if applicable, but not more than four
inches.

4-6. SHIELDEDCABLE SPLICES.

Figure 4-21. Terminating multipleshielded
cables with soldersleeves This section covers selection and installation
procedures used for making environment resistant
d. Pullthe empty partofshield tautandtin the last 1/4 in-linesplices in shieldedcables.
inch unless crimped-on type terminal is to be attached.
1. TOOLSAND EQUIPMENT.
Crimp terminationis then accomplishedas required.
10. MULTIPLE SHIELD TERMINATIONS. When Tools Required
terminating multiple shielded cables using pigtails
M22520/5-O1 CrimpTool with die sets -101 or -102
proceed as follows: as required
a. Form a pigtail on each shielded cable. Referto RayChem model CV-5300 or HT-900 minigun
step9. heating tool (notto be used on fueledaircraft).
b. Crimp a single wire into one end of a splice then Ruler readable to 0.0625 inch.
insert and crimp pigtails in opposite end. Refer to figure Stripping tools forcable jacketand primarywires.
4-23.
Small scissors or diagonal cutters for trimmingcable
c. Solderorcrimpsingle wire in a selectedcontact. braid.

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 BHT-ELEC-SPM

LOOSENED SHIELD

//
\

TWIST NOTE
ANDTIN THIS AREA

Do not tin if crimp terminal is to be installed.

EISPM-4-22

Figure 4-22. Shield termination

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BHT-ELEC-SPM
SOLDERLESS
TERMINAL LUG
PREINSULATED PERMANENT
SPLICE

FORM PIGTAILS
OUTSIDEAREA
TO BE

KEEP POTTING
COMPOUND BELOW
THIS LINE

E/SPM-4-24

Figure 4-24. Terminatingmultipleshieldedcables

3. CABLE PREPARATION. References to cablesA
and B are used to denote opposite sides of splice. All
tolerancesare plus or minus 0.0625 inch unless noted
otherwise. Strip cablesas follows:
a. Removecablejacket as follows:
NOTE
POTTING MOLD OMITTED Both Cables
FOR CLARITY Single ConductorCables 2 in. (50.8mm)
TwoConductorCables 3 in. (76.2mm)
ThreeConductorCables 4.25 in. (107.95 mm)
E/SPM-4-23 Four ConductorCables 5.5 in. (139.7mm)
b. Removeall but0.5 in. (12.7 mm)of braid.

c. Stagger cut conductors. Cables A and B are

mirrorimages e.g. longestprimary conductorin cableA
is shortestin cable B. Referto figure 4-25.
Figure 4-23. Terminating multiple shielded 4. MULTICONDUCTOR CABLES. Measure from
cables using pigtails cablejacket. Referto table4-7 and figure 4-25.
2. INSTALLATION PROCEDURES. Select proper
splicekit fromtables 4-8 and 4-9. Table 4-7. Dimensionsfromcable jacket to end
of conductor
Example: A mixed gage cable having three 20
gage conductors connected to three 16 gage First Conductor 1.25 in. (31.75 mm)
conductors would require D-150-0260 kit.
Second Conductor 2.5in. (63.5 mm)
a. Refer to table 4-10 to determine material Third Conductor 3.75 in. (95.25 mm)
contained in each kit. Fourth Conductor 5.0in. (139.7 mm)
b. Refer to table 4-11 for dimensions material and a. Strip all conductor0.25 to 0.313 in. (6.35 to 7.938
a cross reference of material to kit. mm).

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 BHT-ELEC-SPM

b. Table4-10 providesamaterial listforeach kit. lfthe (5) Apply heat ends of sleeve until sealing rings
two cables to be spliced have different size conductors, meltand flow alongwireinsulation.
place items as follows:
6. INSPECTION.

(1) Large cable. Place outer sleeve, larger a. Wirecolorsinoppositesidesofcrimparecorrect.

terminator, and jumper braid. b. Crimpindentations are clearlyvisible.
C. Sealing sleeve is fully recovered and inserts
(2) Small cable. Place smallerterminator. havelost their shape and flowed alongwire.
d. Sealingsleeve is not split
5. SPLICE ASSEMBLY.
7. BRAIDSPLICE.
a. PrimarySplice: . . . ..
a. Slide jumper braid forward so that trailing end is
. at end of cablejacket.
(1) Place one sealing sleeve onto longer leadof
each matching set of conductors of cableA and B. b. Trimbraid and formboth endsofbraid around the
cableshieldsmaking surethat endofjumper braid does
not extend onto cablejacket.
(2) Installa crimp splice on eachconductorof cable
A. C. Position terminators so that solder preform is
locatedapproximately0.25 in. (6.35mm)from cablejacket.
(3) Crimp matching conductors into open end, of •
d. Heat terminatorsuntil solder melts and flows into
splice
braid.

(4) Center sealingsleeves over completed splices e. Inspection. Ensure terminators have been
and apply heat to center of sleeve to lock in position. heatedenoughand there is no unmelted solder.

Table 4-8. Kits (D-150-XXXX) for 1 to 1 splice

Primary Numberof Primaries

Gage
One Two Three Four
22 -0255 -0256 -0257 -0257
20 -0255 -0256 -0257 -0257
18 -0258 -0259 -0260 -0260
16 -0258 -0259 -0260 -0260
14 -0261 -0262 -0262 -0262
12 -0261 -0262 -0262 -0262

Table 4-9. Kits (D-150-XXXX) for mixed gage splices

SPLICE CONFIGURATION

SIDEA SIDEB KIT

2OAWGTWISTED PAIR 16AWG TWISTEDPAIR -0259
2OAWGTRIO 16AWG TRIO -0260
2X22AWG SINGLE 1X2OAWGSINGLE -0255
2X22AWGSINGLE 1X16AWGSINGLE -0258

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BHT-ELEC-SPM

Table 4-10. Material list

D-150-0255 QTY/ D-1 50-0256 QTY/

ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-01 1 1 D-1 50-0255-01-02 1

2 D-150-0255-02-01 1 2 D-1 50-0255-02-01 1

3 D-1 50-0255-03-01 2 3 D-150-0255-03-02 2

4 D-1 50-0255-04-01 1 4 D-1 50-0255-04-01 2
5 D-1 50-0255-05-01 1 5 D-1 50-0255-05-01 2

D-1 50-0257 QTY/ D-1 50-0258 QTY/

ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-02 1 1 D-1 50-0255-01-01 1

2 D-1 50-0255-02-01 1 2 D-1 50-0255-02-01 1

3 D-1 50-0255-03-03 2 3 D-1 50-0255-03-01 2

4 D-1 50-0255-04-01 4 4 D-1 50-0255-04-02 1

5 D-1 50-0255-05-01 4 5 D-1 50-0255-05-02 1

D-150-0259 QTY/ D-1 50-0260 0Th'/

ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-02 1 1 D-1 50-0255-01-02 1

2 D-1 50-0255-02-01 1 2 D-1 50-0255-02-02 1

3 D-1 50-0255-03-03 2 3 D-1 50-0255-03-03 2

4 D-150-0255-04-02 2 4 D-1 50-0255-04-02 4
5 D-150-0255-05-02 2 5 D-1 50-0255-05-02 4

D-150-0261 QTY/ D-1 50-0262 QTY/

ITEM PART NAME KIT ITEM PART NAME KIT
1 D-1 50-0255-01-02 1 1 D-1 50-0255-01-02 1

2 D-1 50-0255-02-01 1 2 D-1 50-0255-02-01 1

3 D-1 50-0255-03-02 2 3 D-1 50-0255-03-04 2

4 D-150-0255-04-03 1 4 D-1 50-0255-04-03 4
5 D-1 50-0255-05-03 1 5 D-1 50-0255-05-03 4

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 BHT-ELEC-SPM

Table 4-11. Dimensions of kit material and cross reference of material to kits
ITEM NO. 1 OUTER SLEEVE

l.D.
LENGTH USED KITS
PART NAME (NOM.) BEFORE AFTER D-150-
D-150-0255-O1-O1 8.0 0.315 0.080 0255 0258
D-150-0255-01-02 8.0 0.470 0.1 20 0256 0257 0259 0260
0261 0262

ITEM NO. 2 JUMPERBRAID

LENGTH l.D. USED IN KITS

PART NAME (NOM.)* MIN.* D-150-
D-150-0255-02-01 3.5 0.230 0255 0256 0257 0258
0259 0261
D-150-0255-02-02 5.5 0.344 0260 0262
*Measured on mandrel equalto I.D. mm.
ITEM NO. 3 TERMINATOR

LENGTH I.D. USED IN KITS

PART NAME (NOM.) MIN. D-150-
D-150-0255-03-01 0.625 0.180 0255 0258
D-1 50-0255-03-02 0.750 0.235 0256 0261
D-1 50-0255-03-03 0.750 0.280 0257 0259 0260
D-1 50-0255-03-04 0.750 0.370 0262

ITEM NO. 4 SEALING SLEEVE

LENGTH USED IN KITS

PART NAME (NOM.) COLOR D-150-
D-1 50-0255-04-01 0.085 RED 0255 0256 0257
D-1 50-0255-04-02 0.1 10 BLUE 0258 0259 0260
D-1 50-0255-04-03 0.170 YELLOW 0261 0262

ITEM NO. 5 CRIMP SPLICE

LENGTH USED IN KITS

PART NAME (NOM.) COLOR D-150-
D-150-0255-05-01 0.045 RED 0255 0256 0257
D-150-0255-05-02 0.064 BLUE 0258 0259 0260
D-150-0255-05-03 0.097 YELLOW 0261 0262

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BHT-ELEC-SPM

JACKET

SHIELD BRAID

CONDUCTOR
(3 EACH SHOWN FOR
A AND B CABLE)

TERMINATOR CRIMP BARREL

SHIELD BRAID
CABLE A.
(THREE 22 GAGE
CONDUCTORS)

SEALING SLEEVE

SLID BACK OVER CABLE

I
____________ HEAT
f SHRINKAB—
OUTER SLEEVE
I.D.

h CABLE B.
(THREE 22 GAGE
CONDUCTORS)
ITEM 1 OUTER SLEEVE

___________ L___________

ttD.
1.10 IN.

I.D.
ITEM

IIIi
SEALING SLEEVE
-f
ITEM 2 JUMPER BRAID

COLOR
CO.II'
2 PLACES
ITEM 5
O.D.
ITEM 3 TERMINATORS SPLICE
E/SPM-4-25

Figure 4-25. Example— 3-conductor shielded cable splice

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 BHT-ELEC-SPM

8. INSULATION OF SPLICE.
a. Centerheat shrinkableoutersleeveovercompleted
splice.

b. Heatoutersleeve, starting incenter, worktoward

one end and then the other. Move splice through heat
slowing enough to keepsleeve recovering.
c. Inspection. Ensure no splitsor tears are presenton
sleeve.
E/SPM-4-27
NOTE
BAS-KIT-OlO (EC-066) contains materialsand
instructionsto make shieldedcable splices.
9. FILTER LINE CABLE TERMINATIONS.
Figure 4-27. Octadent crimp
Procedures for terminating shieldedand jacketedfilter
line cables are shown in table 4-12. 4. M22520 CRIMP TOOL. Refer to figure 4-28 for
identification and operation of this tool. The basic
M22520/2-O1 and M2252017-O1 tool use locatingdevices
4-7. CONTACT CRIMPING PROCEDURES. known as positioners. They are individual locaterswith a
data plate attached to the top which specifiesthe contact
1. CRIMPING TOOLS. Crimping may be part number(s) accommodated,and correlates the wire
accomplished with hand tools that are cycle controlled size with the tool selector sethng. MIL-C-22520/7
by a precision ratchetthat releases the handles at the positioners can only be used on the M22520/7-O1 basic
proper crimp depth. Crimp tools have a turret or tool. A typical positioner is shown in figure 4-28.
positioner to select the proper crimp depth for a
specified contactand wire size. 5. TURRET HEADS. Turret Heads.These heads have
a turret which hasthree separate POSITIONERSthat are
2. CONTACT CRIMPING. The optimum method of color-coded and marked with the applicable contact size
attachingwire tothecontact is by crimpingthe barrel ofthe accommodated by each individual positioner within the
contactaroundthe wire. Thiscontrolledcompressiongives head. The color and contact size correspond to the
reliable mechanical strength and electrical continuity. informationon thefoil label (data plate)attachedtothe side
Crimping requires exact wire preparationand the proper of the head. The proper positioner is selected for the
tool to maintain manufacturers standards for the contacttypeand sizeto becrimped by referringtothe data
equipment. Each contact has a viewing hole in the barrel plate. A typical turret head is shown in figure 4-28.
to ensure proper placementof the wire.
a. The procedures for crimping contacts to wire
3. CRIMPING CONFIGURATIONS. The four indent conductoris as follows:
crimp provides the most uniform displacement of wire
and contact material and is used as the MIL standard. (1) Select proper positioning head to be usedfor
Refer to figure 4-26. The impression of the crimp contacts being crimped.
horizontally for MIL standard is the octadentwhich is
illustrated in figure 4-27. (2) If the head to be used is a turret head, first
depressthe turret trigger to release the turret to the
indexing or extendedposition as shown in figure 4-28.

(3) Place the head over the retaining ring on the

back of thetool (selectorside) and seated against the
tool body; secure the 9/64 socket head screws with an
Allen wrench. If positioning head is single positioner
type, omit steps4. and 5.

(4) If the positioning head is turret type, it has

three separate positioners that are color coded and
marked with applicable contactsize accommodated by
E/SPM-4-26
each individual positioner. Referto data plateto select
Figure 4-26. 4 Indenture crimp proper positioner to be usedforcontactbeingcrimped.

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BHT-ELEC-SPM

Table 4-12. Termination of shield and jacketed filter line cable

1. Cut slit and remove jacket from end of cable:

CUT SLIT

MINIMUM

2. Bunch, cut, and remove braided shield:

NOTE

Stripping procedures of filter line shielded jacketed cable for

termination intojunctionmodules and otherterminating devices other
than connectors shall be in accordance with paragraph 4-5, step 3.

3. Cut, slit, and remove jacket:

0.250 IN. (6.35 mm)

—H

1 IN. (25.4 mm) MINIMUM

4. Position soldersleeve termination and heat with hot air:

BRAID STRAP _________SOLDER SLEEVE TERMINATOR
WITH ATTACHED BRAID STRAP

5. Install protective sleeve (EC-069) using hot air:

PROTECTIVE SLEEVE

0.5 IN. (13 mm)

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 BHT-ELEC-SPM

M22520/1-O1CRIMP TOOL
9/64 HEXWRENCH

TURRET HEADASSEMBLY

TRIGGER

DATA PLATE

OPEN POSITION

RETAINER

"— TAPPED HOLES

INSERT CONTACT TO BE CRIMPED (THIS SIDE) Instructions for changing Turret head:
1. Press triggerwhich releasesTurret to indexing
position.

r
2. Place selected Turret Head assembly onto
retainer ring with screws lined up with tapped
holes.
TURRET IN TURRETSHOWN IN 3. After Turret Head assembly is seated against
INDEXING ring, tighten socket head screws with 9/64 inch
Allenwrench. Turret should index easilywithout
POSITION177 LOCKIO7 binding.
4. To remove, loosen socket head screws until
threads are disengaged from retainer ring and
removewithastraightlifting motion.
5. Allheads (single position, universalandturret)
are attached by means of two socket head
screws.
COLOR CODED
POSITIONERS Instructions for IndexingTurret Head Assemblies:
1. Press triggerwhich releasesTurret to indexing
position.
2. Selectpositioner desired fromcolorcoded data
plate on side ofTurret Head assembly.
SOCKET 3. IndexTurretuntilcolorcolded positioneris lined
SCREWS up with Index mark on top of Turret Head
assembly,atwhich timethe trigger will position
the Turret.
4. PressTurret until it snaps into locked position.
SELECTOR KNOB
Instructions for Using Indentor Closure Selector:
1. Refer to data plate on Turret Head assembly.
SEL. Below the wire size and opposite the contact
NO. size is listed the correct indentor closure
number.
SPRING CLIP 2. Removethespringcliplockfromselectorknob.
LOCK WIRE 3. Tool must be in open position when using
selector.
4. Raise selector knob and rotate to desired
selector number.
5. Replace thespringclipand toolis readyforuse.
6. Repeat instruction procedures when changing
contact and/or wiresizes.

EISPM-4-28-1

Figure 4-28. Turret head crimper(Sheet 1 of 2)

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BHT-ELEC-SPM

M2252012-01 CRIMP TOOL

DATA PLATE
(TYP)
POSITIONER

INDEXMARK

POSITIONER
LOCKPLATE

Instructions for Changing Positioners

INSERT CONTACT
(THIS SIDE) 1. Select correctpositioner for contact being crimped.
2. Insert positioner into positioner lock plate. Push and
rotate 900 to install.
3. Determinecorrectselector settingfor the wire size
from the data plateon end of positioner.
4. Lift selector knoband rotate until selector number
aligns with Index mark.
5. Tool is nowready for use. Insert contactand complete
crimping cycle.

CRIMPING INSTRUCTIONS

1. Insert contact thru indentor opening into positioner.

2. Insert wire into contact and hold securely to insure
that it bottomsin contact. Close handles until tool
WIRE bottoms and ratchet "Kicks Oft". Releasehandles and
remove crimped contact.

INSERT CONTACT M22520/1-01 CRIMP TOOL

THIS SIDE DANIELS PART NO.AF8

M2252012-01BASIC CRIMP TOOL

DANIELSP/N AFM8
,, WIRE—-1
TURRET IN
LOCKEDPOSITION ___,//

POSITIONER

NOTE: Aftercrimpingcycleis completed, inspectcontact. Make sure the wire is visible thru inspection hole
and thereare no fractures in contact.
E/SPM-4-28-2

Figure 4-28. Turret head crimper(Sheet 2)

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Page 30
 BHT-ELEC-SPM

(5) Rotate turretuntil correctpositioner is linedup

withtheindexmark onturrethead andpushturretinuntil 0.000 TO 0.031 INCH BETWEEN
it snaps intolocked position. CONTACT AND INSULATION

(6) Refer again to data platefor correctselector

settingforwire size being used. Withhandles fully open,
remove spring clip lockwire from selector knob, lift and
rotate selector knob (or slide the thumb button) to the
correctsettingand release. Referto figure 4-28. Install
spring clip lockwire.
WIRE
(7) Determine the proper length of insulation to INSULATION
be stripped. Wire mustbe visible in inspection holeand
thereshould be a 0.000 to 0.031 inch gap between the INDENT CRIMP
contactand the wire insulation. See figure 4-29. CONDUCTOR BARREL

NOTE
WIRE SHOULD BE VISIBLE
When crimping contacts with an insulation IN INSPECTION HOLE

support cup, make sure the insulation

extends into it 0.000 to 0.031 inch (0.40 to CRIMPED CONTACT
0.80 mm)from bottom of cup.
E/SPM-4-29
(8) Insert the stripped wire into wire barrel of
contact until the end ofthe wirecan beseenthrough the
inspection hole. Insert wire and contact through
indenters on front side of tool (opposite from selector Figure 4-29. Correct crimped connector pin
side) until it bottomsand fully seats in positioner.
7. CRIMP INSPECTION. Inspect crimpedcontactfor
(9) Hold the wire and contact in place and thefollowing. Referto figure 4-29.
squeeze toolhandlesuntil theyfully bottomand ratchet
releases, thus allowing handles to automatically return a. Wire isvisiblethroughinspectionhole inwire barrel.
to the open position. No wire strands shall protrudethrough inspection hole.

(10) Remove the crimped contact and inspect. b. Position of crimp impression is midwayon wire
Referto step7 and figure 4-29. barrel. (2 seriesof 4 indents)

6. SINGLE POSITION HEAD (POSITIONER). The c. Insulation gap should be less than 0.031 inch.
procedure for crimping contacts utilizing the positioner d. Contact is not bent or distorted.
is as follows:
a. Select the proper positioner to be used for the e. Wire strandsshall not be nicked or loose.
contact being crimped. f. Contact wire barrel is not cracked and plating is
b. Insert the positioner into the retaining ring on intact.
back of tool selector side. Refer to figure 4-28. The
g. Allwire strands shall be inside contactbarrel and
positioner is spring-loaded and mustbe pushed in then inserted to bottom of barrel.
rotated 90 degrees clockwise until it locksinto position.
Insert spring clip lockwire, if present, through retaining NOTE
ring.
c. Refertothedata plate forcorrectselectorsetting The following instructions in step 8 are to be
for wire size being used. With handles fully open, used as a guideline. Always refer to the tool
remove spring clip lockwire from selectorknob, lift and manufacturers recommended instructions for
rotate selectorknobto correctsettingand release and inspection.
reinstall spring clip lockwire.
8. TOOL INSPECTION GAGING. All crimping tools
d. Strip wire as described in paragraph 4-3.
can be checked for propercalibrationof the crimpingjaws
e. Insert wire and contact; crimpand inspectas per (indenters)by means of GO/NO-GO inspection gages. If
step7 and figure 4-29. the GO gage does not passthrough indenter tips and/or

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BHT-ELEC-SPM

NO-GOgage passes throughthe tips, do not usethe tool on the basic tool only. The tools may be gaged with a
but return it for repair. Thetools should be checked before positioningdevice installed, as long as it does not interfere
each series of crimpingoperations.Proceed as follows: with the gage operation. If the presenceof the positioning
device makes gaging difficult,remove it before inspecting.

b. The inspection procedureis as follows:

DO NOT CRIMP DOWN ON THE GAGE (1) Selecttheproperinspection gage to be used

PINS AS THIS WILL PREVENT THE TOOL from table4-13.
FROM FULLCYCLING TO THE RATCHET
RELEASE POSITION. (2) Set the selectoratthe proper selectornumber
as specified in table4-13.
a. Inspection of the M22520/O1, M22520/2-O1, and
M22520f7-O1 Basic Tool. Inspection gaging is performed (3) Closethe handles completelyand hold.

Table 4-13. Crimp tool inspection gages

Crimping Tool Part Number Inspection GagePart Number SelectorSetting

M2251 0/1-01 M22520/3-1 4
M22520/2-01 M22520/3-1 8

LJ
M22520/7-01 M22520/3-3 8

(4) The GO gage (green end) should passfreely

through the indenter. Referto figure 4-30.

(5) The NO-GO gage (red end) should not enter DO NOT USE TOOLS THAT HAVE BURRS
through the indenter tips. Referto figure 4-30. OR SHARP EDGES. BURRS OR SHARP
EDGES CAN CUT THROUGH GROMMET
WIRE SEALING WEBS AND DESTROYTHE
4-8. CONTACT INSERTION/REMOVAL.
ENVIRONMENTALSEALING CAPABILITIES
OF A CONNECTOR.
1. INSERTIONTO FRONT RELEASECONNECTORS.
Insertion tools for inserting contacts into front release
connector inserts are shown in figure 4-31. There is a a. Insert thecrimpedcontact intotheconnectoras
follows:
separatetoolforeach contact size. Contactsizes are listed
in table4-14. An indicatingband on theworking end of the
tool determines correct depth of tool insertion. Use these (1) Slide rearaccessoriesbackonto wire bundle.
tools to insert contacts in front release connectors with
removablecontacts.
(2) Selectthecorrect insertion tool and insertthe
crimpedend of the contact into the hollow end of the
Table 4-14. Contact and wire size range insertion tooland laywire in handle. Refertotable4-14.

Contact Size Wire Range Size (3) Guidethecontactintothecorrectlynumbered

grommet hole in the rearface of the insert and feed the
20 24—20 contactcarefullyintothehole.
16 22—16 NOTE
12 14—12
8 10—8 Isopropyl alcoholcan be used as a lubricant.
4 6—4
(4) Pushthe tool straight in at right anglesto the
0 2—0 grommet surface until contact is fully seated.

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 BHT-ELEC-SPM

GREEN RED

RED

GREEN

GO
TYPICAL DIE CLOSURE CHECK
E/SPM-4-30

Figure 4-30. Crimp tool inspection tool guide

(5) Withdrawthetool keeping it perpendicular to WILL CAUSE INSERTIONTOOL TO SHEAR

thegrommet face. BARRELWHILE INSIDEGROMMET.SHARP
EDGE OF SHEARED MATERIALWILL CUT
THROUGH THE GROMMET WEB AND
CAUSE A SHORT CIRCUIT.
DO NOTATTEMPTTO RESEATACONTACT
ONCE THE INSERTION TOOL HAS BEEN b. Gently pull on wire to make sure contact is held in
REMOVED. REMOVE CONTACT AND place.
START OVER AGAIN WITH CONTACT
BARREL PROPERLY LOCATED IN TOOL. (1) Fill all unused holes with unwired contacts
FAILURE TO FOLLOW THIS PRECAUTION and sealingplugsof appropriate size.

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BHT-ELEC-SPM

1- __
r
r

MS24256A20
INSERTION TOOLS MS24256A16

THRUSTASSIST COLLAR

THRUST ASSIST
COLLAR—N

MS24256R20
EXTRACTION TOOLS MS24256R16 EISPM-4-31

Figure 4-31. Insertion and extraction tools for frontrelease crimp-type contacts

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 BHT-ELEC-SPM

2. REMOVALFROM FRONT RELEASECONNECTOR. stop and bottomsin the insert hole. A slight rotation of
Tools for extractingcontacts from front releaseconnector thetool may aid the tool insertion.
insertsare shown in figure4-31.Thesizesfor each contact
are listed in table 4-14. Extraction tools have a hollow d. Push thethrust assist collar or slide forwardas
cylindricalprobe whichMssnuglyoverthe pinorsocketend far as it will go.
of the contact and releasesthe insert retentionclip when
e. Withdrawthetool from thecontact, keeping the
pushed over the contact. Two indicatingbands determine
correct depth;the band nearesttheworking end ofthe tool tool perpendicular to the insertface.
is for pin contacts, the other for socket contacts. The f. Remove the contact from the back of the
extractiontool has a thrust assist collar (or slide) which is connector.
pushedforwardto ejectthecontactfromthe insertretention
clip by means of an internalplunger. 3. CONTACT INSERTION FOR REAR RELEASE
CONNECTOR. Insertion tools may be single ended,
a. Selectthe correctextraction tool for the contact or double ended. Each is color-coded to contact size.
to be removed. Referto table 4-15. Connectorrear accessories (cable
clamp, etc.) must be removed prior to installation or
removalof contacts.
NOTE

MAKE SURE THE EXTRACTION TOOL IS Connectorshaving contactswhich are installed

ALWAYS EXACTLY ALIGNED WITH THE and removed from the rear of the connector
have blue color bands around them.
CONTACT TO AVOID DAMAGE TO THE
CONTACT OR INSERT. a. Contactinstallation with singleor double ended
tool. Referto figure 4-33.
b. Working from the front of mating end of the
connector, slipthe hollowend ofthe extractiontool over the (1) Select correct installation tool and place
contact,with the tool parallel to the contact and squarely contact wire in groove of installation tool.
perpendicularto the insert face. Refer to figure 4-32.

NOTE

Someextraction tools havea spacersleeve CONTACT

L2J
MUST BE INSERTED
PERPENDICULAR TO THE FACE OF THE
with positions for either pin or socket
CONNECTOR. DO NOT TIP, SPREAD, OR
contacts. Set to correct position before ROTATE THE TOOL WHILE IN THE
installing tool on contact. CONNECTOR.
c. Push the tool toward the rear of the connector (2) Slide tool downwire ontocontactcrimp barrel
with a firm steadypushuntilthetool comesto a positive until it butts againstthe contact shoulder.
Table 4-15. Insertion/removal toolfor rear release contacts
OPENING

COLORED ENDFORINSERTION WHITEENDFOREXTRACTION

EISPM TABLE#4-20

Tool Part No. Insertion End Removal End

M81969/14-04 Yellow White
M81969/14-03 Blue White
M81969/14-10
Red White
M81969/14-11
M81969/14-01 Green White

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BHT-ELEC-SPM

TOOL AT RIGHT ANGLE

TO INSERT FACE

TOOLAT RIGHT ANGLE

TO INSERT FACE

WIRE LAID IN
TOOL SLOT

REMOVALTOOL

INSTALLING TOOL

NO INSULATION CUP

/
WIRE
CONTACT RETENTION CLIP

GROMMET HOLE

INSTALLING TOOL TIP

INSULATION CUP

PLUNGER SLIDE RETRACTED

(THRUST ASSIST COLLAR)
CONTACT RETENTION CUP

WIRE

REMOVAL TOOL
E/SPM-4-32

Figure 4-32. Installation and removal of crimp contacts

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 BHT-ELEC-SPM

INSTRUCTIONS FOR PLASTIC TOOLS

INSTALLING (COLORED END) REMOVAL (WHITE END)
1. Hold the insertion half of tool 1. Withthe rearofconnector facing
(colored) between the thumb and you,lay thewireofcontact to be
forefinger and lay the wire to be removed along the slot of
inserted along the slot, leaving removal half (White) of the tool,
about 1/2 inch protruding fromthe leaving about1/2 inch from the
end of the tool tothe crimp barrel end ofthe tool to the rear of the
ofthecontact. connector.

2. Squeeze thewire hardintothetool 2. Squeezethe wire hard into the

at the tip, betweenthe thumb and tool between the thumb and
forefinger and at the same time forefinger about 1/2 inch from
quickly pull the protruding wire the tip and at the same time
withtheother hand awayfromthe quicklypull the connector away
tool. fromthe toolwiththe other hand.

3. The wire will now have snapped

into place. Slide the tool down
3. The wire will now have snapped over the wire and into the rear
intoplace.Pullitbackthrough tool seal and push it slowlyinto the
untilthetip seats on thebackend connector until a positive
ofthecrimpbarrel. resistanceisfelt. Atthistime, the
contact retaining clip is in the
unlock position.

4. Holding the connector with the 4. Press the wire of the contact to
be removed against the
rear seal facing you slowly push connections of the plastic tool
the contact straight into the and pull both the tool and the
connector seal. contact-wire assemblyoutofthe
connector.

5. A firm stop will be evident when

the contact positively seats in the
CAJ
connector. DO NOTTIP, SPREAD OR ROTATE
TOOL WHILEIN CONNECTOR.

REARRELEASECONNECTORS
PLASTIC TOOL
IDENTIFICATION
CRIMPED CONTACT
MATED PLUG AND RECEPTACLE INSTALLING TIP
(COLOR CODED)
-RETENTION CLIP

CONNECTOR
(REAR RELEASE)

Connectors having contacts which are installed and

removed from the rear of the connector have BLUE
color bands around them.
E/SPM-4-33

Figure 4-33. M81 969/14Plastic-type insertion/removal tool

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BHT-ELEC-SPM

(3) Griptool,wire,and contact as aunitandguide (2) Slide tool down wire into the connector
contact into connectorthrough sealing grommet and throughthesealinggrommet and intotheinsertuntilthe
insert until contact is firmly seated. tool stops againstcontactshoulder.

(4) Release grip on wire and withdraw tool from (3) Gripwire andtoolas aunitandwithdrawwire,
the connector until it clears the grommet. Hold wire tool, and contactfrom theconnectorsimultaneously.
forwardwhile tool is being removed from wire.

(5) Gentlypull wireto ensurecontact issecurein 4-9. SOLDERLESS TERMINALS.

connector.
1. GENERAL. Electrical copper wires and cables
4. CONTACT REMOVAL FROM REAR RELEASE are terminated with crimp-typetinned copper terminal
CONNECTOR. lugs to provide an easy and reliable method of making
connections and disconnections
NOTE
Crimp-type terminal lugs are tinned copper with the
For unwired contacts, an additional tool may barrel preinsulated or uninsulated depending on
have to be used in conjunction with the application. The insulated types have a tube of
extraction tool to push the unwired contact polytetrafluoroethylene (TFE) or similar material
from the front after the locking tines have permanently affixed to the copperbarrel.
been released by the extraction tool in rear. This paragraph describes recommended methods for
terminatingcopper and aluminum wires, using solderless
a. Remove with tweezer-type installation tool. terminal lugs. It also describesrecommendedmethods for
permanentlyjoining(splicing)wire, usingsolderlesssplices.
(1) Selectcorrect removal tool. Figure 4-34illustratesa typical solderlessterminal.
(2) Compress tweezerhandles to open tips and Hand, portable power, and stationary powertools are
placewire in groove. Reduce pressure on thehandles, available for crimping terminallugs. These tools crimp
allowing tips to close without nicking or cutting the thebarrel totheconductor, and simultaneously formthe
insulation. Slide tool down wire into connector until it insulation supportto the wire insulation. Use standard
stopsto release spring clip. (Class 1) tools; M22520/5-O1 tool with M22520/5-100

ON
dies for sizes 26 through 10 to crimpstandard copper
terminallugs M25036, M7928/1, and M7928/2.

DO NOT EXERT EXCESSIVE FORCE ON

RANGE OF WIRE SIZES
WIRE. IF CONTACT IS NOT EASILY
EXTRACTED, REMOVE TOOL AND TONGUE
REPEAT PROCEDURES. INSULATION
SUPPORT MFR
MARK
(3) To remove contact, pull on wire while
withdrawing tool.
b. Removal with single or double ended contact
removal tool.

(1) Selectcorrectremovaltool and placearound COLOR-CODED

the attached wire to be removed. INSULATION
WIRE
INSULATION STRIPPED
CAUTION WIRE

E/5PM-4-34
TO AVOID DAMAGE TO TOOL AND/OR
CONNECTOR, DO NOTTIP, SPREAD, OR
ROTATE TOOLWHILEIN CONNECTOR. Figure 4-34. Pre-insulated terminal — cutaway

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 BHT-ELEC-SPM

2. TERMINALTYPES. Table 4-17. Color coding of copperterminallug

insulation
a. Copper wire, sizes 26 through 10 are terminated
with crimp preinsulated tinned copper terminal lugs. Figure Terminal lug Wire sizes
4-34 shows the insulation as a permanent part of the insulationcolor usedwith
terminal lug extendingbeyondthe end ofthe barrel so that Yellow 26—24
it covers a portion of the wire insulation. This eliminates
using insulationsleeves. In addition, preinsulatedcopper Red 22—20,18
terminal lugs have a wire insulation grip barrel beneaththe Blue 16—14
insulation sleeve for additional termination mechanical
Yellow 12—10
strength. Pre-insulated crimp-type copper terminal lugs
accommodatemore than one copper wire size therefore
the insulation sleeve is color-coded. This facilitates the
identity of the wire sizes that canbe terminatedby each of
the terminal lugs. Refer to table 4-17to identify the wire
sizes for each color code.

3. HIGH PRESSURE CRIMPING.

a. Wire sizes 8 through 2 require a power operated

crimp tool for terminations and splices. The following
proceduresare referencedtothe AMP Hydraulichand tool
59975-1. Refer to figure 4-35. PLUNGER
(Pressure
Release).
(1) For die selection.

(a) Presshead latch and open crimp head as STRIKER

illustrated in figure 4-36.
SETSCREW

(b) Pull back die latchand rotate thumb knob

until desired die size appears. CAP

(c) Rotate thumbknobleftor right until die latch

lockswheel in desired position.

(d) Closehead. TRIGGER

Table 4-16. Wire strippingfor 2 through8 wire

RESERVOIR
HANDLE

WIRE WIRESTRIP LENGTH

MOVABLE
SIZE TERMINALS BUTT SPLICES LEVER
AND PARALLEL
SPLICES
(AWG) MIN MAX MIN MAX

8 21/64 23/64 13/32 7/16 E/SPM-4-35

6 25/64 27/64 15/32 1/2
4 29/64 31/64 17/32 9/16
2 33/64 35/64 19/32 5/8 Figure 4-35. AMP Hydraulic hand crimper

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BHT-ELEC-SPM

(a) Centering ofcrimp(crimpmaybe off center

but notoff end of wire barrel).
PRESS HEAD

(b) Wire size being used matches wire range

stampedon die position and terminal.
(c) End of wire is flush with or extendsslightly
beyond end of wire barrel.

(d) Thereare no nicked or missing strands.

KNOB

TERMINAL PARALLELSPLICE BUTTSPLICE

PULL
THENTURNTHUMB

E'0 "B" EQUALS WIRE BARREL

EISPM-4-36

Figure 4-36. Hydraulic crimp head

(2) Crimping procedure. SPLICE WIRE BARREL

ISVISIBLE,
POSITION SEAM
(a) Stripwiretodimensions listed intable4-16. TOWARD MOVING
(Lower) DIE
(b) Insert terminal or splice in upper die as
shown in figure 4-37. EISPM-4-37

(c) Pump leveruntil lowerdie gripsterminal or Figure 4-37. Terminal or splicepositioning

splice.
4. HAND CRIMP TOOLS. M22520 hand crimping
toolshaveaself-locking ratchetwhichpreventsthetools
(d) Insert stripped wire into wire barrel of fromopening until crimpiscomplete. Refertofigures39,
terminalor splice. 40, and 41 . This mechanism must never be
disassembled since it ensurespropercrimping closure.
(e) Pump leveruntil an audible pop is heardto These tools are checked by means of a gage for
indicate completion of crimp. assuranceof qualitycrimps. For good crimping results,
gaging is done before each series of crimping
operations. The M22520/5-O1 tool with M22520/5-100
(f) Retract movable die by pulling movable die ischeckedwith gage M22520/3-9 forNo. 12 and No.
leverslightlyoutward. Then,whilesqueezing trigger(to
1 0die closure, and M22520/3-1 0forthe No. 26through
actuate striker) compress levers to depress plunger.
No. 14 die closure. Gaging is done with thetools in the
Movable die will now retract.
fully closed position. Return tools which are out of
tolerance for repair. A hand crimping tool for high
(3) Inspectcrimpfor the following criteria: temperature terminals is shown in figure 4-38.

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 BHT-ELEC-SPM

LOCATOR'

TERMINALBARREL RESTS AGAINST LOCATOR

TERMINALTONGUE SLIDES UNDER

INSULATION ADJUSTMENT LOCKING SCREW

INSULATION ADJUSTMENT PINS

FINISHEDCRIMP

CRIMPING COLOR

QUICKTAKE-UPTRIGGERS

COLOR CODEDHANDLES

EISPM-4-38

Figure 4-38. AMP Crimping tool T-head59250for hightemperature terminals

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BHT-ELEC-SPM

INSERTED AND CRIMPED IN THE

TERMINALBARREL.

a. Strip wireinsulation dimension given intable4-18.

Table 4-18. Wire stripping lengths for small

copperterminallugs (insulation restriction)

Strip length
Wire size (In inches)
26 and 24 5/32 (3.97mm)
22 and 20 3/16 (4.76 mm)
18—14 1/4 (6.35 mm)
12 and 102 9/32 (7.14 mm)

b. Check tool with gage M22520/3-9forNo. 12-10die

closure and M22520/3-10for the No. 26-14 die closure.
Tools out of adjustment must be returned for repairs.

c. Insert terminallug, tonguefirst, into wire side of

tool crimping jaws, until terminal lug barrel buttsflush
againsttool stop on the locator.
d. Squeeze tool handles slowly until tool jaws hold
E/SPM-4-39
terminallug barrel firmly in place,butwithoutdenting it.
e. Insert strippedwire into terminallug barrel until
Figure 4-39. M22520 Series die type crimptool wire insulation butts flush against near end of wire
barrel. Referto figure 4-40.

INSULATION
f. Squeeze tool handlesuntil ratchet releases.
BARREL
6. INSPECTION OF CRIMPED CONNECTIONS.
Examinethe crimpedconnectioncarefullyforthe following:

L=J
DONOTUSE ANYCONNECTIONWHICH IS
FOUND DEFECTIVEAS A RESULTOF THE
VISUAL INSPECTION. CUT OFF
INSULATION
DEFECTIVE CONNECTION AND REMAKE
EISPM-4-40 USING A NEW TERMINAL LUG OR SPLICE.

Figure 4-40. Insertion of wire intoinsulated a. Indent centered on terminallug barrel or splice
terminal lug barrels.

LJ
b. Indentin line with barrel; not cracked.
5. CRIMPING PROCEDURE.
c. Terminal lugor splicebarrel notcracked, nicked,
bent or distorted.

d. Terminal lug or spliceinsulation notcracked.

e. Insulation grip crimped.
IF NOT PROPERLY STRIPPED, SOME OF
THE SMALLER GAGE THIN-WALL WIRE f. All wire strands are inside terminal lug conductor
INSULATION CAN BE INADVERTENTLY barrel.

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 BHT-ELEC-SPM

DIE INSTALLATION
M22520/5-O1&/1O-O1 CRIMP TOOLS
1. Align groove in diewith key in crimping tool and
push shank of die into hole. See detail A. Close
handle to makesure dies are properly seatedand
locked in place.thetool is now ready for use.

DIE REMOVAL

1. Withcrimping tool handleopen, place dieremoval

tool against end of knock-out pad and tap gently.
Seedetail B.The diewill bereleasedfromthe lock
springandejected approximately1/16inch.It can DETAIL A
now be removedbyhand.

2. Close the crimping tool handle and slide the die

removal tool betweenthe die and tool body. See
detail C. Pull handle open witha snap action. The
die will be releasedfromthe lockspringand can
then be removedby hand.

DETAIL B
DETAIL C

NOTE

DIE REMOVAL TOOLPART NO. HX3-82 CAUTION

FURNISHED WITH CRIMPING TOOL. BEFORE ATTEMPTING TO REMOVE DIES
(IFDIEREMOVAL TOOLISNOTAVAIL- FROM TOOL, ASSURETHAT ALLLOCKPINS
ABLE, A ROD, 3/16 INCH X 1-3/4 HAVE BEEN REMOVED. FAILURE TO DO SO
INCHES (APPROX.) MAY BE USED.) MAY RESULT IN SERIOUS DAMAGETO THE
TOOL.

DIE SET IDENTIFICATION

(M22520/10) AND (M22520/5) DIE SETS

WIRE & CONTACT

CAVITY ACCOMMODATED
DESIGNATIONS

HEX DIE CONTACT DIE TERMINALDIE

1,2, OR 3 CAVITIES CONTACT SIZE12, 10, (SEEINSTRUCTIONS BELOW)
8,4 & 0

ACTUAL
SIZE

HX3 (M2252o11o) HX4 (M22520/5)

DIE SET DIE SET
E/SPM-4-411

Figure 4-41. Crimp tools M22520/5-0land /10-01 (Sheet 1 of 2)

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BHT-ELEC-SPM

DIES FOR CRIMPING

TERMiNALLUGS, SPLICESAND ENDCAPS

1. Withdies open (see detail A), place termi-

nal, splice or end cap in proper cavity.
Sizes are stamped beloweach cavityon
side of die.
2. Locate terminal, splice or end cap with
locator (see detail B). Terminal should
locate with tonguebetween the arms of
the locator. Splice is centeredwith notch
in spliceresting on the locator. End caps
locate against the face of the locator.
TERMINAL Insertwireto properdepth.

OR 3. Close handle oftooluntildiesareclosed

SPLICE
and ratchetreleases. The crimp is now
complete. (see detail C.)
OR

ENDCAP DETAIL A

WIRE

11IIll!tIiIiliiIII!llhIIIffI!I!IIIIff1 END

DETAILB E/SPM-4-41-2

Figure 4-41. Crimptools M22520/5-01 and /10-01 (Sheet 2)

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 BHT-ELEC-SPM

4-10. SOLDERLESS SPLICES. b. Checkcrimptoolwith applicable gagefromtable

4-19. Return tools whichare out of tolerancefor repair.
Electrical copper wire may be spliced using C. Strip 5/16 to 11/32 inch of insulation from wires.
environmental or insulated splices. This paragraph
Ensurea gap of 1/32 to 1/16 inch exists between wire
provides the recommended procedures, toolsand parts insulation and crimp barrel.
necessary to performthis operation.
d. Position splicecrimp barrel in applicable die of
1. RESTRICTIONS.
the M22520/5-O1 or M22520/10-01 crimptool, so that
oneend ofcrimpbarrel buttsagainst crimplocator. Lock
a. There shall be not more than one splice in any in place by partially closing handles without denting
onewire segmentbetween anytwo connectors or other crimp barrel.
disconnect points.
e. Insert wire fully into crimp barrel and crimp by
closing handles until ratchetreleases.
b. Splices in bundles must be staggered, and shall
not increase size of bundle so as to prevent bundle from
f. Before completing the splice, slide the sealing
fitting into itsdesignated place orcause congestionwhich sleeveback over one of the wires.
will adversely affectmaintenance. Refer to figure 4-42.

g. Reverse the position of crimpbarrel in crimptool

c. Splices shall not be used to salvage scrap die. The attachedwire will extend through slot in crimp
lengths of wire. locator.

d. Splices shall not be used within 12 inches of a h. Lock crimp barrel in place by partially closing
termination device exceptas allowed in stepe. handleswithoutdentingcrimp barrel.

e. Splices may be used within 12 inches of a i. Insert wire fully into crimp barrel and crimp by
terminating devicewhen attaching to pigtail spare lead closing handles until ratchet releases.
ofaconnector, ortosplicemultiplewirestoasinglewire,
or to adjustwire sizes so that they are compatible with
contactcrimp barrel sizes.
I WARNING 1
2. ENVIRONMENTAL RESISTANT SPLICES.
Environmental resistant splicesare permanent splices DO NOT USE HEAT GUNS WITH
having a heat shrinkable insulating sleeve and meltable ELECTRIC MOTORS WHEN WORKING
environmental seals to protect the splice against ON HELICOPTERS THAT HAVE NOT
corrosion, degradation over time, and harsh BEEN DEFUELED AND PURGED FOR
environments. EXTENSIVE MAINTENANCE.

3. CRIMPING PROCEDURES. j. Slide sealingsleeve over crimp barrel, center it,

and shrinkwith hot airheater(HT-900). Heatthe middle
firstto lock sleevein place;then heat ends until sealing
a. Select the correct environmental splice, crimp ringsmelt and ooze out aroundwire. To ensurea good
tool, and die from table4-19. seal, allowspliceto cool beforehandling.

NOTE 4. PRE-INSULATED SPLICES. Pre-insulated

permanent coppersplices are used tojoin small copper
wires,sizes26through 10. Each splicesizecanbe used
Gaging isdonewiththetoolinthefully closed for morethan one wire size. Splicesare color coded in
position. Refer to crimp tool manufacture the same manner as pre-insulated small copper
manual for gaging procedures. terminallugs.

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Page45
 BHT-ELEC-SPM

E/SPM-4-42

Figure 4-42. Staggered splicesin wire bundle

Table 4-19. Environmental splicesand associated crimp tools

Dies
Color Splice Wire
Code Part No. Sizes M22520/5-01 Tool M22520/10-01 Tool Gauge
Red M81824/1-1 26—20 M22520/5-103 M22520/1 0-104 M22520/3-14
Blue M81824/1-2 20— 16 M22520/5-103 M22520/1 0-104 M22520/3-13
Yellow M81824/1-3 16— 12 M22520/5-102 M22520/1 0-103 M22520/3-12
NOTE: Raychem AD-i377 crimp tool mayalso be used. See figure 4-44.

SEALING SLEEVE METALCRIMP SPLICE

WIRE STOP

5. CRIMPING PROCEDURE. Crimp pre-insulated

CRIMP BARREL copper splices in the26 to 14 wire size rangewith the
M590413tool and the 12 and 10 wire sizes with the
M53316tool as follows:
NOTE
Pre-insulated splices may be crimpedwith
the M22520/5 or /10 tool as described
previously.
a. Check tool for correct adjustment. Tools out of
adjustment must be returnedto the manufacturer for
repairs.
b. Strip wire to length givenin table 4-20.
c. Forthe M590413tool, with tool handlesfully open,
setwire size selector knob to the proper position for wire
size being crimped. Slide terminal lug locatordown below
CRIMP LOCATOR CRIMP TOOLJAWS diesurfaceintofully retractedposition. Referto figure4-45.
FortheM525181 splice,slidethe MS9041 3-2 splice locator
E/SPM-4-43 back into retracted position, and insert splice into tool so
thatthe locatingshoulderon side of spliceto be crimped is
Figure 4-43. Locating sealed splicecrimp barrel in the space betweenthe two crimpingdies and insulation
in crimping dies barrel on this side of splice protrudesfrom wire side of tool.

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 BHT-ELEC-SPM

Forthe M7928/3splice, slide the MS9041 3-2 locator back the locatorgroove in the splice,and the insulationbarrel on
into retracted position, and insert the splice into the the side ofthe splice to be crimped protrudesfrom thewire
stationarydie so thatthe MS90413-2 locatorfinger fits into side of the tool.

Table 4-20. Strippinglengths— splices

Wire Size Stripping Length (Inches)

26—24 5/32
22—14 7/32
12—10 5/16

d. For the M53316 tool, one locator is used for both where the ambient temperature does not exceed 185°F
terminal lugs and M7928/3 splices. For MS25181 splice, (85°C). MIL-S-23586silicone rubbercompound is used to
insert splice intothe tool so that locating shoulder on the seal connectors located in areas where the ambient
side ofspliceto becrimped isinthespace betweenthetwo temperature is 185 to 448°F (85 to 232°C). MIL-24041
crimpingdies.Theinsulationbarrelon this side ofthe splice potting compound is resistantto fuel and oil and can be
used in areas where the ambient temperature is up to
protrudes from wire side of the tool. For M7928/3 splice,
insert splice into the movabledie so that locatoron the tool 258°F (125°C).
fits intothe groove in the splice.Theinsulationbarrelon the 3. GENERAL PRECAUTIONS. Potting compound
side ofthe splice to becrimped protrudesfromwire side of as received fromthemanufacturer isa two-partkit. The
the tool. containers must not be separated until used. The kits
are properlyweighed and require no furtherweighing
e. Squeeze tool handles slowly until tool jaws hold when mixing at least one kit at a time. Follow the
splice barrel firmly in place, but without dentingthe barrel. manufacturer's instructions carefullywhen mixing the
basecompound and accelerator if both are in separate
I. Insert stripped wire into splice barrel which containers. Substitution, partial mixing, or use of
protrudes from wire side of splice until strippedend of incorrectproportions of compound and acceleratormay
wire butts against the stop in the center of the splice. produce a sealantwith inferiorproperties.
This canbe seenthrough the spliceinspection window. a. Makesure that the entire amountof accelerator
is mixed into the entire amountof base. Any changeS in
g. Crimpby closing tool handles. Tool will notopen
until the full crimping cycle has been completed. catalystratiowill effectproperties ofthe sealant and may
also affectpotlife, reversion resistance, and hardness
h. After crimping, checkthat wire end is still visible of the cured compound. Do not mix base compounds
with accelerator componentsofdifferentbatchnumbers
through the inspection window. because substandard electrical properties may result.
i. Reverse position of splice in crimping tool (or b. Small quantitiesof mix (less than 1 kit) must be
location of crimping tool on splice) and repeatsteps b. mixed 100parts(byweight)ofbasematerials to 12parts
through h. to crimpwire intoother side of splice. (by weight) of accelerator.

4-11. CONNECTOR POTTING. I WARNING I

1. GENERAL. Sealingcompound is used to moisture SEALANT CONTAINS SMALL QUANTITIES
proof and reinforcethe wiring, connectedto the backs of OF FLAMMABLE SOLVENTS AND
electrical connectors, against failure caused by vibration RELEASES FLAMMABLE BYPRODUCTS
and lateral pressurewhich fatigue the wire at the solder DURING MIXING AND CURING. OBSERVE
cup. The sealing compound protects electric connectors ADEQUATE VENTILATION AND FIRE
from corrosion, contamination, and arcing by excluding PROTECTION DURING MIXING AND/OR
moisture, metallic particles, and helicopter liquids. This CURING.
section describes the MIL-S-8516C (EC-067) potting
4. PREPARATION OF PARTS.
compound used on helicopter electric connectors, and
gives instructionfor preparingand storingthe compound. a. The surface of the connectors to be protected
2. DESCRIPTION. Sealing compound in accordance with sealermustbe freefrom oil, grease, dirt, etc.Clean
with military specification MIL-S-8516A is a two-part thoroughly with aliphatic naphtha (EC-028). Clean
surfaces bywipingdrywithaclean,lint-freecotton cloth.
polysuffidesynthetic rubber compound, consisting of a
base and anaccelerator(curingagent),packagedtogether. b. Apply to cleaned area a mixtureof equal parts (by
Thiscompoundis usedtoseal connectorslocatedin areas volume)of primer (EC-064)and Tetrahydrofuran(EC-065).

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BHT-ELEC-SPM

DIE 3 (YELLOW)

DIE 2 (BLUE)
DIE I (RED)

SPLICEMUST BUTT AGAINST LOCATOR

CRIMP TOOLAD-l377
(RAYCHEM)

cL
RAYCHEM COLOR
SPLICES

ccc
PARTNO. CODE

cTp D-436-36 RED

cct=c iô
D-436-37 BLUE

ci D43638 YELLOW

D-436-42 BLUE

ct1Z0
( D-436-43 YELLOW

IIO
LO D-436-26 NONE

EISPM-4-44

Figure 4-44. RayChemenvironmental butt splices

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 BHT-ELEC-SPM

STATIONARY

2 SPLICE LOCATOR

WIRE SIDE

WIRE TO BE CRIMPED

TERMINALLUG LOCATOR RETRACTED FORIN-LINE SPLICES

M525181

E/SPM-4-45

Figure 4-45. Locating MS25181 splice in MS90413-2 crimpingtool

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BHT-ELEC-SPM

5. PREPARATIONOF SEALANT.
Equipment and Materials Required

Equipment
1. Automatic mixer
2. Pressure gun and accessories
PylesNo. 950 with variouscartridges and tips or Senco No. 250 with various cartridges and tips.
3. Freezercapableof maintaining a temperature of —30°F(—34.4°C)
4. Heatgun that provides heat of up to 120°F (45.9°C)
5. Centrifugecapable of operating at 2000 RPM
Material
1. Aliphatic Naphtha (EC-028)
2. Methyl-Ethyl-Ketone (MEK) (EC-081)
3. Strippable plasticcoating compound (Hot dipping) (EC-062)
4. MIL-S-8516 (PottingCompound) (EC-067)

To preparesealantproceed as follows:

I WARNING 1

THE ACCELERATOR CONTAINS TOXIC

COMPOUNDS. WEAR RUBBER OR
POLYETHYLENEGLOVES TO AVOID SKIN
CONTACT, AND CLEAN HANDS
PRESS AGAINST
THOROUGHLY IF MATERIALS CONTACT SIDETO FULLY
SKIN. DISTRIBUTE
ACCELERATOR
a. Slowly stiracceleratorto asmooth, creamy paste.
b. Agitate the sealer (MIL-S-8516) for at least two
minutes by hand stirring. Referto figure 4-46.
C. Weighoutthe desired amountof sealer.
d. Weigh out 12 parts of accelerator for each 100
parts of sealer used.
e. Add the required quantity of accelerator to the
basematerial and thoroughly agitate until no accelerator
streaks or traces of unmixed sealer are visible. This
usually requires approximately five minutes. The sealer
mustassume a uniform pink or tan color.
f. To ensure that material is adequately mixed,
spread a thin film on white paper and examineclosely
for accelerator or sealerstreaks.
E/SPM-4-46
g. The working life of the accelerated sealer is
approximately90 minutes at 36 to 75°F (24 to 27°C).
Longerworking life maybe obtained by cooling the sealer
to 5 to 60°F (5 to 15.5°C) just prior to addition of
accelerator. Figure 4-46. Hand mixingpotting compound

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 BHT-ELEC-SPM

h. The accelerated sealer mayalso be stored, for

periods of from 24 to 36 hours, by cooling quickly
immediately after acceleration and keeping at a
temperature of —20°F(—29°C).

i. After storing at low temperature, the accelerated

sealer may be thawed out by blowing compressedair on
the outside of the container.Do not raise the temperature
ofthe sealer by heatingor by blowingairinto thecontainer.

j. If the mixed compound is not to be used

immediately, store it as directedin paragraph 7.

k. Sealants havingan application time of one hour

or less shall be hand mixed on the job.

6. MECHANICAL MIXING PROCEDURE. Mechanical

mixing should be done at 60°F (15°C) or lowerto prolong
theworking life ofthe sealant.The procedureis as follows:

a. Hand mix the accelerator, or use paint shaker

vibrating machine if available. Shake for five to seven
minutes.

b. If the base material is packaged in a metal can,

cut off the topof thecontainerusing a mechanical can
opener. This should leave a smooth wall without any
burr at thetop of the can.

c. Clamp base material containersecurely to drill

pressgeared to 50 RPM minimum to90RPM maximum.
Insert a mixing paddle fashioned from a drill rod and
EISPM-4-47
wire. Referto figure 4-47.

d. Start drill press motor and slowly lower mixing

paddle intothe basecompound to combine anymaterial
which maysettle out.
Figure 4-47. Mixing paddle for potting compound

e. Scrape all accelerator from its container and 7. STORAGE OF UNMIXED SEALING COMPOUND.
placeit inthebase material. Startdrillpressmotoragain Store base compound and accelerator in a cool place,
and mix slowly for approximately two minutes. Stop preferably under refrigeration. Shelf life for MIL-S-8516
machine, raise paddle, and scrape containerwalls as and MIL-S-23586 compounds is approximately six
clean as possible. Start the drill press and lower the months when stored below 73°F (23°C) and can be
mixing paddle again and continue mixing for an extendedto one year whenstored at45°F (7°C)orbelow.
additional three minutes.

f. Make thin spread of sealant on white paper as

described in paragraph 5. If necessary, continue mixing
in two-minutecycles followed by paper test until no DO NOT STORE SEALING COMPOUND
traces of unmixed material are visible. The sealant is AT TEMPERATURESABOVE 26°C. KEEP
then ready for use. BASE COMPOUND AND ACCELERATOR
TOGETHER IN THE CARTON AS
FURNISHED. NOTE MANUFACTURING
g. Ifthemixed compound is notto be usedat once, DATE STAMPED ON CARTON AND USE
store in accordance with instructions in paragraph 8. OLDEST MATERIALFIRST.

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BHT-ELEC-SPM

than MIL-S-8516 compounds after quickfreezing.The

CAUTION storage life of quick-frozen MIL-S-23586 potting
compounds is usually less than three weeksat —40° F
(—40°C). In general, extended storageof mixed, frozen
DO NOT USE SEALING COMPOUND
potting compound shortenspot life and cure time after
WHICH HAS EXCEEDED NORMAL SHELF
thawing.The methodto determine whetherthe frozen
LIFE UNLESS IT HAS BEEN TESTED BY
compound is suitablefor use is to thaw the material. If
AN APPROPRIATE LABORATORY TO it isstill pourable and hassufficient potlife remaining for
EVALUATE ITS ACCEPTABILITY FOR
application purposes it can be considered satisfactory.
FURTHER USE. Mixedcompound intubesshouldnotbe storedin dryice
sincethe material will absorbcarbondioxideand cause
8. STORAGE OF MIXED SEALING COMPOUND. sponging or porosity.
Mixed MIL-S-8516 potting compound can be stored in
cartridgetubesfor periods of 30to 60days provided the 9. APPLICATION OF SEALER. Apply the properly
filled tubes are quick-frozen immediately after mixing mixed, accelerated sealerto the connectorshell with a
and are stored at—40°F(—40°C). Quick-freezing of the spatula,putty knifeor flow gun. A flow tip small enough
filled tubes is done by immersing for five minutes in to reach solderedwire connections at base of plug is
O-T-620 trichloroethane cooled with solid BB-C-104 recommended. Applythe accelerated sealerso that no
carbon dioxideto temperatures below—49°F (—45°C). large entrappedair bubblesremain which result in loss
Freezing by slowcoolingair is not recommended since of strengthand electrical properties. The sealingof the
it reduces the mixed storagelife. Mixed MIL-S-23586 connectors must protect the electrical wiring
potting compounds, usually have shorter storage life connections completely, as shown in figure 4-48.

POTTING COMPOUND
DISPENSER FILLING
CONNECTOR

POTTING
MOLD

FILLING WITH COMPOUND CURING

E/SPM-4-48

Figure 4-48. Fillingand curingof potting

4-00-00
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 BHT-ELEC-SPM

10. CURING OF SEALER. f. Roughen all surfaces of the original sealant

adjacent to the stripped area over at least one inch of
a. Curethe accelerated sealerforat least24 hours their length, usinga micarta scraperor cleanhardwood.
at(22to27° C) beforethe connectors are installed in the Take care nottoscratchthesurrounding metal surfaces.
electrical system. The curing time will be shortened if
temperatures are higher and will be lengthened if 12. CLEANING PRIOR TO RESEALING.
temperatures are lower.

NOTE
I WARNING I
Remove excess sealer from equipment
before it cures, using tolueneTT-T548. TO PREVENT INJURY TO SKIN, HEAVY
RUBBER GLOVES MUSTBE WORN.
b. When a finish,such as primer or lacquer, has been
removedduringstripping, refinish the area aroundthe new
sealantwith the same finish as was used originally. a. Remove all dirt and foreign matter which may
have accumulated duringstripping operations andother
11. REMOVAL OF SEALANT. structuralrepairs.

b. Scrubthe strippedareaand surroundings with a

I WARNING clean cloth dampened with methylene chloride
MIL-M-6998 (EC-027). Apply the cloth to only a small
TO PREVENTINJURY TO HANDS, HEAVY area at a time and change thecloth frequently.
RUBBER GLOVES MUST BE WORN
DURINGTHEFOLLOWINGPROCEDURES. C. Wipe the area thoroughly with a clean cloth
dampened with butyl acetate (EC-082).Apply the cloth to
a. Cut away as much sealant as possible around only a small areaat a time, and wipe off with a clean dry
the repairarea, using a sharp micarta scraper. Do not cloth before the butyl acetate dries. Change both cloths
usea tool made of metal. frequently.

b. Mask off the area surrounding the scraped d. Wipe the whole area under repair with a clean dry
sealantwithfabric-backed masking tape, (EC-049) and cloth.
similarlymaskany areas where the ensuing application
of strippermaysplash or drip.
13. PREPARATION OF CONNECTORS.
C. Apply stripper (EC-047) to the scraped sealant as
heavilyas possible without running or dripping. A micarta a. MS31 00, 3106, and 3108 connectors— Assemble
scraper pushedunderthe sealantwill acceleratethe action the backshell to the connector.Build up the back shell, if
of the stripper.Wipe off immediatelyanystripper that falls necessary, withthe cellophanetape (EC-068)to a depth of
accidentallyon unmaskedsurroundingareas with a clean at least 0.25 inch past the solder pots.
dry cloth, and mark its position for cleaning later, refer to
paragraph 4-11, step 12. b. MS3102connectors— All MS31 02 connectorsshall
have a fittingsleeve ofcellophanetapeoverthebackbarrel
d. At 10 minute intervals, remove the stripperand beforepotting.Tapesleeveshall besufficientheightto allow
any loosened sealant with micarta scraper, and applya pottingto a depth of at least 0.25 inch pastthe solder pots.
fresh quantityof stripper. Do not allowthe stripperto dry Remove tape afterpotting hascured.
out onthesealer. Repeat this cycleofoperations until all
the sealant has been removed. If there is any finish,
such as primeror lacquer, underthesealant, continue c. Other connectors— MS3103, 3110, 3112, 3114,
stripping to bare metal. 3116, and 25183connectorsare supplied with separate
plastic polyethylene molds. They shall be used in
e. Remove all masking tape. accordance with manufacturer's instructions.

4-00-00
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BHT-ELEC-SPM

14. PREPARATION OF UNETCHED TEFLON WIRE. d. Allowthe etchant to remain on the wire insulation
until the insulationbecomes dark (normally 15 seconds to
1 minute).

I WARNING I
e. Using a clean cloth saturated with naphtha or
MEKclean etched area.
ETCHANT SOLUTION (EC-063) IS
FLAMMABLE AND MUST NOT BE f. Peel strippable plastic coating compound from
EXPOSED TO OPEN FLAME. RUBBER connectorpin end of wire.
GLOVES AND SAFETY GOGGLES MUST
BE WORN. ANY ETCHING SOLUTION g. Place unused etchant in suitablecontainer fro
SPILLED ON SKIN MUST BE IMMEDIATELY disposal.
FLUSHED OFF WITH RUNNING WATER.
ETCHANTISTOXIC IFTAKEN INTERNALLY, 15. APPLICATION OF POTTING COMPOUND.
DUE TO CAUSTIC SODA FORMED ON Potted-type connectors differfrom the standard type by
REACTION WITH MOISTURE. IF having a shorterbodyshell. Thepotting compound is to
ACCIDENTALLYSWALLOWED, DRINK MILK be appliedas follows:
OR WATER. DO NOT INDUCE VOMITING.
OBTAIN IMMEDIATEMEDICALSERVICE.
I WARNINGj
a. Before potting, teflon wires not pre-etched shall SEALANT CONTAINS SMALL QUANTITIES
be treated as follows: OF FLAMMABLE SOLVENTS AND
RELEASES FLAMMABLE BYPRODUCTS
(1) Roughen (very lightly) the area to be etched DURING MIXING AND CURING. OBSERVE
using 600 grit sandpaper or Scotchbrite (EC-092). Do ADEQUATE VENTILATION AND FIRE
notsand through braids on outer insulation. PROTECTION DURING MIXING AND/OR
CURING.
(2) Clean roughened area with aliphatic naphtha NOTE
(EC-028), MEK (EC-081). Wipe dry before solvent

LJ
evaporates. Complete potting within two hours after
cleaning.

a. Slide the plastic mold over the wire bundle if

applicable or ensure tape sleeve is in place.

THE ETCHANT CONTAINS INGREDIENTS b. Ensure all wires are soldered or crimped to

LJ
THAT ARE HARMFUL TO METAL connector pins and all connector pins are inserted in
COMPONENTS.THEREFORE CARE MUST connector.
BE TAKEN TO ENSURE ETCHANT DOES
NOT COME IN CONTACT WITH WIRE,
SOLDER, SOLDER PIN, OR CONNECTOR.
ANY ETCHANT SPILLED ON CONNECTOR
MUST BE IMMEDIATELYWIPEDOFF USING POLYTETRAFLUORETHYLENE(TFE) AND
A CLEAN CLOTH SATURATED WITH FLUORINATED ETHYLENE PROPYLENE
NAPHTHA(EC-028),OR MEK (EC-081). (FEP) INSULATED WIRES REQUIRE
SPECIAL PREPARATION PRIOR TO
POTTING. REFER TO PARAGRAPH 4-11,
b. Dip wire connecter end into (hot dipping) STEP 14.
strippable plastic coating compound (EC-062) deep
enough to encapsulate solderpin,solder, and barewire. c. Install spare wires on all unused pins. Use the
largestgage wire that would normallybe attachedto each
c. Dip, pour, orswabthe etchant(EC-063) ontothe contact. Spare wires are approximately9 inches long.
arearequired forpotting.Thisareashall notexceed0.25
inch fromendofinsulation to aminimum of0.75inch and d. Insulate spare wires using MS25274 end caps.
a maximum of 1.5 inch onto insulation. Referto table4-21 to determine end cap part number.

4-00-00
Page54
 BHT-ELEC-SPM

e. Clean the complete connector assembly by a resilient surface or vibrantmechanicallyto help flow
scraping off rosin and then brush vigorously in new compound into all spaces and to releasetrapped air.
unused trichloroethane.

f. Insert pottinggun nozzle between centerwiresso i. Immediatelyafterfillingconnector,tie wires together

that sealantwill flow around contacts. looselyabout 6in. fromthe connector.Make sure that wires
are centrally located in the connectorso that each wire is
g. Maintaintip ofnozzleslightlybelowswell of material completelysurroundedby pottingcompound.Suspendthe
level while movingthe nozzle up as connectorfills. assembly so that the potting material remains level, as
shown in figure 4-48and allow to aircure for at least 1 1/2
h. To prevent air entrapment,pat downcompound, if hours at 75°F (24°C) without any movement. Make sure
necessary, with a 1 inch dowel.Tapconnectorassemblyon that the tie is applied afterpotting.

Table 4-21. Wire end caps

MS NUMBER COLOR WIRESIZE

M25274-1 Yellow 26—24
M25274-1 Red 22—18
M25274-1 Blue 16—14
M25274-1 Yellow 12— 10

4-12. SEMICONDUCTOR MAINTENANCE.

I WARNING I In solid statecircuitsthe impedance's and resistance's
encountered are of much lower values than those
THE ACCELERATORCONTAINS A TOXIC encountered in earlier state of the arts circuitry.
LEAD COMPOUND. AVOID EXCESSIVE Therefore, when measuring values of capacitors an
SKIN CONTACT. CLEAN HANDS instrument accurate in the high ranges must be
THOROUGHLY AFTER USING. WEAR
employed. Capacitorpolarity must be observedwhen
GLOVES.
measuring resistance. Usually more accurate
measurements can be obtained if the semiconductor
are removed from the circuit.
I WARN ING1
1. SEMICONDUCTOR TEST EQUIPMENT. Damage
SEALANT CONTAINS SMALL QUANTITIES to semiconductors by test equipment is usually the
OF FLAMMABLE SOLVENTS AND result of accidentally applying too much current or
RELEASES FLAMMABLE BYPRODUCTS voltage to the elements. Common causes of damage
DURING MIXING AND CURING. OBSERVE from test equipment are discussed in the following
ADEQUATE VENTILATION AND FIRE paragraph.
PROTECTION DURING MIXING AND/OR a. Test equipment with transformerless power
CURING.
supplies is one source of high current. However, this
type of test equipment can be used by employing an
j. Carefully placeassembly, still suspended, intoa isolation transformer in the AC power line.
drying oven for3to4 hours at 100 °F (38°C), or aircure
at 75°F (24°C)for 24 hours. b. It is possible to damage semiconductors from
line current, even though the test equipment has a
NOTE power transformer in the power supply, if the test
equipment is provided with a line filter. This filter may
Full cure with maximum electrical functionas avoltagedividerandapplyhalfvoltage tothe
characteristics is not achieved until 24 hours semiconductor. To eliminatethis condition, connect a
after potting. Do not perform electrical ground wire from the test equipment chassis to the
insulation resistance tests until this period chassisof theequipment undertest beforemaking any
haspassed. other connections.

4-00-00
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BHT-ELEC.SPM

C. Anothercause of semiconductors damage is a TRANSISTOR.IFASHORT CIRCUITEXISTS

multimeter that requires excessive current to provide IN THE CIRCUIT, PUTTING IN ANOTHER
adequate indications. Multimeters with sensitivities of TRANSISTOR WILL MOST LIKELY RESULT
less than 20,000ohms-per-volt should not be used on IN BURNINGOUTTHE NEW COMPONENT.
semiconductors as they could cause damage. If more DO NOT DEPEND UPON FUSES TO
than one milliampere is drawnon any range, this range PROTECTTRANSISTORS.
can not be safely used on small semiconductors.
C. Always check the value of the bias resistors in
d. When using a battery-type powersupply, always series with the various elements. A transistoris very
usefreshbatteriesofthe propervalue.Makecertain that sensitive to improper bias voltage; therefore,a short or
the polarity of the power supply is correct for the open circuit in the bias resistance may damage the
equipmentundertest.Donotusepowersupplieshaving transistor.
poorvoltage regulation
3. REPLACING SEMICONDUCTORS. Neverremove
2. TRANSISTOR TESTING. A transistor checker orreplace asemiconductor with a supply voltageturned
should be used to properly evaluate transistors. If a on. Transients thus produced may damage the
transistor tester is not available, a good multimeter may semiconductor or others remaining in the circuit. If a
be used. Make sure that the multimeter meets the semiconductor is to be evaluated in an external test
requirements outlined in the preceding paragraph. circuit, be sure that no more voltage is applied to the
semiconductor than normallyis used in the circuitfrom
a. To checka PNP transistor, connectthe positive which it came.
lead of the multimeter to the baseof thetransistorand
the negative lead to the emitter. Generally, a resistance a. Use onlyalow heatsoldering iron wheninstalling
or removing soldered-in parts.
reading of 50,000 ohms or more should be obtained.
Reconnect the multimeter with the negative leadto the
base. With positive lead connectedto the emitter or b. When installing or removing a soldered-in
collectora resistance value of 500 ohmsor less should semiconductor grasp the lead to which heat is applied
be obtained. between solder joint and the semiconductor with
long-nosed pliers. This will dissipate someof the heat
that would otherwise conduct into the semiconductor
b. Similartests canbe made on an NPNtransistor.
from the soldering iron. Make certain that all wires
With the negative lead of the multimeterconnected to
the base of the transistor the value of resistance soldered to semiconductor terminals have first been
between the baseand the collectoror emittershouldbe properlytinnedso thatthe necessary connection can be
made quickly. Excessive heat will permanently damage
high. Withthe positive lead ofthe multimeter connected
to the base, the value of resistance between the a semiconductor.
collectoror emittershouldbe low. If theseresults are not
C. In some cases, powertransistorsare mounted
obtained, thetransistoris probablydefective andshould
be replaced. on heat sinks that are designed to dissipate heat away
from them. In some powercircuits, thetransistormust
also be insulated from the ground. This insulating is
A U TION accomplished by means of an insulating washermade
of mica. When replacing transistors mounted in this
manner, be sure that the insulating washers are
IF A TRANSISTOR IS FOUND TO BE replaced in properorder. After thetransistoris mounted,
DEFECTIVE, MAKE CERTAIN THAT THE and before making any connections, check from the
CIRCUIT IS IN GOOD OPERATINGORDER caseof the transistortogroundwith a multimeter to see
BEFORE INSTALLING A REPLACEMENT that the insulation is effective.

4-00-00
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 BHT-ELEC-SPM

CHAPTER 5

CONTENTS — CONNECTOR CONTACTS AND TOOLING

Paragraph Chapter Page
Number Title Number Number

5-1 Connectors ...................................................................................... 5-00-00 3

5-2 Connector contact identification ...................................................... 5-00-00 3
5-3 Contact crimping ............................................................................. 5-00-00 3
5-4 Crimp tools ...................................................................................... 5-00-00 3
5-5 Contact insertion/removal ............................................................... 5-00-00 3
5-6 Connector to power contact per MIL-C-39029 ................................ 5-00-00 3
5-7 Power contacts per MIL-C-39029 .................................................... 5-00-00 3
5-8 Relay socket to power contact to relay cross reference .................. 5-00-00 3
5-9 Connectors and contacts by vendor part number ........................... 5-00-00 3
5-10 Thermocouple contact crimping ...................................................... 5-00-00 3

FIGURES

Figure Page
Number Title Number

5-1 Visual identification guide for MIL-C-39029 contacts .................................................. 4

5-2 Pin and socket identification chart ............................................................................... 5

TABLES

Table Page
Number Title Number

5-1 Crimp contact tooling ................................................................................................... 16

5-2 Connector to power contact per MIL-C-39029 ............................................................. 23
5-3 Power contacts per MIL-C-39029 ................................................................................. 25
5-4 Relay socket to power contact to relay cross reference ............................................... 29
5-5 Connectors and contacts by vendor part number ........................................................ 29
5-6 Thermocouple contact crimping ................................................................................... 30

5-00-00
Page 1/2
 BHT-ELEC-SPM

CONNECTOR CONTACTS AND TOOLING

5-1. CONNECTORS. a specified contactand wire size. Referto Chapter4for

stripping and crimping procedures. Refertotable5-1 for
A connector consistsof two parts: a plug assemblyand contactto tool identification.
a receptacle assembly. Connectors provide a means of
quick connection and disconnection of wires and wire
harnesses, for installation, testing, and maintenance. 5-5. CONTACT INSERTION/REMOVAL.
Each individual wire is terminated into a contact. The
contacts are held in place and insulated from the There are different methods of locking or securing
connector shell and othercontacts by adielectric insert. contactsin the connector. The connectorused will be
specified as afront or rear release. Refer to table5-1 for
5-2. CONNECTOR CONTACT IDENTIFICATION. the tool required and Chapter4 for insertion/removal
Contacts are the conductive elements of a connector procedures.
and easily insertedin or removed. Each contacthas a
color code to identifythe basic identification number
(BIN) number. Refertofigure 5-1. Figure 5-2 providesa
5-6. CONNECTOR TO POWER CONTACT PER
listofcontactpartnumbers andtheBINforeachcontact. MIL-C-39029.
Afterthecontact partnumber isdetermined refertotable
5-1 to identifythe correct crimptool. Thereare special Table 5-2 includes terminal junction module or
contacts used in some circuitson Bell helicopters that connectorpart, series numbers, and associated contact
are not identified with a colorcode.These contactswill partnumberforcontactpins.The Bell Standard contact
be identified with a manufacturers partnumber. Referto part number is also provided for some contacts. After
figure 5-2 for visual identification, item number, part part number is determined, reference mustbe made to
number, and connector application. Table 5-1 will table 5-1 fortool and setup specifications.
specify the proper crimp tool with turret or positioner
setting whenusingthe itemnumber and partnumberas
a cross reference. 5-7. POWER CONTACTS PER MIL-C-39029.
5-3. CONTACT CRIMPING. Table 5-3 provides contact MIL number, BIN number,
mating wire size, and maximum wire entry size. The
The optimummethod of attaching wire to the contact is connectorfamilycolumn includes type of release and if
by crimping the barrel of the contact around the wire. thecontactis a pin orsocket.Referto table 5-1 fortool
This controlled compression gives reliable mechanical
and setupspecifications.
strength and electrical continuity. Crimping requires
exact wire preparation and the proper tool to maintain
manufacturers standards for the equipment. Each
contacthasa viewing holeinthebarrelto ensureproper 5-8. RELAY SOCKET TO POWER CONTACT TO
RELAY CROSSREFERENCE.
placement of the wire. Refer to Chapter4 for contact
crimping procedures.
Table 5-4 includes relay socket part number, contact
part number, quantity of contacts, relay part number,
5-4. CRIMPTOOLS. number of relay poles, and contactampere rating.

NOTE
5-9. CONNECTORS AND CONTACTS BY
For each part number listed in table 5-1,the VENDOR PART NUMBER.
crimptoolturretor positioner, andinstallation
tool is listed. If the same tool is used for Table 5-5 includes connector and contact by part
installation and removal, only that part number, manufacturer, mating end size and maximum
number is listed. If separate tools are wire entry size.
required for removal or installation, it is so
identified.
5-10. THERMOCOUPLECONTACT CRIMPING.
Crimping maybeaccomplished with hand tools that are
cyclecontrolled by a precision ratchetthat releases the Table 5-6 references contactpart number, to crimptool,
handles at the propercrimpdepth. Crimptools have a and the positioner or turretsetting whencontactis used
turretor positioner to selectthepropercrimp depth for in a thermocouple.

5-00-00
Page3
BHT-ELEC-SPM

COLOR BANDS

1. BROWN WIRE BARREL END MATING END

TE I
2. RED
3. ORANGE
4. YELLOW
5. GREEN
6. BLUE
7. VIOLET
8. GREY
9. WHITE
0. BLACK

1st COLOR BAND (1st DIGIT)-WIDER MANUFACTURER'S SYMBOL

OR TRADEMARK
2nd COLOR BAND (2nd DIGIT)
3rd COLOR BAND (3rd DIGIT)

E\SPM-5-1

Figure 5-1. Visual identification guidefor MIL-C-39029 contacts

5-00-00
Page4
 BHTELECSPM

BHTI
BIN MFG.
PART NO. NQ QQQE CONTACT PQNNECTOR FAMIL,Y

(1) M39029/56-348 348 M

(2)] M39029/56-351 351 N #* .

For MIL-C-38999
SERIESI 11,111 &IV

(3) M39029/56-352 352 0 t::4ikt . . ..

. .
.7
(4) M39029/56-353 353 ww . ' '!
'

(5) M39029/57-354 354 A

(6) M39029/57-357 357 B

FOR MIL-C-38999
SERIES II

(7) M39029/57-358 358 C

(8) M39029/57-359 359 AG

uN NO. COLOR BANDS:Each digit ofthe bin number isdesignated onthe contact by a color band in accordance with the following:
OBLACK 2RED 4YELLOW 6BLUE 8GREV
I - BROWN 3 - ORANGE 5 - GREEN 7 - VIOLET 9 WHITE
The width ofthe firstcolor bandwill be twice thewidthofthesecondand third bands.
E/SPM-5-2-1

Figure 5-2. Pin and socketidentification chart (Sheet 1 of 11)

5-00-00
Page 5
BHTELECSPM

BHTI
BIN MFG.
PART NO fAQ CQDE CONTACT CONNECTOR FAMILY

(9) M39029/58-360 360 L

(10) M39029/58-363 363 E

For MIL-C-38999

r
__________________________________
SERIES I, II, III, & IV

(11) M39029/58-364 364 K ;.i. .....

kdtt ... .

(12) M39029/58-365 365 AH IL

tzar•'•

(13) M39029/1-iOO 100 S .... . MIL-T-81714/fl - (*) (*)

(14) M39029/1 101 101 H ifl . . MRTB (**) (*) (**)

(15) M39029/1-102 102 Q 4a MRTB (**) E *4699 (GND

j•
MODULE)

f
(16) M39029/1-103 103 -
se!r ;,
90-072-r)(GND MODULE)
30200(*)
(RES & DIODE MODULE)

(17) M39029/1-507 507 CC jj:;, ..

(RESASSY MODULE)

EISPM-5-2-2

Figure 5-2W Pin and socket identificatIonchart (Sheet 2)

5-00-00
Page 6
 BHT-ELECSPM

BHTI
BIN MFG.
PARTNQ NO CODE CONTACT CONNECTOR FAMILY

(18) M39O29/4i1O 110 JJ

(19) M39029/4-111 111 KK

(20) M39029/4-112 112 ---

MILC-26482 SERIESII

(21) M39029/4413 113 AF

MIL-C-81703SERIES EU

(22) 3O2O6-1 ;•"•• Ss MIL-C-83723SERIES III

MIL-C-83733
(23) M39029/5-115 115 LL

(24) M39029/5-116 116 MM

(25) M39029/5-117 117 ZZ

(26) M39029/5-11B 118 AB

(27) 30-207-1 --- GG

EISPM523
Figure 52. Pin and socket identificationchart (Sheet 3)
5-OO00
Page7
BHT-ELEC-SPM

BHTI
BIN MFG.
PARTNO NQ CODE CONTACT CONNECTOR FAMILY

(28) M39029/29-212 212 1

(29) M39029/29-213 213 RR

1Li;b;ssasas
(30) M39029/30-217 217 QQ MIL-C-501 5

(31) M39029/30-218 218 PP MIL-C-83723SERIES II

(32) M29029/30-219 219 P

(33) M39029/64-369 369 R .

'S 'PS fl:fS

MIL-C-24308
(34) M39029/63-360 368 F

(35) M39029/3124O 240 NN 4€S% :4,ik*r. •.. .... ': .

MIL-C-26482,SERIES I

*'
(36) M39029/32-259 259 HH
0* 4bM "NOTE' 240 &-259SEE

MIL-C-81703SERIES II
CONNECTOR

*t*tas*t :4't'flk#S fl
(37) M39029/31-228 228 X NT '\

EISPM5-2-4
Figure 5-2 Pin and socket identification chart (Sheet 4)

5OOOO
Page 8
 BHT-ELEC-SPM

BHTI

PARTNO. tfQ CODE CQNTAO]T CONNECTOR FAMILY

247
(38) M39029/32-247 II
4:ØMjjWMSS MIL-C-26482,SERIES I

(39) 30-199-1 ,;iJ*s :•

"NOTE" 240 & -249 SEE
--—- MILC-81703 SERIES II

s
CONDUCTOR
(40) 30-204-1 fl
(41) 30-203-1

(42) M39O29/3226O 260 V

(43) M39029/31-241 241 . ow' 4 :*awa*** '". ."

(44) M39O29/32248 248 - MIL-C-26500

(45) M39029/31229 -.
229
JU .

(46) 100-1018P ..
.
..f WINCHESTERCONNECTORS

___________________________ MRAC& XAC TYPE

MIL-C-28748/
(47) 100-10185 ntr

E/SPM5-25
Figure 5-2. Pin and socketidentification chart(Sheet 5)

5-OOOO
Page9
BHT-ELECSPM

BHTI
BIN MFG.
PARTNO. NO. CONTACT CONNECTOR FAMILY

(48) 1OOiO16P
WINCHESTERCONNECTORS

(49) 1004016S MRAC&XACTYPE

MIL-C-28748/
(50) 100-2018P s '

(51) 100-20185 --- T

(52) M28804/9-1 --- Z

MIL-C-22804

(53) M26804110-1 --- 'in,

(54) 10-189002-20F - - - J ......, FOR BENDIX PTO6CE

BELL STD. P/N 30-175-1-3

(55) 1019596320F AA OR 5

EISPM-5-2-6

Figure 5-2. Pin and socketidentification chart(Sheet 6)

5-00-00
Page10
 BHT-ELEC-SPM

BHTI
BIN MFG
PARTNO ffQ± CODE CONTACT CONNEPIOR FAMILY

(56) M39029/34-272 272 VV I.t..

t; r.IA.- .
..%:.

MIL-C-28747/3 & 4
(57) M39029/35-275 275 G .
...iy4.. .

(58) M39029/34-271 271 SS .. ;&az. a; . .

\MNCHESTER CONNECTORS

(59) M39029/35-274 274 D

4$ <?
1% SflS%; MRAC*

(60) M39029/34-273 273 1 : ..' XAC*

. n*, ..

,
(61) M39029/35-276 276 ! I .

:&444 ' ..?*$< .atat*¼

(62) M39029/22-191 191 EE

(63) M39029/22-192 192 DD/FF CTL' ANDCTJ7**

(64) M39029/22193 193 UU t..sast MILCS15I1

SERIES III & IV

(65) M39029/22-605 605 --- ..itI!. : M8I7I4SERIESII

E/SPM5-2-7

Figure 5-2. Pin and socketidentification chart(Sheet 7)

&.oo,,00
Page11
BIThELEC-SPM

BHTI
BIN MFG.
PARTNO. IfQI QDE CONTACT CONNECTOR FAMILY

(66) M39029/69-384 384 ---

(67) M39029/70-387 387 ---

MIL-C-85028
(68) M39029/69-385 385 V
;ifj.
INTERFACE SEAL
M85028/3 OR
HUGHES C11516
(69) M39029/70-388 388
aai
(70) M39029/69-386 386 -- - ts
NII(
••

I' 4t * r wtk

(71) M39029/70-389 389 ---

(72) 372-2514-010 --- BB tk COLLINS PROLINE

E/SPM-5-2-8

Figure 5-2. Pin and socketidentification chart (Sheet 8)

5-00-00
Page 12
 BHT-ELEC-SPM

BHTI
BIN MFG.
PARTI'O NQ CODE CONTACT CONNECTOR FAMILY

(73) M39029/1I-144 144 ---

(74) M39029/11-145 145 --- •.: ' ':'" MIL-C-81969, SERIES II PIN,

CANNON DPX2NE,
AMP MME2&
-146
(75) M39029/11 1 46 --- .

TRI STARTRE2SERIES

(76) M39029/12-1 48 148 -- -

(77) M39029/12-149 149 --- .

. ).ç<:;

(78) M39029/12 150 150

(79) M39029/18-1 66 166

MIL-C-81511,
(80) M39029/16-167 167 XX :' ' SERIES IV SOCKET

(81) M39029/16-168 168 - --

44frj_
—

Figure 5-2. Pin and socket identificationchart (Sheet9)

5-00-00
Page 13
BHT-ELEC-SPM

BHTI
BIN MFG.
PARTNO NP cODE CONTACT CONNECTOR FAMILY

(82) 031-0900-001 --- W

CANNON DPGM/FPJM SERIES

18414-5620 --- TI DEUISCHTJ***SERIES

CNS 081-900 •:, . BELLSID, RELAY BASE

120-118-1

(83) 2841-5-9000

DEUISCH 51186* * * * * *
2803-4-0000 MACDAC SIft

28841-13-9000

(84) 319-2222-171

EISPM 5-2-10

Figure 5-2. Pin and socket identIfication chart (Sheet 10)

5-00-00
Page 14
 BHT-ELEC-SPM

BHTI
BIN MFG
PART NO 4iQ. CODE CONTACT CONNECTORFAMILY

(85) M39029/92-531 531 MIL-S-12883/41

BELLSTD RELAY SOCKET

(86) M39029/92-532 532
:i g:
:i

(87) M39029/92-533 533 - -- MIL-S-12883/41

MIL-S-12883/46
(88) M39029/1O1-553 553

(89) M39029/1O1-554 554 - -- MIL-S-12883/46

(90) CNSO81900 :4?jjj.j BELLSTD 12O118*

(91) 800-20/30-1 •... .: DSO7* * 5

(92) 1O-189000-20F --- --- . ...,..,...,..,,,,.... .,........,.,....

3O175*P
or
PTO6CE8* P
(93) 10 1 95962-20F

________________________________ ,
EJSPM5-2-i1

Figure 5-2. Pin and socket identificationchart(Sheet11)

5-00-00
Page 15
 Table 5-1 . Crimp contact tooling
I
w
TI
m
ITEM CONTACT BASIC TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(I)/ I-
NO. PART NUMBER CRIMP TOOL POSITIONER POSITION REMOVAL(R) TOOL m
C)
1 M39029/56-348 M22520/2-O1 M22520/2-07 22/4, 24/3, 26/2 M81 969/14-01 (I)
•0
M22520/7-01 M22520/7-05 22/3, 24/2, 26/1
2 M39029/56-351 M22520/2-01 M22520/2-10 20/6, 22/5, 24/4 M81 969/14-02
M22520/1-01 M22520/1-04 20/3, 22/2, 24/1 M81 969/14-10
M22520/7-01 M22520/7-08 20/6, 22/5, 24/4
3 M39029/56-352 M22520/1-01 M22520/1-04 1 6/6, 1 8/5, 20/4 M81 969/14-03
M22520/7-01 M22520/7-04 20/7, 1 8/8, 16/8
4 M39029/56-353 M22520/1 -01 M22520/1-04 1 2/8, 1 4/7, ---- M 18969/14-04
5 M29029/57-354 M22520/2-01 M22520/2-06 22/4, 24/3, 26/2 M81 969/14-01

M22520/7-01 M22520/7-06 22/3, 24/2, 26/1

6 M39029/57-357 M22520/1 -01 M22520/1-04 20/3, 22/2, 24/1 M81 969/14-02

M22520/2-01 M22520/2-10 20/6, 22/5, 24/4 M81969/14-10

M22520/7-01 M22520/7-08 20/6, 22/5, 24/4
7 M29029/57-358 M22520/7-01 M22520/7-04 1 6/6, 1 8/5, 20/4 M81 969/14-03
M22520/1-01 M22520/1-04 1 6/8, 1 8/8, 20/7
8 M39029/56-359 M22520/1-01 M22520/1-04 1 2/8, 1 4/7, ---- M&1 969/14-04
9 M39029/58-360 M22520/2-01 M22520/2-09 22/4, 24/3, 26/2 M81 969/14-01
M22520/7-01 M22520/7-07 22/3, 24/2, 26/1
1 0 M39029/58-363 M22520/1-01 M22520/1-04 20/3, 22/2, 24/1 M81 969/14-02
M22520/2-01 M22520/2-10 20/6, 22/5, 24/4 M81 969/14-10

M22520/7-01 M22520/7-08 20/6, 22/5, 24/4

1 1 M39029/58-364 M22520/1-01 M22520/1-04 1 6/6, 1 8/5, 20/4 M81 969/14-03
M22520/7-01 M22520/7-04 1 6/8, 1 8/8, 20/7
12 M39029/58-365 M22520/1-01 M22520/1-04 1 2/8, 1 4/7, ---- M81 969/14-04
 Table 5-1 . Crimp contact tooling (cont)

ITEM CONTACT BASIC TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(I)/

NO. PART NUMBER CRIMP TOOL POSITIONER POSITION REMOVAL(R) TOOL
13 M39029/1-100 M22520/2-O1 M22520/2-11 20/7, 22/4, 24/3 M81969/14-02
26/2 M81969/14-1O
14 M39029/1-1 01 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 M81 969/14-02
M22520/2-01 M22520/2-11 20/7, 22/6, 24/5 M81 969/14-10
15 M39029/1-1 02 M22520/1-01 M22520/1-02 1 6/6, 1 8/5, 20/4 M81 969/14-03
16 M39029/1-1 03 M22520/1-01 M22520/1-02 1 2/8, 1 4/7, ---- M81 969/14-04
17 M39029/1-507 M22520/2-01 M22520/2-32 22/4, 24/3, 26/2, 28/1 M81 969/14-01
1 8 M39029/4-11 0 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 M82969/14-02
M22520/2-01 M22520/2-02 20/7, 22/6, 24/5 M81 969/14-11
M22520/7-01 M22520/7-02 20/6, 22/5, 24/4
1 9 M39029/4-1 1 1 M22520/1-01 M22520/1-02 1 6/6, 1 8/5, 20/4 M81 969/14-03
M22520/7-01 M22520/7-03 1 6/7, 1 8/6, 20/5
20 M39029/4-11 2 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 M81 969/14-02
M22520/7-01 M22520/7-03 20/5 M81 969/14-11
21 M39029/4-11 3 M22520/1 -01 M22520/1-02 1 2/8, 1 4/7, ---- M81 969/14-04
22 BELL STD. M22520/1 -01 M22520/1-02 1 8/4, 20/4, 22/3, 24/2 M81 969/14-02
30-206-1 M22520/2-01 M22520/2-02 18/7, 2017, 22/6, 24/5 M81969/14-11
23 M39029/5-11 5 M22520/1 -01 M22520/1-02 20/4, 22/3, 24/2 M81 969/14-02
M22520/2-01 M22520/2-02 20/7, 22/6, 24/5 M81 969/14-11
M22520/7-01 M22520/7-02 20/6, 22/5, 24/4
24 M39029/5-116 M22520/1-01 M22520/1-02 16/6, 18/5, 20/4 M81969/14-03

25 M39029/5-1 1 7
M22520/7-01
M22520/1 -01
M22520/7-03
M22520/1-02
16/7,
20/4,
18/6,
22/3,
20/5
24/2 M81 969/14-02
I
w

m
M22520/7-01 M22520/7-03 20/5 M81969/14-11
I-
m
C)
C/)
 Table 5-1 . Crimp contact tooling (cont)
I
w
TI
ITEM CONTACT m
BASIC TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(I)/ I-
NO. PART NUMBER CRIMP TOOL POSITIONER m
POSITION REMOVAL(R) TOOL 9
Cl)
26 M39029/5-11 8 M22520/1-02 M22520/1 -02 1 2/8, 1 4/7, ---- M81 969/14-04 -a
27 BELL STD. M22520/1-01 M22520/1-02 18/4, 20/4, 22/3, 24/2 M81969/14-02
30-207-1 M22520/2-01 M22520/2-02 1 8/7, 20/7, 22/6, 24/5 M81 969/14-11
28 M39029/29-212 M22520/1-01 M22520/1-02 1 6/6, 1 8/5, 20/4 M81 969114-03
29 M39029/29-213 M22520/1-01 M22520/1 -02 1 2/8, 1 4/7, ---- M81 969/14-04
30 M39029/29-21 7 M22520/1-01 M22520/1-02 1 6/6, 1 8/5, 20/4 M81 969114-03
31 M39029/29-21 8 M22520/1-01 M22520/1-02 1 6/6, 1 8/5, 20/4 M81 969/14-03
32 M39029/29-21 9 M22520/1-01 M22520/1-02 1 2/8, 1 4/7, ---- M81 969/14-04
33 M39029/64-369 M22520/2-01 M22520/2-08 20/7, 22/6, 24/5 M81 969/1-02
34 M39029/64-368 M22520/2-01 M22520/2-08 20/7, 22/6, 24/5 M81 969/1-02
35 M39029/31-240 M22520/1 -01 M22520/1-02 20/4, 22/3, 24/2 (I) M24256A20
36 M39029/32-259 M22520/2-01 M22520/2-02 20/7, 22/6, 24/5 (R) M24256R20
M22520/7-01 M2252017-02 20/6, 22/5, 24/4
37 M39029/31-228 M22520/1 -01 M22520/1-02 1 6/6, 1 8/5, 20/4 (I) M24256A16
38 M39029/32-247 M22520/7-01 M22520/7-03 1 6/7, 1 8/6, 20/5 (R) M24256R16
39 BELL STD. M22520/1 -01 M22520/1-02 1 6/6, 1 8/5, 20/4 (I) M24256A16
30-1 99-1 (R) M24256R16
40 BELL STD. M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 (I) M24256A16
30-203-1 (R) M24256R16
41 30-204-1
42 M39029/32-260 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 (I) M24256A20
43 M39029/32-241 M22520/2-01 M22520/2-02 20/7, 22/6, 24/5 (R) M24256R20
M22520/7-01 M22520/7-02 20/6, 22/5, 24/4
 Table 5-1 . Crimp contact tooling (cont)

ITEM CONTACT BASIC TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(l)/

NO. PART NUMBER CRIMP TOOL POSITIONER POSITION REMOVAL(R) TOOL
44 M39029/32-248 M22520/1-O1 M22520/1-02 16/6, 18/5, 20/4 (I)M24256A16
45 M39029/32-229 M22520/7-O1 M22520/7-03 16/7, 18/6, 20/5 (R)M24256R16
46 1 00-101 8P M22520/1-01 M22520/1-03 1 6/7, 1 8/7, 20/6 WINCHESTER P/N
47 100-1018S (I) 107-1015
48 100-1016P (R)107R1001
49 100-10165
50 100-2018P
51 100-20185

52 M28804/9-1 M22520/2-01 K473 (Daniels) 16/4, 22/3, 24/2 (I) TR22DIT,

(R) TR22DRT
53 M28804/10-1 616429(Buchannan) (I) ATH1O5O,
(R) ATH2O5O
54 BENDIX P/N M22520/1-01 TH254 (Daniels) 20/5, 22/4, 24/3 BENDIX
10-189002-20F (I) 11-6782
(R) 11-6900
1 0-1 89000-20F ASTRO

(I) ATBX-1-6781
(R)ATBX1 —2-6900
55 BENDIX P/N M22520/1-01 TH254 (Daniels) 16/6, 18/5, 20/4 BENDIX
1 0-1 95963-20F (K) 11-6782

1 0-1 95962-20F
(R) 11-6900
ASTRO
I
w
TI
m
I-
m
(I) ATBX-1 -6781
9
C')
(R)_ATBX-2-6900
0
Table 5-1 . Crimp contact tooling (cont) I
w
TI
ITEM m
CONTACT BASIC TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(I)/ I-
NO. PART NUMBER CRIMP TOOL POSITIONER POSITION m
REMOVAL(R) TOOL 9
Cl)
56 M39029/34-272 M22520/1 -01 M22520/1-03 20/6, 22/5, 24/4 (I) M81 969/1 8-01
57 M39029/35-275 (R) M81 969/20-01
58 M39029/34-271
59 M39029/35-274
60 M39029/34-273 M22520/1-01 M22520/1-03 1 6/7, 1 8/7, 20/6 (I)M81 969/18-01
61 M39029/35-276 (R) M81 969/20-01
62 M39029/22-191 M22520/7-01 M22520/7-11 22/4, 24/3 ---- M81969/16-04
DEUTSCH 81 51 5-23
63 M39029/22-1 92 M22520/7-01 M22520/7-12 20/5, 22/4, 24/3 M81 969/16-01

M81 969/14-10
64 M39029/22-193 M22520/7-01 M22520/7-13 16/8, 18/7, 20/6 M81969/16-02
M81 969/14-03
65 M39092/22-605 M22520/1-01 M22520/1-16 12/8, 14/7, ---- M81969/16-03
66 M39029/69-384 M22520/1-01 M22520/1-1 7 24/3, ---- ---- (I) M81 969/23-02
67 M39029/69-387 (R) M81 969/22-01
68 M39029/69-385 M22520/1-01 M22520/1-1 7 20/5, 22/4, 24/3 (I) M81 969/23-02
69 M39029/69-388 (R) M81 969/22-0 1
70 M39029/69-386 M22520/1-01 M22520/1-1 7 1 6/7, 1 8/6, 20/5 (I) M81 969/23-02
71 M39029/69-389 (R) M81 969/22-01
72 COLLINS P/N COLLINS P/N 22 24 26 COLLINS P/N
372-2514-01 0 372-8091-010
AMP P/N 48698
73 M39029/1 1 -1 44 M22520/2-01 M22520/2-23 22/4, 24/3, 26/3 M81 969/1-01
 Table 5-1 . Crimp contact tooling (cont)

ITEM CONTACT BASIC TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(I)/

NO. PART NUMBER CRIMP TOOL POSITIONER POSITION REMOVAL(R) TOOL
74 M39029/11 -1 45 M22520/2-O1 M22520/2-08 20/7, 22/6, 24/5 M81 969/1-02

M22520/7-01 M22520/7-02 20/6, 22/5, 24/4 M81 969/1-02

75 M39029/11 -1 46 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 M81 969/1-03

M22520/7-01 M22520/7-02 20/6, 22/5, 24/4

76 M39029/1 2-1 48 M22520/2-01 M22520/2-23 22/4, 24/3, 26/3 M81 969/1-01
77 M39029/1 2-1 49 M22520/2-01 M22520/2-08 20/7, 22/6, 24/5 M81 969/1-02

M22520/7-01 M22520/7-02 20/6, 22/5, 24/4

78 M39029/1 2-1 50 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 M81 969/1-03

M22520/7-01 M22520/7-03 20/6, 22/5, 24/4

79 M39029/16-166 M22520/2-01 M22520/2-13 22/4, 24/3, ---- M81969/16-04
80 M39029/1 6-1 67 M22520/2-01 M22520/2-13 22/4, 24/3, ---- M81 969/16-04

81 M39029/16-1 68 M22520/2-01 M22520/2-14 20/5, 22/4, 24/3 M81 969/16-01

M22520/7-01 M22520/7-02 20/6, 22/5, 24/4

82 CANNON P/N M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 CANNON P/N

(I) CIT-20
(R) CET-20-A
031 -0900-001 M22520/2-01 M22520/2-02 20/7, 22/6, 24/5 ASTRO P/N
ATA 1086
ATC 2046L
83 DEUTSCH P/N M22520/2-01 DANIEL P/N 26/3 ---- ---- M15570/22-1

84
2841-13-9000
TRI-STAR P/N M22520/2-01
K127-1

DANIEL P/N 26/3 ---- ---- Ml 5570/22-1

I
w
7'
m
I-
m
31 9-2222-1 71 Ki27-1
9
Cl)
•0
 Table 5-1 . Crimp contact tooling (cont) I
w
7'
ITEM CONTACT BASIC m
TURRET OR WIRE SIZE (AWG)/SELECT INSTALLATION(I)/ I-
NO. PART NUMBER CRIMP TOOL POSITIONER POSITION m
REMOVAL(R) TOOL C)
Cl)
85 M39029/92-531 M22520/2-O1 M22520/2-06 22/4, 24/3, 26/2 M81 969/14-01

M22520/7-01 M22520/7-06 22/3, 24/2, 26/1

86 M39029/92-532 M22520/1-01 M22520/1-02 20/4, 22/3, 24/2 M81 969/14-02

M22520/2-01 M22520/2-02 20/7, 22/6, 24/5 M81 969/14-11

M22520/7-01 M22520/7-02 20/6, 22/5, 24/4
87 M39029/92-533 M22520/1-01 M22520/1-02 1 6/6, 1 8/5, 20/4 M81 969/14-03

M22520/7-01 M22520/7-03 1 6/7, 1 8/6, 20/5

88 M39029/101 -553 M22520/7-01 M22520/7-1 2 20/5, 22/4, 24/3 M81 969/16-01

M81969/14-10
89 M39029/101-554 M22520/7-01 M22520/7-13 16/8, 18/7, 20/6 M81969/16-02
M81 969/14-03

90 PCD P/N M22520/2-01 DANIELS P/N 22/5, 24/4, 26/3 M81 969/14-01
CNSO81900 K642
91 DEUTSCH P/N M22520/1-01 TH244 20/4, 22/3, ---- ATD1 081

800-20/30-1 M22520/2-01 K392 20/8, 24/6, 22/7 ATD2095

92 AMP/BENDIX M22520/1-01 TH254 20/4, 22/3, ---- ASTRO P/N
P/N (I) ATBX 1 -6781
1 0-1 89000-20F (R) ATBX 2-6900
93 AMP/BENDIX M22520/1-01 TH254 16/6, 20/4, ---- ASTRO P/N
P/N (I) ATBX 1 -6781
1 0-1 95962-20F (R) ATBX 2-6900
 BHT-ELEC-SPM

Table 5-2. Connector to power contactper MIL-C-39029

CONTACT PARTNUMBER BELLSTD CONTACT
CONNECTOR and SERIES MALE FEMALE MALE FEMALE
MIL-T-81714 M39029/1-100
M81714/(*)(*)(*) M39029/1-101
MRTB(**)(*)(**) M39029/1-102
MRTB(**)E*4699(gnd module) M39029/1-103
110212(*)(resassy mod) M39029/1 -507
MS2778*** (switch)
10648BH***
(switch_light_assy)
MIL-T-81714, SeriesII M39029/22-191
M81714/60(**)(**) M39029/22-192
M81714/61 0* M39029/22-193
M81714/63(****) M39029/22-605
M81714/65(**)(*)
CT(*)_(**)_(***)In linejunctions
MIL-C-81511 Series Ill & IV
Class L connectors
Flange mounted
5JG020200Gnd Module or
CTJ72OKO1 B Gnd Module
MIL-S-22885/108 or
95******_***** Sw light assy or
18-200
MIL-C-83733 and MIL-C-26482 M39029/4-110 M39029/5-115 30-206-1 30-207-1
Series II M39029/4-111 M39029/5-116 20 AWG 20 AWG
M53470, M53471 , M39029/4-112 M39029/5-11 7 with 18 AWG with 18 AWG
M53472, MS3474, M39029/4-113 M39029/5-11 8 Wire Entry Wire Entry
MS3475, MS3476, and M39029/4-114 M39029/5-119
MIL-C-81703, SeriesIII
M53424, M53446,
MS3464, M53467,
MS3468, and
MIL-C-83723, SeriesIII
M83723/71 , M83723/72,
M83723/73, M83723/74,
M83723/75, M83723/76,
M83723/77, M83723/78,
M83723/82, M83723/84,
M83723/85, M83723/86,
M83723/87, M83723/95,
M83723/96, M83723/97,
M83723/98
MIL-C-5015 M39029/29-212 M39029/30-217
MS3450, MS3451, M39029/29-213 M39029/30-218
MS3452, M53454, M39029/29-214 M39029/30-21 9
MS3456, MS3459 M39029/29-215 M39029/30-220
MIL-C-83723,SeriesII M39029/29-216 M39029/30-221
M83723/17, M83723/18, M39029/30-222
M83723/19, M83723/20,
M83723/21 ,M83723/22,
M83723/23, M83723/24

5-00-00
Page23
BHT-ELEC-SPM

Table 5-2. Connector to power contactper MIL-C-39029(cont)

CONTACT PART NUMBER BELLSTD CONTACT

CONNECTOR and SERIES MALE FEMALE MALE FEMALE

MIL-C-81703, SeriesII M39029/31-240 M39029/32-259

MS3140, M53144, M39029/31-241 M39029/32-260
M53147, M53148, M39029/31-229 M39029/32-248
MIL-C-26500 M39029/31-235 M39029/32-254
M524264, M524265,
M524266
MIL-C-26482, Series I M39029/31-240 M39029/32-259 30-199-1 30-203-1
MS3120, M531 21 , M39029/31-228 M39029/32-247 #20 Contactwith #16 Contactwith
M531 22, M531 24, 1 6 AWG wire 20 AWG wire
MS3126, M53127, Entry Entry
M531 28 30-204-1
PTO(*)SE #16 Contactwith
Examples of Bendix P/N 20 AWG wire
PTO6SE1O-12P Entry
KPSEO(*)
Example of Cannon P/N
KPSEO6E10-12P
MIL-C-28748 M39029/34-271
M28748/3 M39039/34-272
Winchester P/N M39029/34-273
MRAC(**) (*) (*) (*) (**)
XAC(**)_(*)_(**)_(*)_(*)
MIL-C-28748 M39029/35-274
M28748/4 M39029/35-275
Winchester P/N M39029/35-276
MRAC(**) (*) (*) (*) (**)
XAC(**)_(*)_(**)_(*)_(*)
MIL-C-28804
M28804/*
HughesP/N MIL-P/N
RAXX M28804/1 0-1
RBXX M28804/9-1
MIL-C-38999,Series I M39029/58-360 M39029/56-348
M527656, M527466, M39029/58-363 M39029/56-351
M227467, MS27496, M39029/58-364 M39029/56-352
MS27505 M39029/58-365 M39029/56-353
MIL-C-38999, Series II M39029/58-360 M39029/57-354
M527472, M527473, M39029/58-363 M39029/57-357
M527474, M527484, M39029/58-364 M39029/57-358
M527497, M527499, M39029/58-365 M39029/57-359
M527508, M527513
MIL-C-24308 M39029/64-369 M39029/63-368
M24308/2, M24308/4
Cannon or TRW P/N
D*MA Series
Matrix P/N
MD308 Series
Example of Cannon P/N
DDMA-505

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Page24
 BHT-ELEC-SPM

Table 5-2. Connector to power contactper MIL-C-39029 (cont)

CONTACT PARTNUMBER BELL STD CONTACT
CONNECTOR and SERIES MALE FEMALE MALE FEMALE
MIL-C-85028 M39029/70-387 M39029/69-384
M85028/1 , M85028/2 M39029/70-388 M39029/69-385
HughesP/N M39029/70-389 M39029/69-386
C21***
NOTE: Interface seal for all
Contacts listed
MIL #85028/3
Hughes#C211S16
MIL-C-38999, SeriesIll M39029/58-360 M39029/56-348
D38999/20, D38999/24, M39029/58-363 M39029/56-351
D38999/26 M39029/58-364 M39029/56-352
MIL-C-38999, SeriesIV M39029/58-365 M39029/56-353
D38999/40, D38999/42,
D38999/44, D38999/46,
D38999/49
MIL-C-81511 , Series Ill M39029/18-176 M29029/1 7-171
M81511/41 , M81511/45, M39029/18-177 M39029/1 7-172
M81511/46, M81511/49 M39029/18-178 M39029/1 7-173
M39029/18-179 M39029/1 7-174
M39029/1 8-180 M39029/17-175
MIL-C-81511 , Series IV M39029/1 8-176 M39029/16-166
M81511/51, M81511/55, M39029/1 8-177 M39029/16-167
M81511/56 M39029/1 8-178 M39029/16-168
M39029/1 8-179 M39029/16-169
M39029/1 8-180 M39029/16-170
Table 5-3. Power contactsper MIL-C-39029
CONTACT BIN MATING MAX WIRE
MIL NUMBER CODE END SIZE ENTRY SIZE CONNECTOR FAMILY
M39029/1 100 16 22 RearRelease MaleContact
101 16 20 M81714,Seriesl
102 14 16
103 12 12
507 20 22
M39029/4 110 20 20 RearRelease Male Contact
111 16 16 MIL-C-26482, Series II
112 16 20 MIL-C-81703, Series III
113 12 12 MIL-C-83723, Series Ill
114 12 16 MiI-C-83733
30-206-1 Color band 18 20
Green/Red
M39029/5 115 20 20 RearRelease Female Contact
116 16 16 MIL-C-26482, Series II
117 16 20 MIL-C-81703, Series III
118 12 12 MIL-C-83723, Series III
119 12 16 MIL-C-83733
30-207-1 Color band 18 20
Green/Red MIL-C-12883/40-075, /40-08S
MIL-C-12883/41 -065, 075, 095
MIL-C-12883/47-105, /47-115
MIL-C-12883/48-045, /48-085

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BHT-ELEC-SPM

Table 5-3. Power contactsper MIL-C-39029 (cont)

CONTACT BIN MATING MAXWIRE

MIL NUMBER CODE ENDSIZE ENTRY SIZE CONNECTOR FAMILY

M39029/11 144 22 22 Rear Release MaleContact

145 20 20 MIL-C-81659, SeriesII
146 16 16 DPXNE
147 12 12 TRE
MME
M39029/12 148 22 22 RearRelease Female Contact
149 20 20 MIL-C-81659, Series II
150 16 16 DPXNE
151 12 12 TRE
MME
M39029/16 166 23 28 RearRelease Female Contact
167 23 22 MIL-C-81511, Series IV
168 20 20
169 16 16
170 12 12
M39029/17 171 23 28 RearRelease Female Contact
172 23 22 MIL-C-81511 , Series III
173 20 20
174 16 16
175 12 12
M29029/18 176 23 28 RearRelease Male Contact
177 23 22 MIL-C-81511, Series Ill & IV
178 20 20
179 16 16
180 12 12
M39029/22 190 22 28 MIL-T-81714, Series II
1 91 22 22 FemaleContactFor Common
1 92 20 20 Terminal System (CTS) and
193 16 16 MIL-C-81511, Series Ill & IV
605 12 12 Class L Only
M39029/29 212 16 16 Rear Release MaleContact
213 12 12 MIL-C-5015 Series
214 8 8 MS3450 and MIL-C-83723,
215 4 4 Series II
216 0 0
M39029/30 217 165 16 RearRelease Female Contact
218 16 16 MIL-C-5015 Series
219 12 12 MS345OandMlL-C-83723,
220 8 8 Series II
221 4 4
222 0 0
M39029/31 240 20 20 Front Release Male Contact,
30-204-1 Brown 16 20 MIL-C-81703, Series II
M39029/31 228 16 16 For 20 AWGOnly and for
30-199-1 None 20 16 MIL-C-26482, Series I for
16 & 20 AWG Contacts

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 BHT-ELEC-SPM

Table 5-3. Power contactsper MIL-C-39029 (cont)

CONTACT BIN MATING MAXWIRE CONNECTOR FAMILY

MIL NUMBER CODE END SIZE ENTRY SIZE

M39029/31 241 20 20 Front Release Male Contact

229 16 16 MIL-C-26500
235 12 12

M39029/32 260 20 20 Front Release Female Contact

248 16 16 MIL-C-26500
254 12 12
M39029/32 259 20 20 Front release FemaleContact
30-203-1 Bendix/Brown 16 20 MIL-C-81703, Series II for
Burndy 2OAWGonly
Red/Blue For MIL-C-26482, Series I
M39029/32 247 16 16 Use 16 & 20 AWGContacts
M39029/34 272 16 20 Front Release MaleContact
273 16 16 MIL-C-28748/3or
271 20 20 MRAC,XAC
M39029/35 275 16 20 FrontRelease Female Contact
276 16 16 MIL-C-28748/4or
274 20 20 MRAC,XAC
M39029/35 FrontRelease Female Contact
100-10185 None 16 18 MIL-C-28748/4or
100-20185 None 20 18 MRAC,XAC
M39029/56 348 22 22 Rear Release FemaleContact
351 20 20 MIL-C-38999, Series I, III, & IV
352 16 16
353 12 12

M39029/57 354 22 22 RearRelease Female Contact

357 20 20 MIL-C-38999, SeriesII
358 16 16 NOTE: /57-354 Contactcan be
359 12 12 used in MIL-C-24308 connector
for 22 contactcavitysize only

M39029/58 360 22 22 RearRelease MaleContact

363 20 20 MIL-C-38999, SeriesI, II, III, IV
364 16 16 NOTE: /57-360 Contactcan
365 12 12 be used in MIL-C-24308 connector
for 22 contact cavitysize only
M39029/63 368 20 20 RearRelease Female Contact
MIL-C-24308
M39029/64 369 20 20 RearRelease MaleContact
MIL-C-24308
M39029/69 384 16 24 Front Release FemaleContact
385 16 20 MIL-C-85028 (AS)
386 16 16 InterlaceSeal M85028/3
Hughes#C211S16
M39029/70 387 16 24 Front Release MaleContact
388 16 20 MIL-C-85028 (AS)
389 16 16

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BHT-ELEC-SPM

Table 5-3. Power contacts per MIL-C-39029 (cont)

CONTACT BIN MATING MAX WIRE

MIL NUMBER CODE END SIZE ENTRY SIZE CONNECTOR FAMILY

M39029/9 134 20 20 RearRelease Male Contact

Alumel MIL-C-26482, Series II
M39029/9 135 20 20 MIL-C-81703, Series III
Chromel MIL-C-83723, Series III
MIL-C-83733
M39029/10 1 40 20 20 Rear Release FemaleContact
Alumel MIL-C-26482, Series II
M39029/1O 141 20 20 MIL-C-81703, Series III
Chromel MIL-C83723, Series III
MIL-C-83733
M39029/85 455 16 16 Rear Release MaleContact
Alumel MIL-C-5015, Series MS3450
M39029/85 456 16 16 and MIL-C-83723, Series II
Chromel

M39029/86 511 165 16 Rear Release Female Contact

Alumel MIL-C-5015, SeriesM53450
M39029/86 512 165 16 and MIL-C-83723, Series II
Chromel
M39029/86 463 16 16
Alumel
M39029/86 464 16 16
Chromel

M39029187 471 22 22 RearRelease MaleContact

Alumel MIL-C-38999, Series I, II,
M39029/87 472 22 22 III, and IV
Chromel

M39029/88 483 22 22 RearRelease Female Contact

Alumel MIL-C-38999, Series I, III,
M39029/88 484 22 22 and IV
Chromel

M39029/89 495 22 22 Rear Release FemaleContact

Alumel MIL-C-38999, Series II
M39029/89 496 22 22 MIL-C-83733, MIL-C-24308
Chromel

M39029/22 193 16 16 RelaySocket Part Number

M39029192 531 22 22 M12883/41-20S
M39029/92 532 20 20 Ml 2883/44-01 S & 44-025
M39029/92 533 16 16 M12883/45-O1S
M39029/101 553 20 20 Ml 2883/46-015 & 46-025
M39029/101 554 16 16 Bell Std P/N
CNSO81900 PCD P/N 22 22 120-118-, 120-119-, 120-167-1
800-20/30-1 Deutsch 20 20 DS07**S
10-189002-20F Amphenol 20 20 30175**S
10-195963-20F Bendix 20 16 or
10-1 89000-20F Amphenol 20 20 PTO6CE8**P
10-1 95962-20F Bendix 20 16

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Page28
 BHT-ELEC-SPM

Table 5-4. Relay socketto power contactto relaycross reference

RELAY-SOCKET CONTACT RELAY NUMBER OF POLESAND
PART NUMBER PARTNUMBER QTY. PARTNUMBER CONTACT RATING
Ml2883/40-5S M39029/5-11 7 14 MS27400-31
Ml2883/40-07S M39029/5-11 6 14 MS27400-31 4 Pole
M12883/40-08S M39029/5-116 14 MS27400-8 10 AMP Rating
Ml2883/41-06S M39029/5-11 6 8 MS27401-33
Ml2883/41-07S M39029/5-116 8 MS27401-8 2 Pole
M12883/41-09S M39029/5-117 8 MS27401-33 10 AMP Rating
Ml 2883/41-20S M39029/92-531 2 M6106/50-005,
M39029/92-533 8 008
Ml 2883/44-01S M39029/101-553 14 M6106/28-024 4 Pole
Ml2883/44-025 M39029/101 -553 16 M6106/39-002 5 AMP Rating
Ml2883/45-01 S M39029/101 -553 8 M6106/27-024 2 Pole 5 AMP Rating
Ml2883/46-01 S M39029/22-193 9 M6106/29-024
M39029/101 -553 2 3 Pole
Ml2883/46-02S M39029/101 -554 9 M61 06/40-002 10 AMP Rating
M39029/101-553 4
Ml2883/47-1OS M39029/5-116 20 M61 06/8-010 6 Pole
M12883/47-11S M39029/5-116 20 M6106/8-008 10 AMP Rating
M12883/48-045 M39029/5-118 9 M527743-24 3 Pole
M39029/5-116 2 25 AMP Rating
Ml2883/48-085 M39029/5-118 9 MS27743-1 5 3 Pole
M39029/5-116 2 25 AMP Rating
120-1 1 9-1 M39029/92-532 20 110-052-25 6 PoleLow Level
120-167-1 M39029/92-532 20 MS25329-ID 6 Pole5 AMP Rating
120-11 8* CNSO81 900 10 110-1 46-1SP DPDT2 AMP Rating

Table 5-5. Connectors and contacts by vendorpartnumber

CONNECTOR MANUFACTURER CONTACT MATING MAX WIRE
PARTNUMBER PARTNUMBER END SIZE ENTRY SIZE
D507-3S DEUTSCH 800-20/30-1 20 20
DSO7-7S
DSO7-27S-025
PTO6CE8*S AMPHENOL/ 10-189002-20F 20 20
BELL STD#30-1 75*5 BENDIX 10-1 95963-20F 20 16
PTO6CE8*S(SR)
PTO6CE8*P 10-1 89000-20F 20 20
BELL STD #30-1 75*p 10-1 95962-20F 20 16
PTO6CE8*P(SR)

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Page29
BHT-ELEC-SPM

Table 5-6. Thermocouple contactcrimping

ITEM CONTACT BASIC TURRETOR WIRE SIZE(AWG)/SELECT
NO. PART NUMBER CRIMP TOOL POSITIONER POSITION
1 M39029/88-483 M22520/2-O1 M22520/2-07 22/4, 24/3, 26/2
(ALUMEL)
M39029/88-484 M22520/7-O1 M22520/7-05 22/3, 24/2, 26/1
(CHROMEL)
5 M39029/89-495 M22520/2-O1 M22520/2-06 22/4, 24/3, 26/2
(ALUMEL)
M39029/89-496 M22520/7-O1 M22520/7-06 22/3, 24/2, 26/1
(CHROMEL)
9 M39029/87-471 M22520/2-O1 M22520/2-09 22/4, 24/3, 26/2
(ALUMEL)
M39029/87-472 M22520/7-O1 M22520/7-07 22/3, 24/2, 26/1
(CHROMEL)
28 M39029/85-455 M22520/1-01 M22520/1-02 16/6, 18/5, 20/4
(ALUMEL)
M39029/85-456
(CHROMEL)
30 M39029/86-511 M22520/1-01 M22520/1-02 16/6, 18/5, 20/4
(ALUMEL)
M39029/86-512
(CHROMEL)
31 M39029/86-463 M22520/1-01 M22520/1-02 1 6/6, 18/5, 20/4
(ALUMEL)
M39029/86-464
(CHROMEL)

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 BHT-ELEC-SPM

CHAPTER 6

CONTENTS — WIRING HARNESSES AND CABLE ASSEMBLIES

Paragraph Chapter/Section Page

Number Title Number Number

6-1 General ........................................................................................ 6-00-00 5

6-2 Safety practices ........................................................................... 6-00-00 5
6-3 Cable types ................................................................................. 6-00-00 5
6-4 Wire types .................................................................................... 6-00-00 5
6-5 Applications ............................................................................. 6-00-00 6
6-6 Wiring installation ....................................................................... 6-00-00 10
6-7 Chafing protection ........................................................................ 6-00-00 20
6-8 Inspection ................................................................................. 6-00-00 20
6-9 Harness to harness chafing protection .................................... 6-00-00 20
6-10 Harness to component protection ............................................... 6-00-00 24
6-11 Harness to structure protection ................................................. 6-00-00 26
6-12 Harness to line .......................................................................... 6-00-00 27
6-13 Chafing protection instructions .................................................... 6-00-00 28
6-14 Harness to component rework ................................................ 6-00-00 28
6-15 Harness to structure rework .................................................... 6-00-00 28
6-16 Harness to line rework ............................................................. 6-00-00 28
6-17 Insulation damage repair ......................................................... 6-00-00 29
6-19 Stowage of electrical wiring and connectors ................................. 6-00-00 29
6-20 General .................................................................................... 6-00-00 29
6-21 Instructions ............................................................................... 6-00-00 29
6-22 Lacing .......................................................................................... 6-00-00 31
6-23 General .................................................................................... 6-00-00 31
6-24 Single cord lacing .................................................................... 6-00-00 31
6-25 Double cord lacing ...................................................................... 6-00-00 31
6-27 Branch ties ............................................................................... 6-00-00 32
6-28 Tying groups within bundles .................................................... 6-00-00 32
6-29 Spot-ties ................................................................................... 6-00-00 32
6-30 Plastic cable straps ...................................................................... 6-00-00 34
6-31 Installation .................................................................................... 6-00-00 34
6-32 Lacing and tying in high temperature areas ................................ 6-00-00 36
6-33 High temperature pressure sensitive tape ............................... 6-00-00 36
6-34 Protective boot-with cable clamp ................................................. 6-00-00 36
6-35 Harness assembly to connector adapter EMI termination
band-it installation ........................................................................ 6-00-00 37
6-36 Harness assembly to connector adapter EMI termination
detail instruction ........................................................................... 6-00-00 37
6-37 Lockwiring electrical connector .................................................... 6-00-00 41
6-38 Connections to terminal boards .................................................. 6-00-00 46
6-39 Connecting terminal boards ...................................................... 6-00-00 46
6-40 Hardware for wiring terminal boards ........................................ 6-00-00 46
6-41 Installation torques for large copper terminals ............................. 6-00-00 48
6-42 Installation torques for aluminum terminals ................................... 6-00-00 48
6-43 Connections to busbars ............................................................... 6-00-00 49
6-44 Connecting terminal lugs to busbars ........................................ 6-00-00 49

6-00-00
Page 1
BHT-ELEC-SPM

CONTENTS — WIRING HARNESSES AND CABLE ASSEMBLIES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

6-45 Hardware for connecting to busbars ........................................ 6-00-00 49

6-46 Precautions when replacing existing connections ....................... 6-00-00 49
6-47 Connecting two terminals to same point on busbar ................ 6-00-00 49

FIGURES

Figure Page
Number Title Number

6-1 MIL-C-27500 breakdown ............................................................................................. 6

6-2 MIL-W-22759 breakdown ............................................................................................. 7
6-3 MIL-W-25038 breakdown ............................................................................................. 8
6-4 MIL-W-81044 breakdown ............................................................................................. 9
6-5 MIL-W-81381 breakdown ............................................................................................. 9
6-6 Routing bundles ............................................................................................................ 14
6-7 Installation of primary supports .................................................................................... 15
6-8 Wiring support ............................................................................................................. 16
6-9 Service loop antichafing techniques ............................................................................. 18
6-10 Clamping at bulkhead hole .......................................................................................... 19
6-11 Wiring drip loop ............................................................................................................ 21
6-12 ATUM tubing backshell ................................................................................................. 22
6-13 Wire installation across hinge point ............................................................................. 23
6-14 Separation of main wire bundles ................................................................................. 23
6-15 ATUM patch ................................................................................................................. 24
6-16 Wire harness to component chafing ........................................................................... 25
6-17 Wire harness to structure chafing ................................................................................. 26
6-18 Installation of wiring near flammable lines ..................................................................... 27
6-19 Insulation damage repair ............................................................................................. 29
6-20 Coiling and stowing excess wire ................................................................................... 30
6-21 Single cord lacing ........................................................................................................ 31
6-22 Double cord lacing .......................................................................................................... 32
6-23 Lacing branch-off .......................................................................................................... 33
6-24 Making ties ................................................................................................................... 33
6-25 Branch ties ................................................................................................................... 33
6-26 Tying groups within bundles ........................................................................................ 34
6-27 Strap application for wire bundle .................................................................................... 35
6-28 Installing self-clinching plastic cable straps ................................................................... 35
6-29 MS90387 Adjustable hand tool .................................................................................... 35
6-30 Boot installation with expando sleeve .......................................................................... 36
6-31 Banding tool and bands A-100 .................................................................................... 38
6-32 Initial assembly of wire harness ................................................................................... 40
6-33 Cross-sectional view of wire harness ........................................................................... 40
6-34 Fold of individual shields around backshell ................................................................... 40
6-35 Installation of shield terminal band ............................................................................... 41
6-36 Boot installation ............................................................................................................ 41
6-37 Lockwiring of electrical connectors ............................................................................... 42

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 BHT-ELEC-SPM

CONTENTS — WIRING HARNESSES AND CABLE ASSEMBLIES (CONT)

FIGURES (Cont)

Figure Page
Number Title Number

6-38 Lockwiring of RF connectors ........................................................................................ 42

6-39 Wiring AN type connector ............................................................................................ 43
6-40 Lockwiring connector to structure ................................................................................. 43
6-41 Wire split shell assembly screws ................................................................................. 43
6-42 Lockwiring electrical connectors ................................................................................... 44
6-43 Connecting terminal lugs to terminal board ................................................................... 46
6-44 Hardware for wiring terminal boards with copper terminals ......................................... 46
6-45 Hardware for wiring terminal boards with aluminum terminals .................................... 47
6-46 Hardware for wiring terminal boards with combination of terminal ............................... 48
6-47 Connecting aluminum terminal to aluminum busbar .................................................... 49
6-48 Connecting copper terminal to aluminum busbar ........................................................ 50
6-49 Connecting aluminum terminal to copper busbar ........................................................ 50
6-50 Connecting copper terminal to copper busbar ............................................................. 50

TABLES

Table Page
Number Title Number

6-1 Wire and cable data ..................................................................................................... 10

6-2 MIL-C-27500 cable characteristics ............................................................................... 11
6-3 Special wire and cable applications ............................................................................. 12
6-4 Coaxial, triaxial, and twin axial applications ................................................................. 13
6-5 MS21919WDG cushion clamp part number to diameter ............................................. 13
6-6 MS25281 plastic clamp part number to diameter ........................................................ 17
6-7 Washers for use with aluminum terminal lugs ............................................................. 47
6-8 Installation of torques for copper terminal .................................................................... 48
6-9 Installation of torques for aluminum terminal ............................................................... 48

6-00-00
Page 3/4
 BHT-ELEC-SPM

WIRING HARNESSES AND CABLE ASSEMBLIES

6-1. GENERAL. 2. If a switch must remain open or closed until a

maintenance procedure is complete, tag the switch to
alert personnel notto movetheswitch.
This sectiondetails acceptable methods for installing,
handling, and repairing electrical wiring. It also
describes the types of wire and cables authorized for 3. Once maintenance work is completed, ensurethat
use in helicopters. all connectors disturbed are properlyinstalled and that
all switches and controls are in a position to prevent
accidental operation of any component when AC and
NOTE DC systems are energized.

When replacing wire or cable in a helicopter, 4. Remove tags from switches, plastic cable straps,
and tags from circuitbreakers.
alwaysusethesamespecification, or better
than, originally installed in production.
5. Energize electrical systems.

6. Ensure all switches and controls are returned to

6-2. SAFETYPRACTICES. their normal position after completing operational or
functional checks.

I WARNING I 6-3. CABLE TYPES.

HIGH VOLTAGES IN ELECTRICAL AND

ELECTRONICSYSTEMSARE HAZARDOUS
TO PERSONNEL.SERIOUS INJURIES MAY
L=J
DO NOT USE SHIELDED/UNJACKETED
BE CAUSED BY ELECTRICAL SHOCKS.
CABLE ON THE HELICOPTER.
EXPLOSIONMAY OCCUR IF SPARKS ARE
GENERATED IN THE PRESENCE OF
FLAMMABLE VAPORS. EQUIPMENT MAY 1. MIL-C-27500. This specification covers electrical
BE DAMAGED IF METALLIC OBJECTS cable made of2to 7wires. Refertofigure 6-1 . Eachwire
CONTACT LIVE ELECTRICAL is qualified to a basicwire specification as indicated in
CONDUCTORS AND CAUSE SHORT the M27500 part number. The cablesare thefollowing
CIRCUITS. type:

a. Unshielded/Unjacketed: 2 to 7 colorcoded wires

The following procedures are to help avoid injury to spirally laid withoutan overalljacket.
personnel and damageto equipment.
b. Jacketed: 2 to 7 color coded wires spirally laid
with an overall jacket.
I WARNING I
c. Shielded/Jacketed: A singlewire or 2 to 7 color
coded wires spirally laid with one or two shields and
BEFORE ENERGIZING THE ELECTRICAL jacket.
SYSTEMS, INFORM ALL PERSONNEL
WORKING ON THE HELICOPTER.
6-4. WIRE TYPES.
1. If a circuit breaker must remain open until a
maintenance procedure is completed, install a plastic 1. MIL-W-22759. This specification covers
cable strap, or a plastic insert underthecircuitbreaker fluoropolymerinsulated singleconductorelectricwires
button, and tag circuit breaker to alert personnel not to made with tin-coated, silver-coated, or nickel-coated
closethe circuit breaker. conductorsofcopperorcopperalloy. Refertofigure6-2.

6-00-00
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BHT-ELEC-SPM

M27500 - XX XX X X

BASIC
SPECECJ1 tJACKET MATERIAL

WIRE SIZE I SHIELD STYLE AND MATERIAL

BASIC WIRE SPECIFICATION -NUMBER OF WIRES IN CABLE

JACKETED/TWISTED SHIELDED/JACKETED/TWISTED

E/SPM-6-1

Figure 6-1. MIL-C-27500 breakdown

2. MIL-W-25038. This specification covers high 5. MIL-W-5086. This specification covers

temperature and fire-resistant electric wire. Refer to polyvinylchloride (PVC), insulated single conductor
figure 6-3. wire.

3. MIL-W-81044. This specification covers single 6-5. APPLICATIONS.

conductorelectrical wireswith tin-coated, silver-coated,
or nickel-coated copper or copper alloy conductors. Airirame wire and cable application parameters are
Referto figure 6-4. listed in tables6-1 through6-4.Table 6-1 listscableand
wire part numbers, temperature rating, and operating
voltage.
4. MIL-W-81381. This specification covers
fluorocarbon/polyimide insulated single conductor 1. Table 6-2 refers MIL-W-27500 wire specifications,
electrical wires made with silver-coated, or shield descriptions, and jacket styles. Special
nickel-coated conductors of copper or copper alloy. application parameters are listed in table 6-3. Coaxial,
Referto figure 6-5. triaxial,and twinaxialparameters are listed in table 6-4.

6-00-00
Page6
 BHT-ELEC-SPM

PRIMARY INSULATION-
CROSS-LINKED, EXTRUDED,
MODIFIED ETFE
FUSED TFE TAPE JACKET

JACKET-CROSS-LINKED,
COPPER CONDUCTOR EXTRUDED,MODIFIEDETFE
M22759/41

TFE TAPE(S) OR TFE-COATED GLASS TAPE(S)

EXTRUDED TFE AND ADDITIONAL TFE TAPE(S)
OR COMBINATION THEREOF

GLASS BRAID AND TFE

COPPER CONDUCTOR FINISHER

M22759/2

M22759 / X - XX - X

BASIC SPECIFICATION INSULATION COLOR DESIGNATOR

NUMBER

SPECIFICATION SHEET LWIRE SIZE

E/SPM-6-2

Figure 6-2. MIL-W-22759 breakdown

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BHT-ELEC-SPM

TETRAFLUOROETHYLENE RESIN
COATED GLASS BRAID WITH
TETRAFLUOROETHYLENE RESIN
FINISHER

IMPREGNATED INORGANIC
FIBROUS INSULATION

NICKEL COATED
COPPER CONDUCTOR
SUPPORTED OR UNSUPPORTED TAPE
OR COMBINATIONS THEREOF

M25038/1

NICKEL COATED CONDUCTOR

POLYIMIDE TAPE PRIMARY

SILICONE RUBBER INSULATION

IMPREGNATED ASBESTOS BRAID

PTFE JACKET

M25038/2

M25038 / X - -

BASIC SPECIFICATION
NUMBER

SPECIFICATION SHEET
I INSULATION COLOR DESIGNATOR

WIRE SIZE

E/SPM-6-3

Figure 6-3. MIL-W-25038 breakdown

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JACKETCROSSLINKED EXTRUDED
POLYVINYLIDENE FLUORIDE

PRIMARY INSULATION
CROSSLINKED EXTRUDED POLYALKENE
TIN-COATED
COPPER CONDUCTOR

M81044 / X

COLOR DESIGNATOR
BASIC SPECIFICATIOJ
NUMBER

SPECIFICATION SHEET

E/SPM-6-4

Figure 6-4. MIL-W-81044 breakdown

POLYIMIDE FIRST SECOND

FILM TOPCOAT
CONDUCTOR

—-\ W,/ ::;:::

TYPICAL KAPTON INSULATED WIRE

M81381 / X - XX - X

BASIC SPECIFICATION TOPCOAT COLOR DESIGNATOR

NUMBER

SPECIFICATION SHEET WIRE SIZE

E/SPM-6-5

Figure 6-5. MIL-W-81381 breakdown

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BHT-ELEC-SPM

6-6. WIRING INSTALLATION. g. Damage to moving parts

Wiring is fabricatedand installed to achievemaximum

reliability, minimum interference and coupling between h. Minimize Radio Frequency Interference (RFI).
systems, accessibility forinspection, maintenance, and Referto figure 6-6.
prevention of damage.

NOTE 5. INSTALLATION LENGTH. Install wiring with

sufficient slack provided to prevent strain on wires,
and to permit access to equipment during
Original equipment installations should be
followed to maximum extent possible. The maintenance. When wiring is terminated in a
connector (excluding RF connectors), a minimum
following information is supplemental in of one inch of slack for complete connector
regards to replacement of harnesses that
havebeen removed. replacement is provided. Slackis to be between the
connector and the second wiring support clamp.
1. ARRANGEMENT OF WIRING. Wiring is The one inch slack requirement is interpreted
arranged in groups and bundles to facilitate
to mean that with the connector unmated, and the
installation and maintenance. Spot-tie individual first wiring support clamp loosened, wire slack
groups,when thesegroups are bundled,thespot-ties permits the frontend of the shell to extend one inch
are notremoved. beyondthe pointnormally required to properly mate
the connector. At each end of a wire terminated
2. INSPECTION AND MAINTENANCE. In open by a lug, a minimum length of slack equal to twice
thebarrel lengthofthe lug provided. For copperwire,
wiring, groups are installed to permitreplacement of the size 2 and larger, and aluminum wires size 4 and
group withoutremoval of the bundle.
larger, the minimum length of slack is equal to
one barrel length of the lug. The slack is to be
3. DEAD ENDING.Each undesignatedwire end is inthevicinity of thelug and available for replacement
dead ended with M525274 caps or with insulation of the lug by maintenance personnel.
acceptable to the activity. For high density wiring
applications,dead ending is to take place within four
to six inches of connectors.
Table 6-1. Wire and cable data
4. ROUTING. Install wiring so that it is mechanically
and electrically sound and neat in appearance. Wiring
is routed to ensure reliability and offer protection from PARTNUMBER REMARKS
thefollowing hazards (referto figure 6-6):
M22759/1 TEFLON
a. Chafing
M22759/2
b. Use as handholds or as supportsfor personal
M22759/1 6 TEFZEL
equipment
M22759/41 IRRADIATED
c. TEFZEL
Damage by personnel M22759/42
d. Damage by stowed or shifting cargo M25038/1 HIGH TEMPERATURE
FLAME RESISTANT
M25038/2
e. Damage by batteryor acid fumesand fluids
M81381/12 KAPTON
f. Abrasions inwheelwellswhereexposed to rocks,
M81381/13
ice, mud, etc.

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Table 6-2. MIL-C-27500 cable characteristics

M27500 A 22 ML 3 T 08
TYPICAL 1-JacketType
i-Shield Description
PART I NumberofConductors
NUMBER BasicWire Specification
ConductorSize
[ Identification Method
Specification Number
SHIELDDESCRIPTION

SINGLE DOUBLE
SHIELD SHIELD SHIELDMATERIAL
U —
Notshielded
BASIC WIRE SPECIFICATIONS *T V Tin-coated copper, round

BASICWIRE S W Silver-coated copper, round

SYMBOL SPECIFICATION INSULATION TYPE N Y Nickel-coated copper, round
VA MIL-W-2275915 FILLED PTFE F Z Stainlesssteel,round
WA MIL-W-22759/6 FILLED PTFE C R Nickel-clad copper, round
SA MIL-W-22759/7 FILLED PTFE M K Silver-coated high strength copperalloy,
TA MIL-W-22759/8 FILLED PTFE round
LE MIL-W-22759/9 PTFE P L Nickel-coated high strengthcopperalloy,
LH MIL-W-22759110 PTFE round
RC MIL-W-22759/11 PTFE G A Silver-coated copper, flat
RE MIL-W-22759/12 PTFE H B Silver-coated highstrengthcopperalloy,
*TE MIL-W-22759116 TEFZEL flat
TF MIL-W-22759/17 TEFZEL J D Tin-coated copper, flat

MIL-W-22759/18 TEFZEL Nickel-coated high strength copperalloy,

*TG E X flat
TH MIL-W-22759/19 TEFZEL
TK MIL-W-22759/20 PTFE a
This specification also allows wide variety ofjacket materials in
TL MIL-W-22759/21 PTFE both single and double wall constructions. The double jacketed
construction is to be used in conjunction with the doubleshields
TM MIL-W-22759/22 PTFE listedabove. A doublejacket is appliedusing two shieldswith the
TN MIL-W-22759/23 PTFE innerjacketisolating the shields plus an outerjacket.
SB MIL-W-22759/32 XLTEFZEL
JACKET STYLES
SC MIL-W-22759/33 XLTEFZEL
SD MIL-W-22759134 XLTEFZEL SINGLE DOUBLE
JACKET JACKET JACKET MATERIAL
SE MIL-W-22759135 XLTEFZEL
*SM MIL-W-22759141 00 00 No jacket
01 51 Extruded white PVC
SN MIL-W-22759/42
SP MIL-W-22759/43 02 52 Extruded clear nylon

SR MIL-W-22759/44 03 53 Whitenylonbraidover mylar

55 MIL-W-22759/45 04 54 Polyester braidover mylar
ST MIL-W-22759/46 05 55 Extruded clear FEP

MG MIL-W-81044/8 XL POLY/KYNAR 06 56 ExtrudedortapedPTFE

07 57 PTFEcoated glassbraidover PTFE tape
MH MIL-W-81044/9
MJ MIL-W-81044/10
08 58 XLwhiteextruded Kynar
*09 59 Extruded white FEP Teflon
MK MIL-W-81044/11
10 60 Clear Kynar
ML MIL-W-81044/12
14 64 Extruded whiteTefzel
MM MIL-W-81044/13
15 65 Extruded clear Tefzel
* Common usage types
17 67 Extruded whiteHalar
18 68 Extruded clear Halar
20 70 White PFA Teflon
21 71 Clear PFATeflon
23 73 Irradiated modified Tefzel

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Table 6-3. Special wire and cable applications

PART NUMBER WIRESIZE APPLICATION

RAYCHEM P/N (1) 28 AWGTHRU Modified, Extended
TU#05028B 20 AWG Radiation Cross-Linked
TU#10024B ETFE Flat Conductor
TU#10022B Cable
TU#20020B Ref MIL-C-49059
M85485/9(*)7L 22 AWG THRU 10 Filterline
AWG Component Wire
M85485/1O-24-7L (1 ) 24 AWG Filterline
Component Wire
M85485/12(*)T(+)(=) 22 AWG THRU 14 Filterline Wire
AWG Shielded Jacketed
M85485/12-24U-(+)(=) (1 ) 24 AWG Filterline Wire
Shielded Jacketed
WF-14/U 4 CONDUCTOR Audio Head Set Cable
28 AWG Per MIL-C-5898
WF-85/U 5 CONDUCTOR Audio Head Set Cable
28 AWG Per MIL-C-5898
30-237-1 4 CONDUCTOR High Noise Attenuation
24 AWG AudioCable
ShieldedJacketed
140-01 3-1 2 CONDUCTOR High Capacitance
22 AWG ShieldedJacketed
30-267-() 2 CONDUCTOR Modified Cross-Linked
ETFEThermocouple
Alumel/Chromel Wire
Shielded Jacketed and
Non Shielded Jacketed

(*) Insert wire AWG (=) Insert color letter per MIL-C-85485
(+) Insert no. of conductor ( ) Insert no. for construction type
# No. of conductors (1) Usage of 24 AWG wire and smallerfor powerand
signaluseshall be limited tospecialapplication requirements.

6. WIRE HARNESS SUPPORT. Wire harnesses are c. Support limitations.

secured in place by either primary or secondary
supports. (1) Moistureabsorbent materials are not used.
a. Primarysupport of wire harnessis providedby
(2) Cable supports do not interfere with the
MS21919WDG cushion clamps (table 6-5 and figure of shockmounts.
operation
6-7), or by MS25281 plastic clamps(table 6-6). Plastic
clamps are used in electrical bus (circuit breaker)
compartments. Clamp size should be selected to hold (3) String tie, tubing, and/or plastic cable straps
are not to be used as primarycable support.
wiring in placewithoutdamaging insulation. Tape may
be wrappedaround harness between wire and clamps
to provide properfit. (4) Plastic cable straps are not used in the
following situations:
b. Secondarysupportis provided between primary
support points. Secondary support materials are (a) Wheretemperature exceeds185°F(85°C).
MIL-T-43435 lacing tape (EC-052), MIL-S-23190plastic
cablestraps(EC-087) (figure 6-8), and ATUM (EC-073) (b) Wherestrapfailureallows displacement of
heat shrinktubing. thewiring into moving linkages.

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Table 6-4. Coaxial, triaxial, and twinaxialapplications

NOMINALIMPEDANCE
APPLICATION (OHMS)
COAXIALAND TRIAXIALUNSWEPT CABLE
Ml7/170-00001 — Coax 50
Ml7/172-00001 — Coax 50
Ml7/174-00001 — Triax 50
Ml7/175-00001 — Triax 50
Ml7/158-00001 — Triax 50
Ml7/159-00001 — Coax 50
COAXIALCABLE
Mfg Times FiberCom. Inc.
AA-4953 50
AA-4938 185
M17/094-RG-179 75
M17/094-RG-180 95
M17/094-RG-210 93
TRIAXIALCABLE
Mfg Raychem
10598 95
7530A5524 75
TWINAXIALMILSTD-1553
Mfg Raychem
Multiplex DataBus Twinax
Ml7/176-00002
10612 78
EMP Hardened, Multiplex
DataBuslO6l4 78

Table 6-5. MS21919WDG cushion clamp partnumberto diameter

DIAMETER DIAMETER DIAMETER
NUMBER (Inches) NUMBER (Inches) NUMBER (Inches)
1 1/16 14 7/8 28 1-3/4
2 1/8 15 15/16 30 1-7/8
3 3/16 16 1 32 2
4 1/4 17 1-1/16 34 2-1/8
5 5/16 18 1-1/8 36 2-1/4
6 3/8 19 1-3/16 38 2-3/8
7 7/16 20 1-1/4 40 2-1/2
8 1/2 21 1-5/16 44 2-3/4
9 9/16 22 1-3/8 48 3
10 5/8 23 1-7/16 52 3-1/4
11 11/16 24 1-1/2 56 3-1/2
12 3/4 25 1-9/16 64 4
13 13/16 26 1-5/8

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CORRECT: BUNDLE IS AT
RIGHT ANGLES TO RIB
STRUCTURE

CORRECT: BUNDLE IS
PARALLELTO RIB

INCORRECT: BUNDLE
ANGLES ACROSS RIB
STRUCTURE

ROUTING BUNDLES

SECONDARY
SUPPORT

PRIMARY SUPPORT PRIMARY SUPPORT

1/2 IN. MAXIMUM WITHMODERATE HAND PRESSURE

SLACK BETWEEN SUPPORTS

EISPM-6-6

Figure 6-6. Routing bundles

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 BHT-ELEC-SPM

'CUSHION

ENDS OF
CUSHION TOUCH'

PROPER CLAMP INSTALLATION

qP
ALTERNATE ANGLES

450 MAX

PREFERRED ANGLES

SAFE ANGLE FOR CABLE CLAMPS

E/SPM-6-7

Figure 6-7. Installation of primarysupports

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BHT-ELEC-SPM

CABLETIE LACING CLAMP COAXIALCABLES

MIL-T-43435 MS 21919

CORRECT METHOD

CHAFING

INCORRECT METHOD

E/SPM-6-8

Figure 6-8. Wiring support

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Table 6-6. MS25281 plastic clamp partnumber to diameter

DIAMETER DIAMETER DIAMETER

NUMBER (Inches) NUMBER (Inches) NUMBER (Inches)
2 1/8 10 5/8 18 1-1/8
3 3/16 11 11/16 20 1-1/4
4 1/4 12 3/4 22 1-3/8
5 5/16 13 13/16 24 1-1/2
6 3/8 14 7/8 26 1-5/8
7 7/16 15 15/16 28 1-3/4
8 1/2 16 1 30 1-7/8
9 9/16 17 1-1/16 32 2

(c) Where strap failure allowsthe strap to fall The latter clamping technique may be used as a
intomechanical parts. secondarycable supportonly.

11. BEND RADIUS. The minimum bend radius for

(d) In severe wind and in areas of high
supported wires is as follows:
humidity.
a. Minimum bend radius forsupported singlewires
7. RF COAXIAL CABLE SUPPORT. Cushion clamps orcablesis 10 timesthe outsidediameterofthe wireor
provide minimum pressure sufticient to preventslipping cable.However, ifthe wire or cable breakout is fromthe
but not deform the cable so that the electrical wiring harnessand is suitably supported, the radius may
characteristics are degraded. be threetimes theoutsidediameter.

8. SERVICE LOOPS. Panel mounted components b. Wiring harnessminimum bend radiusissixtimes

the harnessdiameter. In no case is the bend radius to
require a service loop harness to allow removal and
installation. The service loopis supported with string tie be less than 10timestheoutsidediameterofthe largest
wire or cable included in the harness.
only. Chafing protection is provided by expando
sleeving (EC-072). Plastic cable straps may snag
12. BUNDLE BREAKOUT POINT. The requirements
expando sleeve and defeatthe chafing protection. Use
onlystringties on and in the vicinityof expandosleeve. for breakout points are as follows:
Figure 6-9 showsantichafing reworktechniques applied
to typical serviceloop. a. Bundle breakout point is adequately supported
with stringtie.
9. HOLE CLEARANCE. Wireharnesses with lessthan b. Does not exceed the service loop maximum
3/8 inch clearance to structure (such as through a bend radius of threetimes the harnessdiameter.
bulkhead routing hole), are protected by a grommet
bonded to structure. Figure 6-10 shows recommended c. Locate breakout point directly behind, beside,
clamping of a wire bundle routed through a hole. below, or abovethe componentso that the serviceloop
harnessdoes not bind othercomponents.
10. FLAMMABLE LINES. When wire harnessesare
routed near flammable lines, maintain as much fixed d. Do not useplasticties between the serviceloop
separation as possible. Whenclearance is lessthan six breakout and the electrical connector.
inches, but two inches or more, clamp the harness
independent offlammablelines to maintain a minimum 13. DRIPLOOP. Adrip loopshouldbe placed in awire
separation of two inches. If clearance is less than two harness whenthe installation will permitliquidto gravity
inches, clamp the wire harnessand the flammable line flow down wires into an electrical connector. Refer to
togetherto maintain a minimum separation of 1/2 inch. figure 6-11.

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BHT-ELEC-SPM

SERVICE LOOP HARNESS

HARNESS IDENTIFICATION
LABEL
C

ATUM TUBING
STRAIN

STRING TIE

SERVICELOOP HARNESS EXPANDO SLEEVE

MAIN HARNESS
F

/4
90° BREAKOUT
OR
"Y" BREAKOUT

DIMENSIONS:

A—3TO6INCHES
B—4TO6INCHES
C—6TO8INCHES
D —3 INCHES
EISPM-6-9

Figure 6-9. Service loop antichafing techniques

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 BHT-ELEC-SPM

DETAIL A
CUSHION CLAMP AT
BULKHEAD HOLE

M521919
CABLE CLAMP

DETAIL B
CUSHION CLAMP AT
BULKHEAD HOLE WITH
MS21266 GROMMET

ANGLE BRACKET WITH

TWO POINT FASTENING

DETAIL C
CUSHION CLAMP AT
BULKHEAD HOLE WITH
MS35489 GROMMET
GROMMET

ANGLE BRACKET WITH

TWO POINT FASTENING

WIRES LESS THAN 3/8 INCH

FROM HOLE EDGE

E/SPM-6-1O

Figure 6-10. Clamping at bulkhead hole

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BHT-ELEC-SPM

14. CONNECTOR STRAIN RELIEF. Strain relief require the removal of components such as radios,
backshells can be added to the back of electrical navigation aids, etc. Pay special attentionto previously
connectersto preventdamageto wires caused by a repaired wire harnesses, areas where harnessesmay
short bend radius and to connectors that require be wrapped with spiral wrap or tape, and areas with
frequent disconnect/connect operations. numerous wire splicesinstalled.

a. Heat shrinkable backshells provide good 2. Chafing protection begins with properly installed
mechanical and someenvironmental protection. These wiring harnesshavinga minimum of 3/8 inch clearance
devices slide over the connector prior to shrinking. and adequate support. When minimum clearance
Sealing materials can be used to add environmental cannot be maintained, protection is provided as
protection. described later in this document.

b. Anotheroption isshown infigure 6-12.Atwoinch 6-9. HARNESS TO HARNESS CHAFING

length of ATUM tubing is placed over the connector. PROTECTION.
Startshrinking theATUM totheaft end of the connector
and complete as shown. Harnessto harnesschafing may occurwhen one wire
harnessrubs againstanotherwire harness. A harness
C. Hold the ATUM tubingto the desired shapeuntil to harnessinspection should verify normal routing, and
cool. Thermal setting plastic will adhere to both that individual harnessesare separated by a minimum
connectorand wire. of 3/8 inch. Serviceloops require specialconsideration
as discussed below.
15. HINGES. Harnesses are installed so thatthey will
twistratherthan bend acrossa hingeas shown in figure 1. NORMAL ROUTING. In confined areas, 3/8 inch
6-13. separation of unsupported cable harnesses maynot be
possible. An M53339spacer bar may be installed with
6-7. CHAFING PROTECTION. plastic tie straps or string ties to maintain separation,
refer to figure 6-14.
Improperly secured wire harnesses may rub against
eachotheror againstotherobjectswhen helicopter is in a. In some areas, harness separation of 3/8 inch
flight. Environmental parameters of temperature, maynotbe practical. Anacceptable solutionistojoin the
humidity, altitude, etc., will not cause chafing. The harnesses by using plastic or string ties. This is
problem is subtle because of an extremely complex consideredsecondarysupport.
airframe vibration mode duringflight.Asmooth ride from
thepilot seatis highly desirable, but doesnot mean that b. The ATUM patch is anothereffective methodto
theentire airframe is freefrom vibration induced wiring controlchafing.
problems. The fundamental portion of any chafing
control plan centers around an inspection of the static
airframe to identifyany postproduction wiring changes (1) First determine the area (harness or
individual wire), tobe protected. Refertofigure 6-15 and
that mayresultin chafing whenthe helicopter is inflight.
A chafing control program should include timely cut a section of thermofit ATUM, available in
BAS-KIT-Ol0 (EC-070) kit, (typically, approximately2
inspections that reveal: inches long.
a. Harness to harness chafing
(2) Cutalongthelength as shown and wrapover
b. Harnessto component chafing thechafearea.

c. Harness to structure chafing (3) Place aclamp(office paperclip or equivalent)

alongthelength. By hand, work the wires to form a flat
d. Harnessto fluid line chafing. "pad" in the chafe area.

6-8. INSPECTION. (4) Use needle nose pliers, forcepsand/orother

available toolsto retain the flat section ofwiringas heat
1. Gain access to each compartmentthat contains is applied to shrink the tubing. The flat section will
electrical wiring. A thorough chafing inspection may distribute chafingforces over a largerarea.

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 BHT-ELEC-SPM

WARNING
DRIP LOOP INSTALLATION MAY
RESULT IN POTENTIAL CHAFING
AND OR WIRE FATIGUE AT THE
CONNECTOR. ENSURE THAT WIRE SPOT TIE
HARNESS DRIP LOOP IS SUPPORTED,
HAS ADEQUATE CLEARANCE AND
HAS A CONNECTOR BACKSHELL
INSTALLED. CONNECTOR

DRIP LOOP

DRIP LOOP

E/SPM-6-11

Figure 6-11. Wiring drip loop

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BHT-ELEC-SPM

1 =
—-——-——
— - —L_

EISPM-6-12

Figure 6-12. ATUM tubing backshell

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 BHT-ELEC-SPM

WIRES BENDACROSSHINGE

B. INCORRECT
A. CORRECT
EISPM-6-13

Figure 6-13. Wire installationacross hinge point

E/SPM-6-14
Figure 6-14. Separation of mainwire bundles

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BHT-ELEC-SPM

EISPM-6-15

Figure 6-15. ATUM patch

c. Spiralwrap can be used on long parallel runs of to figure 6-16. Remove thecomponent and inspectthe
wire harness. Do notextendthespiralwrapto protecta harnessin theareaforchafing. Payparticularattention
bend in harness. Thespacebetween wrapswill be great to large diameter powercables.In mostcases harness
and chafingcan develop. to component chafing is a result of inadequate
clearance. Plasticspiral wrap does not usuallyprovide
sufficient protection in harness to component chafing
2. SERVICE LOOPROUTING. Service loopsshall be
situations. The exception is a parallel arrangementofa
given special attentionwhen installing. Protection for wirebundle to a long flatsurface.Harness tocomponent
serviceloops may include expandosleeving. Referto
chafing shouldbe eliminated by:
figure 6-9. Expando sleeve is a tough,slick, and flexible
braid that slidesoverthewires of a serviceloop. During
flight expando rubs against expando, preventing 1. Changing or adding a primaryclamp,
chafing. The serviceloopshould be of sufficient length
to permit access to the electrical connector of a 2. Adding an ATUM patch per figure 6-15 or,
component.
3. Spiralwrap in selected application.

6-10. HARNESS TO COMPONENT PROTECTION.

a. Spiralwrap can be usedon long parallel runs of
wire harness. Do not extend thespiralwrap to protecta
Damage causedby harnessto component chafingmay bend in harness. Thespacebetween wraps may permit
not be observed whenthecomponent is installed. Refer chafing to develop.

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 BHT-ELEC-SPM

EISPM-6-16

Figure 6-16. Wire harness to component chafing

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BHT-ELEC-SPM

6-11. HARNESS TO STRUCTURE PROTECTION. chafing can damagewire harnessesand/or structure,

as shown in figure 6-17. Refer to the appropriate
NOTE maintenance manual for structure damagelimits and
Do not use ATUM patch, expando sleeve, repair. Rerouting is the best method to eliminate
harnessto structurechafing. Do not use plastic spiral
spiral wrap, or spacer bars in engine
compartment. wrap for this type ofchafing.AnATUM patch perfigure
6-16, expandosleeve per figure 6-9, or spacerbar per
Manywire insulations have betterabrasionresistance figure 6-15,are additional materials that can be usedin
than some structural materials. Harnessto structure this typeof chafing situation.

E/SPM-6-17

Figure 6-17. Wire harness to structurechafing

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 BHT-ELEC-SPM

6-12. HARNESS TO LINE. minimum distance between a clamped line and a

clamped harness is two inches. The minimum distance
Flammable lines are not to contact wire harnesses. between a line clamped to harness is 1/2 inch. A
Refer to figure 6-18. The minimum distance between harness may be clamped to a line to help maintain
unsupported lines and harnessesis six inches. The clearance,but notfor support.

WIRE BUNDLES ON A LEVEL

fl,, WITHOR ABOVE FLAMMABLE
LINESOR EQUIPMENT. I Tfl

p
DETAIL A

61N.MIN. 61N.MIN.

cpp
FLAMMABLE LINES OR EQUIPMENT

)
WIRE ROUTED PARALLELTO FLAMMABLELINES OR EQUIPMENT

WIRE BUNDLES RIGIDLY CLAMPED

ABOVEFLAMMABLELINES OR
EQUIPMENT.

FLAMMABLE 2 IN. MIN.

LINES
DETAILB

SEPARATION OF WIRES AND PLUMBING LINES

(.*— WIRE BUNDLE

1/2 IN. MIN. DETAIL C

FLAMMABLE
LINES

SEPARATION BY BUTTERFLY CLAMPING

E/SPM-6-18

Figure 6-18. Installation of wiring nearflammable lines

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BHT-ELEC-SPM

6-13. CHAFING PROTECTION INSTRUCTIONS. 1. BULKHEAD INSTALLATION. Usecushionclamps,

brackets, and spacers to position a harness that is near
1. Several techniques maybe used to provide chafing a bulkhead. Maintain a minimum of 3/8 inch clearance
protection. In all cases harness routing is the first
to bulkheads. If clearance is less than 3/8 inch, use
cushion clampsto secure harnessto bulkhead.
technique considered. Routing changes are generally
limited by spaceavailable, harnesslength, and physical
space limitations. Harness support, both primary and 2. LIGHTENING HOLES. Wire harnesses routed
secondary, can be added to prevent chafing. Routing through lightening holes should be supported by
and support techniques by themselves do not clear all cushion clamps at each lightening hole as per figure
chafing situations. In some cases, chafing protection 6-10. Install brackets and spacers necessary to
material such as expandosleeves, teflon tape, ATUM maintain 3/8 inch clearance to the lightening hole.
patches and grommets are added to eliminate the Installations where clearance is less than 3/8 inch,
possibility of chafing damage. install grommet MS21266 or MS35489, usingadhesive
(EC-086).
2. The following paragraphs describe chafing
protection reworks thatareproventobeeffective control
measures.
6-16. HARNESS TO LINE REWORK.

6-14. HARNESS TO COMPONENT REWORK. Wire harnesses shall not contactflammablefluid lines.
Rework wire harness routing to maintain clearance.
Referto figure 6-18.
Chafing damage caused by harness to component
contactmaybe controlled by cablerouting, support, and
antichafing material techniques.
WARNING
I I
1. Rework harnessrouting to provide minimum of 3/8
inch clearance. If component is a moving mechanical
SHARP CUTOFFS FROM PLASTIC
part, ensure clearance is maintained throughout
STRAPS MAY CAUSE DAMAGE TO
components range ofmotion. Toomuch ortoolittle slack FLAMMABLE FLUID LINES.
in harness, may require loosening clamps to adjust
harness slack as required. When a harness is
repositioned in this manner, ensure the harness has 1. GREATER THAN SIX INCH CLEARANCE. Rework
adequate clearance, in all installed areas. wire harnessrouting to maintain clearance greaterthan
sixinches. Install string ties, orplasticstrapsat less than
2. SUPPORT. Primary support of wire harness is six inch intervals to prevent a broken wire from
provided by cushion or plastic clamps. String ties or contacting a fluid line.
plasticcablestrapsprovide secondary support. In some
instances clearance mayonly be maintained by adding 2. LESS THAN SIX INCH CLEARANCE. Wire
a clamp to hold harness clear of component. Use harnessesrouted with lessthan six inches to flammable
appropriate clamps, spacers, and brackets to prevent fluid lines must be clamped to maintain two inch
harnessto component contact. Secondary supports at minimum clearance.Install string ties or plastic straps at
breakout points may be moved to provide improved lessthantwo inch intervals topreventabrokenwirefrom
routing. Clamps must not interlere with operation of contacting a fluid line.
shockmounts.
3. LESS THAN TWO INCH CLEARANCE. Harnesses
with less than two inches of clearance to a flammable
6-15. HARNESS TO STRUCTURE REWORK. fluidline mustbe clamped tothefluid lineto maintain 1/2
inch minimum clearance. Clamping a harnessto a fluid
Rework harness installation to eliminate harness to line is done to ensure clearance only. Harness primary
structure chafing. Insulation damage caused by chafing supportis provided by othercushionclampstoairframe
may also damage the airframe structure. Refer to structure. Install string ties only at less than 1/2 inch
appropriate maintenance manual for structural damage intervalsto prevent a broken wirefromcontacting a fluid
limitsand repairprocedures. line.

6-00-00
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 BHT-ELEC-SPM

6-1 7. INSULATION DAMAGEREPAIR. 6-21. INSTRUCTIONS.

ATUM tubing maybe usedto repairinsulation damage

onwires8AWGorlarger. Insulation damaged wiresthat Allsparewiring thathasaterminalorconnectorinstalled
mustbestoredsecurelyand yetbevisiblefor inspection
exposewire strands through thedamaged areamustbe and identification. Observe the followinginstructions:
replaced. If nowire stranddamage hasoccurred, install
a length ofATUMtubing,twoincheslongerthanthearea
of insulation damage, as shown in figure 6-19. 1. All wires are prevented from creepingby tying to a
support cable run or structural member. Adequate
6-18. ATUM tubing. supportis ensured, i.e., a connectormay not be tied to
a cable run of less than half the diameter of the
ATUM tubing has many uses. The 4:1 shrink ratio connector, unless specified.
permits itto be installed over large connectors, lugs and
otherterminalfittings.Theinside diameter is coated with
athermosettingplastic whichmeltsas thetubingshrinks 2. Wheneverpossible, stowed connectorsare visible
when heat is applied. When cool, the thermosetting for ready inspection.
plasticadheresand prevents slipping.
3. Wiresthat do not havea terminallug installed must
6-19. STOWAGE OF ELECTRICAL WIRING
be dead-ended with an M525274 cap or insulation
AND CONNECTORS.
tubing.
6-20. GENERAL.
4. Wires ending in terminal lugs or other special
Stowage of electrical wiring and connectorsis carried purpose terminations are stowed to preserve these
out to ensure adequate protection from short-circuits, ends. Use transparent tubing to show theseendsintact
structural damage, and fire. Refer to figure 6-20. whenever possible.

CHAFED AREA

E/SPM-6-19

Figure 6-19. Insulation damage repair

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BHT-ELEC-SPM

BUNDLE TIES

COIL AND STOW SHORT WIRE HARNESS

COIL AND STOW LONG WIRE HARNESS

EISPM-6-20

Figure 6-20. Coilingand stowingexcess wire

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 BHT-ELEC-SPM

6-22. LACING. NOTE

Space half hitches so that the group or

6-23. GENERAL. bundle is neat and securelyheld.

Continuous lacing may only be used on those wire 3. Terminate lacing with a knot consisting of a clove
groups or bundles installed in panelsorjunction boxes. hitchwith an extra loop.
Usedouble cordlacing on groupsor bundles largerthan
oneinch indiameter. Usesingleor double cord lacing on 4. Trimfree ends of lacing cord to 3/8 inch minimum.
groups or bundles one inch or less in diameter. For
lacing groups which branch off a main bundle, refer to 6-25. DOUBLECORD LACING.
paragraph 6-26.
Lace a wire group or bundle with a double cord as
follows:
6-24. SINGLE CORDLACING.
1. Startlacing atthethick end ofawiregrouporbundle
Lace a wire group or bundle with a single cord as with a bowline on the loop. Refer to figure 6-22.
detailedin steps 1 through 4. Refer to figure 6-21.
2. At regularintervals alongthewire groupor bundle,
1. Startthe lacing atthethick end ofthe wire group or and at each point where a wire group branches off,
continue lacing with half-hitches, holding both cords
bundle with a knot consisting of a clove hitch with an
extra loop. together.

NOTE
2. At regular intervalsalong thewire groupor bundle,
and at each pointwherea wire or wire groupbranches Space half-hitches so that the group or
off, continue lacing with halfhitches. bundle is neat and securelyheld.

A-STARTING KNOT

FIRSTPARTOF FINAL
B-INTERMEDIATE HALF HITCHES KNOTTIGHTENED

FINAL KNOT
EISPM-6-21

Figure 6-21. Singlecord lacing

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BHT-ELEC-SPM

3. Terminate lacing with a knot consisting of a 4. Trimfree endsof lacing cord to 3/8 inch minimum.
half-hitch, using one cord clockwise, and the other
counterclockwise, and then typing cord ends with a 6-27. BRANCHTIES.
squareknotwith an extra loop.
Make ties as shown in figure 6-25. Ties from each
4. Trimfree ends of lacing cord to 3/8 inch minimum. branchfrom main bundle are not necessary. Tie when
wires or groups of wires leave the main bundle and
6-26. Branching off where necessary for support. Allow a minimum of 3/4
inch of slack on each branch. The 3/4 inch slack is
Lacea wire groupthat branches off main wire bundle as essential to preventstrain on terminals.
follows: Referto figure 6-23.
6-28. TYING GROUPS WITHINBUNDLES.
1. Start branch-off lacing with a starting knot located
on the main bundle just past branch-off point. When Spot-tie groups into bundles as described, treating the
single cord lacing is used, make starting knot as wire groupsas individual wires. Referto figure 6-26.
described in paragraph 6-24. When double cord lacing
is used, make starting knot as described in paragraph 6-29. SPOT-TIES.
6-25.
1. Tie all wire groups or bundle where supportsare
2. Continue lacing along branched-off wire group, morethantwelveinches apart.Spacetiestwelveinches
using regularly spacedhalf-hitches. Whendoublecord or less apart.
is used, both cordsare heldtogether.
2. Make ties as follows:
NOTE a. Wrapcord around wire groupor bundle, ashown
in figure 6-24.
Space half hitches so that the group or
bundle is neat and securelyheld. b. Make a clove hitch, followed by a square knot
with an extra loop.
3. End lacing with regular knot used in single and
double cord lacing, as described in paragraph 6-24. c. Trim free ends of lacing cord to 3/8 inch
Referto figure 6-23. minimum.

STARTING KNOTTIGHTENED

-
STARTING KNOT BOWLINE ON A LOOP INTERMEDIATE HALFHITCHES FINAL KNOT
EISPM-6-22

Figure 6-22. Double cord lacing

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 BHT-ELEC-SPM

MAIN BUNDLE LACING

STARTING KNOTFORBRANCH-OFF

WRAPCORD TWICE
OVER BUNDLE

CLOVEHITCHANDSQUAREKNOT

EISPM-6-23 E/SPM-6-24
Figure 6-23. Lacing branch-off Figure 6-24. Making ties

3/4 IN. MIN.SLACK

E/SPM-6-25

Figure 6-25. Branch ties

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BHT-ELEC-SPM

GROUP BINDING WITHIN A BUNDLE (KEEPTO MINIMUM) USE SPOT

SPOT TIES
E/SPM-6-26

Figure 6-26. Tyinggroupswithin bundles

6-30. PLASTICCABLE STRAPS. 5. Settensionselectorknobforwidth of cabletie being

used from settings in figure 6-27. Read knob position
from bottomof tool.
I WARNING 1 6. Pass freeend ofstrap throughslot in endoftool,and
push tool snugagainststrap base.
DONOT USE PLASTIC CABLE STRAPS IN
HIGH TEMPERATURE AREAS. 7. Pull trigger. Tool will tighten cable tie and cut off
excessat preset cabletie tension.

6-31. INSTALLATION. I WARNING I

Use adjustable hand tool MS90387, illustrated in figure USE PROPER TOOLSAND VERIFYTHAT
6-30, to install plastic cable straps on wire bundles. STRAP IS CUT FLUSH IN ORDER TO
Refer to figure 6-28.The procedure is as follows: ELIMINATE CUTS AND SCRATCHES
FROM PROTRUDING STRAP ENDS.
1. Selecta strap of desired length forapplication (of a
size suitablefor wire bundle), fromfigure 6-27.
I WARNING 1
2. Slip plastic strap around bundle, with ribbed side
WHEN USINGSELF-CLINCHING STRAPS
facingbundle.
TOTIE COAXIAL CABLE OR BUNDLES OF
COAXIAL CABLE, SET TENSION
3. Threadtip ofstrapthrough eye in strap bossand pull ADJUSTMENT ON INSTALLATION TOOL
strap tightaroundbundle. TO EXERT THE MINIMUM REQUIRED
TENSION TO PREVENT CABLE
4. Select proper tool for strap used fromfigure 6-27. SLIPPING.

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 BHT-ELEC-SPM

Max Tie Width For Bundle MS Tool No. Tension

MS Part No. (Inch) Diameter (Inch) (M590387-x) Setting
MS3367-1 0.1 90 1/16 — -3/4 -1 Standard

MS3367-2 0.190 1/16 —4 -1 Standard

M53367-3 0.31 0 1/16 — 3-1/2 -2 Heavy

M53367-4 0.100 1/16 — 3-1/2 -1 Minimal

MS3367-5 0.146 1/16 — 5/8 -1 Intermediate

MS3367-6 0.31 0 1/1 6 —8 -2 Heavy

MS3367-7 0.190 1/16 —3 -1 Standard

MS3368-1 0.190 3/8 — 1-3/4 -1 Standard

MS3368-2 0.190 3/4 — 4 -1 Standard

M53368-3 0.190 3/4 — 1-3/4 -1 Standard

MS3368-4 0.190 3/4 — 1-3/4 -1 Standard

M53368-5 0.100 1/16 — 5/8 -1 Minimal

EISPM-6-27
Figure 6-27. Strap application for wire bundle

CONFIGURATION MAY VARY

/////

TENSION ADJUSTMENT
(KNOB SHAPEOPTIONAL)

EISPM6-29

Figure 6-28. Installingself-clinching plasticcable Figure 6-29. M590387Adjustable hand tool

straps

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BHT-ELEC-SPM

6-32. LACING AND TYING IN HIGH 6-34. PROTECTIVE BOOT — WITH CABLE
TEMPERATURE AREAS. CLAMP.

6-33. HIGH TEMPERATURE PRESSURE

SENSITIVE TAPE. The procedure for installing protective boots on
environment resistant connectors with plastic cable
Use MIL-I-23594 hightemperature insulation tape totie clampsis as follows:
all wire groups and cable bundles in areas where the
1. Place cable clamp locking nut and molded cable
temperature maygo above 185°F(85°C).
clampover assembly. Referto figure 6-30.

I WARNING 1 2. Select expando sleeve diameter to fit cable

assemblywithoutgapping or overlapping. A maximum
MIL-I-15126 INSULATION TAPE of 25 percentoverlapping is acceptable at cableclamp.
(INCLUDING GLASS FIBER TYPE) IS 3. Cut lengthof expando sleeve.Make sure there is a
HIGHLY FLAMMABLE AND IS NOTTO BE minimum of 0.5 to 1.5 inches when cable assemblyis
USED IN A HIGH TEMPERATURE flexed180 degreesbackon itself. Usefraylessexpando
ENVIRONMENT. MIL-I-23594 INSULATION sleeve where possible.
TAPE IS DESIGNED FOR HIGH
TEMPERATURE OPERATION (SUITABLE 4. Place expandosleeveover cable assembly.
FORCONTINUOUS OPERATION AT500°F
(260°C) AND IS TO BE USED IN ALL HIGH 5. Install contactson wires and insert them into the
TEMPERATURE ENVIRONMENTS. connector.

APPROXIMATELY 0.125 IN.

REINFORCED SILICONE RUBBER TAPE
MINIMUM ONE LAYER

APPROXIMATELY 0.188 IN.

CLAMP
OR 0.5 TO

CLAMPFINGERS

CABLE CLAMP LOCKING NUT

BRAID
PLASTIC TIEDOWN STRAP

2TO 3 LAYERS SILICONE ADHESIVE TEFLON TAPE WITHIN

0TO 0.25 INCHOF EXPANDO CUT EDGES. EXPANDO
TERMINATION MUST BE MOVABLE.
EISPM-6-30

Figure 6-30. Boot installation with expando sleeve

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 BHT-ELEC-SPM

6. Wrap reinforced silicone rubber tape (EC-053) a a. Thetool pull-up and cutoffhandles mustbe in the
minimum of one layer around the expando sleeve, open position. If the pull-up and cutoff handles are
approximately 0.125 inch fromtheend of thesleevethat locked against the tool body (closed position) unlock
is nearest theconnector. handles by pulling handles away from body.

b. Insert band into slot opening (located directly

7. Position cable clampover end of connector. undercutter knife) of tool. Use only clean undamaged
band. Push tension release leverforwardat this timeto
NOTE facilitateband insertion.
Ensure cable clamp locking nut is securely
C. Insert approximately two inches of the band (up
tightened and wires are not abnormally to line marked on theband), intothe tool. Pushtension
stressed.
release lever toward handle grips of tool. Tighten by
8. Slide cable clamp locking nut over the cable clamp ratcheting pull-uphandle until it locksagainsttool body
and tighten onto the connector. (attainment of tool presettensionvalue).

d. Complete band termination by squeezing cutoff

handle. Remove remaining band material from tool by
pulling it back out oftool (pulltowardoperator).

ENSURE THERE ARE ENOUGH LAYERS e. To loosen or removea band before locking and
OF REINFORCED SILICONE RUBBER cutoff (step d), move tension release leverforward with
TAPE TO PREVENT CLAMP FINGERS thumb and remove the band.
FROM MAIN POINTCONTACT WITHWIRE
BUNDLE. f. To store or carry tool, place pull-up and cutoff
handles in the closed position, lock pull-up and cutoff
handles against tool body by pushing cutoff handle
againsttool body and squeezing pull-up handle until it
locksin position.
ENSURE NO SHARP EDGES ARE 6-36. HARNESS ASSEMBLY TO CONNECTOR
EXPOSED THAT COULD CAUSE INJURY ADAPTER EMI TERMINATION — DETAIL
INSTRUCTION.
TO MAINTENANCE PERSONNEL.
1. Terminate all shieldedcables usingsoldersleeves.
9. Install plastictie downstrap and trim off excess. Refer to Chapter4.

NOTE
Staggersoldersleeves to preventbuildup.

EXPANDO SLEEVES MAY BE REUSED. 2. Install contactson cable assembly.

REPLACE ANY EXPANDO SLEEVE 3. Install braid, expandable sleeve,backshell and heat
WHERE FRAYING EXTENDSINTO AREA shrinkboot. Cut boot intotwo piecesas shown in figure
BETWEEN CABLE CLAMPAND SPOT-TIE. 6-32. Install contactsintotheconnector.

10. With cable assembly straight, wrap two or three NOTE

layers of silicone adhesiveTeflon tape over the cable Cut boot beforeinstalling on cableassembly.
jacket 0.0 to 0.25 inches from the end of the expando
sleeve. The connector band marker may be used in 4. Slide connector backshell down cable assembly
placeof Teflon tape. and tighten fingertight. Measure back on cable
assembly approximately three inches and apply
6-35. HARNESS ASSEMBLY TO approximately one to two and one half turns of tape
CONNECTOR ADAPTEREMI TERMINATION — (EC-055) on cable assemblyas shown in figure 6-33,
BAND-ITINSTALLATION. and cross-sectional view.

1. Tool instruction for installation of Al00(XX) Band-it, a. Ifbundleislarge, moretapeshouldbe used inthe
refer to figure 6-31. centerof cable assembly.

6-00-00
Page 37
BHT-ELEC-SPM

b. The two separate applications of tape on cable c. Using a heat gun meltthetape.
assembly act as a strain relief, molding the wires
togetheras one. Heatmustbe appliedto tape to hold it
in placefor subsequent steps.

WARNING 1

DO NOT LUBRICATE THE TOOLOR BAND

COMPRESS SCREW
TOOL BODY

ADJUSTING SCREW
RELEASE LEVER

CUTTER KNIFE
MOUNTING SCREW

PULL-UP HANDLE•
CUTTER KNIFE

REPLACEMENT MOUNTING
SCREW
CUTTER

- _____REPLACEMENT
CUTTER BLADE
SET SCREW
REPLACEMENT SETSCREW
CUTTER BLADE
REPLACEMENT CUTTER KNIFE
BANDSLOT OPENING

TOOL-OPENED

TOOL-CLOSED
E/SPM-6-31 -1

Figure 6-31. Banding tool and bands A-i00 (Sheet 1 of 2)

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 BHT-ELEC-SPM

DOUBLEWRAPPED

BAND SIDE AND TOP VIEW

EISPM-6-31-2

Figure 6-31. Banding tool and bands A-i00 (Sheet 2)

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BHT-ELEC-SPM

5. Tighten backshell to desired torque value as 6. Slide braid into place and install shield termination
specified for backshells and fold individual shields band as shown in figure 6-35.
around periphery of backshell. Referto figure 6-34.
INDIVIDUAL SHIELDS
CONNECTOR
END

APPROX 1.50

BOOT IN
PIECES
SOLDER SLE
(STAGGER)
EISPM-6-32

Figure 6-32. Initialassembly of wire harness

BACKSHELL

ONNECTOR WIRE HARNESS

S-1048 TAPE

CROSS SECTIONAL VIEW OF WIRE HARNESS

EXAMPLES OF APPLICATION
OF S-1048 TAPE APPLIED
TO HARNESS TYPICAL TWO PLACES
E/SPM-6-33

Figure 6-33. Cross-sectional view of wire harness

SHIELDS S-1048

-CONNECTOR E/SPM-6-34

Figure 6-34. Fold of individual shieldsaround backshell

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 BHT-ELEC-SPM

GROOVE
S-1O48 T
SHIELD TERMINATION BAND

EXPANDABLE SLEEVE

CONNECTOR
EISPM-6-35

Figure 6-35. Installation of shieldtermination band

7. Position all materials into place. Ensure boot is such that required vibration excursions of
positioned on cable assemblyas shown in figure 6-36. equipment is not restricted. Do not lockwire
Apply heat to shrink boot. to fuel, hydraulic, or oxygen lines or another
electrical connector.

LJ
NOTE

This assembly procedure provides for

accessibility to the connector for
maintenance and repair operations.
Precautions should be taken during
assembly procedures to ensure that
backshell can be loosened and pushed up DO NOT WIRE ELECTRICAL OR RF
cable assemblyapproximately three to four CONNECTORS WHICH HAVE A
inches if the cablediameterpermits. MECHANICAL LOCK. LOCKWIRING ACTS
AGAINST LOCKING FEATURE.
BACKSHELLS ON BAYONET COUPLED
6-37. LOCKWIRING ELECTRICAL CONNECTOR. CONNECTORS ARE NOT TO BE
LOCKWIRED TO CONNECTOR
NOTE COUPLING RING. BACKSHELL WITH
LOCKWIRE HOLES ARE LOCKWIRED TO
When lockwired plug is connectedto shock HELICOPTER STRUCTURE OR TO
mounted equipment, Iockwiring of the plugis CONNECTOR.

wssw.ssw.1
*s*;*;*;*;*;*;*;*;*
=
—
"NOTE"
BOOT
I
BACKSHELL —
BOOT MUST FIT IN
BOOTGROOVE OF ADAPTER
CONNECTOR

E/SPM-6-36

Figure 6-36. Bootinstallation

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BHT-ELEC-SPM

1. Lockwire electrical and RF connectorsas follows:

Referto figures6-37through6-42.

a. Attachlockwire to electrical connectorsas shown

in figure 6-37.

b. RF connectorsthat do not have wire holes but

require lockwiring are as shown in figure 6-38.

C. Anchorlockwire from coupling nuts of electrical

connectors to an adjacent structure. Refer to figures
6-39through 6-41.

2. AN/MS connectors (refer to figure 6-39), with

threaded coupling ringsare lockwired as follows:

a. Threadlockwire through hole in coupling ring.

E/SPM-6-37

b. Twist wire approximately six to eight turns per

inch and secure as shown in figure 6-39.

c. Pull one end of twisted wire through hole in

fillister head screw on mounting flange of connector.
Use a fillister head screw so located as to allow 60
degrees or smallerangleof the wire.

Figure 6-37. Lockwiringof electricalconnectors

RECEPTACLE
NUT LOCKWIRE

STRUCTURE

SCREW

CLAMP

COMPLETE ASSEMBLY

E/SPM-6-38

Figure 6-38. Lockwiring of RF connectors

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 LJ
BHT-ELEC-SPM

REQUIRED TO SECURE
ANGLE BACK
LOCKWIRE LUG

DO NOT BACK OFF OR OVERTORQUE

SHELL MOUNTING FILLISTER HEADSCREWSIN
ORDER TO ALIGN HOLES FOR
LOCKWIRING.

d. Form pigtail 1/4 to 1/2 (three to six twists) with

pliers.

e. Bend pigtail back toward body of connectorto

NUT preventinjuryto personnel.

BEND PIGTAILS TO
PROTECT PERSONNEL

E/SPM-6-39

Figure 6-39. Wiring AN type connector

SHEAR WIRE FOR SPLIT SHELL

BEND PIGTAILS TO
PROTECT PERSONNEL

BEND PIGTAIL AROUND

SCREW TO PROTECT
PERSONNEL

LOCKWIRE FOR COUPLING NUT

EISPM-6-40 EISPM-6-41

Figure 6-40. Lockwiringconnector to structure Figure 6-41. Wire split shell assembly screws

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BHT-ELEC-SPM

AVAILABLE HOLE IN
ADJACENT STRUCTURE

LENGTH OF LOCKWIRE
NOT TO EXCEED 6 INCHES

LOCKWIRING CONNECTOR TO ADJACENT STRUCTURE

SADDLE CLAMP

NO LOCKWIRE LOCKWIRE HOLE

HOLE PROVIDED PROVIDED

LOCKWIRING SADDLE CLAMP SCREWS

E/SPM-6-42-1

Figure 6-42. Lockwiring electricalconnectors (Sheet 1 of 2)

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 BHT-ELEC-SPM

CLAMPING NUT

AN500A SCREW•
(TYPICAL)

SCREW
AN500A

MS CONNECTORS

AN500A SCREW•
(REVERSED)

SINGLE OR DOUBLE LOOP

LOCKWIRE OPTIONAL

SM CONNECTORS

DM AND DS CONNECTORS 900 CONNECTORS

EISPM-6-42-2

Figure 6-42. Lockwiring electrical connectors (Sheet 2)

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BHT-ELEC-SPM

6-38. CONNECTIONS TO TERMINAL

BOARDS.
6-39. CONNECTING TERMINALBOARDS.

Installterminal lugs on MilitaryStandardMS27212terminal

boards in such a way that they are locked against
movement in directionof loosening.Refer to figure 6-43.
6-40. HARDWARE FOR WIRING TERMINAL
BOARDS.

NOTE
NOTE
Always refer to applicable maintenance
manuals for hardware stack-up and part Place all terminals so that movement
numbers.
tightens nut
M527212 terminalboards havestuds secured in place
with an AN960 flat washer and an MS35649 or
MS35650 steel nut. Place copperterminallugs directly
on topoftheM535649or M535650 nut. Follow with an
AN960flat washer, an M535388split steel lockwasher,
E/SPM-6-43
an M535649 or MS35650 steel nut, or an M521044
self-locking all metal nut. Referto figure 6-44.
NOTE

Do not eliminatethe M535338 splftlockwasher Figure 6-43. Connecting terminal lugs to terminal
even whenusingan MS21 044 self-locking nut. board

__________________________________________ SELF-LOCKING NUT

ALL METAL
NUT

SPLIT LOCKWASHER

FLAT WASHER

MIL-T-7928
TERMINAL
LUGS, COPPER

TERMINAL STUD OF
TERMINAL BOARD
NUT

FLAT WASHER

E/SPM-6-44

Figure 6-44. Hardwarefor wiring terminal boards with copperterminals

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 BHT-ELEC-SPM

1. MS27212 terminalboards have molded studs and self-locking all metal nut. Referto figure 6-45for details
do not require hardware for attaching studs to the of this assembly.
terminal board. Use same hardware for installing
terminallugs as for MS27212 terminalboards. Referto 3. To join a copper terminal lug to an aluminum
figure 6-44. Mounting screws are insulated with terminallug,placean MS25440flatwasheroverthenut
MS3373 insulators when using MS27212. which holds the stud in place. Follow with aluminum
terminallug,anotherMS 25440washer, copperterminal
lug, an AN960 plain washer, an MS35338 split steel
CAUTION lockwasher, and an M535649or MS35650 plain nut or
M521 044 self locking nut. Refer to figure 6-46 for
details.
DO NOT PLACE ANY WASHER IN THE
CURRENT PATH BETWEEN TWO Table 6-7. Washers for use with aluminum
ALUMINUM TERMINAL LUGS OR terminal lugs
BETWEEN TWO COPPER TERMINAL
LUGS. MS Number Terminal Size StudSize
MS25440-3 8,6,4 No.10

ION -4 8,6,4,2,1,
1/0
1/4

NEVER PLACE A LOCKWASHER

-5 8,6,4,2, 1, 5/16
DIRECTLY AGAINST THE TONGUE OR
1/0, 2/0
PAD OF AN ALUMINUM TERMINAL OR
BUSBAR. -6 8,6,4,2,1, 3/8
1/0, 2/0
2. Place aluminum terminal lugs over an M525440
plated flat washerof correct size forterminaland stud. -6A 3.0, 4/0 3/8
Refer to table 6-7. Follow terminal lugs with another
M525440flat washer, an M535338split steel washer, -8 2, 1, 1/0,2/0, 1/2
andeitheran M535649or M535650 nut oran M521044 3/0, 4/0

SELF-LOCKING NUT
ALL METAL
NUT

SPLIT LOCKWASHER

FLAT WASHER

FLAT WASHER
TERMINAL STUD OF
TERMINAL BOARD

NUT

FLAT WASHER

E/SPM-6-45
Figure 6-45. Hardwarefor wiring terminal boards with aluminum terminals

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BHT-ELEC-SPM

SELF-LOCKING NUT
ALL METAL
NUT

SPLIT LOCKWASHER

FLAT WASHER

MIL-T-7
FLAT WASHER

T-7O99
TERMINAL LUG,

TERMINAL LUG,
ALUMINUM
FLAT WASHER
TERMINAL STUD OF
TERMINAL BOARD

NUT

•FLAT WASHER

EISPM-6-46

Figure 6-46. Hardwarefor wiring terminal boardswith combination of terminal

6-41. INSTALLATION TORQUES FOR LARGE Table 6-8. Installation torques for copper
COPPER TERMINALS. terminal

Inch-pounds of torque
Stud Size Plain nut I Selflocking
Use a torquewrench on 3/8 inch and largerdiameter
studs to ensure sufficient contact pressure. The 3/8 —24 110—120 110—120
tightening torquesfor steel studsare listed in table6-8. 1/2 —20 135— 150 150— 170

Table 6-9. Installation torques for aluminum

terminal
6-42. INSTALLATION TORQUES FOR ALUMINUM Stud Size Inch-pounds oftorque
TERMINALS. #10 32
1/4 100
5/16 150
Use a torque wrench to tighten anystackupcontaining
an aluminum terminal lug. The tightening torquesfor 3/8 250
steel studsare listed in table 6-9. 1/2 480

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 BHT-ELEC-SPM

6-43. CONNECTIONS TO BUSBARS. 3. Use an MS35338 cadmium plated steel split

lockwasher undereveryhead of bolt or screwand also
6-44. CONNECTING TERMINAL LUGS TO underevery nut.
BUSBAR.
4. Use MS25440 plated brass flat washersin contact
In orderto obtain maximum efficiency in the transferof with aluminum. Thewasherdiameter is at leastequal to
power, terminal lug andbusbarareto beindirectcontact tongue diameterof terminal.Referto table 6-7. Do not
with eachother so that the current does not haveto go select a washer so large that it rides on barrel of
through anyofthe attaching partseveniftheseare good terminal.
conductors. As illustrated in figures6-47 through 6-50,
the above applieswhetherterminallugs and busbarare 6-46. PRECAUTIONS WHEN REPLACING
of the same or differentmaterials. EXISTING CONNECTIONS.

6-45. HARDWARE FOR CONNECTION TO When replacing existing terminal lug connections to
BUSBARS. busbars, observethe followingprecautions.

NOTE 1. Check all flat washers. Replace bent washers.

Replace washerswhichhavescratched plating or paint
Always refer to applicable maintenance on faying surface.
manuals for hardware stack-up and part
numbers.
2. Clean busbarconnection areas.
1. Cadmium plated steel hardware (except as noted
3. Check plated copper terminal lugs before
below), is usedto secure terminalsto busbars. Use split
lockwashers under hex nuts and under self-locking connecting to an aluminum busbar. If plating is
nuts. Use plated steelflat washerbetween lockwashers scratched, replace terminallug.
and copperterminals.
6-47. CONNECTING TWO TERMINALSTO SAME
2. Use plated brass washers MS25440 between POINTON BUSBAR.
lockwashers and aluminum terminals. As shown in
figures6-47through 6-50,thehead of the screwor bolt Terminal lugs are always in direct contactwith busbar.
can be located on terminal side or busbar side as Connectoneterminalon top of bus barand theotherto
required to simplify installation. bottom.

MS25435 TERMINAL LUG, ALUMINUM

SCREW OR AN BOLT
INSULATING SLEEVE
SPLIT LOCKWASHER

FLAT WASHER
BUSBAR, ALUMINUM

FLAT WASHER
SPLIT LOCKWASHER

NUT OR SELF-LOCKING NUT, ALL METAL

E/SPM-6-47

Figure 6-47. Connecting aluminum terminalto aluminum busbar

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BHT-ELEC-SPM

MS20659 OR MS25036
TERMINAL LUG, COPPER SCREW OR AN BOLT

INSULATING SLEEVE SPLIT LOCKWASHER

FLAT WASHER
BUSBAR, ALUMINUM

FLAT WASHER
BRASS PLATED
SPLIT LOCKWASHER

NUT OR SELF-LOCKING NUT ALL METAL

EISPM-6-48
Figure 6-48. Connecting copperterminal to aluminum busbar

MS25435 TERMINAL LUG, ALUMINUM SELF-LOCKING NUT ALL METAL

INSULATING SLEEVE SPLIT LOCKWASHER

FLAT WASHER
BUSBAR, COPPER

FLAT WASHER

SPLIT LOCKWASHER

SCREW OR BOLT

EISPM-6-49
Figure 6-49. Connecting aluminum terminalto copperbusbar

M520659 OR M525O36
TERMINAL LUG, COPPER SCREW OR BOLT

INSULATING SLEEVE SPLIT LOCKWASHER

FLAT WASHER
BUSBAR, COPPER

FLAT WASHER

SPLIT LOCKWASHER

NUT OR SELF-LOCKING NUT ALL METAL

E/SPM-6-50

Figure 6-50. Connecting copperterminal to copperbusbar

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 BHT-ELEC-SPM

CHAPTER 7

CONTENTS — RF CABLE ASSEMBLIES

Paragraph Chapter/Section Page

Number Title Number Number

7-1 RF cables and connectors. ......................................................... 7-00-00 3

7-2 General description. .................................................................... 7-00-00 3
7-3 Definitions and description. ......................................................... 7-00-00 3
7-4 RF cable assembly procedures. .................................................. 7-00-00 5
7-5 BNC and TNC series connectors. ............................................... 7-00-00 9
7-6 TNC series connector (braid clamp) ........................................... 7-00-00 20
7-7 C and SC series connectors ........................................................ 7-00-00 20
7-8 C series connector (braid clamp) ............................................. 7-00-00 22
7-9 SC connector. .......................................................................... 7-00-00 24
7-10 N series connectors. .................................................................... 7-00-00 24
7-11 Improved N connectors ........................................................... 7-00-00 24
7-12 Captivated contact N connector ................................................ 7-00-00 27
7-13 Sub-miniature — DM connectors. ............................................... 7-00-00 29
7-14 Assembly — triax type ............................................................... 7-00-00 32

FIGURES

Figure Page
Number Title Number

7-1 Typical coaxial cables ................................................................................................... 3

7-2 Typical RF connectors ................................................................................................. 4
7-3 Basic series of connectors ............................................................................................ 6
7-4 Ideal coaxial cable stripper .......................................................................................... 7
7-5 Coaxial cable stripper blade set ................................................................................... 7
7-6 Correct shape for soldering tip .................................................................................... 8
7-7 Tinning conductor ........................................................................................................ 8
7-8 Tinning inside of contact ................................................................................................ 8
7-9 Soldering contact to coaxial cable ............................................................................... 8
7-10 Tightening braid clampnut in plug of jack body ........................................................... 8
7-11 BNC connector stripping and assembly ...................................................................... 20
7-12 Cable preparation for TNC connectors (braid clamp) .................................................. 21
7-13 C and SC connectors ................................................................................................... 22
7-14 Cable crimping instruction ............................................................................................ 23
7-15 Cable preparation for C-connector (braid clamp) ........................................................... 23
7-16 N connector ................................................................................................................. 25
7-17 Cable stripping instructions .......................................................................................... 25
7-18 Attaching improved N connector ................................................................................... 26
7-19 Improved N connector — exploded view .................................................................... 26
7-20 N connectors with captivated contacts — exploded view ............................................. 27
7-21 N connectors with captivated contacts ........................................................................ 28

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BHT-ELEC-SPM

CONTENTS — RF CABLE ASSEMBLIES (CONT)

FIGURES (Cont)

Figure Page
Number Title Number

7-22 Mating polarities ............................................................................................................... 29

7-23 DM miniature plugs and receptacles ........................................................................... 30
7-24 DM miniature — exploded view and installation .......................................................... 31

TABLES

Table Page
Number Title Number

7-1 Ideal coaxial cable strippers ........................................................................................ 5

7-2 Connector tooling ............................................................................................................ 9

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 BHT-ELEC-SPM

RF CABLE ASSEMBLIES

7-1. RF CABLES AND CONNECTORS. (2) N Series — A general purpose threaded

coupling connector used with medium size coaxial
7-2. GENERALDESCRIPTION. cables.Referto figure 7-3.

RF cable assemblies are used to carry RF (radio (3) C Series — A general purpose threaded
coupling connector used with medium size coaxial
frequency) signals from one point to another with a cables. Referto figure 7-3.
known rate of loss. An assembly consists of RF
connectors attached to coaxial cables. The coaxial
cable describedhere is of theflexible, solid dielectric (4) TNC Series — A small lightweight connector
type, relatively small to medium size. The similar to the BNC series, but having a threaded
characteristicimpedance of most of the cable is 50 coupling usedwherea positive coupling undervibration
ohms, but several of the cables listed have a and a low noiselevel is desirable. Referto figure 7-3.
characteristicimpedanceof 48, 53, 75, or 93 ohms.

This chapter describes and illustrates RF connectors

and coaxial cables most commonly used in Bell
Helicopters and the recommended methods for
assembling coaxialcable to connectors.

This chapteralso describesand gives instructions for

assembling miniature RF connectorsto coaxialcables
used in fuel quantityindicating systems.

7-3. DEFINITIONS AND DESCRIPTION.

A. SINGLE SHIELD
1. CoaxialCable. Coaxialcable consistsof an inner SHIELD (OUTER CONDUCTOR)
(center) conductor separated from the outer
conductor, usually called a shield, by an insulating
dielectric.Thecable isprotectedagainst moistureand
abrasion by a tough outerjacket (sometimescalled a
sheath).Refer to figure 7-1 for typical coaxial cables.
The inner conductor is usuallycopper,either solid or
standard,and maybe bare, tin plated,or silverplated.
The outerconductor (shield) is a copper braid, bare,
tin plated, or silver-plated,woven over thedielectric.
Somecoaxial cables have a double outerconductor
(doubleshield) to provide extra shielding.

2. RF CONNECTORS.RF connectorsare available as

pin-contactor socket-contact plugs. Refer to figure 7-2.
Receptacles are designed for mounting to panels or
chassis.

a. The circuit requirement dictates the series of

connectorstobe used fordifferentcables.Thefollowing
are five basic series used. E/SPM.7-1

(1) 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. Referto figure 7-3. Figure 7-1. Typical coaxial cables

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BHT-ELEC-SPM

RECEPTACLE JAM NUT PLUG-RIGHT ANGLE

REAR MOUNTED

RECEPTACLE JAM NUT RECEPTACLE FLANGE

FRONT MOUNTED MOUNTED

RECEPTACLE JAM NUT PLUG-PIN CONTACT

MOUNTED

RECEPTACLE FLANGE PLUG-SOCKET CONTACT

MOUNTED E/SPM-7-2

Figure 7-2. Typical RF connectors

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 BHT-ELEC-SPM

(5) SC Series — A connectorusedwith medium AT ALL TIMES. ANYTHING WHICH

size coaxial cables similar to the C series with a DAMAGES IT, OR WHICH MIGHT LEAD
threaded coupling. Referto figure 7-3. TO ITS BEING DAMAGED LATER,
REDUCES THE EFFICIENCY OF THE
SYSTEM.
7-4. RF CABLE ASSEMBLYPROCEDURES.
a. Keep soldering iron clean, smooth, and well
1. GENERAL. A good connection depends on holding tinned at all times.
coaxialcables and connectorsto design dimensions. Any
changein these dimensionswill cause added lossestothe b. Use care in starting the braid clamp nut into a
RF signal being carried, and may also cause radiation plug or jack body in orderto prevent crossthreading.
interlerence. It is important that the assembly directions
givenforeach connectionbefollowedto maintaindesigned
C.Pins and socketsfor RF connectorsare usually
perlormance.Thefollowingprecautionsare common to all
coaxial cable assemblies. packed unassembled. Do not misplace them.

_______________ d. Donotusepliersto assemble or disassemble RF

c::i:!EEJ connectors.

e. If at all possible do not use a pocket knife or

WHEN WORKING WITH A COAXIAL
similartool to strip coaxial cable.
CABLE, NEVER STEP ON THE CABLE,
SET ANYTHINGHEAVY ON IT, OR BEND
IT SHARPLY. THIS WILL CHANGE ITS 2. CABLE STRIPPING. Table 7-1 lists the
ELECTRICAL CHARACTERISTICS. recommended Ideal tool part number for specified
HANDLE COAXIAL CABLE CAREFULLY cable diameters.

Table 7-1 . Ideal coaxial cable strippers

REPLACEMENT BLADE SET

CABLE DIAMETER PARTNUMBER PART NUMBER
UPTOO.125INCH 45-162 L9225

0.125 — 0.22 INCH 45-163 L9225

0.200—0.310 INCH 45-164 L9225

0.250—0.56 INCH 45-165 L9226

a. Cable jacket stripping is accomplished as (3) Rotate tool once around circumference of
follows: cable and removetool.

(1) Set depth of one of the side blades and

curved blade on front of tool to approximately 3/4 (4) Flex cable until notch penetrates through
thicknessof cable jacket. Referto figure 7-4 and 7-5. jacketwall.

(2) Positiontool so cablerestsin V-notchdirectly (5) For short strip lengths, slide off section of
underside blade. jacketto be removed.

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BHT-ELEC-SPM

PLUG, PIN CONTACT PLUG, SOCKET CONTACT

M39012/16 M39012/27

SOCKET CONTACT
M39012/17

TYPICAL BNC CONNECTORS TYPICAL TNC CONNECTORS

PLUG, PIN CONTACT PLUG, PIN CONTACT

M39012/35 M39012/06

MOUNTED
SOCKET CONTACT
M39012/07

TYPICAL SC CONNECTORS TYPICAL C CONNECTORS

PLUG, SERIES N PLUG AND RECEPTACLE

MIL-C-39012/1 FLANGE MOUNTED
SERIES N
MIL-C-39012/2

TYPICAL SERIES N CONNECTORS

E/SPM-7-3

Figure 7-3. Basicseries of connectors

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 BHT-ELEC-SPM

d. Flexcable so as to spreadthe notch through the

jacketwall in both positions.
e. Slide off first sectionofjacket.
I. Slide backcomponent braid and using side cutters,
trim back to edge of wire jacket ensuring a good clean
edge.
g. Slideon soldersleeve, remove secondsectionof
E/SPM-7-4 jacket, position and recoverthe soldersleeve.
4. SOLDERING PROCEDURES. The work to be
Figure 7-4. Ideal coaxial cable stripper soldered must be clean and free from oxides.Remove
grease by cleaning with solvent or other approved
cleaner. Oxides, if not too heavy, are removed by the
FRONT
action of the resin fluxduring the soldering operation.
CURVED Heavily oxidized wire cannot becleaned bythe resinflux
BLADE and should be discarded.
a. For good soldering, it is important to select a

I!!1!
soldering iron of the proper size and heat capacity. For
soldering coaxial cable to RF connectors, use an iron
with a heating elementrated at 65 to 100 watts, and a
SIDE
tip of about 1/4 inch diameter. The soldering tip should
L-A-...1
SIDE
BLADE BLADE
be shaped as shown in figure7-6. Ensure soldering iron
is clean, smooth and well-tinned.
E/SPM-7-5

Figure 7-5. Coaxial cable stripper blade set

FORSOLDERING COAXIAL CABLE TO RF
(6) For long strip lengths, position tool so cable CONNECTORS, TIN ONLY ONE FACE OF
restsin notch directlyunderneath front blade. Slide tool THE TIP SO AREAS ADJACENT TO THAT
along section ofjacketto be removed and removetool. BEING SOLDERED WILLNOTBECOATED
Fold cableagainstcut spread notchthroughjacketwall, WITH SOLDER BYACCIDENT.

LJ
thus removing this sectionof cable jacket.
b. For connectorsusing solderpins or sockets, tin
center conductor and contact with soldering iron as
shown in figure 7-7 and 7-8. Use tin lead solderwith a
core of resinflux (EC-039) and the untinned face of tip

LJ
to prevent depositing solderon the outside of contact.
DO NOT DAMAGE DIELECTRIC OR
BREAK SHIELD STRANDS.

(7) To remove dielectric, cut with sharp knife

around circumference, not quite through to center CONTACT MUST BUTT AGAINST
conductor, taking care not to nick or cut strands or DIELECTRIC BEFORE AND AFTER
otherwise damage conductor. Pull off dielectric. SOLDERING.
3. CABLE JACKET STRIPPING FOR SOLDER C. For soldering cable to RF connectors use tin lead
SLEEVE TERMINATION. Cable jacket stripping is solder with a core of resin flux (EC-039).Heatthe parts to
accomplished as follows: be joined, and apply the solder at the junction of the
a. Setthe depth ofall threeblades to approximately soldering iron tip and the work as shown in figure 7-9. Do
3/4ofthethickness of component jacket. not apply heat longerthan is necessaryto melt the solder;
excessiveheat will swell the dielectricand make it difficult
b. Position tool so wire rests in V-notch directly to insert into body shell. Do not allow solder to flow over
underside blade. outside of contact. After the joint has cooled, remove
excess flux by wiping with a clean cloth, using denatured
c. Rotate tool once around circumference of cable alcohol as a solvent if necessary.Remove excess solder
then remove tool. from contact.

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BHT-ELEC-SPM

CONTACT MUST BUTT

FLUSH AGAINST DIELECTRICS

FEED SOLDER
INTO HOLE ONLY
E/SPM-7-6 ROSIN-CORE SOLDERS

Figure 7-6. Correct shape for soldering tip

E/SPM-7-9

Figure 7-9. Soldering contactto coaxial cable

ROSIN-CORE SOLDER
5. ASSEMBLY. When assemblingthe connector,always
start clamping nut into body by hand, then hold body
assembly in a vise using lead or neoprenejaw protectors.
Hold body only on theflats. Do notuseexcessivepressure,
since thebodycanbeeasily distorted.Tighten nutwith end
wrench. Refer to figure 7-10.

E/SPM-7-7

Figure 7-7. Tinning conductor JAWPROTECTORS

LEADOR NEOPRENE
HOLDON FLATSONLY.

UNTINNED SURFACE OF
TIP TOUCHING CONTACT

SOLDER
E/SPM-7-1O

E/SPM-7-8

Figure 7-10. Tightening braid clampnut into

Figure 7-8. Tinning inside of contact plug of jack body

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 BHT-ELEC-SPM

7-5. BNC AND TNC SERIES CONNECTORS.

Thereare threeversionsof BNCand TNC connectors,

differingin themethodof attaching coaxial cableto the DO NOT NICK BRAID, DIELECTRIC OR
connectorbody. Thethreeversionsare listed as follows: CENTERCONDUCTOR.
b. Slide outer ferrule onto cable. Flare end of cable
1. Crimp Ferrule — Crimp center pin or socket — braid slightly to facilitate insertiononto inner ferrule.
Consists of connector body, crimp outer ferrule, and
crimpcenter pin or socket.

2. Crimp Ferrule — Solder center pin or socket —

Consists of connector body, crimp outer ferrule, and ENSURE CORRECT CONTACT IS USED; A
soldercenter pin or socket. MALE CONTACT ALWAYS GOES INTO A
PLUG BODY, AND A FEMALE CONTACT
ALWAYS GOES INTO A JACKBODY.
3. Braid Clamp — Solder center pin or socket —
Consists of connector body, nut, gasket, clamp, c. Place contact on cable center conductorso it butts
bushings, and soldercenterpin or socket. againstcable dielectric.Center conductorshould be visible
through inspectionhole in contact. Crimp or solder center
4. Figure 7-11 is an exploded view of a basic BNC pinor socket in place as follows:
Connectorand stripping dimensions. Attach BNC and
TNC connectors to coaxial cable as follows: (1) Crimp Method: Selectappropriatecrimpingtool
fromtable 7-2. Crimp center pinor socket.

NOTE (2) Solder Method: Solder contact to cable center

conductor. Avoid getting solder on outside surlace of
contact. Avoid excessive heat to prevent swelling of
The following instructions are general; refer dielectric.
to RF connector vendor catalogue for
precise stripping and assemblyprocedures. d. Installcableassemblyinto body assemblyso inner
ferrule portion slides under braid. Push cable assembly
a. Refertofigure7-1 1 . Strip cablejacket,braid, and forward until contact snaps into place in insulator.
dielectric to dimensions shown.All cuts are to be sharp
and square. Tinning of center conductor is not e. Slideouterferruleoverbraid and againstconnector
necessary ifcontactisto becrimped. Forsoldermethod, body.Ciimpouterferrule usingcavity of dieset specifiedin
tin centerconductor, avoiding excessive heat. table 7-2.

Table 7-2. Connector tooling

BNCITNC
RG-58
BNC/ PIN OR TOOLCRIMP TOOL
TNC CONNECTORITYPE SOCKET FERRULE ALTERNATE
BNC Male M39012/16-0504 Positioner CavityA Cavity B
pincontact M22520/1-12 M22520/5-05 M22520/5-1 9
Male M39012/17-0504 Positioner CavityA Cavity B
socketcontact M22520/1-12 M22520/5-05 M2252015-19
Female M39012/18-0504 Positioner CavityA Cavity B
socketcontact, flange mounted M22520/1-12 M2252015-05 M22520/5-1 9
Female M39012/18-0504 Positioner CavityA Cavity B
socketcontact, jamnut mount M22520/1-12 M22520/5-05 M22520/5-1 9
TNC Male M39012/20-0504 Positioner CavityA CavityB
pin contact, right angle M22520/1-12 M22520/5-05 M22520/5-19
Male M39012/26-0501 Positioner Cavity A CavityB
pin contact M22520/1-12 M22520/5-05 M22520/5-19

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BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

BNC/ PIN OR TOOL CRIMP TOOL
TNC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE
BNCITNC
RG-58(Cont)
TNC Female M39012/27-0504 Positioner CavityA Cavity B
socket contact M22520/1 -12 M22520/5-05 M22520/5-1 9
Female M39012/28-0504 Positioner CavityA Cavity B
socket contact, flangemounted M22520/1-12 M22520/5-05 M22520/5-1 9
Female M39012/29-0504 Positioner CavityA Cavity B
socket contact, flangemounted M22520/1-12 M22520/5-05 M22520/5-1 9
Male M39012/30-0504 Positioner CavityA Cavity B
pin contact, right angle M22520/1-12 M22520/5-05 M22520/5-19
RG-141 and RG-303 *RG303 only

BNC Male M39012/16-001 3 Solder CavityB CavityA

pin contact M22520/5-19 M22520/5-1 1
Female M39012/17-0013 Solder CavityB CavityA
socket contact M22520/5-19 M22520/5-1 1
Female M39012/18-0013 Solder Cavity B CavityA
socket contact, flange mount M22520/5-19 M22520/5-1 1
Female M39012/19-0013 Solder Cavity B CavityA
socketcontact, jamnut mount M22520/5-19 M22520/5-11
TNC Male M39012/20-0006 Solder Cavity B CavityA
pincontact, right angle M22520/5-19 M22520/5-11
Male M39012/26-0010* Solder Cavity B CavityA
pincontact M22520/5-19 M22520/5-11
Female M39012/27-0010* Solder Cavity B Cavity A
socketcontact M22520/5-19 M22520/5-11
Female M39012/28-0010* Solder Cavity B Cavity A
socketcontact, jamnut mount M22520/5-19 M22520/5-11
Female M39012/29-0010* Solder Cavity B Cavity A
socket contact, flange mount M22520/5-19 M2252015-11
Male M39012/30-001 0* Solder Cavity B CavityA
pin contact, right angle M22520/5-19 M22520/5-11

RG-223
BNC Male M39012/16-001 4 Solder Cavity B CavityA
pin contact M22520/5-1 9 M2252015-11
Female M39012/17-0014 Solder Cavity B CavityA
socket contact M22520/5-1 9 M22520/5-11
Female M39012/18-001 4 Solder Cavity B CavityA
socket contact, flangemount M22520/5-1 9 M22520/5-11
Female M39012/19-0014 Solder Cavity B CavityA
socket contact, jamnutmount M22520/5-1 9 M22520/5-11
TNC Male M39012/20-0007 Solder Cavity B CavityA
pin contact, right angle M22520/5-19 M22520/5-11

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 BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

BNC/ PIN OR TOOLCRIMP TOOL
TNC CONNECTORIrYPE SOCKET FERRULE ALTERNATE

RG-223 (Cont)

INC Male M39012/26-OO11 Solder CavityB CavityA

pincontact M22520/5-19 M22520/5-1 1
Female M39012/27-OO11 Solder CavityB CavityA
socketcontact M22520/5-19 M22520/5-11
Female M39012/28-OO11 Solder Cavity B CavityA
socketcontact, jamnut mount M22520/5-19 M22520/5-11
Female M39012/29-0011 Solder Cavity B Cavity A
socketcontact, flange mount M22520/5-19 M22520/5-11
Male M39012/30-0011 Solder Cavity B Cavity A
pin contact, right angle M22520/5-19 M22520/5-11
RG-142

BNC Male M39012/1 6-0503 Positioner Cavity A Cavity B

pin contact M22520/1 -12 M22520/5-05 M22520/5-19
Female M39012/17-0503 Positioner CavityA Cavity B
socket contact M22520/1 -12 M22520/5-05 M22520/5-19
Female M39012/18-0503 Positioner CavityA Cavity B
socket contact,flange mount M22520/1 -12 M22520/5-05 M22520/5-1 9
Female M39012/1 9-0503 Positioner CavityA Cavity B
socket contact,jamnutmount M22520/1 -12 M2252015-05 M22520/5-1 9
TNC Male M39012/20-0503 Positioner CavityA Cavity B
pin contact, right angle M22520/1-12 M22520/5-05 M22520/5-19
Male M39012/26-0503 Positioner CavityA Cavity B
pin contact M22520/1-12 M22520/5-05 M22520/5-1 9
Female M39012/27-0503 Positioner CavityA Cavity B
socket contact M22520/1-12 M22520/5-05 M22520/5-1 9
Female M39012/29-0503 Positioner CavityA Cavity B
socket contact, flangemount M22520/1-12 M22520/5-05 M22520/5-1 9
Male M39012/30-0503 Positioner CavityA Cavity B
pin contact, right angle M22520/1-12 M22520/5-05 M22520/5-1 9

RG-59, RG-62, RG14O, RG-210 *does not include RG-140

BNC Male M39012/16-0015 Solder CavityA Cavity B

pincontact M22520/5-19 M2252015-13
Female M39012/17-0015 Solder CavityA CavityB
socket contact M22520/5-19 M22520/5-13
Female M39012/18-0015 Solder CavityA CavityB
socketcontact, flange mount M22520/5-19 M22520/5-13
Female M39012/19-0015 Solder CavityA CavityB
socketcontact, jamnut mount M22520/5-19 M22520/5-13
TNC Male M39O12/26OO12* Solder CavityA CavityB
pincontact M22520/5-19 M22520/5-13

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BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

BNC/ PIN OR TOOL CRIMP TOOL
TNC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE

RG-59,RG-62, RG14O,RG-210 *does not includeRG-140(Cont)

TNC Female M39O12/27OO12* Solder CavityA Cavity B
socket contact M22520/5-1 9 M22520/5-1 3
Female M39O12/28OO12* Solder CavityA Cavity B
socket contact, jamnutmount M22520/5-1 9 M22520/5-1 3
Female M39012/29-001 2* Solder CavityA Cavity B
socket contact, flangemount M22520/5-19 M22520/5-1 3
Male M39012/30-0012 Solder CavityA Cavity B
pin contact, right angle M22520/5-19 M22520/5-13
RG-122

BNC Male M39012/16-0501 Positioner CavityA Cavity B

pincontact M2252011 -12 M22520/5-05 M22520/5-1 9
Female M39012/17-0501 Positioner CavityA CavityB
socket contact M22520/1-12 M22520/5-05 M22520/5-19
Female M39012/18-0501 Positioner CavityA CavityB
socket contact, flange mount M22520/1-12 M22520/5-05 M22520/5-19
Female M39012/19-0501 Positioner Cavity A CavityB
socketcontact, jamnut mount M22520/1-12 M22520/5-05 M22520/5-19
TNC Male M39012/20-0501 Positioner Cavity A Cavity B
pincontact, right angle M22520/1-12 M22520/5-05 M22520/5-19
Male M39012/26-0501 Positioner Cavity A Cavity B
pincontact M22520/1-12 M22520/5-05 M2252015-19
Female M39012/27-0501 Positioner Cavity A Cavity B
socket contact M22520/1 -12 M22520/5-05 M22520/5-19
Female M39012/28-0501 Positioner CavityA Cavity B
socket contact,jamnut mount M22520/1 -12 M22520/5-05 M22520/5-19
Female M39012/29-0501 Positioner CavityA Cavity B
socket contact, flange mount M22520/1 -12 M22520/5-05 M22520/5-1 9
Male M39012/30-0501 Positioner CavityA Cavity B
pin contact, right angle M22520/1 -12 M22520/5-05 M22520/5-1 9
RG-71
BNC Male M39012/16-001 6 Solder CavityA CavityA
pin contact M22520/5-63 M22520/5-1 5
Female M39012/17-001 7 Solder CavityA CavityA
socket contact M22520/5-63 M22520/5-1 5
Female M39012/18-001 7 Solder CavityA CavityA
socket contact, flangemount M22520/5-63 M22520/5-1 5
Female M39012/19-001 7 Solder CavityA CavityA
socket contact, jamnut mount M22520/5-63 M22520/5-1 5

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 BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

BNC/ PIN OR TOOL CRIMP TOOL
TNC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE
RG-71 (Cont)
TNC Male M39012/26-0014 Solder Cavity A CavityA
pincontact M22520/5-63 M22520/5-15
Female M39012/27-0014 Solder Cavity A Cavity A
socketcontact M22520/5-63 M22520/5-15
Female M39012/28-0014 Solder Cavity A Cavity A
socketcontact, jamnut mount M22520/5-63 M22520/5-15
Female M39012/29-0014 Solder Cavity A Cavity A
socketcontact, flange mount M22520/5-63 M22520/5-15
Male M3901 2/30-0014 Solder Cavity A CavityA
pin contact, right angle M22520/5-63 M22520/5-15
RG-302
BNC Male M39012/16-0020 Solder CavityA CavityA
pin contact M22520/5-1 9 M22520/5-1 3
Female M39012/17-0020 Solder CavityA CavityA
socket contact M22520/5-1 9 M2252015-13
Female M39012/18-0020 Solder CavityA CavityA
socket contact, flange mount M22520/5-1 9 M22520/5-1 3
Female M39012/19-0020 Solder CavityA CavityA
socket contact, jamnutmount M22520/5-19 M22520/5-1 3
TNC Male M39012/20-001 0 Solder CavityA CavityA
pin contact, right angle M22520/5-19 M22520/5-1 3
Male M39012/26-0021 Solder CavityA CavityA
pincontact M22520/5-19 M22520/5-13
Female M39012/27-0021 Solder CavityA CavityA
socket contact M22520/5-19 M2252015-13
Female M39012/28-0021 Solder CavityA CavityA
socket contact, jamnut mount M22520/5-19 M22520/5-13
Female M39012/29-0021 Solder CavityA CavityA
socket contactflangemount M22520/5-19 M22520/5-13
Male M39012/30-0021 Solder CavityA CavityA
pincontact, right angle M22520/5-19 M22520/5-13
RG-400
BNC Male M39012/16-0503 Positioner CavityA CavityB
pincontact M2252011 -12 M22520/5-05 M22520/5-19
Female M39012/17-0503 Positioner Cavity A Cavity B
socket contact M22520/1-12 M22520/5-05 M22520/5-19
Female M39012/1 8-0503 Positioner Cavity A Cavity B
socket contact, flange mount M22520/1-12 M22520/5-05 M22520/5-19
Female M3901 2/1 9-0503 Positioner Cavity A Cavity B
socket contact,jamnut mount M2252011-12 M22520/5-05 M22520/5-19
INC Male M39012/20-0503 Positioner Cavity A Cavity B
pin contact, right angle M22520/1 -12 M22520/5-05 M22520/5-19
Male M39012/26-0503 Positioner Cavity A Cavity B
pin contact M22520/1 -12 M22520/5-05 M22520/5-19

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BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

BNC/ PIN OR TOOL CRIMP TOOL

TNC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE

RG-400 (Cont)

TNC Female M39012/27-0503 Positioner Cavity A CavityB

socketcontact M22520/1-12 M22520/5-05 M22520/5-19
Female M39012/28-0503 Positioner Cavity A Cavity B
socketcontact, jamnut mount M22520/1-12 M22520/5-05 M22520/5-19
Female M39012/29-0503 Positioner Cavity A Cavity B
socketcontactflange mount M22520/1-12 M22520/5-05 M22520/5-19
Male M39012/30-0503 Positioner Cavity A Cavity B
pin contact, right angle M22520/1 -1 2 M22520/5-05 M22520/5-19

RG-180

BNC Male M39012/16-0502 Positioner CavityA Cavity B

pin contact M2252011 -12 M22520/5-05 M22520/5-41
Female M39012/17-0502 Positioner CavityA Cavity B
socket contact M22520/1 -12 M22520/5-05 M22520/5-41
Female M39012/18-0502 Positioner CavityA Cavity B
socket contact,flange mount M22520/1 -12 M22520/5-05 M22520/5-41
Female M39012/19-0502 Positioner CavityA Cavity B
socket contact, jamnutmount M22520/1-12 M22520/5-05 M22520/5-41
TNC Male M39012/20-0502 Positioner CavityA Cavity B
pin contact, right angle M22520/1-12 M22520/5-05 M22520/5-41
Male M39012/26-0502 Positioner CavityA Cavity B
pin contact M22520/1-12 M22520/5-05 M22520/5-41
Female M39012/27-0502 Positioner CavityA CavityB
socket contact M22520/1-12 M22520/5-05 M22520/5-41
Female M39012/28-0502 Positioner CavityA CavityB
socket contact, jamnut mount M22520/1-12 M22520/5-05 M22520/5-41
Female M39012/29-0502 Positioner CavityA CavityB
socket contact, flangemount M22520/1-12 M22520/5-05 M22520/5-41
Male M39012/30-0502 Positioner CavityA CavityB
pincontact, right angle M22520/1-12 M22520/5-05 M22520/5-41

RG-174, RG-316

TNC Male M39012/26-0022 Solder CavityA CavityB

pincontact M22520/5-05 M22520/5-41
Female M39012/27-0022 Solder CavityA Cavity B
socketcontact M22520/5-05 M22520/5-41
Female M39012/28-0022 Solder Cavity A Cavity B
socket contact, jamnut mount M22520/5-05 M2252015-41
Female M39012/29-0022 Solder Cavity A Cavity B
socket contact,flange mount M22520/5-05 M22520/5-41
Male M39012/30-0022 Solder Cavity A Cavity B
pin contact, right angle M22520/5-05 M22520/5-41

700-00
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 BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

PINOR TOOLCRIMP TOOL

C/SC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE

CISC
RG-212, RG-304

PIN OR TOOL CRIMP TOOL

CISC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE
C Male M39012/06-0027 Solder Cavity A CavityA
pin contact M22520/5-35 M22520/5-29
Female M39012/07-0014 Solder Cavity A CavityA
socket contact M22520/5-35 M22520/5-29
C Female M39012/08-0013 Solder Cavity A CavityA
socket contact,flange mount M22520/5-35 M22520/5-29
Female M39012/11-0012 Solder CavityA CavityA
socket contact,jamnut mount rear M22520/5-35 M22520/5-29
SC Male M39012/35-001 0 Solder CavityA CavityA
pin contact M22520/5-35 M22520/5-29
Female M39012/36-0009 Solder CavityA CavityA
socket contact M2252015-35 M22520/5-29
Female M39012/38-0008 Solder CavityA CavityA
socket contact,flange mount rear M22520/5-35 M22520/5-29
Female M39012/40-001 4 Solder CavityA CavityA
socket contact,jamnut rear mount M2252015-35 M22520/5-29

RG-213, RG-165 (1 RG-213 ONLY, 2 RG-165 ONLY)

C Male M39012/06-0028 Solder CavityA CavityA
pin contact M22520/5-61 M22520/5-25
Female M39012/07-001 1 Solder CavityA CavityA
socket contact M22520/5-61 M22520/5-25
Female M39012/08-001 0 Solder CavityA CavityA
socket contact, flangemount M22520/5-61 M22520/5-25
Male M39012/10-0006 Solder CavityA CavityA
pin contact, right angle M22520/5-61 M22520/5-25
Female M39012/11-0013 Solder CavityA CavityA
socketcontact,jamnut rear mount M22520/5-61 M22520/5-25
SC1 Male M39012/35-0502 Positioner CavityA CavityA
pincontact M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/36-0502 Positioner CavityA CavityA
socketcontact M22520/1-14 M22520/5-61 M22520/5-25
Female M39012/38-0502 Positioner Cavity A CavityA
socket contact,flange mount rear M22520/1-14 M22520/5-61 M22520/5-25
Male M39012/39-0502 Positioner Cavity A CavityA
pin contact, right angle M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/40-0502 Positioner Cavity A CavityA
socket contact,jamnut rear mount M22520/1 -14 M22520/5-61 M22520/5-25
SC2 Male M39012/35-OO11 Solder Cavity A Cavity A
pin contact M22520/5-61 M22520/5-25
Female M39012/36-0007 Solder Cavity A Cavity A
socket contact M22520/5-61 M22520/5-25

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BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

PIN OR TOOL CRIMP TOOL
C/SC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE

RG-213, RG-165 (1 RG-213 ONLY,2 RG-165ONLY)(Cont)

SC2 Female M39012/38-0006 Solder Cavity A Cavity A
socket contact,flange mount rear M22520/5-61 M22520/5-25
Male M39012/39-0004 Solder Cavity A Cavity A
pin contact, right angle M22520/5-61 M22520/5-25
Female M39012/40-0015 Solder Cavity A CavityA
socket contact,jamnut rear mount M22520/5-61 M22520/5-25

RG-214, RG-225, RG-393 (1 RG-214 ONLY, 2 RG-225 ONLY)

Cl Male M39012106-0029 Solder CavityA CavityA
pin contact M22520/5-61 M22520/5-25
Female M39012/07-001 2 Solder CavityA CavityA
socket contact M22520/5-61 M22520/5-25
Female M39012/08-001 0 Solder CavityA CavityA
socket contact, flange mount M22520/5-61 M22520/5-25
Male M39012/10-0007 Solder CavityA CavityA
pin contact, right angle M22520/5-61 M2252015-25
Female M39012/11-0014 Solder CavityA CavityA
socket contact,jamnut rear mount M22520/5-61 M22520/5-25
C2 Male M39012/06-0030 Solder CavityA CavityA
pin contact M22520/5-61 M22520/5-25
Female M39012/07-0003 Solder CavityA CavityA
socket contact M22520/5-61 M22520/5-25
Female M39012/08-0012 Solder CavityA CavityA
socket contact, flangemount M22520/5-61 M22520/5-25
Male M39012/10-0008 Solder CavityA CavityA
pincontact, right angle M22520/5-61 M22520/5-25
Female M39012/11-0015 Solder CavityA CavityA
socket contact,jamnut rear mount M22520/5-61 M22520/5-25
SC Male M39012/35-0501 Positioner Cavity A CavityA
pincontact M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/36-0501 Positioner Cavity A Cavity A
socketcontact M2252011 -14 M22520/5-61 M22520/5-25
Female M39012/38-0501 Positioner Cavity A Cavity A
socket contact,jamnut mount rear M22520/1 -14 M22520/5-61 M22520/5-25
Male M39012/39-0501 Positioner Cavity A Cavity A
pin contact, right angle M22520/1 -1 3 M22520/5-61 M22520/5-25
Female M39012/40-0015 Positioner Cavity A Cavity A
socket contact,jamnut rear mount M22520/1 -14 M22520/5-61 M22520/5-25
RG-11, RG-144
C Male M39012/06-0031 Solder Cavity A CavityA
pin contact M22520/5-61 M22520/5-25
Female M39012/07-001 5 Solder Cavity A CavityA
socket contact M22520/5-61 M22520/5-25

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 BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

PINOR TOOLCRIMP TOOL

C/SC CONNECTOR/TYPE SOCKET FERRULE ALTERNATE

RG-11, RG-144 (Cont)

C Female M39012/11-0016 Solder CavityA CavityA
socket contact,jamnut rear mount M22520/5-61 M22520/5-25
SC Male M39012/35-001 3 Solder CavityA CavityA
pin contact M2252015-61 M22520/5-25
Female M39012/36-001 0 Solder CavityA CavityA
socket contact M22520/5-61 M22520/5-25
Female M39012/40-0021 Solder CavityA CavityA
socket contact,jamnut rear mount M22520/5-61 M22520/5-25

RG-400, RG-142
SC Male M39012/35-0503 Positioner CavityB CavityA
pin contact M22520/1-14 M22520/5-19 M22520/5-57
Female M39012/36-0503 Positioner CavityB CavityA
socket contact M22520/1-14 M22520/5-19 M22520/5-57
Female M39012/38-0503 Positioner Cavity B CavityA
socketcontact,flange mount rear M22520/1-14 M22520/5-19 M22520/5-57
Male M39012/39-0503 Positioner Cavity B CavityA
pincontact, right angle M22520/1-13 M22520/5-19 M22520/5-57
Female M39012/40-0503 Positioner Cavity B CavityA
socket contact,jamnut rear mount M22520/1-14 M22520/5-19 M22520/5-57

RG-217
SC Female M39012/40-0018 Solder Cavity A
socket contact,jamnut rear mount M22520/5-27

RG-216
SC Female M39012/40-0017 Solder CavityA CavityA
socket contact,jamnut rear mount M22520/5-61 M22520/5-25

N Connector
RG-212, RG-222
PIN OR TOOL CRIMP TOOL
N CONNECTOR/TYPE SOCKET FERRULE ALTERNATE
N Male M39012/02-0016 Solder CavityA CavityA
pin contact M22520/5-35 M22520/5-29
Female M39012/02-001 9 Solder CavityA CavityA
socket contact M22520/5-35 M22520/5-29
Female M39012/02-0027 Solder CavityA CavityA
socket contact, flangemount M22520/5-35 M22520/5-29
Female M39012/03-001 3 Solder CavityA CavityA
socket contact, jamnut mount M22520/5-35 M22520/5-29
Male M39012/05-001 6 Solder CavityA CavityA
— pin contact, right angle M22520/5-35 M22520/5-29

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BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

PIN OR TOOL CRIMP TOOL
N CONNECTOR/TYPE SOCKET FERRULE ALTERNATE

RG-213

N Male M39012/01 -0502 Positioner CavityA CavityA

pin contact M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/02-0502 Positioner CavityA CavityA
socket contact M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/02-051 2 Positioner CavityA CavityA
socket contact, flangemount M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/03-0502 Positioner CavityA CavityA
socket contact, jamnut mount M22520/1-13 M22520/5-61 M22520/5-25
Male M39012/05-0502 Positioner CavityA CavityA
pin contact, right angle M22520/1-13 M22520/5-61 M22520/5-25

RG-214, RG-225, RG-393

N Male M39012/01 -0501 Positioner CavityA CavityA
pincontact M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/02-0501 Positioner CavityA CavityA
socket contact M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/02-0511 Positioner Cavity A CavityA
socketcontact, flange mount M22520/1-13 M22520/5-61 M22520/5-25
Female M39012/03-0501 Positioner Cavity A CavityA
socketcontact, jamnut mount M22520/1-13 M22520/5-61 M22520/5-25
Male M39012/05-0501 Positioner Cavity A Cavity A
pincontact, right angle M22520/1-13 M22520/5-61 M22520/5-25

RG-217

N Male M39012/01-0019 Solder Cavity A

pin contact M22520/5-27
Female M39012/02-0022 Solder Cavity A
socket contact M2252015-27
Female M39012/03-001 6 Solder Cavity A
socket contact,jamnut mount M22520/5-27

RG-165

N Male M39012/01 -0021 Solder CavityA CavityA

pin contact M22520/5-61 M22520/5-25
Female M39012/02-0024 Solder CavityA CavityA
socket contact M22520/5-61 M22520/5-25
Female M39012/02-0041 Solder CavityA CavityA
socket contact, flange mount M22520/5-61 M2252015-25
Female M39012/03-001 8 Solder CavityA CavityA
socket contact, jamnutmount M22520/5-61 M22520/5-25
Male M39012/05-001 5 Solder CavityA CavityA
pin contact, right angle M2252015-61 M22520/5-25

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 BHT-ELEC-SPM

Table 7-2. Connector tooling (Cont)

PIN OR TOOL CRIMP TOOL
N CONNECTORITYPE SOCKET FERRULE ALTERNATE
RG-11 , RG-144
N Male M39012/01-0023 Solder Cavity A Cavity A
pin contact M22520/5-61 M22520/5-25
Female M39012/02-0026 Solder Cavity A CavityA
socketcontact M22520/5-61 M22520/5-25
Female M39012/02-0042 Solder CavityA CavityA
socket contact, flange mount M22520/5-61 M22520/5-25
Female M39012/03-0020 Solder CavityA CavityA
socket contact, jamnutmount M22520/5-61 M22520/5-25
Male M39012/05-0014 Solder CavityA CavityA
pin contact, right angle M22520/5-61 M22520/5-25
RG-216
N Male M39012/01 -0024 Solder CavityA CavityA
pin contact M22520/5-61 M22520/5-25
Female M39012/02-0039 Solder CavityA CavityA
socket contact M22520/5-61 M22520/5-25
Female M39012/02-0030 Solder CavityA CavityA
socket contact, flange mount M22520/5-61 M22520/5-25
Female M39012/03-0021 Solder CavityA CavityA
socket contact, jamnutmount M22520/5-61 M22520/5-25
Male M39012/05-001 7 Solder CavityA CavityA
pin contact, right angle M22520/5-61 M22520/5-25
RG-6
N Male M39012/01 -0027 Solder CavityA CavityA
pincontact M22520/5-35 M22520/5-29
Female M39012/02-0040 Solder CavityA CavityA
socket contact M22520/5-35 M22520/5-29
Female M39012/02-0043 Solder CavityA CavityA
socket contact, flangemount M22520/5-35 M22520/5-29
Female M39012/03-0023 Solder CavityA Cavity A
socketcontact, jamnut mount M22520/5-35 M22520/5-29
Male M39012/05-0013 Solder CavityA Cavity A
pincontact, right angle M22520/5-35 M22520/5-29
RG-400, RG-142
N Male M39012/01-0503 Positioner Cavity B Cavity A
pincontact M22520/1-13 M22520/5-19 M22520/5-57
Female M39012/02-0503 Positioner Cavity B Cavity A
socket contact M22520/1-13 M22520/5-19 M22520/5-57
Female M39012/02-0513 Positioner Cavity B Cavity A
socket contact,flange mount M2252011-1 3 M22520/5-19 M2252015-57
Female M39012/03-0503 Positioner Cavity B CavityA
socket contact,jamnut mount M22520/1 -1 3 M22520/5-1 9 M22520/5-57
Male M39012/05-0503 Positioner Cavity B CavityA
pin contact, right angle M22520/1 -13 M22520/5-1 9 M22520/5-57

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 BHT-ELEC-SPM

7-6. TNC SERIES CONNECTOR (BRAID

CLAMP).
19/32 IN.
Thistype ofconnectorconsistsof a bodyassembled to
7/16 IN. coaxial cableby means ofaclampnut,gasket,and braid
clamp. Refertofigure 7-12for stripping dimensions and
table 7-2 for cable and tooling reference. When
attaching TNC connectorstocoaxialcables perform the
11/32 IN. following procedures.
NOTE

Thefollowing instructions are general. Refer

CABLE STRIPING DIMENSIONS to RF connector vendor catalogue for
precise stripping and assemblyprocedures.
1. Remove 5/16 inch of outerjacketexposing shield.

2. Comb out shield. Take care to prevent breaking

CONTACT MUST
shield strands.

LJ
DO NOT NICKCENTERCONDUCTOR.

3. Disassemble nut, grooved gasket, and sleeve

clamp from plugor jack body.
4. Tapershieldtoward centerconductorandslide nutand
grooved gasket, in that order, over tapered shield onto
CABLE DIELECTRIC MUST BUTT jacket. Then slide sleeve clamp over tapered shield until
inside shoulder of clamp butts flush against cut end of
OUTER FERRULE SHOULD jacket.
BUTT HERE'
5. Comb shield back smoothlyover clamp and trim
shieldwith scissors, evenwith tapered part of clamp.
6. Tin dielectric to 1/8 inch from shield, and cut off
center conductorto 7/64 inch from edge of dielectric.
7. Tin centerconductor.
CABLE DIELECTRIC MUST BUTT INSULATOR — 8. Slip contact over center conductor until contact butts
OUTER FERRULE SHOULD flush againstdielectric.Soldercontact to centerconductor.
BUTT HERE
9. Pushcableassemblyintoconnectorbodyas far as
it will go. Ensure gasket is properlyseated, with sharp
edge of sleeve entering gasket groove. Tighten nut
holding the body stationary. Referto figure 7-10.

7-7. C AND SC SERIESCONNECTORS.

E/SPM.7.11 There are three versions of C and SC connectors,
differingin the method of attaching coaxial cableto the
connectorbody. Thethreeversionsare listed as follows:
Figure 7-11. BNC connector strippingand
assembly 1. CrimpFerrule— Crimp center pin or socket.

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Page20
 BHT-ELEC-SPM

V
5/16 IN.

IN.

7/64 IN.

COMPLETED ASSEMBLY

1/8 IN.

E/SPM-7-12

Figure 7-12. Cable preparation for TNC connectors (Braid clamp)

2. Crimp Ferrule — Soldercenterpin or socket. b. Slide outerferruleontocable. Flareend of cable

braid slightlyto facilitate insertion onto inner ferrule.
3. Braid Clamp — Soldercenter pin or socket.
NOTE
4. When attaching C and SC connectorsto coaxial
Do not comb out braid.
cable,follow theseprocedures: Referto figure 7-13.
c. Place contacton cable centerconductorso that
NOTE itbuttsagainstcabledielectric. Centerconductor should
be visible through inspection hole in contact. Crimp or
Thefollowing instructions are general. Refer solderthe pin or socket in place as follows:
to RF connector vendor catalogue for
precise stripping and assembly procedures. (1) Crimp Method — Select appropriate tool and
crimpcenter pin or socket.Referto table7-2.
a. Referring to figure 7-14strip cablejacket, braid,
and dielectric to dimensions shown. All cuts to be sharp (2) SolderMethod —Soft soldercontactto cable
and square. Tinning of center conductor is not conductor. Avoid solderon outside surtaces of contact.
necessary ifcontactistobecrimped.Forsoldermethod, Avoid excessive heat to preventswellingof dielectric.
tin conductoravoiding excessive heat.
d. Installcable assembly into body assemblyso inner
ferrule portion slides under braid. Push cable assembly
forward until contact snaps intoplace in insulator.

e. Slide outer ferrule over braid and up against

DO NOT NICK BRAID, DIELECTRIC OR connector body. Crimp outer ferrule using cavity of die
CENTER CONDUCTOR. specified.

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BHT-ELEC-SPM

OUTER FERRULE
OUTER FERRULE

CENTER PIN 0 CENTER SOCKET

BODY MALE BODY FEMALE

E/SPM-7-13

Figure 7-13. C and SC connectors

7-8. C SERIES CONNECTOR (BRAID CLAMP). 5. Taper shield toward center conductor and wrap a
piece of thin pressure tape, wide enough to cover the
Thistype of connector consists of a bodyassembled to combed out shield (one layer is sufficient), around the
coaxial cable by means of a nut, gasket, and clamp. shielding, forming a cone with the narrow end toward the
Table 7-2 lists the more common connectors in the C conductor.
series and shows the coaxial cable associated with
each. When attaching C connectorsto coaxial cable 6. Slide sleeveclamp over taperedshield until inside
performthe following procedures: shoulderof clamp buttsagainstcut end of jacket.
NOTE
7. Remove tape and fold shield strands back over
Thefollowing instructions aregeneral. Refer sleeve clamp taper without overlaps. Trim shield with
to RF connectorvendor catalog for precise scissors so that strands end at end of clamp taper.
stripping and assembly procedures.
8. Checkthat dielectric is exposed 3/64 inchas shown
1. Disassemble nut, gasket, and sleeve clamp from in figure 7-15.
plug or jack body.

LJ
9. Tin center conductor.
2. Slide nut and gasket, in that order, over taped
shielding onto jacket. Ensure that grooved side of
gasketfaces awayfrom nut.
3. Strip outerjacketto the 5/16 inch as shown in figure
7-15. ENSURE CORRECT CONTACT IS USED.
A MALE CONTACT ALWAYSGOES INTO A
PLUG BODY, AND A FEMALE CONTACT
CAUTION ALWAYS GOES INTOA JACKBODY.

DO NOT NICKSHIELD. 10. Slip contactovercenterconductors so thatcontact

butts flush againstdielectric. Solder, usinga clean,well
4. Comb out shield and cut dielectric to 5/32 inch as tinnedsoldering iron. Contactmuststill be flushagainst
shown in figure 7-15. dielectric aftersolderhascooled;ifnot, remake thejoint.

7-00-00
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 BHT-ELEC-SPM

A
—11/16 IN.
B
1/2IN. — -H H—
5/16 IN.

13/32 IN.— C 3/16 IN. NOT BREAK STRANDS

CABLE STRIPPING DIMENSIONS

H 5/32 IN.

WRAP

TRIM STRANDS WITH SCIS7

IN.

-0.010 IN.

FEMALE CONTACT

E/SPM-7-15
E/SPM-7-14

Figure 7-15. Cable preparation for C-connector

Figure 7-14. Cable crimping instruction (Braid clamp)

7-00-00
Page23
BHT-ELEC-SPM

11. Push cableassembly intoconnector body as far as C. Place contacton cable centerconductorso that
itwill go. Slide gasket into connectorbody. Ensuregasket itbuttsagainstcabledielectric. Centercontactshouldbe
is properly seated, with sharp edge of sleeve clamp visible through inspection hole in contact. Crimp or
entering groove in gasket. Then slide nut into connector solderthe pin or socket in place as follows:
bodyandfasten bodyinvise. Refertofigure7-10. Startnut
by hand and tighten with end wrench until moderately (1) Crimp method: Select appropriate tool from
tight. Gasket should be cut in half during tightening. In table7-2, crimp center pin or socket.
plugs, the end ofthe contact should beflush with insulator.
In jacks, there should be a clearance of 0.010 inch (2.5 (2) Solder method: Soft solder contact to cable
mm) betweenend of contact and insulator. center conductor. Do not get any solder on outside
surface of contact. Avoid excessive heat to prevent
7-9. SC CONNECTOR. swellingof dielectric.

This type of connector is identical to the C type (3) Install cable assemblyintobodyassemblyso
connectorexceptforthemethod ofcoupling (threaded). inner ferrule portion slides under braid. Push cable
The procedure for attaching SC to coaxial cable is assembly forward until contact snaps into place in
identical to the procedure for C connectors. insulator.

7-10. N SERIESCONNECTORS. (4) Slide outer ferrule over braid and up against
connector body. Crimp outer ferrule using cavity
There are three versionsof N connectors, differingin specified in table 7-2. Refer to figure 7-17.
method ofattaching coaxial cabletotheconnectorbody.

1. The threeversionsare listed as follows: 7-11. IMPROVED N CONNECTORS.

a. Crimpferrule— Crimpcenter pin or socket.
This typeof connectorconsistsof a bodyassembled to
b. Crimp ferrule — Solder center pin or socket. a coaxial cable nut, grooved gasket, and clamp. Plug
UG-18D/U and jack UG-20D/U are typical of this
c. Braid clamp— Soldercenter pin or socket. version.The sleeve clamphasasharp rear face, which
cuts intothegrooved gasketwhenthe nut is tightened.
2. When attaching N connectors tocoaxial cable(refer
to figure 7-16), followthisprocedure: 1. When attaching improved N connectors to coaxial
cable (figure 7-18)followingthis procedure:
NOTE
NOTE
The following instructions are general. Refer
to RF connector vendor catalogue for
Thefollowinginstructions are general. Refer
precise stripping and assemblyprocedures.
to RF connectorvendor catalog for precise
a. Referring to figure 7-17,stripcablejacket, braid, stripping and assembly procedures.

LJ
and dielectric to dimensions shown. All cuts are to be
sharp and square. Tinning ofthe centerconductoris not a. Remove 9/32 inch of outerjacket exposingshield.

LJ
necessary if the contact is to be crimped. For solder
method, tin center conductoravoiding excessiveheat.

DO NOT NICK SHIELD.

b. Comb outshield and strip dielectricto 1/8 inch from

DO NOT NICK BRAID, DIELECTRIC OR end ofjacket exposing5/32 inch of center conductor.
CENTER CONDUCTOR.

b. Slide outerferruleonto cable. Flareend ofcable

braid slightlyto facilitateinsertion onto innerferrule.
DO NOT NICKCENTERCONDUCTOR.
NOTE
C. Disassemble nut, gasket, and sleeve clampfrom
Do notcombout braid. plug or jack body (figure 7-19).

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 BHT-ELEC-SPM

OUTER FERRULE
CENTER CONTACT

CONNECTOR BODY

E/SPM-7-16

Figure 7-16. N connector

11/16 IN.
1/2 IN.
IN.

CABLE STRIPING DIMENSIONS

CONTACT MUST

LEcTRI7
CABLE DIELECTRIC MUST BUTT AGAINST
INSULATION

OUTER FERRULE SHOULD BUTT HERE-

E/SPM.7-17

Figure 7-17. Cable stripping instructions

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Page 25
BHT-ELEC-SPM

9/32 IN.

DO NOT NICK
CENTER CONDUCTOR
DO NOT BREAK
STRANDS
TRIM
DIELECTRIC

/
1/8 IN.
FEMALE CONTACT

E/SPM-7-18

Figure 7-18. Attaching improved N connector

PLUG BODY

CONTACT

GASKET
JACK BODY-

FEMALE CONTACT

NUT

E/SPM-7-19

Figure 7-19. Improved N connector exploded view

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 BHT-ELEC-SPM

d. Tapershieldtowardsthecenterconductorandwrap gasket. Then slide nut into connectorbody, and fasten

a piece of thin pressuretape, wide enough to cover the body in vise. Refer to figure 7-1 0. Start nut by hand,
combed out shield (one layer is sufficient) around the tighten with end wrench until moderately tight. Gasket
shielding,forming a cone with a narrow end towards the should be cut in halfduring tightening.
conductor.
7-12. CAPTIVATED CONTACT N CONNECTOR.
e. Slide nut then gasket over taped shielding, onto
jacket. Ensure that grooved side of gasketfaces away This type of connectorconsistsof body assembled to
fromthenut.Slideclampovershielduntil sideshoulders coaxial cable with nut, grooved gasket, clamp washer,
of clampbuttsflush againstcut end ofjacket. and front and rear insulators. The plugbody assembly
f. Remove tape and fold shield strands back over omits the rear insulator. Plug UG-1185/U and jack
UG-1186/U are typical of this version.
sleeve clamp, taper withoutoverlaps. Trim shield with
scissors so that strands end at end of clamp taper. 1. When attaching Nconnectorstocoaxial cablefigure
7-20 followthisprocedure:
g. Verify that exposed dielectric is 0.045 inch
beyond shield. NOTE
h. Tin center conductor.
Thefollowinginstructions aregeneral. Refer
i. Slip contact over center conductor so that contact to RF connectorvendor catalog for precise
butts flush against dielectric. Solder using a clean, well
stripping and assemblyprocedures.
tinned soldering iron. Contact must still be flush against

LJ
dielectric aftersolder has cooled; if it is not, resolder the NOTE
joint.
While attaching connector, observe all
generalprecautions and procedures listed in
paragraphs 7-11 and 7-12.

BE SURE THAT THE CORRECT CONTACT a. Remove23/64 inch of outerjacket, exposingshield.

ISUSED. AMALE CONTACTALWAYS GOES
INTO A PLUG BODY, AND A FEMALE
CONTACT ALWAYS GOES INTO
BODY.
A JACK L=J
DO NOT NICKSHIELD.
j. Push cable assembly into connector bodyas far
as it will go. Slide gasket into connector body. Be sure b. Comb out shield and cut off dielectric 1/8 inch
that knife edge of sleeve clamp seats into groove of from end of jacket.
MALE CONTACT
•FRONT INSULATOR
PLUG BODY

REAR
NUT

E/SPM-7-20

Figure 7-20. N connectors with captivated contacts — exploded view

7-00-00
Page27
BHT-ELEC-SPM

shoulderbuttsflushagainsttherearinsulator. Solderthe
CAUTIONS contactto centerconductor.

C.
DO NOTNICKTHECENTER CONDUCTOR.

Disassemble nut, gasket, clamp, washer, and

insulator from plug or jack body.
L=J
ENSURE THAT THE CORRECT PIN OR
SOCKET IS USED; A PIN ALWAYS GOES
d. Taper shieldtowards centerconductor, and wrap INTO A PLUG BODY, AND A SOCKET
withtape as shown infigure7-21 . Slidenut, then gasket, ALWAYS GOES INTOA JACK BODY.
overtapered shield ontojacket. Makesure grooved side
of jacket faces awayfrom nut. Then slide clamp over i. Slidefront insulator over pin or socket, ensurethe
tapered shieldand push back against cable jacket. counter-bored end ofthe insulatoris towardthe mating
end of the contact.
e. Remove taper and fold shield strands backover
clamp; taperwithoutoverlaps. Trimshield with scissors j. Pushthecableassemblyintothe connectorbody.
so that strandsend at topof clamptaper. Ensurethesharpedgeoftheclampseatsproperlyinthe
f. Verify that exposed dielectric is 0.045 inch gasket. Tighten the nut, holding the body stationary.
Referto figure 7-10.
beyond shield.
k. Cut two lengthsof heat shrink, one 2.75 inches
g. Tin center conductor as shown in figure 7-7,
usingminimum amountof heat. and one 3.25 inches. Slide the 2.75 inch pieceoverthe
connectorcovering only 5/8 inch of it. Heat the shrink
h. Slide on washer, rear insulator and contact, so tubing until it is secure on the cable and connector.
that the counter-bored end of the rear insulator butts Repeat the same procedure with the 3.25 inch pieceof
flush against the dielectric, and the pin or socket heat shrink tubing.

E/SPM-7-21

Figure 7-21. N connectors with captivated contacts

7-00-00
Page 28
 BHT-ELEC-SPM

7-13. SUB-MINIATURE — DM CONNECTORS. d. Fold braid back. Place first washer, gasket, and
second washer in place. Trim excess braid flush with
DM Series miniature coaxialconnectorshave bayonet washer. Soldercontact on center conductorflush with
lock coupling for interconnections in hostile innerdielectric.Remove excess solder.
environments suchas fuel systems. The seriesoffers a
choiceof polarities determined by bayonet lug position
and contactsex, to prevent accidental mismating. Refer e. Place insulator in position.
to figures7-22 and 7-23.
f. Insert cable assemblyintoconnector(eitherjack
1. ASSEMBLY. Referto figure 7-24. or plug), push firmly in place and tighten nut until it is
a. Cutcableoffsquareonend. Do notdeform. Slide flush with connector.
cable nut and bushing overcable nut and bushing over
cableandpushbackoutofway. Cut jacketto0.344inch,
NOTE
being careful not to nick braid.

b. Comb out braid and trim inner dielectric to 0.94 Turn only nut when tightening. Do not rotate
inch, beingcareful not to nick inner conductor. body or cable.
c. With braid clampsflush with end of jacket, slide
bushing over tapered end of clamp. This procedure 2. After assembly insert front gasket (in plug type
clampscable and braid clampssecurely. only), as shown.

MATING POLARITIES

PLUG LUG LOCATION JACK

Female Contact Male Contact

E!::'I"llT

I!
Male Contact Female Contact

Female Contact Male Contact

l3)O 1200

120
0—0 120
Male Contact Female Contact

120°

E/SPM.7.22

Figure 7-22. Mating polarities

7-00-00
Page29
BHT-ELEC-SPM

0.755
19.2 mm)
IN.

.364
(9.2
IL — 0.125 IN. MAX
(3.2 mm) PANEL 0.050 IN. MAX
(1.3 mm) PANEL
0.296 IN. DIA
mm)

mm)
0.375 IN. DIA x 0.040 IN. THK
0.563 IN. HEX x 0.094 IN. THK
(9.5 mm) (1.0 mm)
(14.3 mm) (2.4 mm)

BULKHEAD RECEPTACLES SOLDER MOUNT RECEPTACLE

IN. CHAIN
0.219 IN. MAX mm) LENGTH
(5.6 mm) PANEL
0.920 IN. 0.380 IN.
0.437 IN. DIA I_____(23.4 mm)

r mm)
(11.1 mm)
F

:r __ _______ 0.750 IN.

(19.1 mm)
0.144 IN. DIA
(3.7 mm)
HOLE

HEX x 0.094 IN. THK

(14.3 mm) (2.4 mm)

BULKHEAD ADAPTERS TEE ADAPTERS MALE CAP & CHAIN

hermetic seal

0.938
(9.7 mm)
IN.
I 0.875 IN. —s 0.625 IN.
(22.2 mm) (15.9 mm)
0.219 IN. MAX
(5.6 mm) PANEL

0.380 IN. DIA 0.437 IN. DIA — 0.500 IN. HEX x 0.094 IN. THK
(9.7 mm) (11.1 mm) (12.7 mm) (2.4 mm)
STRAIGHT PLUGS BULKHEAD JACKS

E/SPM-7-23

Figure 7-23. DM miniatureplugsand receptacles

7-00-00
Page 30
 BHT-ELEC-SPM

NUT
BUSHING
JACK

6
MALE CONTACT
OUTER INSULATION

BRAID
CLAMP
FEMALE CONTACT
INNER INSULATION

FRONT
PLUG GASKET

0.344 IN.
(8.73 mm)

0.094 IN.
(2.38 mm)

E/SPM-7-24

Figure 7-24. DM miniature — exploded viewand installation

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Page 31
BHT-ELEC-SPM

7-14. ASSEMBLY — TRIAX TYPE. j. Position smallclampin place making sure end of
clamp is flush with end of inner jacket.
1. The DageTriax type connector is attachedby the
following procedure: k. Fold back braid over small clamp shoulder. Trim
excess braid at clamp shoulder.
a. Cut off end of cable evenly and squarely. .. .
I. Position small metal bushing on cable against
shield.
b. Slide cable nut and large rubber gasket over
cable. Do not nick braided shield or conductor. m. Cut through and remove 1/10 inch of the
. . conductordielectric.
C. Cutthrough and remove 5/8 inch ofouterjacket.
n. Tin the center conductorand contact hole.
d. Comboutbraid.
o. Solder contact on center conductor flush with
e. Position large cable clamp in placemaking sure inner dielectric.
end of clampis flush with end of outerjacket.

I. Fold backbraid overcableclampandtrim excess

braid at clamp shoulder.

g. Position large metal bushing on cable against

cEJ
TURNNUT ONLY.DO NOTROTATE BODY
shield holding shieldagainstclampshoulder, and install OF CABLE.
small rubber washer.
h. Cutthrough and remove 1/2 inch of innerjacket. p. lnsertcableassemblyintoconnector,
push firmly
in place and tighten nut until flush with body of
i. Comb out braid. connector. Torque to 10 inch-pounds.

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 BHT-ELEC-SPM

CHAPTER 8 — ELECTRICAL BONDING AND GROUNDING

CONTENTS — MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

8-1 General ...................................................................................... 8-00-00 3

8-2 Electrical Bonding Classes ........................................................ 8-00-00 11
8-3 Procedures ................................................................................ 8-00-00 11
8-4 Hardware Selection ................................................................... 8-00-00 12
8-5 Chemical Film Material Preparation........................................... 8-00-00 16
8-6 Surface Preparation................................................................... 8-00-00 16
8-7 Aluminum Surfaces .............................................................. 8-00-00 16
8-8 Magnesium Surfaces............................................................ 8-00-00 19
8-9 Titanium, Copper, and Corrosion Resistant Steel Surfaces . 8-00-00 20
8-10 Painted and Primed Cadmium-plated Surfaces ................... 8-00-00 21
8-11 Non-metallic and/or Composite Surfaces ............................. 8-00-00 22
8-12 Flame-sprayed or IVD Aluminum Surfaces .......................... 8-00-00 23
8-13 Outer Layer of Expanded Copper or Aluminum Foil............. 8-00-00 24
8-14 Carbon/Epoxy Composite Surface ............................................ 8-00-00 25
8-15 Electrical Bonding Methods ....................................................... 8-00-00 25
8-16 Bonding Strap/Jumper.......................................................... 8-00-00 25
8-17 Tubular Component Bonding Clamps .................................. 8-00-00 25
8-18 Direct Contact/Assembly with Fasteners.............................. 8-00-00 33
8-19 Electrically Isolated Structures ............................................. 8-00-00 33
8-20 Direct Contact/Assembly ...................................................... 8-00-00 33
8-21 Flange-mounted Cadmium Plated Components .................. 8-00-00 34
8-22 Cadmium and Nickel Plating — Removal..................... 8-00-00 35
8-23 Chemical Treatment — Removal.................................. 8-00-00 35
8-24 Sealing....................................................................................... 8-00-00 36
8-25 Refinishing ................................................................................. 8-00-00 36
8-26 Bond Resistance — Test ........................................................... 8-00-00 37

FIGURES

Figure Page
Number Title Number

8-1 Bonding Strap — 120-169 (Bell Standard) ..................................................... 4

8-2 Bonding Strap — 120-055 and 120-175 (Bell Standard) ................................ 5
8-3 Bonding Jumper — MS25083 ........................................................................ 8
8-4 Bonding Jumper — MS83413/8 ..................................................................... 9
8-5 Bonding Jumper — 120-172 (Bell Standard).................................................. 10
8-6 Stud Bonding or Grounding to Flat Surface — Hardware............................... 13
8-7 Bolt and Nut Bonding or Grounding to Flat Surface — Hardware .................. 14
8-8 Nutplate Bonding or Grounding to Flat Surface — Hardware......................... 15
8-9 Cleaning Procedures Prior to Bonding ........................................................... 17
8-10 Structure Bonding by Direct Contact .............................................................. 26
8-11 Millivolt Drop Test Method .............................................................................. 38

8-00-00
ECCN EAR99 20 JUL 2012 Rev. 2 Page 1
BHT-ELEC-SPM

TABLES

Table Page
Number Title Number

8-1 MS25083 and M83413/8 Bonding Jumpers ................................................... 7

8-2 Electrical Bond Resistance ............................................................................. 11

8-00-00
Page 2 Rev. 2 20 JUL 2012 ECCN EAR99
 BHT-ELEC-SPM

ELECTRICAL BONDING AND GROUNDING

8-1. GENERAL e. Uneven static charge accumulation on

helicopter structures is prevented.
1. Bell helicopters use a single wire electrical
system with the fuselage as a common ground. 2. For the purpose of this chapter, the following
Attachment of electrical and electronic components to definitions apply:
ground (fuselage) must have a maximum conductivity
and minimum resistance for optimum circuit a. Bond. A bond is an electrically conductive
performance without static build-up. Chapter 8 details joint between two surfaces. Bonds are assembled
procedures and materials to be used for mounting either directly, with fasteners and/or clamps, or
ground terminals and components to helicopter indirectly, with bonding straps or bonding wires.
fuselage. Electrical bonding and grounding of
helicopter structures ensures the following: b. Bond Surfaces. Bond surfaces are areas on
helicopter structures, equipment, and/or electrical
bonding hardware that provide a path for the flow of
a. Helicopter structures, equipment, and
electrical energy.
personnel are protected from the hazards of lightning
discharges.
c. Bonding Strap. A bonding strap is any
conductor that is used for providing low-impedance
b. Homogenous and stable paths for all electrical electrical bonding between two points. Bonding straps
currents are established. are flat copper or aluminum straps of various lengths
(Figure 8-1 and Figure 8-2).
c. Radio Frequency (RF) potentials on
enclosures, antenna bases, and other helicopter d. Bonding Jumper. A bonding jumper is similar
structures are minimized. to a bonding strap. A bonding jumper is made of
stranded aluminum or copper wire with terminal lugs
d. Personnel are protected from shock hazards installed on either end. Refer to Table 8-1 and
that may develop from accidental power ground faults. Figure 8-3 through Figure 8-5.

8-00-00
ECCN EAR99 20 JUL 2012 Rev. 2 Page 3
BHT-ELEC-SPM

ELEC-SPM_08_0017
Figure 8-1. Bonding Strap — 120-169 (Bell Standard)

8-00-00
Page 4 Rev. 2 20 JUL 2012 ECCN EAR99
 BHT-ELEC-SPM

ELEC-SPM_08_0014.

Figure 8-2. Bonding Strap — 120-055 and 120-175 (Bell Standard) (Sheet 1 of 2)

8-00-00
ECCN EAR99 20 JUL 2012 Rev. 2 Page 5
BHT-ELEC-SPM

ELEC-SPM_08_0015
Figure 8-2. Bonding Strap — 120-055 and 120-175 (Bell Standard) (Sheet 2 of 2)

8-00-00
Page 6 Rev. 2 20 JUL 2012 ECCN EAR99
 BHT-ELEC-SPM

Table 8-1. MS25083 and M83413/8 Bonding Jumpers

PART TERMINAL STUD IDENTIFICATION WIRE

TYPE SUPERSEDES
NUMBER HOLE SIZE OPTION BAND COLOR SIZE

MS25083-1 Aluminum A, B, C, D, E No Band 10 —

Bonding

MS25083-2 Copper Bonding A, B, C, D, E No Band 12 —

MS25083-3 Quick Disconnect A, B No Band 12 —

MS25083-3S Short End of -3 A, B No Band 12 —

MS25083-3P Long End of -3 D, E No Band 12 —

MS25083-4 Copper Grounding D, E No Band 12 —

MS25083-5 Copper Bonding A, B, C, D, E No Band 12 —
(Lighting)

MS25083-6 Copper Grounding D, E No Band 8 —

(Lighting)

MS25083-7 Aluminum A, B, C, D, E No Band 10 —

Bonding
M83413/8-A Copper Bonding A through J No Band 12 MS25083-2

M83413/8-B Copper Current K, L, M, N No Band 8 MS25083-4

Return

M83413/8-C Aluminum O, P, Q, R, S Clear 10 MS25083-1

Bonding MS25083-7

M83413/8-D Quick Disconnect A, B, C, D, E No Band 12 MS25083-3

M83413/8-E Short End of -D A, B, C, D, E No Band 12 MS25083-3S

M83413/8-F Long End of -D A, B, C, D, E No Band 12 MS25083-3P

M83413/8-G Copper Bonding A through J Yellow 12 MS25083-5

M83413/8-H Copper Current K, L, M, N Yellow 8 MS25083-6

Return

8-00-00
ECCN EAR99 20 JUL 2012 Rev. 2 Page 7
BHT-ELEC-SPM

ELEC-SPM_08_0013
Figure 8-3. Bonding Jumper — MS25083

8-00-00
Page 8 Rev. 2 20 JUL 2012 ECCN EAR99
 BHT-ELEC-SPM

ELEC-SPM_08_0018
Figure 8-4. Bonding Jumper — MS83413/8

8-00-00
ECCN EAR99 20 JUL 2012 Rev. 2 Page 9
BHT-ELEC-SPM

ELEC-SPM_08_0016
Figure 8-5. Bonding Jumper — 120-172 (Bell Standard)

8-00-00
Page 10 Rev. 2 20 JUL 2012 ECCN EAR99
 BHT-ELEC-SPM

8-2. ELECTRICAL BONDING CLASSES resistance of the terminal lug to ground is

specified as 0.25 milliohms.
The classes of electrical bonding applicable to
commercial helicopters are listed in the following 3. Class C electrical bonding provides a satisfactory
steps. The resistance requirements for each class are current path for equipment that uses the helicopter
listed in Table 8-2. structure for ground currents, as well as for accidental
ground fault currents. Class C electrical bond is also
applied in hazardous areas where a possibility of
explosive fumes exists, such as engine compartment,
Table 8-2. Electrical Bond Resistance
transmission, or fuel systems. Resistance is specified
when requirement exists.
CLASS RESISTANCE

A-I Less than 2.5 milliohms 4. Class H electrical bonding prevents shock
hazards, which can develop as a result of accidental
A-II Less than 10 milliohms power ground faults if voltages in excess of 31 volts is
C Specified as required present within the equipment.

H Less than 100 milliohms 5. Class L electrical bonding provides current paths
L Specified as required that will safely conduct lightning currents while
protecting the helicopter structure and equipment.
R-I Less than 2.5 milliohms

R-I/C Less than 2.5 milliohms 6. Class R-I electrical bonding is required on each
installation of RF sensitive equipment. Class R-I
R-II Less than 10 milliohms electrical bonding is imposed for installations of RF
sensitive equipment and related hardware that
S Less than 1000 milliohms perform critical functions on commercial helicopters.

1. Class A-I electrical bonding is imposed on each 7. Class R-I/C electrical bonding is applied to
antenna installation that requires a good ground plane cadmium plated aluminum components mated to
to ensure proper antenna performance. Class A-I is aluminum structure to minimize the loss of bonding
imposed for antenna installation on antennas that are conductivity with time.
highly sensitive to ground plane variations. This class
requires visual inspection prior to antenna installation 8. Class R-II electrical bonding is required on each
to verify proper surface preparation on ground plane, installation of RF sensitive equipment and related
the antenna base, and at each mounting screw hardware on commercial aircraft. It is applied to
between the antenna and the ground plane, to provide helicopter structures to minimize interference caused
an isotropic antenna. by radio frequency potentials.

2. Class A-II electrical bonding is imposed on each 9. Class S electrical bonding provides protection
antenna installation that requires a good ground plane against accumulation of static charges.
to ensure proper antenna performance unless
superseded by Class A-I requirements. This class
requires visual inspection prior to antenna installation 8-3. PROCEDURES
in order to verify proper surface preparation on ground
plane, antenna base, and each mounting screw When you bond or ground connections in the
between the antenna and the ground plane, to provide helicopter, observe the following:
an isotropic antenna pattern.
1. Bond or ground parts to primary helicopter
structure where practical.
NOTE
The generator ground return is an example 2. Bond or ground electrical connections, making
of a Class C bond requirement. The sure not to weaken any part of the helicopter structure.

8-00-00
ECCN EAR99 20 JUL 2012 Rev. 2 Page 11
BHT-ELEC-SPM

3. Bond parts individually when possible. Where connection is made by aluminum or copper
jumpers to the helicopter structure, which is made of a
4. Bond or ground electrical connections against dissimilar material, a washer of suitable material and
smooth and clean surfaces. finish is installed between the two dissimilar materials
in order to prevent corrosion (Figure 8-6 through
Figure 8-8).
5. Install bond or ground connections so vibration,
expansion/contraction, or relative movement other
than normal service use, does not break or loosen NOTE
connections.
When you repair or replace bond or ground
connections, make sure the type of
6. Locate bond or ground connections in protected
hardware used is the same as the original
areas when possible, near hand holes, inspection
connection. Do not make any changes or
doors, or other accessible areas, to permit easy
use substitutes.
inspection and replacement.
1. Stud Selection. Use the required specification
7. Do not compress-fasten bond or ground screw or bolt of the proper size for the specific jumper
connection through any non-metallic material. terminal. The length of the screw or bolt is such that
when the bond or ground connection is fully tightened,
8. Do not connect more than four ground lugs to one approximately 1 1/2 to 2 threads of the screw protrude
stud. beyond the top of the nut.

9. Each ground for electric power sources (primary, 2. Nut Selection. Use the required specification
secondary, and emergency) is connected to a nuts, either plain or self-locking, where indicated in
separate ground point. Separate ground points shall Figure 8-6 and Figure 8-7. Always use an all-metal,
be used for the following: self-locking nut where current is present. Where
installation conditions require, use the required
• Power grounds (AC power ground and DC specification nutplate riveted to the helicopter
power ground) structure, as shown in Figure 8-8.

• Shield grounds
3. Washer Selection. Use the required
specification plain washers and split lockwashers
• Helicopter reference grounds (signal grounds) where indicated in Figure 8-6, Figure 8-7, and
Figure 8-8. Always use split lockwashers with nuts,
10. Equipment with the same source power may be either plain nuts or self-locking. With aluminum
connected to a common ground point, provided terminals, use a plain washer, of at least the diameter
equipment does not perform duplicate or overlapping of the terminal tongue, next to the aluminum terminal.
functions.

8-4. HARDWARE SELECTION

CAUTION
NOTE
Always refer to the applicable Bulletin DO NOT USE CUSHIONED CLAMPS IN
(ASB, TB), Service or Installation ANY BONDING OR GROUNDING
Instruction, Maintenance Manual, CONNECTION.
Illustrated Parts Breakdown Manual, or
other applicable document for hardware 4. Cable Clamp Selection. For bonding or
specification and stack-up. grounding to cylindrical surfaces, use an AN735
clamp. When such clamp is not available or where
Hardware used to bond or ground electrical installation conditions do not allow the use, an
connections is selected on the basis of mechanical uncushioned AN742 clamp may substitute the AN735
strength, current to be carried, and ease of installation. clamp.

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 BHT-ELEC-SPM

SCREW OR BOLT WASHER A

LOCKWASHER E
STRUCTURE

WASHER B WASHER C
PLAIN NUT

TERMINAL (4 MAXIMUM) WASHER D

LOCKWASHER F LOCKNUT
NOTE
See below for materials.

ALUMINUM TERMINAL AND JUMPER

SCREW OR
BOLT: PLAIN WASHERS WASHERS LOCKWASHER LOCKWASHER
STRUCTURE LOCKNUT NUT A,B C,D E F

ALUMINUM CADMIUM TIN PLATED ALUMINUM CADMIUM CADMIUM CADMIUM

ALLOY PLATED BRASS ALLOY PLATED PLATED PLATED
STEEL STEEL OR STEEL STEEL
ALUMINUM
MAGNESIUM CADMIUM CADMIUM MAGNESIUM CADMIUM CADMIUM CADMIUM
ALLOY PLATED PLATED ALLOY PLATED PLATED PLATED
STEEL STEEL STEEL OR STEEL STEEL
ALUMINUM
STEEL, CADMIUM CADMIUM NONE CADMIUM CADMIUM CADMIUM
CADMIUM PLATED PLATED PLATED PLATED PLATED
PLATED STEEL STEEL STEEL OR STEEL STEEL
ALUMINUM
STEEL, CORROSION CADMIUM NONE CADMIUM CADMIUM CADMIUM
CORROSION RESISTING PLATED PLATED PLATED PLATED
RESISTING STEEL STEEL STEEL OR STEEL STEEL
ALUMINUM

TINNED COPPER TERMINAL AND JUMPER

ALUMINUM CADMIUM CADMIUM ALUMINUM CADMIUM CADMIUM CADMIUM
ALLOYS PLATED PLATED ALLOY PLATED PLATED PLATED
STEEL STEEL STEEL STEEL STEEL OR
ALUMINUM
MAGNESIUM
ALLOY CAUTION

AVOID CONNECTING COPPER TO MAGNESIUM ALLOYS.

STEEL, CADMIUM CADMIUM NONE CADMIUM CADMIUM CADMIUM
CADMIUM PLATED PLATED PLATED PLATED PLATED
PLATED STEEL STEEL STEEL STEEL STEEL

STEEL, CORROSION CORROSION NONE CADMIUM CORROSION CORROSION

CORROSION RESISTING RESISTING PLATED RESISTING RESISTING
RESISTING STEEL STEEL STEEL STEEL STEEL
ELEC-SPM_08_0001
Figure 8-6. Stud Bonding or Grounding to Flat Surface — Hardware

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 13
BHT-ELEC-SPM

SCREW OR BOLT WASHER A

TERMINAL (4 MAXIMUM)

WASHER B

LOCKWASHER

LOCKNUT WASHER C
NOTE
See below for materials.

ALUMINUM TERMINAL AND JUMPER

SCREW OR WASHER WASHER WASHER

STRUCTURE BOLT: LOCKNUT LOCKWASHER A B C

ALUMINUM CADMIUM CADMIUM CADMIUM NONE CADMIUM

ALLOY PLATED PLATED PLATED PLATED
STEEL STEEL STEEL OR STEEL OR
ALUMINUM ALUMINUM
MAGNESIUM CADMIUM CADMIUM MAGNESIUM NONE OR CADMIUM
ALLOY PLATED PLATED ALLOY MAGNESIUM PLATED
STEEL STEEL ALLOY STEEL OR
ALUMINUM
STEEL, CADMIUM CADMIUM CADMIUM CADMIUM CADMIUM
CADMIUM PLATED PLATED PLATED PLATED PLATED
PLATED STEEL STEEL STEEL STEEL STEEL OR
ALUMINUM
STEEL, CORROSION CADMIUM CORROSION CADMIUM CADMIUM
CORROSION RESISTING STEEL PLATED RESISTING PLATED PLATED
RESISTING OR CADMIUM STEEL STEEL STEEL STEEL OR
PLATED STEEL ALUMINUM

TINNED COPPER TERMINAL AND JUMPER

ALUMINUM CADMIUM CADMIUM CADMIUM ALUMINUM CADMIUM
ALLOY PLATED PLATED PLATED ALLOY PLATED
STEEL STEEL STEEL STEEL

MAGNESIUM
ALLOYS CAUTION

AVOID CONNECTING COPPER TO MAGNESIUM ALLOYS.

STEEL, CADMIUM CADMIUM CADMIUM NONE CADMIUM

CADMIUM PLATED PLATED PLATED PLATED
PLATED STEEL STEEL STEEL STEEL

STEEL, CORROSION CADMIUM CORROSION NONE CADMIUM

CORROSION RESISTING STEEL PLATED RESISTING PLATED
RESISTING OR CADMIUM STEEL STEEL STEEL
PLATED STEEL
ELEC-SPM_08_0002
Figure 8-7. Bolt and Nut Bonding or Grounding to Flat Surface — Hardware

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 BHT-ELEC-SPM

SCREW OR BOLT LOCKWASHER

WASHER A TERMINAL (4 MAXIMUM)

WASHER B

RIVET OR WELD
NUTPLATE

NOTE
See below for materials.

ALUMINUM TERMINAL AND JUMPER

SCREW OR BOLT: WASHER WASHER

STRUCTURE LOCKNUT RIVET LOCKWASHER A B

ALUMINUM CADMIUM ALUMINUM CADMIUM CADMIUM NONE

ALLOY PLATED ALLOY PLATED PLATED
STEEL STEEL STEEL OR
ALUMINUM
MAGNESIUM CADMIUM ALLUMINUM CADMIUM CADMIUM NONE OR
ALLOY PLATED ALLOY PLATED PLATED MAGNESIUM
STEEL STEEL STEEL OR ALLOY
ALUMINUM
STEEL, CADMIUM CORROSION CADMIUM CADMIUM NONE
CADMIUM PLATED RESISTING PLATED PLATED
PLATED STEEL STEEL STEEL STEEL OR
ALUMINUM
STEEL, CORROSION CORROSION CADMIUM CADMIUM CADMIUM
CORROSION RESISTING STEEL RESISTING PLATED PLATED PLATED
RESISTING OR CADMIUM STEEL STEEL STEEL OR STEEL
PLATED STEEL ALUMINUM

TINNED COPPER TERMINAL AND JUMPER

ALUMINUM CADMIUM ALUMINUM CADMIUM CADMIUM ALUMINUM
ALLOY PLATED ALLOY PLATED PLATED ALLOY
STEEL STEEL STEEL

MAGNESIUM
ALLOYS CAUTION

AVOID CONNECTING COPPER TO MAGNESIUM ALLOYS.

STEEL, CADMIUM CORROSION CADMIUM CADMIUM NONE

CADMIUM PLATED RESISTING PLATED PLATED
PLATED STEEL STEEL STEEL STEEL

STEEL, CORROSION CORROSION CADMIUM CADMIUM NONE

CORROSION RESISTING RESISTING PLATED PLATED
RESISTING STEEL STEEL STEEL STEEL

ELEC-SPM_08_0003
Figure 8-8. Nutplate Bonding or Grounding to Flat Surface — Hardware

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 15
BHT-ELEC-SPM

8-5. CHEMICAL FILM MATERIAL 8-7. ALUMINUM SURFACES

PREPARATION

MATERIALS REQUIRED
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
C-099 Chemical Film Material
C-099 Chemical Film Material
C-305 Aliphatic Naphtha
C-100 Chemical Film Material
C-385 Isopropyl Alcohol
C-432 Nitric Acid
C-406 Abrasive Cloth or
Paper
NOTE
C-407 Abrasive Pad
Immediately prior to bonding, make sure
that the bond surfaces are prepared in C-436 Paint Remover
accordance with paragraph 8-6.
C-486 Cheesecloth
When you prepare the electrical bonding/grounding
surface, use chemical film material (C-099). When a
fresh solution is required, prepare by adding
1.3 ounces/gallon (9.4 g/L) of chemical film material CAUTION
(C-100) to deionized or distilled water. Check pH of
solution to ensure pH is 1.3 (minimum) to 1.6
(maximum). When required, adjust pH with nitric acid USE EXTREME CARE DURING
(C-432). CLEANING TO PREVENT EXCESSIVE
METAL REMOVAL OR DAMAGE TO THE
8-6. SURFACE PREPARATION BARE METAL BOND SURFACE.

Prepare surfaces for electrical bonding and/or NOTE

grounding connections in accordance with the
When you prepare chemical-filmed
following procedures (paragraph 8-7 through
aluminum washers for bonding, clean
paragraph 8-14). Whenever possible, prepare the
surface by hand abrasion and/or wipe with
bond surface area to at least 0.250 inch (6.35 mm)
solvent prior to assembly (paragraph 8-23).
larger than the area required for the bonding and/or
grounding connection. 1. Prepare aluminum surfaces as follows:

a. Drill a hole (if required) into the surface to be

bonded or grounded, in accordance with the
applicable bulletin (ASB, TB), service or installation
instruction, Maintenance Manual, or other applicable
document (Figure 8-9, Detail A).

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 BHT-ELEC-SPM

FLAT BOND SURFACE

CURVED BOND SURFACE, CLEAN

BOND SURFACE, CLEAN

BONDING STRAP OR
GROUNDING WIRE
BONDING STRAP OR
GROUNDING WIRE

BOND SURFACE, CLEAN

FLAT SURFACE CURVED SURFACE

DETAIL A DETAIL B

ANTENNA

BOND SURFACE, CLEAN

HELICOPTER SKIN

ANTENNA MOUNTING AREA

DETAIL C
ELEC-SPM_08_0004
Figure 8-9. Cleaning Procedures Prior to Bonding

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 17
BHT-ELEC-SPM

4. Wipe the exposed bond surface with clean

cheesecloth (C-486). Use the cheesecloth either dry
CAUTION
or moistened with isopropyl alcohol (C-385) or
aliphatic naphtha (C-305).
DO NOT USE ABRASIVES OTHER THAN
THOSE APPROVED IN THIS
PROCEDURE. CERTAIN ABRASIVES,
CAUTION
SUCH AS EMERY AND CROCUS CLOTH,
CAN INDUCE CORROSION OF BOND
SURFACE.
CHEMICAL FILM MATERIAL (C-099) IS
HIGHLY CORROSIVE. DO NOT ALLOW
2. Remove all organic finishes in accordance with
CHEMICAL FILM MATERIAL OR RINSE
one of the following methods (step a or step b).
WAT E R T O R U N I N T O C R A C K S ,
CREVICES, SEAMS, OR JOINTS.
NOTE
If sandpaper is used, use 100 grit or finer
abrasive cloth or paper (C-406) to remove CAUTION
only the topcoat. Then use 180 grit or finer
abrasive cloth or paper (C-406) and/or
abrasive pad (C-407) for the complete DO NOT ALLOW CHEMICAL FILM
removal of the primer. MATERIAL TO REMAIN ON BOND
S U R FA C E FOR MORE THAN
a. Remove all organic finishes and anodic or 5 SECONDS MAXIMUM.
chemical film by inserting an abrasive brush into a
power drill, or hand sand with either abrasive pad NOTE
(C-407) or abrasive cloth or paper (C-406). Stop the
power drill or hand sanding as soon as the metallic Heavily applied chemical film material
surface is exposed. (C-099) has an iridescent gold to
dark-brown color and is not acceptable for
electrical bonding and/or ground purposes.
b. Apply a chemical paint remover (C-436) to the
bond surface to remove the paint and/or primer.
5. Prepare the chemical film material (C-099)
(paragraph 8-5).
3. Remove chemical film with an abrasive pad
(C-407) until the bare metallic surface is exposed.
6. Apply a coating of chemical film material (C-099)
to bond surface with either a non-metallic brush or
dipping method. This produces a light iridescent
WARNING yellow finish on bond surface. Usually, this color is
obtained by allowing the chemical film solution to
remain on the bond surface for a maximum of
IS OP ROP YL A L COHOL (C-3 85 ) OR 5 seconds.
AL IP HAT I C NA P HT HA ( C- 30 5) A RE
FLAMMABLE AND TOXIC. BOTH CAN
7. Remove excess chemical film material from the
CAUSE BURNS AND IRRITATE SKIN.
bond surface by blotting with clean cheesecloth
USE ONLY IN WELL VENTILATED AREA,
(C-486) moistened with deionized or distilled water.
AWAY FROM HEAT AND OPEN FLAME.
Allow bond surface to air dry or gently wipe bond
WEAR RUBBER GLOVES, GOGGLES,
surface dry with clean cheesecloth.
APRON, AND RESPIRATOR. IN CASE OF
C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST 8. Install the electrical bond and/or ground
1 5 M I N U T E S . G E T I M M E D I AT E (paragraph 8-15) within 2 hours after applying the
ATTENTION FOR EYES. chemical film material.

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 BHT-ELEC-SPM

8-8. MAGNESIUM SURFACES

NOTE
If sandpaper is used, use 100 grit or finer
abrasive cloth or paper (C-406) to remove
MATERIALS REQUIRED only the topcoat. Then use 180 grit or finer
abrasive cloth or paper (C-406) and/or
Refer to BHT-ALL-SPM for specifications. abrasive pad (C-407) for the complete
removal of the primer.
NUMBER NOMENCLATURE
a. Remove all organic finishes including anodic
C-112 Conversion Coating
or chromate conversion coating (C-112) by hand
C-116 Chromic Acid abrading with abrasive pad (C-407) and/or abrasive
cloth or paper (C-406).
C-120 Calcium Sulfate
Dihydrate b. Apply a chemical paint remover (C-436) to the
bond surface to remove the paint and/or primer.
C-305 Aliphatic Naphtha
3. Remove chromate conversion coating with an
C-385 Isopropyl Alcohol abrasive pad (C-407) until the bare metallic surface is
exposed.
C-406 Abrasive Cloth or
Paper

C-407 Abrasive Pad WARNING

C-436 Paint Remover

IS OP ROP YL A L COHOL (C -3 85 ) OR
C-486 Cheesecloth AL IPHATI C N APHTHA (C-30 5) ARE
FLAMMABLE AND TOXIC. BOTH CAN
CAUSE BURNS AND IRRITATE SKIN.
1. Prepare magnesium surfaces as follows: USE ONLY IN WELL VENTILATED AREA,
AWAY FROM HEAT AND OPEN FLAME.
a. Drill a hole (if required) into the surface to be WEAR RUBBER GLOVES, GOGGLES,
APRON, AND RESPIRATOR. IN CASE OF
bonded or grounded, in accordance with the
C O N TA C T, I M M E D I AT E LY F L U S H
applicable bulletin (ASB, TB), service or installation EYES/SKIN WITH WATER FOR AT LEAST
instruction, Maintenance Manual, or other applicable 1 5 M I N U T E S . G E T I M M E D I AT E
document (Figure 8-9, Detail A). ATTENTION FOR EYES.

4. Thoroughly remove abrading residue from bond

surface by wiping with clean cheesecloth (C-486). Use
CAUTION the cheesecloth either dry or moistened with isopropyl
alcohol (C-385) or aliphatic naphtha (C-305).

DO NOT USE ABRASIVES OTHER THAN

NOTE
THOSE APPROVED IN THIS
PROCEDURE. CERTAIN ABRASIVES, Do not apply sealants to the mating
SUCH AS EMERY AND CROCUS CLOTH, surfaces or bonded areas.
CAN INDUCE CORROSION OF BOND
5. Apply a brush-on treatment of conversion coating
SURFACE. (C-112) to the bond surface as follows:

2. Remove all organic finishes in accordance with a. Prepare the conversion coating (C-112)
one of the following methods (step a or step b): solution by adding 1.4 ounces/gallon (10 g/L) of

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 19
BHT-ELEC-SPM

chromic acid (C-116) and 1 ounce/gallon (7.5 g/L) of 8-9. TITANIUM, COPPER, AND CORROSION
calcium sulfate dihydrate (C-120) to deionized or RESISTANT STEEL SURFACES
distilled water.

MATERIALS REQUIRED
CAUTION
Refer to BHT-ALL-SPM for specifications.

M A K E S U R E T H AT C H E M I C A L NUMBER NOMENCLATURE
CONVERSION COATING (C-112) OR
R I N S E WAT E R D O E S N O T G E T C-305 Aliphatic Naphtha
TRAPPED INSIDE THE ASSEMBLED
C-385 Isopropyl Alcohol
BOND.
C-406 Abrasive Cloth or
Paper
CAUTION
C-407 Abrasive Pad

DO NOT ALLOW CHEMICAL C-436 Paint Remover

CONVERSION COATING (C-112) TO
R E M A I N O N B O N D S U R FA C E F O R C-486 Cheesecloth
MORE THAN 1 MINUTE.
1. Prepare titanium, copper, and Corrosion
b. Apply conversion coating (C-112) solution by
Resistant Steel (CRES) surfaces as follows:
either brushing or dipping. Allow the solution to remain
on the bond surface for approximately 1 minute.
a. Drill a hole (if required) into the surface to be
bonded or grounded, in accordance with the
applicable bulletin (ASB, TB), service or installation
CAUTION
instruction, Maintenance Manual, or other applicable
document (Figure 8-9, Detail A).
M A K E S U R E T H AT C O N V E R S I O N
C O A T I N G ( C - 11 2 ) D O E S N O T G E T 2. Remove all organic finishes in accordance with
TRAPPED INSIDE THE ASSEMBLED one of the following methods (step a or step b):
BOND.

c. Remove excess chemical conversion coating

(C-112) solution from the bond surface by blotting with CAUTION
clean cheesecloth (C-486) moistened with deionized
or distilled water. Allow bond surface to air dry or
gently wipe bond surface dry with clean cheesecloth. DO NOT USE ABRASIVES OTHER THAN
THOSE APPROVED IN THIS
6. Install the electrical bond and/or ground within PROCEDURE. CERTAIN ABRASIVES,
2 hours (paragraph 8-15). SUCH AS EMERY AND CROCUS CLOTH,
CAN INDUCE CORROSION OF BOND
SURFACE.

NOTE
If sandpaper is to be used, use 100 grit or
finer abrasive cloth or paper (C-406) to
remove only the topcoat. Then use 180 grit
or finer abrasive cloth or paper (C-406)

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 BHT-ELEC-SPM

and/or abrasive pad (C-407) for the 8-10. PAINTED AND PRIMED CADMIUM-PLATED
complete removal of the primer. SURFACES

a. Remove all organic finishes and anodic or

chemical film by inserting an abrasive brush into a
MATERIALS REQUIRED
power drill, or hand sand with either abrasive pad
(C-407) or abrasive cloth or paper (C-406). Stop the
Refer to BHT-ALL-SPM for specifications.
power drill or hand sanding as soon as the metallic
surface is exposed. NUMBER NOMENCLATURE

b. Apply a chemical paint remover (C-436) to the C-305 Aliphatic Naphtha

bond surface to remove the paint and/or primer.
C-385 Isopropyl Alcohol

C-406 Abrasive Cloth or

WARNING
Paper

C-407 Abrasive Pad

IS OP ROP YL A L COHOL (C-3 85 ) OR
AL IP HAT I C NA P HT HA ( C- 30 5) A RE C-436 Paint Remover
FLAMMABLE AND TOXIC. BOTH CAN
CAUSE BURNS AND IRRITATE SKIN. C-486 Cheesecloth
USE ONLY IN WELL VENTILATED AREA,
AWAY FROM HEAT AND OPEN FLAME.
1. Prepare painted and/or primed cadmium-plated
WEAR RUBBER GLOVES, GOGGLES,
surfaces as follows:
APRON, AND RESPIRATOR. IN CASE OF
C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST a. Drill a hole (if required) into the surface to be
1 5 M I N U T E S . G E T I M M E D I AT E bonded or grounded, in accordance with the
ATTENTION FOR EYES. applicable bulletin (ASB, TB), service or installation
instruction, Maintenance Manual, or other applicable
document (Figure 8-9, Detail A).
CAUTION

CAUTION
MAKE SURE THAT CLEANING SOLVENT
DOES NOT GET TRAPPED INSIDE THE
ASSEMBLED BOND. DO NOT REMOVE ELECTROPLATED
CADMIUM FROM BOND SURFACE. DO
3. Thoroughly remove abrading residue from bond NOT USE ABRASIVES OTHER THAN
surface by wiping with clean cheesecloth (C-486). Use THOSE APPROVED IN THIS
cheesecloth either dry or moistened with isopropyl PROCEDURE. CERTAIN ABRASIVES,
alcohol (C-385) or aliphatic naphtha (C-305). SUCH AS EMERY AND CROCUS CLOTH,
CAN INDUCE CORROSION OF BOND
4. Install the electrical bond and/or ground within SURFACE.
2 hours after abrading (paragraph 8-15).
2. Remove all organic finishes in accordance with
one of the following methods (step a or step b):

NOTE
If sandpaper is used, use 100 grit or finer
abrasive cloth or paper (C-406) to remove
only the topcoat. Then use 180 grit or finer

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 21
BHT-ELEC-SPM

abrasive cloth or paper (C-406) and/or 8-11. NON-METALLIC AND/OR COMPOSITE

abrasive pad (C-407) for the complete SURFACES
removal of the primer.

a. Remove all organic finishes and anodic or

chemical film by hand sanding with either abrasive pad MATERIALS REQUIRED
(C-407) or abrasive cloth or paper (C-406). Stop hand
sanding as soon as the bare electroplated cadmium Refer to BHT-ALL-SPM for specifications.
surface is exposed.
NUMBER NOMENCLATURE
b. Apply a chemical paint remover (C-436) to the C-305 Aliphatic Naphtha
bond surface to remove the paint and/or primer.
C-385 Isopropyl Alcohol
3. Remove the gold-colored conversion coating
from all cadmium-plated bond surfaces by gently C-406 Abrasive Cloth or
hand-abrading with an abrasive pad (C-407). Paper

C-407 Abrasive Pad

WARNING C-486 Cheesecloth

IS OP ROP YL A L COHOL (C-3 85 ) OR 1. Remove non-metallic and/or composite surfaces

AL IP HAT I C NA P HT HA ( C- 30 5) A RE that are finished with either copper-filled polyurethane
FLAMMABLE AND TOXIC. BOTH CAN paint, flame-sprayed aluminum, or Ion Vapor
CAUSE BURNS AND IRRITATE SKIN. Deposited (IVD) aluminum as follows:
USE ONLY IN WELL VENTILATED AREA,
AWAY FROM HEAT AND OPEN FLAME.
WEAR RUBBER GLOVES, GOGGLES,
APRON, AND RESPIRATOR. IN CASE OF CAUTION
C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST
1 5 M I N U T E S . G E T I M M E D I AT E DO NOT REMOVE CONDUCTIVE FINISH
ATTENTION FOR EYES. FROM BOND SURFACE. DO NOT USE
ABRASIVES OTHER THAN THOSE
APPROVED IN THIS PROCEDURE.
CERTAIN ABRASIVES, SUCH AS EMERY
CAUTION
AND CROCUS CLOTH, CAN INDUCE
CORROSION OF BOND SURFACE.
MAKE SURE THAT CLEANING SOLVENT
DOES NOT GET TRAPPED INSIDE THE a. Remove finishes and/or contaminants from
ASSEMBLED BOND. conductive bond surfaces by hand abrading with an
abrasive pad (C-407) and/or 180 grit or finer abrasive
4. Thoroughly remove abrading residue from bond cloth or paper (C-406). Remove only the top coat.
surface by wiping with clean cheesecloth (C-486). Use
the cheesecloth either dry or moistened with isopropyl b. If the conductive finish is coated with a primer,
alcohol (C-385) or aliphatic naphtha (C-305). thoroughly remove the primer and expose the
conductive finish by hand-abrading with an abrasive
5. Install the electrical bond and/or ground within pad (C-407) and/or 180 grit or finer abrasive cloth or
2 hours after abrading (paragraph 8-15). paper (C-406).

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 BHT-ELEC-SPM

MATERIALS REQUIRED (Cont)

WARNING
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE
IS OP ROP YL A L COHOL (C-3 85 ) OR
AL IP HAT I C NA P HT HA ( C- 30 5) A RE C-406 Abrasive Cloth or
FLAMMABLE AND TOXIC. BOTH CAN Paper
CAUSE BURNS AND IRRITATE SKIN.
USE ONLY IN WELL VENTILATED AREA, C-407 Abrasive Pad
AWAY FROM HEAT AND OPEN FLAME.
WEAR RUBBER GLOVES, GOGGLES, C-436 Paint Remover
APRON, AND RESPIRATOR. IN CASE OF
C O N TA C T, I M M E D I AT E LY F L U S H C-486 Cheesecloth
EYES/SKIN WITH WATER FOR AT LEAST
1 5 M I N U T E S . G E T I M M E D I AT E 1. Prepare surfaces finished with either
ATTENTION FOR EYES. flame-sprayed aluminum, or Ion Vapor Deposited
(IVD) aluminum as follows:
c. Thoroughly remove abrading residue and
contaminants from the conductive finish by wiping with
clean cheesecloth (C-486). Use the cheesecloth either
dry or moistened with isopropyl alcohol (C-385) or CAUTION
aliphatic naphtha (C-305).

d. If the conductive finish was not coated with a DO NOT REMOVE THE FLAME
primer, remove the contaminants from the bond SPRAYED OR IVD ALUMINUM COATING
surface by wiping with clean cheesecloth (C-486), FROM BOND SURFACE. DO NOT USE
moistened with wither isopropyl alcohol (C-385) or ABRASIVES OTHER THAN THOSE
aliphatic naphtha (C-305). APPROVED IN THIS PROCEDURE.
CERTAIN ABRASIVES, SUCH AS EMERY
2. If the conductive finish is either flame-sprayed or AND CROCUS CLOTH, CAN INDUCE
Ion Vapor Deposited (IVD) aluminum, refer to CORROSION OF BOND SURFACE.
paragraph 8-12 for application of chemical film
material. a. If the flame-sprayed or IVD aluminum bond
surfaces are not coated with a primer, remove finishes
3. Install the electrical bond and/or ground within 2 and/or contaminants by gently hand abrading with an
hours after preparing conductive finished bond abrasive pad (C-407).
surfaces (paragraph 8-15).

8-12. FLAME-SPRAYED OR IVD ALUMINUM WARNING

SURFACES

IS OP ROP YL A L COHOL (C -3 85 ) OR
MATERIALS REQUIRED AL IPHATI C N APHTHA (C-30 5) ARE
FLAMMABLE AND TOXIC. BOTH CAN
Refer to BHT-ALL-SPM for specifications. CAUSE BURNS AND IRRITATE SKIN.
USE ONLY IN WELL VENTILATED AREA,
NUMBER NOMENCLATURE AWAY FROM HEAT AND OPEN FLAME.
WEAR RUBBER GLOVES, GOGGLES,
C-099 Chemical Film Material APRON, AND RESPIRATOR. IN CASE OF
C O N TA C T, I M M E D I AT E LY F L U S H
C-305 Aliphatic Naphtha EYES/SKIN WITH WATER FOR AT LEAST
1 5 M I N U T E S . G E T I M M E D I AT E
C-385 Isopropyl Alcohol
ATTENTION FOR EYES.

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 23
BHT-ELEC-SPM

b. Thoroughly remove abrading residue and 8-13. OUTER LAYER OF EXPANDED COPPER
surface contaminants by wiping with clean OR ALUMINUM FOIL
cheesecloth (C-486), moistened with either isopropyl
alcohol (C-385) or aliphatic naphtha (C-305).
MATERIALS REQUIRED

CAUTION Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE
MAKE SURE THAT CHEMICAL PAINT
C-305 Aliphatic Naphtha
REMOVER IS APPLIED ONLY TO THE
B O N D S U R FA C E . D O N O T A L L O W C-385 Isopropyl Alcohol
CHEMICAL PAINT REMOVER OR RINSE
WAT E R T O R U N I N T O C R A C K S , C-406 Abrasive Cloth or
CREVICES, SEAMS, OR JOINTS. Paper

c. If the flame-sprayed or IVD aluminum bond C-407 Abrasive Pad

surfaces are coated with primer, remove the primer
sufficiently to expose the flame-sprayed or IVD C-486 Cheesecloth
aluminum bond surface. Apply a chemical paint
remover (C-436) to the bond surface to remove most
of the primer. Then, gently hand-abrade the bond 1. Prepare surfaces finished with an outer layer of
surface, to thoroughly remove the primer, with an expanded copper or aluminum foil cured with, or
abrasive pad (C-407) and/or 400 grit or finer abrasive secondarily bonded to, the underlying material, as
cloth or paper (C-406). follows:

d. Thoroughly remove abrading residue from the a. Drill a hole (if required) into the surface to be
flame-sprayed or IVD aluminum by wiping with clean bonded or grounded, in accordance with the
cheesecloth (C-486). Use the cheesecloth either dry applicable bulletin (ASB, TB), service or installation
or moistened with isopropyl alcohol (C-385) or instruction, Maintenance Manual, or other applicable
aliphatic naphtha (C-305). document (Figure 8-9, Detail A).

2. Prepare the chemical film material (C-099)

(paragraph 8-5).
CAUTION
3. Apply a coating of chemical film material (C-099)
to bond surface with either a non-metallic brush or EXPANDED FOIL MAY BE AS THIN AS
dipping method. This produces a light iridescent 0.003 INCH (0.07 MM). SAND
yellow finish on the bond surface. Usually, this color is C A R E F U L LY O N C E T H E M E TA L I S
obtained by allowing the chemical film solution to EXPOSED. DO NOT USE ABRASIVES
remain on the bond surface for a maximum of OTHER THAN THOSE APPROVED IN
5 seconds. THIS PROCEDURE. C E R TA I N
ABRASIVES, SUCH AS EMERY AND
4. Remove excess chemical film material from the CROCUS CLOTH, CAN INDUCE
bond surface by blotting with clean cheesecloth CORROSION OF BOND SURFACE.
(C-486) moistened with deionized or distilled water.
Allow bond surface to air dry or gently wipe bond b. Remove all finishes and epoxy resin by hand
surface dry with clean cheesecloth. abrading with an abrasive pad (C-407) and/or abrasive
cloth or paper (C-406).
5. Install the electrical bond and/or ground within
2 hours after preparing flame-sprayed or IVD c. Remove topcoat with 100 grit or finer abrasive
aluminum bond surfaces (paragraph 8-15). cloth or paper (C-406).

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 BHT-ELEC-SPM

d. Remove primer and surface epoxy with • Bonding strap/jumper (paragraph 8-16)
180 grit or finer abrasive cloth or paper (C-406) and/or
an abrasive pad (C-407). Gently hand-abrade the • Tubular component bonding clamps
bond surface to thoroughly remove the primer and (paragraph 8-17)
surface epoxy and expose the metallic bond surface.
• Direct contact/assembly with fasteners
(paragraph 8-18)
WARNING
• Electrically isolated structures (paragraph
8-19)
IS OP ROP YL A L COHOL (C-3 85 ) OR
AL IP HAT I C NA P HT HA ( C- 30 5) A RE • Direct contact/assembly (paragraph 8-20)
FLAMMABLE AND TOXIC. BOTH CAN
CAUSE BURNS AND IRRITATE SKIN.
• Flange-mounted cadmium plated components
USE ONLY IN WELL VENTILATED AREA,
(paragraph 8-21)
AWAY FROM HEAT AND OPEN FLAME.
WEAR RUBBER GLOVES, GOGGLES,
APRON, AND RESPIRATOR. IN CASE OF 8-16. BONDING STRAP/JUMPER
C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST 1. Bond with a bonding strap/jumper and threaded
1 5 M I N U T E S . G E T I M M E D I AT E fasteners/ground stud as follows (Figure 8-10, Detail A
ATTENTION FOR EYES. through Detail F):

2. Thoroughly remove abrading residue from the foil a. Assemble the cleaned bond surfaces in
surface by wiping with clean cheesecloth (C-486). Use accordance with Figure 8-10.
the cheesecloth either dry or moistened with isopropyl
alcohol (C-385) or aliphatic naphtha (C-305).
b. Install the bonding strap/jumper, threaded
fasteners/ground stud, and any additional bonding
3. Install the electrical bond and/or ground within hardware (Figure 8-10).
2 hours after abrading the bond surfaces (paragraph
8-15). c. Visually check the assembly for
completeness, proper and complete fit, and alignment
8-14. CARBON/EPOXY COMPOSITE of mating parts.
SURFACE
d. Verify the electrical bonding resistance for the
specified class (paragraph 8-26).
1. Prepare the surface of carbon/epoxy composite
structures for electrical bonding and/or grounding per
the applicable bulletin (ASB, TB), service or e. Seal the bonding area (paragraph 8-24).
installation instruction, Maintenance Manual, or other
applicable document. It is not recommended to do this f. Refinish the bonding area (paragraph 8-25).
type of operation without appropriate instructions.
Carbon/epoxy composite structures are very delicate 8-17. TUBULAR COMPONENT BONDING
and require special procedures. CLAMPS

8-15. ELECTRICAL BONDING METHODS 1. Bond tubular components to structure (conduits,

fluid lines, fuel system components, etc.) as follows
(Figure 8-10, Detail G and Detail H):
Accomplish the electrical bonding and grounding of
helicopter structures in accordance with the methods
listed in paragraph 8-16 to paragraph 8-21. The a. Assemble the cleaned bond surfaces
methods include the following: (paragraph 8-6) in accordance with Figure 8-10.

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 25
BHT-ELEC-SPM

SCREW COMPONENT

LOCKWASHER

WASHER
MOUNTING FLANGE

BONDING PANEL WITH INSERT BOND SURFACES, CLEAN 1

OR PANEL WITH NUTPLATE BONDING STRAP
NOTE: If insufficient edge distance, less than one-half diameter of hole, exists
on the upper surface of the component, the bonding strap may be
installed under the component.
DETAIL A
SEAL 2 WASHER
BONDING STRAP

LOCKWASHER
LOCKNUT
WASHER
SCREW OR BOLT LOCKWASHER BOND SURFACE, CLEAN 1
BONDING STRAP OR
CURRENT RETURN JUMPER WASHER DETAIL B

WASHER (NOT USED

ALUMINUM STRUCTURE, WITH NUTPLATE)
PLATED STEEL, CRES OR
TITANIUM STRUCTURE
LOCKNUT OR
NUTPLATE
SEAL AND REFINISH 2 3 MOUNTING BASE
LOCKWASHER
BONDING STRAP

SHOCK MOUNT

LOCKWASHER
MOUNTING
STRUCTURE
BOND SURFACES, CLEAN MOUNTING
STRUCTURE AND BONDING STRAP 1

BOND SURFACE, CLEAN 1

SEAL AND REFINISH 2 3
NOTE: Use only titanium or CRES
fasteners in titanium
structures.
BOND SURFACES, CLEAN MOUNTING
DETAIL C BASE AND BONDING STRAP IN CONTACT 1
WITH MOUNTING BASE.
NOTE: Install bonding strap under the shock mount so that strap
does not impair operation of the shock mount. All riveted
elements of the shock mount form a conductive bond.
DETAIL D
ELEC-SPM_08_0005
Figure 8-10. Structure Bonding by Direct Contact (Sheet 1 of 7)

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 BHT-ELEC-SPM

BOND SURFACE, HEXAGONAL AND

CLEAN MOUNTING AREA 1 SELF-LOCKING
AND BONDING STRAP NUT FOR SECURING
ACROSS HINGES THE BONDING STRAP

FASTENER

HINGE

DETAIL E

NONMETALLIC OR
COMPOSITE
STRUCTURE

SCREW
BONDING STRAP
WASHER

GROUND PLANE
(METALLIC AIRCRAFT
CLAMP STRUCTURE)
DETAIL F
BONDING STRAP OR
WASHER CURRENT RETURN JUMPER
NUT
BOND SURFACE, CLEAN 1
BOND SURFACE, CLEAN 1 FLEXIBLE UNION AND MOUNTING SURFACE
HOSE RIGID TUBE
ASSEMBLY ASSEMBLY
2 SEAL

NUT
2 SEAL NUT AND WASHER

BOND SURFACE, CLEAN 1

BOND SURFACE, CLEAN
Includes fluid lines, fuel FITTING AND BULKHEAD 1
system components, etc.
DETAIL G DETAIL H

ELEC-SPM_08_0006
Figure 8-10. Structure Bonding by Direct Contact (Sheet 2 of 7)

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 27
BHT-ELEC-SPM

REFINISH
3 AFTER
NUT OR LOCKNUT ASSEMBLY
LOCKWASHER
BOND SURFACE,
1 CLEAN

RIVET OR
STRUCTURE THREADED
FASTENER
WASHER

SEAL 2

STRUCTURE
FASTENER
BOND SURFACE, CLEAN 1
SEAL 2
DETAIL I DETAIL J

BOLT OR SCREW

LOCKWASHER
WASHER

DZUS EDGE-LIT PANEL

NUT WASHER FASTENER OR AVIONIC BOX

BOND SURFACES
1 ON BOTH PIECES
CLEAN

SEAL AFTER
INSTALLATION 2

DETAIL K
BOND SURFACES,
1 CLEAN
DETAIL L

ELEC-SPM_08_0007
Figure 8-10. Structure Bonding by Direct Contact (Sheet 3 of 7)

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 BHT-ELEC-SPM

BOND SURFACE, CLEAN 1

REFINISH AFTER ASSEMBLY

OF DZUS STRIP 3

DZUS STRIP ATTACHMENT

ELECTRONICS
RACK OR CONSOLE

BOND SURFACES, CLEAN 1

DETAIL M

ITEM TO BE BONDED THROUGH

BOND SURFACES, MOUNTING FEET
1 CLEAN
LOCKWASHER

MOUNTING BASE

3 REFINISH

BOND SURFACE,
1 CLEAN

DETAIL N

ELEC-SPM_08_0008
Figure 8-10. Structure Bonding by Direct Contact (Sheet 4 of 7)

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 29
BHT-ELEC-SPM

BOND SURFACES
ON CONNECTOR
AND STRUCTURE,
CLEAN 1
PANEL MOUNT SIDE MOUNT

REFINISH 3

CONNECTOR

DETAIL O

ELEC-SPM_08_0009
Figure 8-10. Structure Bonding by Direct Contact (Sheet 5 of 7)

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 BHT-ELEC-SPM

BOND SURFACES ON
CONNECTOR AND STRUCTURE,
CLEAN
MATING FACE
OF CONNECTOR 1

SEAL 2

REFINISH 3

MOUNTING STRUCTURE SHADED AREA DESIGNATES

MOUNTING SURFACE PREPARATION AREA
(INCLUDES AREA BENEATH
CONNECTOR FLANGE)

FROM THE FAYING SURFACE OF

THE CONNECTOR, REMOVE THE FINISH
FROM THE FOUR CORNERS

DETAIL P
BACK PANEL MOUNTED
“D” HOLE MOUNTED CONNECTOR
CLASS R-I/C

BOND SURFACES ON CONNECTOR

AND STRUCTURE, CLEAN
1

MATING FACE SEAL 2

OF CONNECTOR

REFINISH 3

MOUNTING STRUCTURE SHADED AREA DESIGNATES MOUNTING

SURFACE PREPARATION AREA
(INCLUDES AREA BENEATH
CONNECTOR FLANGE)
TEMPORARILY REMOVE “D” RING
BEFORE REMOVING FINISHES ON
THE FAYING SURFACE OF THE SHADED AREA DESIGNATES
CONNECTOR. FINISH MAY CONNECTOR SURFACE AREA
REMAIN INTERNAL TO “D” TO HAVE FINISHES REMOVED
RING GROOVE.
DETAIL Q
CLASS R-I/C
ELEC-SPM_08_0010
Figure 8-10. Structure Bonding by Direct Contact (Sheet 6 of 7)

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 31
BHT-ELEC-SPM

SHADED AREA DESIGNATES MOUNTING

SURFACE PREPARATION AREA (INCLUDES
AREA BENEATH TERMINAL BLOCK)

REFINISH 3

BOND SURFACES ON TERMINAL BLOCK

AND STRUCTURE. CLEAN
1

DETAIL R

NOTES
1 Clean bond surface (paragraph 8-6).

2 Sealing shall be accomplished (paragraph 8-24).

3 Refinishing shall be accomplished (paragraph 8-25).

ELEC-SPM_08_0011
Figure 8-10. Structure Bonding by Direct Contact (Sheet 7 of 7)

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 BHT-ELEC-SPM

NOTE
CAUTION
If the type of insulative requirements of the
non-conductive material precludes its
removal (such as a fiberglass layer) and
WHEN YOU INSTALL BONDING
sufficient electrical conductivity can be
CLAMPS, DO NOT APPLY FORCE THAT
verified through the installed fasteners,
WOULD CRIMP OR DAMAGE THE
then the surface preparation (paragraph
CONDUIT.
8-6) is optional.
b. Install bonding clamps and/or other bonding
a. If applicable, make sure that each bond
hardware on tubular conduits, fluid lines, or similar
surface has been prepared in accordance with
structures (Figure 8-10).
paragraph 8-6.

c. Visually check the assembly for b. Install fasteners for the bonding of each part.
completeness, proper and complete fit, and alignment
of mating parts.
c. Visually check the assembly for
completeness, proper and complete fit, and alignment
d. Verify the electrical bonding resistance for the of mating parts.
specified class (paragraph 8-26).
d. Verify the electrical bonding resistance for the
e. Seal the bonding area (paragraph 8-24). specified class (paragraph 8-26).

f. Refinish the bonding area (paragraph 8-25). 8-20. DIRECT CONTACT/ASSEMBLY

8-18. DIRECT CONTACT/ASSEMBLY WITH

FASTENERS MATERIALS REQUIRED

1. Bond structures by direct contact/assembly with Refer to BHT-ALL-SPM for specifications.

fasteners as follows (Figure 8-10, Detail I through
Detail O and Detail R): NUMBER NOMENCLATURE

C-139 Sealant
a. Assemble the cleaned bond surfaces
(paragraph 8-6) in accordance with Figure 8-10. C-486 Cheesecloth

b. Visually check the assembly for

completeness, proper and complete fit, and alignment NOTE
of mating parts.
This method is applicable to RF bonding
only. Do not use in applications where
c. Verify the electrical bonding resistance for the significant electrical currents are present.
specified class (paragraph 8-26).
1. Bond structures by direct contact/assembly with
d. When specified in the applicable procedure or electrically conductive sealant (C-139) as follows:
document, seal the bonding area (paragraph 8-24).
a. Make sure that each bond surface has been
e. When specified in the applicable procedure or prepared in accordance with paragraph 8-6.
document, refinish the bonding area (paragraph 8-25).

8-19. ELECTRICALLY ISOLATED STRUCTURES NOTE

Since the activated sealant has a limited
1. Bond structures that are electrically isolated by pot life, do not prepare significantly more
non-conductive materials as follows: than is needed.

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 33
BHT-ELEC-SPM

b. Prior to use, thoroughly mix the two

components of sealant (C-139) to achieve uniform
CAUTION
consistency and color. Blend the components in
accordance with the manufacturer's instructions.
DO NOT USE ABRASIVES OTHER THAN
c. Apply a continuous uniform coat of blended THOSE APPROVED IN THIS
sealant to each prepared faying surface. PROCEDURE. CERTAIN ABRASIVES,
SUCH AS EMERY AND CROCUS CLOTH,
d. Join the surfaces as soon as possible after CAN INDUCE CORROSION OF BOND
sealant application. Assemble, applying sufficient SURFACE.
pressure with the fastening hardware to ensure close
proximity of the faying (bonding) surfaces. The b. From mounting surfaces, such as the
nominal sealant bond line thickness must be connector flange (Figure 8-10, Detail P and Detail Q),
0.007 inch (0.17 mm) or less to reliably achieve a remove all cadmium and nickel plating (paragraph
Class R-II bond. A continuous bead of sealant on all 8-22) or remove all chemical treatment such as
exposed joint edges indicates that sufficient sealant chemical film (paragraph 8-23).
was applied to the mating parts.
c. Prepare chemical film material (C-099) as per
e. Wipe off excess sealant, before it has cured, paragraph 8-5.
with clean cheesecloth (C-486) moistened with
solvent. Do not allow the solvent to flow into the bond
line.
CAUTION
f. Examine the bond line and fill any voids or
undercut areas with sealant. CHEMICAL FILM MATERIAL (C-099) IS
HIGHLY CORROSIVE. DO NOT ALLOW
g. Allow the sealant to cure under contact THE CHEMICAL FILM MATERIAL OR
pressure for 24 hours minimum at 60 to 100°F (15.6 RINSE WATER TO RUN INTO CRACKS,
to 37.8°C) to achieve handling strength. CREVICES, SEAMS, OR JOINTS.

h. Verify the electrical bonding resistance for the

specified class (paragraph 8-26). CAUTION

8-21. FLANGE-MOUNTED CADMIUM PLATED

COMPONENTS DO NOT ALLOW CHEMICAL FILM
MATERIAL TO REMAIN ON BOND
S U R FA C E FOR MORE THAN
MATERIALS REQUIRED 5 SECONDS MAXIMUM.

Refer to BHT-ALL-SPM for specifications. NOTE

NUMBER NOMENCLATURE Liberally applied chemical film material

(C-099), which has an iridescent gold to
C-099 Chemical Film Material dark-brown color, is not acceptable for
electrical bonding and/or ground purposes.
C-486 Cheesecloth
d. Apply a coating of chemical film material
(C-099) to bond surface with either a non-metallic
1. Bond flange-mounted cadmium plated aluminum brush or dipping method. This produces a light
components to aluminum surfaces as follows. iridescent yellow finish on bond surface. Usually, this
color is obtained by allowing the chemical film material
a. Make sure that each bond surface has been to remain on the bond surface for a maximum of
prepared in accordance with paragraph 8-6. 5 seconds.

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 BHT-ELEC-SPM

e. Remove excess chemical film material 3. Stop the power drill as soon as the bare
solution from the bond surface by blotting with clean aluminum bond surface is exposed.
cheesecloth (C-486) moistened with deionized or
distilled water. Allow bond surface to air dry or gently
wipe bond surface dry with clean cheesecloth.
WARNING
f. Install the electrical bond and/or ground within
2 hours after applying the chemical film material
IS OP ROP YL A L COHOL (C -3 85 ) OR
(paragraph 8-15).
AL IPHATI C N APHTHA (C-30 5) ARE
FLAMMABLE AND TOXIC. BOTH CAN
g. Visually check the assembly for CAUSE BURNS AND IRRITATE SKIN.
completeness, proper and complete fit, and alignment USE ONLY IN WELL VENTILATED AREA,
of mating parts. AWAY FROM HEAT AND OPEN FLAME.
WEAR RUBBER GLOVES, GOGGLES,
h. Verify the electrical bonding resistance for the APRON, AND RESPIRATOR. IN CASE OF
specified class (paragraph 8-26). C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST
1 5 M I N U T E S . G E T I M M E D I AT E
i. If Class R-I/C bonding is required, sealant has
ATTENTION FOR EYES.
to be applied to the bonded parts after installation.
Apply sealant to both sides of connectors and
4. Wipe the exposed bond surface with clean
fasteners of the bonded airframe interconnect harness
cheesecloth (C-486). Use the cheesecloth either dry
connectors. Apply sealant only to the exterior
or moistened with isopropyl alcohol (C-385) or
interfaces of the connector and fasteners of
aliphatic naphtha (C-305).
connectors bonded to electrical/electronic boxes
(paragraph 8-24). Sealant shall be applied to the
bonded parts within 7 days of assembly. 8-23. Chemical Treatment — Removal

j. When sealing of other bonding classes is

specified in the applicable procedure or document, MATERIALS REQUIRED
refer to paragraph 8-24.
Refer to BHT-ALL-SPM for specifications.
8-22. Cadmium and Nickel Plating — Removal NUMBER NOMENCLATURE

C-305 Aliphatic Naphtha

MATERIALS REQUIRED C-385 Isopropyl Alcohol
Refer to BHT-ALL-SPM for specifications. C-486 Cheesecloth
NUMBER NOMENCLATURE
1. Remove chemical film by hand abrading with
C-305 Aliphatic Naphtha abrasive pads until the bare metal is exposed.

C-385 Isopropyl Alcohol

C-486 Cheesecloth WARNING

1. Insert an abrasive brush or abrasive wheel into a

IS OP ROP YL A L COHOL (C -3 85 ) OR
power drill.
AL IPHATI C N APHTHA (C-30 5) ARE
FLAMMABLE AND TOXIC. BOTH CAN
2. Start the power drill and remove the metallic CAUSE BURNS AND IRRITATE SKIN.
plating from the bond surface. USE ONLY IN WELL VENTILATED AREA,

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 35
BHT-ELEC-SPM

AWAY FROM HEAT AND OPEN FLAME.

WEAR RUBBER GLOVES, GOGGLES, CAUTION
APRON, AND RESPIRATOR. IN CASE OF
C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST MAKE SURE THAT CLEANING SOLVENT
1 5 M I N U T E S . G E T I M M E D I AT E DOES NOT GET TRAPPED INSIDE THE
ATTENTION FOR EYES. ASSEMBLED BOND.

2. Remove abrading residue from the bond surface NOTE

by wiping with clean cheesecloth (C-486). Use the
Do not apply sealants to the mating
cheesecloth either dry or moistened with isopropyl surfaces or the bonded areas.
alcohol (C-385) or aliphatic naphtha (C-305).
a. Thoroughly remove contaminants from
8-24. SEALING external edges of assembled bond by wiping with
clean cheesecloth (C-486), moistened with either
isopropyl alcohol (C-385) or aliphatic naphtha (C-305).

MATERIALS REQUIRED
b. Thoroughly dry the external edges of the
assembled bond.
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 2. Apply a fillet seal over the entire periphery of the
assembled bond, sealing around the mounting screws,
C-305 Aliphatic Naphtha nuts, and nutplates with sealing compound. Also, seal
the area under the strap (near the hole) to avoid
C-385 Isopropyl Alcohol
moisture entering from the underside of the strap.
C-486 Cheesecloth
8-25. REFINISHING
1. When specified in the applicable procedure or
document, apply sealant to bonded parts within 7 days When specified in the applicable procedure or
of assembly as follows: document, refinish bonded structures within 7 days of
assembly by applying primer and topcoats
(BHT-ALL-SPM, Chapter 4). Refinish bonded
structures in accordance with the following
WARNING requirements:

IS OP ROP YL A L COHOL (C-3 85 ) OR WARNING

AL IP HAT I C NA P HT HA ( C- 30 5) A RE
FLAMMABLE AND TOXIC. BOTH CAN
CAUSE BURNS AND IRRITATE SKIN. PRIMERS ARE FLAMMABLE, TOXIC,
USE ONLY IN WELL VENTILATED AREA, AND CAN CAUSE BURNS AND IRRITATE
AWAY FROM HEAT AND OPEN FLAME. SKIN. USE ONLY IN WELL VENTILATED
WEAR RUBBER GLOVES, GOGGLES, AREA, AWAY FROM HEAT AND OPEN
FLAME. WEAR GLOVES, GOGGLES,
APRON, AND RESPIRATOR. IN CASE OF
APRON, AND RESPIRATOR. IN CASE OF
C O N TA C T, I M M E D I AT E LY F L U S H C O N TA C T, I M M E D I AT E LY F L U S H
EYES/SKIN WITH WATER FOR AT LEAST EYES/SKIN WITH WATER FOR AT LEAST
1 5 M I N U T E S . G E T I M M E D I AT E 1 5 M I N U T E S . G E T I M M E D I AT E
ATTENTION FOR EYES. ATTENTION FOR EYES.

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 BHT-ELEC-SPM

1. Refinish structures that do not consist of Class C and Class L, refer to the applicable bulletin
magnesium within 7 days after removal of original (ASB, TB), service or installation instruction,
finish from structures. Maintenance Manual, or other applicable document for
the resistance value.
2. Refinish magnesium structures within 24 hours
after removal of original finish. 2. Measure resistance across each bond with a
suitable milliohmeter.
3. When electrically bonded surfaces are exposed
to temperatures exceeding 600ºF (316ºC), refinishing 3. When performing resistance measurements on
is not required. bonds that are designed for movement during
helicopter operation or when using bonding sealant,
4. Refinish bonding strap assemblies that were gently vibrate bonded parts to make sure parts are
secured with threaded fasteners. tightened. If resistance requirements are not met, redo
the bonding/ground installation and retest.
8-26. BOND RESISTANCE — TEST
4. When performing resistance measurements
disconnect the electrical cables from the unit under
test, unless otherwise specified. Repair, as required,
CAUTION any probe damage to bond surface.

DO NOT USE THE SHALLCROSS MODEL 5. Measurements should be performed after

670-D OR MEGGER BT51 grounding and bonding mechanical connections are
MILLIOHMETERS WHERE EXPLOSIVE complete to determine if the measured resistance
HAZARDS (PROPELLANTS OR value meets the requirements. A high quality test
V O L AT I L E COMPOUNDS) ARE instrument (AN/USM-21A or equivalent) is required to
P R E S E N T. D O N O T P E R F O R M accurately measure the specified very low resistance
ELECTRICAL R E S I S TA N C E values.
MEASUREMENTS ON SURFACES OF
ELECTRO-EXPLOSIVE DEVICES. 6. Another method of measurement is the millivolt
drop test as shown in Figure 8-11. Make sure the
1. Resistance requirement of each class of electrical components and wire selected are capable of carrying
bond is to be in accordance with Table 8-2. For 10 amps.

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 37
BHT-ELEC-SPM

MV
EQUIPMENT AIRCRAFT STRUCTURE
SURFACE SURFACE
BONDING STRAP
28VDC -
SOURCE +

A
R1

Adjust R1 rheostat for 10 amperes on ammeter.

Record the millivolt reading.

Example: Millivolt reading is 30 MVS

30 MVS
= 3 MILLIOHMS RESISTANCE
10 AMPS

ELEC-SPM_08_0012
Figure 8-11. Millivolt Drop Test Method

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 BHT-ELEC-SPM

CHAPTER 9 — ELECTRICAL TOOLS

CONTENTS — MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

ELECTRICAL TOOLS

9-1 Electrical Tools and Test Equipment ......................................... 9-00-00 3

FIGURES

Figure Page
Number Title Number

9-1 Electrical Tools (Typical)................................................................................. 21

TABLES

Table Page
Number Title Number

9-1 General Electrical Tool List............................................................................. 4

9-2 Electrical Tool List for 206A/B Series Helicopters .......................................... 8
9-3 Electrical Tool List for 206L Series Helicopters .............................................. 10
9-4 Electrical Tool List for 407 Helicopters ........................................................... 12
9-5 Electrical Tool List for 212/412 Helicopters .................................................... 14
9-6 Electrical Tool List for 427 Helicopters ........................................................... 16
9-7 Electrical Tool List for 429 Helicopters ........................................................... 17
9-8 Electrical Tool List for 430 Helicopters ........................................................... 19

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 BHT-ELEC-SPM

ELECTRICAL TOOLS

9-1. ELECTRICAL TOOLS AND TEST Electrical tools used for specific helicopter models are
EQUIPMENT listed in Table 9-2 through Table 9-8. Typical
depictions of standard electrical tools are shown in
Figure 9-1.
The tools listed in this chapter conform to the
component and wire manufacturers specifications for
Electrical tools that meet or exceed the quality and
stripping, crimping, and assembly of connectors. The
functionality of those listed in any BHT manual may be
integrity and reliability of electrical systems and
used as equivalent alternates.
circuits depend upon using specified tools or those
that are equivalent.
There are two connector tool kits listed that contain
most of the tools required to conduct maintenance
NOTE repair or electrical procedures on most Bell
helicopters.
The electrical tool lists provided are
intended to cover the majority of electrical Each includes a variety of common crimpers, crimp
maintenance or repair procedures on dies, wire strippers, and insertion/removal tools.
electrical and avionics systems provided by Contact the manufacturer for a complete listing of
Bell Helicopter Textron (BHT). tools.

The lists have not been developed to cover CMS Connector Microtooling Systems, Inc.
all possibilities of customizing or STC Connector Kit P/N CMS20
installations. www.cms-tools.com

A general electrical tool listing is provided in Table 9-1 Daniels Manufacturing Corporation,
that will assist with electrical maintenance and repair Connector Kit P/N DMC737
on all heliicopter models. www.dmctools.com

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Table 9-1. General Electrical Tool List

ITEM MANUFACTURER DESIGNATION

Automatic Charger/Analyzer Marathon RF80-K

Banding Tool Band-it A-100
Connector Repair Kit Daniels DMC737
Connector Repair Kit Connector Micro Tooling Systems Inc. CMS20
Crimp Tool (Splices) RayChem AD 1377
Crimp Tool Frames Military Standard M22520/1-01
M22520/2-01
M22520/7-01
M22520/5-01
M22520/10-01
Crimp Tool Die Sets Military Standard M22520/5-05
M22520/5-11
M22520/5-13
M22520/5-15
M22520/5-19
M22520/5-25
M22520/5-27
M22520/5-29
M22520/5-35
M22520/5-41
M22520/5-57
M22520/5-61
M22520/5-63
M22520/5-102
M22520/5-103
M22520/10-103
M22520/10-104
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-03
M22520/1-04
M22520/1-12
M22520/1-13
M22520/1-14
M22520/1-16
M22520/1-17

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Table 9-1. General Electrical Tool List (Cont)

ITEM MANUFACTURER DESIGNATION

Crimp Tool Positioners Military Standard M22520/2-02
M22520/2-06
M22520/2-07
M22520/2-08
M22520/2-09
M22520/2-10
M22520/2-11
M22520/2-13
M22520/2-14
M22520/2-23
M22520/2-32
M22520/7-02
M22520/7-03
M22520/2-06
M22520/2-08
M22520/7-11
M22520/7-12
M22520/7-13
Crimp Tool (Hydraulic Hand Tool) AMP 59975-1
Crimp Tool Military Standard MS90413-2
Heat Gun (Flame Proof) or Equivalent Raychem AA-400
Heat Gun Thermo Gun with Reflector Kit Steinel HL 1910E
Insertion/Removal Tools Deutsch 81515-23
Collins 372-8091-010
Insertion/Removal Tools Military Standard M81969/16-04
M81969/16-03
M81969/16-02
M81969/16-01
M81969/14-11
M81969/14-10
M81969/14-04
M81969/14-03
M81969/14-02
M81969/14-01
M81969/1-03
M81969/1-02
M81969/1-01
M15570/22-1
M83723/31-12
M83723/31-16
M83723/31-20

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Table 9-1. General Electrical Tool List (Cont)

ITEM MANUFACTURER DESIGNATION

Insertion Tools Hughes TR22DIT
Astro ATH1050
ADT 1081
ATBX-1-6781
ATA1086
Insertion Tools Military Standard M81969/23-02
M81969/18-01
M81969/14-03
M81969/14-02
MS24256A20
MS24256A16
Cannon CIT-20
Bendix 11-6782
11-6781
Winchester 107-1015
Removal Tools Astro ATD2095
ATH2050
ATBX-2-6900
ATC2046-L
Bendix 11-6900
Removal Tools Military Standard MS24256R20
MS24256R16
M81969/22-01
M81969/19-08
M81969/19-07
M81969/14-11
Cannon CET-20-A
Winchester 107R1001
Hughes TR22DRT
Solder Iron (Adjustable, Multiple Tips) Weller W100PG
Solder Iron (Multiple Tips) Weller W60P
Volt Ohm Meter (Digital) Fluke Model 179
(or Equivalent)
Volt Ohm Meter Digital (or Equivalent) Fluke Model 87-V
Volt Ohm Meter (Analog) Simpson 260
(or Equivalent)
Wire Cutter Ideal 45-123

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Table 9-1. General Electrical Tool List (Cont)

ITEM MANUFACTURER DESIGNATION

Wire Stripper Ideal

Coaxial Cable, RG-174, RG-187 45-162
Coaxial Cable, RG-58 45-163
Coaxial Cable, RG-59 45-165
Coaxial Cable, RG-8 45-164
Wire Stripper Ideal Stripmaster
Kapton Wire, 16-26 AWG 45-1654-1
Kapton Wire, 10-14 AWG 45-1608-1
Poly X Wire, 10-14 AWG 45-1611-1
Poly X Wire, 16-26 AWG 45-1610-1
Wire Stripper Ideal 45-097
Plastic Strap Tool Adjustable MS90387

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Table 9-2. Electrical Tool List for 206A/B Series Helicopters

ITEM MANUFACTURER DESIGNATION

Crimp Tool Frames Military Standard M22520/1-01

M22520/2-01
M22520/5-01 (COAX)
M22520/7-01
Pico 400BHD
AMP 90124-2
Raychem AD-1377
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-03
M22520/1-12
Daniels TH254
Y205 (COAX)
Pico 414DA-8N
Crimp Tool Positioners Military Standard M22520/2-02
M22520/7-02
Pico 4046A
Insertion/Removal Tools Military Standard M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-11
M81969/18-01
M81969/19-07
M81969/20-01
M81969/29-02
AMP 91002-1
1-305183-1
ASTRO ATBX2-6784
ATBX2-6900 (KIT)
Wire Cutter Ideal 45-123
Wire Stripper Ideal 45-1611 (Gauge 10-14)
45-1987 (Gauge 16-26)
Blade Ideal 45-1611-1 (for 45-1611)
45-1987-1 (for 45-1987)
Relay Extractor Military Standard M6106/31-001
Relay Base Extractor Military Standard M6106/32-001
Module Extractor Military Standard M81714/69-01
M81714/69-02

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Table 9-2. Electrical Tool List for 206A/B Series Helicopters (Cont)

ITEM MANUFACTURER DESIGNATION

Multimeter Fluke Model 77
Plastic Strap Tool Adjustable MS90387

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Table 9-3. Electrical Tool List for 206L Series Helicopters

ITEM MANUFACTURER DESIGNATION

Crimp Tool Frames Military Standard M22520/1-01

M22520/2-01
M22520/5-01 (COAX)
M22520/7-01
Pico 400B
AMP 90124-2
Raychem AD-1377
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-03
M22520/1-04
M22520/1-12
Daniels TH254
Y205 (COAX)
Pico 414DA-4N
414DA-0N
Crimp Tool Positioners Military Standard M22520/2-02
M22520/7-02
Pico 4066
4112
Insertion/Removal Tools Military Standard M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-11
M81969/18-01
M81969/19-07
M81969/20-01
M81969/29-02
M81969/29-03
M81969/29-04
AMP 91002-1
1-305183-1
ASTRO ATBX2-6784
ATBX2-6900 (KIT)
Cannon CIT16-1
CET16-3A
Wire Cutter Ideal 45-123
Wire Stripper Ideal 45-1611 (Gauge 10-14)
45-1987 (Gauge 16-26)

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Table 9-3. Electrical Tool List for 206L Series Helicopters (Cont)

ITEM MANUFACTURER DESIGNATION

Blade Ideal 45-1611-1 (for 45-1611)
45-1987-1 (for 45-1987)
Relay Extractor Military Standard M6106/31-001
Relay Base Extractor Military Standard M6106/32-001
Module Extractor Military Standard M81714/69-01
M81714/69-02
Multimeter Fluke Model 77
Plastic Strap Tool Adjustable MS90387

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BHT-ELEC-SPM

Table 9-4. Electrical Tool List for 407 Helicopters

ITEM MANUFACTURER DESIGNATION

Crimp Tool Frames Military Standard M22520/1-01

M22520/2-01
M22520/5-01 (COAX)
M22520/7-01
Pico 400B
AMP 90124-2
Raychem AD-1377
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-03
M22520/1-04
M22520/1-12
M22520/1-14
Daniels TH254
Y110 (COAX)
Y205 (COAX)
Pico 414DA-0N
Crimp Tool Positioners Military Standard M22520/2-02
M22520/2-06
M22520/2-07
M22520/2-08
M22520/2-09
M22520/2-10
M22520/7-02
M22520/7-04
M22520/7-11
M22520/7-12
Pico 4066
Insertion/Removal Tools Military Standard M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-10
M81969/16-04
M81969/18-01
M81969/20-01
M81969/29-04
AMP 91002-1
1-305183-1

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 BHT-ELEC-SPM

Table 9-4. Electrical Tool List for 407 Helicopters (Cont)

ITEM MANUFACTURER DESIGNATION

Insertion/Removal Tools ASTRO ATBX2-6784
ATBX2-6900 (KIT)
Wire Cutter Ideal 45-123
Wire Stripper Ideal 45-1611 (Gauge 10-14)
45-1987 (Gauge 16-26)
Blade Ideal 45-1611-1 (for 45-1611)
45-1987-1 (for 45-1987)
Relay Extractor Military Standard M6106/31-001
Relay Base Extractor Military Standard M6106/32-001
Module Extractor Military Standard M81714/69-01
M81714/69-02
Multimeter Fluke Model 77
Plastic Strap Tool Adjustable MS90387

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BHT-ELEC-SPM

Table 9-5. Electrical Tool List for 212/412 Helicopters

ITEM MANUFACTURER DESIGNATION

Crimp Tool Frames Military Standard M22520/1-01

M22520/2-01
M22520/5-01 (COAX)
M22520/7-01
Pico 400BHD
AMP 90124-2
Raychem AD-1377
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-04
M22520/1-12
M22520/1-14
Daniels TH244
TH254
Y110 (COAX)
Y205 (COAX)
Pico 414DA-0N
414DA-1N-0-1
414DA-8N
Crimp Tool Positioners Military Standard M22520/2-02
M22520/2-07
M22520/2-08
M22520/2-09
M22520/2-10
M22520/2-23
M22520/7-02
M22520/7-12
Pico 4046A
4066
Insertion/Removal Tools Military Standard M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-07
M81969/14-10
M81969/14-11
M81969/29-02
M81969/29-04
MS24256A20

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Table 9-5. Electrical Tool List for 212/412 Helicopters (Cont)

ITEM MANUFACTURER DESIGNATION

Insertion/Removal Tools ASTRO ATBX2-6784
ATBX2-6900 (KIT)
ATD1081
ATD2095
Wire Cutter Ideal 45-123
Wire Stripper Ideal 45-1611 (Gauge 10-14)
45-1987 (Gauge 16-26)
Blade Ideal 45-1611-1 (for 45-1611)
45-1987-1 (for 45-1987)
Relay Extractor Military Standard M6106/31-001
Relay Base Extractor Military Standard M6106/32-001
Module Extractor Military Standard M81714/69-01
M81714/69-02
Multimeter Fluke Model 77
Plastic Strap Tool Adjustable MS90387

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BHT-ELEC-SPM

Table 9-6. Electrical Tool List for 427 Helicopters

ITEM MANUFACTURER DESIGNATION

Crimp Tool Frames Military Standard M22520/1-01

M22520/2-01
M22520/5-01 (COAX)
M22520/7-01
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-03
M22520/1-04
M22520/1-12
M22520/1-14
Daniels Y205 (COAX)
Crimp Tool Positioners Military Standard M22520/2-02
M22520/2-06
M22520/2-07
M22520/2-08
M22520/2-09
M22520/2-10
M22520/2-11
M22520/7-04
Insertion/Removal Tools Military Standard M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-10
Wire Cutter Ideal 45-123
Wire Stripper Ideal 45-1611 (Gauge 10-14)
45-1987 (Gauge 16-26)
Blade Ideal 45-1611-1 (for 45-1611)
45-1987-1 (for 45-1987)
Relay Extractor Military Standard M6106/31-001
Relay Base Extractor Military Standard M6106/32-001
Module Extractor Military Standard M81714/69-01
M81714/69-02
Multimeter Fluke Model 77
Plastic Strap Tool Adjustable MS90387

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Table 9-7. Electrical Tool List for 429 Helicopters

ITEM MANUFACTURER DESIGNATION

Multimeter Fluke or equivalent Model 79

Tool Frame King 071-6041-00
Tool Frame (Long Handle) 47386
Tool Frame (Short Handle) 47386-2
Tool Frame Band-It 5199
Tool Frame AMP 59284-1
Tool Frame Molex 6115
Tool Frame AMP 90296-1
90296-2
Tool Frame Military Standard M22520/1-01
M22520/2-01
M22520/5-01
M22520/7-01
Tool Frame RACHEM AD1377
Tool Frame Belmar WA22P
WT145A
WT145C
Turret Head Military Standard M22520/1-02
M22520/1-04
Positioner Military Standard M22520/2-01
M22520/2-02
M22520/2-06
M22520/2-07
M22520/2-08
M22520/2-09
M22520/2-10
M22520/2-11
M22520/5-09
M22520/5-59
M22520/7-03
M22520/7-04
M22520/7-04
M22520/7-11
M22520/7-12
M22520/7-13
Insertion Tool 455830-1
Insertion Tool 91002-1

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BHT-ELEC-SPM

Table 9-7. Electrical Tool List for 429 Helicopters (Cont)

ITEM MANUFACTURER DESIGNATION

Insertion/Extraction Tool Military Standard M81969/1-02
M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-10
M81969/14-11
M81969/16-01
M81969/16-04
Module Extraction Tool Military Standard M81714-69-01
M81714-69-02
Extraction Tool 005-2012-11
Extraction Tool 1-305183-1
Extraction Tool 458994-1
Extraction Tool Molex HT-1884
Wire Stripper for M22759/41 Ideal Ind. 45-1611 or equivalent
(Gauge 10 to 14)
Blade for Wire Stripper 45-1611 Ideal Ind. 45-1611-1 or equivalent
Wire Stripper for 22759/41 Wire Ideal Ind. 55-2685 or equivalent
(Gauge 18 to 26)
Bade for Wire Stripper 55-2865 Ideal Ind. 55-268-1 or equivalent
Heat Gun with Reflector STEINEL HL1802E or equivalent
Soldering Iron Weller W60P or equivalent

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 BHT-ELEC-SPM

Table 9-8. Electrical Tool List for 430 Helicopters

ITEM MANUFACTURER DESIGNATION

Crimp Tool Frames Military Standard M22520/1-01

M22520/2-01
M22520/5-01 (COAX)
M22520/7-01
Pico 400BHD
Crimp Tool Turrets Military Standard M22520/1-02
M22520/1-03
M22520/1-03
M22520/1-14
Daniels TH254
Y110 (COAX)
Y205 (COAX)
Pico 414DA-0N
414DA-1N-0-1
Crimp Tool Positioners Military Standard M22520/2-02
M22520/2-06
M22520/2-07
M22520/2-08
M22520/2-09
M22520/2-10
M22520/2-23
M22520/7-04
M22520/7-11
M22520/7-12
Pico 4066
Insertion/Removal Tools Military Standard M81969/14-01
M81969/14-02
M81969/14-03
M81969/14-04
M81969/14-10
M81969/14-11
M81969/16-04
M81969/19-07
M81969/29-04
ASTRO ATBX2-6784
ATBX2-6900 (KIT)
Wire Cutter Ideal 45-123
Wire Stripper Ideal 45-1611 (Gauge 10-14)
45-1987 (Gauge 16-26)

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BHT-ELEC-SPM

Table 9-8. Electrical Tool List for 430 Helicopters (Cont)

ITEM MANUFACTURER DESIGNATION

Blade Ideal 45-1611-1 (for 45-1611)

45-1987-1 (for 45-1987)
Relay Extractor Military Standard M6106/31-001
Relay Base Extractor Military Standard M6106/32-001
Module Extractor Military Standard M81714/69-01
M81714/69-02
Multimeter Fluke Model 77
Plastic Strap Tool Adjustable MS90387

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 BHT-ELEC-SPM

WITH
GS CO

U
WE N
T
RT

AC
AB 3.3
C

TS
3.3
4
#3 3.3
3
#3909/1
90 1- 3
9/1 00
1-0
0

MS22520/2-XX
MS22520/1-XX OR
TURRET HEAD MS22520/7-XX
POSITIONER

M22520/1-01
ADJUSTABLE CRIMP TOOL

45-1611
WIRE STRIPPER

M22520/2-01
OR
MSS520/7-01
ADJUSTABLE CRIMP TOOL

AD-1377
CRIMPING TOOL

429_MM_96_0244

Figure 9-1. Electrical Tools (Typical) (Sheet 1 of 3)

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BHT-ELEC-SPM

M6106/31-001 M6106/32-001 ATBX 2-6900

RELAY EXTRACTION TOOL RELAY BASE EXTRACTION TOOL EXTRACTION TOOL KIT

HT-1884 M81969/STYLE M81714/69-01

EXTRACTION TOOL INSERTION/EXTRACTION TOOLS MODULE EXTRACTION TOOL

91002-1 1-305183-1 M81714/69-02

INSERTION TOOL EXTRACTION TOOL MODULE EXTRACTION TOOL

ELEC_SPM_09_0001b

Figure 9-1. Electrical Tools (Typical) (Sheet 2 of 3)

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 BHT-ELEC-SPM

ADJUSTABLE WIRE STRIPPERS ADJUSTABLE

CRIMPING TOOL 55-2685 CRIMPING TOOL
WT145C 5199

ADJUSTABLE ADJUSTABLE ADJUSTABLE

CRIMPING TOOL CRIMPING TOOL CRIMPING TOOL
6115 47386 (LONG HANDLE) 59284-1

ADJUSTABLE ADJUSTABLE ADJUSTABLE

CRIMPING TOOL CRIMPING TOOL CRIMPING TOOL
90296-1 M2252015-01 WT145A
90296-2
429_MM_96_0246_c01+

Figure 9-1. Electrical Tools (Typical) (Sheet 3 of 3)

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 BHT-ELEC-SPM

CHAPTER 10

CONTENTS- CONSUMABLE MATERIALS

Paragraph Chapter Page

Number Title Number Number

10-1 General description ... .. .... ................... .... ....... .. ......... ........ .. .. ... ... .. .... ... 10-00-00 3

Table

Table Page
Number Title Number

10-1 Consumable material list ........ .. ..... ............................... ....... ................. ............................. 4

10-00-00
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 BHT-ELEC-SPM

CONSUMABLE MATERIALS

1o-1. CONSUMABLE MATERIALS. Information Handling Services

Telemarketing Department
Consumable materials required to support the Bell 15 Inverness Way East
Helicopter electrical system are listed in table 10-1 , Englewood, CO 80150
Federal Supply Codes for Manufacturers (FSCM) or
Commercial and Government Entity (CAGE) Codes are U.S. Pho ne Numbers:
listed in the Source column (when known) to provide a 1-800-241-7824 Phone
specific, approved source for material listed. 1-303-799-4085 Fax

NOTE Outside the U.S.:

1-303-790-QSOO, Ext. 59 Phone
Federal Supply Codes for Manufacturers 1-303-799-4097 Fax
(FSCM) listing of vendor names and addresses
(Name-to-Code, or Code-to-Name) may be
obtained from:

1G-OO-OO
Page3
BHT-ELEC-SPM

Table 1o-1. Consumable material list

ITEM CAGEIFSCM/
NO. NOMENCLATURE SOURCE

EC-001 Potassium Hydroxide Commercial

EC-002 Acetone, Q-A-51 Commercial
EC-003 Adhesive 29947-107, Type I, Class 3, (No.7) Spray 97499
EC-004 Adhesive 29947-107 Type II, Class 4 or EC 2126 97499
EC-005 Adhesive 29947-107 Type Ill, Class BIll, or Pro-Seal890 97499
EC-006 Adhesive (Vendor Number EC 776) 763881
EC-007 Adhesive (Vendor Number EC 847) 763881
EC-008 Alcohol, Ethyl, MIL-STD-1201A Commercial
EC-009 Alcohol, Isopropyl, TI-1-735 or P-S-661 Cleaning Solvent Commercial
EC-010 Alcohol, Methyl, 0-M-232 Commercial
EC-011 Aluminum Oxide Cloth, P-C-451 Commercial
EC-012 Anti-Chafing Material MS 339 Spacers Commercial
EC-013 Chemical Film - Compound (MIL-C-81706, Class 1A) (Aiodine 1200 or 1201) Form II Commercial
(Dip Tank) or Ill (Brush On) Apply Per (MIL-C-5541)
EC-014 Chemical Conversion Coating, (MIL-C-81706, Class 3) Commercial
EC-015 Corrosion Preventive Compound (MIL-C-16173, Grade 2) Commercial
EC-016 Corrosive Preventive Compound Type II, (MIL-C-6529) Commercial
EC-01 7 Corrosion Preventive Compound (MIL-C-16173, Grade 3), TECTYL 89 97499
EC-018 Electrolyte 30% KOH Commercial
EC-019 IEstane Accelerator No. A 13438 91427
EC-020 IEstane Cement No. A 15038 91427
EC-021 Estane Primer Thixon P-5 91427
EC-022 Insulation Tubing, Heat Shrinkable (MIL-1-23053/4) 14532
BHT STD 130-054 97499
EC-023 Flux Kester 185, Flux Gardiner 1435 (Use with soft solder for surface conditioning Commercial
before and during soldering process)
EC-024 Freon TF (MIL-C-81302 Type II) Commercial
EC-025 Lockwire (MS20995C32) (0.032 Inch Dia.) Commercial
EC-026 Lockwire (MS20995C41) (0.041 Inch Dia.) Commercial
EC-027 Methylene Chloride (MIL-D-6998) Commercial
EC-028 Naphtha, Aliphatic TI-N-95 Type II Commercial
EC-029 Nitric Acid 0-N-350 Commercial
EC-030 Paint Remover, Alkaline Type, General (MIL-R-81294 or MIL-R-8633A) Turco No. 80244
5469 81349
61102
EC-031 Petrolatum, VV-P-236 Commercial

1o-oo-oo
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 BHT- ELEC-SPM

Table 1o-1. Consumable material list (Cont)

ITEM CAGEIFSCMI
. NO. NOMENCLATURE SOURCE
EC-032 Preservative Oil, Aerosol or Bulk, (MIL-C-81309) 81349
LPS-1, LPS-2, 66724
WD40, 09137
CRC3.36, 10136
ALF-50 (Preferred) Commercial
EC-033 Zinc Chromate Primer, TI-P-1757 Commercial
EC-034 Primer CS9924 M-1 Commercial
EC-035 Primer CS9924 H-1 Commercial
EC-036 Primer, Polyamide Epoxy (MIL-P-23377, MIL-P-85582, Type I.) Refer to text for color. Commercial
EC-037 Sleeve Expando 67755315 Commercial
EC-038 Sleeving, Heat Shrinkable, MMS-809 Commercial
EC-039 Solder, SN60WRMAP, Soft Solder used on Tin-Coated Copper Wire and Coaxial Commercial
Cable
EC-040 Solder, SN62WRMAP, Soft Solder used on Silver-Coated Wire and Silver-Plated Con- Commercial
nections
EC-041 Solder, SN63WRMAP, Soft Solder used on Printed Circuit Boards and Semi-conduc- Commercial
tor Devices
EC-042 Solder, SN60WS, Solid Wire Solder used for General and Electronic Applications. Commercial
(Use with Resin-based flux, Type W.)
EC-043 Solder, SN62WS, Solid Wire Solder used for Silver-Plated Applications Commercial
EC-044 Solder, SN63WS, Solid Wire Solder for Applications that have no Printed Circuit Commercial
Boards and Semi-Conductor Devices
EC-045 Solder, Hard (Brazing Alloy) used when Greater Mechanical Strength or Exposure to Commerc ial
Higher Temperatures is Required 700 to 1600°F (371 to 871 oC)
EC-046 Solvent, Drycleaning, P-D-680 Type II, pH Insignificant Commercial
EC-047 Stripper, LAR 388 Commercial
EC-048 Stripper, Sealant, LAV-388 Commercial
EC-049 Tape, AN-T-12 Commercial
EC-050 Tape, Insulation, No. 34 Commercial
EC-051 Silicone, Adhesive (MIL-T-23594) Commercial
EC-052 Tape, Polyester, Lacing (MIL-T-43435) Commercial
EC-053 Tape, Silicone, Rubber, Reinforced S-25-580 Commercial
EC-054 Tape, Silicone, Rubber (MS70TOS) Commercial
EC-055 Tape, S-1 048 Commercial
EC-056 Tape, Teflon, 29947-11 0 Type Ill Class 1: 3M No. 5490 97499
EC-057 Thinner for Acrylic, Nitrocellulose Lacquer (MIL-T-19544) (Use with Item EC-060) Commercial
EC-058 Thinner, Cellulose, Nitrate, TT-T-32 Commercial
EC-059 Toluene TT-T-548 Commercial
EC-060 Tretrachlorethylene Commercial

1o-oo-oo
PageS
BHT·ELEC·SPM

ITEM CAGEIFSCM/
NO. NOMENCLATURE SOURCE
EC-061 Sealing Compound, Synthetic Rubber (For electrical connectors) Commercial
EC-062 Plastic Coating Compound, Strippable (Hot dipping) (MIL·P-149) Commercial
EC-063 Etchant (For Teflon) Solution (Tetra-Etch) Commercial
EC-064 Primer, Special Potting PR-1523 (Products Research) Commercial
EC-065 Tetrahydrofuran Commercial
EC-066 Chafing Kit, Bas-Kit-010 Benz Airborne System 97499
EC-067 Potting Compound (MIL-C-8516) Commercial
EC-068 Tape, Cellophane 3M #670 Commercial
EC-069 Tubing, Heat Shrinkable (MIL-1-2305315 Class 1) Commercial
EC-070 Sleeving, Heat Shrinkable (thin wall) adhesive-lined (MIL-1-23053/4 Class 2) Commercial
EC-071 Sleevlng, Heat Shrinkable (dual-walled) adhesive-lined (MIL-1-23053/4 Class 3) Commercial
EC-072 Sleeving, Braided, Expandable, 130-053 97499
EC-073 ATUM Tubing (heat shrink) Commercial
EC-074 Sealant Raychem S-1125 Commercial
EC-075 Sodium Bicarbonate Commercial
EC-076 Boric Acid Solution 0-C-265 Commercial
EC-077 Water, Deionized Commercial
EC-078 Water, Distilled Commercial
EC-079 Electrolyte, 30% KOH Commercial
EC-080 Corrosion Preventive Compound (MIL-C-11796, Grade 3) Commercial
EC-081 Methyl-Ethyl-Ketone (MEK) Commercial
EC-082 Butyl Acetate Commercial
EC-083 Sealant, Potting Commercial
EC-084 Braid Metal Sleeving (20-036-11-XX) 97499
EC-085 Chromate Conversion Coating Commercial
EC-086 Adhesive, 3M847 Commercial
EC-087 Straps, MS 3367/MS 3368 Plastic Cable Straps (MIL-S-23190) Commercial
EC-088 Tape, High Temperature Insulation Commercial
EC-089 Sealing Compound (MIL-S-8516) Commercial
EC-090 Antiseize Compound High Temperature (MIL-A-907D) Commercial
EC-091 Cheesecloth Commercial
EC-092 Abrasive Pads (Scotchbrite) Commercial

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 BHT-ELEC-SPM

CHAPTER 11 — NICKEL-CADMIUM ELECTRICAL POWER STORAGE BATTERY

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

NICKEL-CADMIUM ELECTRICAL POWER STORAGE BATTERY

11-1 Nickel-Cadmium Electrical Power Storage Battery.................... 11-00-00 5

11-2 Principal Parts and Materials................................................ 11-00-00 5
11-3 Battery Container.......................................................... 11-00-00 5
11-4 Vented Cell ................................................................... 11-00-00 5
11-5 Cylindrical Sealed Cell.......................................................... 11-00-00 11
11-6 Electrolyte............................................................................. 11-00-00 11
11-7 Principles of Operation .............................................................. 11-00-00 11
11-8 Electrochemical Action ......................................................... 11-00-00 11
11-9 Charge .......................................................................... 11-00-00 11
11-10 Discharge...................................................................... 11-00-00 11
11-11 Capacity ............................................................................... 11-00-00 13
11-12 Factors Affecting Capacity.................................................... 11-00-00 13
11-13 Discharge Rate ............................................................. 11-00-00 13
11-14 Temperature ................................................................. 11-00-00 13
11-15 Discharge Characteristics.......................................................... 11-00-00 13
11-16 Discharge Techniques.......................................................... 11-00-00 15
11-17 Discharge Rates for Capacity Tests ............................. 11-00-00 15
11-18 Constant Current Discharge ......................................... 11-00-00 15
11-19 Discharge with Constant Current Power Supply........... 11-00-00 15
11-20 Fixed Resistance Discharge
(Approximating Capacity) ............................................. 11-00-00 17
11-21 Equalization Discharge ................................................. 11-00-00 17
11-22 Charging Characteristics ........................................................... 11-00-00 17
11-23 Charging Efficiency............................................................... 11-00-00 17
11-24 Charge Techniques .............................................................. 11-00-00 20
11-25 Constant Current Charging........................................... 11-00-00 20
11-26 Constant Potential Charging......................................... 11-00-00 20
11-27 Trickle Charging............................................................ 11-00-00 21
11-28 Thermal Runaway ................................................................ 11-00-00 21
11-29 Overheated Nickel-cadmium Batteries ................................. 11-00-00 22
11-30 Operation of Battery Shop ......................................................... 11-00-00 23
11-31 Training of Personnel ........................................................... 11-00-00 23
11-32 Battery Shop Safety Procedures ............................................... 11-00-00 23
11-33 General Warnings................................................................. 11-00-00 23
11-34 Separation of Nickel-cadmium and Lead-Acid Battery
Facilities................................................................................ 11-00-00 24
11-35 Battery Records.................................................................... 11-00-00 25
11-36 Shop and Helicopter Record of Battery Service ........... 11-00-00 25
11-37 Nickel-Cadmium Battery Service Record ..................... 11-00-00 25
11-38 Special Equipment and Tools............................................... 11-00-00 29
11-39 Calibration of Equipment ...................................................... 11-00-00 29
11-40 Temporary Loss of Capacity................................................. 11-00-00 29
11-41 Cell Gassing ................................................................. 11-00-00 29
11-42 Shock and Vibration ............................................................. 11-00-00 29

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BHT-ELEC-SPM

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

11-43 Extreme Temperature Operation.......................................... 11-00-00 29

11-44 Storage/Shipping .................................................................. 11-00-00 29
11-45 Electrolyte Requirements and Adjustments ......................... 11-00-00 30
11-46 Mixing Electrolyte ......................................................... 11-00-00 30
11-47 Adjustment of Electrolyte Level .................................... 11-00-00 31
11-48 Adding Water ................................................................ 11-00-00 34
11-49 Battery Servicing Procedures ............................................... 11-00-00 34
11-50 Maintenance and Reconditioning Schedules ....................... 11-00-00 34
11-51 Inspection and Maintenance Check ..................................... 11-00-00 37
11-52 Cleaning Procedures .................................................... 11-00-00 37
11-53 Electrical Leak Check ................................................... 11-00-00 38
11-54 Reconditioning Nickel-cadmium Batteries ............................ 11-00-00 39

FIGURES

Figure Page
Number Title Number

11-1 Battery Container............................................................................................ 6

11-2 Battery Construction ....................................................................................... 7
11-3 Stack-up — Preparation ................................................................................. 8
11-4 Terminals are Welded to Stack-up ................................................................. 9
11-5 Entire Unit is Inserted in Cell Case and Sealed.............................................. 10
11-6 Cylindrical Sealed Cell.................................................................................... 12
11-7 Comparison of Discharge Voltage for Typical Lead-Acid and
Nickel-Cadmium Electrical Power Storage Batteries...................................... 14
11-8 Constant Current Power Supply Used as Discharge Unit .............................. 16
11-9 0.5 to 1.0 Ohm Workaid.................................................................................. 18
11-10 Cell Shorting Clips Workaid ............................................................................ 19
11-11 Battery History Card ....................................................................................... 26
11-12 Battery Service Record................................................................................... 27
11-13 Electrolyte Level Checker and Removal Syringe ........................................... 32
11-14 Reading a Hydrometer ................................................................................... 33

TABLES

Table Page
Number Title Number

11-1 Charge and Overcharge Equations ................................................................ 13

11-2 Discharge Equations ...................................................................................... 13
11-3 Internal Resistance — Typical Values ............................................................ 17

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 BHT-ELEC-SPM

TABLES (CONT)

Table Page
Number Title Number

11-4 Nickel-Cadmium Special Equipment and Tools.............................................. 29

11-5 Battery Data.................................................................................................... 35

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 BHT-ELEC-SPM

NICKEL-CADMIUM ELECTRICAL POWER STORAGE BATTERY

11-1. NICKEL-CADMIUM ELECTRICAL The plaque is then impregnated with active material by
POWER STORAGE BATTERY being soaked in a solution of nickel salts to make a
positive plate or in a solution of cadmium salts to make
As numerous nickel-cadmium battery types are used a negative plate (Figure 11-2, Detail A). Soaking is
in Bell Helicopter Textron products, the information repeated until the plaque contains the necessary
contained in this chapter is general in nature. Refer to amount of active material to give it the desired
the battery manufacturers instructions for specific capacity (Detail B). After impregnation, the negative
information concerning servicing and handling and positive plaques are submerged in electrolyte and
procedures. subjected to an electric current, which converts the
nickel and cadmium salts to final form (Detail C). The
plaque is then washed and dried and cut into plates.
11-2. PRINCIPAL PARTS AND MATERIALS
When the cell is assembled, a nickel tab is welded to a
corner of each plate for connection purposes
NOTE (Detail D).
Model 429 helicopters have a lead-acid
battery. Refer to BHT-429-CMM-V, Separator. The separator (Figure 11-3) is a
Chapter 96 for the Teledyne battery continuous thin porous multi-laminate of nylon and
maintenance manual. cellophane, or some other gas barrier material such as
Permion or Celgard, that keeps negative and positive
The fundamental unit of the nickel-cadmium storage plates from coming into contact with each other. In
battery is the cell. The sintered-plate, nickel-cadmium preparing the cell assembly, the continuous separator
cells used in the battery consist of two basic types: is interposed between plates as each successive plate
vented and sealed. Most helicopter nickel-cadmium is added to form a stack-up.
storage batteries employ rectangular vented-type
cells. Sealed cells, of both rectangular and cylindrical Cell. The cell is assembled into its final form by
types, are used in some applications for standby welding tabs of the negative plates to one terminal
power requirements. post and tabs of the positive plates to a second
terminal post (Figure 11-4). Once assembled, it is
11-3. Battery Container inserted into a plastic case and fitted with a
cover-and-vent assembly that permits the terminal
The battery container is a rectangular metal case posts to project through the top of the case. The
enclosing the cells. The container has a removable top complete unit is then sealed. The venting system
to permit access for routine maintenance. Plastic allows excess gasses to escape. A typical cell
liners are used to insulate the inner sides of the assembly is shown in Figure 11-5. The exact number
container. Plastic shims are used to firm up the cell of cells required for a specific battery assembly is
pack within the container (Figure 11-1). determined by the voltage rating of the equipment to
be operated. The nominal voltage of a single
11-4. Vented Cell nickel-cadmium cell ranges between 1.2 and 1.3 volts.
For a 24-volt battery, 19 vented sintered-plate cells are
The principal parts and materials used in vented cells connected in series.
of the nickel-cadmium battery are as follows:
Vent plug. The vent plug on the top of the cell is
Plate. A plate is made from powder in a metallurgy usually constructed of nylon. It can be removed for the
process. Nickel carbonyl powder is lightly compressed addition of distilled water or for adjustment of the
in a mold and then either subjected to a temperature of electrolyte. When excessive gasses develop in the cell
about 1600°F (871°C) in a sintering furnace or to a during charge, they escape through the vent hole,
heavy electric current. These processes cause the which opens when a certain pressure is reached.
individual grains of nickel to weld to their points of Except when releasing gas, the vent automatically
contact, resulting in a porous plaque that is seals the cell to prevent electrolyte leakage and entry
approximately 80% open holes and 20% solid nickel. of foreign material into the cell.

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 5
BHT-ELEC-SPM

(TYPICAL)

ELEC-SPM_11_0001

Figure 11-1. Battery Container

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 BHT-ELEC-SPM

DETAIL A DETAIL B
NICKEL-SINTERED COINED PLAQUE
PLAQUE

ELECTROLYTE

DETAIL D
DETAIL C TABS ARE WELDED
COINED PLAQUE IMPREGNATED TO EACH PLATE
WITH NICKEL OR CADMIUM SALTS
(TYPICAL)
ELEC-SPM_11_0002

Figure 11-2. Battery Construction

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 7
BHT-ELEC-SPM

SEPARATOR

GA NY
S LO
BA N
NY R RI
LO ER
N

PLATE

(TYPICAL)

ELEC-SPM_11_0003

Figure 11-3. Stack-up — Preparation

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 BHT-ELEC-SPM

(TYPICAL)

ELEC-SPM_11_0004

Figure 11-4. Terminals are Welded to Stack-up

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 9
BHT-ELEC-SPM

(TYPICAL)

ELEC-SPM_11_0005

Figure 11-5. Entire Unit is Inserted in Cell Case and Sealed

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 BHT-ELEC-SPM

11-5. CYLINDRICAL SEALED CELL positive plates is brought to a higher state of oxidation
(Table 11-1). These changes continue in both sets of
The cylindrical sealed cell is rechargeable and free of plates as long as charging current is applied, or until
the usual maintenance routines such as adjusting and active material of plates has been completely
checking the electrolyte (Figure 11-6). The electrolyte, converted. The cell emits gas toward the end of this
a viscous solution of potassium hydroxide, does not process because of decomposition of water
take part in the chemical reaction. The active materials components of electrolyte into hydrogen at negative
are contained in molded screens or sintered plates plates and oxygen at positive plates. The electrolyte
that are spirally rolled with a separator to form a core. conducts current between plates of opposite
The core is then jacketed in a metal case that provides polarity and reacts to produce electrochemical
a rigid unit. Generally, the negative plate is welded to changes without producing any significant changes in
the case and the positive plate is welded to the cell its own overall chemical composition. Thus, the
cover. The cover is attached to the case by a plastic measurement of specific gravity of the electrolyte
sealing gasket. A cutaway view of a cylindrical sealed gives no indication of the state of charge in a
cell is shown in Figure 11-6. nickel-cadmium cell.

11-6. ELECTROLYTE The rectangular type of nickel-cadmium cells are

provided with vented cell caps to allow escape of
The electrolyte is normally, by weight, a 30% solution excessive gasses generated during the latter part of
of potassium hydroxide (KOH) in 70% distilled water the charge cycle. In the cylindrical type of cell, which is
(see following formula). It provides a path for current hermetically sealed, it is necessary to dissipate these
that flows between positive and negative plates. The gasses within the cell. This dissipation is achieved by
electrolyte does not take part in the chemical reaction constructing negative plates that have greater
in nickel-cadmium batteries, but acts as an ion carrier. amp/hour capacity than positive plates. The positive
The specific gravity remains the same whether the plate will thus achieve full charge before the negative
battery is in a charged or discharged condition. plate and begin to liberate oxygen into the cell dead
space while the negative plate is still charging, but
ELECTROLYTE II does not liberate hydrogen. However, the negative
30% KOH + 70% H2O plate reacts with oxygen given off by the positive plate
to form cadmium-oxide. Therefore, in overcharge, the
11-7. PRINCIPLES OF OPERATION negative plate is oxidized at a rate that offsets the
charging energy and holds the cell in equilibrium. The
11-8. ELECTROCHEMICAL ACTION length of time this process can continue depends on
cell construction, but excessive overcharging will
The exact chemical reactions that occur within a cell of result in cell rupture.
the nickel-cadmium battery during charge and
discharge are open to question, particularly with 11-10. Discharge
regard to the oxidized states of the active materials.
However, the essential operation can be described. During discharge the chemical reaction is reversed
(Table 11-2). Positive plates gradually return to a state
11-9. Charge of lower oxidation, while negative plates
simultaneously regain lost oxygen. During discharge
When charging current is applied to the cell, process, chemical energy is released as electrical
cadmium-oxide material of the negative plates current through the discharge load. The rate at which
gradually loses oxygen and becomes metallic chemical energy is converted is determined principally
cadmium, and the nickel-oxide active material of by resistance of load to current flow.

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BHT-ELEC-SPM

CELL COVER NYLON SEAL

POSITIVE TAB
SEPARATOR

JACKET

NEGATIVE TAB POSITIVE NEGATIVE

SINTERED SINTERED
PLATE PLATE

(TYPICAL)

ELEC-SPM_11_0006

Figure 11-6. Cylindrical Sealed Cell

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 BHT-ELEC-SPM

Table 11-1. Charge and Overcharge Equations

POSITIVE PLATE NEGATIVE PLATE

Charge: Charge:

2Ni(OH)2+2(OH) 2NiOOH+2H2O+2e Cd(OH)2+2e Cd+2(OH)

(Nickel Hydroxide) (Nickel Oxy Hydroxide) (Cadmium Hydroxide) (Cadmium)

Overcharge: Overcharge:

2(OH) 1/2O2+H2O+2e 2H2 O+2e H2+2(OH)

Table 11-2. Discharge Equations

POSITIVE PLATE NEGATIVE PLATE

2NiOOH+2H2O+2e 2Ni(OH)2+2(OH) Cd+2(OH) Cd(OH)2+2e

(Nickel Oxy Hydroxide) (Nickel Hydroxide) (Cadmium) (Cadmium Hydroxide)

11-11. CAPACITY decrease in temperature from that range causes a

corresponding reduction in cell capacity and charge
Battery capacity can be determined only by making a efficiency.
constant current-time measured discharge. Current is
normally held at the 1/2 C rate until the voltage per cell 11-15. DISCHARGE CHARACTERISTICS
drops to one volt with ambient temperature between
70°F (21°C) and 80°F (26.7°C). The C rate is defined
as the amount of current a battery will deliver if The nickel-cadmium battery is capable of delivering
discharged in 1 hour. For example, a 34 amp/hour very high discharge currents relative to its size. If
battery has a C rate of 34. battery is discharged at currents higher than the
1-hour rate, a noticeable temperature rise may result.
11-12. FACTORS AFFECTING CAPACITY After battery has been discharged in the shop, it shall
be allowed to cool to 77.5°F (25.27°C) before being
The primary factors that influence battery capacity are recharged.
discharge rate and temperature.
A comparison of voltage discharge characteristics for
11-13. Discharge Rate three types of helicopter storage batteries rated at 24
volts and 31 amp/hours is presented in Figure 11-7.
Sustained high current and extreme temperature have Two of these batteries were nickel-cadmium types
a degrading effect on cell capacity. A capacity (one of 20 cells and one of 19 cells). The remaining
measurement is therefore made at the 1/2 C rate. battery was a lead-acid type. The batteries were
discharged at the 1-hour rate of 31 amps. The voltage
11-14. Temperature levels of the nickel-cadmium batteries dropped initially
and then remained somewhat constant almost until
The optimum operating temperature for typical they had reached a state of complete discharge.
rectangular and cylindrical nickel-cadmium cells is 7.5 Voltage level of the lead-acid unit dropped initially and
to 77.5°F (-13.61 to 25.27°C) and an increase or then tended to stabilize.

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BHT-ELEC-SPM

28

26 34 AMPERE-HOURS
BATTERY VOLTAGE (VOLTS)

24

22

20
20-CELL (NICKEL CADMIUM)
19-CELL (NICKEL CADMIUM)
18
(LEAD ACID)

0 10 20 30 40 50 60 70 80 90 120

DISCHARGE TIME (MINUTES) AT 31-AMPERE RATE

ELEC-SPM-11-7

Figure 11-7. Comparison of Discharge Voltage for Typical Lead-Acid and Nickel-Cadmium Electrical
Power Storage Batteries

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 BHT-ELEC-SPM

An important characteristic of a nickel-cadmium 11-19. Discharge with Constant Current Power

battery is that voltage remains almost constant under Supply
normal operating conditions until approximately 95%
of capacity has been delivered (Figure 11-7).
Any constant current power supply can be used to
constant-current discharge a battery provided the
11-16. DISCHARGE TECHNIQUES voltage range and current range of the power supply
are adequate. Figure 11-8 shows the proper method
for using a constant current power supply to discharge
NOTE a battery. The values of components used in
Figure 11-8 are as follows:
Refer to the battery manufacturers
instructions for specific information on
discharge procedures. • Storage Battery. Battery that is to be
discharged.
The amount of electrical energy available from a fully
charged nickel-cadmium battery is defined by the • A. Ammeter of proper value to measure
rating of the battery and is stated in terms of amp/ discharge current.
hours. A reduction in the capacity of a nickel-cadmium
battery occurs at high discharge rates, and an
improvement in capacity occurs at low discharge • V. Voltmeter of proper value to measure
rates. battery voltage.

11-17. Discharge Rates for Capacity Tests • RL. Load resistor whose resistance value is
determined by dividing open circuit voltage of
the battery by discharge current; e.g., 25.0
NOTE volts divided by 18.0 amps equals 1.39 ohms.
A resistance of 1.5 ohms or 2.0 ohms could be
The normal rated capacity used throughout used in this example as they are of a more
this manual is the 1-hour capacity at 80°F common value. The wattage of the resistor is
(26.7°C) determined by P = I2R.

The amp/hour rating for batteries used in helicopters is

• Power Supply. The power supply must be a
based on a 1-hour discharge rate. Example, the
constant-current device with adequate voltage
capacity test of a 19-cell, 18-amp/hour battery would
and current range. Voltage output of the
consist of discharging the battery at a rate of 18 amps
power supply must be as great as the decline
(after it has been charged) until the terminal voltage
in voltage of the battery during discharge; e.g.,
drops to 18.0 volts (0.95 volt/cell). This point will be
a battery with an open circuit voltage of 25.0
reached at the end of 1 hour, or longer, if the battery is
volts is to be discharged to 18.0 volts. This is a
capable of delivering its rated amp/hour capacity.
voltage drop of 7.0 volts, therefore, the power
Some battery manufacturers recommend a discharge
supply must have a voltage range of 7.0 volts.
rate of C/2.
The power supply can have a voltage range
that is greater than the voltage drop of the
11-18. Constant Current Discharge battery, but not less.

The most accurate and repeatable methods of During the discharge, the current through the circuit is
measuring capacity is to discharge the battery at a controlled by the current control device in the power
constant current rate. The load resistance in the supply. The power supply and battery are connected in
method is varied to maintain a constant discharge series and total voltage of both items is impressed
current as the battery voltage decreases. At the end of across the load resistor. (Figure 11-8, View A). The
discharge, the calculation of amp/hour capacity is the output voltage of the power supply increases as the
product of the discharge current times the elapsed battery voltage decreases thereby keeping voltage
discharge time. constant across the load resistor.

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ECCN EAR99 20 JUL 2012 Rev. 2 Page 15
BHT-ELEC-SPM

+ 
A

+ + 
STORAGE V
BATTERY
 POWER
 SW SUPPLY

SEE VIEW A
R
L

R
L

ALIGATOR CLIPS
COVERED WITH
INSULATED SLEEVING

VIEW A
RL LOAD RESISTOR WORKAID

ELEC-SPM-11-8

Figure 11-8. Constant Current Power Supply Used as Discharge Unit

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 BHT-ELEC-SPM

11-20. Fixed Resistance Discharge Since nickel-cadmium cells have extremely low
(Approximating Capacity) internal resistance (Table 11-3). A severely discharged
battery will initially draw very high currents if charged
A method for approximating capacity is to place a fixed by the constant potential method. Because of high
resistor (Figure 11-9) across the battery terminals and current initially drawn by a discharged battery, and
monitor the current and time as the battery discharges. when using the constant potential method of charging,
As the battery discharges, the current drops as the it is advisable to use charging equipment with built-in
battery voltage decreases. To calculate capacity, protective circuitry. Constant potential charging
multiply the average discharge current by the equipment should be capable of delivering current of
discharge time. at least three times the capacity rating of the battery.

11-21. Equalization Discharge Table 11-3. Internal Resistance — Typical Values

Part of the task of reconditioning is an equalization CELL SIZE PLATE MILLIOHMS

discharge or deep cycle. Nickel-cadmium battery AMP/HOURS TYPE PER CELL
capacity does not decrease appreciably with age.
44 SP 0.5
However, there can be a temporary loss of capacity
under certain duty cycles. A temporary loss of capacity 40 SP 0.5
is normally an indication of imbalance between cells.
36 H 0.8
Imbalance can be caused by differences in
temperature, charge efficiency, self discharge rate, 28 SP 0.5
etc. The purpose of deep cycling is to restore a battery
24 H 0.9
to its full capacity and to prevent premature damage
and failure. 24 M 1.1
24 SP 0.75
NOTE 17 SP 0.85
After an individual cell has been 10 H 1.1
determined to be defective, it should be
removed from the battery and identified so 5 H 2.0
as never to be installed in a battery. One 3 H 4.0
method is to spray paint the entire cell red.
A better method is to destroy the cell in NOTES:
accordance with a locally approved SP = Super Power
procedure.
H = High rate
A battery may be equalized by placing individual M = Medium rate
shorting clips across each cell in the battery when
voltage is less than 1 volt. A shorting clip is shown in
11-23. CHARGING EFFICIENCY
Figure 11-10. The shorting clip should remain on the
cells at least 14 hours after the cell voltages reach 0
Charging efficiency is the ratio of amp/hours attained
potential, to ensure a complete discharge. A battery
on discharging to amp/hours returned to a battery
shall not be discharged by placing a resistor across
during charge; this ratio is always less than 1-to-1.
the entire battery as this will cause imbalance of the
Therefore, an excess of charge must always be
individual cells within the battery.
returned to the battery after discharge to restore full
capacity. The total charge necessary may be as low as
11-22. CHARGING CHARACTERISTICS 110% depending on temperature and cell
characteristics. It is generally recommended that the
nickel-cadmium battery be charged for a time that will
NOTE
give 140% of the previously discharged amp/hours.
Refer to the battery manufacturers For example, a battery having been discharged
instructions for additional information 18 amp/hours would be recharged until 1.4 x 18 amp/
concerning charging characteristics. hours are returned to the battery.

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Figure 11-9. 0.5 to 1.0 Ohm Workaid

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Figure 11-10. Cell Shorting Clips Workaid

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11-24. CHARGE TECHNIQUES Any constant current charge or power supply may be
used to charge a nickel-cadmium battery if current and
voltage ratings of the unit are adequate. Generally, a
C/10 charging rate (rated capacity, C, of the battery
WARNING divided by 10) is a safe charging rate. A voltage limit is
not necessary as the charging rate will not overcharge
cells to any great extent. This rate will require
I F T E M P E R AT U R E O F A N I C K E L - approximately 16 hours of charging to fully charge a
CADMIUM BATTERY EXCEEDS 100°F completely discharged battery. Refer to the battery
(37.8°C) WHILE BEING CHARGED ON manufacturer's service manual for recommended
NON-AUTOMATIC TYPE OF CHARGING charging instructions.
EQUIPMENT, THE CHARGE SHALL BE
T E R M I N AT E D . THERE IS NO When a vented or sealed nickel-cadmium battery is
R E Q U I R E M E N T TO M O N I TO R T H E constant current charged on non-automatic type of
TEMPERATURE OF A NICKEL-CADMIUM equipment, the battery voltage, charging current, and
BATTERY THAT IS BEING CHARGED ON battery temperature should be monitored frequently to
A U T O M AT I C T Y P E O F C H A R G I N G minimize any damage that can occur from excessive
EQUIPMENT UNLESS SPECIFIED BY charging or equipment malfunction. The temperature
BATTERY MANUFACTURER OR OTHER of vented batteries may be monitored by placing a
AUTHORITY. suitable thermometer (liquid-in-glass, thermocouple,
thermistor) in, or adjacent to a centrally located cell. A
deterioration of potassium hydroxide electrolyte can
NOTE
take place when vent caps of vented nickel-cadmium
Refer to the battery manufacturers cells are removed and electrolyte is exposed to the
instructions for specific information. atmosphere. Vented nickel-cadmium batteries shall be
charged with vent caps loose but in place. Vent caps
The three charge techniques currently used are may be removed to allow for the inspection of the
constant current (paragraph 11-25), constant potential interior of the cell, inspection of vent caps, adjustment
(paragraph 11-26), and trickle charging (paragraph of the electrolyte levels, or measurement of the
11-27). electrolyte temperature. The temperature of sealed
batteries may be monitored by placing thermometer
11-25. Constant Current Charging adjacent to the battery case in the area of greatest
heat concentration.

NOTE 11-26. Constant Potential Charging

Refer to the battery manufacturers
instructions for specific information. NOTE
Refer to the battery manufacturers
The constant current method is the preferred method instructions for specific information.
of charging nickel-cadmium batteries. As the name
implies, the charge current remains at the constant The constant potential charging method is the fastest
rate regardless of the voltage of the battery. The method of charging a nickel-cadmium battery,
constant current method is effective in correcting cell however, a disadvantage of constant potential
imbalance and temporary loss of capacity, and it charging is that full capacity cannot normally be
permits easy computation of charge capacity in restored if a battery suffers from temporary loss of
amp/hours. capacity.

Time required to charge a nickel-cadmium battery by Vented 19-ceII 24-volt nickel-cadmium batteries will
constant current methods depends on the state of normally be charged in the shop at 28.5 volts when
charge of the battery, charging current, and actual charging with a constant potential voltage. Note that
capacity of the battery. On average, a nickel-cadmium charging a 19-cell battery at 28.5 volts is equivalent to
battery will require a recharge of 140% of the previous charging each cell at 1.50 volts. Initial charging current
discharge. may be as high as 10 times the amp/hour rating of the

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 BHT-ELEC-SPM

battery, depending on the state of charge of the 11-27. Trickle Charging

battery. High initial current will not damage the battery,
but charging equipment should have an inherent
current-limiting capability or be provided with overload CAUTION
protection; a generator capable of delivering at least
300 amps provides an adequate constant potential
charging source. DUE TO THE POSSIBILITY OF A CELL
SHORTING WHILE ON TRICKLE
CHARGE, THE CHARGING CIRCUIT
MUST BE LIMITED AS TO THE
C U R R E N T I T W I L L S U P P L Y. T H E
CAUTION
ELECTROLYTE LEVEL MUST BE
MONITORED AND ADJUSTED TO
INTRODUCTION OF MONITORING COMPENSATE FOR WATER LOSS.
AMMETER INTO THE CHARGE CIRCUIT
MUST BE DELAYED FOR NOTE
APPROXIMATELY 5 MINUTES TO Refer to the battery manufacturers
PROTECT METER FROM POSSIBLE instructions for specific information.
DAMAGE DUE TO CHARACTERISTIC
Trickle charging may be used to maintain the battery in
HIGH CURRENT IN THE EARLY a fully charged condition. The charged battery is
CONSTANT-POTENTIAL CHARGING connected to a constant current or constant potential
STAGE. DC source for charging at a rate sufficient to
compensate for the internal losses. The constant
Time required to charge will depend primarily on the current used is 0.4 to 1.0 milliamperes/amp/hour, and
the corresponding potential is 1.35 to 1.36 volts/cell.
current delivery capability of the charging source. The
When a trickle charged battery has been discharged it
lower the charging current, the longer the time must be recharged by means of a separate charger/
required to charge. Near full charge may be restored analyzer.
within 1 hour at 28.5 volts charging potential, provided
the charging source is also capable of delivering 11-28. THERMAL RUNAWAY
current equal to 2 to 3 times the amp/hour rating of
battery. For monitoring purposes, an ammeter should NOTE
be connected in series with the battery and power
Refer to the battery manufacturers
source. instructions for additional information.

Charging should continue until ammeter indicates a Thermal runaway is a condition in which current for a
charged nickel-cadmium battery rises out of all
current flow of 1 amp or less, or until a maximum time
proportion to the charging voltage.
of 4 hours has elapsed. Should a battery be severely
discharged, charging by the constant potential method Thermal runaway occurs in an overcharged state.
may produce a slight imbalance in cell capacity. After the battery is fully charged, excess charging
Imbalance can be detected by a periodic check of cell energy is dissipated as heat. Continued overcharging
terminal voltages with a precision voltmeter after under certain conditions has the effect of reducing
charging current levels off and while battery is internal battery resistance so that it draws a higher
current from the charging voltage. As temperature of
charging. Should voltage spread between the highest
the battery increases, the effective internal resistance
and lowest cell exceed 0.35 volt, the battery shall be continues to decrease, and current becomes
subjected to an equalization discharge (paragraph progressively greater. This process continues and
11-21). eventually destroys the battery.

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BHT-ELEC-SPM

Thermal runaway may be detected by the following

signs: WARNING

• Battery temperature shows a significant rise at

the end of charge above 100°F (37.81°C). T O A V O I D I NJ UR Y, US E E X T RE M E
CAUTION IF YOU APPROACH AN
• Current gradually rises rather than gradually OVERHEATED NICKEL-CADMIUM
decreasing. BATTERY. PROTECTIVE CLOTHING
INCLUDING HEA D PROTECTION, A
FULL FACE SHIELD, A FULL LENGTH
• If constant current charging method is used, RUBBER OR PLASTIC APRON WITH
runaway will be indicated by a decrease of ARM PROTECTION, AND LONG RUBBER
battery voltage rather than an increase. GLOVES ARE REQUIRED AS A
MINIMUM. IF AVAILABLE, CALL THE
11-29. OVERHEATED NICKEL-CADMIUM FIRE DEPARTMENT FOR ASSISTANCE.
BATTERIES

WARNING
NOTE
Refer to the battery manufacturers
instructions for additional information. IF THE BATTERY IS ON FIRE AND
FLAMES ARE PRESENT, A C02 FIRE
When a nickel-cadmium helicopter battery is being EXTINGUISHER SHALL BE USED TO
serviced in the battery shop on a charger/analyzer, it is EXTINGUISH THE FIRE. DO NOT USE A
highly unlikely that the entire battery will overheat to C02 FIRE EXTINGUISHER IF FLAMES
the dangerous levels sometimes experienced aboard ARE NOT PRESENT, AS THE STATIC
a helicopter. This is because of voltage and current DISCHARGE FROM THE FIRE
control offered by the charger. A true thermal runaway EXTINGUISHER NOZZLE MAY IGNITE
does not occur when the battery is on the charger/ ANY EXPLOSIVE GASSES THAT ARE
analyzer, as by definition. In a thermal runaway the PRESENT WITHIN THE BATTERY SHOP.
charge current increases as battery impedance
decreases, the charge current of the charger/analyzer 1. If the battery is not on fire or fire has been
is present and fixed. extinguished, the personnel required to handle the
battery shall dress with protective gear to complement
their standard work clothes.
It is possible, however, for individual cells within a
battery to overheat to dangerous levels. This occurs 2. Turn off the charger/analyzer and disconnect the
when separator material within a cell breaks down and charge/discharge cable from the battery. The cable
allows a negative and a positive plate to make contact should be removed in such a manner as to direct any
with each other. This action creates a hot spot that is electrolyte spewage away from the personnel
characterized by increased pressure within the cell, involved.
which forces hot electrolyte, steam, and smoke from
the cell vent cap. This hot spot can progressively burn
3. Place a battery cover on the battery. Quickly
itself from one cell to the next unless the cell pack can
transport the battery to a location where the battery
be cooled down.
case can be flooded with cold water. A deep sink,
water spigot, garden hose, etc., will suffice.
Although explosive gasses can be discharged from an
overheated nickel-cadmium battery, the greatest 4. Remove the cover and fill battery case with cold
hazard to battery shop personnel is spewing of hot water. The water should cover the cell pack completely
electrolyte. and it should be allowed to run to dissipate heat within
the cells. Dropping the battery into a container of
Overheated nickel-cadmium batteries shall be handled sufficient size that is full of water may also be used as
as follows: an alternate method of cooling the battery.

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 BHT-ELEC-SPM

5. After the battery cools to the point where gas ARTICLES, SUCH AS WATCH BANDS,
bubbles are no longer visible, water may be dumped BRACELETS, AND RINGS SHOULD BE
from the case and the battery disassembled and REMOVED BEFORE WORKING WITH
repaired. NICKEL-CADMIUM BATTERIES.
INADVERTENT CONTACT OF THESE
This previous procedure is also the procedure for METALLIC OBJECTS WITH CURRENT
handling overheated nickel-cadmium batteries aboard CARRYING PARTS OF THE BATTERY
the helicopter. WOULD RESULT IN THE FUSING OF THE
METAL, VERY HIGH TEMPERATURE, AND
11-30. OPERATION OF BATTERY SHOP SEVERE BURNS TO THE WEARER.

In addition to the following information on battery shop • TOOLS USED TO SERVICE

operation, also refer to information provided by the NICKEL-CADMIUM BATTERIES SHOULD
battery manufacturer. BE COVERED WITH INSULATING
MATERIAL. METAL TOOLS DROPPED INTO
11-31. TRAINING OF PERSONNEL THE BATTERY WILL SHORT-CIRCUIT
CONNECTOR BARS AND CAUSE ARCING,
Servicing of a nickel-cadmium battery requires highly WHICH CAN DAMAGE THE BATTERY AND
skilled personnel. It is recommended that personnel CAUSE INJURY TO THE TECHNICIAN.
engaged in servicing these batteries receive a
minimum of 40 hours of specialized training in the care • THE GASSES EVOLVED FROM A
and servicing of nickel-cadmium batteries. Use of CHARGING BATTERY ARE A MIXTURE OF
properly trained personnel in maintenance and HYDROGEN AND OXYGEN GASSES THAT
servicing of the batteries cannot be overemphasized. WOULD PRESENT AN EXPLOSIVE
The official or individuals responsible for the avionics/ HAZARD IF A SPARK OR FLAME OCCURS
electrical shop (or maintenance facility), shall make NEAR THEM. THEREFORE, THE AREA
sure that all personnel concerned with battery WHERE TESTING IS PERFORMED SHALL
servicing and handling are qualified and are fully BE WELL VENTILATED AND NO SMOKING
aware of proper safety precautions. Personnel training OR OTHER ACTIVITY THAT MAY
records should show that these qualifications were GENERATE SPARKING SHALL BE
authenticated. Normally, personnel with aviation PERMITTED IN THE IMMEDIATE AREA.
electrician ratings will be assigned to the battery shop.
• WHEN NECESSARY TO MOVE OR ALTER
11-32. BATTERY SHOP SAFETY AN EXISTING TEST SETUP,
PROCEDURES CONNECTIONS SHALL BE REMOVED
FIRST FROM THE BATTERY OR POWER
In addition to the safety precautions specified by the SUPPLY AND THEN FROM THE MEASURE
battery manufacturer, the following safety precautions EQUIPMENT. THIS WILL ELIMINATE THE
shall also be observed at all times when working in a CHANCE OF SHORTING AND SPARKING,
nickel-cadmium battery shop. WHICH COULD RESULT IN AN EXPLOSION
OR INJURY FROM EXCESSIVE HEAT.
11-33. GENERAL WARNINGS
• ALL ACTUATING SWITCHES ON CONTROL
• ONLY AUTHORIZED PERSONNEL UNIT SHALL BE IN THE OFF POSITION
INSTRUCTED IN MAINTENANCE PRIOR TO CONNECTING OR
PRECAUTIONS AND ASSOCIATED DISCONNECTING A BATTERY.
HAZARDS SHOULD BE ASSIGNED.
• WHEN NECESSARY TO REMOVE THE
• BECAUSE SERIOUS INJURY CAN RESULT CONNECTORS OR CABLES FROM THE
FROM CARELESSNESS WHILE HANDLING CHARGE UNIT PANEL, EXTREME
AND WORKING WITH NICKEL-CADMIUM CAUTION MUST BE EXERCISED WHEN
BATTERIES, CERTAIN PRECAUTIONS INSTALLING THEM TO ENSURE PROPER
MUST BE OBSERVED. ALL METAL POLARITY AND FIT.

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BHT-ELEC-SPM

• CAUTION MUST BE OBSERVED WHEN 11-34. SEPARATION OF NICKEL-CADMIUM AND

HANDLING BATTERIES. SERIOUS INJURY LEAD-ACID BATTERY FACILITIES
COULD OCCUR BY LIFTING AND
HANDLING INCORRECTLY. ALL
PERSONNEL INVOLVED SHALL BE MATERIALS REQUIRED
PROPERLY INSTRUCTED IN CORRECT
LIFTING AND HANDLING TECHNIQUES. Refer to BHT-ALL-SPM for specifications.

• CLOTHING AND EQUIPMENT WORN OR NUMBER NOMENCLATURE

USED WHILE WORKING WITH BATTERIES
SHOULD BE OF A TYPE NOT LIKELY TO C-488 Sodium Bicarbonate
STORE A STATIC ELECTRICAL CHARGE.
C-489 Boric Acid

• BATTERIES, EQUIPMENT, AND SPACES

MUST BE KEPT CLEAN. POTABLE TAP Nickel-cadmium batteries use potassium hydroxide
WATER IS ADEQUATE FOR CLEANING and distilled water as an electrolyte. Chemically, this
BATTERY SURFACES. electrolyte is the opposite of an acid.

• DELUGE SHOWER AND EYE WASH SHALL

BE PROVIDED. CAUTION

• DO NOT MAKE REPAIRS TO BATTERY

CONNECTIONS WHILE CIRCUIT IS SINCE THE ELECTROLYTE USED IN
ENERGIZED. LEAD-ACID BATTERIES IS A STRONG
SOLUTION OF SULFURIC ACID AND
• MAKE SURE THAT BATTERY SHOP IS DISTILLED WATER, IT IS IMPERATIVE
EQUIPPED, AT ALL TIMES, WITH FIRST AID THAT NICKEL-CADMIUM BATTERIES BE
MATERIAL, PROPERLY LABELED FOR SEPARATED FROM THE LEAD-ACID
NEUTRALIZATION OF ELECTROLYTE THAT TYPES.
MIGHT COME IN CONTACT WITH THE
SKIN. WASH EYES WITH WATER ONLY. Anything associated with the lead-acid batteries (acid
fumes included) should never come in contact with a
nickel-cadmium battery or its electrolyte. Even traces
• DO NOT CARRY ELECTROLYTE IN of sulfuric acid from lead-acid batteries entering the
OPEN-TOP CONTAINERS. KEEP GLASS electrolyte of a nickel-cadmium battery will result in
CONTAINERS PROTECTED AGAINST damage. Acid fumes can damage the hardware of the
BREAKAGE. nickel-cadmium battery.

• CONTAINERS OF ELECTROLYTE SHOULD

Separate battery shops, or at least separate rooms
NEVER BE PLACED NEAR HEATING PIPES
shall be used. The usual battery shop benches, tools,
OR ALLOWED TO STAND IN DIRECT
and other equipment used with lead-acid batteries are
SUNLIGHT.
contaminated by sulfuric acid, which will damage
nickel-cadmium batteries. Potassium hydroxide
• WEAR CHEMICAL GOGGLES, APRON, AND electrolyte of nickel-cadmium batteries will also
RUBBER GLOVES WHEN ADJUSTING OR damage lead-acid batteries.
HANDLING ELECTROLYTE.
Tools and equipment used for the different battery
• ANY NICKEL-CADMIUM BATTERY types should also be color-coded so that they will not
EQUIPMENT WITH AN MS3509 be used interchangeably. If the use of paint to
RECEPTACLE, THAT LEAVES THE color-code tools is contrary to the tool control program
BATTERY SHOP, SHALL HAVE A because of Foreign Object Damage (FOD), the use of
PROTECTIVE PLASTIC COVER(S) OVER hand-dipped insulation should be considered. Ideally,
THE RECEPTACLE PINS. the color-code should be red (pink) for the lead-acid

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 BHT-ELEC-SPM

shop and blue for the nickel-cadmium shop. The on the main body of the battery whenever
color-coding or tools and the color-codes used shall be possible.
as directed by the local tool control.
A form similar to that shown in Figure 11-11 shall be
affixed to each main and spare nickel-cadmium
If there is a shortage of tools and it becomes
helicopter battery as a record of battery service. The
necessary to use the same tools for both the
use of the form on avionics batteries is optional. The
nickel-cadmium and lead-acid batteries, neutralize the
form shall be completed as follows:
tools of any acid contamination prior to use on
nickel-cadmium batteries.
• Serial number. Manufacturers serial number
of the battery, or serial number assigned by
Tools can be neutralized for acid by rinsing them in the user.
clean water, preferably hot water and then immersing
them in a solution of sodium bicarbonate (C-488),
• Cell manufacturer. The manufacturer of the
followed by an additional rinse with clean tap or
cells that make up the battery. This may be
distilled water.
different from the manufacturer of the battery
case.

WARNING • Battery type. The standard number of the

battery.

MAKE SURE THAT A PREMIXED • Helicopter type. The type helicopter in which
CONTAINER OF 3% BY WEIGHT BORIC the battery is installed.
ACID (C-489) IS READILY AVAILABLE TO
CLEAN TOOLS AND NEUTRALIZE • Rated capacity. The rated capacity of the
S P IL L S O N S K IN . D O NO T US E T O battery as determined by the AH standard for
FLUSH EYES. the battery.

A 3% by weight boric acid (C-489) may be used as a • Maintenance interval days. The
neutralizing agent for cleaning tools contaminated with maintenance interval for the battery as
potassium hydroxide solution. In this case, also, use established by the user.
water freely to rinse.
• Next service due date. Date battery is due
for servicing as determined by the user,
11-35. BATTERY RECORDS
figured from the date of issue.

Proper maintenance is essential if the battery is to • Battery issued date/activity. Date the battery
achieve maximum life and performance. Associated leaves battery shop and activity performing
with good maintenance practices is the keeping of maintenance.
accurate records. These records serve as a
verification of maintenance accomplished, provide
• Helicopter number. Serial/registration
information for determining usage rates, establish
number of helicopter.
optimum servicing procedures, and determine cause
for removal of battery from helicopter.
• Initials. The initials of the individual that
installed the battery on the helicopter.
11-36. Shop and Helicopter Record of Battery
Service 11-37. Nickel-Cadmium Battery Service Record

Unless otherwise provided by the battery

NOTE
manufacturer or other accepted source, use and retain
The history card should be posted where it the form shown in Figure 11-12 for each
is visible to inspectors. It should be placed nickel-cadmium battery serviced in the battery shop.

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BHT-ELEC-SPM

NICKEL-CADMIUM HELICOPTER BATTERY HISTORY CARD

SERIAL NO. CELL MFR BATTERY TYPE HELICOPTER TYPE RATED CAPACITY MAINT INTERVAL

AH DAYS
BATTERY SERVICING HELICOPTER INSTALLATION
NEXT SERVICE BATTERY ISSUED HELICOPTER SERIAL\
TAIL NUMBER INITIALS
DUE DATE DATE ACTIVITY

ELEC-SPM-11-11

Figure 11-11. Battery History Card

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 BHT-ELEC-SPM

NICKEL - CADMIUM BATTERY SERVICE RECORD

ORGANIZATION DATE HELICOPTER NO. HELICOPTER TYPE

BATTERY MANUFACTURER BATTERY TYPE SERIAL NO. DATE LAST ISSUED

A- Inspect for: YES NO Clean:

CASE AND/COVER DAMAGE

CELLS: LEAKING BATTERY CASE AND COVER

VENT CAPS (MISSING/BROKEN)

DETERIORATION

DAMAGE CONNECTORS, LINKS, CELL TOPS

CORROSION: LINKS, CONNECTORS

B- Electric leakage test:

LEAKAGE CURRENT: _________ MILLIAMPS/+ TERM. TO CASE _________ MILLIAMPS/- TERM. TO CASE
NOTE: LESS THAN 1.0 MA/RATED A/H ALLOWED. IF EXCESSIVE PERFORM STEP C. THEN F.

C- Capacity determination charge: TIME: start ______ finish ______

1- FIVE TO TEN MINUTES AFTER TURNING ON CHARGER, MONITOR THE ON-CHARGE VOLTAGE OF EACH CELL.
A. LOW VOLTAGE (LESS THAN 1.0 VOLT, SHORTED CELLS, REVERSE POLARITY).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

INDICATE DISCREPANT CELLS

STOP CHARGING OPERATION IF ANY CELL IS SHORTED, MEASURES LESS THAN 1.0 VOLT,
OR HAS REVERSE POLARITY. PERFORM STEP F. THEN STEP G.
2- DURING THE LAST TEN MINUTES OF INITIAL ON-CHARGE, MEASURE THE VOLTAGE OF EACH CELL.
A. CELL VOLTAGE BELOW AVERAGE (0.1 VOLT LESS THAN AVERAGE OF ALL CELLS).
B. CELL VOLTAGE ABOVE ANY MINIMUM CELL VOLTAGE (VOLTAGE OF 0.1 VOLTS OR GREATER THAN CELLS
ABOVE MINIMUM (1.4 VOLTS) CELL VOLTAGE).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

INDICATE DISCREPANT CELLS

A VOLTAGE LESS THAN 1.4 VOLTS INDICATES DAMAGED CELL. PERFORM STEP F. THEN STEP G.
HIGH VOLTAGE INDICATES CELL LOW IN ELECTROLYTE. (ADD ONE (1)/TWO (2) DROPS OF DISTILLED
WATER TO LOWER HIGH VOLTAGE.
3- AFTER 54 MINUTES OF DISCHARGE (1- HOUR RATE) OR 1 HOUR 48 MINUTES (2.0 HOUR RATE) CHECK
THAT EACH CELL IS AT LEAST 1.0 VOLT.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

INDICATE DISCREPANT CELLS

A. IF ALL CELLS MEASURE OVER 1.0 VOLT, ALLOW THE DISCHARGE TO CONTINUE. *
B. IF ANY CELL MEASURES LESS THAN 1.0 VOLT, PERFORM STEP D. AND E. ,THEN C.
* THE CHARGER/ANALIZER AUTOMATICALLY MAKES A GO/NO-GO DECISION AS TO BATTERY CAPACITY AT THE
END OF THE DISCARGE CYCLE.
C. CAPACITY TEST YIELD ________ AMPERE HOURS.
SIDE 1
ELEC-SPM-11-13

Figure 11-12. Battery Service Record (Sheet 1 of 2)

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BHT-ELEC-SPM

NICKEL - CADMIUM BATTERY SERVICE RECORD

D-Cell equalization (Deep discharge)
USING CHARGER/ANALYZER, DEEP DISCHARGE FUNCTION, ALLOW BATTERY TO DISCHARGE UNTIL
1. INDIVIDUAL CELLS DROP BELOW 0.50 VOLT.
SHORT OUT INDIVIDUAL CELLS (BELOW 0.50 VOLT). CONTINUE THIS PROCESS UNTIL OVERALL
2. BATTERY VOLTAGE DROPS BELOW 10 VOLTS. CONNECT INDIVIDUAL 5 WATT 1/2 OHM SHORTING
RESISTORS ACROSS ALL REMAINING BATTERY CELLS.
3. BATTERY SHORTED MINIMUM OF 16 HOURS.

REPLACE DAMAGED CELLS (LEAKING, SHORTED). CELLS THAT FAIL TO CHARGE ABOVE MINIMUM
4. VOLTAGE SHOULD BE DEEP CYCLED TWO/THREE TIMES BEFORE BEING DISCHARGED.

E-Charge after equalization TIME: start ______ finish ______

1. REMOVE ALL SHORTING STRAPS AND PREPARE BATTERY FOR CHARGING.

2. PERFORM CAPACITY DETERMINATION CHARGE PER STEP C.

3. CAPACITY TEST YIELD ________ AMPERE-HOURS.

F-Cell discharge and disassembly

(Cells marked for replacement and cleaning)
CELLS EQUALIZED (DISCHARGED)
1. 5. CLEAN AND DRY ALL PARTS.
MINIMUM FOUR HOURS. STEP D.
REASSEMBLE BATTERY USING
2. DISASSEMBLE BATTERY FOR REPAIR. 6. PROPER TORQUE VALUES.
REMOVE DEFECTIVE CELLS, REPLACE WITH IF CELLS REPLACED, PROCEED
3. NEW/SERVICEABLE CELLS (DISCHARGED TO ZERO VOLTS). 7.
TO STEP E, THEN STEP C.
REPLACE DEFECTIVE PARTS, VENT IF NO CELLS REPLACED, PROCEED
4. 8.
CAPS CONNECTORS, ETC. TO STEP G.

G-Final charge (No cells marked for replacement).

CELL, VENT CAPS CLEANED AND BATTERY CONTAINER AND COVER
1. 5.
CONTAINER VENTS CHECKED FOR OBSTRUCTIONS. PROPERLY MARKED.

2. CHARGE COMPLETED 6.
ELECTRICAL LEAKAGE WITHIN
TIME_________ LIMITS AS PER STEP B.
ELECTROLYTE ADJUSTED INTERCELL CONNECTORS COATED
3. 7.
TIME_________ WITH CORROSION PREVENTIVE.

4. INTERCELL AND TERMINAL CONNECTIONS 8. CELL VOLTAGE BALANCED WITHIN LIMITS.

TORQUED TO PROPER VALUES.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

ACTUAL READINGS OPTIONAL

REMARKS

DATE SERVICING COMPLETED __________________ BOOST CHARGED OR TRICKLE DATE ISSUE FOR
____________ CHARGED BEFORE ISSUED __________ INSTALLATION___________

CERTIFIED BY (SIGNATURE AND TITLE) _____________________________________________________ DATE ______________

SIDE 2
ELEC-SPM-11-12

Figure 11-12. Battery Service Record (Sheet 2 of 2)

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11-38. SPECIAL EQUIPMENT AND TOOLS charge efficiency, and self-discharge rate. Full
capacity is regained when the battery is deep cycled.
In addition to the charger/analyzer, and those
specified by the battery manufacturer, the materials In order to minimize the loss-of-capacity problem,
and tools listed in Table 11-4 are recommended for nickel-cadmium batteries shall be removed from the
servicing nickel-cadmium batteries. helicopter for servicing in accordance with
maintenance and reconditioning schedules.
Table 11-4. Nickel-Cadmium Special Equipment
and Tools 11-41. Cell Gassing

EQUIPMENT AND TOOLS The tendency of nickel-cadmium cells to gas during

the charge increases with cell temperature for a given
Apron, rubber/plastic Applicator, retaining cell voltage. Cell gassing characteristics will vary
ring somewhat among manufacturers and cell types. A
certain amount of gassing is necessary for a battery to
Charger/analyzer Brushes, acid, artist,
become fully charged. The danger is in excessive or
paint violent gassing, which might occur under abnormal
Gloves, rubber Flashlight conditions in a helicopter, leading to possible
explosion or damage to the battery.
Goggles, chemical Gauge, receptacle pin
11-42. SHOCK AND VIBRATION
Multimeter, digital or Needle, hypodermic
analog Nickel-cadmium batteries are capable of withstanding
Shield, face Puller, cell unusual shock and vibration. However, vibration
should be kept to a minimum or electrolyte in cells will
Thermometer Syringe, battery filler tend to bubble and may overflow through vent caps.
Stop watch Syringe, disposable
11-43. EXTREME TEMPERATURE OPERATION
Torque wrench Shorting clips (1/cell)
Nickel-cadmium batteries display significantly greater
11-39. CALIBRATION OF EQUIPMENT low-temperature operation capability than the
lead-acid battery. Its capacity will be somewhat
Periodically calibrate all meters and test equipment degraded at high temperatures.
used to service the nickel-cadmium batteries. Refer to
the manufacturer’s instructions. In general, the lower the battery temperature, the
longer the time required for charging. Charging with
11-40. TEMPORARY LOSS OF CAPACITY constant current at low temperature will usually result
in higher battery voltage than is experienced at
An important characteristic observed in recommended ambient temperatures. The voltage
nickel-cadmium batteries is temporary loss of capacity decreases with an increase in discharge rate and/or a
of sleepiness (also referred to as memory fading). decrease in temperature. Nickel-cadmium batteries
When this temporary loss occurs, the battery is unable seem to charge better at room temperature between
to delivery full capacity. The loss of capacity is a result, 70 to 80°F (21.1 to 26.7°C).
in part, of shallow discharge cycles and recharging
with a constant potential voltage, such as might occur 11-44. STORAGE/SHIPPING
under moderate usage in a helicopter.
Nickel-cadmium batteries can be stored in any
Loss-of-capacity effect is more common when state-of-charge. However, long-term storage in a
recharging a battery across a constant potential bus, charged condition at elevated temperature is not
such as in the helicopter rather than when recharging recommended. The rate of self-discharge is
with constant current. Loss of capacity is usually an approximately 0.7% per day in storage at 80°F
indication of imbalance between the cells because of (26.7°C). At this rate, a battery would deliver about
differences between individual cells in temperature, 90% of its actual capacity 2 weeks after charge.

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Any nickel-cadmium helicopter battery, other than the BODY. USE RUBBER GLOVES, RUBBER
sealed-cell type, that is to be stored for more than 30 APRON, AND PROTECTIVE GOGGLES
days, shall be discharged to 0 volt/cell, have battery WHEN HANDLING THE ELECTROLYTE.
terminals shorted with bus wire, with vent caps in
place, and electrolyte in cells. Under no circumstance IF THE ELECTROLYTE GETS ON THE
shall the electrolyte be dumped or vent caps removed SKIN, WASH AFFECTED AREAS WITH
for storage. LARGE QUANTITIES OF WATER OR
TA K E A S H O W E R I M M E D I AT E LY.
Dumping of electrolyte and removal of vent caps NEUTRALIZE WITH 3% BORIC ACID
results in oxidation of plate materials and SOLUTION AND WASH WITH WATER.
contamination of electrolyte. Both actions are
extremely detrimental to cells and will probably render IF THE ELECTROLYTE GETS INTO THE
them inoperable. E Y E S , WA S H E Y E S W I T H L A R G E
QUANTITIES OF WATER AND SEEK
Nickel-cadmium batteries should be stored at MEDICAL ATTENTION IMMEDIATELY.
temperatures not exceeding 130°F (54°C). Any
nickel-cadmium battery, other than the sealed-cell IF ELECTROLYTE HAS BEEN TAKEN
type, that is to be shipped any distance, should be I N T E R N A L LY, DRINK LARGE
discharged to 0 volt/cell and the battery terminals QUANTITIES OF WATER AND A WEAK
shorted with bus wire. SOLUTION OF LEMON JUICE, ORANGE
JUICE, OR VINEGAR: FOLLOW WITH
Shipping of discharged batteries shall be in WHITE OF EGG, OLIVE OIL, MELTED
accordance with battery manufacturers shipping BUTTER, STARCH WATER, OR MINERAL
instructions and applicable dangerous goods O I L . S E E K M E D I C A L AT T E N T I O N
regulations. Batteries that have to be transported in a IMMEDIATELY.
charged condition shall also be packaged in
accordance with manufacturers instructions and DUR ING PRE PA RATION OF THE
applicable dangerous goods regulations. ELECTROLYTE, ALWAYS POUR THE
POTASSIUM HYDROXIDE INTO THE
Any nickel-cadmium battery equipped with a MS3509 WATER SLOWLY AND ALLOW IT TO
receptacle, that leaves the battery shop, shall have D IS S O LV E . O TH E RW IS E , V I O L E N T
protective plastic cover(s) over the receptacle pins. BOILING WILL OCCUR AND THE
RESULTANT MIXTURE MAY SPLATTER
11-45. ELECTROLYTE REQUIREMENTS AND O N T HE P ERSO N P REPA RING THE
ADJUSTMENTS ELECTROLYTE.

In addition to the following information on electrolyte

requirements and adjustments, also refer to the
information provided by the battery manufacturer.
CAUTION

11-46. Mixing Electrolyte

P O TA S S I U M HYDROXIDE IS
SOMEWHAT CORROSIVE TO GLASS.
ALL GLASS C O N TA I N E R S ,
WARNING HYDROMETERS, OR OTHER DEVICES
THAT CONTAIN GLASS SHOULD BE
T H O R O U G H LY WA S H E D A F T E R
THE ELECTROLYTE USED IN CONTACT WITH ELECTROLYTE.
NICKEL-CADMIUM BATTERIES IS A
STRONG SOLUTION OF POTASSIUM
NOTE
HYDROXIDE THAT IS ALKALINE AND
CORROSIVE. SERIOUS BURNS WILL Due to the hazards involved in mixing
RESULT IF THE ELECTROLYTE COMES electrolyte, it is recommended that only
IN CONTACT WITH ANY PART OF THE premixed electrolyte be used.

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 BHT-ELEC-SPM

The electrolyte used for the nickel-cadmium battery is 1. Insert the electrolyte level checker into the filler
a solution of 70%, by weight, of distilled water and opening deep enough to touch the bottom of the
30% potassium hydroxide. The specific gravity of this baffle. Place a finger over top open end of tube and
mixture is 1.300. When these liquids are mixed, heat is remove tube from filler well. Electrolyte level in the
generated, which raises the temperature of the tube is a measure of electrolyte level in the cell.
mixture. After a battery has been in use for some time,
specific gravity may change slightly. Unless it falls
2. The electrolyte removal syringe will remove
outside the range of 1.240 to 1.320, the effect of the excess electrolyte from the cell. Wash the tool after
change on battery performance is usually insignificant. use.

11-47. Adjustment of Electrolyte Level

Cell cap. To ensure that the electrolyte settled
properly before adjustment, it is advisable to unlock
but not remove the cell cap during charge.
CAUTION
Foam. Although foam will sometimes be noticed in
cells during charge, it does not indicate a defect and is
THE ELECTROLYTE LEVEL OF THE
harmful only if it results in overflow and causes shorts
NICKEL-CADMIUM BATTERY SHALL
or corrosion. If there is enough foam to spill, it may be
NOT BE ADJUSTED ON THE floated off during end of charge by filling cell to the
HELICOPTER. SUCH AN ADJUSTMENT brim with electrolyte. After most of the foam has been
WOULD CREATE RISK OF OVERFILLING eliminated, reduce electrolyte to proper level, clean
A N D R E S U LT I N O V E R F L O W A N D vents and gaskets in water, and reinstall. If required,
POSSIBLE DAMAGE DURING discharge battery, disassemble, and clean with water,
CHARGING. but do not get water into cells. Dry all parts thoroughly,
reassemble, charge, and then return the battery to
The electrolyte level should be adjusted in the shop service. Foaming is more likely to occur after water
during the topping charge and according to battery has been added. It will usually disappear after a few
manufacturers recommendations. When the battery is cycles of operation. Petroleum based contaminates
in a discharged condition, the electrolyte is absorbed are a possible cause of foaming.
within the plates and separators. Immediately after
charge, electrolyte is at maximum height but settled
Specific gravity measurement and temperature
somewhat after the battery stands for a few hours.
correction of electrolyte. A hydrometer is used to
Unless spillage has occurred, the electrolyte level is
determine the specific gravity of the electrolyte. The
adjusted by adding distilled water.
type of hydrometer commonly used consists of a small
sealed glass tube that is weighted on one end so that
The electrolyte level should be adjusted 0.125 to it will float upright. Within the narrow stem of the tube
0.250 inch (3.18 to 6.35 mm) above the cell baffle or in is a scale for reading the specific gravity of the
accordance with manufacturers recommendations. In electrolyte (uncorrected for temperature).
instances where the battery is subjected to severe
vibration and/or overcharging, the electrolyte level Reading hydrometer. Place rubber nozzle of
may be adjusted to the bottom of the cell baffle hydrometer into vent opening of battery and draw
immediately prior to the end of charge. This may be enough liquid into barrel to permit the float to ride free.
necessary to prevent electrolyte flooding the battery The float must not touch side, top, or bottom of barrel.
case during flight. Hold vertical and at eye level. If hydrometer has to be
removed from the vent, pinch nozzle tightly or place
Use of level checker. The electrolyte level checker gloved finger against opening to prevent dripping of
and the electrolyte removal syringe (Figure 11-13) are electrolyte. Read float scale at electrolyte level.
useful in checking the electrolyte level. Use as follows: Disregard curvature of liquid (Figure 11-14).

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BHT-ELEC-SPM

0.250 IN.
(6.350 mm)

0.125 IN.
(3.175 mm) 0.062 IN. (1.57 mm) WIDE
MARKINGS ON BOTH ENDS

POLYSTYRENE TUBE OPEN ON BOTH ENDS,

APPROXIMATELY 0.125 INCH (3.175 mm)
INSIDE DIAMETER. ROUGHEN THE INSIDE OF SUCTION
THE TUBE TO INHIBIT CAPILLARY ACTION. BULB

0.125 TO 0.250 IN.

(3.175 TO 6.350 mm)

0.031 IN. (0.787 mm)

DIAMETER OR SMALLER HOLE

ELEC-SPM-11-14

Figure 11-13. Electrolyte Level Checker and Removal Syringe

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Figure 11-14. Reading a Hydrometer

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No hydrometer reading is to be considered correct INSTRUCTIONS AND EQUIPMENT TO

until a temperature correction has been applied. Some BE USED. THIS INCLUDES THE PROPER
hydrometers have built-in small thermometers and TEST PROCEDURES, CHARGING, AND
correction scales so that temperature correction can DISCHARGING RATES. THE
be readily made. If a temperature-correcting NICKEL-CADMIUM BATTERY
hydrometer is not available, any hydrometer may be SERVICING RECORD (FIGURE 11-12),
used and temperature corrections made from existing OR THAT PROVIDED BY THE BATTERY
electrolyte temperature, as indicated by another MANUFACTURER OR OTHER
thermometer. ACCEPTED SOURCE SHALL BE USED
WHEN SERVICING BATTERY.
11-48. Adding Water
Refer to the battery manufacturer for recommended
battery charger/analyzer equipment and operating
instructions.
CAUTION
Table 11-5 lists the majority of batteries used on Bell
helicopters.
DO NOT ADD WATER TO A
NICKEL-CADMIUM BATTERY WHEN
INSTALLED IN THE HELICOPTER. 11-50. MAINTENANCE AND RECONDITIONING
SCHEDULES

NOTE At no time should a battery be allowed to deteriorate to

Refer to battery manufacturers instructions a point where its performance affects the mission or
prior to adding water. the operation of the helicopter. A proper maintenance
program is required to prevent battery failures. Such a
program requires trained, knowledgeable personnel
Water should not be added to nickel-cadmium cells
familiar with proper battery maintenance and
while the battery is in the helicopter and the state of
reconditioning procedures, and keeping of accurate
charge is unknown. As the battery receives its charge
records.
from the helicopter bus, electrolyte may boil or spew
through cell vent caps if excessive water is present.
Potassium carbonate may eventually plug the vents of The frequency of adding water or reconditioning
the cell caps. Should vents become plugged, pressure cycles is directly dependent upon the following:
immediately builds up in cells as gas accumulates.
When sufficient pressure builds up, electrolyte will be • Type of starting service
forced from the cells. It may then flow over the top of
cells and down into the case bottom between cells.
The overflow of electrolyte eventually starts corrosion • Battery duty cycle
and may cause a short circuit between cell
connectors. The chain of events, particularly the • Operating temperature
accumulation of hydrogen, can lead to an explosion.
An igniting spark could be caused by a loose cell
• Generator voltage regulator setting
connection or a short circuit between cell connectors
resulting from the spewed electrolyte.
Because of widely varied flight profiles encountered in
individual helicopter use, no fixed maintenance and
11-49. BATTERY SERVICING PROCEDURES
recondition period can be specified. These periods
can only be approximated. The user must eventually
BEFORE SERVICING THE BATTERY, apply experience and information gained during the
MAINTENANCE PERSONNEL SHOULD first few maintenance and reconditioning periods to
BE THOROUGHLY FAMILIAR WITH THE determine a schedule that is best suited to his
BATTERY MANUFACTURERS particular type of battery usage.

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Table 11-5. Battery Data

USAGE MFG RATING

BHT VENDOR C
MODEL
PART NUMBER PART NUMBER VENDOR VOLTS RATING CELLS

204B MS24498-1 SONOTONE

24535-10 MARATHON/ 25.2 30 19
24535-010 NORCO
32421-001
205A1 24535-10 MARATHON/ 25.2 30 19
24535-010 NORCO
32421-001
206A/B/B3 For upgrade to 27662-21 MARATHON/ 25.2 13 19
17-amp battery, 27662-021 NORCO
refer to
BHT-206-SI-116
206A/B/B3 S/N 154-4298 Post 29365-01C MARATHON/ 25.2 17 20
BHT-206-SI-116 30135-001 NORCO
206B3 S/N 4299 and 29365-01C MARATHON/ 25.2 17 20
Subsequent 30135-001 NORCO
206L For upgrade to 27662-21 MARATHON/ 25.2 13 19
17-amp battery, 27662-021 NORCO
refer to STC
SH4765SW
206L STC SH4765SW 29365-01C MARATHON/ 25.2 17 20
30135-001 NORCO
206L1/L3/L4 206-075-742-101 30450-001 MARATHON/ 25.2 17 20
NORCO
206L1/L3/L4 206-075-742-101 30554-01C MARATHON/ 25.2 19 20
NORCO
206L1/L3/L4 206-075-742-103 19230 SAFT 24.0 17 20
206L4T G-639E (Lead-Acid) TELEDYNE 24 12
TECHNOLOGIES,
INC.
TSP-9117A MARATHON/ 24 20
NORCO
212 24535-10 MARATHON/ 25.2 30 19
24535-010 NORCO
32421-001
214B Refer to TB 4076-5 SAFT 24.0 20 20
214-03-94

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Table 11-5. Battery Data (Cont)

USAGE MFG RATING

BHT VENDOR C
MODEL
PART NUMBER PART NUMBER VENDOR VOLTS RATING CELLS

214ST Refer to TB RG-214 (Lead-Acid) CONCORDE 24.0 20 20

214ST-02-172 (FALCON CREST
AVIATION
SUPPLY STC)
222A/B 206-075-742-105 31871-001 MARATHON/ 25.2 17 20
NORCO
222U 30703-001 MARATHON/ 25.2 40 20
30703-002 NORCO
230 31908-001 MARATHON/ 25.2 28 20
NORCO
407 206-075-742-101 30450-001 MARATHON/ 25.2 17 20
NORCO
206-075-742-103 19230 SAFT 24.0 17 20
Refer to 31908-001 MARATHON/ 25.2 28 20
BHT-407-II-13 NORCO
412 24535-10 MARATHON/ 25.2 30 19
24535-010 NORCO
32421-001
412SP/HP/ 30703-001 MARATHON/ 25.2 40 20
EP 30703-002 NORCO
024797-000 SAFT 24.0 53 20
(Type BATCH-1)
427 206-075-742-107 32570-001 MARATHON/ 25.2 17 20
NORCO
206-075-742-111 32570-002 MARATHON/ 25.2 17 20
NORCO
31908-001 MARATHON/ 25.2 28 20
NORCO
429 7638-25 (Lead-Acid) TELEDYNE 24 25 12
TECHNOLOGIES,
INC.
Refer to 7638-36 (Lead-Acid) TELEDYNE 24 36 12
BHT-429-II-8, Kit TECHNOLOGIES,
429-706-025-105 INC.

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 BHT-ELEC-SPM

Table 11-5. Battery Data (Cont)

USAGE MFG RATING

BHT VENDOR C
MODEL
PART NUMBER PART NUMBER VENDOR VOLTS RATING CELLS

Refer to 7638-44 (Lead-Acid) TELEDYNE 24 44 12

BHT-429-II-8, Kit TECHNOLOGIES,
429-706-025-103 INC.
Refer to 7638-53 (Lead-Acid) TELEDYNE 24 53 12
BHT-429-II-8, Kit TECHNOLOGIES,
429-706-025-101 INC.
430 31908-001 MARATHON/ 25.2 28 20
NORCO
NOTE:
Not all historical battery part numbers are listed. Refer to applicable Illustrated Parts Breakdown Manual for
battery part numbers and serial number effectivity.

11-51. INSPECTION AND MAINTENANCE CHECK 11-52. Cleaning Procedures

CAUTION WARNING

BATTERY MUST BE DISCHARGED SERIOUS INJURY CAN RESULT FROM

PRIOR TO REPAIRING CONTAINER OR CARELESSNESS WHILE HANDLING
CONNECTORS. AND WORKING WITH NICKLE-CADMIUM
BATTERIES. REFER TO PARAGRAPH
When a battery is received in the shop for routine
11-33 FOR A LISTING OF GENERAL
servicing, it should first be inspected visually for
WARNINGS.
damage to the container, cover, and external battery
connectors. Repair or replace these as necessary.
Refer to battery manufacturers instructions. NOTE
Refer to the battery manufacturers
Check inside of battery for such things as cleanliness,
instructions for specific information on
loose or corroded connectors, leaking cells, and
cleaning procedures.
damaged hardware. Inspect cell vent assemblies.
Tighten loose vent plugs and replace damaged or
Battery should be kept in a clean, dry state for
missing vent plugs or vent rubbers to prevent
optimum performance. Extent of cleaning process
contamination of the electrolyte.
depends upon condition of battery. Several
procedures are described in the following paragraphs.

1. If heavy overcharging has occurred, gassing and

spewing of electrolyte may cause a white powdery
substance (potassium carbonate) to foam on top of the
cells. This may be removed by brushing the cell with a
stiff bristle or a clean cloth.

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2. If necessary, tops of the cells may be flushed with removed from connectors, screws, nuts, and washers
ordinary tap water of low mineral content. Make by washing in alcohol or by degreasing after they are
certain that all cell vent plugs are properly seated. Tip removed from the cells. Use hot water to thoroughly
battery at about a 45° angle with the receptacle (or wash vent assemblies.
power connector) facing upward. Flush with water
from top of battery in a downward direction to prevent, f. If the rubber liner used on some of the older
as much as possible, any water from entering battery batteries has deteriorated, repair or replace it in
container. It is permissible to use a non-conductive accordance with manufacturers instructions.
bristle brush to clean away stubborn dirt particles. Any
excess liquid should be drained off and battery g. Allow all parts to dry thoroughly before
permitted to dry. Drying may be accelerated by use of assembling.
oil-free compressed air.
h. Inspect all parts and replace those that are
damaged or heavily corroded. Replace connecting
straps that are burned, bent, or have defective nickel
CAUTION plating. Polish tarnished connecting straps with a fine
emory cloth being careful not to remove the plating.
WATER USED TO WAS H CELLS OR
i. Check the battery power receptacle for burns,
BATTERY WILL BE COME CAUSTIC;
cracks, and bent or pitted terminals. Replace defective
AVOID CONTACT WITH IT. DO NOT USE
receptacles. Receptacles can overheat, arc, reduce
A METAL BRUSH; THIS MAY RESULT IN
battery voltage, and cause premature battery failure.
A SHORT CIRCUIT, WHICH MAY CAUSE
S K IN B U RN S O R DA M A G E TO T HE
j. Repair or replace bent battery cases and
BATTE RY. D O N O T CL E AN TO P O F
covers, loose or damaged cover gaskets, and cell
CELLS WITH SOLVENTS, ACIDS, OR
hold-down bars.
ANY CHEMICAL SOLUTION. THESE MAY
DAMAGE CELL CASES AND
k. Clean vent caps (vent plugs).
HARDWARE.

3. If battery has loose electrolyte on top of cells, l. Reassemble battery in accordance with
drain off as much as possible, wash with water, and air battery manufacturers instructions.
dry. If electrolyte has overflowed to an extent that it
has run down between the cells, the battery should be 11-53. Electrical Leak Check
completely discharged, disassembled, and completely
cleaned before reassembling. NOTE
Voltage reading between terminals and
a. Disassemble battery in accordance with
battery must not be used as a criteria for
manufacturers instructions.
rejection; current flow is the determining
factor.
b. Wash cells under running water. Do not allow
wash water to enter interior of the cells. Refer to the battery manufacturers
instructions for specific information on
c. Dry cells with clean absorbent toweling or with conducting an electrical leak check.
an air hose.
General. This refers to external electrical leakage
d. Inspect each cell for cracks, holes, or other between a cell terminal or connector and battery
defective condition. If any defects are found, replace container, caused by electrolyte collecting around the
with new or rebuilt cells. cell, usually as a result of spewing from vent caps. It
may also be caused by a damaged cell case-to-cover
e. Wash and clean all hardware to remove seal. A leakage path greater than about
accumulated dirt and carbonate deposits. Heavy 50 milliamperes between battery container and either
deposits may be removed by scrubbing with a stiff positive or negative terminals of battery, is considered
bristle brush. Corrosion preventive grease may be to be excessive.

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5. Repeat step 2 and step 3 current test on both

positive and negative terminals. If tops of the cells
CAUTION
were cleaned properly and current measurements are
still greater than 50 milliamperes, one or more of the
cells may be leaking. To isolate this cell or cells,
DEPENDING UPON CONDITIONS, A
proceed to step 6 through step 8.
POTENTIAL SHOCK HAZARD MAY EXIST
ACROSS EITHER BATTERY TERMINAL
AND THE CONTAINER ON A BATTERY 6. Using a voltmeter of 1000 ohms/volt or greater,
ASSEMBLY HAVING A VOLTAGE OF place one of the meter leads on either the negative or
5 0 V O LT S O R G R E AT E R A N D A positive terminals of the battery and the other lead on
LEAKAGE CURRENT GREATER THAN any exposed metal of the battery container; note the
2 MILLIAMPERES. KEEPING THE meter reading. If the meter reads left of 0 or negative,
LEAKAGE CURRENT BELOW reverse the positions of the meter leads.
2 MILLIAMPERES BY THOROUGH
CLEANING AND INCREASED 7. Keep one meter lead on the exposed metal
MAINTENANCE WILL REDUCE OR surface of the container and move the other lead
ELIMINATE THIS POTENTIAL SHOCK systematically from one cell terminal to another, noting
HAZARD. the voltage reading. Voltage reading will decrease and
finally go to negative, indicating the location of the
Procedure. To determine if external leakage is of such path and possibly a leaky cell.
a magnitude as to require a complete battery cleaning,
proceed as follows: 8. If the cell is leaking, replace the cell or cells
following the procedure in accordance with
1. Set the range selector of a multimeter to the manufacturers instructions. If no leaking cells are
500 milliampere range or higher. found, leakage path may be due to electrolyte along
outside of cells and at bottom of battery container.
Perform procedures in paragraph 11-52.
NOTE
Most batteries are supplied with epoxy 11-54. RECONDITIONING NICKEL-CADMIUM
coated battery containers and covers in BATTERIES
order to completely insulate the cells from
the containers. Where epoxy coated
containers are used, current flow may be NOTE
measured between battery terminals and Refer to the battery manufacturers
the screws that are used to mount the main instructions to recondition nickel-cadmium
connector. batteries.
2. Place positive lead of meter on positive terminal Under certain conditions of usage, nickel-cadmium
of battery receptacle and momentarily touch negative batteries may show a temporary loss of capacity.
lead of the meter to any exposed metal on the battery Usually this loss is due to an imbalance in individual
container. If needle deflection is within meter limits, cell capacities that may have resulted from differences
connect negative lead of meter to battery container. in self-discharge rates, charge efficiencies, etc.
Now, decrease meter current range until the current, if
any current flow exists, is readable. Record this Reconditioning is recommended to restore a battery to
current value. full capacity and to prevent premature damage and
failure.
3. Repeat step 2, connecting negative lead of meter
on negative terminal of battery receptacle and positive Data obtained during reconditioning of a battery is
meter lead to any exposed metal on battery container. invaluable for determining maximum flight hours
between reconditioning services.
4. If either of the previous current measurements
exceed 50 milliamperes, flush tops of cells and dry More frequent reconditioning is recommended
(paragraph 11-52). whenever possible.

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BHT-ELEC-SPM

In helicopters where more than one battery is used,

either in series or parallel starting, care should be
taken that the batteries are not allowed to become
unbalanced. Perform the conditioning service on both
batteries during the same inspection period.

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