Attachment_C-1-1A-15.pdf

TO 1-1A-15

TECHNICAL MANUAL

GENERAL MAINTENANCE INSTRUCTIONS FOR SUPPORT

EQUIPMENT (SE)

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors (Administrative or Operational Use) (30 June 2004). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFLCMC/WNZEA.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

7 JUNE 2010 CHANGE 10 - 20 AUGUST 2017

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . . . . . .7 June 2010 Change . . . . . . . . 1 . . . . . . . 20 May 2011 Change . . . . . . . . 2. . . . .21 October 2012 Change . . . . . . . . 3 . . . . . . . 30 June 2013 Change . . . . . . . . 4. . . .3 November 2013 Change . . . . . . . . 5. . . . . .30 March 2014

Change . . . . . . . . 6. . . . .21 October 2015 Change . . . . . . . . 7. . . . .10 October 2016 Change . . . . . . . . 8 . . . 16 December 2016 Change . . . . . . . . 9 . . . . . . . 9 April 2017 Change . . . . . . . 10 . . . . . 20 August 2017

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 338, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i ii iii iv - v vi vii viii - x xi xii - xiii xiv xv xvi xvii - xx 1-1 1-2 Blank 2-1 2-2 Blank 3-1 - 3-15 3-16 Blank 4-1 - 4-6 5-1 - 5-3 5-4 Blank 6-1 - 6-4 6-5 6-6 7-1 - 7-2 8-1 - 8-9 8-10 Blank 9-1 9-2 Blank 10-1 10-2 - 10-5 10-6 Blank 11-1 - 11-19 11-20 Blank 12-1 - 12-2 13-1 - 13-10 14-1 - 14-17 14-18 Blank

15-1 - 15-33 15-34 15-35 - 15-37 15-38 Blank 16-1 - 16-5 16-6 Blank 17-1 - 17-10 18-1 - 18-7 18-8 Blank 19-1 - 19-5 19-6 Blank 20-1 - 20-9 20-10 Blank 21-1 - 21-8 22-1 - 22-9 22-10 Blank 23-1 - 23-8 24-1 - 24-2 24-3 24-4 - 24-11 24-12 Blank 25-1 25-2 Blank 26-1 - 26-12 26-13 - 26-16 26-17 - 26-21 26-22 26-23 26-24 26-24.1 Added 26-24.2 Blank 26-25 - 26-28 27-1 - 27-2 27-3 27-4 27-5 27-6 Blank 28-1 - 28-14 29-1 29-2 29-2.1 Added

29-2.2 Blank 29-3 - 29-7 29-8 - 29-9 29-10 Blank 29-11 - 29-12 29-12.1 Added 29-12.2 Blank 29-13 - 29-14 29-15 29-16 Blank Index 1 Index 2 Index 3 Index 4 Index 5 Index 6 Index 7 Index 8 - Index 10 Index 11 Index 12 - Index 13 Index 14 Index 15 Index 16 Index 17 Index 18 Index 18.1 Added Index 18.2 Blank Index 19 Index 20

TO 1-1A-15

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

A Change 10 USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . xii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . xv

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . xvii

SAFETY SUMMARY . . . . . . . . . . . . . . . . . xix

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-1

1.1 INTRODUCTION . . . . . . . . . . . . 1-1

1.1.1 Inspection, Repair, and Maintenance

of SE . . . . . . . . . . . . . . . . . . . 1-1

1.1.2 Electrical System and

Hardware . . . . . . . . . . . . . . . . 1-1

1.2 INTENDED USE. . . . . . . . . . . . . 1-1

2 SUBSTITUTION OF PARTS . . . . . . . . . . . . 2-1

2.1 PURPOSE. . . . . . . . . . . . . . . . . . 2-1

2.2 SUBSTITUTION DATA . . . . . . . . 2-1

2.2.1 Miscellaneous Parts . . . . . . . . . . . 2-1

2.2.2 Local Manufacture of

Markings . . . . . . . . . . . . . . . . 2-1

2.3 REMOVAL OF SUBSTITUTE

PARTS . . . . . . . . . . . . . . . . . . 2-1

2.4 PARTS REQUIRED . . . . . . . . . . . 2-1

3 BASIC OVERHAUL/REPAIR INSTRUC-

TIONS GROUND SERVICE CART COU-

PLING HALVES . . . . . . . . . . . . . . . . . . 3-1

3.1 INTRODUCTION . . . . . . . . . . . . 3-1

3.2 TROUBLESHOOTING. . . . . . . . . 3-1

3.3 REPAIR PROCEDURES. . . . . . . . 3-2

3.3.1 Problem . . . . . . . . . . . . . . . . . . . 3-2

3.3.2 Problem . . . . . . . . . . . . . . . . . . . 3-2

3.3.3 Problem . . . . . . . . . . . . . . . . . . . 3-3

3.3.4 Problem . . . . . . . . . . . . . . . . . . . 3-3

3.4 DISASSEMBLY

PROCEDURES . . . . . . . . . . . . 3-3

Chapter Page

3.4.1 -4 Through -8 Size Couplings . . . . 3-3

3.4.2 -10 Through -24 Size

Couplings . . . . . . . . . . . . . . . . 3-4

3.4.3 Aircraft Coupling Half . . . . . . . . . 3-4

3.5 ASSEMBLY PROCEDURES . . . . . 3-5

3.5.1 -4 Through -8 Size Couplings . . . . 3-5

3.5.2 -10 Through -24 Size

Couplings . . . . . . . . . . . . . . . . 3-5

3.5.3 Aircraft Coupling Half . . . . . . . . . 3-6

3.6 ASSEMBLY TOOLS . . . . . . . . . . 3-6

3.7 PRESSURES AND ASSEMBLY

TORQUE . . . . . . . . . . . . . . . . 3-13

4 SHEET METAL REPAIRS AND

BOLTS/STUDS . . . . . . . . . . . . . . . . . . . 4-1

4.1 SHEET METAL REPAIRS . . . . . . 4-1

4.1.1 Cracks . . . . . . . . . . . . . . . . . . . . 4-1

4.1.2 Holes . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 BOLTS. . . . . . . . . . . . . . . . . . . . 4-1

4.2.1 Grip Length. . . . . . . . . . . . . . . . . 4-1

4.2.2 Shank. . . . . . . . . . . . . . . . . . . . . 4-1

4.3 FITTING BOLTS. . . . . . . . . . . . . 4-1

4.4 STUDS. . . . . . . . . . . . . . . . . . . . 4-2

4.4.1 Installing New Stud . . . . . . . . . . . 4-2

4.4.2 Torquing Stud . . . . . . . . . . . . . . . 4-2

5 NUTS AND WASHERS . . . . . . . . . . . . . . . 5-1

5.1 NUTS . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 Purpose . . . . . . . . . . . . . . . . . . . 5-1

5.1.2 Fastener Fatigue Failure . . . . . . . . 5-1

5.1.3 Temperature Limitations . . . . . . . . 5-1

5.1.4 Corrosion Resistant/Stainless Steel

Nuts . . . . . . . . . . . . . . . . . . . . 5-1

5.1.5 Self-Locking Nuts . . . . . . . . . . . . 5-1

5.2 WASHERS . . . . . . . . . . . . . . . . . 5-2

5.2.1 Plain Washers . . . . . . . . . . . . . . . 5-2

5.2.2 Lockwashers . . . . . . . . . . . . . . . . 5-2

6 TIGHTENING NUTS AND BOLTS . . . . . . . 6-1

Change 6 i

6.1 TORQUE . . . . . . . . . . . . . . . . . . 6-1

6.2 TORQUE CHARTS . . . . . . . . . . . 6-1

6.3 DEFINITIONS . . . . . . . . . . . . . . 6-1

6.3.1 Torque . . . . . . . . . . . . . . . . . . . . 6-1

6.3.2 Tension. . . . . . . . . . . . . . . . . . . . 6-1

6.3.3 Fatigue . . . . . . . . . . . . . . . . . . . . 6-1

6.3.4 Tensile Strength . . . . . . . . . . . . . . 6-1

6.3.5 Shear Strength . . . . . . . . . . . . . . . 6-1

6.3.6 Improper Tightening . . . . . . . . . . . 6-1

6.4 REUSE OF SELF-LOCKING

NUTS . . . . . . . . . . . . . . . . . . 6-1

6.4.1 Self-Locking Nuts 3/8 Inch and

Smaller. . . . . . . . . . . . . . . . . . 6-1

6.4.2 Self-Locking Nuts Over 3/8

Inch . . . . . . . . . . . . . . . . . . . . 6-1

6.5 TORQUE WRENCHES . . . . . . . . 6-2

7 PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 PINS . . . . . . . . . . . . . . . . . . . . . 7-1

7.1.1 Taper Pins. . . . . . . . . . . . . . . . . . 7-1

7.1.2 Flathead Pins . . . . . . . . . . . . . . . . 7-1

7.1.3 Cotter Pins . . . . . . . . . . . . . . . . . 7-1

7.1.4 Lockpins/Spring Pins . . . . . . . . . . 7-1

7.1.5 Machine Pins/Quick-Release

Pins . . . . . . . . . . . . . . . . . . . . 7-1

8 TUBING SYSTEMS AND TUBING

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 TUBING SYSTEMS AND TUBING

REPAIRS . . . . . . . . . . . . . . . . 8-1

8.1.1 Stainless Steel Tubing . . . . . . . . . . 8-1

8.1.2 Aluminum Alloy Tubing . . . . . . . . 8-1

8.2 TUBING DAMAGE. . . . . . . . . . . 8-1

8.2.1 Chafing, Galling or Fretting . . . . . . 8-1

8.2.2 Nicks and Scratches . . . . . . . . . . . 8-1

8.3 CUTTING TUBING. . . . . . . . . . . 8-1

8.4 BENDING TUBING. . . . . . . . . . . 8-2

8.5 TUBING JOINTS . . . . . . . . . . . . 8-5

8.5.1 Flared Tubing Joint . . . . . . . . . . . 8-5

8.5.2 Preparing Flaring Tool for

Flaring . . . . . . . . . . . . . . . . . . 8-5

8.5.3 Preparing Tubing End for

Flaring . . . . . . . . . . . . . . . . . . 8-5

8.6 REPAIRING TUBING

FITTINGS . . . . . . . . . . . . . . . 8-5

8.7 REPLACING CRACKED OR

DAMAGED B-NUTS AND FIT-

TING SLEEVES ON STAN-

DARD FLARED AND FLARE-

LESS TUBE

CONNECTIONS . . . . . . . . . . . 8-7

8.7.1 Cracks . . . . . . . . . . . . . . . . . . . . 8-7

Chapter Page

8.7.2 Tool Marks, Scratches, or

Chafes . . . . . . . . . . . . . . . . . . 8-7

8.7.3 Corrosion . . . . . . . . . . . . . . . . . . 8-7

8.7.4 Damage . . . . . . . . . . . . . . . . . . . 8-7

8.7.5 Minor Surface Corrosion . . . . . . . . 8-7

8.8 ALUMINUM BRONZE SLEEVES

TYPE AN819 . . . . . . . . . . . . . 8-7

8.9 TUBING FITTINGS TAPERED

PIPE THREADS . . . . . . . . . . . 8-7

8.10 TUBING FITTINGS THREAD

LUBRICANTS . . . . . . . . . . . . 8-7

8.11 INSTALLATION OF TUBING

ASSEMBLIES. . . . . . . . . . . . . 8-8

8.11.1 Installation . . . . . . . . . . . . . . . . . 8-8

8.11.2 Torquing . . . . . . . . . . . . . . . . . . . 8-8

8.12 INSTALLATION OF GROMMETS

AND CLIPS ON TUBING

ASSEMBLIES. . . . . . . . . . . . . 8-8

8.13 HOSE CONNECTIONS . . . . . . . . 8-8

9 THREAD COMPOUNDS . . . . . . . . . . . . . . 9-1

9.1 THREAD COMPOUNDS . . . . . . . 9-1

10 FLEXIBLE HOSE AND FITTINGS . . . . . . . 10-1

10.1 FLEXIBLE HOSE AND

FITTINGS . . . . . . . . . . . . . . . 10-1

10.2 INSPECTION OF INSTALLED

HOSE ASSEMBLIES . . . . . . . . 10-1

10.3 IDENTIFICATION. . . . . . . . . . . . 10-2

10.4 INSTALLATION OF FLEXIBLE

HOSE . . . . . . . . . . . . . . . . . . 10-2

10.4.1 Installation . . . . . . . . . . . . . . . . . 10-2

10.4.2 Bends. . . . . . . . . . . . . . . . . . . . . 10-2

10.4.3 Brackets and Supporting Clips . . . . 10-2

10.4.4 Supports . . . . . . . . . . . . . . . . . . . 10-2

10.4.5 Chafing. . . . . . . . . . . . . . . . . . . . 10-2

10.4.6 Excessive Temperature . . . . . . . . . 10-2

10.4.7 Engine or Engine Mounted

Accessories . . . . . . . . . . . . . . . 10-2

10.4.8 Vibration. . . . . . . . . . . . . . . . . . . 10-2

10.4.9 Markings . . . . . . . . . . . . . . . . . . 10-2

10.4.10 Torque Values . . . . . . . . . . . . . . . 10-2

11 SECURING SE HARDWARE . . . . . . . . . . . 11-1

11.1 SAFETY METHODS . . . . . . . . . . 11-1

11.2 SECURING SE HARDWARE

WITH LOCK WIRE. . . . . . . . . 11-1

11.2.1 Lock Wiring Procedures . . . . . . . . 11-1

11.2.2 Safetywire Sizes. . . . . . . . . . . . . . 11-2

TO 1-1A-15

TABLE OF CONTENTS - CONTINUED

ii

11.2.3 Twisting with Special Tools . . . . . . 11-2

11.2.4 Safety Wiring Hollow Headed Bolts

with Four Tapped Holes . . . . . . 11-2

11.3 SECURING SE HARDWARE

WITH SAFETY CABLE. . . . . . 11-7

11.3.1 Safety Cable Procedures . . . . . . . . 11-7

11.3.2 Safety Cable Size . . . . . . . . . . . . . 11-7

11.3.3 Safety Cable Installation . . . . . . . . 11-8

11.3.4 Elongated Ferrules . . . . . . . . . . . . 11-11

11.3.5 Safety Cable Jacketing for

Protection . . . . . . . . . . . . . . . . 11-11

11.3.6 Safety Cable Application Tool . . . . 11-11

11.3.7 Types of Safety Cable Tools . . . . . 11-12

11.3.8 Safety Cable Application Tool Main-

tenance and Calibration . . . . . . . 11-14

11.4 MISCELLANEOUS LOCK WIR-

ING AND SAFETY CABLE

APPLICATIONS . . . . . . . . . . . 11-16

11.4.1 Securing Oil Caps, Drain Cocks, and Valves . . . . . . . . . . . . . . . 11-16

11.4.2 Securing Turnbuckles with

Safetywire. . . . . . . . . . . . . . . . 11-16

11.4.3 Securing Turnbuckles with Safety

Cable . . . . . . . . . . . . . . . . . . . 11-18

11.4.4 Securing with Cotter Pins . . . . . . . 11-19

12 INSPECTION AND INSTALLATION OF V-

BAND COUPLINGS . . . . . . . . . . . . . . . 12-1

12.1 V-BAND COUPLINGS. . . . . . . . . 12-1

12.2 PRE-INSTALLATION

CHECKS . . . . . . . . . . . . . . . . 12-1

12.2.1 Cleaning . . . . . . . . . . . . . . . . . . . 12-1

12.2.2 Flange Caps . . . . . . . . . . . . . . . . 12-1

12.2.3 Alignment . . . . . . . . . . . . . . . . . . 12-1

12.2.4 Flange Faces . . . . . . . . . . . . . . . . 12-1

12.2.5 Part Number . . . . . . . . . . . . . . . . 12-1

12.2.6 Reinstallation. . . . . . . . . . . . . . . . 12-1

Chapter Page

12.2.7 T-Bolt. . . . . . . . . . . . . . . . . . . . . 12-1

12.2.8 T-Bolt Straightness . . . . . . . . . . . . 12-1

12.2.9 Trunnion and Latch . . . . . . . . . . . 12-1

12.2.10 Coupling. . . . . . . . . . . . . . . . . . . 12-1

12.3 GASKETS . . . . . . . . . . . . . . . . . 12-1

12.4 TORQUE . . . . . . . . . . . . . . . . . . 12-1

12.5 NUTS . . . . . . . . . . . . . . . . . . . . 12-1

12.6 INSTALLATION . . . . . . . . . . . . . 12-2

12.7 LEAKING . . . . . . . . . . . . . . . . . 12-2

12.7.1 T-Bolt Failure . . . . . . . . . . . . . . . 12-2

12.7.2 Safetywiring . . . . . . . . . . . . . . . . 12-2

13 WIRE AND CABLE PREPARATION . . . . . . 13-1

13.1 WIRE AND CABLE

PREPARATION. . . . . . . . . . . . 13-1

13.2 DEFINITIONS . . . . . . . . . . . . . . 13-1

13.2.1 Insulated Wire . . . . . . . . . . . . . . . 13-1

13.2.2 Cable . . . . . . . . . . . . . . . . . . . . . 13-1

13.2.3 Soft Solder . . . . . . . . . . . . . . . . . 13-1

13.2.4 Flux . . . . . . . . . . . . . . . . . . . . . . 13-1

13.3 CUTTING WIRE AND

CABLE . . . . . . . . . . . . . . . . . 13-1

13.3.1 Cutting Copper Wire and Cable . . . 13-1

13.3.2 Heavy Gauge. . . . . . . . . . . . . . . . 13-2

13.3.3 Light Gauge . . . . . . . . . . . . . . . . 13-2

13.4 IDENTIFYING WIRE AND

CABLE . . . . . . . . . . . . . . . . . 13-2

13.4.1 Identification Methods. . . . . . . . . . 13-3

13.4.2 Marking Objectives . . . . . . . . . . . 13-3

13.4.3 Spacing of Stamped Marks . . . . . . 13-3

13.4.4 Location of Sleeve Marking. . . . . . 13-3

13.4.5 Thermocouple Wire Indication . . . . 13-4

13.4.6 Identification at Terminal Boards

and Enclosures. . . . . . . . . . . . . 13-4

13.4.7 Selection of Identification

Sleeving . . . . . . . . . . . . . . . . . 13-4

TO 1-1A-15

Change 6 iii

13.4.8 Identification Marking

Machines . . . . . . . . . . . . . . . . 13-4

13.5 SETUP OF MARKING MA-

CHINES FOR WIRE

STAMPING . . . . . . . . . . . . . . 13-4

13.5.1 Identification Code . . . . . . . . . . . . 13-4

13.5.2 Marking Foil . . . . . . . . . . . . . . . . 13-5

13.5.3 Wire Guide . . . . . . . . . . . . . . . . . 13-5

13.5.4 Installation . . . . . . . . . . . . . . . . . 13-5

13.6 PROCEDURE FOR WIRE STAMP-

ING BY MACHINE . . . . . . . . . 13-5

13.6.1 Heat . . . . . . . . . . . . . . . . . . . . . . 13-5

13.6.2 Sample . . . . . . . . . . . . . . . . . . . . 13-5

13.6.3 Wire Marking . . . . . . . . . . . . . . . 13-5

13.6.4 Mark Remaining Wire Length . . . . 13-5

13.7 SETUP OF MARKING MACHINE

FOR SLEEVE STAMPING . . . . 13-6

13.7.1 Type Size . . . . . . . . . . . . . . . . . . 13-6

13.7.2 Mandrel . . . . . . . . . . . . . . . . . . . 13-6

13.7.3 Type Preparation . . . . . . . . . . . . . 13-6

13.7.4 Marking Sleeve . . . . . . . . . . . . . . 13-6

13.8 PROCEDURE FOR STAMPING

SLEEVES BY MACHINE. . . . . 13-6

13.9 MACHINE STAMPING FOR

LARGE SLEEVING. . . . . . . . . 13-6

13.10 INSTALLING IDENTIFICATION

SLEEVES ON WIRING . . . . . . 13-6

13.11 IDENTIFICATION OF WIRE

BUNDLES AND

HARNESSES . . . . . . . . . . . . . 13-6

13.11.1 Bundles . . . . . . . . . . . . . . . . . . . 13-7

13.11.2 Cable Identification Strap . . . . . . . 13-7

13.12 STRIPPING WIRE AND

CABLE . . . . . . . . . . . . . . . . . 13-7

13.12.1 Stripping Methods for Copper

Wire. . . . . . . . . . . . . . . . . . . . 13-7

13.12.2 General Stripping Instructions . . . . 13-7

13.12.3 Procedure for Stripping Wire with

Hand Stripper . . . . . . . . . . . . . 13-8

13.12.4 Procedure for Stripping Wire with a

Knife . . . . . . . . . . . . . . . . . . . 13-8

13.13 STRIPPING DIMENSIONS FOR

ASSEMBLY TO

CONNECTORS . . . . . . . . . . . . 13-9

13.14 TINNING COPPER WIRE AND

CABLE . . . . . . . . . . . . . . . . . 13-9

13.14.1 Tinning Methods . . . . . . . . . . . . . 13-9

13.14.2 Extent of Tinning . . . . . . . . . . . . . 13-9

13.14.3 Preparation of Flux and Solder . . . . 13-9

13.14.4 Dip-Tinning Procedure . . . . . . . . . 13-9

13.15 PROCEDURE FOR SOLDERING

IRON TINNING . . . . . . . . . . . 13-10

13.15.1 Soldering Iron . . . . . . . . . . . . . . . 13-10

13.15.2 Prime . . . . . . . . . . . . . . . . . . . . . 13-10

Chapter Page

13.15.3 Procedure . . . . . . . . . . . . . . . . . . 13-10

14 SOLDERLESS TERMINATIONS AND

SPLICES. . . . . . . . . . . . . . . . . . . . . . . . 14-1

14.1 SOLDERLESS TERMINATIONS

AND SPLICES . . . . . . . . . . . . 14-1

14.2 DESCRIPTION . . . . . . . . . . . . . . 14-1

14.3 TERMINAL LUGS/SPLICES AND

TOOLS . . . . . . . . . . . . . . . . . 14-1

14.3.1 Class 1 Lugs and Splices. . . . . . . . 14-1

14.3.2 Class 2 Lugs and Splices. . . . . . . . 14-1

14.4 TYPES AND STYLES OF

TERMINALS . . . . . . . . . . . . . 14-1

14.5 TERMINATING SMALL COPPER

WIRES (SIZES NO. 26

THROUGH NO. 10) WITH

PRE-INSULATED TERMINAL

LUGS . . . . . . . . . . . . . . . . . . 14-1

14.5.1 Crimping Tools . . . . . . . . . . . . . . 14-2

14.5.2 Hand Tool Description . . . . . . . . . 14-2

14.5.3 Hand Tool Inspection . . . . . . . . . . 14-2

14.5.4 Crimping Procedure for MS90413

and MS3316 Standard Hand Tools . . . . . . . . . . . . . . . . . . . 14-2

14.6 TERMINATING LARGE COPPER

WIRES (SIZES NO. 8

THROUGH NO. 4/0) WITH

TERMINAL LUGS . . . . . . . . . 14-6

14.6.1 Insulating Sleeves. . . . . . . . . . . . . 14-7

14.6.2 Crimping Tools . . . . . . . . . . . . . . 14-7

14.6.3 Hand Tools . . . . . . . . . . . . . . . . . 14-7

14.6.4 Hand Tool Adjustment . . . . . . . . . 14-7

14.6.5 Crimping Procedure for Burndy

MYZ8 Tool (Formerly the AN3427 Standard Hand Tool) . . . . . . . . . . . . . . . . . . . 14-7

14.6.6 Crimping Procedure for T & B

Hand Tools . . . . . . . . . . . . . . . 14-8

14.7 HIGH TEMPERATURE TERMI-

NAL LUGS. . . . . . . . . . . . . . . 14-11

14.7.1 Crimping Tools . . . . . . . . . . . . . . 14-11

14.7.2 Hand Tools . . . . . . . . . . . . . . . . . 14-11

14.7.3 Crimping Procedure for AMP Hand

Tools . . . . . . . . . . . . . . . . . . . 14-11

14.7.4 Crimping Procedure for Burndy

Hand Tools . . . . . . . . . . . . . . . 14-11

14.7.5 Crimping Procedure for T & B

Hand Tools . . . . . . . . . . . . . . . 14-11

14.8 SPLICING SMALL COPPER

WIRES (SIZES NO. 26

THROUGH NO. 10). . . . . . . . . 14-12

14.8.1 Crimping Tools . . . . . . . . . . . . . . 14-12

TO 1-1A-15

iv

14.8.2 Crimping Procedure for MS90413

and MS3316 Standard Hand Crimping Tools . . . . . . . . . . . . 14-12

14.9 SPLICING LARGE COPPER

WIRES (SIZES NO. 8

THROUGH NO. 4/0) . . . . . . . . 14-13

14.9.1 Crimping Tools . . . . . . . . . . . . . . 14-13

14.9.2 Crimping Procedures . . . . . . . . . . 14-13

14.9.3 Splicing High Temperature

Wires . . . . . . . . . . . . . . . . . . . 14-13

14.10 VISUAL INSPECTION OF

CRIMPED

CONNECTIONS . . . . . . . . . . . 14-16

15 GENERAL PURPOSE CONNECTORS . . . . . 15-1

15.1 GENERAL PURPOSE

CONNECTORS . . . . . . . . . . . . 15-1

15.2 GENERAL DESCRIPTION OF

AN-MS CONNECTORS . . . . . . 15-1

15.2.1 Receptacle. . . . . . . . . . . . . . . . . . 15-1

15.2.2 Class . . . . . . . . . . . . . . . . . . . . . 15-1

15.3 SOLDER CONTACTS . . . . . . . . . 15-1

15.4 PREPARATION OF WIRES BE-

FORE ASSEMBLY . . . . . . . . . 15-1

15.5 INSULATING SLEEVES . . . . . . . 15-1

15.5.1 Selection of Insulating Sleeves . . . . 15-2

15.5.2 Installation of Insulating

Sleeves . . . . . . . . . . . . . . . . . . 15-2

15.6 SOLDERING PROCEDURE . . . . . 15-3

15.6.1 Precautions . . . . . . . . . . . . . . . . . 15-3

15.6.2 Torch Soldering . . . . . . . . . . . . . . 15-3

15.6.3 Soldering Iron Procedure . . . . . . . . 15-3

15.6.4 Holding Connectors for

Soldering . . . . . . . . . . . . . . . . 15-5

15.6.5 Soldering Sequence . . . . . . . . . . . 15-5

15.6.6 Cleaning Soldered Connections . . . 15-6

15.6.7 Insulating Sleeve Positioning . . . . . 15-6

15.6.8 Preshaping Wires . . . . . . . . . . . . . 15-6

15.7 CRIMP CONTACTS . . . . . . . . . . 15-6

15.8 CONTINUITY TEST . . . . . . . . . . 15-7

15.9 DISASSEMBLY, REASSEMBLY,

AND INSTALLATION OF

CONNECTORS . . . . . . . . . . . . 15-10

15.9.1 Removal of Back Shells . . . . . . . . 15-10

15.9.2 Disassembly Instructions for AN-MS

E and F Connectors . . . . . . . . . 15-10

15.9.3 MS Class R Connector

Disassembly . . . . . . . . . . . . . . 15-11

15.9.4 Amphenol and Cannon MS Class A

Connectors . . . . . . . . . . . . . . . 15-11

15.9.5 Amphenol MS Class B

Connectors . . . . . . . . . . . . . . . 15-14

15.9.6 Amphenol MS Class C

Connectors . . . . . . . . . . . . . . . 15-15

Chapter Page

15.9.7 Amphenol Class E, F, and R

Connectors . . . . . . . . . . . . . . . 15-17

15.9.8 Potting Connectors . . . . . . . . . . . . 15-17

15.9.9 Bendix - Scintilla MS Class A

Connectors . . . . . . . . . . . . . . . 15-21

15.9.10 Bendix - Scintilla MS Class C

Connectors . . . . . . . . . . . . . . . 15-22

15.9.11 Bendix - Scintilla MS Class E

Connectors . . . . . . . . . . . . . . . 15-23

15.9.12 Bendix - Scintilla MS Class R

Connectors . . . . . . . . . . . . . . . 15-24

15.9.13 Cannon MS Class B

Connectors . . . . . . . . . . . . . . . 15-25

15.9.14 Cannon MS Class C

Connectors . . . . . . . . . . . . . . . 15-26

15.9.15 Cannon MS Class E

Connectors . . . . . . . . . . . . . . . 15-26

15.9.16 Cannon MS Class R

Connectors . . . . . . . . . . . . . . . 15-30

15.9.17 Removal of Contacts . . . . . . . . . . 15-30

15.10 INSTALLATION OF MS3057 SE-

RIES CONNECTOR CABLE

CLAMPS . . . . . . . . . . . . . . . . 15-32

15.10.1 MS3057 Clamp . . . . . . . . . . . . . . 15-32

15.10.2 MS3057A Clamp . . . . . . . . . . . . . 15-32

15.10.3 MS3057B Clamp . . . . . . . . . . . . . 15-32

15.10.4 Installation of MS3057 Cable

Clamp . . . . . . . . . . . . . . . . . . 15-32

15.10.5 Installation of MS3057A Cable

Clamp . . . . . . . . . . . . . . . . . . 15-33

15.10.6 Installation of MS3057B Cable

Clamp . . . . . . . . . . . . . . . . . . 15-33

15.11 PROTECTING ELECTRICAL

CONNECTORS . . . . . . . . . . . . 15-34

16 WIRING: LOCK, SHEAR, AND SEAL. . . . . 16-1

16.1 INTRODUCTION . . . . . . . . . . . . 16-1

16.1.1 General Information . . . . . . . . . . . 16-1

16.1.2 Scope . . . . . . . . . . . . . . . . . . . . . 16-1

16.2 DEFINITIONS . . . . . . . . . . . . . . 16-1

16.2.1 Lock Wire. . . . . . . . . . . . . . . . . . 16-1

16.2.2 Shear Wire . . . . . . . . . . . . . . . . . 16-1

16.2.3 Seal Wire . . . . . . . . . . . . . . . . . . 16-1

16.3 GENERAL PROCEDURES FOR

LOCK, SHEAR, AND SEAL

WIRING. . . . . . . . . . . . . . . . . 16-1

16.3.1 Length . . . . . . . . . . . . . . . . . . . . 16-1

16.3.2 Double Twist Lock Wiring. . . . . . . 16-1

16.3.3 Single Wire Method . . . . . . . . . . . 16-1

16.3.4 Twisting with Pliers . . . . . . . . . . . 16-2

16.3.5 Twisting with Special Tools . . . . . . 16-2

16.3.6 Tightness of Wire . . . . . . . . . . . . . 16-3

TO 1-1A-15

v

16.4 SPECIFIC PROCEDURES FOR

LOCK AND SHEAR

WIRING. . . . . . . . . . . . . . . . . 16-3

16.4.1 Lock Wiring Electrical

Connectors . . . . . . . . . . . . . . . 16-3

16.4.2 Lock Wiring AN-MS Connectors

with Threaded Coupling Rings . . . . . . . . . . . . . . . . . . . 16-3

16.4.3 Lock Wiring Connector to

Structure . . . . . . . . . . . . . . . . . 16-4

16.4.4 Shear Wiring Split Shell

Assemblies . . . . . . . . . . . . . . . 16-4

16.4.5 Wiring Solid Shell Angle Plugs . . . 16-4

16.4.6 Shear Wiring Emergency

Devices . . . . . . . . . . . . . . . . . 16-4

17 BONDING AND GROUNDING. . . . . . . . . . 17-1

17.1 INTRODUCTION . . . . . . . . . . . . 17-1

17.2 SCOPE. . . . . . . . . . . . . . . . . . . . 17-1

17.3 REFERENCE

SPECIFICATIONS . . . . . . . . . . 17-1

17.4 DEFINITIONS . . . . . . . . . . . . . . 17-1

17.4.1 Bonding . . . . . . . . . . . . . . . . . . . 17-1

17.4.2 Grounding. . . . . . . . . . . . . . . . . . 17-1

17.4.3 Primary Structure . . . . . . . . . . . . . 17-1

17.5 GENERAL PRECAUTIONS AND

PROCEDURES . . . . . . . . . . . . 17-1

17.6 SELECTION OF

HARDWARE . . . . . . . . . . . . . 17-2

17.6.1 Hardware Material and Finish . . . . 17-2

17.6.2 Selection of Stud . . . . . . . . . . . . . 17-2

17.6.3 Selection of Nuts . . . . . . . . . . . . . 17-2

17.6.4 Selection of Washers. . . . . . . . . . . 17-2

17.6.5 Selection of Cable Clamp . . . . . . . 17-2

17.7 PREPARATION OF BONDING OR

GROUNDING SURFACES . . . . 17-6

17.7.1 Cleaning Procedure for Aluminum

Surfaces . . . . . . . . . . . . . . . . . 17-6

17.7.2 Cleaning Procedure for Magnesium

Alloy Surfaces . . . . . . . . . . . . . 17-6

17.7.3 Cleaning Procedure for Steel

Surfaces . . . . . . . . . . . . . . . . . 17-6

17.8 METHODS OF BONDING OR

GROUNDING . . . . . . . . . . . . . 17-6

17.8.1 Connection to Flat Surfaces . . . . . . 17-6

17.8.2 Connection to Tab Riveted to

Structure . . . . . . . . . . . . . . . . . 17-7

17.8.3 Connection to Cylindrical

Surfaces . . . . . . . . . . . . . . . . . 17-7

17.8.4 Bonding Conduit to Structure. . . . . 17-8

17.8.5 Tightness of Connections. . . . . . . . 17-8

17.9 BONDING AND GROUNDING

JUMPERS. . . . . . . . . . . . . . . . 17-9

Chapter Page

17.9.1 Fabricating Bonding and Grounding

Jumpers . . . . . . . . . . . . . . . . . 17-9

17.9.2 Quick-Disconnect Jumpers. . . . . . . 17-9

17.10 TESTING BONDS AND

GROUNDS . . . . . . . . . . . . . . . 17-9

17.10.1 Resistance Tests After

Connection . . . . . . . . . . . . . . . 17-9

17.10.2 Resistance Test Procedure . . . . . . . 17-9

17.11 REFINISHING . . . . . . . . . . . . . . 17-10

17.11.1 Refinishing Aluminum Alloy

Surfaces . . . . . . . . . . . . . . . . . 17-10

17.11.2 Refinishing Magnesium Alloy

Surfaces . . . . . . . . . . . . . . . . . 17-10

17.11.3 Refinishing Steel Surfaces . . . . . . . 17-10

18 SOLDERING. . . . . . . . . . . . . . . . . . . . . . . 18-1

18.1 SOLDERING . . . . . . . . . . . . . . . 18-1

18.2 DEFINITIONS AND

DESCRIPTIONS . . . . . . . . . . . 18-1

18.2.1 Soldering . . . . . . . . . . . . . . . . . . 18-1

18.2.2 Soldering Methods . . . . . . . . . . . . 18-1

18.2.3 Soft Solder . . . . . . . . . . . . . . . . . 18-1

18.2.4 Hard Solder. . . . . . . . . . . . . . . . . 18-2

18.2.5 Flux . . . . . . . . . . . . . . . . . . . . . . 18-2

18.3 TYPICAL SOLDERING

OPERATIONS. . . . . . . . . . . . . 18-2

18.3.1 Tinning. . . . . . . . . . . . . . . . . . . . 18-2

18.3.2 Soldering . . . . . . . . . . . . . . . . . . 18-2

18.3.3 De-soldering . . . . . . . . . . . . . . . . 18-2

18.4 HEAT APPLICATION

METHODS . . . . . . . . . . . . . . . 18-2

18.4.1 Soldering Iron . . . . . . . . . . . . . . . 18-2

18.4.2 Torch Soldering . . . . . . . . . . . . . . 18-2

18.4.3 Dip Soldering . . . . . . . . . . . . . . . 18-2

18.5 PREPARATION AND MAINTE-

NANCE OF SOLDERING

IRON . . . . . . . . . . . . . . . . . . . 18-2

18.5.1 Preparing the Soldering Iron . . . . . 18-2

18.5.2 Copper Soldering Tips . . . . . . . . . 18-4

18.5.3 Soldering Iron Maintenance . . . . . . 18-4

18.5.4 Daily Maintenance . . . . . . . . . . . . 18-4

18.6 SOLDERING OPERATION-GEN-

ERAL PRECAUTIONS AND

PROCEDURES . . . . . . . . . . . . 18-4

18.6.1 Cleanliness . . . . . . . . . . . . . . . . . 18-4

18.6.2 Pre-Tinning . . . . . . . . . . . . . . . . . 18-4

18.6.3 Selection of Flux and Solder . . . . . 18-5

18.6.4 Heating Capacity . . . . . . . . . . . . . 18-5

18.6.5 Selection of Soldering Iron . . . . . . 18-5

18.6.6 Choice of Soldering Tip . . . . . . . . 18-5

TO 1-1A-15

vi Change 6

18.6.7 Soldering Iron . . . . . . . . . . . . . . . 18-5

18.6.8 Securing the Joint. . . . . . . . . . . . . 18-5

18.6.9 Application of Heat and Solder . . . 18-5

18.6.10 Heat Application Time . . . . . . . . . 18-5

18.6.11 Amount of Solder. . . . . . . . . . . . . 18-5

18.6.12 Soldering Iron Holder . . . . . . . . . . 18-5

18.6.13 Protection Against Overheating. . . . 18-5

18.6.14 Cooling the Solder Joint . . . . . . . . 18-5

18.6.15 Cleaning . . . . . . . . . . . . . . . . . . . 18-5

18.7 INSPECTING A FINISHED SOL-

DER JOINT . . . . . . . . . . . . . . 18-7

18.7.1 Acceptable Solder Joint. . . . . . . . . 18-7

18.7.2 Unacceptable Solder Joint . . . . . . . 18-7

19 INSTALLATION OF BUSBARS, PROTEC-

TIVE DEVICES, AND TERMINAL

BOARDS . . . . . . . . . . . . . . . . . . . . . . . 19-1

19.1 INSTALLATION OF BUSBARS,

PROTECTIVE DEVICES, AND

TERMINAL BOARDS . . . . . . . 19-1

19.2 PREPARATION AND INSTALLA-

TION OF BUSBARS . . . . . . . . 19-1

19.2.1 Preparation of Busbars . . . . . . . . . 19-1

19.2.2 Preparation of Unplated Aluminum

Alloy Busbars . . . . . . . . . . . . . 19-1

19.2.3 Preparation of Plated Aluminum and

Copper Busbars . . . . . . . . . . . . 19-2

19.2.4 Repairing Damaged Plating . . . . . . 19-2

19.3 INSTALLATION OF PROTECTIVE

DEVICES . . . . . . . . . . . . . . . . 19-2

19.3.1 Mounting Hardware . . . . . . . . . . . 19-2

19.3.2 Mounting with Through Bolts or

Screws . . . . . . . . . . . . . . . . . . 19-2

19.3.3 Mounting into Tapped Hole or Nut

Plate. . . . . . . . . . . . . . . . . . . . 19-2

19.3.4 Mounting into Blind Hole . . . . . . . 19-2

19.3.5 Mounting Circuit Breakers. . . . . . . 19-3

19.3.6 Mounting Relays . . . . . . . . . . . . . 19-3

19.4 SPECIAL PRECAUTIONS FOR

BONDING OR GROUNDING

CONNECTIONS . . . . . . . . . . . 19-4

19.4.1 Protection . . . . . . . . . . . . . . . . . . 19-4

19.4.2 Protective Coating for Electrical

Connections. . . . . . . . . . . . . . . 19-4

19.4.3 Identification . . . . . . . . . . . . . . . . 19-4

19.5 INSTALLATION OF TERMINAL

BOARDS . . . . . . . . . . . . . . . . 19-5

19.5.1 Mounting Hardware . . . . . . . . . . . 19-5

19.5.2 Method of Attachment . . . . . . . . . 19-5

19.5.3 Alternative Method of

Attachment . . . . . . . . . . . . . . . 19-5

19.5.4 Insulation . . . . . . . . . . . . . . . . . . 19-5

Chapter Page

20 ELECTRICAL WIRING

INSTALLATION . . . . . . . . . . . . . . . . . . 20-1

20.1 ELECTRICAL WIRING

INSTALLATION . . . . . . . . . . . 20-1

20.2 DEFINITIONS . . . . . . . . . . . . . . 20-1

20.2.1 Open Wiring . . . . . . . . . . . . . . . . 20-1

20.2.2 Wire Group . . . . . . . . . . . . . . . . . 20-1

20.2.3 Wire Bundle . . . . . . . . . . . . . . . . 20-1

20.2.4 Wire Harness. . . . . . . . . . . . . . . . 20-1

20.2.5 Electrically Protected Wiring . . . . . 20-1

20.2.6 Electrically Unprotected Wiring . . . 20-1

20.3 WIRE TYPES . . . . . . . . . . . . . . . 20-1

20.3.1 Size of Wire Bundle . . . . . . . . . . . 20-1

20.3.2 Identity of Groups Within

Bundles . . . . . . . . . . . . . . . . . 20-1

20.3.3 Combing Wires . . . . . . . . . . . . . . 20-1

20.3.4 Twisting Wires. . . . . . . . . . . . . . . 20-1

20.3.5 Spliced Connection in Bundles . . . . 20-1

20.3.6 Slack . . . . . . . . . . . . . . . . . . . . . 20-1

20.4 PRECAUTIONS AND

PROTECTION . . . . . . . . . . . . 20-3

20.4.1 Precautions . . . . . . . . . . . . . . . . . 20-3

20.4.2 Support. . . . . . . . . . . . . . . . . . . . 20-3

20.4.3 Protection . . . . . . . . . . . . . . . . . . 20-4

20.4.4 Protection Against Chafing. . . . . . . 20-4

20.4.5 Separation from Plumbing

Lines . . . . . . . . . . . . . . . . . . . 20-4

20.5 INSTALLATION OF CABLE

CLAMPS . . . . . . . . . . . . . . . . 20-4

20.5.1 MS25281 Plastic Cable Clamp . . . . 20-5

20.5.2 Special Tool . . . . . . . . . . . . . . . . 20-5

20.6 INSTALLING GROMMETS . . . . . 20-5

20.7 CONNECTIONS TO TERMINAL

BOARDS AND BUSBARS . . . . 20-5

20.7.1 Connecting Terminal Lugs to Termi-

nal Boards. . . . . . . . . . . . . . . . 20-5

20.7.2 Hardware for Wiring Terminal

Boards . . . . . . . . . . . . . . . . . . 20-5

20.7.3 Terminal Board MS27212 . . . . . . . 20-5

20.7.4 Installation Torques for Large Cop-

per Terminals. . . . . . . . . . . . . . 20-5

21 LACING AND TYING . . . . . . . . . . . . . . . . 21-1

21.1 LACING AND TYING . . . . . . . . . 21-1

21.2 DEFINITIONS . . . . . . . . . . . . . . 21-1

21.2.1 Tying . . . . . . . . . . . . . . . . . . . . . 21-1

21.2.2 Lacing . . . . . . . . . . . . . . . . . . . . 21-1

21.2.3 Wire Group . . . . . . . . . . . . . . . . . 21-1

21.2.4 Wire Bundle . . . . . . . . . . . . . . . . 21-1

21.3 MATERIALS . . . . . . . . . . . . . . . 21-1

TO 1-1A-15

vii

21.3.1 Vinyl or Glass Fiber Tape . . . . . . . 21-1

21.3.2 Self-Clinching Cable Straps . . . . . . 21-1

21.4 GENERAL PRECAUTIONS . . . . . 21-1

21.4.1 Prevent Slipping. . . . . . . . . . . . . . 21-1

21.4.2 Wire Bundle Inside Conduit. . . . . . 21-1

21.4.3 Avoid Splaying of Contacts . . . . . . 21-1

21.5 LACING. . . . . . . . . . . . . . . . . . . 21-1

21.5.1 Single Cord Lacing. . . . . . . . . . . . 21-1

21.5.2 Double Cord Lacing . . . . . . . . . . . 21-1

21.5.3 Lacing Branch-Offs . . . . . . . . . . . 21-2

21.6 TYING. . . . . . . . . . . . . . . . . . . . 21-2

21.6.1 Making Ties . . . . . . . . . . . . . . . . 21-2

21.6.2 Temporary Ties . . . . . . . . . . . . . . 21-2

21.6.3 Tying Wire Groups into Wire

Bundles . . . . . . . . . . . . . . . . . 21-2

21.6.4 Tying Sleeves to Wire Groups or

Wire Bundles. . . . . . . . . . . . . . 21-2

21.6.5 Securing with Pressure-Sensitive

Tape. . . . . . . . . . . . . . . . . . . . 21-2

21.7 SELF-CLINCHING CABLE

STRAPS . . . . . . . . . . . . . . . . . 21-3

21.7.1 Installing Self-Clinching Cable

Straps . . . . . . . . . . . . . . . . . . . 21-3

22 FUSES USED IN AGE ELECTRICAL

SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . 22-1

22.1 FUSES . . . . . . . . . . . . . . . . . . . . 22-1

22.2 DEFINITIONS AND

DESCRIPTIONS . . . . . . . . . . . 22-1

22.2.1 Fuse Types and Styles. . . . . . . . . . 22-1

22.2.2 Dimensions . . . . . . . . . . . . . . . . . 22-1

22.2.3 Current Rating . . . . . . . . . . . . . . . 22-1

22.2.4 Blowtime Characteristics

(General) . . . . . . . . . . . . . . . . 22-1

22.2.5 Voltage Rating . . . . . . . . . . . . . . . 22-2

22.3 TYPES OF FUSES. . . . . . . . . . . . 22-2

22.4 FUSE HOLDERS. . . . . . . . . . . . . 22-2

22.5 IDENTIFICATION. . . . . . . . . . . . 22-2

22.5.1 Military Fuse Designations . . . . . . 22-2

22.5.2 Commercial Fuse Designations. . . . 22-2

22.6 GENERAL PRECAUTIONS . . . . . 22-2

22.6.1 Remove or Insert . . . . . . . . . . . . . 22-2

22.6.2 Electrical Features . . . . . . . . . . . . 22-2

22.6.3 Plating . . . . . . . . . . . . . . . . . . . . 22-2

22.6.4 Replacement Fuse . . . . . . . . . . . . 22-2

22.6.5 Correct Size . . . . . . . . . . . . . . . . 22-3

23 EMERGENCY REPAIRS . . . . . . . . . . . . . . 23-1

23.1 EMERGENCY REPAIRS . . . . . . . 23-1

Chapter Page

23.2 REPAIRING BROKEN OR DAM-

AGED WIRES . . . . . . . . . . . . 23-1

23.2.1 Methods of Repairing Wire . . . . . . 23-1

23.2.2 Splicing Broken Wires with a Per-

manent Splice . . . . . . . . . . . . . 23-1

23.2.3 Splicing with Terminal Lug

Barrel . . . . . . . . . . . . . . . . . . . 23-1

23.2.4 Splicing with Solder and Potting

Compound . . . . . . . . . . . . . . . 23-2

23.2.5 Splicing Large Wire with Terminal

Lugs. . . . . . . . . . . . . . . . . . . . 23-2

23.2.6 Repairing Damaged Wire

Insulation . . . . . . . . . . . . . . . . 23-2

23.3 REPAIRING SHIELDED

CABLE . . . . . . . . . . . . . . . . . 23-5

23.3.1 Severed Cable . . . . . . . . . . . . . . . 23-5

23.3.2 Alternate Method . . . . . . . . . . . . . 23-5

23.3.3 Repairing Damaged Shielding . . . . 23-5

23.4 REPAIRING DAMAGED MS

CONNECTORS . . . . . . . . . . . . 23-5

23.4.1 Repairing Unpotted Connectors . . . 23-5

23.4.2 Replacement of Connectors . . . . . . 23-6

23.4.3 Repair Complete Wire Bundle . . . . 23-6

23.5 REPLACING TERMINAL BOARD

COVERS . . . . . . . . . . . . . . . . 23-6

24 WHEEL BEARINGS: REMOVAL, CLEAN-

ING, INSPECTION, LUBRICATION, AND

INSTALLATION . . . . . . . . . . . . . . . . . . 24-1

24.1 INTRODUCTION . . . . . . . . . . . . 24-1

24.2 DESCRIPTION . . . . . . . . . . . . . . 24-1

24.3 TYPES OF WHEEL

BEARINGS. . . . . . . . . . . . . . . 24-1

24.3.1 Ball Bearings. . . . . . . . . . . . . . . . 24-1

24.3.2 Cylindrical Roller Bearings . . . . . . 24-1

24.3.3 Tapered Roller Bearings . . . . . . . . 24-1

24.4 FRONT AND REAR WHEEL,

BEARING, AND CUP

REMOVAL . . . . . . . . . . . . . . . 24-2

24.4.1 Removal . . . . . . . . . . . . . . . . . . . 24-2

24.4.2 Wheel Bearing Cleaning . . . . . . . . 24-3

24.4.3 Inspection of Wheel Bearing . . . . . 24-4

24.4.4 Wheel Bearing Inspection . . . . . . . 24-4

24.4.5 Lubrication of Wheel Bearings . . . . 24-4

24.5 HUB ASSEMBLIES. . . . . . . . . . . 24-5

24.6 INSTALLATION PROCEDURES

FOR FRONT AND REAR

WHEEL BEARINGS AND

CUPS. . . . . . . . . . . . . . . . . . . 24-5

TO 1-1A-15

viii Change 6

24.7 CLEAN, INSPECT, AND LUBRI-

CATE MAINTENANCE STAND

SWIVEL CASTERS . . . . . . . . . 24-6

25 STANDARDIZATION OF LUNETTES AND

PINTLES USED IN SAFE TOWING

OPERATIONS . . . . . . . . . . . . . . . . . . . . 25-1

25.1 STANDARDIZATION OF LU-

NETTES AND PINTLES . . . . . 25-1

25.1.1 Equipment. . . . . . . . . . . . . . . . . . 25-1

25.1.2 Maintenance Supervisors . . . . . . . . 25-1

25.1.3 New Pintles. . . . . . . . . . . . . . . . . 25-1

25.1.4 During Towing Operations. . . . . . . 25-1

25.1.5 Following Towing Operations. . . . . 25-1

25.2 PROPER INSTALLATION OF

COTTER PINS . . . . . . . . . . . . 25-1

26 REPAIR OF EXTERNAL POWER

CABLES. . . . . . . . . . . . . . . . . . . . . . . . 26-1

26.1 REPAIR OF EXTERNAL POWER

CABLES . . . . . . . . . . . . . . . . 26-1

26.2 RESPONSIBILITIES . . . . . . . . . . 26-1

26.2.1 Support Equipment (SE) . . . . . . . . 26-1

26.2.2 Applicable References. . . . . . . . . . 26-1

26.3 REPAIRING CABLE

JACKETS. . . . . . . . . . . . . . . . 26-1

26.3.1 Roughen Cable Jacket. . . . . . . . . . 26-1

26.3.2 Cementing. . . . . . . . . . . . . . . . . . 26-1

26.3.3 Wrapping . . . . . . . . . . . . . . . . . . 26-1

26.3.4 Buildup Splice . . . . . . . . . . . . . . . 26-1

26.3.5 Mold and Cure . . . . . . . . . . . . . . 26-1

26.4 PREPARATION AND ASSEMBLY

INSTRUCTIONS FOR EXTER-

NAL AIRCRAFT CABLE PLUG

FIELD REPAIR . . . . . . . . . . . . 26-2

26.4.1 Anderson Cable Plug DC . . . . . . . 26-2

26.4.2 Anderson Cable Plug AC. . . . . . . . 26-5

26.4.3 J & B Aviation Cable Contacts and

Assemblies . . . . . . . . . . . . . . . 26-13

26.5 PREPARATION AND ASSEMBLY

INSTRUCTIONS FOR SPLIC-

ING PIGTAIL CONNECTOR

ASSEMBLY, PN X8349-582 OR

EQUAL, TO AN2551, AIR-

CRAFT EXTERNAL POWER

CABLE . . . . . . . . . . . . . . . . . 26-15

26.5.1 Match Cables . . . . . . . . . . . . . . . 26-15

26.5.2 Remove Jacket and Insulation . . . . 26-15

26.5.3 Shrink Tube . . . . . . . . . . . . . . . . 26-15

26.5.4 Conductor . . . . . . . . . . . . . . . . . . 26-15

26.5.5 Cleaning and Coating . . . . . . . . . . 26-15

Chapter Page

26.6 PREPARATION AND ASSEMBLY

INSTRUCTIONS FOR SPLIC-

ING PIGTAIL CONNECTOR

ASSEMBLY, PN X8354-324 OR

EQUAL TO AN3430 (MS24206)

AIRCRAFT EXTERNAL

POWER CABLE, IF CONNEC-

TOR ASSEMBLY, MS25486-30

IS NOT USED; ALSO PREPA-

RATION AND ASSEMBLY IN-

STRUCTIONS FOR SPLICING

PIGTAIL CONNECTOR AS-

SEMBLY, PN 3150-027-0003 OR

EQUAL TO PN X1806-75, SUP-

PORT EQUIPMENT INPUT

POWER CABLE . . . . . . . . . . . 26-16

26.6.1 Assembly of AC Input Power Con-

nector, MS27265-1 . . . . . . . . . . 26-16

26.6.2 Power and Ground Leads . . . . . . . 26-16

26.6.3 Pilot Leads . . . . . . . . . . . . . . . . . 26-16

26.7 INSPECTION OF ALL EXTER-

NAL POWER ASSEMBLIES

USED ON AIRCRAFT

GROUND SUPPORT GENERA-

TORS SETS . . . . . . . . . . . . . . 26-20

26.7.1 Inspection of External Power

Cables . . . . . . . . . . . . . . . . . . 26-20

26.7.2 Inspection Prior to Installation . . . . 26-20

26.8 CABLE STOWAGE . . . . . . . . . . . 26-21

26.9 BANDING . . . . . . . . . . . . . . . . . 26-21

26.10 USE OF HEAT SHRINKABLE

TUBING FOR EXTERNAL AGE

POWER CABLE REPAIR. . . . . 26-21

26.10.1 Cuts or Abrasions. . . . . . . . . . . . . 26-21

26.10.2 Nicked or Cut Cable Strands . . . . . 26-21

26.11 GENERAL CABLE CARE . . . . . . 26-22

26.11.1 Repairing . . . . . . . . . . . . . . . . . . 26-22

26.11.2 Inspection . . . . . . . . . . . . . . . . . . 26-22

26.11.3 Inspect for Hot Spots . . . . . . . . . . 26-22

26.11.4 Cleaning . . . . . . . . . . . . . . . . . . . 26-22

26.11.5 Discoloration . . . . . . . . . . . . . . . . 26-22

26.11.6 Replacement . . . . . . . . . . . . . . . . 26-22

26.11.7 Storage . . . . . . . . . . . . . . . . . . . . 26-22

26.11.8 Handling Techniques. . . . . . . . . . . 26-22

26.11.9 Responsibility . . . . . . . . . . . . . . . 26-22

26.12 BURTON GROUND POWER

PLUG . . . . . . . . . . . . . . . . . . 26-25

26.12.1 Power Plug Installation . . . . . . . . . 26-25

26.12.2 Test . . . . . . . . . . . . . . . . . . . . . . 26-25

26.13 400HZ AC POWER CABLE

SCUFF JACKETS . . . . . . . . . . 26-28

26.13.1 Scuff Jacket. . . . . . . . . . . . . . . . . 26-28

26.13.2 Installation and Removal . . . . . . . . 26-28

TO 1-1A-15

Change 6 ix

26.13.3 Inspection . . . . . . . . . . . . . . . . . . 26-28

26.13.4 Repair . . . . . . . . . . . . . . . . . . . . 26-28

27 INSPECTION, SERVICE, AND CONTROL

OF SUPPORT EQUIPMENT TIRES . . . . . 27-1

27.1 INSPECTION, SERVICE, AND

CONTROL OF SUPPORT

EQUIPMENT TIRES . . . . . . . . 27-1

27.2 SELECTION . . . . . . . . . . . . . . . . 27-1

27.3 INSPECTION . . . . . . . . . . . . . . . 27-1

27.3.1 Presence of Valve Caps . . . . . . . . . 27-1

27.3.2 Excessive Wear . . . . . . . . . . . . . . 27-1

27.3.3 Cuts and Cracks. . . . . . . . . . . . . . 27-1

27.3.4 Bumps, Bulges, and Damaged Tire

Cord. . . . . . . . . . . . . . . . . . . . 27-1

27.3.5 Imbedded Foreign Objects . . . . . . . 27-1

27.3.6 Tire Inflation . . . . . . . . . . . . . . . . 27-1

27.3.7 Matched Tread Patterns . . . . . . . . . 27-1

27.3.8 Gauge Testing . . . . . . . . . . . . . . . 27-1

27.4 AIRCRAFT TIRES ON MODEL

6200 TRAILERS . . . . . . . . . . . 27-1

27.5 STORAGE OF TIRES . . . . . . . . . 27-1

27.6 USE OF FOREIGN OBJECT DAM-

AGE (FOD) TIRES . . . . . . . . . 27-1

27.6.1 Routine Use . . . . . . . . . . . . . . . . 27-1

27.6.2 Reported Need. . . . . . . . . . . . . . . 27-1

27.6.3 Tire Selection . . . . . . . . . . . . . . . 27-1

27.6.4 Retreading Conventional Tires . . . . 27-2

27.6.5 Matched Tread Patterns . . . . . . . . . 27-2

27.7 MAINTENANCE AND INSPEC-

TION OF PNEUMATIC AND

SOLID RUBBER TIRES. . . . . . 27-2

27.7.1 General Information . . . . . . . . . . . 27-2

27.7.2 Types of Tires . . . . . . . . . . . . . . . 27-2

27.7.3 Types of Mountings . . . . . . . . . . . 27-2

27.7.4 Tread Patterns . . . . . . . . . . . . . . . 27-2

27.7.5 Preventive Maintenance. . . . . . . . . 27-2

27.7.6 Removal and Installation of SE

Tires . . . . . . . . . . . . . . . . . . . 27-3

27.8 REMOVAL OF TIRES FROM

EQUIPMENT PRIOR TO

DISPOSAL . . . . . . . . . . . . . . . 27-3

27.8.1 Criteria for Removal of Tires . . . . . 27-4

27.8.2 Tires Considered Unserviceable on

Equipment Being Processed for Disposal . . . . . . . . . . . . . . . . . 27-4

27.9 INSPECTION, SERVICE, AND

CONTROL OF MUNITIONS SE

TIRES . . . . . . . . . . . . . . . . . . 27-4

27.9.1 Inspection . . . . . . . . . . . . . . . . . . 27-4

27.9.2 Service . . . . . . . . . . . . . . . . . . . . 27-5

27.9.3 MHE Tire Controls. . . . . . . . . . . . 27-5

27.9.4 Criteria . . . . . . . . . . . . . . . . . . . . 27-5

27.10 TIRE PRESSURE GAUGES . . . . . 27-5

Chapter Page

28 HIGH VOLUME AIR DELIVERY DUCT

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 28-1

28.1 GENERAL INFORMATION . . . . . 28-1

28.2 INSPECTION - PERIODIC . . . . . . 28-1

28.3 ASSEMBLY . . . . . . . . . . . . . . . . 28-1

28.4 MINOR REPAIRS . . . . . . . . . . . . 28-2

29 TESTING, PREVENTIVE MAINTENANCE,

AND TROUBLESHOOTING OF START-

ING AND CHARGING SYSTEMS ON

AEROSPACE GROUND

EQUIPMENT . . . . . . . . . . . . . . . . . . . . 29-1

29.1 INTRODUCTION . . . . . . . . . . . . 29-1

29.2 BATTERY SAFETY. . . . . . . . . . . 29-1

29.3 GENERAL INFORMATION . . . . . 29-2

29.4 BATTERY COMPOSITION. . . . . . 29-2.1

29.4.1 Absorbed Glass Matt (AGM) Bat-

tery (e.g., OPTIMA) . . . . . . . . . 29-2.1

29.4.2 Flooded Lead-Acid Battery . . . . . . 29-2.1

29.5 BATTERY TESTING . . . . . . . . . . 29-3

29.5.1 Absorbed Glass Matt (AGM) Bat-

tery (e.g,. OPTIMA) . . . . . . . . . 29-3

29.5.2 Flooded Cell Lead-Acid

Battery . . . . . . . . . . . . . . . . . . 29-3

29.6 BATTERY CHARGING . . . . . . . . 29-4

29.6.1 Absorbed Glass Matt (AGM) Bat-

tery (e.g., OPTIMA) . . . . . . . . . 29-4

29.6.2 Flooded Cell Lead-Acid

Battery . . . . . . . . . . . . . . . . . . 29-4

29.6.3 Connecting Battery Chargers . . . . . 29-5

29.7 BATTERY CONDITION TEST . . . 29-6

29.7.1 Prior to Testing . . . . . . . . . . . . . . 29-6

29.7.2 Battery Test Procedure . . . . . . . . . 29-6

29.7.3 Battery Test Results . . . . . . . . . . . 29-6

29.8 BATTERY CONDITION TEST . . . 29-7

29.8.1 Prior to Testing . . . . . . . . . . . . . . 29-7

29.8.2 Battery Test Procedure . . . . . . . . . 29-7

29.8.3 Battery Test Results . . . . . . . . . . . 29-7

29.9 SYSTEM FUNCTIONAL

CHECK . . . . . . . . . . . . . . . . . 29-8

29.9.1 Battery Inspection . . . . . . . . . . . . 29-8

29.9.2 Charging System Check . . . . . . . . 29-8

29.9.3 Starting System Check Using Com-

mercial Analyzers. . . . . . . . . . . 29-8

29.9.4 Starting System Check . . . . . . . . . 29-8

29.9.5 Starting System Check Using Com-

mercial Analyzers. . . . . . . . . . . 29-9

29.10 BATTERY CABLE TEST . . . . . . . 29-9

29.11 ALTERNATOR WIRING

TEST . . . . . . . . . . . . . . . . . . . 29-9

29.12 CONNECTING MULTIPLE

BATTERIES . . . . . . . . . . . . . . 29-11

TO 1-1A-15

x Change 6

29.13 BATTERY CHARGING AND

MAINTENANCE

EQUIPMENT . . . . . . . . . . . . . 29-11

29.14 BATTERY TEST

EQUIPMENT . . . . . . . . . . . . . 29-11

Chapter Page

29.15 SOLAR CHARGING

EQUIPMENT . . . . . . . . . . . . . 29-11

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

TO 1-1A-15

Change 9 xi

LIST OF ILLUSTRATIONS

Number PageTitle

3-1 Tubular Valve Extractor Tools. . . . . . . . . 3-7 3-2 Valve Sleeve Bleed Tool for Hose

Half . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3-3 Poppet Valve Bleed Tool for Bulkhead

Half . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-4 Cutaway View of Coupling . . . . . . . . . . 3-15 4-1 Typical Skin Repair . . . . . . . . . . . . . . . 4-3 4-2 Studs . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 5-1 Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-2 Washers . . . . . . . . . . . . . . . . . . . . . . . 5-3 6-1 Using Torque Wrench Adapters. . . . . . . . 6-4 7-1 Removing and Replacing Spring Pin . . . . 7-2 7-2 Quick-Release Pins . . . . . . . . . . . . . . . . 7-2 8-1 Cutting Tubing . . . . . . . . . . . . . . . . . . . 8-2 8-2 Tubing Bends. . . . . . . . . . . . . . . . . . . . 8-3 8-3 Bend Radii for Conduit and Fluid

Lines . . . . . . . . . . . . . . . . . . . . . . . 8-3 8-4 Bending Tubing . . . . . . . . . . . . . . . . . . 8-4 8-5 Properly Burred Tubing . . . . . . . . . . . . . 8-5 8-6 Damaged Fittings . . . . . . . . . . . . . . . . . 8-6 8-7 Straight Thread and Pipe Thread . . . . . . . 8-7 8-8 Torque Wrench and Extension . . . . . . . . 8-9 10-1 Hose Line Installation Aids for All Types of Hose. . . . . . . . . . . . . . . . . . . . . . 10-3 11-1 Securing Screws, Nuts, Bolts, and Snap

Rings . . . . . . . . . . . . . . . . . . . . . . . 11-3 11-2 Example of Secured Combustor Can

Hardware . . . . . . . . . . . . . . . . . . . . 11-4 11-3 Safetywiring Procedures . . . . . . . . . . . . 11-5 11-4 Use of Wire Twister . . . . . . . . . . . . . . . 11-7 11-5 Examples of Installed Safety Cable . . . . . 11-9 11-6 Flat Washer Safety Cable Installation. . . . 11-10 11-7 Self-Looping Safety Cable . . . . . . . . . . . 11-10 11-8 Self-Looping Safety Cable Anchored to a

Pin . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 11-9 Self-Looping Safety Cable in High Bend

Exit Applications . . . . . . . . . . . . . . . 11-10 11-10 Safety Cable Flex Limits . . . . . . . . . . . . 11-11 11-11 Low Profile Application for 0.032- and

0.040-Inch Safety Cable . . . . . . . . . . 11-11 11-12 Safety Cable Jacketing for Protection. . . . 11-12 11-13 Safety Cable on Tube Couplings . . . . . . . 11-12 11-14 Preset Tension Safety Cable Tool . . . . . . 11-12 11-15 Safety Cable Tools . . . . . . . . . . . . . . . . 11-12 11-16 Position Safety Cable Tool . . . . . . . . . . . 11-13 11-17 Adjustable Tension Safety Cable Tool . . . 11-13 11-18 Pneumatic Safety Cable Application

Tool . . . . . . . . . . . . . . . . . . . . . . . . 11-14 11-19 Calibration Test Fixture and Torque

Wrench . . . . . . . . . . . . . . . . . . . . . . 11-15 11-20 Electronic Safety Cable Pull Tester . . . . . 11-15

Number PageTitle

11-21 Adjustment of Safety Cable Indenter (Same for Hand or Pneumatic Tool Models) . . . . . . . . . . . . . . . . . . . . . 11-16

11-22 Removal of Safety Cable Tool Nose Assembly . . . . . . . . . . . . . . . . . . . . 11-16

11-23 Securing Turnbuckles with Safetywire . . . . . . . . . . . . . . . . . . . . 11-18

11-24 Routing of Safety Cable on Turnbuckles . . . . . . . . . . . . . . . . . . . 11-18

11-25 Example of Final Safety Cable Turnbuckle Installation. . . . . . . . . . . . . . . . . . . . 11-19

11-26 Securing with Cotter Pins . . . . . . . . . . . 11-19 11-27 Alternate Method of Securing with Cotter

Pins . . . . . . . . . . . . . . . . . . . . . . . . 11-19 12-1 V-Band Coupling Safetywiring

Techniques . . . . . . . . . . . . . . . . . . . 12-2 13-1 Wires After Cutting. . . . . . . . . . . . . . . . 13-1 13-2 Wire Cutting Tools . . . . . . . . . . . . . . . . 13-2 13-3 Spacing of Identification Stamping on

Wire and Cable . . . . . . . . . . . . . . . . 13-3 13-4 Location of Identification Sleeve . . . . . . . 13-4 13-5 Wire Identification at Terminal

Boards . . . . . . . . . . . . . . . . . . . . . . 13-4 13-6 Marking Machine - Hand. . . . . . . . . . . . 13-4 13-7 Marking on Sleeves . . . . . . . . . . . . . . . 13-6 13-8 Identification of Wire Bundles and

Harnesses . . . . . . . . . . . . . . . . . . . . 13-7 13-9 Typical Wire Stripping Tools . . . . . . . . . 13-8 13-10 Dip-Tinning in Solder Pot . . . . . . . . . . . 13-10 13-11 Tinning Wire with a Soldering Iron . . . . . 13-10 14-1 Solderless Terminal Lugs and Splices . . . 14-4 14-2 Pre-insulated Terminal Lug

Cut-Away . . . . . . . . . . . . . . . . . . . . 14-4 14-3 MS90413 Crimping Tool with Terminal

Lug Inserted . . . . . . . . . . . . . . . . . . 14-5 14-4 MS3316 Hand Crimping Tool. . . . . . . . . 14-6 14-5 Proper Insertion of Stripped Wire in Insu-lated Terminal Lug for Crimping. . . . . 14-6 14-6 Insulating Sleeves . . . .