Attachment 3 - Generator Lug Crimping System - TO-1B-52H-2-23 Snip.pdf

1-3.17 INSTALLATION AND REPAIR OF TERMINALS

AND CABLES.

1-3.18 The attachment of terminals and repair of copper and aluminum cables should be made in accordance with the following:

• Replace damaged segment of cable.

• Only terminals of like material will be used; aluminum terminals on aluminum cables and copper terminals on copper cables.

1-3.19 INSTALLATION OF COPPER TERMINALS AND

SPLICES. Terminals and splices should be assembled with the appropriate military standard tool. Vendor recom-mended tools should be used on non-MS (Class 2) hardware where tooling has not been specified as shown in figure 1-4.

Some general procedures for installation of copper termi-nals and splices are as follows:

• When inserting wire conductor into terminal or splice barrels, make sure that all conductor strands enter the barrel.

• Splices are sometimes used as three- or four-way connectors by splicing three or four wires together.

When assembling two wires in a splice end, insert the conductors simultaneously. If necessary to install wires with end of wire insulation outside the splice insulator, provide an additional insulating sleeve over the splice.

• Where necessary to replace a three-way splice and the single wire is undersized for the splice, double back the conductor or use an appropriate size filler wire to obtain proper crimp pressure. Adapters or fillers listed below can be used with the standard size tool to make a satisfactory installation.

UNDER-

SIZED

WIRE SPLICE SIZE

ADAPTER OF

FILLER

18-22 14-16 (blue) AMP (00779) 327635 or Double Wire

18-22 10-12 (yellow) AMP (00779) 327636 or #14 Wire

14-16 10-12 (yellow) AMP (00779) 327637 or Double Wire

• Install terminals against a built-in stop or position to prevent turning in the direction of loosening unless a locking device is provided.

• Nuts attaching terminals should be tightened to torque values listed in table 1-5. For smaller size studs or screws utilizing split lockwashers, tighten until lock-washer is fully compressed.

• Screws or studs should have a minimum of 1/16 inch of the chamfer extend beyond the tightened nut.

• The AN3427 tool (Burndy MY-28) is not a preferred tool. Equivalent power tools are recommended over this hand tool where practicable to use.

• For non-standard termination hardware, install part number(s) noted using tooling for terminating the applicable size wire gauge per T.O. 1–1A-14.

1-3.20 INSTALLATION OF ALUMINUM TERMINALS.

The procedure for installation of aluminum terminals is as follows:

a. Place an insulating sleeve over the cable. The insulating sleeve used in either high or low tempera-ture areas should be silicone rubber covered fiber-glass sleeving per Specification MIL-I-3190 Type D.

Length in inches of insulating sleeve is determined by the wire size as shown below:

INSULATING SLEEVE LENGTHS

WIRE

SIZE

LENGTH

(Inches)

Lug without Insulating Grip

0 2

Lug with Insulating Grip

0 2 1/2

Splice without Insulating Grip

0 7

b. After slipping the insulating sleeve over the cable, strip insulation from cable. Length in inches of insulation to be stripped is determined by wire size as follows:

INSULATING STRIP LENGTHS

WIRE

SIZE

LENGTH

(Inches)

BAC-T13( ) Cast Terminal

0 1 3/16 (+1/8/-0)

*MS25435 Wrought Terminal

0 1 1/16 (+1/16/-0)

MS25439 Wrought Splice

0 1 1/16 (+1/16/-0)

NOTE

* Preferred over Cast Terminal

c. The compound present on the inside of the terminal should not be removed and additional compound should not be added inside the terminal barrel or on the cable. Where terminals and splices are without hole plugs, hold finger over inspection hole (figure 1-11) when inserting wire to prevent compound from escaping.

d. Place terminal on cable making sure that all conduc-tor strands enter the crimp barrel. Apply slight pressure against wire while swaging to keep conduc-tor or insulation bottomed in terminal crimp or insulation barrel as applicable.

e. Swage terminal to cable with crimping tools and hexagonal dies listed in table 1-4.

T.O. 1B-52H-2-23

Change 23 1-39

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1624937070C Highlight