TO_00-25-234.pdf

TO 00-25-234

TECHNICAL MANUAL

GENERAL SHOP PRACTICE REQUIREMENTS

FOR THE REPAIR, MAINTENANCE, AND

TEST OF ELECTRICAL EQUIPMENT

F09603-99-D-0382

FA8501-05-D-0002

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited, (WR-ALC/PA Public Affairs Certification Number 04-10-83).

Other requests for this document shall be referred to 584 CBSS/GBHDE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to 570 CBSS/GBEN.

Published Under Authority of the Secretary of the Air Force

1 AUGUST 1988 CHANGE 36 - 13 AUGUST 2007

BASIC AND ALL CHANGES HAVE BEEN MERGED

TO MAKE THIS A COMPLETE PUBLICATION

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NOTE: The portion of the text affected by the changes is indicated by a vertical line in the margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by miniature point-ing hands or by shaded areas. A vertical line running the length of a figure in the outer margin of the page indicates that the figure is being added.

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

A

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Original . . . . . 0 . . . . . . . . . . 1 August 1988 Change . . . . . 1 . . . . . . . . .16 January 1989 Change . . . . . 2 . . . . . . . . . . . 16 July 1989 Change . . . . . 3 . . . . . . . . . 28 August 1989 Change . . . . . 4 . . . . . . . . . .3 January 1990 Change . . . . . 5 . . . . . . . . . . .3 March 1990 Change . . . . . 6 . . . . . . . . . . . 31 May 1990 Change . . . . . 7 . . . . . . . . 29 October 1990 Change . . . . . 8 . . . . . . . . . . . 30 May 1991 Change . . . . . 9 . . . . . . . .1 December 1991 Change . . . . . 10 . . . . . . . . .10 March 1992 Change . . . . . 11 . . . . . . . . . . 30 July 1992 Change . . . . . 12 . . . . . . . . 30 August 1993

Change . . . . . 13 . . . . . . . . . . 10 May 1994 Change . . . . . 14 . . . . . 30 September 1994 Change . . . . . 15 . . . . . . . . . . 30 June 1995 Change . . . . . 16 . . . . . . . . 22 January 1996 Change . . . . . 17 . . . . . . . . . . 10 April 1996 Change . . . . . 18 . . . . . . . . . . .15 July 1996 Change . . . . . 19 . . . . . .20 November 1996 Change . . . . . 20 . . . . . . . . . . 20 May 1997 Change . . . . . 21 . . . . . . . . . 1 August 1997 Change . . . . . 22 . . . . . . . . 28 January 1998 Change . . . . . 23 . . . . . . . . . . .19 July 1998 Change . . . . . 24 . . . . . . .6 November 1998 Change . . . . . 25 . . . . . . . . 20 August 1999

Change . . . . . .26 . . . . . . 17 November 2000 Change . . . . . .27 . . . . . . . . . .7 August 2001 Change . . . . . .28 . . . . . . 25 November 2001 Change . . . . . .29 . . . . . . . . . . .30 June 2002 Change . . . . . .30 . . . . . . . . . .1 August 2002 Change . . . . . .31 . . . . . . . . . . . .6 June 2003 Change . . . . . .32 . . . . . . . . . . . 1 April 2005 Change . . . . . .33 . . . . . . . . . . .15 June 2005 Change . . . . . .34 . . . . . . . . . 3 October 2005 Change . . . . . .35 . . . . . . . . . . . 12 July 2006 Change . . . . . .36 . . . . . . . . .13 August 2007 Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 322, CONSISTING OF THE FOLLOWING:

Title A - B C Blank i ii iii - vii viii ix x Blank xi xii xiii - xxvi Deleted 1-1 1-2 1-3 - 1-6 2-1 2-2 2-3 - 2-4 2-5 2-6 Blank 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-10A Added 3-10B Blank 3-11 - 3-12 3-13 - 3-14 3-15 - 3-16 3-17 3-18 3-19 - 3-20

3-21 3-22 3-23 3-24 3-25 3-26 3-27 - 3-28 3-29 3-30 Blank 4-1 4-2 4-3 4-4 4-5 4-6 - 4-9 4-10 - 4-11 4-12 4-12A 4-12B Blank 4-13 4-14 4-14A 4-14B 4-15 - 4-16 4-17 4-18 - 4-22 4-22A 4-22B Blank 4-23 4-24 4-25 - 4-26 4-26A - 4-26B Added 4-26C 4-26D Blank 4-27 - 4-31 4-32 4-33 4-34 - 4-35

4-36 - 4-37 4-38 4-38A Added 4-38B Blank 4-39 4-40 4-40A - 4-40B 4-41 4-42 4-43 - 4-44 4-45 4-46 4-46A 4-46B Blank 4-47 - 4-48 4-49 4-50 4-50A 4-50B Blank 4-51 4-52 4-53 - 4-54 4-55 - 4-56 4-57 4-58 Blank 5-1 5-2 - 5-3 5-4 5-5 - 5-7 5-8 5-8A Added 5-8B Blank 5-9 5-10 5-11 5-12 5-13 5-14 *Zero in this column indicates an original page.

USAF Change 36

LIST OF EFFECTIVE PAGES

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

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5-15 5-16 5-17 5-18 - 5-19 5-20 - 5-26 5-26A - 5-26G Added 5-26H Blank 5-27 5-28 5-29 5-30 5-31 5-32 - 5-33 5-34 5-34A 5-34B Blank 5-35 - 5-38 5-39 5-40 Blank 6-1 6-2 6-3 6-4 6-5 6-6 6-6A 6-6B Blank 6-7 6-8 6-9 6-10 - 6-12 6-13 - 6-14 6-15 6-16 7-1 7-2 7-2A Added 7-2B Blank 7-3 - 7-4 7-4A - 7-4B Deleted 7-5 7-6 7-6A - 7-6B Deleted 7-7 7-8 7-9 - 7-10 7-11 7-12 - 7-20 7-21 - 7-24 7-24A - 7-24B 7-25 - 7-26 7-27 7-28 - 7-29 7-30 - 7-32 7-32A - 7-32D 7-33 7-34 7-34A - 7-34B Deleted 7-35 7-36 7-37 7-38 7-38A Added 7-38B Blank

7-39 7-40 7-40A - 7-40B 7-41 7-42 - 7-44 7-44A Added 7-44B Blank 7-45 7-46 7-47 7-48 7-49 - 7-52 Deleted 8-1 - 8-2 8-3 8-4 8-5 - 8-6 8-7 - 8-8 8-9 8-10 - 8-13 8-14 - 8-15 8-16 Blank 9-1 - 9-2 9-3 9-4 9-5 9-6 9-6A Added 9-6B Blank 9-7 9-8 9-9 9-10 - 9-13 9-14 10-1 10-2 Blank Glossary 1 - Glossary 2 Glossary 3 Glossary 4 - Glossary 7 Glossary 8 Index 0 Deleted Index 1 - Index 2 Index 3 - Index 4 Index 4A Added Index 4B Blank Index 5 - Index 10 Index 11 - Index 12 Deleted *Zero in this column indicates an original page.

Change 36 B/(C blank)

TABLE OF CONTENTS

Section/Para Page WARNING AND CAUTION STATEMENTS..................................................................................................................xi WARNING..........................................................................................................................................................................xi USE OF LIQUID SOLDER FLUX, MIL-F-14256 ............................................................................................................xi GIVE CLEANERS/CHEMICALS SPECIAL CARE.........................................................................................................xi DO NOT WEAR JEWELRY..............................................................................................................................................xi PERSONAL PROTECTIVE EQUIPMENT (PPE) ............................................................................................................xi SOLDERING ......................................................................................................................................................................xi KEEP AWAY FROM LIVE CIRCUITS............................................................................................................................xi FINGER RINGS .................................................................................................................................................................xi

I INTRODUCTION.............................................................................................................................................................1-1 1-1 General ........................................................................................................................................................1-1 1-2 Scope ...........................................................................................................................................................1-1 1-3 Organization Of Manual..............................................................................................................................1-1 1-4 Materials And Parts .....................................................................................................................................1-1 1-5 Parts Substitution.........................................................................................................................................1-1 1-6 Economical Repair ......................................................................................................................................1-1 1-7 Recommended Tools...................................................................................................................................1-1

II WORKMANSHIP.............................................................................................................................................................2-1 2-1 General ........................................................................................................................................................2-1 2-2 Wiring..........................................................................................................................................................2-1 2-3 Thermal Bonding.........................................................................................................................................2-1 2-4 Mechanical Bonding....................................................................................................................................2-1 2-5 Insulating .....................................................................................................................................................2-1 2-6 Repair And Refinishing...............................................................................................................................2-1 2-7 Marking .......................................................................................................................................................2-1 2-8 Cleaning.......................................................................................................................................................2-1 2-9 Handling And Storage .................................................................................................................................2-1 2-10 Inspection ....................................................................................................................................................2-5

III SOLDERING ....................................................................................................................................................................3-1 3-1 General ........................................................................................................................................................3-1 3-2 Reference Specifications And Standards ....................................................................................................3-1 3-3 Description ..................................................................................................................................................3-1 3-4 Tools And Equipment .................................................................................................................................3-1 3-5 Materials ......................................................................................................................................................3-4 3-6 Safety Precautions .......................................................................................................................................3-5 3-7 Cleanliness...................................................................................................................................................3-6 3-8 Soldering Iron Preparation ..........................................................................................................................3-7 3-9 Preparation Of Wires...................................................................................................................................3-7 3-10 Preparation Of Shielded Wire Or Cable......................................................................................................3-7 3-11 Tinning Leads..............................................................................................................................................3-9 3-12 Lead Bending .........................................................................................................................................3-10A 3-13 Protection Of Completed Connections......................................................................................................3-11 3-14 Preparation Of Terminals ..........................................................................................................................3-11 3-15 Turret Terminal Connections ....................................................................................................................3-11 Change 28 i

TABLE OF CONTENTS - Continued

Section/Para Page 3-16 Bifurcated Terminal Connections .............................................................................................................3-12 3-17 Hook Or Pierced Terminal Connection.....................................................................................................3-12 3-18 Flat Perforated Terminal Connection........................................................................................................3-12 3-19 General Soldering Procedures...................................................................................................................3-13 3-20 Soldering On Printed Circuit Boards ........................................................................................................3-18 3-21 Microelectronics Soldering Procedures ....................................................................................................3-21 3-22 Desoldering Procedures ............................................................................................................................3-25 3-23 Rework Of Unsatisfactory Solder Connections ........................................................................................3-27 3-24 Soldering/desoldering Of Instrument Cans ...............................................................................................3-28

IV GENERAL REPAIR.........................................................................................................................................................4-1 4-1 General ........................................................................................................................................................4-1 4-2 Safety...........................................................................................................................................................4-1 4-3 Equipment Cases And Panels......................................................................................................................4-3 4-4 Equipment Performance..............................................................................................................................4-3 4-5 Mechanical Fabrication...............................................................................................................................4-4 4-6 Safety Wiring ............................................................................................................................................4-11 4-7 Clamps.................................................................................................................................................... 4-14B 4-8 Welding .....................................................................................................................................................4-15 4-9 Wiring .......................................................................................................................................................4-15 4-10 Shielded And Coaxial Cable .....................................................................................................................4-18 4-11 Cable Binding And Lacing........................................................................................................................4-23 4-11A High Temperature Pressure-sensitive Tape ...........................................................................................4-26A 4-12 Crimped Electrical Connections ............................................................................................................ 4-26B 4-13 Wire Wrapped Electrical Connections......................................................................................................4-28 4-14 Bolted Electrical Connections...................................................................................................................4-29 4-15 Insulating Materials...................................................................................................................................4-29 4-16 Potting Of Connectors...............................................................................................................................4-32 4-17 Cleaning Procedures..................................................................................................................................4-34 4-18 Corrosion Preventive Treatments..............................................................................................................4-38 4-19 Fungus Prevention.....................................................................................................................................4-38 4-20 Pressurization Test ....................................................................................................................................4-38 4-21 Marking And Identification.......................................................................................................................4-39 4-22 Troubleshooting ........................................................................................................................................4-40 4-23 Replacement And Repair Of Parts ............................................................................................................4-40 4-24 Component Substitution............................................................................................................................4-52 4-25 Repair Of Electrical Contact Strips...........................................................................................................4-55 4-26 Repair Of Waveguide................................................................................................................................4-56

V PRINTED CIRCUIT BOARD REPAIR...........................................................................................................................5-1 5-1 General ........................................................................................................................................................5-1 5-2 Types Of Printed Circuit Boards.................................................................................................................5-1 5-3 Tools And Accessories................................................................................................................................5-1 5-4 Materials......................................................................................................................................................5-1 5-5 Handling And Storage Procedures ..............................................................................................................5-1 5-6 Cleaning ......................................................................................................................................................5-4 5-7 Troubleshooting Printed Circuits ................................................................................................................5-4 5-8 Part Removal Procedures ............................................................................................................................5-9 5-9 Lead Forming And Trimming ...................................................................................................................5-12 5-10 Parts Replacement .....................................................................................................................................5-13 5-11 Connector And Contact Repair .................................................................................................................5-16 ii Change 25

TABLE OF CONTENTS - Continued

Section/Para Page 5-12 Cell Contact Replacement .........................................................................................................................5-18 5-13 Component Filleting..................................................................................................................................5-19 5-14 General Printed Circuit Board Laminate Repair .......................................................................................5-20 5-15 General Printed Circuit Board Conductor Repair .................................................................................. 5-26C 5-16 Terminal Mounting, Soldering, and Removal...........................................................................................5-27 5-17 Eyelet Replacement...................................................................................................................................5-28 5-18 Test Connector Contact Repair .................................................................................................................5-30 5-19 Component Staking ...................................................................................................................................5-30 5-20 Component Bonding .................................................................................................................................5-31 5-21 Component Pressure Bonding ...................................................................................................................5-31 5-22 Multilayer Printed Circuit Board Repairs .................................................................................................5-32 5-23 Ceramic Printed Circuit Repair .................................................................................................................5-33 5-24 Protective Coatings....................................................................................................................................5-38 5-25 Inspection of Repaired Boards ..................................................................................................................5-38

VI PROTECTIVE COATINGS .............................................................................................................................................6-1 6-1 General ........................................................................................................................................................6-1 6-2 Special Tools ...............................................................................................................................................6-1 6-3 Special Materials .........................................................................................................................................6-1 6-4 Safety Precautions .......................................................................................................................................6-1 6-5 Repair Sequence ..........................................................................................................................................6-2 6-6 Identification of Coating .............................................................................................................................6-2 6-7 Removal of Coating.....................................................................................................................................6-6 6-8 Recoating Repaired Areas ...........................................................................................................................6-9 6-9 Conformal Coating of Ceramic Printed Circuits (CPC's) .........................................................................6-15 6-10 Protective Coating Acceptance .................................................................................................................6-15 6-11 Varnish-Type Coatings..............................................................................................................................6-16

VII ELECTROSTATIC DISCHARGE CONTROL ...............................................................................................................7-1 7-1 General ........................................................................................................................................................7-1 7-2 References ...................................................................................................................................................7-1 7-3 Summary of ESD Principles........................................................................................................................7-1 7-4 ESD Susceptibility ......................................................................................................................................7-5 7-5 Framework of ESD Control ........................................................................................................................7-6 7-6 Operating Procedures: ...............................................................................................................................7-37 7-7 Work Area ESD Control Surveys ..........................................................................................................7-40A 7-8 Periodic Testing Of ESD Control Products...............................................................................................7-44

VIII FRONT PANEL REPAIR.................................................................................................................................................8-1 8-1 General ........................................................................................................................................................8-1 8-2 Types Of Front Panels.................................................................................................................................8-1 8-3 Tools And Accessories................................................................................................................................8-1 8-4 Materials ......................................................................................................................................................8-1 8-5 General Precautions.....................................................................................................................................8-1 8-6 Cleaning.......................................................................................................................................................8-1 8-7 Inspection ....................................................................................................................................................8-2 8-8 Initial Testing (Front Panel Removed From LRU) .....................................................................................8-3 8-9 Troubleshooting...........................................................................................................................................8-3 8-10 Repair Of Cracked Or Broken Panels .........................................................................................................8-3 8-11 Repair Of Broken Corners...........................................................................................................................8-4 8-12 Repair Of Broken Buss Wire.......................................................................................................................8-4 Change 26 iii

TABLE OF CONTENTS - Continued

Section/Para Page 8-13 Replacement Of Faulty Bulbs .....................................................................................................................8-7 8-14 Removal/Replacement Of Filters/Reflectors ..............................................................................................8-7 8-15 Filling Excavation .......................................................................................................................................8-8 8-16 Removal, Replacement Of Filter Bracket, Pile Fasteners And Annunciators ............................................8-9 8-17 Sanding......................................................................................................................................................8-10 8-18 Mixing And Painting Primer Ink...............................................................................................................8-10 8-19 Mixing And Painting Background Ink......................................................................................................8-11 8-20 Silkscreening .............................................................................................................................................8-11 8-21 Clear Epoxy Ink Application ....................................................................................................................8-11 8-22 Wiring Bulb Location Stenciling ..............................................................................................................8-12 8-23 Connector Plug Removal Replacement ....................................................................................................8-12 8-24 Final Testing..............................................................................................................................................8-13

IX FLEXIBLE PRINTED CIRCUIT REPAIR PROCEDURES...........................................................................................9-1 9-1 General ........................................................................................................................................................9-1 9-2 Types Of Flexible Printed Wiring...............................................................................................................9-1 9-3 Tools And Accessories................................................................................................................................9-1 9-4 Materials......................................................................................................................................................9-1 9-5 General Precautions ....................................................................................................................................9-1 9-6 Cleaning ......................................................................................................................................................9-2 9-7 Inspection ....................................................................................................................................................9-3 9-8 Initial Testing ..............................................................................................................................................9-3 9-9 Troubleshooting ..........................................................................................................................................9-3 9-10 Connector Replacement ..............................................................................................................................9-3 9-11 Cable End Conductor Repair (Single Or Double-Sided) ............................................................................9-4 9-12 Laminating Procedure (Kapton)..................................................................................................................9-6 9-13 Flexible Printed Wiring Multilayer Repair .................................................................................................9-7 9-14 Removal/Replacement Flexible Printed Wiring Layers (Soldered Eyelets)...............................................9-7 9-15 Removal/Replacement Of Flexible Printed Wiring Layers. (Welded Eyelets) ..........................................9-8 9-16 Damaged Pad Replacement.........................................................................................................................9-9 9-17 Skiving (Removing Insulation From Pad Area)..........................................................................................9-9

X MAGNETIC TAPE AND DISK PACKS.......................................................................................................................10-1 10-1 General ......................................................................................................................................................10-1

GLOSSARY..........................................................................................................................................................Glossary 1 iv Change 26

LIST OF ILLUSTRATIONS

Figure Title Page 2-1 Chassis-Type Electronic Assembly, Protective Packaging ............................................................................................2-3 2-2 Circuit Board-Type Electronic Assembly, Protective Packaging ..................................................................................2-4 2-3 Plug-In Type Electronic Assembly, Protective Packaging.............................................................................................2-4 3-1 Typical Soldering Gun ...................................................................................................................................................3-2 3-2 Typical Soldering Irons ..................................................................................................................................................3-2 3-3 Typical Soldering Iron Tips............................................................................................................................................3-2 3-4 Thermal Insulation Stripper............................................................................................................................................3-3 3-5 Precision Cutting Type Stripper .....................................................................................................................................3-3 3-6 Typical Thermal Shunts .................................................................................................................................................3-3 3-7 Wire-Bending Tool.........................................................................................................................................................3-4 3-8 Typical Lead Cleaning Tools .........................................................................................................................................3-4 3-9 Typical Soldering Aids...................................................................................................................................................3-6 3-10 Soldering Iron Preparation .............................................................................................................................................3-7 3-11 Acceptable and Unacceptable Wire Conditions .............................................................................................................3-8 3-12 Preparation of Shielded Wire or Cable...........................................................................................................................3-9 3-13 Correct Method for Tinning Wire ..................................................................................................................................3-9 3-14 Acceptable and Unacceptable Wire Tinning ................................................................................................................3-10 3-15 Lead Bending Method ..................................................................................................................................................3-11 3-16 Typical Stress Relief Bends in Parts Leads ..................................................................................................................3-11 3-17 Minimum Lead Bend....................................................................................................................................................3-12 3-18 Turret Terminal Connections .......................................................................................................................................3-12 3-19 Bottom Route Connection on Bifurcated Terminal......................................................................................................3-13 3-20 Top Route Connection on Bifurcated Terminal ...........................................................................................................3-13 3-21 Side Route Connection on Bifurcated Terminal ..........................................................................................................3-13 3-22 Bifurcated Terminal Showing Wire Fill .......................................................................................................................3-14 3-23 Interconnecting Bifurcated Terminals ..........................................................................................................................3-14 3-24 Hook Terminal Connections.........................................................................................................................................3-14 3-25 Typical Parts Using Flat Perforated Terminals ............................................................................................................3-14 3-26 Correct Wrap for Flat Perforated Terminal ..................................................................................................................3-14 3-27 Interconnecting Flat Perforated Terminals ...................................................................................................................3-15 3-28 Cross Section of Acceptable Solder Connections ........................................................................................................3-15 3-29 Lead Support ................................................................................................................................................................3-15 3-30 Substitute Lead Support ...............................................................................................................................................3-15 3-31 Deleted 3-32 Wire Placement in Solder Cup Terminal......................................................................................................................3-16 3-33 Acceptable Turret Terminal Solder Connections .........................................................................................................3-17 3-34 Unacceptable Turret Terminal Solder Connection.......................................................................................................3-17 3-35 Acceptable Bifurcated Terminal Solder Connection....................................................................................................3-18 3-36 Unacceptable Bifurcated Terminal Solder Connection ................................................................................................3-18 3-37 Acceptable Hook Terminal Solder Connection............................................................................................................3-19 3-38 Unacceptable Hook Terminal Solder Connections ......................................................................................................3-19 3-39 Acceptable Solder Cup Terminal Connections ............................................................................................................3-20 3-40 Unacceptable Solder Cup Terminal Connections.........................................................................................................3-20 3-41 Plated-Through Hole Solder Connection .....................................................................................................................3-20 3-42 Unacceptable Lead Termination Solder Connections ..................................................................................................3-21 3-43 Microcircuit Modules ...................................................................................................................................................3-22 3-44 Glass-to-Metal Packages ..............................................................................................................................................3-22 3-45 Typical Flat Packs ........................................................................................................................................................3-22 3-46 Installed Microcircuit Module ......................................................................................................................................3-23 3-47 Glass-to-Metal Package Mounting ...............................................................................................................................3-23 Change 26 v

LIST OF ILLUSTRATIONS - Continued

Figure Title Page 3-48 Flat Pack with Formed Leads .......................................................................................................................................3-24 3-49 Flat Pack with Tinned Leads ........................................................................................................................................3-24 3-50 Flat Pack Lead Alignment ............................................................................................................................................3-24 3-51 Securing Flat Pack for Soldering..................................................................................................................................3-25 3-52 Soldering Flat Pack Lead .............................................................................................................................................3-25 3-53 Lapflow Soldering........................................................................................................................................................3-25 3-54 Acceptable and Unacceptable Flat Pack Lead Alignment ...........................................................................................3-26 3-55 Desoldering by Wicking...............................................................................................................................................3-26 3-56 Typical Desoldering Equipment...................................................................................................................................3-27 3-57 Desoldering Technique.................................................................................................................................................3-28 3-58 Applying Auxiliary Heat ..............................................................................................................................................3-29 4-1 Typical Scribe.................................................................................................................................................................4-4 4-2 Typical Chassis Punch....................................................................................................................................................4-5 4-3 Application of Dowel Pin...............................................................................................................................................4-5 4-4 Application of Tapered Pins...........................................................................................................................................4-5 4-5 Typical Drive Pins and Spring Pins ...............................................................................................................................4-5 4-6 Clevis Pin .......................................................................................................................................................................4-6 4-7 Countersunk and Skin-Dimpled Rivet Holes .................................................................................................................4-6 4-8 Bucking Bar Recess........................................................................................................................................................4-7 4-9 Rivet Head Criteria.........................................................................................................................................................4-7 4-10 Properly and Improperly Set Rivets ...............................................................................................................................4-7 4-11 Acceptable and Unacceptable Eyelets............................................................................................................................4-8 4-12 Typical Studs and Terminals ..........................................................................................................................................4-8 4-13 Typical Retaining Rings .................................................................................................................................................4-9 4-14 Tapped Hole Specifications..........................................................................................................................................4-10 4-15 Anchor Nuts, Clinch Nut, and Plug Nut.......................................................................................................................4-11 4-16 Typical Lockwashers....................................................................................................................................................4-13 4-17 Double Twist Safety Wiring.........................................................................................................................................4-13 4-18 Single Wire Method .....................................................................................................................................................4-13 4-19 Use of Wire Twister .....................................................................................................................................................4-13 4-20 V-Band Coupling Safety Wiring Techniques ...........................................................................................................4-14A 4-21 Safety Wiring AN Connectors .................................................................................................................................. 4-14B 4-21A Safety Wiring AN Connector to Structure ................................................................................................................ 4-14B 4-22 Safety Wiring AN Split-Shell Assembly Screws .........................................................................................................4-15 4-23 Typical Clamps.............................................................................................................................................................4-15 4-24 Pre-Insulated Permanent Copper Splices .....................................................................................................................4-16 4-25 Terminal Lug Barrel Splice ..........................................................................................................................................4-17 4-26 Splicing Broken Wire by Soldering .............................................................................................................................4-17 4-27 Shop Aids for Stripping Insulation from Coaxial Cables.............................................................................................4-18 4-28 Attaching Improved N Connectors to Coaxial Cable...................................................................................................4-20 4-29 Grounding Sheath Termination for Shielded Wire ......................................................................................................4-20 4-30 Soldered On Pigtail Preparation ...................................................................................................................................4-22 4-31 Common-Point Pigtail Splice.......................................................................................................................................4-22 4-32 Several Shields in One Set of Sleeves..........................................................................................................................4-23 4-33 Typical Cascading Pigtails ...........................................................................................................................................4-23 4-34 Braid Dead-Ending.......................................................................................................................................................4-23 4-35 Starting a Cable Lace ...................................................................................................................................................4-24 4-36 Cable Stitching .............................................................................................................................................................4-24 4-37 Cable Lace Termination ...............................................................................................................................................4-25 4-38 Cable Branching ...................................................................................................................................................