TO_1-1A-14.pdf

NAVAIR 01- 1A- 505- 1

TO 1- 1A- 14

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HEATING TOOLS

INSTALLATION AND REPAIR PRACTICES FOR

AIRCRAFT ELECTRIC AND ELECTRONIC WIRING

This WP supersedes WP 012 00 dated 1 September 2004

Reference Material

Aircraft Fuel Cells And Tanks NAVAIR 01-1A-35 Environmental Test Methods for Aerospace and Ground Equipment MIL- STD- 810

Alphabetical Index

Subject Page No.

CV- 5000, Thermogun Mark II Heating Tool 18 Operation 19 Post- operation 20 Pre- operation 18 Reflector Selection 18

CV- 5300/CV- 5302, Mini- gun Hot Air Tool 20 Operation 22 Post- operation 23 Pre- operation 21 Reflector Selection 21

General 3 Confined Space 4 Motorized Heat Guns Usage Policy 4 Permit Required Confined Space 4 Safety Precautions 3

HT- 900B/HT- 920B Compressed Air/ Nitrogen Heating Tool 4 Operation 6 Post- operation 7 Pre- operation 5 Reflector Selection 5

Termination Sleeve Reflector 5 Miniature Termination Sleeve Reflector 6 Boot and Tubing Reflector 6 Needle Point Reflector 6 Large Boot and Tubing Reflector 6

HT- 71002 Nitrogen/Compressed Air Hot Air Tool 8 Air/Temperature Settings 10 Compressed Air 8 Connecting Air/Nitrogen Supply 8 Nitrogen Gas Supply 9 Observe Warning On Power Cable 8 Operation 9 Powering Up The HT- 71002 9 Shrinking/Curing 10 Solder Sleeve Connectors 10

Introduction 3

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Alphabetical Index

Subject Page No.

IR- 500, Radiant Heating Tool 13 Operation 14 Post- operation 15 Pre- operation 13 Reflector Selection 14

IR- 550 Mark II, Infrared Heating Tool 10 Operation 12 Post- operation 13 Pre- operation 11 Reflector Selection 11

IR- 1759, Miniray Infrared Heating Tool 15 Operation 16 Post- operation 17 Pre- operation 15 Reflector Selection 15

AE- 897 Wide Aperture 16 Standard Aperture Reflector Assembly 15

MCH- 100- A Battery Powered Heat Gun 23 Changing Hot Air Nozzles 27 Charging Batteries 27 Hot Air Tool Controls 25 Installation of Batteries Into Power Pack 24 Introduction 23 Operating Procedures 24 Operation in Unusual Weather Conditions 27 Preparation for Movement After Use 28 Setup Procedures 27 Unpacking Tool 24

Record Of Applicable Technical Directives

None

Support Equipment Required Nomenclature Part Number/Type Designation

Compressed Air/Nitrogen Heat Gun HT-71002

Heat Gun, Compressed Air/Nitrogen HT-900B

Heat Gun, Compressed Air/Nitrogen HT-920B

Heat Gun, Battery Powered MCH-100-A

Heating Tool, Radiant IR-500

Heating Tool, Infrared IR-550

Heating Tool, Infrared IR-1759

Heating Tool, Thermogun CV-5000

Mini-Gun Hot Air Tool CV-5300

Mini-Gun Hot Air Tool CV-5302

Nitrogen Bottle —

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Materials Required

Nomenclature Part Number/Type Designation

Isopropyl Alcohol TT-I-735

Nitrogen Bottle

1 . INTRODUCTION.

2 . This work package (WP) provides information and operating procedures for heating tools used for build-up and repair of aircraft wiring system.

3 . GENERAL.

4 . Performing maintenance on an aircraft can be very hazardous to personnel and equipment. Extreme caution must be observed while using heating tools with electric motors on aircraft. The following paragraphs list the procedures that shall be adhered to while performing aircraft wiring maintenance.

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH- 100- A heating tools are authorized for use on any aircraft whenever

AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Use of nitrogen with the HT-900B/HT-920B heating tool in an enclosed area can be hazardous. Discharge of nitrogen into a poor-ly ventilated area can result in asphyxiation.

Do not perform wire repair while using explosive solvent/paint products on the air-craft.

Nozzle and output air of heating tools get very hot. Use extreme care while operating heating tool to avoid serious burns.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

5 . SAFETY PRECAUTIONS. Prior to performing repair procedures on any aircraft wiring system using heating tools with brush type electric motors, refer to

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NAVAIR 01-1A-35 for procedures concerning gas-free certifications. For definitions of confined spaces, refer to paragraph 7.

6 . MOTORIZED HEAT GUNS USAGE POLICY.

The policy for use of motorized heating tool on aircraft not strictly considered confined space is:

a. Do not perform any other maintenance during defueling, depuddling, purging, or inerting operations.

See NAVAIR 01-1A-35.

b. Aviation Gas Free Environment (AVGFE) check spaces for Oxygen, (19.5% to 23.5%) and 0% flammables (0% Lower Explosive Limit [LEL]) whenever any of the following conditions exist:

(1) Any fuel cell is open.

(2) Any fuel line is open.

(3) Any fuel system component has been re-moved anywhere on the aircraft.

c. If there are no open fuel cells, no fuel lines have been broken, and no fuel system components have been removed, it is not necessary to check Oxygen, and

LEL.

NOTE

This policy also applies to drop tanks and support equipment. For confined spaces, refer to NAVAIR 01-1A-35.

7 . CONFINED SPACE. Confined space is defined as:

a. A space large enough and so confined maintenance personnel can bodily enter and perform assigned work.

b. A space having limited or restricted means for entry or exit.

c. A space not designed for continuous mainte-nance personnel occupancy.

8 . PERMIT REQUIRED CONFINED SPACE.

Permit required confined space means a confined space that has one or more of the following characteristics:

a. A space that contains, or has the potential to contain a hazardous atmosphere.

b. A space that contains a material that has the potential for engulfing an entrant.

c. A space that has an internal configuration such that an entrant could be trapped and asphyxiated by inwardly converging walls or by a floor which slopes downward and tapers to a small cross section.

d. A space that contains any other recognized serious safety hazard.

9 . H T- 9 0 0 B / H T- 9 2 0 B C O M P R E S S E D A I R /

NITROGEN HEATING TOOL.

WARNING

Use of nitrogen with the HT-900B/HT-920B heat gun in an enclosed area can be hazard-ous. Discharge of nitrogen into a poorly ventilated area can result in asphyxiation.

10 . Compressed air/nitrogen heating tool (Figure 1), is a portable source of heat for use with heat-shrinkable tubing, meltable solder fittings, and is qualified for use on fueled aircraft. With the exception of a source of compressed air/nitrogen, the is self-contained. Specifica-tions are listed in Table 1. Tool contains several safety features as follows:

a. If the air/nitrogen pressure monitored at the heating tool falls below a preset minimum, a safety switch shuts off power to the heating element.

b. Cool air passes between the heating element and heating tool handle, keeping the handle cool.

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Figure 1. Compressed Air/Nitrogen Heating Tool With Case

c. If the heating tool is inadvertently connected to an air source in excess of 200 psi, an air safety valve protects both the equipment and the operator.

11 . PRE-OPERATION. Prior to using compressed air/nitrogen heating tool (Figure 1), proceed as follows:

CAUTION

Do not connect the heating tool to a com-pressed air/nitrogen source greater than 200 psig.

a. Push down and fully turn AIR REGULATOR ccw.

b. Remove dust cap from AIR INLET nipple.

Connect nipple to pressurized air/nitrogen source.

c. Push down and turn AIR REGULATOR cw until pressure of 5 to 7 psig is registered on AIR PRESSURE

GAGE.

12 . REFLECTOR SELECTION. The attachments for the air/nitrogen heater consist of five reflectors. These reflectors are attached to the tip of the heat gun and concentrate the heated air/nitrogen output around the material. The uses of the various reflectors are as follows:

13 . Termination Sleeve Reflector. Used for heating solder termination sleeves and shrinking small-diameter tubing (Figure 2).

Figure 2. Termination Sleeve Reflector

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14 . Miniature Termination Sleeve Reflector. Used for heating small solder termination sleeves and making terminations in a confined area (Figure 3).

Figure 3. Miniature Termination Sleeve Reflector

15 . Boot and Tubing Reflector. Used for shrinking tubing and molded components such as strain-relief boots and potting caps (Figure 4).

Figure 4. Boot and Tubing Reflector

16 . Needle Point Reflector. Used where a lower precise air-flow is required to terminate micro-miniature connec-tors, or to repair or modify low-temperature insulated wire termination (Figure 5).

Table 1. Specifications

Electrical Power, HT-900B 115 VAC, 50-400 Hz, single-phase, 7 Amps

Electrical Power, HT-920B 220 VAC, 50-400 Hz, single-phase, 3.5 Amps

Heat gun output temperature 550-920�F (290-495�C)

Compressed air/nitrogen 80-200 psig, 4 SCFM (Dry and oil-free)

Figure 5. Needle Point Reflector

17 . Large Boot and Tubing Reflector. Used for installing large diameter tubing and molded parts (Figure 6).

Figure 6. Large Boot and Tubing Reflector

18 . OPERATION. To operate compressed air/nitrogen heating tool (Figure 7), proceed as follows:

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH-100-A heating tools are authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Do not perform wire repair while using explosive solvent/paint products on the air-craft.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

a. Push reflector over gun tip.

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Figure 7. Compressed Air/Nitrogen Heating Tool

b. Plug in power cord to 115 VAC, 50-400 Hz, single-phase, 7 AMPs minimum power source, for the HT-900 tool, and to 220VAC, 50-400 Hz, single phase,

3.5 AMPs minimum power source for the HT-920B tool.

c. Set POWER switch to ON. POWER lamp and HEATED AIR ON lamp should light.

NOTE

The HEATED AIR ON lamp does not light unless the switch in the heat gun handle is in the forward position. Heated air can be removed from the heat gun at any time during operation, without powering down the control module, by positioning the switch to the rear of the handle.

d. Allow one minute warm- up. After warm- up, air pressure will be 10-15 psig.

e. Adjust TEMP CONTROL knob to desired set-ting.

19 . POST-OPERATION. After using compressed air/nitrogen heating tool (Figure 7), proceed as follows:

a. Push down and fully turn AIR REGULATOR ccw. Observe that AIR PRESSURE GAGE registers 0 psig and HEATED AIR ON lamp goes out.

b. Position heat gun handle switch to rear of handle.

c. Position POWER switch to OFF. Observe that POWER lamp goes out.

CAUTION

Failure to cool the gun, as directed below, will shorten heating element life.

d. Cool heat gun, for a minimum of one minute, by allowing air/nitrogen to flow until cool.

e. Disconnect power connector from power source.

f. Disconnect compressed air/nitrogen source from AIR INLET nipple. Install dust cap.

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Figure 8. HT- 71002 Nitrogen/Compressed Air Hot Air Tool.

g. Allow a few minutes for reflector to cool.

h. Remove reflector and store in case.

20 . HT- 71002 NITROGEN/COMPRESSED AIR

HOT AIR TOOL.

a. The HT- 71002 hot air tool is designed to operate in a potentially hazardous/explosive environment as spelled out in MIL- STD- 810, Method 511.3, Procedure

1. This device produces hot air at temperatures up to 950° F, utilizing compressed air/nitrogen passing through a high resistance electric heat element and is directed or diffused through various types of special purpose nozzle attachments. Some examples of application are:

heat shrinkable tubing, solder sleeve electrical connec-tors, drying and curing applications.

b. This unit comes packaged in a fiberglass/alumi-num carrying case and consists of two major parts: The control unit and heat pistol (Figure 8).

When operating the HT- 71002 in a potentially explosive atmosphere, the following instructions must be followed explicitly.

21 . Observe warning on power cable.

WARNING

Failure to observe connection procedures as described in paragraphs a. and b. may result in explosion and or fire.

Before applying power to the HT- 71002, the following procedures must be adhered to exactly.

a. Disconnect power at the source.

b. If using hangar or ships power, disengage the supply circuit at the circuit breaker panel, connect up the extension cord to the HT- 71002 supply at the circuit breaker panel, activate the 115Vac (50 – 400 Hz) and observe the control unit panel indicator that AC is present.

22 . CONNECTING AIR/NITROGEN SUPPLY.

a. Air input Maximum 150 psi. Air input operating range: 60–150 psi.

23 . COMPRESSED AIR.

a. Air supply must be water and contaminant free.

The HT- 71002 employs a three (3) stage filtration system that purges water from the system automatically, however in order to minimize contamination of the extremely fine particulate and water filtration system of the HT- 71002, the air supply (compressor) should be drained of water prior to connecting up the HT- 71002 to the air supply.

b. Connect the air supply to connection nipple marked AIR INPUT. Observe the Air Pressure gauge and LOW AIR indicator. The minimum operational pressure for the HT- 71002 is 3.5 psi. The LOW AIR lighted indicator will illuminate at approximately 2.0 psi, however steady state operation requires a pressure setting of 3.5 psi minimum.

c. If there is no pressure indicated on the control unit pressure gauge and the air supply to the unit is

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Change 1 Page 9 present at 60–150 psi, rotate the pneumatic control pressure regulator clockwise until pressure is indicated on the pressure gauge, to a setting of 3.5 psi. At approximately 2.0 psi, the LOW AIR lamp will illumi-nate, indicating that the low limit air protection circuitry has determined that air is insufficient and that the tool cannot be powered up.

24 . NITROGEN GAS SUPPLY.

WARNING

Bottled nitrogen is usually contained in high pressure cylinders with pressures in excess of 2000 psi. Be certain that the appropriate input line pressure to the HT- 71002 is observed. Proper regulation of the high pres-sure nitrogen is mandatory.

a. Connect the Nitrogen supply to connection nipple marked AIR INPUT. Observe the air pressure gauge and LOW AIR indicator. The minimum operation-al pressure for the HT- 71002 is 3.5 psi. The LOW AIR lighted indicator will illuminate at approximately 2.0 psi, however steady state operation requires a pressure setting of 3.5 psi minimum.

b. If there is no pressure indicated on the control unit pressure gauge and the Nitrogen supply to the unit is present at 60–150 psi, rotate the pneumatic control pressure regulator clockwise until pressure is indicated on gauge of 3.5 psi. At approximately 2.0 psi, the LOW

AIR lamp will illuminate, indicating that the low limit

Nitrogen protection circuitry has determined that Nitro-gen is insufficient and that the tool may not be powered up.

25 . OPERATION.

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH-100-A heating tools are authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Do not perform wire repair while using explosive solvent/paint products on the air-craft.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

26 . POWERING UP THE HT- 71002.

a. Once the required electrical and air/nitrogen connections have been made, the HT- 71002 is ready for operation.

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(1) Set Air/nitrogen air pressure 3.5 psi mini-mum.

(2) Set Temperature control on heat tool at “0”.

(3) Observe that the LOW AIR lamp is extin-guished.

(4) Depress POWER ON switch and indicator will illuminate.

27 . AIR/TEMPERATURE SETTINGS.

a. The working environment of the HT- 71002 will affect the resultant temperature at the nozzle of the heat tool. Such conditions are:

(1) Wind and air turbulence.

(2) Ambient temperatures that are below freez-ing and above 70 degrees F.

(3) Air compressor supplied input where the compressor is subjected to ambient temperatures.

b. Normal operating air pressure range of the HT- 71002 is between 3.5 and 9.0 psi. With a constant temperature setting and an increased airflow, the result-ant nozzle temperature will decrease, therefore a higher temperature setting will be required to achieve the desired temperatures.

c. With an ambient temperature of 70 degrees F, a “0” setting on the heat tool equals ambient temperature at 3.5 psi and “10” setting on the heating tool at 3.5 psi equals approximately 975 degrees F.

28 . SHRINKING/CURING.

a. Set temperature control on tool between ”4” and “6” with air pressure set between 3.5 – 4.0 psi.

b. If shrinking or curing operation requires more heat, leave air pressure at initial setting and increase temperature.

29 . SOLDER SLEEVE CONNECTORS.

a. Install spoon reflector nozzle on heat tool.

b. Set temperature control between “5” and “8” on heat tool, with air pressure between 3.5 and 4.0 psi.

c. Depending on the connector and wire size, either a higher or lower setting will be required.

(1) Observe the solder ring in the connector for reflow. Do not leave heat on connector longer than is required to achieve a high integrity connection.

30 . IR-550 MARK II , INFRARED HEATING

TOOL.

31 . Infrared heating tool, IR-550 Mark II (Figure 9), is a portable electric heating tool designed for fast reliable installation of solder devices and other heat-shrinkable products. It can be used as a hand tool or as a bench heater. As a hand tool, it is operated by a switch on the handle; as a bench heater, it is operated by a foot switch or the handle switch. This tool provides an unobstructed view of work in process and quiet, hands free operation. Instant on/off heat is generated by an optically filtered, commercially available tungsten-halo-gen lamp. Reflectors focus the heat from the lamp, concentrating heat energy within the work area of the front reflector. Optical filter between the lamp and the work area eliminates glare from the lamp, allowing the operator to observe the heating process. Tool is also equipped with a viewing window to ensure operator eye comfort. These features minimize operator errors and fatigue, significantly reducing installation time and costs.

Specifications are listed in Table 2.

Table 2. Specifications

Electrical Power 115 VAC, 50-60 Hz, 4 1/2 Amps

Normal lamp life Over 1000 hours of intermittent use

Duty Cycle 80%, 90 second heating times

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Figure 9. Infrared Heating Tool, IR-550 Mark II

32 . PRE-OPERATION. Prior to using infrared heating tool (Figure 9), proceed as follows:

a. Visually check front reflector and outer face of lamp filter for contamination.

b. If contamination is found, remove front reflector by lifting upper nose plunger from hole in reflector;

tilt reflector away from housing, lift the reflector off lower plunger and slide it out of the housing.

WARNING

Isopropyl Alcohol, TT- I- 735 is highly flam-mable and toxic. Do NOT use synthetic wipe cloths due to possible electrostatic discharge and ignition. Use in a well ventilated area.

Keep away from open flames. Avoid pro-longed or repeated breathing of vapor or contact with skin. Avoid any contact with eyes. Safety glasses and protective gloves are recommended. Wash hands after use.

c. Clean contaminated surfaces of front reflector and outer face of lamp filter with a soft cloth and isopropyl alcohol.

d. Install front reflector being careful not to contaminate inner reflective surface.

33 . REFLECTOR SELECTION. The attachments for the infrared heating tool consist of four reflectors. These reflectors are attached to the front end of the tool housing and concentrate the heated infrared output around the material. The uses of the various reflectors are as follows:

a. RG-2. Used for heating solder termination sleeves and shrinking large-diameter tubing. Has a 3/4 inch wide aperture and comes with heating tool when ordered.

b. RG-6. Used for heating solder termination sleeves and shrinking large-diameter tubing. Has a 3/4 inch wide aperture and has to be ordered separately (Figure 10).

c. RG-10. Used for heating solder termination sleeves and shrinking small-diameter tubing. Has a 3/8 inch wide aperture and has to be ordered separately (Figure 11).

d. RG-11. Used for heating solder termination sleeves and shrinking small-diameter tubing. Has a 1/2 inch wide aperture and has to be ordered separately (Figure 12).

Figure 10. RG-6 Reflector

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Figure 11. RG-10 Reflector

Figure 12. RG-11 Reflector

34 . OPERATION. To operate infrared heating tool (Figure 3), proceed as follows:

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH- 100- A heating tools are authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Use of nitrogen with the HT-900B/HT-920B heating tool in an enclosed area can be hazardous. Discharge of nitrogen into a poor-ly ventilated area can result in asphyxiation.

Do not perform wire repair while using explosive solvent/paint products on the air-craft.

Nozzle and output air of heating tools get very hot. Use extreme care while operating heating tool to avoid serious burns.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

a. Select the appropriate front reflector for the application.

b. Clip the front reflector onto the front end of the lamp housing by sliding the reflector between the

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Change 1 Page 13 upper and lower nose plungers until the bosses on the clips snap into the upper and lower holes in the reflector.

c. Plug in power cord to 115 VAC, 50-60 Hz, 4 1/2 Amps minimum power source. (For foot switch operation, foot switch must first be plugged into recep-tacle on rear of tool before plugging into power source.)

d. Prepare assembly to be heated.

e. Place the assembly to be terminated into slot of front reflector.

f. Turn heat lamp on by depressing switch on handle or by depressing foot switch.

WARNING

Since front reflector is outside the cooling air stream, it may get hot during the long heating cycles. Therefore, front reflector should not be touched when tool is in use.

g. Observe assembly during heating. After assem-bly has received proper amount of heat (or maximum of 90 seconds), stop heat cycle by releasing switch on handle or removing pressure from foot switch. Repeat if necessary if additional heating time is required.

h. Remove assembly from front reflector and inspect.

35 . POST-OPERATION. After using infrared heating tool (Figure 9), proceed as follows:

a. Disconnect power connector from power source.

b. Allow a few minutes for reflector to cool.

c. Visually check front reflector and outer face of lamp filter for contamination. If contamination is found, clean contamination using steps in paragraph 32.

d. Store reflector in proper place.

e. Periodically check the fan area to see if any dirt or lint has accumulated, when necessary clean with a soft brush. To facilitate cleaning, simply remove two mounting screws located on the rear of the fan cover.

36 . IR-500, RADIANT HEATING TOOL.

37 . Radiant heating tool, IR-500 (Figure 13), is a portable lightweight electric heating tool designed for fast and reliable installation of heat-shrinkable products.

It can be used as a hand tool or as a bench tool and operated with a foot switch. The ellipsoidal reflector focuses the heat produced by halogen quartz lamp into the heating zone in front of the unit. Lamp is optically filtered to eliminate glare which allows the operator to observe the heating process, minimizing faulty installa-tion and thereby assuring a quality finished product.

Specifications are listed in Table 3.

38 . PRE-OPERATION. Prior to using radiant heating tool (Figure 13), proceed as follows:

a. Visually check reflector and outer face of lamp filter for foreign material accumulation.

b. If accumulation is found, remove reflector by lifting the reflector plunger, and tilting reflector away from housing and off reflector anchor pin.

Table 3. Specifications

Electrical Power 115 VAC, 50-60 Hz, 5 Amps

Duty Cycle 50%, 30 second heating times

Figure 13. Radiant Heating Tool, IR-500

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WARNING

Isopropyl Alcohol, TT- I- 735 is highly flam-mable and toxic. Do NOT use synthetic wipe cloths due to possible electrostatic discharge and ignition. Use in a well ventilated area.

Keep away from open flames. Avoid pro-longed or repeated breathing of vapor or contact with skin. Avoid any contact with eyes. Safety glasses and protective gloves are recommended. Wash hands after use.

c. Clean foreign material off surfaces of reflector and outer face of lamp filter with a lint free, soft cloth or paper dampened with isopropyl alcohol.

d. Install reflector, being careful not to touch inner reflective surface.

39 . REFLECTOR SELECTION. The attachments for the radiant heating tool consist of three reflectors. These reflectors are attached to front end of the tool housing and concentrate the heated radiant output around the material. The uses of the various reflectors are as follows:

a. RG-1. Used for installing solder termination sleeves on non-heat sensitive wires; has to be ordered separately.

b. RG-2. Used for installing solder termination sleeves on heat sensitive wires; comes with heating tool when ordered.

c. Tubing Reflector. Used for installing heatshrink-able tubing and molded parts; comes with heating tool when ordered.

40 . OPERATION. To operate radiant heating tool (Figure 13), proceed as follows:

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH- 100- A heating tools are authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Use of nitrogen with the HT-900B/HT-920B heating tool in an enclosed area can be hazardous. Discharge of nitrogen into a poor-ly ventilated area can result in asphyxiation.

Do not perform wire repair while using explosive solvent/paint products on the air-craft.

Nozzle and output air of heating tools get very hot. Use extreme care while operating heating tool to avoid serious burns.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

a. Select the appropriate reflector for the application.

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Change 1 Page 15

b. Install the reflector onto the front end of the lamp housing by putting the bottom of the reflector on the reflector anchor pin and tilting reflector up until it snaps onto reflector plunger.

c. Plug in power cord to 115 VAC, 50-60 Hz minimum power source. (For foot switch operation, foot switch must first be plugged into heating tool power cord before being plugged into power source.)

d. Prepare the assembly to be heated.

e. Place the assembly into heating area.

f. Turn heat lamp on by squeezing handle grip.

Handle grip trigger actuates the on-off switch.

WARNING

During use the reflector may become hot.

Do not touch.

g. Observe assembly during heating. When heating operation is complete (or maximum of 30 seconds) turn lamp off by releasing the handle or removing pressure from foot switch. Repeat as necessary if additional heating time is required.

h. Remove assembly from heating area and inspect.

i. If using foot switch for operation, trigger must be moved forward to take it out of its locked position, then released to turn heating tool completely off.

41 . POST-OPERATION. After using radiant heating tool (Figure 13), proceed as follows:

a. Disconnect power connector from power source.

b. Allow a few minutes for reflector to cool.

c. Visually check reflector and outer face of lamp filter for foreign material accumulation. If material is found, clean using steps in paragraph 32.

d. Store reflector in proper place.

42 . IR-1759, MINIRAY INFRARED HEATING

TOOL.

43 . MiniRay infrared heating tool, IR-1759 (Figure 14), is a small, lightweight, medium-duty hand heating tool designed for quiet, efficient operation. It can significant-ly reduce installation time on a variety of heat-shrinkable products. The low profile allows product installation where work space is restricted. Specifications are listed in Table 4.

44 . PRE-OPERATION. Prior to using infrared heating tool (Figure 14), proceed as follows:

a. Visually check aperture reflector for foreign material accumulation.

b. If accumulation is found, remove aperture re-flector by removing screw, under reflector, and taking aperture reflector off heating tool.

WARNING

Isopropyl Alcohol, TT- I- 735 is highly flam-mable and toxic. Do NOT use synthetic wipe cloths due to possible electrostatic discharge and ignition. Use in a well ventilated area.

Keep away from open flames. Avoid pro-longed or repeated breathing of vapor or contact with skin. Avoid any contact with eyes. Safety glasses and protective gloves are recommended. Wash hands after use.

c. Clean foreign material off reflector surface with soft cloth and isopropyl alcohol.

d. Install aperture reflector, being careful not to touch reflective surface.

45 . REFLECTOR SELECTION. The attachments for the infrared heating tool consist of two reflectors. These reflectors are attached to the front end of the tool housing and concentrate the heated infrared output around the material. The uses of the various reflectors are as follows:

46 . Standard Aperture Reflector Assembly. Used for heating solder termination sleeves and shrinking small-diameter tubing. Used on devices having a maximum outside diameter of l/4 inch and a maximum length of 1 inch and comes with heating tool when ordered (Figure 15).

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Table 4. Specifications

Electronic Control Unit

Electrical Power 115 VAC, 60 Hz, 11 Amps

Infrared Heating Tool

Lamp Type Tungsten-Halogen

Lamp Power 250 W, 24 VAC, 50-60 Hz

Lamp Life Average time continuous use 50 hours

Figure 14. Infrared Heating Tool, IR-1759 with Standard Electronic Control ED-7-004

Figure 15. Standard Aperture Reflector Assembly

Figure 16. AE-897 Wide Aperture

47 . AE-897 Wide Aperture. Used for heating solder termination sleeves and shrinking small-diameter handle tubing. Used on devices having a maximum outside diameter of 3/8 inch and a maximum length of 2 inches and has to be ordered separately (Figure 16).

48 . OPERATION. To operate infrared heating tool (Figure 14), proceed as follows:

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Change 1 Page 17

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH- 100- A heating tools are authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B heat-ing tool is authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

Nozzle and output air of heating tools get very hot. Use extreme care while operating heating tool to avoid serious burns.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

a. Select the appropriate aperture for the application

b. Attach the aperture to heating tool by using screw under front tip of heating tool.

c. Plug in power cord to 115 VAC, 60 Hz, 11 Amps minimum power source.

d. Prepare the assembly to be heated.

e. Place the assembly into heating area.

f. Turn heat lamp on by squeezing trigger on handle.

WARNING

During use the aperture may become hot. Do not touch.

g. Observe assembly during heating. After assem-bly has received proper amount of heat, stop heat cycle by releasing trigger on handle.

h. Remove assembly from heating area and inspect.

49 . POST-OPERATION. After using infrared heating tool (Figure 14), proceed as follows:

a. Disconnect power connector from power source.

b. Allow a few minutes for aperture to cool.

c. Visually check aperture reflector for foreign material accumulation. If material is found, clean as follows:

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WARNING

Isopropyl Alcohol, TT- I- 735 is highly flam-mable and toxic. Do NOT use synthetic wipe cloths due to possible electrostatic discharge and ignition. Use in a well ventilated area.

Keep away from open flames. Avoid pro-longed or repeated breathing of vapor or contact with skin. Avoid any contact with eyes. Safety glasses and protective gloves are recommended. Wash hands after use.

(1) Clean contaminated surfaces of front reflec-tor and outer face of lamp filter with a soft cloth and isopropyl alcohol.

(2) Install front reflector being careful not to contaminate inner reflective surface.

50 . CV-5000, THERMOGUN MARK II HEATING

TOOL.

51 . ThermoGun Mark II heating tool, CV-5000 (Figure 17), is a rugged stand mounted or hand held hot-air tool engineered with a turbo fan driven blower and double jacketed element housing for heavy duty use. Combining features and options such as adjustable side vents, a wide variety of reflectors, and two temperature ranges (deter-mined by model selected). ThermoGun provides precise control when terminating abroad range of heat shrinkable products, including boots and tubing up to 3 inches in diameter. Specifications are listed in Table 5.

Table 5. Specifications

Model 500B & 502B

Electrical Power, Model 500B 115 VAC, 60 Hz, 14 Amps

Electrical Power, Model 502B 220 VAC, 50-60 Hz, 7 Amps

Output temperature 500� - 700�F (260� - 371�C)

Model 750B & 752B

Electrical Power, Model 750B 115 VAC, 60 Hz, 18 Amps

Electrical Power, Model 752B 220 VAC, 50-60 Hz, 9 Amps

Output temperature 750� - 1000�F (399� - 538�C)

52 . PRE-OPERATION. Prior to using heating tool (Figure 17), Proceed as follows:

a. Visually check reflector for foreign material accumulation.

b. If accumulation is found, remove reflector by pulling it straight off ThermoGun nozzle.

Figure 17. ThermoGun Mark II Heating Tool, CV-5000 with Stand

WARNING

Isopropyl Alcohol, TT- I- 735 is highly flam-mable and toxic. Do NOT use synthetic wipe cloths due to possible electrostatic discharge and ignition. Use in a well ventilated area.

Keep away from open flames. Avoid pro-longed or repeated breathing of vapor or contact with skin. Avoid any contact with eyes. Safety glasses and protective gloves are recommended. Wash hands after use.

c. Clean foreign material off surfaces of reflector with a soft cloth and isopropyl alcohol.

d. Install reflector, being careful not to touch reflective surface.

53 . REFLECTOR SELECTION. The attachments for the heating tool consist of six reflectors. These reflectors

TM 1- 1500- 323- 24 012 00

Change 1 Page 19 are attached to nozzle of heating tool and concentrate heated output around the material. The uses of the various reflectors are as follows:

a. TG-12. Used for heating solder termination sleeves and shrinking small-diameter tubing. Used for short lengths of tubing up to 3/4 inch diameter and comes with heating tool when ordered (Figure 18).

Figure 18. TG-12 Reflector

b. TG-13. Used for heating solder termination sleeves and shrinking large-diameter tubing. Used for short lengths of tubing from 3/4 inch to 2 inches in diameter and has to be ordered separately (Figure 19).

Figure 19. TG-13 Reflector

c. TG-13A. Used for heating solder termination sleeves and shrinking small-diameter tubing. Used for splice covers where wires must be shielded from heat and has to be ordered separately (Figure 20).

Figure 20. TG-13A Reflector

d. TG-23. Used for heating solder termination sleeves and shrinking medium-diameter tubing and boots. Used for boots up to 1 3/4 inches in diameter and has to be ordered separately (Figure 21).

Figure 21. TG-23 Reflector

e. TG-24. Used for heating solder termination sleeves and shrinking large-diameter tubing and boots.

Used for boots up to 3 inches in diameter and has to be ordered separately (Figure 22).

Figure 22. TG-24 Reflector

f. TG-135. Used for heating solder terminations sleeves and shrinking small-diameter tubing. Has to be ordered separately (Figure 23).

Figure 23. TG-135 Reflector

54 . OPERATION. To operate heating tool (Figure 17), proceed as follows:

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WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3. Only the HT-900B/HT-920B, HT- 71002, MCH- 100- A heating tools are authorized for use on any aircraft whenever AVGAS, JP-4 or the presence of fuel is imposing an immediate danger.

When using heat guns with electric motors, recertification may be required as work prog-resses, as directed by the Aviation Gas Free Engineering Technician (AVGFET).

The MCH- 100- A heat gun has been electro-magnetic interference (EMI) qualified for flight line or flight deck use. All other electric motor type heat guns are not authorized for flight line or flight deck use due to electro-magnetic interference (EMI). The electric motor type heating tools are safe for use by personnel at the organizational maintenance level to repair aircraft wiring in a hangar or hangar deck environment, provided the aircraft meets the gas-free environment crite-ria (NAVAIR 01-1A-35 or AF T.O. 1-1-3), and there are no EMI restrictions.

Use of nitrogen with the HT-900B/HT-920B heating tool in an enclosed area can be hazardous. Discharge of nitrogen into a poor-ly ventilated area can result in asphyxiation.

Do not perform wire repair while using explosive solvent/paint products on the air-craft.

Nozzle and output air of heating tools get very hot. Use extreme care while operating heating tool to avoid serious burns.

When using a heat tool, do not use electrical power from the aircraft being repaired. Use electrical power from a ground power unit.

a. Select the appropriate reflector for the applica-tion.

b. Install the reflector on front of ThermoGun nozzle by pushing reflector straight on nozzle.

c. Plug in power cord to 115 VAC, 60 Hz, 14 or 18 Amps minimum power source, or 220 VAC, 60 Hz, 7 or 9 Amps minimum power source, depending on the model selected.

d. Prepare the assembly to be heated.

e. Place the assembly into heating area.

f. Turn the heat on by squeezing trigger on handle.

WARNING

During use the reflector may become hot.

Do not touch.

g. Observe assembly during heating. After assem-bly has received proper amount of heat, stop heat cycle by releasing trigger on handle.

h. Remove assembly from heating area and inspect.

55 . POST-OPERATION. After using heating tool (Figure 17), proceed as follows:

a. Disconnect power connector from power source.

b. Allow a few minutes for reflector to cool.

c. Visually check reflector for foreign material accumulation. If material is found, clean using steps in paragraph 52.

d. Store reflector in proper place.

56 . CV-5300/CV-5302, MINI-GUN HOT AIR TOOL.

57 . Mini-Gun hot air tool, CV-5300/CV-5302 (Figure 24), is a lightweight hand-held tool used for applying a variety of heat-shrinkable products and solder termina-

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Change 1 Page 21 tion products. It provides a continuous flow of heated air at temperatures of 450� - 700�F (232� - 371�C), depending on the hot-air reflector used. Specifications are listed in Table 6.

Table 6. Specifications

Electrical Power, CV-5300 115 VAC, 60 Hz, 7 Amps

Electrical Power,CV-5302 220 VAC, 50 Hz, 3.5 Amps

Output temperatures

Without adapter 450�F (232�C)

With adapter only 550�F (288�C)

With MG-1 Reflector 700�F (371�C)

With MG-2 Reflector 450�F (232�C)

58 . PRE-OPERATION. Prior to using mini-gun heating tool (Figure 24), proceed as follows:

a. Visually check reflector for foreign material accumulation.

b. If accumulation is found, remove reflector by pulling it straight off mini-gun adapter.

WARNING

Isopropyl Alcohol, TT- I- 735 is highly flam-mable and toxic. Do NOT use synthetic wipe cloths due to possible electrostatic discharge and ignition. Use in a well ventilated area.

Keep away from open flames. Avoid pro-longed or repeated breathing of vapor or contact with skin. Avoid any contact with eyes. Safety glasses and protective gloves are recommended. Wash hands after use.

c. Clean foreign material off surfaces of reflector with a soft cloth and isopropyl alcohol.

Figure 24. Mini-Gun Hot Air Tool, CV-5300/CV-5302

d. Install reflector, being careful not to touch reflective surface.

59 . REFLECTOR SELECTION. The attachments for the heating tool consist of two reflectors. These reflectors are attached to adapter on nozzle of heating tool and concentrate heated output around the material. The uses of the various reflectors are as follows:

a. MG-1. Used for heating solder termination sleeves and shrinking small-diameter tubing. Used for concen-trated, high-temperature heating and tubing reflector and comes with heating tool when ordered (Figure 25).

Figure 25. MG-1 Reflector

b. MG-2. Used for heating solder termination sleeves, molded parts, and shrinking large-diameter tubing. Used for surrounding heat-shrinkable tubing and molded parts with lower-temperature air, and has to be ordered separately (Figure 26).

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Change 1 Page 22

Figure 26. MG-2 Reflector

c. Barrel Adapter. Permits attachment of either reflector to the mini-gun.

60 . OPERATION. To operate heating tool (Figure 24), proceed as follows:

WARNING

Do not perform hot work without specific authorization of activity Aviation Gas Free Engineer (AVGFE) or Gas Free Engineer

(GFE).

The HT- 900B, HT- 920B, HT- 71002 and MCH- 100- A heat guns are the only autho-rized heat guns to be used when working on aircraft that have not been defueled and purged. The aircraft must be defueled and purged before using any other heat guns listed in this manual.

Aircraft with open fuel cells or broken or open fuel lines shall be certified gas free in accordance with NAVAIR 01-1A-35 or AF T.O. 1-1-3.