SWPM

STANDARD WIRING PRACTICES MANUAL
RRJ-95B
7.92.SWPM.000.000.EN/01
The present Manual (SWPM) contains Section 20 of the "Wiring Diagram Manual" (WDM)
2011
RRJ-95B

RECORD OF REVISIONS
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revised
new
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RRJ-95B STANDART WIRING PRACTICES MANUAL
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RRJ 95B STANDART WIRING PRACTICES MANUAL
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2. REASON OF CHANGE
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RRJ-95B

LIST OF SERVICE BULLETINS
SERVICE BULLETIN
No.
REVISION
SB EXECUTION STATUS IN THE

PRESENT MANUAL
NOTE
LIST OF SERVICE BULLETINS
RRJ-95B
SECTION 20 - STANDARD WIRING PRACTICES MANUAL

TABLE OF CONTENTS
Section,
Subsection,
Subject
20-00-01
Title
GENERAL
APPLICABILITY
20-00-02
STRUCTURE OF THE MANUAL
20-00-03
TERMS AND ABBREVIATIONS
20-00-08
SAFETY PRECAUTIONS
20-00-09
Page
General
Check of the Fuel Vapours Level
Fire Safety
Jet-Type Air Heaters, Soldering Guns and Heat Guns
GENERAL REQUIREMENTS
20-10-00
WIRES AND CABLES USED ON THE AIRCRAFT
20-10-10
General
Wires and cables used on the aircraft
CUTTING OF WIRES, CABLES, TAGS AND TUBES
20-20-10
General
Cutting tool for wires, cables, tags and tubes
STRIPPING OF INSULATION, SPLICING OF WIRES AND CABLES
20-20-20
Stripping of Insulation and Splicing of Various Type Cables
Stripping of Insulation and Splicing of Various Type Wires
MARKING OF EWIS COMPONENTS
20-20-30
General
Marking Methods and Means
Fitting of Identification Tags
Marking of Connectors, Terminal Blocks, Units and Components
13
BINDING OF HARNESSES
20-20-40
Specifications
Binding of Harnesses by Bandage Cord
Binding of Harnesses by Cable Bands
18
PROTECTION OF HARNESSES
20-20-50
General Requirements
Selection of Materials and Standard Termination of Harnesses
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Section,
Subsection,
Subject
Title
TERMINATION OF SCREENED WIRES AND CABLES IN SOLDER
SLEEVES
Page
20-20-60
General
Splicing of Screened Wires and Cables
Termination of Screened Wires and Cables
Fitting of Solder Sleeves
Check of Termination Quality
11
Selection of Solder Sleeves
13
TERMINATION OF WIRES AND CABLES IN CRIMPING SLEEVES
20-20-70
Crimping Sleeves Application Procedure
Selection of Crimping Sleeves
Selection of Solder Sleeves
TERMINATION OF WIRES IN THE LUGS
20-20-80
General
Selection of Lugs and Crimping Tools
Termination of Wires in the Lugs
TERMINATION OF WIRES IN ELECTRICAL DEVICE, INTERNAL WIRING

AND SOLDERING
20-30-10
General
Standard Soldering of Wires in Electrical Device
ELECTRICAL CONNECTORS. GENERAL
20-40-10
General
RVN1, RVN2, RVN3 Type Connectors
SNTs Type Connectors
D38999 and 8D Series Connectors
Designation of Cable Clamps for D38999 and 8D Series Connectors
12
Designation of Cables Sleeves for Screened Wires (Cables) Termination in 38999 and
8D Series Connection
13
Contact Numbers, Crimping and Wiring Tools
14
Arrangement of Contacts in D 38999 and 8D Series Connectors
17
83723 Series Electrical Connectors
21
8635, 8630. 8631, 8656. DD, DEM, RD, D-SUB Series Electrical Connectors
90
Amphenol-Air LB Electrical Connectors, Series 1900
98
ARINC 404 Electrical Connectors, Series 404 DPX, DSXN, RME
102
Modular Electrical Connectors and Terminal Blocks
115
Power Terminal Blocks and Monoblocks
131
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RRJ-95B
Section,
Subsection,
Subject
Rectangular Interchangeable Electrical Connectors, Types S-600. S-700 and NSX, for
Switching of Electronic Equipment in Accordance with ARINC-600 Requirements
Title
Page
132
Crimping of Coaxial Contacts
175
Termination of 506424 Cable in RADIALL 620 179 011 Connectors
188
Qudrax Contacts and Their Characteristics
192
Electrical Connectors ARINC600 and MIL-DTL-38999
194
HF connectors, BNC/TNC series
195
Designation of NIC66S Series Connectors Produced by AMP as per ARINC600
212
TERMINATION OF WIRES AND CABLES IN CONTACTS OF

CONNECTORS BY CRIMPING
20-40-20
General
Installation of Wire in Connector Contact
Crimping of Connector Contact with Wire
Installation of Crimped Contacts in Connector Sockets
Quality Control of Wires Installation in Connector
Crimping Tools
Hand Contact Crimping Tools
10
Type 1 Tool Application Recommendations
11
Contact Crimping Tool Settings
12
Crimping of Contacts by Type 1 Tool
14
Removal of Barrel Head
15
Structure and Adjustment of Type 2 Crimping Tool
15
Fitting of Type 2 Tool Crimping Jaws
15
Removal of Type 2 Tool Crimping Jaws
16
Check of Type 2 Crimping Tool
17
Crimping of Contacts by Type 2 Tool
18
TERMINATION OF DISCONNECTED AND STANDBY WIRES
20-40-30
General
Fitting of the Contacts in General Purpose Connectors
Fitting of the Contacts in Connectors Located in the Pressurized Area
INSTALLATION OF THE CONTACTS IN CONNECTOR
20-40-40
General
Fitting of the Contacts in Connector
Removal of the Contacts with Wire
Instruction on the Check of Contacts Fitting in Connector
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RRJ-95B

Section,
Subsection,
Subject
20-40-50
Title
FITTING OF CABLE CLAMPS
Page
General
Method of Cable Clamp Fitting on Connector No.1
Selection of Adapter-Blankings and Assembly Tools
10
Tool for Fitting of Adapter-Blankings and Adapters (Connectors) for Cable Clamps of
Connectors
19
Calibration Tools
22
Belt Wrenches
23
Installation of the Block Parts under the Clamping Nut
25
WIRING OF HARNESSES
20-40-60
Wiring Specifications
Routing and Attachment of Harnesses
Routing of Harnesses with Regard to Electromagnetic Compatibility Requirements
Conduits
12
Protectors
13
Sealed Lead-ins for Termination of Cables and Harnesses
14
Cable Fasteners
16
Plastic Cable Fasteners
19
Fitting of Cable Fasteners
22
INSTALLATION AND CONNECTION OF NEGATIVE WIRES
20-40-70
Aircraft Bonding. General
Selection of Components
Installation of the Cylindrical Grounding Modules and of the Grounding Modules with
Attachment Brackets
Surface Treatment for Bonding and Grounding
11
Connection Tightening Force
12
Bonding and Grounding Links
12
LOCKING OF COMMON AND THREADED CONNECTORS
20-40-80
General
1
TM
SAFE-T-CABLE
SAFETY WIRE FITTING PROCEDURE
Structure and Termination Materials
Special Elongated Ferrules
Fiberglass Sleeving
Filler Washer
Self-Looping Wire
10
EFFECTIVITY:
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Section,
Subsection,
Subject
Title
TM
Page
Branded SAFE-T-CABLE
10
Selection of SAFE-T-CABLE
11
SAFE-T-CABLE Application
12
SAFE-T-CABLE Installation
13
SAFE-T-CABLE Application
18
MAINTENANCE OF ELECTRICAL WIRING INTERCONNECTION SYSTEM
20-50-10
Definitions
Wire Degradation
Causes of Wire Degradation
EWIS PROTECTION DURING AIRCRAFT MAINTENANCE, REPAIR AND

MODIFICATION
20-50-20
EWIS Maintenance, Repair and Modification
Airframe Repair and Aircraft Modification
Aircraft Ice Control
Weather Factors
Equipment Installation/Removal, when EWIS is Arranged in the Operating area
Purging
Water/Waste System Maintenance, Modification or Repair
Oil System Maintenance, Repair or Modification
Hydraulic System Maintenance, Repair or Modification
Personnel Transfer in the Operating Area
Use of Corrosion-Preventive Compounds
INSPECTION OF THE ELECTRICAL WIRING INTERCONNECTION

SYSTEM
20-50-30
EWIS Inspection Types
Zonal Inspection Manual
EWIS Components and EWIS Arrangement Zones Requiring Special Attention
CLEANING OF THE ELECTRICAL WIRING INTERCONNECTION SYSTEM
20-60-00
General requirements
REPAIR OF ELECTRICAL WIRES AND CABLES
20-70-10
General
Typical Damages of Wires and Cables, Repair Conditions
Repair of Wires and Cables External Insulation
Repair of Unscreened Wire or Cable in Case of Current-Carrying Conductor (s) Cores

Damage
Repair of Screened Wire or Cable in Case of Screen Strands Damage
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RRJ-95B
Section,
Subsection,
Subject
Repair of Screened Wire in Case of Current-Carrying Conductor (s) Cores Damage
Title
Page
17
Replacement of Wire for Grounding (Bonding) of Screened Cable
21
Repair of Wire Contact Connections
22
INFORMATION ADAPTED BY OPERATOR
20-90-00
EFFECTIVITY:
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RRJ-95B

GENERAL
This Manual contains the information required for maintenance of RRJ-95B aircraft electrical wiring
interconnection system:
Data on standard components of the electrical wiring interconnection system:

harnesses, cables and wires;
connectors;
contacts;
fasteners, etc.
Instructions on installation of the electrical wiring interconnection system.

Standard requirements for quality of the electrical wiring interconnection system installation.
Data on standard tools and accessories, materials used during maintenance and repair of the
electrical wiring interconnection system.
General instructions on inspections of the electrical wiring interconnection system (detailed tasks of
inspection of the electrical wiring interconnection system circuits included in particular functional
systems of the aircrafts are described in the corresponding sections of Aircraft maintenance manual).
Instructions on cleaning of the electrical wiring interconnection system components.

Instructions on repair and replacement of the electrical wiring interconnection system components.
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Applicability
Data contained in the present Manual is applicable to all RRJ-95B series aircrafts (this is indicated by
"EFFECTIVITY : ALL" text at the page bottom), if only applicability to particular aircrafts is not specified in
the statement "EFFECTIVITY: list of applicability codes of particular aircrafts".
EFFECTIVITY:
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STRUCTURE OF THE MANUAL
The present Manual (SWPM) contains Section 20 of the "Wiring Diagram Manual" (WDM).
Section 20, in its turn, is subdivided into the sections. The sections have 6-figure numbers like: 20-XX-YY.
Pages in each Section are sequentially numbered, beginning with 1.
The sections consist of the subjects. The subjects describe particular topics and are numbered by Arabic
numerals. The subjects, in their turn, are subdivided in sub-topics if required (they are numbered by
capital letters of the Latin alphabet).
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ALPHABETICAL INDEX
SECTION
NO.
ALPHABETICAL INDEX
20-00-06
20-20-40
INFORMATION ADAPTED BY OPERATOR
20-90-00
TERMINATION OF DISCONNECTED AND STANDBY WIRES
20-40-20
TERMINATION OF WIRES IN THE LUGS
20-20-80
TERMINATION OF WIRES IN ELECTRICAL DEVICE, INTERNAL WIRING AND

SOLDERING
20-30-10
TERMINATION OF WIRES AND CABLES IN CONTACTS OF CONNECTORS BY

CRIMPING
20-40-10
TERMINATION OF WIRES AND CABLES IN CRIMPING SLEEVES
20-20-70
TERMINATION OF SCREENED WIRES AND CABLES IN SOLDER SLEEVES
20-20-60
EWIS PROTECTION DURING AIRCRAFT MAINTENANCE, REPAIR AND

MODIFICATION
20-50-20
20-20-50
LOCKING OF COMMON AND THREADED CONNECTORS
20-40-70
MARKING OF WIRES AND HARNESSES
20-20-30
SAFETY PRECAUTIONS
20-00-09
WIRING OF HARNESSES ON THE AIRCRAFT
20-40-50
NORMATIVE REFERENCES
20-00-07
MAINTENANCE OF THE ELECTRICAL WIRING INTERCONNECTION SYSTEM
20-50-10
GENERAL
20-00-01
20-40-10
GENERAL REQUIREMENTS
20-10-00
INSPECTION OF THE ELECTRICAL WIRING INTERCONNECTION SYSTEM
20-50-40
20-00-04
LIMIT PERMITTED DAMAGES OF EWIS
20-60-10
APPLICABILITY
20-00-02
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SECTION
NO.
CHECK, ACCEPTANCE AND TEST OF HARNESSES
20-40-80
20-10-10
20-20-10
20-70-10
STRIPPING OF INSULATION, SPLICING OF WIRES AND
20-20-20
MANUAL CONTENT
20-00-05
MANUAL STRUCTURE
20-00-03
20-00-08
INSTALLATION AND CONNECTION OF NEGATIVE WIRES
20-40-60
FITTING OF THE CABLE CLAMPS
20-40-40
FITTING OF THE CONTACTS IN CONNECTOR
20-40-30
20-50-30
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The following terms are used in the present Manual:

group of wires two or more wires running to one and the same component and bundled together for
logical and physical structuring of the electrical connections system;
cable harness two or more groups of wires bundled together by bandage cord or bandage strings for
connection of wires;
bundle of harnesses an individual group of harnesses bundled together and laid on one route segment;
wiring branch any group of wires running from the harness body;
tag tube or plate with schematic designation of the wire or harness on it;
connector connector or splice sleeve.
grounding electrical connection of the current-carrying object to the base structure (main structure,
fuselage, aircraft wing structure integrated in one unit, which is called the "frame") or to the negative
terminal of the source for reverse current providing.
Operator company that uses the aircraft.
The following abbreviations are used in the present Manual:
AWG (American Wire Gauge) wire core gauge (standard size)
EWIS Electrical Wiring Interconnection System
toper operating temperature
Fig. Figure
Rev. Revision
SNTs LF Cylindrical Connector
RC RF cable
DB Distribution Box
FBW Fly-by-Wire Control System
RF Radio Frequency
LF Low Frequency
EMC Electromagnetic Compatibility
WDM Wiring Diagram Manual
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SAFETY PRECAUTIONS
1.
General
Operation with any energized electrical system constitutes the following threats for the maintenance
personnel:
Electrical shock due to contact with energized wiring.
Short circuits due to metal tools falling on the electrical contacts/conductors.
Explosions due to electrical sparks in the area, where flammable vapours are present.
The maintenance personnel must strictly obey the following safety precautions:
A.
Prior to beginning of maintenance operations

The following safety precautions must be obeyed in order to prevent injures of the personnel
and damages of the equipment during maintenance of electrical equipment or during repair
of any part of the electrical/electronic system:
(1)
Define the system requiring maintenance or repair.
(2)
Open the circuit breakers and set the switches to OFF, make sure that all system
components are de-energized.
(3)
Install the following warning notice on all circuit breakers:
CAUTION:
DO NOT CLOSE THIS CIRCUIT BREAKER. THE CIRCUIT
BREAKER MUST BE OPENED TILL COMPLETION OF THE
MAINTENANCE PROCEDURES.
(4)
In order to provide opened state of the circuit breaker install a plastic locking rim on it,
which prevents circuit closing by this circuit breaker. List of the approved rims is given
in Table 1:
TABLE 1
SAFETY RIMS FOR CIRCUIT BREAKERS

Designation
Supplier
10164
Paramount Plastics
10237
Paramount Plastics
20266
Paramount Plastics
G57NB-5
Nylon Molding Corp./Union Plastics
S-4933959
Paco Plastics
(5)
Install the following warning notice on all switches:

CAUTION:
DO NOT MOVE THIS SELECTOR SWITCH FROM OFF

POSITION, TILL MAINTENANCE IS COMPLETED.
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B.
After completion of the maintenance procedures:

(1)
(2)
(3)
(4)
(5)
C.
Make sure that all selector switches and control are in position, in which accidental
actuation of any component is impossible.
Remove the warning notices and close the circuit breakers, which were locked before
maintenance.
Switch on the system power supply.
Perform the necessary system functional checks.
If the check results are satisfactory, set selector switches and control back to deenergized state.
Automatic opening of the circuit breakers

In case an automatic opening of the circuit breaker occurs, do not try to return it to operating
position, till the cause of failure or fault is found.
2.
Check of the fuel vapours level

A.
Permissible fuel vapours level

When sparking devices are used, only zero fuel vapours level is safe.
B.
Measurement of fuel vapour concentration level

The fuel vapour concentration level can be measured using the calibrated equipment, e.g.
such as Mine Safety Appliances Model 2 or Davis Model D-6. When the vapour
concentration is more than zero, this equipment shows two vapour level grades:
PERCENT LOWER EXPLOSIVE LIMIT
PERCENT EXPLOSIVE
In any case these readings indicate that:
liquid fuel or fuel vapour source is nearby;
vapour concentration level in this place is hazardous;
the ventilation is not sufficient.
These tools should be used in order to:
define that initial vapours level is low;
monitor change of the explosive vapours level during maintenance and repair
operations.
C.
Ignition sources
WARNING:
DO NOT use any ignition sources near the opened fuel tanks,
fuel drained from the fuel system or near the spilled fuel, where
vapour concentration is unpredictable and uncontrolled.
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3.
Fire safety
If ignition source is used somewhere inside or near the aircraft, where smoking is not allowed,
personnel of the local fire brigade or a person responsible for fire safety of the aircraft must monitor
the works performed inside or near the aircraft.
The following is recommended:
operation with any component of the fuel system should never be started or continued, if an
ignition source is present.
quantity of the maintenance personnel and quantity of personnel that provides safe execution
of the operations must be reduced to minimum.
quantity of the emergency and firefighting equipment at the work site must be defined by the
local firefighting personnel or by other bodies responsible for fire safety and for defining the
performed work risk level.
4.
Jet-type air heaters, soldering guns and heat guns

The present Subject defines the minimum required safety precautions to be obeyed during
operation with jet-type air heaters, soldering guns and heat guns inside of near the aircrafts under
maintenance.
A.
General
All recommendations given below are intended both for international and for local use.
Regulations established by the local agencies and/or maintenance procedures developed by
the air lines can also be used. In any case the Operator is responsible for safe use of this
equipment.
B.
Explosion probability
The jet-type air heaters, soldering guns and hat guns are not explosion-proof.
These devices can contain:
components, which are heated to temperature more than 232.2 C (fuel vapours ignition
temperature);
electrical switches, which can spark and thus result in inflammation of the vapours.
C.
Use in the fuel tanks

The heaters should not be used in the fuel tanks, which are empty and are not filled with
such inert gas as nitrogen.
D.
Use near the fuel and flammable fluids

The jet-type air heaters, soldering guns or heat guns should not be used at distance less
than 30 meters from:
the aircraft during refuelling;
the aircraft during unloading;
the aircraft, when the fuel tanks are opened;
the fuel tank drain holes;
the spilled fuel;
other inflammable fluids.
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E.
Use in the smoking areas

The jet-type air heaters, soldering guns or heat guns can be used on the aircraft or near the
aircraft in the areas, where smoking is allowed. If it is necessary to use these tools in the
non-smoking areas, one must make sure that there is no hazardous fuel vapours level in this
area.
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The following requirements must be observed during maintenance and repair of the aircraft electrical
wiring interconnection system:
1.
The aircraft harnesses must correspond to the drawings given in Section 91 of the aircraft WDM.
2.
When replacement of the electrical wiring interconnection system components is required, the
replacing components and materials must be selected in accordance with equipment and materials
specifications given together with harness drawings in Section 91 of the aircraft WDM as well as in
accordance with limiting lists given in the present Manual.
3.
Instructions of the present Manual must be observed during maintenance and repair of the
electrical wiring interconnection system.
4.
It is recommended to use the tools and accessories specified in the present Manual during
maintenance and repair of the electrical wiring interconnection system in order to provide the
necessary quality of the working results and to prevent fast degradation of the electrical wiring
interconnection system.
5.
When replacement of the entire harnesses is required, the harnesses must be made according to
the drawings given in Section 91 of the aircraft WDM. The replacing harnesses must comply with
replaced ones as the standard ones. Gauges (sections) and grades of the wires must correspond to
equipment and materials specifications as well as to the wiring charts attached to the harness
drawings.
6.
Minimum size of the aircraft network wire is 24 AWG, section 0.24 mm with hardened core. Colour
of the used wires is white, color of the multicore cables is standard (white sheath, cores of different
colours). The three-phase circuits are made by: red wires phase A; yellow wires phase B; blue
wires phase C. Colour tags like TMS, RNF-3000 can be used.
7.
When making the harnesses for replacement DO NOT:
place wires with damaged insulation in the harnesses;

extend the wires by soldering or other methods;
twist and lay the wires in the harness, if this is not specified in the aircraft WDM;
8.
When the harnesses are made, length reserve must be provided for triple re-termination but not
more than 50 mm from each wire (harness) end in the places of connection of the wires having
2
section up to 1.94 mm inclusively. For this purpose the harness is routed down and the loop
provided will be used as a repair reserve.
9.
The negative wires must have length not more than 500 mm.
10.
When the wires are made and installed, prevent connection of the negative wires and screen
grounding wires to one negative terminal or grounding module.
11.
Bend radius of the RF cables must be not less than 6d (where d cable diameter at the external
sheath).
12.
Bending of the wires (harnesses) is permitted with bend radius equal to 3 diameters of the wire
(harness) with turning by 180. It is permitted to install the heat-shrinking branches of the types
301A 562A in the junction places.
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13.
Wires of the harnesses during stocking, assembly, transportation and installation on the aircraft
must be bent with radii specified in the Table 1.
TABLE 1
RELATION OF THE HARNESS (WIRE) INNER BEND DIAMETER TO THE

HARNESS (WIRE) DIAMETER
Harness inner bend diameter,
minimum (mm)
Diameter of harness wire, mm
Unscreened
Screened
Wires with section up to 2.98 mm2 inclusively AWG
5D
5D
From 4.75 mm2 (AWG10) to 84.8 (AWG 000)
10D
10D
Harness with diameter up to 10 mm incl.
3D
4D
Harness with diameter from 10 mm to 30 mm
2.5D
3.5D
Harness with diameter from 30 mm to 40 mm
2.2D
3.2D
Harness with diameter more than 40 mm
2D
3D
14.
It is permitted to connect jack-in parts of the stainless steel connectors with aluminium cable parts
with nickel plating, contacts of which are nickel- and gold-plated.
15.
Cable clips with semiclamps can be used to remove mechanical loads from the areas of the wires
crimping / soldering to the contacts of connectors. It is permitted to use the cable clamps for
moulding parts of 222K type. Tube DR25 (RNF 3000, K) 50-60 mm long can be used instead of
the shoe 222K. Wind the tape 67N or 66N, 68N on the harness under the cable clip semiclamps to
provide tight crimping of the harness or install a heat-shrinking sealing sleeve URHR.
16.
Attach the bundle of wires to the connector or connector shank by the plastic cable strip or by
bandage cord, if this is provided for by structure of the connector or cable clip shank.
17.
During ringing test or check of the harnesses DO NOT connect different feelers of the test
equipment to contacts of connectors. Temporary connectors or feelers made from contacts of
connectors having corresponding sizes are used for this.
18.
DO NOT carry the equipment holding it by the harness or cable.
19.
Temporary protection or containers shall be used to protect the harnesses against contamination
and damages during transportation and wiring on the aircraft.
20.
Photos of the places of harnesses arrangement, where many equipment units are installed, must
be taken before harnesses removal, so that these photos are used as wiring standards during
further wiring and electrical wiring check.
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21.
Electrical connectors must be horizontally installed. Vertical installation of the connectors is

permitted with mandatory use of the angle cable clips. Provide the distance between the
attachment flanges not less than 20 mm during standard installation of connectors. In some cases it
is permitted to install the connectors at distance not less than 10 mm between the attachment
flanges, as for the bayonet connectors - not less than 5 mm.
22.
Screened wires in protective sheath, twisted screen wires in the common sheath and unscreened
wires are laid in one harness, if it is not otherwise specified in the wiring diagrams contained in the
WDM.
23.
The moving sections of the harnesses must be made by means of flexible wires of grade 82A in the
places of transition from the aircraft moving part to the fixed one.
24.
The harnesses must be laid along the routes shown in Section 91 of the aircraft WDM.
25.
The harnesses and cables corresponding to the redundant channels must be laid in individual
routes. Harnesses of the flight control system (FCS) must be laid with regard to triple redundancy.
26.
The RF cables must be laid in individual routes.
27.
The power wires must be laid in individual routes with regard to redundancy of the 1-st category
sources.
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1.
General
.
Peculiarities of the wires (cables) use on the aircraft

The following wires and cables are used on the aircraft:
(1) wires and cables of 55PC, 82 type in the pressurized area, for avionic systems, ARINC429, DB, RF cables, switching units, panels and other systems.
(2) particularly flexible wires of 82 type in the deflected, movable structures and hinged
panels.
(3) wires and cables of EN2267, EN2714 type outside the pressurized area: wing, center
wing, horizontal stabilizer, vertical stabilizer, in the protected and unprotected areas; for
intraunit and interunit wiring.
(4) high-temperature wires of TMF-VRA type - in the fire-protection systems and in the high
temperature areas.
(5) thermal compensation cables MBBN3320YH in the temperature measuring circuits.
(6) power leads of the type 2100, ABC 0949 AD, BMS 13-58, 82A in the circuits of electrical
power supply from the main sources irrespective of the installation area.
NOTE: Cables laid in the high temperature areas must have fluoroplastic insulation.
NOTE: It is permitted to use the home-produced wire BS-35 U3583-001-00217069-2005
analog of the wire 55 PC with acceptance grade 5.
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B.
Interpretation of designations of the wires of different specifications
TABLE 1
007
EN2267(EN2714)008(010, 011, 013)
009
INTERPRETATION OF THE WIRES OF EN2267, EN2714 SPECIFICATION
-A(B,C,D)
-002
004,
006,
010,
012,
020, 030)
-P(F,S)
Colour code
(red,
blue,
yellow,
green,
white)
Wire
size
code
(AWG12)
Wire
size code (AWG14)
Wire size
code (AWG16)
Wire size code (AWG18)
Quantity of wires: single, twisted double wire
twisted triple wire; D twisted quadruple wire
Basic specification
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TABLE 2
M27500
INTERPRETATION OF 27500 SPECIFICATION WIRE

-22
-SB
23
Sheath code
00 no sheath;
23 single-layer insulation;
73 double-layer insulation
Structure
U base unscreened wire;
T round wire screen, tinned;
J flat wire screen, tinned;
S - silver round wire screen;
G - silver flat wire screen
N - nickel-plated round wire screen;
V tinned double round wire screen;
W silver double round wire screen.
Quantity of wires (from 1 to 9)
Base code as per MIL-W-22759
SB-32 = 55AO111; SC-33 = 55AO114; SD-34 = 55AO811,
from AWG 2 and higher 558039; SE-35 = 55AO814; SM41 = 55AO813, from AWG 2 and higher 558595; SN-42 =
55AO816; SP-43 = 55AO812, from AWG and higher
556089; SR-44 = 55AO112; SS-45 = 55AO113; ST-46 =
55AO116.
Wire gauge
Base specification
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TABLE 3
55
INTERPRETATION OF 55, 82 SPECIFICATION WIRES

-
gauge
-/
External sheath colour (MIL-STD-681),

preferably white
Wire insulation color (MIL-STD-681)
(1-st- wire color, 2-nd - hatchwork color)
0-black
3-orange
7-violet
1-brown
4-yellow
8-grey
2-red
5-green
9-white
2L-pink
6-blue
AWG core size (diameter)
Core coating type
1 - tin-coated t oper.=+150
2 - silver-plated t oper.=+200
3 - nickel-plated t oper.=+200
4 - coated with high-strength silver
5 - coated with high-strength nickel
Quantity of wires from 1 to 9
(2, 3, 4 twisted wires)
Conductor grade
1-600, lightweight construction () (single-layer insulation 0.15 mm)
2-600, lightweight aircraft conductor (double-layer insulation 0.20 mm)
3-600, ultralight space conductor
4-450, ultralight wiring conductor (55, sizes only of gauge 24-12 only)
7-600, reinforced aircraft conductor
8-600, normal weight aircraft conductor
Structure
0 - primary wire, unscreened
1 - in the common round wire screen, with external sheath
2 - in the common flat wire screen, with external sheath
3 - in the common round wire screen, without external sheath
4 - unscreened with additional external sheath
5 - spiral screen with external sheath
69 - special structures
Wire type
- conductor in AWG system, - metric conductor, PC - lightweight structures
Main specification number 82 with great number of strings - flexible
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TABLE 4
INTERPRETATION OF M22759/34 SPECIFICATION WIRE
M22759/34
-22
-9
Sheath colour (white)
Wire gauge (section)
Base military specification
NOTE: The specified wire corresponds to SPEC-55 specification wire.
TABLE 5
TMF
INTERPRETATION OF TMF HIGH-TEMPERATURE WIRE
-VRA
-US
-2
-22
Wire gauge (AWG22)
Sheath
Screened cable
Quantity of wires (1-3)
USA gauge scale
Conductor made of hardened alloy,
nickel-plated
Basic number
TABLE 6
MBBN 3320
INTERPRETATION OF MBBN TEMPERATURE-COMPENSATED CABLE
YH
006
(004)
Wire size code AWG 22
Wire size code AWG 20
Twisted screened pair in the sheath:
chromel - white
alumel - green
Base specification
EFFECTIVITY:
Page 5
ALL
20-10-10
Sep 30/11
RRJ-95B
TABLE 7
RF
cable
-50
INTERPRETATION OF RF CABLES
-3
-2
1
Development No.
1 - common heat-resistance with solid insulation up to +125
2 - increased heat-resistance, solid insulation
3 - common heat-resistance, semi-air insulation
4 - increased heat-resistance, semi-air insulation
5 - common heat resistance, air insulation
6 - increased heat resistance, air insulation (125250)
7 - high heat resistance more than +250
Nominal diameter with insulation
(0.6; 0.87; 1.0; 1.5; 2.2; 2.95; 3.7; 4.6; 4.8; 5.6;
7.25; 9.0; 11.5; 13.0; 17.3; 24.0; 33.0)
Nominal wave resistance
50 (75 ; 100; 150 and 200)
Coaxial cable
EFFECTIVITY:
Page 6
ALL
20-10-10
Sep 30/11
RRJ-95B
TABLE 8
XX
XX
INTERPRETATION OF CHEMINAX SERIES CABLES (5020A1311)

a
-X
Cable sheath colour code
0 - black
9 - white
Conductor material
0 - tinned copper
1 - silver-plated copper
4 - silver-coated high-strength copper alloy
7 - steel, coppered, tinned

1 - steel, silver
2 - steel, copper-coated, silver
Dielectric material
1 - foamed irradiated
polyolefine Rayfoam L (100C)
2 - foamed irradiated
fluoroplastic Rayfoam H (200C)
3 - irradiated polyethylene Rayolin (125C)
4 - fluoroplastic FEP (200C)
Sheath material
1 - irradiated polyvinylidene fluoride Spec44 (150C)
2 - PVF2
3 - irradiated polyolefine Thermorad (125C)
4 - fluoroplastic FEP (200C)
5 - irradiated Tefzel ETFE
6 - Spec55 (200C)
7 - Flexline
8 - irradiated halogen-free material Zerohal (125C)
Screen structure
1 - one screen
2 - one screen braiding
3 - two screens (triax)
5 - three screens
Structure variant. Letter indicating development modification
Core size (AWG 3012)
Impedance (50, 75, 95 and 125 Ohm) (if it is more than 100, only two last figures)
NOTE: Lightweight import aircraft wires and RF cables are used for termination in the import
and home-produced electrical connectors.
NOTE: Current-carrying cores of the wires and cables have protective tin, silver or nickel
coatings.
EFFECTIVITY:
Page 7
ALL
20-10-10
Sep 30/11
RRJ-95B
2.
Wires and cables used on the aircraft
TABLE 9
WIRE GRADES
()
Min.
Max.
(Hz)
Max. frequency
(V)
Max. voltage
Weight (kg/km)
Resistance
(Ohm/km)
Outer diameter
(mm)
AWG
Section
(mm2)
Insulation colour
Grade
55021424-9
55021122-9
55021120-9
55021118-9
55021116-9
55021114-9
55021112-9
55021110-9
550211-89
550211-69
550211-49
550211-29
550211-09
55021100-9
22759/3324-9
22759/3422-9
22759/3420-9
22759/3418-9
22759/3416-9
22759/3414-9
22759/3412-9
22759/3410-9
22759/348-9
Manufacturer
Current load
()
Wire type
Unscreened aircraft wire
Operating temperature
White 24 0.24
1.00 93.17
2.95
600
-60
200
Tyco Electronics 10.0 White 22 0.38
1.16 53.15
4.32
600
-60
150
1.37 32.15
6.58
600
-60
150
1.61 20.34
9.87
600
-60
150
1.80 15.75 12.56
600
-60
150
2.18
9.87
19.23
600
-60
150
2.66
6.60
29.14
600
-60
150
3.28
4.10 46.218
600
-60
150
Tyco Electronics 78.0 White
4.97
2.30
86.28
600
-60
150
6 13.50 6.15
1.46 135.64
600
-60
150
21.6
7.90
0.92 219.75
600
-60
200
33.6
9.73
0.60 328.77
600
-60
150
0 52.70 11.84 0.38 510.45
600
-60
150
Tyco Electronics 305.0 White 00 67.20 13.34 0.30 669.685
600
-60
150
Tyco Electronics 7.5
8.62
White 24 0.24
1.14 93.17
3.50
600
-60
150
1.32 53.15
5.08
600
-60
150
1.52 32.15
7.9
600
-60
200
1.80 20.34 10.89
600
-60
150
1.98 15.75 12.90
600
-60
150
2.36
9.87
20.58
600
-60
150
Tyco Electronics 37.5 White 12
3.0
2.90
6.60
31.20
600
-60
150
3.50
4.10
48.48
600
-60
150
5.03
2.30
87.70
600
-60
150
8.62
EFFECTIVITY:
Page 8
ALL
20-10-10
Sep 30/11
Max.
7.5
24
0.24
0.686 85.96
3.12
600
-60
150
Tyco Electronics
10.0
22
0.38
0.84 53.15
4.32
600
-60
150
Tyco Electronics
13.0
20
0.60
1.09 32.15
6.25
600
-60
150
Tyco Electronics
17.5
18
0.96
1.35 20.34
9.97
600
-60
150
Tyco Electronics
20.0
16
1.23
1.70 15.75
15.18
600
-60
150
Tyco Electronics
28.0
14
1.94
2.50
9.87
24.60
600
-60
150
(Hz)
Tyco Electronics
(V)
Min.
Max. frequency
Max. voltage
Weight (kg/km)
Resistance (Ohm/km)
Manufacturer
Section
(mm2)
Outer diameter (mm)
Operating
temperature ()
AWG
Insulation colour
Grade
Current load
()
Wire type
820111-249
820111-229
820111-209
820111-189
820111-169
820111-149
820111-129
820111-109
820111-8-9
820111-6-9
820111-4-9
820111-2-9
820111-1-9
820111-0-9
820111-009
Screened lightweight wire in common sheath
Unscreened flexible wire
RRJ-95B
White
Tyco Electronics
37.5
12
3.00
3.10
6.60
36.90
600
-60
150
Tyco Electronics
53.0
10
4.75
4.00
4.10
62.80
600
-60
150
Tyco Electronics
Tyco Electronics
Tyco Electronics
Tyco Electronics
Tyco Electronics
Tyco Electronics
78.0
105.0
142.0
179.0
210
243.0
8
6
4
2
1
0
8.62
13.50
21.6
33.6
41.80
52.70
4.95
5.99
8.08
9.78
11.3
13.1
2.30
1.46
0.92
0.60
0.49
0.38
98.60
152.00
252.00
375.00
472.00
606.0
600
600
600
600
600
600
-60
-60
-60
-60
-60
-60
150
150
150
150
150
150
00 67.20
14.4
0.30
747.00
600
-60
150
55211424-9- 9
Tyco Electronics
7.5
24
0.24
1.45 93.17
5.59
600
-60
200
55211122-9-9
Tyco Electronics
10.0
22
0.38
1.60 53.15
7.34
600
-60
150
55211120-9-9
Tyco Electronics
13.0
20
0.60
1.80 32.15
9.95
600
-60
150
55211118-9-9
Tyco Electronics
17.5
White 18
0.96
2.03 20.34
13.85
600
-60
150
55211116-9-9
Tyco Electronics
20.0
16
1.23
2.24 15.75
16.96
600
-60
150
55211114-9-9
Tyco Electronics
28.0
14
1.94
2.59
9.87
24.36
600
-60
150
55211112-9-9
Tyco Electronics
37.5
12
3.00
3.10
6.60
36.03
600
-60
150
EFFECTIVITY:
Page 9
ALL
20-10-10
Sep 30/11
Resistance (Ohm/km)
Weight (kg/km)
Min.
Max.
600
-60
200
22
0.38
2.77
53.15
12.92
600
-60
200
20
0.60
3.20
32.15
18.22
600
-60
200
24
0.24
2.67
93.17
12.77
600
-60
200
22
0.38
3.00
53.15
17.41
600
-60
200
20
0.60
3.48
32.15
24.98
600
-60
200
24
0.22
0.96
114.0
2.64
600
2000
-55
260
8.5
22
0.34
1.10
60.0
3.89
600
2000
-55
260
Nexans
11.5
20
0.60
1.34
33.2
6.57
600
2000
-55
260
Nexans
15.0
18
0.93
1.61
21.1
10.15
600
2000
-55
260
Nexans
19.5
16
1.34
1.92
14.5
14.05
600
2000
-55
260
Nexans
24.0
14
1.82
2.24
10.9
19.31
600
2000
-55
260
Nexans
35.0
12
2.98
2.70
6.8
29.25
600
2000
-55
260
Nexans
43.0
10
4.91
3.30
4.1
47.37
600
2000
-55
260
Nexans
68.0
8.98
4.40
2.3
87.81
600
2000
-55
260
Nexans
85.0
13.40
5.70
1.58
132.41
600
2000
-55
260
Nexans
6.5
24
0.21
2.40
117.00
10.23
600
2000
-55
260
Nexans
8.5
22
0.34
2.70
61.70
13.64
600
2000
-55
260
Nexans
11.5
20
0.60
3.22
34.10
21.05
600
2000
-55
260
Nexans
15.0
18
0.93
3.71
21.70
29.52
600
2000
-55
260
Nexans
19.5
16
1.34
4.38
14.90
41.20
600
2000
-55
260
Nexans
24.0
14
1.82
5.04
11.20
55.83
600
2000
-55
260
7.5
Tyco
Electronics
10.0
Tyco
Electronics
13.0
Nexans
6.5
Nexans
white blue
Tyco
Electronics
Blue
13.0
white orange blue
10.0
EFFECTIVITY:
(Hz)
Max. frequency
Outer diameter
(mm)
9.64
(V)
Section
(mm2)
93.17
Max. voltage
AWG
2.46
Insulation colour
0.24
7.5
green
EN 2267010A-004
EN 2267010A-006
EN 2267010A-010
EN 2267010A-012
EN 2267010A-020
EN 2267010A-030
EN 2267010A-051
EN 2267010A-090
EN 2267010A-140
EN 2714013B 002F
EN 2714013B 004F
EN 2714013B 006F
EN 2714013B 010F
EN 2714013B 012F
EN 2714013B 020F
Operating
temperature
()
24
Tyco
Electronics
Tyco
Electronics
Tyco
Electronics
red blue
Twisted screened
double, triple, quadruple wires in common
sheath
Unscreened general purpose wires
EN 2267010A-002
Current load
()
Grade
55212424-9/96-9
55212222-9/96-9
55212220-9/96-9
55213424-9/93/969
55213422-9/93/969
55213420-9/93/969
Manufacturer
Wire type
Screened twisted double, triple wires in
common sheath
RRJ-95B
Page 10
ALL
20-10-10
Sep 30/11
Min.
Max.
2000
-55
260
8.5
22 0.34
2.91
61.70
19.76
600
2000
-55
260
11.5
20 0.60
3.48
34.10
30.44
600
2000
-55
260
18 0.93
4.00
21.70
42.96
600
2000
-55
260
19.5
16 1.34
4.73
14.90
60.67
600
2000
-55
260
24.0
14 1.82
5.39
11.20
78.83
600
2000
-55
260
35.0
12 2.98
6.50
6.99
122.72
600
2000
-55
260
6.5
24 0.21
2.84
117.00
18.47
600
2000
-55
260
8.5
22 0.34
3.19
61.70
25.04
600
2000
-55
260
11.5
20 0.60
3.82
34.10
38.81
600
2000
-55
260
18 0.93
4.41
21.70
55.22
600
2000
-55
260
18 0.93
4.41
21.70
55.22
600
2000
-55
260
19.5
16 1.34
5.23
14.90
78.02
600
2000
-55
260
24.0
14 1.82
6.06
11.20
107.36
600
2000
-55
260
24 0.21
1.45
114.00
5.76
600
2000
-55
260
8.5
light-green 22 0.34
1.60
60.00
7.51
600
2000
-55
260
11.5
20 0.60
1.84
33.20
10.77
600
2000
-55
260
15.0
18 0.93
2.08
21.10
14.97
600
2000
-55
260
16 1.34
2.43
14.50
20.97
600
2000
-55
260
24.0
14 1.82
2.74
10.90
27.03
600
2000
-55
260
35.0
12 2.98
3.20
6.80
39.70
600
2000
-55
260
43.0
10 4.91
3.89
4.10
61.94
600
2000
-55
260
15.0
15.0
15.0
6.5
red blue
yellow
red blue
yellow
green
White
19.5
(Hz)
600
(V)
14.72
Max. frequency
117.00
Max. voltage
2.59
Section (mm2)
24 0.21
AWG
6.5
Insulation colour
Weight (kg/km)
Operating
temperature
()
Resistance (Ohm/km)
EN 2714Nexans
013C 002F
EN 2714Nexans
013C 004F
EN 2714Nexans
013C 006F
EN 2714Nexans
013C 010F
EN 2714Nexans
013C 012F
EN 2714Nexans
013C 020F
EN 2714Nexans
013C 030F
EN 2714Nexans
013D 002F
EN 2714Nexans
013D 004F
EN 2714Nexans
013D 006F
EN 2714Nexans
013D 010F
EN 2714013D
Nexans
010F
EN 2714013D
Nexans
012F
EN 2714013D
Nexans
020F
EN 2714Nexans
013A 002F
EN 2714Nexans
013A 004F
EN 2714Nexans
013A 006F
EN 2714Nexans
013A 010F
EN 2714Nexans
013A 012F
EN 2714Nexans
013A 020F
EN 2714Nexans
013A 030F
EN 2714Nexans
013A 051F
Current load
()
Grade
Manufacturer

Outer diameter (mm)
Screened wire in common sheath
Screened twisted
double, triple, quadruple wires in common sheath
Wire type
RRJ-95B
White
EFFECTIVITY:
Page 11
ALL
20-10-10
Sep 30/11
Twisted high-temperature
screened double, triple cables in
common sheath
Screened hightemperature wire in

common sheath
Min.
Max.
2000
2000
2000
-50
-50
-50
250
250
250
34.50 10.60
0.61
396.0
600
2000
-50
250
1
0
41.80 11.80
52.70 13.10
0.50
0.40
470.0
600.0
600
600
2000
2000
-50
-50
250
250
00
67.20 14.20
0.31
750.0
600
2000
-50
250
135
34.50
8.57
0.94
113.1
600
2000
-65
180
Nexans
160
41.80
9.50
0.75
139.17
600
2000
-65
180
Nexans
181
52.70 10.93
0.60
175.81
600
2000
-65
180
Nexans
211
00
67.20 12.37
0.43
222.96
600
2000
-65
180
Nexans
245
000 84.80 13.71
0.36
267.57
600
2000
-65
180
Nexans
22
0.38
1.37
77.8
6.18
600
2000
-65
260
Nexans
20
0.61
2.11
50.1
13.40
600
2000
-65
260
Nexans
18
0.96
2.46
30.0
15.60
600
2000
-65
260
2100-2
Nexans
181
2100-1
2100-0
Nexans
Nexans
211
245
Nexans
283
Nexans
grey
(Hz)
Weight (kg/km)
600
600
600
Blue
Blue
Blue
red blue
yellow
Blue
Blue
red blue
yellow
(V)
Resistance
(Ohm/km)
108.0
160.0
245.0
75
100
135
Grade
Max. frequency
Outer diameter
(mm)
2.30
1.60
0.97
Nexans
Nexans
Nexans
Max. voltage
Section
(mm2)
5.30
7.00
9.00
Current load
()
8.98
13.40
21.80
2100-8
2100-6
2100-4
ABS 0949
AD 2
ABS 0949
AD 1
ABS 0949
AD 0
ABS 0949
AD 00
ABS 0949
AD 000
TMF-VRAUS-22
TMF-VRAUS-20
TMF-VRAUS-18
TMF-VRAUS-16
TMF-VRAUS-14
TMF-VRAUS-12
TMF VRAUS1SJ22
TMF VRAUS1SJ20
TMF VRAUS1SJ18
TMF VRAUS1SJ16
TMF VRAUS2SJ 24
TMF VRAUS2SJ 22
TMF VRAUS2SJ 20
TMF VRAUS2SJ 18
TMF VRAUS2SJ 16
TMF VRAUS3SJ 24
Operating
temperature
()
8
6
4
Manufacturer
2100-00
Insulation colour
AWG
Unscreened high-temperature
wire
Aircraft aluminium nickelplated power leads
Aircraft copper power

leads
Wire type
RRJ-95B
White
Nexans
16
1.23
2.62
22.5
20.10
600
2000
-65
260
Nexans
14
1.93
3.12
14.2
29.00
600
2000
-65
260
Nexans
12
3.08
3.61
9.12
41.70
600
2000
-65
260
Nexans
22
0.38
2.18
77.76
12.17
600
2000
-65
260
Nexans
20
0.61
2.82
50.10
20.89
600
2000
-65
260
White
Nexans
0.96
3.33
27.89
28.57
600
2000
-65
260
Nexans
16
1.23
3.48
21.85
32.23
600
2000
-65
260
Nexans
24
0.24
3.38
127.13
19.27
600
2000
-65
260
Nexans
22
0.38
3.71
79.40
23.85
600
2000
-65
260
Nexans
20
0.61
4.78
51.18
36.99
600
2000
-65
260
Nexans
18
0.96
5.77
28.54
51.74
600
2000
-65
260
Nexans
16
1.23
6.07
22.31
58.90
600
2000
-65
260
Nexans
white,
24
red, blue
0.24
3.58
127.13
25.05
600
2000
-65
260
white,
red
EFFECTIVITY:
Page 12
ALL
20-10-10
Sep 30/11
Weight (kg/km)
Min.
Max.
3.94
79.40
31.55
600
2000
-65
260
Nexans
20 0.61
5.08
51.18
49.94
600
2000
-65
260
TMF VRAUS3SJ 18
Nexans
18 0.96
6.15
28.54
70.86
600
2000
-65
260
TMF VRAUS3SJ 16
Nexans
16 1.23
6.48
22.31
81.25
600
2000
-65
260
MBBN
3320 YH
004
Nexans
22 0.34
4.00
2.411/
0.951
24.3
600
2000
-55
260
MBBN
3320 YH
006
-001822(20-16)9/5-9
Nexans
Tyco
Electronics
20 0.60
22 0.40
4.55 1.357/0.534
3.61 2198/919
31.4
20.24
600
600
2000
-55
-65
260
150
Raychem
7.5
24 0.24
1.85
92.52
8.48
600
-65
150
10.0
22 0.38
2.01
61.68
10.27
600
-65
150
13.0
20 0.60
2.26
38.39
13.24
600
-65
150
18 0.96
2.59
23.43
18.60
600
-65
150
20.0
16 1.23
3.00
14.86
25.45
600
-65
150
28.0
14 1.94
3.58
9.71
37.65
600
-65
150
12 3.00
4.22
6.20
53.28
600
-65
150
53.0
10 4.75
5.23
3.67
84.38
600
-65
150
78.0
6.30
2.34
126.05
600
-65
150
105.0
6 13.50 7.50
1.61
187.51
600
-65
150
142.0
4 21.60 9.96
1.07
309.54
600
-65
150
179.0
2 33.60 11.84
0.67
449.43
600
-65
150
243.0
0 52.70 15.75
0.44
730.70
600
-65
150
305.0
00 67.20 17.17
0.335
888.449
600
-65
150
82A111124-9-9
82A111122-9-9
82A111120-9-9
82A111118-9-9
82A111116-9-9
82A111114-9-9
82A111112-9-9
82A111110-9-9
82A11118-9-9
82A11116-9-9
82A11114-9-9
82A11112-9-9
82A11110-9-9
82A111100-9-9
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
Raychem
white, red, blue

white Cr,
green - Al
17.5
37.5
White
White
8.62
Operating
temperature ()
(Hz)
Max. frequency
(V)
Resistance (Ohm/km)
22 0.38
Max. voltage
Outer diameter
(mm)
AWG
Section
(mm2)
Nexans
TMF VRAUS3SJ 22
TMF VRAUS3SJ 20
Insulation colour
Current load
()
Screened high-temperature
double, triple wires in
common sheath
Temperature
compensating
wires
Flexible screened wires
Flexible screened wires
Manufacturer
Grade
Wire type
RRJ-95B
NOTE: Permissible current load values are given for single wires at conductor heating up to 135
during 30 minutes.
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18
12
0.93
2.98
4.90
10.97
10.97
47.77
109.98
8.64
21
0.61
4.95
50
22.62
EFFECTIVITY:
-55
125
Black
Max.
40.28
Min.
Cable insulation colour
3.74
Black
0.24
200
White
24
-90
-55
250
200
125
Black
Tyco
Electronics
Operating
temperature
()
-55
Black
5021D1331-0
85.30
Max. voltage
(V)
Tyco
Electronics
Weight (kg/km)
50123311-0
Wave resistance (Ohm/km)
MIL-C-17
50.0
10015
From 1 to 100 MHz
RG-225
RG-393
86.61
120
502
Tyco
Electronics
5.51
502
Analogue
5019D3311-0
Outer diameter
(mm)
MIL-C-17
Section (mm)
RG-142
RG-400
AWG
0.24
Insulation colour
44.0
At 100MHz
Nexans
white blue
Manufacturer
ET 2PF 870,
ABS 1503
KD24
24
red blue yellow green
Grade
Axon
Capacity
(PF/m)
Cable type
506424
Coaxial RF cables
Twisted double sheathed cable in common

screen for CAN protocol lines
GRADES OF RF CABLES
Twisted sheathed quadruple cable in the

common screen for digital transmission
lines
TABLE 10
-55
250
200
125
125
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Max.
Outer diameter
(mm)
Insulation colour
Min.
95.1
Cable insulation colour
PIC
White
L2201 TX
50
-60
250
70.26
3.20.25
50
-60
200
24
0.25
2.0
114
10.0
-55
200
20
0.61
6.2
50
8.93
transparent
130
Max. voltage
(V)
Nexans
Weight (kg/km)
ASNE0291SW24
EN 3375006D
70.8
mm
Wave resistance (Ohm/km)
95
Section (mm)
GOST 11326.7479
AWG
RK50-2-22
RK50-9-45
White
Operating
temperature
()
transparent
Capacity
(PF/m)
GOST11326.3879
TUOKh505.51992
RK50-7-22
Coaxial RF cables
Manufacturer
Grade
Cable type
RRJ-95B
-55
200
7.25
9.00.5
NOTE: Coded designation of wires: EN2267-007A(008A)-DM; N2267-007B-PN; N2267-007C-QL;

N2267-007D-RK; N2267-010A-DR; N2267-009A-DRA; N2267-009B-DRB; N2267-009CDRC; N2267-009D-DRD; N2714-013A-MLA; N2714-013B-MLB; N2714-013C-MLC;
N2714-013D-MLD; N2714-011A-GJ; EN2714-011B-MH; N2714-011C-UU; N2714-011DVV.
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1.
General
Prior to cutting the wire or cable must be checked in the coil according to data specified in the
certificate or on the tag for correspondence with data contained in Section 91 of the WDM. It is
recommended not to remove the tag of the wire or cable till it is completely used (Fig.1):
Fig. 1 Wire coil marking

2
.
Cutting tool for wires, cables, tags and tubes
Tool selection
The tool for wire (cable) cutting is selected in relation to size of the wire (cable):
(1)
Single wires with section 26-10 AWG, twisted cables (double, triple,quadruple) with section up
to 12 AWG are cut by means of cutter IDEAL 45-075, 45-223 (Fig.2):
Fig. 2 Cutter IDEAL 45-075, 45-223

(2)
Single wires with section up to 10 AWG, cables with outer diameter up to 13.0 mm are cut by
IDEAL 45-123 type cutter (Fig.3):
Fig. 3 Cutter IDEAL 45-123
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(3)
Power cables with section up to 107.8 mm and harnesses with diameter up to 100 mm are cut
by the ratchet cutter of IDEAL 35-053 type (Fig.4):
Fig. 4 CUTTER IDEAL 35-053

(4)
Coaxial cables with diameter up to 12.7 mm are cut by IDEAL 45-074 type cutter or similar
tool, which provides right angle of the shear plane to longitudinal axis of the wire, cable or tube
(Fig.5):
Fig. 5 CUTTER IDEAL 45-074

B.
Tool use procedure

(1)
Quality of the wires and cables cutting is provided by the tool, only if it is correctly used.
(2)
The marking tags, tubes and bandage elements are cut by the Electrician's scissors 35-088,
HS 6000 ("LINDSTROM"), IDEAL 45-344.
(3)
Cutting of the wires and cables must be performed by the tools, which provide quality of
cutting at right angle to the wire longitudinal axis without flattening and damage of the wire
core (Fig.6 and 7).
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Fig. 6 Tool providing shear angle 90 to the wire longitudinal axis
Fig. 7 Shear plane 90 to the wire longitudinal axis

(4)
A quantity of wires more than 3000 mm long is cut by means of the wire cutting machine with
strict observance of instructions attached to it (Fig.8).
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Fig. 8 Wire cutting machine

CAUTION: Prior to beginning of wire/cable cutting make sure that blades of the cutter are
sharp and clean. Dull blades can deform and tear end of the wire/cable. Shear
plane on the wires must be 9010 to the wire longitudinal axis. Deformation of
the insulation and core is not permitted (Fig.9):
Fig. 9 Shear plane
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REMOVAL OF INSULATION, STRIPPING OF WIRES AND CABLES

1.
Removal of insulation and splicing of cables of different types

.
Removal of insulation from the round section screened cables

Insulation from the screened cables with round or almost round section in the sheath is
removed by the tool IDEAL STRIPPER 45-401 for sheath thickness 0.15 mm, 45-402
for sheath thickness 0.20-0.25 mm, including Kynar (Fig.1):
Fig. 1 IDEAL STRIPPER 45-401, 45-402

Outer sheath from the screened single wires, twisted double, triple or quadruple wires in
the common sheath and from the RF cables is removed by the tool IDEAL 45-162, 45163, 45-164, 45-165.
In order to guarantee stable fixed length of the removed insulation, the IDEAL Stripper
tool is fitted with adjustable limit stop (Fig.2):
Fig. 2 Limit stop on IDEAL Stripper 45-401, 45-402

The tool is positioned in such a way, so that the cable is in the "V" shaped slot of the tool
and the cutting edges are in the place of cutting. IDEAL logo must be at the top, i.e. the
cutting edges must be placed above the cable (Fig.3).
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Fig. 3 The cable must be in the "V" shaped slot of the tool
By downward motion turn the tool once or twice (in relation to type of the sheath) around
the cable, then remove the tool (Fig.4):
Fig. 4 Cutting of the cable insulation

Ben the cable in the place of cutting several times to expand the cut up to the screen
braiding (Fig.5):
Fig. 5 Cable bending up to screen braiding
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Using the non-skidding pad carefully pull off the insulation segment by 3
hands (Fig.6):
4 mm by
Fig. 6 Insulation pulling-off by means of the non-skidding pad

Pull the insulation backward so that a "skirt" is formed by the screen braiding around
perimeter of the cut (Fig.7):
Fig. 7 Insulation pulling-off till formation of "skirt" of the screen braiding around perimeter
of the cut
Using side cutters cut the screen braiding around perimeter of the cut in several motions
(Fig.8):
Fig. 8 Removal of screen braiding by the diagonal-sharpened side cutters RK-106,

8131, IDEAL 45-344
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Pull off the sheath section together with separated screen braiding (Fig.9). If required, turn
the sheath in direction of cable twisting (for twisted structures):
Fig. 9 Removal of the sheath with separated screen braiding.

B.
Stripping of insulation of the coaxial cables and multicore wires

Stripping of insulation of the coaxial cables and multicore wires is performed by the tools
IDEAL 45-162, 45-163, 45-164, 45-165 according to Table 1.
TABLE 1
USE OF IDEAL TOOL
Cable diameter
Tool No.
Reserve cutting edge No.
Up to 3.2 mm
45 - 162
L9225
3.2 mm - 5.5 mm
45 - 163
L9225
4.8 mm - 7.9 mm
45 - 165
L9225
6.4 mm - 14.3 mm
45 - 164
L9226
(mm)
Cable insulation stripping procedure:

- Set height of one of the side edges and of the bent edge in the tool front part. These height
values must be equal to about 3/4 of the cable insulation thickness.
- Place the cable in the V-shaped slot of the tool right under the side cutting edge.
- Turn the tool once around its axis and remove the insulation (Fig.10).
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Fig. 10 TOOL USE PROCEDURE

- Bend the cable, so that the cut extends on the insulation surface.
- If the stripped section is short, just pull off and insulation section.
C.
Removal of insulation from the power cable

Insulation is removed from the power cable by the tool in accordance with Subject 2 of the
present Subsection and with Figure 11:
Fig. 11 Removal of insulation from the power cable

If the stripped segment is long, the cable is placed in the V-shaped slot of the tool right under
the forward cutting edge. The tool is stretched along the stripped segment and is removed.
The cable is bent in direction opposite to that of cutting, so that the cut propagates on the
insulation surface, after that this segment of the cable insulation is removed (Fig.12).
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Fig. 12 TOOL USE PROCEDURE

2.
Removal of insulation from the wires

Insulation is removed from the wires by the tool in relation to the wire grade.
Insulation of the single wires is stripped by precision tool with splicing blades (Fig.13):
Fig. 13 Precision tool with splicing blade IDEAL Stripmaster

In order to prevent brooming out of the wire strands during operation it is recommended to perform
incomplete stripping of insulation (Fig.14). The latch on the tool limits distance between the cutting
dies to about 4 mm, this corresponds to insulation pull-off distance.
Fig. 14 Partial removal of insulation using L-5269 latch
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The notched part of insulation is pulled off manually prior to wire termination in the contact using the
non-skidding pad IDEAL Gripper (Fig.15):
Fig. 15 Non-skidding pad IDEAL Gripper

To provide guaranteed stable fixed length of the removed insulation, IDEAL Stripmaster tool is fitted
with adjustable limit stop. The limit stop is screwed into a hole in the tool frame side face on the side
of the cutting die (Fig.16):
Fig. 16 Limit stop on IDEAL Stripmaster

Length of the stripped insulation segment is defined by position of the limit stop, which can be moved
on the rod. The limit stop is fixed by the attach screw.
It is recommended to strip the insulation by means of the tool with splicing blades.
Structure of these blades provides for a sharp polished cutting edge calibrated to diameter of wire
core and of two seating centering cylindrical contours, diameter of which is somewhat less than outer
diameter of the wire (Fig.17).
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Fig. 17 Tool with splicing blades for stripping of insulation

The insulation stripping tool is selected according to Table 2:
TABLE 2
SELECTION OF THE WIRE STRIPPING TOOL

Wire type
55PC011X,
BS-35
55PC021X
82A0111
EN 2267-010A
MBBN 3320 YH
TMF-VRA
Large sections and RF cables, 55PC, 82

2100
ABC0949AD-X
P506424, ET2PF870
Section (AWG)
Tool designation
16 - 26
16 - 26
10 - 14
16 - 26
16 - 26
10 - 14
16 - 26
16 - 24
14 - 10
20 - 22
16 - 26
6-8
4 - 00
4 - 00
4 - 2 - 00
24
45-1610
45-1987, S5-1987
45-1611, S5-1611
45-1610
45-1987, S5-1987
45-1611, S5-1611
45-1987, S5-1987
45-2824-9
45-2825-9
45-1773
45-097
45-163-341
45-164-341
45-164-341
45-164-341
45-402
It is recommended to remove insulation of a quantity of wires using the insulation removal

machine with strict observation of instructions attached to it (Fig.18):
Fig. 18 Insulation removal machine IDEAL 45-950
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NOTE: Cutting die of the wire insulation removal tool must correspond to gauge, outer diameter
and insulation type of the wire.
As for installation by crimping method, length of the insulation removed from the wire is defined
by the contact size. Length of the stripped core must be such, so that wire edge bears against
the bottom of the contact tail; wire core must be seen through the contact check hole at that.
Besides, a clearance must be left between wire insulation and edge of the contact tail.
The clearance must be 1.0 mm max (Fig.19):
Fig. 19 Clearance value

Recommended length of the removed insulation for the most common wire gauges is given in
Table 3:
TABLE 3
RECOMMENDED LENGTH OF INSULATION REMOVED FOR CRIMPING

Wire gauge
Length of removed insulation
(AWG)
(mm)
22 D or 22
4.00.5
20
5.00.5
16
7.00.5
12
8.00.5
It is recommended to define length of the removed insulation for wiring by soldering method
according to Table 4:
TABLE 4
RECOMMENDED LENGTH OF INSULATION REMOVED FOR SOLDERING

Contact size
Length of removed insulation (mm)
20
5.00.5
16
7.00.5
12
8.00.5
16.01
16.01
19.01
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Serial number of the tool and wire gauge must be indicated on the blades of the used tool.
Length of the removed insulation is adjusted by means of the limit stop.
The wire is placed in the gauged slot of the cutter, then it is pressed and released - insulation is
removed (Fig.20, 21):
Fig. 20 Wire installation in the slot of the tool cutting die

The handle is fully pressed and then released (Fig.21).
Fig. 21 Full pressing and releasing of the handle

Quality of insulation stripping is provided by the tool. The wire must have no insulation in the
area of insulation removal without traces of damages or cutting of the current-carrying conductor
cores.
When insulation is correctly stripped, an even clean cut is formed along the cutting line, there is
no contact of the cutting edges with surface of conductor cores and conductor cores are not
deformed (Fig.22).
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Fig. 22 Conductor with correctly removed insulation

The following is not permitted: cut wires of the cores on the insulation cut, broken, tangled core
wires, punching, deformation, stretching of the insulation material, notching and tangled core and
insulation of the wire (Fig.23).
Fig. 23 Defects of insulation removal

Notches on the insulation cut: 1 - burrs on the core wires; 2 - tangled core and insulation; 3 scratched core wires; 4 - cut and scratched wires, cores, tangled insulation; 5 - stretched
insulation.
When sheath is removed from the twisted screened cable, damages of the screen braiding such
as cuts and scratches, burrs of the cable outer sheath are not permitted.
The cut made through the insulation must be even and clean, there must be no traces of blades
contact with component wires and screen braiding.
Edges of the stripping tool must be subjected to monthly check. Serviceability of the edges is
defined by quality of stripping of the test samples of not less than three wires of each gauge
(section) using 4-magnifier - there must be no damages of insulation, cuts on the currentcarrying wire core.
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MARKING OF EWIS COMPONENTS
1.
General
Marking of wires, harnesses and cables during installation and operation of equipment must provide
the possibility of check of the electrical circuits and fault isolation.
Electrical wires must have markings corresponding to those used in Section 91 of WDM and
meeting requirements of the present document.
Marking applied on the wire must be read horizontally from left to right, vertically downward.
2.
Marking application methods

In relation to drawing requirements the cables and harnesses are marked using the following
methods:
(1)
Laser beam marking along the wire length (Fig.1):
Fig. 1 Laser marking of the twisted double, triple, quadruple screened cables
NOTE: Wire colours: W white; B blue; G green; Y yellow; R red
(2)
Identification sleeves TMS-SCE, HT-SCE (Fig.2):
C274N:32R:34B
C274N:36Y:38G
Wire color
(W-white, G-green,B-blue, R-red, Y-yellow)
Fig. 2 Marking of single wires by identification sleeves 275N161
Marking of the twisted screened cables:
double cables 274S32R:34B or 274S32R, 274S32B;
triple cables - 274S32W:34B:36Y or C274S32W:34B, 274S34(B):36Y;
quadruple cables - 274S32R:34B:36G:38Y or 274S:32R:34B, C274S36G:38Y;
Marking of the negative wire: 6G9:H360-A;
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Marking of the three-phase circuit wire: 300A2M(E)01A(B,C)1(2)

Marking by TMS-SCE identification sleeves is used in the areas with permanent operating
temperature up to +135, HT-SCE. Marking can be made on the sleeves RNF-3000, RW175, OTK, which are installed on the ends of the wires in places of their joint at distance 501155 mm.
Marking by HT-SCE identification sleeves is used in the areas with permanent operating
temperature up to +225.
Power cables with diameter more than 6.00 mm and harnesses are marked by the
identification sleeves or tags CM-SCE, which are attached on the cable by means of plastic
cable bands (Ref. Fig.3). The splice sleeves are marked on the tag CM-SCE (12-C275 M) or
on the identification sleeve. Identification tag CM-SCE (HTCM-SCE) or PVF tape tag with
wire designation, aircraft number revision and series is installed on the harness. The
identification tags are installed along the harness length with pitch 1000-1500 mm (pitch
1250250 mm is permitted) as well as on the branches at distance 25050 mm from the
branch point.
Fig. 3 Marking on CM-SCE tag

Laser marking is applied directly on the wire or cable by means of the wire laser marking
machine with strict observation of instructions attached to it (Fig.4):
Fig. 4 Wire laser marking machine

Laser marking is applied only on the special insulation on the wires and cables as
per 55PC specification and wires as per EN2267-10 specification, cables EN2714013, BS-35;
Recommended marking pitch - 75-1155 mm from beginning of the wire, then minimum pitch 380 mm along the whole wire length;
Most laser machines are provided with integrated wire cutting function. Laser machine
"CAPRIS 60-200" is used for production of RRJ-95 aircrafts.
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Marking can be made on the sleeves TMS, HT-SCE, RNF-3000, RW-175, OTK and
installed in places of wire joints at distance 75-1155 mm from beginning (end) of the
wire (cable), then with pitch 152020 mm along the whole wire (cable) length. The
interval is measures from the end of the marking till beginning of the next marking.
Number of connector contact, e.g. 274S 161-A(1), can be applied on the
identification sleeves.
Wires up to 151.0 mm long and jumpers between terminals of connectors are not
subject to marking.
The identification sleeves are arranged in the places of wires connection to electrical
connectors (Fig.5):
Fig. 5 Identification sleeves (are located at distance 50-1155 mm from the rubber seal or from the
end face of connector contact)
Marking information is applied on the identification sleeves by means of 208 thermal
transfer printer for limited production, by means of 312 printer for series production in
accordance with attached instructions (Fig.6). Software TMC-WINTOTAL-SWARE is
required for marking information printing on 312 printer.
Fig. 6 Thermal transfer printer 208
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TABLE 1
MARKING MATERIALS
Material grade
Printer ribbon (cartridge)
Printer
TMS-SCE
TMS-RJS-RIBBON-4RPSCE
HT-SCE
TMS-RJS-RIBBON-4HT
CM-SCE
TMS-RJS-RIBBON-4HT 1966- RIBBON
HTCM-SCE
TMS-RJS-RIBBON-4HT
347, , PVF
1330-3300-10
TMS-SCE
TMS-101-RIBBON-4RPSCE
T312M
T208M
Font types used for application of the marking information, which are implemented in the
software TOTAL (TMS System SIX), are selected in relation to width of the identification tag,
quantity of characters and lines.
Sharpness of marking on the identification tags is checked visually (Fig.7):
Fig. 7 EXAMPLES of clear and unclear marking on the identification tags
Marking can be applied on the identification sleeves, THT tapes, PVF, TTP labels on the
portable thermal transfer printer TLS 2200 produced by "BRADY" or T208M.
Quality of marking is checked on the samples prior to heat shrinkage - the samples are wiped
by dry lint-free cloth twenty times but not earlier than after 24 hours. Information rub-off is not
permitted (Fig.8):
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Fig. 8 Example of information rub-off on the identification sleeve

After installation on the wire the surface of the identification sleeve must be even,
without cracks, burnt spots, swelling, dents, foreign inclusions visible to unaided eye
and must have homogeneous colour. Edges of the identification sleeve must be even
(Fig.9):
Fig. 9 Correct marking
FIG. 10 Incorrect (deformed) marking
Fig. 11 Irregular edges of the identification sleeve
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Length of the identification sleeve depends on the quantity of characters and on the
font height, minimum length is 182 mm, maximum - 4010 mm plus not less than 2
mm from each side of applied information.
Tags for marking of the wires and harnesses are selected according to Table 2:
TABLE 2
SELECTION OF THE TAGS FOR MARKING OF WIRES AND HARNESSES

Inner diameter of
the tag before
shrinkage (mm)
Inner diameter of the

tag after shrinkage
Operating
temperature
(mm)
()
TMS-SCE-3/32-2.0-9
2.36
0.79
0.81
1.90
1.50
TMS-SCE-1/8-2.0-4
3.18
1.07
1.11
2.66
2.03
TMS-SCE-3/16-2.0-9
4.75
1.57
1.75
4.06
2.68
TMS-SCE-1/4-2.0-4
6.35
2.11
2.31
5.46
3.51
TMS-SCE-3/8-2.0-9
9.53
3.18
3.47
8.12
5.04
TMS-SCE-1/2-2.04(6,2)
12.70
4.22
4.64
10.79
6.81
TMS-SCE-3/4-2.0-9
19.05
6.35
7.0
16.3
12.0
TMS-SCE-1-2.0-4
38.10
19.05
21.0
33.0
27.5
TMS-SCE-1-2.0-4
25.40
8.46
9.3
21.6
15.4
TMS-SCE-2-2.0-4
57.15
19.05
22.0
51.0
42.0
HT-SCE-3/32-2.0-9
2.36
0.79
0.81
1.90
1.50
HT-SCE-1/8-2.0-4
3.18
1.58
1.75
2.66
2.03
HT-SCE-3/16-2.0-9
4.75
2.36
2.54
4.06
2.68
HT-SCE-1/4-2.0-4
6.35
3.18
3.40
6.00
3.51
HT-SCE-3/8-2.0-9
9.53
4.75
5.30
8.10
5.04
HT-SCE-1/2-2.04(6,2)
12.70
6.35
6.60
11.40
6.81
HT-SCE-3/4-2.0-9
18.00
9.00
9.90
15.30
12.0
HT -SCE-1-2.0-4
25.40
12.70
13.30
23.00
15.35
HT-SCE-1-2.0-4
38.10
19.05
21.0
34.0
27.5
Designation
Wire (harness)
component diameter
(mm)
Weight of
10 pcs.
(g)
-55 +135
-55 +225
Colour code: 2 red, 2L pink, 4 yellow, 6 blue, 9 white.
EFFECTIVITY:
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3.
Fitting of identification tags

.
Fitting of identification tags on the wires

(1) Remove the tape with printed tags from the printer (Fig.12):
Fig. 12 Marking tape

(2) Remove the tags from the backing strip. For that take the edges of the adhesive
strips, remove them and release the tags (Fig.13):
Fig. 13 Removal of the identification sleeve

(3) When necessary, the perforated tags are separated by the scissors. The cut
must be even, at right angle to the tag axis and have no burrs.
(4) The identification tags are fitted on the wire or cable in places of their joint at
distance 25-755 mm from the edge of finished product (terminals, lugs etc.)
contact. As for non-insulated lugs to be crimped or soldered, the tags can be
fitted for insulation of this unmarked segment.
(5) Shrinkage of the identification tags and heat-shrinking tubes is performed by the
heat gun HG2310LCD with reflectors P/N 073015, 070519, 074616, 075811; HL
2010E with reflectors P/N 70519, 70618, 74616; CV-1981-MK2 P/N 813914-000
with reflectors R12 P/N 991973-000; PR-13C P/N 991974-000; PR-24A P/N
991989-000; PR-25D P/N 989523-000; PR-26 P/N 991967-000.
(6) The released tags are fitted on the wires. For that the tag is taken by one hand
by the faces, is slightly pressed and fitted on the wire.
EFFECTIVITY:
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Fig. 14 Fitting of the identification sleeve on the wire

(7) The sleeves are uniformly shrunk by means of the heat gun with corresponding
adapters (Fig.15). Recommended shrinkage temperature is +30030C. Shrinkage
period is 8-12 sec.
Fig. 15 Shrinkage of the identification sleeve by means of the heat gun

(8) Quality of printing and correctness of applied information are visually checked.
B.
Fitting of the cable and harness identification tags:

(1) Remove the tape with printed tags from the printer.
(2) Remove and cut the tags from the tape.
(3) Check quality of printing and correctness of the applied marking.
(4) The cables and harness identification tags are fitted at distance 15050 mm from the
end of the branch with indication of wire designation and branch position.
(5) The cable tags are selected according to Table 3.
TABLE 3
SELECTION OF CABLE TAGS
EFFECTIVITY:
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Size
Designation
(h for printing)
Length for printing

(mm)
(mm)
CM-SCE-1/4-4H-9
Operating
temperature
Application
scope
()
6.40
50.80
12.70
50.80
CM-SCE-TR-1/4-H-4
6.40
50.80
5.08-12.50
HTCM-SCE-1/4-4H-9
6.40
50.80
5.08-12.50
HTCM-SCE-TR-1/4-4H-4
6.40
50.80
12.70
50.80
CM-SCE-1/2-4H-4
HTCM-SCE-1/2-4H-4
5.08-12.50
-55 +225
12.50 and
more
12.2
25.4
57.2
19.1
66.7
PVF100743WE1
35.6
25.4
38.1
27.9
87.3
PVF200743WE1
48.3
50.8
38.1
27.9
87.3
EFFECTIVITY:
Manufacturer
Electronic
Tyco
Operating temperature ()
-55 +135
(F) Grid width (mm)
() Vertical width (mm)
9.7
195.3
31.8
195.3
9.7
(D) Horizontal pitch (mm)
25.4
() Print area (mm)
11.4
188.9
5000
19.1
188.9
(V) Marker height (mm)
Max. diameter of harness (cable) (mm)
in relation of material width

3
labels
1000
PVF-318097-104(9)
PVF100225WE5
Quantity of markers
3
() Marker width (mm)
PVF-191114-154
PVF-254097-104
12.50 and
more
-55 +135
LABELS, SELF-LAMINATING MARKERS PDF FOR MARKING AND

WRAPPING AROUND THE CABLE (HARNESS)
Quantity in the pack
Article code (designation)
TABLE 4
5.08-12.50
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Manufacturer
Operating temperature ()
(F) Grid width (mm)
() Vertical width (mm)
(D) Horizontal pitch (mm)
() Print area (mm)
(V) Marker height (mm)
() Marker width (mm)

Max. diameter of harness (cable) (mm)
in relation of material width
Quantity of markers
Quantity in the pack
Article code (designation)
RRJ-95B
5.08
THT-1-437 -10
19.05
6.35
20.32
8.89
85.09
THT-2-437 -10
22.86
6.35
28.58
8.89
85.09
THT-5-437
W(YL)-10
25.40
12.7
15.24
85.09
THT-29-437YL10
31.75
9.53
12.07
69.85
Tyco
16.51
27.31
-40 +150
THT-14-437-W10
-65 +135
BRADY
74.93
7.62
50.80
(BK)-10
17.78
33.02
TTP200YW
Electronic
Self-adhesive tapes, labels for marking of finished products, units, panels, modules.
10000
(6)
Selection of cable bands for attachment of the tags on the harness is performed
according to Table 5.
EFFECTIVITY:
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(kgf)
32
45
178
50
91
(100 pcs)
100
Weight
Screw
diameter
(mm)
Minimum
breaking
load (kg)
Maximum harness
diameter (mm)
PANDUIT
Tightening
torque
()
Designation
Thickness (mm)
Length
tool
(mm)
Type of attachment
Type of
SELECTION OF CABLE BANDS
Width
TABLE 5
Tightened
TEFZEL
PLT1,M-C
702Y
GS-2B; 8.1
102.0
2.5
1.2
PLT2S-C
702Y
GS-2B;GS4H;18.1
188.0
3.6
1.3
PLT3S-C
702Y
GS-4H; 18.2
295.0
4.8
1.3
178
76
145
PLT4H-C 76
GS-4H; 22.2
371.0
4.8
1.3
222
102
181
PLT1M-C76
STS-2; 8.1
102.0
2.5
1.1
100
32
45
PLT 2S-C76
STH-2H;18.2
188.0
3.6
1.2
178
50
91
-46 +150
-46 +150
PLT 3S-C76
STH-2H;18.2
290.0
4.8
1.3
178
76
145
PLT 4S-C76
STH-2H;22.2
371.0
4.8
1.3
222
102
181
100
22
16
100
32
45
NYLON 6,6
Attachment for screw
Tightened
PLT.1M-C
GS-2B;STS-2
100.0
2.5
1.1
PLT1.5M-C
GS-2B;STS-2
142
2.5
1.1
PLT2I-C
GS-4H;STH-2
203
3.6
1.2
100
51
59
PLC1.5I- C
GS-4H;STH-2
3.4
1.2
100
32
45
PLC2S-S6-C
GS-4H;STH-2
4.8
1.2
100
47
59
PLC3S-S10C
GS-4H;STH-2
4.8
1.3
100
76
145
156
M4
201
M3
305
M5
Pressurized
area
-40 +85
Cord for banding

-52084 type V
- 52081 type II
723 Z
23 DZ
2
2
2.5-3.1
2.5-3.0
0.280.43
-55 +260
0.29
-73 +177
22.7
100
26.3
EFFECTIVITY:
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RRJ-95B
(7)
Two marking lines are applied on the field 6.450 mm on the cables having
diameter 5-12 mm by means of the tags CM-SE-1/4-4H, HTCM-SE-1/4-4H.
(8)
Cable bands or bandage cord of required size are passed in the tag holes and
turned around the harness using the tightening tool according to Table 9 (Fig.16):
Lock
PLT band or
bandage cord
Fig. 16 Tag fitting by means of PLT cable bands

NOTE: The tags can be fitted by means of bandage cord - 52084 (- 52081).
(9)
Select the applicable tool for cable bands fitting and set the required tension force
value.
(10) Place the end of the cable band in the tool bit slot.
(11) Hold the tool in front of the band head, compress the tool handle several times. The
band is tightened at that, and when the assigned force is reached, the tool cuts
excessive band automatically (Fig.17, 18, 19):
Fig. 17 Tightening and cutting of the cable bands
EFFECTIVITY:
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Fig. 18 Final tag fitting operation
Fig. 19 Harness attachment under screw

4.
Marking of connectors, terminal blocks, units and elements

All electrical wiring elements installed on the aircraft must have marking (position) that
corresponds to their designations in the Section 91 of the aircraft WDM.
The devices are marked by means of typewritten tags fitted (sticked) near device or on it in a
clearly seen place (Fig.20):
Fig. 20 Marking of connectors by means of self-adhesive tags fitted on the structure

Connectors and modules can be marked by means of typewritten identification tags or sleeves
fitted on the harness near the connector at distance not more than 150 mm (Fig.21).
EFFECTIVITY:
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Fig. 21 Marking of connectors with use of the tags fitted on the harness by means of cable bands
The lead-ins are marked by identification tags fitted on both sides of the structure. Places of tags
arrangement are specified in the wiring diagrams, Ref. Section 91 of the aircraft WDM.
Module blocks are marked by the self-adhesive identification tag fitted on the housing of the
module block or by the tag fitted near the module block.
Marking of the electrical wiring elements, electrical units etc. is provided by means of self-adhesive
tapes PVF, B437, , TTP200WE (BK), types and overall dimensions of which are specified in
the equipment and material specifications attached to the harness drawings, Ref. Section 91 of the
aircraft WDM.
After information has been applied on the tag, polymerization of the protective layer is performed
by means of TMS-PERMATIZER-220V device or standard heat gun with operating temperature
from +175 to +200 .
It is recommended to mark the units, switchboards, junction boxes, panels, connectors, terminal
blocks, finished products and components by means of laser unit of ULS type, or by means of the
similar small-size laser engraving, or using the labels 200, 437, PVF, THT-437.
EFFECTIVITY:
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1.
Specifications
The wires are bound in the harnesses by means of cords, cable bands or tapes.
Harnesses protected by heat-shrinking tubes are not subject to binding. Harnesses with common
screen can be bound by means of 3 - 4 layers of SKLF-4D tape 0.07x20 or by two layers of tape
69 with pitch 55050 mm.
The wires are bound in the harnesses in accordance with requirements specified in the present
Manual.
Types and sections of the wires in the harness must strictly comply with values given in the
specification and in the table of wires in Section 91 of WDM.
The wires and cables after cutting before laying are stored in the marked state, attached by paper
strips in the process containers (Fig.1):
Fig. 1 Wires and cables after cutting prior to laying of the harnesses
One, two or more coils of the binding tape are applied with tension in relation to the grade and
quantity of the wires, harness diameter and configuration as well as equipment operating conditions.
2.
Binding of harnesses by bandage cord

Continuous binding is used on the harnesses for internal wiring of the DB, control units, panels and
instrument boards. Double cord binding is advisable on the harnesses having diameter more than
25 mm. Both types of binding by single or double cord - can be used for binding the harnesses
having diameter less than 25 mm. Continuous binding of the harness on some segments is
permitted.
.
Single-wire continuous binding:

(1)
A group of wires or a harness is bound by a single cord as follows (Fig.2- 5).
EFFECTIVITY:
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FIG. 2 Beginning of single-cord binding

(Initial knot at a distance 455 mm from connector sheath)
Fig. 3 Intermediate knot

(2)
Half-loop binding is continued with similar interval along length of the group or harness
and in each point, where a wire or a group of wires is branched.
EFFECTIVITY:
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Fig. 4 Final loop binding
Fig. 5 End of final knot binding
(3) The cord is cut by IDEAL 45-344 tool.
EFFECTIVITY:
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B.
Double-cord binding of the group of wires(Ref. Fig.6 8)
Fig. 6 Initial knot
Fig. 7 Intermediate half-knot
EFFECTIVITY:
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Fig. 8 Final knot

C.
Binding of branches
Binding of branches must be performed in accordance with Figure 9.
The binding interval is selected in relation to harness diameter according to Table 1 (for
continuous and discontinuous binding of CDB, DB, control units, panels):
TABLE 1
SELECTION OF CORD BINDING INTERVAL

Harness diameter
Binding interval
(mm)
(mm)
Up to 10
255
From 10 to 20
405
From 20 to 30
505
More than 30
705
EFFECTIVITY:
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Fig. 9 Binding of branches
NOTE: Slack of individual wires in the harness is not permitted.
EFFECTIVITY:
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Continuous binding of harnesses
D.
Fig. 10 Continuous binding of harnesses (types 1, 2)
EFFECTIVITY:
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Fig. 11 Continuous binding of harnesses (types 3, 4, 5)
EFFECTIVITY:
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E.
Flat binding
Is used to make flat harnesses (Ref. Fig. 12):
Fig. 12 Binding of flat harness

The flat binding interval is selected according to Table 2:
TABLE 2
SELECTION OF FLAT BINDING INTERVAL

Harness width b (mm)
Harness binding interval l (mm)
Up to 30
80-100
More than 30
100120
Binding of aircraft power system harnesses is performed with interval 15050 mm.
Length of bandage is selected according to Table 3 (for types 1,2):
TABLE 3
BANDAGE LENGTH SELECTION

Harness diameter
Bandage length
(mm)
(mm)
Up to 10
82
From 10 to 20
102
From 20 to 30
122
More than 30
142
The harnesses are bound by means of the tape as per MIL-T-43435. The tape (cord) is
selected according to Table 4.
EFFECTIVITY:
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Width (mm)
Designation
Type
Size
Thickness
(mm)
min
max
min
max
()
TAPE SELECTION
Operating
temperature
TABLE 4
Minimum
breaking
force
.
harness
diameter
(kg)
(mm)
23DZ
2.5
3.0
0.29
0.46
18DZ
2.0
2.4
0.28
0.43
82DZ
1.4
1.7
0.23
0.38
11.3
- 52084 type
V
723Z
2.5
3.1
0.28
0.43
22.7
NOMEX
718Z
1.6
2.1
0.23
0.38
A-A 52081, type

II
POLIESTER
26.3
-73 +177
22.7
Up to
100
-55 +260
15.9
General requirements for binding of harnesses

Harness binding must be tight, lace that connects the knots must run straight along the
harness and not in twists and turns in order to prevent loose binding (Figures 13, 14).
The harnesses having diameter up to 20.0 mm can be bound by means of the tubes RNF,
DR25, RW175, OTK 202 mm long.
The harnesses having diameter from 20.0 mm and up to 100 mm can be bound by the tape
- 52081-2 (3, 4, 1); - 52084-2(3,1).
Fig. 13 Correctly bound harness
EFFECTIVITY:
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Fig. 14 Binding of individual bunches by Nomex cord

Monitoring of correct and impermissible binding of harnesses - according to Figures 15-30:
Fig. 15 Binding of harness body (the first and the last knots are double)
Fig.16 Initial knot
EFFECTIVITY:
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Fig.17 Intermediate knots
Fig. 18 End of binding
EFFECTIVITY:
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Fig. 19 Binding of harness by closed lock stitch
Fig. 20 Example of surgeon's knot
EFFECTIVITY:
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Fig. 21 Bound harness with branches (correct binding)

The first and the last stitch of continuous binding by builder's knot is performed by square
knot, surgeon's knot or any other approved knot.
Continuous binding is performed by the lock stitches.
A double lock knot is tied before and after each branch of 4 and more wires.
The bandage cord is cut at a distance of 101 mm from the knot. If the cord is not
impregnated, it must be cut by a hot knife to prevent its brooming out.
Continuous binding begins on the harness body.
Examples of correct and incorrect binding of harnesses:
FIG. 22 Correct binding (the binding begins and ends with a double knot)
EFFECTIVITY:
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Fig. 23 Impermissible binding of harness (loose harness and overtightened harness)

1 - the knots are not tightened during binding, the wires are loose
2 - the knots are overtightened and are impressed in the insulation
Fig. 24 Impermissible binding of branches

1 - binding of harness begins not on the harness body
2 - the bandage cord is cut too close to the knot (less than 6 mm)
3 - the bandage cord is cut too far from the knot (more than 12 mm)
EFFECTIVITY:
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Fig. 25 Correct binding of branches (binding of branches by means of bandage cord)

The branches begin right after the knot
In case of continuous binding the branches begin from the double knot.
The double knot is tied before and after the branch consisting of 4 and more wires.
Fig. 26 Incorrect binding of branches

1 - The branch is too far from the knot,
groups of three and more wires are located too close to each other
Fig. 27 -branch (correctly located initial knot of the branch)
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Fig. 28 Double -branch (correct)
Fig. 29 -branch (correct)

1 - simple builder's knot
2 - double builder's knot
Fig. 30 Incorrect -branch

1 the branch is not bound, 2 the wire is tensioned, bend radius was changed,
3 binding on the radial part, bend radius was changed,
4 beginning of the binding is not fixed and can move along the harness.
EFFECTIVITY:
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3.
Binding of harnesses by cable bands

The cable bands are selected in accordance with Table 5 of Section 20-20-30.
Interval of binding by cable bands or bandage cord for interunit wiring is specified in Table 5.
Distance from connector tail to beginning of binding by the cable bands or bandage cord is
specified in Table 6.
TABLE 5
SELECTION OF INTERVAL OF BINDING BY CABLE BANDS

Harness diameter, mm
Binding interval, mm
Up to 10
255
From 10 to 20
405
From 20 to 30
505
More than 30
705
TABLE 6
DISTANCE FROM CONNECTOR TAIL TO BEGINNING OF BINDING
Distance from connector tail to beginning of binding, mm
Up to 12.7
25.4-50.8
From 12.7 to 25.4
50.8-76.2
More than 25.4
76.2-101.6
Required value of tension force is set in relation to the size of the used plastic cable band.
For the most common bands 2.5 mm wide (MINIATURE classification) the tension force selector
must be set to position 1-3. For cable bands 3.5 mm wide (STANDARD classification) the tension
force selector must be set to position 3-5. Value of tension force of different tools can differ.
Tightening of the cable band is performed in accordance with Figures 31-34.
EFFECTIVITY:
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Fig. 31 Cable band placing around the harness to be bound (insert the band end in the head and raise
it by hand to reduce time of operation with the tool to minimum)
Fig. 32 Band tail placing in the tool grip
Fig. 33 Tail of the cable band is correctly placed in the tool grip and does not slide
EFFECTIVITY:
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Fig. 34 Tightening of the cable band by pressing on the tool lever in one or several movements
When the set tightening force is reached, the tool cuts the band tail aflush with band end.
Similar procedure is used for attachment of the cable harnesses in the plastic cable attachments
(Fig.35 and 36):
Fig. 35 Cable harness binding by plastic bands near the modules
Fig. 36 Attachment of cable harnesses by plastic bands to the cable fasteners
EFFECTIVITY:
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Projecting part must not be more than thickness of the cable band (Fig.37):
Fig. 37 Correctly cut band

The cut must be at right angle to the band axis:
Fig. 38 Correct fitting of the cable bands: the bands are uniformly fitted on the harness with interval S not
less than 100 mm
Means of reinforcement of the harness branching points by the plastic cable bands:
Fig.39 Correct -branch
EFFECTIVITY:
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The cable bands are located before, after and on each branch at a distance of 40-50 mm.
Arrangement of the cable bands provides retaining their shape and location and transfers no loads
on the branch wires.
The cable bands are located at a distance more than 2.2D of the harness or more than 40-50 mm
from the branch on the harness (Fig.40):
FIG. 40 Incorrect branching:

(the cable bands are at a distance more than three harness diameters)
-shaped binding of branches is performed according to Figures 40 - 41:
Fig. 41 -branch made by two cable bands
Fig. 42 -branch made crosswise by two cable bands
EFFECTIVITY:
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1.
Protection of the harnesses enhances their reliability, prevents ingress of dust, moisture, oil, fluid,
environmental influence and mechanical damages.
The harnesses are protected against mechanical damages in accordance with instructions of the
present Manual.
Calculation of outer diameter of the harness, cable, wires is performed as per
formula: D
1, 24
n1 d12 ni di2 , where
n quantity of wires of assigned size,

d outer diameter of the wire of assigned size.
From two to four drain holes having diameter 3 - 5 mm are cut out in the harness protective
material on the lower segment of the routed down harness.
Protective material must reach electrical element of the finished product (relay, circuit breaker etc.)
with clearance up to 255 mm.
Protective material in electrical connectors must go under the coupling nut (sheath clamps) of the
connector or must be blanked before the sheath with clearance 255 mm (Fig.31 of Section 2020-60).
The heat-shrinking tubes and protective material are joined with 25+5 mm overlapping.
Selection of the screen braiding is performed according to Table 1.
2.
Selection of materials and standard termination of the harnesses
TABLE 1
Designation
SELECTION OF SCREEN BRAIDING
Nominal inner
diameter (mm)
Braiding
length (m)
Operating
temperature ()
Harness diameter
(mm)
min
max
Weight
(g/m)
103-026-(027)-004
3.2
2.4
3.5
3.20
4.92
103-026-(027)-008
6.4
3.2
7.9
5.90
7.87
103-026-(027)-012
9.5
6.4
11.1
7.546
12.8
500
-80
+200
103-026-(027)-016
12.7
6.4
15.0
12.14
19.69
103-026-(027)-020
15.9
9.5
17.8
14.44
21.0
103-026-(027)-024
19.1
12.7
21.1
17.06
23.62
EFFECTIVITY:
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TABLE 1
Designation
SELECTION OF SCREEN BRAIDING (continued)
Nominal inner
diameter (mm)
103-026-(027)-032
25.4
103-026-(027)-040
31.8
Braiding
length (m)
500
Operating
temperature ()
-80
Harness diameter
(mm)
Weight (g/m)
min
max
19.8
27.94
26.25
36.09
23.8
33.3
32.81
49.21
+200
103-026-(027)-048
38.1
30.1
40.37
49.87
82.68
103-026-(027)-064
50.8
33.3
53.10
72.18
105.0
Polymer screen braiding, nickel plated. Amber colour.

Composite screen braiding 103-009- made of ARACON fiber, silver-coated; nickel-plated (Table
2).
Import polymer braiding 103-026-(103-009-) provides screening of the harness along its whole
length. It is permitted to use the home-produced lightweight screen braiding POMSK/POSMLK
U4833-001-14621444-2005, PSKO/PSKS U 16K.168-004-2007.
A heat-shrinking tube RNF 3000 455 mm long is fitted on the harness end for screen braiding
installation on the harness (cable). It is also permitted to use the tubes OTK, RADPLAST 2.
A braided grip is put onto the cable (harness) with compression of local segments in order to
increase the diameter and is pulled on the cable. Braiding is pulled on one end of the cable and is
fixed on it, a heat-shrinking tube 355 mm long is fitted and heat-shrunk. RNF tube is removed from
the harness end.
A braided grip is tightly pulled on the cable along its length with use of fabric gloves and is fixed on
the end of the heat-shrinking tube of corresponding diameter.
The braiding is visually checked for uniform covering and absence of damages.
Termination of the common screens of the branched harnesses is provided by 68N tape wound with
50% overlapping on the segment 45-50 mm in the area of harness branching (Fig.1). It is permitted
to use the tape SKLF-4D-0.0720; 69 with indication in Section 91 of WDM.
68N, 69 tape
Fig. 1 Harness termination in the branching area
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Harness diameter
(mm)
Weight (g/m)
Lightweight
screen braiding
CHARACTERISTICS OF SCREEN BRAIDINGS

Harness nominal size
(mm)
Designation U 4833001-14621444-2005
TABLE 2
Designation
24
1.4
103-009004N/008N
3.2; 6.4
3.28; 5.91
2.3; 3.2
6.0; 10.0
36
2.1
103-009-012N
9.5
7.546
4.8
14.3
610
4.4
103-009-016N
12.7
12.74
6.4
19.1
1016
8.2
103-009-020N
15.9
14.44
11,0
22.2
1624
9.6
103-009-024N
19.1
17.06
12.7
25.4
2432
12.4
103-009-032N
25.4
26.25
22.0
32.0
3240
15.6
103-009-040N
31.8
32.81
25.4
38.0
4055
21.4
103-009-048N
38.1
49.87
35.0
48.0
Harness
nominal size
(mm)
Weight
(g/m)
min
max
POMSK/
POSMLK
To install the screen braiding, a heat-shrinking tube RNF-3000 455 mm long is fitted on the ends
of the branches to provide smooth overlapping.
The screen braiding is pulled on the cable branch by compression of local segments in order to
increase the diameter and by braided grip pulling along the cable till the end on the branching
area. RNF tube is removed.
The screen braidings are attached in the branching area by the double, triple and quadruple
twisted wire with diameter 0.26 mm (the wire can be the core of any silvered wire, e.g. 26-132
0.35 mm or similar) and are tightened. To prevent brooming out of the screen braiding use the
tape 68N, 69.
Operations described in the three previous items are repeated during installation of the screen
braiding on the second branch.
For screen braiding installation on the main harness body, a heat-shrinking tube RNF-3000 455
mm long is fitted on the harness end to provide smooth overlapping.
The screen braiding is pulled on the harness branch by compression of local segments in order to
increase the diameter and by screen braiding pulling along the harness till the end on the
branching area. RNF tube is removed. The main braiding is attached by triple wire having
2
diameter of 0.26 mm (the wire can be the core of any silvered wire, e.g. 26-13-0.35 mm or
similar) at a distance 10 2 mm (Fig.3).
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Fig. 2 Screen braiding attachment in the branching area

Bring out the wire through the outer screen
1-2
DR25. K tube L=355
8+1
8+1
1-2
Braiding 103-026, 103-009
205
Solder
Type 1 termination
5+1
102
Braiding 59569
Type 2 bandage
205
Type 2 termination
Fig. 3 Termination of screened harness before fitting of solder sleeve

A small quantity of flux HF-532, IF2008, IF14 is added above the screen braiding overlapping
area.
A solder sleeve is fitted, Ref. Fig. 4:
Fig. 4 Fitting of solder sleeve

The solder sleeve is heated by the heat gun HG2310LCD with reflector P/N073015 or by device
IR550, IR1759-MK4, till the solder ring is completely melted and flows on the screen braiding.
Recommended shrinkage temperature is 36030.
The solder sleeves are selected according to Table 3.
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TABLE 3
Designation
SELECTION OF SOLDER SLEEVES
Inner diameter of
thermoplastic,
min
Inner
diameter of
case, min
Case
length,
max
Cable
diameter,
max
(mm)
(mm)
(mm)
(mm)
Diameter
of
screened
cables,
min
(mm)
Screen
segment
stripping
length, min
(mm)
-053-70
13.3
13.8
29.7
13.3
8.9
29.7
-053-70-01
10.0
11.6
31.2
10.0
4.4
8.0
-053-70-02
6.9
7.4
23.8
6.9
3.6
23.5
-053-70-03
5.8
6.6
25.3
5.8
3.2
25.3
-053-70-04
4.4
4.9
19.5
4.4
2.4
95
-053-70-05
8.6
9.7
26.2
8.6
4.5
26.2
-051-00-01
17.0
19.0
27.0
17.0
10.0
27.0
-051-01-01
23.0
25.0
27.5
23.0
12.7
27.5
-051-02-01
33.0
34.0
33.2
33.0
19.1
33.2
Area of termination must not be subjected to any impact till it becomes cooled, when the soldering
alloy can harden.
Instead of using a solder sleeve, this area can be wrapped by 5-6 coils of soldering alloy
Sn96/Ag3(4); VPr9 having diameter 0.7-1.2 mm prefitted flux IF14 (HF-532, IF2008). A heatshrinking tube RW 175, DR 25, 305 mm long is fitted above after soldering and is shrunk. It is
permitted to solder the screen braidings by -610 soldering iron or a similar one. Termination of
the solder sleeves is performed using IR device IR-550 MARK II.
A visual check is performed using the test photos, in order to make sure that the solder ring is fully
spread and formed a reliable soldered joint along the whole surface.
The following is checked: absence of the screen deformation under the case, absence of
damages and burns on the case, pressure-tight joint of the case ends and lower layer insulation.
It is recommended to perform braiding of the harnesses, both straight and branched, by means of
24- or 48- spindle braiding machine TVH24MRIRU3.7.
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Fig. 5 Braiding machine

During braiding of harness segment the end of the screen braiding is tucked inside in order to
prevent brooming out of the screen and a bandage made of "Nomex" tape is provided.
25+5 mm
Fig. 6 Screen braiding end tucking

At first the branches of the harness are braided one after another, then the main harness body is
braided.
25 mm
minimum
Fig. 7 Braiding procedure

This machine provides the possibility of braiding the harnesses by different fibers (Poliester,
Nomex, RACON XN0400E-018) to provide screening of the harness mechanical protection.
In order to protect the harnesses against flame, high temperature and mechanical friction, a
flexible expandable sleeve HTNS L/HO is used (Ref. Table 4):
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TABLE 4
CHARACTERISTICS OF HTNS L/HO TYPE SLEEVES

Inner diameter
(mm)
Designation
Standard pack
Weight
()
(m)
(g/m)
min
max
HTNS-L/HO 6-5
4.0
8.0
100
8.0
HTNS-L/HO 8-5
6.0
12.0
50
12.0
HTNS-L/HO 10-5
8.0
16.0
50
14.0
HTNS-L/HO 15-5
10.0
20.0
50
17.0
HTNS-L/HO 20-5
12.0
24.0
50
22.0
HTNS-L/HO 25-5
15.0
30.0
50
32.5
HTNS-L/HO 30-5
20.0
40.0
50
4.0
HTNS-L/HO 4-5
2.0
4.0
100
4.0
-60 +240
RNF-3000 tube 455 mm long is fitted on the branch harness end to provide a smooth overlapping
during protective braiding fitting along the whole harness length and in the branch joint area.
The protective braiding is fitted on the harness by compression at local segments in order to
increase the diameter and is pulled on the harness in such a way, so that the branch area is
overlapped by 455 mm. RNF tube is removed.
The braiding is attached in the branch area by the bandage cord - 52084 type 723Z (bandage
type 2, Ref. Fig.10 of Section 20-20-40).
Operations described in the three previous items are repeated during installation of the screen
braiding on the second branch. Procedure of the screen braiding fitting on the main body is
performed similarly. In order to prevent brooming out of the screen braiding, it is recommended to
perform cutting by HSG-0 heat cutter, blade type R.
The outer braiding is tucked inside by 305 mm. The branching point must coincide with the
bandage cord that attaches the braiding (Fig.8).
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Fig. 8 Procedure of attachment by the bandage cord

A wrap-around sleeve Roundit 2000 NX is used to protect the harnesses against mechanical
impact. The sleeves are selected according to Table 5:
TABLE 5
CHARACTERISTICS OF SLEEVES
Nominal dimension
Standard length
Weight
(mm)
(mm)
()
(g/m)
Roundit2000NX5-5
150
13
Roundit2000NX8-5
100
18
Roundit2000NX13-5
13
50
Designation
26
-60 +200
Roundit2000NX19-5
19
25
38
Roundit2000NX25-5
25
25
47
Roundit2000NX32-5
32
25
65
A special tool Roundit Toold 5 -19 is used to install this wrap-around sleeve. One side of the tool is
intended for sleeves of the sizes 5 and 8, another side - for sleeves of the sizes 13 and 19.
Fig. 9 Roundit Toold 5 -19
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The cable is placed in the slot of the tool:
Fig. 10 Slot of the tool is parallel to the cable axis in the beginning of the tool setting
Fig. 11 Handle of the tool is at right angle to the cable axis the tool is ready for sleeve fitting
Fig. 12 Sleeve fitting on the tool
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Hold the sleeve on its place and move the tool along the cable
Fig. 13 Fitting of wires in the sleeve by means of the tool

The branching places and the sleeve are attached by bandage cord with interval 25050 mm.
Selection of the bandage cord type depends on the harness operating temperature according to
Table 12, Section 20-20-40.
Fig. 14 Attachment of the branching area and of the sleeve (to prevent its turning)
The harnesses are protected against ingress of the oils, fuels, hydraulic fuels by means of heatshrinking tubes specified in the Tables 6 9.
EFFECTIVITY:
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TABLE 6
Designation
HEAT-SHRINKING TUBE DR25

Tube inner
diameter
before
shrinkage
(mm)
Tube inner
diameter after
shrinkage
(mm)
Operating
temperature
Wire (harness)
element diameter
(mm)
()
min
max
Weight
(g/m)
DR25-1/8''-0
3.20
1.60
1.76
2.72
7.00
DR25-3/16''-0
4.80
2.40
2.64
4.08
12.00
DR25-1/4''-0
6.40
3.20
3.52
5.44
15.00
DR25-3/8''-0
9.50
4.80
5.28
8.10
25.00
DR25-1/2''-0
12.70
6.40
7.04
10.80
39.00
DR25-3/4''-0
19.00
9.50
8.10
16.15
68.00
DR25-1''-0
25.40
12.70
10.80
24.60
111.00
DR25-1-1/2''-0
38.00
19.00
16.50
32.30
233.00
-75 +150
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TABLE 7
OTK-FLUOROPOLYMER FLEXIBLE HEAT-SHRINKING TUBE U2247-56400203521-01, PREMIUM GRADE

Tube inner
diameter before
shrinkage
Tube inner
diameter after
shrinkage
(mm)
(mm)
OTK-2,0/1,0
2.00
OTK-2,7/1,35
Designation
Operating
temperature ()
Wire (harness)
element diameter
Weight
(mm)
(g/m)
min
max
1.00
1.10
1.70
2.4
2.70
1.35
1.48
2.30
3.2
OTK-4,5/2,25
4.50
2.25
2.47
3.83
4.0
OTK- 6,0/3,0
6.00
3.00
3.30
5.10
6.5
OTK-8,1/4,05
8.10
4.05
4.45
6.90
8.5
OTK-8,8/4,4
8.80
4.40
4.84
7.48
8.8
OTK-10,2/5,0
10.00
5.00
5.50
8.50
10.5
OTK-11,4/5,7
11.40
5.70
6.27
9.70
11.5
OTK-12,0/6,0
12.00
6.00
6.60
10.20
12.4
OTK-13,8/6,9
13.80
6.90
7.60
11.73
14.0
OTK-15,0/7,5
15.00
7.50
8.25
12.80
16.0
OTK-19,0/9,5
19.00
9.50
10.50
16.20
32.0
OTK-24,0/12,0
24.00
12.00
13.20
20.40
43.0
OTK-30/15,0
30.00
15.00
16.50
25.50
51.6
OTK-38,0/19,0
38.00
19.00
21.00
32.30
61.3
-50+200
The tubes RNF-100 are used to protect the harnesses (cables) against impact of mold fungi,
hydraulic fluids, aviation gasoline and fuel.
EFFECTIVITY:
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RNF-3000 HEAT-SHRINKING TUBE WITH SHRINKAGE FACTOR 3:1 FOR PROTECTION

OF THE HARNESSES, FINISHED PRODUCTS AND RADIO COMPONENTS
TABLE 8
Tube
diameter
before
shrinkage
(mm)
Tube diameter
after
shrinkage
(mm)
RNF100-1/8-0
3.2
RNF-1003/16-0
4.8
Designation
Operating
temperature
()
Wire (harness) component

diameter (mm)
Weight (g/m)
min
max
1.6
1.75
2.7
3.81
2.4
2.6
4.0
5.15
RNF100-1/40
RNF30001,5/0,59
6.4
1.50
3.2
0.50
3.5
0.55
5.4
1.35
9.36
2.0
RNF100-3/80
RNF30003/1-2
9.5
3.00
4.8
1.00
5.24
1.10
8.1
2.70
13.24
3.2
RNF100-1/20
RNF30006/2-4
12.7
6.00
6.4
2.00
7.0
2.20
11.0
5.40
17.0
6.5
RNF100-3/40
RNF30009/3-6
19.0
9.00
9.5
3.00
10.5
3.30
16.2
8.10
29.2
9.0
RNF100-1-0
RNF300012/4-9
25.4
12.00
12.7
4.00
14.0
4.40
21.6
10.80
45.93
12.5
RNF100-10
RNF300018/62(4,6)
38.0
18.00
19.0
6.00
21.0
6.60
32.3
16.20
74.5
32.0
RNF100-2-0
RNF300024/8-6
51.0
24.00
25.4
8.00
28.0
8.80
43.2
21.60
109.12
50.0
RNF100-3-0
RNF300039/13-9
76.0
39.00
38.0
13.00
42.0
14.30
64.6
35.10
173.86
60.0
RNF100-4-0
-55
+135
102.
51.0
56.0
86.7
EFFECTIVITY:
267.55
Page 13
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Fig. 15 Tube shrinkage procedure

The heat-shrinking tube is cut by the Electrician's scissors 35-088 of required length, then the tube
is fitted on the harness or on the branching area.
As for the branched harnesses, shrinkage of the heat-shrinking tube is started in the branching
places.
The shrinkage begins from the beginning (end) or from the middle of the tube with slow movement
to the right or to the left till complete shrinkage on the harness (Fig.15).
The heat-shrinking tubes are shrunk by the heat gun G2310LCD or HL2010 using adapters
(reflectors).
Then a visual check is performed for absence of air bubbles, breakages, folds (ruffles), burns and
nonuniform shrinkage.
Heat-shrinking tube
min 75 mm
Apply S-1125 glue on the

moulded branching area after
installation on the harness
10-15
Harness
Fig. 16 Heat-shrinking moulded branch
The heat-shrinking moulded branches, tubes and formed parts are selected in relation to
operating temperature, diameter, quantity of branches in the harness according to Tables 9-13.
Inner surfaces of the heat-shrinking moulded branch and harness (cable) insulation are degreased
by a wiry brush wetted in ethyl alcohol GOST 18300-87.
The heat-shrinking branch is fitted on the harness. Glue S-1125 is applied on the segment 10-15
mm of the moulded branch or tape S-1048-TAPE-30 is wound with 50% overlapping of the
harness under the moulded branch on the segment 51 mm and is heat-shrunk by means of the
heat gun HG2310LCD and adapters. Recommended shrinkage temperature is 30030.
Excessive glue is removed by a cloth napkin. After that uniformity of complete shrinkage as well
as absence of burns are checked.
EFFECTIVITY:
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TABLE 9
ATUM HEAT-SHRINKING TUBE WITH SHRINKAGE FACTOR 4:1 WITH

INNER GLUE LAYER FOR SEALING AND PROTECTION OF HARNESSES
(CABLES) AS WELL AS FOR INSTALLATION ON THE CABLE CLAMPS
Tube inner
diameter before
shrinkage
Tube inner
diameter after
shrinkage
(mm)
(mm)
ATUM-4/1-0
4.0
ATUM-8/2-0
Designation
Operating
temperature
Wire (harness)
component
diameter (mm)
()
Weight
(g/m)
Min
Max
1.0
1.1
3.6
7.0
8.0
2.0
2.2
7.2
15.0
ATUM-12/3-0
12.0
3.0
3.3
10.8
39.0
ATUM-16/4-0
16.0
4.0
4.4
14.6
60.0
ATUM-24/6-0
24.0
6.0
6.5
22.0
110.0
ATUM-32/8-0
32.0
8.0
8.6
29.0
165.0
ATUM-52/13-0
52.0
13.0
14.0
48.0
233.0
-55 +110
Fig. 17 Branch type 301022

TABLE 10
HEAT-SHRINKING TUBE, TYPE 3010

H,J & K
Designation
Weight
min
max
10%
10%
10%
10%
30%
10
301A034-25
26.9
13.5
120.1
60.0
60.2
2.3
30
90
31.3
301A022-25
13.2
6.9
58.7
29.5
29.5
1.5
30
90
4.1
NOTE: The dimensions in the table are given: () at delivery in mm, (b) after shrinkage in
mm, weight - in grams.
EFFECTIVITY:
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TABLE 11
Designation
Weight
min
max
min
max
min
max
10%
10%
10%
10%
5%
Norm.
382012-25
13.2
6.1
6.6
3.3
6.6
3.3
22.4
19.3
23.9
15.5
22.5
1.81
382023-25
26.9
12.4
13.2
6.1
13.2
6.1
38.1
43.2
53.3
33.0
22.5
11.79
382034-25
38.6
18.0
26.9
12.4
26.9
12.4
65.5
78.7
78.7
55.9
22.5
63.96
382046-25
55.6
25.9
26.9
12.7
26.9
12.7
85.1
94.0
111.8
71.1
22.5
112.95
381301-50
19.8
6.6
13.2
6.6
13.2
6.6
40.6
40.6
40.6
Fig. 19 Branch type 462011 up to 060
EFFECTIVITY:
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TABLE 12

H
Designation
J,K & L
Max 10%
10%
10%
10%
10% 5
Weight
Min
Max
Min
Nom
462A011-25
13.2
6.6
6.6
3.6
46.2
25.4
20.8
30.5
15.7
30
2.27
462A023-25
26.9
13.2 13.2
6.9
93.2
50.3
42.9
57.2
33.0
30
16.33
462A034-25
38.6
18.8 19.3
9.7
135.1
73.7
61.5
88.9
45.7
30
44.91
462A048-25
55.6
25.4 26.9 12.4 192.0
103.1
88.9
121.9
71.1
30
142.88
462A060-25
91.4
54.6 45.7 27.4 390.4
211.1
179.3
254.0
127.0 30
861.83
462A060-25
91.4
54.6 45.7 27.4 390.4
211.1
179.3
254.0
127.0 30
861.83

TABLE 13
BRANCH TYPE 5620

H
Part No
J, K, L & N
HW
Min
Max
Min
Max
10%
10%
10%
20%
20%
562A011-25
13.2
6.9
6.6
3.4
24.1
43.9
18.0
1.52
1.02
562A022-25
19.3
9.7
9.4
5.3
35.6
43.2
23.1
1.78
1.02
562A032-25
19.3
9.7
13.2
6.9
49.3
50.5
25.4
1.78
1.52
562A043-25
26.9
13.0
13.2
6.9
49.3
65.8
33.5
2.54
1.52
562A054-25
38.6
18.5
19.3
9.7
71.9
95.3
46.5
3.05
1.78
562A067-25
55.6
26.7
26.9
13.0
101.6
135.1
65.5
4.57
2.54
EFFECTIVITY:
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Angle and straight moulded heat-shrinking cable clamps for connectors are given in the Table 14:
TABLE 14
ANGLE AND STRAIGHT MOULDED HEAT-SHRINKING CABLE

CLAMPS
Diameter for
connector
Diameter J for
cable
(mm)
(mm)
Designation
Type of glue, tape for

harness sealing
Weight
(g)
min
max
min
max
222K121-25
24.0
10.4
24.0
5.6
222K132-25
30.0
14.2
30.0
6.0
222K142-25
31.0
18.0
31.0
7.1
222K152-25
36.0
22.4
36.0
8.4
10
222K163-25
43.0
28.2
43.0
9.9
10
222K174-25
60.0
35.1
60.0
15.7
202K153-25-01
36.0
22.4
36.0
8.4
Glue S-1125 or tape S1048-TAPE-1x100FT-CS8731
222D211-25
22.4
11.4
22.4
6.4
(-8469,-8431,-7238);
222D221-25
25.7
15.0
25.7
7.4
S-1048-TAPE-30M;
222D232-25
29.5
18.8
29.5
8.4
222D242-25
34.0
22.9
34.0
9.7
222D253-25
37.3
29.5
37.3
10.4
222D263-25
43.7
34.0
43.7
12.2
222D274-25
50.0
41.1
50.0
14.2
20
202D232-25
29.5
18.8
29.5
8.4
10
Tape S-1081
20
10
10
10
17
EFFECTIVITY:
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TERMINATION OF SCREENED WIRES AND CABLES IN SOLDER SLEEVES

1.
General
Termination of grounding wires to the cable screen braiding is performed by means of solders
sleeves S200-, SO-63, SO-96, B-023 (Fig.1):
Fig. 1 Solder sleeve SOLDER SLEEVE

Interpretation of designations of the solder sleeves, series SO-63, SO-96, B-023, S200is performed according to Table 1:
TABLE 1
INTERPRETATION OF SOLDER SLEEVES, SERIES SO-63, SO-96,

023, S200-
SO-63 (SO-96, B-023, S200-)
-1,2,3,4,5
-(00)
-55
B-
-24,22,20
-90
Color - black and white
stripes
Wire gauge (section)
Specification number
Delivery without grounding wire
01-delivery with grounding braid
Standard size
Series
NOTE: SO-96 and S200 are intended for wires with nickel-plated current-carrying cores.
Operating temperature is up to +200. It is permitted to use wires with tin- or silverplated current-carrying cores;
SO-63, S200 are intended for wires with tin- or silver-plated current-carrying cores.
Operating temperature is up to +150.
-023 is intended for high-temperature wires. Operating temperature is up to +260.
It is permitted to use SO-63 for soldering of screen braiding with nickel-plated cores with
application of flux IF 2008, IF2010F.
Screens of the wires (cables) are screened to each other by means of non-screened wire or
preset wire AWG2422 (50-11010 mm long) in relation to fitting of the soldering sleeves with
offset, in one line or in criss-cross manner. Grounding of the screen braiding of the wires (cables)
to the frame is provided by AWG2220 wire min 150 mm long, max 190+10 long.
EFFECTIVITY:
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Termination of the grounding wires to the screen braiding is performed on the harness (cables)
ends, if it is not otherwise stated in the harness drawings and relating specifications. As for cables
up to 500 mm long, the grounding wire is installed on them on one side only.
Terminals M7928/4- are used to connect the grounding wires to the frame or under the screws of
electrical connector shank. It is permitted to crimp and solder up to two - three wires in the
terminals.
When two wires are connected to the screen braiding, the wires must be diametrically placed.
Insulation is removed from the grounding wires by means of the tool, Ref. Section 20-20-20.
Fig. 1 Insulation removal from the grounding wire

Make sure that cores of the grounding wire are not broomed out and stick out in different
directions. To prevent this, perform partial removal of the insulation with further manual pulling-off
of the removed insulation with slight turning in the core twist direction.
Fig. 2 Partial removal of the insulation with further pulling-off combined with turning in twist direction
2.
Splicing of screened wires and cables

To remove the insulation (sheath) from the screened cable use the tool, Ref. Section 20-20-20.
.
Splicing of the cable with sleeves fitted at a distance of 905 mm is performed as follows:
- Cut the cable insulation in circular direction by means of the tool 45-402 in required place,
distance between the cuts is 6-8 mm for the sleeves of the series SO-63, SO-96, S200. For
sleeves of the series B-023 - 6-10 mm.
Fig. 3 Cable insulation cutting
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- Make a longitudinal cut. For that use front edge of the tool 45-163-341 set to depth of
about 0.1 mm.
Fig. 4 Longitudinal cut

- Bend the cable in the cut area several times in different planes, so that the insulation
fractures along the cuts, and remove the insulation:
Fig. 5 Insulation removal

B.
Splicing of wire (cable) with spiral or flat screen braiding

Splicing of the cable with solder sleeves fitted at distance 455 mm is performed according
to below given items:
- Use the tool 45-402 to cut the cable insulation in circular direction at distance 47 and 402
mm from the cable end. Distance from the cable end to the place of cutting depends on the
type of cable termination in the connector. Bend the cable in the cut area several times in
different planes, so that the insulation fractures along the cuts. Hold the removed segment
by means of non-skidding pad 45-333 and pull off the insulation. As for out-of-round
structures and great length, the insulation is pulled off with turning in direction of the cable
components twist (Fig.6):
Fig. 6 Cable insulation removal

- Push back the screen braiding till a "skirt" 3-5 mm is formed and cut the braiding along
perimeter using IDEAL 45-344 tool. (Fig.7):
Fig. 7 Screened braiding pushing back till "skirt" formation
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The "skirt" is cut as close as to the cable insulation as possible. Use side-cutting pliers for
thin wires, such as 66046110 Stahlwille, or IDEAL 45-344 tool (Fig.8):
0.5-1.0 mm
Fig. 8 Insulation cutting after cut-off of the pulled off screen "skirt"
- Use the tool 45-402 to cut the cable insulation at distance of 6-8 mm for the sleeves of
series SO-63 and SO-96, S200-. For sleeves of series -023 at distance of 6-10 mm.
Bend the cable several times in the area of cut in different planes to make the insulation
fracture along the cuts (Fig.9):
Fig. 9 Cable cutting

- Hold the removed segment by the non-skidding pad 45-333 and pull off the insulation
along the cable axis:
Fig. 10 Insulation removal from the cable

Make sure that bare screen braiding is not broomed out and tightly adjoins the cable
insulation.
3.
Termination of the screened wires (cables)

Termination of the screened wires (cables) made of the round, flat and spiral wires is performed in
accordance with Figures 11-12.
EFFECTIVITY:
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6-8
71
455
6-8
71
382
10-12
905
Fig. 11 Termination of the wire with standard screen braiding made of round or flat wires (series 55PC,
EN, BSEO)
Fig. 12 Termination of the wire (cable) with spiral or flat screen braiding, series EN, 55PC
To prevent brooming out of the spiral or flat screen, pull off the cable sheath having size 6+1 per
3 mm to the screen end (Fig.12).
Fig. 13 Permissible termination of the screened wire (cable) by means of heat-shrinking tube
EFFECTIVITY:
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Three coils of flux VPr 9, Sn96 having diameter 0.7-1.0 mm with flux IF14 are wound on the
middle of the screen and on the wire core, RW-175 tube is fitted above and termination is
performed like in the example with solder sleeve.
Soldering can be performed by soldering iron, Ref. Section 20-30-10.
.
Termination of the grounding wires to the cable screen braiding is performed by means of
the solder sleeves according to the following procedure:
(1) Apply a coat of flux Sn96/Ag4, VPr 9 on the grounding wire core in relation to
operating temperature of the wire (cable).
(2) Do not apply flux on the wires with silver-plated cores. Tin-plating of the nickel-plated
wires is performed using flux of the grades IF-2008, IF14.
(3) Place the tin-plated core of the grounding wire to the wire (cable) screen and fit a
solder sleeve on the prepared screened wire (cable).
(4) Align the solder ring of the solder sleeve with screen of the wire (cable) in the middle
and adjust its position, if necessary (Fig.14):
6-8
905
Fig. 14 Solder sleeve fitting on the wire

(5) Place the wire with the solder sleeve in the holding fixture AD-1319 (Fig.15):
Fig. 15 Fitting of the wire with solder sleeve in the holding fixture AD-1319
(6) Shrink the solder sleeve by hot air by means of the heat gun HG 2310 LCD with
adapter 074616, HL2010E using the adapters (Fig.16). It is recommended to use the
IR heater IR1759.
EFFECTIVITY:
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Fig. 16 Heat gun for solder sleeves shrinkage
Fig. 17 Setting of temperature for solder sleeve shrinkage on the heat gun HG 2310 LCD
It is recommended to warm up the heat gun during 30 sec up to the operating temperature.
(7) Shrinkage temperature for the solder sleeves is selected according to Table 2:
TABLE 2
SELECTION OF SHRINKAGE TEMPERATURE
Solder sleeve grade
Shrinkage temperature ()
SO-63, S200
SO-96
B-023
36030
40050
45050
Series connection of the wire (cable) screen in groups (not more than ten in one line) is
performed according to Figure 18:
Fig. 18 Fitting of the solder sleeves in a line of several groups with grounding wires connected to the
screws of connector tail or to the grounding bus
EFFECTIVITY:
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Fig. 19 Fitting of the solder sleeves in the line of one group

B.
The following is performed at series connection of the screen braidings of several groups of
wires (cables) by means of solder sleeves:
(1) Fit the first solder sleeve with beforehand fitted grounding lead wire on the screen "";
(2) Connect this wire with screen "";
(3) Connect the installed grounding lead wire from the screen "" to the screen that is next
in the series. Finish the end termination in the point "" for the first group of connection
in one line;
(4) Repeat three above described items for the next groups. Connection of the screens of
the wires with fitted screen braiding by means of solder sleeves SO96-2-01 is similarly
performed.
(5) Check quality of the wire screen termination, Ref. Subject 5.
4.
Fitting of solder sleeves

Fitting of the solder sleeves on each screened wire (cable) with wires connected to the grounding
module is performed according to Figure 20:
6-8
455
Fig. 20 Fitting of solder sleeves

(1) Fitting of solder sleeve on the group of up to four screened wires with grounding wire
connected to the grounding terminal or to the grounding bus is performed according to Figure
21:
Fig. 21 Fitting of solder sleeve on the group of up to four screened wires
EFFECTIVITY:
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(2) Fitting of the solder sleeves on the wires (cables) in the groups of not more than ten wires with
grounding wire connected to the connector terminal under connector tail screws or to the
grounding bus is performed according to Figure 22:
Fig. 22 Fitting of the solder sleeves on the wires (cables) in the groups of not more than ten wires with
grounding wire connected to the grounding terminal
(3) Fitting of the solder sleeves on the groups of four screened wires with grounding wire
connected to connector tail screw or to the grounding bus is performed according to Figure
23:
Fig. 23 Fitting of the solder sleeves on the groups of four screened wires with grounding wire connected
to connector tail screw or to the grounding bus
(4) Check insulation resistance between the central wire and grounding lead wire using the
electronic megohmmeter -2002. The value of insulation resistance must be not less than
20.0 MOhm. It is permitted to use similar electronic devices with measurement accuracy error
not less than 2.5%.
(5) In case termination of the solder sleeve is impermissible (faulty) , the sleeve must be
removed. For that:
- carefully cut the end of the sleeve by a sharp blade, do not damage the insulation and wire
screen.
EFFECTIVITY:
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- heat the solder sleeve by the heat gun, till it becomes soft.
- remove the solder sleeve from the wire by means of pincers. For that pull it out by the edge
that is opposite to the cut made.
(6) Termination of the screen braiding without grounding wire connection is performed by means
of transparent heat-shrinking tube RW-175 (Fig.24) or RNF-3000, K.
Fig. 24 Correct termination of the screen braiding (the tube is completely shrunk, there are no traces of
discoloration of the tube (no burns) and wire insulation)
Fig. 25 Splicing of cable P/N 382410, P/N 422408, D100-08240 2-01 for LVDS data bus
(7) Selection of the heat-shrinking tubes RW-175 is performed according to Table 3:
TABLE 3
SELECTION OF THE HEAT-SHRINKING TUBES
Designation
Tube inner
diameter before
shrinkage
(mm)
Tube inner
diameter after
shrinkage
(mm)
RW-175-1/16-X
RW-175-3/32-X
RW-175-1/8-X
RW-175-3/16-X
RW-175-1/4-X
RW-175-3/8-X
RW-175-1/2-X
RW-175-3/4-X
RW-175-1-X
RW-175-1-1/2-X
RW-175-2-X
1.6
2.38
3.175
4.76
6.35
9.53
12.70
19.05
25.40
38.0
50.8
0.8
1.19
1.59
2.38
3.175
4.765
6.35
9.75
12.70
19.0
25.4
Operating
temperature
()
-55 +175
Wire (harness)
element diameter
(mm)
Weight
(g/m)
min
0.87
1.30
1.75
2.60
3.5
5.24
7.0
10.50
14.00
21.0
28.0
2
2.5
3.2
5.0
6.5
9.0
12.5
32.0
50.0
60.0
140.0
EFFECTIVITY:
max
1.4
2.00
2.70
4.0
5.4
8.1
11.0
16.20
21.60
32.3
43.2
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5.
Check of quality of termination of the wire (cable) braiding by the solder sleeves
(1) Make sure that the sleeve overlaps the wire insulation ends.
(2) make sure that the solder ring has completely spread and formed a reliable soldered joint
along the whole surface of the wire screen (Fig.26):
Fig. 26 Permissible termination quality

(3) Make sure that the fusible gaskets (if used) provide tight joint of the sleeve ends and wire
insulation. Insignificant extension of the sealing fusible gaskets beyond the solder sleeve is
permitted (Fig. 27).
(4) Make sure that structure of the screen is well seen under the sleeve and that the screen has
no deformations (Fig.27):
Fig. 27 Permitted termination quality

(5) Make sure that none of the wires punctured the sleeve.
(6) Presence of non-melted soldering alloys inside the sleeve due to insufficient heating is not
permitted (Fig.28):
Fig. 28 Impermissible termination quality

(7) Presence of burnt spots on the sleeve surface or its darkening due to overheating is not
permitted (Fig.29).
EFFECTIVITY:
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Fig. 29 Impermissible termination quality

(8) Termination of the solder sleeves must be performed by means of the manual IR device
IR1759-MK-3-AT3130-ED P/N 898738-000 (Fig.30):
Fig. 30 Manual IR device IR1759-MK-3-AT3130-ED P/N 898738-000

CAUTION: Shrinkage temperature and quality of the soldered joint are tested on the samples.
EFFECTIVITY:
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6.
Selection of solder sleeves for bringing out the grounding of the screened wires and cables
TABLE 4
Screened wire in common sheath
Type of wire
(cable)

Solder sleeve for connection of
screens
Solder sleeve for connection to

frame
SO63-1-55-22-90
SO96-1-55-22-90
SO96-1-01, S-200-1-00
SO63-1-55-22-90
SO96-1-55-22-90
SO96-1-01
SO63-2-55-22-90
SO96-2-55-22-90
SO96-2-01, S-200-2-01
SO63-2-55-22-90
SO96-2-55-22-90
SO96-2-01
SO63-3-55-22-90,
SO96-3-55-22-90
SO96-3-01, S-200-3-00
SO63-3-55-22-90,
SO96-3-55-22-90
SO96-3-01
SO96-1-55-22-90
SO96-1-01, S-200-1-00,
S200-2-W1-22-9
SO96-1-55-22-90
SO96-1-01
SO96-2-55-22-90
SO96-2-01, S-200-2-01, S-200-2-00
SO96-2-55-22-90
SO96-2-01
SO96-3-55-22-90, S200-4-W1-22-9,
S200-3-00
SO96-3-55-22-90
SO96-2-55-22-90
SO96-2-01,
B-023-02
SO96-2-55-22-90
SO96-2-01,
B-023-02
TMF-VRA-US1SJ20
TMF-VRA-US1SJ18
TMF-VRA-US1SJ16
SO96-3-55-22-90
SO96-3-01
B-023-03
SO96-3-55-22-90
SO96-3-01
B-023-03
55PC2124-24-9/96-9
SO96-2-55-22-90, S200-2-00
SO96-2-55-22-90,
SO96-2-01
SO96-3-55-22-90
SO96-3-01, S200-3-01
SO63-3-55-22-90
SO96-3-55-22-90
SO63-4-55-22-90, S20-4-00
SO96-4-55-22-90
SO96-2-55-22-90, S20-2-00
SO96-2-01
SO96-3-55-22-90, S200-3-01
SO96-3-01
SO96-4-55-22-90
SO96-4-01,S200-4-01
SO96-3-55-22-90
SO96-3-01
SO63-3-55-22-90
SO96-3-55-22-90
SO63-4-55-22-90
SO96-4-55-22-90
SO96-2-55-22-90
SO96-2-01
SO96-3-55-22-90
SO96-3-01
SO96-4-55-22-90
SO96-4-01
SO96-3-55-22-90
SO96-3-01,
B-023-01
SO96-3-55-22-90
SO96-3-01,
B-023-01
SO96-4-55-22-90
SO96-4-01
B-023-04, S200-3-01
SO96-4-55-22-90
SO96-4-01
B-023-04
S096-3-55-22-90,
S096-3-01
S096-4-55-22-90,
S096-4-01, S200-4-00
S096-3-55-22-90,
S096-3-01
S096-4-55-22-90,
S096-4-01
10612-24-9
10613-24-9
S096-3-55-22-90, S200-3-00
S096-3-55-22-90
P5064-24
S096-4-55-22-90, S200-4-00
S096-4-55-22-90
Grade of screened wire

55PC2114-24-9-9
55PC2111-22-9-9
55PC2111-20-9-9
55PC2111-18-9-9
55PC2111-16-9-9
55PC2111-14-9-9
55PC2111-12-9-9
55PC2111-10-9-9
EN2714-013A-002F
EN2714-013A-004F
EN2714-013A-006F
EN2714-013A-010F
EN2714-013A-012F
EN2714-013A-020F
EN2714-013A-030F
EN2714-013A-051F
TMF-VRA-US1SJ24
Twisted double screened wires in common sheath
TMF-VRA-US1SJ22
55PC2122-22-9/96-9
55PC2122-20-9/96-9
55PC2121-18-9/96-9
55PC2121-16-9/96-9
55PC2121-14-9/96-9
55PC2121-12-9/96-9
EN2714-013B -002F
EN2714-013B -004F
EN2714-013B -006F
EN274-013B-010F
EN274-013B-012F
EN274-013B-020F
TMF-VRA-US2SJ24
TMF-VRA-US2SJ22
TMF-VRA-US2SJ20
TMF-VRA-US2SJ18
TMF-VRA-US2SJ16
MBBN3320YH004
MBBN3320YH006
EFFECTIVITY:
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Type of wire
(cable)

Solder sleeve for connection of
screens
SO96-2-55-22-90, S200-2-00
SO96-3-55-22-90, S200-3-00
SO96-3-00
SO96-3-55-22-90
SO96-4-55-22-90
SO96-4-01, S200-4-01
SO96-2-55-22-90
SO96-2-01, S200-2-00
SO96-3-01
SO96-3-55-22-90
SO96-4-55-22-90
SO96-4-01, S200-4-00
SO96-5-55-22-90
SO96-5-01, S200-5-00
SO96-3-55-22-90
SO96-3-01,
B-023-01
SO96-4-55-22-90,
B-023-04
Solder sleeve for connection to

frame
SO96-2-55-22-90
SO96-3-55-22-90
SO96-3-01
SO96-3-55-22-90
SO96-3-01
SO96-4-55-22-90
SO96-4-01
SO96-2-55-22-90
SO96-2-01
SO96-3-01
SO96-3-55-22-90
SO96-4-55-22-90
SO96-4-01
SO96-5-55-22-90
SO96-5-01
SO96-3-55-22-90
SO96-3-01,
B-023-01
SO96-4-55-22-90,
B-023-04
SO96-5-55-22-90
SO96-5-01,
B-023-04
SO96-5-55-22-90
SO96-5-01,
B-023-04
SO96-3-55-22-90
SO96-3-01, S200-3-00
SO96-3-55-22-90
SO96-3-01
SO96-4-55-22-90
SO96-4-0, S200-4-00
SO96-4-55-22-90
SO96-4-01
SO96-5-55-22-90, S200-5-00
SO96-5-55-22-90,
SO96-5-01
SO63-3-55-22-90
SO63-3-55-22-90
SO96-3-55-22-90
SO96-3-01, S200-3-00
SO63-3-55-22-90
SO63-3-55-22-90
SO96-3-55-22-90
SO96-3-01
S200-4-W1-22-9, SO63-4-55-22-90
SO96-4-55-22-90
SO63-4-55-22-90
SO96-4-55-22-90
SO96-4-55-22-90
SO63-4-01, S200-4-00
SO96-4-55-22-90
SO63-4-01
SO63-5-55-22-90
SO96-5-55-22-90
SO96-5-01, S200-5-00
SO63-5-55-22-90
SO96-5-55-22-90
SO96-5-01
B-020-22-N
B-053-70
B-020-20-N
B-053-70
S200-(S063)-3(4, 5)-00
B-020-22-N
B-053-70
B-020-20-N
B-053-70
S200-(S063)-3(4, 5)-00
Grade of screened wire

55PC2134-24-9/93/96-9
55PC2134-22-9/93/96-9
55PC2134-20-9/93/96-9
Twisted triple screened wires in common sheath
55PC2134-18-9/93/96-9
55PC2134-16-9/93/96-9
EN2714-013C -002F
EN2714-013C -004F
EN2714-013C -006F
EN2714-013C -010F
EN2714-013C -012F
EN2714-013C -020F
EN2714-013C -030F
TMFVRA-US3SJ24
TMFVRA-US3SJ22
TMFVRA-US3SJ20
TMFVRA-US3SJ18
Group of four screened wires
Twisted quadruple
screened wires in common
sheath
TMFVRA-US3SJ16
EN2714-013D-002F
EN2714-013D-004F
EN2714-013D-006F
EN2714-013D-010F
EN2714-013D-012F
EN2714-013D-020F
EN2714-013D-030F
ABS1503KD24, ET2PF-870
55PC2114-24-9-9
55PC2114-22-9-9
EN2714-013A-002F
EN2714-013A-004F
55PC2111-20-9-9
55PC2111-18-9-9
55PC2111-16-9-9
EN2714-013A-006F
EN2714-013A-010F
EN2714-013A-012F
55PC2111-14-9-9
EN2714-013A-020F
RF cables
5021D1331-0
RG 142, RG225, RG 400
ASKE091SW, 5019D3311-0
5012A3311, PK50-7-22
PK50-9-45,
L2201TX
(1) Termination of the grounding wires to the screen braiding and to the central core of the RF
cable is performed by means of solder sleeves -020 according to procedure described in
Subject 3.
(2) Standard termination of the screened harness in the common braiding with screening 360 is
performed according to Figure 31.
(3) For sleeves fitting, Ref. Subject 4.
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Fig. 31 Standard termination of the screened harness in the common braiding with screening
360
(4) Standard termination of the cable in the common braiding is performed according to Figure
32:
Fig. 32 Standard termination of the cable in the common braiding

(5) Standard termination of the screened harness with screens connected to (under) the cable
clamp screw (Fig.33):
Fig. 33 Standard termination of the screened harness with screens connected to (under) the
cable clamp screw
(6) Selection of metal bands for screen braiding termination is performed according to Table 5.
EFFECTIVITY:
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Thickness
(mm)
. diameter
(mm)
Quantity in the
pack
Pack weight
(kg)
flat
flat
flat
207
362
457
3.05
3.05
6.1
0.38
0.38
0.51
23
48
64
100
100
100
0.43
0.71
1,1
(7)
Detachable
blades
Width
(mm)
31189
31089
11089
Fitting tool
Type
Length
(mm)
SELECTION OF METAL BANDS
Designation
TABLE 5
301999
46799
40199
40699
Standard termination of the screened cables for FBW system harnesses with screening 360
by means of "" sleeves is performed according to Figure 34:
Fig. 34 Standard termination of screened cables for FBW system harnesses

(8)
Designation system for "" sleeves is described in Subject Section 20-40-10.
(9)
Preparation of wires, termination in "HEX"sleeves, assembly of "HEX"clamp
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A
10.01.0
Fig. 35 Splicing of wires for "" sleeve fitting

NOTE: Size for straight housings 802 mm. For angle housings: 09 - 801.0 mm; 11(13) 90.0;
15(17) 100.0; 21 115.0; 23 1200.0; 25 125.01.0 mm
(10) When 3 - 4 screened wires are fitted in "HEX" sleeve, they are attached by 4 - 5 coils of the
2
tin-plated copper wire of the wire core, e.g. 26-13-0.35 mm (Fig.36):
L/2
L
Fig. 36 Fitting of copper wire bandage

(11) When one screened wire (single wire, one twisted pair, etc.) or two screened single wires, two
twisted pairs etc. are fitted in the "HEX" sleeve, RW-175 tube (153) mm long is fitted till the
wire screen cut (Fig.37):
RW-175
Fig. 37 RW-175 TUBE FITTING

(12) For "HEX" sleeve assembly Ref. Figure 38:
RW-175
Sleeve
SolderShield sleeve
Fig. 38 Assembly of "" SLEEVE
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(13) The assembly is placed in the holding fixture AD-1319-9. At that dimension must be observed,
Ref. Figure 39:
Shrink the sleeve at t-36030C

20-30
18.01.0
AD-1319-9 fixture
85-95
Fig. 39 Assembly fitting in AD-1319-9 FIXTURE
NOTE:
The soldering alloy must melt completely and spread along the wire screen. The
following is not permitted: screen deformation, overheat traces and mechanical
damages of the sleeves and wires.
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TERMINATION OF THE WIRES AND CABLES IN THE CRIMPING SLEEVES

1.
Crimping sleeve use procedure

The wires are joined by means of crimp bushings (splice sleeves) D-436
(Fig.1):
Fig. 1 Joining of wires by means of crimp bushings

Crimp bushing (splice sleeve) consists of the copper crimping tube and sealing sleeve with two
fusible rings (Fig.2):
SEALING SLEEVE
Fig. 2 Crimp busing and sealing sleeve

The splice sleeves are used to join the wires of grades 55PC, EN2267, EN2714, BMS13-58 with
greater gauge (section) transition to lesser one and vice versa, as well as for branching of wires.
Applicability of the splice sleeves during initial wiring is specified in Section 91 of the WDM. Use of
the splice sleeves during repair is described in Section 20-70-10.
The splice sleeves are placed at distance 300-350 mm between the harness attachment elements
in stepwise or criss-cross manner on a straight segment. Designation of sleeves 12-C275M is
applied on the CM-SCE identification sleeve, which is attached on the harness. Marking can be
applied on the identification sleeves TMS-SCE, HT-SCE, RNF-3000, K, DR25, RW-175 having
length 182 mm and installed on the sealing sleeve.
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Not more than two splice sleeves can be installed on one electrical circuit.
The wires are prepared according to Sections 20-20-10, 20-20-20.
Length of the removed insulation for joining by crimping is 7-9 mm (Fig.3):
Fig. 3 Length of removed insulation

The wires are crimped in the splice sleeves by the tool AD-1377S (M22520/37-01) together with
AD-1386 gauge.
Joining of the wires can be performed by the tool, which has a certificate, passed the checks and
approved as suitable for operation.
The crimping tools and the gauges must be subjected to regular (at least once in three months)
checks of:
- state of the working surfaces of die parts and dies (they must have no chips, cracks, burrs);
- locking device serviceability (the tool must not open at incomplete crimping);
- state of gauges (gauge dimensions).
It is recommended to perform periodic check of the crimping tool after each 5000 crimping cycles
on the current production samples in quantity not less than three samples of each section and of
wire grade, which is used for aircraft electrical wiring. The samples are subjected to tests for
particular breaking load.
Quality of termination is provided by the crimping tool, which is checked by means of AD-1386
gauge before beginning of each crimping operation (Fig.4):
Fig. 4 AD-1386 gauge

NOTE: "Go" - go gauge, "No Go" - no-go gauge.
During check of the tool end of the "GO" gauge must freely pass through the grips, when the
handles are fully pressed. The "NO GO" gauge must not pass through the grips, when the tool
handles are fully pressed. If the mentioned requirements are not met, the tool must be discarded
and sent for repair.
Before the wire is terminated in the splice sleeve, a sealing sleeve is fitted on the of the wires.
The crimp bushing is installed together with the wire in the tool slot and is crimped on each side,
clearance between the insulation end and crimp bushing must be maintained within 0.5-1.6 mm for
one and more wires (Fig.5).
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Fig. 5 Maintaining the clearance between the end of insulation and crimp bushing
Quality of wire crimping is checked by means of 4x magnifier through the check hole of the sleeve there must be no cracks, dents and damaged coating on the current-carrying cores of the wires
(Fig.6):
Fig. 6 Check of the wires crimping quality by means of magnifier

NOTE: Correct crimping: - ends of the wires core are seen in the check hole; - crimping dents
are centered and correctly formed.
After that a sealing sleeve is fitted on center of the crimp bushing and is completely shrunk at
temperature 200 - 300 by means of the heat gun, Ref. Subject 3., Subsubject Section 20-2060.
Quality of the sealing sleeve shrinkage is visually checked for spreading of the fusible O-rings
along the wire insulation from the sleeve (Fig.7):
Fig. 7 Correct shrinkage of the sealing sleeve
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The following is not permitted: presence of burnt spots on the surfaces of the sleeves or their
darkening due to overheat, mechanical damages (cracks, fractures, melted areas) on the surface
of the wire insulation.
2.
Selection of crimping sleeves

- The crimping sleeves for wires splicing and branching are selected according to Table 1:
TABLE 1
SELECTION OF CRIMPING SLEEVES
Splicing
sleeve
Quantity of wires
(input)
D-436-36
D-436-36
D-436-36
D-436-36
D-436-36
D-436-36
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-368
D-436-36
D-436-36
D-436-36
D-436-36
D-436-36
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-36
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Wire
gauge
(AWG)
24
24
24
22
22
20
20
20
20
18
18
16
16
16
16
14
12
24
24
24
22
22
22
24
24
24
22
22
22
20
20
20
20
20
20
18
18
18
18
16
16
16
16
24
Quantity of
wires
(output)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Wire gauge
(AWG)
Marking
colour
Weight
(g)
24
22
20
22
20
20
20
18
16
18
16
16
16
14
12
12
12
24
22
20
24
22
20
20
18
16
20
18
16
20
18
16
16
14
12
18
16
14
12
18
16
14
12
24
Red
Red
Red
Red
Red
Red
Blue
Blue
Blue
Blue
Blue
Blue
yellow
yellow
yellow
yellow
Yellow
Red
Red
Red
Red
Red
Red
Blue
Blue
Blue
Blue
Blue
Blue
Blue
Blue
Blue
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
Yellow
Red
0.463
0.463
0.463
0.463
0.463
0.463
0.730
0.730
0.730
0.730
0.730
0.730
1.234
1.234
1.234
1.234
1.234
0.463
0.463
0.463
0.463
0.463
0.463
0.730
0.730
0.730
0.730
0.730
0.730
0.730
0.730
0.730
1.234
1.234
1.234
1.234
1.234
1.234
1.234
1.234
1.234
1.234
1.234
0.463
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Splicing
sleeve
Quantity of wires
(input)
D-436-36
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-37
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
D-436-38
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
D-436-60
D-436-61
Wire
gauge
(AWG)
24
24
24
24
22
22
20
20
18
18
16
20
20
20
20
min 0.38
2
mm
min 0.95
2
mm
Quantity of
wires
()
2
2
2
2
2
2
2
2
2
2
2
1
2
2
2
Wire gauge
(AWG)
Marking
colour
Weight
(g)
22
24
22
20
22
20
20
18
18
16
16
14
20
18
16
Red
Blue
Blue
Blue
Blue
Blue
Blue
yellow
yellow
yellow
yellow
yellow
yellow
yellow
Yellow
0.463
0.730
0.730
0.730
0.730
0.730
0.730
1.234
1.234
1.234
1.234
1.234
1.234
1.234
1.234
AWG24 5
max 1.34 mm
Blue
2.468
AWG20 5
max 3.37 mm
Yellow
2.468
- Termination of the branched screened twisted wires in the common sheath with screen integrity
provided is performed by means of the D-436 type crimp bushing with sealing sleeve, solder
sleeves SO63-X-00 (SO96-,S-200-), braiding 103-009- and heat-shrinking tube RW175 (DR25,
RNF 300, OTK) with application of D436 sleeve designation marking (Fig.8).
- Standard termination of the twisted screened wires in the common sheath made of standard
elements is performed according to Figure 8:
7-8
42
7-8
75+
1
1
Final termination
4
12-C275M
70+1
Fig. 8 Standard termination of twisted screened wires in common sheath
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NOTE: 1 - screened cable;

2 - crimp bushing;
3 - sealing sleeve;
4 - braiding 103-026-, L=751 mm or 103-009-;
5 - solder sleeve SO63 (SO96-, S-200-);
6 - heat-shrinking tube RW175 (DR25, RT-555-3/8-2,75-260-0, RNF3000,OTK) L=70+1
mm;
D436 crimp bushings must be arranged stepwise.
- Termination of wires (cables) in the crimp bushings with sealing sleeve is performed according to
Subject 1. Branching of the wires (cables) is performed by means of crimping bushing D436 (Ref.
Table 1). Termination of braiding with cable screen is performed by means of solder sleeves SO63
(SO96), Ref. Section 20-20-60.
3.
Selection of solder sleeves

The solder sleeves SO63-X-00 (SO96-, S200-) are selected according to Table 2:
Screened wires, twisted screened double and triple wires

in common sheath
Wire (cable) type
Grade of screened wire (cable)

55PC2114-24-9-9, EN2714-013A-002F
55PC2111-22-9-9, EN2714-013A-004F
55PC2111-20-9-9, EN2714-013A-006F
55PC2111-18-9-9, EN2714-013A-010F
55PC2111-16-9-9, EN2714-013A-012F
55PC2111-14-9-9, EN2714-013A-020F
55PC2111-12-9-9, EN2714-013A-030F
55PC2111-10-9-9, EN2714-013A-051F
EN2714-013B-002F, 55PC2124-24-9/96-9
EN2714-013B-004F, 55PC2122-22-9/96-9
EN2714-013B-006F, 55PC2121-20-9/96-9
EN2714-013B-010F, 55PC2121-18-9/96-9
EN2714-013B-012F, 55PC2121-16-9/96-9
Solder sleeves
SO63-1-00
SO96-1-00
S200-2-00
SO63-2-00
SO96-2-00
EN2714-013B-020F, 55PC2121-14-9/96-9
EN2714-013B-030F, 55PC2121-12-9/96-9
EN2714-013C-002F, 55PC2134-24-9/93/96-9
EN2714-013C-004F, 55PC2133-22-9/93/96-9
EN2714-013C-006F, 55PC2133-20-9/93/96-9
EN2714-013C-010F, 55PC2133-18-9/93/96-9
EN2714-013C-012F, 55PC2133-16-9/93/96-9
EN2714-013C-020F, 55PC2133-14-9/93/96-9
EN2714-013C-030F, 55PC2133-12-9/93/96-9
S200-4-00
TABLE 2
SO63-3-00
SO96-3-00
S200-3-00
SO63-2-00
SO96-2-00
S200-4-00
SO63-3-00
SO96-3-00
SO63-4-00
SO96-4-00
SO63-2-00
SO96-2-00
S200-2-00
SO63-3-00
SO96-3-00
SO63-4-00
SO96-4-00
Standard termination of the screened wires and twisted screened wires in the common sheath
made of standard elements is performed according to Figure 9.
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7-8
30+
1
7-8
75+1 mm
12-
C2
75
70+1 mm
4
5
Final termination
6
Fig. 9 Standard termination the screened wires and twisted screened wires in the common sheath
NOTE: 1 - screened cable;
2 - crimp bushing;
3 - sealing sleeve;
4 - braiding 103-009- (103-027) L=751 mm;
5 - solder sleeve SO63 (SO96-, S200-);
6 - heat-shrinking tube RW175 (DR25, RNF 3000,OTK, RT-555-3/8-2,75-2600).
- Permissible variant of AWG 20 wire termination in the crimp bushing D436-38, Ref. Fig.5 and Fig.
10.
Fig. 10 Wire core bending

Heat-shrinking tube RW175,K, 12 1 mm long is fitted on AWG 20 wire and is shrunk. Wire
termination in the crimp bushing is performed according to Subject 1 of the present Section.
The splice sleeves are arranged in the line connectors of the group of wires or in the harness in
criss-cross manner between the attachments (Fig.11). Fitting of bandage units on the sealing
sleeves of the splice sleeves is permitted.
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Fig. 11 Arrangement of the splice sleeves on the line connectors
Fig. 12 Termination of 3 splice sleeves in stepwise manner during harness splicing

NOTE: Length of the fitted braiding for splicing is 75+1 mm, length of the heat-shrinking tube is
701 mm.
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WIRES TERMINATION IN TERMINALS
1.
General
- Termination of wires of grades 55, 82, EN2267, EN2714, BMS-13-58, 2100, ABS 0949 in
the terminals MS25036, M7928/4, 277147, MS0659 is performed by means of crimping tool
59250, 59239-4, 69120-2 or similar tool by cold crimping method.
- Quality of termination is provided by the crimping tool, which must be checked after each 5000
crimping cycles, Ref. Subject 1, Section 20-20-70.
- Insulation is removed from the wires by the tools specified in Table 2, Ref. Section 20-20-20.
- If required, ends of the stranded wire core are twisted after insulation removal in direction of
natural twisting of the conductor wires by means of pliers with polished jaws.
2.
Selection of terminals and crimping tools

- Termination of wires of the distribution boxes, units, panels can be performed by means of
insulated copper terminals as per Specification MS25036 designed for operating temperature
up to +105 or by means of insulated copper terminals as per Specification 7928/4 with
additional fitting of the tube RNF-, DR25, 182 mm long. The wires are soldered in the
terminals by means of soldering alloy 02, VPr9, Sn96/g3(4) having diameter 0.7-1.2 mm with
flux IF14 or IF2008.
- Termination of the aircraft power network light-section wires is performed by means of the
insulated copper terminals as per Specification M7928/4 designed for operating temperature
up to +150. It is permitted to use MS20659 terminals with additional fitting of the tube DR25,
RNF-, K, 182 mm long.
- Termination of the copper and aluminium nickel-plated gauges (from AWG10 and further) is
performed by means of non-insulated copper terminals as per standard MIL-T-7928,
COPALUM with additional insulation heat-shrinking tube DR25 (K, RW-175), 555 mm
long. Application of marking on the insulating tube is permitted.
- Connection of the wires to the fire warning sensors is performed by means of terminals as per
standard MIL-T-7928 P/N 321885 designed for operating temperature up to +649.
- Termination of the aluminium nickel-plated wires can be performed by means of non-insulated
copper terminals as per standard OST 1 13697-81 with soldering of additionally fitted
insulating tube DR25, 355 mm long. The wires are coated with soldering alloy 02, VPr9,
Sn96/g3(4) using IF-2008 flux by immersion in the soldering bath with digital temperature
regulator "Magistr Ts20-V". The wires are soldered in the copper terminals as per standard
OST 1 41468-91.
- Connection of the wires to the finished products with flat and cylindrical leads is performed
with use of -106 type terminals designed for operating temperature -55 +125. Crimping
of the terminals 640909 is performed by means of the hand tool 59824-1,90185-1.
- It is permitted to crimp up to three AWG24-22 wire in the terminals 7928/4-149(150), on
condition that the wire cores are twisted and that fluxing and tin-coating is performed by
immersion in the soldering bath "Magistr Ts20-V".
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- Straight terminals 7928/4-, MS20659, MS25036-XX, 277148-2277152-4 can be bend

by the angle not more than 90 on condition that the bend radius is not less than two
thicknesses of the terminal with use of mandrels. As for the lug terminals, distance from the
lug end to bending beginning is not less than one terminal diameter. It is not necessary to
remove the attachment screw, when providing bending degree of the lug terminal. Quality
control after bending: cracks and damaged coating are not permitted. Recommended variants
of the terminals bending angles are given in the Table 1.
TABLE 1
RECOMMENDED VARIANT OF TERMINAL BENDING ANGLES

Variant
CAUTION!
Terminal type
277148-
277148-
277148-
277149-
277149-
277149-
277150-
277150-
277150-
277151-
277151-
277151-
277152-
277152-
277152-
Weight
L*
L1*
S*
D*
(kg)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
0.0166
48.26
22.44
32
2.24
10
0.0194
50.8
29.46
33
2.08
11.8
,019
60.2
38.00
33
2.36
11.8
0.053
63.75
41.11
44
2.57
17.5
0.08
77.47
46.96
51
6.5
3.25
19.8
When coating of the terminal is damaged, restore the coating by immersion in the
soldering bath with soldering alloy (tin 02 or VPr9).
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MS20659-165
MS20659-105
MS20659-105
MS20659-106
MS20659-128
MS25036-111
MS25036-156
MS25036-112
MS25036-157
MS25036-113
MS25036-115
MS25036-116
MS25036-117
MS25036-118
MS25036-119
MS25036-120
MS25036-121
MS25036-122
MS25036-123
MS25036-124
MS25036-125
MS25036-126
MS25036-127
MS25036-128
MS25036-129
MS25036-130
MS25036-131
MS25036-132
MS25036-133
MS25036-134
MS25036-135
MS25036-136
MS25036-137
MS25036-138
M7928/4-144
M7928/4-145
M7928/4-146
M7928/4-147
M7928/4-148
M7928/4-102
M7928/4-149
M7928/4-103
M7928/4-150
M7928/4-153
(-108)
M7928/4-154
M7928/4-109
M7928/4-156
M7928/4-112
M7928/4-157
M7928/4-113
M7928/4-158
Operating
temperature
+649
12-10
yellow
12-10
red
blue
yellow
red
natural
blue
yellow
00
red
000
yellow
2624
red
2216
blue
1614
yellow
1210
orange
2216
2.91
2.90
2.90
0.58
3.17
2.91
2.90
2.90
3.04
3.17
5.96
5.96
5.39
6.64
7.7
7.5
7.1
7.2
8.6
8.8
8.9
17.2
18.5
17.8
19.5
19.6
19.0
28.5
27.7
29.7
35.0
34.0
36.3
36.5
0.58
0.58
0.55
0.55
0.58
0.58
0.55
0.55
0.97
8.50.5
Heavy Head
59239-4
101
47820
-
69120-2
69051
141
47821
161
69051
47822
181
69051
47823
201
69120-2
69120-2
47824
69066
and
58422-1
241
47825
251
47915
4.50.5
T-HEAD
Tool
59250
5.50.5
0.87
0.94
1.25
2.91
2.90
3.04
3.17
3.17
0.58
0.58
0.58
8.50.5
59239-4
5.50.5
46673
Number
designation for
order
Head die
3.6
4.9
4.93
4.93
9.5
3.6
4.3
4.93
6.6
8.2
4.93
6.6
8.2
6.6
4.93
6.6
8.2
9.54
6.6
8.2
9.54
6.6
9.54
12.7
6.6
9.54
12.7
6.6
9.54
12.7
8.2
9.54
12.7
9.54
2.85
3.5
4.3
4.83
2.85
3.5
4.3
4.83
6.6
4.3
(4.9)
6.6
8.2
4.3
4.83
6.6
8.2
12.7
3.6
4.3
4.83
Head
3.5
4.8
4.8
8
9.5
3.5
4.2
4.8
6.4
7.9
4.8
6.4
7.9
6.4
4.8
6.4
7.9
9.5
6.4
7.94
9.5
6.4
9.5
M 12
6.4
9.5
M 12
6.4
9.5
M 12
7.94
9.5
M 12
9.5
2.8
M3
4.2
4.8
2.8
M 3.5
4.2
4.8
6.4
4.2
(4.8)
6.4
7.94
4.2
4.8
6.4
7.94
m12
3.5
4.2
4.8
Hydraulic
crimping machine
max
Hand crimping
tool
min
Weight
(g)
Wire gauge
(AWG)
Bolt diameter
(mm)
Length of
removed
insulation (mm)
SELECTION OF TERMINALS AND CRIMPING TOOLS

Colour of terminal
marking
Designation as per
MIL-T-7928
TABLE 2
2-35476-1
33457
2-33457-2
2-33459-6
33220
320567
320568
36161
320569
320576
324043
324082
324044
324045
324046
324047
324048
324049
324050
324051
324052
324053
324054
324055
324056
324057
324058
324113
324057
324058
324083
324084
324085
324185
53401-1
53402-1
53403-1
53404-1
53405-1
53407-1
53408-1
53409-1
53410-1
53417-1
(53418-1)
53419-1
53420-1
53424-1
53425-1
53426-1
53427-1
53429-1
321889
321890
321891
NOTE: The terminals MS25036 are used only for stands and test lot of the aircrafts (for crimping of
AWG24AWG14 wires).
EFFECTIVITY:
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RRJ-95B
Number for
order
SELECTION OF THE TERMINALS AND CRIMPING TOOLS

Wire gauge
(AWG)
277147-3
Diameter of bolt for

thread
Al
Cu
10
, (6)
5/16, (8)
277148-2
Length of removed
Weight
insulation
(g)
(mm)
11.11
10.0
, (6)
277148-3
16.2
, (6)
15.0
277149-2
, (6)
19.4
277149-8
17.50
5/16, (8)
18.9
, (6)
277150-1
Head die
314979-1
69120-2
69066
68006
314979-1
69120-2
69066
68007
314979-1
69120-2
69066
68008
314979-1
69120-2
69066
68009
314979-1
69120-2
69066
68010-1
314979-1
69120-2
58422-1
68011-1
16.6
12.7
277148-7
277149-3
Crimping
tool
Head
TABLE 3
18.5
, (6)
36.0
277151-3
, (6)
277151-1
3/8. (9.52)
277151-7
5/16, (8)
53.0
277152-3
00
5/16, (8)
80.0
277152-1
00
, (6)
277152-4
00
3/8 (9.52)
277152-5
00
, (12)
277153-1
000
00
, (9.52)
25.4
103.0
314979-1
69120-2
58422-1
59877-1
55995-1
0000
000
, (9.52)
25.4
100.0
314979-1
69120-2
58422-1
314948-1
277150-3
19.10
3/8. (9.52)
34.0
53.3
25.4
53.0
81.0
25.4
81.0
78.0
NOTE: Crimping of AWG8000 wire in the terminals MS 25036 and OS1 1369 can be performed
by means of the hand crimping tool K 354 SETHR with set of dies.
TABLE 4 SELECTION OF TERMINALS AND LENGTH OF INSULATION REMOVED FROM THE WIRES
Designation as per standard
MS20659-140
324061
MS20659-141
33461
MS20659-108
31808
MS20659-129
33463
MS20659-130
321298
MS20659-109
321598
MS20659-131
33468
MS20659-110
33467
MS20659-111
31811
MS20659-132
33115
MS20659-113
320383
MS20659-147
322870
MS20659-114
321600
MS20659-119
321870
MS20659-120
321871
MS20659-136
321873
1-25-OST113697-81
2-25-OST113697-81
3-25-OST113697-81
4-25-OST113697-81
5-25-OST113697-81
6-25-OST113697-81
7-25-OST113697-81
8-25-OST113697-81
Wire gauge
(AWG)
8
6
4
2
00
6
4
2
1
0
Bolt diameter
(mm)
4.8
6.4
8
9.4
4.8
6.4
8
9.5
6.4
8
6.4
8
3/8
8
9.5
12
4.93
6.6
8.2
9.6
4.93
6.6
8.2
9.54
6.6
8.2
6.6
8.2
9.5
8.2
9.54
12.7
5.3
6.5
5.3
6.5
6.5
8.5
6.5
8.5
Length of
removed
insulation (mm)
101
141
161
181
241
181
201
211
211
EFFECTIVITY:
Weight
(g)
5.96
5.96
5.39
6.64
7.7
7.5
7.1
7.2
8.6
8.8
17.2
18.5
17.8
35.0
34.0
36.3
5.8
5.2
8.1
7.9
13.2
12.7
19.2
22.6
Page 4
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20-20-80
Sep 30/11
RRJ-95B

Wire gauge
(AWG)
Designation as per standard

9-25-OST113697-81
10-25-OST113697-81
11-25-OST113697-81
12-25-OST113697-81
13-25-OST113697-81
14-25-OST113697-81
15-25-OST113697-81
16-25-OST113697-81
17-25-OST113697-81
TABLE 5
Number for order
-106-3281
-106-3481
-106-8401 F(S)
-106-8502 F(S)
-106-7401 M(P)
-106-7502
M(P)
Bolt diameter
(mm)
Length of
removed
insulation (mm)
10.5
6.5
8.5
10.5
12.5
6.5
8.5
10.5
12.5
00
000
Weight
(g)
21.9
26.7
26.1
25.4
24.6
33.5
32.9
32.2
31.4
221
231
SELECTION OF THE TOOL AND LENGTH OF INSULATION REMOVED FROM

THE WIRES
Wire gauge
Marking colour
22-18
Red
22-18
16-14
22-18
Red
Blue
Red
Diameter
(mm)
2.79
4.75
3.81
5.08
3.81
16-14
Blue
5.08
Length of removed
insulation
Crimping tool and heat gun

P/N047011-000
AD1522
HG2310LCD
6.5
NOTE: Holes of the terminals having size (4.8 4.93)#10; #1/4 and # (9.52 mm) can be
expanded by means of reamer bits up to the size 5.2; 8.2 and 10.2 mm with restoration of
the terminal coating by tin-plating.
3.
Termination of wires in the terminals

- Termination of wires in the terminals -106 for the finished products is performed by crimping
by means of AD-1522 crimping tool with subsequent shrinkage of the insulating tip by
HG2310LCD heat gun according to Figure 1.
Fig. 1 Correct crimping and shrinkage of the insulating tip on the wire terminal
EFFECTIVITY:
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RRJ-95B
- Termination of AWG24-10 gauge wires in the terminals MS25036, M7928/4 is performed by

means of the crimping tool 59250, 59239-4 according to Figure 2:
Fig. 2 Correct crimping

NOTE: End face of the wire core must be insulated by EP-076 primer, U6-10-755-74
according to VIAM No.850-76.
- Termination of AWG 10-000 gauge wires in the terminal 277147-277153 is performed by
crimping by means of hydraulic tool 69120-2 (completed with head and die) according to Figure
3:
Fig. 3 Correct crimping

NOTE: Insulating tube RW-175, K is omitted for clarity.
- Termination of AWG 22-16 gauge wire in the terminal 321885-321890 is performed by crimping
by means of the tool 46673 according to Figure 2.
Fig. 4 Dimensions of gauge for AD-1377S tool (Tolerance for "GO" dimensions GATE: +0.0005/
0.0000; "NO GO": +0.000/-0.0005)
NOTE: The dimensions are given in inches.
Insulation of the gauge housing for the tools RAYCHEM AD-1377 and AD-1377S CRIMP
TOOLS can be insulated by plastic.
EFFECTIVITY:
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Fig. 5 Dimensions of the dome-shaped gauge for the tool 46673
Fig. 6 Die configuration

TABLE 5
Tool type
46673
46673-1
46988
CALIBRATION SIZES FOR CORRESPONDING TOOLS

GO
NO-GO
1.499-1.506 [.0590-.0593]
1.648-1.651 [.0649-.0650]
1.702-1.709 [.0670-.0673]
1.851-1.854 [.0729-.0730]
"R" (Radius)
1.57 [.062]
Fig. 7 Gauge dimensions for rectangular tool 46673
EFFECTIVITY:
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TABLE 6
Tool type
46673
46673-1
46988
"W" (Width) (Max)
GO
NO-GO
0.762-0.770 [.0300-.1313]
1.267-1.270 [.0499-.0500]
1.702-1.709 [.0670-.0673]
1.521-1.524 [.0599-.0600]
3.05 [.120]
Fig. 9 Dimensions of the dome-shaped gauges

TABLE 7
Tool type
59170 and 59250
59275
59300
59170 and 59250

Wire gauge
AWG
22-16
16-14
26-22
24-20
24-20
22-16
12-10
Size "B"
GO
NO-GO
2.769-2.776 [.1090-.1093]
2.918-2.921 [.1149-.1150]
3.023-3.030 [.1190-.1193]
3.172-3.175 [.1249-.1250]
1.600-1.608 [.0630-.0633]
1.750-1.753 [.0689-.0690]
2.261-2.268 [.0890-.0893]
2.410-2.413 [.0949-.0950]
2.261-2.268 [.0890-.0893]
2.410-2.413 [.0949-.0950]
2.769-2.776 [.1090-.1093]
2.918-2.921 [.1149-.1150]
4.2926 [.1690+0.0003]
4.4450 [.1750-0.0001]
- Dimensions of the dome-shaped gauges for AD-1522 tool (Ref. Table 8):
TABLE 8
Tool type
AD-1522

Wire gauge
AWG
Size "B"
22-18
GO
2.2860
NO-GO
2.3876
16-14
2.6543
2.7813
12-10
3.6830
3.8354
EFFECTIVITY:
Page 8
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RRJ-95B
Fig. 11 Dimensions of flat gauges
""
TABLE 9
Tool type
59170 and
59250
59275
59300

AWG wire
gauge
22-16
16-14
26-22
24-20
24-20
22-16
Size "D"
GO
NO-GO
0.762-0.770 [.03000-.0303]
2.791-2.794 [.1099-.1100]
1.016-1.024 [.040-.0403]
3.045-3.048 [.1199-.1200]
0.762-0.770 [.0300-.0303]
2.029-2.032 [.0799-.0800]
0.762-0.770 [.0300-.0303]
2.791-2.794 [.1099-.1100]
"W"
(Max)
3.18
[.125]
2.36
[.093]
3.18
[.125]
- Check of the tool by the gauges for crimping of "COPALUM" terminals
Fig. 13 Check of the tool for crimping of "COPALUM" terminals
EFFECTIVITY:
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TABLE 10
Die
designation
59877-1
68006
68007
68008
68009
68010
68010-2
68011-1
314948-1
314964-1
1976441-1
1976442-1
1976443-1

GO
NO-GO
7.518-7.526 [.2960-.2963]
2.870-2.877 [.1130-.1133]
3.200-3.208 [.1260-.1263]
3.937-3.944 [.1550-.1553]
5.003-5.011 [.1970-.1973]
6.197-6.205 [.2440-.2443]
6.579-6.586 [.2590-.2593]
7.924-7.932 [.3120-.3123]
9.550-9.558 [.7360-.3763]
10.922-10.930 [.4300.4303]
7.924-7.932 [.3120-.3123]
7.518-7.526 [.2960-.2963]
9.550-9.558 [.3760-.3763]
7.769-7.772 [.3059-.3060]
3.045-3.048 [.1199-.1200]
3.375-3.378 [.1329-.1330]
4.112-4.114 [.1619-.1620]
5.179-5.181 [.2039-.2040]
6.372-6.375 [.2509-.2510]
6.754-6.756 [.2659-.2660]
8.100-8.102 [.3189-.3190]
9.802-9.804 [.3869-.3860]
11.097-11.100 [.4369.4370]
8.100-8.102 [.3189-.3190]
7.769-7.772 [.3059-.3060]
9.802-9.804 [.3859-.3860]
"R" RADIUS
(Max.)
7.62 [.300]
3.16 [.125]
3.556 [.140]
4.34 [.171]
5.54 [.218]
6.73 [.265]
6.73 [.265]
7.52 [.396]
8.13 [.320]
9.91 [.390]
6.35 [.250]
6.35 [.250]
6.35 [.250]
9.91 [.390]
9.91 [.390]
9.91 [.390]
9.91 [.390]
9.91 [.390]
7.52 [.296]
9.91 [.390]
7.52 [.396]
7.62 [.300]
8.13 [.320]
9.91 [.390]
9.91 [.390]
9.91 [.390]
"C" DIM
EFFECTIVITY:
Page 10
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RRJ-95B
TABLE 11
Die designation
GO
NO-GO
59877-1
68006
68007
68008
68009
68010 68010-2
68011-1
314948-1
314964-1
1976441-1
1976442-1
1976443-1
16.205-16.213 [.6380-.6383]
6.248-6.256 [.2460-.2463]
7.518-7.526 [.2960-.2963]
9.195-9.202 [.3620-.3623]
11.379-11.387 [.4480-.4483]
13.818-13.825 [.5440-.5443]
15.037-15.044 [.5920-.5923]
16.205-16.213 [.6380-.6383]
15.037-15.044 [.5920-5923]
15.037-15.044 [.5920-.5923]
16.205-16.213 [.6380-.6383]
16.205-16.213 [.6380-.6383]
16.609-16.612 [.6539-.6540]
6.652-6.665 [.2619-.2620]
7.922-7.925 [.3119-.3120]
9.599-9.601 [.3779-.3780]
11.783-11.786 [.4639-.4640]
14.221-14.224 [.5599-.5600]
15.441-15.443 [.6079-.6080]
16.609-16.612 [.6539-.6540]
15.441-15.443 [.6079-.6080]
15.441-15.443 [.6079-.6080]
16.609-16.612 [.6539-.6540]
16.609-16.612 [.6539-.6540]
"R" RADIUS
(Max.)
16.15 [.636]
6.20 [.244]
7.47 [.294]
9.14 [.360]
11.33 [.446]
13.77 [.542]
14.99 [.590]
16.15 [.636]
14.99 [.590]
14.99 [.590]
16.15 [.636]
16.15 [.636]
"C" DIM
8.08 [.318]
3.10 [.122]
3.73 [.147]
4.57 [.180]
5.66 [.223]
6.88 [.271]
7.49 [.295]
8.08 [.318]
7.49 [.295]
7.49 [.295]
8.08 [.318]
8.08 [.318]
- Termination of the wires of gauge AWG 6, 4, 2, 1, 0, 00, 000 in the terminals OST1 13697 is
performed by soldering according to Fig.16:
Fig. 16 Termination of the wires of gauge AWG 6, 4, 2, 1, 0, 00, 000 in the terminals OST1 13697
EFFECTIVITY:
Page 11
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20-20-80
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RRJ-95B
EFFECTIVITY:
Page 12
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RRJ-95B
TERMINATION OF WIRES IN ELECTRICAL DEVICES,

INNER WIRING AND SOLDERING
1.
General
The present Section applies to the inner electrical wiring and soldering of the electrical devices and
avionic systems. The notion "electrical devices" includes:
central distribution boxes;
distribution boxes;
relay boxes;
electrical system panels;
panels;
instrument boards.
The present Section specifies the main specifications and norms to be observed during interunit
electrical wiring.
Requirements for electrical wiring:
Electrical wiring must provide reliable operation of equipment in conditions of mechanical
impacts and climatic factors, which take place during aircraft operation.
Electrical wiring of the relay boxes, distribution boxes, panels etc. must be performed after
complete mechanical assembly and operation check of all installed circuit elements and after the
check of their safe attachment.
The wires used during wiring must have no damages (burns, cuts and other defects), which
reduce mechanical and electrical strength of their insulation.
Splicing of the wires must be performed in accordance with requirements of Sections 20-20-10,
20-20-20 of the present Manual.
Connection of the wires to each other, of the wires with leads of the hook-up wiring elements
and of leads of the hook-up wiring elements to each other must be provided by means of
connectors, easy wiring modules, terminal blocks and other elements specified in WDM.
Termination of wires in the contacts of the radio components must be performed in accordance
with requirements of the present Section.
Electrical wiring must be performed by means of the wires of the following types: 55, EN,
82A0111, BS.
The harnesses with cable (jack-in) parts of connectors, which can move during work or
operation, must be made of the wires 82 in the flexible protective sheath.
Minimum bend radius of the wire must be not less than three outer diameters of the wire.
Connecting wires running from the harness and connected to the radio components (installation
equipment) must have length reserve that provides triple re-termination. Reserve of the wires is
provided during electrical wiring, when there is a technical possibility to meet this requirement.
Wires of the point-to-point wiring must not touch the cover and other assemblies.
The wiring must be performed in full compliance with connection diagrams and drawings.
Wiring of the harnesses of similar devices must be identical for all elements.
EFFECTIVITY:
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Screen braidings of the wires must be grounded to the frame of electrical device via terminals of
connectors, if the frame is metal. Screen braidings of the wires must be grounded via the
current-carrying frame of the electrical device in accordance with requirements of the present
Manual.
Jumpers between the contacts of the electrical device must be made of the insulated wire.
Three and more insulated (inclusive of the screened ones) wires running in parallel in one path
more than 50 mm long must be tied in a bundle.
Jumpers between the neighbouring contacts can be laid under the harness wires.
Measures aimed at protecting against static electricity must be taken during works relating to
use of the conductors and microcircuits:
the working tools must be grounded;
an antistatic bracelet connected via 1 MOhm resistance to the common ground frame must be
put on the hand.
Markings and placards applied on the electrical devices must not be covered by the harnesses,
cables and fasteners.
Structure and wiring of the equipment must provide access to equipment components for
inspection, check, replacement of the elements and connection of the test equipment.
Parts of the electrical connectors must be protected against dust and moisture from the contacts
during installation and assembly by means of blankings.
The moving segments of the harnesses must be made by flexible wires in the places of
transition from the aircraft moving part to the fixed one in accordance with requirements of OST1
00239-77 and of the present Manual.
Type of connector, terminal, finished product, wire grade and size as well as soldering alloy
grade are specified in the equipment and material specifications attached to the wire diagrams,
Ref. Section 91 of the WDM.
2.
Standard soldering procedure for electrical device wires

Soldering of the wires in connector contacts, to the terminals or other elements must be
performed by Sn96 soldering alloy with 0.7-1.2 mm diameter with flux IF I4. All-climate soldering
alloy PSr05 GOST 19738-74 designed for operating temperature from -60 to +150 , 02
GOST 860-75 can be used.
CAUTION: The contacts must be protected by blanking caps to prevent ingress of the dust,
moisture, oils on the connector contacts during installation and transportation of the
connectors as well as on the contacts of connectors installed on the aircraft without
connected mating part.
Soldered wire joints provide safe operation of the aircraft power network under all operating
conditions.
In order to provide safe and reliable soldered joint, ends of AWG 2416 gauge wire must be tinplated before soldering with use of heat guns.
The wires must be coated with soldering alloy of the same grade, which is used for soldering.
It is permitted not to tin-coat the wires with current-carrying cores made of the silver-plated
copper wires.
Tin-coating must be performed by immersion in the soldering bath with digital temperature
regulator "Magistr Ts20-V" with performance data (Ref. Fig.1).
Tin coating and soldering of a small quantity of wires can be performed by means of the
soldering station "Magistr Ts20-3" with performance data (Ref. Fig.2).
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Fig. 2 Soldering station "MAGISTR Ts20-3"
Quality of tin-coating is checked visually (Fig.3):
Fig. 3 Wire tin-coating quality check

NOTE: A uniform layer of tin is applied on the wire strands, contours of the strands
remain clearly visible at that. Length of the untinned segment of wire must be
not more than one wire diameter D.
Soldering and unsoldering of the wires in contacts of connectors or other elements must
be performed using the pulse soldering system 105-3 with performance data (Fig.4).
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FIG. 4 TW-15 single-circuit pulse-type soldering tweezers

TABLE 1
W-15 PERFORMANCE DATA
Performance data
Power supply
Max. output power
Output
voltage
Overall dimensions
(H, W, D in mm)
Weight of
control unit
Nominal values
Order
number
Designation
230 V, 50 Hz
105-3
105-3
100 W
0719
7013-0004
0-2.6 V
0720
7009-0005
9895133
0722
7020-0001
2 kg
0723
7012-0002
Description
Control unit with pedal and
cable
LF-15 pulse solder
TW-15 single-circuit pulsetype tweezers
CT-15 double-circuit pulsetype tweezers
TS-15 pulse wire stripper
The wires must be soldered in the contacts of connectors in lines, starting from the lower line,
from right to left (Fig.5):
Fig. 5 Sequence of wire soldering in connector

NOTE: Sequence of wires fitting on the contacts of connector must be strictly observed.
Soldering of wires in the contacts, terminals and other elements must be performed according
to Subjects 1-6:
- Start the pulse control unit 105-3 together with single-circuit soldering tweezers;
- Place the connector in the wiring device and attach it;
- Place the tin-coated wire core in the contact (terminal);
- Place the pulse-type tweezers on the joint and start the tweezers by pressing on the tongues;
- Heat the soldering joint by current pulse with application of soldering alloy Sn96/Ag3, VPr9
and IF14 flux, till 100% of the contact (terminal) cavity is filled;
- Open the tweezers after completion of operation.
Pulse soldering (unsoldering) of the wires in the contacts of connectors (Ref. Fig.6).
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Fig. 6 Use of the single-circuit pulse-type tweezers

Check soldering quality visually (Fig.7):
100%
41
75%
0%
Fig. 7 Correctly soldered contact:

the soldering alloy moistened the whole surface inside the soldering cavity, 100% of the cavity is filled
with soldering alloy; there is no soldering alloy outside the soldering cavity
Acceptable soldering quality (Fig.8 and 9):
41
Fig. 8 Permissible soldering of contacts: a thin layer of soldering alloy outside the soldering cavity
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Fig. 9 Permissible soldering of contacts: soldering alloy fills more than 75% of the soldering cavity
Impermissible soldering of contacts (Fig.10):
Remaining of the soldering alloy are outside the soldering cavity, this affects the shape, functionality and
safety
75%
Fig. 10 The soldering alloy fills less than 75% of the soldering cavity
As for the wires of grades 55 (), EN, clearance between the insulation cut and contact end
face must be equal to 41 mm.
Heat-shrinking tubes K, TMS-SCE, RW-175 must be fitted on the soldered joints for
protection against external actions, vibration and in order to reduce the path of the arc
discharge between the contacts 182 mm long. Protective tubes can be used as marking
tubes. Identification tags can be fitted in the places of wire connection to the finished product
(terminals, lugs etc.).
High-quality fitting of insulating tube (Ref. Fig.11).
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Fig.11 High-quality fitting of insulating tube

NOTE: The insulating tube is located on the contact and overlaps the wire insulation on the
segment, length of which is equal to 4 wire diameters. Cut of the insulating tube is
located at distance 1.0 mm max. from the point of the contact insertion into connector.
Permissible quality of insulating tube fitting (Fig.12):
Fig. 12 Permissible quality of insulating tube fitting

NOTE: The insulating tube is located on the contact and overlaps the wire insulation
on the segment, length of which is equal to 2 wire diameters.
NOTE: Cut of the insulating tube is located at distance maximum 1.5 mm from the
point of the contact insertion in the connector.
Impermissible fitting of insulating tube (Fig.13).
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Fig. 13 Impermissible fitting of insulating tube

NOTE: insulating tube is damaged;
insulating tube overlaps the insulation on the length that is less than two wire
diameters;
insulating tube is at a distance more than 2 diameters of wire insulation from the
point of the contact insertion in connector;
D insulating tube is not shrunk, can move during vibration, overlaps the contact and
wire insulation more than it is required.
Do not fit the protective tubes, if the connector is sealed by the sealing compound.
Protective tubes RW-175 must be shrunk by the heat gun HG 2310 LCD with 5 mm diameter
adapter. Temperature of the hot air flow must be 300, shrinkage period is 8-12 sec.
Overheating of the heat-shrinking tubes and soldering place is not permitted.
The tools, standard size of the contact, gauges (section) of the connected wires to be
terminated in the relay bases must be selected according to Table 2:
TABLE 2
SELECTION OF TOOLS, STANDARD SIZES OF THE CONTACTS AND

GAUGES
AWG wire
gauge
(section)
Crimping tool
Designation
Contact code
Contact
size, type
S210A2A1
S220A2A1
S230A2A1
39029/22-192
39029/101-553
SO-1064-003
SO-1065-003
#20
slots
24-20
0.24; 0.38;
0.61
(22520/1-01)
AFM 8
(M22520/2-01)
(22520/102,1)
K13-1
(M22520/2-08)
S215A2A1
S230A2A1
S400D2A2
S500A1A10
39029/22-193
SO-1065-003
39029/92-532
#16
slots
20-16
0.61; 0.96;
1.23
AF 8
(M22520/1-01)
163,
TH1A
(M22520/12-02)
500A1A10
SO-1065-003
39029/92-535
#12
slots
AF 8
(M22520/1-01)
T1, 163
M22520/1-02
W260
L304-85 1350
45
#22
#20
slots
85150139
16-14
1.23; 1.93
24-20
0.24;0.38;0.61
24-20
0.24;0.38;0.61
DMC (MIL)
positioner
Soldering
(22520/2-01)
UT6521
UT6526
Insertion/removal tool p/n M81969/14-01
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Installation of rubber caps on the input studs for short-circuit protection of the current-carrying
bolts and cable lugs.
The rubber caps must be selected in accordance with size of the stud, nut and cable lug as per
GOST 19323-73.
The rubber caps must be fitted on the wires prior to crimping of the terminals.
Fig. 14 Main rubber caps fitting method
Permissible rubber caps fitting method (Fig.15):
Fig. 15 Permissible rubber caps fitting method

To lock the projecting parts of threaded joints (nuts, heads of attachment screws, bolts and
studs) after the terminals are fitted on them, apply EP-140 enamel or AK-070 primer (red, as
per OST1 80023-80) on the whole head of the assembly or apply a 3-5 mm wide strip, or on 34 screws of threaded joint.
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1.
General
The following connectors are used in the aircraft electrical equipment: connectors of series 8D,
D38999, M83723, 8533, 8525, MS347, 891, 1900ND, DPX, SB600, NSXN etc., as well as special
connectors delivered with finished products.
The following requirements must be met, when selecting the connectors:
current intensity on the contact and combination of contacts in relation to quantity and
diameters;
operating voltage;
tightness;
heat-resistance;
tropical resistance;
wiring conditions.
It must be also noted that the inserts and blocks (sockets) with sockets are installed on the
voltage supply side.
2.
Connectors RVN1, RVN2, RVN3

Connectors of RVN1, RVN2, RVN3 type are intended for operation in the DC or AC electrical
circuits (frequency up to 3 Hz) in the headsets.
RVN1 connectors are manufactured in accordance with specifications NKTsS.434410.107U,
RVN2(3) NKTsS.434410.103U, for cut-in connection. Coating of contacts in the connectors:
RVN1 P - silver, S palladium, RVN2 silver, RVN3 gold.
The following symbolic notations are assigned to the connectors (Ref. Table 1):
TABLE 1
RVN
SYMBOLIC NOTATIONS OF RVN TYPE CONNECTORS

5 -
P(O)
1
Type of connector
Development No.
Quantity of contacts
Designation of contacts combination conventional No.
Connector component: P plug, O outlet
Type of housing
Wires with section 0.96 mm (AWG18) are connected to contacts tails by soldering.
Designation of connectors during order: Plug RVN 1-5-2Sh1, Outlet RVN 1 -5-2G1.
3.
SNTs type connectors

Connectors of SNTs-22 type correspond to specifications GEO.364.239U "Low-frequency, lowvoltage, circular, subminiature, bayonet, multiposition electrical connectors with gold-plated
detachable contacts connected to wires by crimping. Diameter of contacts - 1 mm".
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The connectors are intended for application in the DC and AC electrical circuits with frequency up
to 3 Hz, at voltage up to 500V (amplitude value) and ambient temperature from -60 to +155
(without retaining of pressurization).
The plugs and sockets have symbolic notations:
TABLE 2
SNTs-22 4 /
SYMBOLIC NOTATION OF SNTs-22 PLUGS AND OUTLETS

10 P
(S)
1 (2, 6, 11, 12, 13)
(b, c, d)
All-climate design
Angular position of sockets in the
connector housing insulator
Cable part with collar for tubes
Jack-in part with collar for heat-shrinking tubes
Cable part without casing
Cable part with straight casing
Jack-in part with straight casing
Jack-in part without casing
Connector part - socket
Connector part - plug
Conventional diameter of the housing 10 (12, 14, 18, 22, 27)
Quantity of contacts 4 (7, 10, 19, 32, 50)
Type of connector
SNTs-30 type connectors (plug with flange for welding), SNTs-31 type connectors (plug with
flange for screws), SNTs-32 type connectors (plug with flange for nut bR.364.039U) - sealed
connectors with nickel contacts for soldering - are intended for operation in the DC and AC
electrical circuits with frequency up to 3 Hz.
The plugs are intended for connection with SNTs-22 sockets of corresponding type (nominal
diameter of the housing and quantity of contacts) and angular position of the insulator in
accordance with specifications GEO.364.239U.
For example: Plug SNTs 31-4/10 V 1 V bRO364.039TU.
Connectors of SNTs-23, SNTs-23 (left) type correspond to specifications GEO.364.241U.
These are low-frequency, low-voltage, circular, subminiature, bayonet, multiposition electrical
connectors with gold-plated detachable contacts connected to wires by crimping and intended for
operation in the DC and AC electrical circuits with frequency up to 3 Hz at ambient temperature
from -60 to +155 (without retaining of pressurization).
SNTs-23L connectors are manufactured in the following design variants: 6, 8, 11,13.
Symbolic notations are assigned to the plugs and sockets (Ref. Table 3).
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TABLE 3
SNTs 23
SYMBOLIC NOTATION OF SNTs-23 PLUGS AND OUTLETS

4/
14
(S)
(2,
4,
6,
8,
11,
12, 13)
(b, c, d)
All-climate
design
Angular position of sockets
in the housing insulator
Cable part with collar for tubes
Jack-in part with collar for heatshrinking tubes
Cable part without casing
Cable part with angular casing
Cable part with straight casing
Jack-in part with angular casing
Jack-in part with straight casing
Jack-in part without casing
Connector part - socket
Connector part - plug
Conventional size of the housing 14 (18, 22, 24, 27, 30, 33, 36, 39)
Quantity of contacts 4 (3, 7, 10, 19, 24, 28, 32, 41, 43, 45, 55, 61)
Type of connector
SNTs-23 type connectors provide 10-time insertion and removal of the contacts by means of
wiring tool.
The contacts tail provide connection of the following wires:
for contacts 1mm with section from 0.20 to 0.75mm, gauge 2420;
for contacts 1.5mm with section from 0.75 to 1.5mm, gauge 1816;
for contacts 2.0mm with section from 2.5 to 4.0mm, gauge 1412.
The connectors delivery set includes:
plug or socket without collar and casings;
collar or casing (straight or angular);
set of contacts (+5% reserve);
set of sealing plugs for free holes in the rubber insulators during fitting of contacts;
wiring tool for contacts insertion and removal.
Connectors of SNTs-27 type plug with flange for nut bR.364.038U are intended for
operation in the DC and AC electrical circuits with frequency up to 3 Hz, sealed, with nickelplated contacts. The plugs are intended for connection with SNTs-23 sockets of corresponding
type (nominal diameter of the housing and quantity of contacts) and angular position of the
insulator in accordance with specifications GEO.364.241U.
The sections (gauges), outer diameter of connected wires, insulation stripping door and
crimping tools are specified in the Table 4.
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TABLE 4
CHARACTERISTICS OF SNTs-23, 22 TYPE CONNECTORS AND USED

TOOLS
Wire
Wire
Contact
Stripping
section, diameter
Connector diameter
length
gauge
(mm:
(mm)
(mm)
(mm) min-max)
Position of
positioner
(head)
0.240.61
20
SNTs23
1.0
SNTs23
1.5
SNTs23
2.0
SNTs22
1.0
TABLE 5
SNTs
24, 22, 20
0.961.23
18, 16
1.943.0
14, 12
24-22
1.2-2.1
60.5
RED
16
1.8-2.7
8.50.5
2.8-4.3
8.50.5 12 YELLOW
1.45
5.00.5
BLUE
Position of
selector
Crimping
tool
2; 3; 4
5; 6
Wiring tool
M15570-20
M22520/101
AF-8
7; 8
M15570-16
M15570-12
22520/2part of
01
delivery set
K-40
SYMBOLIC NOTATION OF SNTS147 UNSEALED CONNECTORS

(ANALOGUE OF CONNECTORS 8533)
147
-3
0
P
-N
W
C1 1
(3,4,7)
(S)
(6,7,8,9,Y) (R,K,E)
S
Type of connector
Development No.
Quantity of contacts:
3
(4,5,6,7,8,10,12,14,15,16,19,24,30,31,39,41,42,55,61)
Conventional size of the housing:
8 (10,12,14,16,18,20,22,24,28)
Contact type: P pin (plug)
S socket (outlet)
Wiring method: C crimping
Tail type: 1 circular tail for three-dimensional wiring
Coating of the contact working part: 1 gold
Polarization of the keys (key slots) of the housing:
N normal, 6,7,8,9,Y according to Table 2 of Specifications
Material and coating of basic parts:
W aluminium alloy, olive green cadmium;
R aluminium alloy, nickel;
K, E stainless steel, passivation
Type of the housing: 0 instrument type with rectangular flange; 3 cable type with self-locking
joint and protection against RF interferences; 4 cable type with self-locking joint; 7 instrument
type with lock nut; S with serrations along the whole circumference.
Diagram of insert arrangement in SNTs-23 electrical connectors is shown in Fig.1.
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Fig. 1 Diagram of insert arrangement in SNTs-23

4.
Electrical connectors, series D38999 and 8D, by "SOURIAU"

Electrical connectors of series D38999 and 8D by "SOURIAU" are manufactured as per MIL-C38999, series III, IV. The said connectors relate to the miniature series, circular connectors with
threaded joint and are used with gold-plated detachable and thermocouple contacts connected to
the wires by crimping method. They are produced by many manufacturers as per MIL--38999,
except for change of the military number by manufacturer company designation.
Interpretation of D38999 connectors, series III, IV is given in the Table 6.
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TABLE 6
D38999
DESIGNATION OF D38999 CONNECTORS, SERIES III, IV

20
35
Polarization: N, A, B, C, D, E
Contact type:
P pin. : the connector is delivered without pin contacts or with special
contacts (marking of connector: +polarization)
S socket. : the connector is delivered without socket contacts or with
special contacts (marking of connector: +polarization)
Diagram of insert arrangement
Size of the housing: A-B-C-D-E-F-G-H-J
Material and coating of the housing: TF - titanium - nickel plated; - titanium, without coating;
W olive green cadmium plating - AL; C; S - steel; - composite - nickel plated;
F - nickel AL; J - composite - green cadmium plating.
Type of the housing:
20 outlet with rectangular flange
24 outlet with lock nut
26 plug with protection against RF interferences
Main series
Designation of SNTs-144 connectors (analogue of D38999 and 8D) (Ref. Table 7):
TABLE 7
DESIGNATION OF SNTS-144 CONNECTORS (ANALOGUE OF D38999 AND

8D)
SNTs
144
-3 /9 P(O) 01 1
-N
(A,B,C,D,E)
W(F)
I(C)
Type of connector
Development No.
3 (4,5,6,8,10,11,12,13,16,19,21,23,24,26,29,
32,37,39,41,43,53,55,56,61,66,79,100,128)
Conventional size of the housing plug (socket) 9(11,13,15,17,19,21,23,25)
Connector part: P - plug (O - outlet)
Wiring method: 0 - crimping, 1 - circular tail
Coating of contact working part: 1 - gold
Position of the keys on the housing, where N is normal position
A,B,C,D,E - according to Tables 3 and 4 of Specifications
Coating of the basic parts: W - current-carrying (olive green cadmium) - temperature range from -65 to +175 ; F- currentcarrying (nickel) - temperature range from +65 to +200
Type of the housing: I - instrument, C - cable
Designation of stainless steel connectors by "SOURIAU" (Ref. Table 8).
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TABLE 8
FD38999
DESIGNATION OF STAINLESS STEEL CONNECTORS BY "SOURIAU"

20
35
WF
Mandatory suffix
Contact type:
P, H pin. : the connector is delivered without pin contacts or with special
S, J socket. : the connector is delivered without socket contacts or with
Size of the housing:
A-B-C-D-E-F-G-H-J
Coating:
K passivation
S - nickel-plating
Basic series
NOTE: Designation of stainless steel connectors as per MIL-C-38999: D38999 20 KJ 35 PN.

Designation of composite connectors as per MIL-DTL-38999 (Ref. Table 9):
TABLE 9
D38999
DESIGNATION OF COMPOSITE CONNECTORS AS PER MIL-DTL38999

20
35
N
Contact type:
P, H pin. : the connector is delivered without pin contacts or with special
S, J socket. : the connector is delivered without socket contacts or with
P&S=500 cycles
J&H=1500 cycles
A-B-C-D-E-F-G-H-J
Coating:
J olive green cadmium plating
M - nickel
Basic series
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Designation of connectors 8D, series III (Ref. Table 10):

TABLE 10
DESIGNATION OF CONNECTORS 8D, SERIES III
8D 0 - 11 W 35 P N
Specification:
046: Straight tin-coated contact-studs
251: Connector with power contacts (diagrams with contacts #8)
022: Fuel tank
326: Reinforced seal for severe conditions
L: only for the pin or socket contacts, the connectors are delivered without
contacts, the connectors are marked as P or S plus polarization
Contact type:
P, H pin. : the connector is delivered without pin contacts or with special contacts
(marking of connector: +polarization)
S, J socket. : the connector is delivered without socket contacts or with special
Material and coating of the housing: TF - titanium - nickel plated; - titanium, without
coating;
W olive green cadmium plating - AL; K steel - passivation; S - steel - nickel plated; composite - nickel plated; composite, without coating; L black zinc-nickel; Z - green zinccobalt-AL;
F- nickelAL; J composite - cadmium coating.
Dimensions of the housing:
09-11-13-15-17-19-21-23-25
Type:
-: connectors with standard contacts for crimping
L: Outlet with long contact-studs (pin and socket dimension 22D)
C: Outlet with short contact-studs (pin and socket dimension #22D, #20, #16)
S: Outlet with special contact-studs (pin and socket dimension #22D)
W: Outlet with pin contacts #22D for twisting (3 coils)
: Outlet with pin contacts #22 for twisting (2 coils)
Main series
Designation of stainless steel connectors (Ref. Table 11).
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TABLE 11
8D
DESIGNATION OF STAINLESS STEEL CONNECTORS

11
35
**
Specification:
022: Fuel tank
Contact type:
P pin. : the connector is delivered without pin contacts or with special contacts (marking of
connector: +polarization)
S socket. : the connector is delivered without socket contacts or with special contacts
Coating:
K passivation
S - nickel-plating
09-11-13-15-17-19-21-23-25
Type:
7 socket with lock nut
Basic series
Thermocouple contacts for connectors 8D, 8LT, 8ST (Ref. Table 12).
TABLE 12
THERMOCOUPLE CONTACTS FOR CONNECTORS 8D, 8LT, 8ST
Contact
material
Contact designation
No. for order
Contact type
8599-0749
Yellow
8599-0753
8599-0949
Pin
Cr
8599-0953
socket
8599-0761
Black
8599-0765
8599-0961
Pin
8599-0965
socket
Al
MIL-C
Marking colour
Contact size
Yellow, purple, blue

Yellow, grey, grey
#20
Yellow, purple,
green
Yellow, grey,
purple
#20
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Designation of composite connectors as per MIL-DTL-38999 (Ref. Table 13):

TABLE 13
DESIGNATION OF COMPOSITE CONNECTORS AS PER MIL-DTL-38999
8D 0 - 11 M 35 P N
Specification:
022:Fuel tank
L: only for P or S type contacts, the connectors are delivered without contacts,
the connectors are marked as P or S plus polarization
Contact type:
P, H pin. : the connector is delivered without pin contacts or with special contacts
S, J socket. : the connector is delivered without socket contacts or with special
P&S=500 cycles
J&H=1500 cycles
Coating:
J olive green cadmium plating
M nickel
X no coating
09-11-13-15-17-19-21-23-25
Type:
Basic series
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Designation of connectors as per MIL--38999, series II (Ref. Table 14):

TABLE 14
DESIGNATION OF CONNECTORS AS PER MIL--38999, SERIES II
8T 3 - 14 G 35 P N
Polarization: N, A, B, C, D
Contact type:
pin
pin connector delivered without contacts or with specified contacts
S socket
socket connector delivered without contacts or with specified contacts
Contacts insert arrangement
Coating:
G olive green cadmium ( 309)
F - -nickel
B olive green cadmium (MIL--38999)
hard anodizing
08-10-12-14-16-18-20-22-24
Index:
- - connectors with standard contacts for crimping
L outlet with long stud
outlet with short stud
2 outlet with rectangular flange without rear nut
3 outlet with rectangular flange (rear wiring)
1 cable connection outlet
Main series
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5.
Designation of cable clamps for connectors of the series D38999 and 8D
TABLE 15
85049/ 14(
DESIGNATION OF CABLE CLAMPS FOR CONNECTORS OF THE

SERIES D38999 AND 8D
1516,
3839,
69, 88-89-90, 91-92) -S
-11 -(J,M)
-W(
N,
A)
Clamp Alanodized
black
Nickel-plated
Cadmium-plated
Composite clamp
nickel-plated
J cadmium-plated
Standard size of housing
(09,11,13,15,17,19,21,23,25)
With/without self-locking no index
Composite clamp
91 straight 92 angular 90
Clamp for common screen
88 straight, 89 angular 45, 90 angular 90
Clamp for fitting of the moulded heat-shrinking tube
Unscreened clamp with semiclamps
38 straight, 39 angular 90
Lightweight unscreened clamp
15 - angular 45, 16 - angular 90
Clamping nut
Basic number
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16 angular 90
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Designation of cable sleeves for termination of the screened wires (cables) in connectors
D38999 and 8D
TABLE 16
40
(41, 54)
DESIGNATION OF CABLE SLEEVES
-00 -21 -9 -3 -DS

Optional sizes for Std.
Designation of additional inserts
(15-30,17-60,19-9.0,21-12,
23-15,25-18) for unscreened
wires
Type of the rear clamping nut
1 rear clamping nut
2 clamping nut with circular latch (self-locked)
3 clamp with tip for metal strip
Code of sleeves in the collar
Std.1,2,3,5,6,7,9,10,12 for housing A,B,C,D,E,F,G,H,J
Code No Std.Designation: the collar has insert for screened wires
(cables) with sizes of the housing 7-E, 11-G, 13-H,17-J
Size of the housing (09,11,13,15,17,19,21,23,25)
Type of the cable clamp housing
00 - straight
45 - angular 45
90 angular 90
Coating code
cadmium-plated
- nickel-plated
Code of the housing material
aluminium
Cable clamp code
40 for D38999, series 3 and 4
41 for D38999, series 1 and 2
54 for 83723, series 1 and 3
TABLE 17
SYSTEM OF DESIGNATION OF THE SLEEVES FOR ORDER
--02-
Minimum size sleeve with solder sleeve for screens termination
--03-
Sleeve for termination of unscreened wires with RW-175 tube fitting
--04-
Maximum size sleeve with solder sleeve for screens termination.

Clamp coating type:
cadmium-plated
nickel-plated
07-(V)
Blanking cap - is used for closing the empty holes in the collar
EFFECTIVITY:
ALL
Page 13
20-40-10
Sep 30/11
D38999/XX-X XX XX, 8D-8LTX-XX X XX, MS2747X XX XX

X , MS27497 X XX XX X
Designation
ALL
Orange
Yellow
Black
DRK95-20B
(M81969/8-06)
MS27488-20-1
DRK95-22B
(M81969/8-10)
MS27488-22-1
K43
(M22520/2-10)
Orange
Green
Brown
DAK95-20B
(M81969/8-05)
K42
(M22520/209)
AF8
(M22520/2-01)
Orange
Blue
Orange
DAK95-22B
(M81969/8-03)
K40
(M22520/207)
Orange
Blue Black
socket
Orange
Green
Orange
DMC (MIL)
fitting
EFFECTIVITY:
20-40-10
Tool test gauge
Plastic blanking caps
DMC (MIL)
removal
MS27488-12-1
Positioner DMC (MIL)
Crimping tool DMC

(MIL)
Contact marking colour
Wiring tool
MS27488-16-1
DRK95-12B
(M81969/8-10)
DRK95-16B
(M81969/8-08)
Orange
Blue Yellow
DAK95-12B
(M81969/8-09)
G 125
M22520/3-1
TH163
(M22520/1-04)
AF8
(M22520/1-01)
Orange
Blue Yellow
DAK95-16B
(M81969/8-07)
Orange
Green
Red
Contact type
pin
22
pin
22
socket
20
pin
20
socket
16
pin
Contact size
TABLE 18
socket
Contact code
MIL
39029/58365
39029/56353
26,24,22
0,76-1.37
39029/58364
24,22,20
1.02-2.11
8D-8LT16
39029/56352
20,18,16
1.68-2.77
12
39029/58363
14,12
2.46-3,61
12
39029/56351
Gauge,
AWG
Wire
diameter
min max
39029/58362
7.
39029/56350
RRJ-95B
Numbers of contacts, crimping and wiring tools

CONTACTS AND USED TOOLS
Page 14
Sep 30/11
D38999/XX-X XX XX, 8D-8LTX-XX X XX,

MS2747X XX XX X , MS27497 X XX XX X
ALL
pin
Orange
Blue Black
22D
Orange
Yellow
grey
None
MS27488-22-1
Crimping tool DMC

(MIL)
Contact type
Contact size
MIL
Contact code
DMC (MIL)
DMC (MIL)
fitting
removal
EFFECTIVITY:
20-40-10
Tool test gauge
Wiring tool
G856
M81969/14-05
M81969/8-12
DRK95-22MB
(M81969/8-02)
WA 23-102L
TP986
WA 23-101DA
M81969/14-05
M81969/8-11
K42
(M22520/209)
none
pin
DAK95-22MB
(M81969/8-01)
K40
(M22520/207)
10
M300BT,
WA 23
(M22520/23-01)
none
socket
min max
AF8
(M22520/2-01)
22D
socket
26,24,22
0,761.37
39029/58528
12.10
2.973.88
39029/56527
Wire
diameter
39029/58360
Gauge,
AWG
39029/56348
Designation
RRJ-95B
Page 15
Sep 30/11
RRJ-95B
TABLE 19
Contact
type
TRIAXIAL CONTACTS #8 FOR DATA TRANSMISSION LINES

Contacts of
"Soldert cts" series
according to D-6002
Contact as
specification of
per MIL-C"Raychem" company
39029
without
Sleeve
protective
for
Contact
sleeve
protection
designation
of cable
exit point
M39029/90529
DK-602-0156-1
D-6020125
Pin
DK-602-0156-2
Pin
DK-602-0156-3
D-6020125
DK-602-0157-1
Socket
DK-602-0157-2
DK-602-0157-3
Contacts without
colour
identification with
protective sleeve
"Souriau"
8599-5210
Cable type
Contact size
Screening
One screen braiding
Double screen
braiding
Double screen
braiding + metallized
strip
One screen braiding
D-6020125
Double screen
braiding
Double screen
braiding + metallized
strip
Designation
RAYCHEM
CHEMINAX
10612
FILECA F.
2703/14
MILC17/176.00002
FILOTEX M
17/176.00002
RAYCHEM
CHEMINAX
10613
RAYCHEM
CHEMINAX
10614
RAYCHEM
CHEMINAX
10612
FILECA F.
2703/14
MILC17/176.00002
FILOTEX M
17/176.00002
RAYCHEM
CHEMINAX
10613
RAYCHEM
CHEMINAX
10614
#8
#8
#8
NOTE: Triaxial contacts are not part of the electrical connector delivery set and are ordered
individually.
NOTE: Connectors of the series D38999 and 8D are interchangeable and intermateable with
connectors SNTs-144 TsSNK430-421-008U. It is permitted to use plugs and blanking caps
manufactured according to the drawing 30.7200.8536.003 (005, 007, 009).
EFFECTIVITY:
ALL
Page 16
20-40-10
Sep 30/11
RRJ-95B
8.
Insert arrangement in D 38999 and 8D series connectors
Fig. 2 Diagrams of insert arrangement in connectors as per MIL--38999, series I, III, IV (part 1)
EFFECTIVITY:
ALL
Page 17
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RRJ-95B
Fig. 2 Diagrams of insert arrangement in connectors as per MIL--38999, series I, III, IV

(part 2)
EFFECTIVITY:
ALL
Page 18
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RRJ-95B

(part 3)
EFFECTIVITY:
ALL
Page 19
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RRJ-95B

(part 4)
EFFECTIVITY:
ALL
Page 20
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RRJ-95B
TABLE 20
257-
DESIGNATION OF FEEDTHROUGH CONNECTORS 257-093 AS PER MILDTL-38999, SERIES III
093
Z1
19-
35
PP
Polarization
N normal position
A,B,C,D,E angular position of the key
Contact type
P=PIN - pins
S=SOCKET - sockets
PP=PIN-PIN - pins
SS= SOCKET- SOCKET - sockets
Diagram of insert arrangement (Ref. Fig.2)
Size of the housing 9-11-13-15-17-19-21-23-25
Material and coating of the housing (passivation - stainless steel)
Basic number with lock nut
Series No.
TABLE 21
TORQUE MOMENT OF FEEDTHROUGH CONNECTORS LOCK NUT
Size of the housing
Torque, Nm, 5%
Size of the housing
Torque, Nm, 5%
0.9
10.73
17
22.03
11
12.43
19
24.29
13
15.82
21
26.55
15
19.21
23, 25
29.38
9.
Electrical connectors, series 83723

Electrical connectors of the series 83723 comply with military specification MIL-C-83723, series
III; NF-L-54143 series , JT, RT French specification, EN-2997 European specification.
Connectors of series 83723 are of miniature, circular type. Are used for all types of electrical
connections as well as in the engine areas. Types of connection to each other - threaded, bayonet,
quick-disconnect.
Advantage of this type of electrical connectors is that they are reliable, they are used on many
aircraft types, are issued by many manufacturers, are used with thermocouple contacts; rear portion
of the connector has serrations of antirotation system, self-locking of all plugs is provided.
Designation of electrical connectors of 83723 series as per MIL-C-83723 (Ref. Tables 21 - 22).
EFFECTIVITY:
ALL
Page 21
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Sep 30/11
RRJ-95B
DESIGNATION OF ELECTRICAL CONNECTORS OF 83723 SERIES AS

PER MIL-C-83723
TABLE 22
83723
/74
12
03
Polarization key
N normal position of the key
A,B,C,D (6,7,8,9) angular position of the key
Insert arrangement 2 (3,4,5,6,7,8,10,12,14,15,
16,19,24,25,29,28,31,32,39,4142,55,61)
Standard size of housing 8 (10,12,14,16,18,20,22,24,28)
Coating of the housing
Al-anodized, fluid-resistant housing
R Al-nickel-plated, current-carrying housing
G stainless steel, passivated housing
W Al-cadmium-plated, current-carrying housing
K stainless steel, passivated housing,
S stainless steel, passivated, heat-resistant, self-locking housing with protection
against RF interferences
Y stainless steel, sealed, passivated, fluid-resistant housing
71-72 bayonet
182-96m threaded
82/71 jack-in part, square flange sockets
83/72 jack-in part, square flange pins
84/73 jack-in part, attachment by nut sockets
85/74 jack-in part, attachment by nut pins
86/75 cable part sockets
87/76 cable part pins
91/77 cable part sockets with protection against RF interferences
92/78 cable part pins with protection against RF interferences
95/96 cable part self-locking sockets/pins
Basic series
Type of connector MIL-C-83723 series 3
EFFECTIVITY:
ALL
Page 22
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RRJ-95B
TABLE 23
MT,MB
DESIGNATION OF ELECTRICAL CONNECTORS OF 83723 SERIES AS

PER MIL-C-83723
34
12
03
N-
***
Modification No.
Polarization key
N - normal position of the key
A,B,C,D(6,7,8,9) angular position of the housing
Contact type
pins
S sockets
Insert arrangement
2(3,4,5,6,7,8,10,12,14,15,16,19,24,25,28,29,31,32,39,41,42,55,61)
Standard size of housing 8(10,12,14,16,18,20,22,24,28)
Al-anodized, black, fluid-resistant housing
R Al-nickel-plated, current-carrying housing
G stainless steel, passivated housing
W Al-cadmium-plated, current-carrying housing
K stainless steel, passivated housing
S stainless steel, passivated, heat-resistant, self-locking housing with protection against RF interferences
Y stainless steel, sealed, passivated, fluid-resistant housing
MB bayonet
MT threaded
30 jack-in part, square flange sockets
34 jack-in part, attachment by nut sockets
36 cable part
38 cable part with protection against RF interferences
Basic series "AMPHENOL"
Diagrams of insert arrangement, their quantity and size (Ref. Table 24-27):
TABLE 24
CHARACTERISTICS OF CONTACTS
1. The first two figures - sheath size,

2. The next two figures - contact location code
3 (12)
Quantity of contacts - size 12
4 (16)
5 (20)
EFFECTIVITY:
ALL
Page 23
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RRJ-95B
TABLE 25
DIAGRAMS OF INSERT ARRANGEMENT IN , CONNECTORS (PART 1)
DIAGRAM
1
2
3 (12)
4 (16)
5 (20)
0803
3
0898
5
1005
5
1006
6
1203
3
3
DIAGRAM
1
2
3 (12)
4 (16)
5 (20)
1212
12
1407
7
1415
15
1610
10
10
12
15
DIAGRAM
1
2
3 (12)
4 (16)
5 (20)
1624
24
1808
8
8
1814
14
1831
31
14
24
31
DIAGRAM
1
2
3 (12)
4 (16)
5 (20)
2016
16
2039
39
2041
41
16
2
37
41
EFFECTIVITY:
ALL
Page 24
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RRJ-95B
TABLE 25
DIAGRAM
1
2
3 (12)
4 (16)
5 (20)
2212
12
12
2219
19
2255
55
19
55
DIAGRAM
1
2
3 (12)
4 (16)
5 (20)
2430
30
2461
61
30
61
EFFECTIVITY:
ALL
Page 25
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Sep 30/11
RRJ-95B
TABLE 25
DIAGRAMS OF INSERT ARRANGEMENT IN , CONNECTORS

(PART 3)
EFFECTIVITY:
ALL
Page 26
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Sep 30/11
RRJ-95B
TABLE 25
EFFECTIVITY:
ALL
Page 27
20-40-10
Sep 30/11
RRJ-95B
TABLE 26
DESIGNATION OF 8D CONNECTORS WITH QUADRAX CONTACTS
Basic series
8D
0
Type of the housing
0 - instrument, with rectangular flange
7 - instrument, with lock nut
5 - cable, with protection against RF
interferences
Code
C - connector with twinaxial socket contacts
Q - connector with crimping contacts
11- 17- 21- 25- Size of the housing
Material and coating of the housing
W: AL - green cadmium-coating
F: AL - nickel-plated
K: Steel - passivation
S: Steel - nickel-plating
J: Composite - green cadmium plating
M: Composite - nickel plating
X: Composite, no coating
TF: Titanium - nickel plating
TT: Titanium - no coating
Insert arrangement (Ref. Fig.2)
TABLE 27
BT K 17 E 12 12 P D
11
81
284
Specification:
284 - with grounded contact
308 - with ungrounded contact
384- with grounded contact
408- with ungrounded contact
Polarization codes:
N, A, B, C, D, E
Contact type:
P- pin
S- socket
A- connector delivery
P - with short contacts
B - connector delivery
S - with short contacts
DESIGNATION OF ELECTRICAL CONNECTORS AMPHENOL AS PER MIL-C83723, SERIES III

06 Y144
Variants
Y144-Temp. 260 (Europe) Y163-Temp. 200 (Europe) Y175-Replaced with Y144
Y176-Temperature 260 as per GE M50TF3564, grade , without serrations on the tail portion
Y185-Replaced with Y163 Y186-Temperature 260 as per GE M50TF3564, grade
Y188-Temperature 260 as per GE M50TF3564, grade
Key position, not specified normal, 06,07,08,09,10

Coating of contacts
D-Gold as per MIL-C-39029
E-Without contacts as per ESC 10
Contact types
P-Standard contact-pin K-Contact-pin, size 20 with size 18 for crimping
S-standard contact-socket L-Contact-socket, size 20 with size 18 for crimping
Insert arrangement
Size of the housing (12, 14, 16, 18, 20, 22, 24)
Housing modification
E-Serrations along perimeter 360 on the tail part as per MS3155
F-Serrations along perimeter 360 on the tail part as per MS3155 and grounded circular spring on the cable part
Sheath type
12 - cable part 17 jack-in part, square flange for 4 screws 19 - jack-in part with clamping nut
Connector grade
R-Aluminium, chemically restored nickel plating (200 )
W-Aluminium, olive brown cadmium plating above the nickel plating (175 )
G-Stainless steel
K-Stainless steel, fire-resistant
Type of electrical connector
BT-Threaded, "O" O-ring
BJ-Threaded, static / dynamic seal (option)
EFFECTIVITY:
ALL
Page 28
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RRJ-95B
TABLE 28
N 3155
DESIGNATION OF CONNECTOR FOR CARGO COMPARTMENT LIGHTS

016
20
18(20)
Contact size code
Size
Contact type
Basic series
Standard basic No.
Crimping of the contacts is performed by means of crimping tool 22520/1-01, head 22520/1-02,
wiring tool 81969/1. Maximum length of removed insulation is not more than 4.5 mm.
Fig. 3 Termination of wires in EN3155- series connectors

Termination of the cable 100613-24 (KVSFM-75) in the RF connector SR-75-425FV (DK621):
The cable cores are tinned prior to soldering with use of heat gun. Soldering is performed with
use of tin 02 or VPr9 soldering alloy
The cable is spliced in accordance with sizes specified (Fig.4):
Fig. 4 Splicing of cable 100613-24 (KVSFM-75)
EFFECTIVITY:
ALL
Page 29
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RRJ-95B
RF-connector is disassembled and is fitted in the cable of the part 10, 9, 8, 7, 6, 5 of connector
(Fig.5):
2
Insulator
3
Sleeve
6
Bushing
4
Contact
8
End fitting
5
Insulator
9
Bushing
7
Insulator
10
Nut
Fig. 5 Disassembly of RF-connector

The tip (8) is inserted in the insulator (7) on the braiding, till the braiding is aflush with edge of
the tip cone (Fig.6):
Contact
Bushing
Fig. 6 Fitting of RF-connector detachable parts on the cable

The white wire is bent at an angle, the blue wire is placed in the cable center.
Bushing (6) is fitted through the central hole on the central core, till it bears against the insulator
(7), and the white wire is passed out through one of the side sockets of the bushing (6).
Contact (4) is fitted in the blue wire central core, till it bears against the bushing (6), and is
soldered through the side hole of the contact tail. Insulator is fitted on the contacts, till it bears
against the bushing (6).
Insulator (5) is fitted in the contact sleeve (3) until stop, cores of the white wire are passed out
through the side slot of the sleeve (3) (sockets of the sleeve (3) are aligned with sockets of the
bushing (6).
Insulator (2) is fitted on the contact sleeve (3), till it bears against the insulator (5), then the
whole assembly is fitted in the housing (1) of the connector (Fig.7).
EFFECTIVITY:
ALL
Page 30
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RRJ-95B

Housing 1
Fig. 7 Final cable termination in the RF-connector

Bushing (9), nut (10) are fitted on the conical portion of the cable braiding tip (8), and the nut (10)
is connected to the housing (1). The nut (10) is tightened by the wire with tightening torque not
more than 5 kgf cm (-10%). Tube RNF-3000, DR25, AW175, 505 mm long is fitted on the
housing of connector and on the cable.
TABLE 29
DESIGNATION OF EN2997 SERIES CONNECTORS
EN2997 KE 0 12 12 M N
No designation - is delivered with contacts

L is delivered without contacts or with specified special contacts
Key position: N normal;
6,7,8,9,Y - angular
M - pin,
F socket
Diagram of insert arrangement 3 (5,6,7,8,10,12,14,15,16,19,24,30,31,39,41,55,61)
Size of the housing 08 (10,12,14,16,18,20,22,24)
Type of the housing
0 - Jack-in part, flange for 4 screws, with seal, crimping contacts,
1 - Jack-in part, flange for 4 screws, sealed, soldered contacts
6 - Cable part, crimping contacts
7 - Jack-in part, flange for nut, with seal
Grade of electrical connector
Standard temperature
RS-Similar to grade R, additionally - grounding circular spring on the cable part
WS-Similar to grade W, additionally - grounding circular spring on the cable part
K-Stainless steel, fire-resistant (200 )
S-Similar to grade K, additionally - grounding circular spring on the cable part
Y-Stainless steel, sealed, contacts for soldering, (200 )
High temperature (260 )
KE-Stainless steel, fire-resistant
SE-Similar to class KE, additionally - grounding circular spring
YE-Stainless steel, sealed, contacts for soldering
Basic military specification
EFFECTIVITY:
ALL
Page 31
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TABLE 30
DESIGNATION OF SERIES 983 CONNECTORS AS PER DEUTSCH
9 83 0 K 12 12 P N -X
L is delivered without contacts or with specified special contacts
Key position: N normal;
6,7,8,9,Y - angular
P - pin, S socket
Diagram of insert arrangement 3 (4,5,6,7,8,10,12,14,15,16,19,24,30,31,39,41,55)
Size of the housing 08 (10,12,14,16,18,20,22,24)
KE-Stainless steel, fire-resistant
SE-Similar to grade KE, additionally - grounding circular spring
Type of the housing
1 - Jack-in part, flange for 4 screws, sealed, soldered contacts
6 - Cable part, crimping contacts
7 - Jack-in part, flange for nut, with seal
Basic series
Manufacturer
TABLE 31
DESIGNATION OF SERIES 8533 CONNECTORS AS PER SOURIAU
8533 0 E S 12 12 P N L
Are delivered without contacts or with specified contacts
Key position, N normal;
6,7,8,9,Y - angular
P - pin, S socket
Diagram of insert arrangement 3 (4,5,6,7,8,10,12,14,15,16,19,24,30,31,39,41,55,61)
Size of the housing 08 (10,12,14,16,18,20,22,24,26,28)
Designation for locking system (with serrations arranged along the circumference 3600)
A-Aluminium, black anodizing (200 )
E-Stainless steel, fire-resistant
S-Similar to grade E, additionally - grounding circular spring
Type of the housing
3 - Jack-in part, with electromagnetic protection, with self-locking
4 Plug with self-locking
7 Outlet with lock nut
Basic series
EFFECTIVITY:
ALL
Page 32
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0(7)
8DB
TABLE 32
DESIGNATION OF FEEDTHROUGH CONNECTORS 8DB AS PER MIL-DTL38999, SERIES III
1
W 35 PS N
5
... - Specification
Polarization: N-normal position of the key. ---D- angular position of the key
Contact type: PS-pins-sockets, - pins-pins.
Diagram of insert arrangement: Ref. Fig. 2
Material and coating of the housing: Aluminium: W-Olive cadmium, F-Nickel, Z-Green zinc-cobalt, L-Black zincnickel
Stainless steel: K-Passivation.
Titanium: -Without coating, TF-Nickel
Bronze:
Size of the housing: 09-11-13-15-17-21-23-25
Contact type:
Only pilot and power ones #22D, #20, #16, #12, #10, #8. Connectors with coaxial, quadrax, twinaxial contacts are
ordered individually.
Type of attachment:
0 flange for 4 screws,
7 - lock nut
Basic series
6.50.5
AWG 20-18-16
6.50.5
AWG 24-22
12-13
Fig. 8 Standard splicing of wires
Contacts 472 (sockets), 47N2 (pins) of size (#16) are crimped by the crimping
tool 22520/1-01, head 22520/1-02. Wiring tool P/N: 81969/17-04, MS24256R16. Plugs P/N:
MS27488-16-3.
Fig. 9 Termination of wires in connectors of AMC (5162) series
EFFECTIVITY:
ALL
Page 33
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TABLE 33
DESIGNATION OF CABLE CLAMPS FOR CONNECTORS OF THE SERIES

83723, MS 3470, 8526 AS PER MIL-C-26482G, SERIES II
85049/
31(
51-52,
24,
82)
-S
-10
-W(P)
-N,
A,
Steel, passivated
Al-anodized black clamp
Nickel-plated
Cadmium-plated
Standard size of housing 08 (10,12,14,16,18,20,22,24,28)
With/without self-locking no index
Clamp for common screen with self-locking without index S
82 straight
83 angular 45
84 angular 90
Angular clamp 90
Lightweight clamp
51 angular 90, 55G(S)
52 straight
Clamping nut
Basic number
TABLE 34
852-
DESIGNATION OF THE CABLE CLAMPS FOR CONNECTORS OF THE SERIES

8533, MS 3440, 8526 AS PER SPECIFICATION MIL-C-26482G, SERIES II
31(
52-
51)-
N,
W,
A-
08
Size of the housing 10 (12,14,16,18,20,22,24)
Black anodizing Al
Cadmium-plated
Nickel-plated
Angular clamp - 90
Straight clamp
Clamping nut
Main series (Al)
8527-
01(02)-
14
Suffix only for clamp type 02
Size of the housing 08(10,12,14,16,18,20,22,24)

01 clamping nut,
02 straight cable clamp
Main series made (stainless steel)
TABLE 35
Contact
size
Plugs and thermocouple contacts for connectors 8533

Designation
MIL
Designation
FCI Souriau
Colour
Contact
size
Contact
type
Contact
designation
8522-875
8522-877
8522-876
8522-878
20
MS27488-20
8522-389 A
Red
#20 Cr
Pin
socket
16
MS27488-16
8522-390 A
Blue
#20 Al
Pin
socket
12
MS27488-12
8522-391 A
Yellow
EFFECTIVITY:
ALL
Colour
Brown, orange,
green
Brown, yellow,
green
Brown, orange,
yellow Brown,
yellow, black
Page 34
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TABLE 36
DESIGNATION OF POWER CONNECTORS OF 8533-ABS SERIES
Basic series
8533
0
R S 24 04 P N
0: Outlet with rectangular flange
Type of the
3: Plug with protection against RF interferences
housing:
7: Outlet with lock nut
Housing material and coating:
Aluminium
W: Olive green cadmium-plated
R: Nickel 200
175
A: Black anodized
Stainless steel
K: Corrosion-resistant 200
E: Nickel 260
Titanium
TF: Nickel
TT: without coating 260
200
Sealed
Y: Size of the housing only 20-04 and 24-03, index
112
S: with serrations located along the circumference 360
Size of the housing: 18-20-24-28
Contact diagram Ref. Fig. 10
Contact type: P: Pin S: Socket
Polarization: N 6 7 8 9 Y
Indexes:
109: with contacts #4 for cable #6 + protective caps (diagram 24-04)
112: with contacts #6 for cables #6-8 for soldering without casing (diagram 20-04, 24-03) - sealed
115: with contacts #4 for cable #8 + protective caps (diagram 24-04)
121: with contacts #6 for cable #10/12 + protective caps (diagram 18-02, 20-04, 28-06)
125: with quadrax contacts + protective caps (diagram 18-02, 20-04, 28-06)
126: with casing, without contacts + protective caps (diagram 18-02, 20-04, 24-04, 28-06)
136: with contacts #6 for cable #6 + protective caps (diagram 18-02, 20-04, 28-06)
138: with contacts #6 for cable #8 + protective caps (diagram 18-02, 20-04, 28-06)
L: without contacts + protective caps
The connectors comply with specification EN 2997-ESC10 for power transmission lines and have
threaded joint; multilevel cable protection protective caps ABS 1340-1343, 1426-1427; cables of
different diameters are used for each connector; provide high resistance to impact of aggressive
fluids (fuel, oil etc.); a lightweight modification in titanium housing is provided.
Fig. 10 Contact diagram

NOTE: Fitting of the quadrax contacts is possible. Maximum current on the contact of size #4 80A; of size #6 -60A
EFFECTIVITY:
ALL
Page 35
20-40-10
Sep 30/11
RRJ-95B
ABS - cross references (Ref. Table 37):

TABLE 37
ABS - CROSS REFERENCES
Steel housing
Aluminium housing
Plug
SOURIAU Reference
8533 3RS2004PNL
8533 3RS2004PN126
8533 3RS2004PNL
8533 3RS2004PN126
8533 3RS2404PNL
8533 3RS2404PN126
8533 3RS2404PNL
8533 3RS2404PN126
8533 3RS2806PNL
8533 3RS2806PN126
8533 3RS2806PNL
8533 3RS2806PN126
8533 3ES2004PNL
8533 3ES2004PN126
8533 3ES2004PNL
8533 3ES2004PN126
8533 3ES2806PNL
8533 3ES2806PN126
8533 3ES2806PNL
8533 3ES2806PN126
Outlet type 0
ABS Reference
ABS1343 C-2004 NF
ABS1343 P-2004 NF
ABS1343 D-2004 NF
ABS1343 S-2004 NF
ABS1343 C-2404 NF
ABS1343 P-2404 NF
ABS1343 D-2404 NF
ABS1343 S-2404 NF
ABS1343 C-2806 NF
ABS1343 P-2806 NF
ABS1343 D-2806 NF
ABS1343 S-2806 NF
ABS1340 C-2004 NF
ABS1340 P-2004 NF
ABS1340 D-2004 NF
ABS1340 S-2004 NF
ABS1340 C-2806 NF
ABS1340 P-2806 NF
ABS1340 D-2806 NF
ABS1340 S-2806 NF
SOURIAU Reference
8533 3RS2004PNL
8533 3RS2004PN126
8533 3RS2004PNL
8533 3RS2004PN126
8533 3RS2404PNL
8533 3RS2404PN126
8533 3RS2404PNL
8533 3RS2404PN126
8533 3RS2806PNL
8533 3RS2806PN126
8533 3RS2806PNL
8533 3RS2806PN126
8533 3ES2004PNL
8533 3ES2004PN126
8533 3ES2004PNL
8533 3ES2004PN126
8533 3ES2806PNL
8533 3ES2806PN126
8533 3ES2806PNL
8533 3ES2806PN126
ABS Reference
ABS1343 C-2004 NF
ABS1343 P-2004 NF
ABS1343 D-2004 NF
ABS1343 S-2004 NF
ABS1343 C-2404 NF
ABS1343 P-2404 NF
ABS1343 D-2404 NF
ABS1343 S-2404 NF
ABS1343 C-2806 NF
ABS1343 P-2806 NF
ABS1343 D-2806 NF
ABS1343 S-2806 NF
ABS1340 C-2004 NF
ABS1340 P-2004 NF
ABS1340 D-2004 NF
ABS1340 S-2004 NF
ABS1340 C-2806 NF
ABS1340 P-2806 NF
ABS1340 D-2806 NF
ABS1340 S-2806 NF
Cable plug with contact-pins, with casing (Fig.11):
Casing
Sealant
Insulator
Plug housing
Protective caps
Pin contacts
Front sealant
Fig. 11 Cable plug assembly

Set outlet with contact-sockets, with casing (Fig.12).
EFFECTIVITY:
ALL
Page 36
20-40-10
Sep 30/11
RRJ-95B

Casing
Sealant
Outlet housing
Protective caps
Socket contacts
Insulator
Fig. 12 Set outlet assembly

Dimensions of the plug, type 3 ABS 1340-1343 (Fig. 13) are given in the Table 38:
Fig. 13 Plug, type 3 ABS 1340-1343

TABLE 38
PLUG DIMENSIONS
Size of the housing (mm)

A max
B (inch)
C max
20
41.91
1-3/16 18
UNEF 2A
34.50
24
47.24
1-7/16 18
UNEF 2A
34.50
28
52.00
1-3/4 18
UNEF 2A
34.50
Sizes of the outlet, type 0 ABS 1426-1427 (Fig. 14) are specified in the Table 39.
Fig. 14 Outlet, type 0 ABS 1426-1427
EFFECTIVITY:
ALL
Page 37
20-40-10
Sep 30/11
RRJ-95B
TABLE 39
OUTLET DIMENSIONS
Size of the housing

(mm)
A max
B max
C max
D max
E max
F max
G
H max
20
24
28
33.32
18.35
1.45
30.12
36.00
36.63
29.36
3.10
39,67
18.35
1.45
36.47
36.00
43.88
34.92
3.90
45.99
18.35
1.45
44.41
36.00
50.83
39.67
3.90
Dimensions of the outlet, type 7 (Fig.15) are given in the Table 40:
Fig. 15 Outlet, type 7

TABLE 40
OUTLET DIMENSIONS
Size of the housing (mm)

A max
B max
C max
D max
E max
F max
G max
20
33.32
19.84
3.18
1.57
36.00
49.63
44.86
24
39.67
19.84
3.18
1.57
36.00
55.42
52.81
EFFECTIVITY:
ALL
Page 38
20-40-10
Sep 30/11
RRJ-95B
Sealed outlet, type 7, housing size 20 (Fig.16):

Performance data
Mechanical
- Housing: Stainless steel.
- Coating: passivated.
- Sealant: silicone
elastomer.
- Insulator: Glass.
Electrical
- Max operating current: 46.
Climatic
- Operating temperature :
-65 +200 .
- Pressurization: 1.10-9.
- Contacts: Gold-plated
steel.
- Sea fog: 48 h.
Fig. 16 Performance data of the sealed outlet, type 7, housing size 20

Designation 8533 7Y 20-04 PN 112 (Fig.17):
Fig. 17 Dimensional characteristics

Sealed outlet, type 7, housing size 24 (Fig.18):
Performance data
Mechanical
- Insulator: Glass.
Electrical
- Max operating current: 46
.
Climatic
- Operating temperature :
-65 +200 .
- Pressurization: 1.10-9.
- Contacts: Gold-plated steel.
- Sea fog: 48 h.
- Housing: Stainless steel.

- Coating: Passivated.
- Sealant: silicone elastomer.
Fig. 18 Performance data of sealed outlet, type 7, housing size 24
EFFECTIVITY:
ALL
Page 39
20-40-10
Sep 30/11
RRJ-95B
Designation 8533 7Y 24-03 PN 112 (Fig. 19):
Fig. 19 Dimensional characteristics

A clearance 82 mm is recommended between the contact end and cut of the wire insulation to
provide insulation, protection and unloading of the soldered joints. A tube DR25 (K, RW-175)
455 mm long with applied marking must be shrunk on the contact - wire soldering place. The
harness must be attached at 15050 mm from the connector by means of 28001 clamp or by a
plastic clamp, Ref. harness drawing, Section 91 of the WDM.
When AWG-6 wire is terminated in the contact of connector, it is permitted to unwind up to 5 - 7
wires from the upper layer of the core, wind them twice around the core and cut the wire excesses.
Tin the wire core and solder in the contact.
Straight casing ABS 1452 (Fig.20).
EFFECTIVITY:
ALL
Page 40
20-40-10
Sep 30/11
RRJ-95B
Fig. 20 STRAIGHT CASING ABS 1452

TABLE 41
PERFORMANCE DATA OF STRAIGHT CASING ABS 1452
Diagram of
Souriau
contacts
20-04
8533
Alumel
8250
20-04
8533
Steel
8281
24-04
8533
Alumel
8223
24-04
Steel
L1
L2
Max
0.05
1.20
0.12
30.12
24.1
0.05
0.1
Quantity of
holes
Thread
type 2
Weight
(g)
41.87 38.28 33.21
1.1875-18
UNEF
73
1.7/16/18
UNEF
95
1.750018UNS
116
ABS 1452 A 2004

22.94 27.72
ABS 1452 C 2004
ABS 1452 A 2404

29.8
33.71
38
31.2
48.8
46.28
45
34.74
39.7
44.4
37.7
41.78 38.28 47.49
Consult
ABS 1452 C 2404
us
28-06
8533
Alumel
8245
28-06
85338288
Steel
ABS
ABS 1452 A 2806
ABS 1452 C 2806
Main series. Sealed connectors (Ref. Table 42):

TABLE 42
IDENTIFICATION OF SEALED CONNECTORS

8533
-1
14
-15
Type of electrical connector

Type of the housing
2 jack-in part, with rectangular flange
7- cable part, self-locking and with protection against RF interferences
Material and coating of the base part:
Y stainless steel, sealed design;
YE - stainless steel, sealed design.
Standard size of housing
08, 10, 12, 14, 16, 18, 20, 22, 24
Insert arrangement, Ref. Subject 29
P - pin; S socket.
Key position N,6,7,8,9,Y
EFFECTIVITY:
ALL
Page 41
20-40-10
Sep 30/11
RRJ-95B
Contacts (Fig.21):
Socket contact ABS 1344
Pin contact ABS 1403
Fig. 21 Socket and pin type contacts

TABLE 43
PERFORMANCE DATA OF THE CONTACTS
Size
Type
Designation
Souriau
Pin
8533-8202
Pin
8533-8201
Socket
8533-8171
Socket
8533-8120
Pin
8533-8246
Pin
8533-8272
Pin
8533-8248
Socket
8533-8247
Socket
8533-8273
Socket
8533-8249
Designation
ABS
ABS 1403
104KZ06
ABS 1403
104KZ04
ABS 1344
104KZ06
ABS 1344
104KZ04
ABS 1403
1K6LZ06
ABS 1403
1K6LZ08
ABS 1403
1K6LZ10
Cable
Section
2
(mm )
AWG
Material
9 and 14
8 and
6
Copper
14.55
5.74
22
Copper
14.55
5.74
9 and 14
8 and
6
Copper
11.15
9.6
22
Copper
11.15
9.6
14
Copper
13.7
4.59
Copper
13.7
4.59
5 and 3
10
and
12
Copper
13.7
4.59
14
Copper
15.3
7.33
Copper
15.3
7.33
5 and 3
10
and
12
Copper
15.3
7.33
ABS 1344
1K6LZ06
ABS 1344
1K6LZ08
ABS 1344
1K6LZ10
Dimensions
L
D
Max
Max
Protective caps ABS 0992 (Ref. Table 44):
Designation ABS
Grade 200
#6
Copper
8533-8296
ABS0992- 03
#6
Copper
8533-8236
ABS0992- 05
#6
10 and 12
Copper
8533-8287
ABS0992- 02
85338308
85338307
85338306
Designation ABS
Grade 260
AWG
cable
Designation
SOURIAU Grade
260
Contacts
Designation
SOURIAU Grade
200
PERFORMANCE DATA OF PROTECTIVE CAPS

Cable material
TABLE 44
Consult us
Consult us
Consult us
EFFECTIVITY:
ALL
3.30
4.83
3.30
4.83
3.30
4.83
13
max
13
max
13
max
Page 42
20-40-10
Sep 30/11
Designation ABS
Grade 200
#6
Copper
85338236
ABS0992-
01
#4
Copper
85994591
ABS099204
Consult us
#4
Copper
85338163
ABS099205
Consult us
Consult us
#4
Copper
85338163
ABS099205
Consult us
Consult us
#4
10 and 12
Copper
85338262
Consult us
Consult us
Designation ABS
Grade 260
AWG
cable
Designation
SOURIAU Grade
200
Designation
SOURIAU Grade
260
Contacts
Cable material
Quadraxial
ABS0973/0974
RRJ-95B
3.30
4.83
13 max
3.30
4.83
3.30
4.83
3.30
4.83
3.30
4.83
Consult us
23 0.005
23 0.005
23 0.005
23 0.005
#4
Blue PTFE
Plugs
85338253
ASNE0616B
C0400
ASNE0616B
B0400
Consult us
Consult us
3.30
4.83
23 0.005
3.30
4.83
13 max
3.30
4.83
13 max
Protective caps ABS 0992 (Ref. Table 45):
Designation
SOURIAU
Grade 200
Designation ABS
Grade 200
Designation SOURIAU
Grade 260
#6
Copper
8533-8296
8533-8308
#6
Copper
8533-8236
8533-8307
EFFECTIVITY:
ALL
Designation ABS
Grade 260
Cable
material
Consult us
AWG cable
Consult us
Contacts
ABS0992- 03
CHARACTERISTICS OF PROTECTIVE CAPS S 0992
ABS0992- 05
TABLE 45
Page 43
20-40-10
Sep 30/11
Copper
8533-8236
ABS0992- 01
#4
Copper
8599-4591
ABS099204
#4
Copper
8533-8163
#4
Copper
8533-8163
#4
10 and 12
Copper
8533-8262
Consult us
Consult us
Designation ABS
Grade 260
Quadraxial
ABS0973/0974
Consult us
ABS0992- 02
#6
Consult us
8533-8287
Consult us
Copper
Consult us
10 and 12
Consult us
#6
Designation
SOURIAU Grade
260
Designation
SOURIAU
Grade 200
8533-8306
Cable
material
Consult us
AWG cable
Consult us
Contacts
ABS099205
Designation ABS
Grade 200
ABS099205
RRJ-95B
3.30
4.83
13 max
3.30
4.83
13 max
3.30
4.83
23 0.005
3.30
4.83
23 0.005
3.30
4.83
23 0.005
3.30
4.83
23 0.005
3.30
4.83
23 0.005
Blue PTFE
8533-8253
Consult us
Consult us
#4
ASNE0616BC0400
ASNE0616BB0400
Plugs
EFFECTIVITY:
ALL
Page 44
20-40-10
Sep 30/11
RRJ-95B
Tools (Ref. Table 46):
SOCKET
85338171
SOCKET
85338120
PIN
85338246
PIN
85338272
PIN
8201
85338248
85338247
85338273
85338249
(mm2)
AWG
Extruder
9 and 14
8 and 6
Copper
22520/23-01
22520/23-02
22
Copper
22520/23-01
22520/23-04
8 and 14
8 and 6
Copper
22520/23-01
22520/23-02
22
Copper
22520/23-01
22520/23-04
14
Copper
22520/23-01
22520/23-03
8533-8193
Copper
22520/23-01
22520/23-02
8533-8193
5 and 3
10 and 12
Copper
22520/23-01
WA23-112DA
8533-8193
14
Copper
22520/23-01
22520/23-03
8533-8193
Copper
22520/23-01
22520/23-02
8533-8193
5 and 3
10 and 12
Copper
22520/23-01
WA23-112DA
8533-8193
EFFECTIVITY:
ALL
Retainer for protective caps
Wire section
Cable material
Contact type
Contact designation
8533-
SOCKET
8202
SOCKET
8533-
SOCKET
PIN
PIN
Contact size
Cable
Set
Crimping
TOOL SELECTION
Pneumatic
TABLE 46
8533-8193
8533-8141
8533-8193
8533-8193
8533-8141
8533-8193
Page 45
20-40-10
Sep 30/11
RRJ-95B
Set ( 22520/23-02)
Crimping tool ( 22520/23-01)
Retainer ( 22520/2311)
Fig. 22 Pneumatic tools

Extruders (Fig.23):
Contact
size
06
Material
Plastic
Metal
04
Plastic
Metal
Designation
M 811969/1406 (red)
860-197
M 811969/1406 (blue)
8533-8175
Fig. 23 Extruders and their characteristics

Diagram of insert arrangement in connectors of the main series 8533 (Fig.24).
EFFECTIVITY:
ALL
Page 46
20-40-10
Sep 30/11
RRJ-95B
Fig. 24 Diagram of insert arrangement in connectors of the main series 8533

Connectors of SNTs 147 type TsSNK.430421.011 U are interchangeable and intermateable with
connector of the series 8533 and 983
Numbers of contacts, gauges of the connected wires, crimping and wiring tools must be selected
EFFECTIVITY:
ALL
Page 47
20-40-10
Sep 30/11
ALL
socket
brown
green
12
pin
brown
orange
brown
yellow
Contact marking
colour
M81969/14-03
M81969/14-02
G 125
M22520/3-1
DRK83-16B
(M81969/8-208)
DRK83-20B
(M81969/8-206)
EFFECTIVITY:
20-40-10
Tool test gauge
Plastic blanking
caps
DMC (MIL)
removal
DMC (MIL)
fitting
Positioner
DMC (MIL)
brown
white
TH1A
(M22520/1-02)
brown
Crimping tool
DMC (MIL)
brown
blue
Contact type
Contact size
AF8
(M22520/1-01)
brown
red
DAK83-16B
(M81969/8-207)
brown
purple
DAK83-20B
(M81969/8-205)
brown
black
pin
20
socket
20
pin
16
socket
16
pin
M39029/4112
Contact
code
MIL
socket
M39029/5116
16
M39029/5117
AWG gauge, wire

diameter
min max
Designation
TABLE 47
pin
M39029/4114
M39029/5119
M39029/4111
16
M39029/4110
20,18,16
1.20-2.77
16
M39029/5115
24,22,20
0.85-2.10
16
M39029/4113
14,12
1.93-4.01
M83723/XX X XX XX
983-XX XXX X
8533-X X X XX-XX
RRJ-95B
SELECTION OF CONTACTS, GAUGES OF CONNECTED WIRES AND TOOLS

Wiring tool
Page 48
Sep 30/11
ALL
M39029/4110
20
pin
brown
black
20
socket
brown
green
M81969/
14-02
G 125
M22520/3-1
M81969/14-03
EFFECTIVITY:
20-40-10
Tool test gauge
DMC (MIL)
removal
DMC (MIL) fitting
Positioner
DMC (MIL)
Crimping tool
DMC (MIL)
Wiring tool
M81969/1404
DRK83-12B
(M81969/8210)
DRK83-16B
(M81969/8208)
DRK83-20B
(M81969/8-206)
brown
white
DAK83-12B
(M81969/8209)
brown
DAK83-16B
(M81969/8-207)
TH1A
(M22520/1-02)
AF8
(M22520/1-01)
brown
blue
16
brown
red
Contact type
brown
grey
socket
brown
yellow
16
pin
socket
M39029/4111
16
M39029/5116
pin
M39029/5119
16
socket
M39029/4114
16
pin
AWG gauge, wire

diameter
min max
Contact size
M39029/5118
12
M39029/4112
20,18,16
1.20-2.77
Designation
Contact
code
MIL
DAK83-20B
(M81969/8-205)
brown
purple
socket
M39029/5117
16
M39029/5115
24,22,20
0.85-2.10
8525-XX X XX XX X
MS347X X XX XX
RRJ-95B
Page 49
Sep 30/11
ALL
M39029/31-240
20
red
yellow
black
M39029/31-259
20

DRK16B
(M81969/19-01)
M81969/14-03
DRK20B
(M81969/19-06)
M81969/14-02
EFFECTIVITY:
20-40-10
M81969/14-04
DRK12B
(M81969/19-02)
DMC (MIL) fitting
Tool test gauge
Plastic blanking
caps
DMC (MIL)
removal
G 125
M22520/3-1
DAK16B
(M81969/17-04)
Positioner
DMC (MIL)
Contact marking
colour
TH1A
(M22520/1-02)
red
orange
yellow
Crimping tool
DMC (MIL)
red
green
orange
AF8
(M22520/1-01)
red
grey
DAK20B
(M81969/17-03)
red
yellow
purple
DAK12B
(M81969/17-05)
16
Contact type
M39029/31-247
pin
16
socket
M39029/31-228
pin
12
socket
M39029/31-253
red
green
white
AWG gauge, wire

diameter
min max
12
pin
14-12
1.93-4.01
M39029/31-234
socket
20,18,16
1.2-2.77
Designation
Contact code
MIL
Contact size
24,22,20
0.85-2.1
851-XX X XX XX X
RRJ-95B
Wiring tool
Page 50
Sep 30/11
ALL
AWG gauge, wire
diameter
min max
20
M39029/29213
12
M39029/30219
12
M39029/29212
16
TH1A
(M22520/1-02)
DAK83-12B
(M81969/8-209)
DRK83-12B
(M81969/8-210)
M81969/14-04
TH1A
(M22520/102)
DAK83-16B
(M81969/8207)
DRK83-16B
(M81969/8208)
M81969/1403
red
yellow
brown

red
white
EFFECTIVITY:
20-40-10
M81969/14-03
DRK16B
(M81969/19-01)
DAK16B
(M81969/17-04)
TH1A
(M22520/1-02)
AF8
(M22520/1-01)
red
yellow
grey
red
orange
green
DRK12B
(M81969/19-02)
DAK12B
(M81969/17-05)
red
green
yellow
DMC (MIL) fitting
Positioner
DMC (MIL)
Crimping tool DMC

(MIL)
Tool test gauge
DMC (MIL)
removal
M81969/14-02
DRK20B
(M81969/19-06)
DAK20B
(M81969/17-03)
red
blue
black
Wiring tool
G 125
M22520/3-1
AF8
(M22520/1-01)
AF8
(M22520/101)
red
brown
orange
Contact type
M39029/32260
pin
20
socket
M39029/31241
pin
16
socket
M39029/32248
pin
16
socket
M39029/31229
pin
12
red
brown
white
14,12
1.93-4.01
M39029/32254
red
brown
red
20,18,16
1.2-2.77
Designation
12
socket
24,22,20
0.85-2.1
MS242X X XX-XX
M39029/31235
pin
14-12
1.93-4.01
MS34XX X XX XX
Contact
code
MIL
Contact size
16,18,20
1.34-2.62
891-XX X-XX-XX X
RRJ-95B
Page 51
Sep 30/11
ALL
22520/206
22520/706
DRK250-0
(M81969/1408)
red
black
red
brown
green

not used
DRK250-4
(M81969/1407)
not used
Crimping tool
DMC (MIL)
Positioner
DMC (MIL)
DMC (MIL) fitting
red
brown
grey
AF8
(M22520/1-01)
TH1A
(M22520/1-02)
DAK83-16B
(M81969/8-207)
red
brown
yellow
DRK250-8
(M81969/1406)
M81969/14-03
EFFECTIVITY:
20-40-10
Tool test gauge
Contact type
socket
pin
DMC (MIL)
removal
DRK83-16B
(M81969/8-208)
Contact size
WA23-9
and
WA23-2
socket
pin
WA23-11
and
WA23-4
Contact code
MIL
M39029/30-218
M39029/29214
8
81969/1-04
81969/14-01
22520/2091
22520/7071
red
brown
red
brown
blue
M39029/30220
M39029/29215
4
WA23 (POS)
socket
0
pin
AWG gauge, wire

diameter
min max
16,18,20
1.34-2.62
Designation
16
8-10
3.35-6.48
MS34XX X XX XX
22520/2-01
22520/7-01
red
orange
green
yellow
orange
blue
black
M39029/30221
M39029/29216
4-6
6.01-9.40
891-XX X-XX-XX X
WA23-13
and
WA23-5
M39029/30222
2-0
9.14-13.97
socket
22D
socket
M39029/57354
0
pin
M39029/58360
26,24,22
0.71-1.37
1900NDXXXXXXX
RRJ-95B
Wiring tool
G693
G695
G696
001109 190 38
G125
M22520/3-1
green
G145
Page 52
Sep 30/11
ALL
EFFECTIVITY:
20-40-10

G856
G125
M22520/3-1
001109 400
41
81969/14-04
81969/14-05
81969/8-12
yellow
81969/14-04
81969/14-05
81969/8-11
22520/1-04
G145
blue
G125
M22520/3-1
001109 300
40
81969/14-03
81969/14-03
22520/7-04
orange
blue
grey
red
G 125
M22520/3-1
001109 210
42
81969/39-01
81969/39-01
22520/2-08
22520/2-01
orange
blue
white
DMC (MIL)
fitting
Positioner
DMC (MIL)
Crimping tool
DMC (MIL)
Tool test gauge
DMC (MIL)
removal
001109 600
41
22520/1-04
414DA-10N
WA23-102L
WA23-101DA
986
orange
green
grey
22520/1-01
22520/7-02
orange
blue
yellow
Contact type
Wiring tool
green
22520/1-01
22520/23-01
WA 23
300
orange
green
white
green
red
orange
blue
green
orange
white
10
socket
socket
M39029/58528
pin
10
socket
12
pin
12
socket
16
pin
Contact size
AWG gauge, wire

diameter
min max
Contact
code
MIL
pin
M39029/63368
M39029/64369
M39029/57358
M39029/58364
24,22,20
0.85-1.73
16
M39029/57369
20,18,16
1.31-2.40
20
M39029/58365
14,12
1.93-3.70
20
M39029/57527
12-10
2.41-5.20
Designation
RRJ-95B
Page 53
Sep 30/11
RRJ-95B
Connectors of the series JT, JMS 27473/ JMS 27484 produced by Amphenol comply with military
specification MIL-DTL-38999, series II.
These are electrical connectors, subminiature, circular, bayonet type, multiposition, with improved
sealing of each contact outer surface, standard and sealed, with gold-plated removable contacts
connected to the wires by crimping, as well as with contacts for soldering, are intended for
operation in the electrical circuits of 900 V AC, 1250 V DC at sea level within temperature range
from -65 to +175 for cadmium-plated aluminium housings; from -65 to +200 for nickelplated aluminium and steel housings. Breakdown voltage at sea level is 2300 V.
Standard sizes of the section (gauges), outer diameter of connected wires, length of stripped
insulation are specified in the Table 48:
22 24 26
0.76-1.37
0.38 0.22 0.15
3.2+0.8
k42
RED
20
1.0
20 22 24
1.02-2.11
0.60 0.38 0.22
4.8+0.8
KIS
RED
M22520/1-02
16
1.57
16 18 20
1.34 0.93 0.6
1.68-2.77
5.3+0.8
M22520/1-02
TH 1A
BLUE
12
2.36
12 14
3.3 1.94
2.46-3.61
5.3+0.8
M22520/1-02
YELLOW
TH 163
1,2,3
M22520/2DAK95-22B
01
DRK95-22B
AFM 8
M15570-20
2,3,4
DAK95-22B
M22520/1- DRK95-22B
01
M15570-16
M22520/2- DAK95-16B
4,5,6
01
DRK95AFM 8
16B12
AF 8
M15570-12
7,8
DAK95-12B
DRK95-12B
EFFECTIVITY:
ALL
Wiring tool
0.76
Wire
diameter
(mm)
(min-max)
Crimping tool
22D
Contact
standard size
Position of
positioner,
head type
Contact tail
Gauge, section
inner diameter
(mm)
(mm)
Position of
selector
STANDARD SIZES OF CONNECTORS AND WIRES, TOOL SELECTION

Stripping length
(mm)
TABLE 48
Page 54
20-40-10
Sep 30/11
RRJ-95B
Designation of electrical connectors of the series JT, JMS as per MIL-DTL-38999 (Ref.
Table 49):
TABLE 49
JT
06
R
T
12
DESIGNATION OF ELECTRICAL CONNECTORS OF THE SERIES JT, JMS AS

PER MIL-DTL-38999
35 S
(P)
014
Coating of the housing cadmium
plating
023 coating of the housing - nickel
plating
Contact type plug (pins)

Contact type outlet (sockets)
Conventional number of the contact set combination
Standard size of housing 8(10,12,14,16,18,20,22,24)
Jack-in part with flange, thread, without cable clamp
RE jack-in part with flange and cable clamp
02RE jack-in part without thread and cable clamp
00 outlet with flange
02 outlet with flange for installation on the unit
JMS27473T-06 cable plug without clamp; with cable clamp
JMS27473T-07 outlet, attachment by nut without clamp; with cable clamp
08 Outlets and plugs with angular (casing) clamp
Series
Designation of cable clamps for connectors of the series JT, 8, M83723 (Ref. Table 50)
TABLE 50
JT
DESIGNATION OF CABLE CLAMPS FOR CONNECTORS OF

THE SERIES JT, M83723, 8
SRD
12
014
Cadmium-plated aluminium housing
Design variant
Standard size of housing (8,10,12,14,16,18,20,22,24)
Straight clamp
Series
M85049/
51(47)
49-2
(52)
S 12
Cadmium-plated aluminium housing

N nickel-plated housing
S with self-locking; 1 without self-locking
Straight clamp
Angular clamp
Basic number
Diagram of insert arrangement in JMS, JT connectors (Fig.25).
EFFECTIVITY:
ALL
Page 55
20-40-10
Sep 30/11
RRJ-95B
Fig. 25 Diagram of insert arrangement in JMS, JT connectors

Connectors of MS series correspond to MIL-C-26482 specification, series II. These are electrical
connectors, circular, small-sized, bayonet type, sealed, with gold-plated contacts that are
connected to the wires by crimping. They are intended for operation in the electrical circuit with
maximum voltage 600 V AC and 850 V DC within the temperature range from -55 to +175
(grade W and H), from -55 to +200 (grade L).
The contacts tails provide connection of the wires by crimping or soldering. Crimping of the
contacts must be performed by means of the tool 22520/1-01 with head 22520/1-02.
Symbolic notations are assigned to the plugs and outlets (Ref. Table 51):
EFFECTIVITY:
ALL
Page 56
20-40-10
Sep 30/11
RRJ-95B
TABLE 51
MS
SYMBOLIC NOTATION OF PLUGS AND OUTLETS
3110-
3116(
TABLE 52
MS
27497
27484
27474
27473
3120-
3126)
F)
18
32
S(
P)
W(X,Y,Z)
Insert arrangement
counterclockwise
(0 normal arrangement)
Connector part plug (pins)
Connector part outlet (sockets)
2(3,4,5,6,8,10,11,12,15,16,18,19,20,23,24,
26,28,30,32,36,39,41,55,57,61)
Size of the housing with combination of the
contact set 8(10,12,14,16,18,20,22,24)
Type (grade) of connector straight casing
Type (grade) of connector sealed casing
Circular cable part
Jack-in part with flange
Circular cable part
3112 - Jack-in part with flange
3113 Sealed jack-in part for soldering
Series
DESIGNATION OF MS SERIES CONNECTORS AS PER MIL-C27599, MIL-DTL-38999

E
14.
18
S(
P)
A,B,C,D angular position of the

keys and key sockets in the
housing (is not specified for
normal position)
Conventional number of the contact set combination
Coating: A, B, 014 cadmium plating after nickel plating
F, 023,424 nickel plating (from -65 to +200 )
anodized aluminium housing
Grade:
corresponds to RE type with cable clamp,
T,RT without cable clamp, - corresponds to RP type with cable clamp
27497 jack-in part with flange,
27484 cable part,
27474 jack-in part, attachment by nut
27473 cable part
Series
Designation of MS series electrical connectors as per MIL-C-26500 (Ref. Table 54):
EFFECTIVITY:
ALL
Page 57
20-40-10
Sep 30/11
RRJ-95B
TABLE 54
MS
24266
DESIGNATION OF MS SERIES ELECTRICAL CONNECTORS AS PER

MIL-C-26500
R,
E,
W,
22
55
S(
P)
6,7,8,9
Y
Polarization key
Angular position of the key
Normal position of the key
Plug pins
Outlet sockets
Quantity of contacts 2(3,4,5,7,9,10,12,14,15,16,
19,24,27,30,31,32,39,40,42,43,55,57,61)
Connection type crimping
Standard size of housing 8,10,12,14,16,18,20,22,24
Al-chromated housing
Housing cadmium-plated
Steel passivated housing
Al-anodized housing
Cable part:
24265 jack-in part, attachment by nut
24264 - jack-in part with flange
Series
NOTE: Electrical connectors manufactured as per MIL-C-2650 specification, are replaced with MILC-83723, series III for new developments.
Code, contact number, sizes of connected wires, crimping and wiring tools for MS, ZZW
connectors are specified in the Table 55:
248
White
Crimping tool
AF8 AFM8
Gauge, section
(mm2)
20
18
Type of
positioner
Wiring tool
DAK 16
M81969/17-4
16
DRK 16
MS24256-R
-16
0.60 0.93 1.34
Designation of
blanking cap
MS Amphenol
Colour of
marking stripes
on the contact
tail
Black
32
Red
MS24255
-16S
229
Yellow
31
Red
MS24254
-16P
Red
Contact designation and

size
CHARACTERISTICS OF THE WIRES, CONTACTS AND USED TOOLS

BIN-code as per
standard
M39029/
TABLE 55
MS27488
-16
10-405996-16
241
Brown
31
Yellow
MS24254
-20P
Red
1
24
22
DAK 20
M81969/17-9
20
MS27488
-20
10-405996-20
260
MS24254
-12P
MS24255
-12S
31
32
235
254
Black
32
Blue
MS24255
-20S
Red
K.1S
DRK 20
MS24256-R
-20
0.21 0.38 0.60
12-14
3.0-1.94
22520/1
-01
M81969/17-5
MS24256-R
-12
MS27488--12
10-405996-12
Designations of the cable clamps are given in Subject 9.

Designation of Amphenol connectors as per MIL-C-26500 (Ref. Table 56):
EFFECTIVITY:
ALL
Page 58
20-40-10
Sep 30/11
RRJ-95B
TABLE 56
ZZY-
DESIGNATION OF AMPHENOL CONNECTORS AS PER MIL-C-26500

C-
10
22-
55
06
D-
N(A,B,C,D)
Polarization code
A,B,C,D angular position of the key
Coating of the contacts:
D gold radium
Number of insert arrangement
06,07,08,09,10,12,14,16,18,20,22,24,28
Contact type
P pin S socket
Insert arrangement diagram
(2,3,4,5,7,8,10,11,12,14,16,19,24,25,27,28,
30,31,32,39,40,41,42,43,55,57,61)
Standard size of housing 8,10,12,14,16,18,20,22,24,28
10-cable part
12-cable part with latch
15-jack-in part, attachment by nut
17-jack-in part with square flange
Delivery index:
No - non index, delivered with cable clamp
- with contacts, without cable clamp
D - without contacts and cable clamp
O - either without contacts or without cable clamp
Grade of the housing
- Al-anodized housing
- Al-chromated housing
R - steel passivated housing
F - Al-cadmium-plated housing
Amphenol designation:
ZZY - threaded ZZW - bayonet
EFFECTIVITY:
ALL
Page 59
20-40-10
Sep 30/11
RRJ-95B
Diagram of insert arrangement in MS, ZZW series connectors as per MIL-C-26500 (Fig.26):
Fig. 26 diagram of insert arrangement in MS, ZZW series connectors as per MIL-C-26500
Designation of cable clamps for MS, ZZW series connectors (Ref. Table 57):
TABLE 57
DESIGNATION OF CABLE CLAMPS FOR MS, ZZW SERIES CONNECTORS
ZZL-MZZL-R-
5308(5310-5312-5314-5316-5318-5320-5322-5324)
5308-A(5310-A,5312-A,5314-A,5316-A,5318-A,5320-A,5322-A,5324-A)
Size of the housing
Amphenol designation
- Al-chromated clamp
R - Al-anodized clamp
MS2729113(1-2-3-4-5-14-6-15)
Straight anodized cable clamp
13 - for size 08 1 - for size 10
2 - for size 12
3 - for size 14
4 - for size 16
5 - for size 18
14 - for size 20 6 - for size 22
15 - for size 24
Designation of MS series
Straight chromated cable clamp
701 - for size 08
101 - for size 10
201 - for size 12
301 - for size 14
401 - for size 16
501 - for size 18
801 - for size 20
601 - for size 22
901 - for size 24
Connectors of MIL-C-26500-48 specification are intended for connection of the special-purpose
wires.
The cable connectors are small-sized and have a wide scope of application. The connection is
performed by pushing, the disconnection - by screwing-out.
The connector consists of the retaining metal collet lock, seal bushing, standards pins 39029/31229 and sockets 39029/32-248 of the size #16.
EFFECTIVITY:
ALL
Page 60
20-40-10
Sep 30/11
RRJ-95B
The crimping and wiring tools are specified in the Subject 9.

Designation of connectors of MIL-C-26500-48 series (Ref. Tables 58 and 59):
TABLE 58
CABLE CONNECTOR OUTLET
Amphenol
series 48
Part No.
48-7191
48-7191-1
AIS 16R Burndy
AIS 16R-1 Burndy
TABLE 59
Amphenol
series 10
Part No.
10-804342
10-804342-1
Viking
Viking
Order No.
size #16
Colour
Blue
Red
Blue
Red
Pin ZZL-4016-36LD
Socket ZZL-4116-36LD
CABLE CONNECTOR PLUG
Amphenol
series 48
48-7190
48-7190-1
AIS 16 Burndy
AIS 16-1 Burndy
Amphenol
series 10
10-804341
10-804341-1
Viking
Viking
Order No.
size #16
Pin ZZL-4016-36LD
Socket ZZL-4116-36LD
Colour
Blue
Red
Blue
Red
Designation of connectors of the series MS, 8526 as per MIL-C-26482G, series II (Ref. Table
60):
TABLE 60
DESIGNATION OF CONNECTORS OF THE SERIES MS, 8526 AS PER
MIL-C-26482G, SERIES II
MS
8526
3470
OW
Polarization key
N - normal position of the key
W,X,Y,Z - angular position of the key
Contact type
P - pin
S - socket
A - short contacts - P
B - short contacts - S
Insert arrangement 3(4,5,6,8,10,12,14,15,16,
19,21,26,31,32,39,41,55,61)
W - Al-cadmium-plated
L - Al-nickel-plated
Bayonet. Type of the housing:
0W-3470 - jack-in part, square flange
7W-3474 - jack-in part, attachment by nut
5W-3475 - cable part, protection against RF interferences
6W-3476 - cable part
MS - Basic series
8526 - Souriau
Designations of the cable clamps are given in the Tables 33 and 34.
Designation of the sealed connectors of MS, 8526 series as per MIL-C-26482G, series II
(Ref. Table 61).
EFFECTIVITY:
ALL
Page 61
20-40-10
Sep 30/11
RRJ-95B
TABLE 61
MS
DESIGNATION OF THE SEALED CONNECTORS OF MS, 8526 SERIES AS

PER MIL-C-26482G, SERIES II
3440
**
**
*
Polarization key:
W, X, Y, Z angular position of the key
Contact type: pin
Insert arrangement:
3(4, 5, 6, 8, 10, 11,12,14,15,16,19,21,26,31,32,39,41,55, 61) - soldering
Material of the housing:
steel welded cylinder
Standard size of the housing:
8-10-12-14-16-18-20-22-24
- sealed
8526-2- 3440 - jack-in part, square flange
8526-1- 3443 - jack-in part, attachment by soldering
8526-7- 3449 - jack-in part, attachment by nut
Sealed connector Basic series
Diagram of insert arrangement in connectors of the series MS 3440, 8526 (Fig.27):
FIG. 27 Diagram of insert arrangement in connectors of the series MS 3440, 8526
EFFECTIVITY:
ALL
Page 62
20-40-10
Sep 30/11
RRJ-95B
Designation of connectors in the series 8525 SOURJAU (Ref. Table 62):

TABLE 62
8525
-10
DESIGNATION OF CONNECTORS OF THE SERIES 8525 SOURJAU

R
1832
***
Index:
the connector is delivered without the back nut, without index
L - the connector is delivered without contacts
008 - the connector is delivered with special contacts #20 for cable from
0.38 to 0.93 mm or #16 for cable from 0.93 to 1.91 mm.
068 - combined diagram of the insert arrangement (#20 and 16), the
connector is delivered with special contacts #20 for cable from 0.38 to
0.93 mm and with standard contacts #16
009 - outlet 10 or 17 with straight pin contacts of size 20 (1.02 mm)
size 16 (1.59 mm) for fitting on the printed circuit board, connector with
maximum length 7.30 mm is delivered without back nut
001 - back nut
007 - housing for the heat-shrinking tube
002 - straight cable clamp
057 - nut for heat-shrinking tube
003 - angular cable clamp
012 - straight cable clamp (*)
011 - back nut (*)
017 - housing for heat-shrinking tube (*)
013 - angular cable clamp (*)
018 - housing for fitting of the screen for soldering (*)
Mandatory suffix:
3 rear serrations (120 deg)
K rear serrations along the whole circumference
Orientation:
N normal
W,X,Y,Z see below
Contact types:
pin
S - socket
Insert arrangement diagram
Coating:
R black anodizing (non current-carrying)
N nickel plating (current-carrying)
G yellow cadmium plating (current-carrying)
10 socket with rectangular flange
16 plug
Main series
NOTE: The connector is delivered with special contacts (elongated sleeve).

Designation of the sealed connectors of the series 8525 (Ref. Table 63).
EFFECTIVITY:
ALL
Page 63
20-40-10
Sep 30/11
RRJ-95B
TABLE 63
8525
-1
DESIGNATION OF THE SEALED CONNECTORS OF THE SERIES 8525
1832
***
Specification:
002 - Design variant with big flange 02
Mandatory suffix
Orientation:
N normal
W,X,Y,Z see below
Contact types:
- pin
S - socket
Sealed variant:
stainless steel
1 outlet with fixation for nut
02 socket with rectangular flange
Main series
Designation of the cable clamps are specified in the Tables 33 and 34.
Diagram of insert arrangement in series 8525 connectors is shown in Fig. 26.
TABLE 64
DESIGNATION OF CONNECTORS OF "" SERIES AMPHENOL AS PER

ARINC 600
Series
Modification:
Design variant
00 Fitting of contacts backwards for crimping

Power and pilot contacts are delivered as a set
F0 the contacts are not included, set with connector
D - protected
backward fitting of contacts for crimping
- protected
backward fitting of contacts for crimping
FR contacts fitted backwards

SA contacts fitted at the front, soldered,
pilot; contacts fitted backwards for crimping power
F unprotected
front fitting of soldered contacts #22, the rest with wire core winding
WA contacts fitted at the front with wire core wound on the

contact
- the same as - without O-ring or sealant

around the inserts
Polarization of the key position:
From 01 to 216 (Ref. ARING)
Polarization keys are delivered completed with connector
S - protected with O-ring

Size of the housing for insert arrangement
1.- max quantity of contacts 160
2.- max quantity of contacts 400
3.- max quantity of contacts - 800
Designation of insert arrangement and No. of modifier of
the insert of housing standard size 3 connector:
F
71W1 71W1 13W2 71W1 71W1 13W2
Connector fitting method modifier:

00 Standard structure, hole diameter 3.76 mm
01 #6-32 size (#12 size 2-62)
(#12 size 2-62)
3 Plug (on frame)
4 Outlet (on block)
EFFECTIVITY:
ALL
Page 64
20-40-10
Sep 30/11
RRJ-95B
Sealed outlets are available

Special (SHTP)
FIG. 28 Diagram of insert arrangement in connectors of the series 8525

NOTE: View from the side of the outer insulator end-face.
Connectors of FDBA series produced by "Deutsch" correspond to MIL-C-26482
specification. These are electrical connectors, circular, small-sized, bayonet type,
sealed, multiposition with gold-plated removable contacts that are connected to the
wires by crimping as well as with contacts for soldering, are intended for operation in AC
and DC electrical circuits with voltage up to 750 V within the temperature range from 55 to +200.
Crimping of the contacts must be performed by means of the crimping tool 22520/101, with head 22520/1-02.
EFFECTIVITY:
ALL
Page 65
20-40-10
Sep 30/11
RRJ-95B
The connectors provide 10-time insertion and removal of the contacts by means of the
wiring tool 15570-20, 15570-16.
Symbolic notations are assigned to the plugs and outlets (Ref. Table 65):
TABLE 65
FDBA
50
SYMBOLIC NOTATION OF PLUGS AND OUTLETS

H
14
19
(S)
-A5559
(059)
(A285)
Straight casing with seal

Straight cable clamp
081 angular cable clamp
Angle of the contact group turn relative to the housing in
degrees (16349)
Insert arrangement normal
W-X-Y-Z counterclockwise arranged contacts
Quantity of contacts 3 (5, 6, 8, 10, 12, 15, 16, 19, 21, 26, 32, 39, 41, 55, 61)
Size of the housing with combination of the contact set 8,10,12,14,16,18,20, 22, 24
Design variant sealed
Type of the housing
50 jack-in part with flange
53 jack-in part, unsealed, for soldering
54 sealed part for soldering
56 straight cable part
57 straight jack-in part
58 block jack-in part for soldering (sealed)
Type of connector
NOTE: Contact designation according to Manufacturer's designation and colour code: 006-091220 red- red; 006-0912-16 blue-blue.
Diagram of insert arrangement in connectors FDBA, 8525, 8526, MS 3440 (Fig. 29).
EFFECTIVITY:
ALL
Page 66
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RRJ-95B
Fig. 29 Diagram of insert arrangement in connectors FDBA, 8525, 8526, MS 3440

Designation of connectors of the series 851 as per MIL-C-26482, series II (Ref. Table
66).
EFFECTIVITY:
ALL
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TABLE 66
851
-00
DESIGNATION OF CONNECTORS OF THE SERIES 851

AS PER MIL-C-26482, SERIES II
8-
50
mandatory suffix for the housing with cont.82/8-3/8-4/12-14

Specification:
- olive green cadmium-plating (without
designation)
02 - white cadmium plating
29 - black anodizing (contacts for soldering)
031 - black anodizing (contacts for crimping)
44 - nickel plating
38 - nickel plating (casing of * and RT* type)
42 - olive green cadmium-plating (casing of *
and RT* type)
Mandatory index:
50 - gold-plated contacts for crimping contacts for
soldering of size 20 contacts with gold-plated working
area and tin-plated tail
51 - gold-plated contacts for soldering of size 20
52 - coating: olive green zinc cobalt (contacts - the
same as 50)
Polarization:
normal (without letter designations)
W,X,Y,Z angular position of the key
Contact types:
- plug
S - outlet (socket)
8-10-12-14-16-18-20-22-24
Type of the casing (cable clamp) is specified in the type of the housing
for soldering for crimping
00
00
- outlet with square flange and straight casing
01
01
- cable outlet
02
02R - outlet with square flange without possibility of casing installation
07
07
- outlet with round flange with possibility of casing installation
07
- outlet with round flange without possibility of casing installation
06
06
- plug for use with straight casing
08
08
- plug for use with angle casing (90)
36
36
- screened plug for use with straight casing
76
76
- screened plug with locking member
Basic series: for soldering, R for crimping
Designation of sealed connectors of the series 851 (Ref. Table 67):
EFFECTIVITY:
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TABLE 67
851
-02
DESIGNATION OF SEALED CONNECTORS OF THE SERIES 851

8
-3
50
Coating of the housing:
- 02 and 07, yellow cadmium. IH, nickel (without
designation)
44 02 and 07, nickel
Digital designation:
50 - Contacts of size 20 tin plating of the terminal, gold plating of
working area the contacts of other sizes and tin plating of the tail
51 - gold plating of the contacts of size 20
Polarization:
N (normal, not indicated)
Contact types:
- only pin
8-10-12-14-16-18-20-22-24
02 outlet with square flange
07 outlet with round flange
IH outlet for soldering
Basic series
Diagram of insert arrangement in connectors of series 851 (Fig.30).
EFFECTIVITY:
ALL
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FIG. 30 Diagram of insert arrangement in connectors of series 851
EFFECTIVITY:
ALL
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Designation of connectors of series 97 AMPHENOL (Ref. Table 68):

TABLE 68
97
DESIGNATION OF CONNECTORS OF SERIES 97 AMPHENOL
3101
28
21
(847)
(639)
Coating of the cable clamp
standard cadmium-plated
(604) grey, anodized
(608) black, anodized
(621) black, zinc-coated
(624) green, zinc-coated
(639) cadmium-plated
(640) black, zinc-coated
(689) nickel-plated
Structure
Standard structure - without and
Non-standard structure
(115) plug with small flange
(426) structure with gold-plated contacts
(438) special structure
(936) plug with special nut
Polarization:
standard position of the key
W, X, Y, Z angular position of the key
Contact type:P PinS Socket
Size of the housing: 8S, 10SL, 12S, 14S, 14, 16S, 16, 18, 20, 22, 24, 28, 32, 36
Cable clamp structure: solid split-type
3100 jack-in part
3102 jack-in part
3107 quick-release clamp
Series No.:
3101 cable part

3106 cable part
3108 for moulded tube
97 corresponds to the series MS AMPHENOL
TABLE 69
DESIGNATION OF POWER SEALED CONNECTORS OF TV AMPHENOL

-6
SERIES (10 cm 3/S)
TV
S06/07
Series
S06 - straight AL-nickel plug
S07 - block outlet with lock nut
Material of the housing, coating and contact type:
Aluminium alloy, nickel-plated 200, crimping
Size of the housing and insert arrangement:
25-16, 25L-3, 25-1, 33-5, 33-6, 37-5, etc.
RF
25/37-1A/5
P/S
N
Polarization:
Normal position of the key
Contact type:
P- pins, S - sockets
Diagram of insert arrangement in connectors of the series 97 AMPHENOL (Ref. Table 70).
EFFECTIVITY:
ALL
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TABLE 70
DIAGRAM OF INSERT ARRANGEMENT IN CONNECTORS OF

THE SERIES 97 AMPHENOL (PART 1)
EFFECTIVITY:
ALL
Page 72
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TABLE 70
DIAGRAM OF INSERT ARRANGEMENT IN CONNECTORS OF THE SERIES

97 AMPHENOL (PART 2)
EFFECTIVITY:
ALL
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TABLE 70

EFFECTIVITY:
ALL
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TABLE 70

EFFECTIVITY:
ALL
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TABLE 70
DIAGRAM OF INSERT ARRANGEMENT IN CONNECTORS OF THE SERIES 97

AMPHENOL (PART 5)
EFFECTIVITY:
ALL
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Designation of connectors of the series MS3450, 944 as per MIL-C-5015 specification (Ref. Table
71):
TABLE 71
MS
DESIGNATION OF CONNECTORS OF THE SERIES MS3450, 944 AS PER

MIL-C-5015 SPECIFICATION
3456
16S-
Polarization
W,X,Y,Z-angular position of the key
Contact type:
P-pinS-socket
-pins short pins -sockets short sockets
Insert arrangement
Size of the housing
L Al-nickel-plated housing W Al-cadmium-plated housing
LS steel passivated housing
K steel, cadmium-plated, fire-proof housing
KS - steel passivated fire-proof housing
Type of the housing
3450 jack-in part, square flange
3451 cable part, attachment by nut
3452 jack-in part, square flange without thread for clamp
3454 jack-in part with hold-down nut
3456 cable part 3459 cable part with self-locking
Basic series
944
16S-
***
Modification code
189 cable clamp with nut 85049/31
190 straight cable clamp 85049/52
191 angular cable clamp (90) 85049/51
Polarization
Contact type
P-pin
S-socket
Insert arrangement
Size of the housing
Al-anodized
housing F Al-nickel-plated housing
W Al-cadmium-plated
housing FS steel passivated housing
RS moisture-proof housing
K steel, cadmium-plated, fire-proof housing
KS steel passivated fire-proof housing
Type of the housing
9440-jack-in part. square flange
9441-cable part, attachment by nut
9442-jack-in part, square flange without thread for cable clamp
9444-jack-in part with hold-down nut
9446-cable part
9816-cable part with self-locking
9817-quick-disconnect (umbilical) with eyes for the plain-laid rope
9818-quick-disconnect without eyes
Basic series Amphenol
EFFECTIVITY:
ALL
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Diagram of insert arrangement in connectors of the series MS3450, 944 (Fig.31):
Fig. 31 Diagram of insert arrangement in connectors of the series MS3450, 944 (PART 1)
EFFECTIVITY:
ALL
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EFFECTIVITY:
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EFFECTIVITY:
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ALL
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EFFECTIVITY:
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TABLE 72
DESIGNATION AND DIMENSIONS OF CONNECTOR ADAPTER AS PER MIL-C39029, MIL-C-5015

0 1 2 - * * 0- ** **
Series No.
Coating: 1 gold plating; 2 silver
plating.
Contact size
Wire gauge AWG
Series P/N
012-1100104
012-1100408
012-1100410
012-1100810
012-1100812
012-1100816
012-1101216
012-1101220
012-1101620
012-2200102
012-2200104
012-2200108
012-2200408
012-2200412
012-2200810
012-2200812
012-2200816
012-2200820
012-2200822
Contact
size
Gauge
(AWG)
(mm)
11.35
-0.20
10
10
12
16
-0.23
7.39
D (mm)
14.30
E, 0.406
-0.20
13.97
4.95
-0.21
-0.22
9.53
11.43
3.73
-0.15
4.47
-0.17
-0.10
0.787
-0.23
3.58
2.67
9.65
-0.21
6.71
4.52
16
2.46
12
20
2.46
20
2
4
1.78
-0.20
3.58
-0.17
-0.13
-0.23
1.346
-0.126
1.65
11.35
0
11.43
-0.10
-0.15
12
16
-0.20
-0.23
5.84
0.406
-0.21
2.62
-0.15
13.56
-0.30
13.614
-0.23
14.30
-0.20
13.97
-0.15
13.564
9.22
7.39
11.38
3.81
4.80
-0.30
13.614
-0.23
-0.20
6.93
4.95
-0.20
12
10
12
16
20
1.37
22
0.99
-0.20
9.53
2.69
-0.20
4.47
0.787
-0.22
3.73
-0.20
2.69
-0.10
-0.10
4.52
1.78
11.43
-0.21
6.71
-0.14
-0.13
EFFECTIVITY:
ALL
F, 0.254
-0.23
-0.20
6.93
4
B (mm)
Page 89
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RRJ-95B
10.
Electrical connectors of the series 8635, 8630, 8631, 8656, DD, DEM, RD, D-SUB
Electrical connectors of the series 8635, 8630, 8631, 8656, DD, DEM, RD, D-SUB comply with
specification MIL-DTL-24308, MIL-C-39029. These are rectangular subminiature cut-in connectors.
They are intended for operation in electrical circuits with voltage up to 1250V AC in the temperature
range from -55 to +125 with contacts of the sizes #22, #20 with current load of 7.5 for
contact of the size #20, 5 for size #22.
Designation of connectors of the series 8635, DEM, DA Ref. Table 73:
TABLE 73
8635
F-
DESIGNATION OF CONNECTORS OF THE SERIES 8635, DEM, DA

15
(S)
012
L
Delivered without contacts; no index delivered with standard
contacts
Contacts for soldering; no index contacts fro crimping

Contact type sockets
Contact type pins of the size #22
Quantity of contacts: 15 (26, 44, 62, 78)
F floating attachment,
no index standard attachment (3.1 mm)
Series
Perform crimping of the contacts by means of the crimping tool 22520/2-01 for type contacts;
22520/2-06 for S type contacts. Wiring tool 81969/14-01
TABLE 74
DEM (DA)
DESIGNATION OF THE CASING: DA24658

09
(S)
52
Housing cadmium-plated
Soldering
Contact type sockets
Contact type pins
Quantity of contacts: 9(E), 15(A), 25(B), 37(C), 50(D)
Series
Perform crimping of the contacts in DA(DEM) series connector by means of the crimping tool
22520/1-01, head 22520/1-02, wiring tool 81969/14-11(12). Length of insulation stripping
is not more than 5.0 mm.
Designation of connectors of the series 501, 8630, 508, 8631 Ref. Table 75.
EFFECTIVITY:
ALL
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TABLE 75
8630
DESIGNATION OF CONNECTORS OF THE SERIES 501, 8630, 508,

8631
25
012
N
N mandatory for 508 series except for soldered 012 and dustproof 015
No index - delivered with standard contacts of the size #20 for the wire AWG
2024
L delivered without contacts
Contact type:
No index standard contacts: for crimping
012 contacts for soldering
015 dust-proof contacts
Contact type:
P - Pin
S Socket
09, 15, 25, 37, 50
501, 8630 standard attachment
Series 508, 8631 floating attachment
Designation of connectors of the series D, 8656 Ref. Table 76.
EFFECTIVITY:
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TABLE 76
D
DESIGNATION OF CONNECTORS OF THE SERIES D, 8656

P
25
00
X
Standard housing (plug) with -contacts
Standard coating - tin plating
Accessories
Grade
31 industrial
00 telecommunication, for soldered joints
43 top grade
Contact type
0 contacts for soldering
3 straight contacts
5 angular contacts
4 contacts for twisting (3 coils)
6 contacts for twisting (2 coils)
Contact type:
P - Pin
S Socket
09, 15, 25, 37, 50
Standard attachment (3.1 mm)
L - attachment by screws and nuts 3
V - thread size
S - retainers for screws
index for DP series
Size of the housing
, , , , D
Series
8656
25
X
standard housing (plug) with -contacts
standard coating tin plating

L delivered without contacts, no index delivered with contacts
Contact type:
P - Pin
S Socket
Quantity of contacts 09, 15, 25, 37, 50
Standard attachment (3.1 mm)
0 threaded attachment by screws and nuts
Series
EFFECTIVITY:
ALL
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TABLE 77
DESIGNATION OF CONNECTORS OF THE SERIES SUB-D AS PER MIL-C24308
Perform crimping of the contacts in connectors of SUB-D series by means of the crimping tool
22520/2-01, head 22520/2-08, wiring tool 81969/39-01, contact S-39029/63-368; 39029/63-369. Length of the stripped insulation is not more than 5.0 mm.
EFFECTIVITY:
ALL
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TABLE 78
DD
62
DESIGNATION OF CONNECTORS OF THE SERIES DD

F
R7
T6
-X
Special option
0-zinc-coated
S-steel
X-tin-coated -cadmium-plated
Z-tin-coated for connector P-with contacts
Polarization and locking system
0-no polarization
V3-locking latch, the connector is installed on the front panel
V5-locking latch, the connector is installed on the rear panel
VL-locking latch, is used for the casing only
T-fixed threaded socket 2-fixed threaded socket
6-fixed polarization screw sockets and pins
- rotating threaded pins 2-rotating threaded pins with a latch
3-rotating hexagon screws with thread 3/32
6-rotating screws with polarization and threaded sockets
Type of casing
0-no casing
J-plastic casing, open-top
L-plastic casing, open-side
Y-plastic casing, open-top, with rotating threaded pins only for sizes 78 and 104
Y6-plastic casing, open-top, with rotating polarized threaded sockets and pins for sizes 78 and 104
Z-plastic or composite material casing with maximum height, open-top and -side, with rotating
threaded pins for sizes 15, 26, 44, 62 and 78
-metal casing, open-top, for sizes 26, 44, 62 and 78
G-metal casing with protection against RF interferences
W-plastic casing, open-top and -side, for sizes 15, 26 and 44
N-bracket 90 with press-type fasteners
**F-casing with ferrite filter
Type of attachment
0-by screws with locating holes 3.05 mm
02-by screws with locating hole 3.91 mm
3-90 bracket with metal plate
8-90 bracket with plastic plate
F-floating attachment
- threaded attachment 5.71 mm long
2-threaded nylon attachment 5.71 mm long
R2-90 bracket with fixed threaded sockets
R6-90 metal bracket with locating holes 3.05 mm and with a plate
R7- metal bracket with threaded plate
R8-90 metal bracket with threaded plate and locknut
S-crimping formed gasket, thread 4-40, length 5.71 mm
S2-crimping formed gasket, thread 4-40, length 3.18 mm
S5-formed nut, thread 4-40
S6-crimping formed gasket with press-type fasteners, thread 4-40, length 9.53 mm
S7-crimping formed gasket with press-type fasteners with use of the ferrite filter, thread 4-40, length 13.08
mm
Delivery type
0-without contacts
1-with crimping contact for AWG22-26 2-with contacts for soldering for AWG22-26
3-with contacts for printed circuit wiring 3.81 mm long 32-with contacts for soldering, 7.62 mm long
4-with contacts for soldering, angular 90, 11.43 mm long
Contact type
M-Male P-Pins
F-Female S-Sockets
Quantity of contacts: 15,26,44,62,78,104
Basic series: DD-series
EFFECTIVITY:
ALL
Page 94
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Diagram of insert arrangement (Fig.32):

1
11
10
15
1
10
1
16
9
18
19
DD 26
DD 15
15
30
31
26
44
DD 44
1
1
1
22
21
42
43
20
39
59
21
40
50
62
DD 62
78
21
22
42
53
43
64
84
85
104
DD 78
DD 104
Fig. 32 Diagram of insert arrangement

TABLE 79
RD
15
DESIGNATION OF RD SERIES CONNECTORS

M
12
-X
Special option

0-zinc-coated
S-steel -cadmium-plated
X-tin-plated Z-tin-plated for connector P-contacts
0-without polarization
T-fixed threaded socket 2-fixed threaded socket
6-fixed polarization threaded sockets and pins
- rotating threaded pins 2-rotating threaded pins with a latch
3-rotating hexagon screws with thread 3/32
Type of casing
0-no casing J-plastic casing, open-top
Y-plastic casing, open-top, with rotating threaded pins only for size 50
Y6-plastic casing, plastic casing, open-top, with rotating polarized threaded sockets and pins for size
50
Z-plastic or composite material casing with maximum height, open-top and -side, with rotating
threaded pins for sizes 9, 15, 25, 37 and 50.
-metal casing, open-top, for sizes 15, 25, 37 and 50.
G-metal casing with protection against RF interferences for sizes 9, 15, 25, 37 and 50.
W-open-top and -side, for sizes 9, 15 and 25.
Type of attachment
02-by screws with locating holes 3.91 mm F-floating attachment
S2-formed brace (plate), 3.81 mm long S5-formed threaded locknut
Delivery type: 0-without contacts 1-with crimping contacts for AWG20-24 12-with crimping contacts for AWG2630 14-with crimping contacts for AWG20-24
5-split-type contact
Contact type M-Male P-pins F-Female S-sockets
Basic series:
9,15,25,29,37,50
RD-series
EFFECTIVITY:
ALL
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Designation of connectors of HDC series (Ref. Table 80):

TABLE 80
HDC
15
DESIGNATION OF CONNECTORS OF HDC SERIES

F
B3
-X
Special option
X-tin-coated S-steel -cadmium-plated
0-zinc-coated Z-tin-coated for connector S-contacts
0-without polarization
T-fixed threaded socket
2-fixed threaded socket
6-fixed polarization threaded sockets and pins
- rotating threaded pins
2-rotating threaded pins with latch 3-rotating
hexagon screws with thread 3/32
Type of casing
0-no casing J-plastic casing, open-top
Y-plastic casing, with rotating threaded pins only for size 50
Y6-plastic casing, open-top, with rotating polarized threaded sockets and pins.
Possibly for size 50
Z-plastic or composite material casing with maximum height, open-top and -side,
with rotating threaded pins
-metal casing, open-top, for sizes 15, 25, 37 and 50
G-metal casing with protection against RF interferences
W-plastic casing, open-top and -side, for sizes 9, 15 and 25
N-bracket 90 with press-type fasteners
**F-casing with ferrite filter
Type of attachment
3-90 bracket with metal plate
8-90 bracket with plastic plate F-floating attachment
-threaded attachment 5.71 mm long
2-threaded nylon attachment 5.71 mm long
R2-90 bracket with fixed threaded sockets
R6-90 metal bracket with locating holes 3.05 mm and with a plate
R7- metal bracket with threaded plate
R8-90 metal bracket with threaded plate and locknut
S-crimping formed gasket, thread 4-40, length 5.71 mm
S2-crimping formed gasket, thread 4-40, length 3.18 mm
S5-formed nut, thread 4-40
S6-crimping formed gasket with press-type fasteners, thread 4-40, length 9.53 mm
S7-crimping formed gasket with press-type fasteners with use of the ferrite filter, thread
4-40, length 13.08 mm
Contact type:
2-contact for soldering
3-contact for printed circuit wiring, 4.32 mm long
42-contact for printed circuit wiring, angular 90, with projecting part 9.40 mm long
5-contact for printed circuit wiring, angular 90, with projecting part 7.19 mm long
6-contact for wire core winding
Contact type: M-Male P-pins F-Female S-sockets
Quantity of contacts: 9,15,25, 37,50
Basic series: HDC - series
EFFECTIVITY:
ALL
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Diagram of insert arrangement (Fig. 31, 32):
RD 9
11
12
13
14
15
16
17
18
19
22
23
24
13
14
15
14
15 16 17
25 26
27
28
29
20
21 22 23
24
25
10 11 12
29 30
27 28
26
RD 29
18
19
13
10 11 12
23 24
20 21 22
25
RD 25
10
1
21
RD 15
20
10 11 12
13 14
31 32
15
33
16
34
17 18
35
36
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
16 17
19
37
34
35
36
37
38
39 40
41
42
43
44
45
46
47
48
33
49
50
RD 50
RD 37
HDC 9
10 11 12
13 14 15
10 11 12 13 14 15 16 17
10 11 12 13
18 19 20 21 22 23 24 25
HDC 15
HDC 25
1
14 15 16 17
10 11 12 13 14 15 16 17
18 19
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
37
34 35 36 37 38 39 40 41
HDC 37
42 43 44 45 46 47 48 49 50
HDC 50

Crimping of the contacts as per specification MIL-DTL-24308, MIL-C-24308,MIL-C-39029 is
performed by means of the crimping tool 22520/1-01, head 22520/1-02; 22520/2-01, head
22520/2-08.
TABLE 81
Contact size
WIRING TOOL FOR CONNECTORS MIL-C-24308, MIL-C-81659

Contact type
Designation P/N
22
Pin/Soc
M81969/1-01
20
Pin/Soc
M81969/1-02
16
Pin/Soc
M81969/1-03
22D
Pin/Soc
M81969/1-04
Colour
green
white
red
white
blue
white
green
white
Plugs for connectors of the series: SD P/N 4901-7-0-0, DD P/N 4804-7-4-0, RD P/N 4705-7-1-0.
EFFECTIVITY:
ALL
Page 97
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11.
Connectors Amphenol-Air LB series 1900

Are developed on the basis of ASNE 0390 standard and comply with requirements of AECMA
3545.
Are made of thermoplastic. Are delivered in two variants: sealed / unsealed along the wire
insulation.
The joined assembly consists of one jack-in connector () with contact - pins and of the cable
connector (S) with contact sockets, which are completely installed and correspond to MIL-C39029. Contacts for crimping, for soldering or for soldering on the printed circuit boards with
straight or bent contacts can be installed in the housings.
The wrenches and hexagon screws F1 and 1 provide joining of the connectors, 36 configurations
of the wrenches are available. The tightening torque is from 0.06 to 0.10 m.daN.
The wrenches are also used for attachment of the base (maximum 1.6 mm thick) by means of the
split nuts and spring washers. The tightening torque during joining is from 0.125 to 0.150 m.daN (1
m.daN.=10 Nm).
There are 6 variants of wrench installation for convenience of the consumers. Complete leaktightness is provided by compression of the insulator. There are two variants of the insulator rear
part:
- with crimping of the wire insulation (tight)
- without crimping of the wire insulation (untight)
Fig. 35 Electrical connectors Amphenol-Air LB series 1900
EFFECTIVITY:
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Performance data of the connectors (Ref. Table 82):

TABLE 82
PERFORMANCE DATA
MECHANICAL
Housing
Material:
Insulator
Material:
Material:
Protection:
Thermoplastic
Silicone elastomer
Copper alloy
Contact
Gold-plated nickel
NF C 20 616 Severity 2000-10
Vibration:
From 10 to 2000Hz - 2012 cycles
20 608 Severity 50
Impact loads:
50g 11 ms
Size 22D
4.5 daN
Size 20
6 daN
Force of contact tearSize 16
11 daN
out from the insulator
Size 12
13.3 daN
Size 10
13.3 daN
CLIMATIC
Operating temperature :
- 55 +175 constantly
Salt fog:
48 hours
LEAK-TIGHTNESS
Resistance to drainage
ELECTRICAL
Withstand voltage:
1500 V eff. 50 Hz
(1300 V, size 22)
13700 m
400 V eff. 50 Hz
Insulation resistance:
up to 5000 MW at 500 Vcc
Contact resistance
As per MIL-C-39029
Voltage drop
As per MIL-C-39029
Current load at 20
Size 22D
5
Size 20
7.5
Size 16
13
Size 12
23
Size 10
33
Fluid resistance
As per MIL-L-23699 - MIL-L-7870/A AIR 3660/A
MIL-D-16791 (type 1) PD 680 (type 1) Glycol Trichlorethane
Methylethyl Ketone Skydrol 500 4 Skydrol LD4 Hijet IV
Marking on connector (Ref. Table 83).
EFFECTIVITY:
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RRJ-95B
TABLE 83
MARKING ON CONNECTOR
Manufacturer
AIR
LB
**
**
Date of manufacture
Year
Week
Designation system (Ref. Table 84):
TABLE 84
CONNECTORS DESIGNATION SYSTEM
Designation according to norms of Aerospatiale
ASN-E0390 D D
Designation Amphenol
1900 N D
02
00
Designation according to norms of Aerospatiale

Configuration of contacts
50 contacts size 20-01; 78 contacts size 22D-02;
49 contacts 39 size 22D + 10 size 16-03; 13 contacts size 12-05
Designation Amphenol
Configuration of contacts
50 contacts - size 20 01 78 contacts - size 22D 02
Combined 39 size 22D + 10 size 16 03 21 contacts - size 16 04
13 contacts - size 12-05; 7 contacts - size 10-06
CONTACT TYPE
Contact - pin (jack-in part) P. Contact socket (cable part) -S
SEALING CODE
With wire sealing 1. Without wire sealing 2.
EQUIPPING CODE
Housing with key sockets F1-F2-; Housing with key-pins 1-2-
POLARIZATION CODE
Components of the keys are not installed 00 Polarization code for installed
ones is
PACKAGE CODE
With keys, without contacts ; With keys, with contacts -
Without keys, without contacts ; Without keys, with contacts - D
EFFECTIVITY:
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Designation AECMA (Ref. Table 85):

TABLE 85
DESIGNATION AECMA
Designation AECMA
EN 3545
SEALING CODE
With wire sealing E; Without wire sealing - D
CONFigURATION OF CONTACTS
50 contacts - size 20 01; 78 contacts - size 22D
- 02
Combined 39 size 22D + 10 size 16 - 03 21 contacts - size 16
- 04
13 contacts - size 12 05; 7 contacts - size 10
- 06
CONTACT TYPE
Contact - pin (jack-in part); - P;
Contact socket (cable part) - S
CONTACT
Crimping contacts -
EQUIPPING CODE
Housing with keysockets F1-F2 - ; Housing with key-pins 1-2 -
POLARIZATION CODE
Components of the keys are not installed
- 00
Polarization code of the installed ones is
PACKAGE CODE
With keys, without contacts - ; With keys, with contacts (variant 1)
- ;
With keys, with contacts (variant 2)
- ;
Without
keys, without contacts
- No code
02
00
Numbers of contacts, gauges of the connected wires, crimping and wiring tools are specified in
Table 47 of the present Chapter.
Installation of spare contacts and plastic blankings is mandatory.
Diagram of arrangement in connector with sealing of series 1900 is shown in the Figure 36.
FIG. 36 Diagram of arrangement in connectors with sealing of series 1900
EFFECTIVITY:
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12.
Electrical connectors as per ARINC 404, series 404 DPX, DSXN, RME
Electrical connectors as per ARINC 404, series 404 DPX, DSXN, RME comply with specification
MIL-C-81659, MIL-C-81659D, are produced by "RADIALL" completed with casings. These are
rectangular, cut-in, single, double, triple, quadruple connectors. Are intended for operation in
electrical circuits with voltage up to 1000 V in the temperature range from -65 to +125. Code of
the casing for connectors 610902-nod; 610906-NIC.
Designation of connectors of the series DSX as per ARIN 404 (MIL-C-81659B) Ref. Table 86:
TABLE 86
DESIGNATION OF CONNECTORS OF THE SERIES DSX

DSX
H(P)
13(26)
N-non protected
S40
S8S
S26S
S54P
00
01
T-semiprotected
12
14S
16S
25S
00
01
12
00
01
-protected
3
G
12
S
Series of
Design variant
connector
Size of the housing: 4-housing with 4
inserts
1 housing with one insulator
(1 insert)
2 housing with two insulators (inserts)
3 housing with three insulators (inserts)
(P), cable part for installation on the frame
(R),G jack-in part for installation on the equipment
Designation of contacts combination in the insulator Ref. Table 87
Type of wire termination in the contact and type of contact for insert:
S contacts for crimping, come with connector (see Note 1).
Z nonremovable contacts with tails for soldering
connector is delivered without contacts
For insulators with coaxial contacts (see Notes 2 and 3)
S- socket; - pin
02
12
01
Designation of contacts combination in the insulator
Plug
Plug
DSX
DSX
DSX
Type of wire termination in the contact
Plug
Designation of contacts combination in the insulator

Type of wire termination in the contact
Design of the housing of connector 02 casing attachment insert
Mechanical interlocking:
Note:
It this digit group is absent, the connector is delivered with uninstalled code pins or bushings, assembly in this case
must be performed by the consumer.
If there is 00 in the designation, the connector is delivered without code pins and bushings.
EFFECTIVITY:
ALL
Page 102
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RRJ-95B
Connectors of this type are manufactured in non-protected N, semiprotected and protected

design.
NOTE 1: When contacts with shortened tail are used for termination of wires, designation is
used, and the contacts are separately ordered. For example: DSX 1 G20 X 00 01 + 57
contacts 610 221.
NOTE 2: If the connector includes combination of contacts 322, 324 and 401, where the lowfrequency contacts are used together with coaxial contacts, structure of which depends
on the type of the terminated RF cable, the respective coaxial contacts must be
separately ordered.
NOTE 3: When the connector includes combinations of contacts 2, 3 and 8, where only
coaxial contacts are used, designation is used and the respective contacts are
separately ordered. For example: DSX 1 H31 X 00 01 + 8 coaxial contacts 610 040 (Ref.
Table 87):
TABLE 87
Designation of
the block
Combination of
contacts
With pins
With
sockets
DESIGNATION OF BLOCK
00
26
40
45
57
67
106
322
401
DS
32C4
10
12
14
16
18
20
22
24
26
28
30
34
36
38
40
11
13
15
17
19
21
23
25
27
29
31
35
37
39
41
Designation of the insert for casing attachment in connectors of the series DSX when ordering
616933030 ALU cad. yellow; 616933031 ALU nic; 616933032 ALU cad. black.
Designation of DPX connectors produced by "ITT CANNON" with housing for two insulators with
contacts fixation, Ref. Table 88.
EFFECTIVITY:
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TABLE 88
DESIGNATION OF DPX CONNECTORS PRODUCED BY ITT CANNON
DX
2
MEA106
Connector series
Housing for two insulators
Grade (design):
- protected: with rubber seal on the electrical
wiring side and with rubber routing of local
protection on the front side of the plug insulator.
- non-protected: without rubber seal on the
electrical wiring side and without rubber routing of
local protection on the front side of the plug
insulator.
Contacts are retained in these types of connectors
(DPXMA, DPXME) by means of "LITTLE CAESAR"
system spring pins
Designation of contacts combination in the insulator (block )
Ref. Table 91
Contact type: pins, S - sockets
Ref. Table 91
Contact type: pins, S - sockets
33 cable part for installation on the frame
34 jack-in part for installation on the equipment
Housing of ARINC "" type
Connector housing design
Mechanical interlocking
A106
P-
33
B-
04
01
Connectors with permanent (fixed) contacts with tails for connection of wires by soldering, Ref.
Table 89.
EFFECTIVITY:
ALL
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RRJ-95B
TABLE 89
CONNECTORS WITH FIXED CONTACTS AND TAILS FOR WIRES

CONNECTION BY SOLDERING
DX
2-
40
57
S-
33
B-
04
01
Connector series
Ref. Table 91
Contact type: - pins, S - sockets
Ref. Table 91
Contact type: - pins, S - sockets
33 cable part for installation on the frame
34 jack-in part for installation on the equipment
Housing of ARINC "" type
Designation of RME connectors produced by AMP with housing for two insulators (Ref. Table 90):
TABLE 90
DESIGNATION OF RME CONNECTORS PRODUCED BY AMP

RME
P-
26
106
P-
74
01
Connector series
RME protected: with rubber seal on the electrical wiring side
and with rubber routing of local protection on the front side of
the plug insulator.
cable part for installation on the frame
R jack-in part for installation on the equipment
Ref. Table 91
Contact type:
- pins
S - sockets
Ref. Table 91
Contact type:
- pins
S - sockets
Insulators for connectors DSX, DPX, RME are specified in the Table 91.
EFFECTIVITY:
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TABLE 91
INSULATORS FOR CONNECTORS DSX, DPX, RME
View of cable part on the wiring

side
4
8 contacts #12
4 contacts #16
4 contacts #12
D8
D8
D8
26 contacts # 16
26
26
26
40 contacts # 20
40
40
40
45 contacts # 20
45
45
45
57 contacts # 20
57
57
57
64 contacts #
20HD
3 contacts #16
67
67
67
106 contacts # 22
106
106
106
39 contacts # 20
1 coaxial contact
#5
40 1
40 1
13
7
14
19
26
20
1
7
14
23
15
31
40
24
32
15
25
16
35
26
45
36
1
10
19
28
20
29
38
39
47
57
48
17
29
18
42
30
54
43
67
55
12
25
39
52
66
79
93
13
28
40
53
67
80
94
106
1
8
13
19
31
Contacts
Designation of insert arrangement

ITT
RADIALL(DSX)
CANNON
AMP(RME)
(DPX)
14
24
20
25
39
32
Wire or cable wiring variants:

non-removable contacts with tails for soldering;
non-removable contacts, termination by crimping;
removable contacts, termination by crimping for protected design connectors.
EFFECTIVITY:
ALL
Page 106
20-40-10
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RRJ-95B
Low-frequency contacts for connectors of the series DSX produced by RADIALL are specified
in Table 92:
LOW-FREQUENCY CONTACTS FOR CONNECTORS OF THE SERIES DSX
PRODUCED BY RADIALL
39029/12-150
616 331
39029/11-147
39029/12-151
Crimping tool
Positioner
Position of the tool selector
Tools for contacts installation and removal
22520/2-01
22520/2-23
22520/2-01
22520/2-08
7
6
5
81969/14-02
Installation - red
Removal - white
3.5
20
22
24
0.6
0.38
0.24
0.5
0.35
0.2
1.8
4.0
20
22
24
0.6
0.38
0.24
0.5
0.35
0.2
1.8
4.0
16
18
20
1.34
0.93
0.6
1.5
1.0
0.5
2.6
616 231
81969/1-02
Installation - red
Removal - white
1.4
22520/1-01
39029/11-146
7
6
5
0.35
0.2
20
22
24
0.60
0.38
0.24
0.5
0.35
0.2
12
14
3.18
1.91
2.5
3.14
6.0
6.0
22520/1-02
20
81969/1-01
Installation green
Removal - white
0.38
0.24
22520/1-01
610 321*
4
3
22
24
22520/1-04
39029/12-149
20HD
610 221*
mm
mm2
39029/12-148
22
39029/11-145
mm
mm2
22520/1-01
39029/11-144
Socket
Gauge
Pin
Tools
22520/1-02
As per AWG
Length of the core insulation

stripping
Parameters of terminated wires

Core section
. of wire along the core
insulation
Contact gauge
Contact type and designation as per MIL-C-39029
As per GOST
TABLE 92
EFFECTIVITY:
ALL
6
5
4
81969/1-03
Installation - blue
Removal - white
5
5
4
8
7
81969/14-04
Installation yellow
Removal - white
Page 107
20-40-10
Sep 30/11
RRJ-95B
Correspondence of designations of the contacts produced by different manufacturers to

designations as per MIL-C-39029 for connectors as per ARINC 404 series DSX produced by
RADIALL and RME connectors produced by are specified in Table 93:
TABLE 93
Contact gauge
22
(22-22)
20HD
(20-20HD)
20
(20-20)
20 with
increased tail
16
(16-16)
16 with
shortened tail
12
(12-12)
CORRESPONDENCE OF CONTACTS DESIGNATION

Wire
standard
size as per
AWG
26-22
24-20
24-20
18
20-16
24-20
22-18
14-12
Contact designation
Contact type
As per MIL-C-39029
RADIALL
AMP
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
39029/11-144
39029/12-148
39029/11-145
39029/12-149
204873-4
205103-3
204938-3
205116-1
39029/11-147
616200
616300
616210
616310
610231
610331
616230
616330
616231
616331
616240
Socket
39029/12-151
616340
205851-2
39029/11-146
39029/12-150
-
133128-2
132155-1
204978-3
205117-1
132199-1
205763-3
Wire terminated by crimping method in the low-frequency contacts of DSX and RME series
connectors are specified in the Table 94.
EFFECTIVITY:
ALL
Page 108
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RRJ-95B
TABLE 94
WIRES FOR CRIMPING IN THE LOW-FREQUENCY CONTACTS OF DSX

AND RME SERIES CONNECTORS
Permitted outer
diameters of wire
along insulation
(mm)
Core section
Gauge
mm
as per
AWG
as per GOST (mm)
min
max
22
from 0.14 to 0.38
26-24-22
0.12 0.2 0.35
0.76
1.4
20HD
from 0.2 to 0.60
24-22-20
0.2 0.35 0.5
1.02
1.8
20
from 0.2 to 0.60
24-22-20
0.2 0.35 0.5
1.0
1.8
20 with increased
tail (RME)
0.93
18
1.0
1.0
1.8
16
from 0.60 to 1.34
20-18-16
0.75 1.0 1.5
1.7
2.6
16 with shortened
tail (DSX)
from 0.2 to 0.60
24-22-20
0.2 0.35 0.5
1.7
2.6
16
from 0.38 to 0.93
22-20-18
0.35 0.5 0.75 1.0
1.7
2.6
12
from 1.91 to 3.18
14-12
2.5
2.4
3.4
Wire grade
22759/; 2613; 55; EN;

BS; 82
22759/; 26-13
55; EN
BS; 82
22759/; 26-13
55; 82
EN; BS
22759/
55, BS, 82
EN
22759/; 26-13
55; EN
BS; 82
22759/; 26-13
55; EN
BS; 82
22759/; 55
EN; BS; 82
22759/; 26-13
55; EN; BS;
82
Permanent low-frequency contacts with tail for soldering for DSX series connectors are specified
in Table 95.
Requirements for splicing of wires terminated by soldering in the low-frequency contacts of DSX
series connectors, Ref Section 20-30-10.
TABLE 95
PERMANENT LOW-FREQUENCY CONTACTS WITH TAIL FOR SOLDERING

FOR DSX SERIES CONNECTORS
Length of he
core
insulation
stripping
(mm)
Core section
Gauge
Designation of contacts combination
20HD
20
16
mm
as per
AWG
as per GOST
(mm)
from 0.2
to 0.60
24-22-20
0.2 0.35 0.5
Wire grade
67; 32C4
40; 45; 57
32C2; 40C1
26; 67
32C4
from 0.2
to 1.34
20-18-16
4.50.5
In accordance with
wiring diagram
0.35 0.5
0.75 1.0
5.0+2
12
8; D8
from 1.91
to 3.18
14-12
1.5 2.5
EFFECTIVITY:
ALL
Page 109
20-40-10
Sep 30/11
RRJ-95B
Low-frequency contacts of DPXME series connectors produced by ITT CANNON are provided
with "LITTLE CAESAR" type contacts fixation system, this differentiates them from DSX series
connectors produced by RADIALL and from RME series connectors produced by (Ref. Table
96):
Low-frequency contacts of DPXME series connectors produced by ITT
CANNON
Contact type and
designation by ITT
CANNON

Core section
Crimping tool
Positioner
Position of
the tool
selector
Tools for
contacts
installation
and removal
10
11
12
22
030-1975-002
031-1113002
22
24
1.4
3.5
22520/2-01
22520/2-23
4
3
81969/1-01
Installation - green
Removal - white
22HD 030-1892-002
031-1047002
20
22
24
1.78
4.0
22520/2-01
22520/2-08
7
6
5
81969/1-02
Installation - red
Removal - white
2.03
4.0
22520/1-01
22520/1-02
7
6
5
81969/14-02
Installation - red
Removal - white
2.79
6.0
22520/1-02
6
5
4
81969/1-03
Installation - blue
Removal - white
6.0
22520/1-04
Length of
the core
insulation
stripping
22520/1-01
Max. of
wire by
as per
core
as per AWG
GOST
insulation
Tools
22520/1-01
Contact gauge
Table 96
8
7
81969/14-04
Installation yellow
Removal - white
Pin
Socket
0.38 0.24
0.35
0.2
0.6 0.38 0.24
0.5
0.35
0.2
20
030-2040-000
031-1046002
20
22
24
0.6 0.38 0.24
0.5
0.35
0.2
16
030-1893-002
031-9206021
16
18
20
1.34 0.93 0.6
1.5
1.0
0.75
12
031-1059030-2045-000
002
12
14
3.18 1.91
gauge mm mm
2.5
mm
mm
3.81
EFFECTIVITY:
ALL
Page 110
20-40-10
Sep 30/11
RRJ-95B
WIRES TERMINATED IN THE LOW-FREQUENCY CONTACTS OF

DPXME SERIES CONNECTORS
Permitted outer
diameters of wire by
insulation (mm)
Core section
Gauge
max
from 0.14 to
0.38
26-24-22
0.12 0.2
0.35
0.91
1.4
20HD
from 0.2 to
0.60
24-22-20
0.2 0.35
0.5
1.02
1.78
20
from 0.2 to
0.60
24-22-20
0.2 0.35
0.5
1.02
2.03
16
from 0.60 to
1.34
22-20-18
0.75 1.0
1.5
1.35
2.79
12
from 1.91 to
3.18
14-12
2.5
2.06
3.81
EFFECTIVITY:
ALL
22759/; 26-13
55, 82
EN; BS
22759/; 26-13
55; EN
BS; 82
22
22759/; 26-13
55; EN
BS; 82
min
Wire grade
22759/; 26-13
55; EN
BS; 82
mm
as per GOST
as per AWG
(mm)
22759/; 26-13
55; EN
BS; 82
TABLE 97
Page 111
20-40-10
Sep 30/11
RRJ-95B
Low-frequency contacts of DPXME series connectors produced by ITT CANNON are

provided with "LITTLE CAESAR" type contacts fixation system, this differentiates them
from DSX series connectors produced by RADIALL and from RME series connectors
produced by (Ref. Table 98):
LOW-FREQUENCY CONTACTS OF DPXME SERIES CONNECTORS
PRODUCED BY ITT CANNON
Core section
Max. of Length of
as per wire by insulation
as per AWG
GOST insulation stripping
Pin
Socket
gauge mm mm
22-22
030-1975-000
031-1113000
22
24
0.38 0.35
0.24 0.2
20-20 HD 030-9081-003
031-9134004
20
22
24
20
22
24
16
18
20
20
22
24
0.6 0.5
0.38 0.35
0.24 0.2
0.6 0.5
0.38 0.35
0.24 0.2
1.34 1.5
0.93 1.0
0.6 0.5
0.60 0.5
0.38 0.35
0.24 0.2
12
14
3.18
1.91
20-20
030-9081-000
031-9134001
16-16
030-9083-001
031-9084001
16-20
12
Tools
030-9123-001
031-9124001
031-1059030-1909-001
001
2.5
Crimping tool
Positioner
Contact gauge
Contact type and

designation by ITT
CANNON
Position of the tool selector
TABLE 98
Tools for contacts

installation and
removal
mm
mm
10
11
1.52
3.5
22520/2-01
22520/223
4
3
1.8
4.0
22520/2-01
22520/208
2.03
4.0
22520/1-01
22520/102
2.79
6.0
22520/1-01
22520/102
6.0
22520/122520/1-01
04
3.81
7
6
5
7
6
5
6
5
4
5
5
4
8
7
12
81969/1-01
Installation - green
Removal - white
81969/1-02
Installation - red
Removal - white
81969/14-02
Installation - red
Removal - white
81969/1-03
Installation - blue
Removal - white
81969/14-04
Installation yellow
Removal - white
Wire terminated in the low-frequency contacts of DPX series connectors are specified in the
Table 99.
EFFECTIVITY:
ALL
Page 112
20-40-10
Sep 30/11
RRJ-95B
TABLE 99
WIRE TERMINATED IN THE LOW-FREQUENCY CONTACTS OF DPX

SERIES CONNECTORS
Permitted outer
diameters of wire
by insulation
(mm)
Core section
Gauge
mm
as per AWG
as per GOST
(mm)
22-22
from 0.14 to 0.38
26-24-22
0.12 0.2 0.35
1.4
20-20HD
from 0.2 to 0.60
24-22-20
0.2 0.35 0.5
1.78
20-20
from 0.2 to 0.60
24-22-20
0.2 0.35 0.5
2.03
16-16
from 0.60 to 1.34
20-18-16
0.5 0.75 1.0

1.5
16-20 with
shortened tail
from 0.20 to 0.60
24-22-20
0.75 1.0 1.5
12
from 1.91 to 3.18
14-12
2.5
max
Wire grade
22759/; 26-13
55; EN
BS; 82
22759/; 26-13
55; EN
BS; 82
22759/; 26-13
55, 82
EN; BS
2.79
22759/; 26-13
55; EN
BS; 82
3.81
22759/; 26-13
55; EN
BS; 82
Permanent low-frequency contacts with tail for soldering for DPX series connectors are specified
in Table 100.
Requirements for splicing of wires terminated by soldering in the low-frequency contacts of
Permanent low-frequency contacts with tail for soldering for DPX series connectors are specified
in Table series connectors (Ref. Section 20-30-10).
TABLE 100
PERMANENT LOW-FREQUENCY CONTACTS WITH TAIL FOR

SOLDERING FOR DPX SERIES CONNECTORS
Core section
Gauge
Designation of
contacts
combination
Contact tail
code
20
40; 45; 57
32C2; 40C1;
30C4
16
26; 67
30C4
Pin-N
12
8; D8
Socket-
mm
as per
AWG
as per GOST
(mm)
from 0.2 to
0.60
24-22-20
0.2 0.35
0.5
from 0.60
to 1.34
20-18-16
Length of
the core
insulation
stripping
(mm)
4.50.5
In accordance
with wiring
diagram
0.5 0.75
1.0 1.5
6.50.5
from 1.91
to 3.18
14-12
1.5 2.5
EFFECTIVITY:
ALL
Wire grade
Page 113
20-40-10
Sep 30/11
RRJ-95B
In case connectors of the protected and semiprotected design are used, it is recommended to
install all spare pilot and power contacts in the insulators. It is permitted to not install the spare
contacts. Corresponding holes in the rubber seals on the wiring side must be blanked by sealing
plugs. Example of installation of the plugs of gauge 22, 20, 16, 12 is shown in Figure 37:
FIG. 37 Installation of the plugs of gauge 22, 20, 16, 12

Table 101 contains correspondence data for the plugs according to military specification MS27488.
TABLE 101
CORRESPONDENCE DATA FOR THE PLUGS ACCORDING TO

MILITARY SPECIFICATION MS27488.
Contact gauge
Designation as per MS27488
22
MS27488-22
20
MS27488-20
16
MS27488-16
12
MS27488-12
Spare contacts are not installed in the holes intended for installation of the coaxial and triaxial
contacts, their corresponding holes in the rubber insulators must be blanked by sealing plugs (Fig.
38):
Fig. 38 Installation of the sealing plug

When connectors of non-protected design are used, all spare pilot and power contacts must be
installed in the insulators.
EFFECTIVITY:
ALL
Page 114
20-40-10
Sep 30/11
RRJ-95B
13.
Modular electrical connectors and terminal blocks

Easy-wiring modular connectors comply with French specification NF/UTE 93-462: module HL
105 corresponds to type I750, module HL 103 corresponds to 1100, module HL 102 corresponds to
1400 and lightweight type 1767 PA.
The modular connectors are intended for operation in the electrical circuits with voltage 1500 V 50
Hz above sea level in the temperature range from -55 to +175. The modular connectors are
produced in the sealed and non-sealed design variants.
HL 102 module is the prototype of American specification NAS 1748.
The crimping contact - pins on the conductors correspond to several specifications NF L53-105,
NAS 1749, EN3155-016.
Crimping, installation and removal of these contacts is performed by standard tools.
For maximum effect the following modules of different configurations can be installed on one rail:
combined modules;
power connecting blocks with screw attachment;
modules with built-in diodes;
wide range of electronic components in the module of type 1765.
Accessories for easy wiring:
round grounding modules, grounding modules with brackets for attachment;
line connectors;
line connectors for components with built-in diodes, resistors and fuses;
terminals.
The modules are attached on the metal or composite rail. The composite rail is more preferable,
since it is 60% lighter than the metal one and has other advantages.
Lightweight modular connectors of type 1767 are used to decrease the weight.
EFFECTIVITY:
ALL
Page 115
20-40-10
Sep 30/11
RRJ-95B
TABLE 102
DESIGNATION OF EASY-WIRING MODULAR CONNECTORS

00
****
**
**
Order No.
Type 1750 HL 105
Standard modules
Grounding modules
Lightweight modules
Type 1765
Modules containing electronic components
1755
1758
1767
1765
Type 1100 HL 103 / HL 104

Modules HL 104
Modules HL 103
Grounding modules
Modules with diodes
Feedthrough modules
1105
1115
1118
1130
1145
Type 1400 HL 102

Standard modules
Grounded modules
Feedthrough modules
1405
1408
1440
Contacts
Size 22
Size 20
Size 16
Size 12
5-6 Combined modules
1
2
3
5-6
Configuration of shunts
01
02
03 etc.
Types 1750 1100 1765 1767
Gold-plating of the contacts
Type 1400
Gold-plating of the contacts and shunts
02
00
Sealed modules HL105 (Ref. Table 103).
EFFECTIVITY:
ALL
Page 116
20-40-10
Sep 30/11
RRJ-95B
TABLE 103
WIRING DIAGRAM AND DIMENSIONS (PART 1)

Size 22
36 contacts
Current to contact
5
Size 20
18 contacts
Current to contact
7.5
Weight: 16.6 g
Standard
Weight: 8.5 g
Standard
No. for order
No. for order

Weight: 8.10 g
001755 101 02
001767 101 02
Weight: 8.0 g
001755 201 02
001767 201 02
Weight: 8.10 g
001755 102 02
001767 102 02
Weight: 8.0 g
001755 202 02
001767 202 02
Weight: 8.20 g
001755 103 02
001767 103 02
Weight: 8.10 g
001755 203 02
001767 203 02
Weight: 8.10 g
001755 104 02
001767 104 02
Weight: 8.10 g
001755 204 02
001767 204 02
Weight: 8.20 g
001755 105 02
001767 105 02
Weight: 8.10 g
001755 205 02
001767 205 02
Weight: 8.20 g
001755 106 02
001767 106 02
Weight: 8.10 g
001755 206 02
001767 206 02
Weight: 8.20 g
001755 107 02
001767 107 02
Weight: 8.0 g
001755 207 02
001767 207 02
Weight: 9.8 g
Size #20 18 contacts
001767 220 02
Weight: 8.10 g
001755 208 02
001767 208 02
Weight: 13.4 g
2(1 cont. #12+6 cont.
#20)
18 contacts
001767 502 02
001755 209 02
Weight: 13.5 g
001767 503 02
2 cont. #12 + 12 cont. #20
001755 211 02
EFFECTIVITY:
ALL
Page 117
20-40-10
Sep 30/11
RRJ-95B
TABLE 103
WIRING DIAGRAM AND DIMENSIONS (PART 2)

Weight: 13.5 g
8 contacts size #12
001767 401 02
001755 212 02
Size 16
Size 12
10 contacts
8 contacts
Current for contact 13
Current for contact

23
Weight 18.0 g
Weight 19.0 g
No. for order
No. for order

Weight: 13.50 g
001755 401 02
001767 401 02
001755 301 02
001755 302 02
001755 402 02
001755 303 02
001755 403 02
001755 304 02
001755 305 02
001755 306 02
Modules with combined contacts (Ref. Table 104).
EFFECTIVITY:
ALL
Page 118
20-40-10
Sep 30/11
RRJ-95B
TABLE 104
WIRING DIAGRAM AND DIMENSIONS

8 contacts
2#12+6x#16
001755 501 02
Weight:19.0
g
:24.5(.964)
16 contacts
2(1#12+7x#20)
001755 502 02
Weight:18.0
g
:24.5(.964)
16 contacts
2#12+14x#20
001755 503 02
Weight:17.0
g
:24.5(.964)
6 contacts
2(1#12+2x#16)
001755 504 02
Weight:19.0
g
:24.5(.964)
12 contacts
1#10+3x#16+8x#20
001755 601 02
Weight:19.0
g
:26.2(.964)
Sealed modules HL103 (Ref. Table 105 and 106).
TABLE 105
EFFECTIVITY:
ALL
Page 119
20-40-10
Sep 30/11
RRJ-95B
Size 22
21 contacts (5)
Weight 8.75 g
Size 20
10 contacts (7.5)
Weight:
J1-6.61 g
J1-6.61 g
HL 103
HL 103
001115 101 02
001115 201 02
J4
001115 102 02
001115 202 02
J4
001115 103 02
001115 203 02
J1
001115 104 02
001115 204 02
J4
001115 105 02
001115 205 02
J1
001115 106 02
001115 206 02
J4
001115 207 02
J4
001115 208 02
J4
001115 209 02
J4
001115 210 02
J1
001115 211 02
J4
Combined modules
10 contacts
212+820
Weight 10.90 g
Interval: 12
=25
001115 501 02
18 contacts
212+416+1220
Weight 17.50 g
Interval: 25
=23
001115 503 02
EFFECTIVITY:
ALL
Page 120
20-40-10
Sep 30/11
RRJ-95B
TABLE 106

Size 16
8 contacts
(13)
Weight 12.20
g
Size 12
6 contacts (23)
Weight 15.80 g
HL 103
HL 103
001115 301
02
001115 401 02
001115 302
02
001115 402 02
001115 303
02
001115 403 02
001115 304
02
001115 404 02
001115 305
02
001115 306
02
001115 308
02
Designation of contacts, gauges of connected wires, crimping and wiring tools are specified in
the Table 107.
EFFECTIVITY:
ALL
Page 121
20-40-10
Sep 30/11
RRJ-95B
DESIGNATION OF CONTACTS, GAUGES OF CONNECTED WIRES,

CRIMPING AND WIRING TOOLS
16
001104
400 02
12
001104
202 02
20
HL 103
HL 105
0.74
1.37
001112 200 25
001131 201 60
Red/white
24-22-2018
001132 202 60
Red/white
001112 300 25
001131 301 60
Blue/white
001132 302 60
Blue/white
001112 400 25
001131 401 60
Yellow/white
001132 402 60
Yellow/white
2.20
4.01
001112 200 25
001750 702
02
Green/white
Installation of
modules
26-24-22
0.95
2.10
K673
pin
22520/101
22520/102
pin
pin
22520/201
22520/2-02
10
pin
300
1716-1
001112 600 25
Black/white
DRK95-10B
DAK95-10B
Green/white
WA23101DA
TP 986
1.34
2.62
14 12
8 - 10
4.0
5.5
22520/23-02
22520/2301
0.95
2.10
16 - 18 20
Blanking cap
26 - 24
22
001109190 38
Green
Green/white
001109200
42
Red
Positioner
Crimping tool
Contact type
001112 100 25
-
pin
0011104
620 02
0011104
630 02
min
max
001109300
40
Blue
001104
300 02
Colour marking
installation/
removal
001109
400 41
Yellow
20
22520/201
Installation/
removal
001109 200
1767
001104
200 02
pin
Wire
diameter
10 12
2.4
5.2
001109 600 00
Green
HL103,
HL-105
1767
22
Plastic / metal wiring tool for

installation / removal
12 10
2.4
5.2
Gauge
G394
G415
001104
100 02
AWG
gauge
Contact size
Module type
Contact designation
TABLE 107
NOTE: Spare contacts are not installed in the modular connectors. Plastic blanking caps must be
installed.
.
Composite positioning rail for model range 1750

New positioning rail is similar to the metal rail. Installation on the positioning rail is a
very easy and fast method both of modules installation and removal without use of
special tools.
EFFECTIVITY:
ALL
Page 122
20-40-10
Sep 30/11
RRJ-95B
The following is proposed: 4 "STANDARD" lengths 5 10 15 20 for installation of

modules with 14 mm interval (Ref. Table 108):
TABLE 108
PERFORMANCE DATA
Rails
5 modules
10 modules
15 modules
20 modules
Order No.
001751 605 00
001751 610 00
001751 615 00
001751 620 00
Packing
10
10
10
10
Weight of metal part,

g
23.3
46.6
69.9
93.2
Weight of composite
part, g
9.5
19.0
28.5
38.0
Weight saving, g
13.8
27.6
41.4
55.2
FIG. 39 Installation of the modules on the composite rail

NOTE: It is permitted to join the modules one to another and cut them in parts.
- Inserting: insert projecting parts a and b of the module in grooves a1 and
b1. Slightly press on the module till the rail is clicked (Fig. 40);
- Removal: insert the screwdriver blade (maximum thickness of the blade
is 5 mm) on the side, where designation is applied on the module,
between the rail component f module. Then slightly raise the module and
remove it from the rail (Fig. 41).
Fig. 40 Module installation
EFFECTIVITY:
ALL
Page 123
20-40-10
Sep 30/11
RRJ-95B
Fig. 41 Module removal

B.
Line connectors.
Fig. 42 Contacts sizes 22, 20 and 16

Line connectors developed by Amphenol Air LB company consist of the socket contacts S
inserted in the sleeve made of the polymer material.
The same
technique as for the modules is used. From 1 to 3 contacts can be installed.
These line connectors are intended for the pin crimping contacts , which comply with
standards NF L53-105, NAS 1749 and EN 3155-016.
EFFECTIVITY:
ALL
Page 124
20-40-10
Sep 30/11
RRJ-95B
TABLE 109
PERFORMANCE DATA OF THE PIN CRIMPING CONTACTS

CONTACT
Size
1
2
20
20
16
16
CONTACT
Size
1
16
16
L
max
mm
29
37
Diameter
mm
6
7.2
No. FOR ORDER

001119 201 02
001119 301 02
g
1.7
2.9
22
20
29
001119 503 02
2.15
20
20
29
29
12.7
12.7
001119 202 02
001119 203 02
6.1
6.8
20
20
29
12.7
001119 222 02
6.4
20
20
29
12.7
001119 223 02
6.9
20
20
29
12.7
001119 224 02
6.9
16
16
37
15
001119 322 02
11.7
2
16
mm
37
Diameter
0.1
mm
15
20
33.5
12.7
L max
No. FOR ORDER
Weight
001119 302 02
g
11.7
001119 501 02
7.7
EFFECTIVITY:
ALL
Weight
Page 125
20-40-10
Sep 30/11
RRJ-95B
C.
Line connectors for components
Fig. 43 Line connectors for components

Line connectors developed by Amphenol Air LB company consist of 2 socket contacts
S located in the heat-resistant sleeve. The structure is leak-tight and can be used in
different modules with such components as diodes, fuses etc.
These line connectors are intended for crimping pin contacts , which correspond to
the standards NF L53-105, NAS 1749 and EN 3155-016.
TABLE 110
LINE CONNECTORS WITH BUILT-IN DIODES

Data on the diode
Part No.
Maximum current at
temperature
Voltage
DIODE
LINE CONNECTORS with builtin diodes
l = 2A at 25
VRF = 200 Volts
1 N 5551
001119 702 02
l = 1A at 140
VRF = 600 Volts
1 N 5619
001119 703 02
lo = 4A
VRF = 400 Volts
UT4040*
001119 704 02
l = 1A at 75
VRF = 1000 Volts
1 N 4007
001119 711 02
1N5554
001119 731 02
l = 1A at 75
VRF = 50 Volts
1 N 4001
001119 741 02
l = 1A at 75
VRF = 100 Volts
1 N 4002
001119 742 02
l = 3A at 75
VRF = 400 Volts
BY 252
001119 746 02
l = 5A at 75
VRF = 800 Volts
BY 550
001119 751 02
lo = 4A
VRF = 400 Volts
UT4040
001119 760 02
lo = 1A
VRF = 600 Volts
1 N 5551
001119 765 02
lo = 2A
VRF = 1000 Volts
BYW56
001119 768 02
TABLE 111
LINE CONNECTORS WITH BUILT-IN FUSES

Fuse data
Part No.
Maximum current
Voltage + VRM
Line connectors with built-in fuses
lo = 4A
VRF = 125 Volts
001119 745 02
lo = 1A
VRF = 125 Volts
001119 801 02
lo = 2A
VRF = 125 Volts
001119 802 02
EFFECTIVITY:
ALL
Page 126
20-40-10
Sep 30/11
RRJ-95B
D.
Modules with built-in diodes (resistors), type 1130. Wiring diagram.

Rail with modules of type HL103. Wiring diagram is given below.
Sealed modules with 2 built-in diodes D1-D2.
The diodes are built-in between 2 series of quickly built-in contacts with size 20.
Pair inlet contacts S1-S3, outlet contacts S2-S4
2
Contacts of size 20. Cable section from 0.21 to 0.93 mm . Gauge 18-20-22-24.
Module with built-in resistors 1.5 K P N 001130 809 02
Install external jumpers S5,S6 L=755 mm in MR1 module.
Fig. 44 Modules MD and MR
EFFECTIVITY:
ALL
Page 127
20-40-10
Sep 30/11
RRJ-95B
TABLE 112
EXAMPLES OF DIFFERENT DESIGN VARIANTS OF THE MODULES WITH

BUILT-IN DIODES, TYPE 1130, AND WIRING DIAGRAM
Data on the diode

Max. current at
temperature
lo = 1A at 25
lo = 1A at 25
lo = 1A at 140
lo = 1A at 140
lo = 3A at 140
Voltage VRM
Diagram
DIODE
VRM = 600 Volts

VRM = 1000 Volts
VRM = 1000 Volts
VRM = 1000 Volts
VRM = 1300 Volts
MD1
MD (R1)
MD2
MD3
MD1
JAN 1 N 3613
lo = 6A at
VRM = 600 Volts
MD5
lo = 1A at 75
lo =
Data
0.5 W; 5%
E.
Part No.
1.5 K
1 N 5623
1 N 5623
BY 225
P 600 J ou/or 60
S10
1 N 4007
VRM = 1000 Volts

MD4
VRM =
MD6 (R6)
120 K
Line connectors with built-in resistors
Voltage
Contact size
Resistor
350V
#20
120
5%
MODULE with builtin diode

001130 901 02
001130 809 02
001130 903 02
001130 904 02
001130 905 02
001130 906 02
001130 907 02
001130 802 02
Designation
001119 817 02
-^^-
TJ SE 20566
-^^- B -^^- D
Threaded connecting unit

Power connecting unit, which can be located in the following modules. Interval 13.2 and 31.2
mm.
Fig. 45 Power connecting unit
EFFECTIVITY:
ALL
Page 128
20-40-10
Sep 30/11
RRJ-95B
TABLE 113
CONNECTING UNIT IN RELATION TO QUANTITY OF TERMINALS,

JUMPERS, WASHERS, NUTS, PARTITIONS, LIMITERS, COVERS
SEPARATELY (PART 1) (are separately ordered)
Insulation material: epoxide

(-55 +175)
Terminal: Stainless steel
Terminal
size
M5
No.
0.190032 UNF
3A
0.138032 UNC
3A
M8
M5
inch
1.110
1.228
mm
12.0
15.0
inch
.472
.590
001152 932 37 (10.12 g)

001152 935 37 (10.18 g)
28.2
1.110
12.0
.472
001150 949 37 (10.6 g)
28.2
1.110
12.7
.500
001150 943 37 (6.48 g)

001150 938 37 (32 g)
M5
0.1900-32 UNF 3A
Nut
0.1380-32 UNC 3A
M8
Tightening force m.dN
Data
Nominal section
Voltage
1
2
3
4
5
6
2
7
M8
mm
28.2
31.2
Current .
Wiring / installation
Rail
left
G
Limiter
right
D
Spacer
Spacer
Cover
Type of blank for unit designation
Sh 5
Jumper
Sh 8
Cover spacer
Limiter
Non-oxidizing steel
000842 050 60
000863 190 99
000862 138 60
0.25
000842 080 60
1.34
16 mm
500 V
70 mm
500 V
60
125
001101 202 10
001102 007 60
001102 004 60
001126 000 39
001123 000 39
024055 005 04
001121 000 37
Cover spacer
Thermoplastic
Separator
Epoxide
EFFECTIVITY:
ALL
Page 129
20-40-10
Sep 30/11
RRJ-95B
TABLE 113
CONNECTING UNIT IN RELATION TO QUANTITY OF TERMINALS,

JUMPERS, WASHERS, NUTS, PARTITIONS, LIMITERS, COVERS
SEPARATELY (PART 2)
Width 9 mm
No.:
001102 007 60
No.:
001102 004 60
:LH side
No.:
001126 000 39
No.:
001121 000 37
Weight: 2.2 g
Weight: 5.1 g
:RH side
Weight: 8.5 g
Shunt washer
Nickel-plated copper (5 holes)
Spacer
Epoxide
Part No.:024055 005 04
No.: 001123 000 39
Weight: 3.15 g
Weight: 0.8 g
Cover
Teflon stainless steel captive
screw
Cover
Cover
Weight
(g)
BJT No.
Weight
(g)
001129 101 39
4.90
001129 201 39
001129 102 39
6.40
001129 202 39
9.40
001129 103 39
8.40
001129 203 39
11.30
001129 104 39
10.00
001129 204 39
12.80
001129 105 39
11.90
001129 205 39
14.80
001129 105 39
13.40
001129 206 39 207,208 etc.
15.40
EFFECTIVITY:
ALL
7.50
Page 130
20-40-10
Sep 30/11
RRJ-95B
14.
Power terminal monoblocks

Designation system (Ref. Table 114):
TABLE 114
STANDARD DESIGNATION of THE POWER TERMINAL MONOBLOCKS

3240
****
***
Power terminal monoblock

Quantity of terminals from 01 to 12
0 Monoblock assembly with cover retainers and nuts
1 Monoblock assembly with cover retainers, cover and

nuts
2 Monoblock assembly without retainers, with nuts only
Power terminal monoblocks: numbers for order and sizes Ref. Table 115.
EFFECTIVITY:
ALL
Page 131
20-40-10
Sep 30/11
RRJ-95B
PERFORMANCE DATA
Presence of
jumper
3240 5024 001

3240 5034 001
2
3
None
None
4.82
4.82
100
100
From -60 to 230

From -60 to 230
54.0
68.0
46.2
60.7
59.22
73.7
3240 5064 001
None
4.82
100
From -60 to 230
110.0
104.2
117.2
3240 5039 001

3240 5069 001
3240 8024 001
3240 8045 001
3240 8028 001
3240 6263 001
3240 9001 002
FX 240-73
FX 240-74
3
6
2
4
2
6
6
2
3
None
None
None
None
Yes
Yes
Yes
Yes
Yes
6.35
6.35
9.52
9.52
9.52
9.52
9.52
4.82
4.82
125
125
250
250
250
250
250
100
100
From -60 to 230

From -60 to 230
From -60 to 230
From -60 to 230
From -60 to 230
From -60 to 230
From -60 to 230
From -60 to 230
From -60 to 230
86.0
154.0
120.0
182.0
140.0
154.0
154.0
54.0
68.0
75.7
134.2
43.2
129.2
73.2
134.2
134.3
46.2
60.7
88.7
147.2
86.2
142.2
86.2
147.2
147.2
59.2
73.7
Terminal
diameter
(mm)
Quantity of
terminals
Sizes
No. for order
TABLE 115
Operating
current
()
Operating
temperature
()
Weight
0.5
(g)
(mm)
L max
(mm)
Fig. 46 Dimensions of the monoblocks

NOTE: Operating time 4000 hours at temperature 250
15.
Rectangular, interchangeable electrical connectors of the types S-600, S-700 and NSX are
used for switching of the electronic equipment in accordance with requirements of ARINC-600.
The connectors comprise two parts:
jack-in part installed on the unit rear wall;
cable part installed on the frame.
The connectors S-600 and NSX have high density of contacts, small engaging force and
provide switching of the wires with section from 0.12 to 2.5 mm of the RF cables and wave
guides.
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The pilot contacts are connected to the wires with section from 0.12 to 0.35 mm, the RF
contacts to the RF cables with waveguide resistance of 50, 75 Ohm. The wires are
connected to the contact tails by crimping.
In relation to quantity of the pilot contacts the connectors are produced in three standard sizes:
standard size 1 for 120 contacts; for S-700 150 contacts;
standard size 2 for 300 contacts;
standard size 3 for 600, 750 contacts.
In relation to method of contacts installation and removal the connectors are produced in two
series:
the connectors with installation and removal of the pilot and power contacts on the wiring
side;
the connectors with installation and removal of the pilot contacts on the side of joining the
jack-in and cable part of the connector. In this case the wires are connected to the contact
tails by soldering.
The electrical connectors are produced in non-protected, semiprotected and protected design
variants. Coating of the housings of connectors is current-carrying. Mounting on the article is
rigid. Accuracy of connectors mounting on the article is provided by the retainers located on
the flanges of connector housings. Mechanical interlocking of the joined cable and jack-in part
of the connector is performed by means of the interlocking code pins and bushings. Quantity
of mutual arrangement combinations 99.
The insulators are colour painted to provide easy determination of the side of the contacts
installation in the insulators of connectors: blue on the wiring side, pink on the side of joining
the cable and jack-in parts of connectors.
.
Alphanumerical marking of the mounting sockets and of the contacts is provided for
connectors S-600 and NSX. All insulators of connectors are grouped in the windows,
which have letter designations: "", "", "", "D", "", "F", "G", "J", "K", "H" (the
designations are given on the housings of connectors).
Insulators of the pilot contacts are arranged in the connectors of standard sizes 1 and 2
in the windows "" and "", insulators of the power and RF contacts are arranged in the
window ""; insulators of the pilot contacts are arranged in the connectors of standard
size 3 in the windows "", "", "D" and "", insulators of the power and RF contacts are
arranged in the windows "" and "F".
Alphanumeric marking of connectors of the protected and semiprotected design variants
on the wiring side is applied on the local protection insulators, and on the side of the jackin and cable parts - on the plastic insulators. As for connectors of non-protected design
variant, alphanumeric information is applied on both sides of the insulators.
The initial letter "A" and figure "1" in connectors of all design variants on the insulators of
the pilot contacts are located on the side of joining the jack-in and cable parts, the final
letter "D" - on the insulators for 60 pilot contacts and letter "K" - on the insulator for 70,
100, 150 pilot contacts on the wiring side.
Designation of marking of the sockets for the pilot, power and RF contacts in the
insulators of the connector cable part have mirror reflection.
Arrangement of the windows in connectors S-600 and NSX is described in the Subject
B. Wave guides can be installed instead of insulators in the windows "", "" of
connectors of standard size 2.
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Interpretation of alphanumerical designation of S-600 series electrical connector is

described in the Subject .
Interpretation of alphanumerical designation of NSX series electrical connector is
described in the Subject . Installation of the spare contacts and plugs according to the
wiring diagram is mandatory. Quantity of the plugs is specified in the documents.
NOTE: Connectors of S-600 type and interchangeable and intermateable with
connectors of the type SNP (SKP)-345 TsSNK.430 421. 007 U.
TABLE 116
SYMBOLIC NOTATION OF THE PLUGS IN THE WIRING DIAGRAM FOR

CONNECTORS OF THE SERIES S600, S700, AND NSX
A,B,CJ
A,B,CJ
A,B,CJ
1
15
LTP (A)
RTP (D)
1
15
TP (A)
TP top plug
1
15
LMP (B)
RMP (E)
1
15
MP (B)
MP middle plug
LBP (C)
RBP (F)
BP (C)
BP bottom plug
NOTE: Structure of the connectors provides for increase of the pilot contacts up to 400 in the
housing of the second size and up to 800 contacts in the third size housing by means
of replacement of the insulators for the power contacts and pilot contacts.
B.
Arrangement of the windows in connectors of the series S-600, NSX (Fig. 47).
Insulator of the pilot block contacts of

standard size I connector block part.
Insulator of the pilot contacts of the jack-in part of standard size 2 and 3 connector.
Insulator of the power and RF contacts of the jack-in part of

standard size I connector.
Insulator of the power and RF contacts of the jack-in part of

standard size 2 and 3 connector.
Fig. 47 Arrangement of the windows in connectors of the series S-600, NSX

NOTE: Designation of marking of the sockets for the pilot, power and RF
contacts: on the side of joining the jack-in and cable parts of connector,
on the harness wiring side
.
Interpretation of alphanumerical designation of electrical connector S-600 "SOURIAU" (Ref.

Table 117).
EFFECTIVITY:
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TABLE 117
ALPHANUMERIC DESIGNATIONS OF S-600 ELECTRICAL CONNECTOR BY

"SOURIAU"
S6 0 I M G 05 W2 S 00 01
Connector series
Housing design:
0 Protected. Is protected by:
- rubber O-ring along the perimeter of connector housing (only from the cable part);
- additional rubber routing of local protection glued to the insulators on the side of the
harness;
- inner sealing of the insulator by means of sealing compound.
1 Unprotected.
3 Semiprotected. Is protected only by the rubber routing of local protection glued to the
insulators.
Size of the housing: 1 - housing for arrangement of 120 pilot contacts.
2 - housing for arrangement of 300 pilot contacts.
Connector components:
Cable part (temporary blanking on the connector in as delivered state yellow
colour).
Jack-in part (temporary blanking on the connector in as delivered state red colour).
Variant of the contacts installation in the connector:
G Installation of the pilot and power contacts for crimping on the harness side.
H Installation of the pilot contacts for soldering in the printed circuit board on the side of
joining the connector parts.
Method of connector housing mounting on the article:
05 rigid mounting of the housing 1 (by 4 screws)
13 rigid mounting of the housings 2 and 3 (by 4 screws).
Arrangement of the insulators for the power and RF contacts:
W2 standard arrangement of the insulators for the power and RF contacts of standard
size No.5, in the zones and F of the housings 1, 2, 3.
K1 2 insulators for 100 pilot contacts of standard size 22, in the zone and F of the
housing 3.
K2 insulator for the power and RF contacts, in the zone , and insulator for 100 pilot
contacts of standard size 22, in the zone of the housing 3.
K3 insulator for the power and RF contacts, in the zone F, and insulator for 100 pilot
contacts of standard size 22, in the zone F of the housing 3.
Type of the pilot contacts:
pin
S socket
Arrangement of the pilot and special insulators in connector housings:
00 standard arrangement of the insulators for the pilot contacts of standard size 22 in the housings 1, 2 and 3.
01 special insulator for 70 pilot contacts of standard size 22 and one RF contact of standard size 1 in the zones
and , housing 2.
02 - standard insulator in the zone , and special insulator for 70 pilot contacts of standard size 22 and one RF
contact of standard size 1 in the zone of the housing 2.
03 - standard insulator in the zone and special insulator for 70 pilot contacts of standard size 22 and one RF
contact of standard size 1 in the zone of the housing 2.
00 - code pins and bushings are not installed in the cable and jack-in part of the
connector.
01 - standard position of the installed code pins and bushings in the cable and jack-in
part of the connector.
01-99 variants of location of the installed code pins and bushings in the cable and jackin part of the connector.
Completing of the connectors with contacts during installation with reference to method of installation.
Designation of completing and methods of the contacts installation comprises 2 letters:
The first letter:
connector with a set of uninstalled pilot contacts for installation by crimping.
connector with a set of installed pilot contacts for installation by soldering in the printed circuit boards and with a set of
uninstalled power contacts for installation by crimping.
The second letter: connector with a set of uninstalled RF contacts of standard size 5 and 1.
D.
Interpretation of alphanumerical designation of NSX electrical connector by "RADIALL" (Ref.

Table 118).
EFFECTIVITY:
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TABLE 118
ALPHANUMERIC DESIGNATIONS OF NSX ELECTRICAL CONNECTOR BY

"RADIALL"
Connector series
NSX 2 R 202 S 00 01
Housing design:
E Protected against environmental impacts. Protected by
- rubber O-ring along the perimeter of connector housing (only from the cable part);
- additional rubber routing of local protection glued to the insulators on the side of
the harness;
- inner sealing of the insulator by means of sealing compound.
N Unprotected
F SemiprotectedIs protected only by the rubber routing of local protection glued
to the insulators.
Connector parts:
R Jack-in part (temporary blanking on the connector in as delivered state red
colour).
P Cable part (temporary blanking on the connector in as delivered state yellow
colour).
Arrangement of the insulators for the power and RF contacts:
101 - 2 standard insulators (designation 60) for 60 pilot contacts of standard size 22 in the zones
and and special insulator (designation 52) for the power and RF contacts in the zone of
the housing 1.
201 - 2 standard insulators (designation 150) for 150 pilot contacts of standard size 22 in the
zones and and special insulator (designation 132) for the power and RF contacts in the
zone of the housing 2.
zones and and special insulator (designation 132) for the power and RF contacts in the
zone of the housing 2.
zones and and special insulator (designation 34) for the power and RF contacts in the zone
of the housing 2.
202 special insulator (designation 711) for the pilot and RF contacts in the zone , standard
insulator (designation 150) for 150 pilot contacts of standard size 22, in the zone and special
insulator (designation 132) for the power and RF contacts in the zone of the housing 2.
205 standard insulator (designation 150) for 150 pilot contacts of standard size 22 in the zone
, special insulator (designation 711) for the pilot and RF contacts in the zone and special
insulator (designation 132) for the power and RF contacts in the zone of the housing 2.
203 2 special insulators (designation 711) for the pilot and RF contacts in the zone and
and special insulator (designation 132) for the power and RF contacts in the zone of the
housing 2.
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213 wave guide in the zone , special insulator (designation 711) for the pilot and RF contacts
in the zone and special insulator (designation 132) for the power and RF contacts in the zone
of the housing 2.
301 4 standard insulators (designation 150) for 150 pilot contacts of standard size 22 in the
zones , C, E, F and 2 special insulators (designation 132) for the power and RF contacts in
the zones and F of the housing 3.
zones , C, E, F and special insulator (designation 100) for 100 pilot contacts of standard size 22
in the zone and special insulator (designation 132) for the power and RF contacts in the zone
F of the housing 3.
zones , C, E, F and special insulator (designation 132) for the power and RF contacts in the
zone and special insulator (designation 100) for 100 pilot contacts of standard size 22 in the
zone F of the housing 3.
zones , C, E, F and 2 special insulators (designation 100) for 100 pilot contacts of standard size
22 in the zones and F of the housing 3.
Completing of the connectors with contacts during installation with reference to method of
installation.
connector of the uninstalled pilot contacts for installation by crimping is delivered without
contacts.
S connector of the contacts for installation by soldering in the printed circuit boards and of the
uninstalled power contacts for installation by crimping is delivered as a set.
connector with a set of installed pilot contacts for installation by soldering in the printed circuit
boards.
Method of connector housing mounting on the article
00 rigid mounting by 4 screws, maximum diameter of the attachment holes on the article is 3.80
mm (0.148 bia)
00 - code pins and bushings are not installed in the cable and jack-in part of the connector.
01 - standard position of the installed code pins and bushings in the cable and jack-in part of the
connector.
01-99 variants of location of the installed code pins and bushings in the cable and jack-in part of the
connector.
TABLE 119
Code
101
102
103
104
105
106
Plug A
60
60
blank
60
blank
60
NSX ARINC 600: COMBINATION CODE FOR THE PLUGS (FOR SIZE 1):
Plug
Plug B
60
60
60
blank
blank
blank
Plug
5C2
blank
5C2
5C2
5C2
blank
Code
107
108
109
110
111
112
Plug A
30T2
60
blank
60
blank
60
Plug
Plug B
30T2
60
60
60
30T2
4C
EFFECTIVITY:
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Plug
40
40
blank
4
40
5C2
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RRJ-95B
TABLE 120
Plug B
Plug
Code
Plug A
Plug B
Plug
150
13C2
230
121
121
66
260
wave
guide
150
85
150
13C2
231
121
1010
66
261
wave
guide
150
100
71C1
71C1
13C2
232
120T2
60
66
262
150
60
34
204
wave
guide
150
13C2
233
120T2
150
100
263
24
24
66
205
150
71C1
13C2
234
60
60
132
264
blank
24
100
206
150
150
100
235
150
C4
34
265
24
150
132
207
71C1
150
100
236
C4
C4
34
266
121
121
85
208
150
71C1
100
237
150
120T2
100
267
24
24
6P6
209
71C1
71C1
100
238
blank
60
66
268
60
121
59
210
wave
guide
71C1
100
239
1202
120T2
66
269
1010
150
13C2
211
150
150
blank
240
1202
1010
132
270
150
150
59
212
71C1
71C1
Blank1
241
150
60
6T6
271
1202
13C2
213
71C1
wave
guide
13C2
242
150
1010
13C2
272
150
150
20T4
214
wave
guide
71C1
13C2
243
150
blank
100
273
150
13C2
215
150
73C3
13C2
244
150
blank
blank
274
711
85
216
C2
1C71
85
245
711
711
85
275
150
60
34
217
150
150
13C2
246
711
blank
blank
276
150
blank
100
218
150
wave
guide
13C2
247
blank
150
85
277
171
150
13C2
219
150
2C
13C2
248
blank
150
220
71C1
C2
85
249
221
71C1
71C1
13C2
250
blank
222
blank
150
13C2
251
Code
Plug A
Code
Plug A
Plug
Plug
Plug
Plug B
Plug
201
150
202
71C1
203
223
blank
blank
224
150
225
150
226
227
100
278
171
171
13C2
blank
279
150
121
13C2
711
blank
280
1202
121
34
blank
blank
100
281
150
121
34
wave
guide
100
282
blank
13C2
13C2
252
blank
blank
13C2
253
C2
150
132
283
150
60
13C2
71C1
blank
254
C2
171
100
284
1202
1202
13C2
150
150
85
255
C2
171
132
285
24
60
100
150
150
34
256
C2
711
132
286
60
60
34
228
150
13C2
257
C2
132
287
blank
60
100
229
1202
120T2
100
259
C4
85
288
blank
121
blank
289
blank
blank
85
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TABLE 121
150
100
150
303
150
150
13C2
304
150
150
100
305
150
150
306
150
307
711
308
13C2
150
309
150
150
13C2
150
310
13C2 blank
Plug F
150
Plug E
302
Plug D
150
Plug
13C2
100
711
100
132 blank
150
132
Plug B
150
Code
Plug A
Plug D
150
Plug F
Plug
301
Plug E
Code
Plug B
Plug
Plug A
Plug
150
132
335
711
C4
150
132
336
blank
150
150
150
100
337
blank
blank
100
blank
150
150
100
338
150
100
150
150
100
blank
150
150
blank
339
C2
100
100
711 13C2
150
711 132
340
C2
132
132
711 132
341
C4
100
100
100
342
C4
132
132
711
100
343
blank
150
100
150
150
132
150
100
344
24
150
132
24
150
132
150
85
711 13C2 71C1
150
311
150
345
60
24
blank
60
24
blank
312
blank
blank 13C2 blank
blank 132
346
150
24
100
150
150
34
313
blank
blank 13C2 blank
blank
100
347
150
150
66
121
314
blank
blank 13C2 blank
150
100
348
1202
100
150
150
132
315
150
316
24
150
85
150
blank 132
1010 132
13C2
150
150
blank
349 1010 1202
100
150
1202
59
blank 13C2
150
150
blank
350
150
1202
100
150
1202
59
317 1202
150
34
1202
150
34
351
150
150
34
150
150
34
318
121
121
616
121
121
66
352
24
24
100
24
24
34
319
121
1202
6T6
121
1202
66
353
150
150
59
150
150
59
320
150
60
100
150
60
100
354
150
150
34
150
321
150
150
100
150
355
150
322
150
150
100
150
150
34
356
150
150
100
323
150
150
100
711
711
100
357
324
150
150
100
358
C4
325
150
150
13C2
132
359
326
150
711
100
150
150
100
327
150
711
100
150
150
328
13C2
150
329
13C2
330
13C2 blank
331
711
150
100
150
150
332
13C2
333
711
711
100
711
334
711
711 blank 711
24
100
150
13
60
60
100
132
150
150
100
132
121
150
100
121
121
132
121
121
132
360
150
150
66
24
24
132
132
361
150
150
150
blank
150
132
362
24
24
34
150
121
34
150
100
363
150
150
59
24
60
59
364
60
24
59
150
150
59
100
365
24
60
100
24
60
100
85
366
150
150
84
150
150
100
711
100
367
150
150
59
368
150
150
59
blank blank
blank blank
blank blank
711 blank
132 blank
blank 132
1202 1202
150
150
100
34
Designation of marking of the sockets for the pilot, power and RF contacts in the insulators of
the connector cable part have mirror reflection.
EFFECTIVITY:
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Wave guides can be installed instead of insulators in the windows "", "" of connectors of
standard size 2.
Interpretation of alphanumerical designation of S-600 series electrical connector is described
in the Table 122.
Installation of the spare contacts and plugs according to the wiring diagram is mandatory.
Quantity of the plugs must be specified in the documents.
TABLE 122
DESIGNATION OF THE AS-DELIVERED STATE OF THE CONNECTOR
1-st letter
Pilot and power

contacts
Connector delivered with

complete set of the pilot
and power contacts of
crimping type
Connector delivered only

with pilot contacts of
crimping type
Connector delivered without pilot and power contacts
2-nd letter
Coaxial contacts,
gauge 5
is delivered as a set of pilot contacts, the power

contacts are not installed
D
A
Connector delivered with
coaxial contacts of gauge 5.
Connector delivered
Connector delivered with coaxial contacts of gauge 5
The contacts are delivered
without coaxial contacts
for termination of cable 5021K1011.
as a set. For termination of
RG-142 /U cable
NOTE: The suffixes N and L are not used together.

Designation of the insulators for the pilot and RF contacts indicated in the
"Interpretation of the alphanumeric designation of NSX electrical connector" (Ref.
Table 123):
TABLE 123
DESIGNATIONS OF THE INSULATORS FOR THE PILOT AND RF

CONTACTS
Designation 52
2 power contacts of standard size 16;
1 power contact of standard size 12;
2 coaxial contacts of standard size 5.
Designation 132
2 coaxial contacts of standard size 5
Designation 711
70 pilot contacts of standard size 22;
1 coaxial contact of standard size 1.
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Performance data of connectors S-600 and NSX:

Operating voltage - 115 V, 400 Hz
Operating current for the contacts:
Standard size 22 - 5;
Standard size 20 - 7.5;
Standard size 16 - 13;
Standard size 12 - 23.
Minimum insulation resistance:
under normal conditions 5000 Ohm;
at increased temperature 1000 Ohm.
Insulation strength:
under normal conditions - 1500V;
at decreased pressure - 500V.
Operating conditions:
operating temperature range from - 65 to +125;
quantity of connections / disconnections - 500.
Connection force at 100% contact filling of connectors:
of standard size 1 - 120 N (12.0kGs);
of standard size 2 - 267 N (26.7kGs);
of standard size 3 - 467 N (46.7kGs)
Minimum operating time
1000 h at 125;
10000 h at 20.
Sinusoidal vibration:
within frequency band from 50 to 2000 Hz acceleration (mean-root-square) up to 16.4.
Multiple shock
acceleration - 50
duration, ms - 11
Atmospheric pressure decreased - 50000 feet (15240 m)
Increased humidity relative humidity, 98% at temperature 50.65
E.
Characteristics of the standard contacts
TABLE 124
CABLE CONNECTOR
Method of contact
Contact standard
connection to the
size
conductor
Contact No.
Contact type
SOURIAU
Radiall
22
8660-202
620 200
Pin
20
8660-248
620 310
Socket
16
8660-249
620 330
Socket
12
8660-250
620 340
Socket
Crimping
NOTE: Numbers of the contacts are specified on the tags.
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TABLE 125
BLOCK CONNECTOR
Method of
connection to the
contact
Contact
standard size
Crimping
Contact No.
Radiall
8660-206
620 300
Socket
8660-555
620 360
620 361
620 362
620 363
Socket
8660-230
620 210
Pin
8660-233
620 230
Pin
8660-236
620 240
Pin
22
Soldering on the
printed circuit
boards
20
16
12
Crimping
Contact type
SOURIAU
The power and pilot contacts connected to the conductor by crimping are installed in
the cable and jack-in part of the connector on the harness side.
The contacts connected to the conductor by soldering are installed in the connector on
the side of joining the cable and jack-in parts.
Length "L" of the tail of contact for soldering in the printed circuit board is defined by the
number of the contact in accordance with Table 126.
TABLE 126
DEFINING TAIL LENGTH "L"

Length L
(mm)
3.8 4.3
6.4 7.2
9.5 10.3
12.8 13.1
Contact No.
620 360
620 361
620 362
620 363
TABLE 127
ARRANGEMENT OF THE CONTACTS IN THE INSULATORS OF

CONNECTOR
Contact standard
size
Contact purpose
22
Contact type
Connector cable part
Connector jack-in part
pilot
pin
socket
20, 16, 12
power
socket
pin
5, 1
RF
socket
pin
EFFECTIVITY:
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Fig. 48 Arrangement of the pilot contacts in the connector
Fig. 49 Arrangement of the power contacts in the connector

Tool for termination of the wires and cables in the electrical connectors S-600 and NSX
(Ref. Table 128).
EFFECTIVITY:
ALL
Page 143
20-40-10
Sep 30/11
RRJ-95B
TABLE 128
TOOLS FOR TERMINATION OF THE WIRES AND CABLES IN ELECTRICAL

CONNECTORS S-600 AND NSX (PART 1)
Designation of the tool
"SOURIAU" company
Purpose
"Radiall" company
8365
282 291
Crimping tool for contacts of standard sizes 16

and 12
22520/1-01
IROK-2
8476-01
282 281
Crimping tool for contacts of standard size 22

and 20
22520/2-01
22520/5-01
282 293
Crimping tool for outer bushing of RF contact of
standard size 5.
8362-02
282 972
Head for the crimping tool 22520/1-01 for
crimping of the contacts of standard size 16 and
12.
Standard
size
16
22520/1-02
12
Contact
Contact No.
SOURIAU
Radiall
pin
8660-233
620 330
socket
8660-249
620 230
pin
8660-236
620 240
socket
8660-250
620 340
EFFECTIVITY:
ALL
Page 144
20-40-10
Sep 30/11
RRJ-95B
TABLE 128

"SOURIAU" company
Purpose
"Radiall" company
8476-08
282 971
Positioner for the crimping tool 2250/2-01 for crimping

contacts of standard size 20
Standard
size
20
22520/2-08
8476-14
Contact
Contact No.
SOURIAU
Radiall
pin
8660-230
620 210
socket
8660-248
620 310
282 550
Positioner for the crimping tool 22520/2-01 for inner RF
coaxial contacts of standard size 5
Standard
size
22520/2-14
8660-216
282 970
Contact
Contact No.
SOURIAU
Radiall
pin
socket
8660-2480
Semiprotected
620 121
620021
socket
8660-2280
Unprotected
620 230
Positioner for the crimping tool 22520/2-01 for crimping

contacts
Standard
size
2250/2-23
22520/5-45
282 246
(22520/5-05)
282 945
8522-12
22
Contact
Contact No.
SOURIAU
Radiall
pin
8660-202
620 200
socket
8660-206
620 300
Stamp for the crimping tool 22520/5-01 for bushings of

the contacts of RF coaxial cables
Tool for installation and removal of the contacts of
standard size 12 installed in the insulator on the wiring
side
EFFECTIVITY:
ALL
Page 145
20-40-10
Sep 30/11
RRJ-95B
TABLE 128

"SOURIAU" company
Purpose
"Radiall" company
8522-16
282 929 installation

282 892 removal
8660-160
(91066-1)
Tool for installation and removal of

the crimping contacts of standard
size 16, which are installed in the
insulator on the wiring side


282 890 removal
8660-188

282 891 removal

EFFECTIVITY:
ALL
Page 146
20-40-10
Sep 30/11
RRJ-95B
TABLE 128

"SOURIAU" company
Purpose
"Radiall" company
8660-162
282 500

the contacts of standard size 22 for
soldering in the printed circuit
boards, which are installed in the
insulator on the side of joining the
jack-in and cable parts of the
connector
8660-187 (81969/28-01)
8660-197 (81969/46-12)
Tool for removal of the RF contacts
of standard size 5, 8, which are
installed in the insulator on the
wiring side
282 946
22520/3-1
81969/28-01
Gauge for check of serviceability of
the crimping tool 22520/1-01 and
22520/2-01
TABLE 129
GUARANTEED OPERATING LIFE OF THE WIRING TOOL
Tool
Quantity of cycles
Tool
Quantity of cycles
22520/1-01
22520/2-01
22520/1-02
22520/2-08
22520/2-14
22520/2-23
22520/5-01
22520/5-45
200000
200000
200000
25000
25000
25000
200000
200000
8660-160
8660-188
8522-16
8522-12
8660-187
1000
1000
40
40
1000
EFFECTIVITY:
ALL
Page 147
20-40-10
Sep 30/11
RRJ-95B
Crimping tool 22520/2-01 coming with positioner (Fig. 50):

22520/2-08 for crimping of contacts of standard size 20;
22520/2-23 for crimping of contacts of standard size 22;
22520/2-14 for crimping of inner RF contacts of standard size 5.
Fig. 50 Crimping tool 22520/1-01 coming with head 22520/1-02 for crimping of contacts of standard
size 16, 20, 12
Fig. 51 Crimping tool 22520/2-01 coming with positioner

Contact No., sizes of the connected wires are specified in the Table 130.
EFFECTIVITY:
ALL
Page 148
20-40-10
Sep 30/11
RRJ-95B
Socket
8660-206
620 300
green
Pin
8660-230
620 210
22
orange
Socket
8660-248
620 310
red
Pin
8660-233
620 230
20
orange
620 330
blue
8660-236
620 240
orange
8660-250
620 340
Socket
12
yellow
Socket
8660-249
Pin
16
10
11
12
22520/2-01 22520/2-01
(8476-01)
(282 281)
3
3
4
0.24
0.38
0.60
1.0
5
6
7
0.96
1.23
1.7
2.7
6.35-7.21
22520/1-01 22520/1-01
(8365)
(282 291)
4
5
6
2.5
2.4
3.4
6.35-7.21
22520/1-02 22520/1-02
(8365-02)
(282 972)
0.15
0.24
0.38
0.66
1.4
3.3-4.06
22520/2-23 22520/2-23
(8660-216) (282 970)
22520/2-01 22520/2-01
(8476-01)
(282 281)
1.8
3.99-4.72
22520/2-08 22520/2-08
(8476-08)
(282 971)
EFFECTIVITY:
ALL
Position of the crimping tool selector
Wiring tool
620 200
orange
81969/1-01
Pin
8660-202
81969/1-02
81969/14-03
81969/14-04
Radiall
set
Section
mm
Crimping tool and

positioner MIL
SOURIAU
set
Contact type
SOURIAU Radiall
Range of the
outer
diameters by
insulation
(mm)
Min Max
Depth of the hole for contact tail (mm)
Contact standard size
Contact No.
Sizes of the
connected wire
SELECTION OF THE TOOL IN RELATION TO ELECTRICAL CONNECTORS

Marking of contacts (colour annular
strip)
TABLE 130
Page 149
20-40-10
Sep 30/11
RRJ-95B
F.
Control of the quality of wire termination in the contact

Quality of the wire termination in the contact of connector is provided by the tool.
Transient resistance and breaking strength of termination must comply with requirements
of MIL-DTL-22520 and requirements of Section 20-40-80.
The following is checked during visual inspection of the crimped joint:
- presence of the clearance 1.0 m between the end face of the insulation and end
face of the contact tail;
- cores of the conductor must be seen through the check hole in the contact tail;
Fig. 52 Integrity of the contact electroplated coating

In case damages of the contacts coating are found during crimping, check the crimping tool
and remove it from use if necessary.
G.
Installation of the plugs in the insulators:

Contacts can be absent in the insulators of the electrical connectors in accordance with
the wiring diagram.
In order to protect the connectors against moisture, dust and to provide steady air
exchange the plug must be installed in the insulator or in the rubber routing of local
protection, in relation to design of the electrical connector.
In the connectors, housings of which are made in protected and semiprotected design, the
plugs are installed instead of the absent crimping pilot, power and coaxial contacts and RF
contacts in the rubber routing of local protection on the wiring side (Fig. 53).
Fig. 53 Installation of the plugs in the insulators of the electrical connector of semiprotected and
protected design
EFFECTIVITY:
ALL
Page 150
20-40-10
Sep 30/11
RRJ-95B
NOTE: 1,2,6,7 plug; 3,8 rubber local protection routing; 4,9 plastic insulator; 5,10
housing.
NOTE: Connectors ARINC-600, ARINC-404 in the unprotected design installed in the
pressurized zone can be used without installation of the plug, this is reflected in the
harness drawings, Ref. Section 91 of the WDM.
Casings should be used for connectors of the unprotected design.
TABLE 131
PLUGS FOR ARIN-600 CONNECTORS
Contact size
22
20
16
12
.
Designation P/N as per MIL

MS27488-22
MS27488-20
MS27488-16
MS27488-12
Designation P/N
225-1013-000
225-0070-000
225-0071-000
225-0072-000
Check of the crimping tool:

Operational check of the crimping tools 22520/1-01 and 22520/2-01 is performed by
individual gauges from the set 88-100; 88-200 prior to beginning of the working shift in
accordance with Table 132 and after every 5000 contact crimping operations, Ref. Section
20-20-70.
Fig. 54 Gauge
TABLE 132
Crimping tool
OPERATIONAL CHECK OF THE CRIMPING TOOLS

Gauge / set of gauges
SOURIAU
22520/1-01
SOURIAU
8365
RADIALL 282 291
22520/3-1
88-100
22520/2-01
SOURIAU
8476-01
RADIALL 282 281
22520/3-1
88-200
22520/5-01
G-140
RADIALL
81 969/1-02
dgo
3.60680.0025
Position of the selector

4
From the set of gauges for each
selector position
8
From the set of gauges for each
selector position
dno-go 3.70840.0025
EFFECTIVITY:
ALL
Page 151
20-40-10
Sep 30/11
RRJ-95B
Check of the tool by means of go gauge (Fig. 55):

- Set the selector to position 4 (8) and fully press on the tool handles.
- The go gauge green colour - must freely pass between the crimping dies. The check can be
performed with positioner or without it.
Fig. 55 Check of the tool by the go gauge

Check by the no-go gauge (Fig. 56):
- Set the selector to position 4 (8) and fully press on the tool handles.
- No-go gauge red colour - must not pass between the crimping dies.
Fig. 56 Check of the tool by the no-go gauge

Gauge for check of the crimping tools is manufactured at the enterprise in accordance with the given
sizes or is ordered together with crimping tools.
CAUTION:
Check of the crimping tool by the gauge must be performed every day before the
work begins. Check of the tool for installation and removal of the contacts must be
performed by the serviceable tools. Quality of the tools must be visually checked by
4 magnifier. Do not use the tools that have mechanical damages.
I.
Connectors BKAD/E/F ARINC600 ITT CANNON

- Pilot contacts.
- Protected and unprotected design variants.
- Polarization of the code pins and bushings.
- Replaceable plug with insulator of size 22 and power contacts.
- Up to 800 contacts of size 22 are installed in one connector.
- Crimping of the coaxial and power contacts;
- Installation of the contacts on the board with wire core twisting on the terminal;
- Specification of DPX series is used with contacts crimping (insertion/removal by the wiring
tool);
- A possibility of wave guides installation is provided.
Connector BKAD/E:
- Installation and removal of the contacts on the wiring side aft;
- Connection of the wires to contact tails by crimping. Sizes of the contacts #22, #20, #16,
#12;
- The connectors are installed on the frame (panel);
EFFECTIVITY:
ALL
Page 152
20-40-10
Sep 30/11
RRJ-95B
- Pilot contacts are interchangeable with contacts of DPX series.

Connector BKAF:
- Installation and removal of the contacts at the front. Contact size #22 is used for soldering,
the terminal is used for twisting of the wire core on the contact (terminal);
- Only pilot contacts of size #22 are used in connectors of the series ARINC600;
- The plug is delivered in the form on the pins only, the outlet in the form of sockets of size
#22.
TABLE 133
SPECIFICATION OF MATERIALS
591/A380
Housing and
wave guide
Material
BKAD
Aluminium alloy
BKAE
Aluminium alloy
BKAF
Aluminium alloy
Specifications
QQA-591/A380
Coating
Special alloy
Special alloy
Special alloy
MIL-C-5541
Insulator
Material
Contacts
Material
Termination
Heat-resistant
material
Copper alloy
Gold above
nickel
Crimping
Heat-resistant
material
Copper alloy
Gold above
nickel
P.C./Wrap Post
Material
None
Material
None
Heat-resistant
material
Copper alloy
Gold above
nickel
Crimping
Silicone
elastomer
Silicone
elastomer
Coating
Sealant
O-ring
TABLE 134
None
QQ-C-533
MIL-G-45204
None
None
None
None
None
ORDER INFORMATION
BKA
A234
00
01*
F0
Connector series
Grade
Size of the housing
Description of connector configuration
Size 1 Coaxial modifier
Boeing Coaxial modifier
Type of the housing
Connector installation method modifier
Key positions
NOTE: Add the third figure for key positions more than 99.
Connector series: BKA (as per ARINC600).
Grade (design in relation to external impacts):
D Unprotected. Installation of the contacts on the wiring side aft, for crimping;
E Protected. Installation of the contacts on the wiring side aft, for crimping;
F Unprotected. Installation of the contacts at the front for soldering, for size #22 aft installation;
C Protected, Ref. Subject , except for BKAD connector, where there is no O-ring
in the plug;
S Protected there is O-ring between the housing of connector and the insulator.
Installation of the contacts on the wiring side for crimping;
T Unprotected, connector with filter.
EFFECTIVITY:
ALL
Page 153
20-40-10
Sep 30/11
RRJ-95B

maximum quantity of contacts 125;
maximum quantity of contacts 400;
maximum quantity of contacts 800.
Description of connector configuration
SIZE 1 coaxial modifier
The connector has plugs 71W or 2W2 for installation of the coaxial contacts of
different manufacturers.
TABLE 135
DESIGNATIONS OF THE COAXIAL MODIFIER
Boeing code of coaxial

modifier designation
AB
AC
AD
AE
AF
ITTC code
None
B
C
D
E
F
Delivered coaxial ITTC contacts

Connector Plug
Connector Outlet
None
None
349-0013-000
349-0014-000
349-0015-000
349-0016-000
349-0013-000 349-0017-000
349-0014-000 349-0002-000
349-0015-000 349-0018-000
349-0016-000 349-0004-000
349-0015-000 349-0017-000
349-0016-000 349-0002-000
TYPE OF HOUSING: Plug (on the support, frame), Outlet (on the unit)
CONNECTOR INSTALLATION METHOD MODIFIER:
00 Standard structure, hole diameter 148
01 #6-32 size (#12 size 2-62)
Clamping nuts
Connector size
Plug
4
4
8
1
2
3
Outlet
4
6
10
02 Size 1, outlet only less than three attach screws for installation in the printed circuit
board.
03 #4-40 size (#22 size 2-40) for locating holes.
08 Size 2 and 3, plug and outlet only- #4-40 size (#22 size 2-40) for all locating holes.
09 Size 2 and 3, plug and outlet only - #6-32 size (#12 size 2-62) for all locating holes.
16 00 for all the other, except for nickel-plated housings with plating thickness .0008 .00012 with protection against RF interferences for unprotected "C" plugs.
17 00 for all the other, except for nickel-plated housings with plating thickness .0008 .00012 with protection against RF interferences for unprotected "C" plugs.
23 Floating holes for attachment of size .048 min by 4 attach screws.
TABLE 136
Connector
configuration
-005
-060
A060
-065
A065
-120
-125
-013
-017
-071
DESCRIPTION OF CONNECTOR CONFIGURATION

Size of the
housing
1
1
1
1
1
1
1
2
2
2
A
OPEN
OPEN
60
OPEN
60
60
60
OPEN
2W2
OPEN
Identification of insulators (plugs)

B
C
D
OPEN
5W2
60
OPEN
OPEN
OPEN
60
5W2
OPEN
5W2
60
OPEN
60
5W2
OPEN
13W2
2W2
13W2
71W1
OPEN
EFFECTIVITY:
ALL
ARINC
data
Page 154
20-40-10
Sep 30/11
RRJ-95B

Connector
configuration
Size of the
housing
A071
-085
A085
86M
-093
-100
-137
-T141
-142
-155
155M
V155M
158M
-A158M
-163
A163
-164
A164
165M
-A165M
-167
173M
-T173
234
A234
-246
-248
250
250A
-251
-300
-306
-313
-370
-400
-021
-026
-113
-A113
-114
-284
-310
-330M
-A330M
-496
-600
-626
-713
A713
-734
-764
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
71W1
Wave guide
71W1
2W2
4W4
OPEN
121
120T2
71W1
71W1
71W1A
71W1B
2W2
2W2
OPEN
150
150
Wave guide
150
2W2
4W4
2W2
150
150
71W1
120T2
121
OPEN
150
Wave guide
150
150
150
150
150
4W4
OPEN
OPEN
OPEN
4W4
71W1
71W1
2W1
150
121
150
150
150
150
150
150
OPEN
71W1
Wave guide
71W1A
4W4
OPEN
10T10
10T10
71W1
71W1
71W1A
71W1A
71W1B
71W1B
150
OPEN
Wave guide
150
2W2
150
150
71W1B
10T10
71W1
150
120T2
121
150
NONE
150
150
150
150
120T2
150
4W4
OPEN
OPEN
OPEN
4W4
71W1
71W1
2W2
150
121
150
150
150
150
150
150
OPEN
13W2
13W2
13W2
85
100
6T6
13W2
OPEN
13W2
13W2
13W2
85
85
13W2
13W2
13W2
13W2
13W2
13W2
13W2
100
13W2
13W2
13W2
6T6
6T6
100
100
100
OPEN
6T6
13W2
100
100
13W2
13W2
100
13W2
4W4
OPEN
13W2
13W2
13W2
121
OPEN
13W2
100
13W2
100
64
Connector
configuration
Size of the
housing
-800
-269M
271C
271M
-326
3
3
3
3
3
150
2W2
4W4
2W2
OPEN
150
2W2
4W4
2W2
150
100
13W2
13W2
13W2
13W2
ARINC
data
708
709
727
NONE
OPEN
OPEN
OPEN
4W4
71W1
71W1
150
2W2
121
150
150
150
150
150
150
OPEN
OPEN
OPEN
OPEN
13W2
71W1
71W1
150
2W2
6T6
150
150
150
150
150
150
OPEN
13W2
13W2
100
85
OPEN
13W2
13W2
13W2
6T6
OPEN
13W2
13W2
100
3W
100
150
2W2
NONE
4W4
OPEN
150
150
150
150
150
100
100
100
100
13W2
EFFECTIVITY:
ALL
ARINC
data
732
Page 155
20-40-10
Sep 30/11
RRJ-95B
NOTE:
- Diagram of combinations and plugs as per ARINC 702, 710, 711, 712, 714, 715,
716, 723;
- Diagram of combinations and plugs as per ARINC 707, 718, 730;
- Diagram of combinations and plugs as per ARINC 701, 702, 703, 704, 705,
706, 724, 725;
- Diagram of combinations and plugs as per ARINC 701, 717, 726, 729.
KEY POSITIONS (POLARIZATION) FROM 01 TO 99 (ARINC600):

Polarization keys are delivered separately from connector plugs.
Modification (Contact, Coating, Material)
Without insulator Installation on the wiring side. The pilot and power contacts in the plug ""
of connector are not delivered.
FO Contacts in the plug "" of connector are not delivered.
FOO Short contacts. The plug for the wave guide is not delivered.
SA Forward installation for soldered contacts. Contacts installation for crimping on the wiring
side. Power contacts come with the connector.
SB Forward installation for soldered contacts. Contacts installation for crimping on the wiring
SC Forward installation for soldered contacts. Contacts installation for crimping on the wiring
SD Forward installation for soldered contacts. Contacts installation for crimping on the wiring
WA Installation of the contacts for twisting at the front. The contacts for crimping are
installed on the wiring side. Power contacts come with the connector.
WB Installation of the contacts for twisting at the front. The contacts for crimping are
WC Installation of the contacts for twisting at the front. The contacts for crimping are
WD Installation of the contacts for twisting at the front. The contacts for crimping are
NOTE: COAXIAL CONTACTS ARE SEPARATELY ORDERED.
EFFECTIVITY:
ALL
Page 156
20-40-10
Sep 30/11
RRJ-95B

BKAF (Outlet installed at
the front)
BKAD/BKAE (PLUG rear part on the wiring side)

Arrangement of the insulators in the housing
or
30T2
28#22
2#8
TWINAX/COAX
(#8

)
Arrangement of the
insulators in the housing
60
60#22
4
4#12
5W2
1#12
2#16
2#5 COAX
or
40
20#22
60
60#22
5W2
1#12
2#16
2#5 COAX
Installed and removed at

the front
Removed aft
Fig. 57 Configurations of contacts - housing size 1
BKAD/BKAE (Plug on the wiring side). Arrangement of the insulators in the housing or F.
6**
6#8
6T6**
6#8
Metal plug
13W2
4#20, 4#12, 3#16
2#5 COAX
24T4**
20#20, 4#8
24#20, 10#18
*Is not implemented in
ARINC system
59**
50#20, 5#16, 4#12
85
80#22, 4#20, 1#16
100
100#22
Fig. 58 Configurations of contacts housing sizes 2 and 3
EFFECTIVITY:
ALL
Page 157
20-40-10
Sep 30/11
RRJ-95B
NOTE: Combinations of size #22 and other contacts of size 20HD, 16, 12 are used in the
plugs (insulators) "C". Contact type of size 22 can be as follows in the
insulator: pin - pin or socket socket. The contacts are installed and
removed aft. The pilot and power contacts are standard. Arrangement of
the contacts in the insulator - as per ARINC600
BKAD/BKAE (Plug - on the wiring side). Arrangement of the insulators in the housing A, B, D, E.
2W2
2#1 COAX
4W4
4 Modified
#1 COAX
(Metal plug)
10T10*
10#8 TRIAX/COAX
(#8 Frame ground)
(Metal plug)
24*
24#12
49T2*
47#20
2#8
60*
60#20
71W1
70#22
1#1 COAX
71W1B
70#22
1#1 COAX
5#12; 110* 5#20

100#22
150
150#22
2#8 TWINAX/COAX; 120T2

118#22
(#8 Frame ground)
5#16; 121* 6#20

110#22
FIG. 59 Configuration of contacts Housing sizes 2 and 3

NOTE: ** - Is not implemented in ARINC system. The contacts are installed and removed
aft. The pilot and power contacts are standard. Insert arrangement in the insulator as per ARINC600.
EFFECTIVITY:
ALL
Page 158
20-40-10
Sep 30/11
RRJ-95B
Arrangement of the insulators in the housing A, B, D, E
Fig. 60 Configurations of the contacts - housing sizes 2 and 3, BKAF outlet installed at the front
NOTE: The contacts are installed and removed at the front. The pilot and power contacts are
standard.
Arrangement of the insulators in the housing C, F
Fig. 61 BKAF outlet housing, the contacts are removed at the front
NOTE: ** - Is not implemented in ARINC system. Contacts of size #22 in the "socket"
insulator, contacts of size #20HD, 16, 12 - in the "pin" insulator. The contacts are
installed and removed at the front.
The pilot and power contacts are standard. Insert arrangement in the insulator - as
per ARINC 600.
EFFECTIVITY:
ALL
Page 159
20-40-10
Sep 30/11
RRJ-95B
BKA *1
BKA *2
BKA *3
Fig. 62 Polarization and positions of the keys

TABLE 137
Position
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
KEY POLARIZATION: PLUG HOUSING
Left Center Right

Key polarization
1
1
1
2
1
1
3
1
1
4
1
1
5
1
1
6
1
1
1
1
6
2
1
6
3
1
6
4
1
6
5
1
6
6
1
6
1
1
5
2
1
5
3
1
5
4
1
5
5
1
5
6
1
5
1
1
4
2
1
4
3
1
4
4
1
4
5
1
4
6
1
4
1
1
3
2
1
3
3
1
3
4
1
3
Plug housing
Left Center Right
Position
Key polarization
76
4
3
1
77
5
3
1
78
6
3
1
79
1
3
6
80
2
3
6
81
3
3
6
82
4
3
6
83
5
3
6
84
6
3
6
85
1
3
5
86
2
3
5
87
3
3
5
88
4
3
5
89
5
3
5
90
6
3
5
91
1
3
4
92
2
3
4
93
3
3
4
94
4
3
4
95
5
3
4
96
6
3
4
97
1
3
3
98
2
3
3
99
3
3
3
100
4
3
3
101
5
3
3
102
6
3
3
103
1
3
2
Position
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
EFFECTIVITY:
ALL
Left
Center Right
Key polarization
1
5
6
2
5
6
3
5
6
4
5
6
5
5
6
6
5
6
1
5
5
2
5
5
3
5
5
4
5
5
5
5
5
6
5
5
1
5
4
2
5
4
3
5
4
4
5
4
5
5
4
6
5
4
1
5
3
2
5
3
3
5
3
4
5
3
5
5
3
6
5
3
1
5
2
2
5
2
3
5
2
4
5
2
Page 160
20-40-10
Sep 30/11
RRJ-95B
Position
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
Left Center Right

Key polarization
5
1
3
6
1
3
1
1
2
2
1
2
3
1
2
4
1
2
5
1
2
6
1
2
1
2
1
2
2
1
3
2
1
4
2
1
5
2
1
6
2
1
1
2
6
2
2
6
3
2
6
4
2
6
5
2
6
6
2
6
1
2
5
2
2
5
3
2
5
4
2
5
5
2
5
6
2
5
1
2
4
2
2
4
3
2
4
4
2
4
5
2
4
6
2
4
1
2
3
2
2
3
3
2
3
4
2
3
5
2
3
6
2
3
1
2
2
2
2
2
3
2
2
4
2
2
5
2
2
6
2
2
1
3
1
2
3
1
3
3
1
Plug housing
Left Center Right
Position
Key polarization
104
2
3
2
105
3
3
2
106
4
3
2
107
5
3
2
108
6
3
2
109
1
4
1
110
2
4
1
111
3
4
1
112
4
4
1
113
5
4
1
114
6
4
1
115
1
4
6
116
2
4
6
117
3
4
6
118
4
4
6
119
5
4
6
120
6
4
6
121
1
4
5
122
2
4
5
123
3
4
5
124
4
4
5
125
5
4
5
126
6
4
5
127
1
4
4
128
2
4
4
129
3
4
4
130
4
4
4
131
5
4
4
132
6
4
4
133
1
4
3
134
2
4
3
135
3
4
3
136
4
4
3
137
5
4
3
138
6
4
3
139
1
4
2
140
2
4
2
141
3
4
2
142
4
4
2
143
5
4
2
144
6
4
2
145
1
5
1
146
2
5
1
147
3
5
1
148
4
5
1
149
5
5
1
150
6
5
1
Position
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
EFFECTIVITY:
ALL
Left
Center Right
Key polarization
5
5
2
6
5
2
1
6
1
2
6
1
3
6
1
4
6
1
5
6
1
6
6
1
1
6
6
2
6
6
3
6
6
4
6
6
5
6
6
6
6
6
1
6
5
2
6
5
3
6
5
4
6
5
5
6
5
6
6
5
1
6
4
2
6
4
3
6
4
4
6
4
5
6
4
6
6
4
1
6
3
2
6
3
3
6
3
4
6
3
5
6
3
6
6
3
1
6
2
2
6
2
3
6
2
4
6
2
5
6
2
6
6
2
Page 161
20-40-10
Sep 30/11
RRJ-95B
Position
Left Center Right

Key polarization
TABLE 138
Position
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

Plug housing
Left Center Right
Position
Key polarization
Position
KEY POLARIZATION - OUTLET HOUSING
Left Center Right

Key polarization
4
4
4
4
4
3
4
4
2
4
4
1
4
4
6
4
4
5
5
4
4
5
4
3
5
4
2
5
4
1
5
4
6
5
4
5
6
4
4
6
4
3
6
4
2
6
4
1
6
4
6
6
4
5
1
4
4
1
4
3
1
4
2
1
4
1
1
4
6
1
4
5
2
4
4
2
4
3
2
4
2
2
4
1
2
4
6
2
4
5
3
4
4
3
4
3
3
4
2
3
4
1
3
4
6
3
4
5
4
3
4
4
3
3
4
3
2
4
3
1
4
3
6
4
3
5
Outlet housing
Left Center Right
Position
Key polarization
76
4
2
1
77
4
2
6
78
4
2
5
79
5
2
4
80
5
2
3
81
5
2
2
82
5
2
1
83
5
2
6
84
5
2
5
85
6
2
4
86
6
2
3
87
6
2
2
88
6
2
1
89
6
2
6
90
6
2
5
91
1
2
4
92
1
2
3
93
1
2
2
94
1
2
1
95
1
2
6
96
1
2
5
97
2
2
4
98
2
2
3
99
2
2
2
100
2
2
1
101
2
2
6
102
2
2
5
103
3
2
4
104
3
2
3
105
3
2
2
106
3
2
1
107
3
2
6
108
3
2
5
109
4
1
4
110
4
1
3
111
4
1
2
112
4
1
1
113
4
1
6
114
4
1
5
115
5
1
4
116
5
1
3
117
5
1
2
Position
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
EFFECTIVITY:
ALL
Left
Center Right
Key polarization
Left
Center Right
Key polarization
5
6
4
5
6
3
5
6
2
5
6
1
5
6
6
5
6
5
6
6
4
6
6
3
6
6
2
6
6
1
6
6
6
6
6
5
1
6
4
1
6
3
1
6
2
1
6
1
1
6
6
1
6
5
2
6
4
2
6
3
2
6
2
2
6
1
2
6
6
2
6
5
3
6
4
3
6
3
3
6
2
3
6
1
3
6
6
3
6
5
4
5
4
4
5
3
4
5
2
4
5
1
4
5
6
4
5
5
5
5
4
5
5
3
5
5
2
5
5
1
5
5
6
5
5
5
Page 162
20-40-10
Sep 30/11
RRJ-95B
Position
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
Left Center Right

Key polarization
5
3
4
5
3
3
5
3
2
5
3
1
5
3
6
5
3
5
6
3
4
6
3
3
6
3
2
6
3
1
6
3
6
6
3
5
1
3
4
1
3
3
1
3
2
1
3
1
1
3
6
1
3
5
2
3
4
2
3
3
2
3
2
2
3
1
2
3
6
2
3
5
3
3
4
3
3
3
3
3
2
3
3
1
3
3
6
3
3
5
4
2
4
4
2
3
4
2
2
Plug housing
Left Center Right
Position
Key polarization
118
5
1
1
119
5
1
6
120
5
1
5
121
6
1
4
122
6
1
3
123
6
1
2
124
6
1
1
125
6
1
6
126
6
1
5
127
1
1
4
128
1
1
3
129
1
1
2
130
1
1
1
131
1
1
6
132
1
1
5
133
2
1
4
134
2
1
3
135
2
1
2
136
2
1
1
137
2
1
6
138
2
1
5
139
3
1
4
140
3
1
3
141
3
1
2
142
3
1
1
143
3
1
6
144
3
1
5
145
4
6
4
146
4
6
3
147
4
6
2
148
4
6
1
149
4
6
6
150
4
6
5
Position
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
EFFECTIVITY:
ALL
Left
Center Right
Key polarization
6
5
4
6
5
3
6
5
2
6
5
1
6
5
6
6
5
5
1
5
4
1
5
3
1
5
2
1
5
1
1
5
6
1
5
5
2
5
4
2
5
3
2
5
2
2
5
1
2
5
6
2
5
5
3
5
4
3
5
3
3
5
2
3
5
1
3
5
6
3
5
5
Page 163
20-40-10
Sep 30/11
RRJ-95B

FIG. 63 Pin code
3559 8001 000

P/N of the housing for the pin part
3559 8000 000

P/N of the housing for the socket part
355 7000 301

P/N of the cable clamp
3559 0004 341

P/N of protective cover for the socket part
Fig. 64 Housing P/N and sizes

TABLE 139
DESIGNATION OF SIM MODULES
EFFECTIVITY:
ALL
Page 164
20-40-10
Sep 30/11
Unified
3559 8000 000
3559 8001 000
ALL
SIM E0816 P
N-C
MIL-C39029/58-364
SIM E0412 S
N-C
MIL-C39029/57-359
12
P
SIM E0816 S
N-C
MIL-C39029/57-358
S
16
EFFECTIVITY:
20-40-10
M 81969/14-04
001112 300
25
M 81969/14-03
3357 0001 301
001112 200
25
006101 000 00
006101 006 00
M 81969/1410
M 22520/1-40
ou../2-10,../7-08
MIL-C39029/58-363
M22520-1-04
ou../7-04
SIM E1220 P
N-C
M22520/1-04
20
M 22520/1-01
ou../2-01,../7-01
M22520-1-01
ou../7-01
MIL-C39029/57-357
M22520/1-01
26 24 22
0.71 1.37
001714 100
02
001704 100 02
M 22520/2-06
M 22520/7-06
M 22520/2-01
M 22520/7-01
001109 190 38
Green
SIM E1220 S
N-C
001109 210 42
Red
001109 300 40
Blue
MIL-C39029/58-360
001109 400 41
SIM E2022 P
N-C
24 22 20
1.01 2.10
22
20 18 16
1.31 2.40
MIL-C39029/57-354
Tool for SIM

module
Plastic extracting tool
For removal of
P/N
For installation of
P/N
Crimping tool DMC (MIL)
Plug P/N, colour
AWG cable, min. max. diameter
Contact size and type
SIM E2022 S
N-C
14 12
P/N of the outlet

and plug housing
Contact code for MIL-C- "Amphenol"
order
TABLE 140
P/N of SIM module

with contacts
*- without contacts, delivered with
housing
RRJ-95B
P/N OF THE HOUSINGS, MODULES, CONTACT CODES AND SIZES, AWG

GAUGE, WIRE DIAMETER, CRIMPING AND WIRING TOOLS
Page 165
Sep 30/11
Standard
3559 9120
000
ALL
Standard
3559 9123
000
SIM E1220 S
N-*
001714 203 02
Standard
3559 9124
000
SIM E0816 P
N-*
001704 301 02
22
Standard
3559 9121
000
SIM E2022 S
N-*
001714 100 02
P
Standard
3559 9122
000
SIM E1220 P
N-*
001704 203 02
S
20
16
EFFECTIVITY:
20-40-10
M 81969/14-03
001112 200
25
M 81969/1410
001704 100
02
3357 0001 301
001714 100
02
006101 008 00- removal of SIM modules with contacts
006101 006 00
M 22520/2-06
M 22520/7-06
M 22520/2-01
M 22520/7-01
M 22520/1-40
ou../2-10,../7-08
M22520-1-04
ou../7-04
001704 100 02
M 22520/1-01
ou../2-01,../7-01
SIM E2022 P
N-*
M22520-1-01
ou../7-01
001112 700
25
M 81969/1406
SP593
TP986
M300 BT
001109 705 49
Grey
001109 19088
Green
UTE C 93425 HE
513
001109 21042
Red
SIM E0108 S
N-C
001109 300 40
8
10 8
3.8 5.15
UTE C 93425 HE
513
001112 400
25
Yellow
1.93 3.70
26 24 22
0.71 1.37
SIM E0108 P
N-C
12
24 22 20
1.01 2.10
MIL-C-39029/58365
20 18 16
SIM E0412 P
N-C
Tool for SIM

module
For removal of P/N
For installation of
P/N
Plug P/N, colour
Contact size and type

order
P/N of the
outlet and
plug housing
P/N of SIM module
with contacts
housing
RRJ-95B
Page 166
Sep 30/11
3559 9121 000
ALL
SIM E2022 P N-*
001714 001 02
3559 9142 000

SIM E0412 S N-*
001714 400 02
P
3559 9130 000

SIM E0108 P N-*
001704 700 02
S
3559 9145 000

SIM E0108 p N-*
001714 700 02
P
3559 9134 000

SIM E2022 S N-*
001704 001 02
S
22
EFFECTIVITY:
20-40-10
001714 100
02
001704 100
02
001112 700
25
3357 0001 301
M 81969/1406
001112 400
25
M 81969/1404
001112 300
25
For removal of P/N
Tool for SIM

module
006101 008 00
M22520/1-04
Plug P/N, colour
For installation of
P/N
SP593; TP986
22520/2-06
22520/7-06
M22520/1-01
Blue
1.31 2.40
006101 006 00
M300 BT
M22520/2-01
22520/7-01
001109 400 41
Yellow
001109 705
49
12
Grey
001704 400 02
P
001109 190 88
Green
SIM E0412 P N-*

14 12
1.93 3.70
3559 9127 000

16
10 8
001714 301 02
3.8 5.15
SIM E0816 S N-*
26 24 22
0.71 1.20

order
3559 9139 000

Contact size and type.
P/N of the outlet

and plug
housing
P/N of SIM module
with contacts
housing
RRJ-95B
Page 167
Sep 30/11
RRJ-95B
TOOLS FOR CRIMPING CONTACTS TERMINATION
16
995- 4
99522520/122520/181969/10001- 5
000101
02
03
585 6
736
12
99599522520/17 22520/181969/140001000201
8
04
04
585
027
Length of
insulation
stripping
Max. diameter
AWG
Plug /
extractor
Extractor
Used on the
plug 0311302-000
Plug
Used on the
outlet 0311287-000
20HD
99599522520/26 22520/281969/10001000101
7
08
02
584
604
Used on the plug

031-1303-000
ITT Cannon
22
CITCETDPXMA995- 3
995DPXMA22520/222520/281969/122-1
0001- 3
000222 Metal
01
23
01
Metal
584 4
015
0703170702560000
0000
Used on the
plug 0311308-000
MIL
Used on the
plug 030-2259000
MIL
Wire size
ITT Cannon
Used on the
outlet 0302273-000
MIL
Positioner
Selector
Socket
Tool designation
Installation/removal tool
Used in the outlet

030-2280-000
Pin
Crimping tool
Used in the
outlet 0302286-000
Size
Contact size and

designation
Designation
ITT Cannon
TABLE 141
9800004804
Metal
26
.054 ,130/,110
24
(1.4) (3.3)/(2.8)
22
9800004805
Metal
22 ,071 ,167/,147
20 (1.8) (4.2)/(3.7)
CET 16-9
Plastic
9800004806
Metal
20
,103 ,207/,230
18
(2.6) (6.9)/(5.8)
16
CET 12-4 CIET-12 14 ,135 ,270/,230

Plastic Plastic 12 (3.4) (6.9)/(5.8)
NOTE: Sizes are given in inches (mm). BKA - thermocouple contact
EFFECTIVITY:
ALL
Page 168
20-40-10
Sep 30/11
RRJ-95B
TOOL FOR TERMINATION OF BKA - THERMOCOUPLE CONTACTS

Wire size
Extractor
Plug /
extractor
CET-DPXMA-22 Metal 070317-0000
980-0004-804 Metal
81969/1-01
Plug
CIT-DPXMA-22-1 Metal 070256-0000
ITT Cannon
MIL
ITT
Cannon
995-0002-015
3
3
4
MIL
22520/2-23
Used on the outlet

031-1113-009
Used on the outlet
031-1113-010
Contact type
ITT
Cannon
Positioner
Toggle switch #
Used on the plug

030-1975-009
Used on the plug
030-1975-010
TABLE 143
MIL
995-0001
84
Socket
22520/2-01
Pin
20
Chromel
Size
Designation
22
Alumel
Designation
Installation/removal tool
AWG
Max.
diameter
26
24
22
Length of
insulation stripping
Crimping tool
,130/,110
(3.3)/(2.8)
Contact size and

designation
.054
(1.4)
TABLE 142
SELECTION OF CONTACTS
Designation
Quantity of coils
Min. pin length
WA
031-1351-000
.250 (6.35)
WB
031-1351-001
.375 (9.52)
WC
031-1351-002
.500 (12.70)
WD
031-1351-003
.641 (16.28)
Extractor
CET-BKAF 22S
BKAF: contacts for soldering in the insulator "" of size 22 (outlet only).
The pilot contacts of size 22 in the new plugs "" are provided with forward installation
of the contacts for soldering in BKAF connector, have unprotected outlet and are
delivered with connector (Ref. Table 144):
TABLE 144
Contact type
SA
SB
SC
SD
BKAF CONTACTS FOR SOLDERING OF SIZE 22 IN THE INSULATOR ""

(OUTLET ONLY)
Designation
031-1352-000
031-1352-001
031-1351-002
031-1352-003
Minimum pin length

.150(3.81)
.250(6.35)
.375(9.52)
.500(12.70)
Wiring tool for removal

CET BKAF 22S
EFFECTIVITY:
ALL
Page 169
20-40-10
Sep 30/11
RRJ-95B
TABLE 145
BKAD/F: SOLDERED PIN - CONTACTS (OUTLET ONLY)
Contact size
Designation
Contact diameter
Min. pin length
20HD
030-2358-000
.032(0.81)
.150(3.81)
16
030-2357-000
.050(1.27)
.150(3.81)
12
030-2356-000
.081(2.06)
.150(3.81)
TABLE 146
BKAF: SOLDERED PIN - CONTACTS (INSTALLED

AT THE FRONT)
Contact size
Designation
Terminal diameter
Min. terminal
diameter
Extractor
20HD
030-3287-000
.030(0.76)
.300*(7.62)
317-1798-00
16HD
030-3287-001
.050(1.27)
.300*(7.62)
317-1798-02
12HD
030-3287-002
.081(2.06)
.300*(7.62)
317-1798-02
NOTE: * - Only for BKAF 13W2 and 5W2 with plugs.

TABLE 147
PIN - CONTACTS OF SIZE 20 AND 16 (INSTALLED AT THE FRONT)
Contact size
Designation
Terminal diameter
Min. pin length
20
030-3296-001
.034(0.86)/.030(0.76)
.260(6.60)
20
030-3296-002
.034(0.86)/.030(0.76)
.385(9.78)
16
030-3297-001
.052(1.32)/.048(1.22)
.260(6.60)
16
030-3297-002
.052(1.32)/.048(1.22)
.385(9.78)
16
030-3297-005
.052(1.32)/.048(1.22)
.300(7.62)
20
030-3296-004
.034(0.86)/.030(0.76)
.300(7.62)
NOTE: The sizes are given in inches and can be changed

COAXIAL CONTACT, SIZE 5 (AFT INSTALLED / REMOVED)
Designation
Central contact ARINC 600

Crimping tool
Cable grade
Pin (outlet)
RG-142/U 349-0014BA-5903/G
000
5021K1011
(Raychem)
349-0016000
RG-223
349-1060100
RG-400
RG-316
Socket
(plug)
3490013000
3490015000
3491059000
3491003000
3491004000
MIL
ITT
Cannon
Crimping of outer housing
Positioner
Daniels
ITT
Cannon
MIL
ITT Cannon
Die
M22520/299501
0001-584
K-345
995-0002-049 M22520/5-01
M22520/545B
CCT- CETHX3-156 C8
M22520/299501
0001-584
K-345
995-0002-049 M22520/5-01
M22520/545B
CCT- CETHX3-156 C8
M22250/299501
0001-584
K-345
995-0002-049 M22520/5-01
M22520/545B
CCT- CETHX3-156 C8
M22250/299501
0001-584
K-345
995-0002-049 M22520/10-01 M22520/10-23
CETC8
M22250/299501
0001-584
K-345
995-0002-049 M22520/10-01 M22520/10-23
CETC8
EFFECTIVITY:
ALL
Wiring tool
TABLE 148
Page 170
20-40-10
Sep 30/11
RRJ-95B
TABLE 149
SCREENED CONTACT, SIZE 12

REMOVED)
(AFT INSTALLED /
Crimping tool .
Central contact ARINC 600
Crimping of outer housing
Cable
ITT
Crimping tool
Positioner
MIL
grade
Cannon
Socket
Pin (outlet)
(plug)
ITT
ITT
MIL
Daniels
Die
Cannon
Cannon
995995995RG249-1767M22520/2M22520/1- M22520/100001- K-182 00020001196A/U
000
01
01
05A
584
051
071
995995995249-1767M22520/2M22520/1- M22520/105071 (HW)
0001- K-182 00020001001
01
01
05A
584
051
071
249995995995M22520/2M22520/1- M22520/10RG-174/U
17680001- K-182 0002000101
01
05A
000
584
051
071
249995995995BMSM22520/2M22520/1- M22520/1022030001- K-182 000200011348(BG)
01
01
05A
000
584
050
071
Designation
TABLE 150
Extractor
MIL
ITT
Cannon
M81969/28- CET-1202
4 Plastic
M81969/28- CET-1202
4 Plastic
M81969/28- CET-1202
4 Plastic
M81969/28- CET-1202
4 Plastic
MODIFIED COAXIAL CONTACTS IN THE PLUG 4W4 OF SIZE 1

(CONNECTOR - PLUG)
Cable grade
Designation
Housing (type)
Set for soldering
Set for termination by

crimping
RG214
349-1043-001
Straight
320-1066-000
320-1066-016
AA-5886
349-1048-000
Straight
320-1066-002
320-1066-018
RG393
349-1051-000
Straight
320-1066-003
320-1066-019
ECS 311201
349-1046-000
Straight
320-1066-001
320-1066-017
AA-5887
349-1049-000
Straight
320-1066-004
320-1066-013
AA-5888
349-1050-000
Straight
320-1066-005
320-1066-014
RG142
349-1047-000
Straight
320-1066-006
320-1066-015
NOTE: The set 349-0000-305 of all coaxial contacts is used for the housing variant TNC
349-1047-001. Set #320-0000-306 is used for termination by crimping.
Termination for soldering is performed using the set #320-0000-304.
TABLE 151
SELECTION OF CONTACTS (CONNECTOR - OUTLET)
Cable
Designation
Housing
Set for soldering
Set for termination by crimping
RG316DS
349-1051-002
Straight
320-1066-008
None
RG142
349-1044-000
Straight
320-1066-007
None
Variant
349-1042-000
SMA
None
None
NOTE: Set #349-0000-304 is used for coaxial contacts 349-1051-002 and 349-1044-000.
Set #320-1042-000 is used for coaxial contacts 349-1042-000i.
Coaxial contacts of size 1 are used for plugs 71W1 only.
The standard coaxial contacts are similar to connectors of DPX series as per
ARINC 404.
EFFECTIVITY:
ALL
Page 171
20-40-10
Sep 30/11
RRJ-95B
TABLE 152
CONNECTOR - OUTLET
Cable grade
RG-214/U
RG-393/U
NSA 935354 NSA
935355
RG-142/U RG-400/U
RG-142/U, RG-225/U
RG-402/U UT-141
RG-402/U UT-141
SMA Termination
TABLE 153
Designation
Housing
(type)
Set for termination
249-1521-000
Housing assembly set
249-1521-002
Straight
021-0144-000
249-2201-000
249-1554-000
249-1604-001
249-1604-002
249-5027-008
249-5027-017
Straight
249-1554-002
021-0144-003
90
249-1604-003
021-0144-006
Straight
Straight
249-5027-016
-
021-0144-001
-
CONNECTOR - PLUG
Cable grade
NSA 935354 NSA
935355
RG-142/U
RG-402/U
RG-393/U
RG-115/U
Designation
-
Housing
(type)
Straight
249-1882-000
249-1885-002
249-5123-000
249-5123-001
Straight
Straight
Set for termination
Housing assembly set
249-2202-000
320-0051-000
249-5027-013
249-5027-015
021-0144-011
021-0144-008
NOTE: The coaxial contacts of size #1 in the insulator "" in the plugs 71W1A, 71W1B and
2W2 of modification "" are produced by different manufacturers.
TABLE 154
CONNECTOR - OUTLET
Cable grade
RG-142B/U
RG-402/U UT-141
SMA termination
RG-214/U RG-393/U BA-6903 (BG)
5012H3012 (Raychem)
RG-142B/U
RG-402/U UT-141
TABLE 155
Cable grade
RG-214/U
RG-393/U
BA-6903
5012H3012
(Raychem)
RG-142B/U
RG-402/U UT-141
AA-5888
ECS-310801
AA-5886
BSX-7004-502
ECS-311201
AA-5887
Designation
349-0021-000
349-0022-000
349-0023-000
349-0002-000
349-0004-000
349-0006-000
349-0008-000
CONNECTOR - PLUG
Modular size 1
Designation
349-0017-000
349-0017-000
349-0017-000
Modular size 1
Designation
349-1053-003
349-1053-007
349-0018-000
349-0005-000
349-0007-000
none
-
349-1053-006
349-1053-008
349-1053-005
349-1053-004
349-1053-003
349-1053-002
349-1053-001
Set for termination of modular

size 1
320-1066-000
320-1066-003
Type
(housing)
Straight
Straight
320-1066-006
320-1066-005
320-1066-002
320-1066-001
320-1066-004
EFFECTIVITY:
ALL
Type (housing)
Right straight
Right straight
Straight
-
Page 172
20-40-10
Sep 30/11
RRJ-95B
NOTE: Coaxial contact, size #8:

TABLE 156
CONNECTOR - PLUG
Contact type
socket:
designation
Type
Short
Crimping
RR-RR
Elongated
349-1087-000
349-1087-001
Termination
Crimping
Soldering
FR-RR
.250(6.35)
FR-FR
.375(9.52)
RF
Cable
AdamsRussell
Co. Inc.
FC11Z
AdamsRussell
Co. Inc.
FC14Z
Soldering
.375(9.52)
RF
Cable
TABLE 157
CONNECTOR - OUTLET
Contact type
socket.
Designation
349-1084-000
349-1084-001
349-1084-002
349-1084-003
Type
Short
Crimping
RR-RR
Elongated
X
X
-
X
X
Termination
Crimping
FR-FR
FR-RR
.250(6.35)
X
X
X
X
349-1086-000
349-1086-001
AdamsRussell
Co. Inc.
FC11Z
AdamsRussell
Co. Inc.
FC14Z
NOTE: Twinax contacts, size 8.

TABLE 158
Contact type
socket
Designation
CONNECTOR - PLUG
Type
Short
Termination
Elongated
Crimping
RR-RR
349-1006-000
349-1081-000
Crimping
FR-RR
Soldering
.250(6.35)
FR-FR
.375(9.52)
M17/176-00002
Tensolite Co.
24463/9
EFFECTIVITY:
ALL
RF Cable
Page 173
20-40-10
Sep 30/11
RRJ-95B
TABLE 159
CONNECTOR - OUTLET
Contact type
socket.
Designation
349-1007-000
349-1080-000
349-1080-001
349-1080-002
349-1080-003
Type
Short
Crimping
RR-RR
X
Elongated
Termination
Crimping
FR-RR
.250(6.35)
FR-FR
.375(9.52)
M17/176-00002
X
X
X
X
X
X
349-1082-000
349-1082-001
349-1088-000
TABLE 160
RF Cable
Tensolite Co.
24463/9
B017X-2(LD)
Tensolite Co.
24463/9
B017X-2(LD)
Tensolite Co.
24463/9
B017X-2(LD)
CONTACTS WITH FRAME GROUND, SIZE 8

Type
Contact type Socket. Designation
Short
Elongated
Short
Elongated
031-3300-000
Connector - outlet
Contact type Socket Designation
030-3306-000
030-3306-001
030-3676-000
Crimping
RR-RR
X
Crimping
RR-RR
*Termination
Crimping
Soldering
FR-RR
.250(6.35)
FR-FR
.375(9.52)
Wire
gauge
8.10AWG
Crimping
FR-RR
FR-FR
.375(9.52)
Wire
gauge
8.10AWG
8.10AWG
8.10AWG
X
X
Soldering
.250(6.35)
X
NOTE: Elongated contacts 3.81 mm;

** - RR-RR aft installation and removal;
FR-RR front installation, aft removal;
FR-FR front installation and removal.
TABLE 161
P/N 225-0090-000
Material: Teflon
PLUGS FOR PROTECTED CONNECTORS BKAE

Designation
Contact size
Colour
225-1013-000
22
Black
.063(1.6)
.040(1.0)
.469(11.9)
225-0070-000
20
Red
.085(2.2)
.065(1.6)
.469(11.9)
225-0071-000
16
Blue
.115(2.9)
.075(1.9)
.469(11.9)
225-0072-000
12
Yellow
.171(4.3)
.121(3.1)
.564(14.3)
225-0090-000
#5 and #8
coaxial
White
.365(9.3)
.287(7.3)
.835(21.2)
EFFECTIVITY:
ALL
Page 174
20-40-10
Sep 30/11
RRJ-95B
TABLE 162
PLUGS FOR PROTECTED CONNECTORS BKAD
P/N 225-0099-000
Material: Teflon
Designation
225-0094-000
Contact size
22
Colour
Black
.069(1.7) .051(1.3) .420(10.7)
225-0095-000
225-0096-000
20
Red
.083(2.1) .069(1.7) .350(8.9)
16
Blue
225-0097-000
.131(3.3) .108(2.7) .320(8.1)
12
Yellow
.187(4.7) .156(4.0) .320(8.1)
225-0098-000 #5 Coaxial (plug)
White
.275(7.0) .251(6.4) .450(11.4)
#5 and #8 Coaxial
(outlet)
White
.275(7.0) .251(6.4)
225-0099-000
1.061
(26.9)
BKAF P/N 225-1058-000 (Size 22 - black)
TABLE 163
CAVITY REDUCER
The cavity reducer is used for fitting of

size #12 contacts in the coaxial contact
#5.
Pin
P/N 021-8756-000
TABLE 164
Socket
P/N 021-8757-000
DUST CAPS
Designation
Description
Designation
025-1121-001
BKAD1-A&B-Plug
025-1155-001
025-1122-001
BKAD 1--Plug
025-1156-001
025-1123-001
BKAD2&3-A&B-Plug
025-1157-001
025-1124-001
BKAD 2&3-C-Plug
025-1158-001
Description
BKAD1-A&BOutlet
BKAD 1-Outlet
BKAD2&3-A&BOutlet
BKAD 2&3-COutlet
Note: Is delivered together with BKA connector only
16.
Crimping of the coaxial contacts

.
Data about the coaxial contacts:

The coaxial contacts are used in the low-frequency connectors during wiring of the RF
cables and provide continuity of the cable outer conductor.
The contact consists of the central contact, in which the cable core is terminated, and of
the outer contact, to which the cable external conductor (braiding) is connected.
In relation to the structure of the electrical connector the coaxial contacts can be installed
on the place of the low-frequency contact of the same gauge or on special places in the
insulator.
The coaxial contacts are usually not part of the set of the electrical connector and are
separately ordered.
Contacts as per MIL-C-39029 have colour marking of the tail, which includes three colour
stripes. The colour code is represented in the contact designation as per MIL-C-39029 by
the last three figures.
EFFECTIVITY:
ALL
Page 175
20-40-10
Sep 30/11
RRJ-95B

The 3rd digit
The 1st digit
The 2nd digit
Fig. 65 Example of arrangement of the colour code stripes

B.
Termination of the coaxial cable RG-179B/U (KX22) in coaxial sockets of gauge 16.
Designation by SOURIAU company: 8599-0920,
Designation as per MIL-C-39029: 39029/77-428.
Colour code: 4 yellow, 2 red, 8 grey.
Fig. 66 Contact structural diagram

(1)
Wash all parts of the contact by ethyl alcohol and dry in the air before the installation.
Do not mix the sets.
(2)
Crimping of the central contact:

(a) Remove the cable protective sheath in accordance with sizes shown in Figure
67. Before that cut the cable end in such a way, so that the shear plane is at
right angle to the cable axis.
15.3
13,5
-0.2 -0,2
Fig. 67 Removal of the cable protective sheath
EFFECTIVITY:
ALL
Page 176
20-40-10
Sep 30/11
RRJ-95B
CAUTION: Do not damage the external conductor during wire stripping.

(b) Install a metal bushing from the contact set onto the cable. Cut the
external conductor according to the sizes shown in Figure 68. Separate
the strands of external conductor, thus putting the braiding a conical
shape, and then bend it backwards:
Metal bushing for external conductor crimping
Fig. 68 Cutting of the bushing and external conductor

(c) According to the sizes shown in Figure 69 cut and remove the insulation
from the internal conductor.
CAUTION: The insulation cut must be uniform and at right angle to the conductor axis.
Do not damage the central conductor wire.
+0
4,5 -0,2
Fig. 69 Cutting and removal of insulation of the internal conductor

(d) Install the insulating bushing and the central contact on the central
conductor in such a way, so that end faces of the parts and insulation of
the internal conductor are tightly pressed to each other (Fig. 70).
Conductor core must be seen through the check hole at that.
Insulation bushing
Central contact
Fig. 70 Insertion of the insulation bushing

(e) Crimp the contact using the tool 22520/2-01 and positioner 22520/2-35.
The tool selector must be set to position 3 and locked.
(f) After crimping check the joint visually - the core must bee seen in the check
hole. If necessary, slightly align the joint by hand to remove bending, do not
apply axial forces at that.
(3)
Crimping of the outer contact:
EFFECTIVITY:
ALL
Page 177
20-40-10
Sep 30/11
RRJ-95B
(a) Insert the crimped central contact in the housing of the coaxial contact until
stop; at that make sure that axis of the central contact coincides with axis of
the housing (Fig. 71):
Fig. 71 Insertion of the crimped central contact in the housing of coaxial

contact
(b) Apply the strands of the cable external conductor on the contact tail and
distribute them uniformly along the tail perimeter, then move the metal bushing
on the screen in such a way, so that size from the rear end face to the contact
shoulder is provided, as it is shown in Figure 71.
(c) Crimp the metal bushing by means of the tool 22520/4-01 and positioner
22520/4-02.
(d) The contacts must be protected by the safety covering after crimping to
prevent ingress of the foreign objects, contaminations etc. in the internal
cavities of the contacts for the period of wiring till the moment of installation in
the insulator of connector.
(e) Wires of external conductor must not project from under the crimping bushing
end face. If necessary they can be cut by a knife with a thin sharp blade with
force applied at right angle to the contacts axis so that the coating of the
contact housing is not damaged.
C.
(f) Wash the contact by a brush wetted in ethyl alcohol and put it in a
polyethylene bag.
Termination of the coaxial cable RG-179B/U (K-22) in the coaxial sockets of gauge 12.
Designation by SOURIAU company: 8667-D03-12R-01/01
Designation by SNC company: SN 2176K12-1-001
The contacts have no colour code.
(1)
Prior to installation wash all parts of the contact in ethyl alcohol and dry in the air. Do not
mix the sets.
(2)
Crimping of the central conductor:
(a)
Remove the cable outer sheath in accordance with sizes shown in Figure 72.
Before that cut the cable end in such a way, so that the shear plane is at right
angle to the cable axis. Install a metal bushing from the contact set onto the cable.
Fig. 72 Removal of the cable outer sheath
EFFECTIVITY:
ALL
Page 178
20-40-10
Sep 30/11
RRJ-95B
CAUTION: Do not damage the external conductor wires during stripping.

(b)
In accordance with sizes shown in Figure 73 bend the external conductor wires
back and cut them. Press the wires tightly to the bushing end face (the wires must
be uniformly distributed along the perimeter).
Fig. 73 Cutting and removal of insulation of the internal conductor, insertion of the
central contact
CAUTION: The insulation cut must be uniform and at right angle to the conductor axis.
Do not damage the central conductor wire.
(c)
Cut excessive length of the central conductor, provide the size 6+0.5 mm.
(d)
Install the central contact on the cable, Ref. Figure 65. At that the core must be
seen through the check hole, and the end face of the cable insulation must bear
against the bottom of hole in the contact insulator.
(e)
Crimp the contact using the tool 22520/2-01 and positioner SN2176K100
(K881S). The tool selector must be set to position 4 and locked.
(f)
(3)
After crimping check the joint visually - the core must bee seen in the check hole. If
necessary, slightly align the joint by hand to remove bending, do not apply axial
forces at that. The contact must be aligned with the cable after crimping. Contact
bending is not permitted.
Crimping of the external conductor:
(a)
Insert the crimped central contact with cable in the housing of the coaxial contact
until stop, at that provide the size from the bushing rear end face to the contact
housing rear end face, Ref. Figure 74.
(b) Use special pincers with stop to hold the cable and transmit the axial force to the
bushing rear end face.
CAUTION: If the contact assembly is correct, axis of the central contact must be
aligned with axis of the housing (Fig. 74, View ).
(c)
Make sure that strands of external conductor are uniformly distributed along the
bushing perimeter.
EFFECTIVITY:
ALL
Page 179
20-40-10
Sep 30/11
RRJ-95B
View
Crimp
Fig. 74 Insertion of the crimped central contact with cable in the housing of coaxial
contact
D.
(d)
Crimp the outer contact by the tool 22520/31-01 and positioner SN2173K101
(G2P844).
(e)
The contacts must be protected by the covering after crimping to prevent ingress
of the foreign objects, contaminations etc.inside the contacts for the period of
wiring till the moment of installation in the insulator of connector.
(f)
Wires of external conductor must not project from under the contact housing.
(g)
If necessary they can be cut by a knife with a thin sharp blade with force applied at
right angle to the contacts axis so that the coating of the contact housing is not
damaged.
(h)
Wash the contact by a brush wetted in ethyl alcohol and put it in a polyethylene
bag.
Termination of the coaxial cable K4 (RG213) in the coaxial sockets of gauge 3.

Designation by RADIALL company: 616112.
The contact has no colour code.
Contact design diagram is shown in Figure 75.
Fig. 75 Contact design diagram

(1)
(2)
Prior to installation wash all parts of the contact in ethyl alcohol and dry in the air, do not
mix the sets.
(a)
Install the metal bushing on the cable and move it along the cable from the place of
termination.
(b)
In accordance with sizes shown in Figure 76 remove the protective sheath, internal
insulation from the cable and cut the external conductor (braiding).
CAUTION: Internal insulation cut must be flat and at right angle to the cable axis.
Shear plane of the protective sheath must be at right angle to the cable axis.
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CAUTION: Do not damage the core and the external conductor during wire stripping.
9
5,5
12,5
Fig. 76 Removal of protective sheath, insulation and cutting of the external conductor
(c)
Insert the central conductor of cable in the central contact tail. At that the tail end
face must bear against the cable insulation end face, and the cable core must be
seen through the check hole (Fig. 77):
Fig. 77 Insertion of the cable central conductor in the central contact tail
(d)
Crimp the contact using the tool 22520/1-01 and positioner 22520/1-13. The
selector must be set to position 8 and locked. The contact can be soldered with
soldering alloy 02, VPr9.
(e)
(3)
Check the crimped joints visually after crimping. The core must be seen through
the check hole, the contact must not be bent or have cracks.
Crimping of the external conductor
(a)
Slightly stretch the strands of external conductor thus putting the braiding into the
conical shape.
(b)
Carefully insert the central contact with cable in the contact housing until stop, at
that the screen braiding must be put onto the knurled tail of the housing.
(c)
Then move the metal bushing on the braiding, Ref. Figure 78. Wires of the external
conductor (braiding) must not project outside the bushing. If necessary, cut the
projecting wires. Make sure that strands of braiding are uniformly distributed along
the tail perimeter.
Fig. 78 Move the metal bushing on the braiding
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CAUTION: Make sure that there are no foreign objects in internal spaces of the
braiding.
E.
(d)
Crimp the bushing by the tool 22520/5-01 and crimping dies 22520/5-61. Use a
hexagon socket with marking .
(e)
Check the contact visually. Wires of the braiding must not project outside the
crimping bushing. There must be no cracks on the bushing, no contaminations on
the contact, the central contact must be located along the socket axis.
(f)
bag.
Termination of the coaxial cables K15 (RG-58), RG141 in the coaxial contact of gauge 7 /n
616030, of cable RG142 in the contact No.616031
616030, 616031 designation by RADIALL company

(1)
Prior to installation wash all parts of the contact in ethyl alcohol and dry in the air.
(2)

(a)
Install the bushing on the cable and move it along the cable from the place of
termination.
(b) In accordance with sizes shown in Figure 80 remove the protective sheath, internal
insulation from the cable and cut the external conductor (screen).
9
Fig. 80 Removal of protective sheath, internal insulation and cutting of the external
conductor
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CAUTION: Internal insulation cut must be flat and at right angle to the cable axis. Shear
plane of the protective sheath must be at right angle to the cable axis. Do
not damage the core and the external conductor during wire stripping.
(c)
seen through the check hole (Fig. 81).
(d)
Crimp the contact using the tool 22520/2-01 and positioner K345 (designation by
DMC company). The tool selector must be set to position 6 and locked. Selector
position for crimping of the cores of cables RG141 and RG142 - 8.
(e)
(3)
Check the joint visually after crimping. The core must be seen through the check
hole, the contact must not be bent or have cracks.
(a)
conical shape.
(b) Carefully insert the central contact with cable in the contact housing until stop, at
that the screen braiding must be put onto the notched tail of the housing.
(c)
Then move the metal bushing on the braiding, Ref. Figure 82. Wires of the
external conductor must not project outside the bushing. If necessary, cut the
projecting wires. Make sure that strands of braiding are uniformly distributed along
the tail perimeter:
Fig. 82 Installation of the metal bushing on the braiding

braiding.
(d)
Crimp the bushing by the tool 22520/5-01 and crimping dies 22520/5-05, use
hexagonal socket with marking .
(e)
Check the contact visually.
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(f)
Wires of the braiding must not project outside the crimping bushing. There must be
no cracks on the bushing, no contaminations on the contact, the central contact
must be located along the socket axis.
(g)
bag.
Termination of the coaxial cable RG142 in the coaxial sockets of gauge 5 /n 61022001,
620 021.
61022001 designation by RADIALL company.

(1)
Prior to installation wash all parts of the contact in ethyl alcohol and dry in the air.
(2)
Installation of the central contact:

(a)
Install the metal bushing on the cable and move it along the cable from the place
of termination.
(b)
In accordance with sizes shown in Figure 84 remove the protective sheath,

internal insulation from the cable and cut the external conductor (braiding) (cable
RG142 has double braiding).
CAUTION: Internal insulation cut must be flat and at right angle to the cable axis.
Shear plane of the protective sheath must be at right angle to the cable
axis.
Do not damage the conductor core wires during stripping.
6.5
3.5
11
Fig. 84 Removal of the protective sheath, internal insulation from the cable and cutting
of braiding
(c)
seen through the check hole (Fig. 85):
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(d)
(3)
The contact can be soldered with soldering alloy 02, VPr9. There must be no
excess soldering alloy on the contact outer side.
(a)
conical shape.
(b)
Carefully insert the central contact with cable in the contact housing until stop, at
that the screen braiding must be put onto the knurled tail of the housing. Then
move the metal bushing on the braiding, Ref. Figure 86. Wires of the external
conductor must not project outside the bushing. If necessary, cut the projecting
wires. Make sure that strands of braiding are uniformly distributed along the tail
perimeter.
Fig. 86 Installation of the metal bushing on the braiding

braiding.
(c)
Crimp the bushing by the tool 22520/5-01 and crimping dies 22520/5-05. Use
a hexagon socket with marking .
(d)
Check the contact visually.
(e)
Wires of the braiding must not project outside the crimping bushing. There must
be no cracks on the bushing, no contaminations on the contact, the central
contact must be located along the socket axis.
(f)
bag.
CAUTION: Termination of the low-frequency wires in the coaxial contacts of size 5

must be performed using adapters p/n 620 941, (contact size 16,12) p/n
620 340, 620 341.
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Fig. 87 Termination of the cable RG142,RG400,5019D3311,ASNE0291SW,AA6343 in

connector 620 145
G.
Termination of the coaxial cable RG179B/U (K22) in the coaxial pins of gauge 16
Designation by SOURIAU company: 8599-916.
Contact designation as per MIL-C-39029: 39029/76-424.
Colour code: 4- yellow, 2 - red, 4 - yellow.

(1)
Prior to installation wash all parts of the contact in ethyl alcohol and dry in the air. Do
not mix the sets.
(2)

(a)
Remove the cable outer sheath in accordance with sizes shown in Figure 89.
Before that cut the cable end in such a way, so that the shear plane is at right
angle to the cable axis.
+0
6.5 -0,3
Fig. 89 Removal of the cable outer sheath

CAUTION: Do not damage the external conductor during wire stripping.
(b)
Install a metal bushing from the contact set onto the cable. Cut the external
conductor according to the size shown in Figure 90. Separate the strands of
external conductor, thus putting the braiding a conical shape, and then bend it
backwards:
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Fig. 90 Installation of the bushing on the cable and backward bending of the braiding
(c)
Cut and strip insulation of the internal conductor, Ref.Fig. 91.

CAUTION: The insulation cut must be uniform and at right angle to the
conductor axis. Do not damage wires of the central conductor.
4.50.5
Fig. 91 Internal conductor insulation stripping

(d)
Install the insulating bushing and the central contact on the central conductor in
such a way, so that end faces of the parts and insulation of the internal
conductor are tightly pressed to each other (Fig. 92). Conductor core must be
seen through the check hole at that:
Fig. 92 Installation of the insulating bushing and central contact on the conductor
(3)
(e)
Crimp the contact using the tool 22520/2-01 and positioner 22520/2-35. The
tool selector must be set to position 3 and locked by retainer.
(f)
After crimping check the joint visually - the core must bee seen in the check hole.
If necessary, slightly align the joint by hand to remove bending, do not apply
axial forces at that.
Crimping of the outer contact:

(a)
Insert the crimped central contact in the housing of the coaxial contact until stop,
Ref. Fig. 93, make sure that axis of the central contact is aligned with axis of the
housing. Apply the strands of the cable external conductor on the contact tail and
distribute them uniformly along the tail perimeter, then move the metal bushing
on the screen in such a way, so that size from the bushing rear end face to the
contact shoulder is provided, as it is shown in Figure 93.
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Fig. 93 Installation of the crimped central contact in the housing of coaxial contact
(b)
17.
Crimp the metal bushing by means of the tool 22520/4-01 and positioner
22520/4-02.
(c)
The contacts must be protected by the safety covering after crimping to prevent
ingress of the foreign objects, contaminations etc. in the internal cavities of the
contacts for the period of wiring till the moment of installation in the insulator of
connector.
(d)
Wires of external conductor must not project from under the crimping bushing
end face. If necessary they can be cut by a knife with a thin sharp blade with
force applied at right angle to the contacts axis so that the coating of the contact
housing is not damaged.
(e)
bag.
Termination of 506424 cable in connectors RADIALL 620 179 011

Description of connector in accordance with Figure 94.
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23* After crimping
Insulator polarization key
RADIALL
620 179 011
Contact outer
housing
Black band
Polarization key
For bushing installation
Alignment insert
Polarization
groove
Insulator
Corrugated screen sleeve
0.85
2#24 central
contacts
Polarization
groove
+0.5*
Insert
Fig. 94 Description of connector RADIALL 620 179 011

Use the following tools for wires termination: extractor 18969 (RADIALL 282549001) or
81969/14-06.
Minimum holding capacity of the harness: 20 N.
Engagement face end

Without
contacts
Rx-
Rx+
Fig. 95 Extractor 18969 (RADIALL 282549001) or 81969/14-06
.
Cable termination procedure:

(1)
Adjusting insert is installed for the plug-contact (not external). As for the external
contact, insulating insert is installed on the cable prior to its stripping. Strip the cable,
Ref. Fig. 96:
20,0
Insert
Fig. 96 Cable stripping
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(2)
Unbraid wire braiding to required length. Cut internal (2 or 4) wires to required length,
Ref. Fig.97:
Fig. 97 Cutting of internal wires

(3)
Move the corrugated sleeve-screen on the braiding against the hair. Before that wind
the braiding end in order to promote movement (Fig.98) of the corrugated sleevescreen:
Fig. 98 Installation of the corrugated sleeve-screen

(4)
Bend the braiding backwards above the corrugated sleeve-screen. Cut the braiding
and strip the wires (2 or 4), Ref. Fig.99:
Fig. 99 Removal of the braiding and stripping of wire

(5)
Move the central contacts on the wires: 2 or 4 central contacts in the quadrax contactplug; 2 or 4 central contacts in the quadrax contact-socket, Ref. Fig.98. Crimp the
central contacts (Ref. Fig. 100).
Crimping tool : 22520/2-01 (RADIALL 282 281)
Cable JSFY Selector 6.
Cable AXON P506424 Selector 5.
Positioner : DANIELS K709 (RADIALL 282581010).
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Fig. 100 Crimping of the central contacts

(6)
The wires (2 or 4) are laid in the grooves of the insert. Corresponding polarization keys
are aligned, when the insulator is installed above the contacts (Fig. 101):
Fig. 101 Wires laying in the grooves

(7)
External housing of the contact-plug and contact-socket have polarization key in the
insulator. The insulator and the inserts have polarization groove. When the
subassembly is installed in the contact external housing, respective keys are aligned
(Fig. 102, 103). External housing of the contact is crimped in the specified area:
crimping tool 22520/5-01 (RADIALL 282 293):
Fig. 102 Contact - socket insulator
Fig. 103 Die 22520/5-07 or 22520/5-13

Plane of the hexagon die hole (gauge 6.5)
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After all components are correctly laid in required sequence, the cable is inserted and
completely closed (Fig. 104):
Fig. 104 Quadraxial contact-plug

18.
Quadraxial contacts and their characteristics:

-
Four pin contacts of size 24 with 360 screening;
Compact structure can be installed in the windows of size 8;
It can be used instead of 2 twinaxial contacts, time of connection to the cable is reduced by
30%, electrical performances are enhanced;
There are front and rear removal variants as well as variants of the contacts for crimping and
straight contact-studs;
Pilot contacts for crimping, crimped housing of size 8;
Standard tools for insertion/removal in the window of size 8, 8660-19/7;
Connection to frame grounding of the cable braiding is possible only via the external housing
of the contact of size 8;
Cables for termination 2236, 2PF870 or ABS1503KD24, F4703-38, F4704-5KD24;
Impedance characteristics: 100 Ohm or 150 Ohm at 100MHz;
Operating temperature : from -65 to +200.
Fig. 105 Quadraxial contacts
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Cable termination:
(1)
Select the cable for the pin contact.
(2)
Remove braiding by 20 mm.
(3)
Insert the sleeve (Fig. 106):

P-MALE
20
S-FEMALE
Fig. 106 Sleeve installation

NOTE: Male pin; Female socket.
(4)
Twist the braiding around the sleeve. Strip the wires to length of 13 mm 0.5 (Fig. 105). All four
wires must have equal length. Cut the braiding, rear part of the sleeve must be left opened.
Strip 3.5 mm of insulation from the wires (Fig. 107). Crimp the contacts by means of the tool
22520/2-01 and positioner K709, pos.5:
13 0,5
3,5
Fig. 107 Stripping of the wires

(5)
Insert the contacts with wires in the insulator (for positioning refer to the front face end view).
Fig. 108 Installation of the contacts in the insulator

NOTE: Insulator key; Male pin, Female socket.
(6)
Align the insulator key with reference marks. Insert till notched part of the sleeve is inside the
housing.
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Polarization
Insulator key
Rx+yellow
Tx+red
Rx+yellow
Tx+red
Tx-blue
Rx-green
Rx-green
Tx-blue
Fig. 109 Alignment of the insulator key with reference marks

(7)
Prior to and during crimping make sure that all parts are on their places. The braiding and
external sheath are crimped by means of the tool 22520/5-01 and die 22520/5-45. Crimping
length is 5 mm
Fig. 110 Crimping of the braiding and external sheath

19.
Electrical connectors ARINC600 and MIL-DTL-38999

.
Connectors ARINC600:
Fig. 111 Sizes and designations for ARINC600 connectors
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B.
Connectors MIL-DTL-38999:
Fig. 112 Quadraxial contact 8 pin for connector 38999
Fig. 113 Quadraxial contact 8 socket for connector 38999
Fig. 114 Quadraxial contact 8 pin for connector 38999 for printed circuit wiring
20.
High-frequency connectors of BNC/TNC series
FIG. 115 Coaxial connectors of BNC/TNC series: installation
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The coaxial connectors BNC/TNC (plugs) 50 and 75 Ohm consisting of the preassembled structure
adapter, insulator, brass housing and heat-shrinking tube - are used for termination of the central
core and and braiding of wide range of the coaxial cables. Temperature range is from -55 to
+150. They are fully connected to connectors as per MIL-C-39012B specification.
Coaxial connectors BNC/TNC implement two Raychem technologies providing high-quality
connection of the coaxial cables. The insulating sleeve is preassembled with adapter and is used for
termination of the central conductor and screen braiding.
Simple installation lies in insertion of the spliced coaxial cable in connector. When heated by hot air
internal solder ring is melted and flows into the check holes. External insulating sleeve is heat
shrunk at heating and solders the screened braiding of the cable along perimeter of 360.
Good hardening protects against vibration and mechanical impact.
Guaranteed reliable soldering and central contact with internal chamber provide general strength of
the system.
There is a quality check possibility after the joint is terminated by soldering.
Splash-proof design provides protection against moisture and other impacts, enhanced mechanical
and electrical characteristics during long time period.
Significant reduction of the time of termination if compared to other termination methods.
This is a recoverable connection, without breakage of the cable end. Just heat and pull out.
Simple installation does not require use of the expensive crimping tools, which must be periodically
inspected and calibrated.
Correctly installed connector provides small voltage drop.
360 circular termination of the screen provides excellent electromagnet compatibility.
The connectors can be used on a wide range of the cables.
Fig. 116 Components of the coaxial connector of BNC/TNC series

The connectors are installed by insertion of the protected end of coaxial cable into connector.
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TABLE 165
CONNECTORS DESIGNATION PROCEDURE

Type of the
housing
No.
RX
-XX
-XX
Type of connector - BNC, TNC
-XX
-00(-H)
Straight
cable part
-01(-H)
Angle cable
part
-02
Straight jackin part for

clamping nut
-03
Straight jackin part
Straight jackin part for

flange
Size of connector:
L - large
M - medium
S - small
50 = 50 Ohm
75 = 75 Ohm
D Brass nickel-plated
housing, gold-plated
brass contact
B = BNC - bayonet
T = TNC - thread
-04
Selection of connector size by the cable type

Selection of connector size by the cable size
Selection by the cable size:
Fig. 117 Standard sizes of the cable
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TABLE 166
SELECTION OF CONNECTOR BY THE CABLE SIZE

Designation by connector type
D
(min-max.)
outer
E
(min-max.)
of screen
F (max.)
of insulation
E (max.)
of the
core
Connector
Size
Nominal
wave
resistance
(Ohm)
5.0-12.5
4.1-9.5
7.3
2.45
large
50
3.5-7.0
2.1-5.0
3.0
1.25
medium
50
1.5-5.5
0.9-3.0
1.5
0.65
small
50
5.0-12.5
4.1-9.5
7.3
2.45
large
75
3.5-7.0
2.1-5.0
3.0
1.25
medium
75
1.5-5.5
0.9-3.0
1.55
0.65
small
75
BNC
RBD-50-LXX
RBD-50-MXX
RBD-50-SXX
RBD-75-LXX
RBD-75-MXX
RBD-75-SXX
TNC
RTD-50-L-
RTD-50--
RTD-50-S-
RTD-75-L-
RTD-75--
RTD-75-S-
NOTE: Stripping of the coaxial cable must be performed using the tool, Ref. Table 1, Section 2020-20.
TABLE 167
CABLE SELECTION BY THE TYPE OF CONNECTOR
RG cables
as per MIL-C-17
RG-165
RG-213
RG-214
RG-58
RG-141
RG-142
RG-174
RG-178
RG-188
RG-6
RG-11
RG-12
RG-59
RG-215
RG-225
RG-303
RG-400
RG-196
RG-316
Raychem
cables
5012F3332
5012A3311
5012E1339
5018D3311
5019D3318
5021D1331
5020A1311
5026A1311
5028A1317
5030A1317
Connector size
Nominal
wave
resistance
(Ohm)
large
BNC
TNC
50
RBD-50-L-XX
RTD-50-L-XX
medium
50
RBD-50-MXX
RTD-50-M-XX
small
50
RBD-50-SXX
RTD-50-S-XX
RBD-75-L-XX
RTD-75-L-XX
RG-144
RG-216
7518A1311
7520A1311
large
75
7526A1317
7524A1311
7528A1317
medium
75
7530A1317
small
75
RG-179
RG-187
Designation by connector type
RBD-XX-X-04
RBD-75-MXX
RBD-75-SXX
RTD-75-M-XX
RTD-75-S-XX
RBD-XX-X-02
Fig. 118 Attachment of connector on the panel

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NOTE: Maximum wall thickness is 3.2 mm.

.
Procedure of installation (soldering and assembly) of the coaxial connectors BNC and
TNC
(1)
Connectors/cables.
TABLE 168
CONNECTORS/CABLES: DESIGNATION CORRESPONDENCE
Connector
RG series cables
Raychem cables
50123311
50121339
5012F3332
5018D3311
5019D3318
5020A1311
5021D1331
RBD-50-L-XX - bayonet
RTD-50-L-XX - threaded
RG 165 U
RG 213 U
RG 214 U
RG 215 U
RG 225 U
RBD-50-M-XX
RTD-50-M-XX
RG 58 CU
RG 141 AU
RG 142 BU
RG 303 U
RG 400 U
RBD-50-P-XX
RTD-50-P-XX
RG 223
RBD-50-S-XX
RTD-50-S-XX
RG 174 U
RG 178 BU
RG 188 AU
RG 196 AU
RG 316 U
5026A1311
5028A1317
5030A1317
RBD-75-L-XX
RTD-75-L-XX
RG 6 U
RG 11 U
RG 12 U
RG 215 U
RG 225 U
7518A1311
7520A1311
RBD-75-M-XX
RTD-75-M-XX
RG 179 BU
RG 187 AU
RBD-75-S-XX
RTD-75-S-XX
(2)
7524A1311
7526A1317
7528A1317
7530A1317
Wiring equipment:
. Heat gun HD 2310 LDC with reflector P/N 073015, 074616 or PR 25-D, 070311 or
similar.
Temperature mode setting:
Recommended temperature = 36030.
b. Heat gun HL 1802 (or more updated version) with reflector for soldering PR 25
(size S or ), or PR 25-D (size L) can be used together with HL1802 adapter.
Temperature mode setting:
Temperature: +360. It is recommended to warm up the heat gun during 30 sec
to operating temperature.
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(3)
Cable preparation:
Fig. 119 Cable preparation before assembly
(4)
NOTE: It is recommended to perform tin-plating of the central wire prior to

installation of size S connector.
Assembly
a. Install the black heat-shrinking tube (3) on the prepared wire (Fig. 120).
b. Push the cable inside the adapter, till the cut of the cable dielectric
bears against the insulator in the adapter (Ref. Fig. 120):
Fig. 120 Procedure of heat-shrinking tube installation on the wire
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(5)
Final assembly:
Fig. 121 Final assembly

c. Warm up the heat gun to the recommended temperature with suitable reflector.
d. Install the adapter in the reflector in such a way, so that the solder ring (1) is in
position (). Perform heating, till the solder ring is melted and flows inside the holes
for soldering alloy and disappears completely. Continue heating during 3 5
seconds.
e. Set the reflector to position (V) within the hexagon flange. Perform heating, till the
solder ring on the tin-plated braiding starts melting and flowing. The soldering must
melt and flow (size L or M).
f. Heat shrink the transparent heat-shrinking tube on the cable insulation. Let it cool
down prior to further use. Avoid direct heating of the low-temperature cable
braiding.
(6)
Check
Make sure that:
a. The solder rings (1) and (2) have melted and completely lost their physical form;
b. The heat-shrinking tube and insulation of the cable have not mechanical damages
or overheat traces.
(7)
Connector assembly
a. Insert the insulator in the housing;
b. Install the O-ring in the housing of connector, if it is part of the set;
c. Screw the adapter into the housing of connector, till the hexagon flange of the
adapter goes inside the housing of connector;
d. Recommended tightening force: 3 N.m.
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(8)
Straight and angular cable connectors
Insulator
Housing
Adapter
FIG. 122 Straight cable connector
Housing
Adapter
FIG. 123 Angular cable connector

(9)
Adapter protection:
For sizes L and perform heat-shrinking of the heat-shrinking tube on the
housing of connector or on the adapter itself.
For size S install the heat-shrinking tube on the adapter.
Heat, till the tube is heat shrunk on the wire insulation and on the soldering
alloy.
Tube on the housing of connector (, L)
Tube on the adapter (S, M, L)
Reflector
Reflector
555
RNF-3000 tube
RNF-3000 tube
RNF-3000 tube
Fig. 124 Tube installation procedure

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B.
Adapter replacement procedure

The adapter can be replaced without cable cutting, if the cable meets the following
requirements:
C.
(1)
Temperature range of the cable is more by 125;
(2)
The dielectric is hard (non-foaming) material such as FEP or TFE.
Removal and replacement of the adapter:
D.
(1)
Cut the black reinforcing heat-shrinking tube along its length. Do not cut it completely;
(2)
Heat the tube. The tube must get separated along the cutting line. Remove the tube
by means of the pliers;
(3)
Remove the housing of connector from the adapter and remove the O-ring;
(4)
Cut the tube above the screen. Heat, till the soldering alloy is melted and flows;
(5)
Remove the adapter from the cable;
(6)
Make sure that the wire is not damaged and re-terminate it, if required. Perform reassembly. Replace all damaged components.
Replacement of the adapter set
TABLE 169
TRA-
ADAPTERS DESIGNATION SYSTEM

NN-
Y-
00-
KT*
M contact pin
F contact socket S
S small size
M medium size
L large size
50 50 Ohm
75 75 Ohm
NOTE: (*) - Including the Teflon insulator and the reinforcing tube.
E.
Housings of connectors:
TABLE 170
RXD-
CONNECTOR HOUSING DESIGNATION SYSTEM

B
-0
Y0 straight cable part

1 angular 90 cable part
2 straight feedthrough jack-in part
3 straight jack-in part for flange
4 straight jack-in part for flange
bayonet, thread
Type
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NOTE: Is used only with adapter and contact-pin. Teflon insulator, which is part of the
set, can not be used together with 90 angular cable part.
F.
Assembly of connector 680 09 03 29 000 12

(Cable assembly in the contacts of connector ACFPZB, AC5FDZ by soldering)
(1)
Prior to soldering perform tin-plating of the wire core using heat gun;
(2)
Perform soldering only by tin 02 or PSr05(VPr9);
(3)
Clearance between the contact face end and insulation face end is 3-4 mm;
(4)
Perform heat shrinking of the tube RNF3000, RW175, K (182 mm long) on

the place of soldering and on the wire;
(5)
Perform heat shrinking of the tube RNF3000 on the housing of connector. L=555
mm.
Fig. 125 Assembly of connector 680 09 03 29 000 12

G.
Connectors of N series (designations: R143.XXX; R176.; R166.XXX; R161.XXX)

Standard termination in connectors 620.119; R143.XXX; R166.XXX; 620.101; R176.:
(1)
Remove the cable sheath 161mm long using the tool, Ref. Subject 7.11;
(2)
Strip the cable to 4.5mm length;
(3)
Cut the cable screen to length of 9.50.5 mm;
(4)
Insert the cable core until stop in the central contact and solder. Use soldering alloy
Sn96/Ag4 or Vpr9 (only for cables with dielectric; PTFE). Crimping is permitted.
(5)
Install the clamping nut, washer, gasket and the split ring on the cable;
(6)
Wind the cable braiding on the ring cone. Cut excessive screen braiding of the cable;
(7)
Install the joint elements in the housing. Recommended tightening torque for clamping
nut is 4.5 Nm. Perform heat shrinking of the tube RNF, ATUM,K (505 mm long) on
the housing of connector
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TABLE 171
STANDARD SIZES OF CONNECTORS
Type of connector
R 161.083
620.119.100
R143.008
R 143.018
R 166.012
R 176.006
620.101
R 166.160
R 166.005
R 176.018
a
4.50.5
6.50.5
Cable splicing sizes (mm)

b
c
1.50.5
8.00.5
2.00.5
9.50.5
d
14.0
0
4.50.5
3.00.5
9.50.5
16.0
3.50.5
4.00.5
6.00.5
1.50.5
3.50.5
3.00.5
7.00.5
9.50.5
0
0
KD 59-202-06 angular
Fig. 126 Standard termination in connectors 620.119; R143.XXX; R166.XXX; 620.101; R176.
H.
Termination of RF cables in the LF connector
Fig. 127 Termination of RF cables in the LF connector
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I.
Assembly of N series connector (Designation R161 083.000)
Fig. 128 Assembly of N series connector

(1)
Install the bushing on the cable. Remove the sheath and insulation of the cable by the
tool, Ref. Table 1, Section 20-20-20.
Fig. 129 Installation of the bushing on the cable

(2)
Insert the cable core until stop in the central contact and solder. Use soldering alloy
Sn/Ag4 or Vpr9 (only for cable with PTFE dielectric).
Fig. 130 Insertion of the cable core in the central contact

(3)
Make an umbrella of the cable braiding. Install the cable on the housing with insulator.
Install the metal clamping ring on the braiding in direction F:
Fig. 131 Installation of the metal clamping ring
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TR 00-002 SWPM
K.
The 35303 connector assembly
Fig. 129 The 35303 connector assembly

(1) Do the cable termination referring to the given dimensions:
13-14
Tin the 9 (Cyrillic)

Sn96/Ag4
2.0
11-12
Fig. 130 Wire termination procedure

(2) Install the details 10, 9 on the wire.Terminate the screened wire as umbrella (fan) and
spread it (Ref.Fig. 131).
Fig.131 Installation of the details 10, 9 and screened wire termination as umbrella
(3) Install the details 8,7 on the wire until stop. Install the details 6,5 consecutively. Install the
cable cord in the contact P/n 06-134724004 for the connector 35303-116; or in the P/n
contact 06-232356 for the connector 35303-117 on the wire core and do a tight crimping
with the AF8 seelctor 3, positioner TH-1A.
Fig. 132 Installation of the details 8, 7, 6, 5 and the contact with its consecutive crimping
(4) Place the screen wire strands along the crimping barrel 8. Move the crimping ferrule 10 on
the braided screen and do the crimping by the HX4 (Y141A) tool.
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TR 00-002 SWPM
Apply enamel or fixer on the all turns of thread

for details 2 and 3
Fig. 133 Location of the crimping sleeve before crimping

NOTE: TO DO THE LOCK-UP OF THE DETAIL 9 TO DETAILS 2 OR 3 CONNECTION PRIOR TO
ASSEMBLY PUT ON THE ALL TURNS OF THREAD OF DETAILS 2 AND 3: IN PYLON - THE
ENAMEL KO-856 (Cyrillic) OR THE THREAD LATCH LOCTITE ANALOG AN302-60; IN
PRESSURIZED AREA - THE ENAMEL -140() (Cyrillic) OR AN302-60. THE ENAMEL DRY OF
THE KO-856 AND -140() IS 12 HOURS. THE THREAD LATCH DRY OF THE LOCTITE AND
AN302-60 IS 30 MINUTES. DRY TEMPERATURE IS FROM +15C TO 25C.
It is recommended to install the contact of detail 1 into detail 2 by TZ-3600 tool.
(1) Fix the detail 9 in universal assembly clamp BT-VS-511 with four sides fixing. Screw in details 9-2 or
9-3 and tighten to 5.65-6.78 Nm (50.0-60.0 lbfin) torque.It is recommended to use the 64-032 torque
wrench, spanner CW12 and TH1599 adapter to do the assembly of connections, or use the
dynamometer BT-ST-701, screw keys TG 69, TG 70-1-12 and Number 10 (Ref. Fig. 134).
Fig. 134 Assembly of the connection details 9-3 and 9-2

(2) Put the heat-shrinkable tubing on the wire and details 2, 3, 9, 10. After completion of connectors
assembly do the isulation resistance test between the central core and the connector case. Normal
value is 1000 and more at 500VDC voltage. Do the electric circuit continuity test.
(3) Prior to plugging the leak sensors connectors do the washing of contact surfaces by isopropyl alcohole
and drying. Referring to Fig. 136 do the filling of the inside components 3 and 4 with Dow Corning 4
(DC4) insulation compound, prevent the ingress of dirt and join the connectors.
NOTE: WHEN DISCONNECTING THE CONNECTOR FROM THE LEAK SENSOR DURING
ASSEMBLY WORKS OR AIRCRAFT MAINTENANCE IT IS NECESSARY TO UNLOCK AND
UNSCREW THE WIRE SECTION OF THE CONNECTOR (DETAIL 3) I.M. PLUG ASSEMBLY WITH
TAIL PIECE. IT IS PROHIBITED TO UNSCREW THE TAIL NUT 9. AFTER ASSEMBLY WORKS OR
AIRCRAFT MAINTENANCE CONNECT, SCREW ON AND LOCK-UP THE CONNECTOR.
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Glue S1255-04 or S1125
Fig. 135 Installation of the heat-shrinkable tubing ATUM on the assembled connector and application of
paint strip to monitor the details 9-2 and 9-3 for unscrewing
Fig. 136 Filling the inside components 3 and 4 with insulation compound before plugging
the leak sensors connectors
Page 209
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L.
STANDART WIRING PRACTICES MANUAL
RF wire fitting into the low frequency connector
Fig. 137 Techniques of the RF wire fitting into the LF connector

M.
Termination of the wires P/N 382410A, P/N 422408, D100-08240 2T-01

for the LVDS bus
Joint guard
20-25
Twisted pair guard
81
5 twisted pairs
m
a
x
Cable 382410
RNF100 (ATUM)
RW,DR for cable with t = +150; 200
ATUM, RNF (RW,DR)

100-110
71
Solder 61 (Cyrillic)
9 (cyrillic) for cable with t = +150; 200
Bandage is 5-6 spires 0.5mm
Fig. 138 Termination of the P/N 382410A, P/N 422408, D100-08240 2T-01 wires
for the LVD bus
Page 210
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TABLE 172
DESIGNATIONS OF THE CONTACTS, CRIMPING AND WIRING TOOLS FOR

TERMINATION
Crimping and wiring
tools
Contact
designation
Manual
MOLEX
43030-0007
43030-0009
43031-007
43031-009
794610-2
170364-1
02-06-5103
104480-9
653-9079-006
523-0750702
372-2514-110
M.
Extraction
Installation
571255000;
63811
Type
2,4,5
57125-5000
Manual
AWG
gauge,
section
(mm)
24-20
0.240.60
Length of
insulation
stripping,
(mm)
2.02.5+0.5
Min, max
wire
diameter
(mm)
1.0-1.85
Connector
designation
43645-0400
43645-0200
43640-0401
43640-0201
794617-4
172233-1
03-06-1032
1625-3R1
104257-2
653-4005-001
Recommended method of wires termination in the contacts of connectors by crimping:
Fig. 143 Recommended method of wires termination in the contacts of connectors by

crimping
N.
Permitted method of wires termination in the contacts by soldering:
Fig. 144 Permitted method of wires termination in the contacts by soldering
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21.
Designation of connectors of the series NIC66S by AMP as per ARINC 600
TABLE 174
DESIGNATION OF CONNECTORS OF THE SERIES NIC66S

BY AMP AS PER ARINC 600
Series designation
Housing type/coating
P plug with chrome-plated conversion coating
PN plug with chemical nickel-plating
R socket (outlet) with chrome-plated conversion coating
RN socket (outlet) with chemical nickel-plating
F size 1 cable part; E size 1 jack-in part;
H size 2 cable part; J size 2 jack-in part;
K size 3 cable part; G size 3 jack-in part
Grade (protection against external impacts)
A non-protected (the contact is aft installed)
B protected (the contact is aft installed)
C protected (the contact is aft installed without O-ring or sealing around the
insertion)
FA non-protected the contact of size 22 if forward installed (contacts of other sizes
are aft installed)
FF non-protected contacts of all sizes are forward installed, except for the coaxial
contact of size 1, which is aft installed.
Plug (Use plugs of the modules modules A, B, D, size 2 and 3)
Wiring identifier standard wiring, holes diameter .146-.156 [3.71 - 3.96]
(4) clamping nuts of size 4-40 (4) clamping nuts of size 6-32
NIC66S
150
01
Manipulation codes
01-36 manipulation codes
Installation of the contacts
X the contacts with connector are not included (are also used for fiber-optical
inserts)
A rear installed clamped contacts are included
B forward installed contacts, diameter .025 [.64] .150[3.81] soldered sockets, size
22
C forward installed contacts, diameter .025 [.64] .250[6.35] soldered sockets, size
22
D forward installed contacts, diameter .025 [.64] .375[9.35] soldered sockets, size
22
E forward installed contacts, diameter .025 [.64] .500[12.70] soldered sockets, size
22
F forward installed contacts, .025 [.64] in the square 150[3.81] sockets, size 22 (1
twist with wire-wrapping) of the wire core (cable part)
G forward installed contacts, .025 [.64] in the square 375[9.52] sockets, size 22 (2
twists with wire-wrapping) of the wire core
H forward installed contacts, .025 [.64] in the square 500[12.70] sockets size 22 (3
twists with wire-wrapping) of the wire core (cable part)
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TERMINATION OF THE WIRES AND CABLES IN THE CONTACTS OF CONNECTORS

1.
General
A.
Types of the connectors, grades and characteristics of the wires must be selected according
to the Sections 20-40-10 and 20-10-10 of the present Manual respectively.
B. In order to prevent ingress of dust, moisture, oils during wiring and transportation, install
protective blankings on the connector contacts. Connectors installed on the aircraft without
connected mating part must also be protected by means of protective blanking caps.
C.
Preparation and splicing of the wires installed in the connector is performed according to
instructions of the Sections 20-20-10. 20-20-20.
D.
Check delivery set prior to the wiring operation: type of connector, contacts, presence of the
wiring tools according to the data specified in the certificate or on the tag (Fig. 1):
Fig. 1 Connector delivery set

E.
The tools for contacts crimping in the connector are selected in relation to the type of
connector, contact and wire size (Fig. 2):
Fig. 2 Connector contact crimping tool
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2.
F.
Quality of the wire termination in the contact of connector is provided by the tool.
G.
Contact crimping quality control is visual.
Wire installation in the connector contact

A.
Distance between the insulation end face and contact tail must be 0.51.0 mm (Fig. 3):
Fig. 3 Correct installation of wire in the contact for crimping (the conductor bears against the bottom of
the crimping cavity, conductor strands are seen in the inspection port)
B. Permissible installation of wire in the contact (Fig. 4):
Fig. 4 Permissible installation (the conductor is partially seen in the inspection port)
C.
Incorrect installation of wire in the contact (Fig. 5 - 7).
Fig. 5 Incorrect installation of wire in the contact (the conductor is not seen in the inspection port)
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Fig. 6 Incorrect installation of wire in the contact (wire insulation is seen in the inspection port)
Fig. 7 Incorrect installation of wire in the contact (conductor strands are outside the crimping
cylinder, distance between the contact end face and wire insulation is more than 1.0 mm)
3.
Crimping of connector contact with wire

A.
Correct contact crimping (Fig. 8):
Fig. 8 Correct contact crimping (eight crimping dents must be arranged in the middle of the tail crimping
part between the inspection port and contact face end; the dents must be uniformly arranged in a circle
and have equal depth)
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B. Permissible contact crimping (Fig. 9):
Fig. 9 Permissible contact crimping (the crimping zone is not in the center of the crimping area; the
inspection port is not deformed)
C.
Incorrect crimping (Fig. 10-12).

Incorrect crimping can be caused by:
- incorrectly selected positioner head;
- getting of foreign objects inside the positioner-head;
- non-aligned and incomplete contact installation in the positioner-head.
Fig. 10 Incorrect crimping (inlet part of the contact was deformed during crimping)
Fig. 11 Incorrect crimping (inspection port was deformed during crimping)
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Fig. 12 Incorrect crimping (multiple contact re-crimping)

D.
The following is not permitted after contacts crimping:

(1)
Formation of cracks on the contact tail (Fig. 13):
Fig. 13 Cracks on the contact tail

(2)
Damaged protective coating of the contact (Fig. 14):
Fig. 14 Damaged protective coating of the contact
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(3)
Axial deformation of the contact (Fig.15):
Fig. 15 Axial deformation of the contact

(4)
Presence of uncrimped wire strands (Fig.16):
Fig. 16 Presence of uncrimped wire strands

(5)
Significant displacement of eight dents to the left or to the right from the set crimping area
(Fig.17, 18):
.
Fig. 17 Significant displacement of eight dents to the right from the set crimping area
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Fig. 18 Significant displacement of eight dents to the left from the set crimping area
4.
E.
If damages of the contact coating are detected, the crimping tool must be checked. If
required, the crimping tool is discarded.
F.
At all stages of the technological cycle the contacts must be protected against ingress of dust,
splashes of water, oil etc., as well as against ingress of the foreign objects inside: chips, wire
cuts. For that the contacts are packed in a fabric covering.
G.
The contaminated contacts are cleaned by ethyl alcohol GOST 18300-87 with further drying
in the air.
Installation of the crimped contacts in the connector sockets

A.
Installation of the crimped contacts in the sockets of connector is performed according to the
present Manual with strict observation of the Operating Manual for the selected tool.
B. The tool for contacts installation in connector is selected depending on the type and size of the
contact (Fig. 19):
Fig. 19 Tool for installation and removal of the contacts DAK 95-, DRK 95C.
The set of the delivered connector includes the plastic tool for contact installation and
removal (Fig. 20).
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Fig. 20 Plastic tool for installation and removal of the contacts 81969-, 15570D.
After installation of the wires all spare contacts are inserted in the connector.
E.
Blanking caps from the set of the connector are installed in the free holes (Fig. 21):
Fig. 21 Blanking caps from the set of connector

5.
Quality control of the wires installation in the connector

.
Check correctness of wiring for compliance with the wiring diagram or wire table.
Check visually presence of blanking caps in the spare contacts of the connector.
Tension the wire to check safe attachment of the contacts in the insulator. At that the force
applied to the wire must be longitudinal and insignificant (Fig. 22):
Fig. 22 Check of safe contacts attachment in the connector insulator by wires tensioning
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6.
Crimping tool
A.
Special-purpose tools must be used for correct crimping.
B. Do not use the tools or equipment that are not intended for these purposes.
C.
The hand tools for contacts crimping can be of two types:

Type 1 (22520/1-01, 22520/2-01);
Type 2 (22520/5-01).
D.
The tools of Type 1 provide crimping by making several dents (Fig. 23-25):
Fig. 23 The tool of Type 1 is used for crimping of the cylindrical point contacts in the electrical connectors
Fig. 24 Contact with installed wire prior to crimping
Fig. 25 Section of the contact in the dents after crimping (four dents are shown). Crimping is performed
by forming several dents (usually there are eight of them)
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E.
The tool of Type 2 is used for moulded crimping by the set of replaceable dies (Fig. 2 6, 27).
Fig. 26 The tool of Type 2 is used for crimping of the coaxial contacts, tips
Fig. 27 Sections of the crimped areas obtained by the tool of Type 2 with different crimping dies
7.
Hand tool for contacts crimping

A.
Base crimping tool M22520/l-0l is used for contacts of the size from 12 to 20 wit wires from 12
to 26 AWG. The crimping depth is manually set depending on the wire size / contact size
combination. Crimping is performed by simultaneous movement of 4 dies to the center, which
form 4 double dents. In relation to the type of the contact, required positioner-barrel or
positioner-head is installed on the tool.
B. Base crimping tool M22520/2-01 is used for contacts of the size from 20; 22 with wires from 18
to 30 AWG. The crimping depth is manually set depending on the wire size / contact size
form 4 double dents. A necessary barrel head is installed on the tool in relation to the contact
type.
C.
This tool is recommended for crimping of the most common contact size 22 in the connectors,
high density modules MIL-DTL-22520/7.
D.
Base crimping tool M22520/7-01 is used for contacts of the size from 16 to 22 with wires from
14 to 26 AWG. The crimping depth is manually set depending on the wire size / contact size
form 4 double dents. A necessary positioner-head is installed on the tool in relation to the
contact type.
This tool has smaller size than M22520/1-01 and correspondingly is more easy-to-use.
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8.
Recommendations for operation with type 1 crimping tool

.
After crimping the toll of Type 1 leaves 8 dents on the crimped part of the contact tail. These
dents provide maximum strength. Only four dents can be seen on one side of the contact
(Fig. 28), another four dents are located on the other side. This is provided by the uniform
distribution of the dents around the crimped part of the contact tail.
Fig. 28 Contact crimped by the tool of Type 1

B.
Structure of the tool of Type 1 (Fig.29):
Fig. 29. Structure of the tool of Type 1 for contacts crimping

C.
Basis of the tool is a double-action ratchet mechanism, which provides similar precise
crimping at each operation. The mechanism opens after the full crimping cycle.
D.
Since this tool is used for a wide range of contact sizes, it is necessary to adjust the crimping
depth. If this requirement is not met, defects can occur: small contacts will not be sufficiently
crimped, big contacts will be over-crimped. The crimping depth is set by means of the eightposition selector (selector button) located on the tool housing. After the required crimping
depth is set in relation to the wire gauge, the selector switch is locked by the spring-type
retainer (Fig. 30).
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Fig. 30 Eight-position selector switch with spring-type retainer on the tool body
E.
The barrel head (Fig. 31) is used for contact positioning during crimping. Variety of the heads
makes it possible to set different contact sizes. Each barrel head has three positioners for
installation of the contacts of different sizes. The positioner have colour code for identification
purposes and are selected by rotation of the positioner barrel on the upper surface of the
barrel head.
Fig. 31 Barrel head
9.
F.
Position of the positioner is selected according to the table attached on the surface of the
turret head in relation to the contact surface.
G.
Prior to use check the crimping tool by the gauges, Ref. Section 20-40-10 (Subject 15.).
Adjustment of the contact crimping tool

A.
Release the handles of the contact crimping tool.
B. Select the barrel head in relation to the contact type.

C.
Release the latch-button on the side face of the barrel head, this sets the positioner barrel to
position providing rotation of the barrel (indexing position) (Fig. 32).
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Fig. 32 Tool adjustment

D.
Set the selected positioner on the retaining ring in such a way, so that the attachment screws
are in front of the threaded holes, and fix them.
E.
After that fix the positioner head by tightening the hexagon screws. The wrench 9/64 is part of
the set (Fig. 33):
Fig. 33 Attachment of the barrel head

F.
Carefully study the information applied on the data table (tag) of the barrel head (Ref. Table
1). Select the colour of the positioner in the Colour code column, the colour must correspond
to the contact designation and size for crimping.
TABLE 1
SELECTION OF THE POSITIONER AND SELECTOR
Contact size
Wire size
Selector position
Colour code
20
24
Red
20
22
Red
20
20
Red
16
20
Blue
16
18
Blue
16
16
Blue
12
14
Yellow
12
12
Yellow
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G.
When the tool is opened, the barrel head is in the indexing position (raised), the positioner
barrel turns, till the colour code on the positioner coincides with indexing marker. The
positioner barrel is recessed till a click is heard (Fig. 34):
Fig. 34 Selection of the positioner for corresponding contact
10.
H.
Select position of the selector according to Table 1 or on the information tag on the tool body
in relation to the wire size.
I.
Remove the spring-type retainer from the selector. Raise the selector and rotate it, till the
selected number (wire gauge) is in front of the selection mark. Install the spring-type retainer.
Crimping of the contacts by the tool of Type 1

A.
Insert the contact with set wire in the positioner on the side of the crimping jaws (Fig. 35).
B.
Press on the tool handles till the ratchet mechanism is actuated. The handles must return to
the opened state.
C.
Pull out the contact and check quality of crimping in accordance with requirements of Subject
3 of the present Section.
Fig. 35 Installation of the contacts in the tool positioner
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11.
Removal of the barrel head

A.
When the tool is in the opened state, raise the positioner barrel. Remove the attachment
screws and remove the head by slight raising.
B. The tool handles must be opened during execution of all procedures: installation, removal of
the head and raising of the positioner barrel.
C.
It is recommended to wipe the crimping jaws of the tool by a thin-haired brush.

DO NOT: - immerse the tool in the cleaning solvents.
- inject the lubricant inside the tool.
- disassemble or repair the tool on your own.
12.
Structure and adjustment of the crimping tool of Type 2

A.
The ratchet mechanism of the crimping tool adjusts the travel of the handles in both directions
and provides identical precise crimping at each operation. The mechanism opens after the full
crimping cycle.
Fig. 36 Tool structure

B. Adjustment of the tool provides the mechanical and electrical strength of crimping. The
following must be done prior to the crimping procedure:
Select the required tool.
Select the required crimping jaws.
Select the corresponding gauge.
Install the crimping jaws.
Calibrate the tool.
C.
13.
Selection of the tool and crimping jaws depends on the crimping type.
Installation of the crimping jaws of the tool of Type 2

A.
Select the required crimping jaws.
B. Align the groove on the crimping jaws with key on the tool.
C.
Fully release the tool handles.
D.
Install the crimping jaws in the corresponding holes on the tool (Fig. 37).
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Fig. 37 Installation of the crimping jaws

E.
Fully press on the tool handles for final installation of the crimping jaws.
F.
When the tool is in the closed state, check visually that the crimping jaws are closed and
correctly positioned in relation to each other.
G.
Install the pins of corresponding diameter in the holes of the tool and pusher (Fig. 38):
Fig. 38 Installation of the pins

14.
Removal of the crimping jaws of tool of Type 2

A.
Remove the pins from the holes of the tool and pusher.
B. Fully release the tool handles.

C.
Carefully remove the upper die by means of a special tool and hammer (Fig. 39).
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Fig. 39 Removal of the crimping jaws

D.
Close the tool handles.
E.
Install a special tool between the pusher and tool body (Fig. 40):
Fig. 40 Removal of the crimping jaws
15.
F.
Open the tool handles.
G.
Remove the pusher.
Check of the crimping tool of Type 2

A.
Carefully check the contact crimping toll prior to its use. Use the gauge 'G 140' for the check
(Fig. 41). The check by the gauge is performed prior to beginning of each crimping procedure.
B. End the 'Go' gauge must freely pass through the serrations, when the tool is in the fully closed
state. The 'No Go' gauge must not pass through the serrations in the fully closed state. If at
least one of the requirements is not met, the tool must be discarded and sent for repair or
calibration (Fig. 41).
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Fig. 41 Check of the tool of Type 2 by G-140 gauge

16.
Contacts crimping by the tool of Type 2

A.
Prepare the wire in accordance with Subjects 6, 7 of the present Section.
B. Install the connector tail in the crimping jaws of the tool (Fig. 42).
C.
Tightly close the tool handles till the ratchet mechanism is actuated.
Fig. 42 Crimping of the coaxial connector

D.
Check crimping of the contact.

The following is not permitted:
formation of cracks on the contact tail.
presence of uncrimped wires.
damaged protective coating of contact.
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TERMINATION OF THE DISCONNECTED AND STANDBY WIRES

1.
General
A.
Optional branches (wires) that are not used according to the wiring diagram are insulated and
tied to the main harness body with observation of the harness (cable) branch bending radius.
B. The disconnected and standby wires are connected to the common harness or are attached to
the structure at distance minimum 75 mm from the connector cable clamp.
C.
Ends of the wires must be insulated from the possible electrical contact as follows:
(1)
By termination by a section of RNF-3000 heat-shrinking tube, 20-25 mm long with

subsequent heat shrinking and flattening of the tube one end by compression (for
operating temperatures up to 100 and wire size up to 10 AWG).
(2)
By termination by a section of RW-175 heat-shrinking tube on the bent end of the wire
with subsequent heat shrinking of the tube (for operating temperatures up to 175
and wire size 2414 AWG). It is permitted not to bend the wire end for wire of big
sizes.
(3)
By termination by means of heat-shrinking blanking caps TC CAPS

Tube
diameter
before
shrinkage
(mm)
Tube
diameter after
shrinkage
(mm)
4001 (-9)
1.6
0.8
4003 (-2)
3.2
1.3
4005 (-8)
6.4
2.5
Designation
Operating
temperature
()
-55+135
Element, wire diameter (mm)
min
max
0.90
1.4
1.50
2.80
3.0
5.5
Designation for order: TC CAPS-4003-2
Fig. 1 Correct termination (the wire is bent backwards to length of 18+2 mm, is insulated by RW-175
heat-shrinking tube, 25+2 mm long and is tied in a harness)
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Fig. 2 Correct termination (the heat-shrinking tube is heat-shrunk on the wire length more than 15 mm)
Fig. 3 Incorrect termination (wire end is not insulated and the wire is not tied in a harness)
D.
Group termination of the wires (jumpers) in the contacts of connector is performed by means
of the insulating solder sleeves of SGRS-1 (2,3,4) series (Table 1):
TABLE 1
CHARACTERISTICS OF THE INSULATING SOLDER SLEEVES OF SGRS1(2,3,4) SERIES

Total
Length Diameter diameter /
Colour
L
section
Number
code
(mm) (mm) (min-max)
2
(/mm )
AWG 24
22
20
18
16
14
12
10
SGRS-1 green
34.8
3.4
1400-4800
0.7-2.4
SGRS-2
red
34.2
4.8
4000-8000
2.0-4.0
SGRS-3 blue
42.0
7.3
700016000
3.5-8.0
41.5
9.1
1500024000
7.5-12.0
CMA 475 754 1216 1900 2426 3831 5874 9354 16983 SGRS-4 yellow
2
mm 0.24 0.38 0.61 0.95 1.21 1.92 2.94 4.74
8.61
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E.
Group termination of not more than seven wires (jumpers) in the contacts of
connector is performed according to Fig. 4:
SGRS-
Bandage
cord
URHR bushing,
66N-68N tape
Fig. 4 Termination of the wires (jumpers) in the connector by means of SGRS-series sleeves
F.
(1)
Take a wire for jumper 11010 mm long, remove insulation from it and
terminate it in the contacts of connector.
(2)
Remove the insulation 81 mm from the ends of the jumpers. Remove the
insulation 91 mm long at distance 10010 mm from the contact.
(3)
Install the SGRS-series solder sleeve on the cores of the wires (jumpers)
and terminate it in accordance with instruction given in the Section 20-2060.
Standard termination of the protected harness

Harness screen is
terminated in the
clamp
Tube
RNF-3000, K
Installation of SO-96 Ref. Section 20-20-60, Subject 3

HCTE
or HTNS tube
355
10-12
S1
252
URHR busing or
66N-68N tape
Fig. 5 Standard termination of the harness protected by HTCE TUBE OR HTMS

braiding with screens setting under the cable clamp screws
HTCE tube is blanked at segment 252 mm from the housing of connector by
means of the heat-shrinking tube RNF, ATUM, DR, K.
The grounding wire can be passed through the separated strands of the braiding
and screen.
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G.
Group termination of the wires (jumpers) in the connector can be performed by means of
splice sleeves of D436-60 type in the quantity of 10 wires, Ref. Section 20-20-70.
H.
Sockets of the contacts in the fire-resistant connectors must be blanked by the standby
contacts with standby wires 100150 mm long (Fig. 6):
Fig. 6 Installation of the standby wires in the fire-resistant connectors

The standby wires must have operating temperature 260C EN series.
Crimp the contact of required size on the core of the standby wire and install it in the
spare socket.
The standby wire must end at distance 75-150 mm from the cable clamp of the connector
tail.
Isolate the end of the standby wire by RW-175 heat-shrinking tube.
Attach the ends of the standby wires by bandage cord Nomex A-A52084 type V. Do not
use polyether bandage cord.
2.
Installation of the contacts in the general purpose connectors

A.
Installation of the spare contacts in the general purpose connectors and installation of the
plastic blankings is mandatory.
B.
Install the standby contacts in the spare sockets and insert the plastic blankings. Select the
blankings in accordance with connector type and contact size.
C.
The plastic blanking is installed in the contact by pushing by finger until stop. At correct
installation head of the blanking must project by 3 6 mm above the connector sealing (Fig.
9). Remove by pincers or fingers. Be careful during installation removal: multiple
installations and removals of the plastic blankings can result in the damage of the connector
insulator.
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Fig. 7 Permissible method: head of the plastic blanking is installed in the insulator
Fig. 8 Incorrect: no plastic blanking is installed
Fig. 9 Correct: head of the plastic blanking projects above the connector sealing
3.
Installation of the contacts in connectors located in the pressurized area

A.
Connectors located in the pressurized area can be subdivided in two classes sealed
and unsealed.
B.
Do not use spare contacts of the sealed connectors installed in the pressurized area.
C.
Installation of the contacts in the spare sockets for sealed connectors installed in the
pressurized area is not mandatory. Installation of the plastic blankings is mandatory.
Installation of the contacts is mandatory, when possible updating of the systems is
required during operation of the test machines (Fig. 10).
Fig. 10 Pressurization of the sockets of the spare contacts in the non-pressurized area (section)
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D.
Termination of the wires (cables) in the contacts of LF connectors is performed as per OST1
04013-83.
E.
Termination of the coaxial cables in the contacts of LF connectors is performed as per OST1
04013-83.
F.
Termination of the coaxial cables in the HF connectors is performed according to instructions

VR0.364.007 (008, 015, 018) IE, OST.G0.054.086 or according to the Manufacturer's
documents.
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INSTALLATION OF THE CONTACTS IN CONNECTOR

1.
General
Selection of the contact crimping tool is performed in relation to the wire or contact size.
2.
Installation of the contacts in connector

A.
Set the wire with contact in the wiring tool groove (Fig.1):
Fig. 1 Installation of the wire with contact in the wiring tool

B. The contacts installation sequence depends on the type of the connector sockets arrangement
(Fig. 2):
Fig. 2 Sequence of the contacts installation in the connector with circular contacts arrangement
C.
Hold the tool with contact at right angle to the surface of the rubber insulator of connector (Fig.
3).
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Fig. 3 Installation of the contacts in connector socket

D.
Carefully insert the tool with contact and wire in connector socket till a slight click is heard (Fig.
4):
Fig. 4 Installation of the contact with wire in connector socket

E.
Remove the tool from the socket of connector, at that hold the tool at right angle to the rubber
insulator of connector. Install all contacts of connector in such a way one after another.
F.
Install all contacts in the connector and insert the plastic blankings (Fig. 5).
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Fig. 5 Installation of the blankings
3.
Removal of the contact with wire

A.
Remove the cable clamp of the connector by TG-69 tool with soft jaws (Ref. Fig. 2, Section
20-40-40).
B. Select the required tool for contacts removal in relation to the contact size.
C.
Hold the tool at right angle relative to the rubber insulator of connector and set the wire in the
cutout of the tool (Fig. 6):
Fig. 6 Installation of wire

D.
Carefully insert the tool in the connector socket till full opening of the clamping lock lugs (Fig.
7).
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Fig. 7 Installation of the wiring tool for contact removal from the connector
E.
Carefully remove the contact, at that hold the wiring tool with wire firmly (Fig. 8):
Fig. 8 Removal of the contact with wire

F.
The spare contacts of the connector must be removed by a special tool RD-103 or a similar
one (Fig. 9):
Fig. 9 Tool for removal of spare contacts
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4.
Instruction on the check of contacts installation in the connector

A.
Installation of the contacts in the connector is checked by a special tool DMC (Fig.
10):
Fig. 10 DMC tool for check of the contacts installation in connector

This tool is used to check the quality of contacts installation in connector sockets.
The tool tips are made of aluminium. All tips are replaceable.
Protective nylon handle is part of the set of each tool.
DMC tool is used to check installation of the contacts of connector types described in the Table 1:
TABLE 1
TYPES OF CONNECTORS TO BE CHECKED BY DMC TOOL

MIL-C-5015
MIL-C-38999
MIL-C-24308
MIL-C-81511
MIL-C-26482
MIL-C-81659
MIL-C-26500
MIL-C-81703
MIL-C-28748
MIL-C-83723
B. Adjustable tool for check of the contacts installation, HT250 type

Designation of HT250 type tool includes only the housing without the tip (Fig. 11).
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Fig. 11 HT250 type tool

C.
Adjustment of HT250 type tool:

(1) Remove the protective handle, remove the lock nut from the housing of connector to
provide free rotation of the adjusting screw.
(2) Align the slide edge with indicting line.
(3) Set the required force, for that turn the adjusting screw in clockwise direction by the
wrench in order to increase the force and counterclockwise - to reduce the force. After
setting the required force tightly attach the lock nut, at that hold the slide on the
indicating line.
TABLE 2
LIST OF HT250 TYPE TOOLS AND FORCE RANGE
TABLE 3
Handle P/N
Force range
(Lbs - 0.4095 kg)
HT250-1
1.5 - 3.0
HT250-2
3.2 - 5.5
HT250-3
4.0 - 8.0
HT250-4
7.0 - 18.0
HT250-5
17.0 - 25.0
HT250-6
24.0 - 40.0
DESIGNATION OF REPLACEABLE TIPS
Contact size
Colour code
Socket tester
Pin tester
12
Yellow
67-012-01
68-012-01
16
Blue
67-016-01
68-016-01
20
Red
67-020-01
68-020-01
22, 22M, 22D
Copper
67-022-01
68-022-01
23
Black
67-023-01
68-023-01
D.
Non-adjustable tool for check of contacts installation, HT210 type.

Each HT210 type tool is provided with special fixed tips (Fig. 12).
Designations of HT210 type tools and the check force in relation to the tip type are given in
the Table 4.
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Fig. 12 Fixed tips for 210 type tool

TABLE 4
LIST OF HT210 TYPE TOOLS
Designation
Socket tester
Pin tester
Force
(lb - 0.4095 kg)
HT210-12
67-012-01
68-012-01
10 3
HT210-16
67-016-01
68-016-01
10 3
HT210-20
67-020-01
68-020-01
10 3
HT210-22
67-022-01
68-022-01
10 3
HT210-23
67-023-01
68-023-01
10 3
HT210-26
67-026-01
68-026-01
21
E.
Contacts installation in the connector is checked as follows:

(1)
(2)
Select the tip for the tool in relation to the contact type. Socket tester pin is
used for the socket, pin tester is used for the pin.
Align the tip of the tool with contact, at that hold the connector in fixed state
(Fig. 13):
Fig. 13 Procedure of the check of contacts installation in connector

(3)
(4)
Press on the tool along g the contact axis till alignment of the slide edge with indicating
line.
The check is satisfactory, if the contact of connector did not move relative to the
previous position.
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INSTALLATION OF THE CABLE CLAMPS

1.
General
Prior to installation check the cable clamp according to data specified in its certificate or on the tag
(Fig. 1):
Fig. 1 Check of the cable clamp according to data specified in the certificate or on the tag
2.
Method of the cable clamp fitting on connector No.1

.
Used tools and accessories

(1)
Tool with soft jaws (Fig. 2):
Fig. 2 Tool TG69P or p/n 8498-03, 5676 with soft jaws for cable clamps tightening
(2)
Blankings for outlet part of the connector (Fig. 3):
Fig. 3 Set of blankings for connector outlet part
(3)
Torque wrench (is usually part of set of blankings for connector outlet part) (Ref. Fig.
4).
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Fig. 4 Set of blankings with torque wrench and tools with -handle
B.
Fitting of the cable clamp according to method No.1:

(1)
Install the cable clamp on the harness.
(2)
Tighten the cable clamp by hand on the connector (Fig. 5):
Fig. 5 Cable clamp fitting on the self-locking connector

(3)
Make sure that none of the wires is clamped. Prior to use of the tool define correct
position of the cable clamp: it must adjoin the connector "tooth".
(4)
Select a blanking for connector outlet part and install it on the connector.
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Fig. 6 Selection of blanking for connector outlet part
Fig. 7 Installation of the blanking on connector

(5)
Install the torque wrench on the blanking (Ref. Fig. 8).
Fig. 8 Torque wrench installation on the blanking

(6)
Tighten the clamp by means of TG-69 tool and click listening adapter (Fig. 9)
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Fig. 9 Tightening of the clamp by TG-69 tool and adapter

(7)
3.
Check quality of the cable clamp tightening, for that turn it in direction of tightening with
a force or use the torque wrenches with tightening torque specified in the Table 1.
Method of cable clamp fitting on connector No.2

.
Tools:
(1)
Belt box wrench (Fig. 10):
Fig. 10 Belt box wrench
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(2)
Dynamometer (Fig. 11):
Fig. 11 Dynamometer
(3)
B.
Blanking of connector outlet part (Ref. Fig. 3).
Fitting of the cable clamp according to method No.2

(1)
Fit the cable clamp on the harness branch.
(2)
Manually tighten the adapter on the connector.
(3)
Make sure that none of the wires is clamped. Prior to use of the tool define correct
position of the adapter: it must adjoin the connector "tooth".
(4)
Select a blanking for connector outlet part for the given connector.
(5)
Set the torque value on the dynamometer in accordance with Table 1 in relation to
connector housing size (Fig. 12):
Fig. 12 Torque value setting on the dynamometer
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TABLE 1
VALUE OF THE CABLE CLAMP TORQUE IN RELATION TO THE

CONNECTOR
Torque value
(lb = 0.4095 kg)
Size of the housing

MIL-C-5015
MIL-C-38999
MIL-C-26482
30
45
30
45
10 & 10SL
30
45
11
30
45
12
50
55
13
50
55
14
50
55
15
50
90
16
70
110
Torque value
(lb = 0.4095 kg)
Size of the housing

MIL-C-5015
MIL-C-38999
MIL-C-26482
17
70
110
18
70
110
19
70
110
20
90
120
21
90
120
22
90
120
23
90
120
24
110
120
25
110
120
28
110
120
32
120
150
36
120
150
(6)
Place the blanking on the connector and install the dynamometer on the blanking (Ref.
Fig. 13).
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Fig. 13 Dynamometer installation on the blanking

(7)
Fit the belt box wrench in the adapter center (Fig. 14):
Fig. 14 Belt wrench fitting

(8)
Tighten the adapter by means of the belt box wrench. At the moment, when fitting of
the adapter becomes tight, turn the tool backwards by 90 degrees, then clamp again
and continue tightening. Repeat this operation, till the tightening level mark indicates
that the adapter is fixed tightly enough dynamometer lamp must come ON at that
(Ref. Fig. 15).
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Fig. 15 Dynamometer with a lamp for tightening level indication

(9)
4.
Repeat tightening four times. Each time check the tightening level.
Method of the cable clamp fitting on the connector No.3

.
Tools:
(1)
Belt box wrench (Fig. 10).
(2)
Dynamometer (Fig. 11).
(3)
Vice with replaceable jaws (Fig. 16):
Fig. 16 Vice with replaceable jaws

B.
Fitting of the cable clamp according to method No.3:

(1)
Install the cable clamp on the harness.
(2)
Manually tighten it on the connector. Make sure that none of the wires is clamped.
Prior to use of the tool define correct position of the cable clamp: it must adjoin the
connector "tooth".
(3)
Select the jaws in relation to the size of connector housing from the set and fit them in
the vice (Ref. Fig. 17).
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Fig. 17 Set of jaws to be installed in the vice

(4)
Fit the cable clamp - adapter in the vice (Fig. 18):
Fig. 18 Cable clamp fitting in the vice

(5)
Set the torque value on the dynamometer in accordance with Table 1 in relation to
connector housing size.
(6)
Install the dynamometer on the belt wrench (Fig. 19):
Fig. 19 Dynamometer fitting on the belt box wrench
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5.
(7)
Fit the belt box wrench in the adapter center.
(8)
Tighten the adapter by the belt box wrench, for that turn the handle of the
dynamometer. At the moment, when fitting of the adapter becomes tight, turn the tool
backwards by 90 degrees, then clamp again and continue tightening. Repeat this
operation, till the tightening level mark indicates that the adapter is fixed tightly enough
dynamometer lamp must come ON at that.
(9)
Repeat tightening four times. Each time check the tightening level.
Selection of the adapter-blankings and assembly tool

Use of the tool for installation of connector tails is based on the following:
Special adapter blankings for connectors, which are installed instead of the mating connector.
They are subdivided according to connector series, size of the housing and by two main
materials of connector housing stainless steel and aluminium alloy. They can be used both
just to retain the connector during manual tightening of the self-locking tail or as part of
equipment complex in different combinations.
Vice for fixation of connectors, which are fitted with a set of 6 pairs of removable V-shaped
jaws. They can be used for fixation of the connectors having diameter from 10 to 100 mm. Vshaped replaceable jaws can be attached in one of 12 positions thus providing required position
of the connector. A layer of polyurethane is applied on the jaws to prevent damages of the
connector. The vice is delivered in a suitable box.
Torque wrenches, which have two options - on the rack and for holding in the hands. Both
structures are fitted with indicating lamp (power supply from the battery), which is actuated at
tightening force from 0 to 200 inches per pound assigned by the Operator. Both structures are
fitted with a square 1/4" for connection to the adapter-blankings. They are calibrated for
correspondence with specification GGG-W-00686C.
General purpose belt wrenches for execution of small scope of works during assembly of repair
of the connectors. The belt width can be from 8 to 25 mm, grip diameter from 12 to 100 mm.
Models with grip diameter up to 300 mm are the most widely used.
.
Adapter-blankings:
(1)
Adapter-blanking is intended to retain the corresponding cylindrical connector with

different positions of the keys. Structure of the adapter blanking minimizes the
required quantity of the tools for operation with different structure of the connectors.
(2)
One tool for connectors with different keys, i.e. one size of connector housing is
designed for the maximum quantity of the possible joints.
(3)
Most adapter - blankings are connected by the connectors, which have six or more
different positions of the keys (Ref. Fig. 20).
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Tails and additional tools
Fig. 20 Standard key arrangement methods

B.
Engagement with several keys

The main factor that defines structure of the tools for connectors clamping is thinness of the
walls of their structure and significant impact of the coating damage on the article
functionality. Therefore engagement with several keys is used for such connectors. This
provides more uniform torque distribution along the cylindrical surface of the connector and
adjacent parts.
C.
Adapter-blanking is available both for the plugs and outlets.

(1)
Most plug-connectors have use threaded connection, and adapter-blankings for plugs
are used for them. But many consumers understand advantages of adapter-blankings
use for assembly and servicing of the outlet-connectors. Both versions are available
for most series of the cylindrical connectors.
(2)
All DMC ADAPTER-BLANKINGS are manufactured with a standard square hole (3/8
or 1/4 in.) for simple use with most torque wrenches and other tools. This eliminates
the necessity in the use of the special fasteners and other problems that occur during
use of the false outlets and similar equipment.
(3)
All DMC ADAPTER-BLANKINGS have indicator (point), which provides visual

orienting on position of the main key on connector. Due to this the user can orient two
components for faultless joint.
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D.
Selection of the adapter-blankings according to specifications of the connectors is performed

(1)
Tools kits produced by "FACOM", "STAHLWILLE" can be used.
(2)
Spacing sleeves OST 1 11113-73 or washers OST 1 34509-80 can be used for
complete tightening of the harness under connector semiclamps.
(3)
For torque value of the coupling nut and lock nut for the connectors (Ref. Table 4):
TABLE 2
SELECTION OF THE SETS OF ADAPTER-BLANKINGS ACCORDING TO

CONNECTOR SPECIFICATIONS
CONNECTOR
ADAPTER-BLANKING SETS
Colour
SPECIFICATION
PLUGS (cable part)
OUTLETS (jack-in part)
MIL-C-5015
CM-S-5015
CM-S-5015R
CHROM.
MIL-C-26482 SERIES 1 & 2
CM-S-264
CM-S-264R
ORANGE
MIL-C-26500
CM-S-837
CM-S-837RB*
GREEN
MIL-C-28840
CM-S-288
CM-S-288R
WHITE
MIL-C-38999 SERIES I
CM-S-389L
CM-S-389LR
BLUE
MIL-C-38999 SERIES II
CM-S-389S
CM-S-264R
GRAY / ORANGE
MIL-C-38999 SERIES III
CM-S-389T
CM-S-389TR
LAVENDER
MIL-C-38999 SERIES IV
CM-S-389B
CM-S-389BR
BEIGE
CM-S-815L
CM-S-815R
YELLOW
CM-S-815S
CM-S-815R
RED
MIL-C-83723 SERIES I
CM-S-264
CM-S-264R
ORANGE
MIL-C-83723 SERIES II
CM-S-5015
CM-S-5015R
CHROM.
MIL-C-83723 SERIES III
CM-S-837
CM-S-837RB
GREEN
PATTERN 602
CM-S-602
CM-S-264R
PURPLE
PATTERN 615
CM-S-SJT
CM-S-264R
GOLDEN
NOTE: (*) - Only bayonet joints (series of outlets with threaded joint is not available).
E.
Adapter-blankings for connectors as per MIL-DTL-38999 series 3
TABLE 3
D38999/26
DESIGNATION SYSTEM
F
30
Specification
Grade
Size of the housing
Contact diagram
Contact type (pin/ socket)
Key position
EFFECTIVITY:
Page 12
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RRJ-95B
Size of
the
housing
TIGHTENING TORQUE VALUES FOR THE COUPLING NUT AND LOCK NUT
FOR CONNECTORS
Coupling nut
min
max
Lock nut
min
Nm
Pressure seal*
max
Torque, N m
5%
Coupling nut
Housing size
TABLE 4
min
Nm
08
0.20
0.7
09
0.20
0.9
10
0.30
1.2
11
0.35
1.4
12
0.35
1.8
13
0.35
1.8
14
0.40
2.3
15
0.40
2.3
16
0.40
2.7
6,0
10.73
5.3
8.0
12.43
8.6
max
min
10.0
15.82
13.0
190012
4.1
6,0
190052
14.0
26,0
19.21
Pressure seal*
max
Torque, N m
5%
9.8
20.0
22.03
10.9
23.0
24.29
12.7
25.0
26,55
13.8
26,0
29.38
15.0
28.0
29.38
Nm
4.1
6,90
Lock nut
Nm
17
0.40
2.7
18
0.60
3.2
19
0.60
3.2
20
0.70
3.6
21
0.70
3.6
22
0.80
4.1
23
0.80
4.1
24
0.90
4.1
25
0.90
4.6
28
1.40
5,5
(*) - Value of the tightening torque for lock nut of the feedthrough connectors 257-093
TABLE 5
BASIC IDENTIFICATION
D38999/26/Straight
D38999/29/Breakaway
D38999/30/Breakaway
D38999/31/Breakaway
CABLE PART
SIZE OF THE
HOUSING
KEY POSITION
ADAPTER
BLANKING:
DESIGNATION
COLOUR
9(A)
N, C, E
CM389T-9A
LAVENDER
9(A)
A, B, E
CM389T-9B
LAVENDER
11(B)
N, D, E
CM389T-11A
LAVENDER
11(B)
A, B, C
CM389T-11B
LAVENDER
13(C)
N, D, E
CM389T-13A
LAVENDER
13(C)
A, B, C
CM389T-13B
LAVENDER
15(D)
N, D, E
CM389T-15A
LAVENDER
15(D)
A, B, C
CM389T-15B
LAVENDER
17(E)
N, A, B
CM389T-17A
LAVENDER
17(E)
C, D, E
CM389T-17B
LAVENDER
19(F)
N, A, B
CM389T-19A
LAVENDER
19(F)
C, D, E
CM389T-19B
LAVENDER
21(G)
N, A, B
CM389T-21A
LAVENDER
21(G)
C, D, E
CM389T-21B
LAVENDER
23(H)
N, A, B
CM389T-23A
LAVENDER
23(H)
C, D, E
CM389T-23B
LAVENDER
25(J)
N, A, B
CM389T-25A
LAVENDER
25(J)
C, D, E
CM389T-25B
LAVENDER
EFFECTIVITY:
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TABLE 6
SET OF ADAPTER-BLANKINGS
Q-TY OF ADAPTERS IN THE
SET
FOR SIZES OF THE

HOUSINGS
CM-S-389T
18
From 9 to 25
Aluminium
CM-S-389T-SS
18
From 9 to 25
Stainless steel
DESIGNATION
TABLE 7
Material of the housing
JACK-IN PART
D38999/20/ flange
D38999/21/Sealed housing
D38999/23/Sealed, for nut
D38999/24/For clamping nut
D38999/25/Sealed, for soldering
D38999/27/Sealed, for welding
TABLE 8
SIZE OF THE
HOUSING
KEY POSITION
ADAPTER BLANKING:
DESIGNATION
COLOUR
9(A)
M389TR-9A
LAVENDER
11(B)
M389TR-11A
LAVENDER
13(C)
M389TR-13A
LAVENDER
15(D)
M389TR-15A
LAVENDER
17(E)
M389TR-17A
LAVENDER
19(F)
M389TR-19A
LAVENDER
21(G)
M389TR-21A
LAVENDER
23(H)
M389TR-23A
LAVENDER
25(J)
M389TR-25A
LAVENDER
9(A)
A, B, C, D, E
CM389TR-9B
LAVENDER
11(B)
A, B, C, D, E
CM389TR-11B
LAVENDER
13(C)
A, B, C, D, E
CM389TR-13B
LAVENDER
15(D)
A, B, C, D, E
CM389TR-15B
LAVENDER
17(E)
A, B, C, D, E
CM389TR-17B
LAVENDER
19(F)
A, B, C, D, E
CM389TR-19B
LAVENDER
21(G)
A, B, C, D, E
CM389TR-21B
LAVENDER
23(H)
A, B, C, D, E
CM389TR-23B
LAVENDER
25(J)
A, B, C, D, E
CM389TR-25B
LAVENDER
Designation
Q-TY OF
ADAPTERS IN THE
SET
FOR SIZES OF THE

HOUSINGS
Material of the
housing
CM-S-389TR
18
From 9 to 25
Aluminium
Adapter-blankings for connectors MIL-C-83723, series 1
TABLE 9
M83723/23
DESIGNATION SYSTEM
G
22
55
Specification
Grade
Size of the housing
Contact diagram
Key position
EFFECTIVITY:
Page 14
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TABLE 10
CABLE PART
BASIC IDENTIFICATION.
M83723/23
M83723/24
M83723/52
M83723/53
Straight
Straight
Straight housing,
self-locking nut
Straight housing,
self-locking
nut
TABLE 11
SIZE OF
THE
HOUSING
KEY
POSITION
ADAPTER BLANKING:
DESIGNATION
COLOUR
ALL
CM5015-8
CHROM.
10
ALL
CM5015-10
CHROM.
12
ALL
CM5015-12
CHROM.
14
ALL
CM5015-14
CHROM.
16
ALL
CM5015-16
CHROM.
18
ALL
CM5015-18
CHROM.
20
ALL
CM5015-20
CHROM.
22
ALL
CM5015-22
CHROM.
24
ALL
CM5015-24
CHROM.
28
ALL
CM5015-28
CHROM.
32
ALL
CM5015-32
CHROM.
36
ALL
CM5015-36
CHROM.
40
ALL
CM5015-40
CHROM.
44
ALL
CM5015-44
CHROM.
48
ALL
CM5015-48
CHROM.
DESIGNATION

SET
FOR SIZES OF THE

HOUSINGS
CM-S-5015
15
From 8 to 48
TABLE 12
JACK-IN PART (STATIONARY)
M83723/17 Straight
M83723/18 Straight
M83723/19 Jack-in part
M83723/20 Jack-in part
M83723/21 Jack-in part M83723/22
Jack-in part M83723/25 Jack-in part,
sealed
M83723/26 Sealed,
for soldering
SIZE OF THE
HOUSING
KEY
POSITION
ADAPTER BLANKING:
DESIGNATION
COLOUR
ALL
CM5015R-8
CHROM.
10
ALL
CM5015R-10
CHROM.
12
ALL
CM5015R-12
CHROM.
14
ALL
CM5015R-14
CHROM.
16
ALL
CM5015R-16
CHROM.
18
ALL
CM5015R-18
CHROM.
20
ALL
CM5015R-20
CHROM.
22
ALL
CM5015R-22
CHROM.
24
ALL
CM5015R-24
CHROM.
28
ALL
CM5015R-28
CHROM.
32
ALL
CM5015R-32
CHROM.
36
ALL
CM5015R-36
CHROM.
40
ALL
CM5015R-40
CHROM.
44
ALL
CM5015R-44
CHROM.
48
ALL
CM5015R-48
CHROM.
EFFECTIVITY:
Page 15
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TABLE 13
DESIGNATION

SET
FOR SIZES OF THE

HOUSINGS
CM-S5015R
15
From 8 to 48
G.
Adapter-blankings for connectors as per MIL-C-83723, series 3
TABLE 14
DESIGNATION SYSTEM
M83723/75
22
55
Specification
Grade
Size of the housing
Contact diagram
Key position
TABLE 15
CABLE PART
SIZE OF THE
HOUSING
8
MS83723/75 Straight
MS83723/76 Straight
MS83723/86 Straight
MS83723/87 Straight
MS83723/77 Straight housing, grounding
10
MS83723/95 Straight housing, self-locking

nut
MS83723/96 Straight, self-locking nut
MS83723/97 Straight, self-locking nut,
grounding
ADAPTER BLANKING:
DESIGNATION
COLOUR
5
N, 8, 9
CM837-8A*
6, 7
CM837-8B*
N, 8, 9
CM837-8C**
6, 7
CM837-8D**
N, 8, 9
CM837-10A
6, 7, 10
CM837-10B
N, 6, 8
CM837-12A
7, 9, 10
CM837-12B
N, 6, 8
CM837-14A
7, 9, 10
CM837-14B
16
N, 6, 8
CM837-16A
16
7, 9, 10
CM837-16B
18
N, 6, 8
CM837-18A
18
7, 9, 10
CM837-18B
N, 6, 8
CM837-20A
7, 9, 10
CM837-20B
N, 6, 8
CM837-22A
7, 9, 10
CM837-22B
N, 6, 8
CM837-24A
7, 9, 10
CM837-24B
28
N, 6, 8
CM837-28A
28
7, 9, 10
CM837-28B
12
14
KEY POSITION
20
22
24
GREEN
MS83723/98 Straight, self-locking nut,

grounding
MS83723/66 Straight
MS83723/67 Straight
MS83723/68 Straight
housing, quick-disconnect sling
MS83723/69 Straight
NOTE: (*) - For bayonet joint only; (**) - For threaded connectors only.
EFFECTIVITY:
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TABLE 16
DESIGNATION

SET
FOR SIZES OF THE

HOUSINGS
CM-S-837
22
8 28
TABLE 17
JACK-IN PART
SIZE OF THE
HOUSING
KEY POSITION
ADAPTER BLANKING:
DESIGNATION
COLOUR
ALL
CM837RB-8
GREEN
10
ALL
CM837RB-10
GREEN
12
ALL
CM837RB-12
GREEN
14
ALL
CM837RB-14
GREEN
16
ALL
CM837RB-16
GREEN
18
ALL
CM837RB-18
GREEN
20
ALL
CM837RB-20
GREEN
22
ALL
CM837RB-22
GREEN
24
ALL
CM837RB-24
GREEN
MS83723/71 Jack-in part

MS83723/79 Jack-in part, sealed
MS83723/88 Jack-in part, sealed
MS83723/73 For clamping nut
MS83723/81 For clamping nut, sealed
MS83723/80 For soldering, sealed
NOTE: Bayonet joint only. The adapter-blanking is not suitable for threaded connectors..
TABLE 18
DESIGNATION

SET
FOR SIZES OF THE

HOUSINGS
CM-S-837RB*
From 8 to 24
H.
Adapter-blankings
TABLE 19
IDENTIFICATION DESIGNATIONS
MS
Design as per military
standard
3114
12
10
Housing design
Grade
Size of the housing
Contact type/ Material of the housing
(for sealed outlets only)
Contact diagram
Contact type (pin or socket)
Key position
EFFECTIVITY:
Page 17
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TABLE 20
CABLE PART
SIZE OF THE
HOUSING
KEY POSITION
ADAPTER BLANKING:
DESIGNATION
COLOUR
MS3116/Straight
ALL
CM264-8
ORANGE
MS3126/Straight
10
ALL
CM264-10
ORANGE
12
ALL
CM264-12
ORANGE
14
ALL
CM264-14
ORANGE
16
ALL
CM264-16
ORANGE
18
ALL
CM264-18
ORANGE
20
ALL
CM264-20
ORANGE
22
ALL
CM264.22
ORANGE
24
ALL
CM-264-24
ORANGE
MS3475/Straight/RFI
Grounding MS3476/Straight
MS3111/Straight MS3121/Straight
TABLE 21
DESIGNATION
Q-TY OF ADAPTERS IN THE SET
FOR SIZES OF THE HOUSINGS
CM-S-264
From 8 to 24
TABLE 22
JACK-IN PART
ADAPTER BLANKING:
DESIGNATION
COLOUR
ALL
CM264R-8
ORANGE
ALL
CM264R-10
ORANGE
12
ALL
CM264R-12
ORANGE
14
ALL
CM264R-14
ORANGE
16
ALL
CM264R-16
ORANGE
18
ALL
CM264R-18
ORANGE
20
ALL
CM264R-20
ORANGE
22
ALL
CM264R.22
ORANGE
24
ALL
CM264R-24
ORANGE
SIZE OF THE
HOUSING
KEY POSITION
MS3110/Jack-in part
MS3112/Jack-in part
10
MS3113/Sealed
For soldering
MS3114/For clamping nut MS3119/Jack-in
part
grounding
MS3120/Jack-in part
MS3122/Jack-in part
MS3124/For clamping nut
MS3127/Jack-in part
MS3128/Jack-in part
MS3440/Sealed jack-in
part
part
MS3443/Sealed
Soldering
MS3449/Sealed
For clamping nut
MS3470/Straight
MS3471/Straight
MS3472/Jack-in part
MS3473/Sealed
Soldering
MS3474/For clamping nut
part
MS3479/Sealed For
clamping nut
EFFECTIVITY:
Page 18
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TABLE 23
6.
DESIGNATION

SET
FOR SIZES OF THE HOUSINGS
CM-S-264R
From 8 to 24
Tools for installation of the adapter-tools and adapters (connector-tails) of the cable clamps of
connectors
A.
During most operations the adapter - blanking is connected to the connector and is held in
one hand. This provides fixed position of the connector, while the operation of cable clamp
fitting is performed by another hand.
Fig. 21 Adapterblanking, connector and cable clamp
Fig. 22 Tool with soft jaws TG-69 for cable clamp, connector and adapter-blanking, wrench with Thandle
B. When mechanical means are required for tail fitting, the adapter - blanking can be held by one
of several tools. As in the above described operation, the connector is fixed by means of the Thandle installed in the hole of the adapter-blanking, while the tail is fitted by means of the tool
with soft jaws.
NOTE: It is not recommended to rotate the connector due to strain that takes place in the
wire, contacts and sealing components. The adapterblankings and corresponding
tools have retain the connector in fixed position, while the tail is fitted.
EFFECTIVITY:
Page 19
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RRJ-95B
C.
If it is necessary to measure / set the torque during cable assembly, this can easily be done
by means of the stationary torque wrench. The adapter-blanking is installed with its square
hole on the torque wrench and retains the connector in fixed state, while the tail is fitted on it
by means of the belt wrench. When the set torque value is reached (on the wrench dial), a
light signal is transmitted for the Operator.
Fig. 23 Torque wrench (stationary installed), adapter-blanking, connector, cable clamp, belt wrench
D.
Stationary installed vice is used to provide the optimum repeatability and production efficiency
for fixation of the adapter-blankings with connectors. As it is shown on the figure below, the
vice is used for reliable attachment of the adapter-blanking, while the belt wrench is used for
fitting of the cable clamp (tail) on the connector.
Fig. 24 Belt wrench, tube, connector, adapter-blanking, vice
Fig. 25 Belt wrench, cable clamp, tube (in the vice jaws), connector, vice, torque wrench
EFFECTIVITY:
Page 20
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E.
As for tail assemblies, the torque value on the tail required for clamping can be reached only
in case of efficient fixation of the adjacent parts. As in the above given example, the
connector with attached tail, on which the tail for clamping is fitted by means of the belt
wrench, is fixed in the stationary vice. At that the torque value is monitored by the torque
wrench. Thus the necessary tightening torque can be applied to each cable clamp.
F.
The assembly vice provides the fast and safe fixation for different combinations of the
connectors and their auxiliary parts. Use of the replaceable inserts with soft jaws provides fast
resetting to different diameters of the connectors.
G.
This is a safe method to prevent damages to the coating and preserve the cylindrical shape of
the connector.
H.
The assembly vice consists of the wearproof clamping inserts and specially designed vice for
their attachment. They can be used for attachment of any cylindrical parts without diameter
limitations.
I.
One clamp of the stationary vice is fixed, the second clamp moves by means of the screw
mechanism. The stationary assembly vice differ in the use of the counter-threaded
mechanism, which provides synchronous movement of both clamps. This provides the
following during assembly of connectors:
(1)
Fast attachment: the part can be attached faster, thus providing improvement of
productivity.
(2)
High strength: significant gain in strength and durability of the thread due to use of the
double-start thread.
(3)
Self-alignment: since the clamps move to each other, the operation is always carried
out in the vice center, thus providing absence of the lateral stress and reducing
movement of the clamps to minimum.
(4)
Fixed position: additional possibility for convenient and efficient operation fixed
position of the jaws during clamping. This provides the stable repeated clamping of the
article, when used on the straight production lines.
J.
The size range of the set of jaws provides clamping of the parts having diameter from 0.375"
to 3.00" (3/8" to 3") using 6 standard sizes. This provides flexible use: one system can be
used for the most or for all cylindrical connectors and their adjacent parts during cable
assembly.
K.
The jaws can be delivered in two design variants: with width 0.4 in. and 1.000 in. Narrow jaws
provide better access to the part that have lesser diameter than the adjacent parts, while the
wide jaws with greater clamping area provide the possibility of application of greater torque
values during fitting.
L.
The jaws are made of the material with great friction factor, which does not damage the
connector and adjacent parts and provides efficient clamping for most operations.
M.
Deformation of the cylindrical connectors and adjacent parts is prevented by distribution of

clamping pressure between 4 points arranged in a circle. Thus the clamping force is applied
radially and is distributed in a circle, and the thin-wall structure takes up the load without
deformation.
N.
If the clamping force is applied only on the two opposite sides, the sheath can be deformed
and this can corrupt the tightening torque value due to thread friction increase.
O.
Uniform clamping on four sides reduces deformations that can occur during fitting to
minimum.
EFFECTIVITY:
Page 21
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RRJ-95B
P.
Position of the insert jaws in the vice can be changed, so that the work can be performed in
the place that is more convenient for assembly.
Q.
Set of the replaceable insert jaws is delivered in a suitable metal container, which provides
safe storage and easy use. The delivery set also includes the operating manual. Twelve pairs
of jaws are delivered, which provide clamping of the diameters from 3/8 to 3 inches.
R.
Multipurpose assembly vice
TABLE 24
MULTIPURPOSE VICE FOR ASSEMBLY ORDER DESIGNATION
BT-VS-511
Assembly vice with 24 sets of insert jaws
BT-VS-500
Assembly vice (without insert jaws)
BT-S-550
7.
24 sets of insert jaws to be used with BT-VS-500 vice
Calibration tools
A.
Advance technologies of the high-precision, high reliable electrical products use the set
torque values for assembly. This requires precise torque measurement.
B. It is generally believed that the torque value determines only resistance of the joint to loosening
at vibration or other external impacts. But it is very important in the modern electrical structures
to minimize the deformations during assembly of the thin-walled sensitive components, which
result in the risk of damaging the thread and coating, thus reducing their efficiency and service
life.
C.
DMC company offers a line of calibration tools that provide an easy and efficient method of
torque measurement during assembly of the cable assembly components. These tools were
specially designed to meet all requirements during connectors installation.
D.
Required torque values for particular connector or adjacent parts can vary greatly in relation
to the installation conditions. Guideline documents for selection of the limit torque values are
the recommendations of the components Manufacturers.
E.
The stationary tools became common use due to convenience of their use on the straight
lines (in this case the hands can be used for precise torque measurement). They have
compact size can be easily installed in any place
F.
In some cases, when use of the stationary tools is impracticable, the required precision and
convenience of use can be reached by the use of the hand-held tools.
NOTE: All calibration tools with dial indicator are delivered with adapterblankings having
size 1/4 and 3/8 in.
EFFECTIVITY:
Page 22
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Fig. 26 Calibration tools

G.
Hand-held calibration tools
TABLE 25
DESIGNATIONS AND CHARACTERISTICS
BT-ST-751
Tool with double indicator, illumination,

calibration 0-200 Inch Foot*
SCTD0001
Torque wrench 3/8",

force 20-150 lbf
H.
Stationary calibration tools
TABLE 26
C
Not shown
8.
BT-ST-701
Tool with double indicator, illumination, with support, calibration 0-200

inch foot*
BT-D-0551
Adapter - from 3/8 in. to socket 1/4 in.
BT-D-0622
Adapter - from 1/4 in. to socket 3/8 in.
NOTE: (*) error is 4% at measurement of the values in the range from 20% to 100% of the
maximum torque. The error is not monitored at measurements in the range
from 0 to 20% of the maximum torque. DMC torque wrenches are
calibrated according to NIST.
Belt wrenches
A.
DMC-belt wrenches were specially designed for assembly of the connectors. The modern
connectors, which consist of the light materials combinations with torque-sensitive thread and
function-responsible coatings, require assembly by means of the belt wrenches, use of which
provides uniform distribution of the clamping force along the whole diameter and prevents
deformation at contact with metal tools.
B. The tools are designed with several variants of the handle, belt width and length in order to
provide a wide scope of application.
C.
Belt wrenches
EFFECTIVITY:
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TABLE 27
Group
C
C
D
D

Wrench P/N
Belt P/N
Belt width
(inch) (colour)
Belt looping
Functional
diameter
(inch)
BT-BS-609
BT-A-6010
1/2" (Black)
Yes
From .50" to 2.50"
BT-BS-609B*
BT-A-6010B*
1/2" (Blue)
Yes
From .50" to 2.50"
BT-BS-609W
BT-A-6010W
1/2" (White)
Yes
From .50" to 2.50"
BT-BS-610
BT-A-6010
1/2" (Black)
Yes
From .50" to 2.50"
BT-BS-610B*
BT-A-6010B*
1/2" (Blue)
Yes
From .50" to 2.50"
BT-BS-610W
BT-A-6010W
1/2" (White)
Yes
From .50" to 2.50"
BT-BS-611
BT-A-6175
5/8" (Black)
Yes
From 2.00" to 4.00"
BT-BS-611B*
BT-A-6175B*
5/8" (Blue)
Yes
From 2.00" to 4.00"
BT-BS-611W
BT-A-6175W
5/8" (White)
Yes
From 2.00" to 4.00"
BT-BS-618
BT-A-6185
1" (Black)
Yes
From 2.00" to 4.00"
BT-BS-618B*
BT-A-6185B*
1" (Blue)
Yes
From 2.00" to 4.00"
BT-BS-618W
BT-A-6185W
1" (White)
Yes
From 2.00" to 4.00"
BT-BS-609SS
BT-A-6010-BK
1/2" (Black)
Yes
From .50" to 2.50"
BT-BS-609BSS*
BT-A-6010B-BK*
1/2" (Blue)
Yes
From .50" to 2.50"
BT-BS-610SS
BT-A-6010-BK
1/2" (Black)
Yes
From .50" to 2.50"
BT-BS-610BSS*
BT-A-6010B-BK*
1/2" (Blue)
Yes
From .50" to 2.50"
BT-BS-611SS
BT-A-6175-BK
5/8" (Black)
Yes
From 2.00" to 4.00"
BT-BS-611BSS*
BT-A-6175B-BK*
5/8" (Blue)
Yes
From 2.00" to 4.00"
BT-BS-618SS
BT-A-6185-BK
1" (Black)
Yes
From 2.00" to 4.00"
BT-BS-618BSS*
BT-A-6185B-BK*
1" (Blue)
Yes
From 2.00" to 4.00"
TABLE 28
E
UPGRADE KIT
BT-BS-625
BT-A-6250
1/2" (Black)
Yes
From .50" 2.0"
BT-BS-630
BT-A-6300
7/16" (Black)
Yes
From .50" 2.0"
BT-BS-609SS-RK
BT-A-6010-BK
1/2" (Black)
No
From .50" to 2.50"
BT-BS-610SS-RK
BT-A-6010-BK
1/2" (Black)
No
From .50" to 2.50"
BT-BS-611SS-RK
BT-A-6175-BK
5/8" (Black)
No
From 2.00" to 4.00"
BT-BS-618SS-RK
BT-A-6185-BK
1" (Black)
No
From 2.00" to 4.00"
BT-BS-609BSSRK
BT-A-6010
1/2" (Blue)
No
From .50" to 2.50"
BT-BS-610BSSRK
BT-A-6010
1/2" (Blue)
No
From .50" to 2.50"
EFFECTIVITY:
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TABLE 29
TORQUE CONVERSION FOR SERIES BTBS-609, 610
Conversion
factor (on the line and
column crossing point)
Functional
diameter (inches)
Required torque values (pound per inch)

40
60
80
100
120
140
160
180
200
.50
33
49
65
82
.75
35
52
69
87
104
1.00
34
51
68
85
102
120
1.50
33
50
67
83
100
117
133
1.75
33
49
66
82
99
115
132
148
2.00
33
49
65
81
97
114
130
146
162
2.25
32
48
65
80
96
112
128
144
160
2.50
32
48
62
79
95
111
127
143
158
TABLE 30
TORQUE CONVERSION FOR SERIES BTBS-611, 618
Conversion
column crossing
point)
Functional
diameter
(inches)
Required current torque values (LBS IN)

40
60
80
100
120
140
160
180
200
.50
33
49
65
82
.75
32
48
64
81
97
113
1.00
32
48
64
80
96
112
128
1.50
31
47
62
78
93
109
125
140
1.75
31
46
62
77
92
108
123
139
154
2.00
30
46
61
76
91
107
122
137
152
2.25
30
45
60
75
90
105
120
135
150
2.50
30
45
59
74
89
104
119
134
149
2.75
29
44
59
74
88
103
118
132
147
3.00
29
44
58
73
87
102
116
131
145
3.25
29
43
58
72
86
101
115
129
143
3.50
28
43
57
71
85
100
114
128
142
3.75
28
42
56
70
84
99
113
127
140
4.00
28
42
56
70
84
98
111
125
139
NOTE: These values are given as recommendations.

9.
Fitting of the jack-in parts under the clamping nut

A.
Correct tightening is required for connectors, which are attached on the panel by the clamping
nut. The sealing device (usually it is O-ring) must be clamped in the proper way, but in no way
it can be damaged. Another important issue is mechanical strength of the thread. This is
especially important for the composite and aluminium connectors.
EFFECTIVITY:
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RRJ-95B
Fig. 27 Dolly for tightening of the clamping nut and connector for the clamping nut
B. The dollies are specially designed for fitting of the clamping nuts on the block connectors. They
are produced of the composite material, aluminium alloy and stainless steel.
C.
The composite dollies are produced according to a special technology with adding a greater
quantity of the fiberglass providing maximum strength and reduction of weight. They do not
scratch or damage the coatings on the unit or partition, if they are correctly used.
D.
Dollies made of the anodized aluminium alloy are used for operation with metal jack-in parts.
They have similar sizes as the composite dollies, with square hole for installation of the
tightening wrench.
E.
Opened cylindrical dollies made of stainless steel with holes for tommy (Fig. 28).
F.
Maximum thickness for installation on the panel is 3.2 mm, minimum thickness is 1.6 mm. For
connector with rectangular flange of the type 0. forward fitting - 3.2 mm, minimum 1.5 mm.
No grinding for fitting is not required in this case except for requirements of the design
documents.
Fig. 28 Aluminium dollies with square hole and stainless steel dollies for tommy
NOTE: It is recommended to lock the clamping nut by the locking system.
EFFECTIVITY:
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Fig. 29 Defining the dolly size

G.
In order to select the dolly and define the correct size, measure the distance between the parallel
flats of the clamping nut (Fig. 29) and select the size designation according to the Tables 31 and 32.
TABLE 31
TIGHTENING DOLLIES DESIGNATION SYSTEM

Designation
BT-J
XXX
XX
Base designation
Size designation, Ref. Table 32
Material:
Empty = Composite
AL = Aluminium
S = Steel
Special configurations:
Empty = Standard
From 1 to X = Non-standard
EFFECTIVITY:
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TABLE 32
Size designation
COMPOSITE OR METAL DOLLIES
134
135
136
137
138
139
140
141
142
143
144
145
For clamping nuts

(inch)
.608 to .628
.628 to .649
.671 to .693
.693 to .717
.741 to .765
.765 to .791
.791 to .818
.818 to .845
.845 to .873
.873 to .902
.902 to .933
.933 to .964
.964 to .996
.996 to 1.030
1.030 to 1.064
For clamping nuts
(inch)
1.064 to 1.100
1.100 to 1.137
1.137 to 1.175
1.175 to 1.214
1.214 to 1.255
1.255 to 1.297
1.297 to 1.340
1.340 to 1.385
1.385 to 1.432
1.432 to 1.480
1.480 to 1.529
1.529 to 1.580
For clamping nuts

(mm)
15.41 to 15.95
15.95 to 16.48
17.04 to 17.60
17.60 to 18.21
18.82 to 19.43
19.43 to 20.09
20.09 to 20.77
20.77 to 21.46
21.46 to 22.17
22.17 to 22.91
22.91 to 23.69
23.69 to 24.48
24.48 to 25.29
25.29 to 26.16
26.16 to 27.02
For clamping nuts
(mm)
27.02 to 27.94
27.94 to 28.87
28.87 to 29.84
29.84 to 30.83
30.83 to 31.87
31.87 to 32.94
32.94 to 34.03
34.03 to 35.17
35.17 to 36.37
36.37 to 37.59
37.59 to 38.83
38.83 to 40.13
Square
size
1/4"
1/4"
1/4"
1/4"
1/4"
1/4"
1/4"
1/4"
1/4"
1/4"
1/4"
3/8"
3/8"
3/8"
3/8"
Square
size
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
Outer
diameter
.914"
.955"
.010"
1.04"
1.10"
1.13"
1.16"
1.19"
1.22"
1.26"
1.29"
1.33"
1.36"
1.41"
1.45"
Outer
diameter
1.51"
1.55"
1.59"
1.63"
1.69"
1.73"
1.78"
1.84"
1.89"
1.95"
2.00"
2.06"
146
1.580 to 1.633
40.13 to 41.47
3/8"
2.12"
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
1.633 to 1.688
1.688 to 1.745
1.745 to 1.803
1.803 to 1.864
1.864 to 1.926
1.926 to 1.991
1.991 to 2.057
2.057 to 2.126
2.126 to 2.197
2.197 to 2.271
2.271 to 2.347
2.347 to 2.426
2.426 to 2.507
2.507 to 2.591
2.591 to 2.678
2.678 to 2.769
2.769 to 2.860
2.860 to 2.956
2.956 to 3.055
41.47 to 42.87
42.87 to 44.32
44.32 to 45.79
45.79 to 47.34
47.34 to 48.92
48.92 to 50.57
50.57 to 52.24
52.24 to 54.00
54.00 to 55.80
55.80 to 57.68
57.68 to 59.61
59.61 to 61.62
61.62 to 63.67
63.67 to 65.81
65.81 to 68.02
68.02 to 70.33
70.33 to 72.64
72.64 to 75.08
75.08 to 77.59
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
2.19"
2.25"
2.32"
2.39"
2.46"
2.54"
2.61"
2.69"
2.78"
2.87"
2.95"
3.04"
3.14"
3.24"
3.34"
3.44"
3.54"
3.66"
3.77"
166
3.055 to 3.157
77.59 to 80.18
3/8"
3.89"
117
118
120
121
123
124
125
126
127
128
129
130
131
132
133
Size designation
EFFECTIVITY:
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TABLE 33
GENERAL-PURPOSE DOLLIES FOR CLAMPING NUTS
DMC designation
For clamping
nuts
(inch)
Amphenol BCO
designation
Hex Ref. Dim

(inch)
Composite equivalent
CS8
.755 to .763
11-6266-3
3/4"
N/A
CS10
.880 to .888
11-6266-5
7/8"
BT-J-128
CS12
1.068 to 1.077
11-6266-8
1 1/16"
BT-J-134
CS14
1.194 to 1.204
11-6266-10
1 3/16"
BT-J-137
CS16
1.320 to 1.331
11-6266-12
1 5/16"
BT-J-140
CS18
1.446 to 1.457
11-6266-14
1 7/16"
BT-J-143
CS20
1.571 to 1.580
11-6266-16
1 9/16"
BT-J-145
CS22
1.696 to 1.708
11-6266-18
1 11/16"
BT-J-148
CS24
1.822 to 1.835
11-6266-20
1 13/16"
BT-J-150
CS22-1
2.011 to 2.025
11-6266-23
2"
BT-J-153
CS24-1
2.137 to 2.151
11-6266-25
2 1/8"
BT-J-155
CS32
2.640 to 2.687
11-6266-33
2 5/8"
BT-J-161 & BT-J-162
H.
General purpose tools for operation with cable clamps with tails/accessories:
(1)
Adjustable wrench JR700 multipurpose tool for servicing and production of small
series. A safe whole-metal structure makes this tool a good choice under hard
operating conditions.
(2)
The tool can be used for hexagon nuts having size from 0.75 to 3.25 inches. Maximum
gripping depth is 1.0 in. Such adjustment range allows using the tool for majority of the
connectors.
(3)
Standard 3/8 in. torque wrench can be used together with this tool for monitoring of the
maximum torque. Overall length is 11.5 in. and weight is about 2 lb.
(4)
Adjustable pliers with soft jaws of BT-SJ-468 series is an addition to the tools kit used
for servicing. This tool provides a safe clamping during assembly, disassembly and
positioning of the parts.
(5)
The fitted soft jaws can be delivered separately (order number for one jaw is BT-SJ468-1), two jaws can be used for this tool. Overall length is 9.5 in., weight is about 0.5
lb.
EFFECTIVITY:
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TABLE 34
TORQUE CONVERSION FOR JR700 SERIES TOOLS
Conversion
column crossing point)
Functional
diameter
(inches)
I.
Required current torque values (LBS IN)

40
60
80
100
120
140
160
180
200
.50
7.04
10.57
14.09
17.62
.75
7.23
10.84
14.46
18.08
21.69
1.00
7.42
11.13
14.85
18.56
22.27
25.99
1.50
7.84
11.77
15.69
19.61
23.54
27.46
31.39
1.75
8.07
12.11
16.15
20.18
24.22
28.26
32.30
36.34
2.00
8.31
12.47
16.63
20.79
24.95
29.11
33.27
37.46
41.59
2.25
8.57
12.86
17.15
21.44
25.72
30.01
34.30
38.59
42.88
2.50
8.83
13.24
17.66
22.07
26.49
30.90
35.32
39.73
44.15
2.75
9.14
13.71
18.28
22.85
27.42
31.99
36.56
41.13
45.70
3.00
9.45
14.18
18.90
23.63
28.36
33.08
37.81
42.54
47.27
3.25
9.78
14.68
19.57
24.46
29.36
34.25
39.14
4.04
48.93
NIPPERS WITH round jaws

The nippers with round jaws DRP-XX are specially designed for gripping of the cylindrical
connectors and tails, which can be deformed when clamped by another methods. Rubber
coating of the jaws provides soft non-scratching compression of the part and can be replaced
when worn out. They are attached by means of the special pins pressed into the material.
TABLE 35
TOOL SELECTION
REFERENCE DIAMETER
INCHES
MILLIMETRES
0.618
15.69
0.734
18.64
0.858
21.79
0.954
24.23
1.112
28.24
1.198
30.42
1.322
33.57
1.448
36.77
1.574
39.97
1.674
42.51
1.970
50.03
TOOL No.
DRP-08
DRP-10
DRP-12
DRP-14
DRP-16
DRP-18
DRP-20
DRP-22
DRP-24
DRP-26
DRP-28
NOTE: Each tool has total length of 9 inches and approximate weight of 0.5 pounds.
J.
Nippers for connectors fixation

(1)
The nippers for fixation of connectors of CW100-X series are intended for service and
assembly operations, when the connector and its components must not move during
further assembly or disassembly.
EFFECTIVITY:
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(2)
These operations include installation / removal of the contacts, soldering, installation of

the safety wire, installation of the clamps or other tails for components clamping,
installation of the screws that attach the connector outlet and many other functions.
(3)
The segmentary structure provides gripping of different diameters and using of the
segmentary jaws of different diameter on the opposite sides of the tool. In most cases the
lesser diameter is used to grip the connector plug, and the greater diameter usually
corresponds to connector socket.
NOTE: As for operations, where torque must be used, e.g. tightening of the tails, another
tools must be used, e.g.adapter-blankings.
(4)
Table 36 contains diameters of the tools and approximate sizes of the connectors, with
which they can be used:
TABLE 36
TOOL SELECTION
Tool designation
CW100-1
CW100-2
CW100-3
CW100-4
CW100-5
CW100-6
Big diameter (in. mm)

.605
1.54
.690
1.75
.930
2.36
1.172
2.98
1.388
3.53
1.551
3.94
Small diameter (in. - mm)

.415
.530
.800
1.022
1.280
1.530
1.05
1.35
2.03
2.60
3.25
3.89
Housing size range

8-11
12-15
16-19
20-23
24-25
26-28
NOTE: Each tool has total length of 19.05 cm and approximate weight 338 g.
TABLE 37
a
TOOL DESIGNATION
BT-HT-110
Handle with square hole 1/4"
BT-HT-210
Lever with square 1/4"
BT-HT-211
Lever with square 3/8"
BT-D-0551
Adapter from 3/8 in. to socket 1/4 in.
BT-D-0622
Adapter from 1/4 in. to socket 3/8 in.
BT-HT-107
Wrench with -handles and 3/8 in. square
BT-HT-100
Wrench with -handles and 1/4 in. square
BT-A-0513
Ratchet handle with 3/8 in. square
4-1149
B
C
Magnifier with illumination
EFFECTIVITY:
Page 31
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EFFECTIVITY:
Page 32
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RRJ-95B

WIRING OF HARNESSES
1.
Wiring specifications
A.
Wiring of the harnesses is performed after all drilling-countersinking, preparatory-filing and

riveting works, installation of the tubing of all systems and their pressure testing, thorough
cleaning of the wiring zones from dust, chips, foreign objects and closing of the process
certificates for execution of the said works.
NOTE: During operation in the process of removal or updating of the tubing, cables and control
rods the harnesses in the updating zone must be released, wrapped in protective
material (cellophane, fabric etc.) and set aside in order to provide protection of the
harnesses against damages, ingress of foreign objects and different fluids; blankings
must be installed on connectors.
CAUTION: Do no blow off the wiring areas with compressed air.
B.
Wiring of the harnesses on the aircraft includes the following operations:

(1)
Preparation for wiring (studying of the technical documents, inspection of the harnesses,
inspection of the wiring zones, preparation of the tools etc.);
(2)
Installation of protectors through the holes of the airframe components for harnesses
protection against mechanical damages;
(3)
Routing of harnesses along the route and their temporary attachment;
(4)
Providing the necessary clearances between the harnesses, tubing, control elements etc.;
(5)
Monitoring of correct routing of harnesses with check of the bend radius, clearances,
absence of tension and slack of the wires, distances between the attachment points etc.,
elimination of violations from requirements of the technical documents;
(6)
Removal of the process protection;
(7)
Final attachment of the harnesses;
(8)
Connection of the harnesses to the units and equipment, locking of the electrical
connectors.
C. In the places of routing the harnesses are attached by the cable holders made of thermoplastic
with silicone seal or metal clamps with silicone shaped liner.
D.
The harnesses subjected to impact of moisture, sand, breakstone, ice, oils, fuel, aggressive
media or other fluids must be protected.
E.
Wiring of the harnesses is performed in accordance with wiring drawings, electronic analogs,
standard wiring and with requirements of the given process.
F.
During wiring the harnesses and cables are placed in parallel or at right angle to the stringers,
ribs (Ref. Fig. 3).
G.
The splice sleeves and line connectors are placed in the harness on the straight segment
between two - three harness attachment elements in a "stepwise" or criss-cross manner at
distance not less than 300 - 350 mm (Ref. Fig. 11, Section 20-20-70).
H.
The harness is tied with 2 - 3 layers of tape 69; SKLF-4D-0.07 U 301-05-49-90 with interval
55050 mm under the screen braiding.
EFFECTIVITY:
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2.
Routing and attachment of the harnesses

.
Routing and attachment of the harnesses must be performed in compliance with requirements
of OST 1 00239-77, Ref. Table 1:
TABLE 1
REQUIREMENTS TO CLEARANCES DURING WIRING OF HARNESSES
No.
Clearances between the harnesses with regard for slack
Minimum,
mm
Oxygen, cold water, cold air supply tubing, static and dynamic tubing.
Hot air tubing (up to 100) without heat insulation
Heat-insulated hot air tubing (up to 250)
Tubing of the hydraulic, fuel and oil systems
Moving part of structural components
Control rods
10-15
Shock-mounted units in extreme position
8-10
Non shock-mounted units
5-8
Unprotected sharp edges of the structural components
5-10
10
Heat insulation of the compartment. The harness can touch the insulation.
20-40
10
10-15
10
B. Attachment of the moving segments of the harnesses (transition from the fixed part to the
moving one, hinged panels, harnesses on the thrust levers, control sticks and LG) is performed
with regard to requirements of OST1 00239-77, Subj.22, 23, 24.
C.
Operational reserve of the wires is arranged in the lower segment of the harness before the
connector or is distributed along the route in three - four attachment points, if count from the
connector or from the lug (for power leads).
D.
Attachment of the segments of the harnesses, which run from the connectors, terminal blocks
must preclude ingress of moisture or another fluid to the contacts. For this purpose the harness
is lowered near the connectors and one or three drain holes with 4 mm diameter are made in the
lower point of the protected harness as per OST 1 00239-77 Subj.27 (Ref. Fig. 2) for fabricprotected harnesses).
E.
DO NOT route single wires of AWG24-22 gauge on the article without laying other harnesses in
the routes.
F.
Distances between the harness attachment elements on the aircraft must correspond to Table 2:
TABLE 2
RELATION OF FASTENERS LOCATION TO HARNESS DIAMETER
Distance between the attachment elements, mm, maximum
Up to 10 incl.
30050
From 10 to 30 incl.
45050
More than 30 incl.
55050
G.
Significant slack of the group of wires or of the harness is not permitted. Slack
between two attachment points must not exceed 13.0 mm (Fig. 1).
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13.0
mm max
max
12,7
Fig. 1 Slack between attachment points must be from 5.0 mm to 13.0 mm
Fig. 2 Providing drain at the lowered segment of the harness

H.
The cables and harnesses are laid parallel or at right angle to the stringers or ribs, Ref.
Fig.3:
Fig. 3 Laying and attachment of the harness

I.
The coaxial cables must be straight laid, if possible. Bends of the coaxial cable with radius
less than 6d of the cable are not permitted. All attachments to the ribs are arranged along
the fuselage, to each stiffener - in the routes located in the wing. The RF cables are tied with
bandage cord - 52081 type II or - 5284 type V.
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J.
The following safety precautions must be observed during installation of the electrical wires,
cables and harnesses on the aircraft:
(1)
There must be no contact between the wires (cables) or harnesses with any other
aircraft components during movement of friction;
(2)
There must be no contact between the wires (cables) or harnesses with sharp edges of
the structure, holes etc.;
(3)
Do not use unprotected tools for installation;
(4)
Do not damage thread of the connected devices by excessive tightening or tightening

with a skew;
(5)
Do not damage the wires in the harness by excessive bending during installation;
(6)
Accumulation of dirt, chips, lost fasteners, cuts of bandage cords etc. in the units or
harnesses is not permitted;
(7)
Do not hang the hand tools or personnel things on the cable harnesses;
(8)
Do not use the cable harnesses as a footstep, step or as handrails;
(9)
Do not compensate for the excessive length of the wires by backward laying and laying
this loop in a harness;
(10) Do not twist or pull the wires during manufacturing or wiring, this can result in contacts
pulling off from the connector or can damage the connector or the wires;
(11) Do not pull the wires for connection of connectors; easy connection is provided by
sufficient length reserve.
K.
The following requirements must be met during attachment of the wires and harnesses:
(1)
Prevention of harnesses wear due to friction;
(2)
Attachment of the wires, cables and harnesses in places of their passing through the
walls and structural components;
(3)
Prevention of mechanical loads, which can result in rupture of the conductors and
connections;
(4)
Prevention of the arc discharge or overheating of the wires caused by damages by the
control cables;
(5)
Prevention of excessive movement in the high vibration areas;
(6)
Use of the high-temperature wires (cables) during their routing in the corresponding
compartments;
(7)
Prevention of using the harnesses as handrails, footsteps and steps or as brackets for
equipment and things;
(8)
Prevention of the damages caused by personnel movement in the aircraft as well as

damages caused by laying and transfer of the cargos.
(9)
Prevention of damages of the harnesses caused by vapours of the accumulator acids,

their aerosols or leaks, damages caused by the solvents or fluids.
(10) Prevention of attrition in the LG wells due to impact of the stones, ice, dirt etc.
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L.
The wires (cables) and harnesses are installed in such a way, so that they are protected
against attrition due to friction and against mechanical attrition in the places of contact with
sharp edges or with other wires. Damages of the insulation can result in the short circuit, fault
or malfunction of the equipment. Approved cable holders (binding clips) can be used in the
places of passing through the holes in the wall (Fig. 4). If distance from the wires to the hole
edge is less than 6.3 mm, a protector is installed on the cutting edge (Fig. 5).
Clamp
02213 DAL
Clearance
6.3 mm min
Angular bracket
Fig. 4 Installation of the binding clips in the places of passing through the holes in the wall
Distance between the
harness and the hole
edge is less than 6.3 mm
Protector
22529/1
Fig. 5 Binding clip and harness protection in the places of passing through the hole
NOTE: Clearance not less than 2 mm between the harness and protector is permitted, if the
harness is protected. Permissible clearance between the harness and protector
according to OST1 00361-79 is not less than 5 mm.
M.
In order to prevent deterioration of the wires insulation properties, the wires (harnesses) are
protected against high temperature by the high-temperature materials (sheathes), or hightemperature fire-resistant wires are used.
N.
Do not use the coaxial cables with polyethylene sheath in the high-temperature zones.
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O.
The wires (harnesses) are installed in such a way, so that they are protected by the structure.
P.
Structural components or conduits are used to protect the harnesses against squeezing in the
cargo compartments.
Q.
When the harnesses (wires) are laid in the compartments located below the accumulators, the
harnesses are protected by means of DR-25, K tubes against impact of acid vapours and
fluids. Similar protection is provided for the harnesses in the compartments below the
lavatories. Avoid places, where the harnesses (wires) can be subjected to impact or damage
by the fluids. Ends of the tube must be located outside the moisture impact zone and be safely
protected.
R.
The wires (harnesses) located in the LG wells are subjected to numerous additional impacts,
such as fluids, compression and bending during the operation.
S.
There must be no relative displacement of the harnesses in the attachment points. There
must be no excessive tension during maximum movement of the parts.
T.
The harnesses are made of extra-flexible wires 82 and are protected by the flexible
corrugated tubes. The tubes are selected in accordance with Table 3:
TABLE 3
SELECTION OF PROTECTIVE TUBES FOR THE HARNESS
Series
HCTE-
Size
Inner diameter,
Min-Max (mm)
Outer diameter,
Max (mm)
Wall thickness,
Max
(mm)
Operating
temperature
Weight
(kg/100m)
0187 Black
4.75
4.60
8.13
0.46
1.8
0281 Black
7.14
6.93
10.52
0.46
2.2
0375 Black
9.53
9.25
12.96
0.46
3.0
0437 Black
11.10
10.85
14.50
0.46
3.7
0500 Black
12.70
12.32
16.51
0.58
5.2
0625 Black
15.88
15.44
19.56
0.58
0750 Black
19.05
17.90
23.62
0.58
0875 Black
22.23
21.84
27.25
0.58
9.6
1000 Black
25.40
24.77
31.14
0.58
11.2
1250 Black
31.75
30.74
35.30
0.58
13.0
1500 Black
38.10
36.50
46.53
0.58
16.9
1625 Black
41.28
39.67
50.17
0.58
17.7
From 55 to +200
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U.
The flexible heat-resistant tube is resistant to the fluids and high temperature up to
+300.
V.The wires (harnesses), which are located parallel to the tubing with flammable fluids or to the
oxygen lines, are attached with interval not less than 15 mm.
W.
The harnesses (wires) are placed on the lever of above the level of the tubing. Attachment is
arranged in such a way, so that the wires do not touch the tubing, if the attachment is broken.
X.If it is impossible to provide a 15 mm clearance, the harness and the tubing are attached to one
and the same structural component in order to prevent relative displacement.
Y.When the distance is less than 15.0 mm but more than 12.5 mm, additional protection must be
used together with two clamps located in opposite directions (Ref. Figure 6) to provide the
fixed distance:
Fig. 6 Providing clearance between the wires and the tubing

AA. Do not attach the wires or harnesses to the tubing with flammable fluids. Attachment must only
be used to provide the specified distance.
BB. When the wires (harnesses) are laid, distance of not less than 20 mm from the control cables is
provided (Ref. Table 1)
CC. When the said distance can not be provided, mechanical protection is installed to prevent the
contact between wires and cables.
3.
Routing of harnesses with regard to electromagnetic compatibility requirements

Each harness must pertain to particular electromagnetic compatibility group. Classification in
groups must unambiguously define the degree of compatibility, interfering and sensibility to
interferences.
.
Electrical circuits of the systems are subdivided in 5 groups according to degree of

interfering and sensibility to interferences:
(1)
EI extra interfering wires and cables. Conditionally - the 1st group of electromagnetic
compatibility;
(2)
I interfering wires and cables. Conditionally - the 2nd group of electromagnetic

compatibility;
(3)
N neutral wires and cables. Conditionally - the 3rd group of electromagnetic

compatibility;
(4)
IS interference-sensitive wires and cables. Conditionally - the 4th group of

electromagnetic compatibility;
(5)
EIS extra interference-sensitive wires and cables. Conditionally - the 5th group of
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electromagnetic compatibility;
One harness can contain wires of the groups IS and EIS; I and EI; I and N; I and IS.
B.
The first group of electromagnetic compatibility

This group includes AC power wires, high-power circuits, carrier currents, which can cause
interferences and are relatively insensitive to interferences of all frequencies. These are the
following circuits:
C.
(1)
Single-phase AC 115V 400 Hz with current value more than 1 and three-phase
current 200V 400 Hz with current value more than 1;
(2)
Wires with pulse current more than 1 extra-interfering wires.
The second group of electromagnetic compatibility

This group includes the DC and AC power wires:
D.
(1)
Secondary AC power circuits and synchronizing circuits;
(2)
Single-phase and three-phase power wires with current value less than 1;
(3)
Switching and control wires;
(4)
Wires with pulse current less than 1.
The third group of electromagnetic compatibility

This group includes the control and automatic wires with discrete signals 6-27V and lowresistance load. These circuits are made of insensitive and non-interfering wires.
E.
The fourth group of electromagnetic compatibility

These are analog and code signals of low level (up to 6V) transmitted by the screened
single-wire circuits with low-resistance load. These circuits include:
F.
(1)
Discrete signal circuits sensitive to impact of the electromagnetic signals;
(2)
Noise-proof digital data communication lines;
(3)
Circuit for transmission of the power signals from the low-voltage stabilized power
sources.
The fifth group of electromagnetic compatibility

These are low-frequency and high-frequency low level (up to 1V) signals transmitted by the
high-frequency cables and screened wires, twisted pairs with high-resistance load. This
category includes:
G.
(1)
Wires that are extremely sensitive to the induced interferences (e.g., antenna-feeder
unit and microphone circuits);
(2)
Wires for transmission of the signals with zero level and level up to 1 V;
(3)
Input circuits of the receiving-amplifying devices.
Symbolic notation of electromagnetic compatibility groups is introduced for the cables:

The sixth group HF cables of interference-sensitive transmitters.
The seventh group HF cables of interference-sensitive transceivers.
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When defining the electric compatibility group of the wires comply with GOST 18977-79,
which specifies that the wires that provide transmission of the discrete commands by closing
and opening of the contacts, which are connected to one of the aircraft power sources, can
be conditionally related to the power wires.
A
power wire is a wire connected to one of the power sources directly or via the contact. The
power wires relate as a rule to the first or second electromagnetic compatibility group to the
power wires.
H.
Electromagnetic compatibility of the wires of pilot contacts of ARINC600 and ARINC404

type connectors.
(1)
Theoretically the pilot contacts can no carry great current, which can provide
interferences that can not be suppressed inside the harness by twisting and
screening.
(2)
The wires of the collection units and systems of pilot contact groups carry low-power
and low current rate signals, which must be protected against the induced
interference that can result in signal distortion. It is recommended to relate them to
the third group of electromagnetic compatibility.
(3)
It should be noted that conventional subdivision of the wires of the system units and
collection units into different groups of electromagnetic compatibility results
unambiguously lead in collection of interferences from all the routs of the two sides
instead of the route of one electromagnetic compatibility group.
(4)
The harnesses must be formed for the units with regard to:
(a)
(b)
I.
Specifying one group of electromagnetic compatibility for the pilot contact

groups;
One side, on which the unit is installed;
(c)
termination of the branches by connectors on opposite aircraft side;
(d)
installation of temporary side-dividing connectors.
Electromagnetic compatibility of the wires of the power supply units

(1)
The power supply units 28V of the DB or CDB type are connected by the wires of the
second electromagnetic compatibility group.
(2)
The power supply units 200/115V are connected by the wires of the first and second
electromagnetic compatibility group.
(3)
The avionics system and annunciators actuation signals are connected by the wires
of the second or third electromagnetic compatibility group. Considering the fact that
connectors for all routes of the electromagnetic compatibility groups will be installed
on the racks in the service compartments, where the avionics units are installed, no
rebinding of harnesses is required in the external circuits.
NOTE: In order to exclude the additional technological isolations between harnesses
of the complexes, which are located in one route on the common devices,
connectors for the route wires are formed. For example, connector for wires
of the fourth electromagnetic compatibility group is installed on DB 28V for
power supply to the radio communications equipment.
(4)
Insulation requirements are defined by the signal type.
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J.
The power lines are subdivided into the following types (electromagnetic compatibility
groups) in the process of development of the design documents for manufacture and
routing of the aircraft electrical harnesses:
(1)
AC power cables;
(2)
DC power cables;
(3)
Extra-sensitive signals less than 6V;
(4)
Analog audio signals;
(5)
High-frequency signals;
(6)
Normal level signals up to 32V.
NOTE:
K.
The said subdivision takes into account requirements of the foreign suppliers of
avionic equipment set for electrical interfaces, foreign and home experience in
production of the civil aircraft cable network with use of the significant quantity of
imported equipment, materials, cable products.
Physical subdivision between electrical harnesses of different groups is described in Table

4 and is justified by:
(1)
Use of the modern imported electrical cables, protective and screening materials,
cable clamps, which provide 360 screening in the most important circuits, imported
electrical connectors; requirements of the foreign designers and manufacturers,
which supply the aircraft avionic equipment;
(2)
Experience of the foreign manufacturers of the passenger aircrafts and electrical

harnesses, which act as consultants for RRJ project, as well as experience of the
home manufacturers of the civil aircrafts.
TABLE 4
DISTANCE BETWEEN CABLES OF DIFFERENT ELECTROMAGNETIC
COMPATIBILITY GROUPS
Division of the
routing zones
Designation
AC power
cables
DC power
cables
Extrasensitive
wires
Analog
audio
signals
Highfrequency
signals
Normal level
signals
AC power
cables
(1)
50 mm
150 mm
100 mm
150 mm
100 mm
DC power
cables
50 mm
(2)
150 mm
100 mm
150 mm
100 mm
L
AFDX
Extra-sensitive
wires
150 mm
150 mm
(3)
50 mm
75 mm
75 mm
combined
routing is
permitted
Analog audio
signals
100 mm
100 mm
50 mm
(4)
100 mm
100 mm
Coaxial cables
150 mm
150 mm
75 mm
100 mm
(5)
75 mm
100 mm
75 mm
combined
routing is
permitted
100 mm
75 mm
(6)
N
A429
CAN
Normal level
signals
100 mm
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L.
High-frequency cables of the transceivers are routed separately or screening measures are
taken (special cables are used). Possibility of the combined routing of the cables with regard
to performances of equipment of the systems (articles) is defined by the designers of the
systems, which include these cables.
M.
Requirements for wiring harnesses of the fly-by-wire system:

(1)
FBW harnesses must be routed separately from the harnesses of the other aircraft
systems. Distance between the FBW harnesses and harnesses of the other aircraft
systems is not less than 20 mm. When wiring harnesses of FBW are connected to
other aircraft systems, combined routing in the common harnesses is permitted.
(2)
The FBW harnesses are routed with regard to the triple redundancy.
(3)
Length of the negative power wires must be not more than 500 mm.
(4)
Double screening must be provided for all cables located in the aircraft nonpressurized zone. All wires located in the pressurized zone must have single
screening. 360 screening must be provided on the whole surface of the connector.
The screened cable must be grounded on both sides (Ref. Fig. 7):
Fig. 7 Grounding of the screened cable

(5)
It is recommended to perform routing of the FBW wiring harnesses with regard for the
following in order to provide redundancy, safety and reliability:
a.
Wires relating to different FBW subsystems (aileron, elevator, rudder, flaps, slats,
horizontal stabilizer) must be physically divided.
b.
Wires that provide control and testing of the channels must be physically divided.
c.
Wires relating to different actuators of one and the same FBW subsystem must
be physically divided.
N.
If the wires relate to one system, they are as a rule combined in a separate common system
harness (if the wires are compatible according to the electromagnetic compatibility).
O.
The harnesses are formed according to the following principles:

(1)
Providing flight safety;
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Q.
(2)
Providing maintainability, easy removal and replacement;
(3)
Economical efficiency of production;
(4)
Elimination of damages;
(5)
Redundancy.
Redundancy:
(1)
Redundancy of wiring harnesses of the aircraft systems is provided during

development of the documents for electrical harnesses and their routing.
(2)
The redundant channels must be arranged in the physically divided harnesses. The
harnesses that contain redundant channels must be laid in different routes according
to the principles of redundant channels arrangement on the sides (LH, RH), on top,
below.
(3)
Electrical cables of the redundant channels must not relate to one and the same
bundle of harnesses.
(4)
Routing of the redundant channels of the vital aircraft systems takes into account
requirements for unlocalized dispersion of fragments of rotors of the propulsion power
plants, APU, pneumatic equipment.
Requirements for harness components

When the harnesses were formed, the designer was governed by the following
requirements:
(1) It is permitted to connect wires of the different harnesses of one electromagnetic
compatibility group of one side in the connectors on the common devices of distribution
boxes, junction boxes, panels, instrument panels. In this case the wires are branched
inside the devices. Use of the prefabricated structures is in many cases more efficient
than creation of the additional branching devices.
(2) Individual connectors must be provided on the common devices, racks for wires
branching to the opposite side (unit).
(3) One and the same connectors can not contain wires relating to different
electromagnetic compatibility groups.
(4) Negative wires of the avionic systems must be branched on the negative grounding
modules (panels).
(5) Branching of the wires of different harnesses relating to one complex of one
electromagnetic compatibility group of one side is performed on the modular
connectors, this provides complete assembly of the module in the mould loft as part of
the combined harness.
(6) When branching of the wires into different harnesses of different electromagnetic
compatibility groups of different complexes and different sides is required, it is
performed by means of the modular assemblies. The modules assembly is formed by a
brigade with great number of the modules or signals.
(7) Installation of the terminal blocks for the branching screw is used for the wires
beginning with AWG 16 (1.5 mm) and of greater section.
4.
Conduits
They are used for protection of the wires, harnesses and cables against mechanical impact,
corrosive fluids, high temperatures during the operation.
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The conduits are produced metal and non-metal. It is recommended to use non-metal (flexible)
conduits (Ref. Subject 2.T and Table 3 of the present Section). Diameter of the protected harness
must not be more than 80% of the conduit (tube) inner diameter.
5.
It is permitted to use heat-shrinking tubes instead of the flexible conduits for harnesses protection.
Protectors
Series of protectors is certified in accordance with specifications NASM22529/1 and
NASM22529/2, is approved by FAA and has the following advantages:
- Strong stainless steel frameworks is clicked during a few seconds and is fixed on the sheet
metal;
- Absence of the main problems caused by environmental impact;
- Protection of the wires and cables against attrition;
- Polymer coating and support sub-protector provide smooth and durable electroinsulating
surface;
- Flame resistance as per FAR 25.853;
- Safe fixation of a wide range of thicknesses of the materials and two-dimension contours;
- Retaining of the functional properties after painting.
Fig. 8 Use of the protectors for surfaces of different shape

The main coating for "" series is:
- Nylon black and approved by FDA - white;
- Epoxide blue and white for use in the aerotechnics;
- Epoxide light-green (FAA-approved as per NASM22529/1).
The "" series is abrasion resistant, resistant to the chemicals and prolonged heating +145.
All protectors can be delivered as section of different length, sets of coils having length 7.6 m, 30.5
m and 152.4 m.
If the protectors were delivered as a solid tape, use 830 S model scissors to provide cutting without
protector damaging.
It is recommended to use the bench pneumatic press Model 830P to produce a great quantity of
sections having equal length.
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Delivery and ordering of the protectors M22529/1 and 22529/2 (with gasket) Ref. Table 5 and 6:
TABLE 5
22529/2
ON COIL
4
R-
25
22529/1
- with gasket
- without gasket
Length in feet (7.6 m)
Coil
Thickness 0.070 - 0.093 in (1.8 mm - 2.4 mm)
TABLE 6
22529/2
DELIVERY IN THE FORM OF CUT SEGMENTS

4
22529/1
85
- with gasket
- without gasket
Quantity of segments 12.75 in (0.3 m)
Cut in segments by the Manufacturer
Thickness 0.025 - 0.036 in (0.6 mm - 0.9 mm)
TABLE 7
Designation
22529/1
22529/2
DESIGNATION AND DIMENSIONS OF THE PROTECTORS

Type
Min hole diameter

(mm)
-1R-25
50.80
-1R-100
57.15
-2R-25
63.50
-2R-100
69.85
-3R-25
76.20
-3R-100
82.55
-4R-25
88.90
-4R-100
95,25
-5R-25
101.06
-5R-100
107.95
-6R-25
114.30
-6R-100
120.65
-7R-25
127.00
-7R-100
133.35
-8R-25
139.70
-8R-100
146.05
Partition thickness
(mm)
0.6-0.9
0.9-1.6
1.5-1.9
1.8-2.4
2.3-2.8
2.7-3.4
4.5-5,0
6.1-6.6
Length,
L-Feet
Width
(mm)
25
100
25
100
5,1
25
100
25
100
25
6.1
100
25
100
25
8.1
100
25
100
9.7
152.40
6.
Sealed lead-ins for termination of the cables and harnesses

Sealed passing through the wall (partition) is provided by used of the feedthrough connectors of
TCFS/R specification with formed part cavity filled with sealing compound RRJ0000-RE-314-071.
The wires are prepared for filling-in as per PI03-243-06 Manual, Part 2.
The feedthrough connectors provide sealing of the harnesses, cables at heating of the formed parts
with installation of the thermal insert using S-1125 glue.
TABLE 8
DESIGNATION OF THE FEEDTHROUGH CONNECTOR
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TC
FX*-
12
62C-

0-
20
-100
H
Type of the binding substance:
S-1030 glue
E epoxide glue
W S-1125 glue
Type of the formed part

straight, unscreened
90, unscreened
straight, screened
D 45 angle, screened
E 90 screened for size 16-36 only
Type of the formed part material
-25 semirigid elastomer
-100 heat-resistant
Thread length
3 digits must be specified at thread more than 95 mm
Housing assembly code
0 standard assembly
1 double-sided assembly (only for the straight unscreened formed parts)
2 the same as 1 but with a hole for sealing compound (glue)
3 lock nut
4 - 60 metal work
5 the same as 0 but with a hole for S-1125 insert
Material and coating of the housing
01W aluminium, bronze nickel-plated
19 aluminium-cadmium-plated, on the top - nickel-plated
19 aluminium-nickel-plated
19Q aluminium-zinc-cobalt coated
62 steel nickel-plated
Size of the feedthrough connector
Formed part design:
S elongated
R short (only for straight assemblies)
Specification
Single-side assembly
Double-side assembly
FIG. 9 Structure and sizes of the feedthrough connector (lead-in)
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Fig. 10 Structure of the feedthrough connector

TABLE 9
DIMENSIONS OF THE FEEDTHROUGH CONNECTOR (TIGHTENING

TORQUE OF THE LOCK NUTS DEPENDING ON THE HOUSING SIZE 10%:
12-15N-M; 16-20 N-M;20-30 N-M;24-35 N-M;30-40 N-M; 36-45 N-M;48-55 N-M.)
J-diameter
(mm)
Design
and size of the
Unscreened
Screened
feedthrough connector
B A min a min
-100S b max
max 25S
Length
10%
(mm)
A max
A/F
A/F
Size of
the
mounting
Unscreened
hole
(mm)
P
PS
PR
Diameter
(mm)
M
thread
TCFS/R-12
11
5.6
7.5
6.5
5.0
M12x1.5
7.5
24
17
52
50
43
13.0
TCFS/R-16
15
5.9
12.5
8.5
6.0
M16x1.5
10.2
29
22
57
65
48
17.0
TCFS/R-20
19
7.1
14.5
10.5
7.2
M20x1.5
14.0
34
27
61
77
52
21.0
TCFS/R-24
23
8.4
18.5
16.5
8.5
M24x1.5
19.2
38
30
74
90
65
25.0
TCFS/R-30
29
9.9
23.5
20.5
10.0
M30x1.5
24.2
48
36
73
115
64
31.0
TCFS/R-36
35
15.7
32.5
28.5
15.8
M36x1.5
30.2
52
41
104
140
95
37.0
TCFS-48
45
16.8
38.5
35.5
N/A
M48x1.5
40.2
67
55
144
110
135
50.0
7.
Cable fasteners
Cable fasteners with silicone seal are used for attachment of the harnesses and RF cables,
including attachment of the cable harnesses in the zones with fuel vapours, they must be resistant
to impact of the hydraulic fluids, mineral and synthetic oils.
TABLE 10
028001
DESIGNATION SYSTEM
DA
24
Delivery with fitted seal 7

Shaped silicone seal
Clamp inner diameter (38.1 mm)
Profile option
Material - aluminium strip with paint coating
Base designation p/n

The silicone seals are used in the general purpose zones as well as in the zones subjected to
impact of the fluids, oils and fuel vapours. They have high resistance to ozone and can be resistant
to fluids on the basis of the complex ether phosphates. Colour - solid white. Attachment clamps
with silicone seal are specified in the Table 11.
EFFECTIVITY:
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TABLE 11
DESIGNATION AND SIZES OF THE CLAMPS WITH SILICONE SEAL

Inner
diameter
(mm)
Designation
Weight (g)
Designation
Inner
diameter
(mm)
Weight (g)
028001DAL02HA
3.2
1.27
028001DAL18HA
28.6 (29.0)
7.45
028001DAL03HA
4.8 (5,0)
1.47
028001DAL19HA
30.20
7.78
028001DAL04HA
6.4
1.56
028001DAL20HA
31.8 (32.0)
8.07
028001DAL05HA
8.0
1.72
028001DAL22HA
35,0
8.64
028001DAL06HA
9.5 (10.0)
1.84
028001DAL23HA
36.5 (37.0)
8.93
028001DAL07HA
11.10
2.01
028001DAL24HA
38.1
9.21
028001DAL08HA
12.7 (13.00)
2.17
028001DAL25HA
39.7 (40.0)
9.50
028001DAL10HA
15,9 (16.0)
4.22
028001DAL26HA
41.3
9.83
028001DAL11HA
17.5 (18.0)
4.46
028001DAL27HA
43.0
10.115
028001DAL12HA
19.1
4.71
028001DAL28HA
44.5
10.40
028001DAL13HA
20.6 (21.0)
4.955
028001DAL29HA
46.0
10.69
028001DAL15HA
23.8 (24.0)
5,405
028001DAL30HA
47.6 (48.0)
10.98
028001DAL16HA
25,4
5,65
028001DAL31HA
49.2
11.30
028001DAL17HA
27.0
5,90
028001DAL32HA
50.8 (51.0)
11.60
A. Clamps with silicone shaped seal for attachment of the harness protected by a corrugated tube.
TABLE 12
DESIGNATION SYSTEM
028000
DA
24
Delivery with fitted seal 3

Shaped silicone seal

Option
B. Attachment clamps with silicone shaped seal are used in the zones with operating temperature
from -54 to +200. The clamps used for attachment of the harness in the corrugated tube
and of RF cables are specified in the Table 14.
C. Attachment claps with silicone seal are used for attachment of the harnesses protected by DR25, K tube or by the sleeve Roundit 2000 NX, and for attachment of the harnesses in the
general-purpose zones (e.g., clamps of the type TA02213DAL24HA). Dimensions of the
clamps are specified in the Table 14.
D. Dimensions of the clamps with seal for attachment of the harness in the corrugated heatshrinking tube, for attachment of the RF cables and harnesses are specified in the Table 14.
TABLE 13
02213
DESIGNATION SYSTEM
DA
24
Delivery with fitted seal

Silicone shaped seal

Option
EFFECTIVITY:
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TABLE 14
DESIGNATIONS AND SIZES OF THE CLAMPS WITH SILICONE SEAL

Inner
diameter,
(mm)
9.5 (10.0)
11.10
12.7 (13.00)
15.9 (16.0)
17.5 (18.0)
19.1
20.6 (21.0)
23.8 (24.0)
4.8 (5.0)
6.4
8.0
9.5 (10.0)
12.7 (13.00)
15.9 (16.0)
19.1
22.2
Designation
TA028000DAL06HA
TA028000DAL07HA
TA028000DAL08HA
TA028000DAL10HA
TA028000DAL11HA
TA028000DAL12HA
TA028000DAL13HA
TA028000DAL15HA
TA02212DAL03HA
TA02212DAL04HA
TA02212DAL05HA
TA02212DAL06HA
TA02212DAL08HA
TA02213DAL10HA
TA02213DAL12HA
TA02213DAL14HA
Designation
TA028000DAL16HA
TA028000DAL17HA
TA028000DAL18H
TA028000DAL19HA
TA028000DAL20HA
TA028000DAL22HA
TA028000DAL23HA
TA028000DAL24HA
TA02213DAL16HA
TA02213DAL18HA
TA02213DAL20HA
TA02213DAL22HA
TA02213DAL24HA
TA02213DAL27HA
TA02213DAL29HA
TA02213DAL32HA
Inner diameter,
(mm)
25.4
27.0
28.6 (29.0)
30.20
31.8 (32)
35.0
36.5 (37.0)
38.1
25.4
29.0
32.0
35.0
38.1
43.0
46.0
50.8 (51.0)
E. Designation system for the fluorsilicone fasteners

TABLE 15
MS21919
DESIGNATION SYSTEM FOR THE FLUORSILICONE FASTENERS

W
CJ
8
Fastener 12.7 mm (inner diameter)
Stainless steel strip.

Fluorosilicone, 200C
Tapered seal
Base designation
F. Clamps with fluorosilicone seal are used in the zones of high temperatures, in the zones
contaminated with petroleum-based fluids (are specified in the Table 16). They are not
subjected to ozone impact, but can not resist to the fluids based on the complex phosphateethers. Colour - solid blue.
G. It is permitted to use the attachment clamps as per OST1 12090-75.
It is
permitted to fit the heat-shrinking tube DR25-3/4-0. K-15,0/7,5 on the clamps as per OST1
12091 - OST1 12093, 02213DAL.
TABLE 16
Designation
DESIGNATIONS AND SIZES OF THE CLAMPS WITH FLUOROSILICONE

SEAL
Inner diameter
(mm)
Designation
Inner diameter
(mm)
MS21919WCJ2
3.18
MS21919WCJ16
25.40
MS21919WCJ3
4.75
MS21919WCJ17
26.97
MS21919WCJ4
6.35
MS21919WCJ18
28.58
MS21919WCJ5
7.92
MS21919WCJ19
30.15
MS21919WCJ6
9.53
MS21919WCJ20
31.75
EFFECTIVITY:
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Inner diameter
(mm)
Designation
MS21919WCJ7

Designation
Inner diameter
(mm)
11.10
MS21919WCJ21
33.32
MS21919WCJ8
12.70
MS21919WCJ24
38.10
MS21919WCJ9
14.27
MS21919WCJ26
41.28
MS21919WCJ10
15.88
MS21919WCJ28
44.45
MS21919WCJ11
17.45
MS21919WCJ30
47.63
MS21919WCJ12
19.05
MS21919WCJ32
50.80
MS21919WCJ13
20.62
MS21919WCJ36
57.15
MS21919WCJ14
22.22
MS21919WCJ40
63.50
MS21919WCJ15
23.08
MS21919WCJ48
76.20
8.
Plastic cable fasteners

. The plastic attachment system is used in the zones with operating temperature range from 55 to +135C for different cables (harnesses) with maximum diameter up to 30 mm and for all
cable routes.
(1)
The plastic cable fasteners are produced of the cylinder-structure thermoplastic

rubber.
(2)
The flat single and double cross fasteners for the harnesses for the cable band are
shown below.
Cable band
Harness
Fig. 11 Flat single and double cross fasteners for the harnesses for cable band
EFFECTIVITY:
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Fig. 12 Flat longitudinal single fasteners for the harnesses for cable band
Fig. 13 Cross and longitudinal fasteners for the harnesses single, on support, for one screw,
. The plastic cable holders are used in the zones with operating temperature from -55C to
+150C for the cables (harnesses) having diameter 5 45 mm and are used in the cable
routes.
(1)
Attachment of the cable holder is provided by 5 screw (tightening torque is 0.42 m.

da N30%). Attachment of the cable (harness) is provided by the cable band having
width up to 5.0 mm (tightening torque 120 N).
(2)
The plastic cable holders ate produced of thermoplastic with a layer of protective
elastomer-silicone.
(3)
The plastic holder with sizes for attachment of the harnesses and cables is shown in
Fig. 14:
Fig. 14 Plastic cable holder (clamp width 14.5 mm)
EFFECTIVITY:
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DESIGNATION AND CHARACTERISTICS
No. for order
Colour
003262 101 00
Brown
003262 111 00
Blue
003262 102 00
Brown
003262 112 00
Blue
003262 103 00
Brown
003262 113 00
Blue
003262 104 00
Brown
003262 114 00
Blue
003262 105 00
Brown
003262 115 00
Blue
003262 106 00
Brown
003262 116 00
Blue
003262 107 00
Brown
003262 117 00
Blue
Cable diameter
Distance
between
centers
Thickness D
Length L
Height H
Weight
(mm)
(mm)
(mm)
(mm)
(mm)
(g)
5-7
17
3.5
34.8
15,4
2.51
7-10
18.5
3.5
37.9
18.7
3.06
10-14
20.4
3.5
41.5
23
3.85
14-19.5
23.05
3.5
47.5
28.8
4.91
19.5-26.5
26.75
3.5
54.4
36
6.36
26.5-35
31
5,8
62.7
45
10.14
35-45
36
8.4
72.3
54.9
14.27
Size
TABLE 17
NOTE: Blue sealant; is resistant to the impact of fluids,oils and to fuel ingress.
. Designations of the plastic cable fasteners are given in the Table 18:
TABLE 18
Designation of No.
for order
HOLDERS FOR THE CABLE BAND AND BINDING CLIPS PCL.

Designation of No. for
order
Harness diameter
(mm)
Operating
temperature
()
Weight
(g)
Designation of No. for

order
Single
PCL 150 110
003261 202 59
24.6; 30; 30.5
15; 3.1; 24
PCL 250 020
PCL 150 111
003261 116 59
27.0; 30; 33.8
18; 2.4; 23.5
PCL 250 022
PCL 150 112
003261 501 59
29.4; 30; 35,3
20; 3.5 24
PCL 250 023
PCL 150 113
003261 113 59
31.8; 15; 38.4
21; 2.2; 25,4
PCL 250 025
PCL 150 114
003261 167 59
34.1; 30; 40.0
23.5; 3.2; 25,8
PCL 250 026
PCL 150 115
003261 220 59
36.5; 30; 49.5
25,8; 3.0; 33.1
PCL 250 032
-55 +135
-55 +110
Double
003261 201 59
15
003261 503 59
30
TABLE 19
Designation of No. for order
-55 +135
3.7
6.15
SHAPED CABLE HOLDERS CHARACTERISTICS

Length
(mm)
Width
(mm)
()
Attachment
points
Weight (g)
ALBCBS 303 59-3
58.42
14.605
1.86
ALBCBS 303 59-5
83.82
14.605
2.63
ALBCBS 303 59-7
109.22
14.605
3.90
ALBCBS 303 59-9
134.62
14.605
4.17
ALBCBS 303 59-11
160.02
14.605
4.99
-55 +85
EFFECTIVITY:
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9.
Fitting of the cable fasteners

A. The cable fasteners MS21919W, PCL 150. PCL 250. TA028001, TA02213DAL are fitted in
accordance with Figures 15 - 18:
Fig. 15 Permissible and impermissible fitting of the cable fasteners
Fig. 16 Correct fitting angles of the cable fasteners
Fig. 17 Correct clamps fitting
Fig. 18 Correct alignment of the fasteners on the aircraft

B. The fasteners (Ref. Fig.17) are used for fitting of the cable fasteners on the structure. If the
harness is less than the most close fastener size, then plastic attachment is used or the
harness is wrapped in two layers of the silicone tape 66N, 69, 68N for reliable attachment of
the harness in the fastener. If the fastener can not be installed without biting or pinching of the
wires, the fastener is replaced with a plastic one, which will provide reliable attachment of the
harness (cable).
EFFECTIVITY:
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Cable attachment with gasket MS21919W, TAO28001DA
Screw MS51957
OST 1 31529
Common washer
AN960
Nut MS35649
OST 1 33055
Common washer
AN960, OST 1 14088
Washer with serrations AN9368,

OST 1 11532
Fig. 19 Correct fitting of the fasteners

C. The plastic cable fasteners are used for the harnesses having diameter up to 45 mm in the
open routes, in the pressurized areas, panels, on the racks and in the junction boxes.
D. The cable fasteners are attached directly to "Z" - shaped structural components. Angular
brackets are used with two attachment fasteners for attachment to the angular structural
component, Ref. Fig.18. Fitting using the plastic holders is performed via the intermediate
elements. The intermediate elements are attached to by non-blind rivets with
compensators. The plastic holders are attached to the fasteners by 5 screws:
Fig. 20 Fitting of the cable fastener to the structure

E. Cable racks are used to provide the clearance between the cable and structural component or
equipment (Fig. 21). The cable racks are described in the Table 20:
TABLE 20
CHARACTERISTICS OF THE CABLE RACKS

Rack length
(mm)
Designation
Thread size
L35064A2B075
19.6
0.1640-32UNJC(8/32) (4.125)
L35064A2B100
25.4
0.1640-32UNJC(8/32) (4.125)
L35064A2B125
31.75
0.1640-32UNJC(8/32) (4.125)
L35064A2B150
38.10
0.1640-32UNJC(8/32) (4.125)
L35064A2B175
44.45
0.1640-32UNJC(8/32) (4.125)
EFFECTIVITY:
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Rack length
(mm)
Designation
Thread size
L35064A2B200
50.8
0.1640-32UNJC(8/32) (4.125)
L35064A2C075
19.6
0.1900-32UNJF (10/32) (4.826)
L35064A2C100
25.4
0.1900-32UNJF (10/32) (4.826)
L35064A2C125
31.75
0.1900-32UNJF (10/32) (4.826)
L35064A2C150
38.10
0.1900-32UNJF (10/32) (4.826)
L35064A2C175
44.45
0.1900-32UNJF (10/32) (4.826)
L35064A2C200
50.8
0.1900-32UNJF (10/32) (4.826)
Fig. 21 Cable fasteners on the racks

NOTE: It is permitted to use the bushings as per OST1 11113-73.
F. The assigned distance between the harnesses is provided and electromagnetic interaction is reduced
by use of the dividers p/n 3308.8301.000 - 3308.8309.000.
TABLE 21
DESIGNATION OF THE HARNESS DIVIDERS

Q-ty of components
Designation
Airbus
Designation
head 1
3308 8301000
head 2
ABS1144A25A
3308 8302000
ABS1144A50A
3308 8303000
ABS1144A75A
3308 8304000
ABS1144B25A
3308 8305000
3308 8306000
ABS1144B50A
ABS1144B75A
3308 8307000
ABS1144C25A
3308 8308000
ABS1144C50A
3308 8309000
ABS1144C75A
rack 1
rack 2
1
-
1
-
1
-
rack 3
1
1
1
Harness
diameter
,
mm
From 0 to
16
From 16
to 45
From 0 to
16
From 16
to 45
EFFECTIVITY:
Length
L,
mm
Weight,
g
(10%)
25
4.65
50
6.33
75
7.81
25
6.96
50
75
8.63
10.11
25
5.81
50
7.48
75
8.96
Page 24
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G. The tools used for fitting of the cable fasteners (Fig. 22) is similar to the common combined
pliers with updated upper jaw and with cutting width 5 mm. This tool provides retaining of the
fastener at the moment of the nut installation on the bolt (screw). The tool is used for fitting of
the cable fasteners in the narrow spaces as well as for fitting of the groups consisting of two
or three fasteners.
Cable fastener
Attachment
screw
Safety device for

fastener retaining
Fig. 22 Tool for fitting of the cable fasteners

H.
Fitting of the cable fasteners on the tubular structures

Fastener AN735 (without gasket) is used for attachment to the tubing. The fastener must be
tightly fit, but must not be deformed when fitted. The cable fastener 02213DA is attached
to the fastener AN735 using the AN fasteners (Fig. 23):
Tubing
02213DA - cable fastener
AN735 cable fastener without gasket
Fig. 23 Fitting of the cable fastener on the tubular structure component

(it is permitted to use the dividers p/n 3308 8301 000)
I.
Designation and sizes of the protectors are given in the Table 7 of the present Section.
J.
Fitting of the protectors is shown in Figure 24.
EFFECTIVITY:
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Fig. 24 Installed protectors: harness passing through the hole and attachment with use of the racks p/n
BACNGH 3-6 (8,10,12,14,16,18,20,22,24,26)-C; WS1-332-6 (0,12,14,16,18,20,22,24,26,28,30)-C. P/N
BACN10TL 3-6 (8,10,12,14,16,18,20,22, 24)-B; WS1-4-6 (8,10,12,14,16,18,20,22,24)-B-STRAIGHT.
K. The cable fasteners are used for retaining the harness wires in the swivelling devices, so that
the wires are twisted during movement of the moving parts (Fig. 25).
CORRECT: The wires in the harness are twisted across the hinge axis
INCORRECT: The wires are bent across the hinge axis

Fig. 25 Examples of correct and incorrect location of the cable fasteners inside the JB, panel, access
panel
EFFECTIVITY:
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FITTING AND CONNECTION OF THE NEGATIVE WIRES

1.
Aircraft bonding General

A.
Bonding is the electrical connection to the airframe for protection of the maintenance
personnel against the static electricity and electric shock. The grounding modules, negative
terminals, bolts, negative bonding (grounding) panels are fitted as per OST 100723-74 and in
accordance with the present procedure.
B. Bonding (grounding) of the screened wires (harnesses, cables), avionic equipment units as
well as instrument boards, panels etc. are connected to the airframe as per OST 101025-82
and in accordance with the present procedure.
C.
The following requirements must be met during connection of bonding or grounding on the
aircraft:
(1)
Connection must be performed to the aircraft base structure, where possible.
(2)
Bonding or grounding connections must not reduce strength of the airframe.
(3)
Separate bonding must be provided, where possible.
(4)
Bonding or grounding must be performed on the smooth and clean surfaces.
(5)
The bonding or grounding connections must be fitted in such a way, so that vibration,
expansion, compression or any other relative motions characteristic of the normal
operating conditions do not result in the rupture or disconnection.
(6)
The bonding or grounding connections must be arranged in the protected areas, where
possible. The connections must be arranged near the access panels and in other places
that provide easy inspection and fast replacement.
(7)
Do not crimp the bonding or grounding connections by means of any nonmetal

materials.
(8)
The grounding and bonding braidings must be checked for absence of corrosion and
cuts or brooming out more than 25% as compared to the initial state.
(9)
Not more than four grounding wires can be connected to one negative grounding
terminal (screw, bolt).
(10) The grounding modules as per specifications L53-105, NAS 1749, NF/UTE C 93-462,
EN 3155-016. pressurized round, and modules with attachment brackets of type 1100
are used in order to increase quantity of the grounding points. Not more than 12
grounding points can be provided for the round modules (Fig.1) and not more than 18
grounding points - for rectangular modules (Fig.2). Blanking caps are installed on the
spare contacts.
EFFECTIVITY:
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Fig. 1 Round grounding modules
Fig. 2 Rectangular grounding modules

(11) grounding of the different electrical power sources (main, secondary, emergency) must
be connected to different grounding points. grounding of the consumers can be
combined, when they are supplied with power from one and the same power source.
2.
Selection of components
A.
Metal components used for creation of the bonding or grounding connections are selected on
the basis of mechanical strength, current load and fitting simplicity. When the connections are
made on the structures made of the dissimilar materials, washers made of corresponding
materials must be used, which must be fitted between the dissimilar materials in such a way,
so that any corrosion, which can occur, occurs on the expendable washer and not on the
structure.
B. Materials of the metal components and their coatings are selected according to the Table
depending on the structure material (Ref. Table 1).
C.
Fitting of the metal bonding (grounding) components is performed according to Figures 3, 4.
EFFECTIVITY:
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Screw (bolt)
Lock
washer
Washer
Washer
Structure
Washer
Wire
Common nut
Washer D
End fitting
Self-locking nut
Fig. 3 Bonding or grounding to the flat surface using a bolt or screw (not more than four lugs with wires
2
having section up to 1.23 mm inclusively)
Screw (bolt)
Washer
Structure
End fitting
Wire
Lock washer
Washer
Self-locking nut
Fig. 4 Bonding or grounding to the flat surface using a bolt or nut (not more than 4 lugs with wires
2
having section up to 1.23 mm inclusively)
EFFECTIVITY:
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Cadmium-plated
steel
Cadmium-plated
steel
No
No
Cadmium-plated
steel
Cadmium-plated
steel
Cadmium-plated
steel
Stainless steel
Cadmium-plated
steel
No
No
Cadmium-plated
steel or
aluminium
Stainless steel
Cadmium-plated
or stainless steel
Stainless steel
Cadmium-plated
steel
ALL
EFFECTIVITY:
20-40-70
Cadmium-plated
steel
Cadmium-plated
steel
Cadmium-plated
steel or
aluminium
Magnesium alloy
Cadmium-plated
steel
Cadmium-plated
steel
Cadmium-plated
steel or
aluminium
Lock washer F
Lock washer
Washer C&D
Washer B
Aluminium alloy
Common nut
Washer A
Tin-plated brass
Cadmium-plated
steel
Screw or bolt;
self-locking nut
Aluminium alloy
Cadmium-plated
steel
Cadmium-plated
steel
Structure
TABLE 1
Magnesium alloy
Aluminium alloys
Magnesium alloys
RRJ-95B
SELECTION OF METAL BONDING (GROUNDING) COMPONENTS IN

RELATION TO THE STRUCTURE MATERIAL
DO NOT CONNECT COPPER AND CADMIUM
D. Fitting of the anchor nut (bolt) for bonding (grounding) is performed according to Figure 5.
Page 4
Sep 30/11
RRJ-95B
Screw (bolt)
Washer
Structure
End fitting
Wire
Washer
Lock washer
Self-locking nut
Fig. 5 Bonding or grounding on the flat surface with threaded nut (not more than 4 lugs with wires having
2
section up to 1.23 mm )
E.
Fitting of the negative terminals for bonding (grounding) is performed as per OST 1 00723-74
(Fig. 6):
D
Negative terminal
Washer
Common washer
End fitting
Wire
Clsmp
Tag
Nut
Rivet
Housin
g
Fig. 6 Fitting of the negative terminals for bonding

F.
Base of the negative terminal, bus, anchor bolt is attached to the aircraft main framework by
rivets without coating.
G.
Negative wires and grounding wires are connected by means of the grounding modules,
negative terminals, panels, bolts (screws).
H.
The connections are arranged in the places accessible for fitting and protected against direct
ingress of water, fuel, hydraulic mixtures and oil.
I.
Each system must have its own negative buses to enhance safety of the systems and provide
easy repair.
J.
Not more than 2 lugs with wires having section from 1.94 mm to 4.75 mm , not mote than one
2
2
lug with wires having section from 8.62 mm to 84.80 mm are connected to the negative
terminal, bus,bolt.
K.
Fitting of the grounding modules, negative terminals, panels and bolts is performed using the
current-conducting compound VP-1 U6-10-11- VIAM-93-87 on the rigid elements (frames,
beams, stringers, profiles etc.). The current-conducting compound VP-1 is applied according
to R1.2.511-85 VIAM. Do not install the grounding elements on the vibrating surfaces (false
ribs, thin partitions etc.).
L.
Metal components for bonding or grounding in relation to the structure material are specified
in the Table 2.
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Washer B
No
No
Washer A
Cadmium-plated
steel or
aluminium
Cadmium-plated
steel or
aluminium
Lock washer
Cadmium-plated
steel
Cadmium-plated
steel
Aluminium alloy
Cadmium-plated
steel
Cadmium-plated
steel
Aluminium alloy
Structure
Aluminium alloys
Magnesium alloys
Rivet
SELECTION OF THE METAL COMPONENTS IN RELATION TO THE

STRUCTURE MATERIAL
Screw or bolt;
threaded base
TABLE 2
Cadmium-plated
steel
Stainless steel
Cadmium-plated
steel
Cadmium-plated
steel
No
Stainless steel,
cadmium-plated
steel
Stainless steel
Cadmium-plated
steel
Cadmium-plated
steel
No
Stainless steel
Cadmium-plated
steel
DO NOT CONNECT COPPER AND MAGNESIUM
M.
Bolts or screws of corresponding size for the specified jumper are used. Length of the bolt or
screw must project from the nut cut by not more than 3.0 mm (3 turns). Fasteners of the
bonding (grounding) connection screws (bolts) and nuts must be tightened till complete
compression of the split lock washer.
N.
Both common and self-locking nuts are used, Ref. Figures 1 - 4. Use of the solid-metal, selflocking nuts is the most efficient. If this is necessary for fitting, threaded base riveted to the
structure is used.
O.
Both common and split washers can be used, Ref. Figures 1 - 4. It is not otherwise stated in
the documents, split washers are used for the common nuts and not for the self-locking ones.
Common washers with diameter equal minimum to diameter of the tab of the aluminium lug of
the next standard size are used for the aluminium lugs.
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P.
Bonding or grounding is brought out onto the cylindrical surface by means of AN735 clamps.
If AN735 clamps are not available or can not be used according to the fitting conditions, they
can be replaced with AN742 clamps without gasket (Fig. 7).
Q.
Negative wires, screen grounding wires, housing thickness, diameter of the fasteners and
distance of attachment are specified in the Table 3:
TABLE 3
CHARACTERISTICS OF THE FASTENERS IN RELATION TO WIRE

SECTION
Distance L
(mm)
Minimum housing
thickness
(mm)
Diameter of terminal, bolt

(screw)
0.38 1.23
80+20
1.0
1.94 4.75
13020
1.5
1.5
2.5
3.0
3.0
10
4.0
10
Wire section
(mm)
8.62 13.50
21.80 34.50
15050
41.80 52.70
67.20
84.80
150+50
R.
In order to increase thickness of the housing, splice strips, angle bars, buses and other parts
are riveted in the fitting place according to the drawing instructions (Fig. 8).
S.
The negative terminals, buses, anchor bolts, grounding modules, fasteners and attachment
normals as well as the lugs must be degreased by BR-1 benzene or by Nefras S2(3)-80/120
U38.401-67-108-92.
T.
Surface of the structure under the base of the negative terminals, buses, anchor bolts and
grounding modules must be thoroughly ground to metallic lustre not earlier than 3 hours prior
to fitting and connection of the lug with wire. Dimensions of the ground surface must be by 3 4 mm more than the contact surface of the fitted parts. After fitting of the negative terminals,
buses, bolts, rivets without coating and grounding modules on the aluminium alloy structure
the excessively ground place must coated with two layers of red K-84 enamel U6-10-60485, after that cold drying must be performed in accordance with effective series documents.
U.
Only corrosion-resistant metals and alloys must be used for the bonding (grounding)
assemblies operating in aggressive media.
V.
Attachment to the tubular structure is performed according to Figure 7:
Fig. 7 Bonding attachment to the tubular structure
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W.
Attachment to the structural components for fitting of the negative wires AWG 4.0 to AWG
0000 to the elements riveted to the structure (Fig.8).
Fig. 8 Bonding (grounding) to the elements riveted to the structure, of the wires with AWG 4.0 to AWG
0000 lugs
X.
3.
When bonding (grounding) to the additional structure riveted element is used, electrical
performances are provided, which are similar to direct connection to the structure.
Fitting of the cylindrical grounding modules and grounding modules with attachment brackets
A.
The cylindrical grounding modules contain 12 contacts installed in the insulating housing,
which is installed on the metal base with threaded pin 1900-32 UNF2A. The technology is
similar to the connecting modules.
B. Designation and sizes of the round grounding modules (Fig.9):
Fig. 9 Round grounding module
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TABLE 4
ROUND GROUNDING MODULE AND FITTING TOOL

Size
(mm)
20
Sealed module
Diameter
Fitting tool
001174 260 00
*002014 000 61
001174 250 00
10.32 UNF 2 **002015 000 61
Contact
001104 200 02
C.
Distance between the two grounding modules must be not less than diameter of three
modules.
D.
Designation, sizes and installation of the grounding modules with attachment brackets are
shown in Figure 10.
E.
The grounding modules can be installed on the negative panel with use of the rivets without
coating with interval 30 mm.
Fig. 10 Designation, sizes and fitting of the grounding modules with attachment brackets (rectangular)
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Fig. 11 Type 1100 module
F.
Grounding modules on a metal rail, designation and sizes (Fig.12).
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14
Fig. 12 Grounding modules on a metal rail
4.
G.
Metal rail with bichromated cadmium coating must be used for the given module type. No. for
order: 001751 ** 07, where ** - quantity of modules 01-02, -03 etc.
H.
Crimping, wiring tools and plastic plugs are specified in the Table 107, Subject 13, Section
20-40-10.
I.
Distance between the two groudning modules must be not less than 42 mm.
Surface preparation for bonding and grounding

A.
The surface must be cleaned for bonding and grounding. Size of the ground surface must be
by 3-4 mm more than size/diameter of the contact zone. The paint, anodising film and
corrosion traces are removed from the planned contact spot by the abrasive material A-A58054 or similar as per OST1 00723-74.
CAUTION: Do not use such abrasives as emery cloth, cloth with iron oxide, steel chips etc.,
which can leave particles on the ground surface or scratch it and thus cause
future corrosion.
B. A vaseline compound coating is applied on the surface for bonding/grounding on the aluminium
structure. The surface is thoroughly ground using the brushes made of stainless steel wires
with a guide, Ref. Fig.13. Wipe the vaseline compound with a dry clean cloth.
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Fig. 13 Stainless steel wire brush with a guide for cleaning of the aluminium surfaces
C.
5.
The steel surfaces are cleaned for bonding/grounding to remove the lubricants and oils with
use of the solvent P-D-680 type 3, the paint coating is removed using the varnish thinner -857.
WARNING: The solvents are toxic for skin, eyes and respiratory system. The skin and eyes
must be protected. Continuous and repeated contact is not permitted. General
ventilation and prevention of solvent vapours concentration must be provided.
The solvent --857 is inflammable and toxic for skin, eyes and respiratory
system. The skin and eyes must be protected. Continuous contact is not
permitted. General ventilation must be provided.
CAUTION: Do not remove the zinc or cadmium coating from the steel surfaces.
Tightening torque of the connections

The self-locking bolts, screws, nuts for the wires with lugs and for the terminals are fitted with the
following tightening torque:
TABLE 5
TIGHTENING TORQUES FOR FASTENERS

Tightening torque
(N*m/kgf*m)
Wire size
(AWG)
Wire section
2
(mm )
Thread
For steel
For brass
12 - 10
3.0 4.91
3.900.2/0.400.02
1.960.2/0.20.02
24 - 14
0.24 1.94
1.760.2/0.180.02
0.980.1/0.100.01
10 - 4
5.0 21.80
6.400.3/0.650.03
3.430.3/0.350.03
2-0
34.50 52.70
16.200.4/1.650.04
9.801.0/1.00.1
00 - 000
67.20 84.80
10
35.80.5/3.650.05
18.642.0/1.90.2
12
55.20.5
29.43.0/3.00.3
6.
Bonding and grounding links

A.
In order to solve the bonding/grounding tasks, current-carrying path must be provided in the
places, where there is no direct electrical contact.
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B. For this purpose the links are used between the moving parts, shock-mounted equipment and
structure as well as between the current-conducting objects and structure. The links must be as
short as possible. Two or more successive links can not be used.
C.
Bonding of the structural components and assemblies is performed as per OST 101025-82.
D.
The bonding links can be used as per OST1 11303-73 and produced according to the
normative documents effective at the enterprise.
E.
The small section wires are terminated in the copper insulated lugs of required size according
to specification M7928/4. Crimping pincers M22520/5-01 with M22520/5-100 dies are used
for crimping. Non-insulated copper lugs according to specifications M7928/4, MS20659,
277147 with additional insulating heat-shrinking tube RNF 3000. DR-25, RW-175, K are
used for larger section wires (8AWG and more).
F.
Values of transient resistance between the lug and the housing must not exceed the norms
specified in the Table 6:
TABLE 6
G.
CHECK OF THE TRANSIENT RESISTANCE AFTER FITTING OF THE

BONDING AND GROUNDING LINKS
Wire size
(AWG)
Wire section
2)
(mm
Maximum
transient resistance
(mcOhm)
22 -14
(0.35 2.5) 0.38 1.94
600
12 - 8
(4.0 10.0) 2.98 8.98
500
6-4
(16.0 25.0) 13.40 21.80
400
2-1
(35.0) 34.50 41.80
300
0 - 00
(50.0 70.0) 52.70 67.20
200
000
(95.0)84.80
100
Transient resistance of the bonding/grounding link (between the bonded object and the
frame) must be less than 0.1 Ohm in the general bonding cases, when bonding links are
used, or in case of direct connection of the metal components. When HF bonding is required,
resistance must be maximum 0.0025 Ohm (2.5 MOhm) (Basis: Standard MIL-STD-464).
NOTE: Resistance values given in the Subject 6.G are general for the basic cases. Special
requirements specified by the designer have higher priority.
H.
The test must be performed after mechanical assembly and lies in measurement of the
resistance value between the cleaned airframe surfaces and the structure.
I.
Value of the transient resistance is measured by means of a special high-precision calibrated

ohmmeter. it is recommended to use Avtron T477W or its functional equivalent, e.g.,
AN/USM-21A device. The AN/USM - 21A device can be used under safe conditions. Study
the device operating manual prior to measurement:
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(1)
When the device is in "Functional test ON" position, set the range monitoring to
"0.1Ohm" position;
(2)
Connect the device probes with good electrical contact on the cleaned surface near the
link end and the structure;
(3)
Set the functional monitoring to "Calibration" position, then use monitoring of calibration
adjustment to obtain the value 0.1 Ohm for the whole scale;
(4)
Set the functional monitoring to "Ohm" position and read the connection value; it must
be not less than 0.1Ohm.
NOTE: Other devices with accuracy class 0.05 can also be used.
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LOCKING OF THE CONNECTORS AND THREADED CONNECTION ELEMENTS

1.
General
A.
Primarily self-locking protective tails (cable clips), designation of which includes letter S (e.g.,
85049/38S), are fitted on the modern connectors. Fitting procedure of the self-locking cable
clips is described in the Section 20-40-50 of the present Manual. Bayonet connectors are not
subject to locking.
B. The lock nuts in the connectors, screws on the cable clips installed in the high vibration zones
(wing, pylons, engine, LG - NLG, MLG, F6. horizontal stabilizer, vertical stabilizer), sealed
connectors, feedthrough connectors of the series 257-093 or 8DB are locked in accordance
with the present Section in order to prevent unscrewing.
C.
When threaded connectors are connected, the coupling nuts must be tightened using the tool
with tightening torque (Ref. Table 4, Section 20-40-50). State of the final connection of
connectors is defined at full alignment of the blue strips of the coupling nut and of the jack-in
part, at that the red strip must not be seen. Fitting and removal of the coupling nut and cable
clip on/from the connectors are performed by special wrenches. All home-produced
connectors, except for the self-locking and bayonet ones, are locked after connection.
D.
Locking of the Russian produced connectors is performed by safety wire 0.5-S12Kh18N10

GOST 18143-72 as per OST1 00247-77 (Ref. Fig.1):
Fig. 1 Common locking by twisted wire

This method used in aviation is complicated and old. it is recommended to perform locking
using the SAFE-T CABLE system.
E.
The SAFE-T-CABLE system (Fig. 2) was developed to enhance the locking procedure. Set
of equipment/materials can be used in different cases, the tools provide safe and reliable
fitting.
TM
Fig. 2 Locking by SAFE-T-CABLE
SYSTEM
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2.
Safe-T-Cable
TM
Safety Wire Fitting Procedure:
Fig. 3 Safety wire threading through the locking hole of the secured items
Fig. 4. Safety wire threading through the tool nose part, tension of the safety wire
Fig. 5 Crimping of the retaining ferrule and cutting of excess safety wire
Fig. 6 Secured item
Fig. 7 Locking of the screws on the cable clip in the increased vibration zones (in accordance
with Subject 1.B)
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NOTE: Locking of the screws of the cable clips is provided by application of EP 140 enamel or
K 070 primer (red) on 3 - 4 turns of threaded joint, 2 - 3 mm wide.
Fig. 8 Locking of the lock nuts of connector fitted on the pressure wall, panel etc.
3.
F.
When URHR sleeve, tube DR25, RNF, ATUM, OTK, 222K or tape 66N, 67N, 68N is fitted
under the semiclamps of the cable clip and on the harness for connectors without selflocking, the clips as well as connectors installed in the increased vibration zones and lock
nuts of the single connectors are locked with EP-140 enamel.
G.
Connectors with automatic locks are not subject to locking.
H.
The cable clips without self-locking are locked by EP-076 primer or EP-140 enamel, GOST2
4709-81 applied on three thread turns.
Structure and termination materials

SAFE-T-CABLE is constructed of high tensile strength, stranded wire. It is more flexible than its
safety wire counterpart, although the working diameters are equivalent. This provides a stronger
assembly which has greater strength and lighter weight. The wire ends are electrically fused to
form an easy threading end.
TM
Fig. 9 Sectional view of SAFE-T-CABLE
wire
The wire is pre-cut to various lengths, and is supplied with a square-formed end cap attached to
one end.
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Fig. 10 The end cap prefitted on the safety wire on one side
SAFE-T-CABLE is available in three diameters:
diameter .040 in. consists of 7 twisted strands, each of which includes 7 wires;
diameter .032 in. consists of 3 twisted strands 7 wires in each;
diameter .020 in. consists of 1 strand including 7 wires.
The ferrules are precisely manufactured to a size and hardness which assures their compatibility
with the wire and application tooling. They are delivered in cartridges 50 pcs. in each. Easy
release of the ferrules from the cartridge is provided. This feature minimizes the possibility of
foreign object damage (Fig. 11):
Fig. 11 Cartridge ferrules (fitted and in bulk)
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.
Cable kits, assemblies and ferrules
TABLE 1
DMC DESIGNATION SYSTEM

C
10
Components
C = kit (wire and ferrules)
A = assemblies
(wire only)
F = ferrules only
TABLE 2
MATERIAL
09 =INCONEL
10 = 321
CRES
18
Wire diameter
1 = .020 /.026
2 = .032 /.038
3 = .040 /.046
length
9 = 9"
12 = 12"
15 = 15"
18 = 18"
21 = 21"
24 = 24"
XX
Special
configuration*
SAE DESIGNATION
AS3510
MATERIAL
AS3509 = INCONEL
AS3510 = 321 CRES
B.
02
Wire diameter
1 = .020 / .026
2 = .032 / .038
3 = .040 / .046
18
Length
9 = 9"
12 = 12"
15 = 15"
18 = 18"
21 = 21"
24 = 24"
Configuration*
K = kit (wire and ferrules)
C = assemblies (wire only)
F = ferrules
Material options:
AS3509 = AMS5687 (INCONEL)
AS3510 = AMS5689 (321 CRES)
CRES = corrosion-resistant stainless steel.
NOTE: 321 CRES is considered as standard for the aviation industry.
C.
Standard length options of the safety wire:

9", 12", 15", 18", 21" & 24" (sizes in inches),
304.8; 381.0; 457.2; 533.4;609.6 (sizes in mm)
228.6;
NOTE: Length of 18 inches is the most common.

D.
SAFE-T-CABLE - kit: safety wire and ferrules
Fig. 12 Safety wire and ferrules (kit)
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TABLE 3
MATERIAL, DESIGNATION AND CHARACTERISTICS
MATERIAL / DESIGNATION
321 CRES
DIAMETER
(INCH)
INCONEL
LENGTH
C10-312
C09-312
.040/1.02
12"/304.8
C10-318
C09-318
.040/1.02
18"/457.2
C10-321
C09-321
.040/1.02
21"/533.4
C10-324
C09-324
.040/1.02
24"/609.6
C10-212
C09-212
.032/0.813
12"/304.8
C10-218
C09-218
.032/0.813
18"/457.2
C10-221
C09-221
.032/0.813
21"/533.4
C10-224
C09-224
.032/0.813
24"/609.6
C10-112
C09-112
.020/0.51
12"/304.8
C10-118
C09-118
.020/0.51
18"/457.2
C10-121
C09-121
.020/0.51
21"/533.4
C10-124
C09-124
.020/0.51
24"/609.6
TABLE 4
DESIGNATION AND TYPE OF THE LOCKING TOOL ACCORDING TO SAFET-CABLE SYSTEM
Tool type
Hand
Electrical
P/N of the tool nose
E.
P/N
of the tool for DMC order
SCTR203
SCTR207
SCTE203
SCTE207
SCTN20-3
Diameter
inch, mm
.022 / 0.56
.022 / -//.022 / -//.022 / -//.022 / -//-
Tool nose length

inch, mm
3" / 76.2
7" / 178.0
3" / 76.2
7" / 178.0
3" / 76.2
SCTE20-7
.022 / -//-
7" / 178.0
SAFE-T-CABLE - assemblies: only wire with prefitted ferrule
Fig. 13 Wire with prefitted ferrule
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TABLE 5
MATERIAL / DESIGNATION
321 CRES
A10-312
A10-318
A10-321
A10-324
A10-212
A10-218
A10-221
A10-224
A10-112
A10-118
A10-121
A10-124
INCONEL
A09-312
A09-318
A09-321
A09-324
A09-212
A09-218
A09-221
A09-224
A09-112
A09-118
A09-121
A09-124
DIAMETER
(INCH)
.040/1.02
.040/1.02
.040/1.02
.040/1.02
.032/0.813
.032/0.813
.032/0.813
.032/0.813
.020/0.51
.020/0.51
.020/0.51
.020/0.51
LENGTH
12"/304.8
18"/457.2
21"/533.4
24"/609.6
12"/304.8
18"/457.2
21"/533.4
24"/609.6
12"/304.8
18"/457.2
21"/533.4
24"/609.6
NOTE: When length of the safety wire is calculated, additional length must be provided for
fitting in the tension mechanism. It is necessary to add 6 - 8 inches (150-200 mm)
for the tool with nose of 3 inches (76 mm) and 10-12 inches (250-300 mm) for the
tool with nose of 7 inches (175 mm).
F.
SAFE-T-CABLE - ferrules
Fig. 14 Ferrules
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TABLE 6
Wire diameter
(inch)
STANDARD FERRULES
321 CRES
LENGTH
(inch)
INCONEL
DIAMETER
(inch)
.020
F10-1
F09-1
.095 max
.090
.032
F10-2
F09-2
.164 max
.105
.040
F10-3
F09-3
.164 max
.105
4.
Special elongated ferrules

Most Safe-T-Cable installations can be made with standard components and applications tools.
However there are conditions that require modification or alterations to the standard product lines
to incorporate simple solutions.
Fasteners that have limited clearance between the safety wire hole (less than 2.5 mm) can
present a challenge to the installation of Safe-T-Cable. This is due to the clearance required by
the application tool nose, adjacent to the fastener.
Fig. 15 Elongated ferrule

The longer reach of the ferrule provides a stand off to the tool nose. Combine that with the radius
on the end next to the fastener. The ferrules for thin wire 0.20 in. do not have radius end duel to
smaller diameter. The angle allows the ferrule to be installed at an angle without loss of tension on
the wire when the ferrule returns to the straight position.
A.
Fitting of the elongated ferrules:
INCORRECT
CORRECT
Fig. 16 Fitting of the ferrule in restricted space
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TABLE 7
DESIGNATION FOR FERRULE ORDER

ELONGATED FERRULES
Wire diameter
.020 in.
.032 in.
.040 IN.
Designation
F10-08
F10-04
F10-07
Diameter (inch)
.090
.105
.105
length (inch)
.180
.320
.320
Radius
No
yes
yes
NOTE: Elongated ferrules produced of 321 CRES (AMS5689) material are delivered in packs, 50
pcs each.
5.
Fiberglass sleeving
It is recommended that a tubular jacket be placed over Safe-T-Cable when it is installed in an
area where it will be in contact with obstructions or surfaces that may damage the Safe-T-Cable.
It shall also be resistant to oil and chemical environments.
Fig. 16 Safety protected by jacket
6.
NOTE: Is delivered in the form of 50 ft (15 m) segments

Designation for order SCTD010
Filler washer
Applications where Safe-T-Cable is to be installed through a hole having a diameter greater than
0.095 inch (2.4 mm), but less than 0.200 inch (5.08 mm) can be accommodated by a filler washer:
Fig. 17 Use of the filler washer

NOTE: Materials compatibility and measures aimed at prevention of washer loss during safety
wire removal must be provided.
Designation for order: washer - FW10-1, material - 321 CRES.
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7.
Self-looping wire
There are many applications for lockwire where holes do not exist in a fastener or other
part of the assembly. In this case the self-looping wire is used. The loop is passed
around the structural components:
Fig. 18 Self-looping wire

TABLE 8
DESIGNATION SYSTEM
Material/designation
321 CRES
Diameter
(inches)
INCONEL
Length
C10-312JA
CF
.040
12"
C10-318JA
CF
.040
18"
C10-324JA
CF
.040
24"
C10-212JA
CF
.032
12"
C10-218JA
CF
.032
18"
C10-224JA
CF
.032
24"
C10-112JA
CF
.020
12"
C10-118JA
CF
.020
18"
C10-124JA
CF
.020
24"
8.
Branded SAFE-T-CABLE
The wire with distinctive brand on the wire end fitting (is used for manufactured products
traceability) can be delivered by order.
Fig. 19 Branded wire
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9.
Selection of SAFE-T-CABLE
A.
AS3510 series (UNS S321000 CRES) Safe-T-Cable shall be selected for general
purpose use on all applications up to 649C (1200F).
B. AS3509 series (UNS N6600 Nickel Alloy) Safe-T-Cable shall be selected for
applications where temperature range is up to to 982C(1800F).
C.
Only Safe-T-Cable and ferrules supplied by a manufacturer that meets all the
requirements of AS4536 shall be allowed.
D.
SAFE-TCABLE locking tools can not be used for other purposes.
E.
Safe-T-Cable shall be installed with a calibrated tool which is supplied by the Safe-TCable manufacturer for the purpose of applying a predetermined wire tension,
crimping the ferrule, and cutting the excess wire.
F.
Selection of required standard size of SAFE-T-CABLE wire:

(1)
0.020 inch diameter Safe-T-Cableis intended for use on parts having nominal
hole diameter of 0.045 inch (1.14 mm) or smaller;
(2)
0.032 inch diameter Safe-T-Cable is intended for use on parts having nominal
(3)
0.040 inch diameter Safe-T-Cable is intended for use on parts having nominal
(4)
The specified length of the wire shall be selected to accommodate the span
between fasteners added to the length of wire required to correctly engauge the
application tool;
(5)
Applications where Safe-T-Cable is to be installed through a hole having a

nominal diameter of greater than .095 inch (2.41 mm), but less than .200 inch
(5.08 mm) shall require a flat washer made of the same material as the wire
(Fig. 20):
Fig. 20 Flat washer used for locking of the large diameter holes
(6)
Safe-T-Cable shall be installed with an application tool which has been

calibrated to meet the performance requirements of AS4536 (SAE) and of the
present Section.
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10.
SAFE-T-CABLE APPLICATION
Safe-T-Cable may be used as a substitute for lockwire to prevent loosening during service.
NOTE: Routing of Safe-T-Cable may vary from that of lockwire in order to achieve a proper
installation.
Threaded parts, such as drilled-head bolts, fillister head screws, turnbuckles, hose fittings, and
electrical connectors, plugs, caps, and similar items are within the scope of the Safe-T-Cable
application.
The following rules shall apply when using SAFE-T-CABLE:
(1)
When Safe-T-Cable is being substituted for lockwire in an existing installation

(maintenance, rework, etc.), equivalent diameter Safe-T-Cable to that of the lockwire
shall be selected for use, providing that selection criteria for Safe-T-Cable as defined
in the present Section are met.
(2)
Safe-T-Cable shall be installed in such a manner that any tendency for a fastener to
loosen with be counteracted by an additional tension on the wire. Safe-T-Cable shall
be threaded through the fasteners in such a way as to produce installed Safe-TCable with either positive or neutral pull.
(3)
Maximum Span: the maximum span of Safe-T-Cable between tow termination points
shall be 6 inches (152.4 mm) unless otherwise specified
(4)
Any wire defect (nick, fray, or any other mutilation of the Safe-T-Cable) found prior to,
during, or subsequent to installation, is not acceptable.
NOTE: Avoid kinks or sharp bends while handling and threading Safe-T-Cable. Retainer will not
allow the jumper to fall out, when SAFE-T-CABLE is installed or removed.
Fig. 21 Self-looping SAFE-T-CABLE

(5)
Safe-T-Cable must be installed through the holes intended for this purpose in the
part being secured. The self-looping wire with a jumper attached on it can be used for
applications on other holes (Ref. Fig. 22). In applications where holes are not provided
for SAFE-T-CABLE in the component to which it is attached the self looping Safe-TCable may be used in a manner like, or similar to Figure22:
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Fig. 22 Self Looping Safe-T-Cable anchored to a pin assembly

(6)
11.
Safe-T-Cable and ferrule shall be new upon each application. Reuse is not allowed.
SAFE-T-CABLE INSTALLATION
Various examples of Safe-T-Cable installation are shown below. All possible combinations and
application are not shown. Unless otherwise specified in the application engineering drawing.
Safe-T-Cable shall be installed in two or three bolt patterns with two bolt patterns being the
preferred method where an even number of fasteners are to be secured.
A.
Hose Fittings and electrical coupling nuts shall have Safe-T-Cable installed in the same
manner as tube coupling nuts.
B. After installing Safe-T-Cable, excess wire from the crimped ferrule shall be cut by the
installation tool. The maximum allowable length of wire extending beyond the ferrule shall be
0.031 inch (0.79 mm).
C.
Crimping requirements (pull-off load, Ref. Table 9): Safe-T-Cable shall be installed with the
SAFE-T-CABLE manufacturers recommended tools, which has been tested and calibrated in
accordance with procedures specified in this Section.
TABLE 9
CRIMP REQUIREMENTS
Nominal wire diameter

(inch)
Minimum pull-off load, lbs

(N)
Wire structure
0.020
17
30 (133.4)
0.032
37
70 (311.4)
0.040
77
110 (489.3)
D.
Hole alignment. Under-torquing or over-torquing to obtain proper alignment of the holes in

not permitted. Apply recommended torque values to parts to be secured, and alignment of
holes shall be evaluated before attempting to proceed with Safe-T-Cable installation.
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CAUTION: The maximum, bend exit limit of Safe-T-Cable, when applied to a threaded
fastener head, shall be 135. This does not apply to hose fittings, electrical
connector coupling mechanisms, turnbuckles, and similar applications where the
Safe-T-Cable is constrained by the shape of the component being secured. In
applications where Safe-T-Cable shall be required to exceed the 135
maximum bend exit limit in order to achieve neutral to positive pull on a threaded
fastener head, a self looping device which is secured to the Safe-T-Cable may
be used to obtain a secured installing.
This method should only be used in applications where the Safe-T-Cable
cannot "flip" over the corner or over the head of the fastener being secured!
Fig. 23 Self Looping Safe-T-Cable in high bend exit application

E.
Wire flex limits.

After installing Safe-T-Cable, the maximum flex between termination points shall be no
greater than that specified in the normative documents.
NOTE: When calculating the maximum flex limits (B and C) for locking of three fasteners,
the total length (A) is calculated as per formula: A = D + E (Ref. Fig. 24),
i.e. from exit from the first fastener to entry into the last fastener. This total
length is used to define the maximum flex limit of the wire.
Fig. 24 SAFE-T-CABLE wire flex limits

NOTE: Light finger pressure of approximately 2 pounds shall be applied at mid-span when
inspecting total flex limit of installed SAFE-T-CABLE.
CAUTION: It is important to hold the tool as steady and perpendicular to the fastener as
possible during the crimp/cut cycle in order to maintain consistent tensioning of
the wire after the tool is removed (Fig. 25).
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Fig. 25 Correct application of Safe-T-Cable

F.
Elongated ferrules
Ferrule of extra length, having a radius at one end and a straight surface at the other end,
may be used in applications which restrict the clearance for the installation tool nose to be
placed in correct alignment with the fastener (such as low profile fastener heads, recess
locations, or obstructions by structures or installed components (Fig. 26).
NOTE: Always install elongated ferrules with the radius end toward the fastener, and the
straight end in the tool crimp cavity. Double check wire tension between
fasteners after removal of application tool.
Elongated ferrules 0.032 inch and more are delivered with radius end. As for the elongated
ferrules having diameter 0.020 inch, the radius end is optional and must be specified for
order.
Fig. 26 Low profile application for .032 & .040 inch Safe-T-Cable
Elongated ferrules can be used to lock any parts (Ref. Fig. 27).
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Fig. 27 Locking application variants
Fig. 28 Standard hardware

G. Safe-T-Cable Identification stamp.
In applications where the user requires a logo or ID code to be a permanent part of the SafeT-Cable installation (for warranty or traceability), it shall be applied by the Safe-T-Cable
manufacturer to one or more surfaces of the square end fitting of the Safe-T-Cable. Only
impression stamping is permitted, no paint, ink, or labels are acceptable (Fig. 29):
Fig. 29 Safe-T-Cable Identification Stamp
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H. Safe-T-Cable on Turnbuckles
The standard procedure for securing turnbuckles with Safe-T-Cable is shown in Fig. 30 and
31:
Fig. 30 Routing of Safe-T-Cable on Turnbuckles

(1)
Self looping Safe-T-Cable is threaded through the turnbuckle. One end shall be
wrapped in one direction around the turnbuckle. The Safe-T-Cable is then threaded
through the hole in the self looping jumper, and terminated with the appropriate
application tool.
Fig. 31. Example of Final Safe-T-Cable on Turnbuckles Installation

(2)
Safe-T-Cable diameter selection for turnbuckle applications:

(a)
I.
.032 inch (diameter) wire shall be used on assemblies where wire diameter in
1/16 inch (1.6 mm) or smaller, and .040 inch diameter wire or greater shall be
used on turnbuckle wire diameter greater than 1/16 inch.
Safe-T-Cable Jacketing for Protection

It is recommended to use a tubular jacket over Safe-T-Cable when it is installed in a
location where it is in contact with (or may contact) surfaces which may damage the wire.
The tubular jacket material shall be capable of meeting the temperature range of the
application and shall be resistant to oil and chemical environments (Ref. Fig. 32).
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Fig. 32 Safe-T-Cable Jacketing for Protection

12.
SAFE-T-CABLE Application Tools.

.
Procedures
When Safe-T-Cable is used, the following basics apply for the application tools and
calibration equipment:
- Minimize mixing of safety wire and Safe-T-Cable.
- Install the ferrule cartridge into the tool body under the handle grip.
Fig. 33 Preset Tension Safe-T-Cable Tool

NOTE: When loading and using the Safe-T-Cable hand tool, be certain that the correct size
Safe-T-Cable kit is being used with the tool.
(1)
Install the Safe-T-Cable through the fasteners to be secured.
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(2)
The nose can be manually turned up to 360 (Ref. Fig. 33).
(3)
Insert the free end of the wire through the ferrule in the cartridge, and remove the ferrule
by pulling the wire away from the end of the cartridge (Fig. 34):
Fig. 34 Pre-set Tension Safe-T-Cable Tool

NOTE: Do not release the free end of the wire until it has been inserted through the
tool nose
(4)
Insert the free end of the wire through the tool nose (Fig. 34) and slide the tool along
the wire to the fastener being secured (Fig. 35):
Fig. 35 Position of Safe-T-Cable Tool

B.
Pre-set tension SAFE-T-CABLE tool (Ref. Fig. 33, 34):

(1)
Insert the free end of the wire into the wire entrance and continue to push the
wire into the cavity.
(2)
When the free end of the wire appears at the bottom of the tool, grip the wire
and pull the slack from the wire until resistance is felt.
(3)
Begin removing slack from the wire by repeatedly closing the tool handle
allowing the handle to open fully before closing again.
(4)
When all slack is removed from the wire, snug the tool against the fastener by
using several short strokes of the handle.
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(5)
Release the handle to the full open position and fully close the handle to crimp
securely and cut flush.
CAUTION: It is important on this final stroke to hold the tool as steady and
perpendicular to the wire as possible while completing a full stroke. This
assures consistent tensioning of the wire (Ref. Fig. 35).
C.
Adjustable tension SAFE-T-CABLE tool:

(1)
Thread the Safe-T-Cable through the fastener, ferrule, and tool nose in the
same way as with other models.
(2)
Wrap the wire one full revolution (clockwise) around the tension wheel, and with
slight pressure applied by pulling the wire, secure the wire into the slot.
(3)
Rotate the tension knob until several clicks are heard and felt. If additional
tension is required, adjustment can be made with the tension adjuster on the
opposite side of the tool (Fig. 36).
CAUTION: Do not over-tension SAFE-T-CABLE. Such tension must be set,
which allows elimination of all slacks (with regard to bending
capabilities of wire), but does not damages the wire.
(4)
Completely close the handle to crimp and cut the wire. Hold the tool steady and
perpendicular to the wire to maintain consistent wire tension. Release the
handle and remove the tool from the crimped ferrule. Remove the excess wire
segment from the tool prior to the next application.
(5)
If it is more convenience to use the adjustable tension tool with the knob
located on the opposite side, you may remove the retaining ring located below
the tension adjuster, slide the knob assembly out of the tool body, and re-insert
it on the opposite side (Ref. Fig. 36).
NOTE: When using a hand tool, the tool handle is to remain fully open during
the wire entry process (in both tool models). The handle is to be
actuated in the pre-set tension model after the tension pawl is engaged
with the wire, and in the adjustable tension model only after the desired
tension is achieved.
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Fig. 36 Adjustable tension Safe-T-Cable Tool

D.
Pneumatic Safe-T-Cable application tool.

(1)
Connect the Pneumatic Safe-T-Cable Tool to a clean, dry air supply of 80 to

100 psi (5.5-6.9 BAR)
(Ref. Fig. 37).
(2)
Install the Safe-T-Cable through the fasteners which are to be secured.
(3)
The tool nose can be turned any position in the range of 360.
(4)
Insert the free end of the wire through the ferrule in the cartridge and remove
the ferrule by pulling the wire away from the end of the cartridge.
NOTE: Do not release the free end of the wire until it has been inserted
through the tool nose.
(5)
Insert the free end of the wire through the nose of the tool and slide the tool
along the wire to the desired position.
(6)
Rotate the wire tensioning wheel clockwise if necessary to move the wire entry
slot to an accessible position. Align the nose such that the ferrule is pressed
squarely against the fastener. Make certain that the ferrule is fully seared into
the nose. Insert the free end of the wire into the wire entry slot of the wire
tensioning wheel. When the end of the wire exits the wheel, grip the wire and
pull the slack from the wire. Do not leave more than 1-1/2 inch (12-25 mm) of
total slack in the wire.
(7)
Press the trigger and hold. The tool will apply tension to the wire, crimp and cut.
When the trigger is released, the crimp mechanism will retract (after the cycle is
complete), and the tool nose can be removed from the ferrule. The excess wire
shall be discarded.
(8)
The tension is adjustable by inserting the manufacturer supplied adjustment

key into the adjustment port located on the tool handle. Clockwise rotation
increases tension, and counter clockwise rotation decreases tension.
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Fig. 37 Pneumatic Safe-T-Cable application tool

E.
SAFE-TCABLE tool maintenance and verification

The tool must be kept in a dry and clean place. Any contamination (especially in the
crimping tool cavity on the tool nose) shall be removed by a small brush and solvent (if
required). The crimping tool cavity must be regularly lubricated.
(1)
Verification of SAFE-T-CABLE tool can be done using the test device or an

electronic torque verification block.
NOTE: Verification should be done periodically and in cases, when the nose
assembly has been removed or changed.
(2)
The diagram of the verification device application with torque metering lever is given
below (Ref. Fig. 38). Thread the wire into the left swivel and through the right swivel,
holding the lever in the home
position. If the lever is not kept in the home position the results may be adversely
affected. Terminate the wire, making sure to close the handles completely.
(3)
Apply approximately 2 Lb force to the wire with your finger at the line marked "TEST
AREA". If the wire slacks and touches bottom surface of the
test area, remove the cable from the test block and terminate another wire as
described above, holding
the tool perpendicular to the wire.
(4)
Place a calibrated drive torque wrench into the square drive hole. Apply the proper
pull-off load and turn the wrench counterclockwise. The necessary torque values are
given in the Table 9. Do not apply additional tension to the wire.
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TABLE 9
TEST TORQUES
SAFE-T-CABLE wire diameter (inch)
Minimum pull-off load (lbf)
.020
30
.032
70
.040
110
(5)
The SAFE-T-CABLE ferrule must not move during testing. Apply approximately 2 Lb
force to the wire with your finger at the line marked "TEST AREA". If the wire slacks and
touches the bottom surface of the tool, the ferrule is undercrimped and the tool must be
re-adjusted.
Fig. 38 Verification tool and torque metering lever

F.
Electronic torque verification tester.

Breakaway force of SAFE-T-CABLE wire must be defined in some cases. Electronic
torque tester can be sometimes used instead of the calibration tool for that. This device is
shown in Fig. 39:
Fig. 39 Electronic torque tester SAFE-T-CABLE -250-SC or SCT-4 with SCT-1 torque
verification block
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G.
Adjustment of crimp force for all SAFE-T-CABLE tool models

NOTE: Adjustment must be checked by the verification tool with measuring wrench or
electronic torque tester.
(1)
Remove the nose assembly by removing the two 8-32 socket head cap screws for
9/64 inch hex wrench (Fig. 40).
(2)
Adjust the pushrod adjustment screw using a straight edge screwdriver or a special
wrench delivered by the manufacturer. Turn the pushrod adjustment screw clockwise
to loosen the
crimp (enlarge gaging dimensions). Turn the adjustment screw counterclockwise to
tighten the crimp
(reduce gaging dimensions).
(3)
Install the tool nose on its place and install two 8-32 socket head cap screws for 9/64
inch hex wrench. Check the verification as described above.
NOTE: Jamnut on the adjustment screw is used on some models. Loosen the jamnut
prior to adjustment operation and lock it after adjustment by a special wrench
delivered by the manufacturer.
CAUTION: Do not adjust the pushrod more than a quarter of a turn at a time. Severe
adjustments may damage the tool.
Fig. 40 Removal of SAFE-T-CABLE tool nose
Fig. 41 Adjustment of SAFE-T-CABLE tool crimp (for hand and pneumatic tool models only)
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MAINTENANCE OF ELECTRICAL WIRING INTERCONNECTION SYSTEM

1.
Definitions
.
Significant Structural Item (SSI)

Component, failure of which has effect on the execution of flight, landing, load monitoring etc,
or can affect integrity of the structure required for aircraft safety.
B.
Conduction path formation

Phenomenon, at which a conduction carbonic path is formed through the wire insulation. This
results in subsequent short circuits. As a rule the conduction path appears due to electric arc
breakdown.
C.
Inflammable (combustible) materials

The term "inflammable" relates to ability of some solid, liquid or gaseous materials to cause
formation of stable flame after elimination of the ignition source. The term "inflammable" is
used instead of the term "fire-hazardous"'. Materials, which can burn only at constant action
of the strong heating source, do not relate to inflammable materials.
D.
Detailed Inspection (DET)

Detailed inspection of the EWIS harnesses and equipment aimed at detection of the possible
damages, faults or deviations of EWIS state from the norm. During inspection the lighting
available in EWIS arrangement zones must be complemented with direct light source of
required brightness. Such auxiliary facilities as mirrors, magnifying lenses etc can be
necessary during inspection. Clearing access to the EWIS harnesses and equipment as well
as clearing the surfaces of the harnesses and equipment may be necessary before the
inspection.
E.
Contamination
Contamination of EWIS system can include the following:
F.
(1)
Presence of the foreign objects, chips, oils, liquids, inflammable and aggressive
materials in the cable harnesses, which results in fast deterioration of the EWIS and
failures of electrical systems caused by this deterioration.
(2)
Presence of inflammable materials in EWIS arrangement zones.
Lightning and High Intensity Radio-Frequency Radiation Protection (L/HIRF)

Protection of the aircraft electrical systems and structure against induced potential or current
by means of screens of the wires and cable ducts, grounding jumpers, connectors, composite
fairings with conducting grid, static dischargers grounded to the electrical conducting
airframe; it can comprise special protection devices, e.g. gaskets for radiation protection.
G.
Zonal inspection
This is a collective term used for indication of general inspection and visual inspections,
which are applicable to each zone (some area with particular access) for check of EWIS
harnesses and equipment located in the zone.
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H.
Maintenance Significant Item (MSI)

Maintenance significant item is a component subject to mandatory maintenance. Obligation
and periodicity of component maintenance is defined by the aircraft Manufacturer in relation
to the following factors:
I.
(1)
Component failure can affect aircraft safety (on the ground or during flight).
(2)
Component failure can not be detected during flight.
(3)
Component failure can have significant effect on economical efficiency of the aircraft
operation.
EWIS maintenance
This term indicates scheduled maintenance or required unscheduled repair, modification of
the aircraft including inspection of the aircraft, removal and installation of the aircraft
components, with exception of:
J.
(1)
Aircraft elementary sanitary clean-up;
(2)
EWIS routine periodic maintenance
General Visual Inspection (GVI) of EWIS

Visual inspection of EWIS harnesses and equipment arrangement zone in order to detect
obvious damages, failures or deviations from the norm. This inspection is performed within
arm's reach from EWIS harnesses and equipment, if it is not otherwise specified in the
instructions. A mirror can be required to provide better visual access to all surfaces in the
inspected area. General visual inspection is performed at common lighting day light, hangar
lighting, electrical torch or portable light. Movement or opening of the removable panels or
doors can be required. Besides, supports, stairs or platforms may be required in order to
reach for the zone to be inspected.
K.
Independent general visual inspection

General visual inspection, which is performed not as part of the zonal inspection. Even when
interval of the independent general inspection coincides with that of the zonal inspection, the
independent general inspection must be provided with an independent mark in the working
chart.
L.
Electrical Wiring Interconnection System (EWIS)

(1)
Electrical wiring interconnection system (EWIS) comprises all wires, connecting

devices and connecting units, wire terminal aggregation units installed in any aircraft
part for the purpose of electrical power transmission, including the data and signals
between two or more endpoints. EWIS comprises:
a. Electrical wires and cables.
b. Buses.
c.
Circuit endpoints and terminal units on electrical devices including contacts on

relays, selector switches, interrupters, contactors, automatic protection stations
and on other circuit protection devices.
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d.
Connectors including connectors of the cables running through the airframe

components (pressure seals).
e.
Blanking caps and other connecting appliances.
f.
Wire grounding devices.
g.
Wire segment joining devices splice sleeves etc.
h.
Materials and objects providing additional protection of the cables, including

flexible sheathes for the harnesses and cables.
i.
Polymer screen braidings and flexible screen braidings of the cables.
j.
Clamps and other appliances used for attachment of the laid harnesses.
k.
Accessories for cables coupling in harnesses.
l.
Labels, tags and other wires and cables identification means.
m.
Tight protective sheathes for cables and harnesses connection.
(2)
The above mentioned EWIS components on the racks, panels, struts, inside the
junction boxes, distribution panels as well as rear rack panels with equipment
including but not limited to the rear surfaces of the printed boards, wire integration
units, external wires and equipment cables.
(3)
EWIS components do not include:

a. Electrical equipment and avionic equipment, which are not part of the airframe
standard structure and are used during aircraft repair or tests.
b. Portable electrical devices, which are not part of the airframe standard structure,
including personal entertaining equipment and laptops of the passengers.
M.
Chips.
The term is used to indicate metal particles formed during drilling and machining of the
airframe structure performed during aircraft maintenance. Such particles can be accumulated
on the wires and between the wires inside the harnesses.
N.
Puncture of the wire insulation.

Impermissible method of providing the contact with the wire strand in order to check integrity
of the circuit or wire voltage.
O.
Functional failure.
Failure of the component, which performs its assigned function in strictly defined limits.
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2.
EWIS degradation
Common aircraft maintenance works can become the factors that cause EWIS degradation, even
when permissible methods, technical and practical procedures are used. In the zones with high
level of aircraft maintenance activity the harnesses can be contaminated with chips, oils and
aggressive fluids, which causes fast ageing and breakage of the wire insulation, if compared with
the zones, which are not subjected to frequent maintenance. Degradation of the wires is
accelerated, when incorrect methods of EWIS components treatment are used. Examples of such
methods are the practice of puncturing the wire insulation for check of the circuits integrity and
electrical potential presence or attachment of the new wires to the existing harnesses using a hard
metal wire or rod. Such actions can damage the wire insulation and puncture of insulation with
electrical arc formation.
3.
Wire degradation causes

Main factors resulting in EWIS degradation:
A.
Vibration.
Severe vibration can result in contacts rattling and current pulsation. When elements of the
harnesses attachment are damaged, vibration of the fasteners can result in abrasion and
damage of the insulation. If the wires are in contact with airframe components, this also can
result in abrasion and damage of the insulation.
B.
Humidity.
Corrosion of the lugs, leads, contacts is accelerated in high humidity conditions. Electrical
equipment and wiring located in the clean, dry areas with moderate temperature are kept
quite well and age slowly.
C.
Maintenance.
Contamination and damage of EWIS that occur during scheduled and unscheduled aircraft
maintenance procedures in the zones, where EWIS components are located, result in
accelerated degradation of the EWIS and in failures of electrical equipment. It is
recommended to intrude the zones, where electrical harnesses are located, as seldom as
possible. And when maintenance procedures are carried out in such zones, all possible
measures must be taken to prevent incidental damages of the EWIS. After maintenance
procedures in such zones are finished, the harnesses must be thoroughly inspected in order
to detect and eliminate the possible incidental contamination and damages of the EWIS that
occurred during maintenance of other aircraft systems (according to "clean as you go"
principle).
D.
Indirect damages.
Such events as pneumatic tube breakage or hydraulic tube leaks can result in EWIS
damages. In some cases pressure from the broken tube can result in wire separation from
the connector. Results of the indirect damages caused by such events can be breakage of
the clamps, damaged wire insulation or even damaged current-carrying cable core.
If the zones, where electrical harnesses are arranged, have high probability of such events,
then inspections of the harnesses in these zones must be thoroughly performed in order to
guarantee absence of the damages or their possible occurrence.
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E.
EWIS contamination.
EWIS contamination signs:
-
Presence of foreign objects and materials, which can result in EWIS degradation.
Presence of the foreign objects, which can sustain combustion after elimination of the
high temperature heating source.
The contaminant can be solid or liquid. The solid contaminants such as metal cuts, small
metal chips, fragments, household wastes, dust can accumulate on the EWIS components
thus complicating their cooling and causing mechanical damages and fast degradation of
EWIS.
Liquid chemicals such as brake fluid, battery electrolyte, fuel, anticorrosion compounds,
waste disposal system chemicals, cleaning agents, de-icing fluids, paint, soft drinks and
coffee also facilitate EWIS degradation.
The brake fluid, de-icing fluid and battery electrolyte need special attention. These fluids can
damage the laid connectors, clamps of the harnesses, wire holders, can cause abrasion of
the insulation and electrical arc formation. The harnesses affected by these fluids must be
thoroughly checked during the inspection. Contaminated wire insulation with visible cracks
and damages results in bare conducting cable core and eventually in formation of arc
discharge and fire. The harnesses affected by the chemicals or laid in close proximity to
these chemicals must be regularly inspected for presence of damages or degradation.
When the chemicals are used in the aircraft zones, in which EWIS components are
arranged, special safety precautions must be observed. Such measures can comprise
protection of the harnesses, cables and connectors by their covering with materials, which
protect them against aggressive chemicals.
Fluid leaks from the waste disposal system also have harmful impact on EWIS. When such
contaminations are detected, all contaminated EWIS components must be thoroughly
inspected, completely cleaned and repaired or replaced, if required. The spill or leak source
must be eliminated.
F.
Heating.
High temperature action accelerates harnesses degradation due to drying and cracking of
the wires and cables' insulation. Direct contact with the heat source can damage the
insulation. The burnt, charred or melted insulation is the most typical sign of such damages.
Long time low temperature action also causes fast degradation of EWIS.
When the cables are affected by high temperature, they must be provided with heat shields,
or heat-resistant cables must be used.
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EWIS PROTECTION DURING AIRCRAFT MAINTENANCE, REPAIR AND MODIFICATION

The present instruction must be applied to all maintenance and repair procedures, including unscheduled
ones. Meeting the requirements of the present instruction can prevent fast degradation of EWIS.
.
EWIS maintenance, repair or modification

Cable harnesses, connecting and other EWIS equipment (fasteners, cable ducts etc.) form the part
of the aircraft functional systems, which is most sensitive to maintenance and repair. EWIS
installation/removal, repair and maintenance must be performed with particular care and with
observation of the appropriate procedures in order to provide accurate operation of the aircraft
systems. During EWIS repair one must select the cables, connecting equipment and fasteners
according to limiting lists described in the Sections 20-20-40 20-40-70 and must strictly follow
instructions contained in the present Manual.
During repair, maintenance and modification of any aircraft systems all possible measures must be
taken to prevent damages of EWIS components located in the zones, where the aircraft systems
maintenance, repair and modification procedures are performed.
B.
Airframe repair and aircraft modification

Airframe repair and aircraft modification suppose machining and associated wastes, which can
damage EWIS. Airframe repair and aircraft modification frequently require removal of EWIS
components to get access to the working area. Cable insulation can be damaged during electrical
harnesses movements, which results in their degradation, arc discharge formation or failures of the
electrical and electromechanical equipment circuits. The cables must be safely protected against
mechanical damages during harnesses displacement as well as against damages, which can be
caused by the tools and accessories used during airframe repair or modification.
Blind drilling must be prevented in the zones of cable harnesses arrangement, since this can
damage the cable harnesses and connectors.
The chips, fragment of the tools and equipment must not contaminate the zones, where EWIS
components are located. EWIS cleaning from contamination exposes EWIS components to
danger. Prior to beginning of the structure repair or modification the working area must be
thoroughly inspected in order to define EWIS components that can be damaged or contaminated.
All EWIS components in the working area must be covered or moved to prevent their
contamination or damage. Besides, the used drilling and cutting tools must be fitted with devices
for vacuum removal of the chips.
If the contamination failed to be prevented, EWIS components must be cleaned according to
instructions of the present Manual.
C.
Aircraft ice control.

Possible damages of EWIS components must be prevented in such areas as the wing leading and
trailing edges, LG well and LG during anti-icing fluid spraying. Direct pressure spraying can result
in direct damages and contamination of EWIS by aggressive fluids and in fast degradation of EWIS
in these zones.
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D.
Weather factors
EWIS components located in the doorways, removable panels and service compartments are
easily affected by corrosion or contamination due to impact of external and weather factors. Snow,
dirt or moisture must be removed from these areas prior to doors and panels closing. Accumulated
snow/dirt must be removed from all objects (e.g., cargo containers) prior to their loading in the
aircraft. During nasty weather it is recommended to keep the doors/panels closed, if possible, to
prevent ingress of the snow, dirt or moisture.
E.
Equipment installation/removal, when EWIS is arranged in the operating area

Electrical components can be damaged during installation/removal of equipment, when EWIS is
arranged in this zone. It is necessary to use special wrenches with soft jaws (e.g., wrench TG69P
or wrench p/n 6576) in order to loosen or tighten the screw attachment of the connector plug and
receptacle. Do not apply excessive force or use the torque wrench. The cable harnesses must not
be too strained after connector tightening.
When the connector is disconnected, the connector plug and receptacle must be protected by the
temporary caps to prevent contamination or damages of the contacts. If the caps are not available,
insulating tubes or polyethylene bags can be used. Use of the insulating tubes or polyethylene
bags must be short-term, since moisture condensate formation on the contacts is possible. It is
recommended to use moisture desiccant bags together with insulating tubes or polyethylene bags.
F.
Purging.
In order to prevent damages to the unprotected EWIS components in such areas as wing leading
and trailing edges, LG and LG bay, care must be taken during use of water or cleaning fluids under
pressure for purging and cleaning in these areas. Direct action under pressure on the electrical
parts and harnesses must be prevented, since this can cause direct damages, contamination and
degradation of EWIS components. The cables and connectors must be protected prior to purging
procedures. Water rinsing must be performed after the purging in order to remove remaining
cleaning solutions. The insulation degradation risk increases at long-term action of the cleaning
solutions on the cable insulation.
G.
Water/waste system maintenance, modification or repair.

EWIS components located near the water/waste system equipment are subjected to
contamination. EWIS components must be covered to prevent ingress of fluids and solid wastes
during water/waste system maintenance, repair or modification. Besides, any leaks must be
prevented during aircraft operation.
H.
Oil system maintenance, repair or modification.

EWIS components located near the oil system equipment are subjected to contamination with oils.
This contamination must be precluded, since presence of oil in EWIS components accelerates their
degradation and increases the fire risk.
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I.
Hydraulic system maintenance, repair or modification.

EWIS components located near the hydraulic system equipment are subjected to contamination
with hydraulic fluids. Contamination of EWIS during hydraulic system maintenance, modification or
repair must be precluded.
J.
Personnel transfer in the operating area

EWIS damages resulting from personnel transfer in the operating area must be precluded. In order
to prevent EWIS components damages use the protective shields and boards/platforms. Do not
use the harnesses as the handrails, steps and supports. Working lighting must not rest on the
harnesses or suspended on them.
K.
Use of corrosion-preventive compounds

When corrosion-preventive compounds are used in the aircraft zones with EWIS components,
special care must be taken to prevent contact of these compounds wit wires and parts. The
corrosion-preventive compounds also have devastating impact on the wire insulation and cause
fast degradation of EWIS.
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INSPECTION OF THE ELECTRICAL WIRING INTERCONNECTION SYSTEM

1.
EWIS inspection types

.
Detailed Inspection (DET)

Detailed inspection of individual units, items or assemblies of equipment aimed at detection of
possible damages, faults or deviations of equipment state from the normal one. Lighting
available in the zone can be complemented with direct light source of required brightness. It is
recommended to use additional devices such as mirrors, magnifying lenses etc during the
inspection. Preliminary surface cleaning and clearing the access to the inspected equipment
may be necessary.
Detailed inspection is performed more thoroughly than the common visual inspection and it
can include the tactile (by tactile perception) assessment of device integrity and proper
installation. The tactile method can be the only one efficient method for check of such EWIS
components as harness jumpers, connectors etc.
B.
General Visual Inspection (GVI)

Visual inspection of equipment external and internal areas in order to detect obvious
damages, failures or deviations from the norm. This inspection type is usually performed
within arm's reach, if it is not otherwise specified in the additional instructions. A mirror can be
used for better visual access to the closed unseen surfaces of the inspected area. Such level
inspection is performed at common lighting such as day light, hangar lighting, electrical torch
or portable light and can require opening or moving of the removable panels and doors.
Besides, supports, stairs or platforms may be required in order to reach for the surface to be
inspected.
Removal and displacement of EWIS equipment without urgent need must be avoided.
It is assumed that the inspected area is sufficiently clean, so that the accumulated dirt and
lubricant do not hide the state of the inspected equipment. Any cleaning of EWIS equipment
must be performed in accordance with procedures specified in the present Manual and using
the specified cleaning agents.
C.
Zonal inspections
The term denotes general visual inspections performed according to plans in the aircraft
zones in order to define state of EWIS equipment in the zone and to detect possible
deviations from the norm. As distinct from the independent general visual inspection,
orientation to inspection of particular EWIS equipment is absent here.
2.
Zonal inspection manual

Below there are typical signs of EWIS abnormal state and degradation, to which attention must be
paid during zonal inspection.
.
Cable harnesses
Contact with airframe structure, abrasion.
Excessive slack of the harnesses, incorrect attachment of the harnesses.
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Damaged wires: visible damages due to mechanical impact, change of insulation colour
due to overheat, abrasion traces.
Incorrectly installed fasteners.
Deformation of protective tubes and cable ducts or their incorrect installation.
Harness brace is absent or incorrectly installed.
Edge of the protective tube or cable duct rubs against the connected device.
Absence of protectors in the holes for harnesses laying or damages of the protectors.
Accumulation of dust and lint.
Contamination of EWIS equipment surfaces with metal chips.
Contamination with fluids.
Incorrect repair of the harnesses (e.g., incorrectly selected protective material, incorrectly
installed splice sleeves and solder sleeves).
Incorrect division of the harnesses and tubing with fluids.
Absence of EWIS components protection against heat sources.
B.
Connectors
Oxide film on the contacts of the plugs and receptacles.
Broken casings of the connectors.
Absence of the seal sleeve or underwinding tape 67N under the semiclamps of connector
casings.
Absence of attachment of the contact with wire at breakage of the connector lock.
Rupture of the wires and cables or low-quality crimping of the cables in connectors.
Discoloration of the terminal units, which is the sign of overheating.
Corrosion of the contact lugs and terminals (e.g., in the fluid contaminated areas).
C.
Selector switches
Damages of protective caps.
D.
Grounding points
Contamination and corrosion of the lugs and terminals.
Breakage of the lug in its bending place
E.
Grounding units
Rupture or disconnection of the screen braiding.
Damage of the unit bonding.
Unit breakage.
F.
Cable clips and clamps

Oxide film on the cable clips.
Breakage.
Bending or twisting.
Incorrect attachment: loose attachment or absence of the fasteners.
Damaged protective gaskets.
G.
Support assemblies (guide profiles, L-bars)

Breakage.
Deformation.
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Absence or loosening of the fasteners.

Absence of protective gaskets on the rims of the holes in structural components, through
which the cable harnesses are laid.
Contamination of the drain holes of the tubes and cable ducts.
H.
Circuit breakers
Overheat traces.
Electrical arc discharge formation signs.
3.
EWIS components and EWIS arrangement zones requiring special attention

A.
EWIS components requiring special attention

(1)
Clamps
The cables can get abraded due to clamp damages, displacement of the clamp silicone
cushions or incorrect installation of the clamps.
During clamps replacement use only the clamps allowed in the limiting lists of EWIS
permitted equipment contained in the present Manual.
(2)
Connectors
Damage of the silicone sealing insert, unattached connectors, absence of blanking
plugs on the free contacts, absence of the cable clip, oxide film and contaminated
contacts.
(3)
Lugs
The lugs are subjected to mechanical damages, rupture, corrosion, thermal damage
and contamination with chemicals, dust and lint.
(4)
Connector casings
The wires in the connector casings must be attached with silicone tape 67N wound
under the cable clip semiclamps in order to prevent free play and faulty sealing.
(5)
Tubes and cable ducts

Damages of the protective tubes and cable ducts can result in damages of the cables.
Therefore if damages of the tubes and cable ducts are detected, further inspection
must be performed to check state of the cables inside the tubes and cable ducts.
(6)
Grounding points
Proper attachment in the grounding points must be visually checked. The lugs and
terminals must have no contamination or corrosion signs, the reference hairline (strip)
must have no damages.
(7)
Splice sleeves
The splice sleeves can be subjected to mechanical damages.
B.
Special attention zones
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(1)
Harness laying ducts

Too tight laying of the harnesses complicates their monitoring, accelerates their wear
and facilitates harnesses abrasion.
(2)
Wings
EWIS in the wing leading and trailing edges require special attention, since in these
areas EWIS components are very close to the mechanical devices and are subjected to
mechanical damages.
(3)
Engine, pylon and engine nacelle zones

In these zones the EWIS is affected by the severe vibration, high temperatures,
chemical contamination and incidental damages due to frequent maintenance
procedures.
(4)
Auxiliary compartments and zones with mechanical equipment

In these zones the EWIS is close to the mechanical equipment, is affected by the
severe vibration, high temperatures, contamination and incidental damages due to
frequent maintenance of the mechanical equipment.
(5)
Auxiliary power unit

Similar to the engine/nacelle zones, in the APU zone the EWIS is subjected to severe
vibration, heating, contamination and incidental damages due to APU frequent
maintenance.
(6)
LG and LG bay
In this zone the EWIS has insufficient protection against the environmental factors, is
subjected to severe vibration and contamination.
(7)
Electrical panels
Electrical panels located in the zones with high maintenance and repair intensity are
subjected to mechanical damages and contamination.
(8)
Storage batteries
EWIS components located near the aircraft storage batteries are subjected to
electrochemical corrosion and discoloration.
(9)
Power cables
Power cables and interconnecting equipment are subjected to active heating due to the
heavy currents. Signs of power cables overheating (discoloration and burnt insulation)
must be visually checked and terminal connections tightening force must be checked.
Loose connections are overheated and are subjected to severe corrosion. EWIS
degradation is enhanced, when the cables and connectors are overheated.
(10)
Space under the galleys, lavatories and flight compartments

Areas under the galleys, lavatories and flight compartment are subjected to
contamination by food, coffee, water, soft drinks, fluids from the lavatories, dust, lint
etc.
(11)
Water supply tubing
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Leaks of the water supply tubing can result in EWIS components flooding with fluid. In
addition to visual inspection of the EWIS it is necessary to check the leaks and clean
the water supply tubing.
(12)
Cargo compartment
In this area the EWIS is subjected to mechanical damages that occur during handling
operations.
(13)
Cable harnesses subjected to bending and displacement

Cable harnesses subjected to bending and displacement during common flight
procedures (in such places as the doors, power drives, LG mechanisms, removable
electrical panels) must be frequently and thoroughly inspected.
(14)
Removable panels
Harnesses laid near the removable panels can be subjected to accidental damages
due to recurrent maintenance procedures, therefore special attention must be paid to it.
(15)
Areas under the doors

Areas under the cargo, passenger and service doors are subjected to ingress of fluid
due to rain, snow and spilled fluids. The drain devices and leak-tightness of the floor
panels must be checked on a regular basis and repaired, if required.
(16)
Space under the flight compartment sliding windows

Areas under the flight compartment sliding windows are subjected to the rain and snow
melt water leaks.
(17)
Hard-to-reach areas
Areas, in which access to EWIS is complicated (e.g., flight compartment instrument
panel, center pedestal), can accumulate dust and other contaminations due to
insufficiently frequent cleaning.
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1.
The EWIS components must be cleaned very carefully in order to prevent damages of the EWIS
and related failures of the EWIS and aircraft functional systems.
When cleaning from non-aggressive contamination is performed, harnesses displacement and
connections disassembly must be avoided. In case of contamination with aggressive substances
(e.g., biowastes, saline water, battery electrolyte), harnesses displacements and connections
disassembly can be necessary. In these cases the harnesses must be released from attachment in
order to prevent overtension in the cables and connectors. It the liquid contaminants got in the
harness between the cables, the braces must be removed in order to separate the wires.
Only contaminated EWIS areas and components must be cleaned, since excessive impact on the
EWIS results in its degradation. Prior to cleaning one must make sure that use of the available
cleaning agents and materials will not result in greater contamination.
Clean lint-free dry fabric cloth wetted with ethyl spirit GOST 18300-87 must be used for grease
contamination cleaning. The connectors must be properly dried prior to connections restoration. Any
fluids left on the connectors can cause destructive effect on the connectors and EWIS.
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This section contains the following information:
- Criteria for necessary repair of wires and cables, which have the significant damages;
- Procedures for repair of wires and cables, which have the significant damages.
1.
General
A.
Types of wires and cables repair described in the present Section
TABLE 1
TYPES OF WIRES AND CABLES REPAIR DESCRIBED IN THE PRESENT SECTION

Reference to description of processes
Type of repair
Repair of wire or cable external insulation
Repair of unscreened wire or cable in case of
current-carrying conductor (s) cores damage
Repair of screened wire or cable in case of screen
strands damage
Repair of screened wire in case of current-carrying
conductor (s) cores damage
Replacement of wire for grounding (bonding) of
screened cable
Repair of wires contact connections
B.
Criteria of damages
Repair procedures
Subject 2
Subject 3
Subject 2.
Subject 4
Subject 2.B
Subject 5
Subject 2.B
Subject 6
Subject 2.D
Subject 7
Subject 8
Subject 8
General requirements for wires and cables repair.

Before wire or cable repair the following conditions must be met:
(1)
Cause resulting in damage must be eliminated.
(2)
If it is required to repair the damaged wire or cable with use of wire or cable segment,
make sure that this segment is of the same grade as damaged wire or cable.
(3)
Temporary repair is permitted only if this is specified in the corresponding repair

conditions or repair procedures.
(4)
The specialist, which performs the repair works, must keep the cleanliness and
neatness to prevent contamination, which can cause the degradation and damage of
wires or cables insulation.
(5)
The area under repair must not be located:

between harness and harness attachment component;
at wire or cable bend;
at harness area, which is frequently bent (e.g. at harness attached on the movable
instrument panel or door);
on wires inside fuel tanks.
(6)
The following components are not repaired and must be replaced:

- temperature compensating wires and cables in case of screen braiding and currentcarrying conductors damage;
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- high-temperature wires and cables in case of screen braiding and current-carrying

conductors damage;
- RF cables, waveguides, pulse current and digital transmission lines cables in case of
main screen braiding damage to prevent degradation of performances (repair of only
external additional screen braiding, if available, is permitted).
C.
General requirements for wire or cable repair by solder sleeves and crimping splice sleeves.
It is recommended not to repair the damaged wire (cable), but replace the whole wire (cable).
NOTE: Repair of damaged wire or cable with use of splice sleeves and solder sleeves may
be sufficient alternative to replacement of damaged wire or cable, if such replacement
is not possible for objective reasons (but if the actual performances of electrical
connections system are kept).
The following requirements are set for repair with use of solder sleeves and splice sleeves:
general requirements for wires and cables repair given in Subject 1.B of the present Section;
all solder sleeves and splice sleeves must be installed strictly in accordance with the
requirements of Sections 20-20-60 and 20-20-70 of the present Manual;
maximum quantity of splice sleeves, which can be installed on one wire maximum two;
if it is required to perform repair of more than one wire in the harness, place the splice
sleeves at straight segment stepwise or in checkerboard order at distance not less than 300350 mm between harness attachment elements (ref. Fig. 1 and Fig. 25);
- the splice sleeves must be placed at the distance not less than 300 mm from the connector
(lug);
NOTE: If the harness or wire is damaged near the connector (lug), if technological reserve is
available, perform cutting and repeated attachment of harness (wire) in given
connecting device.
Fig. 1 Location of splice sleeves at straight segment of harness

NOTE: Installation of banding assemblies on sealing sleeves of splice sleeves is permitted
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2.
Typical damages of wires and cables, conditions of their repair

A.
Unscreened wire and cable

(1)
Repair of unscreened wire or cable is required, if the following damages occur:

damage of external insulating sheath;
- damage of one or several cores (wires) of current-carrying conductor (s).
(2)
Repair of cable is not performed in case of non-significant discontinuities: scratches

and abrasions of its external protective sheath (Fig. 2):
External insulation
surface
Scratches and abrasions

on the material
Scratches and abrasions

on the material
Fig. 2 Permissible damages of wire (cable) external insulation

B. Screened wire and cable
(1)
Repair of screened wire (cable) is required, when the following types of damages are
available:
damage of external protective sheath of wire or cable (Fig. 3);
- damage of external protective sheath of jam-resistant wire with additional damage of
screen braiding (Fig. 4);
- damage of one or several cores (wires) of wire current-carrying conductor (Fig. 5).
Damaged area borders
External protective
sheath
Wire screen
braiding
Internal
insulation
Current-carrying conductor
Fig. 3 Example of damage to external protective sheath of screened cable (wire) requiring repair
Length of external sheath damaged segment
Wire external sheath

Screen
Length of the screen damaged segment

Internal sheath
Current-carrying
conductor
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Fig. 4 Example of damage to external insulating sheath and screen braiding of jam-resistant wire
requiring repair
Length of external sheath damaged segment
Length of screen damaged segment
Screen
Length of the current-carrying conductor damaged segment

Internal sheath
Current-carrying
conductor
Fig. 5 Example of damage to current-carrying conductor cores of jam-resistant wire requiring repair
(2) Repair of cable is not performed in case of non-significant discontinuities: scratches and
abrasions of its external protective sheath (Ref. Fig. 2).
C.
RF cable (pulse current and digital transmission lines cable)

(1)
Repair of RF-cable is required, when the following types of damages are available:
- damage of cable external protective sheath (ref. Fig. 3);
- damage of strands of cable external (additional) screen braiding (Fig. 6):
Damaged segment borders
External protective
sheath
Internal
(primary)
insulation
Internal (primary) screen

braiding
External
(additional) screen
braiding
Fig. 6 Example of damage to additional screen braiding of RF cable requiring repair

(3)
Repair of RF cable is not performed in case of non-significant discontinuities: scratches and

abrasions of its external protective sheath (Ref. Fig. 2).
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D.
Bonding (grounding) wire of cable screen (Fig. 7)

In case of damage of one and more cores of bonding (grounding) wire, replace the whole
wire.
S-200 (SO-96) solder sleeve
Damages of the central conductor cores

Screen bonding (grounding) wire
Wire for screen grounding in connector

contact
Fig. 7 Wires for screen grounding

3.
Repair of wires and cables external insulation

A.
Repair of wire (cable) external protective sheath at length of damaged area not more than 10
mm
Refer to Subject 1.B, which contains the general requirements for repair of wires and cables.
Refer to Subject 2., which contains the typical damages of unscreened wires and cables.
(1)
Clean the area of insulation around the damage with ethyl alcohol, GOST 18300-87
and dry (Fig. 8):
10-15 mm
10-15 mm
External sheath
Circular area to be cleaned
Fig. 8 Area around damage of external protective sheath subjected to cleaning

(2)
Select tape S1081(S1048) with glue underlayer (for operating temperature up to

150) or silicone adhesive tape of 66N (67N, 68N, 69) type (for operating temperature
up to 250).
(3)
Wrap the damaged area of external sheath with two layers of tape, at that observe the
dimensions, as shown in Figure 9 (the length of damaged area is not more than 10
mm).
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5 mm
up to 10 mm
5 mm
Edges of the damage
External protective
sheath
Edges of the insulating tape
leayers
Insulating tape layers
Fig. 9 Two-layer wrapping of damage of wire (cable) external sheath with protective insulating tape
B.
Repair of wire (cable) external protective sheath at length of damaged area more than 10 mm
(1)
At length of damaged area of external sheath more than 10 mm it is required wrap the
protective tape with 50% of self-overlapping. At that two layers of tape must overlap the
damage by not less than 7 to 10 mm (Fig. 10).
minimum 7-10 mm
minimum 7-10 mm
External protective
sheath
Outer edge of the

damaged sheath
Outer edge of the

damaged sheath
Adhesive tape winding with

50% overlapping
Fig. 10 Wrapping of damaged area of external protective sheath with adhesive tape with 50% of
self-overlapping
(2)
After wrapping of S1081-Tape (S1048-Tape) adhesive tape provide its temperature

stabilization using HG2310LCD heat gun with adequate reflector. For that heat up the
area to temperature of 300 for 10 to 15 s (the procedure of heat gun use is described
in Section 20-20-50 of the present Manual).
NOTE: For self-adhesive tape of 66N (67N, 68N, 69) type the temperature stabilization
is not required. Select the tape using Table 2.
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Silicon tape
Thickness
Width
66N
0.3 mm
19 mm
Red
Brown
15 rolls
67N
0.5 mm
19 mm
Black
15 rolls
0.3 mm
19 mm
Red
Brown
15 rolls
(1 roll of 15
m)
Silicone tape made

of fiber glass 68N
Colour
Packing
-60
+250
Dielectric
breakdown, KV/mm
Item
Rupture force
SILICONE SELF-ADHESIVE TAPES OF 66N, 67N, 68N TYPE

Operating
temperature,
TABLE 2
50 N
13
16.3 N
16
90 N
17
NOTE: 68N is the tape, which consists of fiber glass base with coating of silicone selfadhesive elastomer. It provides mechanical and electrical protection at high
temperature. It serves for protection of harnesses (cables) in places of joints
and soldering of screen braidings, as well as for repair of cable network.
NOTE: Tapes of 66N, 67N, 68N types are resistant to fuels, hydraulic fluids, synthetic
and mineral oils.
4.
Repair of unscreened wire or cable in case of current-carrying conductor (s) cores damage
A.
Repair of wire
Refer to Subject 1.C, which contains the general requirements for repair of wires and cables
with use of solder sleeves and splice sleeves.
(1)
Remove the damaged area of wire.

a.
Cut the wire on one end from the damaged area.

Make sure that the end of wire is perpendicular to the longitudinal axis of wire.
b.
Cut the wire on the other end from damaged area.

(2)
Remove insulation from both ends, refer to Fig. 11, and degrease with ethyl alcohol,
GOST 18300-87.
(3)
In one end of wire fit the crimping bushing of splice sleeve (ref. Fig. 11 and 12).
(4)
Before that on the other end of wire fit the insulating sleeve of splice sleeves and insert
the wire itself in the crimping bushing.
(5)
Perform crimping of busing using tool.
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CAUTION: The selection of splice sleeves for wire and the procedure of its installation is
described in Section 20-20-70 of the present Manual.
The splice sleeve is installed on the wire at the distance not less than 300 mm
from lug (connector). In case of corresponding damage of wire at the distance
less than 300 mm perform cutting and repeated attachment of wire in lug, for that
use its technological reserve. The procedure of wire attachment in lug is
described in Section 20-20-80.
Cylinder length
0.5-1.6
7-9
Fig. 11 Procedure of wire preparation and installation of crimping bushing of splice sleeve in it
Crimping bushing
0.5-1.6
Wire insulating sheah
Sealing sleeve
Fig. 12 Splicing of damaged wire using splice sleeve

B.
Repair of cable
(1)
Remove the damaged area of cable.

a.
Cut the cable on the one end from damage.

Make sure that the end of cable is perpendicular to the longitudinal axis of cable.
b. Cut the cable on the other end from damage.

(2)
Clean and degrease the cable sheath and the ends of wires to be spliced with ethyl
alcohol, GOST 18300-87.
(3)
Install crimping splice sleeves on each wire of cable and heat-shrinking tube on the
cable area to be attached (before that the tube must be put on the one end of damaged
cable) to provide final attachment (Ref. Fig. 13).
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(4)
Shrink the heat-shrinking tube using HG2310LCD heat gun with the appropriate
reflector (the procedure of heat-shrinking tube shrinkage on the harness is described in
Section 20-20-50). After shrinkage the tube must overlap the repair area at each side by
20 to 25 mm.
NOTE: If the harness is the bundle of wires without external protective sheath or the
covering, then the heat-shrinking tube is not installed.
Cable outer
protective sheath
Crimping sleeve assembly

Wire insulating sheath
251
251
Heat-shrinking tube
RW175(DR25, RNF3000, K,
RT-555-3/8-2,75-260-0)
371
Fig. 13 Splicing of damaged multi-core unscreened cable using crimping sleeves

NOTE: The selection of splice sleeves and the procedure of their installation are
described in Section 20-20-70 of the present Manual.
NOTE: The selection of heat-shrinking tube for harness is performed in accordance with
Sections 20-20-50. 20-20-60.
CAUTION: If there is technological reserve of harness, when the damage occurs near
its attachment in connector, the splicing is not required, but you should
perform the repeated attachment of cable in connector in accordance with
procedure for wires attachment in electrical devices (refer to Sections 2030-10 and 20-40-10).
5.
Repair of screened wire or cable in case of screen strands damage

.
The damage of common screen of single-core wire (twisted pair, triplet, quad) is the breaking
of up to 2 strands of braiding (width must be not more than 10 mm)
Refer to Subject 2.B, which contains the typical damages of screened wires.
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Damaged segment borders

maximum 10 mm
minimum 5mm
Two layers of protective
tape
minimum 5 mm
External protective
sheath
Internal
(primary)
insulation
Wire screen
braiding
Fig. 14 Damage (breaking of not more than 2 strands) of wire screen and repair by applying of two layers
of insulating tape
(1)
Clean the area of wire insulation around the damage with ethyl alcohol, GOST 1830087 and dry.
(2)
Straighten the broken strands of screen and put them along the wires guide to prevent
damage of applied protective tape.
(3)
Select tape S1081-Tape (S1048-Tape) with glue underlayer (for operating

temperature up to 150) or silicone adhesive tape of 66N (67N, 68N, 69) type (for
operating temperature up to 250).
(4)
Wrap the damaged area of external sheath with two layers of tape, at that observe the
dimensions, as shown in Figure 14 (the length of damaged area is not more than 10
mm).
(5)

area to temperature of 300 for 10 to 15 s (the procedure of shrinkage is described in
Section 20-20-50 of the present Manual).
NOTE: For self-adhesive tape of 66N (67N, 68N, 69) type the temperature
stabilization is not required.
B.
The damage of common screen of individual single-core wire (twisted pair, triplet, quad) is the
breaking of more than 3 strands of braiding (the width is more than 10 mm)
NOTE: Installation of solder sleeves and screen material is possible upon disconnection of
wire from the lug or connector, if the conductor is integer. Otherwise the wire is
subjected to repair in accordance with Subject 6 of the present Section or must be
replaced entirely.
If the damage of wire occurs near the connector, then use the technological reserve
of wire and cut the wire in the area of damage and perform its repeated attachment in
the connector.
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Edge of the wire external

sheath

Damaged area (more than
10 mm)
Screen
Wire stripping area
Fig. 15 Removal of protective sheath and stripping of wire screen around the damage area
Screen material outer diameter
Maximum 2 mm
Tin-plated screen material
Edge of external sheath
Screen
Screen material edge
Outer diameter of the wire

protective sheath
Fig. 16 Installation of screen material on the prepared area for repair

(1)
Select the solder sleeve for splicing of screen in accordance with wire performances
(ref. Sections 20-20-60. Table 4 and 20-20-70. Table 2).
(2)
Remove the portion of external wire sheath around the area of damage:
- Determine the length of sheath portions to be removed according to dimensions of
selected solder sleeves.
- Carefully cut the wire sheath in a circumferential direction on each side from the
damaged area of screen.
- Make sure that the damaged area is located in the middle between two ends of cable
sheath.
CAUTION: Do not cut through the whole thickness of sheath in order not to damage
the screen and internal sheath of wire.
- Carefully cut through the wire sheath along wire axis.
- Remove the wire sheath, at that pull it off by the lines, which were cut through.
CAUTION: Do not apply excess forces to prevent damage of wire. Carefully cut through
the sheath additionally in place, where it was cut through insufficiently. If
required, the wire can be bent by the lines, were the sheath was cut
through.
CAUTION: Do not bend the wire in a circumferential direction with radius less than 3
diameters of wire to prevent its damage.
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NOTE: In case of tool 45-402 use refer to the wire termination procedure described in
Subject 2 of Section 20-20-60.
(3)
Clean the terminated area of wire with ethyl alcohol, GOST 18300-87 and dry.
(4)
Spread the wires of damaged screen:

- over the surface of main insulation;
- uniformly and symmetrically along the circumference of damaged area.
(5)
Select the material of screen braiding in accordance with Tables 1 and 2, Section 2020-50 of the present Manual.
(6)
Install the screened material of screen on the damaged area of wire so that its face
ends come closer to both ends of external sheath with minimum clearance not more
than 2 mm.
(7)
Place the first sleeve on the wire to be repaired.
(8)
Pull the sleeve on the area, from which the wire sheath was removed, over the screen
braiding.
(9)
Make sure that the end of wire sheath is located between O-ring and tin-plated material
inside the sleeve (Fig. 17).
(10)
Heat up and shrink the solder sleeve using HG2310LCD heat gun until the rings of
solder are melted completely and spread over the braiding. The recommended
shrinkage temperature is 36030.
NOTE: Procedure and quality control of solder sleeve installation are described in
Section 20-20-60.
Edge of sheath
Solder ring
Screen braiding closing the
cable screen
Large end of solder sleeve

Internal edge of O-ring
Fig. 17 Installation of solder sleeve for attachment of one end of screened material joint
(11)
Additionally perform Steps 7 to 10 for other end of external wire sheath cut. Make sure
that the screened material is tightly pulled on before you install the solder sleeve on
the other end.
(12)
In accordance with wire performances select the heat-shrinking tube, refer to Section
20-20-70, and put it on the area to be repaired.
NOTE: The selected tube must be of minimum diameter, with which it will be installed
on solder sleeves.
The segment of tube must be of such length that its ends completely overlap
each solder sleeve after shrinkage.
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(13)
Heat up and shrink the heat-shrinking tube using HG2310LCD heat gun with reflector
for wire (shrinkage procedure is described in Section 20-20-50).
(14)
If you use the protective self-adhesive tape instead of heat-shrinking tube, select S
1081-Tape (S1048-Tape) tape with glue underlayer (for operating temperature up to
up to 250).
(15)
Tightly wrap the splice sleeves with one layer of tape. Make sure that the tape layer
begins at 20 mm after the rear end of solder sleeve on one end of attachment and
ends at 20 mm after rear end of solder sleeve on the other end of wire attachment.
Each wrap of tape must overlap the previous wrap by 50 % along circumference.
(16)
Tightly wrap the solder sleeve with second layer of tape in direction opposite to the first
layer.
(17)

Solder sleeve
rear edge
Solder sleeve
Screen
material
Wire external protective

sheath
Wire or wires in the common

screen braiding
Solder sleeve
Heat-shrinking tube
Fig. 18 Repair of screened wire with use of two solder sleeves and heat-shrinking tube
Solder sleeve
rear edge
Solder sleeve
Screen
material
End of tape
Wire or wires in the common

screen braiding
Solder sleeve
First tape layer
Minimum 20 mm
Second tape layer
Fig. 19 Repair of screened wire with use of two solder sleeves and protective tape
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Sleeve solder ring

Edge of the wire external
sheath
Tin-plated screen material
Sleeve O-ring
Solder sleeve
Fig. 20 Repair of screened wire with use of one solder sleeve (in case of relatively narrow damage of
screen braiding, that allows installation of only one sleeve)
As a variant of screened wire repair using two solder sleeves, you can put the prepared
material of screen and pull it off backward over the protective sheath of wire:
(1)
Remove the portion of external wire sheath around the damage area and prepare the
screen in accordance with Fig. 15 and Subject 5.B of the present Section.
(2)
Carefully cut the screen in a circumferential direction on each side from damaged area,
at that make sure that the distance from the end of wire sheath to the screen is within 8
to 10 mm.
(3)
Remove the screen area with damage.
(4)
Pull the both ends of cut screen off backward over the wire sheath.
(5)
Select the material of screen braiding in accordance with Tables 1 and 2, Section 2020-50 of the present Manual.
(6)
Install the screened material on the damaged area of wire so that its ends come
closely to the ends of cut and pulled off backward wire screen (ref. Fig. 21).
(7)
Place the first sleeve on the wire to be repaired.
(8)
Make sure that the solder ring of sleeve is located above the middle portion of screen
wire pulled off to the sheath and that the external O-ring is located at wire sheath.
(9)
Heat up and shrink the solder sleeve using HG2310LCD heat gun until the rings of
solder are melted completely and spread over the braiding. The recommended
shrinkage temperature is 36030.
NOTE: Procedure and quality control of solder sleeve installation are described in
Section 20-20-60.
(10)
Place the second sleeve and additionally perform Steps 7 to 9 for the other end of
attachment area. Make sure that the screen material is tightly pulled on before you
install the solder sleeve on the other end.
(11)
In accordance with wire performances select the heat-shrinking tube, refer to Section
20-20-70, and put it on the area to be repaired.
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NOTE: The selected tube must be of minimum diameter, with which it will be installed
on the solder sleeves.
The segment of tube must be of such length that its ends completely overlap
each solder sleeves after shrinkage.
(12)
Heat up and shrink the heat-shrinking tube using HG2310LCD heat gun with reflector
for wire (shrinkage procedure is described in Section 20-20-50).
(13)
If you use the protective self-adhesive tape instead of heat-shrinking tube, select S
1081-Tape (S1048-Tape) tape with glue underlayer (for operating temperature up to
up to 250).
(14)
Tightly wrap the splice sleeves with one layer of tape. Make sure that the tape layer
begins at 20 mm after the rear end of solder sleeve on one end of attachment and
ends at 20 mm after rear end of solder sleeve on the other end of wire attachment.
Each wrap of tape must overlap the previous wrap by 50 % along circumference.
(15)
Tightly wrap the solder sleeves with second layer of tape in direction opposite to the
first layer (ref. Fig. 22).
(16)

Screen material
Screen material outer

diameter
Rear edge of screen of

backward pulled off wire
Fig. 21 Positioning of screened material on the prepared wire area
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Fig. 22 Repair of screened wire with use of two solder sleeves and protective tape by the method,
when wire screen to be spliced is pulled off backward over the wire sheath
C.
Damage of external (additional) screen of RF cable: breaking of up to 2 strands (the length of

damage is not more than 10 mm)
Refer to Subject 2.C, which contains the typical damages of RF cables with double screen
braiding.
(1)
Clean the area of cable insulation around the damage with ethyl alcohol, GOST 1830087 and dry.
(2)
Straighten the broken strands of screen and put them along the cable guide to prevent
damage of wrapped protective tape.
(3)
Select tape S1081(S1048) with glue underlayer (for operating temperature up to

up to 250).
(4)
Wrap the damaged area of external cable sheath with two layers of tape, at that
observe the dimensions, as shown in Figure 23 (the length of damaged area is not
more than 10 mm).
(5)

stabilization using HG2310LCD heat gun with adequate reflector for cable. For that
heat up the area to temperature of 300 for 10 to 15 s (the procedure of shrinkage is
described in Section 20-20-50 of the present Manual).
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Damaged area borders

maximum 10 mm
Two layers of protective
tape
minimum 5 mm
minimum 5 mm
External protective
sheath
Internal
(primary)
insulation
Wire external
(additional) screen
braiding
Internal (primary) screen

braiding
Fig. 23 Damage (breaking of not more than 2 strands) of additional cable screen and repair by applying
of two layers of insulating tape
CAUTION: In case of breaking of more than 2 strands of RF cable additional screen
(digital transmission lines and pulse current cable) the cable is not
subjected to repair and must be replaced.
(6)
If the length of damaged area on additional screen is more than 10 mm (this area
includes maximum three small areas of damages with broken strands in each one), it is
required to wrap the protective tape with 50% of self-overlapping. At that two layers of
tape must overlap the damage by not less than 7 to 10 mm (ref. similar Fig. 10).
(7)

stabilization using HG2310LCD heat gun with reflector for cable. For that heat up the
6.
Repair of screened wire in case of current-carrying conductor (s) cores damage

A.
Repair of single-core screened wire

Refer to Subject 1.B, which contains the general requirements for repair of wires and cables
CAUTION: In case of screened wire damage near its attachment in the lug and if there is the
adequate technological reserve perform its repeated attachment in
accordance with the attachment procedure described in Sections 20-20-80
and 20-40-10.
(1)
Remove the damaged area of wire.

a.
Cut the wire on one end from the damaged area.

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b.
Cut the wire on the other end from damaged area.

(2)
Perform termination of wire on the both ends to install the crimping splice sleeves in
accordance with Subject 2 of Section 20-20-60 and Subject 1 of Section 20-20-70.
Length of insulation removed from the wire core for fitting in the crimping sleeve must
be 79 mm. Length of the external protective sheath removed from the wire screened
braiding for fitting of the screen material on it must be 6-8 mm (Ref. Fig. 24).
(3)
Clean the sheathes and cores of wire with ethyl alcohol, GOST 18300-87 and dry.
(4)
Beforehand put on the sealing sleeve on one of the wire areas for crimping sleeve
protection, two solder sleeves for attachment of screen material, the screen material
itself, as well as heat-shrinking tube for final attachment.
CAUTION: Select the adequate solder sleeves in accordance with Table 4, Section 2020-60. crimping sleeves in accordance with Table 1, Section 20-20-70.
screen material in accordance with Tables 1 and 2, Section 20-20-50.
(5)
Observe the required dimensions to install the crimping splice sleeve in the breakage of
damaged wire in accordance with Figure 11 and Section 20-20-70. which contains the
procedure of single wires attachment in crimping splice sleeves and the procedure of
check after installation.
CAUTION: It is permitted to install not more than two splice sleeves on one wire.
(6)
Position the screen material at the attachment area so that to provide end-to-end joint
of both stripped areas of wire screen braiding.
(7)
Assemble the solder sleeve on the one end of external wire sheath termination
a.
b.
Place the solder sleeve on wire (Fig. 24). For that align the sleeve solder ring with
the center of wire screen area (34 mm from the edge of external sheath towards
the attached sleeve). Make sure that the external edge of the sleeve O-ring is
located at external wire sheath
Heat up and shrink the solder sleeve using HG2310LCD heat gun until the rings
of solder are melted completely and spread over the braiding. The recommended
shrinkage temperature is 36030 during 15 s maximum.
NOTE: The quality of solder sleeve installation is checked in accordance with
Section 20-20-60.
(8)
Assemble the solder sleeve on the other end of external wire sheath termination, refer
to the procedure described above.
(9)
On the area to be attached install the heat-shrinking tube of RW175, OTK type with
length of 70+1 mm and shrink it using HG2310LCD heat gun (shrinkage procedure is
described in Section 20-20-50).
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Insulating sealing case
Wire protective sheath
Crimp bushing
0,5-1,6
7-8
Screen braiding
type 103-026-,
L=75+1 mm
or
type 103-009-,
L=75+1 mm
301
75-76
Solder sleeve
Heat-shrinking tube
RW175, K
L=70+1 mm
Wire final termination
70-71
Fig. 24 Standard attachment of screened single-core wire in protective sheath

NOTE: Instead of heat-shrinking tube of RW175 and OTK type it is possible to use
DR25, RNF300 tubes.
B.
Repair of twisted screened wires (cables) in common sheath
Refer to Subject 1.C, which contains the general requirements for repair of wires and cables with
use of solder sleeves and splice sleeves.
Refer to Subject 2.B, which contains the typical damages of screened wires and cables with use of
solder sleeves and splice sleeves.
CAUTION: In case of screened twisted wire damage near its attachment in the connector and if
there is the adequate technological reserve perform its repeated attachment in the
connector in accordance with the attachment procedure described in Section 20-30-10.
(1)
Remove the damaged area of cable.

a.
Cut the cable on the one end from damage.

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b.
Cut the cable on the other end from damage.

(2)
Perform termination of screened cable on both ends in accordance with Subject 2 of

Section 20-20-60. as well as perform subsequent installation of crimping sleeves on the
damaged area in checkerboard order (ref. Fig. 25).
(3)
Clean the sheathes of wires with ethyl alcohol, GOST 18300-87 and dry.
(4)
Beforehand put the heat-shrinking tube on one area of the wire to be repaired for final
attachment and two selected solder sleeves for attachment of screen material to be
installed, the screen material itself, as well as sealing sleeves for crimping splice
sleeves on each damaged wire.
CAUTION: Select the adequate solder sleeves in accordance with Table 4, Section 2020-60. crimping sleeves in accordance with Table 1, Section 20-20-70,
screen braiding material in accordance with Tables 1 and 2, Section 2020-50.
(5)
Install the crimping splice sleeves on each wire of cable and the solder sleeves on the
ends of common attachment in accordance with Figure 11.
CAUTION: To select the splice sleeves and solder sleeves for cable according to
sequence of their installation and attachment quality check refer to Sections
20-20-60. 20-20-70.
It is permitted to install not more than two splice sleeves on one wire.
Place the splice sleeves in group of wires in checkerboard order
(dimensions for installation are given in Fig. 25).
(6)
Install the screen braiding on the damaged area of cable so that its face ends come
closer to the ends of external sheath cut with permissible clearance not more than 2
mm.
(7) Assemble the solder sleeve on the one end of external wire sheath termination
a.
b.
Place the solder sleeve on wire (Fig. 25). For that align the sleeve solder ring with
the center of cable screen area (34 mm from the edge of external sheath towards
the attached sleeve). Make sure that the external edge of the sleeve O-ring is
located at external wire sheath.
Heat up and shrink the solder sleeve using HG2310LCD heat gun until the rings
of solder are melted completely and spread over the braiding. The
recommended shrinkage temperature is 36030 during 15 s maximum.
NOTE: The quality of solder sleeve installation is checked in accordance with
Section 20-20-60 (Subject 5).
(8)
Assemble the solder sleeve on the other end of external cable sheath termination
(9)
On the wire area to be attached install the heat-shrinking tube of RW175, OTK type with
length of 70+1 mm and shrink it using HG2310LCD heat gun (shrinkage procedure is
described in Section 20-20-50).
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Insulating sealing sleeve of the
splice sleeve
Screen braiding
Cable protective sheath
0,5-1,6
Splice sleeve
crimp bushing
Splice
sleeve
center
251
7-8
371
251
501
Screen braiding
type 103-026-,
L=75+1 mm
or
type 103-009-,
L=75+1 mm
75-76
Solder sleeve
Heat-shrinking tube
RW175, K
L=70+1 mm
Cable final termination
70-71
Fig. 25 Standard attachment of twisted screened wires in common sheath

NOTE: Instead of heat-shrinking tube of RW175 and OTK type it is possible to use
DR25, RNF300 tubes.
7.
Replacement of wire for grounding (bonding) of screened cable

Refer to Subject 2., which contains the typical damages of screened wires and cables.
In case of damage of pulled-out wire core for cable screen grounding the wire must be replaced
entirely.
To replace the wire, which enters the connector contact, do the following:
- remove the screws of connector cable clamp;
- remove the reeling tape 66N (67, 68, 69N);
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- turn off the cable clamp using TG-69 mounting tool with soft jaws;
- select the required tool for extraction of contacts depending on contact size and carefully extract
the contact with wire;
- carefully cut the sleeve edge with sharp blade on the other end of wire, at that do not damage the
insulation and cable screen;
- use heat gun to heat up the solder sleeve until it becomes soft;
- remove solder sleeve from cable using tweezers, for that pull it by the end opposite to made cut;
- prepare the identical wire for screen grounding, at that perform its termination in accordance with
Subject 2 of Section 20-20-60 and attachment in the lug in accordance with Section 20-20-80 of the
present Manual;
- perform attachment of grounding wire to screen braiding of cable using solder sleeve in
accordance with procedure described in Subject 3. of Section 20-20-60 (Fig. 26);
- perform attachment of wire in the lug in accordance with Section 20-20-80.
- perform attachment of wire with lug in connector in accordance with Section 20-40-40.
In case of wire core damage in initial or middle link of series connection of screen braidings of
several wire groups for leading to grounding module it is required to remove two adjacent solder
sleeves, replace the wire and perform attachment with new sleeves in accordance with procedure
described above.
Fig. 26 Standard attachment of screen grounding wire using solder sleeve

After installation of solder sleeve it is required to check the insulation resistance between central
conductor and grounding terminal wire using -2002 electronic megohmmeter or similar electronic
instrument with measurement error less than 2.5%. The value of insulation resistance must be not
less than 20 MOhm.
8.
Repair of wire contact connections

.
Damage of electrical connector contacts locks (inadequate attachment of connector contact

with wire, that cause the variable contact or high transient resistance)
In case of such type of damage perform replacement of electrical connector and repeated
attachment of wires in it in accordance with Section 20-40-40 of the present Manual.
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B.
Damage of grounding or multiplexing module contacts locks (inadequate attachment of

module contact with wire, that cause the variable contact or high transient resistance)
In case of such type of damage perform replacement of the module and repeated attachment
of wires in it in accordance with Section 20-40-40 of the present Manual.
C.
Damage of wire lug (break)

In case of lug breaking it is required to replace the wire lug:
- cut the wire near the protective tube;
- select the adequate lug and terminate the wire for installation in new lug in accordance with
Section 20-20-20;
- install wire in the lug and crimp in accordance with Sections 20-20-80 and 20-40-20 and
then check the transient resistance.
D.
Oxidization of electrical connector contacts

To remove the oxide on socket and pin contacts of electrical connector it is required to
perform cleaning of contacts with rigid brush with ethyl alcohol, GOST 18300-87, at that the
contaminations must flow down from the split chambers. Then dry the connector.
E.
Damage of paint coating of electrical connector housing

To restore the paint coating of the connector housing it is required to perform touchup with
EP-140 enamel of appropriate color or with VL-02 primer.
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STANDARD WIRING PRACTICES MANUAL

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WIRING DIAGRAM MANUAL

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RRJ-95B STANDART WIRING PRACTICES MANUAL

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LIST OF SERVICE BULLETINS

STANDARD WIRING PRACTICES MANUAL

SECTION 20 - STANDARD WIRING PRACTICES MANUAL

STRUCTURE OF THE MANUAL

TERMS AND ABBREVIATIONS

Check of the Fuel Vapours Level

Jet-Type Air Heaters, Soldering Guns and Heat Guns

WIRES AND CABLES USED ON THE AIRCRAFT

Wires and cables used on the aircraft

CUTTING OF WIRES, CABLES, TAGS AND TUBES

Cutting tool for wires, cables, tags and tubes

STRIPPING OF INSULATION, SPLICING OF WIRES AND CABLES

Stripping of Insulation and Splicing of Various Type Cables

Stripping of Insulation and Splicing of Various Type Wires

MARKING OF EWIS COMPONENTS

Marking Methods and Means

Fitting of Identification Tags

Marking of Connectors, Terminal Blocks, Units and Components

Binding of Harnesses by Bandage Cord

Binding of Harnesses by Cable Bands

Selection of Materials and Standard Termination of Harnesses

STANDARD WIRING PRACTICES MANUAL

Splicing of Screened Wires and Cables

Termination of Screened Wires and Cables

Fitting of Solder Sleeves

Check of Termination Quality

Selection of Solder Sleeves

TERMINATION OF WIRES AND CABLES IN CRIMPING SLEEVES

Crimping Sleeves Application Procedure

Selection of Crimping Sleeves

Selection of Solder Sleeves

TERMINATION OF WIRES IN THE LUGS

Selection of Lugs and Crimping Tools

Termination of Wires in the Lugs

TERMINATION OF WIRES IN ELECTRICAL DEVICE, INTERNAL WIRING

Standard Soldering of Wires in Electrical Device

ELECTRICAL CONNECTORS. GENERAL

RVN1, RVN2, RVN3 Type Connectors

SNTs Type Connectors

D38999 and 8D Series Connectors

Designation of Cable Clamps for D38999 and 8D Series Connectors

Contact Numbers, Crimping and Wiring Tools