ARMY TM 9-4120-380-14
AIR FORCE TO 35E9-136-21
WIRE HARNESS. Continued
REPAIR - Continued
b. Soldering Connections. Wire connections must be made mechanically sound before they are soldered. Solder
alone does not provide sufficient strength to prevent breakage. Joining surfaces of connections to be soldered
must be clean and bright. If a separate flux is used, it should conform to Specification, MIL-F- 14256, rosin base
flux, and should be brushed onto the joint before soldering. If a flux-core solder is used, it should be rosin core
electrical solder. If uncored solder is used, it should be lead-tin solder, conforming to Specification QQ-S-571.
Wires should always be heated to the point at which the solder will melt completely and flow into all parts of the
joint. Excessive buildup of solder on the joint should be avoided or removed.
Insulating Joints The preferred method of insulating electrical joints is by the use of heat-shrink tubing. To apply,
cut a piece of heat-shrink tubing of suitable diameter to a i-inch length for covering joints at terminals or
connectors, or to a length about 1/2 inch (1 3 cm) longer than the joint to be insulated, and slide the tubing over
the wire before making the joint. After the joint is made slide the tubing so that it covers the joint, and shrink m
place with moderate heat.
d. Splicing Wires To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced. A commercial butt splice can be crimped onto the ends to join them, or a "Western Union" wire splice
can be made. The latter is made by stripping 1/4 - 1/2 inch (0.6 - 1.3 cm) of insulation from the wire ends,
holding the ends parallel and facing opposite directions, then twisting each end around the other wire at least
three turns. Apply insulation and solder as described above.
e. Crimping Terminals. To install a terminal on the end of a wire, strip 1/4 - 1/2 inch (0.6 -1.3 cm) of insulation from
the end of wire, apply a 1-inch piece of heat-shrink tubing (if the terminals are of the uninsulated type), and insert
wire end into the shank of the terminal. Crimp the shank and shrink tubing.
FOLLOW ON PROCEDURES
d. Connect air conditioner input power at source.