TM 1-1270-476-30
2-8
2-5. CABLE AND WIRING HARNESS ASSEMBLY REPAIR (cont)
1. TERMINAL LUG REPLACEMENT
REMOVAL
a. Remove wire harness clamps and spot ties
as necessary to access wiring to terminal
lug being replaced.
NOTE
Cut wire as close to terminal lug as possible.
b. Cut wire from terminal lug.
INSTALLATION
c. Strip wire to proper length for insertion in
terminal lug barrel.
d. Solder or crimp wire as applicable.
e. Lightly tug on wire to check that wire
contact holds.
f. Place wire in bundle. Secure harness
assembly using spot ties and clamps.
g. Perform electrical tests.
(1) With multimeter set on lowest
resistance scale, make a point-to-point
continuity measurement. Verify meter
indicates less than 1 ohm for each wire.
(2) With multimeter set on highest
resistance scale, test each conductor to
all other conductors, conductor shields
and connector shells. Verify resistance
is 100 megohms or more.
h. Have connector installation inspected.
END OF TASK
2. UNPOTTED CONNECTOR REPLACEMENT
REMOVAL
a. Remove wire harness clamps and spot ties
as necessary to access wiring to connector
being replaced.
b. Tag wires attached to faulty connector.
c. Cut wires from faulty connector. Discard
faulty connector.
d. Remove old heat shrinkable insulation
sleeving from wires.
INSTALLATION
e. Strip wires to proper length for insertion in
contact wire barrel.
NOTE
Stripped portion of conductor must be long
enough to bottom in contact wire barrel, but
bare wire must be less than 0.032 inch above
barrel.
f. Slide heat shrinkable insulation sleeving on
wires to be soldered and away from the end
to make room for soldering. Do not apply
heat. This will be done in a later step.
g. Solder wires to identified contact or, if
applicable, attach crimp contacts (4 below).
h. Install crimped contacts into connector
inserts using installing tool specified in
table.
i. Lightly tug on each wire to check that wire
contact holds.
j. Remove tags.
