37. CONNECTOR BUILD-UP SERIES 1 AND 2.
Be careful if using metal tools (M81969). These
tools can damage the wire sealing grommet in
the connector. Plastic tools are preferred.
Do not perform hot work without specific
authorization of activity Aviation Gas Free
Inspect tool tips for damage such as nicks,
Engineer (AVGFE) or Gas Free Engineer(GFE).
burrs, or distortion before use. Damage to the
connector wire sealing grommet can occur.
The HT-900B, HT-920B, HT-71002 and
MCH-100-A heat guns are the only authorized
Avoid using metal tooling to remove and install
heat guns to be used when working on aircraft
backshells. These tools can damage the
that have not been defueled and purged. The
backshell and connector. Non-metallic tools
aircraft must be defueled and purged before
are designed to wear before damaging
using any other heat guns listed in this manual.
connector or backshell.
Aircraft with open fuel cells or broken or open
Do not remove a contact attached to a broken
fuel lines shall be certified gas free in accordance
wire with an unwired contact removal tool.
with NAVAIR 01-1A-35, or AF T.O. 1-1-3. Only
The tool and connector may be damaged,
the HT-900B/HT-920B, HT-71002, MCH-100-A
heating tools are authorized for use on any
Wire strands may be encountered at any point
aircraft whenever AVGAS, JP-4 or the presence
up to 5/16 inch of tool insertion. Do not force tool
of any type of fuel is imposing an immediate
if wire strands are encountered.
Withdraw tool any time it cannot be advanced
When using heat guns with electric motors,
into connector. Inspect tool tip for nicks, cracks,
recertification may be required as work
mushrooming, and other damage that will
progresses, as directed by the Aviation Gas
prevent proper functioning. Replace removal
Free Engineering Technician (AVGFET).
tool and repeat procedure if required.
The MCH-100-A heat gun has been
38. WIRE DIAMETER BUILD-UP. If wire outside
diameter is not large enough to fill wire sealing
for flight line or flight deck use. All other
grommet holes, build up wire outside diameter by
electric motor type heat guns are not authorized
applying heat-shrinkable insulating sleeving. This
for flight line or flight deck use due to
must be accomplished prior to contact insertion.
motor type heating tools are safe for use by
39. SINGLE CONDUCTOR WIRE AND CONTACT
personnel at the organizational maintenance
ASSEMBLY. The procedures for attaching power and
level to repair aircraft wiring in a hangar or
thermocouple contacts to single conductor wire are the
hangar deck/flight line environment, provided
same for all connector specifications in series 1 and 2.
the aircraft meets the gas-free environment
After selecting tooling for a specific contact part
criteria (NAVAIR 01-1A-35, or AF T.O. 1-1-3),
number (Tables: 5, 6, 8, or 9), refer to (NAVAIR
and there are no EMI restrictions.
01-1A-505-1, WP 013 00) for assembly procedures.
Do not perform wire repair while using explosive
40. WIRE STRIPPING.
solvent/paint products on the aircraft.
a. Cut wire to proper length. Ensure enough wire
When using a heat tool, do not use electrical
remains for adequate strain relief without leaving
power from the aircraft being repaired. Use
electrical power from a ground power unit.
b. Strip insulation from end (NAVAIR
Use of nitrogen with the HT-900B/HT-920B
01-1A-505-1 WP 009 00) to dimension given for
heat gun in an enclosed area can be hazardous.
applicable connector. Select contact from Table 3, 4, or
Discharge of nitrogen into a poorly ventilated
area can result in asphyxiation.