Insert stripped wire into contact conductor
barrel. Ensure all wire strands are inside contact
conductor barrel and visible in contact inspection hole
d. If insulation gap is too large, trim conductor
as required. If insulation gap is too small, trim
insulation as required (NAVAIR 01-1A-505-1,
Figure 9. Insulation Gap
WP 009 00)
41. CONTACT CRIMPING.
a. Select crimp tool frame and positioner (Table 5,
6, 8 or 9).
b. Perform die closure check, install positioner,
and set selector knob for gage of wire. Crimp contact
to wire (NAVAIR 01-1A-505-1, WP 013 00).
42. CONTACT INSERTION. The following procedure
covers installation of wired or unwired, power,
thermocouple, and coaxial contacts:
Series 1 and 2 connectors are front release type,
and ganged retention. The contacts are inserted
and removed from the rear of the connector.
Figure 10. Unlocking Connector
a. If not previously removed, remove backshell
from rear of connector. Turn rear nut assembly
counterclockwise until slight resistance is felt (2 1/2 turns
or 5/64 inch space, minimum). Yellow stripe will be
visible (Figure 10).
b. Remove sealing plug and/or contact from
Route wire or cable through backshell.
Start contact insertion near center contact
cavities and work outward.
d. Hand insert contact into corresponding hole
until only crimp barrel portion of contact extends from
grommet (Figure 11).
Select insertion tool specified in applicable
contact tooling table (Table 5, 6, 8 or 9).
Figure 11. Inserting Contacts into Connector