b. Remove sealing plug and/or contact from
81. CONNECTOR BUILD-UP SERIES 3 AND 4.
82. WIRE DIAMETER BUILD-UP. If wire outside
Route wire or cable through backshell.
diameter is not large enough to fill wire sealing
grommet holes, build up wire outside diameter by
d. Select insertion tool specified in applicable
applying heat-shrinkable insulating sleeving. This
contact tooling table (Table 15, 16, for shielded contacts
must be accomplished prior to contact insertion.
see Figure 28).
83. SINGLE CONDUCTOR WIRE AND CONTACT
ASSEMBLY. The procedures for attaching power and
thermocouple contacts to single conductor wire are the
Insertion is accomplished from the rear of the
same for all connector specifications in series 1 and 2.
After selecting a specific contact part number (Tables:
11, 12, 13, or 14), select tooling (Tables: 15, 16) and refer
Place wire and and contact assembly into
to (NAVAIR 01-1A-505-1, WP 013 00) for assembly
colored tip of insertion tool (Figure 29). Ensure tool
tip is over conductor the conductor barrel and butted
up against the contact shoulder.
84. WIRE STRIPPING.
a. Cut wire to proper length. Ensure enough wire
remains for adequate strain relief without leaving
Start contact insertion near center contact
cavities and work outward.
b. Strip insulation from end (NAVAIR
Position insertion tool around rear of contact
01-1A-505-1 WP 009 00) to dimension given for
(Figure 30). Contact and tool should be aligned within
applicable connector. Select contact from Table 11, 12,
hole as straight as possible to avoid damage to wire
13, or 14.
sealing grommet. Press insertion tool against contact
shoulder firmly to seat contact in cavity.
Insert stripped wire into contact conductor
barrel. Ensure all wire strands are inside contact
g. Remove insertion tool by sliding back along
conductor barrel and visible in contact inspection hole
wire insulation until it clears grommet.
h. Seal connector (Paragraph 85), and install
d. If insulation gap is too large, trim conductor
backshell (WP 004 03).
as required. If insulation gap is too small, trim
insulation as required (NAVAIR 01-1A-505-1,
87. CONNECTOR SEALING.
WP 009 00).
88. Sealing Plugs.
85. CONTACT CRIMPING.
a. Fill all unused cavities with un-crimped
a. Select crimp tool frame and positioner
contacts and sealing plugs.
(Table 15, 16).
b. Perform die closure check, install positioner,
and set selector knob for gage of wire. Crimp contact
All MIL-C-81511 connectors use a straight
to wire (NAVAIR 01-1A-505-1, WP 013 00).
sealing plug, without a knob at the end
86. CONTACT INSERTION. The following procedure
covers installation of wired or unwired, power,
b. Select sealing plug according to size of contact
thermocouple, and coaxial contacts:
a. If not previously removed, remove backshell
Fill all cavities with un-crimped contacts.
from rear of connector.
Insert sealing plug until bottomed in each contact