45. CONNECTOR BUILD-UP.
46. WIRE DIAMETER BUILD-UP. If wire outside
diameter is not large enough to fill wire sealing grommet
holes, build-up wire outside diameter by applying
heat-shrinkable insulating sleeving. This must be
accomplished prior to contact insertion.
47. WIRE STRIPPING. Strip wire in accordance with
a. Cut wire to proper length. Ensure enough wire
remains for adequate strain relief without leaving excess
b. S t r i p i n s u l a t i o n f r o m e n d ( N A V A I R
01-1A-505-1, WP 009 00). Select contact (Table 3 or 4).
48. CONTACT CRIMPING. Crimp contact in
accordance with following procedure:
Select correct crimp tool (Table 5).
b. Perform die closure check, install positioner,
and set selector knob for gage of wire.
Figure 8. Insulation Gap
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
Crimp contact to wire.
49. CONTACT INSERTION. Insert wired or unwired
contacts in accordance with following procedure:
a. Remove sealing plug and/or contact from
contact cavity (Paragraph 53.)
b. Ensure wire or cable on contact is routed
through connector backshell.
Select correct insertion tool (Table 5).
d. Place wire and contact assembly into colored
tip of insertion tool (Figure 9). Ensure tool tip is over
conductor barrel and butted against contact shoulder.
Figure 9. Inserting Contact into Insertion Tool