Figure 9. Insulation Gap
47. CONNECTOR BUILD-UP.
48. 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.
49. WIRE STRIPPING.
Figure 10. Inserting Contact into Insertion Tool
a. Cut wire to proper length. Ensure enough wire
remains for adequate strain relief without leaving excess
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, WP 009 00).
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 2, 3, or
Crimp contact to wire.
51. CONTACT INSERTION. Insert wired or unwired
50. C O N T A C T C R I M P I N G . C r i m p c o n t a c t i n
contacts in accordance with following procedure:
accordance with following procedure:
a. Remove sealing plug and/or contact from
a. Select crimp tool frame, positioner, and
contact cavity (Paragraph 55).
inspection gage (Table 5 or 6).
b. Ensure wire or cable on contact is routed
When removing broken wire contacts ensure
Place wire and contact assembly into tip of
wire sealing grommet is not damaged. A new
insertion tool. Ensure tool tip is over contact conductor
connector must be installed (Paragraph 61) if a
barrel and butted against contact shoulder (Figure 10).
broken wire contact cannot be removed.
d. Insert tip of contact into cavity. Start contact
b. Perform die closure check. Install positioner
insertion near connector center cavities and work
and set selector knob for gage of wire.
Insert stripped wire into contact conductor
Axially align contact with contact cavity.
barrel. Ensure all wire strands are inside contact
conductor barrel and visible in contact inspection hole
With firm even pressure, press tool against
contact shoulder and seat contact into cavity (Figure 11).
A slight click may be heard as retention tines snap into
place behind contact shoulder.