d. If insulation gap is too large, trim conductor as
42. COAXIAL CONTACTS. When routing coaxial cable
required. If insulation gap is too small, trim insulation
through connectors, coaxial contacts are superior to
other coaxial cable shield termination methods. The
shield integrity is maintained across the contact body.
Crimp contact to wire.
The coaxial cable groups listed (Table 2) can be
interconnected through MIL-DTL-26500 connector size
49. CONTACT INSERTION. Insert wired or unwired
8 and 12 contact cavities. Match the required contact
contacts in accordance with following procedure:
size to connector application and cable group. When
crimping center contact for these cables, use crimp
a. Remove sealing plug and/or contact from
tool selector knob settings specified. Socket and pin
contact cavity (Paragraph 53).
contact part numbers are listed along with
corresponding color bands. Socket coaxial contacts
b. Ensure wire or cable on contact is routed
have a pin center contact. Pin coaxial contacts have a
socket center contact.
Select correct insertion tool (Table 3).
43. CABLE AND COAXIAL CONTACT ASSEMBLY.
To assemble coaxial contacts to applicable cable
d. Place wire and contact assembly into colored
identify cable by part number. Select proper tooling
end tip of insertion tool (Figure 9). Ensure tool tip is
by contact size (Table 3).
over contact conductor barrel and butted against contact
44. CABLE CLAMP/STRAIN RELIEF REMOVAL
AND INSTALLATION. For cable clamp/strain relief
Insert tip of contact into cavity. Start contact
removal and installation refer to WP 009 03.
insertion near connector center cavities and work
45. CONNECTOR BUILD-UP.
Axially align contact with contact cavity.
46. WIRE DIAMETER BUILD-UP. If wire outside
diameter is not large enough to fill wire sealing
g. With firm even pressure, press tool against
grommet holes, build-up wire outside diameter by
contact shoulder and seat contact into cavity
applying heat-shrinkable insulating sleeving. This
(Figure 10). A slight click may be heard as retention
must be accomplished prior to contact insertion.
tines snap into place behind contact shoulder.
47. WIRE STRIPPING. Strip wire in accordance with
h. Pull tool straight out of contact cavity. Remove
the following procedure:
tool from wire. Pull back lightly on wire to ensure
contact is properly seated.
a. Cut wire to proper length. Ensure enough
wire remains for adequate strain relief without leaving
Seal connector as required (Paragraph 50) and
b. Strip insulation from end (NAVAIR 01-1A-
50. CONNECTOR SEALING.
505-1, WP 009 00). Select contact (Table 2).
51. Sealing Plugs. Seal connector in accordance with
48. 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
accordance with following procedure:
a. Select crimp tool frame and positioner
a. Fill all unused cavities with un-crimped
contacts (Paragraph 49).
b. Perform die closure check. Install positioner
b. Insert sealing plug, large diameter first, until
and set selector knob for gage of wire.
bottomed in contact cavity (Figure 11). Fill all cavities
that have un-crimped contacts. Preserve connector in
Insert stripped wire into contact conductor
accordance with NAVAIR 01-1A-505-1, WP 026 00.
barrel. Ensure all wire strands are inside contact
conductor barrel and visible in contact inspection hole