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MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
CSP−SPM
ELECTRICAL STANDARD PRACTICES
WIRING REPAIR
barrel plus 0.032 in. (0.81 mm) (Ref.
Wire Terminations).
1. Wire Repair
A. Non−Shielded Wire Repair
(5). Put one wire end into crimp barrel of
splice and put splice in crimping tool
(T1013).
(Ref. Table 801 and Figure 801)
Item
Consumable Materials
(Ref. Section 91−00−00)
Nomenclature
C824
Splice, Crimp Style, Sealed
Item
Special Tools
(Ref. Section 91−00−00)
Nomenclature
T1013
T2004
Crimping Tool
Heat Gun
(6). Fully actuate tool, and remove splice.
(7). Put other wire end into empty end of
crimp barrel, and put splice in crimping
tool (T1013). Turn crimp barrel so that
crimp indentation will be 180 degrees
to first crimp.
(8). Fully actuate tool.
(9). Examine installation as follows:
(a). Make sure you can see bare wire in
inspection window of crimp barrel.
NOTE: Do this procedure when wire condition
is unacceptable, and wire length is suffi­
cient.
(b). Make sure no bare wire is out of
inspection window or crimp barrel.
(1). Cut wire the minimum necessary to
remove damaged part.
(c). Make sure crimp indentations are
approximately in center of crimp
barrel.
(2). Make a selection of the applicable splice
(C824) and crimping tool (T1013).
(3). Put sealing sleeve on wire, and move
away from maintenance area.
(d). Make sure crimp indentations are
not at barrel ends or on inspection
window.
(4). Remove wire insulation from both ends
of wire, equal to the length of the crimp
(e). Replace splice if installation is
unsatisfactory.
Table 801. Splice and Crimp Tool Selection
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Part Number
Color Code
Wire Size (AWG)
M81824/1−1
RED
26−24−22−20
M81824/1−2
BLUE
20−18−16
M81824/1−3
YELLOW
16−14−12
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Crimp Tool
AD−1377
Raychem Part No.
992008−000
(MIL−C−22520/37−01)
(10). Put sealing sleeve on completed splice.
Align center of sleeve with center of
splice.
(a). Heat sealing sleeve until seals at
ends of sleeve melt and flow along
wire insulation.
(11). Install sealing sleeve as follows, use
heat gun (T2004).
(b). Heat sealing sleeve until sleeve stops
shrinking.
20-60-00
Page 801
Revision 17
CSP−SPM
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(b). Replace in-line splice if installation
is unsatisfactory.
MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
(12). Examine sealing sleeve as follows:
(a). Too much heat has caused sleeve to
darkened or make visual inspection
of crimp not possible.
INSPECTION WINDOW
CRIMP BARREL LENGTH
0.032 IN. ( 0.81 MM ) MAXIMUM
BARE WIRE
SEALING SLEEVE
CRIMP BARREL
ÌÌ
ÌÌ
ÌÌ
ÌÌ
COLOR STRIPE (NOTE)
SEAL MATERIAL
ÌÌ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
BARE WIRE CAN BE SEEN IN INSPECTION WINDOW
0.032 IN. ( 0.81 MM ) MAXIMUM
INDENTATIONS IN CRIMP BARREL
180 DEGREES TO EACH OTHER
SEAL MATERIAL MELTED AND
FLOWED ALONG WIRE INSULATION
SEAL MATERIAL
ÌÌ
ÌÌÌ
ÌÌ
ÌÌÌ
ÌÌ
ÌÌÌ
SEALING SLEEVE SHRUNK
TO FIT WIRE INSULATION
COMPLETED REPAIR
ÌÌÌ
Ì
ÌÌÌ
Ì
ÌÌÌ
Ì
NOTE: ON ONE END OF SEALING SLEEVE, THE SEAL MATERIAL WILL HAVE THE SAME COLOR CODE AS THE COLOR CODE ON
THE CRIMP BARREL. IT IS NOT NECESSARY TO HAVE THE COLOR CODES STRIPES OF THE SEALING SLEEVE AND
CRIMP BARREL ON THE SAME END OF THE INSTALLED SPLICE.
Figure 801. Non−Shielded Wire Repair
Page 802
Revision 12
20-60-00
9G20−077A
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B. Shielded Wire Repair
MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
CSP−SPM
Table 802. Solder Sleeve Selection
Part Number
Size
(Ref. Table 802 and Table 803)
MHS5471−1009
0.175−0.335 in.
(4.45−8.51 mm)
(Ref. Figure 802)
MHS5471−1012
0.250−0.450 in.
(6.35−11.4 mm)
MHS5471−1015
0.375−0.570 in.
(9.53−14.48 mm)
MHS5471−1018
0.475−0.690 in.
(12.02−17.53 mm)
Item
Consumable Materials
(Ref. Section 91−00−00)
Nomenclature
C819
Insulation Sleeving, Electrical, Heat
Shrinkable
MHS5471−1021
0.580−0.800 in.
(14.73−20.32 mm)
C824
Splice, Crimp Style, Sealed
MHS5471−1025
0.675−0.965 in.
(17.15−24.5 mm)
C825
Splice, Shield
C826
Braided Wire, Tubular
CAUTION
D Do not repair EMI category 4 or 5
shielded wire. Contact Field Service Engi­
neering.
D Shield braid that is damaged more than
limits must be replace. Damaged shields
can cause component malfunction be­
cause of unsatisfactory signal.
D Do the repair in wire harness so as to pre­
vent a strain at a bend or divide.
NOTE: This procedure gives instructions for
many installations. Not all steps are appli­
cable.
(1). Cut cable the minimum necessary to
remove damaged part.
(2). Make a selection of the correct size heat
shrinkable sleeving (C819) (Ref. Wire
Maintenance).
(3). Cut heat shrinkable sleeving (C819) to
a length sufficient to seal repair.
(4). Make a selection of the smallest size
solder sleeve (C825) that will fit on
cable.
(5). Make a selection of the correct size
shield (C826).
(6). Cut shield (C826) to a length sufficient
to overlap repair at both ends after
splice(s) have been installed.
Table 803. Shield Selection
Part Number
Dimension
QQB575R36T0250
.250 in.
(6.35 mm)
QQB575R36T0375
.375 in.
(9.53 mm)
QQB575R36T0500
.500 in.
(12.7 mm)
(7). Put heat shrinkable sleeving, two
solder sleeves, and repair shield on
cables. Move away from maintenance
area.
NOTE:
D Insulation removal lengths for cable and
cable wires will change, because of the
number of splices in the repair.
D Remove cable wire insulation so center of
first splice is 1.0 in. (25.4 mm) from end
of shield.
D Remove cable wire insulation so center of
each second splice is 1.25 in. (31.8 mm)
more from end of shield than first splice.
(8). Prepare both ends of shield and wire for
termination, use end strip method (Ref.
Wire Terminations).
(9). Install splices (Ref. Non-Shielded Wire
Repair).
20-60-00
Page 803
Revision 17
CSP−SPM
(10). Move repair shield so that it overlaps
cable shield at both ends.
(11). Make repair shield tight on cable along
its length with your hand, to keep gaps
in shield material to a minimum.
(12). Trim repair shield and cable shield
material as necessary to correct braid
length and remove braid wires that are
out from braid.
Page 804
Revision 17
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(13). Move solder sleeve so solder is on
overlap between repair shield and cable
shields.
MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
20-60-00
(14). Install solder sleeves (Ref. Solder
Sleeve Installation).
(15). Move heat shrinkable sleeving and trim
as necessary to get a minimum overlap
of 0.5 in. (12.7 mm) beyond solder
sleeves at both sides.
(16). Install heat shrinkable sleeving (Ref.
Heat Shrinkable Sleeving).
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MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
CSP−SPM
HEAT SHRINKABLE SLEEVING
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
REPAIR BRAID
SOLDER SLEEVE
SEALING SLEEVE
CRIMP BARREL
SHIELD REPAIR COMPONENTS
ÌÌÌ
ÌÌÌ
ÌÌÌ
ÌÌÌ
1 IN.
(25.4 MM)
1 IN.
(25.4 MM)
ONE WIRE ONE SPLICE
ÌÌÌ
ÌÌÌ
ÌÌÌ
ÌÌÌ
1 IN. (25.4 MM)
1 IN. (25.4 MM)
2 WIRES 2 SPLICES
1 IN. (25.4 MM)
ÌÌÌ
ÌÌÌ
1.25 IN.
(31.75 MM)
1.25 IN.
(31.75 MM)
3 WIRES 3 SPLICES
NOTE 1
ÌÌÌ
ÌÌÌ
1 IN. (25.4 MM)
WIRE INSULATION REMOVAL FOR WIRE SPLICE
ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
SOLDER SLEEVE
ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌ
SOLDER SLEEVE
HEAT SHRINKABLE SLEEVING
REPAIR SHIELD
END 1
END 2
NOTE 2
SOLDER SLEEVE (2 PL)
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
REPAIR SHIELD
NOTE 3
SOLDER SLEEVE (2 PL)
HEAT SHRINKABLE SLEEVING
NOTE 4
SHIELD REPAIR COMPONENT INSTALLATION
NOTES:
1. MAXIMUM DIMENSION TO PERMIT INSTALLATION OF SHIELD REPAIR COMPONENTS.
2. ALIGN REPAIR SHIELD ENDS WITH END OF CABLE INSULATION OR CABLE SHIELD FOLD BACK.
3. ALIGN SOLDER WITH AREA WHERE REPAIR SHIELD AND CABLE SHIELD OVERLAP. MAKE SURE NO SHIELD WIRES
ARE OUT OF SOLDER SLEEVE.
4. MAKE SURE HEAT SHRINKABLE SLEEVING GOES A MINIMUM OF 0.5 IN (12.7 MM) FARTHER THAN END OF SOLDER SLEEVE.
9G20−078A
Figure 802. Shielded Wire Repair
20-60-00
Page 805
Revision 17
CSP−SPM
C. Shielded Wire − Picked Shield Repair
(Ref. Table 804)
Consumable Materials
(Ref. Section 91−00−00)
Nomenclature
Splice, Shield Termination
Item
C822
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(4). Install solder sleeve on cable (Ref.
Solder Sleeve Installation).
MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
(5). Terminate braid wire (Ref. Wire
Terminations).
(a). If braid wire is too short for termina­
tion, repair or replace shielded wire.
D. Wire Insulation Repair
NOTE: Do this procedure when a picked shield
is too short or is damaged more than limits.
(1). Cut picked shield to align with end of
cable insulation.
(2). Remove 0.25-0.34 in. (6.35-8.64 mm)
cable insulation.
NOTE: You can fold cable shield on cable in­
sulation or let stay straight.
(3). Make a selection of the correct size
solder sleeve (C822).
Table 804. Solder Sleeve Selection
Part Number (1)
Size
MHS4786−632
0.080−0.140 in.
(2.03−3.56 mm)
MHS4786−633
0.110−0.200 in.
(2.79−5.08 mm)
MHS4786−634
0.150−0.250 in.
(3.81−6.35 mm)
MHS4786−635
0.200−0.300 in.
(5.08−7.62 mm)
NOTES:
(1) These solder sleeves have a flat, bare
braid wire attached.
Page 806
Revision 17
20-60-00
Item
Consumable Materials
(Ref. Section 91−00−00)
Nomenclature
C602
Rubber Strip, Self Fusing
NOTE:
D Do this procedure when damage is in lim­
its.
D This procedure is applicable to coax
cables.
(1). Clean damaged area (Ref. Wire Clean­
ing and Protection).
(2). Wind rubber tape (C602) a minimum of
two times around damaged part of wire.
(3). If applicable, attach wire to harness
with tying tape. Apply tying tape less
than 4.0 in. (102 mm) from damage
(Ref. Wire Maintenance).
(4). If applicable, install anti-rub sleeving.
Overlap repair 4.0 in. (102 mm) on
each side of damage (Ref. Wire Mainte­
nance).