CHAPTER 5
WIRING HARNESS REPAIR INSTRUCTIONS
5-1. General.
Electrical interconnection of control devices and
indicators is accomplished through wiring harnesses.
Wires in the harnesses are bundled and secured to
prevent unnecessary movement and chafing, and to
conserve space.
Internal wiring harnesses for the
relay boxes, kits and other electrical assemblies
are also provided in this section.
5-2. Wiring Harness Removal and Inspection.
a. Refer to Operator and Organizational Mainten-
ance Manual for harness removal procedures.
b. Refer cooperator and Organizational Main-
tenance Manual for inspection procedures.
5-3. Wiring Harness Repair and Rebuild.
a. Repair.
(1) Repair procedures for individual wires are
covered in the Operator and Organizational Mainten-
ance Manual.
(2) If a wiring harness has sustained damage
to 30 percent or more of the wires in the harness,
the wiring harness must be completely rebuilt.
b.
—
of the
set.
Rebuild.
(1) Figures 5-l through 5-40 are illustrations
wiring harnesses installed on the generator
(3) Refabricate anew wire harness using the
illustration for dimension and the wire run list for
proper wire connection.
(4) If a wiring harness cannot be identified,
compare it with the illustrations until proper identi-
fications made. Check numbers stamped on wires
against those in the wire run list to insure proper
identification before proceeding with refabrication.
(5) Wiring shall be neatly laced through the
use of self-locking nylon straps, located at intervals
not to exceed three inches, and also at each wire
break out.
(6) Soldering shall be in accordance with re-
quirement 5 of MIL-STD-454 using SN60 solder.
(7) Wire numbering shall be in accordance
with MIL-W-5088, except that length between ad-
jacent groups of numbers shall not exceed six
inches.
(8) Cut insulation tubing in one-half inch
pieces and install around wires at pins of connec-
tors and receptacles.
(9) Install nylon filler plugs MS25251-16 in
unused openings of connectors.
5-4. Installation.
Refer to Operator and Organizational Maintenance
Manual for installation procedures.
(2) Each illustration includes a wire run list
providing wire origination, destination, identifica-
tion number, wire length, and preparation require-
ments, and end preparation. Find numbers
(circled) related to specific components.
5-1
