ARMY TM 9-6115-604-12
NAVY NAVFAC P-8-633-12
Strip end of each wire to be spliced approximately 0.5 inch (13 mm). If a piece of wire is to be
spliced into an existing wire, ensure the new section is of the same color and AWG size.
Twist all stripped ends tightly together, so as to form neat joints of uniform size. Solder joints in
accordance with MIL-S-6872 using solder with rosin flux.
Position shrink-down sleeve over solder joint, and heat sleeve to 250 F (121 C) so that it shrinks to
form a tight seal around soldered joint.
If harness sleeving was cut to expose broken wire, repair sleeving with three layers of half-lapped
insulating tape MIL-T-638.
Replace damaged lugs as follows:
Remove damaged lugs by cutting wire as close as possible to lug. If wires are too short, splice in
accordance with step (1), above.
Install shrink-down sleeve PO-135 of adequate diameter and length to cover shank of lug, over cut
Strip 0.15 Inch (3.8 mm) of insulation from end of wire. Crimp new lug in place, and solder in
accordance with MIL-S-6872, using solder with rosin flux.
Position shrink-down sleeve over shank of lug and shrink as In step (d), above.
Replace damaged electrical connections as follows:
Before removing any damaged connector, prepare a diagram showing the location of each wire in
relation to the connector by matching the wire number and the pin letter on the connector.
Remove pins and wires from connector. Cut wires as close to pins as possible.
Strip 0.25 inch (6.4 mm) of insulation from the end of each wire.
Remove pins from new connector. Crimp pins to wire ends.
Insert pins In proper location in connector.
All soldering will be performed in accordance with standard shop practices using solder MIL-S-6872.
Replace. Harnesses are usually repairable. Replacement is necessary only d substantial damage (such as by
fire) has occurred. If inspection of the damaged harness indicates replacement is necessary, proceed as
Tag and identify wires.
Start at the end of the harness. Remove all hangers, clamps, ties, and hardware attaching the harness
to the generator set. Disconnect connectors as required. When 3 to 6 feet (1 to 2 meters) of the harness
is free, go to step (3), below.
Begin to Install the replacement harness Use existing hangers, clamps, ties, and hardware where
serviceable. Use replacement parts as necessary. Connect connectors as required. Install up to the point
where the defective harness is still fastened down.
Remove another 3 to 6 feet (1 to 2 meters) of the defective harness as in step (2), above. Then install
more of the replacement harness in accordance with step (3), above. Repeat the procedure until the
replacement harness has been completely installed. Remove tags.
Reconnect battery power.