ARMY TM 9-6115-604-12NAVY NAVFAC P-8-633-12c. Repair.(1) Splicing. Expose damaged wires by cutting harness sleeving as necessary, being careful not to cutthe insulation of serviceable wires when cutting the sleeving. It Is normally most efficient to guidethe tip of the cutting instrument between parallel wires in the harness. The cuts in the sleevingshould always be made parallel with the harness assembly. When the wires to be spliced areexposed, proceed as follows:To avoid injury to personnel, do not breathe fumes generated by soldering. Eyeprotection is required. Remove rings and watches while soldering.(a)Install shrink-down sleeve PO-135 of adequate length and diameter to cover finished splice, overone end of broken or cut wire. Position shrink-down sleeve far enough from break so that it we notinterfere with splicing or soldering operations.(b) Strip end of each wire to be spliced approximately 0.55 inch (13 mm). If a piece of wire Is to bespliced into an existing wire, ensure the new section is of the same AWG size.(c) Twist all stepped ends tightly together, so as to form neat joints of uniform size. Solder joints inaccordance with MIL-S-6872, using solder with rosin flux.(d) Position shrink-down sleeve over solder joint, and heat sleeve to 250°F (121°C) so that sleeveshrinks to form a tight seal around soldered joint.(e) If harness sleeving was cut to expose broken wire, repair sleeving with three layers of half-lappedinsulating tape MIL-T-638.(2) Replace damaged lugs as follows:(a) Remove damaged lugs by cutting wire as close as possible to lug. If cutting leaves wires too short,splice in accordance with step (1), above.(b) Install shrink down sleeve PO-135, of adequate length and diameter to cover shank of lug, over cutwire.(c) Strip 0.15 inch (3.8 mm) of insulation from end of wire. Crimp new lug In place, and solder inaccordance with MIL-S-6872, using solder with rosin flux.(d) Position shrink-down sleeve over shank of lug and shrink as in step (1), above.(3) Replace damaged electrical connectors as follows:(a) Before removing any damaged connector, prepare a diagram showing the location of each wire inrelation to the connector by matching the wire number to the pin letter on the connector.(b) Remove pins and wires from connector. Cut wire as close to pins as possible.(c) Strip 0.25 Inch (6.4 mm) of insulation from the end of each wire.(d) Remove pins from new connector. Crimp pins to wire ends.(e) Insert pins into connector. Reassemble connector.(4) All soldering will be performed in accordance with standard shop practices and MIL-S-6872.d. Install.(1 ) See the appropriate wiring diagram FO-4 through FO-12 for the routing of harness being replaced.(2) Carefully feed replacement wires in the harness past any obstruction into positions noting the following:(a)There should be no strain on any wire when it is in place and its connectors and mounting lugs areattached to the generator set4-96
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