T M 9 - 4 9 3 1 - 3 8 1 - 1 4 & P -2
When replacing diodes, coat mica washers and mount with silicone compound (Item 27, appendix
C). Put one washer on threaded end of diode before inserting diode in mounting hole. When
replacing potentiometers, switches, and circuit breakers, be sure keyways, washers, and tabs
are lined up in mounting holes before tightening hardware. When soldering capacitors, relays,
circuit breakers, wires, and diodes, hold terminal Iugs and leads with long round nose pliers to
keep parts from overheating.
g. Removing and lnstalling Connectors. If connectors cannot be removed by hand, use
slip joint conduit style pliers with plastic jaw inserts to loosen them. Finish removal by hand.
Straighten any bent pins with long round nose pliers. When installing connectors on larger
harnesses, another soldier maybe needed to help aline the mating ends of the cable. Make sure
that pins and keyways line up. Tighten twist-snap-type connectors until a click is heard and
tighten screw-on-type until the ratchet noise is no longer heard to indicate that connectors are
h. Replacing Connectors. Cut boot from adapter with knife. If shielding is installed,
remove shielding. Unscrew adapter and slide back over cable. Unsolder wires from connector
contacts. If wires are crimp type, remove contacts and wires from connector with insert-
extract tool. Slide new boot and adapter over cable. Solder wires to connector. If wires are
crimp type, crimp wires to contacts and insert them in connector using insert-extract tool.
Screw on adapter. Lace shielding to cable in three places if required. Slip boot over adapter
and shrink with thermal gun.
i. Repairing Connectors and Modules. Hold connector with back end toward you. Slide
extract end of insert-extract tool over wire of contact to be taken out. Slide tool along wire
and into hold until it engages contact, and a slight pressure is felt; the contact is now unlocked.
Pull contact and wire out of connector. Cut off bad contacts. Strip insulation from wire with
thermal stripper and place new contact in crimping tool. Put bare wire in contact and crimp it.
Look through wire in contact. If you do not see bare wire, remove wire and crimp it again.
Hold colored end of insertion tool toward connector. Lay wire along slot in tool. Leave at least
1/2-inch of wire sticking out of end of tool. Pull wire back through tool until crimped shoulder
seats against tips of tool. Push contact into connector until it stops. Contact is now locked in
connector. Put sealing plugs in all empty contact holes in connector. Tighten retaining nut
with slip joint conduit style pliers with plastic inserts. To remove modules, slide points of
extract tool into indents of module and push tool until clips unlock. Hold extract tool tight and
pull module out. To
and a click is heard.
install new module, push module into rail assembly until a firm snap is felt
Look into inspection hole to be sure clip is in place.
Use solvent in a well-ventilated area away from open flame.
Solvent can burn easily and may give off harmful vapors.
Clean dirt, grease, dust, and old compounds off cable harnesses, parts, connectors, and
receptacles by dipping them into a container filled with solvent cleaning compound (item 30,
appendix C). Shake parts in solvent or wipe them clean with a Iint-free cloth (Item 9, appendix
C). Clean dirt, grease, and dust off recessed areas with acid swabbing brush (ltem 8, appendix
C) or lint-free cloth. Dry components/parts, connectors, and receptacles completely with low-
pressure, dry compressed air, or with a clean, Iint-free cloth.