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16PR145 - March 2011

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16PR145 - March 2011

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DISTRIBUTION STATEMENT D ‐ Distribution authorized to the DoD and DoD contractors only; Criticial

Technology; 28 August 2003. Other requests for this document shall be referred to the appropriate
technical office.
ENGINEERING INSTRUCTIONS
FOR
MANUFACTURE AND INSTALLATION
OF
WIRING HARNESSES - F16

Prepared by: Approved by:

/s/ Vernon G. Johnson /s/ Tom H. Luu

_________________________ ___________________________
Vernon G. Johnson Tom H. Luu
Electrical Engineer Staff Manager
Harness Integration Harness Integration

Approved by: Approved by:

/s/ Anthony Wedgeworth /s/ John Roberts

___________________________ ___________________________
A. C. Wedgeworth John W. Roberts
Sr. Manager Sr. Manager
Engineering Core Vehicle Systems Engineering

Approved by:

/s/ Mike McSpadden

___________________________
C. M. McSpadden
Director
Systems Engineering

Important Notice: A hard copy of this document may not be the document currently in effect.
The current version is always the version on the Lockheed Martin Network.
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

PAGE NO.: a

Rev Date By Description of Change & Reason Pages Affected

G 12/17/99 Revised and reprinted All

G1 05/31/00 Revised Para 3.1.6.3 & 3.6.1.4 Twisting of

Wire Harnesses Page 5

Revised Para 3.2.1.4 Deleted semicolon to

existing paragraph Page 7

Revised –5 to -105 and Revised Title of

Table 3.2.1-1 Page 8

Unbolded two words in Table 3-2.4-2 Page 9

Revised Para 3.2.5.6 Added new words Page 10

Revised Para 3.7.2 Changed word from

Twisting to Untwisting Page 56

Revised Para 4.1.3.1 Added a word Page 66

Revised Fig(s) 4.2.1.3 and 4.2.1.4 Page 68

Revised Para 4.3.4.2 Added a word Page 77

Added new Para 4.36 Circular Threaded

RF Coax Connectors and 4.3.6.1 (Torque
Requirements

Deleted Fab Aids MIL-C-39029-75,

MIL-C-39019-76, MIL-C-39029-77,
MIL-C-39029-78, MIL-C-39029-90, Appendix A

Replaced Fab Aids MIL-C-39029-27,

MIL-C-39029-28, MIL-C-39029-91,
C10751-4, C10970-1, C8831-X Appendix A

Revised Fab Aids C8804-9, 16VE049

M7928-1C Appendix A

PAGE NO.: b
Rev Date By Description of Change & Reason Pages Affected

G2 04/02/01 Updated Title Page, Signature Page, and Title Page, Sign.
the change description pages a through c Page, Pages a-
to incorporate Change 2 c

Corrected hyperlinks in table of contents

which were not translated into EDMS Page I-vii
correctly in Change 1 to Revision G. Page 16-20

Added Section 1.1 ―Fiber Optics‖ per new

program requirements Page 1

Added new fiber optic harness documents

to Section 2 - 'APPLICABLE
DOCUMENTS' per new program
requirement Page 2

Revised paragraph 3.1.4.1 to add

requirement for splice staggering Page 4

Table 3.2.1-1 spelling correction Page 6

Revised paragraph 3.2.4.1 and added

section 3.2.6 ―Labeling Wire Insulation
using Laser Marking Equipment‖ to permit
use of laser marking of
polytetrafluoroethylene/polyimide insulation
(TKT) wire insulation per new program
requirements Pages 9,11-16

Added sentence to paragraph 3.2.5.2,

3.2.5.6, and 3.2.5.7 to clarify that tubing is
to be shrunk securely onto harness Pages 10-11

Added paragraph 3.2.5.9 to allow markings

for manufacturing data Page 11

Added Section 3.4.9.19 "Termination Using

MS21980-X and MS21981-X Type Crimp
Ferrules‖ per Aerotec request. (Information
had been present in Revision F, but
deleted in Revision G because it was
thought to be unused.) Pages 47-48

PAGE NO.: c
Rev Date By Description of Change & Reason Pages Affected

Added Section 3.4.9.20 "Shield

Termination for Slotted Backshell
(C20815 and C20816)" per F-16 MLU
requirements. Pages 48-51

G2 04/02/01 Revised torque callout in paragraph

3.7.6.1(5) back to 30-35 inch-lbs. (Value
was 30-35 inch-lbs in revision F, but had
been revised in revision G to be consistent
with M016 without knowledge of relevant
in-service experience.) Page 59

Revised paragraph 4.2.1.3 and paragraph

4.2.1.3.1 for clarification Page 68

Revised section 5.1.2.2 to add alternate

method of braid repair per shop request Page 94

Revised section 5.1.3.1 to add alternate

method of shrink tubing repair per shop
request. Page 95

Added instructions for repair of multi-

shielded wiring harnesses (Reference
JHMCS design) Page 98

Revised Fig 1-1 and Fig.1-2 in Fabrication

Aids for TERMINATION PROCEDURE
FOR SOLDER CONTACTS M39029/73
and TERMINATION PROCEDURE FOR
SOLDER CONTACTS M39029/74. A30-5

Revised Fig 1-1 and Fig.1-2 in Fabrication

Aids for TERMINATION PROCEDURE
FOR SOLDER CONTACTS M39029/73
and TERMINATION PROCEDURE FOR
SOLDER CONTACTS M39029/74. A31-5

G-3 10-31- Updated title page, signature page, and Title Page
03 added Change description pages to Signature Page
incorporate Change 3 Pages d - j

PAGE NO.: d
Rev Date By Description of Change & Reason Pages Affected

Added statement to Scope & Applicable

Documents to clarify documents referenced Page 1
within the documents Page 2

Added applicable document 2.17

SAE-AS50881. Added applicable
document 2.18 FPS-1002. Added
applicable document Page I
2.19 FPS-3008 Page 2

Revised paragraph 3.1.4.1 to clarify

staggering for shield termination per
MK64633 Page 4

Added paragraph 3.1.4.2 to add

instructions that HAD splice location is
approximate within sleeving area per
Dwaine Armentor Page 4

Revised paragraph 3.1.6.3 to add twisting

requirement for harnesses 0.5 and greater
in diameter per CN001 Page 5

Revised paragraph 3.1.6.4 by removing

tape requirements of 8 to 12 inches Page 5

Added paragraph 3.2.2.2.1 termination

requirements per CN004 Page 8

Revised paragraph 3.2.5.2 to add

requirement for clear tape applied over
tape used for panel harness identification
per REA MJ38662 Page 11

Revised paragraph 3.2.5.6 to reference

paragraph 3.7.9.7 for reference designators
on panel harnesses per REA MJ48907 and
to specifically prohibit flag type reference
designators per REA MJ49546 & MJ49177 Page 12

PAGE NO.: e
Rev Date By Description of Change & Reason Pages Affected

Revised section 3.2.5.8 to reference hand

marking of reworked harnesses per James
Blagrave; REA MK38551 Page 12

Revised section 3.3.2(a) to allow string tie

of trunk harnesses as required to maintain
configuration per W.R. Murrell Page 16

Revised 3.4.1.4 to clarify that the assembly

person is the first inspector Page 16

Removed 3.4.2.1 C10980-3/-4 because it

was a duplicate of 3.4.5.3.2 Page 17

Removed 3.4.3 C8855 because it was a

duplicate of 3.4.6 Page 18

Remove 3.4.5.1 M83733 because it was a

duplicate of 3.4.5.2, revised C10959,
C10960, C10963 to state Fabrication Aid
not available Page 18

Combined 3.4.5.3.2 C10980-3/-4 to state

Fabrication Aid A118 (from Fab Aid to be
developed) Page 19

Revised 3.4.5.5 MS90335 to state

Fabrication Aid not available Page 19

Revised 3.4.6 C10961, C10995, C8839,

C8839-3, C8839-4, C8856 & MS24523 to
state Fabrication Aid not available (from
Fab Aid to be developed) Page 20

Revised paragraph 3.4.7.1 to include -5 for

C8807 connector per REA MK58497 Page 21

Added 3.4.7.3 to change MS27488 filler

plug orientation per CN004 Page 22

Added 3.4.8.3.2 to address Water Proofing

Electrical Connectors with C10979-X Pages 26-27

PAGE NO.: f
Rev Date By Description of Change & Reason Pages Affected

Revised 3.4.9.5 & 3.4.9.5.2 for clarification

per MK64633 Page 30

Revised 3.4.9.11.2 to include NOTE from

Rev. F to clarify termination for single
shield coax Page 39

Revised 3.4.9.20 to add C20855 and clarify

termination procedure REA MK25379,
MK25619, MJ95889, CAI-3543 Page 46

Added section 3.4.9.21 to address C20947

Backshell termination per David Metzler Pages 49-51

Revised paragraph 3.4.10 to add SAE-

AS50881
as reference Page 52

Revised paragraph 3.5.3.3 to clarify that

lug shall be terminated to the strain relief
clamp under screw head per QAR
CA95430 Page 54

Added 3.5.8 to allow substitution of longer

screws for ones supplied with backshells to
attach saddle bar per CN003 Page 56

Added paragraph 3.6.2 & 3.6.3 for C8844

Sleeving termination instructions per REA
MJ72552 & QAR 80313 Pages 57-58

Revised paragraph 3.6.3.1 NOTE for

clarification Page 58

Revised paragraph 3.7.1.1, 3.7.1.2, 3.7.1.3

for clarification MK45645 Page 58

Clarified paragraph 3.7.5.1 that it applies to

toggle switches similar to MS24523 per
shop squawk Page 59

PAGE NO.: g
Rev Date By Description of Change & Reason Pages Affected

Added paragraph 3.7.7.3 for torque value

on Diode per shop request Page 60

Added paragraph 3.7.8.2 for torque value

on Diode per shop request Page 61

Revised paragraph 3.7.9.1 to remove

statement that (clear tape) ‗P5393 is not
required on P5269.‘ per Pauline Finley Page 61

Revised paragraph 4.1.3.2.1 to remove

terminal torque requirement per Ron Marek Page 68

Revised paragraph 4.2.1.4 to address RF

cable clamping issues per MK60242 Page 69

Revised NOTE to paragraph 4.2.1.7 to

address routing of RF cable per MK60242 Page 71

Added paragraph 4.3.4.7 to address wires

slipping out of strain relief bar inserts on
16VE049 per REA MJ30949 Page 78

Revised paragraph 4.4.1.3 to add SAE-

AS50881 reference per D. Armentor Page 79

Added Paragraph 4.4.1.7 to specify

clearance Page 79

Added Paragraph 4.4.1.8 and illustrations

from revision F section 30 for terminal
stacking per Tim Secor Page 79

Revised paragraph 5.1.2.2 to include

C20955 procedure Pages 94-95

Revised Paragraph 5.1.8.1.1.(c) to correct

paragraph reference per REA MK23564
and clarify hardware Page 97

Added note 5.2.2.1 to define power feeders

that can be spliced per George Parks Page 98

PAGE NO.: h
Rev Date By Description of Change & Reason Pages Affected

Added section 5.2.5 to allow hand marking

of dash number of reworked harness per J.
Blagrave Page 99

Added paragraph 5.2.6 to allow relocation

of harness identifier or reference
designator for visibility Page 100

Add section 5.3 to allow Rework for

Incorporation Of Engineering Changes per
CN006 Pages 100-105

Revised Fabrication Aid for M39029/91-530

to correct graphics for Figure 4-0 & 4-1 & 4-
2 per Scott McGarrah Appendix A17

Revised Fabrication Aid for M39029/73-397

per REA MK64406 Appendix A30

Revised Fabrication Aid for C11788-1

contact per KAI-166 and REA MK20393 Appendix A32

Revised Fabrication Aid for C11788-2

contact per KAI-166 Appendix A33

Revised Fabrication Aid for C11788-3

contact per KAI-166 and REA MK20393 Appendix A34

Revised Fabrication Aid for C11788-4

contact per KAI-166 Appendix A35

Revised Fabrication Aid for C11788-5 & -6

contact per REA MK20393 Appendix A36

Revised Fabrication Aid for C8825-1-1

connectors to correct crimp die Appendix A52

Revised Fabrication Aid for C8826-1-1

connectors per CAI GRE-0101 Appendix A59

PAGE NO.: i
Rev Date By Description of Change & Reason Pages Affected

Revised Fabrication Aid for C8828 to limit

to C8828-1.1 and C8828-1-2 (separate
Fabrication Aid added for C8828-2-1) per
REA‘s MJ40157 & MJ81083 Appendix A61

Revised Fabrication Aid for M39012 to add

strip dimensions for M39012/57 per REA
MJ59420 (CAI-3399) Appendix A71

Revised Fabrication Aid for 16VE049

connectors for Alumel-Chromel connectors
per Aerotec request; also added
requirement that wires be between rubber
inserts in strain relief bar per REA
MJ30949; Also revised to add Steinel Heat
Gun per Royce Walker Appendix A72

Revised Fabrication Aid to revise torque

value for C4870 relay socket to 6-8 inch/lb.
per REA MJ50509 Appendix A80

Revised Fabrication Aid to revise filler

length allowance per QAR CB17741 Appendix A113

Revised Fabrication Aid for General

Assembly Instructions for Coax Connectors
to remove strip dimensions for connectors
covered by other Fabrication Aids REA
MJ40156 Appendix A119

Added Fabrication Aid for C11788-8

contact per REA MJ55585, MK20393,
MK62234 & CN005 Appendix A120

Added Fabrication Aid for C11788-9

contact per REA MJ55585 & MK20393 &
CN005 Appendix A121

Added Fabrication Aid for C8828-2-1

connector manufactured by Phoenix
Logistics per REA MJ40157 and REA
MJ81083 Appendix A122

PAGE NO.: j
Rev Date By Description of Change & Reason Pages Affected

Added Fabrication Aid for C8832-2

connector per REA MJ48899 Appendix A123

Added Fabrication Aid for C20348

connector per REA MJ76436 & MK13468 Appendix A124

Added Fabrication Aid for C20783

connectors per Elfon and buyer request Appendix A125

Added Fabrication Aid for Sumimoto

Product Triax Cable Specification C20773
REA MK60225 Appendix A126

Added Fabrication Aid for 16VE141

Harnesses attached to Interphone Filter
Assembly per CN002 Appendix A127

Added Fabrication Aid for M39029/75

contact Appendix A128

Added Fabrication Aid for M39029/76-424

contact per REA MJ69312 Appendix A129

Added Fabrication Aid for M39029/77-428

contact per REA MJ76128 Appendix A130

Added Fabrication Aid for M39029/78

contact Appendix A131

Added Fabrication Aid for M39029/90

contact Appendix A132

Added Fabrication Aid for C9718-1 & -2

connector per REA MJ41316 & MK13468 Appendix A133

Added Fabrication Aid for C9718-3 & -4

connector per REA MJ41316 & MK13468 Appendix A134
Added Fabrication Aid for C20857-1
contact for CN005A Appendix A135

Added Fabrication Aid for C20858-1

contact for CN005A Appendix A136

PAGE NO.: k
Rev Date By Description of Change & Reason Pages Affected

Added Fabrication Aid for C20895-1

contact for CN005A Appendix A137

Added Fabrication Aid for C20896-1

contact for CN005A Appendix A138

Added Fabrication Aid for C8804-12

connector per REA MK13468 Appendix A139

Added Fabrication Aid for C8825-2-4

connector per REA MK13468 Appendix A140

Added Fabrication Aid for C8804-3-1

connector per REA MK13468 Appendix A141
Added Fabrication Aid for MS27488 filler
per CN004 Appendix A142

Added Fabrication Aid for C20777

Backshell REA MK00991 Appendix A143

Added Fabrication Aid for C20778-1 & -3

Ferrules REA MK00991 Appendix A144

Added Fabrication Aid for M39029/103-559

socket contact per REA MK62234 Appendix A145

Deleted Appendix B which contained

obsolete revision F of 16PR145 Appendix B

G-4 11/1/05 Revised 3.2.5 to include labeling 11, 12

procedures for retrofit activity

Added 3.2.5.11 to clarify wafer stacking

order 14

Revised 3.4.7.1 to add new p/n‘s requiring

only filler plugs for grommet sealing 22

Revised figure 3.4.7-1 to add 8 / 10 awg

cavity 22

PAGE NO.: l
Rev Date By Description of Change & Reason Pages Affected

Added 3.4.8.3.2.9 for alternate

waterproofing 29

Revised 3.4.9.4.1 to clarify wire cut length 32

Revised 3.4.9.6.17 to correct fab aid

reference 37

Revised 3.5.3.2 to add p/n for tape build up 57

Revised 3.5.6.1 to clarify shield termination

in the absence of strain relief 58

Revised 3.6.1.1 and 3.6.1.4 to clarify braid

requirements 59

Added 4.1.3.2.2 to allow spacer variation

for achieving positive thread protrusion 71

Added (Note) for backshell screw

replacement 72

Revised 4.5.3.1 to define drip-loop 88

Revised crimp-die p/n for C8830-1

connectors A62-1, A62-2

Added strimp dimension requirements for

/27 and /55 M39012 connectors A71-3

Added figure 1 to clarify strip dimensions

for C20778-1 and -3 ferrules A144-1

TABLE OF CONTENTS

1.0 SCOPE ....................................................................................................... 1

1.1 Fiber Optics .................................................................................................... 1
2.0 APPLICABLE DOCUMENTS ..................................................................... 2
2.1 FPS-1004 - Sealing Specification Integral Fuel Tanks F-16 and F-111
Airplanes ........................................................................................................ 2
2.2 FPS-1013 - Application of Room Temperature Vulcanizing Silicone Rubber
Base Adhesives .............................................................................................. 2
2.3 FPS-3017 - Metal Removal Procedures and Limitations ................................ 2
2.4 FPS-1047 - Installation and Assembly of Parts with Anaerobic Retaining ...... 2
2.5 FPS-3024 - Electrical bonding requirements for F-16 Air Combat Fighter...... 2
2.6 FMS-1044 - Sealant, Integral Fuel Tank, General .......................................... 2
2.7 16PR106 - F-16 Airplanes: Engineering Instructions for Fabricating Wiring
Harness Braided Jackets ................................................................................ 2
2.8 M358 - Connector Backshell Clocking Specification....................................... 2
2.9 16PR4559 - F16 Airplanes: Engineering Instructions for Fabricating Wiring
Harness Braided Metal Shielding ................................................................... 2
2.10 FZM-8027 - Workmanship Standards for Electrical Assemblies ..................... 2
2.11 MTPA 002 - Authorized tool list of electrical crimping, insertion and extraction
tools for F-16 wiring harnesses and other authorized programs. .................... 2
2.12 J-STD-001, Class III - Solder Requirements................................................... 2
2.13 F16 Airplanes: 16PR15634 – Instructions for Fiber Optic Termination and
Assembly ........................................................................................................ 2
2.14 F16 Airplanes: 16PR15635 – Instructions for Assembly and Installation of
Fiber Optic Harnesses .................................................................................... 2
2.15 F16 Airplanes: 16PR15636 – In-Process Fiber Optic Testing ....................... 2
2.16 F16 Airplanes: 16PR15637 – Maintenance and Repair of Fiber Optic
Harnesses ...................................................................................................... 2
2.17 SAE-AS50881 – Wiring, Aerospace Vehicle .................................................. 3
2.18 FPS-1002 – Design, Manufacture, and Application of Markings, and Marking
Plates, Process Specification for .................................................................... 3
2.19 FPS –3008 – Marking of Aircraft and Aerospace Ground Equipment Parts ... 3
3.0 MANUFACTURING/FABRICATION REQUIREMENTS ............................. 4
3.1 General Requirements ................................................................................... 4
3.1.1 Source Data ................................................................................................ 4
3.1.2 Inspection .................................................................................................... 5
3.1.3 Tolerances .................................................................................................. 5
3.1.4 Splice Location ............................................................................................ 5
3.1.5 Soldering Processing Process .................................................................... 6
3.1.6 Pre-forming Wires/Cables Assemblies ........................................................ 6
3.2 Wire/Cable/Harness Identification .................................................................. 7
3.2.1 Wire/Cable Identifier Number ...................................................................... 7
3.2.2 Installation of the Wire/Cable Identifier. ....................................................... 8

I
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.2.3 Selection of Heat Shrinkable Tubing for Wire/Cable ................................... 9

3.2.4 Wire Gauge Color Code: ........................................................................... 11
3.2.5 Identification of Wiring Harness Assemblies ............................................. 12
3.2.6 Labeling Wire Insulation Using Laser Marking Equipment ........................ 15
3.3 Harness Lacing Tape (String Tie) ................................................................. 18
3.3.1 General Requirements .............................................................................. 18
3.3.2 String Tie Areas: ....................................................................................... 18
3.4 Terminations ................................................................................................. 19
3.4.1 General Wire Preparation ......................................................................... 19
3.4.2 Contacts (See Appendix for associated Fab Aid) ...................................... 20
3.4.3 TERMINAL Lugs (See Appendix for associated Fab Aid) ......................... 21
3.4.4 SPLICES (See Appendix for associated Fab Aid) ..................................... 21
3.4.5 Connectors ................................................................................................ 21
3.4.6 TERMINATING Devices (See Appendix for associated Fab Aid).............. 23
3.4.7 Connector Sealing Crimp and Solder Contact Types ................................ 24
3.4.8 Connector Sealing Boots .......................................................................... 27
3.4.9 Shield Termination .................................................................................... 33
3.4.10 Wire dead ending ...................................................................................... 62
3.4.11 Shield Float - Assembly Procedure ........................................................... 63
3.5 Strain Relief and Backshells ......................................................................... 63
3.5.1 General Requirements .............................................................................. 63
3.5.2 Application of P5407-1 .............................................................................. 64
3.5.3 Strain Relief and Backshell Installation ..................................................... 64
3.5.4 C8822-XX-X Type: .................................................................................... 65
3.5.5 C8820-XX-X Type. .................................................................................... 66
3.5.6 Rack & Panel (M83733 Type): .................................................................. 66
3.5.7 MS3154-X Type. ....................................................................................... 66
3.5.8 Substitution of longer screws for ones supplied with backshell to attach
saddle bar: ................................................................................................ 66
3.6 Protective Coverings .................................................................................... 67
3.6.1 General Requirements .............................................................................. 67
3.6.2 SELECTION AND PREPARATION OF EXPANDABLE BRAIDED
SLEEVING ................................................................................................ 67
3.6.3 INSTALLATION OF EXPANDABLE BRAIDED SLEEVING ...................... 68
3.7 Panels and Matrices ..................................................................................... 69
3.7.1 Exposed Solder Terminal/Lugs/Studs. ...................................................... 69
3.7.2 Untwisting of Wire ..................................................................................... 69
3.7.3 Splicing Within Relay Matrices. ................................................................. 70
3.7.4 Insulating Mounting Hardware .................................................................. 70
3.7.5 Procedure for the Installation of the C8853-( ) Covers on Switch Toggles.
70
3.7.6 Torque values for fastener installed in electrical attachments. .................. 71
3.7.7 Assembly Procedure for Mounting a Diode. .............................................. 72
3.7.8 Alternate Assembly Procedure for Mounting a Diode................................ 73
3.7.9 Reference Designation Numbers in Panels and Matrices. ........................ 73

II
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.7.10 Termination to Multiplex Networks Having Solder Pins C8839-( ), C10995-(

), C10961( ). .............................................................................................. 74
3.7.11 Termination to (MS90335-X) Edgelight Receptacle .................................. 75
3.7.12 Mounting of Toggle/Rotary Switches......................................................... 76
3.7.13 Keyway washers on electrical components. .............................................. 76
3.7.14 Installation of lighted control knobs ........................................................... 76
3.8 Testing Requirements .................................................................................. 76
3.8.1 Minimum Requirements ............................................................................ 76
3.8.2 Airframe Wiring Harness Assembly Area. ................................................. 76
3.8.3 Panel Wiring Harness Assembly Area. ..................................................... 77
3.8.4 Tests to be conducted after installation in the end item (Major
Components) prior to mating. .................................................................... 78
3.8.5 Testing Requirements of Out-Of-Station Installations on a completed end
Item. .......................................................................................................... 79
4.0 INSTALLATION/ROUTING REQUIREMENTS......................................... 80
4.1 General Requirements ................................................................................. 80
4.1.1 Scope ........................................................................................................ 80
4.1.2 Source Data .............................................................................................. 80
4.1.3 Harness Installation Drawings ................................................................... 80
4.2 Harness Support and Routing ...................................................................... 82
4.2.1 Harness Assembly Installation .................................................................. 82
4.2.2 Flight Control Wiring.................................................................................. 87
4.2.3 Power Feeders .......................................................................................... 88
4.3 Connector Mounting ..................................................................................... 88
4.3.1 Circular Connectors – General .................................................................. 88
4.3.2 Circular Connectors – Installation, Non-Pressure Bulkhead ..................... 90
4.3.3 Circular Connectors – Pressure Bulkhead Installation .............................. 91
4.3.4 Rectangular (16VE049 & C8916 series) Connectors ................................ 92
4.3.5 Rectangular (MIL-C-83733) Connectors ................................................... 95
4.3.6 Circular Threaded RF Coax Connectors ................................................... 95
4.4 Terminal Lug Connections ............................................................................ 95
4.4.1 General Requirements .............................................................................. 95
4.5 Special Installation Situations ....................................................................... 99
4.5.1 Wiring Across Hinges/Doors ..................................................................... 99
4.5.2 Gun Bay/EPU Bay................................................................................... 100
4.5.3 Wheel Well/Airstream .............................................................................. 100
4.5.4 Aerial Re-Fuel Receptacle ...................................................................... 102
4.5.5 Installation of C8922 Assemblies in Fuel/Wet/Pressurized Areas ........... 102
4.5.6 Installation of Fuel Cell Molded Cables and Probe Harness Connectors 104
4.5.7 Wiring Through Conduits ........................................................................ 106
4.5.8 Special instructions for weapon stations 3, 4, 6, 7 and intake duct ―hard-
points‖: .................................................................................................... 106
4.5.9 Radome – Pitot Probe Heater ................................................................. 108
4.5.10 Convoluted Tubing/Spiral Wrap .............................................................. 108
4.5.11 Bulkhead Feedthru Insulator ................................................................... 110
4.5.12 Split Grommet Installation ....................................................................... 112

III
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.0 REPAIR/REWORK ................................................................................. 113

5.1 Repair ......................................................................................................... 113
5.1.1 General Requirements ............................................................................ 113
5.1.2 Braid Repair ............................................................................................ 113
5.1.3 Shrink Tubing Repair .............................................................................. 114
5.1.4 Replacing a C8839-3 or –4 Multiplex Network. ....................................... 114
5.1.5 Repair of conduit (C2026-X-X) internal fuel tanks. .................................. 115
5.1.6 Repair for C8855 flexible bus bar. ........................................................... 115
5.1.7 Repair of connectors with waterproofing. ................................................ 115
5.1.8 Incorporation of Engineering Changes to a Braided Harness. ................ 116
5.1.9 METAL Braid Repair ............................................................................... 117
5.1.10 Repair of Multiple-Shielded Wiring Harnesses ........................................ 117
5.2 Rework ....................................................................................................... 118
5.2.1 General Requirements ............................................................................ 118
5.2.2 Allowable Rework.................................................................................... 118
5.2.3 Adding additional wires to a trunk harness already installed in the aircraft.
118
5.2.4 Touch up procedure for surface marks on electrical connectors. ............ 118
5.2.5 Reworked Harness Dash Number Change ............................................. 119
5.2.6 Relocation of harness IDENTIFIER or reference designator identification
119
5.3 Rework for Incorporation of Engineering Changes ..................................... 120
5.3.1 General Requirements ............................................................................ 120
5.3.2 Braided Harness ..................................................................................... 120
5.3.3 Rework of Multiple-Shielded Wiring Harnesses ...................................... 121
5.3.4 Splicing ................................................................................................... 122
5.3.5 SHRINK TUBING REWORK ................................................................... 122
5.3.6 Rework OR Replacement OF BRAID...................................................... 123
5.3.7 Rework of Metal Braid ............................................................................ 123
5.3.8 Replacing a C8839-3 or –4 Multiplex Network. ....................................... 123
5.3.9 Rework of Conduit (C2026-X-X) Internal Fuel Tanks. ............................. 123
5.3.10 Rework of C8855 Flexible Bus Bar. ........................................................ 124
5.3.11 Rework of Connectors with Waterproofing. ............................................. 124
5.3.12 Touch up Procedure for Surface Marks on Electrical Connectors. .......... 124

Appendix A Fabrication Aids ................................................................................... A-1

IV
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

LIST OF FIGURES

Figure 3.2.1-1 Typical Wire Identifier ........................................................................... 7

Figure 3.2.5-1 Shrink Tubing Part Number Breakdown ............................................. 12
Figure 3.2.5-2 Typical Production and Synthetic Wire Harness Identifier .................. 12
Figure 3.2.5-3 Typical Synthetic Wire Harness Identifier * ......................................... 13
Figure 3.2.5-4 Typical Loose Wire Assembly (LWA) Identifier ** ............................... 13
Figure 3.2.5-5 Typical Reference Designator Identifier .............................................. 14
Figure 3.2.6-1 Examples of Horizontal and Vertical Wire Identification...................... 16
Figure 3.2.6-2 Example of Laser Wire Marking and Information to be Laser Marked
onto Wire Jacket ............................................................................... 16
Figure 3.2.6-3 Typeface Heights for Horizontal and Vertical Marking ........................ 17
Figure 3.2.6-4 Maximum Distance Between Identification Markings .......................... 18
Figure 3.4.7-1 Typical Sealing Plug ........................................................................... 26
Figure 3.4.9-1 Wire Strip Lengths – Non EMI Backshell Shield Terminations ........... 33
Figure 3.4.9-2 Typical Solder Sleeve ......................................................................... 34
Figure 3.4.9-3 EMI Connector with Compression Ring Backshell .............................. 35
Figure 3.4.9-4 Wire Strip Lengths – EMI Right Angle Backshell ................................ 37
Figure 3.4.9-5 Termination Bus Horseshoe Backshell ............................................... 38
Figure 3.4.9-6 Termination Bus (Shield Comb) .......................................................... 39
Figure 3.4.9-7 EMI Backshell (Horseshoe Style) Arrangement .................................. 39
Figure 3.4.9-8 Wire Prep for C8898-1 Triax Shield Termination ................................ 41
Figure 3.4.9-9 Wire Prep for Shield Splices No Window ............................................ 43
Figure 3.4.9-10 EMI Shield Splice.............................................................................. 44
Figure 3.4.9-11 Wire Prep for C8898 Triax Using C2099-1 & C8951 Solder Sleeves
(Preferred Method) ............................................................................ 44
Figure 3.4.9-12 Installation of C2099-1 & C8951 Solder Sleeves on C8898 Triax .... 45
Figure 3.4.9-13 Strip Lengths for C8898 Triax (Alternate Method) ............................ 46
Figure 3.4.9-14 Installation Sequence for C2099-1 & C8951 (Alternate Method) ...... 46
Figure 3.4.9-15 Alternate Triax Shield Jumper Terminations ..................................... 47
Figure 3.4.9-16 Shield Preparation 1 ......................................................................... 48
Figure 3.4.9-17 Shield Preparation 2 ......................................................................... 48
Figure 3.4.9-18 Shield Preparation 3 ......................................................................... 48
Figure 3.4.9-19 C2004-10-X Assembly Procedure 1 ................................................. 49
Figure 3.4.9-20 C2004-10-X Assembly Procedure 2 ................................................. 49
Figure 3.4.9-21 C2004-10-X Assembly Procedure 3 ................................................. 50
Figure 3.4.9-22 C2004-10-X Assembly Procedure 4 ................................................. 50
Figure 3.4.9-23 Adding Wires to Harness With Metal Braid Sock .............................. 53
Figure 3.4.9-24 Adding Wires to Harness with Metal Braiding ................................... 54
Figure 3.4.9-25 C20816 backshell with shields/pigtails bundled into even groups .... 56
Figure 3.4.9-26 C20816 backshell with string tie and EMI band applied .................... 57
Figure 3.4.9-27 C20816 backshell with AA59569 (QQB575) braid in place ............... 58
Figure 3.4.9-28 C20947 Backshell Location of Split Support Ring ............................ 59
Figure 3.4.9-29 C20947 Backshell Dressing of Pigtails over Split Support Ring ....... 60

V
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

Figure 3.4.9-30 C20947 Backshell Braid Sock Extension Folded End....................... 60

Figure 3.4.9-31 C20947 Backshell EMI Shield Termination ....................................... 61
Figure 3.4.10-1 Assembly Procedure for Dead Ending Wire ..................................... 62
Figure 3.5.4-1 Hardware Arrangement for Terminal Lug to Backshell Shield
Termination ....................................................................................... 65
Figure 3.6.2-1 Expandable Braided Sleeving ............................................................. 68
Figure 3.7.7-1 Assembly Procedure for Mounting a Diode ........................................ 72
Figure 3.7.8-1 Alternate Procedure for Mounting a Diode .......................................... 73
Figure 3.7.10-1 Cable Stripping Dimensions ............................................................. 75
Figure 4.1.3-1 (Drawing representation) .................................................................... 81
Figure 4.1.3-2 (actual harness configuration may have breakout as shown) ............. 81
Figure 4.2.1-1 Installation of Clamps ......................................................................... 84
Figure 4.2.1-2 Orientation of Clamps ......................................................................... 85
Figure 4.2.1-3 Double Clove Hitch and Surgeons Knot ............................................. 86
Figure 4.2.1-4 Clove Hitch and Surgeons Knot .......................................................... 86
Figure 4.3.1-1 Master Keyway Orientation ................................................................. 89
Figure 4.3.2-1 Connector Mounting, Non-Pressure BHD Installation ......................... 90
Figure 4.3.3-1 Connector Mounting, Pressure BHD Installation ................................ 91
Figure 4.3.4-1 Rectangular Connector/Receptacle Stack Mounting .......................... 93
Figure 4.3.4-2 Rectangular Connector/Receptacle Panel Mounting .......................... 94
Figure 4.4.1-1 Typical Ground Stud Installation ......................................................... 96
Figure 4.4.1-2 Terminal Lug Arrangement ................................................................. 97
Figure 4.4.1-3 Terminal Lug Arrangement ................................................................. 97
Figure 4.4.1-4 Terminal Lug Under Fastener Head ................................................... 98
Figure 4.5.1-1 Routing Across Hinge/Door ................................................................ 99
Figure 4.5.3-1 Drip Loop with Straight Connector .................................................... 101
Figure 4.5.3-2 Drip Loop with Right Angle Connector .............................................. 101
Figure 4.5.5-1 Fuel Cell Bulkhead Feedthru ............................................................ 103
Figure 4.5.5-2 Fuel Cell Bulkhead Feedthru ............................................................ 103
Figure 4.5.6-1 Fuel Cell Connector, Installed ........................................................... 104
Figure 4.5.6-2 Fuel Cell Molded Cables and Probe Harness Connectors ................ 105
Figure 4.5.8-1 Bending of C8865 Mounting Tabs for Routing Through Conduit ...... 107
Figure 4.5.10-1 Straight Cut Tubing Installation ....................................................... 108
Figure 4.5.10-2 Spiral Cut Tubing Installation .......................................................... 109
Figure 4.5.10-3 Spiral Wrap ..................................................................................... 110
Figure 4.5.11-1 Bulkhead Feedthru Insulator ........................................................... 111
Figure 4.5.12-1 Example of Correctly Installed MS35489 Split Grommet ................ 112

VI
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

LIST OF TABLES

Table 3.2.1-1 Shrink Tube Color to Numeric Value Cross-Reference.......................... 8

Table 3.2.3-1 Suggested Tubing Sizes ...................................................................... 10
Table 3.2.4-1 Wire Gauge Color Code Cross-Reference........................................... 11
Table 3.2.4-2 Special Wire Color Codes .................................................................... 11
Table 3.2.6-1 Insulation Diameter, Type Face Size and Reading Direction ............... 17
Table 3.4.7-1 Tubing Requirements........................................................................... 25
Table 3.4.7-2 Crimp Type Connectors ....................................................................... 26
Table 3.4.7-3 Solder Type Connectors ...................................................................... 26
Table 3.4.7-4 Sealing Plug Installation Tools ............................................................. 27
Table 3.4.9-1 C20947 Backshell Sizes of Split Support Rings ................................... 58
Table 3.7.6-1 Torque Value Table for Electrical Attachments .................................... 71
Table 4.5.6-1 Torque Requirements, Fuel Cell ―Jam Nut‖ Connectors .................... 105
Table 4.5.10-1 Size Reference for P5434 ................................................................ 110

VII
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

1.0 SCOPE

This document establishes engineering requirements for the assembly and

installation of electrical wiring and wiring devices in F-16 aircraft. It supplements but
does not supersede the requirements of the released engineering data. Document
references are included for clarification and do not supersede or override this
document. Wiring harness boards (HRBDs) are to conform to the revision of this
document in effect at the time of sell off. Changes to this document are not
intended to cause rework of completed HRBDs or harnesses built to those HRBDs.

1.1 Fiber Optics

Any fiber optic link that is to be installed into a production F-16 shall be
manufactured, assembled into a harness, tested and maintained per the below
listed specifications.

All part numbers for fiber optic components are listed in the below listed
specifications and are not listed in 16PR145.

a) 16PR15634 – Instructions for Fiber Optic Termination and Assembly

b) 16PR15635 – Instructions for Assembly and Installation of Fiber Optic
Harnesses
c) 16PR15636 – In-Process Fiber Optic Testing
d) 16PR15637 – Maintenance and Repair of Fiber Optic Harnesses

1
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

2.0 APPLICABLE DOCUMENTS

Documents referenced within the documents cited herein shall not be applicable to
this specification because of such reference.

2.1 FPS-1004 - Sealing Specification Integral Fuel Tanks F-16 and F-111 Airplanes

2.2 FPS-1013 - Application of Room Temperature Vulcanizing Silicone Rubber Base

Adhesives

2.3 FPS-3017 - Metal Removal Procedures and Limitations

2.4 FPS-1047 - Installation and Assembly of Parts with Anaerobic Retaining

2.5 FPS-3024 - Electrical bonding requirements for F-16 Air Combat Fighter

2.6 FMS-1044 - Sealant, Integral Fuel Tank, General

2.7 16PR106 - F-16 Airplanes: Engineering Instructions for Fabricating Wiring

Harness Braided Jackets

2.8 M358 - Connector Backshell Clocking Specification

2.9 16PR4559 - F16 Airplanes: Engineering Instructions for Fabricating Wiring

Harness Braided Metal Shielding

2.10 FZM-8027 - Workmanship Standards for Electrical Assemblies

2.11 MTPA 002 - Authorized tool list of electrical crimping, insertion and extraction tools
for F-16 wiring harnesses and other authorized programs.

2.12 J-STD-001, Class III - Solder Requirements

2.13 F16 Airplanes: 16PR15634 – Instructions for Fiber Optic Termination and
Assembly

2.14 F16 Airplanes: 16PR15635 – Instructions for Assembly and Installation of Fiber
Optic Harnesses

2.15 F16 Airplanes: 16PR15636 – In-Process Fiber Optic Testing

2.16 F16 Airplanes: 16PR15637 – Maintenance and Repair of Fiber Optic Harnesses

2
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

2.17 SAE-AS50881 – Wiring, Aerospace Vehicle

2.18 FPS-1002 – Design, Manufacture, and Application of Markings, and Marking

Plates, Process Specification for

2.19 FPS –3008 – Marking of Aircraft and Aerospace Ground Equipment Parts

3
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.0 MANUFACTURING/FABRICATION REQUIREMENTS

3.1 General Requirements

3.1.1 Source Data

3.1.1.1 Information required to begin fabricating a wire/cable assembly.

3.1.1.2 Build To Package – (BTP)

3.1.1.3 Logical Data – Released engineering data in the forms listed below. This data
is incorporated on the harness routing board and included in the bill of
materials.
a) Application List - (A/L) defines the aircraft serial number (or end item
effectivity) that is associated with the detail part assignment.
b) Parts List - (P/L) defines the parts in the assembly.
c) Wire List - (W/L) defines the individual wire/cable numbers, military or
company specification, wire/cable type, endpoint terminations, terminating
device and reference designator of the endpoints. It also provides an
approximate wire/cable length in some instances. The Harness Board
(HRBD), Harness Assembly Drawing (HAD) or Visual Aid is the defining
geometry of the completed harness assembly. As such, the Harness
Board (HRBD), Harness Assembly Drawing (HAD) or Visual Aid wire
length requirement supersedes the wire length field noted in the harness
wire list. (Note: formally this was referred to as the R/L or routing list.)
d) Reference Designator List - (RDL) lists the endpoints for the assembly
and their associated hardware.

3.1.1.4 Physical Data

a) Harness Routing Board – (HRBD) is the tool the wire harness/cable
assembly is built on.
b) Harness Assembly Drawing – (HAD) the engineering drawing.

3.1.1.5 Planning Data

a) Harness Identification System – (HIS) data that consists of engineering,
sizes, lengths, types, markings, and I.D. instructions. This data is
developed from the tool.
b) Bill of Materials – (BOM) the parts and materials required to fabricate a
wire harness/cable assembly.

3.1.1.6 Planning Data – Procurement may be made to this document when 16PR145
is called out on the wiring harness W/L.

4
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.1.1.7 Fabrication – Specific methods shown herein for electrical processes, such as
wire terminations and connector assembly, are shown for guidance.
Workmanship standards are contained in FZM-8027.

3.1.2 Inspection

3.1.2.1 Approved accept-reject criteria are contained in FZM-8027.

3.1.3 Tolerances

3.1.3.1 Unless otherwise noted, tolerances shall be as follows:

a) Tolerance for breakout lengths shall be +0.5, -0.0.
b) Tolerance for strip lengths shall be +/- 0.03 for wire and +/- 0.01 for
coaxial/triaxial cable.
c) Tolerance for convoluted tubing lengths shall be +/- 0.25 inches.
d) Tolerance for point to point harnesses that do not have HRBDs or HADs
shall be +0.5, -0.0.

3.1.4 Splice Location

3.1.4.1 If HRBD‘s are used, the locations of splices, solder sleeves, tubing, sleeving
and braid are to be determined by Mock-up or Computer Modeling and will be
documented on the HRBD. Multiple splices in the same area of a harness are
to be staggered as much as possible to minimize harness diameter, shield
terminating devices can be staggered as long as the shielding requirements set
forth within this document for the respective devices are met.

3.1.4.2 For braided harnesses sealed crimp type splices shall be located in the area
that is covered with expandable braided sleeving (C8844-X). For unbraided
harnesses, sealed crimp splices shall be located in an accessible visible area if
possible. The harness board or computer model shall identify the connector at
which the splice is to be located. The drawing symbol on a HAD that depicts
where the splice (s) is/are to be located is only an indication of the endpoint
location for the splice(s) and not be interpreted as a dimensioned or exact
location.

5
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.1.5 Soldering Processing Process

3.1.5.1 The following applies to soldering processes for F-16 wire harness assemblies:

3.1.5.2 Condition 1: When a solder process is not directly specified on a harness

drawing or harness P/L, the applicable solder process shall meet the
requirements of those sections of J-STD-001, Class 3 that apply to wire
harnesses, and be inspected to FZM-8027 and IPC-A-610 workmanship
standards.

3.1.5.3 Condition 2: When a solder process is directly specified on the harness

drawing or harness P/L, the applicable soldering processes in those sections of
J-STD-001, Class 3 that apply to wire harnesses, are acceptable for use as an
alternate method of soldering.

3.1.6 Pre-forming Wires/Cables Assemblies

3.1.6.1 In congested areas, such as relay sockets/rails (C4936 and C4937) and 90
backshells (C8820 and C8822), the conductors must make an abrupt 90 bend.
In this case, individual conductors may be formed to the desired shape (the
bend radius must be 3 times the conductor diameter or greater) by bending
approximately 15 more than desired and releasing.

NOTE: The cores of C8811-X coaxial cable, C8898-1 triaxial cable, and
C4930-X multiplex cable are very fragile and must be handled with
care. A short piece of shrink tubing, such as P5034 or C2070, may
be placed over the cores to provide additional protection. The tubing
may be extended up under the shield.

NOTE: Twisting of wires and cables, including triax and coax, is required
where designated by the harness board and/or engineering.

3.1.6.2 At connectors where C4931 conductors are terminated, the black shrink tubing
that is listed in the parts list may be the installed over cable jacket to prevent
jacket splitting.

3.1.6.3 Twisting is required on all harnesses containing coax or triax, or harnesses

with trunk ½ inch or greater in diameter, or breakout ½ inch or greater in
diameter. Twisting may also be required for other harnesses as indicated by
notation on the harness parts list, harness assembly drawing, the harness
fabrication tool, or Production Outsourcing Information Sheet.

6
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.1.6.4 Direction of twist should be established on a case-by-case basis throughout the

harness (in some cases it is not possible to have all branches twisted in the
same direction) the preferred direction is a left-hand lay. Harnesses or harness
breakouts with diameters of ½ inch or less should contain approximately two
twists per 12 inches of harness. Harnesses or harness breakouts with
diameters of more than ½ inch should contain a minimum of one twist per 12
inches of harness. Care should be taken to avoid over-stressing of the wires
during twisting, and at breakouts.

3.2 Wire/Cable/Harness Identification

Information in this Section to be used for Harness Identification System (H.I.S.)
Data.

3.2.1 Wire/Cable Identifier Number

3.2.1.1 Typical Wire/Cable number as appears in a WL:

W609-284-22-2

W---------Wire Harness Class Letter

609--------Wire Harness Number Identifier
284--------Wire Identifier
22----------Wire Gauge (AWG)
2------------Number of Conductor in Multi-conductor cable*

*In multi-conductor cables, conductor No. 1 may or may not have a number
marked; all others have the number or colored bands depicting the number.

TYPICAL WIRE IDENTIFIER

284

NOTE: ARROWHEAD DEPICTS FIRST NO.

0.3
0.75

Figure 3.2.1-1 Typical Wire Identifier

(P5382-X-X, or M23053/5-XXX may be used)

7
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.2.1.2 The ―Wire Identifier‖ number shall be printed on a piece of heat shrinkable
tubing ** per FPS-1002 and FPS-3008 and placed on each wire/cable end.
P5382-X-X is the preferred part.

**If colored heat shrinkable tubing is used, then the numerical value of the
identification tubing color depicts the last number of the wire identifier. In
Figure 3.2.1-1 the tubing color would be yellow because the last number of
the Typical Wire Identifier is 4. (The numerical value of yellow is 4) in Table
3.2.1-1 below.

Table 3.2.1-1 Shrink Tube Color to Numeric Value Cross-Reference

COLOR NUMERICAL
VALUE
BLACK 0
BROWN 1
RED 2
ORANGE 3
YELLOW 4
GREEN 5
BLUE 6
VIOLET 7
GRAY 8
WHITE 9

3.2.1.3 Wires (jumpers) three inches or less in length need not be identified.

3.2.1.4 Colored shrink tubing may be used to identify individual conductors in a multi-
conductor wire/cable when the existing conductor identifier code is not visible.

3.2.1.5 Individual conductors in a multi-conductor cable shall NOT be identified with a

wire number.

3.2.2 Installation of the Wire/Cable Identifier.

3.2.2.1 At Connectors: The identifiers shall be located as close as practical to the back
of the sealing grommet of the connector and under the expandable braided
sleeving (C8844-X). Wire identifiers may touch the grommet to allow proper
staggering when there are many wires. The wire identifier may NOT be used
for grommet sealing as described in Paragraph 3.4.7.2, and never located
under the cloth braid.

8
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.2.2.2 At Terminals, Grounding Blocks, Relay Sockets, etc: The identifiers shall be
located as close to the device as possible, but not to exceed 4 inches from the
device.

3.2.2.2.1 Harnesses which have wires to be terminated at the next assembly level
(excluding round, rectangular, and wafer connectors) should have
identification on heat shrinkable M23053 tubing on each wire adjacent to
termination hardware. The identification to be used shown in PSL column of
harness wire list.

3.2.2.3 Panel Harnesses: On short wires (4 to 12 inches in length) only one identifier is
required. It should be placed in the most visible location.

3.2.2.4 Shrinking the identifiers in place. Before performing the shrinking operation,
identifiers should be ―staggered‖ within the identifier area to minimize bundle
size. The identification tubing may be shrunk in place by one of the following
methods:

a) Using an approved heat gun.

b) Placing in an oven pre-heated in excess of 100 degrees Centigrade (212
degrees Fahrenheit), for approximately three minutes.

3.2.2.5 Wire marker bands are to be installed if the last laser-marked wire identifier is
not visible after the harness is braided.

3.2.3 Selection of Heat Shrinkable Tubing for Wire/Cable

3.2.3.1 The following list contains suggested tubing sizes. It is permissible to use
other sizes providing there is some resistance to moving the tubing after
shrinking.

3.2.3.2 It is permissible to use all white tubing in lieu of colored providing only white is
used at any given end point.

3.2.3.3 For tubing sizes larger than P5382-5, it is permissible to use black tubing with
white letters.

9
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

Table 3.2.3-1 Suggested Tubing Sizes

*Refer to Table 3.2.1-1 for applicable color dash number.
WIRE TUBING PART
PART NO. P5382-( )-* M23053/5-1XX-*
C4928-26 -1 -102
C4928-22 -1 -102
C4928-20 -1 -102
C4929-26 -1 -102
C4929-22 -1 -102
C4929-20 -1 -102
C4929-18 -2 -103
C4929-12 -3 -104
C4930-26-1P -3 -104
C4931-26L1 -3 -104
C4931-26L2 -3 -104
C4931-26L3 -3 -104
C4931-26L4 -3 -104
C4931-26L5 -106
C4931-26L7 -106
C4931-22L1 -2 -103
C4931-22L2 -4 -105
C4931-22L3 -4 -105
C4931-22L4 -4 -105
C4931-22L5 -106
C4931-22L7 -106
C4931-20L1 -3 -104
C4931-20L2 -4 -105
C4931-20L3 -4 -105
C4931-18N1 -4 -105
C4931-18N2 -4 -105
C4931-18N3 -4 -105
C4931-18N4 -5 -105
C4932-26L2 -2 -103
C4932-26L3 -2 -103
C4932-26L4 -3 -104
C4932-26L5 -3 -104
C4932-26L7 -3 -104
C4932-26N2 -103
C4932-26N3 -103
C4932-26N4 -104
C4932-26N5 -104
C4932-26N7 -106
C4932--22N2 -106
C4932-22N3 -104
C4932-20N3 -106
C4932-20N4 -106
C4933-18P2 -4 -105
C4933-18P3 -4 -105
C4933-18P4 -4 -105
C4933-12P2 -5 -106
C4933-12P3 -5 -106
C4933-12P4 -5 -106
C4939-22CA -5 -106

10
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.2.4 Wire Gauge Color Code:

3.2.4.1 Colored electrical wire that is color coded by gauge size, will be shown in the
table below, with the exception of the wires covered in Paragraph 3.2.4.2 and
laser marked wires:

Table 3.2.4-1 Wire Gauge Color Code Cross-Reference

WIRE GAUGE COLOR

26 BLACK
22 GREEN
20 RED
18 WHITE
12 YELLOW

3.2.4.2 The following wires utilize special color coding to identify individual wires as
follows:
Table 3.2.4-2 Special Wire Color Codes

PART CONDUCTOR CONDUCTOR CONDUCTOR CONDUCTOR

NUMBER NUMBER 1 NUMBER 2 NUMBER 3 NUMBER 4

C4930 WHITE VIOLET

C10989 WHITE BLUE N/A N/A

GREEN WHITE
C4939
(alumel) (chromel)

C20714 RED RED/BLACK BLUE BLUE/BLACK

11
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

3.2.5 Identification of Wiring Harness Assemblies

3.2.5.1 A piece (1.5 inches – 3.0 inches) of shrink tubing (M23053/5-XXX-X) or tape
(P5269) shall be used to identify the Harness Assembly.

M23053/5-1 XX-X

BASIC PART NUMBER

CLASS

SIZE IDENTIFIER

COLOR CODE

Figure 3.2.5-1 Shrink Tubing Part Number Breakdown

3.2.5.2 White shrink tubing M23053/5-XXX-9 with black ink shall be used for trunk
harness identification, and point to point harnesses. Tubing to be shrunk
securely onto harness. White tape part number P5374 or P5431 or P5269 with
P5393 applied over it, may be used for panel harness identification or for trunk
harness rework identification. Reference Paragraph 3.7.9 for Panels and
Matrices.

3.2.5.3 The number shall be printed with contrasting ink and with a character size of 6
or 12 points.

3.2.5.4 The following information should be represented on the harness identifier

tubing.

81755 / H16DW222-01 FOF

XXXXXXXXXX
XXXXXXX

CODE IDENTIFCATION

Figure 3.2.5-2 Typical Production and Synthetic Wire Harness Identifier

12
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

81755 / H16DW222A01 FOF

XXXXXXXXXX
XXXXXXX
MANUFACURER ID
optional unless required
CODE IDENTIFCATION WIRING HARNESS NUMBER
(i.e., POIS/ADAP/PODS P/N)

MFG DATE UNIQUE TRACKING NUMBER

Figure 3.2.5-3 Typical Synthetic Wire Harness Identifier *

* Harness number to be stamped on P5269 tape. To insure visibility after
installation, harness number to be stamped multiple times, equally spaced.

H16DW222

Figure 3.2.5-4 Typical Loose Wire Assembly (LWA) Identifier **

** Harness number to be stamped on P5269 tape. To insure visibility after
installation, harness number to be stamped end to end, with ¼‖ spacing.

3.2.5.5 The wire harness assembly identifier should be located (positioned), as

indicated on the HRBD or the HAD. The harness identifier symbol on the
HRBD or the HAD represents the center location +/- .5 inch of the identifier.

3.2.5.6 At each termination, one piece of heat shrinkable tubing (M23053/5-XXX-0) or

a suitable tape will be used to identify the termination reference designator
number. (The tape must meet or exceed the requirement of P5269.) The
numbers should be stamped in contrasting colored ink, using 6-12 point
characters. Tubing to be shrunk securely onto harness, centered over the area
designated by the ref/des symbol, reference paragraph 3.7.9.7 for reference
designator used on panel harness. Flag-type reference designators which have
tabs protruding are prohibited.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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WIRING HARNESS ―W‖

NUMBER
CONNECTOR ―REFERENCE
DESIGNATION NUMBER

1.0
3.0

Figure 3.2.5-5 Typical Reference Designator Identifier

NOTE: The wiring harness ―W‖ number, connector reference designation, and
mating connector numbers may be on the same line. A dash or slash shall be
between the ―W‖ number and the connector number.

3.2.5.7 The reference designator identification tubing may be used to terminate the
expandable braided sleeving or the convoluted tubing. On pre-braided 18- and
12-AWG cables, the identifier shall be used as the braid terminator (P5381-X is
preferred), or as determined on the HRBD. Tubing to be shrunk securely onto
harness.

3.2.5.8 Hand marking of one character with permanent ink is permitted, but the
character must be legible and similar to stamped characters. Reworked
harnesses may have dash number hand marked per 5.2.5.1.

3.2.5.9 Additional lines of markings such as manufacturer identification may be added

for manufacturing and quality assurance purposes but must be clearly
separated from engineering required markings.

3.2.5.10 The reference designator identification tubing should be located (positioned) as

indicated on the HRBD or the HAD. The reference designator identification
symbol on the HRBD or the HAD represents the center location +/- .5 inch of
the identifier.

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3.2.5.11 When two or more 16VE049 or C8916 connectors are stacked together at the
same location, the reference designator label for each connector shall be
located between the connector stack breakout location and the connector. (A
general guide would be to center the reference designator between the two
noted points, unless otherwise noted on the drawing). When two or more
16VE049 or C8916 connectors are stacked together at the same location, the
listed order of the reference designators on the HRBD or HAD, from top to
bottom, is the stacking order for manufacturing.

3.2.6 Labeling Wire Insulation Using Laser Marking Equipment

3.2.6.1 General

3.2.6.1.1 Laser marking shall be used only on wire with polytetrafluoroethylene/

polyimide insulation (TKT), color white, such as MIL-W-22759/86.

3.2.6.1.2 Color coding of insulation by wire gauge shall not be used for laser marked
wires.

3.2.6.1.3 Marking shall be per FPS-1002 and FPS-3008 except as specified in this
document.

3.2.6.1.4 Short wires and cables less than six inches (6.00") in length need not be
identified in the aircraft, but shall be completely identified on the drawing.

3.2.6.1.5 All lettering shall be upper case. All numerals shall be in ―Arabic‖. Roman
Numerals will not be used.

3.2.6.2 Marking Requirements

3.2.6.2.1 Identification marking shall be printed in either of the following modes.

a) Horizontal - left to right. THIS IS PREFERRED. The example is shown
in Figure 3.2.6-1a, below.
b) Vertical - Top to bottom. The example is shown in Figure 3.2.6-1b, below.

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Figure 3.2.6-1 Examples of Horizontal and Vertical Wire Identification

3.2.6.2.2 Wires shall be Laser-marked with the wire number as listed in LM AERO Co.
engineering documentation (reference FPS-1002 and FPS-3008).

3.2.6.2.3 Where practical, all wires in a harness shall have the markings run such that
they can be read from same direction, horizontal and vertical can be mixed in
one bundle.

3.2.6.2.4 Where practical, the harness wire number shall run the same direction as the
wire part number printed on by the wire manufacturer.

3.2.6.2.5 Where practical, start the wire numbers such that they fall in between the wire
part number to prevent overlapping of the marks.

3.2.6.2.6 See Figure 3.2.6-2 for an example of a wire number and a wire number build-
up.

W 6 2 4-0 2 1-2 6

WIRE GAUGE (AWG)

WIRE NUMBER IN HARNESS

HARNESS IDENTIFICATION

Figure 3.2.6-2 Example of Laser Wire Marking and Information to be Laser

Marked onto Wire Jacket

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.2.6.2.7 For horizontal marking, the typeface height is the actual height of the letter,
where, as for vertical marking, the typeface height is the width of a letter.
Actual height may vary (See Figure 3.2.6-3). The typeface requirements for
size are specified in Table 3.2.6.1.

Figure 3.2.6-3 Typeface Heights for Horizontal and Vertical Marking

Table 3.2.6-1 Insulation Diameter, Type Face Size and Reading Direction
INSULATION MINIMUM HEIGHT READING
DIAMETER OF TYPEFACE DIRECTION

0.030 to 0.038 0.015 VERTICAL

0.039 to 0.048 0.02 VERTICAL
0.049 to 0.060 0.025 VERTICAL
0.061 to 0.090 0.025/0.031 VERTICAL or
HORIZONTAL
0.091 to 0.122 0.031/0.046 HORIZONTAL
0.123 to 0.154 0.046 HORIZONTAL
0.155 to 0.185 0.062 HORIZONTAL
0.186 to 0.248 0.078 HORIZONTAL
0.249 to 0.310 0.09 HORIZONTAL
0.311 to 0.374 0.093/0.125 HORIZONTAL
0.375 to 0.436 0.125 HORIZONTAL
0437 to 0.498 0.125 HORIZONTAL
0.499 to 0.560 0.125 HORIZONTAL
0.561 to 1.000 0.125 HORIZONTAL
OVER 1.000 0.187 HORIZONTAL

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3.2.6.2.8 Individual wires shall have identification markings with spacing of not more
than three inches (3.0 inches) or less than two inches (2.0 inches) between
consecutive markings along the entire length of the wire as shown in Figure
3.2.6-4.

Figure 3.2.6-4 Maximum Distance Between Identification Markings

3.3 Harness Lacing Tape (String Tie)

3.3.1 General Requirements

3.3.1.1 P5289 or approved equivalent is the required material. This material is

commonly referred to as ―string tie‖.

3.3.2 String Tie Areas:

a) Trunk Harnesses – As required to maintain the configuration of the harness

or in areas specified on the HRBD or on the HAD.
b) Panel Harnesses – As required to maintain the configuration of the harness.

3.3.2.1 String ties – should be tight enough to secure the bundle, but should not
degrade the intended electrical performance of the harness/cable.

3.3.2.2 Knots – For preferred tying knots see Figures 4.2.1-3 and 4.2.1-4.

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3.4 Terminations

3.4.1 General Wire Preparation

3.4.1.1 Wire being prepared for termination must first be cut to ―cut length‖. Cut length
is defined as the ―terminated length‖ plus 6-12 inches. Terminated length is the
length of the wire including the terminating device.

3.4.1.2 The wire end must first be prepared for the type of termination that is called out
by the engineering. The end of the conductor must be cut even. In most cases
the wire insulation must be stripped away from the actual electrical conductor.
This is to be accomplished using an approved stripping tool. The approved
tool can be found listed in the Authorized Tool List document MTPA 002, or in
the applicable Military Specification.

3.4.1.3 Strip lengths will vary according to the device being terminated to and the
receptacle that the wire will have to terminate into. These strip lengths are
defined by the terminating device.

3.4.1.4 After stripping the insulation away from the conductor, the conductor must first
be inspected by the assembly person for nicked or otherwise damaged strands
of the conductor. For the applicable accept/reject criterion see FZM-8027.

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3.4.2 Contacts (See Appendix for associated Fab Aid)

3.4.2.1 Crimp Style Contacts (See Appendix for associated Fab Aid)
a) M39029/4 (see Fab Aid A1)
b) M39029/5 (see Fab Aid A2)
c) M39029/9 (see Fab Aid A3)
d) M39029/10 (see Fab Aid A4)
e) M39029/16 (see Fab Aid A5)
f) M39029/17 (see Fab Aid A6)
g) M39029/18 (see Fab Aid A7)
h) M39029/22 (see Fab Aid A8)
i) M39029/27 (see Fab Aid A9)
j) M39029/28 (see Fab Aid A10)
k) M39029/29 (see Fab Aid A11)
l) M39029/30 (see Fab Aid A12)
m) M39029/31 (see Fab Aid A13)
n) M39029/32 (see Fab Aid A14)
o) M39029/56 (see Fab Aid A15)
p) M39029/58 (see Fab Aid A16)
q) M39029/59 (see Fab Aid A115)
r) M39029/60 (see Fab Aid A116)
s) M39029/75 (see Fab Aid A128)
t) M39029/76 (see Fab Aid A129)
u) M39029/77 (see Fab Aid A130)
v) M39029/78 (see Fab Aid A131)
w) M39029/90 (see Fab Aid A132)
x) M39029/91 (see Fab Aid A17)
y) M39029/101 (see Fab Aid A18)
z) M39029/103-559 (see Fab Aid A19)
aa) M39029/103-560 (see Fab Aid A20)
bb) C10751-4 (see Fab Aid A21)
cc) C10753-X (see Fab Aid A117)
dd) C10970-1 (see Fab Aid A22)
ee) C10994-3 (see Fab Aid A23)
ff) C2063-56 (see Fab Aid A24)
gg) C2063-57 (see Fab Aid A25)
hh) C20857-1 (see Fab Aid A135)
ii) C20858-1 (see Fab Aid A136)
jj) C20895-1 (see Fab Aid A137)
kk) C20896-1 (see Fab Aid A138)
ll) C4870-12-12 (see Fab Aid A26)
mm) C4870-12-16 (see Fab Aid A27)

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3.4.2.2 Solder Style Contacts (See Appendix for associated Fab Aid)
a) M39029-73 (see Fab Aid A30)
b) M39029-74 (see Fab Aid A31)
c) M39029/103-559 (see Fab Aid A145)
d) C11788-1 (see Fab Aid A32)
e) C11788-2 (see Fab Aid A33)
f) C11788-3 (see Fab Aid A34)
g) C11788-4 (see Fab Aid A35)
h) C11788-5, -6 (see Fab Aid A36)
i) C11788-8 (see Fab Aid A120)
j) C11788-9 (see Fab Aid A121)

3.4.3 TERMINAL Lugs (See Appendix for associated Fab Aid)

a) C10984 (see Fab Aid A110)
b) C8950-1 (see Fab Aid A111)
c) C8950-2 (see Fab Aid A112)
d) M7928/1C (see Fab Aid A113)

3.4.4 SPLICES (See Appendix for associated Fab Aid)

a) C4812-XX (see Fab Aid A37)
b) C4813 (see Fab Aid A38)

3.4.4.1 Solder Splices (See Appendix for Associated Fab Aid)

a) C20773-4 (see Fab Aid A126)

3.4.5 Connectors

3.4.5.1 Round Connectors (See Appendix for Associated Fab Aid)

a) AN3116 (see Fab Aid A39)
b) C10959 (Fab Aid not available)
c) C10960 (Fab Aid not available)
d) C11603 (Fab Aid not available)
e) M26482 (see Fab Aid A41)
f) M38999 (see Fab Aid A42)
g) M5015 (see Fab Aid A43)
h) M81511 (see Fab Aid A44)
i) M83723 (see Fab Aid A45)

3.4.5.2 Rectangular Connectors (See Appendix for associated Fab Aid)

a) C10937 (see Fab Aid A46)
b) C8807 (see Fab Aid A47)
c) M83733 (see Fab Aid A48)
d) C8916 (see Fab Aid A114)

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3.4.5.3 Coax Connectors (See Appendix for associated Fab Aid)

3.4.5.3.1 General Coax Connector Assembly Instructions: (See Fab Aid A119)

3.4.5.3.2 Special Coax Connector Assembly Instructions:

a) C8804-8 (see Fab Aid A49)
b) C8804-9 (see Fab Aid A50)
c) C8804-12 (see Fab Aid A139)
d) C8814 (see Fab Aid A51)
e) C8825-1-1 (see Fab Aid A52)
f) C8825-1-2 (see Fab Aid A53)
g) C8825-1-3 (see Fab Aid A54)
h) C8825-1-4 (see Fab Aid A55)
i) C8825-2-1 (see Fab Aid A56)
j) C8825-2-3 (see Fab Aid A57)
k) C8825-2-4 (see Fab Aid A140)
l) C8825-3-1 (see Fab Aid A141)
m) C8825-4-1 (see Fab Aid A58)
n) C8826 (see Fab Aid A59)
o) C8827 (see Fab Aid A60)
p) C8828 (see Fab Aid A61)
q) C8828-2-1 (see Fab Aid A122)
j) C8830-1 (see Fab Aid A62)
k) C8830-2 (see Fab Aid A63)
l) C8831-2 (see Fab Aid A40)
r) C8838 (see Fab Aid A64)
s) C8952-1-2 (see Fab Aid A65)
t) C8952-1-3 (see Fab Aid A66)
u) C8952-1-5 (see Fab Aid A147
v) C8918-1 (see Fab Aid A67)
w) C8918-2 (see Fab Aid A68)
x) C8918-3 (see Fab Aid A69)
y) C10980-3/-4 (see Fab Aid A118)
z) M25516 (see Fab Aid A70)
aa) M39012 (see Fab Aid A71)

3.4.5.4 Wafer Connectors (See Appendix for associated Fab Aid)

a) 16VE049 (see Fab Aid A72)
b) C20783 (see Fab Aid A125)

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3.4.5.5 Special Connectors (See Appendix for associated Fab Aid)

a) 8340709-1P (see Fab Aid A28)
b) 8340709-1S (see Fab Aid A29)
c) 16VE141 (see Fab Aid A127)
d) 16VH019-2 (see Fab Aid A73)
e) C20274-1 (see Fab Aid A74)
f) C20348 (see Fab Aid A124)
g) C8832-2 (see Fab Aid A123)
h) C9718-1 & -2 (see Fab Aid A133)
i) C9718-3 & -4 (see Fab Aid A134)
j) M9177/3-1 (see Fab Aid A75)
k) C10575-1 (see Fab Aid A76)
l) C192 (see Fab Aid A77)
m) C192-3 (see Fab Aid A78)
n) C193 (see Fab Aid A79)
o) MS90335 (Fab Aid not available)

3.4.6 TERMINATING Devices (See Appendix for associated Fab Aid)

a) C10961 Audio Transformer (Fab Aid not available)
b) C10995 Power Transformer (Fab Aid not available)
c) C20777 Backshell (see Fab Aid A143)
d) C20778-1 & -3 Ferrules (see Fab Aid A144)
e) C4870 Relay (see Fab Aid A80)
f) C4870-2 Relay (See Fab Aid A80)
g) C4934-2 Relay (see Fab Aid A81)
h) C4934-4 Relay (see Fab Aid A82)
i) C4935-1 Relay (see Fab Aid A83)
j) C4936-1 Relay Track (see Fab Aid A84)
k) C4937-2 Relay Track Mounted (see Fab Aid A85)
l) C4937-3 Relay Track Mounted (see Fab Aid A86)
m) C4937-4 Relay Track Mounted (see Fab Aid A87)
n) C4940-1-1 Timing Module, Relay Driver (see Fab Aid A88)
o) C4940-1-2 Timing Module, Relay Driver (see Fab Aid A89)
p) C4940-1-3 Timing Module, Relay Driver (see Fab Aid A90)
q) C4940-2-1 Timing Module, Relay Driver (see Fab Aid A91)
r) C4940-3-1 Timing Module, Relay Driver (see Fab Aid A92)
s) C8817 Relay (see Fab Aid A93)
t) C8839 Transformer (Fab Aid not available)
u) C8839-3 Transformer (Fab Aid not available)
v) C8839-4 Transformer (Fab Aid not available)
w) C8855 Bus Bar, Flexible (see Fab Aid A94)
x) C8856 Relay Socket (Fab Aid not available)
y) M6106/21-003 Relay (see Fab Aid A95)

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z) M6106/22-003 Relay (see Fab Aid A96)

aa) M6106/23-001 Relay (see Fab Aid A97)
bb) M6106/23-002 Relay (see Fab Aid A98)
cc) M6106/23-003 Relay (see Fab Aid A99)
dd) M6106/24-003 Relay (see Fab Aid A100)
ee) M6106/25-002 Relay (see Fab Aid A101)
ff) M83726/24-0103 Relay Driver (see Fab Aid A102)
gg) M83726/24-0303 Relay Driver (see Fab Aid A103)
hh) M83726/24-1803 Relay Driver (see Fab Aid A104)
ii) M83726/25 Relay Driver (see Fab Aid A105)
jj) MS24523 Toggle Switch (Fab Aid not available)
kk) MS27212 Terminal Strip (see Fab Aid A106)
ll) MS27400 Relay (see Fab Aid A107)
mm) MS27401 Relay (see Fab Aid A108)
nn) MS27745-5 Relay (see Fab Aid A109)

3.4.7 Connector Sealing Crimp and Solder Contact Types

3.4.7.1 For spare contacts, insert both contacts and sealing plugs in all unused contact
cavities except for the following devices, where only the sealing plug will be
installed.

MS24236 (Interphone Ampl. Conn.)

MS83733 (185 contacts only)
MIL-C-38999 type connectors (MS27XXX Series), D38999/( ),
M12883/40-( ), M12883/48-( ), M12883/52-( ), M81714/60-( ), P954-( )
M81511, C8944-10-4, C8944-2X, C12444-X, C20764- ( ),
C10959- ( ), C10960
C8916, C2063, C2064, C10937- ( ), C8856- ( ), M6106/23-( ),
M83723/65H, C8806- ( ), C11603- ( )
C8807-5, C8829- ( ), C8713- ( ), C4870- ( ), C8831-2, C10754-X, C8889-1

NOTE: In all type connectors having 12-AWG, 16-AWG and 22-AWG contact
cavities, insert a sealing plug ONLY in the 12-AWG, 16-AWG and 22-
AWG cavities.

3.4.7.2 For all wires with diameters below the minimum sealing capability of connector
grommet as specified in the following table, the wire diameter shall be
increased by the application of a 0.6-1.0 inch long piece of heat shrinkable
tubing (M23053/5-X, C4804-X, or P5034-X-X or P5382).

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HOW TO USE TABLE

Select wire gauge and go across until you find the connector contact size. The
number listed at that point is the number of pieces of heat-shrinkable
(M23053/5 or equivalent) tubing required to seal the connector.

Table 3.4.7-1 Tubing Requirements

WIRE CONTACT SIZE

GAUGE 22 20 16 12 10 8
D
26 0 1* 2 3 N/A N/A
22 0 0* 1 2 N/A N/A
20 N/A 0 1 2 N/A N/A
18 N/A 0 1 1 N/A N/A
12 N/A N/A N/A 0 N/A N/A
10 N/A N/A N/A N/A 0 6**
* For MS3110, MS3116 or C20883 solder type connectors with size 20 contacts, two
pieces of tubing are required for 26-gauge wire and one piece of tubing for 22-gauge
wire.
** To allow for rework, only use 6 pieces of heat-shrinkable (M23053/5 or equivalent)
tubing. To completely seal connector and to allow for NO rework, use 7 pieces of heat-
shrinkable (M23053/5 or equivalent) tubing.

3.4.7.3 Installation of sealing plug. When installing sealing plugs in connector or

module grommets, the head of the sealing plug shall be inserted first per
Fabrication Aid for MS27488 (see Fab Aid A142). The sealing plug shall then
be pushed into the grommet until the head is positioned against the end of the
unwired contact or just past the sealing rings of the grommet and shall not be
inserted past the contact locks. After placement and during the connector build
up, the portion of the sealing plug that protrudes outside the grommet shall be
inspected to ensure that it is not deforming due to interference with another
part to cause a gap between the sealing plug and grommet. If a gap is being
introduced then the plug can be trimmed as needed to eliminate the
interference as needed or to no less than 0.1 inches above the grommet face.
Contact installation tools listed in Table 3.4.7-4 below may be used for
installing the sealing plugs. The use of tools for sealing plugs size 12 and
smaller will aid in the installation by supporting the plug during head first
insertion. The tool rides against the shoulder on the back of the plug head
during insertion. The tools will not remove the sealing plugs. Plugs must be
removed by grasping tail end of the plug that is left protruding outside the
grommet. Contact insertion tools are not recommended for sealing plugs size
8 and larger.

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Figure 3.4.7-1 Typical Sealing Plug

Table 3.4.7-2 Crimp Type Connectors

Connector Sealing Grommet Diameter (Min/Max) vs. Wire Diameter (Min/Max)

CONTACT MIL-C- MIL-C- MIL-C- MIL-C- WIRE M81381 M22759/11 CIR

SIZE 005015 83723 83733 38999 AWG. (AIR FRAME) (HOOK UP) MIL.
- - - - - 26 0.031/0.034 0.036/.040 304
22D - - 0.030/0.060 0.030/0.054 24 0.034/0.037 0.041/0.045 475
22 - - - 0.034/0.060 22 0.041/0.044 0.047/0.051 754
20 - 0.040/0.083 0.040/0.083 0.040/0.083 20 0.049/0.052 0.056/0.060 1216
16 0.053/0.103 0.053/0.103 0.063/0.103 0.0651/0.109 18 0.063/0.067 0.066/0.070 1900
12 0.085/0.158 0.097/0.158 0.081/0.158 0.097/0.142 12 0.100/0.105 0.108/0.114 5874

Table 3.4.7-3 Solder Type Connectors

CONTACT SIZE MIL-C-26482

20 0.060/0.085
16 0.066/0.109
12 0.097/0.142

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Table 3.4.7-4 Sealing Plug Installation Tools

Sealing plug Tool Part Number
MS27488-22-X M81969/14-01
MS27488-20-X M81969/14-11
MS27488-16-X M81969/14-03
MS27488-12-X M81969/14-04

3.4.8 Connector Sealing Boots

3.4.8.1 Assembly Procedure - C2023, C2086, C1472, C1473, and C4020

C2023-2-( ) RIGHT ANGLE
BOOT AS SUPPLIED

HARNESS

3.4.8.1.1 Slide a boot over the harness and position as shown. Using an approved tool,
shrink the front section of the boot first allowing boot to grip the connector.

3.4.8.1.2 Then, slowly apply heat to the rest of the boot working from the connector to
the other end. Hold the harness in a right angle position until the boot has
cooled.

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3.4.8.1.3 All other procedures are the same as for a straight boot. Rework can be
accomplished without removing a connector.

COMPLETED
ASSEMBLY

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3.4.8.1.4 Slide a boot over the harness and position the connector as shown.
C2023-2-( ) RIGHT ANGLE
B O O T A S S U P P L IE D

HARNESS

3.4.8.1.5 Heat the boot with an approved tool until the boot conforms to the connector
and harness.

3.4.8.2 Adhesive - If an adhesive is specified, coat the front and back inside surface of
boot and the back of connector with the specified adhesive and proceed as
above. Remove any excess adhesive with an approved cleaning agent.

3.4.8.3 Rework - If rework of a harness is required, a boot can be removed and

replaced. Using a knife, split the boot and remove it. After the necessary
rework has been accomplished, slide a new boot over the installed connector
and proceed as illustrated above.

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3.4.8.3.1 Splicing procedure for convoluted tubing, C2026-X-X.

EXCESSIVE ADHESIVE
IN THIS AREA 1" MAX
(2 PLACES)
PERMISSIBLE AFTER BUTT TUBING AT SPLICE AND WRAP WITH
HEAT SHRINK P5372 TAPE BEFORE SHRINKING
(2 PLACES)

C2026 TUBING C2026 TUBING

3" MAX

P5381 TUBING WRAP WITH P5436-20-100 ADHESIVE

BEFORE SHRINKING P5381 TUBING
(2 PLACES)

3.4.8.3.2 Water Proofing Electrical Connectors – The purpose of this procedure is to

prevent entry of water (liquids) into the back of electrical connectors.

3.4.8.3.2.1 Connectors to be sealed with C10979-1 through -6 sleeves.

3.4.8.3.2.2 Measure 3 inches for the 20 shell size connector and 2.5 inches for the 14
shell size connector from the front of the backshell coupling ring. Place a slit
adhesive sleeve over each wire flush with the 3 inch or 2.5 inch dimension,
depending on connector shell size. Place a 1.0 to 1.25 inch long piece of
C2070-22 shrink tubing over the wires and adhesive sleeves.

3.4.8.3.2.3 With the connector pointing down, apply heat to shrink tubing, and slit
adhesive sleeves until sleeves have melted, and the tubing has
recovered. To accelerate melting the adhesive sleeves, it is desirable to work
the bundle during the heating operation. The operator should wear gloves
and every 5–10 minutes work the bundle between thumb and index finger. If
a ―Mini Gun 3‖ is an approved tool, it is not to be used on the aircraft under
any circumstances. Leave 0.13 to 0.24 inch between boot and reference
designator shrink tubing. Then cover exposed wires with expandable
braided sleeving (C8844-X).

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.8.3.2.4 Remove the strain relief bars and screws. Position boot over the backshell
coupling ring. Apply heat to the boot; guide the lip over forward edge of the
coupling ring; continue applying heat until the boot has recovered. The boot
should bridge the coupling ring to approximately the mid-point of the C2070
shrink tubing.

3.4.8.3.2.5 Connectors to be sealed with C10979-20 through -50 sleeves. This

procedure is preferred because of the low-temperature meltable sleeves.

3.4.8.3.2.6 Measure 3 inches for the 20 shell size connector and 2.5 inches for the 14
shell size connector form the front of the backshell coupling ring. Place a slit
adhesive sleeve over each wire flush with the 3 inch or 2.5 inch dimension,
depending on connector shell size. Wrap 2 turns of P5476-1 tape over the
sleeve assembly. Place a 2.0 to 2.25 inch long piece of C2070 shrink tubing
over the wires and adhesive sleeves (-20N for J235 and J239, -22N for J236
and J237).

3.4.8.3.2.7 With the connector pointing down, apply heat to the shrink tubing, and slit
adhesive sleeves until sleeves have melted, and the tubing has recovered.
To accelerate melting the adhesive sleeves, it is desirable to work the bundle
during the heating operation. The operator should wear gloves and every 5-
10 minutes work the bundle between the thumb and index finger. If a ―Mini
Gun 3‖ is an approved tool, it is not to be used on the aircraft under any
circumstances. Do not shrink reference designator shrink tubing over boot;
leave 0.13 to 0.25 inch between boot and tubing. Cover exposed wires with
expandable braided sleeving (C8844-X).

3.4.8.3.2.8 Remove the strain relief bars and screws. Apply one wrap of P5476-1 tape
around the connector/backshell area. Apply one wrap of tape around the
tubing. Position boot over the backshell coupling ring and connector up to
the flange. Apply heat to the boot; guide lip over forward edge of the
coupling ring; continue applying heat until the boot has recovered. The boot
should bridge the coupling ring to approximately the mid-point of the C2070
shrink tubing.

3.4.8.3.2.9 An alternative method of moisture proofing a connector is to install

convoluted tubing from the connector backshell and extend the tubing into a
dry area of the aircraft. The convoluted tubing shall extend into the dry area
a minimum of 12‖. Terminate the convoluted tubing at the connector using
P5381 shrink tubing or a C2023 shrink boot as described in this section. The
convoluted tubing shall be terminated in the dry area by using P5381 shrink
tubing.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.8.4 C2086-4-(X).

3.4.8.4.1 The area shown on back of the connector should be sanded lightly, and then
cleaned with an approved cleaning agent prior to installation of the adapter.
C2086-4-(X)
CONNECTOR ADAPTER

THIS AREA OF THE CONNECTOR

SHOULD BE SANDED LIGHTLY
AND THEN CLEANED WITH AN
APPROVED CLEANING AGENT.

3.4.8.4.2 Apply P6011 adhesive to sanded area of the connector. Slide an adapter over
the connector until the inside shoulder of adapter fits against the back of
connector. Shrink in place using an approved heating tool.

3.4.8.5 C2086-5-(X).

3.4.8.5.1 Using an approved cleaning agent, clean the area of adapter where the
adhesive is to be applied. When that area is completely dry, apply P6011
adhesive in the area shown.
C2086-5-(X) CONDUIT ADAPTER SLEEVE

APPLY P6011 ADHESIVE IN THIS AREA

C2026-(X)-(X) TUBING
CLEAN THIS AREA OF BOTH THE
ADAPTER AND THE INSIDE OF THE
TUBING WITH AN APPROVED CLEANING
AGENT PRIOR TO USE OF ADHESIVE.

3.4.8.5.2 Slide the adapter into convoluted tubing until the tubing bottoms on adapter
shoulder.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9 Shield Termination

3.4.9.1 General Considerations:

3.4.9.1.1 Shield terminations and shield dead ends should be as close to the end of the
wires as possible. Shield ground wires should be as short as possible and
never longer than six inches. Shields should be terminated with a solder
sleeve (no window or dead end) where possible. The 1.5 to 3.0 inch distances
between a solder sleeve and shield dead end should be maintained where
possible, see Figure 3.4.9-1. C2099 black and white leads should be as short
as possible, see Figure 3.4.9-12 and Figure 3.4.9-14.

3.4.9.2 Non EMI backshells with shield termination.

3.4.9.2.1 At connectors with a non-EMI Backshell where one or more shields are
terminated, the shields shall be terminated by means of a solder sleeve, a
short piece of 22-AWG wire, and a terminal lug or contact (as specified on the
engineering drawing). Engineering prefers to terminate the shield with a
solder sleeve, and not use a window and dead end. However, the window
application is acceptable if the 2.3 inch dimension cannot be maintained. To
dead end a shield, fold it back over the outer jacket and shrink a piece of
M23053/5-XXX-X shrink tubing over it.
M23053/5-1XX-X WITH SOLDER SLEEVE
AT WINDOW LOCATION.
WINDOW WHEN REQUIRED
SOLDER SLEEVE WHEN 2.3 DIMENSION
CAN BE MAINTAINED

* SOLDER SLEEVE WHEN 2 3. MAX

2.3 MAX 1.5/3.0 0.2/0.3
DIMENSION CANNOT BE MAINTAINED
* PREFERRED FOR -300 AND ON HARNESSES, 0.5 / 3.0 FOR PRIOR HARNESSES

Figure 3.4.9-1 Wire Strip Lengths – Non EMI Backshell Shield Terminations
a) Prepare the cable to the dimensions shown, taking care not to nick the
conductor or shield braid strands.

NOTE: The size of a solder sleeve may be varied one size at installation
providing the maximum Circular Mill (CM) is not exceeded.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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Figure 3.4.9-2 Typical Solder Sleeve

b) When terminating a shield with a solder sleeve, it is recommended that the

shield be folded back upon the outer jacket. This procedure is done to avoid
shorts between the conductor and shield.
c) Position the shield ground wire as shown and center the solder sleeve over
stripped area. The ground wire should exit from the end of the solder sleeve
that makes the ground wire as short as possible. Heat the solder sleeve with
an approved tool.
d) Methods of terminating jumper wire from solder sleeve:
1) For terminal lugs (see Paragraph 3.4.3 for Fab Aids)
2) Terminating to contact (see Contact Part Number for Fab Aid)
3) Splice termination and jumper (See Paragraph 3.4.4 for Fab Aid)

NOTE: Unless otherwise specified ―Daisy Chaining‖ is not acceptable.

e) For C2099- ( ) splice see Paragraph 3.4.9.10.

3.4.9.3 Shield Termination Using an EMI Backshell. (C8824-X) (Not for coaxial or
triaxial cable.)

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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OUTER JACKET
CONNECTOR BACKSHELL BODY
COMPRESSION RING

CONDUCTOR STRAIN RELIEF NUT

Figure 3.4.9-3 EMI Connector with Compression Ring Backshell

*A shield breakout is that point at which the prime conductor is no longer

covered by the shield. A shield breakout must not be outside EMI Backshell
saddle bars.

3.4.9.4 EMI Backshells having only compression ring.

3.4.9.4.1 Cut the cable 1.5 inches beyond cut point indicated on HAD/HRBD, and strip
the outer jacket approximately 3 inches as described in Figure 3.4.9-16, taking
care not to nick the shield braid strands. Cut cable to HAD/HRBD at cut point.

3.4.9.4.2 Place all Backshell components over the cable in the following order: (1)
strain relief nut, (2)compression ring, and (3) Backshell body (see Figure
3.4.9-3).

3.4.9.4.3 Open the individual wire shielding with a dull-pointed tool, and pull the
conductor through. Pull shields braid back over the cable and secure. It is
acceptable for up to ten shield strands to be severed during this step.

3.4.9.4.4 Terminate conductors, and insert into the connector.

3.4.9.4.5 Bring the Backshell body up, and install on the connector.

3.4.9.4.6 Bring the shield strands through the compression ring, and up between the
compression ring and backshell body. Place the strands as evenly around
circumference of the compression ring as possible.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.4.7 Before trimming, verify there is sufficient slack in the shield strands inside the
Backshell body to accommodate retermination.

3.4.9.4.8 With the compression ring in place, trim the excess shield braid length with
sharp scissors.

3.4.9.4.9 Tighten the strain relief nut and the saddle bar screws, ensuring the
shields/braid sleeves do not twist in the tightening process.

3.4.9.5 Shield Termination Using A Solder Sleeve. (Not for Coax and Triax Cables)

3.4.9.5.1 This method may be used with any type of EMI Backshell.

3.4.9.5.2 Prepare the shielded wire as shown in Figure 3.4.9-1. Engineering prefers to
terminate the shield with solder sleeve, and not use a window and dead end.
To terminate with a solder sleeve, fold shields back over the outer jacket, and
place a solder sleeve over the shield and apply heat. To dead end the
shields, fold it back over the outer jacket, and place a short piece of M23053/5
shrink tubing over the shield and apply heat.

3.4.9.5.3 When the 2.3-inch dimension shown in Figure 3.4.9-1 cannot be maintained
the shields may be terminated with a window.

3.4.9.5.4 Bring the Backshell body up, and install on the connector.

3.4.9.5.5 Bring the compression ring into position, taking care that solder sleeve braids
have sufficient slack for retermination and are placed evenly around the
circumference of the compression ring.

3.4.9.5.6 Trim the excess braid using sharp scissors.

3.4.9.5.7 Tighten the strain relief nut ensuring the shields/braid sleeves do not twist in
the tightening process and tighten saddle bar screws.

3.4.9.6 Shield Termination for the 90 EMI Backshell (C8820-1, -2, -3, -7, &-17).

3.4.9.6.1 This Backshell is of modular construction; that is, from 1 through 4 spacers
(C8866-1) and shield combs (C8865-1) may be used. Five four-conductor
shielded cables may be terminated to each comb.

3.4.9.6.2 Unshielded wires shall be protected from the bus tabs by either attaching to
tabs or by covering any unused tabs with shrink tubing (P/N M23053/X).

3.4.9.6.3 Cut the cable end even, and strip outer jacket and shield to the dimensions
shown in Figure 3.4.9-4, taking care not to nick the shield braid strands.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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OUTER JACKET SHIELD

UNSHIELDED WIRE

0.2/0.3 3.5 MIN.

Figure 3.4.9-4 Wire Strip Lengths – EMI Right Angle Backshell

3.4.9.6.4 Trim to final dimension during assembly.

3.4.9.6.5 Position the shielded and unshielded cables and solder sleeves on a shield
comb as shown in Figure 3.4.9-7 with the solder preform centered +/- 0.03
over the bus tabs and stripped shield.

3.4.9.6.6 Conductors must be placed on shield combs such that the bottom comb wires
are terminated in contacts nearest to comb, see Figure 3.4.9-7. Always use
the same number of combs (C8865-1) and spacers (C8866-1) unless specified
by Engineering.
Shields and wires terminated to each C8865 tab:
(1 each) 4 conductor shielded cable,
Or
(2 each) 1 conductor shielded cables,
Or
(1 each) 2 conductor shielded and (2 each) unshielded,
Or
(1 each) 3 conductor shielded and (2 each) unshielded,
Or
(4 each) braided shields from C8951-1, -2, -3 solder sleeves.
Or
(6 each) Unshielded conductors.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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BUS
TABS

Termination Bus(Shield Comb)

Figure 3.4.9-5 Termination Bus Horseshoe Backshell

3.4.9.6.7 After all cables and solder sleeves are in place, heat the solder sleeves taking
care that sleeves and cables do not shift on bus tabs during the shrinking
operation.

3.4.9.6.8 Special Requirements for the Termination of the Multiplex Cable Shield
(C4930-26-1P1).

3.4.9.6.9 The shield on this cable is constructed of 38-AWG nickel-coated copper wire,
which requires more heat and flux than tin or silver-plated copper wire.
Following are additional items required:

a) Only one cable per shield comb tab.

b) Loosen and bunch the shield such that conductors are visible through it.
c) Insert the shield comb tab and bunched up shield into a solder sleeve.

NOTE: A drop of flux, type ROL1 per J-STD-004, may be applied to the
shield to enhance solder flow.
d) Position the reflector behind the solder sleeve.
e) Apply heat, using an approved heat gun.
f) Continue to apply heat for 15 - 30 seconds after the solder starts to flow.
g) The solder sleeve will take on a brown tint due to the additional heat and
flux.

3.4.9.6.10 After all shields are terminated and contacts in place on the conductors,
place the adapter body on the connector. Check the master keyway
orientation in relation with the Backshell orientation.

3.4.9.6.11 Insert the contacts.

3.4.9.6.12 Place P5372 tape over edge on termination bus to prevent wires from
coming in contact with rolled-over edge. Additional tape may be used to
support wires as necessary. Insert spacers between termination buses; install
the end plate and strain relief.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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APPLY TAPE
OVER THIS
EDGE

Figure 3.4.9-6 Termination Bus (Shield Comb)

NOTE: In selecting screws for each assembly, use:

(5) 5/8 inch screws when 1 spacer is required.

(5) 3/4 inch screws when 2 spacers are required.
(5) 7/8 inch screws when 3 spacers are required.
(5) 1 inch screws when 4 spacers are required.

NOTE: On C8820-17W25 backshells, the endplate is bent

approximately 20 degrees. The bus bars will bend appropriately as the
unit is assembled and screws tightened.
BODY

TERMINATION BUS

SPACER

END PLATE

STRAIN RELIEF BAR

SOLDER SLEEVE

Figure 3.4.9-7 EMI Backshell (Horseshoe Style) Arrangement

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.6.13 Termination of C8898-1 triaxial cable to a C8820-1, -2, -3 & -7 Backshell.

3.4.9.6.14 Prepare and install the contact per the Fab Aid for the particular contact
part number (see paragraph 3.4.2.2).

3.4.9.6.15 When the outer shield is to be terminated to the C8865-1 termination bus,
prepare in accordance with Paragraph 3.4.9.6 of this section.

3.4.9.6.16 When the outer shield is to be terminated with a solder sleeve:

a) Window is required when sleeve location is greater than 3.5 inches
from end of wire. Dead end the outer shield within 3.5 inches from the
end of the conductor by folding the shield back over the jacket (0.125)
inch and installing a 0.5 inch (max) length of M23053/5 shrink tubing
over the shield. Install solder sleeve using a 0.2 - 0.3-inch window.
b) The ground wire should exit from the end of the solder sleeve that
makes the ground wire as short as possible.
c) Window is not required when sleeve location is less than 3.5 inches
from end of wire. Install solder sleeve within 3.5 inches from end of
wire.
d) Terminate the solder sleeve braid to a shield comb tab.

3.4.9.6.17 Shield termination for the 16VE049 series connectors. (See Fab Aid for
16VE049, Appendix Page A72).

3.4.9.6.18 Termination of C8898-1 triaxial cable to backshells other than C8820-1, -

2, -3, -4 & -7, using soldertacs.

3.4.9.6.19 Prepare the cable as shown below:

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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1.0 / 2.5 0.37

0.19

0.25 0.09

Figure 3.4.9-8 Wire Prep for C8898-1 Triax Shield Termination

3.4.9.6.20 Install a contact per Paragraph 3.4.2.2-a/b of this document to the

conductor and inner shield.

3.4.9.6.21 Fold outer shield back over outer jacket.

3.4.9.6.22 Install a shield ground wire to the outer shield using a C8951- (x) solder
sleeve. The ground wire should exit from the end of the solder sleeve that
makes the ground wire as short as possible. Terminate the ground wire to the
strain relief clamp screw or to the shield comb as applicable. Shield ground
wires should be as short as possible.

3.4.9.6.23 Shield termination for C21013, C8820-5, -6, -9, through -16, -18, -19, and
-20 backshell, is the same as described in Paragraph 3.4.9.6.18 with the
exception being the shield breakout dimension (1.0/2.5) shown in Figure 3.4.9-
8, should be 3 to 4.5 inches depending on the length of the backshell.

3.4.9.7 Installation of Lightning Voltage Suppresser Devices.

3.4.9.7.1 The suppresser-retaining device, C8866-2 is to be assembled as a part of

C8820-X-X 90 EMI Backshell.

3.4.9.7.2 Insert the suppressers (Transzorbs), large end first, into holes provided in the
retaining device. Route the protruding leads under retainer, and terminate to a
shield comb (C8865-1) using C8867-1 solder sleeves. Terminate 2 leads to
each of the center 3-bus tabs.

3.4.9.7.3 Terminate multiplex cable shields to the other 2 tabs per Paragraph 3.4.9.6.9.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.7.4 Obtain short pieces (approximately 3 inches long) of the multiplex cable core.
Strip one end of this mux cable and the appropriate conductor of the mux
cable whose shield was terminated in paragraph 3.4.9.6.18. Now position the
2-mux conductors and a suppresser lead into a C8839-50 solder sleeve, with
the solder sleeve over the 0.1 diameter part of the transzorb. Cut the
transzorb lead to length. Heat the solder sleeve with an approved heat gun,
taking care to shield other leads.

3.4.9.7.5 Strip the other end, terminate to a contact, and insert the contact(s) into the
connector.

3.4.9.7.6 Repeat Steps in paragraphs 3.4.9.7.4 and 3.4.9.7.5 for the remaining
suppressers and mux cable conductors and the 2 discrete.

3.4.9.7.7 Place the retaining device and shield comb on top of the C8866-1 spacer,
shield comb in contact with the spacer. Place the C8820 cap in place, and
start the 2 restraining screws near the strain relief end. Place the horseshoe
shaped part of the retaining device in position, and insert the remaining screw.
Now tighten all screws and install the strain relief bar.

3.4.9.8 Shield Splicing - No Window.

3.4.9.8.1 To accomplish the splicing of shield and not have a window is simply to use
bulk metal shield braid soldered to the conductor shields.

3.4.9.8.2 Parts Required:

QQ-B-575-XXX or C2065- ( )-Length per
engineering callout Bulk shield braid

NAS1744- ( ) Solder sleeve (2)

P5381- ( ) Shrink tubing (Preferred)

C4812- ( ) Splice for Conductors

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.8.3 Prepare the conductors as shown in Figure 3.4.9-9:

. .
0.75/2.5

0.37 0.25

Figure 3.4.9-9 Wire Prep for Shield Splices No Window

3.4.9.8.4 Place the shield braid, solder sleeves, and shrink tubing over the cables; then,
splice the conductors using a C4812- ( ) splice.

3.4.9.8.5 Move the QQ-B-575/C2065- ( ) shield braid such that it covers the splice(s)
and exposed cable shields.

3.4.9.8.6 Position solder sleeves over the shield braid with solder perform centered over
exposed cable shields.

3.4.9.8.7 Heat the solder sleeves with an approved heat gun until the solder flows.

3.4.9.8.8 Position shrink tubing over the splice area as shown in Figure 3.4.9-10 and
heat until the tubing is fully recovered. (P5381- ( ) or M23053/8 or M23053/5).

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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NAS1744 SOLDER SLEEVES (2)

C4812 SPLICE KIT

C2065 BRAID
SHIELDED WIRE
P5381 SHRINK TUBING

Figure 3.4.9-10 EMI Shield Splice

3.4.9.9 Termination of C2065- ( ) Braid.

3.4.9.9.1 Cut the braid to length.

3.4.9.9.2 Pull over the wires.

3.4.9.9.3 Terminate per Paragraph 3.4.9.2.1.

3.4.9.10 Termination of C8898-1 Triaxial Cable with C2099 and C8951 Solder Sleeves.
(Preferred Method)

3.4.9.10.1 Strip cable as shown in Figure 3.4.9.11

INNER SHIELD
0.25 0.19

OUTER SHIELD 0.19

0.10 0.69
0.2

Figure 3.4.9-11 Wire Prep for C8898 Triax Using C2099-1 & C8951 Solder Sleeves
(Preferred Method)

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.10.2 Installation sequence should be as follows:

OVERLAP

C8951-( ) C2099-1

2.0 MAX WHITE

LEAD

SHIELD GND W IRE

AS SHORT AS POSSIBLE BLACK LEAD

Figure 3.4.9-12 Installation of C2099-1 & C8951 Solder Sleeves on C8898 Triax
(Preferred Method)

a. Place the C8951 solder sleeve over the stripped cable.

b. Position the C2099 solder sleeve over the inner shield and center
conductor assuring that the solder preforms are centered over the
conductor/exposed shield.
NOTE: Strip dimensions and lengths are the same for coax such as
C8811, except that M23053 and C8951 are not required and outer shield
preparation is not required.
c. Heat the C2099 with an approved heat gun until the solder flows and the
insulating sleeve has fully recovered.
d. Position the C8951 over the exposed outer shield assuring that the solder
preform is centered over the exposed shield. The C8951 may overlap the
C2099.
e. Heat the C8951 solder sleeve with an approved heat gun until the solder
flows and the insulating sleeve has fully recovered.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.11 Alternate Method

3.4.9.11.1 Strip cable as shown below.

OUTER SHIELD 0.19

INNER SHIELD

0.19
0.3
0.5 0.69
0.25

Figure 3.4.9-13 Strip Lengths for C8898 Triax (Alternate Method)

3.4.9.11.2 Installation sequence should be as follows:

C8951-( )
M23053 C2099-1 2.0
MAX
WHITE
LEAD

0.3 BLACK LEAD

0.5
3.7
5.0 *

Figure 3.4.9-14 Installation Sequence for C2099-1 & C8951 (Alternate Method)

a. Position the C8951 over the exposed outer shield assuring that the solder
preform is centered over the exposed shield.
b. Heat the C8951 solder sleeve with an approved heat gun until the solder
flows and the insulating sleeve is fully recovered.
c. Cut and fold back the end of the outer shield over the outer jacket.
d. Place the M23053 shrink tubing over the folded back shield as shown in
Figure 3.4.9.14 and shrink in place.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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e. Position the C2099 solder sleeve over the inner shield and center
conductor assuring that the solder preforms are centered over the
shield/center conductor and overlaps the end of the M23053 by
approximately 1/16 inch.
NOTE: Strip dimensions and lead lengths are the same for coax such as
C8811, except that M23053 and C8951 are not required and outer shield
preparation is not required.
f. Heat the C2099 with an approved heat gun until the solder flows and the
insulating sleeve has fully recovered.

3.4.9.11.3 It is permissible and preferred to lay a solder sleeve on a Backshell as

shown. In all cases, proper staggering must be maintained.

Figure 3.4.9-15 Alternate Triax Shield Jumper Terminations

3.4.9.11.4 Terminating C8898 Triax to C8822 backshells

3.4.9.11.5 When C2099-1 black lead connects to a splice, it may be 3.25 inches long
maximum. Total length of the black lead plus ground wire should not exceed 6
inches, and should be as short as possible.

3.4.9.11.6 When the C2099-1 black lead connects to a ground lug, it may be 5.0
inches long maximum; but it should be as short as possible.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.12 ASSEMBLY PROCEDURE - C2004

3.4.9.12.1 Shield wire preparation

Figure 3.4.9-16 Shield Preparation 1

3.4.9.12.2 Strip outer insulation to approximately 3‖ as shown unless specified on

HRBD. Push shield braid back slightly.

Figure 3.4.9-17 Shield Preparation 2

3.4.9.12.3 Using a probe move the braid strands exposing the center conductor. Do
not damage shield or insulation on center conductor.

Figure 3.4.9-18 Shield Preparation 3

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
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3.4.9.12.4 Pull the conductor through hole in the shield. Strip the center conductor
and crimp on the required contact using an approved crimping tool.

3.4.9.12.5 Note: when separating center conductor or conductors from outer shield of
all shielded wires, it is acceptable for up to 10 strands in the shields to be
severed.

3.4.9.13 HARDWARE ASSEMBLY (C2004-10-X)

3.4.9.13.1 Orient hardware on the cable as shown below. Make sure the largest of
the two rings is oriented as shown.

LARGE COMPRESSION RING

SMALL COMPRESSION RING

Figure 3.4.9-19 C2004-10-X Assembly Procedure 1

3.4.9.13.2 Bring the smallest ring down cable bundle to the point where leads break
out of the shield.

3.4.9.13.3 Dress shield pigtails evenly around the small ring as shown below:
SMALL COMPRESSION RING

Figure 3.4.9-20 C2004-10-X Assembly Procedure 2

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3.4.9.13.4 Spot tie shield pigtails and orient the hardware as indicated in the
following diagram:

SMALL COMPRESSOR RING

LARGE COMPRESSOR RING SPOT TIE

Figure 3.4.9-21 C2004-10-X Assembly Procedure 3

3.4.9.13.5 Slide the large ring over harness and position it against the shield braids
captivating shields between the large ferrule and the small ferrule.

3.4.9.13.6 Complete assembly by threading the two end components together.

3.4.9.13.7 Using the wrench flats, tighten to 18-20 inch-pounds torque for C2004-10-
1 thru -10-4 and 35-40 inch-pounds torque for C2004-10-5 thru -10-9.

END COMPONENTS

Figure 3.4.9-22 C2004-10-X Assembly Procedure 4

3.4.9.13.8 Place a piece of shrink tubing, 2.5-3.0 inches long over the assembly and
shrink in place.

3.4.9.14 Special Instructions for Shield Termination to Connector 2843P423 (Fuel

Quantity) and to Connector 9154P528B (H16DW2602).

3.4.9.14.1 Terminate the shields 4 to 6 inches back from the connector using a
C2004-10-X assembly per Paragraph 3.4.9.12.

3.4.9.14.2 Install a shield ground wire from the shield termination assembly to strain
relief bars of the connector Backshell.

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3.4.9.15 Triax Outer Shield Termination - Coax Connectors.

3.4.9.15.1 Fold the outer shield wire back approximately 3 inches from the terminal
up over the solder sleeve. The solder sleeve or dead end should be installed
within 1.5 to 3.5 inches from the back of the connector.

3.4.9.16 Termination to C8820-6-X and C8820-5-X type Backshell.

NOTE: C8820-6-X is a low profile 90 Backshell. Do not use this procedure
for triax or coax.

3.4.9.16.1 Disassemble the Backshell by removing the strain relief assembly,

washer, coil spring/shield cone, and cap.

3.4.9.16.2 Slide the strain relief assembly, washer, and coil spring/shield cone back
on the harness.

3.4.9.16.3 With the adapter and bottom half of Backshell attached to the connector,
determine the shield breakout location. Prepare the shield for termination in
accordance with Paragraph 3.4.9.12, except use a shield breakout length of
approximately 2.5 inches if not shown on HRBD.

3.4.9.16.4 Insert the contacts.

3.4.9.16.5 Position the shields and wires back through the cable entry; now position
the cap.

3.4.9.16.6 Bring the coil spring/shield cone up the cable entry, and insert the shields
around its outer periphery.

3.4.9.16.7 Position the washer, and tighten the strain relief assembly and strain relief
bars.

3.4.9.17 Termination of Metal Shielding to EMI Backshells Having a Compression Ring.

3.4.9.17.1 Place all Backshell components over the metal braid or C100086 pre-
braided metal sleeve in the following order: strain relief nut, compression ring,
and Backshell body.

3.4.9.17.2 Terminate the conductors, and insert into the connector.

3.4.9.17.3 Bring the Backshell body up, and install on the connector.

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3.4.9.17.4 Bring the compression ring up over the metal braid or pre-braided metal
sleeve and the individually shielded wire strands. Bend overall metal braid or
pre-braided metal sleeve back over hi-ring (the intent is to capture the full 360
degree diameter in the hi-ring). Bend the individual shielded wire shield
strands back over ring, placing strands as evenly around circumference of the
compression ring as possible.

3.4.9.17.5 With the ferrule in place, trim any excess shield braid length with sharp
scissors.
NOTE: Before trimming, verify that shield strands are loose (have slack)
inside the Backshell body.

3.4.9.17.6 Tighten the strain relief nut and saddle bar screws.

3.4.9.18 Rework of metal shielded harnesses (braided per 16PR4559) to add wires.
NOTE: Preparation of the added wires shall conform to applicable instructions
in 16PR106, this document, (see figures 3.4.9-23 and 3.4.9-24) and
16PR4559. Metal braid for the added wires may be tin-coated tubular copper
braid in lieu of braided P5440 wire, provided the added wire bundle diameter
does not exceed 0.25 inches. The tubular braid must have a specified inside
diameter of 0.109 inches or larger as applicable. As installed, the braid inside
diameter must not be larger than specification value. Tubular braid shall
comply with C2065 or QQB575R36T ( ).

3.4.9.18.1 Loosen saddle bar clamp. Remove end of expandable braid, and fold it
back away from clamp.

3.4.9.18.2 Remove strain relief nuts, and move it back away from compression ring.

3.4.9.18.3 Check diameter of added wires and their shield to see if they are small
enough to penetrate metal shield of completed trunk harness.

3.4.9.18.4 If added wires and shield are small enough in diameter, penetrate metal
shield of completed trunk harness with a dull-pointed tool close to
compression ring. Insert added wires and their shield into overall metal shield
of completed trunk harness. If added wires and shield are too large to
penetrate the completed trunk harness metal shield, repair hole in the metal
shield by pushing the weave back together.

3.4.9.18.5 Work added wires and shield through compression ring.

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3.4.9.18.6 Open the added shield with a dull-pointed tool and pull the wires through.
Bend added shields pigtail or shield strands back over compression ring.
Comb out added shield for even distribution of strands, and trim excess length.

3.4.9.18.7 Remove Backshell body from connector. Put wires through Backshell
body, and insert contacts into connector.

3.4.9.18.8 Reinstall Backshell body, compression ring, and strain relief nut. Put
expandable braid back under saddle bar clamp, and tighten clamp.

3.4.9.18.9 Added wires and shield shall be secured to the completed harness with
P5289-1 tying cord.

Figure 3.4.9-23 Adding Wires to Harness With Metal Braid Sock

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Figure 3.4.9-24 Adding Wires to Harness with Metal Braiding

3.4.9.19 Termination Using MS21980-X and MS21981-X Type Crimp Ferrules.

3.4.9.19.1 Preferred Method.

a) Strip the shield approximately 0.50 inches.
b) Place the inner ferrule over the shield, flush with the outer jacket.
c) Position the shield braid back over the inner ferrule.
d) Place the outer ferrule over the inner ferrule and shield, and ground
wire if required.
e) Crimp the ferrules using approved tools.
f) Trim any excess braid using sharp scissors.

3.4.9.19.2 Alternate Method.

a) Strip the shield approximately 0.3 inches.
b) Place the inner ferrule under the shield, flush with the outer jacket.
c) Place the outer ferrule over the shield, inner ferrule, and ground wire.
d) Crimp the ferrule using approved tools.
e) Trim excess braid using sharp scissors.

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3.4.9.20 Shield Termination for Slotted EMI Backshell (C20815, C20816 and C20855).

3.4.9.20.1 These backshells can be used with wire shields, solder sleeves with
pigtails, or any combination.

3.4.9.20.2 Bundle shields/pigtails into even groups, according to the number of slots
and relative position in the backshell. Feed the shield bundles through the
slots and temporarily tape each resulting shield bundle together for ease of
handling.

3.4.9.20.3 Build up the wire bundle diameter with P5372 tape until the combined
backshell halves have a 1/8‖ to 1/4 ― gap at the back of the backshell while
under manual compression.

3.4.9.20.4 Place a temporary string tie around the backshell preferably as close as
possible to the end of the backshell to hold the halves together prior to
applying the EMI band. Remove the temporary tape from around shield
bundles and comb shields, fanning them down evenly past the end of the
backshell. Figure 3.4.9-25

NOTE: If an inner AA59569 (QQB575) shield is used in the wire bundle

being inserted into the backshell, the inner shield should be pig-tailed and
pulled through the backshell slots to insure proper contact with the slotted
backshell design.

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Figure 3.4.9-25 C20816 backshell with shields/pigtails bundled into even groups

3.4.9.20.5 If the sring tie covers parts of the knurled portion at the end of the
backshell, slide the string tie further towards the end until it does not cover any
of the knurled area. With the shields through the slots and fanned down
evenly past the end of the backshell, pull the shields snug against the
backshell. While holding the shields snug against the backshell, install a
double looped EMI band over the knurled portion at the end of the backshell
using an approved EMI band installation tool. Avoid pinching the wires and
shields between the edges of the backshell halves as they‘re drawn together
during the EMI banding process. Removing the temporary string tie.

NOTE: In order to ensure the proper bond between the shields and the
backshell, it is important that the EMI band be double looped and installed
using an approved EMI band installation tool, and that the string tie does
not lie under the EMI band.

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3.4.9.20.6 Trim the excess shield material, allowing 1 inch of additional length
beyond the end of the backshell. Ensure P5372 tape coverage on the wire
bundle is sufficient to prevent potential chaffing of excess shield material
against the bundle. Apply 1-2 turns of glass P5041 tape over the finished EMI
band. Figure 3.4.9-26.

Figure 3.4.9-26 C20816 backshell with string tie and EMI band applied

3.4.9.20.7 For AA59569 (QQB575) sleeving or metal overbraid, prepare the wire
bundle under the braid by applying P5372 tape with 50% overlap per
16PR4559. The tape shall cover all the wire bundle that will be in contact with
the metal braid.

3.4.9.20.8 Prepare shields (if present) and close out backshell per paragraphs
3.4.9.20.3 thru 3.4.9.20.6 in order to achieve maximum pushback, stretch the
metal braid until snug around the bundle. Slide the metal braid (fish mouthed)
over the completed backshell up past the slots, and secure the metal braid to
the backshell over the slots with an additional double looped EMI band
installed with an approved EMI band installation tool. Apply 1-2 turns of glass
P5041 tapeover the finished EMI band. Figure 3.4.9-27.

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Figure 3.4.9-27 C20816 backshell with AA59569 (QQB575) braid in place

(glass tape is not yet applied)

3.4.9.20.9 Attach C8844-X expandable sleeving (fish mouthed) to the backshell past
the metal braid termination with a string tie. The C8844-X expandable sleeving
should cover the metal braid at the backshell completely. Terminate the
opposite end through the normal means.

3.4.9.21 Cable Shield Termination to C20947 Backshell Braid Sock and/or Harness
Metal Overbraid.

Table 3.4.9-1 C20947 Backshell Sizes of Split Support Rings

M85049/93-XX INSIDE DIA. M85049/93-XX INSIDE DIA.

±0.010 INCH ±0.010 INCH
02 0.125 16 1.000
04 0.250 18 1.125
06 0.375 20 1.250
08 0.500 22 1.375
10 0.625 24 1.500
12 0.750 26 1.625
14 0.875 28 1.725

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3.4.9.21.1 Table 3.4.9-1 shall be used for selection of split support ring when not
called out on engineering drawing. It is permissible to go up or down one size
split ring from the call out on the engineering drawing.

3.4.9.21.2 Mark the area of split support ring with P5372 tape. This marks an area
where the solder sleeve can be located. (See Figure 3.4.9-29)

3.4.9.21.3 Make sure that the first solder sleeves is located as close to the split
support ring mark as possible. This distance shall be no greater than 1.00
inch, staggering remaining solder sleeves.

5.0 ± 2.0 INCH SPLIT SUPPORT RING

Figure 3.4.9-28 C20947 Backshell Location of Split Support Ring

3.4.9.21.4 Install shield termination (C8951-X) on the cables from the bundle or
create shield pigtail by opening a hole in the cable braid and extracting the
cable. Place the split support ring as close to the first terminated shields as
possible. If necessary, build up the harness at the shield termination area with
additional P5372 tape to ensure a snug fit.

3.4.9.21.5 Terminate any overall metal braid from the trunk of the harness to the split
support ring over the metal braid and folding it back over the split support ring.

3.4.9.21.6 Dress all the shield braid pigtails over the split support ring (See Figure
3.4.9-29) evenly and temporarily tie in place beyond the split support ring.

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Figure 3.4.9-29 C20947 Backshell Dressing of Pigtails over Split Support Ring

3.4.9.21.7 Cut the excess shield braid pigtails even with the back of the split support
ring.

3.4.9.21.8 Slide the braid sock (of backshell) over the split support ring, the shield
braid pigtails and the overall harness metal braiding (if used). Fold back under
itself 0.25 inch to 0.50 inch to prevent any contact with unprotected harness
wiring. (See Figure 3.4.9-30)

VIEW A-A
VIEW A-A
0.25 - 0.50 inch

Figure 3.4.9-30 C20947 Backshell Braid Sock Extension Folded End

3.4.9.21.9 Install an EMI band (C20828-3) with a double wrap to achieve the proper
tension on the shield termination using an approved tool.

3.4.9.21.10 The overall termination shall be as shown in Figure 3.4.9-31.

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Figure 3.4.9-31 C20947 Backshell EMI Shield Termination

3.4.9.21.11 Cover the EMI band with glass tape (P5041-X). Bring C8844-X sleeving
forward over braid sock and secure in backshell clamp.

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3.4.10 Wire dead ending

1.0

T U B IN G

0. 5

0.75

TUBING

Figure 3.4.10-1 Assembly Procedure for Dead Ending Wire

NOTE: All unused conductors must be dead ended, dead ending shall take place
with in 4 to 6 inches of connector, per SAE-AS50881 Rev. B, paragraph
3.10.5.

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3.4.10.1 Alternate method - Cut the tubing to specified length. Slip one-half inch of
tubing over end of wire, and shrink tubing. Fold remainder of tubing back over
wire. (See Figure 3.4.10-1)
Note: When dead ending a wire with contact installed, use shrink tubing 1.0
inch longer than the contact.

3.4.10.2 Slip a three-fourth inch length of tubing over all the wires to be dead ended,
and shrink. (See Figure 3.4.10-1)

3.4.10.3 Preferred method - Place a C2105-X end cap over the conductor end.

3.4.10.4 Shrink in place with an approved heating tool.

NOTE: M81786/X may be used in lieu of C2105-X.

3.4.11 Shield Float - Assembly Procedure

3.4.11.1 Fold the shield back over the outer jacket.

3.4.11.2 Position a short piece of shrink tubing (M23053/5) over the jacket and shield.
The tubing must overlay inner and outer jackets at least 0.25 inches.

3.4.11.3 Heat the tubing with an approved tool.

NOTE: Care must be exercised not to overheat the tubing.

3.5 Strain Relief and Backshells

3.5.1 General Requirements

3.5.1.1 Before installing the strain relief onto a round connector, check for evidence of
P5407-1 on both the coupling ring and saddle clamp screw threads. If there is
no evidence of P5407-1, then apply it (See Paragraph 3.5.2) to provide
resistance to loosening by vibration (P5407-1 does not provide backshell
locking). P5407-1 should be applied to all of the threads of either the strain
relief or connector, and allowed to cure before assembly.
NOTE: Clean when there is evidence of any foreign substance on threads.

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3.5.2 Application of P5407-1

1) Assure the threads are clean and dry. Threads may be cleaned with an
approved cleaning agent.
2) Apply enough P5407-1 on external threads so the threads to be engaged
are covered.
3) With applicator brush or cotton swab, spread P5407-1 completely around
threads.
4) Allow the P5407-1 to cure before assembly. (Approximately 30 minutes.)
Tighten the strain relief securely on the connector.

3.5.3 Strain Relief and Backshell Installation

3.5.3.1 Apply P5407-1 to both the inside threads of the backshell and the outside
threads of the rear access cover after the wires have been pulled through the
backshell. Allow P5407-1 to cure for approximately 30 minutes. Attach and
tighten the rear access cover until it bottoms out using an approved tool.

3.5.3.2 Compare the wire bundle diameter to the fully-closed diameter of saddle clamp
bars. If the wire bundle diameter is smaller, then build the diameter up using
P5269 tape or P5372-1-1, P5153-2, P5067-2 or M23053/5 tubing. Position the
expandable braided sleeving under clamp bars and pull tight; then tighten the
screws securely. If the wire bundle diameter is larger than fully closed
diameter of saddle bars, wrap the wire bundle with 1 1/2 rounds of tape and
tighten screws only until saddle bars contact wire bundle. Tighten screws 1 full
turn (360 degrees) to complete tightening process. A metal to metal contact is
not required. This process also applies to C8821-1-10. On C8821-( )-8
backshells, the strain relief bars may be turned over to prevent wire pinching.

NOTE: When a shield lug is terminated to a clamp bar screw, a washer is not
required between the bar and lug.

3.5.3.3 When a terminal lug is specified, all of the shield ground wires shall be
terminated per paragraph 3.4.3 for particular lug part number, and the lug shall
be terminated to the strain relief clamp under screw head. The total length of
any one shield ground wire should not exceed six inches, and shield ground
wires should be as short as possible.

NOTE: Unless otherwise specified ―Daisy Chaining‖ is not acceptable.

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3.5.3.4 When a wire bundle is too large for the strain relief bars to make metal to metal
contact and a shield ground lug is required, insert NAS620A-( ) (or equivalent)
washers between the bars and backshell. This washer build-up must be
sufficient to have metal to metal contact between the terminal lug and
connector.

3.5.4 C8822-XX-X Type:

3.5.4.1 For -1,-2, and -4 backshells in shell sizes 16 to 28, insert expandable braided
sleeving through the snap-ring (snap-ring comes as a loose part with the
backshell.) Roll braided sleeving up over (fishmouth) the snap-ring; then insert
the snap-ring with braided sleeving into the groove in top of the backshell. For
other backshells, P5289-1 string or shrink tubing (M23053/5) may be used in
lieu of the snap-ring. Now, bend the wires (taking care to not open wire sealing
grommets in the connector) 90 degrees, and secure to the tab with P5289-1
lacing tape. Shrink tubing (P5381 preferred) may be used in lieu of lacing tape.

NOTE: When the braided sleeving is cut, fraying must be prevented.

NOTE: The 0.14 diameter hole on bottom of the tab is for terminating a shield
wire by means of NAS1101-06 screw, MS21042L06 nut, two AN960JD6L or
NAS620-( ) washers, and M7928/1-X terminal lug.

NOTE: Screw direction is optional. Lugs

should be fanned and may be placed
on either side of backshell tab (max
4 lugs per side). Washer orientation
should be maintained as shown.

Figure 3.5.4-1 Hardware Arrangement for Terminal Lug to Backshell Shield Termination

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3.5.5 C8820-XX-X Type.

3.5.5.1 Position the braided sleeving over wires and solder sleeves and under the end
plate. Insert screws through holes in the end plate, through shield combs, and
through the braided sleeving; then engage the strain relief bar. Tighten screws
securely.

3.5.6 Rack & Panel (M83733 Type):

3.5.6.1 Remove the ―junction shell‖ from rear of the connector and discard. Install the
strain relief (M83733/16-X) using junction shell screws. Dress the wires into a
ribbon (flat); position the braided sleeving under strain relief bars and tighten
screws securely. When strain relief is not used, terminate shields with one of
the four screws located on the back of the connector.

NOTE: Two pieces of braided sleeving, installed as a ―Y‖, may be required due
to the width of the bars.

3.5.7 MS3154-X Type.

3.5.7.1 The expandable sleeving shall be secured to conductors by means of P5289-1

tying cord as near the connector as possible.

3.5.8 Substitution of longer screws for ones supplied with backshell to attach saddle
bar:

3.5.8.1 Screws used to attach saddle bars to backshells shall have threads extending
beyond the face of the saddle bars after harness is completed.

3.5.8.2 When thread protrusion is negative, then the screws shall be substituted. The
substituted screw shall be one (1) or up to two (2) grip lengths longer than the
supplied screws. Two (2) grip lengths longer shall only be used if one (1) grip
length longer will not provide positive thread protrusion in the finished
assembly. P5407 shall be applied to the new screws to accomplish self
locking. The supplied screws can be substituted as described:

3.5.8.2.1 For C8821 and C8824 backshells substitute with NAS1101E04-X (where X
represents the substituted grip length) screws.

3.5.8.2.2 For C8820-5, C8820-9, C8820-10, C8820-11, C8820-12, C8820-13, C8820-

14, C8820-15, C8820-16, C8820-18, C8820-19, C8820-20, and C8820-21
backshells substitute with NAS1101E04-X (where X represents the substituted
grip length) screws.

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3.5.8.2.3 For C8820-6 backshells substitute with NAS1101E06-X (where X represents

the substituted grip length) screws.

3.6 Protective Coverings

3.6.1 General Requirements

3.6.1.1 Braiding of wiring harnesses shall be in accordance with 16PR106. Use

P5372-X, P5372-1-1 preferred, tape for spot taping the wires before braiding.
Wires that are pre-braided from the manufacturer do not require additional
machine braiding.

3.6.1.2 Wiring harnesses identified as flight control system shall have two (2) light
color tracers interwoven criss-crossing with the dark color threads. This
pattern is to provide for their identification.

3.6.1.3 All wiring harnesses, other than flight control, shall have one (1) light color
tracer.

3.6.1.4 Areas of the harness to be braided shall be established on the harness board
or specified on the HAD and approved by engineering prior to board sell-off.

NOTE: Loose Wire Assemblies/Retro-fit Kits/Synthetic Harnesses, the braid

stop for each wire or group of wires shall be located at a point 6‖ from the end
of the wire or group of wires +/- .5‖.

3.6.2 SELECTION AND PREPARATION OF EXPANDABLE BRAIDED SLEEVING

3.6.2.1 The braided sleeving size must be compatible with both the connector
backshell and cable diameters

3.6.2.2 The length shall be such that after termination to the connector backshell, the
braid shall overlap the cable outerbraid a minimum of 0.5 inch and a maximum
of 2 inches.

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Figure 3.6.2-1 Expandable Braided Sleeving

NOTE: When only one wafer is called for, the braided sleeving shall be
terminated only to the overbraid. On assembly of the wafers into the
connector housing, both braids shall be terminated between the strain
relief bars.

3.6.2.3 The braided sleeving may be cut with scissors or a high temperature thermal
device.
NOTE: When braided sleeving is cut, fraying must be prevented.

3.6.3 INSTALLATION OF EXPANDABLE BRAIDED SLEEVING

3.6.3.1 Connector end. Under the cable clamp (strain relief) bars for all types except
the C20777 and C8822( ) series. (The C8822-( ) series has a sleeving securing
ring contained in the body.) (C20777 series the sleeving shall be terminated
externally in the grove between the clamping nut and the connector coupling
ring and secured with P5289 lacing string).
NOTE: A short piece of P5381 shrink tubing (1-1.5 inches in length) may be
used to terminate the expandable sleeving to the shield bus bar.

3.6.3.2 After sleeving is secured to the backshell, position it to overlap the overbraid by
a minimum of 0.5 inch and a maximum of 2 inches.

NOTE: The sleeving may be placed under the overbraid rather than over it.
Also, sleeving may be increased or decreased one size.

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3.6.3.3 Position the identification tubing as shown in Figure 3.6.2-1. Heat the
shrinkable tubing with an approved tool.
NOTE: The tubing should be positioned, where feasible, such that the printed
information is visible after wiring harness installation. (Locate per HRBD.)

3.7 Panels and Matrices

3.7.1 Exposed Solder Terminal/Lugs/Studs.

3.7.1.1 NOTE: Junctions and buses located within enclosed areas containing only
electrical and electronic equipment are not considered exposed.

3.7.1.2 Before performing the soldering operation, position a short piece of clear
C2070-X (M23053/5 may be used in lieu) shrinkable tubing over the wires.
Solder wires to the terminal per applicable drawing note. Move the tubing over
exposed terminals, and shrink using an approved heat gun. This operation
also applies to trunk harness connectors with solder terminals.

3.7.1.3 As an alternate method to shrink tubing, two (2) coats of MIL-I-46058-TYAR

conformal coating may be applied to soldered terminals on electrical panel
assemblies or matrices (except where noted on engineering drawing to use
shrink tubing). Apply coating per FPS-1103 to solder connections and bare
wire sections except in cases where it is possible for transient wires to come in
contact with soldered connections.

3.7.2 Untwisting of Wire

3.7.2.1 Wires going into relay sockets, grounding modules, terminal junction modules,
etc., shall be untwisted for at least 3 inches before termination.
NOTE: Untwisting does not apply to C4930 or C10561 type cable. Untwist
only as much as required for installation.

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3.7.3 Splicing Within Relay Matrices.

3.7.3.1 If possible, all splices shall be located under the relay reference designator I.D.
tubing.

3.7.3.2 Ties are acceptable over splices in panel/matrix assemblies.

3.7.4 Insulating Mounting Hardware

3.7.4.1 To insulate screws, such as mounting screws for terminal strips, etc., it is
permissible to apply a coat of P6076-3 adhesive over the screws. Apply per
FPS-1013.

3.7.5 Procedure for the Installation of the C8853-( ) Covers on Switch Toggles.

3.7.5.1 Clean toggle switches similar to MS24523 to remove dirt, oil, and fingerprints.

3.7.5.2 Preheat toggle with an approved heat gun for short time until warm.

3.7.5.3 Install C8853-( ) cover, orient so sides are parallel to panel edges, and hold in
this position with toggle end at bottom of cover cavity, by pushing against
square end of cover with flat blade of screwdriver.

3.7.5.4 Heat lower 3/4 of cover on all sides by moving heat gun around the C8853-2
cover until all lower sides shrink and some melted adhesive is squeezed out
from under the cover.

3.7.5.5 Turn off heat gun, remove screwdriver pressure, check alignment to ensure
cover sides are parallel to panel edges, and allow to cool for at least five
minutes before handling.

3.7.5.6 Check to see that cover is secure on switch toggle.

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3.7.6 Torque values for fastener installed in electrical attachments.

NOTE: Unless specified on Engineering drawings, applicable fasteners shall be
torqued to values listed.

Table 3.7.6-1 Torque Value Table for Electrical Attachments

TORQUE (IN-LBS)
NUTS SCREWS
FASTENER SELF WRENCHING
THREAD PLAIN LOCKING FROM HEAD
SIZE
0.086-56 1.5 TO 3.0 3 TO 4 1.5 , TO 2.5
0.086-64
0.112-40 4.0 TO 6.0 6 TO 8 4.0 TO 6.8
0.112-48
0.138-32 6.0 TO 9.0 12 TO 15 6.0 TO 8.0
0.138-40
0.164-32 8.0 TO 12.0 15 TO 20 8.0 TO 12.0
0.164-36
0.190-24 15.0 TO 20.0 20 TO 25 15.0 TO 20.0
0.190-32
0.250-20 30.0 TO 45.0 35 TO 50 30.0 TO 45.0
0.250-28
OR
GREATER

3.7.6.1 For circuit breaker nut assembly:

1) Assure circuit breaker mounting threads are clean and dry. Threads may
be cleaned with an approved cleaning agent.
2) With the circuit breaker plunger pushed in, apply P5407-1 with an
applicator brush or cotton swab to approximately 1/2 of the circumference
of the circuit breaker mounting threads. Exercise caution to ensure
P5407-1 is confined to the threaded area only and does not come into
contact with the circuit breaker plunger or other areas that may inhibit
circuit breaker function.
3) Allow the P5407-1 to cure at least 30 minutes.
4) Verify circuit breaker plunger engages and disengages.
5) Upon installation of the circuit breaker into the panel assembly, torque nut
to 30-35 in-lbs.

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3.7.7 Assembly Procedure for Mounting a Diode.

SEMICONDUCTOR

WASHER, FLAT

WASHER, MICA

APPLY P6032-1 HEAT SINK

BUSHING, TEFLON
COMPOUND TO BOTH SIDES
OF (3) WASHERS AND BOTH
WASHER, MICA
SIDES OF SUPPORT
BRACKET.
WASHER FLAT

TERMINAL

WASHER, LOCK

HEX NUT

Figure 3.7.7-1 Assembly Procedure for Mounting a Diode

3.7.7.1 The teflon bushing goes in the heat sink (chassis) mounting hole.

3.7.7.2 When two or more terminals are installed, all terminals will be stacked barrel up
and fanned.

3.7.7.3 The prescribed torque values of 15 in- lbs for a 10-32 plain nut and 30 in-lbs for
a 25-28 plain nut are excessive for this application and may cause damage to
the diode assembly. Tighten the nut until "snug tight". "Snug Tight" is tight
enough to prevent movement of the assembly, but not tight enough to deform
the material held together.

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3.7.8 Alternate Assembly Procedure for Mounting a Diode.

SEMICONDUCTOR

TERMINAL

WASHER, FLAT

APPLY P6032-1 WASHER, MICA

HEAT SINK
COMPOUND TO BUSHING, TEFLON
BOTH SIDES OF
TERMINAL, (3) WASHER, MICA
WASHERS, & BOTH
SIDES OF SUPPORT WASHER FLAT
BRACKET. WASHER, LOCK

HEX NUT

Figure 3.7.8-1 Alternate Procedure for Mounting a Diode

3.7.8.1 When two or more terminals are installed, all terminals will be stacked barrel up
and fanned.

3.7.8.2 The prescribed torque values of 15 in- lbs for a 10-32 plain nut and 30 in-lbs for
a 25-28 plain nut are excessive for this application and may cause damage to
the diode assembly. Tighten the nut until "snug tight". "Snug Tight" is tight
enough to prevent movement of the assembly, but not tight enough to deform
the material held together.

3.7.9 Reference Designation Numbers in Panels and Matrices.

3.7.9.1 The numbers may be printed on P5374-( )-( ) or P5392-1 pressure sensitive
tape, cut to size, and (after cleaning the location in the panel) applied to the
panel. Apply P5393 tape over the P5374 tape and P5393-1 over the P5392
tape to prevent smearing. P5269-( ) may be used in place of P5374 or P5392.

3.7.9.2 The numbers must be located to be visible after installation.

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3.7.9.3 When one wiring harness assembly is used in more than one place, i.e.: two
or more in the same panel or in different panels, the ―reference designation‖
numbers of all installations shall be affixed to these assemblies. For example,
if two identical assemblies are in the same panel and for one the connector
reference designation is ―P3 and the other is ―P4‖, then both ―P3 & P4‖ shall be
printed on the identification tubing or tape.

3.7.9.4 A different reference designation number is not justification for another

assembly number.

3.7.9.5 Reference designator for stack mounted rectangular connectors.

3.7.9.6 When a list of reference designators is used to identify the order of a stack of
rectangular connectors, the first reference designator on the list refers to the
connector closest to the list. (See 3.2.5.11)

3.7.9.7 For reference designator tubing on a panel harness, only the reference
designator number is required.

3.7.10 Termination to Multiplex Networks Having Solder Pins C8839-( ), C10995-( ),

C10961( ).

3.7.10.1 Strip the cables per Figure 3.7.10-1.

3.7.10.2 Position the network solder sleeve over pins, make sure they rest on the
header.
NOTE: Two conductors may be terminated in one sleeve.
a) Use the C8839-50 solder sleeve for the C8839 mux transformer.
b) Use either a 16VE049012-1 or a C8839-50 solder sleeve for the
C10995 power transformer and the C10961 audio transformer. The
16VE049012-1 is preferred.

3.7.10.3 Position the stripped conductors inside a solder sleeve and apply heat until
solder flows and the sleeve has recovered.
NOTE: A heat shield must be used to prevent heating the adjacent sleeves.
Repeat for the remaining conductors and solder pins.

3.7.10.4 Position a C8951-( ) solder sleeve over the stripped area of the cable shields
and apply heat until solder flows and the sleeve has recovered. Crimp the
required terminal to pig-tail and attach to the ground stud.

3.7.10.5 For C8839-3 and C8839-4, if use of ground connection is not called for on the
drawing, perform the following:

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3.7.10.5.1 Remove the shield braid from network case, by removing screw and
terminal and fill hole with P6141-2* or FMS-3076 Form II.
*P6141 was made inactive for new design after September 1989.

0.15 0. 3 5

Figure 3.7.10-1 Cable Stripping Dimensions

NOTE: When the grounding shield braid on a network is used:

(a) It is permissible for approximately 30% (6 strands) to be broken.
(b) It is permissible for the solder from a solder sleeve to wick 0.15
inch.

3.7.11 Termination to (MS90335-X) Edgelight Receptacle

3.7.11.1 A) MS35333-36 lock washer installed both on ground contact and center
contact should each be located between contact and terminal lug of
wire being attached rather than between 4-40 screw head and terminal
lug of wire being attached to increase resistance to rotation of terminal
lug and loosening of 4-40 screw.
B) Before installing locking washer and jam nut onto the lighting
receptacle, check for evidence of P5407-1 (Vibratite) on the external
threads of the lighting receptacle. If there is no evidence of P5407-1,
apply it per 3.7.11.2.

3.7.11.2 1) Assure the threads are clean and dry. Threads may be cleaned with an
approved cleaning agent.
2) Apply enough P5407-1 on external threads so the threads to be
engaged are covered.
3) With applicator brush or cotton swab, spread P5407-1 completely
around threads.
4) Allow the P5407-1 to cure before assembly. (Approximately 30
minutes.) Attach locking washer and jam nut onto light receptacle
―snug tight‖. Snug tight is defined as tight enough to prevent movement
of the installed parts, but not deform the material being held together.

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3.7.12 Mounting of Toggle/Rotary Switches.

3.7.12.1 Install switch with bottom locking nut and keyway washer (with anti-rotation key
up) to back surface of mounting plate, adjusted to allow 2 to 3 threads to
protrude above lockwasher and top locking nut, when switch is installed on
mounting plate.

3.7.13 Keyway washers on electrical components.

3.7.13.1 Install electrical components with bottom locking nut and keyway washer (with
anti-rotation key up) to back surface of mounting plate. Lockwasher and top
locking nut are installed on front surface of mounting plate.

3.7.14 Installation of lighted control knobs

3.7.14.1 For push to turn control knobs, locate the knob on control post so that bottom
edge of the painted black band on knob is in line with top surface of light
transmitting panel (when post/knob assembly is viewed from the side). This
prevents panel lighting from emitting extraneously through lower portion of
knob.

3.7.14.2 All other type control knobs require a 0.025 +/- .010 distance between bottom
surface of knob skirt and top surface of light transmitting panel for correct
positioning on control post.

3.8 Testing Requirements

3.8.1 Minimum Requirements

3.8.1.1 As a minimum, all F-16 wiring harnesses, except for power feeders terminated
with terminal lugs, shall be subjected to the following tests. Specific test
equipment to perform these tests is to be identified or approved by LMTAS
Airframe Team, Manufacturing Test Equipment Engineering. Unless otherwise
noted, measurement tolerances are +/- 5% for continuity & dielectric tests.

3.8.2 Airframe Wiring Harness Assembly Area.

a) Continuity Test. All conductors* shall be checked for continuity (four ohms
maximum**), endpoint to endpoint.
b) Dielectric Test. All conductors*** shall be subjected to a 1500-VDC minimum,
100 Mohms minimum dielectric test.
c) Unused connector cavities will be subjected to a low voltage (30 VDC or less)
dielectric test to verify that the contacts are empty.

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*NOTE: End capped wires will have the end cap removed and a continuity
test performed unless otherwise stated in the Engineering routing list or
Planning operations sheet, stating that testing is not required.
**NOTE: Wire or component specifications may require a higher than four
ohm test value, e.g. chromel wires have a resistance of 0.0465 ohms per
inch, therefore, chromel wire greater than 86 inches will require more than
four ohms.
***NOTE:: Coaxial, triaxial cables, C4930-26-1P, and those conductors
terminated in High Density Connectors (i.e. MIL-C-38999 22 AWG contacts)
shall be subjected to 500 VDC, 35M ohms dielectric test. No product shall be
placed under a test requirement beyond its stated operating limits. All wire
connected to common earth ground will not be subject to a dielectric test of
any kind.

3.8.3 Panel Wiring Harness Assembly Area.

3.8.3.1 Test* to be conducted before installation into the panel:

1) Continuity Tests. All conductors** shall be checked for continuity (four
ohms maximum***), endpoint to endpoint.
2) Dielectric Test: All conductors**** shall be subjected to a 1500 VDC
minimum, 100 Mohms minimum dielectric test.
3) Unused connector contracts will be subjected to a low voltage (30 VDC or
less) dielectric test to verity that the contacts are empty.
*NOTE: Does not apply to some panel harness‘, such as circuit breaker,
avionics, or multiplex matrix panels. Panel harnesses with more than 50%
loose wires will be tested at the installation level rather than the harness
level. (loose wires are defined as wires not terminated in a connector or a
component.)
**NOTE: End capped wires will have the end cap removed and a
continuity test performed unless otherwise stated in the Engineering
routing list or Planning operations sheet.
***NOTE: Wire or component specifications may require a higher than
four ohm test value, e.g. chromel wires have a resistance of 0.0465 ohms
per inch, therefore, chromel wire greater than 86 inches will require more
than four ohms.
****NOTE: Coaxial, triaxial cables, C4930-26-1p, and those conductors
terminated in High Density Connectors (i.e. MIL-C-38999 22 AWG
Contacts) shall be subjected to 500 VDC, 35M ohms dielectric test. No
product should be placed under a test requirement beyond its stated
operating limits. All wires connected to common earth ground will not be
subject to a dielectric test of any kind.

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3.8.3.2 Tests to be conducted after installation into the panel:

1) Continuity Test: All conductors shall be checked for continuity (four ohms
maximum*), endpoint to endpoint.
2) Dielectric Test: All conductors** shall be subjected to a low voltage (30
VDC maximum), 1M ohms dielectric test.
3) Unused connector contacts will be subjected to low voltage (30 VDC or
less) dielectric test to verity that the contacts are empty.
4) The proper operating voltages shall be applied such that all relays, lights,
etc., are exercised. The purpose of energizing/operating the installed
components is not to functionally test the component, but to verity that the
electrical wiring is correct.

*NOTE: Wire or component specifications may require a higher than four

ohm test value, e.g. chromel wires have a resistance of 0.0465 ohms per
inch, therefore, chromel wire greater than 86 inches will require more than
four ohms.

**NOTE: No product should be placed under a test requirement beyond its

stated operating limits. All wires connected to common earth ground will
not be subject to a dielectric test of any kind.

3.8.4 Tests to be conducted after installation in the end item (Major Components) prior
to mating.

3.8.4.1 Continuity Tests. All conductors* shall be checked for continuity (four ohms
maximum**), endpoint to endpoint.

3.8.4.2 Dielectric Test: All conductors*** shall be subjected to a low voltage (30 VDC
maximum), 1M ohms dielectric test.

3.8.4.3 The proper operating voltages shall be applied such that all relays, lights etc.,
are exercised. The purpose of energizing/operating the installed components
is not to functionally test the component, but to verity that the electrical wiring is
correct.

3.8.4.4 Unused connector contacts will be subjected to a low voltage (30 VDC or less)
dielectric test to verify that the contacts are empty.

*NOTE: Does not apply to single strand coax cables or wires identified as
―SPARE‖.

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**NOTE: Wire or component specifications may require a higher than four

ohm test value, e.g. chromel wires have a resistance of 0.0465 ohms per inch,
therefore, chromel wire greater than 86 inches will require more than a four
ohms test

***NOTE: No product should be placed under a test requirement beyond its

stated operating limits. All wires connected to common earth ground will not
be subject to a dielectric test of any kind.

3.8.5 Testing Requirements of Out-Of-Station Installations on a completed end Item.

a) In-process inspection and sign-off must be accomplished for production.
b) A continuity test of the completed installation shall be accomplished.

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4.0 INSTALLATION/ROUTING REQUIREMENTS

4.1 General Requirements

4.1.1 Scope

4.1.1.1 This section of 16PR145 address requirements of installing electrical wire

harnesses (bundles) into the F16 airframe.

4.1.1.2 Since harness installation is not an ―exacting‖ operation (compared to

mechanical parts fabrication and installation), shop personnel must rely many
times on standard/acceptable unwritten practices and personal judgment as to
what constitutes an acceptable or quality harness installation. Installers should
not hesitate to call upon manufacturing engineering or quality department
personnel for consultation in questionable circumstances.

4.1.2 Source Data

4.1.2.1 Prior to and during installation, shop personnel are advised to have all
necessary and reference data readily available, including but not limited to:

a) Engineering installation drawing(s)

b) Planning paperwork/instructions
c) Reference documents
d) Visual aids
e) Process standards
f) Computer access (for ―on-line‖ documents/information)

4.1.3 Harness Installation Drawings

4.1.3.1 Purpose: The harness installation drawing provides the attaching hardware for
support of the harnesses, protection barriers for harnesses and the ―road map‖
for which the harnesses are to be routed. The drawing does not necessarily
depict the harness detail definition itself such as breakout locations,
identification locations, backshell definitions, braided or non-braided areas,
splice locations, etc. This drawing shows the paths in which the harness
routes from endpoint to endpoint and orientation of clamps/brackets.

Example: The drawing shows the harness breakout after a clamp proceeding
to an endpoint (shown in Fig. 4.1.3-1). In reality the breakout is prior to the
clamp that the harness is to be routed through (shown in Fig. 4.1.3-2).

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Clamp
Connector

Breakout

Figure 4.1.3-1 (Drawing representation)

Clamp

Connector

Breakout

Figure 4.1.3-2 (actual harness configuration may have breakout as shown)

4.1.3.2 Torquing of screws/fasteners used for harness installation.

4.1.3.2.1 Fasteners used to install wiring support clamps, connectors and other
components of harness installation shall be torqued ―snug tight‖ unless
otherwise noted in the specific instructions of that component, or noted on the
engineering drawing. ―Snug tight‖ is tight enough to prevent movement of the
installed parts, but not deform the material being held together.

4.1.3.2.2 Thread Protrusion—Due to manufacturing tolerance build-ups, manufacturing

personnel are authorized to substitute spacers (PLS parts only) at all harness
attach points in order to meet the minimum thread protrusion requirement per
M131, so as not to compromise the integrity of the harness installation.
Substitute spacers shall be of the same material and finish as the replaced
spacer. Variation in spacer length is authorized for +/- four sizes. This
deviation is authorized only to achieve the minimum thread protrusion
requirement, and to ensure that the nuts do not ―bottom out‖ on unthreaded
portions of the attaching studs, screws or bolts. In repetitive situations where
minimum thread protrusion or secure clamping cannot be achieved using
hardware specified on the drawing, Engineering shall be notified for corrective
action to prescribe proper hardware. It is production installation responsibility
to ensure that minimum thread protrusion requirements are met at all harness
attach points.

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4.2 Harness Support and Routing

4.2.1 Harness Assembly Installation

4.2.1.1 One of the primary considerations in the design and installation of wiring
harnesses is the prevention of harness chafing. Chafing is defined as:

a) Chafing – repeated relative motion between wiring system components, or

between a wiring component and structure or equipment that can cause
deleterious wear. Restrained contact (by design) with fixed planar or
tangential surfaces does not constitute chafing.

NOTE: During harness installation, if excessive length on the connector

backshell clamp screws creates a fouling condition, replace with shorter
screws of the same base part number while maintaining positive thread
protrusion.

4.2.1.2 Many of the subsequent requirements (physical separation, protective barriers,

etc) have been established as a means of preventing chafing. Chafing may be
the result of an improper harness installation, but it is more likely that the
condition actually observed on the aircraft is fouling. Fouling is defined as:

a) Fouling – contact between a wire and a harness assembly and structure or

equipment. In general, the term fouling is used to describe contact of a
harness when there is no evidence of damage or deleterious wear, but there
is a concern that chafing may occur. The term chafing is only used when
there is evidence that damage or deleterious wear, i.e. chafing has occurred.

4.2.1.3 Physical separation of 3/8 inch (minimum) from equipment, structure, and
liquid-gas carrying tubes will be maintained when possible. When 3/8-inch
clearance cannot be obtained, maintain the maximum possible clearance, even
when utilizing chafe protection (see 4.2.1.3.1). Contact between an
unprotected wire harness/bundle and flammable gas/liquid carrying tube is not
acceptable. The only situations where direct contact between a wire
harness/bundle and equipment and/or structure is permissible will be where
both of the following conditions are met:

a) The surface is smooth and non-abrasive, and the contact is without

pressure.
b) Relative movement between the wire bundle and contact surface in normal
operation conditions (i.e. panels/doors are secured in ―ready for flight‖
position) does not exist.

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4.2.1.3.1 Where the 3/8-inch clearance requirement in accordance with paragraph

4.2.1.3 cannot be complied with, suitable protection barriers (i.e., grommets,
convoluted tubing, etc.) shall be installed. In repetitive situations where the
required clearance cannot be achieved, the engineering drawing will prescribe
the proper barrier. However, the engineering drawing may not always identify
the need for these barriers. It is a production installation responsibility to
ensure that barriers are installed where needed, only after reasonable efforts
have been exhausted to provide the specific clearance, even if they are not
identified as being required by the engineering drawing.

4.2.1.3.2 Swing Lock Fasteners - For harnesses routed adjacent to equipment

mounted with ―swing lock (MIL-F-85731/1 and MS14108)‖ latches, route
harness to allow maximum ―swing‖ of the latch for removal of the equipment,
noting that due to the congestion/constraints of installations on the F-16, full
―swing‖ of the latches may not always be possible. In these situations, the
installer should insure that the harness has chafing/fouling protection applied
to it to prevent damage from the ―swing lock‖ in the removal position.

4.2.1.4 Clamp size callout on the engineering drawing and parts list is approximate.
The wire bundle clamp shall be of a size that will secure a wire bundle in place,
but shall not crush or deform the bundle. This pertains to standard loop clamps
such as: MS21919WDG, C2874D, etc. See Figure 4.2.1-1. The particular
clamp specification/standard may also contain installation information inherent
to that specific clamp. If multiple braided wire harnesses are routed with RF
cable assemblies, the RF cables should be routed between the braided
harnesses (center of the bundle if possible) at clamp locations to reduce
possible damage to RF cables.

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Clamp too tight Clamp too small

Crushes harness or cable
Unacceptable
Unacceptable

Clamp cushion has slipped Clamp size too large

Metal of clamp contacts harness
Unacceptable
Unacceptable

Proper size clamp

Acceptable

Figure 4.2.1-1 Installation of Clamps

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4.2.1.5 When the smallest cable clamp is too large for small wire bundles/breakouts,
wrapping with approved silicone or Teflon tapes should increase the bundle
diameter. Current approved tapes are P5067, P5372, and P5384-1. Tape is
not to be used in a fuel area.

4.2.1.6 Clamp orientation noted on field of the drawing is defined by the installation
direction of the ―barrel‖ of the clamp. See Figure 4.2.1-2

Barrel will be noted as;

Clamp FWD w/barrel INBD
INBD

Figure 4.2.1-2 Orientation of Clamps

4.2.1.7 Lacing tape (part number P5289-1 and sometimes referred to as ―string tie‖) is
to be used to ―dress up‖ areas after all harnesses have been routed within the
area. It is also to be used to eliminate minor touching of harnesses against
structure, equipment, and tubing, etc. Only those harnesses that are clamped,
restrained, or routed together should be laced together (see also Paragraph
4.2.2.3). The engineering drawing will not specify when or why string tie or
lacing tape will be required. It is a production installation responsibility to
ensure that all areas are ―dressed up‖ after the harnesses have been installed.
See Figure 4.2.1-3 and 4.2.1-4 for installation of lacing tape.

NOTE: When lacing tape is installed around a harness bundle, it shall not be
drawn so tight as to crush/deform the harness nor degrade the electrical/signal
performance of the harness. This is especially important for COAX/TRIAX
harnesses. When multiple braided wire harnesses are routed with RF cable
assemblies, the RF cables should be routed between the braided harnesses
(center of the bundle if possible) at string tie locations to reduce possible
damage to RF cables.

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Figure 4.2.1-3 Double Clove Hitch and Surgeons Knot

Figure 4.2.1-4 Clove Hitch and Surgeons Knot

4.2.1.8 The minimum bend radius of a wiring harness shall be six times the cross-
sectional dimension in the plane of the bend unless the installation is designed
by engineering for less than 6 times bend radius. The minimum bend radius is
applied in the following manner.
a) Six times diameter of the full cross-sectional diameter of a braided harness.
b) Ten times diameter of the individual wires (10 times for individual triax/coax
whichever is greater) when there is no braid or when the wires are
contained in expandable sleeving.

NOTE: The bend radius may be less than stated above providing the harness
jig board is constructed in that manner.

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4.2.1.9 Slack in wires and cables. Excess slack shall be minimized in wires, cables,
and breakouts from high-density harnesses except for drip loops and service
requirements. However, enough slack shall be provided to meet the following
requirements:

a) Allow replacement of terminations at least two times, except for wire sizes 2
for copper and 4 for aluminum, and larger, where only one replacement is
required. This slack shall be available in the area of termination.
b) Allow at least one service replacement of connectors. This slack shall be
readily available in the area of the connector.
c) Prevent mechanical strain on wires, junctions, and supports.
d) Permit free movement of shock and vibration mounted equipment.
e) Permit shifting of wiring and equipment while performing maintenance
within the aircraft.

4.2.2 Flight Control Wiring

4.2.2.1 The fly-by-wire flight control system is quadruple redundant, which is; there are
four independent channels. Each channel of primary flight control signal wiring
is contained in dedicated harness assemblies for the purpose of isolation from
other system wiring.

4.2.2.2 Flight control wire harnesses are distinguished from other harnesses by two
light colored tracers interwoven crisscrossing with the dark color threads of the
harness braiding. All other braided harnesses have only one tracer.
Generally, power wires are black and without tracers. Flight control signals,
primary or otherwise cannot be distinguished by visual inspection. The
difference between high voltage and other power wires also cannot be
distinguished by visual inspection.

4.2.2.3 Provide maximum separation and isolation of flight control harnesses

(minimum of one inch), except at equipment, harness junctions, the flight
control computer, servo actuator, control panels, etc. Do not route flight control
harnesses with less than one inch separation, string tie or clamp them with
other flight control harnesses or power wires unless specified on engineering.
Note: Per engineering, no two harnesses containing primary flight control
signals will be clamped together. (See also Paragraph 4.2.1.7)

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4.2.3 Power Feeders

4.2.3.1 The primary power feeder harnesses (H16DW2651 and H16DW2652) contain
3 each #6 gauge wires. These harnesses are braided throughout the center
portion of the harness and the ends having the individual conductors with only
their protective sheathing. This sheathing is a Teflon impregnated fiberglass
and is very fragile. Prior to installation into the aircraft, these non-braided ends
should have a temporary covering applied to protect them from being damaged
during installation (i.e. the 3 conductors bundled together with adhesive Teflon
tape wrapped with the adhesive away from the harness and then wrapped
back upon itself with the adhesive toward the first wrap). After installation is
complete into the airframe, the temporary protective cover is to be removed
prior to final connection to the generator or main bus contactor.

4.3 Connector Mounting

4.3.1 Circular Connectors – General

4.3.1.1 When circular connectors are installed in the airframe with the axis in a
horizontal direction, the connector shall be positioned so the master keyway is
located ―up‖ (in relation to aircraft). When installed with the axis in a vertical
direction, the master keyway shall be located forward (See Fig 4.3.1-1).

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Figure 4.3.1-1 Master Keyway Orientation

4.3.1.2 Verify that connector reference designator (―Ref Des‖) corresponds to

mounting location.

4.3.1.3 Connector plugs (―P‖ – side) must be fully engaged and locked into the
receptacle (―J‖ – side). Ensure that locking tabs are visible through the viewing
holes in the connector turn-ring for circular connectors.

4.3.1.4 Minor adjustments to the connector endbell/backshell clocking by the

production line may be necessary to provide a minimum 3/8-inch clearance
between the connector endbell/backshells and adjacent structure/components.
This minor adjustment is authorized, providing the adjustment does not exceed
a maximum movement of 15 degrees in either direction from the original
clocking established by the HRBD or HAD. If the adjustment to the clocking of
the endbell/backshell requires more than 15 degrees movement to
accommodate the 3/8-inch minimum clearance, the nonconforming installation
shall be documented on a Quality Assurance Record (QAR) and processed per
established procedures. If it is determined that a change to the HRBD or HAD
is required, then a REA will be submitted to Engineering.

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Anytime a repetitive minor adjustment to the established clocking called out by

the HRBD or HAD is necessary, a REA must be written to Engineering
identifying the condition. This does not mean that each minor adjustment
requires a REA, but, when a particular endbell/backshell has to be re-clocked
consistently for a production sequence of aircraft, one REA will be written
identifying the condition for all applicable aircraft.

4.3.1.5 Ensure that mounting surface/panel is prepared to requirements of FPS-3024,

―Bonding Requirements F-16‖, or applicable engineering drawing for receptacle
(―J‖ – side) mounting.

4.3.2 Circular Connectors – Installation, Non-Pressure Bulkhead

4.3.2.1 Assemble connector receptacle and mounting hardware (as specified by

engineering drawing) into mounting panel as shown below and torque
mounting screws/fasteners. See Figure 4.3.2-1.

4.3.2.2 Verify electrical bond as specified.

Figure 4.3.2-1 Connector Mounting, Non-Pressure BHD Installation

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4.3.3 Circular Connectors – Pressure Bulkhead Installation

4.3.3.1 Assemble connector receptacle, gasket and mounting hardware (as specified
by engineering drawings) into mounting panel as shown below and torque
mounting screws/fasteners. See Figure 4.3.3-1.

4.3.3.2 Verify electrical bond as specified.

4.3.3.3 Apply sealant around connector (as specified on engineering drawings).

Figure 4.3.3-1 Connector Mounting, Pressure BHD Installation

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4.3.4 Rectangular (16VE049 & C8916 series) Connectors

4.3.4.1 Ensure that mounting surface/panel is prepared to requirements of FPS-3024,

or applicable engineering drawing.

4.3.4.2 When mounting connectors/receptacles, the ―A‖ side shall be ―up‖ (that is,
away from main/base mounting structure) unless otherwise noted (or depicted)
by applicable engineering drawing. (See Figure 4.3.4-1 and 4.3.4-2)

4.3.4.3 Verify connector reference designator (―Ref Des‖) corresponds to mounting

location.

4.3.4.4 When mating plug to receptacle, torque screws to 8 inch/pounds, plus/minus 1

inch/pound. Visibly ensure that plug fully mates to the receptacle upon
torquing of screws.

4.3.4.5 Stack mounting – Two No. 6 screw holes are provided for stack mounting the
connectors. Install screws through connectors into nuts/nutplates, and torque.
See Figure 4.3.4-1.

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Figure 4.3.4-1 Rectangular Connector/Receptacle Stack Mounting

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4.3.4.6 Panel mounting – Washers are provided between the adapter nuts and
connector flange. One or all of the washers must be removed for panel
mounting. For maximum mounting panel thickness of .093 inches, remove all
washers. For minimum mounting panel thickness of .031 inches, remove one
washer. For mounting panel thickness between the minimum and maximum,
remove washers accordingly. (Figure 4.3.4-2)

1. Remove adapter nuts and washers.

2. Insert connector through panel.
3. Install washers, and adapter nuts.
4. Tighten screws to 8 inch/pounds torque, plus/minus 1 inch/pound.

Figure 4.3.4-2 Rectangular Connector/Receptacle Panel Mounting

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4.3.4.7 If wires are outside of the rubber inserts of the strain relief bar of the 16VE049
backshell, reposition wires between rubber inserts.

4.3.5 Rectangular (MIL-C-83733) Connectors

4.3.5.1 M83733-04 type – These connectors are supplied with four captive, non-
rotation spring assemblies for mounting. Position the connector in its panel
cutout. Insert mounting screws through the mounting plate and torque.

4.3.5.2 M83733-12 type – These connectors are supplied with two spring assemblies.
The installation procedure is the same as above, except spring assemblies
must be restrained when tightening screws.

4.3.6 Circular Threaded RF Coax Connectors

4.3.6.1 In assembling threaded RF (TNC, SMA, N-series) connectors, first clean all
exposed surfaces. Connector threads shall be free of contaminants and oils.
Engage threads and tighten by hand until snug. Then, using an appropriately
sized open end or strap wrench, tighten another 1/12 turn or approximately 15
degrees. This additional turn yields a connection with 27 – 30 inch pounds of
torque. Then install safety wire if required.

4.4 Terminal Lug Connections

4.4.1 General Requirements

4.4.1.1 Various attachments of electrical terminals have been used and are currently
being used on the F-16. This section is to be used as a guide for installation of
ground/power/signal terminals, thus allowing flexibility of installation.

4.4.1.2 Installation must comply with FPS-3024, using hardware specified on the
engineering drawing.

4.4.1.3 Maximum of 4 terminals per stud/screw per SAE-AS50881 Rev. B, paragraph

3.12.2.

4.4.1.4 Orientation of first (bottom) terminal is optional ―up‖ or ―down‖ for aluminum
substructure.

4.4.1.5 When 2 or more terminals are used on one mounting screw, they should be
―fanned‖ or alternately stacked to facilitate installation, and not unduly deform
any of the terminals. Orientation of terminal ―barrel‖ is optional.

4.4.1.6 Terminal stacking/orientation, which is specifically noted on engineering

drawings, takes precedence over this section.

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4.4.1.7 If terminal lugs are installed so that the insulation is touching another terminal
or structure, slight bending of the terminal is acceptable.

4.4.1.8 Figure 4.4.1-1 depict typical ground stud installation which may vary by
engineering drawing requirements or physical constraints or other criteria as
long as terminal bending and harness fouling is minimized.

(See Note 1)
*
L O CK N U T

FLAT
WASHER

T E R M IN A L U P

T E R M IN A L D O W N
T ERM I NAL U P
3
2

S T R U C T UR E

T E R M IN A L D O W N

* If plain nut is used,

lockwasher is installed
between flatwasher and nut.

Figure 4.4.1-1 Typical Ground Stud Installation

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Figure 4.4.1-2 Terminal Lug Arrangement

Figure 4.4.1-3 Terminal Lug Arrangement

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NOTES:

1. Washer to be used between structure and terminal. If a plain nut (a nut without a
self-locking feature) is required on the engineering drawing, a lock-washer must
be installed between the flat washer and the nut.
2. The installation orientation of terminal lugs may differ from what is depicted in
above figures, as follows:

a. When terminal lug 1 is installed barrel down, install a washer (NAS1149-type)

sufficiently thick to permit installation with minimal terminal lug bending.

b. The installation orientation of terminal lugs 2-4 may vary from what is
depicted in above figures, provided the terminal lugs are ―fanned‖ to ensure
maximum surface contact and to minimize terminal lug bending. Terminal lug
―fanning‖ is permissible and often required to maximize surface contact and
minimize terminal lug bending.

c. When terminal lugs are installed under a fastener head, notes 1 and 2 apply,
except a washer is not required between the terminal lug and fastener head,
unless one is required to maximize surface contact and minimize terminal lug
bending.

Terminal lug
Installation

Locknut
(See
Note)

Figure 4.4.1-4 Terminal Lug Under Fastener Head

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4.5 Special Installation Situations

4.5.1 Wiring Across Hinges/Doors

4.5.1.1 When installing harnesses across hinges and onto doors, insure that
prescribed harness protection (I.E. convoluted tubing, grommet, etc.) is in
place per engineering print.

4.5.1.2 After installing the harness the installer must check/inspect for fouling of the
harness across the hinge, especially when the door is cycled open and closed.

4.5.1.3 For harnesses mounted on hinged doors, check for fouling when door is in
closed position against stationary structure and/or equipment mounted on
aircraft structure.

4.5.1.4 Check for fouling of the door or equipment mounted on the door against wiring
installed onto the stationary aircraft structure.

4.5.1.5 See Figure 4.5.1-1.

Figure 4.5.1-1 Routing Across Hinge/Door

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4.5.2 Gun Bay/EPU Bay

4.5.2.1 Sealing around wire bundles in the gun and emergency power unit
compartments.

4.5.2.2 When a split grommet (MS35489-X) is called for:

4.5.2.3 Position wire bundles into the center of hole and, when there is more than one
bundle, position bundles to minimize the open space between them. Insert
grommet into the hole, taking care that it is properly sealed.

4.5.2.4 When a closure assembly (16D702-X) is called for:

4.5.2.5 Position wire bundles as near the center of the hole as possible with minimized
space between bundles. Position the skirt tightly around the wire bundles and
secure by means of a ―draw-string‖ in the skirt. Secure the ―draw-string‖ with a
double clove-hitch knot.

4.5.3 Wheel Well/Airstream

4.5.3.1 When routing harnesses in the wheel wells, insure that drip loops are provided
at all connectors and terminals that are not moisture-proofed as described in
section 3.4.8, so that rain/tire splash will drain away from connectors. (See
Figure 4.5.3-1 and Figure 4.5.3-2) A drip loop is defined as having been
accomplished when the top of the harness bundle is located at or below the
centerline of the connector.

4.5.3.2 After installing harnesses (per engineering print) check that there is adequate
clearance between the tire, wheel, struts and linkages through the full cycle
and stowage of the landing gear.

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Figure 4.5.3-1 Drip Loop with Straight Connector

Figure 4.5.3-2 Drip Loop with Right Angle Connector

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4.5.4 Aerial Re-Fuel Receptacle

4.5.4.1 Sealing the wiring conduit servicing the refueling receptacle.

4.5.4.2 Install an MS35489- (X) grommet around the wiring harness and insert 0.25 –
1.0 inch forward into the routing tube.

4.5.4.3 Apply FMS-1044-5 sealant into the routing tube such that, in conjunction with
the grommet, a fuel-tight seal is provided.

4.5.4.4 Note: All metal surfaces must be cleaned with an approved cleaning agent
before applying the sealant.

4.5.5 Installation of C8922 Assemblies in Fuel/Wet/Pressurized Areas

4.5.5.1 Installation of the Fuel Cell Bulkhead Feedthru

4.5.5.2 Clean around the mounting hole in the bulkhead approximately 3 inches in
diameter, both sides, and both sides of both boot flanges with lint-free
cheesecloth using an approved cleaning agent. Apply P6140 primer to the
cleaned area.

4.5.5.3 Position one pair of split-retaining plates (with nuts) on one side of the
bulkhead and one without nuts on the other side of the bulkhead. Install and
tighten the machine screws, six (6) places, ―snug tight.‖ (See Figure 4.5.5-2)

NOTES:
1. The screws must be ―wet‖ with FMS-1044-5 sealant.
2. For retainer on opposite side of structure, locate ―split‖ in one of these two
locations shown in Figure 4.5.5-2.
3. Apply sealant to the sides of the split retaining rings that make contact and
per Figure 4.5.5-2 to reduce fuel seep thought bulkhead hole.

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Figure 4.5.5-1 Fuel Cell Bulkhead Feedthru

Figure 4.5.5-2 Fuel Cell Bulkhead Feedthru

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4.5.6 Installation of Fuel Cell Molded Cables and Probe Harness Connectors

4.5.6.1 Clean the mounting hole in the bulkhead and connector mounting surfaces with
lint-free cheesecloth using an approved cleaning agent and apply P6140
primer.

4.5.6.2 Apply FMS-1044-5 sealant to the prepared surfaces and to male threads of the
connector and install in the bulkhead. See Figure 4.5.6-1.

4.5.6.3 Tighten to the value in Table 4.5.6-1.

Note: Discard the connector ―O‖ ring.

Figure 4.5.6-1 Fuel Cell Connector, Installed

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BULKHEAD

SEALANT

FILLET
SEALANT

JAM NUT SEALANT

MOLDED
HARNESS

DRY SIDE FUEL SIDE

Figure 4.5.6-2 Fuel Cell Molded Cables and Probe Harness Connectors

Table 4.5.6-1 Torque Requirements, Fuel Cell “Jam Nut” Connectors

CONNECTOR TORQUE TORQUE

SIZE INCH/POUNDS INCH/POUNDS
ADAPTER 5 LBS CONNECTOR 4 LBS
10 65 55
12 - 65
14 75 85
16 75 100
18 75 100
20 85 125
22 85 125
24 85 150

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4.5.7 Wiring Through Conduits

4.5.7.1 When routing wires/bundles through conduits, follow guidelines as noted:

4.5.7.2 Insure there is a grommet or protective shield where the wires enter/exit the
conduit per the engineering drawing.

4.5.7.3 For wires ―de-pinned‖ for the purpose of routing through conduit; protect the
individual wires when inserting harness through conduit for installations
requiring ―de-pinned‖ connector (i.e. wrap with adhesive tape prior to putting
wires through conduit).

4.5.7.4 DO NOT permanently string tie or tape the harness bundles together for
routing through conduit.

4.5.7.5 Sequence the harnesses/connectors through the conduit for ―best-fit‖ condition.

4.5.7.6 Upon completion of routing the harnesses through the conduits, ―re-pin‖ the
connectors.

4.5.8 Special instructions for weapon stations 3, 4, 6, 7 and intake duct ―hard-points‖:

4.5.8.1 The diameter of the conduit will not allow the one inch rectangle connector
(16VE049001 or 16VE049003) to go through it; however, the individual wafers
(16VE049010) will route through the conduit provided the shield terminating
bus (C8865-2) mounting tabs are bent-over onto the shield bus. After routing
through the conduit, straighten/flatten the shield terminating bus and assemble
it and the ―wafer‖ to the connector shell.

4.5.8.2 The insert of C8916 type connectors will route through the conduit also, but the
connector shell will not. After routing the conduit, assemble the insert into the
connector shell.

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Figure 4.5.8-1 Bending of C8865 Mounting Tabs for Routing Through Conduit

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4.5.9 Radome – Pitot Probe Heater

4.5.9.1 Assembly Procedure – 16VH019-2 (See Fab Aid page A78)

4.5.10 Convoluted Tubing/Spiral Wrap

4.5.10.1 Convoluted plastic tubing (M81914/1 or C2026-X) is sometimes called out on

engineering drawings to provide additional harness protection.

4.5.10.2 For installations denoting ―straight cut‖ installation, cut tubing length wise along
longitude axis. Tubing size/diameter should be selected to allow 1/8‖ – 3/8‖
overlap. Fit tubing over harness bundle and position overlap away from
structure/equipment which is potentially chafing or fouling the harness. See
Figure 4.5.10-1.

Figure 4.5.10-1 Straight Cut Tubing Installation

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4.5.10.3 Secure tubing in place with P5289-1 lacing tape (string tie) spaced
approximately one inch apart along length of tubing.

4.5.10.4 For installation denoted as ―spiral cut‖, cut is to be not more than one revolution
in two inch lengths and not less than one revolution in 12 inches. Fit tubing
around harness bundle insuring that cut edge is ―butted‖ to itself; see Figure
4.5.10-2.

Figure 4.5.10-2 Spiral Cut Tubing Installation

4.5.10.5 Secure tubing in place with P5289-1 lacing tape (string tie) spaced
approximately one inch apart along length of tubing.

4.5.10.6 Spiral wrap (P5434) may be called out on engineering drawings to provide
additional harness protection. Engineering drawing should specify
size/diameter of spiral wrap. After installing spiral wrap on harness, secure
ends with Teflon tape (P5067) approximately 1-inch length with 50% overlap.
Secure Teflon tape with P5289 lacing tape (string tie). Secure spiral wrap with
P5289 spaced approximately one inch apart along length of spiral
wrap/harness. See Figure 4.5.10-3.

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P5067
HARNESS
1” 1” ADHESIVE TAPE
SPIRAL WRAP
HARNESS

P5289
LACING TAPE
EVERY 1 INCH

Figure 4.5.10-3 Spiral Wrap

Table 4.5.10-1 Size Reference for P5434

The bundle diameter range for –1 is .06 to .5
inches
The bundle diameter range for –2 is .18 to 2.0
inches
The bundle diameter range for –3 is .75 to 4.0
inches

4.5.11 Bulkhead Feedthru Insulator

4.5.11.1 Install C10975 feedthru as shown below (See Figure 4.5.11-1)

4.5.11.2 Torque split nut tight enough to hold insulator securely, but do not over-
tighten. Excess torque will cause the split nut to separate.

4.5.11.3 See engineering drawing for specific sealant.

NOTES:

1. Apply faying surface sealant to the two halves of the split nut.
2. Apply faying surface sealant between split nut and structure/bulkhead.
3. Apply fillet sealant to insulator body for pressure installations.

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Figure 4.5.11-1 Bulkhead Feedthru Insulator

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4.5.12 Split Grommet Installation

4.5.12.1 When a split grommet (MS35489) is called for: Position wire bundles as near
the center of the hole as possible and, when there is more than one bundle,
position bundles to minimize the open space between them. Insert grommet
into the hole, taking care that it is properly seated and insuring that the ―split‖ of
the grommet is away from the pull of the harness thru the hole. See Figure
4.5.12-1.

Figure 4.5.12-1 Example of Correctly Installed MS35489 Split Grommet

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5.0 REPAIR/REWORK

5.1 Repair

5.1.1 General Requirements

5.1.1.1 This paragraph is intended to be used as a guide for the ―Material Review
Board‖ (MRB), or other authorized ―Board or Team‖ for recommended repairs
or rework to wires/wiring harnesses after their completion.

5.1.1.2 No repairs (splicing) shall be allowed on primary power wires, flight control
wires, coaxial cables, or multiplex bus.

5.1.1.3 Wires broken near a connector. Remove wires from the connector, and splice
in new wires within 2 to 6 inches of the connector. Only the C4812-( ) sealed
crimp splice shall be used.

5.1.1.4 If wires are broken in areas other than as above and if the break is accessible,
it may be spliced using the C4812-( ) splice. For wires broken in an
inaccessible area, braid and route a new wire outside the braided bundle
(under the same clamps) terminate, and dead end the broken wires. The new
wire must be the same part number as the one it is replacing.

5.1.2 Braid Repair

5.1.2.1 Broken shield pig-tail. If the pig-tail is of sufficient length, a shortened solder
sleeve may be used to splice on a like piece of shield. If there is not sufficient
pigtail length, the preferred repair is a C8951-X solder sleeve installed per
Section 8, but using a short piece of shrink tubing over the lower shield if
required. Also, it is permissible to remove approximately 0.2 inches of the
outer jacket, and splice a short piece of shield to the shield using NAS1744-X
solder sleeve.

5.1.2.2 When braid must be repaired

5.1.2.2.1 Preferred Method:

Remove the damage braid and tape the remaining edges with P5372-1-2.
String tie the proper size of C20955 sleeving in place. Overlap any braid,
sleeving, or convoluted tubing that is encountered approximately 0.5 inches
and secure the ends using P5381-X.

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5.1.2.2.2 Alternate Repair Method:

If the damage is no larger than one-half the wiring bundle diameter, P5384-X
tape may be applied. Spiral wrap the tape with 50% overlap. When the
damage is larger than this, P5381-X tubing up to six inches long may be used
for repair follows: Slit tubing and position on bundle; tie (in at least 2 places)
around bundle overlapping the tubing; apply heat to overlapped area of the
tubing until adhesive starts to melt, then to the remaining tubing. M23053/5-
115-0 through M23053/5-118-0 overexpanded tubing may be used.

5.1.2.2.3 Second Alternate Repair Method:

Tape next larger size C8844 braided sleeving to damaged sleeving (which
has been seared at braid) with P5372 -1-2 tape and then shrink new length of
P5381 heat-shrinkable tubing over taped section. If connector prevents P5381
from slipping onto wire/wiring harness, split and wrap P5381 before shrinking.

NOTE: This procedure must be approved by the ―Material Review Board‖ or

other authorized ―Board or Team‖.
NOTE: When a small diameter harness (less than 0.5 inch diameter) must be
re-braided, it is not necessary to remove the old braid.

5.1.3 Shrink Tubing Repair

5.1.3.1 When shrink tubing must be replaced on a wiring harness, M23053/5-115-0

through M23053/5-118-0 overexpanded tubing may be used. Also, P5381-X
may be used. Slit the tubing and position on bundle; tie (in at least 2 places)
around bundle overlapping the tubing or alternately use P5372-1-2 tape spiral
wrapped around the entire length of the tubing; apply heat to overlapped area
of the tubing until adhesive starts to melt, then to the remaining tubing. If the
P5372-1-2 tape is used, remove tape after tubing cools (for neater
appearance).

5.1.4 Replacing a C8839-3 or –4 Multiplex Network.

5.1.4.1 Use an approved heat gun to unsolder conductors; cut the braid near network
being removed; and remove old sealing material from conductors. Remove
network from the panel, and check that mounting area on the panel is clean.

5.1.4.2 Terminate conductors and network braid to the old braid using a NAS1744-1
solder sleeve.

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5.1.5 Repair of conduit (C2026-X-X) internal fuel tanks.

5.1.5.1 Obtain a piece of P5381-X shrink tubing of sufficient length to extend

approximately 0.5 inch on either side of the damaged area and of a diameter
such that after slitting, the tubing will overlap at least 0.25 inch. After slitting
the tubing, position it on the conduit and tie. A tie should be placed about
every 1.5 inches. Apply heat to the overlapped area until adhesive starts to
melt, then to the remaining tubing, taking care that hot air stream does not
impinge on the conduit. Now remove the tie string.

NOTE: Shrink boots may also be repaired in this manner.

5.1.5.2 When wire numbers are not legible. The tubing may be replaced with a piece
of P5269-( ) tape with wire number affixed.

5.1.6 Repair for C8855 flexible bus bar.

5.1.6.1 When insulation is damaged, it may be repaired using P5381-X shrink tubing.
Slit the tubing and position on bus; tie in place; apply heat to overlapped area
of the tubing until adhesive starts to melt, then to the remaining tubing. After
installation in panel, there may be uninsulated areas of 0.3 inch of the bus.

5.1.7 Repair of connectors with waterproofing.

a) Score the boot lengthwise. Do not cut through boot into the wires.
b) Heat the boot until it becomes flexible and can be peeled off by twisting
around pliers.
c) Score the clear shrink tubing lengthwise. Do not cut through tubing into the
wires.
d) Heat the tubing until it becomes flexible and can be peeled off by twisting
around pliers.
e) Heat the melted adhesive sleeves and clean off as much adhesive as
possible.
f) Remove any corrosion from the connector and backshell by an approved
method.
g) Clean wires and connector plus the boot contact area of backshell with an
approved cleaning agent. Let dry.
h) Accomplish repair/rework of connector.
i) Cover connector face and spray corroded or de-plated areas on connector
and backshell with MIL-C-85054(AS), Type 1 corrosion preventative
compound. Let dry.
j) Install new C2023 shrink boot.

115
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.1.8 Incorporation of Engineering Changes to a Braided Harness.

5.1.8.1 Adding/Deleting Wires to Completed Wiring Harness.

5.1.8.1.1 Added wires shall be braided, to within 6 inches of each end, with the same
single- or double-tracer scheme as that used with the original harness. The
added wires shall be secured to the trunk and harness as indicated below in
(a) or (b). The unbraided portion of the wire(s) at the terminating ends should
be placed under the C8844 sleeving, shrink tubing, backshell arrangement,
convoluted tubing, etc. of the original harness.

a) Adding additional wires to a completed, but not installed, trunk harness.

The additional wires shall be secure to the trunk harness by string ties
(P5289-1) at intervals no greater than 6 inches.
b) Adding additional wires to a trunk harness already installed in the airplane.
The additional wires shall be routed to follow the same path as the
installed harness. The added wires shall be tied to the harness bundle
containing the original harness by string ties (P5289-1) at intervals no
greater than two feet. In cases where the original harness and added
wires are contained within convoluted tubing, conduits, spiral wrap, etc.
string ties are not required, but may be used. The added wires shall be
clamped in the same clamps as the trunk harness.
c) Deleting Wires. Wires to be deleted shall be dead-ended per Paragraph
3.4.10 of this document.
d) When kits are supplied to rework installed trunk and panel harnesses, all
miscellaneous hardware must be included such as:
1. Dead-ending caps - C2105-X.
2. Solder sleeves - NAS1744-X, C8951-X, C8839-50, 16VE049012-1,
etc.
3. Cable clamps - when the size must change.
4. For circular connectors, spare contacts already in the connectors
should be used.

NOTE: The clamp size may be increased if incorporation of the additional

wires so require.

116
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.1.8.2 Broken shield pigtail. If the pigtail is of sufficient length, a shortened solder
sleeve may be used to splice on a like piece of shield. If there is insufficient
pigtail length, the preferred repair is a C8951-X solder sleeve, but using a short
piece of shrink tubing over the lower shield if required. Also, it is permissible to
remove approximately 0.2 inches of the outer jacket, and splice a short piece of
shield to the shield using NAS1744-X solder sleeve.

5.1.9 METAL Braid Repair

5.1.9.1 Refer to Protective Coverings Paragraph 3.6.

5.1.10 Repair of Multiple-Shielded Wiring Harnesses

5.1.10.1 For multiple-shielded wiring harnesses, the following repair procedure is

recommended:

5.1.10.2 Replace shielded wires that require redundant shielding by establishing the
required layers of shielding per the engineering drawings and prepare the
replacement wire in accordance with 16PR106 and 16PR4559, using
appropriate QQB575 overbraid.

5.1.10.3 Piggy-back the replacement wire outside the harness bundle.

5.1.10.4 Prior to terminating to the connector, at a point in the braided sleeving area,
penetrate the existing QQB575 or metal overbraid prior to the endpoint
backshell by creating an opening with an approved tool just large enough to
allow for entry of the replacement wire and metal braid.

5.1.10.5 Feed the replacement wire through the overbraid and into the backshell.

5.1.10.6 Terminate the conductors, wire shield and QQB575 overbraid pig-tail to the
backshell and re-assemble.

5.1.10.7 Use Teflon tape (P5067) to wrap the resulting intersection of the replacement
wire bundle and the existing wiring harness to provide good contact with
existing shielding, ensuring stability to the resulting intersection, and preventing
the migration of gaps in the shield material at the intersection.

5.1.10.8 Cover with appropriate expandable sleeving, terminating with heat shrinkable
tubing (P5381 or M23053) or tape.

5.1.10.9 Secure piggy-backed wire to harness with string-tie (P5289-1) as needed.

117
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.2 Rework

5.2.1 General Requirements

5.2.1.1 This portion is to be used as a guide for the ―Material Review Board‖ (MRB), or
other authorized ―Board or Team‖ for recommended repairs or rework to
wires/wiring harnesses after their completion.

5.2.2 Allowable Rework

5.2.2.1 No repairs (splicing) shall be allowed on primary power wires, flight control
wires, coaxial cables, or multiplex bus.
NOTE: Power feeders that are on the protected side of breakers, over current
sensing contactors/over current sensing modules can be spliced. This does
NOT include over current sensing transformers on main and stand by power
feeders (current donuts).

5.2.3 Adding additional wires to a trunk harness already installed in the aircraft.

5.2.3.1 The additional wires shall be routed to follow the same path as the installed
harness. The added wires shall be tied to the harness bundle containing the
original harness by string ties (lacing tape P5289-1) at intervals no greater than
two feet. In cases where the original harness and added wires are contained
within convoluted tubing, conduits spiral wrap, etc., string ties are not required,
but may be used. The added wires shall be clamped in the same clamps as
the trunk harness.

5.2.4 Touch up procedure for surface marks on electrical connectors.

5.2.4.1 The finish of connectors and backshells having an olive drab (―OD‖) cad finish
may be compromised during assembly due to movement of the aircraft and
assembly/installation handling, and may require a touch up to pass inspection.

5.2.4.2 The parts are manufactured from aluminum with a nickel underplate followed
by cadmium and finally an olive drab conversion (chromate) coating.

5.2.4.3 The recommended procedure, which is stated below, should be used to touch
up all olive drab connectors, backshells, and accessories. Exceptions are
engine connectors who see a high temperature environment and connectors
that have had the nickel underplate compromised.

5.2.4.4 To determine if a damaged surface can be touched-up, reference FPS-3017

Section 3.8.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.2.4.5 Parts that are not found to be rejectable may be touched up by using the
following procedure:

NOTE: DO NOT cover with OD paint those markings that include but are not
limited to (1) manufacture name or symbol, (2) date code, (3) manufacturer
part number, (4) military or industry or LMTAS part number. DO NOT cover
with OD paint more than 1/3 total of the blue rear release color band, or the red
fully mated color band.

1. Surfaces to be touched up shall be cleaned with approved solvents or

degreasing solutions and dried.
2. Apply chem film by brush to surfaces to be touched up per MIL-C-5541
(Alodine or Iridite) and dry.
3. Apply 1 coat MIL-P-85582 epoxy primer (preferred), or FMS-3027 or MIL-
P-23347, and dry.
4. Apply polyurethane top coat (OD paint) M/N 45981052 (REF: color
#34127 or #34102, MIL-C-85285), to surfaces to be touched up,
complying with above caution note and dry.

5.2.5 Reworked Harness Dash Number Change

5.2.5.1 If a reworked harness requires a dash number change, hand lettering of the
characters necessary to change the dash number is permissible. This may only
be done once per harness. The hand lettering must be legible and the
characters must be similar to those stamped characters remaining from the
original harness part number.

5.2.6 Relocation of harness IDENTIFIER or reference designator identification

5.2.6.1 When harness identifier or reference designators on a harness are not visible
when installed on the aircraft, re-position harness so that harness identifiers or
reference designators are visible.
If the harness identifiers or reference designators cannot be made visible by
repositioning the harness, then the harness identifier or reference designators
should be relocated on the harness by either moving the existing ones or
removing existing ones and replacing with new ones:
a) Identifiers being relocated should be heated only enough to make flexible
enough to relocate within 4 inches of location specified on HAD (previous
location).
b) Harness identifier or reference designators being replaced should be
located in visible locations within 4 inches of location specified on HAD
(previous location). Re-identification should be per Paragraph 3.2.5 of this
document.

119
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

NOTE: In repetitive situations where harness identifiers or reference

designators are not visible when installed on the aircraft, the HAD should
be revised to specify a visible location without a dash number change.

5.3 Rework for Incorporation of Engineering Changes

5.3.1 General Requirements

5.3.1.1 This port is to be used as a guide for ―Approved Suppliers‖ or other authorized
―Teams‖ for recommended rework to wires/wiring harnesses after their
completion when authorized by an appropriate Q/A, planning, purchase order
or other procuring document.

5.3.2 Braided Harness

5.3.2.1 Adding/Deleting Wires to Completed Wiring Harness

5.3.2.1.1 Added wires shall be braided, to within 6 inches of each end, with the same
single- or double-tracer scheme as that used with the original harness. The
added wires shall be secured to the trunk and harness as indicated below in
(a) or (b) (Piggybacks). The unbraided portion of the wire(s) at the terminating
ends should be placed under the C8844 sleeving, shrink tubing, backshell
arrangement, convoluted tubing, etc. of the original harness.
a) Adding additional wires to a completed, but not installed, trunk harness.
The additional wires shall be secure to the trunk harness by string ties
(P5289-1) at intervals no greater than 6 inches.
b) In cases where the original harness and added wires are contained
within convoluted tubing, conduits spiral wrap, etc., string ties are not
required, but may be used.

5.3.2.1.2 Deleting Wires. Wires to be deleted shall be dead-ended per Paragraph 3.4.10
of this document.

5.3.2.1.3 When kits are supplied to rework trunk and panel harnesses, all miscellaneous
hardware must be included such as:
a) Dead-ending caps - C2105-X.
b) Solder sleeves - NAS1744-X, C8951-X, C8839-50, 16VE049012-1, etc.
c) For circular connectors, spare contacts already in the connectors should
be used.

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Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.3.2.2 Rework of Shield Pigtail

5.3.2.2.1 If the pigtail is of sufficient length, a shortened solder sleeve may be used to
splice on a like piece of shield. If there is insufficient pigtail length, the
preferred repair is a C8951-X solder sleeve, but using a short piece of shrink
tubing over the lower shield if required. Also, it is permissible to remove
approximately 0.2 inches of the outer jacket, and splice a short piece of shield
to the shield using NAS1744-X solder sleeve.

5.3.3 Rework of Multiple-Shielded Wiring Harnesses

5.3.3.1 For multiple-shielded wiring harnesses, the following rework procedure is

recommended:

5.3.3.2 Replace shielded wires that require redundant shielding by establishing the
required layers of shielding per the engineering drawings and prepare the
replacement wire in accordance with 16PR106 and 16PR4559, using
appropriate (AA59569) QQB575 overbraid.

5.3.3.3 Prior to terminating to the connector, at a point in the braided sleeving area,
penetrate the existing (AA59569) QQB575 or metal overbraid prior to the
endpoint backshell by creating an opening with an approved tool just large
enough to allow for entry of the replacement wire and metal braid.

5.3.3.4 Feed the replacement wire through the overbraid and into the backshell.

5.3.3.5 Terminate the conductors, wire shield and (AA59569) QQB575 overbraid pig-
tail to the backshell and re-assemble.

5.3.3.6 Use Teflon tape (P5067) to wrap the resulting intersection of the replacement
wire bundle and the existing wiring harness to provide good contact with
existing shielding, ensuring stability to the resulting intersection, and preventing
the migration of gaps in the shield material at the intersection.

5.3.3.7 Cover with appropriate expandable sleeving, terminating with heat shrinkable
tubing (P5381 or M23053) or tape.

5.3.3.8 Secure piggy-backed wire to harness with string-tie (P5289-1) at intervals no

greater than 6 inches.

121
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.3.4 Splicing

5.3.4.1 No rework by splicing shall be allowed on primary power wires, flight control
wires, coaxial cables or multiplex bus.
NOTE: Power feeders that are on the protected side of breakers, over current
sensing contactors/over current sensing modules can be spliced. This does
NOT include over current sensing transformers on main and stand by power
feeders (current donuts).

5.3.4.2 Wires to be re-terminated near a connector. Remove wires from the connector,
and splice in new wires within 2 to 6 inches of the connector. Only the C4812-(
) sealed crimp splice shall be used.

5.3.4.3 Re-termination of wires in areas other than as above and if accessible, it may
be spliced using the C4812-( ) splice. For wires in an inaccessible area, braid
and route a new wire outside the braided bundle, terminate, and dead end the
unused wires. The new wire must be the same part number as the one it is
replacing.

5.3.5 SHRINK TUBING REWORK

5.3.5.1 When shrink tubing must be replaced on a wiring harness, M23053/5-115-0

through M23053/5-118-0 over-expanded tubing may be used. Also, P5381-X
may be used. Slit the tubing and position on bundle; tie (in at least 2 places)
around bundle overlapping the tubing or alternately use P5372-1-2 tape spiral
wrapped around the entire length of the tubing; apply heat to overlapped area
of the tubing until adhesive starts to melt, then to the remaining tubing. If the
P5372-1-2 tape is used, remove tape after tubing cools (for neater
appearance).

122
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.3.6 Rework OR Replacement OF BRAID

5.3.6.1 When braid must be reworked: Preferred method: remove the affected braid
and tape the remaining edges with P5372-1-2. String tie the proper size of
C20955 sleeving in place. Overlap any braid, sleeving, or convoluted tubing
that is encountered approximately 0.5 inches and secure the ends using
P5381-X. Alternate Method: if the affected area is no larger than one-half the
wiring bundle diameter, P5384-X tape may be applied. Spiral wrap the tape
with 50% overlap. When the affected area is larger than this, P5381-X tubing
up to six inches long may be used as follows: Slit tubing and position on
bundle; tie (in at least 2 places) around bundle overlapping the tubing; apply
heat to overlapped area of the tubing until adhesive starts to melt, then to the
remaining tubing. M23053/5-115-0 through M23053/5-118-0 over-expanded
tubing may be used. Second Alternate Method: Tape next larger size C8844
braided sleeving to affected sleeving (which has been seared at braid) with
P5372 -1-2 tape and then shrink new length of P5381 heat-shrinkable tubing
over taped section. If connector prevents P5381 from slipping onto wire/wiring
harness, split and wrap P5381 before shrinking.
NOTE: When a small diameter harness (less than 0.5 inch diameter) must be
re-braided, it is not necessary to remove the old braid.

5.3.7 Rework of Metal Braid

5.3.7.1 Refer to Protective Coverings Paragraph 3.6.

5.3.8 Replacing a C8839-3 or –4 Multiplex Network.

5.3.8.1 Use an approved heat gun to unsolder conductors; cut the braid near network
being removed; and remove old sealing material from conductors. Remove
network from the panel, and check that mounting area on the panel is clean.

5.3.8.2 Terminate conductors and network braid to the old braid using a NAS1744-1
solder sleeve.

5.3.9 Rework of Conduit (C2026-X-X) Internal Fuel Tanks.

5.3.9.1 Obtain a piece of P5381-X shrink tubing of sufficient length to extend

approximately 0.5 inch on either side of the affected area and of a diameter
such that after slitting, the tubing will overlap at least 0.25 inch. After slitting the
tubing, position it on the conduit and tie. A tie should be placed about every 1.5
inches. Apply heat to the overlapped area until adhesive starts to melt, then to
the remaining tubing, taking care that hot air stream does not impinge on the
conduit. Now remove the tie string.
NOTE: Shrink boots may also be reworked in this manner.

123
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.3.9.2 When wire numbers are not legible, The tubing may be replaced with a piece of
P5269- ( ) tape with wire number affixed.

5.3.10 Rework of C8855 Flexible Bus Bar.

5.3.10.1 When insulation is affected, it may be reworked using P5381-X shrink tubing.
Slit the tubing and position on bus; tie in place; apply heat to overlapped area
of the tubing until adhesive starts to melt, then to the remaining tubing. After
installation in panel, there may be un-insulated areas of 0.3 inch of the bus.

5.3.11 Rework of Connectors with Waterproofing.

a) Score the boot lengthwise. Do not cut through boot into the wires.
b) Heat the boot until it becomes flexible and can be peeled off by twisting around
pliers.
c) Score the clear shrink tubing lengthwise. Do not cut through tubing into the
wires.
d) Heat the tubing until it becomes flexible and can be peeled off by twisting
around pliers.
e) Heat the melted adhesive sleeves and clean off as much adhesive as
possible.
f) Remove any corrosion from the connector and backshell by an approved
method.
g) Clean wires and connector plus the boot contact area of backshell with an
approved cleaning agent. Let dry.
h) Accomplish rework of connector.
i) Cover connector face and spray corroded or de-plated areas on connector and
backshell with MIL-C-85054(AS), Type 1 corrosion preventative compound.
Let dry.
j) Install new C2023 shrink boot.

5.3.12 Touch up Procedure for Surface Marks on Electrical Connectors.

5.3.12.1 The finish of connectors and backshells having an olive drab (―OD‖) cad finish
may be compromised during assembly due to movement of the aircraft and
assembly/installation handling, and may require a touch up to pass inspection.

5.3.12.2 The parts are manufactured from aluminum with a nickel underplate followed
by cadmium and finally an olive drab conversion (chromate) coating.

124
Engineering Instructions for Manufacture and Installation of Wiring Harnesses
F-16
16PR145

5.3.12.3 The recommended procedure, which is stated below, should be used to touch
up all olive drab connectors, backshells, and accessories. Exceptions are
engine connectors who see a high temperature environment and connectors
that have had the nickel underplate compromised.

5.3.12.4 To determine if the part can be touched up. Surface marks which are
discernible by touch (typically greater than .001‖ deep) on the part are subject
to rejection or other disposition that is beyond the scope of 16PR145. A
fingernail or plastic indicator shall be used to determine the presence of a
rejectable surface mark. (REF: PP 3.8.2., FPS-3017)

5.3.12.5 Parts that are not found to be rejectable may be touched up by using the
following procedure:
NOTE: DO NOT cover with OD paint those markings that include but are not
limited to (1) manufacture name or symbol, (2) date code, (3) manufacturer
part number, (4) military or industry or LMTAS part number. DO NOT cover
with OD paint more than 1/3 total of the blue rear release color band, or the red
fully mated color band.

1. Surfaces to be touched up shall be cleaned with approved solvents or

125
Appendix A Fabrication Aids

A-1
F. A. MIL-C-39029-4
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/4 CONTACTS

(MIL-C-39029/4 Contacts, Electrical Connector, Pin, Crimp, Removable Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/4
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and shall
have no more than 0.03 inch exposed bare conductor at rear of crimp barrel.

A1-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

6. Minimum acceptable insulation gap – flush with the contact barrel. Under no
circumstances is the wire to be bent sharply at the contact to verify insulation
gap. A gentle bend (approximately 15 degrees) is allowable when the
insulation end cannot be located otherwise.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A1-2
F. A. MIL-C-39029-5
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/5 CONTACTS

(MIL-C-39029/5 Contacts, Electrical Connector, Socket, Crimp, Removable
Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/5
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A2-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A2-2
F. A. MIL-C-39029-9
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/9 CONTACTS

(MIL-C-39029/9 Contacts, Electrical Connector, Pin, Crimp, Removable,
Thermocouple Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/9
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A3-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A3-2
F. A. MIL-C-39029-10
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/10 CONTACTS

(MIL-C-39029/10 Contacts, Electrical Connector, Socket, Crimp, Removable,
Thermocouple Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/10
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A4-1
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and shall
have no more than 0.03 inch exposed bare conductor at rear of crimp barrel.

4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A4-2
F. A. MIL-C-39029-16
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/16 CONTACTS

(INACTIVE for NEW DESIGN)
(MIL-C-39029/16 Contacts, Electrical Connector, Socket, Crimp, Removable,
Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/16
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A5-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A5-2
F. A. MIL-C-39029-17
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/17 CONTACTS

(INACTIVE for NEW DESIGN)
(MIL-C-39029/17 Contacts, Electrical Connector, Socket, Crimp, Removable,
Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/17
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A6-1
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and shall
have no more than 0.03 inch exposed bare conductor at rear of crimp barrel.

4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A6-2
F. A. MIL-C-39029-18
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/18 CONTACTS

(INACTIVE for NEW DESIGN)
(MIL-C-39029/18 Contacts, Electrical Connector, Pin, Crimp, Removable, Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/18
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A7-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A7-2
F. A. MIL-C-39029-22
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/22 CONTACTS

(MIL-C-39029/22 Contacts, Electrical Connector, Socket, Crimp, Removable,
Type)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/22
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor).

A8-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A8-2
F. A. MIL-C-39029-27
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/27 CONTACTS

(MIL-C-39029/27 Contacts, Electrical Connector, Socket, Crimp, Removable,
Shielded, Size 12)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS production operations for terminating
M39029/27 contact for coax cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. Basic crimping tool M22520/2-01 with M22520/2-34 positioner or Daniels

K323 positioner.
2. Basic crimping tool M22520/31-01 with M22520/31-02 positioner.

CABLE/WIRE PREPARATION

1. Different parts are identified in Figure 1.

a) Shield Crimp Bushing/Sleeve

b) Rear Insulator
c) Inner Pin Contact
d) Outer Socket Contact

A9-1
2. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

NOTE: Different dimension for Amphenol product.

3. Insert the shield crimp bushing over the cable jacket and flare the shield to
expose the dielectric. Strip the center conductor in accordance with Figure 3.
4. Carefully slide the rear insulator over the center conductor and under the
cable shield until the dielectric bottoms against the rear insulator recess.
5. Carefully slide the inner pin contact over the conductor, making sure that the
conductor is visible in the inspection window and butts against the rear
insulator. (See Figure 4) Trim the center conductor, if necessary.
6. Crimp the inner pin contact using an approved tool (MTPA-002).
7. Slide the outer socket contact over the inner pin contact assembly until the
inner pin contact is fully seated.
8. Slide the shield crimp bushing over the cable shield in accordance with Figure
5. Trim the excess shield between the shield crimp bushing and the outer
socket contact.
9. Crimp the shield crimp bushing with an approved tool (MTPA-002).

ACCEPT/REJECT CRITERIA

1. There shall be no gap between the inner pin contact and the inner insulator
(Figure 4).
2. The center conductor shall be visible in the inspection window of the inner pin
contact (Figure 4).
3. Gap between outer jacket of the cable and shield crimp bushing shall not
exceed 0.06 inch (Figure 5).
4. The distance between the shield crimp bushing and the outer socket contact
―neck‖ shall be in accordance with the Figure 5.
5. There shall be not cracks/peeling after crimping the inner pin contact or shield
crimp bushing.

A9-2
A9-3
A9-4
F. A. MIL-C-39029-28
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/28 CONTACTS

(MIL-C-39029/28 Contacts, Electrical Connector, Pin, Crimp, Removable,
Shielded, Size 12)
SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS production operations for terminating
M39029/28 contact for coax cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. Basic crimping tool M22520/2-01 with M22520/2-34 positioner or Daniels

K323 positioner.
2. Basic crimping tool M22520/31-01 with M22520/31-02 positioner.

CABLE/WIRE PREPARATION

1. Different parts are identified in Figure 1.

a) Shield Crimp Bushing/Sleeve

b) Rear Insulator
c) Inner Pin Contact
d) Outer Socket Contact

A10-1
2. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

NOTE: Different dimension for Amphenol product.

ACCEPT/REJECT CRITERIA

A10-2
A10-3
A10-4
F. A. MIL-C-39029-29
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/29 CONTACTS

(MIL-C-39029/29 Contacts, Electrical Connector, Pin, Crimp, Removable)

SCOPE

1. 1This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/29 contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A11-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A11-2
F. A. MIL-C-39029-30
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/30 CONTACTS

(MIL-C-39029/30 Contacts, Electrical Connector, Socket, Crimp, Removable)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/30
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A12-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A12-2
F. A. MIL-C-39029-31
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/31 CONTACTS

(MIL-C-39029/31 Contacts, Electrical Connector, Pin, Crimp, Removable)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/31
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A13-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A13-2
F. A. MIL-C-39029-32
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/32 CONTACTS

(MIL-C-39029/32 Contacts, Electrical Connector, Socket, Crimp, Removable)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/32
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A14-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A14-2
F. A. MIL-C-39029-56
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/56 CONTACTS

(MIL-C-39029/56 Contacts, Electrical Connector, Socket, Crimp, Removable)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/56
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A15-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A15-2
F. A. MIL-C-39029-58
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/58 CONTACTS

(MIL-C-39029/58 Contacts, Electrical Connector, Pin, Crimp, Removable)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/58
contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A16-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A16-2
F. A. MIL-C-39029-91
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in effect.
The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/91-530 CONTACTS

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) operations for installing M39029/91-530 contacts.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools for
F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. The following instructions provide procedures for installing the M39029/91-530

contact based on engineering requirements. The procedure selected should be
based on applicable engineering. (i.e. A harness which requires M39029/91-530
contact, P5381-2 tubing, and C10979 sealant should utilize Option B – Steps 1-
10 and, where engineering requires the M39029/91-530 contact only, Option A –
Steps 1-9 is applicable.) Figure 4-0 is an illustrated parts breakdown (IPB) of the
M39029/91-530 contact. Verify that you have all the parts before starting the
assembly.

OPTIONS A & B

NOTE
All strip dimensions have +/- .010‖ tolerance.

A17-1
a) Step 1 – Strip the cable as shown in Figure 4-1.
b) Step 2 – Screw bushing over cable jacket as shown in Figure 4-2.
Flare shield and strip inner wires as shown.
c) Step 3 – Assemble spacer over #1 and #2 wires. Assemble the back
insulator over #1 wire and align the slot with #2 wire. This is shown in
Figure 4-3. Present to Inspection.
d) Step 4 – Slide inner socket onto wire #1. Butt the socket firmly against
the wire insulation; trim the conductor if necessary. Wire must be
visible in the inspection hole. See Figure 4-4. Crimp the inner socket
on wire #1 using an M22520/2-01 tool and a M22520/2-37 positioner.
Use tool selector setting number ―5‖.
e) Step 5 – Assemble inner front insulator over the contact and align slot
with wire #2 as shown in Figure 4-5.
f) Step 6 – Slide the intermediate pin contact over the inner front
insulator, being sure that all strands of the #2 wire enter the small hole
in the large end of the contact. See Figure 4-6. Crimp the
intermediate contact, using tool M22520/5-01 and die set M22520/5-
200. Present to Inspection.
g) Step 7 – Slide the large front insulator over the contact assembly as
shown in Figure 4-7. Assure that it butts firmly.
h) Step 8 – Slide the outer socket contact over the insulators until the
inside components butt firmly. As noted in Figure 4-8, a 0.06 gap will
occur at the bushing/outer socket contact interface. Crimp the bushing
and outer socket contact tool M22520/5-01 and die set M22520/5-200.
Present to Inspection.

OPTION A ONLY

i) Step 9 – Slide the heat shrink seal over the outer socket contact until
the end is even with the base of the chamfer on the contact and shrink
seal in accordance with M151. See Figure 4-9A. Present to
Inspection.

OPTION B ONLY

j) Step 9 – Slide the C10979 sealant such that it butts against the
bushing, shown as surface ―A‖ in Figure 4-9B.

OPTION B ONLY

k) Step 10 – Slide the P5381-2 tubing over the outer socket contact until
the ―A‖ end of the tubing is approximately even with the chamfer on the
contact and shrink in accordance with M151 and in the following order:
(See Figure 4-10)

a) Shrink side ―A‖, first ensuring that tubing shrinks against the base of
the chamfer. Note that the maximum gap allowed is .25‖.
b) Shrink side ―B‖.
c) Shrink from ―A‖ to ―B‖. Present to Inspection.

A17-2
H
EA
T
SH
* * RIN
** K
BU SE
SH AL
IN
G
(IF S
AV PA
AI CE
LA R
BL
IN B E
SU AC 0
LA K
TO
IN R
N
ER
SO
C
KE
T
IN
N
I N ER
SU F
LA RO

A17-3
TO N
R T
INSTALLATION OF M39029/91-530 CONTACT

IN
PI TE
N RM
C E
O D
N IA
TA T
C E
T
R
LA INS
R
G ULA
E T
F O
NT
O R

O
UT
C ER
O S
NT O
AC C K
T ET
A17-4
FIGURE 4-9A –Heating Shrink Seal

A17-5
A17-6
F. A. MIL-C-39029-101
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/101 CONTACTS

(MIL-C-39029/101 Contacts, Electrical Connector, Socket, Crimp, Removable)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/101 contacts on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A18-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A18-2
F.A. M39029/103-559
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/103-559 CONTACTS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for terminating
M39029/103-559 contacts.
2. This Fabrication Aid is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002
3. Workmanship Standards for Electrical Assemblies – FZM-8027.
4. LMAero Soldering Process J-STD-001, Class III.

TOOLS REQUIRED:
1. Crimp tool M22520/5-01 with M22520/5-03 positioner.
2. Soldering Iron
3. Heat source CV-5300 or equivalent.

CONTACT ASSEMBLY PARTS:

1. Different parts are identified in Figure 1.
A. Outer Ferrule
B. Contact
C. Body Assembly

A19-1
PIN

OUTER BODY
FERRULE CONTACT ASSEMBLY

SOCKET

FIGURE 1

CABLE PREPARATION
1. Strip the cable in accordance with Figure 2. All cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

FIGURE 2

CABLE PREPARATION FOR M17/152-00001 CABLE

1. Strip the cable in accordance with Figure 3. All cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

0.160‖
0.250‖

0.460‖

FIGURE 2 3
FIGURE
INSERTING PREPARED CABLE INTO CONTACT
1. Slide the outer ferrule over the cable jacket.
2. SLIGHTLY flare the braid for the body assembly to bottom out against
dielectric.

A19-2
3. Pre-tin the center conductor, making sure there is no solder spikes or
excess solder on the pre-tinned wire.
4. Place the contact on the center conductor against the dielectric of the
cable. The center conductor shall be visible in the inspection hole. Trim
the center conductor, if necessary. See Figure 4.

CONTACT
OUTER FERRULE
FIGURE 3 4
FIGURE

5. Using a CV-5300 heat gun (or equivalent), solder the contact flush with
the cable dielectric.
NOTE: Excessive heat will "swell" cable.
6. Push cable assembly into body assembly until bottomed. Make sure body
assembly is under the braid of the cable. Trim braid if necessary. See
Figure 5.

OUTER FERRULE

BODY ASSEMBLY
FIGURE 4
FIGURE 5

7. Slide the outer ferrule on the braid assembly. Crimp the outer ferrule with
crimp tool M22520/5-01 and position M22520/5-03. See Figure 6.

BODY ASSEMBLY
OUTER FERRULE

FIGURE 5
FIGURE 6

A19-3
ACCEPT/REJECT CRITERIA:
1. Soldered contact shall be examined for the following criteria:
a. Contact butts against the dielectric.
b. No solder on the outside surface of the contact.
2. The crimped connector shall be examined for crimping of the outer ferrule.
THE BODY OF THE ASSEMBLY SHALL NOT BE DEFACED DURING
CRIMPING.
3. Crimping shall be examined for correct crimping indentations, no cracked
ferrules.
4. Reference LMAero Soldering Process J-STD-001, Class III
5. FZM 8027, shall be referenced for accept/reject criteria.

A19-4
F. A. M39029/103-560
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/103-560 CONTACTS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/103-560 contacts.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document.

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Crimp tool number M22520/5-01.

2. Crimp die number M22520/5-03.

3. Soldering iron.

4. Heat source CV-5300 or equivalent.

WIRE/CABLE PREPARATION:

1. Different parts are identified in Figure 1.

2. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of braid, dielectric, and center
conductor.

3. Pre-tin the center conductor, making sure that there is no excess solder.

4. Slide the outer ferrule on the cable (Figure 3)

A20-1
5. SLIGHTLY flare the braid for the body assembly (Figure 3).

6. Place the contact on the center conductor such that it butts against the
dielectric of the cable (Figure 3). Trim if necessary. The center conductor
should now be visible in the inspection hole.

7. Using CV-5300 (or equivalent) as a heat source, gently heat the contact until
it solders to the center conductor. Precaution shall be taken to avoid solder
on outside surface of the contact.

NOTE: Excessive heat will "swell" the dielectric of the cable.

8. Install the body assembly so that the inner ferrule slides under the braid of the
cable. Push the cable assembly so that contact bottoms in the body
assembly (Figure 3).

9. Slide the outer ferrule on the braid up against the body assembly. Crimp the
outer ferrule using cavity "A" of the die (M22520/5-03). During crimping,
ensure that ONLY ferrule is crimped. There is no guide for the crimping.
Hence "eye-balling" is required for crimping the ferrule (Figure 3).

ACCEPT/REJECT CRITERIA

1. Soldered contact shall be examined for the following criteria:

a) Contact butts against the dielectric.

b) No solder on the outside surface of the contact.

2. The crimped connector shall be examined for crimping of the outer ferrule.
THE BODY OF THE ASSEMBLY SHALL NOT BE DEFACED DURING
CRIMPING.

3. Crimping shall be examined for correct crimping indentations, no cracked

ferrules.

4. FZM 8027 shall be referenced for accept/reject criteria.

A20-2
A20-3
F. A. C10751
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C10751 CONTACTS

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) production operations for terminating C10751 contact
for coaxial cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for reference F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED

1. Crimp tool M22520/2-01 with positioner M22520/2-34, selector setting

number 3.

2. Crimp tool M22520/31-01 (or equivalent) with positioner M22520/31-02 (or

equivalent).

CABLE/WIRE PREPARATION:

1. Different parts are identified in Figure 1, Attachment 1.

2. Strip the cable in accordance with Figure 2, Attachment 1. All the cuts shall
be square. Precautions shall be taken against nicks of shield, insulation, and
conductors.

A21-1
3. Slide the shrinkable tubing and shield crimp sleeve back over the cable
jacket.

4. Flare the cable shield (Figure 3, Attachment 1).

5. Slide inner sleeve over the cable dielectric.

6. Slide the rear insulator over the center conductor until it is flush with the
dielectric (Figure 3, Attachment 1).

7. Slide the inner pin contact over the center conductor. Set the contact flush
with the rear insulator and crimp it. M22520/2-01 with positioner M22520/2-
34 (selector setting number 3) shall be used for crimping the inner contact.

8. Assure that the center conductor is visible in the inspection window of the
inner contact.

9. Insert the outer socket contact over the inner assembly and under the shield
until the center and front insulator is fully seated (figure 4, Attachment 1).

10. Push the shield forward (trim if necessary). Slide the shield crimp sleeve over
the shield and the connector barrel (Figure 4, Attachment 1). Assure that
maximum terminated length is met (Figure 4, Attachment 1).

11. Crimp the shield crimp sleeve with M22520/31-01 (or equivalent) with
positioner M22520/31-02 (or equivalent). Crimp once, rotate 90 degrees, and
crimp again. The diameter over the crimp sleeve, after crimping, should not
be greater than 0.156 inch sleeve.

12. Slide the heat shrinking tubing over the shield crimp sleeve and shrink using
an approved heat source (Figure 5, Attachment 1).

ACCEPT/REJECT CRITERIA

1. Inner pin contact shall be examined for correct crimping (Figure 3, Attachment
1).

2. Shield termination shall be examined for proper crimp to the body of the outer
socket contact.

3. As a final assembly, the heat shrinking tubing over the assembly shall be
verified for proper shrinking.

4. FZM-8027 shall be referenced for accept/reject criteria.

A21-2
A21-3
A21-4
F. A. C10970-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C10970-1 CONTACTS

(C10970-1 Contact, Coax, Crimp, Socket,)

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS) production operations for terminating
C10970-1 contact on coaxial cable.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED:

1. Crimping tool M22520-2/01 – w – positioner 2/24.

2. Crimping tool M22520-10-01 –w- die M22520/10-06.

3. NOTE: LISTING OF ALL APPROVED TOOLS IS GIVEN IN MTPA-002.

CABLE/WIRE PREPARATION:

1. Different parts of the contact are identified in Figure 1.

2. Crimping may be achieved by either using filler wire or doubling the center
conductor. It is preferable, however, to use filler wire, since it is easy to get
contact flush with the insulating bushing. If the center conductor is doubled,
the applicable steps are 4, 8, and 9.

A22-1
3. Slide, sealing boot, tubing, and ferrule over cable. Strip per Figure 2 as
applicable. Fold the shield back over cable jacket.

4. Insert the insulating bushing over the center conductor of coax so that it
covers the inner insulation of the coax.
5. Using Filler Option: Trim the center conductor as required s that the inner
conductor contact is flush with the insulating bushing. DO NOT CRIMP YET.

6. Strip a filler wire and insert in the contact barrel. Trim it flush with ―well rim‖ of
the inner conductor contact. At this stage, the contact needs to be held so
that ―well opening‖ faces upwards.

7. Carefully insert the center conductor until the contact is flush with the
insulating bushing. (At this stage, the filler wire is inside the well also.) Now
go to Step 10.

8. Using Optional Assembly (Doubling Conductor): Insert the center conductor

gently into the insulating bushing and double the conductor towards the
insulating bushing.

9. Gently insert the conductor (doubled) into the barrel of contact. Ensure that
wire is visible in the inspection window and the contact is flush with the
insulating bushing. (Figure 3A)

10. Crimp the contact using tool in Paragraph 1 of Tools Required (or equivalent
per MTPA-002).

11. Insert the contact into the contact body. Ensure that it locks into the contact
body.

12. Roll the shield on the contact body. Trim the excess of shield as required.

13. Slide the ferrule over the shield and against the contact body. (Trim excess
of shield with scissors if necessary.) (Figure 3B)

14. Crimp the ferrule using tool in Paragraph 2 of Tools Required (or equivalent
per MTPA-002).

15. Slide the shrink tubing (M23053 type) over the crimped ferrule and shrink it
over the coax and ferrule. Ensure that the sleeving (after shrunk) overlaps
the crimped ferrule a minimum of 80%. (Figure 3C)
16. Insert the coaxial contact assembly into the connector and slide sealing boot
to seal the connector entry. (Figure 3C)

A22-2
ACCEPT/REJECT CRITERIA:

1. Verify that the center conductor is visible in the inspection window of contact.

2. Proper crimping of contact and ferrule shall be verified.

3. FZM 8027 shall be referenced to delineate accept/reject conditions.

A22-3
A22-4
A22-5
F. A. C10994-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C10994-3 CONTACTS

(C10994-3 Contact, Socket, Crimp,)
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS) Vendor/Supplier operations for
terminating C10994-3 contact on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION:

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

A23-1
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA:

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A23-2
F. A. C2063-56
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C2063-56 CONTACTS

(C2063-56 Contact, Relay, Socket, Crimp,)
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS) Vendor/Supplier operations for
terminating C2063-56 contact on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION:

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

A24-1
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA:

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A24-2
F. A. C2063-57
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C2063-57 CONTACTS

(C2063-57 Contact, Relay, Socket, Crimp,)
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS) Vendor/Supplier operations for
terminating C2063-57 contact on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION:

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact
.

A25-1
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.
6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA:

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A25-2
F. A. C4870-12-12
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C4870-12-12 CONTACTS

(C4870-12-12 Contact, Relay, Socket, Crimp,)

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS) Vendor/Supplier operations for
terminating C4870-12-12 contact on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION:

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

A26-1
4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA:

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A26-2
F. A. C4870-12-16
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C4870-12-16 CONTACTS

(C4870-12-16 Contact, Relay, Socket, Crimp,)
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Tactical Aircraft Systems (LMTAS) Vendor/Supplier operations for
terminating C4870-12-16 contact on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs – MTPA-002.

3. Workmanship Standard for Electrical Assemblies – FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

CABLE/WIRE PREPARATION:

1. Cut the wire to the correct length as defined by the Engineering/Tool ensuring
that there is enough slack to allow re-termination as defined by Engineering
requirements.

2. All cuts shall be square. (Perpendicular to the centerline of the conductor)

4. Position the contact in the jaws of the crimping tool to hold the contact while
the wire is inserted in the barrel of the contact.

A27-1
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.

6. Crimp the contact on to the wire fully and release the crimping tool.

ACCEPT/REJECT CRITERIA:

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection

hole exists).

3. As visually determined, the depth and configuration of the crimp impression

shall be consistent with impressions made by the tool approved for this
particular application.

4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable

provided:

a) Cracking does not occur.

b) The conductor termination meets wire pull requirements (found in the
applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is 0.03
inch.

7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A27-2
F. A. 8340709-1P
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF 8340709-1P CONTACTS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating 8340709-
1P contacts for twin-axial cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document.

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard For Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. AA-400 Super heater with minisolder sleeve terminator reflector or equivalent

heat source.

WIRE/CABLE PREPARATION:

1. Different parts are identified in Figure 1.

A. Strain Relief Sleeve
B. Braid Terminator
C. Contact
D. Connector Body

A28-1
STRAIN RELIEF BRAID
SLEEVE TERMINATOR CONTACT CONNECTOR
BODY

FIGURE 1

2. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of braid, insulation, and conductors.

0.250‖

0.60‖

FIGURE 2

3. Pre-tin the conductors, making sure that there is no excess solder.

4. Trim the conductors in accordance with Figure 3. Note that the white wire is
signal wire and is the center conductor.

0.400‖

0.200‖

FIGURE 3

5. Slide strain relief tubing and braid terminator on the twin-axial wire.

6. Insert the conductors as follows (Figure 4):

A28-2
NOTE: THE TWIST IS SHOWN TO IDENTIFY THAT WHITE WIRE IS THE CENTER CONDUCTOR

FIGURE 4

a) Signal conductor (white) into the inner insulating sleeve.

b) Purple conductor in between the two insulating sleeves.

c) Hold the contact with holding tool type Raychem AD-1480 or equivalent.

d) Using AA-400 (or equivalent) as a heat source, heat the contact until it
solders to the two conductors. The conductor contours should be visible
in the inspection windows.

e) Insert the contact into the rear of the connector until the retention slip
locks(Figure 5).

f) Comb the braid forward (trim if necessary). Slide the braid terminator over
the braid and the connector barrel (Figure 6).

FIGURE 6

g) Heat the terminator assembly until solder pre-forms melt and flow (Figure
7).

FIGURE 7

A28-3
h) Slide the strain relief tubing over the terminator assembly and gently
shrink it, starting from the body of the connector towards the wire.

ACCEPT/REJECT CRITERIA:

1. Braid termination shall be examined for proper flow of solder to the braid and
the body of the connector.

2. As a final assembly, the strain relief tubing over the assembly shall be
examined for correct shrinking. The numbers over the tubing shall be legible.

3. FZM 8027 shall be referenced for accept/reject criteria.

A28-4
F. A. 8340709-1S
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF 8340709-1S CONTACTS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating 8340709-
1S contacts for twin-axial cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document.

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard For Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. AA-400 Super heater with minisolder sleeve terminator reflector or equivalent

heat source.

WIRE/CABLE PREPARATION:

1. Different parts are identified in Figure 1.

A. Strain Relief Sleeve
B. Braid Terminator
C. Contact
D. Connector Body

A29-1
STRAIN RELIEF BRAID
SLEEVE TERMINATOR CONTACT CONNECTOR
BODY

FIGURE 1

2. Strip the cable in accordance with Figure 2 . All the cuts shall be square.
Precautions shall be taken against nicks of braid, insulation, and conductors.

0.250‖

0.60‖

FIGURE 2

3. Pre-tin the conductors, making sure that there is no excess solder.

4. Trim the conductors in accordance with Figure 3. Note that the white wire is
signal wire and is the center conductor.

0.400‖

0.200‖

FIGURE 3

5. Slide strain relief tubing and braid terminator on the twin-axial wire.

6. Insert the conductors as follows (Figure 4):

A29-2
NOTE: THE TWIST IS SHOWN TO IDENTIFY THAT WHITE WIRE IS THE CENTER CONDUCTOR

FIGURE 4

a) Signal conductor (white) into the inner insulating sleeve.

b) Purple conductor in between the two insulating sleeves.

c) Hold the contact with holding tool type Raychem AD-1480 or equivalent.

d) Using AA-400 (or equivalent) as a heat source, heat the contact until it
solders to the two conductors. The conductor contours should be visible
in the inspection windows.

e) Insert the contact into the rear of the connector until the retention slip
locks(Figure 5).

f) Comb the braid forward (trim if necessary). Slide the braid terminator over
the braid and the connector barrel (Figure 6).

FIGURE 6
g) Heat the terminator assembly until solder pre-forms melt and flow (Figure
7).

FIGURE 7

A29-3
h) Slide the strain relief tubing over the terminator assembly and gently
shrink it, starting from the body of the connector towards the wire.

ACCEPT/REJECT CRITERIA:

1. Braid termination shall be examined for proper flow of solder to the braid and
the body of the connector.

2. As a final assembly, the strain relief tubing over the assembly shall be
examined for correct shrinking. The numbers over the tubing shall be legible.

3. FZM 8027 shall be referenced for accept/reject criteria.

A29-4
F. A. M39029-73
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION PROCEDURE FOR SOLDER CONTACTS

M39029/73
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations and describes the methods
for terminating M39029/73 solder contacts for shielded cables and twisted
pairs on F-16 wire harnesses.

2. This Fabrication Aid is applicable for all F-16 programs.

3. These contacts may be inserted in any M83723 12-AWG contact cavity.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved heating tool, reflector and holding fixture.

CABLE/WIRE PREPARATION:

1. Part numbers are identified with color bands in accordance with Table 1.

TABLE 1

MIL P/N COLOR BAND

M39029 FIRST SECOND THIRD
/73-396 Orange White Blue
/73-397 Orange White Violet
73/-398 Orange White Gray

A30-1
2. Strip cable in accordance with Figure 1. Ensure that all strands of shield are
cut square and even. For twisted pair, a sequence of sketches is identified in
Figure 1-4. The white wire shall be inserted into the center pin (C4930-26-
1P1).

3. Gently heat the center conductor with an approved soldering iron and apply
solder (SN63) to the center conductor to pre-tin the stranded center
conductor.

4. Assure that there are no solder spikes or excess solder on the center
conductor.

5. A small amount of flux may be applied to the shield to aid in shield

termination; however, it is not always required. If flux is used, type RMA (MIL-
F-14256) shall be used.

6. Gently push a contact over the prepared cable until it stops. Rotating the
contact slightly during cable insertion will assist shield strands from catching.

If a twisted pair cable is used, the longer (white)

wire will go into inner insulation sleeve and the
shorter ground/violet wire will go between outer and
inner insulation sleeve. (See Figures 1-4.)

NOTE: The ground conductor must not be positioned in

one of rear inspection windows, but shall be
positioned between the two rear windows.

7. Insert the mating end of the contact into a holding fixture (AD-1319 or AD-
1494).

8. Using an approved heat source, shrink the insulating sleeve down around the
cable/wire, then direct heat towards the forward inspection window (smaller
solder pre-form). The shield pre-form will melt first. When the solder pre-
form flows, move the heat closer towards forward window (smaller solder pre-
form) until the pre-form flows.

IT IS ESSENTIAL TO IDENTIFY FLOWING OF THE SOLDER

NOTE: The approved heat source must be used with a reflector.

9. Removing heat, do not move the wire (or the connection) until the solder
solidifies.

A30-2
10. Verify the accept/reject criteria (Paragraph 3.0) and FZM 8027 requirements
are fulfilled. Precautions shall be taken not to overheat the solder contact.
Some of the symptoms of overheating are as follows:
(a) Insulation separating the center contact/pin
oozes out of the little holes above the inner
inspection window.
(b) Conductor insulation is damaged.
(c) Insulating sleeve is darkened.

11. The following method should assist from overheating:

(a) When Superheater AA-400 is used, the solder contact should be

closer to the end of the reflector (near L barrier).

(b) As the solder preform melts, the solder contact needs to be moved
closer to the nozzle of the AA-400 so that concentration of heat may
be applied to the forward preform.

ALWAYS WATCH FOR MELTING/FLOWING OF SOLDER PREFORM

NOTE: Preferred conditions are shown in Figure 2.

ACCEPT/REJECT CRITERIA:

1. Verify that the contour of shield can be seen through one of the rear
inspection windows. On twisted pair cables, the ground conductor shall be
between two rear inspection windows and NOT in one of the two rear
inspection windows.
2. Verify that the contour of the center conductor is visible in the forward
inspection window.

3. Verify that insulating sleeve is fully shrunk over the cable and that there are
no tears in the sleeve.

4. Minor browning of sleeve is acceptable.

5. Cable insulation shall not be damaged.

6. Minor amount of "squirting" of solder from under the sleeve on the contact is
acceptable, provided "solder protrusions" are removed.

7. Solder preforms shall have melted and flowed. The solder shall lose all
appearance of ring shape and contours of the solder pre-form shall not be
visible.

A30-3
8. A maximum of 0.125 inch gap between insulation of cable and rear end of
contact body for the M39029/73-397 contacts and 0.0625 for the M39029/73-
398 contacts is acceptable. Minimum gap is abutted to contact.

Figure 1
STRIP LENGTH FOR M17/152-00001 (M39029/73-397)
Both shields should be stripped to the same length and terminated in the contact as one

.185+.015 .185+.015

.090+.015

STRIP LENGTH FOR C8811-1, C8811-2 COAX OR C8898-1

TRIAX (M39029/73-397 AND M39029/74-400)

FIGURE 1 - 1

.180+.030 .185+.015

.090+.015

FOR RG-178 OR RG-196 COAX, FOLD SHIELD BACK OVER

OUTER JACKET (M39029/73-397 and M39029/74-400)

FIGURE 1 – 2
ALL DIMENSIONS HAVE TOLERANCE OF PLUS/MINUS 0.015 INCH
FIGURE 1

A30-4
0.625‖

PRETINNED

0.0625 MAX.

0.225‖

0.350‖

TWISTED PAIR WIRE

FIGURE 1 - 4

ALL DIMENSIONS HAVE TOLERANCE OF PLUS/MINUS 0.015 INCH EXCEPT AS NOTED

FIGURE
FIGURE 11 -- CONTINUED
CONTINUED

A30-5
INSULATING FORWARD INSPECTION WINDOW
SLEEVE
REAR INSPECTION WINDOW

INSULATING FORWARD INSPECTION WINDOW

SLEEVE
REAR INSPECTION WINDOW

CONTOURS OF CENTER CONDUCTOR IS VISIBLE IN THE FORWARD INSPECTION WINDOW

CONTOURS OF SHIELD BRAID IS VISIBLE IN THE REAR INSPECTION WINDOW

INSULATING SLEEVE IS TRANSPARENT

SOLDER PREFORMS ARE COMPLETELY MELTED

FIGURE 2
FIGURE 2

A30-6
INSERTING PREPARED M17/152-00001 CABLE INTO CONTACT

A30-7
F. A. M39029-74
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION PROCEDURE FOR SOLDER CONTACTS

M39029/74
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations and describes the methods
for terminating M39029/74 solder contacts for shielded cables and twisted
pairs on F-16 wire harnesses. This Fabrication Aid is applicable for all F-16
programs.

2. These contacts may be inserted in any M83723 12-AWG contact cavity.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved heating tool, reflector and holding fixture.

CABLE/WIRE PREPARATION:

1. Part numbers are identified with color bands in accordance with Table 1.

TABLE 1

MIL P/N COLOR BAND

M39029 FIRST SECOND THIRD
/74-399 Orange White White
/74-400 Yellow Black Black
/74-401 Yellow Black Brown

A31-1
2. Strip cable in accordance with Figure 1. Ensure that all strands of shield are
cut square and even. For twisted pair, a sequence of sketches is identified in
Figure 1-4. The white wire shall be inserted into the center pin (C4930-26-
1P1).

3. Gently heat the center conductor with an approved soldering iron and apply
solder (SN63) to the center conductor to pre-tin the stranded center
conductor.

4. Assure that there are no solder spikes or excess solder on the center
conductor.

5. A small amount of flux may be applied to the shield to aid in shield

termination; however, it is not always required. If flux is used, type RMA
(MIL-F-14256) shall be used.

6. Gently push a contact over the prepared cable until it stops. Rotating the
contact slightly during cable insertion will assist shield strands from catching.

If a twisted pair cable is used, the longer

(white) wire will go into inner insulation sleeve
and the shorter ground/violet wire will go
between outer and inner insulation sleeve.
(See Figures 1-4.)

NOTE: The ground conductor must not be positioned in

one of rear inspection windows, but shall be
positioned between the two rear windows.

7. Insert the mating end of the contact into a holding fixture (AD-1319 or AD-
1494).

NOTE: The approved heat source must be used with a reflector.

9. After removing heat, do not move the wire (or the connection) until the solder
solidifies.

A31-2
10. Verify the accept/reject criteria and FZM 8027 requirements are fulfilled.
Precautions shall be taken not to overheat the solder contact. Some of the
symptoms of overheating are as follows:

(a) Insulation separating the center contact/pin oozes out of the little holes
above the inner inspection window.

(b) Conductor insulation is damaged.

(c) Insulating sleeve is darkened.

11. The following method should assist from overheating:

(a) When Superheater AA-400 is used, the solder contact should be closer to
the end of the reflector (near L barrier).

(b) As the solder preform melts, the solder contact needs to be moved closer
to the nozzle of the AA-400 so that concentration of heat may be applied
to the forward preform.

ALWAYS WATCH FOR MELTING/FLOWING OF SOLDER PREFORM

NOTE: Preferred conditions are shown in Figure 2.

ACCEPT/REJECT CRITERIA:

2. Verify that the contour of the center conductor is visible in the forward
inspection window.

3. Verify that insulating sleeve is fully shrunk over the cable and that there are
no tears in the sleeve.

4. Minor browning of sleeve is acceptable.

5. Cable insulation shall not be damaged.

6. Minor amount of "squirting" of solder from under the sleeve on the contact is
acceptable, provided "solder protrusions" are removed.

7. Solder preforms shall have melted and flowed. The solder shall lose all
appearance of ring shape and contours of the solder pre-form shall not be
visible.

A31-3
8. A maximum of 0.125 inch gap between insulation of cable and rear end of
contact body for the M39029/74-400 contacts and 0.0625 for the M39029/74-
401 contacts is acceptable. Minimum gap is abutted to contact.

.185+.015 .185+.015

.090+.015

STRIP LENGTH FOR C8811-1, C8811-2 COAX OR C8898-1

TRIAX (M39029/73-397 AND M39029/74-400)

FIGURE 1 - 1

.180+.030 .185+.015

.090+.015

FOR RG-178 OR RG-196 COAX, FOLD SHIELD BACK OVER

OUTER JACKET (M39029/73-397 AND M39029/74-400)

FIGURE 1 - 2

ALL DIMENSIONS HAVE TOLERANCE OF

PLUS/MINUS 0.015 INCH

FIGURE 1

A31-4
0.625‖

PRETINNED

0.0625 MAX.

0.225‖

0.350‖

TWISTED PAIR WIRE

FIGURE 1 - 4

ALL DIMENSIONS HAVE TOLERANCE OF PLUS/MINUS 0.015 INCH EXCEPT AS NOTED

FIGURE 1 - CONTINUED

A31-5
INSULATING FORWARD INSPECTION WINDOW
SLEEVE
REAR INSPECTION WINDOW

INSULATING FORWARD INSPECTION WINDOW

SLEEVE
REAR INSPECTION WINDOW

CONTOURS OF CENTER CONDUCTOR IS VISIBLE IN THE FORWARD INSPECTION WINDOW

CONTOURS OF SHIELD BRAID IS VISIBLE IN THE REAR INSPECTION WINDOW

INSULATING SLEEVE IS TRANSPARENT

SOLDER PREFORMS ARE COMPLETELY MELTED

FIGURE 2

A31-6
A31-7
F. A. C11788-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C11788-1 SOCKET CONTACTS

SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C11788-1
contacts for C20910-1 triax cables.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
4. 16PR145 paragraph 3.4.9.5 Solder Sleeve Terminations

TOOLS REQUIRED
1. AD-1319 holding fixture with AT-1319-27 or AT-1319-78 adapter.
2. AA-400 Super Heater with No. 979663 Mini-Solder Sleeve reflector, CV-
5300 MiniGun Heater with MG-1 reflector, or PH-1200 Proheat Varitemp
Heat Gun with No. 50379 and No. 51598, or No. 3027 reflectors.

SOLDER SLEEVE FOR TERMINATION OF SECOND SHIELD

1. Slide solder sleeve onto cable for termination after contact completed.

Figure 2

A32-1
CABLE PREPARATION FOR C8811-1 OR -2 OR RG179 COAX CABLE
1. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

Figure 1

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.

INSERTING PREPARED C8811-1 OR -2 OR RG179 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in
Figure 2.

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bend conductor.
NOTE: The distance from the rear end of the contact body to the wire
insulation must not exceed .05 inch.

CABLE PREPARATION FOR C20910-1 COAX CABLE

1. Strip the cable in accordance with Figure 3. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” .4” .15”

.15”

Figure
Figure 1 3

A32-2
2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin strand wire.

CABLE PREPARATION FOR C20910-1 COAX CABLE WITH C8865-2 or -3

BUS
1. Strip the cable in accordance with Figure 4. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” 1.5” .4”

.15”

Figure
Figure 1 4

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C20910-1 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in Figure 5
.05”

Figure 5

CABLE PREPARATION FOR C8898-1 OR -2 COAX CABLE

1. Strip the cable in accordance with Figure 6. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” .5” .2”

.110”

Figure
Figure 1 6

A32-3
2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary. Tin wire.
3. Pretin strand wire.

INSERTING PREPARED C8898-1 OR -2 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in
Figure 7.
.05”

Figure 7

A32-4
E. Heat the contact as follows:
1. Using the holding fixture, position the contact in the heating
tool
reflector as shown in Figure 8, with the forward inspection
window centered I the reflector, the inspection windows
aimed for good visibility, and the side with the ground
conductor facing down.
2. Continue heating until the smaller solder perform on the
forward inspection window has melted and flowed. The large
solder perform in the rear inspection window should have
melted and flowed by this time. If it has not, direct hot air at
the rear inspection window until the perform melts.
F. Allow the contact to cool for at least 19 seconds, remove the
contact and cable from the holding fixture.

G. Verify proper termination according to accept/reject criteria.

A32-5
Figure 8
Figure 3

A32-6
SOLDER SLEEVE TERMINATION
1. Solder sleeve should be placed 1.5 to 3.5 inches behind connector.

2. Make a window in the outer jacket .35 inches maximum in length. See
figure 9.

.35”

Figure 5
Figure 9

3. Place solder sleeve over shield, and shrink using approved heat gun.

NOTE: Instructions For Right Angle Backshell See Fab Aid A72 For
16VE049.

ACCEPT/REJECT CRITERIA
1. Reference FZM-8027, and/or requirements specified in this procedure
2. Reference 16PR145 paragraph 3.4.9.9 for solder sleeve termination
procedure.
3. The distance from the rear end of the contact body to the wire insulation
must not exceed .05 inch

A32-7
F. A. C11788-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C11788-2 PIN CONTACT

SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C11788-2
contacts for C20910-1 triax cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
4. 16PR145 Paragraph 3.4.9.5 Solder Sleeve Termination

TOOLS REQUIRED
1. AD-1319 holding fixture with AT-1319-27 or Adapter.
2 AA-400 Super Heater with No. 979663 Mini-Solder Sleeve reflector, CV
5300 MiniGun Heater with MG-1 reflector, or PH-1200 Proheat Varitemp
Heat Gun with No. 50379 and No. 51598, or No. 3027 reflectors.

SOLDER SLEEVE FOR TERMINATION OF SECOND SHIELD

3. Slide solder sleeve onto cable for termination after contact completed.

Figure 2

A33-1
CABLE PREPARATION FOR C8811-1 OR -2 OR RG179 COAX CABLE
1. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

Figure 1

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and
smooth the strands if necessary.

INSERTING PREPARED C8811-1 OR -2 OR RG179 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in
Figure 2.

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.

CABLE PREPARATION FOR C20910-1 COAX CABLE WITH C8865-2 or -3

BUS
1. Strip the cable in accordance with Figure 3. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” 1.5” .4”

.15”

Figure 1 3
Figure

A33-2
2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C20910-1 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in

Figure 2.

Figure 4

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.

Note: The distance from the rear end of the contact body to the wire
insulation must not exceed .05 inch.

HEATING PROCEDURES
1. Select the appropriate holding fixture and adapter for the contact to be
terminated. See TOOLS REQUIRED.
NOTE: A suitable fixture must be used, to prevent damage to the
contacts.
2. A. Insert the contact/cable assembly into the appropriate end of the
adapter.
B. Clamp the cable in the AD-1319 holding fixture
1. The cable must remain fully inserted in the contact.
2. The contact must be fully inserted in the adapter.
3. The cable must be straight between the contact and the cable
clamp.
C. Attach the appropriate reflector and other applicable accessories to
the heating tool.
1. For AA-400 SuperHeater: No. 979663 Mini-Solder Sleeve
reflector.
2. For CV-5300 MiniGun: MG-1 Reflector.
3. For PH-1200 Proheat Varitemp heat gun: No. 50379 and No.
51598, or No. 35027 reflectors.
D. Turn heating tool on and allow to warm up.
E. Heat the contact as follows:
A33-3
1. Using the holding fixture, position the contact in the heating
tool reflector as shown in Figure 5, with the forward inspection
window centered in the reflector, the inspection windows
aimed for good visibility, and the side with the ground
conductor facing down.
2. Continue heating until the smaller solder perform on the
forward inspection window has melted and flowed. The large
solder perform in the rear inspection window should have
melted and flowed by this time, if it has not, direct hot air at the
rear inspection window until the perform melts.
F. Allow the contact to cool for at least 19 seconds, remove the
contact and cable from the holding fixture.

A33-4
Figure 3

Figure 5

A33-5
SOLDER SLEEVE TERMINATION
1. Solder sleeve should be placed 1.5 to 3.5 inches behind connector.
2. Make a window in the outer jacket .35 inches maximum in length. See
figure 6.

.35”

Figure 5
Figure 6

3. Place solder sleeve over shield, and shrink using approved heat gun.

NOTE: Instructions For Right Angle Backshell See Fab Aid A72 For
16VE049.

ACCEPT/REJECT CRITERIA
1. Reference FZM-8027, and/or requirements specified in this procedure.
2. Reference 16PR145 paragraph 3.4.9.5
3. The distance from the rear end of the contact body to the wire insulation
must not exceed .05 inch.

A33-6
F. A. C11788-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C11788-3 SOCKET CONTACTS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C11788-3
contacts for coax cables.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
4. 16PR145 Paragraph 3.4.9.5, Solder Sleeve Terminations

TOOLS REQUIRED:
1. AD-1319 holding fixture with AT-1319-27 or AT-1319-78 adapter.
2. AA-400 Super Heater with No. 979663 Mini-Solder Sleeve reflector, CV-
5300 MiniGun Heater with MG-1 reflector, or PH-1200 Proheat Varitemp
Heat Gun with No. 50379 and No. 51598, or No. 3027 reflectors.

CABLE PREPARATION FOR C8811-1 COAX CABLE

1. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

A34-1
Figure 1

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.

INSERTING PREPARED C8811-1 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in
Figure 2.

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.
Note: The distance from the rear end of the contact body to the wire
insulation must not exceed .05 inch.

CABLE PREPARATION FOR C8898-1 COAX CABLE

1. Strip the cable in accordance with Figure 3. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.
.025” .1” .5” .2”
.110”

Figure 1 3
Figure

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.

A34-2
INSERTING PREPARED C8898-1 CABLE INTO CONTACT.
1. Push conductor into the contact until it is fully seated as shown in Figure
4.

Figure 4
2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.
Note: The distance from the rear end of the contact body to the wire
insulation must not exceed .05 inch

A34-3
for good visibility, and the side with the ground conductor facing
down.
2. Continue heating until the smaller solder perform on the forward
inspection window has melted and flowed. The large solder
perform in the rear inspection window should have melted and
flowed by this time. If it has not, direct hot air at the rear
inspection window until the perform melts.
F. Allow the contact to cool for at least 19 seconds, remove the contact
and cable from the holding fixture.

Figure
Figure 3 5

A34-4
ACCEPT/REJECT CRITERIA:
1. Reference FZM-8027, and/or requirements specified in this procedure.
2. Reference 16PR145 paragraph 3.4.9.5.
3. The distance from the rear end of the contact body to the wire insulation
must not exceed .05 inch.

A34-5
F. A. C11788-4
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C11788-4 PIN CONTACTS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C11788-4
contacts for coax cables.
2. This Fabrication Aid is applicable for all F-16 programs..©

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs. MTPA-
002.
3. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
4. 16PR145 paragraph 3.4.9.5 Solder Sleeve Terminations.

TOOLS REQUIRED:
1. AD-1319 holding fixture with AT-1319-19 adapter.
2. AA-400 Super Heater with No. 979663 Mini-Solder Sleeve reflector, CV-
5300 MiniGun Heater with MG-1 reflector, or PH-1200 Proheat Varitemp
Heat Gun with No. 50379 and No. 51598, or No. 3027 reflectors.

CABLE PREPARATION FOR C8811-1 COAX CABLE:

1. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

A35-1
Figure 1

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.

INSERTING PREPARED C8811-1 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in
Figure 2.

HEATING PROCEDURES:
1. Select the appropriate holding fixture and adapter for the contact to be
terminated. See TOOLS REQUIRED.
NOTE: A suitable fixture must be used, to prevent damage to the contacts.
A. Insert the contact/cable assembly into the appropriate end of the
adapter.
B. Clamp the cable in the AD-1319 holding fixture.
1. The cable must remain fully inserted in the contact.
2. The contact must be fully inserted in the adapter.
3. The cable must be straight between the contact and the cable
clamp.
C. Attach the appropriate reflector and other applicable accessories to
the heating tool.
1. For AA-400 SuperHeater: No. 979663 Mini-Solder Sleeve
reflector.
A35-2
2. For CV-5300 MiniGun: MG-1 reflector.
3. For PH-1200 Proheat Varitemp heat gun: No. 50379 and No.
51598, or No. 35027 reflectors.
D. Turn heating tool on and allow to warm up.
E. Heat the contact as follows:
1. Using the holding fixture, position the contact in the heating tool
reflector as shown in Figure 3, with the forward inspection
window centered in the reflector, the inspection windows aimed
for good visibility, and the side with the ground conductor facing
down.
2. Continue heating until the smaller solder perform on the forward
inspection window has melted and flowed. The large solder
preform in the rear inspection window should have melted and
flowed by this time, if it has not, direct hot air at the rear
inspection window until the preform melts.
F. Allow the contact to cool for at least 19 seconds, remove the
contact and cable from the holding fixture.

A35-3
Figure 3

ACCEPT/REJECT CRITERIA:
1. Reference FZM-8027, and/or requirements specified in this procedure.
2. Reference 16PR145 paragraph 3.4.9.5
3. The distance from the rear end of the contact body to the wire insulation
must not exceed .05 inch.

A35-4
F. A. C11788-5 & -6
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATON OF C11788-5 SOCKET CONTACT

TERMINATION OF C11788-6 PIN CONTACT
SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C11788-5 and
C11788-6 contact for twist-pair cable.
2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Assembly Procedures or equivalent document (reference
only).
2. Workmanship Standards for Electrical Assemblies – FZM-8027

TOOLS REQUIRED:
1. AD-1319 holding fixture with AT-1319-27 or AT-1319-78 adapter.
2. AA-400 Super Heater with No. 979663 Mini-Solder Sleeve reflector or CV-5300
Mini Gun heater with MG-1 reflector, or PH-1200 Proheat Varitemp Heat Gun
with No. 50379 and No. 51598, or No. 35027 reflectors.

CABLE PREPARATION FOR TWISTED PAIRS:

1. Untwist and straighten the wires for a length of approximately 1.5 inches, see
Figure 1.

2. Strip the cable to the dimensions shown in Figure 2A.

NOTE: The insulation on the two conductors must be stripped to the same
length within 0.030 inch.

A36-1
3. Make sure that stranded conductors are twisted into their normal lay, re-twist
and smooth the strands if necessary.
4. Pre-tin the stranded wires to within 0.05 inch of the insulation, see Figure 2B.

5. Trim the cable conductors as shown in Figure 3.

6. Fold the Lo potential (ground) conductor back in a loop as shown in Figure 4.

INSERTING PREPARED CABLE INTO CONTACT:

1. Assure that the end of the HI potential (signal) conductor is straight, and that
the LO potential (ground) conductor is folded as specified in Figure 4.
2. Start the conductors into the contact as follows:
a) Guide the HI potential (signal) conductor into the inner insulating sleeve.
b) Guide the LO potential (ground) conductor between the two insulating
sleeves, along the side of the contact that will be nearest the heat source
when the contact is heated.
3. Push both conductors into the contact until they are fully inserted as shown in
Figure 5.
a) While pushing the conductors in, rotate the contact slightly back and forth
to prevent the conductors from catching.
b) Do not force or twist the signal conductor after it is fully inserted.

A36-2
c) If the conductors cannot be positioned correctly, remove then and check
for improper strip dimensions, splayed or bent conductors, and excess
solder on conductors.

CABLE PREPARATION FOR C20807-26-1P(1) CABLE

1. Strip outer insulation, and shield, removing Mylar, See Figure 6.

.250”

FIGURE
Figure 1 6

2. Strip the cable to the dimensions shown in Figure 7A.

.300‖

FIGURE 7A

3. Make sure that stranded conductors are twisted into their normal lay, retwist
and smooth the strands if necessary.
4. Pretin the stranded wires to within 0.05 inch of the insulation. See Figure 7B.

FIGURE 7B

5. Fold the LO potential (ground) conductor back in a loop as shown in Figure 8

FIGURE 8

A36-3
6. Shield termination per Section 3.4.9 or 3.4.11 of this document.

INSERTING PREPARED C20807-26-1P(1) CABLE INTO CONTACT:

1. Assure that the end of the HI potential (signal) conductor is straight, and that
the LO potential (ground) conductor is folded as specified in Figure 8.
2. Start the conductors into the contact as follows:
a. Guide the HI potential (signal) conductor into the inner insulating sleeve.
b. Guide the LO potential (ground) conductor between the two insulating
sleeves, along the side of the contact that will be nearest the heat source
when the contact is heated.
3. Push both conductors into the contact until they are fully inserted as shown in
Figure 9.
a. While pushing the conductors in, rotate the contact slightly back and forth
to prevent the conductors from catching.
b. Do not force or twist the signal conductor after it is fully inserted.
c. If the conductors cannot be positioned correctly, remove then and check
for improper strip dimensions, splayed or bent conductors, and excess
solder on conductors.

FIGURE 9

HEATING PROCEDURES:

1. Select the appropriate holding fixture and adapter for the contact to be
terminated, see TOOLS REQUIRED.
NOTE: A suitable holding fixture must be used, to prevent damage to the
contacts.

2. Heating Procedure
a) Insert the contact/cable assembly into the appropriate end of the adapter.
b) Clamp the cable in the AD-1319 holding fixture.
1. The cable must remain fully inserted in the contact.
2. The contact must be fully inserted in the adapter.
3. The cable must be straight between the contact and the cable clamp.
4. The folded ground conductor may be visible through either one of the
inspection windows, and should be positioned against the downward
facing side of the contact, as shown in Figure 10.

A36-4
FIGURE 10

c) Attach the appropriate reflector and other applicable accessories to the

heating tool.
1. For AA-400 Super Heater: No.979663 Mini-Solder Sleeve reflector.
2. For CV-5300 Mini Gun: MG-1 reflector.
3. For PH-1200 Proheat Varitemp heat gun: No. 50379 and No. 51598, or
No. 35027 reflectors.
d) Turn the heating tool on and allow to warm up.
e) Heat the contact as follows:
1. Using the holding fixture, position the contact in the heating tool
reflector as shown in Figure 11, with the forward inspection window
centered in the reflector, the inspection windows aimed for good
visibility, and the side with the ground conductor facing down.
2. Continue heating until the small solder pre-form on the forward
inspection window has melted and flowed. The large solder pre-form in
the rear inspection window should have melted and flowed by this
time; if it has not, direct hot air at the rear inspection window until the
pre-form melts.
f) Allow the contact to cool for at least 10 seconds, remove the contact and
cable from the holding fixture.
g) Verify proper termination according to the Accept/Reject criteria.

A36-5
FIGURE 11

A36-6
ACCEPT/REJECT CRITERIA

1. Reference FZM 8027 and the following for accept/reject criteria.

2. CRITERIA FOR PROPER ASSEMBLY
Verify the completed termination for correct assembly according to the
following criteria:
a) The distance from the rear end of the contact body to the wire insulation
must not exceed 0.05 inch.
b) The HI potential (signal) conductor must be visible through one of the
forward inspection windows.
c) The LO potential (ground) conductor must be soldered to the inside
surface of the contact body. The conductor may be visible through one of
the inspection windows.
3. CRITERIA FOR PROPER HEATING
Verify the completed termination for proper heating using the following
criteria:
a) The solder pre-form in the forward inspection windows must be melted
and flowed so that:
1. No trace of pre-form shape remains.
2. Solder fillet is visible between the HI potential (signal) conductor and
inner contact soldering surface.
b) The solder pre-form in the rear inspection window must be melted and
flowed so that:
1. No trace of pre-form remains.
2. Solder pre-form has flowed into the contact through the rear inspection
window.
c) The insulating sleeve must be fully shrunk onto the wires at the rear of the
contact.
d) The insulating sleeve must not be darkened so as to obscure the solder
joints or hinder examination.
e) The twisted-pair cable insulation must not show signs of damage of
overheating outside the insulating sleeve.

A36-7
F. A. C4812
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATING C4812 SPLICES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating C4812
splices in F-16 wire harness assemblies.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping an Insertion and Extraction Tools

for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

GENERAL GROUND RULES FOR SPLICES:

1. Splice location.

a) For braided harnesses sealed crimp type splices shall be located in the
area that is covered with expandable braided sleeving (C8844-X). For
unbraided harnesses, sealed crimp splices shall be located in an
accessible visible area if possible.

A37-1
CONNECTOR

WIRE/CABLE SPLICE AREA

EXPANDABLE BRAIDED SLEEVING

WIRE STRAIN RELIEF CLAMP

b) Two wires may be terminated in any one hole in the sealing rings.

c) When crimping wire smaller than the minimum allowable in a splice,

double the strip length and double the conductor back or insert a piece of
stripped conductor the same length as the strip length to have enough
material to obtain a crimp that passes a pull test.

d) Dash 29 may be interchanged with -38, and -31 may be interchanged with
-37.

e) Splices shall be considered congested when the design of the harness

assembly prevents staggering of splices by at least one splice length.

f) For harness boards built prior to Revision D, C4812-X splices may be

used like butt splices (C4812-53-X). Put all wires through the shrinkable
seal insert and no wires in the single wire end.

ASSEMBLY PROCEDURE:

1. FOR 1 TO 1, 2, OR 3 WIRES.*

A37-2
FIG. 1

.25 (.5) .30 (-6&-7)

.22 .26

FIG. 2

0.03 MAX GAP

TYPICAL
a) Strip the required wires to the dimension shown. Crimp the splice to the
single wire. (Fig. 1)
b) Slide the insulator over the stripped wires as shown. (Fig. 2)
c) Crimp the splice onto the stripped wires.

FIG. 3

FIG. 4

d) Position the crimped splice between the sealing inserts as shown. (Fig. 3)
e) Using the approved heating tool, shrink the insulator down on the splice, first
heating one seal area, then the other and finally, the remainder of the
insulator. (Fig. 4)

*WHEN SPLICING 3 OR 4 TOTAL WIRES WITH A -23 SPLICE, ONE

20-GAUGE WIRE IS THE MINIMUM WIRE THAT MAY BE INSTALLED
IN ONE END OF THE SPLICE. ANY COMBINATION OF TWO OR
THREE 22 OR 26 GAUGE WIRES MAY BE INSTALLED IN THE
MULTIPLE WIRE END OF THE SPLICE.
A37-3
2. FOR 2 OR 3 WIRES TO 2 OR 3 WIRES.
REQUIRED WIRES
FIXED SINGLE OR
MULTIPLE WIRE
SEAL INSERT

FIG. 5 .25 (-5) .30 (-6&-7)

.22 .26
TYPICAL

INSULATOR

SPLICE

MULTIPLE WIRE
SEAL INSERT
(SUPPLIED LOOSE)

FIG. 6

a) Strip the required wires to the dimension shown. (Fig. 5)

b) Slide the insulator over the stripped wires as shown. Slide the loose three
wire seal insert over the remaining wires as shown. (Fig. 6)

FIG. 7

MAX 0.03 GAP TYPICAL

FIG. 8

FIG. 9

c) Crimp the splice onto the stripped wires. (Fig. 7)

A37-4
d) Position the crimped splice inside the insulator as shown. Slide the loose
three-wire seal insert over the wires and position in the insulator as
shown. (Fig. 8)
e) Using the approved heating tool, shrink the insulator down on the splice,
first heating one seal, then the other, and finally the remainder of the
insulator. (Fig. 9)

3. STUB (OR BUTT) SPLICE (C4812-53-X).

The wires enter this splice from one side only. Each kit consists of a sealing
insert, a metal barrel, and an insulating sleeve.

a) Strip the conductor 0.27/0.31 inches.

b) Insert through the sealing insert holes.

c) Insert the stripped wires into the splice.

d) Crimp the barrel using the approved tool.

e) Position the sleeve over the splice and the sealing insert such that the
sleeve overlaps the sealing insert a minimum of 0.1 inch.

f) Apply heat first to the sealing insert end until the sealing insert is trapped,
then continue applying heat until the sleeve has recovered.

A37-5
F. A. C4813
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATING C4813 SPLICES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating C4813
splices in F-16 wire harness assemblies.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping an Insertion and Extraction Tools

for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

GENERAL GROUND RULES FOR SPLICES:

1. Splice location.

A38-1
CONNECTOR

WIRE/CABLE SPLICE AREA

EXPANDABLE BRAIDED SLEEVING

WIRE STRAIN RELIEF CLAMP

b) Two wires may be terminated in any one hole in the sealing rings.

c) When crimping wire smaller than the minimum allowable in a splice,

double the strip length and double the conductor back or insert a piece of
stripped conductor the same length as the strip length to have enough
material to obtain a crimp that passes a pull test.

d) Dash 29 may be interchanged with -38, and -31 may be interchanged with
-37.

e) Splices shall be considered congested when the design of the harness

assembly prevents staggering of splices by at least one splice length.

ASSEMBLY PROCEDURE:

1. Strip the required wires to the dimensions shown.

2. Crimp the splice onto the required wires. If required, filler wire or doubling the
strip length and folding it over may be needed in order to have enough
material for a crimp that passes appropriate pull test.

3. Center C4812-40 insulating sleeve on splice, and shrink.

A38-2
0.43
0.40 TYPICAL

SPLICE

MAX 0.03 GAP

TYPICAL

A38-3
F. A. AN3116
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF AN3116 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembly of AN3116
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturers Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved soldering iron.

2. Approved heat source.

ASSEMBLY PROCEDURE

1. Strip wire to dimension shown, and tin with solder called for by engineering
drawings to within 1/32 inch of insulation. Slide ferrule assembly and
retaining bushing back over outer jacket.

2. Solder contact to center conductor with a clean iron. Use only the solder
called for by engineering drawings. Slide pin insulator over contact against
retaining shoulder.

A39-1
SOLDER WIRE FERRULE ASSEMBLY
HERE
RETAINING BUSHING

PIN CONTACT
HOLE
0.21
UNSHIELDED WIRES

3. Slide above assembled portion of connector into connector body, and tighten
ferrule assembly.

PIN INSULATOR BODY

4. Installation of Ground Wire.

a) Drill a hole 0.15 inches from the back of the ferrule using a number 50 drill
bit.

b) Strip the ground wire approximately 0.188 inches.

c) Insert the conductor through hole from the inside of the ferrule.

d) Press conductor strands forward down against the ferrule body, and
solder in place.

e) Slide shrink tubing (C4804-8-0 or P5034-32-B or P5381-X) in place over

the ferrule and ground wire. Shrink in place using an approved tool.

NOTE: Recommend that two pieces of shrink tubing be used. One 1/2
inch long piece installed over the wires and one approximately 1
inch long piece installed over the connector and wires.

A39-2
F. A. C8831-X
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8831 COAX CONNECTOR

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembly of C8831
coax connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturers Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURE:

1. Braid must be combed for RG 196/U cable. Strip coaxial cable to dimensions
shown on next page. (Dimensions may be altered to suit characteristics of
cable.)

BRAID MUST BE COMBED

FOR RG 196/U CABLE

2. Crimp Tool

a) Assemble stepped outer hyring onto cable.

b) Assemble supporting sleeve over inner dielectric and under braid.

A40-1
c) Assemble inner hyfen pin or socket to inner conductor and crimp with an
approved tool.

SUPPORT ING SLEEVE INNER HYFEN PIN (OR

( R C M X B- - - ) SOCKET ) (RMM--W---)
(RF M--W---)

ST E PP E D O U T ER
HYRING (YORX)

3. Snap-lock pin (or socket) into outer female (or male) contact. Small
diameter on outer contact must slide over supporting sleeve and under
braid.

4. Slide stepped outer hyring over exposed braid, and crimp hyring onto braid
with an approved tool. Assembly can now be snap-locked into connector
block.

SUPPORT ING SLEEVE IN POSIT ION

MINIAT URE OUTER FEM ALE (OR M ALE )

CONTACT (RCM X---)(RMMX----)

B E FO R E

AF T E R SNAP -LOCK PIN(OR SOCKET) INTO

OUTER FEMALE (OR MALE) CONTACT.
SMALL DIAMET ER ON OUTER CONTACT
MUST SLIDE OVER SUPPORTING
A N D U N D E R B R A ID .

C10753-X Contact C8831-X Connector

A40-2
STRIPPING DIMENSIONS.

CONNECTOR P/N A B C D
C8831-X (C10753-X*) 0.36 0.50 0.16 0.66

*CONTACT

A40-3
F. A. M26482
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M26482 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling M26482
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Cut the conductor end even, and strip the insulation using an approved
stripping
STRIP LENGTH

CONTACT GAUGE M26482

22D --
22 --
20 0.19
16 0.25
12 --

2. Crimp the contacts using approved tools.

A41-1
3. When crimping wire smaller than the minimum allowable in a contact, double
the strip length and double the conductor back or insert a piece of stripped
conductor the same length as the strip length to have enough material for a
crimp that passes a pull test. When installing a C2107-50-X bushing, use a
crimping tool sized for the contact, not for the wire gauge.

INSERTION OF THE CONTACTS

1. Using the approved tool, insert the contact. The contacts may be wet with
Isopropyl Alcohol.

CHECK FOR CONTACT BEING LOCKED IN POSITION.

1. Grasp the wire near the sealing grommet-

a) pull on the wire then

b) push on the wire* then

c) pull on the wire*

*A slight movement of the contact will be detected, thus verifying the retaining
tines are engaged.

2. Insert stripped wire into contact crimp barrel. Wire must be visible through
inspection hole.

3. Using correct crimp tool and locator, cycle the tool once to be sure indentors
are open. Insert contact and wire into locator. Squeeze tool handles firmly
and completely to insure proper crimp. The tool will not release unless the
crimp indentors in the tool head have been fully actuated.

4. Release crimped contact and wire from tool. Be certain the wire is visible
through inspection hole in contact.

CONTACT INSERTION

1. Remove hardware from plug or receptacle, and slip hardware over wire
bundle in proper order for reassembly.

2. Using proper insertion tool for corresponding contact, position wire in tip of
the tool so the tool tip butts up against the contact shoulder.

3. Press tool against contact shoulder, and insert wired contact and tool tip into
center contact cavity with firm and even pressure. A slight click may be heard
as the retaining tines snap into place behind the contact shoulder.

A41-2
4. Remove tool and pull back lightly on wire to make sure contact is properly
seated. Beginning with the center cavity and working outward in alternating
rows, repeat this operation with remainder of contacts to be inserted.

5. After all contacts are inserted, fill empty cavities with sealing plugs in
accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle hardware.

CONTACT EXTRACTION

1. Remove hardware from plug or receptacle and slide hardware back along
wire bundle.

2. Using extraction tool with proper color code corresponding to contact size,
place wire in tool.

3. Insert tool into contact cavity until tool tip bottoms against the contact
shoulder, expanding clip retaining tines.

4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation
for all contacts to be extracted.

5. Fill empty wire cavities with sealing plugs in accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle.

A41-3
F. A. M38999
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M38999 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling M38999
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Cut the conductor end even, and strip the insulation using an approved
stripping

STRIP LENGTH

CONTACT GAUGE M38999

22D 0.13 to 0.15
22 --
20 0.17 to 0.21
16 0.17 to 0.21
12 --

A42-1
2. Crimp the contacts using approved tools.

3. When crimping wire smaller than the minimum allowable in a contact, double
the strip length and double the conductor back or insert a piece of stripped
conductor the same length as the strip length to have enough material for a
crimp that passes a pull test. When installing a C2107-50-X bushing, use a
crimping tool sized for the contact, not for the wire gauge.

INSERTION OF THE CONTACTS

1. Using the approved tool, insert the contact. The contacts may be wet with
Isopropyl Alcohol.

CHECK FOR CONTACT BEING LOCKED IN POSITION.

2. Grasp the wire near the sealing grommet-

a) pull on the wire then

b) push on the wire* then

c) pull on the wire*

*A slight movement of the contact will be detected, thus verifying the retaining
tines are engaged.

3. Insert stripped wire into contact crimp barrel. Wire must be visible through
inspection hole.

4. Using correct crimp tool and locator, cycle the tool once to be sure indentors
are open. Insert contact and wire into locator. Squeeze tool handles firmly
and completely to insure proper crimp. The tool will not release unless the
crimp indentors in the tool head have been fully actuated.

5. Release crimped contact and wire from tool. Be certain the wire is visible
through inspection hole in contact.

CONTACT INSERTION

1. Remove hardware from plug or receptacle, and slip hardware over wire
bundle in proper order for reassembly.

2. Using proper insertion tool for corresponding contact, position wire in tip of
the tool so the tool tip butts up against the contact shoulder.

A42-2
3. Press tool against contact shoulder, and insert wired contact and tool tip into
center contact cavity with firm and even pressure. A slight click may be heard
as the retaining tines snap into place behind the contact shoulder.

4. Remove tool and pull back lightly on wire to make sure contact is properly
seated. Beginning with the center cavity and working outward in alternating
rows, repeat this operation with remainder of contacts to be inserted.

5. After all contacts are inserted, fill empty cavities with sealing plugs in
accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle hardware.

CONTACT EXTRACTION

1. Remove hardware from plug or receptacle and slide hardware back along
wire bundle.

2. Using extraction tool with proper color code corresponding to contact size,
place wire in tool.

3. Insert tool into contact cavity until tool tip bottoms against the contact
shoulder, expanding clip retaining tines.

4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation
for all contacts to be extracted.

5. Fill empty wire cavities with sealing plugs in accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle.

A42-3
F. A. M5015
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M5015 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling M5015
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Cut the conductor end even, and strip the insulation using an approved
stripping

STRIP LENGTH

CONTACT GAUGE M5015

22D --
22 --
20 --
16 0.24
12 0.24

A43-1
2. Crimp the contacts using approved tools.

INSERTION OF THE CONTACTS

1. Using the approved tool, insert the contact. The contacts may be wet with
Isopropyl Alcohol.

CHECK FOR CONTACT BEING LOCKED IN POSITION.

2. Grasp the wire near the sealing grommet-

a) pull on the wire then

b) push on the wire* then

c) pull on the wire*

* A slight movement of the contact will be detected, thus verifying the
retaining tines are engaged.

3. Insert stripped wire into contact crimp barrel. Wire must be visible through
inspection hole.

4. Using correct crimp tool and locator, cycle the tool once to be sure indentors
are open. Insert contact and wire into locator. Squeeze tool handles firmly
and, completely to insure proper crimp. The tool will not release unless the
crimp indentors in the tool head have been fully actuated.

5. Release crimped contact and wire from tool. Be certain the wire is visible
through inspection hole in contact.

CONTACT INSERTION

1. Remove hardware from plug or receptacle, and slip hardware over wire
bundle in proper order for reassembly.

2. Using proper insertion tool for corresponding contact, position wire in tip of
the tool so the tool tip butts up against the contact shoulder.

A43-2
3. Press tool against contact shoulder, and insert wired contact and tool tip into
center contact cavity with firm and even pressure. A slight click may be heard
as the retaining tines snap into place behind the contact shoulder.

5. After all contacts are inserted, fill empty cavities with sealing plugs in
accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle hardware.

CONTACT EXTRACTION

1. Remove hardware from plug or receptacle and slide hardware back along
wire bundle.

2. Using extraction tool with proper color code corresponding to contact size,
place wire in tool.

3. Insert tool into contact cavity until tool tip bottoms against the contact
shoulder, expanding clip retaining tines.

4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation
for all contacts to be extracted.

5. Fill empty wire cavities with sealing plugs in accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle.

A43-3
F. A. M81511
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M81511 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling M81511
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Cut the conductor end even, and strip the insulation using an approved
stripping
STRIP LENGTH

CONTACT GAUGE M81511

22D --
22 0.14 to 0.17
20 0.15 to 0.21
16 --
12 --

A44-1
2. Crimp the contacts using approved tools.

INSERTION OF THE CONTACTS

1. Using the approved tool, insert the contact. The contacts may be wet with
Isopropyl Alcohol.

CHECK FOR CONTACT BEING LOCKED IN POSITION.

2. Grasp the wire near the sealing grommet-

a) pull on the wire then

b) push on the wire* then

c) pull on the wire*

*A slight movement of the contact will be detected, thus verifying the retaining
tines are engaged.

3. Insert stripped wire into contact crimp barrel. Wire must be visible through
inspection hole.

5. Release crimped contact and wire from tool. Be certain the wire is visible
through inspection hole in contact.

CONTACT INSERTION

1. Remove hardware from plug or receptacle, and slip hardware over wire
bundle in proper order for reassembly.

2. Using proper insertion tool for corresponding contact, position wire in tip of
the tool so the tool tip butts up against the contact shoulder.

A44-2
3. Press tool against contact shoulder, and insert wired contact and tool tip into
center contact cavity with firm and even pressure. A slight click may be heard
as the retaining tines snap into place behind the contact shoulder.

5. After all contacts are inserted, fill empty cavities with sealing plugs in
accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle hardware.

CONTACT EXTRACTION

1. Remove hardware from plug or receptacle and slide hardware back along
wire bundle.

2. Using extraction tool with proper color code corresponding to contact size,
place wire in tool.

3. Insert tool into contact cavity until tool tip bottoms against the contact
shoulder, expanding clip retaining tines.

4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation
for all contacts to be extracted.

5. Fill empty wire cavities with sealing plugs in accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle.

A44-3
F. A. M83723
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF MIL-C-83723 CONNECTORS (circular)

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling MIL-C-
83723 connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Cut the conductor end even, and strip the insulation using an approved
stripping

STRIP LENGTH

CONTACT GAUGE MIL-C-83723 & MIL-C-83733

22D 0.13 / 0.15
22 --
20 0.19
16 0.25
12 0.25

A45-1
2. Crimp the contacts using approved tools.

INSERTION OF THE CONTACTS

1. Using the approved tool, insert the contact. The contacts may be wet with
Isopropyl Alcohol.

CHECK FOR CONTACT BEING LOCKED IN POSITION.

2. Grasp the wire near the sealing grommet-

a) pull on the wire then

b) push on the wire* then

c) pull on the wire*

*A slight movement of the contact will be detected, thus verifying the retaining
tines are engaged.

3. Insert stripped wire into contact crimp barrel. Wire must be visible through
inspection hole.

5. Release crimped contact and wire from tool. Be certain the wire is visible
through inspection hole in contact.

CONTACT INSERTION

1. Remove hardware from plug or receptacle, and slip hardware over wire
bundle in proper order for reassembly.

2. Using proper insertion tool for corresponding contact, position wire in tip of
the tool so the tool tip butts up against the contact shoulder.

A45-2
3. Press tool against contact shoulder, and insert wired contact and tool tip into
center contact cavity with firm and even pressure. A slight click may be heard
as the retaining tines snap into place behind the contact shoulder.

4. Remove tool and pull back lightly on wire to make sure contact is properly
seated.

5. Beginning with the center cavity and working outward in alternating rows,
repeat this operation with remainder of contacts to be inserted.

6. After all contacts are inserted, fill empty cavities with sealing plugs in
accordance with Paragraph 3.4.7.

7. Reassemble plug or receptacle hardware.

CONTACT EXTRACTION

1. Remove hardware from plug or receptacle and slide hardware back along
wire bundle.

2. Using extraction tool with proper color code corresponding to contact size,
place wire in tool.

3. Insert tool into contact cavity until tool tip bottoms against the contact
shoulder, expanding clip retaining tines.

4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation
for all contacts to be extracted.

5. Fill empty wire cavities with sealing plugs in accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle.

A45-3
F. A. C10937
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C10937 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C10937
ACIU connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. An approved heating device.

ASSEMBLY PROCEDURES:

1. Shield termination for the C10937 backshell. This backshell is of modular

construction, and consists of two or three spacers and two or three terminal
plates. Only two spacers and two terminal plates are required. When three
are provided, extra parts shall be discarded. Nine four-conductor shielded
cables may be terminated to each terminal plate.

NOTE: Unshielded wires shall be attached to the bus tabs. Cover

each bus tab not used for shielded wire termination with a
piece of P5034 tubing on tab. Secure unshielded wires to
covered bus tabs with a piece of C2070 tubing.

2. Cut the cable end even, and strip the outer jacket and shield to dimensions
shown, taking care not to nick the shield braid strands.

A46-1
OUTER JACKET
SHIELD
CONDUCTOR

0.2/0.3 2.0 MIN.

APPROX.
PER PROOFED LENGTH

(Trim to final dimension during assembly)

3. Position shielded and unshielded cables and solder sleeves on the terminal
plate with each solder sleeve centered 0.03 over the bus tab and stripped
shield.

NOTE: Conductors should be placed on the terminal plates such that

bottom plate wires are terminated in the contact nearest to
plate, etc.

4. Maximum number of shields and wires terminated to each terminal plate bus
tab:

(1 each) 4-conductor shielded cable

or
(2 each) 1-conductor shielded cables
or
(1 each) 2-conductor shielded and (2 each) unshielded
or
(1 each) 3-conductor shielded and (2 each) unshielded
or
(4 each) Braided shields from C8951-1,-2,-3 solder sleeves
or
(6 each) Unshielded conductors

5. With an approved heating device (after cables and solder sleeves are in
place), heat solder sleeves taking care that the sleeves and cables do not
shift on bus tabs during the heating and shrinking operation.

A46-2
6. After all shields are terminated and contacts in place on conductors, place
body of the adapter on the connector. Check orientation of the backshell with
connector.

7. Insert the contacts and fillers.

8. Install backshell assembly per Paragraph 3.5.

NOTE: During closing procedures, expandable braided sleeving

(C8844-X) should be clamped between clamping bar and backing
bar and between back plate and backing bar. Do not let the
expandable sleeving become entwined in the screw threads.

9. Use two each terminal plate and spacers in this order: plate, spacer, plate,
spacer.

C10937 ACIU Connector (Assembly)

SCREW (TYP 5 PLACES)

SPACER
TERMINAL PLATE BUS 2

SPACER

TERMINAL PLATE BUS 1

FINGERS

DO NOT OVERTIGHTEN JACKSCREW

(SEE SECTION 40 FOR TORQUE)

SCREW
WASHER
NUT
(TYP 2 PLACES)

NOTE: This connector uses rear entry and rear extraction contacts.

A46-3
Use two each terminal plates and spacer in this order: plate, spacer, plate,
spacer.

C10937 ACIU Connector Alternate (Assembly)

NOTE: This connector uses rear entry and rear extraction contacts.

A46-4
F. A. C8807
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8807 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8807
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Wire/Cable Preparation.

a) Cut the conductor end even and strip the insulation using an approved
stripping device at 0.16 to 0.18 inches. Care must be taken not to nick or
damage the conductor strands.

NOTE: When stripping wire with dual insulation, care must be exercised
to be sure both layers are removed.

b) Crimp the contacts using approved tools, and perform a visual inspection
for a proper crimp and for wires visible in the inspection hole.

A47-1
c) Insert contacts into the connector using an approved insertion/extraction
tool.

2. Assemble the cable clamp to the connector body by pushing the clamp on the
body until holes in the clamp snap over retaining ears on the body.

3. Mating the connectors is accomplished by applying firm pressure to the plug

until it snaps into position - pull on the plug to verify that it is locked.

4. A tool is provided for unmating connectors. This tool is inserted into the
receptacle allowing the plug to be removed.

A47-2
F. A. M83733
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF MIL-C-83733 CONNECTORS (Rectangular)

SCOPE

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling MIL-C-
83733 connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURES:

1. Cut the conductor end even, and strip the insulation using an approved
stripping method.

A48-1
STRIP LENGTH

CONTACT GAUGE MIL-C-83723 & MIL-C-83733

22D 0.13 / 0.15
22 --
20 0.19
16 0.25
12 0.25

2. Crimp the contacts using approved tools.

INSERTION OF THE CONTACTS

1. Using the approved tool, insert the contact. The contacts may be wet with
Isopropyl Alcohol.

CHECK FOR CONTACT BEING LOCKED IN POSITION.

2. Grasp the wire near the sealing grommet-

a) pull on the wire then

b) push on the wire* then

c) pull on the wire*

*A slight movement of the contact will be detected, thus verifying the retaining
tines are engaged.

3. Insert stripped wire into contact crimp barrel. Wire must be visible through
inspection hole.

5. Release crimped contact and wire from tool. Be certain the wire is visible
through inspection hole in contact.

A48-2
CONTACT INSERTION

1. Remove hardware from plug or receptacle, and slip hardware over wire
bundle in proper order for reassembly.

2. Using proper insertion tool for corresponding contact, position wire in tip of
the tool so the tool tip butts up against the contact shoulder.

5. After all contacts are inserted, fill empty cavities with sealing plugs in
accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle hardware.

CONTACT EXTRACTION

1. Remove hardware from plug or receptacle and slide hardware back along
wire bundle.

2. Using extraction tool with proper color code corresponding to contact size,
place wire in tool.

3. Insert tool into contact cavity until tool tip bottoms against the contact
shoulder, expanding clip retaining tines.

4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation
for all contacts to be extracted.

5. Fill empty wire cavities with sealing plugs in accordance with Paragraph 3.4.7.

6. Reassemble plug or receptacle.

A48-3
F. A. C8804-8
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8804-8 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8804-8
coax connectors manufactured by Phoenix Logistics, Inc. For connectors
produced by manufacturers other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-49 die.
2. Approved torque wrench.
3. Approved soldering iron.

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.

1. Shrink sleeve
2. Crimp sleeve
3. Rear nut

A49-1
4. Braid terminator
5. Rear contact
6. Rear dielectric
7. Spacer
8. Front contact
9. Front dielectric
10. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve on to the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All cuts
shall be square. Precautions shall be taken to avoid cutting the underlying
layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator, gently slide the tapered end of
the braid terminator over the dielectric and under the braid until it butts
against the jacket.

b) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

c) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
number M22520/5-49.

d) Apply heat to the crimp sleeve using soldering iron and feed solder into
the crimp sleeve holes, insuring adequate evidence of wetting.

3. INSTALLATION OF CONTACT:

a) Trim the dielectric flush with the face of the braid terminator being careful
not to nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pretin center conductor and the rear of the front and rear contacts.

d) Solder the rear contact flush with the cable dielectric.

e) Install the rear dielectric and spacer over the rear contact.

f) Solder the front contact onto the rear contact; it should be fully seated
against the rear contact and dielectric - see Figure 4.

A49-2
4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the front dielectric over the front contact.

b) Insert the cable into the connector housing - Figure 4.

c) Torque the rear nut to 25-35 in. lbs.

d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A49-3
F. A. C8804-9
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8804-9 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8804-9
coax connectors, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).
2. Workmanship Standard for Electrical Assemblies - FZM 8027.
3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.
4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-49 die.
2. Approved torque wrench.
3. Approved soldering iron.

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator

A50-1
5. Rear contact
6. Rear dielectric
7. Spacer
8. Front contact
9. Front dielectric
10. Connector housing

b) Load shrink sleeve onto cable.

2. INSTALLATION OF REAR ASSEMBLY:

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator being careful
not to nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pretin center conductor and the rear of the front and rear contacts.
d) Solder the rear contact flush with the cable dielectric.
e) Install the rear dielectric and spacer over the rear contact.
f) Solder the front contact onto the rear contact; it should be fully seated
against the rear contact and dielectric - see Figure 4.

A50-2
4. INSTALLATION OF CABLE ASSEMBLY:
a) Insert the front dielectric over the front contact.
b) Insert the cable into the connector housing - Figure 4.
c) Torque the rear nut to 25-35 in. lbs.
d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A50-3
F. A. C8814
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8814 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8814
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. An approved heating device.

2. An approved soldering iron.

ASSEMBLY PROCEDURES:

1. Soldering the shielded contact:

a) Assemble the backshell and sealing grommet over the shielded cable,
back 2 to 6 inches.

b) Position a piece of C2070-6 (approximately 3 inches long) over the

cable.

c) Assemble the grounding shield over the shielded cable.

d) Cut the shielded cable even, and strip the cable per diagram below.

A51-1
e) Position a solder sleeve (C8951-1) over the exposed shield with the
braid toward the cut end of the cable.

f) Heat the solder sleeve with an approved tool until the solder flows.

g) Solder the center conductor to the shielded contact of the insert

assembly.

h) Slide the grounding shield forward onto the center contact shield.
Rotate the grounding shield so the braid (off C8951-1 solder sleeve)
will pass through the slot.

i) Place a hot soldering iron on the grounding shield until a ―sweated‖

solder joint is made between the ground and center contact shield.

j) ―Tack solder‖ the solder sleeve braid a minimum of 90 from the slot on
the grounding shield.

NOTE: Slack must be present in the braid. Trim the braid to length.

k) Position the C2070 shrink tubing over the center grounding shield and
the C8951 solder sleeve; heat with an approved tool.

2. Soldering the unshielded contacts:

a) Cut the conductors to length.

b) Strip the insulation to 0.19 inches and solder.

3. Bring the backshell and sealing grommet into position and tighten securely.
Tighten the strain relief bars securely.

STRIP LENGTH
0.19

0.38

2.0+0.25
2.25+0.25

A51-2
F. A. C8825-1-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-1-1 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-1-1
coax connectors manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).
2. Workmanship Standard for Electrical Assemblies - FZM 8027.
3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.
4. LMTAS Soldering Process J-STD-001, CLASS III.
TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-25 die.
2. Approved torque wrench.
3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear contact
6. Rear dielectric
7. Spacer
8. Front contact

A52-1
9. Front dielectric
10. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve on to the cable with the internal taper and hole
positioned towards the end of the cable.
d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.
2. INSTALLATION OF REAR ASSEMBLY:
a) Load the rear nut onto the braid terminator, gently slide the tapered end of
the braid terminator over the dielectric and under the braid until it butts
against the jacket.
b) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
c) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
number M22520/5-25.
NOTE: After crimping - a gap between cable jacket and crimp sleeve is
acceptable. The maximum allowable gap is .05 inch.
d) Apply heat to the crimp sleeve using soldering iron or hot air gun and feed
solder into the crimp sleeve holes, insuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.
3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator being careful
not to nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pre-tin center conductor and the rear of the front and rear contacts.
d) Solder the rear contact flush with the cable dielectric.
e) Install the rear dielectric and spacer over the rear contact.
f) Solder the front contact onto the rear contact; it should be fully seated
against the rear contact and dielectric - see Figure 4.
4. INSTALLATION OF CABLE ASSEMBLY:
a) Insert the front dielectric over the front contact.
b) Insert the cable into the connector housing - Figure 4.
c) Torque the rear nut to 25-35 in. lbs.
d) Slide the shrink sleeve forward and shrink in place.

A52-2
ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A52-3
F. A. C8825-1-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-1-2 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-1-2
coax connectors manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).
2. Workmanship Standard for Electrical Assemblies - FZM 8027.
3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.
4. LMTAS Soldering Process J-STD-001, CLASS III.
TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-05 die.
2. Approved torque wrench.
3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear dielectric
6. Contact
7. Front dielectric
8. Connector housing

A53-1
b) Load shrink sleeve onto cable.
c) Load the crimp sleeve on to the cable with the internal taper and hole
positioned towards the end of the cable.
d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator, gently slide the tapered end of
the braid terminator over the dielectric and under the braid until it butts
against the jacket.
b) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
c) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
number M22520/5-05 Closure A.
NOTE: After crimping - a gap between cable jacket and crimp sleeve is
acceptable. The maximum allowable gap is .05 inch.
d) Apply heat to the crimp sleeve using soldering iron or hot air gun and feed
solder into the crimp sleeve holes, ensuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator being careful
not to nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pre-tin center conductor and the rear of the front and rear contacts.
d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter-bore faces the braid
terminator.
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the front dielectric over the front contact.
b) Insert the cable into the connector housing - Figure 4.
c) Torque the rear nut to 25-35 in. lbs.
d) Slide the shrink sleeve forward and shrink in place.

A53-2
ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. For exceptions to this criteria see 2.c - NOTE (above).

A53-3
F. A. C8825-1-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-1-3 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-1-3
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-05 die.

2. Approved basic crimping tool M22520/1-01 with positioner M22520/1-12.

3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Steel sleeve

A54-1
4. Dielectric
5. Contact
6. Connector housing

b) Load shrink sleeve onto cable and crimp it.

c) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

d) Trim the cable dielectric to expose the center to the dimension shown in
Figure 2, being careful not to nick the center conductor.

2. INSTALLATION OF CONTACT:

a) Load the steel sleeve and teflon dielectric over the cable dielectric (see
Figure 3).

b) Pre-tin center conductor and the rear of contact.

c) Solder the contact flush to the teflon dielectric.

d) Optional: If crimping is desirable, crimp the contact using tool number

M22520/1-01 with positioner M22520/1-12 with a blue setting on four (4).

3. INSTALLATION OF CONNECTOR HOUSING:

a) Insert cable assembly, cable with contact, teflon dielectric, and steel
sleeve into the connector housing until the center contact locks into the
dielectric of the housing (see Figure 4).

b) Comb the braid forward, and slide the crimp sleeve over the braid until it
butts against the connector housing.

c) Position the crimp sleeve in Closure A of tool M22520/5-01 and die

M22520/5-05 Closure B, and crimp in place.

NOTE: After crimping, a gap between the cable jacket and the crimp
sleeve is acceptable. Maximum acceptable gap is 0.05 inch.

d) Optional: If desirable, apply heat to crimp sleeve, using a soldering iron or

hot air gun, and feed solder into the crimp sleeve holes, ensuring
adequate evidence of wetting. Caution should be exercised when using
the hot air gun to avoid damage to the outer jacket of the cable.

e) Clean affected areas

A54-2
f) Slide the shrink sleeve forward until it butts against the connector housing
, then shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. For exceptions to this criteria see 3.c - NOTE (above).

A54-3
F. A. C8825-1-4
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-1-4 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-1-4
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-05 die.
2. Approved torque wrench.
3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear dielectric
6. Contact

A55-1
7. Front dielectric
8. Connector housing
b) Load shrink sleeve onto cable.
c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.
d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator.
b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.
c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-05 Closure A
NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.
e) Apply heat to crimp sleeve, using a soldering iron or hot air gun, and feed
solder into the crimp sleeve holes, ensuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pre-tin center conductor and the rear of contact.
d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counterbore faces the braid
terminator.
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Load the front dielectric onto the contact.
b) Insert the cable into the connector housing - see Figure 4.

A55-2
c) Torque the rear nut to 25-35 inch lbs.
d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:
1. Reference FZM 8027 for accept/reject criteria.
2. For exceptions to this criteria see 2.d - NOTE (above).

A55-3
F. A. C8825-2-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-2-1 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-2-1
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-49 die.
2. Approved torque wrench.
3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear contact
6. Rear dielectric

A56-1
7. Spacer
8. Contact
9. Connector housing
b) Load shrink sleeve onto cable.
c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.
d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator..
b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.
c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-49.
NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.
e) Apply heat to crimp sleeve, using a soldering iron or hot air gun, and feed
solder into the crimp sleeve holes, ensuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pre-tin center conductor and the rear of the front and rear contacts.
d) Solder the rear contact flush with the cable dielectric.
e) Install the rear dielectric and spacer over the rear contact.
f) Solder the front contact onto the rear contact; it should be fully seated
against the rear contact and dielectric - see Figure 4.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the cable into the connector housing - see Figure 4.
b) Torque the rear nut to 25-35 inch lbs.

A56-2
c) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:
1. Reference FZM 8027 for accept/reject criteria.
2. For exceptions to this criteria see 2.d - NOTE (above).

A56-3
F. A. C8825-2-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-2-3 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-2-3
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-05 die.
2. Approved torque wrench.
3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear dielectric
6. Connector housing
b) Load shrink sleeve onto cable.

A57-1
c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.
d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator..
b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.
c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-05 Closure B.
NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.
e) Apply heat to crimp sleeve, using a soldering iron or hot air gun, and feed
solder into the crimp sleeve holes, ensuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pre-tin center conductor and the rear of contacts.
d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counterbore faces the braid
terminator.
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the cable into the connector housing - see Figure 4.
b) Torque the rear nut to 25-35 inch lbs.
c) Slide the shrink sleeve forward over the crimp sleeve until it butts against
the connector housing, then shrink in place.

A57-2
ACCEPT/REJECT CRITERIA:
1. Reference FZM 8027 for accept/reject criteria.
2. For exceptions to this criteria see 2.d - NOTE (above).

A57-3
F. A. C8825-4-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-4-1 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8825-4-1
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Feeler gage - 0.014.

2. Approved soldering iron.

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Score the jacket of the cable a full 360 degrees; do not cut through the
jacket.
b) Pre-tin the cable jacket, ensuring full solder coverage from the score line
to approximately .300 inch up the cable jacket.
Gently flex the cable to break the jacket at the score line. Remove the
jacket to expose the dielectric.

A58-1
c) Trim the dielectric flush with the enc of the jacket, exercising caution not to
nick the center conductor.

d) Trim the center conductor to dimensions shown in Figure 2.

2. INSTALLATION OF CONTACT:

a) Pre-tin center conductor.

b) Pre-tin and wick the rear hole of the contact.

c) Using a solder iron and feeler gage, solder the contact onto the center
conductor with a 0.014 gap between the rear of the contact and the trim
line of dielectric and cable jacket (see Figure 3).

3. INSTALLATION OF CONNECTOR:

a) Pre-tin the rear hole of the connector housing.

b) Fully insert the contact and cable into the rear of the connector housing
(the cable should stop at the rear of the internal housing dielectric).

c) Solder the connector housing to the cable jacket.

d) Clean the connector and solder joint after soldering operation is

performed.

e) Verify the contact height to the dimension shown in Figure 4.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. Verify the contact height to the dimension shown in Figure 4.

3. Ensure solder meets the requirements of J-STD-001, Class III.

A58-2
A58-3
F. A. C8826-1-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8826-1-1 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8826-1-1
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-57 die.

2. Approved torque wrench.

3. Approved soldering iron or hot air gun (AA-400 Super Heater).

A59-1
ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:

a) Parts are identified in Figure 1.

1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Match Sleeve
6. Rear Dielectric
7. Contact
8. Front Dielectric
9. Connector housing
b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

A59-2
2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator..

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut and is butted against the braid terminator.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-57 Closure A.

NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin center conductor and the rear of contact (for solder termination
only).

NOTE: Contact may be crimped using M22520/5-01 basic tool with

M22520/5-57 die Closure B.

d) Slide the rear dielectric and match sleeve onto the center conductor until it
butts against the braid terminator. Ensure that the small step on the rear
dielectric faces the contact.

e) Solder or crimp the contact onto the center conductor, ensuring that the
contact shoulder is fully bottomed against the rear dielectric.

A59-3
4) INSTALLATION OF CABLE ASSEMBLY:

a) Install the front dielectric over the contact.

b) Insert the cable into the connector housing - see Figure 4.

FIGURE 4

c) Torque the rear nut to 25-35 inch lbs.

d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. For exceptions to this criteria see 2.d - NOTE (above).

A59-4
F. A. C8827-1-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8827-1-2 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8827-1-2
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.
2. This Fabrication Aid is applicable for all F-16 programs.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-57 die.
2. Approved torque wrench.
3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear Dielectric
6. Contact
7. Connector housing

A60-1
b) Load shrink sleeve onto cable.
c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.
d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator.
b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.
c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-57 Closure A.
NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.
e) Apply heat to crimp sleeve, using a soldering iron or hot air gun, and feed
solder into the crimp sleeve holes, ensuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the step on the dielectric faces the contact.
d) Slide the contact onto the center conductor , ensure that the rear of the
contact butts against the step on the rear dielectric.
e) Crimp the contact in place using tool number M22520/5-01 with die
number M22520/5-57 Closure B.

4. INSTALLATION OF CABLE ASSEMBLY:

A60-2
ACCEPT/REJECT CRITERIA:
1. Reference FZM 8027 for accept/reject criteria.
2. For exceptions to this criteria see 2.d - NOTE (above).

A60-3
F. A. C8828-1-1 & C8828-1-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8828-1-1 AND C8828-1-2 COAX CONNECTOR

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembly of C8828-1
and C8828-1-2 coax connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturers Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURE:

1. Braid must be combed for RG 196/U cable. Strip coaxial cable to dimensions
shown on next page. (Dimensions may be altered to suit characteristics of
cable.)

BRAID MUST BE COMBED

FOR RG 196/U CABLE

2. Crimp Tool
a) Assemble stepped outer hyring onto cable.
b) Assemble supporting sleeve over inner dielectric and under braid.

A61-1
c) Assemble inner hyfen pin or socket to inner conductor and crimp with an
approved tool.

SUPPORT ING SLEEVE INNER HYFEN PIN (OR

( R C M X B- - - ) SOCKET ) (RMM--W---)
(RF M--W---)

ST E PP E D O U T ER
HYRING (YORX)

3. Snap-lock pin (or socket) into outer female (or male) contact. Small
diameter on outer contact must slide over supporting sleeve and under
braid.

4. Slide stepped outer hyring over exposed braid, and crimp hyring onto braid
with an approved tool. Assembly can now be snap-locked into connector
block.

SUPPORT ING SLEEVE IN POSIT ION

MINIAT URE OUTER FEM ALE (OR M ALE )

CONTACT (RCM X---)(RMMX----)

B E FO R E

AF T E R SNAP -LOCK PIN(OR SOCKET) INTO

OUTER FEMALE (OR MALE) CONTACT.
SMALL DIAMET ER ON OUTER CONTACT
MUST SLIDE OVER SUPPORTING
A N D U N D E R B R A ID .

A61-2
STRIPPING DIMENSIONS.

CONNECTOR P/N A B C D
C8828-1-1, C8828-1-2 0.41 0.50 0.19 .069

MIL-CRIMP

OUTER MALE CONTACT

FERRULE PLUG BODY ASSEMBLY
MIL-CRIMP

FEMALE CONTACT

JACK BODY ASSEMBLY

0.10 A B C

For RG-174, 179, 187, 188/u cables only, slit jacket back 0.10 0.02 as
shown. Before attaching center contact, slide metal spacer and teflon
sleeve (not shown) over cable dielectric. The center contact should butt
against the dielectric and teflon sleeve

A61-3
CONTACT MUST BUTT AGAINST
CABLE DIELECTRIC

CABLE DIELECTRIC MUST

BUTT INSULATION
OUTER FERRULE SHOULD
BUTT HERE

CABLE DIELECTRIC MUST

BUTT INSULATION
OUTER FERRULE SHOULD
BUTT HERE

A61-4
F. A. C8830-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8830-1 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8830-1
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-09 die.

2. Basic crimping tool M22520/1-01 with positioner M22520/1-12.

3. Approved soldering iron.

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.

1. Shrink sleeve
2. Crimp sleeve

A62-1
3. Steel sleeve
4. Dielectric
5. Contact
6. Connector housing

b) Load shrink sleeve onto cable.

c) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

d) Trim the cable dielectric to expose the center, to the dimensions shown in
Figure 2. Precautions shall be taken to avoid cutting the center conductor.

2. INSTALLATION OF CONTACT:

a) Load the steel sleeve and teflon dielectric over the cable dielectric - see
Figure 3.

b) Pre-tin the center conductor and contact.

c) Solder the contact flush to the teflon dielectric.

d) Optional: If crimping is desirable, crimp the contact using tool number

M22520/1-01 with positioner M22520/1-12 with blue setting on five (5).

3. INSTALLATION OF CONNECTOR HOUSING:

a) Insert cable assembly, cable with contact, teflon dielectric and steel sleeve
into the connector housing until the center contact locks into the dielectric
of the housing - see Figure 4.

b) Comb the braid forward and slide the crimp sleeve over the braid until it
butts against the connector housing.

c) Position the crimp sleeve in tool M22520/5-01 with die M22520/5-09

Closure A and crimp in place.

d) Optional: If desirable, apply heat to the crimp sleeve and feed solder into
the crimp sleeve holes until solder flows into the braid, ensuring adequate
evidence of wetting.

e) Clean affected areas.

f) Slide the shrink sleeve forward until it butts against the connector housing,
then shrink in place.

A62-2
ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A62-3
F. A. C8830-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8830-2 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8830-2
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for
F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.
4. LMTAS Soldering Process J-STD-001, CLASS III.
TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-09 die.

2. Approved torque wrench.

3. Approved soldering iron.

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator

A63-1
5. Rear Dielectric
6. Contact
7. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.
2. INSTALLATION OF REAR ASSEMBLY:
a) Load the rear nut onto the braid terminator..

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-09 Closure A.

e) Apply heat to crimp sleeve, using a soldering iron or hot air gun, and feed
solder into the crimp sleeve holes, ensuring adequate evidence of wetting.
Caution should be exercised when using the hot air gun to avoid damage
to the outer jacket of the cable.
3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin the center conductor and the rear of contact.

d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter bore faces the braid
terminator.

e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

A63-2
4. INSTALLATION OF CABLE ASSEMBLY:
a) Insert the cable into the connector housing - see Figure 4.
b) Torque the rear nut to 25-35 inch lbs.
c) Slide the shrink sleeve forward over the crimp sleeve until it butts against
the connector housing, and shrink in place.

ACCEPT/REJECT CRITERIA:
1. Reference FZM 8027 for accept/reject criteria.

A63-3
F. A. C8838-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8838-1 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8838-1
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Approved soldering iron.

2. Approved heat gun.

3. Approved torque wrench.

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:

a) Trim back jacket, braid and dielectric 0.20 inches from the end of the
cable, see Figure 2, being careful not to nick the center conductor.
b) Trim jacket and braid back 0.10 inches from end of dielectric, see Figure
2.
c) Make two (2) horizontal slits 0.20 inches in length in the jacket 180
degrees apart, see Figure 2.

A64-1
2. INSTALLATION OF LOCKNUT AND SLEEVE:

a) Load the shrink sleeve and lock nut onto the cable.

b) Slide the sleeve onto the cable, ensuring that the tapered end of the
sleeve goes under the braid and jacket, see Figure 3.

c) Install rear dielectric into the sleeve. Apply pressure to the front of the
rear dielectric until it is firmly seated against the cable dielectric.

d) Slide the lock nut forward to ensure the braid is in contact with the sleeve.

e) Apply heat to the sleeve until the solder flows into the braid.

3. INSTALLATION OF REAR CONTACT:

a) Strip center conductor to dimensions shown in Figure 2.

b) Pre-tin the center conductor and rear of the contact.

c) Solder the contact onto the center conductor, ensuring that the shoulder of
the contact is seated in the counter bore of the rear dielectric.

4. INSTALLATION OF CONNECTOR HOUSING:

a) Insert the contact and sleeve subassembly into the connector housing,
see Figure 4.

b) Thread the lock nut into the connector housing and torque to 25-35 inch
lbs.

c) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A64-2
A64-3
F. A. C8952-1-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8952-1-2 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LM Aero) Vendor/Supplier operations for assembling C8952-1-2
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-05 die.

2. Approved torque wrench.

3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve

A65-1
3. Rear nut
4. Braid terminator
5. Rear Dielectric
6. Contact
7. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator..

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-05.

NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.

3. INSTALLATION OF CONTACT:

a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin center conductor and the rear of contact (for solder termination
only).

A65-2
d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the step on the dielectric faces the contact.

e) Solder the contact onto the center conductor, ensuring that the contact is
fully bottomed against the rear dielectric.

NOTE: Contact may be crimped using a M22520/5-57 Closure B crimp

tool.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the cable into the connector housing - see Figure 4.

b) Torque the rear nut to 25-35 inch lbs.

c) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. For exceptions to this criteria see 2.d - NOTE (above).

A65-3
A65-4
F. A. C8952-1-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8952-1-3 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LM Aero) Vendor/Supplier operations for assembling C8952-1-3
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-49 die.

2. Approved torque wrench.

3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:

a) Parts are identified in Figure 1.

1. Shrink sleeve
2. Crimp sleeve

A66-1
3. Rear nut
4. Braid terminator
5. Rear Dielectric
6. Contact
7. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator.

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-49 Closure A.

NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin center conductor and the rear of contact.

d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter bore faces the braid
terminator.
A66-2
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

NOTE: Contact may be crimped using a M22520/5-57 Closure B, crimp

tool.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the cable into the connector housing - see Figure 4.

b) Torque the rear nut to 25-35 inch lbs.

c) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. For exceptions to this criteria see 2.d - NOTE (above).

A66-3
A66-4
F. A. C8918-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8918-1 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C8918-1
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-09 die.

2. Approved torque wrench.

3. Approved soldering iron.

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:

a) Parts are identified in Figure 1.

1. Shrink sleeve

A67-1
2. Crimp sleeve
3. Rear nut
4. Braid terminator
5. Rear dielectric
6. Contact
7. Front dielectric
8. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator..

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-09 Closure A.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.
b) Trim the center conductor to the dimension shown in Figure 3.
c) Pre-tin center conductor and the rear of contact.
d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter bore faces the braid
terminator.
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.
A67-2
4. INSTALLATION OF CABLE ASSEMBLY:

a) Load the front dielectric onto the contact.

b) Insert the cable into the connector housing - see Figure 4.

c) Torque the rear nut to 25-35 inch lbs.

d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A67-3
A67-4
F. A. C8918-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8918-2 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8918-2
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-09 die.

2. Approved torque wrench.

3. Approved soldering iron.

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut
4. Braid terminator

A68-1
5. Rear dielectric
6. Contact
7. Front dielectric
8. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator.

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-09 Closure A.

3. INSTALLATION OF CONTACT:

a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin center conductor and the rear of contact.

d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter bore faces the braid
terminator.

e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.
A68-2
4. INSTALLATION OF CABLE ASSEMBLY:

a) Load the front dielectric onto the contact.

b) Insert the cable into the connector housing - see Figure 4.

c) Torque the rear nut to 25-35 inch lbs.

d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A68-3
A68-4
F. A. C8918-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8918-3 COAX CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for assembling C8918-3
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-09 die.

2. Approved torque wrench.

3. Approved soldering iron.

ASSEMBLY PROCEDURES:
1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
1. Shrink sleeve
2. Crimp sleeve
3. Rear nut

A69-1
4. Braid terminator
5. Rear dielectric
6. Contact
7. Front dielectric
8. Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator..

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-09 Closure A.

3. INSTALLATION OF CONTACT:

a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin center conductor and the rear of contact.

d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter bore faces the braid
terminator.

A69-2
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Load the front dielectric onto the contact.

b) Insert the cable into the connector housing - see Figure 4.

c) Torque the rear nut to 25-35 inch lbs.

d) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A69-3
A69-4
F. A. M25516
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M25516 CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LM Aero) Vendor/Supplier operations for assembly of M25516
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturers Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved soldering iron.

2. Approved heat source.

ASSEMBLY PROCEDURE:

1. Slide cable nut, bushing, washer, gasket (.25 dia.), retainer, and gasket (.20
dia.) over cable; and trim insulation from center conductor to dimension
shown.

2. Solder contact assembly to center conductor, and insert 2 piece cable clamp
into bushing. Hold all parts against contact assembly, and insert into
connector body. Tighten nut until cable clamp grips cable securely. Do not
permit connector body or cable to rotate while tightening cable nut.

3. The shielded wire version has a ―BRAID CLAMP & V-GROOVE‖ gasket that
goes between the ―Retainer‖ and ―Washer‖. Strip the outer jacket 0.4 inches.

A70-1
GASKET
.25 DIA. FEMALE
CONTACT ASS'Y.
BUSHING WASHER GASKET
.20 DIA.

CABLE CABLE BRAID

NUT CLAMP RETAINER MALE PLUG BODY
2 PIECE CONTACT ASS'Y

0.11

SOLDER

A70-2
ALTERNATE ASSEMBLY INSTRUCTIONS FOR M25516 CONNECTOR:

1. Place cable nut, ―O‖ ring, bushing, and braid clamp over cable outer jacket.
Trim cable jacket, braid, and dielectric to the dimensions shown. Rotate
cable dielectric with pressure applied to cable to flare out shield. Twist center
conductor strands and lightly tin conductor.

2. Slide contact assembly (pin or socket) over inner dielectric and center
conductor. Ensure center conductor is visible through hole, and contact
assembly is pushed on cable as far as possible. Solder the center conductor
to the contact. Push braid clamp and bushing over shield as far as possible.

3. Slide ―O‖ ring over bushing against contact assembly. Insert finished cable
assembly into connector body. Slide cable nut forward against back end of
contact assembly, and tighten cable nut.

"O" RING BUSHING CONTACT ASSEMBLY

PIN OR SOCKET

CABLE BRAID
NUT CLAMP CONNECTOR BODY
(PLUG OR JACK)

0.31
0.29

0.19
0.17
0.52
0.51

Installation of a C2023-2 boot:

1. To prepare the boot for termination, first sand the inside and clean with an
approved solvent, then apply P6011-1 adhesive. Shrink boot onto both the
M25516 connector and expandable braid sleeving C8844-1. For further
protection, shrink the reference designator about 0.20 inches over the boot
end.

A70-3
F. A. M39012
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M39012 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembly of M39012
coax connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturers Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

ASSEMBLY PROCEDURE:

1. Braid must be combed for RG 196/U cable. Strip coaxial cable to dimensions
shown on next page. (Dimensions may be altered to suit characteristics of
cable.)

BRAID MUST BE COMBED

FOR RG 196/U CABLE

2. Crimp Tool
a) Assemble stepped outer hyring onto cable.
b) Assemble supporting sleeve over inner dielectric and under braid.
c) Assemble inner hyfen pin or socket to inner conductor and crimp with an
approved tool.

A71-1
SUPPORT ING SLEEVE INNER HYFEN PIN (OR
( R C M X B- - - ) SOCKET ) (RMM--W---)
(RF M--W---)

ST E PP E D O U T ER
HYRING (YORX)

3. Snap-lock pin (or socket) into outer female (or male) contact. Small
diameter on outer contact must slide over supporting sleeve and under
braid.

4. Slide stepped outer hyring over exposed braid, and crimp hyring onto braid
with an approved tool. Assembly can now be snap-locked into connector
block.

SUPPORT ING SLEEVE IN POSIT ION

MINIAT URE OUTER FEM ALE (OR M ALE )

CONTACT (RCM X---)(RMMX----)

B E FO R E

AF T E R SNAP -LOCK PIN(OR SOCKET) INTO

OUTER FEMALE (OR MALE) CONTACT.
SMALL DIAMET ER ON OUTER CONTACT
MUST SLIDE OVER SUPPORTING
A N D U N D E R B R A ID .

A71-2
STRIPPING DIMENSIONS.

CONNECTOR P/N A B C D
M39012/01, /02, /05 0.41 0.50 0.19 0.69
M39012/16, /18, /20, /26, /27, 0.34 0.44 0.16 0.60
/28, /29, /30
M39012/55, /57 0.281 0.390 0.14 0.53

MIL-CRIMP

OUTER MALE CONTACT

FERRULE PLUG BODY ASSEMBLY
MIL-CRIMP

FEMALE CONTACT

JACK BODY ASSEMBLY

0.10 A B C

A71-3
CONTACT MUST BUTT AGAINST
CABLE DIELECTRIC

CABLE DIELECTRIC MUST

BUTT INSULATION
OUTER FERRULE SHOULD
BUTT HERE

CABLE DIELECTRIC MUST

BUTT INSULATION
OUTER FERRULE SHOULD
BUTT HERE

A71-4
F. A. 16VE049
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF 16VE049 SERIES CONNECTORS

SCOPE:
1. This Fabrication Aid is applicable to Lockheed Martin Aeronautics (LMAero)
Vendor/Supplier operations and describes proper procedure for preparation
and termination of non-shielded wires and shielded wires/cables for
assemblies of 16VE049 series connectors for electrical harnesses. This
series of connectors is often known as "wafer connectors".
2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:
1. Manufacturer's Operating Procedures or equivalent document (reference
only).
2. This Fabrication Aid is applicable to all programs utilizing 16VE049 series
connectors.
3. Workmanship Standards for Electrical Assemblies FZM 8027.

TOOLS REQUIRED:
1. The following Raychem tools are approved for the termination of the wires:
a) CE-1200100 Manual wafer termination station
b) CE-120010000 Manual wafer termination station (Teflon)
c) AA 400 SuperHeater
d) HT 900B Hot air gun
e) Steinel Heat Gun
f) Leister Triac S Heat Gun with 31D7 Attachment
or LM Aero equivalent.

NOTE: The Triac S Heat Gun can only be used on same gauge wires at once
on wafers. Multiple gauges of wire on a wafer must be heated
separately with heat foil protecting other wires in close proximity of the
concentrated heat.

2. The following listed Raychem tools are approved for the termination of the
shielded wires/cables:
a) CE-1200200 Shielded bus station
b) CE-1200300 Repair fixture

A72-1
3. The following listed Raychem tools are approved for connector wafer insertion
and/or removal:
a) D659-0001 MTC Connector wafer removal tool
b) CE-1201900 MTC Connector wafer insertion/removal tool

GENERAL REQUIREMENTS:
1. The process is essentially divided into two major sections - preparation of
wires/ cables, and termination of wires/cables.

WIRE/CABLE PREPARATION:
1. Using approved tool, wire/cable shall be stripped at one end to the
dimensions in accordance with wafer specification Figure 1, or contact Fab
Aid.
2. Tinning of wires prior to solder operation is not required, except for alumel-
chromel type wires.

WIRE/CABLE TERMINATION: (One Wire at a Time)

1. 16VE049012 sleeves, containing Sb5 solder (95% tin, 5% antimony) shall be
used to terminate the wire on the connector.
2. Insert the wafer in the wafer-holding fixture.
3. Slide the solder sleeve terminator back over the wire to be terminated.
4. Position the stripped wire end as shown in Figure 2, and slide the solder
sleeve terminator over the tab until it contacts the wafer body.
5. Position the tape/foil reflector behind the tab to be soldered and in front of the
rest of the tabs as shown in Figure 3. The reflector foil may cover the entire
sleeve area.
6. Direct hot air from the AA 400 SuperHeater or HT 900B hot air gun, held
approximately 1/8 to 1/4 inch distance, at the solder preform until it melts and
flows and wets the connection. Allow to cool before moving. Verify that
solder has flowed and sealing inserts have melted without squirting solder
outside the sleeve.

WIRE/CABLE TERMINATION: (All Wires at One Time)

1. 16VE049012 sleeves, containing Sb5 solder (95% tin, 5% antimony), shall be

used to terminate the wires on connector. Insert the sleeves on the terminals
to which a wire will be soldered. Do not insert the sleeves on the terminals
that will get wires soldered at a later time, but insert the solder sleeves on
terminals that will not get any wire soldered (i.e., empty terminals).
2. Insert the wafer in a wafer-holding fixture, and secure the wafer in place with
the retainer clip.
3. Slide the solder sleeves back over the wires to be terminated.
A72-2
4. Position the stripped wire ends as shown in Figure 2 on the appropriate
terminals.
5. Push the solder sleeve up against wafer body while holding the wires firmly.
6. Press the wires into spring clip.
7. Close and latch the wire clamp.
8. Verify that all wires are positioned as shown in Figure 2. (If not, move the
individual wires accordingly to do so.)
9. Using an approved heat source, direct hot air at the solder pre-form until it
melts and flows and wets the connection. Allow to cool before moving. Verify
that solder has flowed and sealing inserts have melted without squirting
solder outside the sleeve.

TERMINATION OF ALUMEL-CHROMEL CONDUCTORS.

1. Cut and strip both conductors approximately one inch.
2. Clean the conductors with a wire brush separating the strands so that each
strand is brushed. Retwist strands.
3. Immediately flux the conductors using Kester 817 or Alpha 90 flux.
4. Immediately pre-tin using Sb5 solder. The solder should be in a solder pot at
a temperature of 600 -650 F. Hold conductors in the solder for at least 10
seconds.
5. Inspect the conductors for proper tinning.
6. Dip the conductors in a neutralizer (Kester 5760 or equivalent).
7. Cut the conductors (0.15 - 0.19 inch) and terminate in a normal manner
except additional heat is required.

SHIELD TERMINATION:
1. Shield shall be terminated using shielded bus termination station (Figure 4A).
2. Install a bus bar such that shield braid lays on the bus tab.
3. All the wires shall be held to bus tabs with heat-shrinking sleeve. Table 1
identifies number of wires that can be attached to one tab of bus bar.

TABLE 1
TYPE OF WIRE #BUS BAR TAB
4-Conductor Shielded 1
1-Conductor Shielded 2
2-Conductor Shielded + 2 Unshielded 1
3-Conductor Shielded + 2 Unshielded 1
Unshielded 6
Braided shields from solder sleeves 4
Multiplex cable shield 1

A72-3
4. Move the sliding cover (shielded bus termination station) just far enough over
the bus bar ears to lock the bus bar in place.
5. Install the wafer assembly into the shielded bus termination station with the
wafer-keying ridges down to fit into the channel.
6. Move the cover over the wafer to lock it in place.
7. Dress the shield out to its original length. The shield shall overlap the bus tab
a minimum of 0.20 inch and shall not extend beyond the sleeve maximum.
8. Slide the solder sleeve terminator over the shield and bus bar tab with the
solder ring centered over the cupped area.
9. Shrink the shield terminator with an approved heat source. Direct hot air at
the solder pre-form until it melts and flows and wets the connection. Allow to
cool before moving. Verify that solder has flowed and sleeve has shrunk.
Since the heat-shrinking tube fully encloses the solder termination, it is not
necessary (nor required) to clean the solder joint.
10. P5034 or C2070-X-X sleeves shall be used to secure unshielded wires to the
bus bar tab.
11. All unused bus bar tabs shall be covered with C2070-X-X or P5034 heat-
shrink sleeves.

ASSEMBLY OF CONNECTORS:
1. Hold one "A" wafer (one keying notch) and one "B" wafer (two keying
notches) flat together with keying ridges facing out.
2. Insert both wafers together into the housing with "A" wafer towards "A" side of
housing, and "B" wafer towards "B" side of housing. Assure that both wafers
snap into place.
3. If a clamp or bus bar is used, attach these parts to the ears on the rear of the
housing.
MAKE SURE THE WAFERS ARE STRAIGHT AND WIRES ARE DRESSED
BEFORE ASSEMBLING THE CLAMP BARS.
4. When an Expando sleeving is used, the following steps shall be taken:
a) Position the expando over the wires and solder sleeves
b) Insert the wafers into the housing.
c) Assemble the strain relief bars.
d) Tighten the screws.
1. C8844 EXPANDO may be used without slitting.

A72-4
NOTE: When the assembly includes a shield comb(s), the expando must be slit
on each side for approximately 0.75 to 1.00 inch to allow the attaching
tabs to protrude. The slits must be cut with an approved thermal device.
A short piece of P5381 may be used to terminate the expando to the
shield comb or backshell.

5. Shield Termination to C10558 (P809) Type Backshell:

6. Dead-end the shields on all cables 1.25 inches from end of wire/cable.
7. If the assembly has large number of shielded cables, then it is acceptable to
dead-end the shield without folding it back.
8. Group the required cables and slide a C8951 solder sleeve over the group.
9. Terminate the conductors on wafer or contact.
10. Insert contacts into connector inserts.
11. Insert the wafers or connector inserts into connector shell. Form the cables to
accept the C10558 (P809) type backshell.
12. Temporarily install backshell on connector shell and spot tie cables to the
backshell.
13. Stagger the solder sleeves so that they do not overlap if more than four solder
sleeves are terminated to one backshell.
14. Cut windows for C8951 solder sleeves from 1.5 inches to 3.5 inches behind
the backshell (Figure 5).
15. Remove the backshell and terminate the solder sleeves.
16. Thread solder sleeves shield braid through the holes in the backshell. Make
sure that "A" wafer/connector braids go to one half of the backshell and "B"
wafer/connector braids go to the other half of the backshell.
17. Install the backshell on connector housing. Make sure that sufficient slack is
left in solder sleeve braid for re-terminating at least two times.
18. Solder the braids to the recessed area of the backshell with braid threaded
through holes and trim braid, if necessary.
19. Secure the conductors (and expandable sleeving where applicable) to the
backshell with P5289 tying cord. When terminated C8844 on outside of
backshell, only one thickness of the cord is allowable. Examples of
termination are shown in Figure 6
20. If wires are outside of the rubber inserts of the strain relief bar of the 16VE049
backshell, re-position wires between rubber inserts.

A72-5
ACCEPT/REJECT CRITERIA:

WIRE TERMINATION:

a) The stripped wire shall overlap the solder terminal a minimum of twice the
conductor diameter without extending past the cup portion of the terminal.
b) The wire insulation shall extend to within 0.050 inch of the solder terminal
without overlapping.
c) The conductor shall not extend beyond the edges of the terminal.
Skewing within this limitation is acceptable.
d) Solder preform shall melt, flow, and wet the connection. The solder shall
lose all appearance of ring shape, and contours of the solder pre-form
shall not be visible.
e) The insulating sleeve shall be shrunk down fully over the terminal bosses,
terminals, wires, and bus tabs.
f) Partially squeezed-out sealing inserts at the ends shall be acceptable
provided each insert has lost its original shape and shows evidence of
flow.

ASSEMBLY OF CONNECTORS:
a) Verify that both wafers have snapped into place by gently pulling on the
cables.
b) Verify that wafers are squarely and fully inserted into housing.
c) Insure the strain relief bar/backshell screw threads are at least flush.
Requirements of M131 are not applicable to these connectors unless
specified by Engineering.
d) The housing is not damaged by the assembly process.

SHIELD TERMINATION:

a) Verify that shield overlaps the tab a minimum of 0.20 inch and does not
extend beyond the sleeve-maximum. (See Figure 4B.)
b) Verify that the shrink sleeve is not torn/cracked or overheated. Minor
browning is acceptable.

GROUND BRAID SOLDERING:

a) Verify that ground braid is threaded into C10558 backshell holes.
b) Verify that proper solder joint exists. Excess solder/cold joint is not
acceptable.
c) FZM 8027 shall be referenced for accept/reject criteria.

A72-6
0.4/0.45‖

0.13/0.17‖
1.35/1.40‖

FIGURE 1

LONG END OF SLEEVE SHORT END OF SLEEVE

WAFER (SIDE VIEW)

WIRE MUST END IN THIS AREA

MINIMUM OVERLAP OF
TWO WIRE DIAMETER

PINK SEALING INSERT

SEALING INSERT
CUPPED AREA OF TERMINAL
SOLDER PREFORM

FIGURE 2

TERMINATION BEING
WORKED ON

APPLY HEAT HERE

REFLECTOR

TAB SUPPORT

WAFER

FIGURE 3

A72-7
A72-8
EXPANDABLE SLEEVING ON OUTSIDE AND WIRE BUNDLE FILLS
BACKSHELL SUCH THAT TYING CORD COMPRESSES WIRE BUNDLE

EXPANDABLE SLEEVING ON INSIDE WHEN WIRE BUNDLE WILL NOT FILL

CONNECTOR. TIE BUNDLE AND LOOP AND TIE AGAIN TO BACKSHELL.

FIGURE 6

A72-9
F. A. 16VH019-2
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF 16VH019-2 CONNECTOR

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling 16VH019-2
connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. An approved crimping tool.

ASSEMBLY PROCEDURES:

1. Remove the screws that hold two halves of the connector together.
TWO SCREWS SUPPLIED AS
PART OF CONNECTOR

LONG SCREW

BACK HALF

FRONT HALF

A73-1
2. Strip wires to the dimension shown, and slide through back half of the
connector. Crimp contacts to the wires using an approved tool.

LONG SCREW

0.25

BACK HALF

INDEXING PIN

RETAINING PLATE

3. Pull the contacts back into back half of the connector. Slide front half of the
connector over contacts, and position against back half of the connector.

4. Position indexing pin in the small hole in front half of the connector. Install the
provided screws through the connector as shown, and tighten.

A73-2
F. A. C20274-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C20274-1 INTERPHONE JACK CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C20274-1
Interphone jack connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. An approved crimping tool.

2. An approved soldering iron.

ASSEMBLY PROCEDURES:

1. Remove cap, wire clamps, ferrules and connector barrel and install them on
the two C10575 cables.

2. Strip outer jacket of C10575 cable 1.80 inches.

3. Trim outer shield to within 0.30 inch of the outer jacket.

4. Trim inner shield to within 0.36 inch of the outer jacket.

5. Strip correct wires back 0.20 inch; cut back other wires 1.0 inch and insulate
with C2105-1 end caps.

A74-1
6. Tin ends of the four wires to be soldered to terminals.

7. Solder the four wires to correct terminals.

8. Install shrink tubing over back of inner connector assembly and terminals to
keep wire or terminals from shorting to outer barrel.

9. Slide connector barrel over terminated wires, and screw the barrel in place by
holding inner connector assembly.

10. Slide the first wire clamp into place beyond shield.

11. Slide both ferrules beyond shield, then fold outer shield back over the outer
jacket.

12. Slide both ferrules back over the turned back braid. Front edge of the ferrule
must line up with the outer shield where it folds back over the outer jacket
end.

13. While holding the ferrules in this position, crimp them in place with an
approved tool.

14. Trim inner shield as close to outer shield as can be done with reasonable
effort (0.02 to 0.06 inch), and flare ends out against front edge of the turned
back outer shield.

15. Push wires into outer barrel of connector, so that first wire clamp is in place
and ferrules are against the wire clamp.

16. Slide second wire clamp against the ferrules.

17. Apply P5407-1 (Vibra-tite) to the connector barrel threads.

18. While holding in on the two cables to keep wire clamps between barrel
fingers, screw the cap in place.

A74-2
R E D W IR E T O T E R M I N A L 1

GREEN WIRE TO TERMINAL 3

CUT BACK BLACK AND WH ITE W IRE AND

INSULATE WITH C2105-1

FIRST WIRE CLAMP 0 .36

0 .3

0 .2
F ER RU L E
CA P S E C O N D W IR E C L A M P

C U T B A C K R E D A N D G R E E N W IR E
AND INSULATE WIT H C2105-1
1 .0
W H I T E W IR E TO T E R M IN A L 2

B L A C K W IR E T O T E R M I N A L 4
1 .8

FIGURE 1

A74-3
F. A. M9177/3-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF M9177/3-1 INTERPHONE JACK CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling M9177/3-1
Interphone jack connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. An approved crimping tool.

2. An approved soldering iron.

ASSEMBLY PROCEDURES:

1. Cut cable end square and slide jack case over outer jacket. Strip jacket back
approximately two inches, and trim the fabric-cored, tinned copper braid; the
conducting cotton shield around each pair of conductors, and all fillers flush
with end of jacket. Work end of conducting cotton shield and copper braid
back under jacket to prevent contact with any part of the jack assembly.

CAUTION:

Do not damage insulation of individual wires or stay cord, or disturb

lay of conductors in jacket.

A75-1
2. Trim green wire to 0.50 inch; red, white, and black wires to 0.85 inch; then
strip all four wires back 0.25 inches as shown. Do not nick center conductors.
Knot and trim stay cord as shown so that tightened knot is 0.25 inch from end
of jacket.

3. Insert knotted stay cord into anchor slot* of jack body, and solder individual
leads to proper terminals as shown using solder called for by engineering
drawings. For type without anchor slot. Before crimping cord to No. 1
contact, orient crimp die so that the flat of contact No. 1 is aligned with one of
the flats of crimp die, and the side of die is flush with end of sleeve.

NOTE: When properly assembled, stay cord shall withstand a pull force of
20 lbs. without strain on the conductors. Install clamp so that it fits
into groove on tongue of jack body, and crimp around tongue and
cord just back of end of outer jacket.

*For one type of jack.

1. Slide case forward and screw onto jack body until body extends
approximately 0.03 inch out of case. Check completed assembly for
continuity and shorts between terminals.

2. Solder per applicable drawing note.

3. When soldering or installing a solder sleeve, shrink tubing (P5034-X-X) may

be installed over the WF-14/U conductors. Shrink tubing should be the same
color as WF-14/U conductors.

A75-2
.85 TYP.
0.5
ANCHOR SLOT
0.25
0.25
TYP.

WF-14/U CORD CASE

JACK BODY
STAY CORD

STAY CORD

CLAMP
TERMINAL WIRE COLORS:
1 GREEN
2 WHITE
3 RED
4 BLACK

JACK ASSY.

NO.1 CONTACT HEX CRIMP

SLEEVE

3/16 MIN. JACKET

(TYPE WITHOUT ANCHOR SLOT)

A75-3
F. A. C10575-1
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C10575-1 INTERPHONE JACK CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C10575-1
Interphone jack connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. An approved crimping tool.

2. An approved heating device.

ASSEMBLY PROCEDURES:

1. Termination to U-92A/U and U-93A/U Jack and Plug.

a) Strip outer shields (two) back 0.85 + 0.0, -0.03 inches from the end of
conductors.

b) Strip the outer jacket back 0.3/0.35 inches from the end of shields.

c) Trim the filler flush with shields.

A76-1
d) Push shields back and insert a piece of P5381-1 shrink tubing under
shields 0.4 inches in length. Shrink the tubing, making sure that no
strands extend beyond the tubing.

e) Place a piece of M23053/4-104-0 shrink tubing over shields and the

jacket. Overlap the jacket 0.2/0.25 inches and the shrink tubing by
0.03/0.05 inches and shrink into place.

f) Crimp the clamp ring/sleeve in place and terminate conductors.

NOTE:
1. Terminate the ―stay cord‖ when required.

2. Shield termination with an ―NAS‖ solder sleeve.

a) Strip the jacket and shields off the conductors as required.

b) Remove the fillers and ―stay cord‖ flush with the jacket.

c) Strip the jacket off to expose 0.25 inch of the shields.

d) Install an NAS1744-8 solder sleeve and a 22 AWG wire centered over the
shield. Apply heat to the solder sleeve until it has recovered.

A76-2
F. A. C192
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C192 INTERPHONE JACK CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C192
Interphone jack connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. An approved crimping tool.

2. An approved soldering iron.

ASSEMBLY PROCEDURES:

CAUTION:

Do not damage insulation of individual wires or stay cord, or disturb

lay of conductors in jacket.

A77-1
2. Trim green wire to 0.50 inch; red, white, and black wires to 0.85 inch; then
strip all four wires back 0.25 inches as shown. Do not nick center conductors.
Knot and trim stay cord as shown so that tightened knot is 0.25 inch from end
of jacket.

3. Insert knotted stay cord into anchor slot* of jack body, and solder individual
leads to proper terminals as shown using solder called for by engineering
drawings. For type without anchor slot; Before crimping cord to No. 1 contact,
orient crimp die so that the flat of contact No. 1 is aligned with one of the flats
of crimp die, and the side of die is flush with end of sleeve.

*For one type of jack.

1. Slide case forward and screw onto jack body until body extends
approximately 0.03 inch out of case. Check completed assembly for
continuity and shorts between terminals.

2. Solder per applicable drawing note.

3. When soldering or installing a solder sleeve, shrink tubing (P5034-X-X) may

be installed over the WF-14/U conductors. Shrink tubing should be the same
color as WF-14/U conductors.

A77-2
.85 TYP.
0.5
ANCHOR SLOT
0.25
0.25
TYP.

WF-14/U CORD CASE

JACK BODY
STAY CORD

STAY CORD

CLAMP
TERMINAL WIRE COLORS:
1 GREEN
2 WHITE
3 RED
4 BLACK

JACK ASSY.

NO.1 CONTACT HEX CRIMP

SLEEVE

3/16 MIN. JACKET

(TYPE WITHOUT ANCHOR SLOT)

A77-3
F. A. C192-3
DATED: 30 March 2011

FABRICATION AID

Copyright ©2011 By Lockheed Martin Corporation

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C192-3 INTERPHONE JACK CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C192-3
Interphone jack connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

1. An approved crimping tool.

2. An approved soldering iron.

ASSEMBLY PROCEDURES:

1. Remove cap, wire clamps, ferrules and connector barrel and install them on
the two C10575 cables.

2. Strip outer jacket of C10575 cable 1.80 inches.

3. Trim outer shield to within 0.30 inch of the outer jacket.

4. Trim inner shield to within 0.36 inch of the outer jacket.

5. Strip correct wires back 0.20 inch; cut back other wires 1.0 inch and insulate
with C2105-1 end caps.

A78-1
6. Tin ends of the four wires to be soldered to terminals.

7. Solder the four wires to correct terminals.

8. Install shrink tubing over back of inner connector assembly and terminals to
keep wire or terminals from shorting to outer barrel.

9. Slide connector barrel over terminated wires, and screw the barrel in place by
holding inner connector assembly.

10. Slide the first wire clamp into place beyond shield.

11. Slide both ferrules beyond shield, then fold outer shield back over the outer
jacket.

12. Slide both ferrules back over the turned back braid. Front edge of the ferrule
must line up with the outer shield where it folds back over the outer jacket
end.

13. While holding the ferrules in this position, crimp them in place with an
approved tool.

14. Trim inner shield as close to outer shield as can be done with reasonable
effort (0.02 to 0.06 inch), and flare ends out against front edge of the turned
back outer shield.

15. Push wires into outer barrel of connector, so that first wire clamp is in place
and ferrules are against the wire clamp.

16. Slide second wire clamp against the ferrules.

17. Apply P5407-1 (Vibra-tite) to the connector barrel threads.

18. While holding in on the two cables to keep wire clamps between barrel
fingers, screw the cap in place.

A78-2
F. A. C193
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C193 INTERPHONE JACK CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C193
Interphone jack connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

TOOLS REQUIRED:

7. An approved crimping tool.

8. An approved soldering iron.

A79-1
ASSEMBLY PROCEDURES:

U
A
2
9
U

1. Cut cable end square and slide plug body over outer jacket. Strip jacket back
approximately two inches and trim the fabric-cored, tinned copper braid; the
conducting cotton shield around each pair of conductors; and all fillers flush
with end of jacket. Work copper braid back under jacket to prevent contact
with any part of plug assembly.

WF-14/U CORD BODY

CLAMP RING

CAUTION:

Do not damage insulation of individual wires or stay cord or disturb

lay of conductor in jacket.

A79-2
2. Trim wires to dimension shown. Do not nick center conductors.

0 .2 5 .8 5 TYP.
0 .2

WF -14/U CORD

STAY CORD

NOTE: Single Stay Cord - tie overhand knot on stay cord 1 inch from end of
jacket (WF-14/U), and assemble as shown.

U-93A/U

TERMINAL #1

3. Install clamp ring over groove on contact No. 1. Slide cable thru clamp and
position as shown. Loop stay cord over the retaining post and under clamp
ring. Crimp clamp ring in place. Solder individual leads to proper terminals
as shown. Slide body forward and screw onto main assembly.

TERMINAL WIRE
CABLE
1 GREEN
2 WHITE
3 RED
4 BLACK

To Terminate Wires Other Than WF-14/U Type.

1. Terminate wire shields with staggered NAS1744-X splices outside the

connector case.

2. Build up the wire bundle diameter with shrink tubing to provide a snug fit in
the connector case.

3. Pull the braided sleeving over conductors, and tie to jack body just back of the
clamp using P5289-1 string.

A79-3
F. A. C4870
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4870 SOCKET MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4870
socket mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

2. Approved torque wrench.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip insulation to 0.25 inches using an
approved stripping device. Care must be taken not to nick or damage the
conductor strands.

2. Crimp contacts using an approved crimping tool. Perform a visual inspection

for a proper crimp, and verify that wires are visible in the inspection hole.

3. Insert contacts into the relay socket using an approved insertion/extraction

tool. After insertion, pull back lightly on the wire to be sure the contact is
seated.

A80-1
MOUNTING THE RELAY SOCKET:

NOTE: The operation may be performed before wires are inserted into
the socket.

1. Position the socket in panel, perform a visual check that it is in the correct
location.

2. Assemble the washers and nuts that contact the socket and tighten to 3-4
inch-lbs. Of torque.

3. Assemble the socket to the panel using 10-32 washers and nuts. Tighten to
10-12 inch-lbs. of torque.

4. Discard unused hardware when installing relay sockets with fixed mounting
posts.

ASSEMBLY OF THE RELAY TO ITS SOCKET

1. Position relay on the socket and apply firm pressure on the relay body to
engage contacts. Care must be taken not to dent or otherwise bend the relay
housing when applying firm pressure.

NOTE: Minor scratches and dings to the relay housing are allowable
providing the integrity of the housing is not damaged.

2. Assemble the washers and nuts and tighten to 6-8 inch-lbs. of torque.

NOTE: For C4870-2 sockets with wire gauge smaller than contact size,
M23053/5 shrink tubing approximately 0.3/0.5 inches long must
be added to seal the contact cavities as shown in the following
table:

SHRINK TUBING TABLE

CONTACT WIRE TUBING

SIZE GAUGE REQUIRED
16 18 M23053/5
16 20 M23053/5
16 22 M23053/5
12 18 M23053/5
12 20 2 PCS. M23053/5

A80-2
A80-3
F. A. C4934-2
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4934-2 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4934-
2 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A81-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

2. Insertion of relay sockets into the mounting rail. Place a socket in position on
the rail (one 2P socket per ―relay latch‖ spring and one 3 or 4P socket for
each (2) ―relay latch‖ springs). Apply firm pressure to the mating face seal
surface until the socket snaps into place.

3. Assembly of the relay into the mounting rail. Place a relay in position on the
rail; ensure that the polarizing pin is oriented correctly; apply firm pressure to
the relay until it snaps into position.

A81-2
PRODUCTION PRODUCTION PART FSD
CALL OUT CALL OUT NAME CALL
(OLD) (* NEW) OUT

M6106/21-003 * M83636/2-028M Relay (2P 5A) C4934-2

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A81-3
F. A. C4934-4
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4934-4 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4934-
4 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised
to be sure both layers are removed.

A82-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A82-2
PRODUCTION
PRODUCTION CALL OUT PART FSD
CALL OUT (* NEW) NAME CALL
(OLD) OUT

M6106/22-003 * M83536/6-025M Relay (4P 5A) C4934-4

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A82-3
F. A. C4935-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4935-1 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4935-
1 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

8. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be

exercised to be sure both layers are removed.

A83-1
CONTACT MATING END WIRE BARREL
PART NO. SIZ COLOR SIZ COLOR STRIP LGT.
E E
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A83-2
PRODUCTION PRODUCTION PART FSD
CALL OUT CALL OUT NAME CALL
(OLD) (* NEW) OUT
M6106/24-003 * M83536/22-025M Relay (3P 10A) C4935-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A83-3
F. A. C4936-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4936-1 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4936-
1 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A84-1
CONTACT MATING END WIRE BARREL
PART NO. SIZ COLOR SIZ COLOR STRIP LGT.
E E
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A84-2
PRODUCTION PRODUCTION PART FSD
CALL OUT CALL OUT (* NEW) NAME CALL
(OLD) OUT
M6106/25-002 M6106/25-002 Track C4936-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A84-3
F. A. C4937-2
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4937-2 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4937-
2 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A85-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A85-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (NEW) NAME OUT
M6106/23-001 M6106/23-001 Socket-Relay C4937-2
(2P)

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A85-3
F. A. C4937-3
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4937-3 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4937-
3 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A86-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved

insertion/extraction tool. Fill unused cavities with sealing plugs (M83723
type), no contacts.

2. Insertion of relay sockets into the mounting rail. Place a socket in position
on the rail (one 2P socket per ―relay latch‖ spring and one 3 or 4P socket
for each (2) ―relay latch‖ springs). Apply firm pressure to the mating face
seal surface until the socket snaps into place.

3. Assembly of the relay into the mounting rail. Place a relay in position on
the rail; ensure that the polarizing pin is oriented correctly; apply firm
pressure to the relay until it snaps into position.

A86-2
PRODUCTION PRODUCTION PART FSD
CALL OUT CALL OUT (* NEW) NAME CALL
(OLD) OUT
M6106/23-003 M6106/23-003 Socket- C4937-3
Relay (3P)

4. Removal of a relay from the mounting rail. A tool is provided that will
open the relay latch allowing the relay to be removed.
5. Removal of a socket from the mounting rail. A tool is provided that will
spring the rail allowing the relay to be removed.

A86-3
F. A. C4937-4
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4937-4 TRACK MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4937-
4 track mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A87-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A87-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (NEW) NAME OUT
M6106/23-002 M6106/23-002 Socket-Relay (4P) C4937-
4

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A87-3
F. A. C4940-1-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4940-1-1 TIMING MODULE, RELAY DRIVER ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4940-
1-1 timing module relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A88-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A88-2
PRODUCTION PRODUCTION PART FSD
CALL OUT (OLD) CALL OUT (* NEW) NAME CALL OUT
M83726/24-0103 M83726/24-0103 Relay Driver C4940-1-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A88-3
F. A. C4940-1-2
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4940-1-2 TIMING MODULE, RELAY DRIVER ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4940-
1-2 timing module relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A89-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A89-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL OUT
(OLD) (NEW) NAME
M83726/24-0303 M83726/24-0303 Relay Driver C4940-1-2

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A89-3
F. A. C4940-1-3
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4940-1-3 TIMING MODULE, RELAY DRIVER ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4940-
1-3 timing module relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A90-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A90-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL OUT
(OLD) (NEW) NAME
M83726/24-1803 M83726/24-1803 Relay Driver C4940-1-3

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A90-3
F. A. C4940-2-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4940-2-1 TIMING MODULE, RELAY DRIVER ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4940-
2-1 timing module relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A91-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A91-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL OUT
(OLD) (NEW) NAME
M83726/25- M83726/25- Relay Driver C4940-2-1
0033 0033

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A91-3
F. A. C4940-3-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C4940-3-1 TIMING MODULE, RELAY DRIVER ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C4940-
3-1 timing module relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A92-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A92-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (NEW) NAME OUT
C4940-3-1 C4940-3-1 Timing Module C4940-
3-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A92-3
F. A. C8817
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

C8817 SOCKET MOUNTED RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of C8817
socket mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

2. Approved torque wrench.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip insulation to 0.25 inches using an
approved stripping device. Care must be taken not to nick or damage the
conductor strands.

2. Crimp contacts using an approved crimping tool. Perform a visual inspection

for a proper crimp, and verify that wires are visible in the inspection hole.

3. Insert contacts into the relay socket using an approved insertion/extraction

tool. After insertion, pull back lightly on the wire to be sure the contact is
seated.

A93-1
MOUNTING THE RELAY SOCKET:

NOTE: The operation may be performed before wires are inserted into
the socket.

1. Position the socket in panel, perform a visual check that it is in the correct
location.

2. Assemble the washers and nuts that contact the socket and tighten to 3-4
inch-lbs. Of torque.

3. Assemble the socket to the panel using 10-32 washers and nuts. Tighten to
10-12 inch-lbs. of torque.

ASSEMBLY OF THE RELAY TO ITS SOCKET

1. Position relay on the socket and apply firm pressure on the relay body to
engage contacts. Care must be taken not to dent or otherwise bend the relay
housing when applying firm pressure.

NOTE: Minor scratches and dings to the relay housing are allowable
providing the integrity of the housing is not damaged.

2. Assemble the washers and nuts and tighten to 3-4 inch-lbs. of torque.

A93-2
F. A. C8855
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION IN C8855 TERMINAL LUGS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating wires in
C8855 terminal lugs.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip the insulation to dimensions shown in
the following table.

STRIP LENGTH TABLE

TERMINAL C8855
STRIP LENGTH 0.50

A94-1
PROCEDURE:

1. Insert the stripped conductor end into the terminal lug barrel with the
insulation butted against the inner shoulder.

2. Crimp the terminal lug.

NOTE: The conductor double-stripped and doubled over or a piece of

stripped conductor may be inserted in the terminal lug to obtain a
crimp that passes the pull test.

A94-2
F. A. M6106/21-003
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/21-003 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/21-003 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A95-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A95-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (* NEW) NAME OUT
M6106/21-003 * M83636/2-028M Relay (2P 5A) C4934-2

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A95-3
F. A. M6106/22-003
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/22-003 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/22-003 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A96-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A96-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (* NEW) NAME OUT
M6106/22-003 * M83536/6-025M Relay (4P 5A) C4934-4

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A96-3
F. A. M6106/23-001
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/23-001 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/23-001 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A97-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A97-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL OUT
(OLD) (NEW) NAME
M6106/23-001 M6106/23-001 Socket-Relay (2P) C4937-2

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A97-3
F. A. M6106/23-002
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/23-002 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/23-002 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A98-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A98-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (NEW) NAME OUT
M6106/23-002 M6106/23-002 Socket-Relay (4P) C4937-4

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A98-3
F. A. M6106/23-003
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/23-003 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/23-003 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A99-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A99-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL OUT
(OLD) (NEW) NAME
M6106/23-003 M6106/23-003 Socket-Relay (3P) C4937-3

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A99-3
F. A. M6106/24-003
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/24-003 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/24-003 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A100-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A100-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (* NEW) NAME OUT
M6106/24-003 * M83536/22-025M Relay (3P 10A) C4935-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A100-3
F. A. M6106/25-002
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M6106/25-002 RELAY ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M6106/25-002 relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A101-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A101-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (NEW) NAME OUT
M6106/25-002 M6106/25-002 Track C4936-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A101-3
F. A. M83726/24-0103
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M83726/24-0103 RELAY DRIVER ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M83726/24-0103 relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A102-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A102-2
PRODUCTION CALL OUT PRODUCTION FSD
(OLD) CALL OUT PART CALL OUT
(NEW) NAME
M83726/24-0103 M83726/24-0103 Relay Driver C4940-1-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A102-3
F. A. M83726/24-0303
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M83726/24-0303 RELAY DRIVER ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M83726/24-0303 relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A103-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A103-2
PRODUCTION CALL OUT PRODUCTION FSD
(OLD) CALL OUT PART CALL OUT
(NEW) NAME
M83726/24-0303 M83726/24-0303 Relay Driver C4940-1-2

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A103-3
F. A. M83726/24-1803
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M83726/24-1803 RELAY DRIVER ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M83726/24-1803 relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A104-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A104-2
PRODUCTION CALL OUT PRODUCTION FSD
(OLD) CALL OUT PART CALL OUT
(NEW) NAME
M83726/24-1803 M83726/24-1803 Relay Driver C4940-1-3

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A104-3
F. A. M83726/25-0033
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

M83726/25-0033 RELAY DRIVER ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
M83726/25-0033 relay drivers.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even and strip the insulation using an approved
stripping device to dimensions shown below. Care must be taken not to nick
or damage the conductor strands.

NOTE: When stripping wires with dual insulation, care must be exercised to
be sure both layers are removed.

A105-1
CONTACT MATING END WIRE BARREL
PART NO. SIZE COLOR SIZE COLOR STRIP LGT.
M39029/22-22-28 22 GREEN 28 WHITE 0.18
0.16
M39029/22-22-22 22 GREEN 22 GREEN 0.18
0.16
M39029/22-20-20 20 RED 20 RED 0.18
0.16
M39029/22-16-16 16 BLUE 16 BLUE 0.18
0.16

FOR SIZE 12 CONTACTS USE MS27492-12

2. Crimp the contacts using approved tools. Perform a visual inspection for a
proper crimp and for wires visible in the inspection hole.

WIRE TERMINATIONS: APPLICABLE AS SPECIFIED HEREIN.

WIRE SIZE TO BE
ACCOMMODATED
CONTACT
BARREL (AWG)
SIZE MAX MIN
28 28 30 32
22 22 24 26
20 20 22 24
16 16 18 20

ASSEMBLY PROCEDURE:

1. Insert contacts into the relay socket using an approved insertion/extraction

tool. Fill unused cavities with sealing plugs (M83723 type), no contacts.

A105-2
PRODUCTION PRODUCTION FSD
CALL OUT CALL OUT PART CALL
(OLD) (NEW) NAME OUT
M83726/25-0033 M83726/25-0033 Relay Driver C4940-2-1

4. Removal of a relay from the mounting rail. A tool is provided that will open
the relay latch allowing the relay to be removed.

5. Removal of a socket from the mounting rail. A tool is provided that will spring
the rail allowing the relay to be removed.

A105-3
F. A. MS27212
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

MS27212 TERMINAL STRIP ASSEMBLY PROCEDURES

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
MS27212 terminal strip.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

ASSEMBLY PROCEDURE:

1. This sheet shows a typical hardware build-up for an MS27212 terminal strip.
For information, the terminal strip part number breakdown is as follows.

MS27212-X-XX

MS27212--------------Basic number
X-------------------------Dash no. To indicate size
XX-----------------------Number of studs

A106-1
NUT LOCK WASHER (NOT
REQUIRED IF A
LOCKNUT IS USED)

FLAT
WASHER

TERMINAL UP

TERMINAL DOWN
TERMINAL UP

BUSBAR (IF REQUIRED)

TERMINAL DOWN

USE OF FLAT WASHER

AND NUT OPTIONAL

MOUNTING NUT
INSULATOR

NAS 1063-( ) TERMINAL

NUMBER STRIP IF REQUIRED

NOTE: When a bus bar is used, the maximum number of lugs that may
be on one stud is three.

2. Mount required terminal strip using required hardware either from the top or
bottom shown.

3. Slide an MS3373( ) insulator over the stud adjacent to the mounting hole. If a
bus bar is specified, place it on the terminal studs. If required by engineering
drawings, a flat washer and a nut may be used to retain the bus bar and
insulator.

4. Place terminals on the stud with barrels turned terminals alternately down and
then up. Place a flat washer on the stud over terminals. Next, slide a lock
washer on the stud. Put the required nut on stud, and tighten with a wrench.

A106-2
F. A. MS27400
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

MS27400 SOCKET MOUNTED RELAY ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
MS27400 socket mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

2. Approved torque wrench.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip insulation to 0.25 inches using an
approved stripping device. Care must be taken not to nick or damage the
conductor strands.

2. Crimp contacts using an approved crimping tool. Perform a visual inspection

for a proper crimp, and verify that wires are visible in the inspection hole.

3. Insert contacts into the relay socket using an approved insertion/extraction

tool. After insertion, pull back lightly on the wire to be sure the contact is
seated.

A107-1
MOUNTING THE RELAY SOCKET:

NOTE: The operation may be performed before wires are inserted into
the socket.

1. Position the socket in panel, perform a visual check that it is in the correct
location.

2. Assemble the washers and nuts that contact the socket and tighten to 3-4
inch-lbs. Of torque.

3. Assemble the socket to the panel using 10-32 washers and nuts. Tighten to
10-12 inch-lbs. of torque.

ASSEMBLY OF THE RELAY TO ITS SOCKET

1. Position relay on the socket and apply firm pressure on the relay body to
engage contacts. Care must be taken not to dent or otherwise bend the relay
housing when applying firm pressure.

NOTE: Minor scratches and dings to the relay housing are allowable
providing the integrity of the housing is not damaged.

2. Assemble the washers and nuts and tighten to 3-4 inch-lbs. of torque.

A107-2
F. A. MS27401
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

MS27401 SOCKET MOUNTED RELAY ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
MS27401 socket mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

2. Approved torque wrench.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip insulation to 0.25 inches using an
approved stripping device. Care must be taken not to nick or damage the
conductor strands.

2. Crimp contacts using an approved crimping tool. Perform a visual inspection

for a proper crimp, and verify that wires are visible in the inspection hole.

3. Insert contacts into the relay socket using an approved insertion/extraction

tool. After insertion, pull back lightly on the wire to be sure the contact is
seated.

A108-1
MOUNTING THE RELAY SOCKET:

NOTE: The operation may be performed before wires are inserted into
the socket.

1. Position the socket in panel, perform a visual check that it is in the correct
location.

2. Assemble the washers and nuts that contact the socket and tighten to 3-4
inch-lbs. Of torque.

3. Assemble the socket to the panel using 10-32 washers and nuts. Tighten to
10-12 inch-lbs. of torque.

ASSEMBLY OF THE RELAY TO ITS SOCKET

1. Position relay on the socket and apply firm pressure on the relay body to
engage contacts. Care must be taken not to dent or otherwise bend the relay
housing when applying firm pressure.

NOTE: Minor scratches and dings to the relay housing are allowable
providing the integrity of the housing is not damaged.

2. Assemble the washers and nuts and tighten to 3-4 inch-lbs. of torque.

A108-2
F. A. MS27745-5
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

MS27745-5 SOCKET MOUNTED RELAY ASSEMBLY

PROCEDURES
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for the assembly of
MS27745-5 socket mounted relays.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Approved crimping and insertion/extraction tool.

2. Approved torque wrench.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip insulation to 0.25 inches using an
approved stripping device. Care must be taken not to nick or damage the
conductor strands.

2. Crimp contacts using an approved crimping tool. Perform a visual inspection

for a proper crimp, and verify that wires are visible in the inspection hole.

3. Insert contacts into the relay socket using an approved insertion/extraction

tool. After insertion, pull back lightly on the wire to be sure the contact is
seated.

A109-1
MOUNTING THE RELAY SOCKET:

NOTE: The operation may be performed before wires are inserted into
the socket.

1. Position the socket in panel, perform a visual check that it is in the correct
location.

2. Assemble the washers and nuts that contact the socket and tighten to 3-4
inch-lbs. Of torque.

3. Assemble the socket to the panel using 10-32 washers and nuts. Tighten to
10-12 inch-lbs. of torque.

ASSEMBLY OF THE RELAY TO ITS SOCKET

1. Position relay on the socket and apply firm pressure on the relay body to
engage contacts. Care must be taken not to dent or otherwise bend the relay
housing when applying firm pressure.

NOTE: Minor scratches and dings to the relay housing are allowable
providing the integrity of the housing is not damaged.

2. Assemble the washers and nuts and tighten to 3-4 inch-lbs. of torque.

A109-2
F. A. C10984
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION IN C10984 TERMINAL LUGS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating wires in
C10984 terminal lugs.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip the insulation to dimensions shown in
the following table.

STRIP LENGTH TABLE

TERMINAL C10984
STRIP LENGTH 0.50

A110-1
PROCEDURE:

1. Insert the stripped conductor end into the terminal lug barrel with the
insulation butted against the inner shoulder.

2. Crimp the terminal lug.

NOTE: The conductor double-stripped and doubled over or a piece of

stripped conductor may be inserted in the terminal lug to obtain a
crimp that passes the pull test.

A110-2
F. A. C8950-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION IN C8950-1 TERMINAL LUGS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating wires in
C8950-1 terminal lugs.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip the insulation to dimensions shown in
the following table.

STRIP LENGTH TABLE

TERMINAL C8950-1
STRIP LENGTH 0.31

A111-1
PROCEDURE:

1. Insert the stripped conductor end into the terminal lug barrel with the
insulation butted against the inner shoulder.

2. Crimp the terminal lug.

NOTE: The conductor double-stripped and doubled over or a piece of

stripped conductor may be inserted in the terminal lug to obtain a
crimp that passes the pull test.

A111-2
F. A. C8950-2
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION IN C8950-2 TERMINAL LUGS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating wires in
C8950-2 terminal lugs.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip the insulation to dimensions shown in
the following table.

STRIP LENGTH TABLE

TERMINAL C8950-2
STRIP LENGTH 0.50

A112-1
PROCEDURE:

1. Insert the stripped conductor end into the terminal lug barrel with the
insulation butted against the inner shoulder.

2. Crimp the terminal lug.

NOTE: The conductor double-stripped and doubled over or a piece of

stripped conductor may be inserted in the terminal lug to obtain a
crimp that passes the pull test.

A112-2
F. A. M7928/1C
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION IN M7928/1C TERMINAL LUGS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating wires in
M7928/1C terminal lugs.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

3. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. For proper crimping tool see MTPA-002.

WIRE/CABLE PREPARATION:

1. Cut the conductor end even, and strip the insulation to dimensions shown in
the following table.
STRIP LENGTH TABLE

WIRE GAUGE 26 22 20 18 12
STRIP LENGTH 0.26 0.29 0.26 0.29 0.4
TERMINAL
STRIPE COLOR BLACK GREEN RED WHITE YELLOW

A113-1
PROCEDURE:

1. Insert the stripped conductor end into the terminal lug barrel with the
insulation butted against the inner shoulder.

2. Crimp the terminal lug.

NOTE: The conductor double-stripped and doubled over or a piece of

stripped conductor may be inserted in the terminal lug to obtain a
crimp that passes the pull test. If a piece of strip conductor is used as
filler the stripped conductor shall not extend beyond the end of the
terminal barrel opposite the eyelet.

A113-2
F. A. C8916
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C8916 CONNECTORS

SCOPE

1. This connector will accept C4906-XX coaxial contacts and/or M83723-( ) B12
contacts.

a) C8916-2 is supplied as a kit, i.e., the plug housing and insert are
separated.

NOTE: After an insert has been installed in its housing, it cannot be

removed.

b) C8916-1,5,6, & 7 are one-piece assemblies consisting of a receptacle or

plug housing with a fixed insert (not a kit).

2. Coaxial Cable Termination to M39029/73 and M39029/74 contacts:

a) Prepare and terminate the cable and contact.

WIRE TERMINATION

1. Cut and strip (0.25/0.31 inches). Crimp the contact on wire using an
approved crimp tool with an approved positioner.

A114-1
2. Triaxial Cable: C8898-1 shall be terminated to contacts M39029/73-12C,/74-
12C (C4906-3 or -13).

a) Prepare the cable as shown below:

0.19

0.25
0 .1 9 0.09

1.3 + 0.1 for connectors without right angle backshells.

1.5 - 2.5 for connectors with right angle backshells.

b) Install the contact per Section 15 of this document to the conductor and
inner shield.

c) Install a C8951 solder sleeve to the outer shield as shown above, and
terminate the solder sleeve ground wire to the strain relief clamp screws
(using a C8950-1 flag terminal).

INSERT INSTALLATION

1. Align the insert keyway with the key in housing.

2. Push tool and insert into the housing until insert bottoms and locking tabs are
positioned in the housing ―window‖.
3. Check for proper insert location.

A114-2
F. A. M39029/59
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/59 CONTACTS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/59
contacts for coaxial cables.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Assembly Procedures or equivalent document (Reference

only).

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses - MTPA-002.

3. LMTAS Soldering Process J-STD-001, Class III.

4. Workmanship Standards for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Basic crimping tool M22520/2-01 with M22520/2-31 die.

2. Basic crimping tool M22520/5-01 with M22520/5-05 die.

3. Soldering iron.

4. Torque wrench.

A115-1
GENERAL:

1. Parts for M39029/59 contact are identified in Figure 1; Figures 2 through 9 show
detailed assembly procedure.

2. Parts for M39029/60 contact are identified in Figure 10; Figures 11 through 18
show detailed assembly procedure.

WIRE/CABLE PREPARATION:

1. Strip the jacket from the cable to dimensions shown in Figure 2/11, being careful
not to cut, nick or damage the shield braid. Ensure that all cuts are clean and at
a right angle to the axial plane of the cable.
2. Slide the crimp sleeve over the shield braid until it is flush with the edge of the
cable jacket (see Figure 3/12).
3. Trim the shield braid flush with the edge of the crimp sleeve (see Figure 3/12).
Slide the crimp sleeve back over the cable jacket.
4. Load the nut over the retainer; then slide the retainer/nut assembly over the
dielectric and under the shield braid until the retainer butts against the cable
jacket (see Figure 4/13).
5. Trim the dielectric flush with the end of the retainer, exposing the conductor (see
Figure 4/13).
6. Trim center conductor to dimension shown in Figure 4/13.
7. Remove the retainer/nut assembly from cable end.

INSTALLATION OF CONTACT:

1. Insert the cable conductor into the inner contact. Ensure that the conductor is
visible in the contact inspection hole.

2. Crimp the inner contact using basic tool M22520/2-01 with positioner M22520/2-
31.

INSTALLATION OF CRIMP SLEEVE:

1. Slide the retainer/nut assembly over the inner contact, dielectric and under the
shield braid. Assure that the retainer bottoms against the cable
jacket.(Reference Figure 5/14.)
2. Slide the crimp sleeve forward over the shield braid. Verify the .010-.050 gap
between crimp sleeve and nut (see Figure 6/15).
3. Crimp the crimp sleeve in place using basic tool M22500/5-1 with a M22520/5-
05 die in Closure B.

A115-2
NOTE: The nut must rotate freely after crimping the crimp sleeve.

INSTALLATION OF FRONT AND REAR INSULATORS:

1. Slide the rear insulator onto expander tool (see Detail A); then slide the tool over
the inner contact. Using a push tool (see Detail B) or equivalent, slide the rear
insulator down until it seats between the end of the retainer and the inner
contact shoulder (see Figure 7/16).

2. Slide the front insulator, large end first, over the inner contact until the insulator
seats against the inner contact shoulder (see Figure 8/17).

INSTALLATION OF OUTER CONTACT:

1. Slide the outer contact over the insulator and retainer assembly.

2. Thread the nut into the rear of the outer contact.

3. Tighten the nut with wrenches until metal to metal bottoming is achieved
between the shoulder of the retainer and the outer contact. Torque the nut to
30-36 inch ounces. Reference Figure 9/18 for completed assembly.

NOTE: The cable must not rotate while tightening the nut.

ACCEPT/REJECT CRITERIA:

1. Reference J-STD-001, Class III and/or FZM 8027 for accept/reject criteria.

A115-3
A115-4
A115-5
A115-6
F. A. M39029/60
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/60 CONTACTS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for terminating M39029/60
contacts for coaxial cables.

2. This Fabrication Aid is applicable to all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Assembly Procedures or equivalent document (Reference

only)

2. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses - MTPA-002.

3. LMTAS Soldering Process J-STD-001, Class III.

4. Workmanship Standards for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Basic crimping tool M22520/2-01 with M22520/2-31 die.

2. Basic crimping tool M22520/5-01 with M22520/5-05 die.

3. Soldering iron.

4. Torque wrench.

A116-1
GENERAL:

1. Parts for M39029/59 contact are identified in Figure 1; Figures 2 through 9

show detailed assembly procedure.

2. Parts for M39029/60 contact are identified in Figure 10; Figures 11 through 18
show detailed assembly procedure.

WIRE/CABLE PREPARATION:

2. Slide the crimp sleeve over the shield braid until it is flush with the edge of the
cable jacket (see Figure 3/12).

3. Trim the shield braid flush with the edge of the crimp sleeve (see Figure
3/12). Slide the crimp sleeve back over the cable jacket.

4. Load the nut over the retainer; then slide the retainer/nut assembly over the
dielectric and under the shield braid until the retainer butts against the cable
jacket (see Figure 4/13).

5. Trim the dielectric flush with the end of the retainer, exposing the conductor
(see Figure 4/13).

6. Trim center conductor to dimension shown in Figure 4/13.

7. Remove the retainer/nut assembly from cable end.

INSTALLATION OF CONTACT:

1. Insert the cable conductor into the inner contact. Ensure that the conductor is
visible in the contact inspection hole.

2. Crimp the inner contact using basic tool M22520/2-01 with positioner
M22520/2-31.

INSTALLATION OF CRIMP SLEEVE:

1. Slide the retainer/nut assembly over the inner contact, dielectric and under
the shield braid. Assure that the retainer bottoms against the cable
jacket.(Reference Figure 5/14.)

2. Slide the crimp sleeve forward over the shield braid. Verify the .010-.050 gap
between crimp sleeve and nut (see Figure 6/15).
A116-2
3. Crimp the crimp sleeve in place using basic tool M22500/5-1 with a
M22520/5-05 die in Closure B.

NOTE: The nut must rotate freely after crimping the crimp sleeve.

INSTALLATION OF FRONT AND REAR INSULATORS:

1. Slide the rear insulator onto expander tool (see Detail A); then slide the tool
over the inner contact. Using a push tool (see Detail B) or equivalent, slide
the rear insulator down until it seats between the end of the retainer and the
inner contact shoulder (see Figure 7/16).

2. Slide the front insulator, large end first, over the inner contact until the
insulator seats against the inner contact shoulder (see Figure 8/17).

INSTALLATION OF OUTER CONTACT:

1. Slide the outer contact over the insulator and retainer assembly.

2. Thread the nut into the rear of the outer contact.

NOTE: The cable must not rotate while tightening the nut.

ACCEPT/REJECT CRITERIA:

1. Reference J-STD-001, Class III and/or FZM 8027 for accept/reject criteria.

A116-3
A116-4
A116-5
A116-6
F. A. C10753-X
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C10753-X COAX CONTACTS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C10753-X
coax contacts.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

ASSEMBLY PROCEDURES:

1. Braid must be combed for RG 196/U cable. Strip coaxial cable to dimensions
shown on next page. (Dimensions may be altered to suit characteristics of
cable.)

BRAID MUST BE COMBED

FOR RG 196/U CABLE

A117-1
2. Crimp Tool.

a) Assemble stepped outer hyring onto cable.

b) Assemble supporting sleeve over inner dielectric and under braid.

3. Assemble inner hyfen pin or socket to inner conductor and crimp with an
approved tool.

SUPPORT ING SLEEVE INNER HYFEN PIN (OR

( R C M X B- - - ) SOCKET ) (RMM--W---)
(RF M--W---)

ST E PP E D O U T ER
HYRING (YORX)

4. Snap-lock pin (or socket) into outer female (or male) contact. Small
diameter on outer contact must slide over supporting sleeve and under
braid.

5. Slide stepped outer hyring over exposed braid, and crimp hyring onto braid
with an approved tool.

6. Assembly can now be snap-locked into connector block.

SUPPORT ING SLEEVE IN POSIT ION

MINIAT URE OUTER FEM ALE (OR M ALE )

CONTACT (RCM X---)(RMMX----)

B E FO R E

AF T E R SNAP -LOCK PIN(OR SOCKET) INTO

OUTER FEMALE (OR MALE) CONTACT.
SMALL DIAMET ER ON OUTER CONTACT
MUST SLIDE OVER SUPPORTING
A N D U N D E R B R A ID .

C10753-X Contact C8831-X Connector

A117-2
F. A. C10980-3/-4
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C10980-3 & -4 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling C10980-3
and C10980-4 coax connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-05 die.

2. Approved torque wrench.

3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:

1. Parts are identified in Figure 1.

a) Connector housing
b) Nut
c) Plug
d) Gasket
e) Insulator
f) Male Contact Sub-assembly
g) Connector housing

A118-1
h) Load shrink sleeve onto cable if required to build up cable diameter.

i) Load the hex nut on cable with threads towards the end of the cable.

j) Trim the cable jacket and braid to the dimensions shown in Figure 2.
All cuts shall be square. Slit outer jacket .25 inch 2 places 180
degrees apart as shown. Precautions shall be taken to avoid cutting
the underlying layers.

.438 .25 SLIT2 PLACES

.125
.05

FIGURE 2

2. INSTALLATION OF ASSEMBLY:

a) Insert center conductor onto contact assembly and force the edge of
the tapered clamping sleeve between the braid and the dielectric.
Dielectric and center conductor slide into tapered clamping sleeve
(cone) while braid and outer jacket should ride well up on taper.

b) Insert sub assembly onto connector body, tighten cable nut onto body,
compressing outer jacket onto braid.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

A118-2
F. A. GEN ASSY INSTR
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

GENERAL ASSEMBLY INSTRUCTIONS FOR COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for assembling coax
connector. This Aid is to be used for the assembly of coax connectors or
contacts not covered by 3.4.5.3.2 Special Assembly Instructions for Coax
Connectors.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

STRIPPING DIMENSIONS.

A119-1
A B C D
0.41 0.50 0.19 0.69

MIL-CRIMP

OUTER MALE CONTACT

FERRULE PLUG BODY ASSEMBLY
MIL-CRIMP

FEMALE CONTACT

JACK BODY ASSEMBLY

0.10 A B C

For RG-174, 179, 187, 188/U cables only, slit jacket back 0.10 0.02 as
shown. Before attaching center contact, slide metal spacer and Teflon
sleeve (not shown) over cable dielectric. The center contact should butt
against the dielectric and Teflon sleeve.

A119-2
CONTACT MUST BUTT AGAINST
CABLE DIELECTRIC

CABLE DIELECTRIC MUST

BUTT INSULATION
OUTER FERRULE SHOULD
BUTT HERE

CABLE DIELECTRIC MUST

BUTT INSULATION
OUTER FERRULE SHOULD
BUTT HERE

A119-3
F. A. C11788-8
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C11788-8 CONTACTS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C11788-8
contacts.
2. This Fabrication Aid is applicable for all programs.

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
4. Reference 16PR145 paragraph 3.4.9.5 for Solder Sleeve Terminations.

SOLDER SLEEVE FOR TERMINATION OF SECOND SHIELD

1. Slide solder sleeve onto cable for termination after contact completed.

CABLE PREPARATION FOR C8898-1: Figure 2

1. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

A120-1
.15” .05” .350” .250”

Figure 1

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.

INSERTING PREPARED C8898-1 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
2.

.070 inch

CABLE PREPARATION FOR C8898-2:

1. Strip the cable in accordance with Figure 3. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.05” .15” .4” .3”

.110”

Figure 13
Figure

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

A120-2
INSERTING PREPARED C8898-2 CABLE INTO CONTACT.
1. Push conductor into the contact until it is fully seated as shown in Figure
4.
.1”

Figure 4

2. If the conductor cannot be positioned correctly, remove then and check

for improper strip dimensions, splayed or bent conductor.
NOTE: The distance from the rear end of the contact body to the wire
insulation must not exceed .1 inch.

CABLE PREPARATION FOR C20826-1:

1. Strip the cable in accordance with Figure 5. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.
2. Outer shield needs to be unbraided to get full contact with inner shield.
3. Tape between inner and outer shield is to be stripped to base of jacket.

.15” .05” .10” .25”

Figure
Figure 1 5
4. Tin center conductor to insure proper installation into contact.

INSERTING PREPARED C20826-1 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
6.

.070 inch

Figure 6

A120-3
CABLE PREPARATION FOR C8811-1 & C8811-2:
1. Strip the cable in accordance with Figure 7. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

Figure 1 7
Figure
2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C8811-1 & -2 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
8.
.05”

Figure 8

CABLE PREPARATION FOR C20910-1:

1. Strip the cable in accordance with Figure 9. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” .4”

.15”

Figure
Figure1 9

A120-4
2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

CABLE PREPARATION FOR C20910-1 COAX CABLE WITH C8865-2 or -3

BUS
1. Strip the cable in accordance with Figure 10. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” 1.5” .4”

.15”

Figure1 10
Figure

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C20910-1 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
11.

.05”

Figure 11

CABLE PREPARATION FOR M17/152-00001 & P998-1 CABLE

1. Strip the cable in accordance with Figure 12. All the cuts shall be square.
Precautions shall be taken against nicks of conductor. Overlapping shield
needs to be cut back to expose underneath shield to dimensions shown.

A120-5
Figure 1
Figure 12

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED M17/152-00001 & P998-1 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in Figure
13.

Figure 13

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.

HEATING PROCEDURES:
1. Select the appropriate holding fixture and adapter for the contact to be
terminated.
NOTE: Tools required for a suitable fixture to be used, to prevent damage
to the contacts.
2. A. Insert the contact/cable assembly into the appropriate end of the
adapter.
B. Clamp the cable in the AD-1319 holding fixture.
1. The cable must remain fully inserted in the contact.
2. The contact must be fully inserted in the adapter.
3. The cable must be straight between the contact and the cable
clamp.
C. Attach the appropriate reflector and other applicable accessories to
the heating tool.

A120-6
1. For AA-400 SuperHeater: No. 979663 Mini-Solder Sleeve
reflector.
2. For CV-5300 MiniGun: MG-1 reflector.
3. For PH-1200 Proheat Variemp heat gun: No. 50379 and No.
51598, or No. 35027 reflectors.
D. Turn heating tool on and allow to warm up.
E. Heat the contact as follows:
1. Using the holding fixture, position the contact in the heating
tool reflector as shown in Figure 14, with the forward
inspection window centered in the reflector, the inspection
windows aimed for good visibility, and the side with the ground
conductor facing down.
2. Continue heating until the smaller solder preform on the
forward inspection window has melted and flowed. The large
solder preform in the rear inspection window should have
melted and flowed by this time, if it has not, direct hot air at the
rear inspection window until the preform melts.
F. Allow the contact to cool for at least 19 seconds, remove the contact
and cable from the holding fixture.
G. Verify proper termination according to accept/reject criteria.

A120-7
Figure 3
Figure 14

A120-8
SOLDER SLEEVE TERMINATION
1. Solder sleeve should be placed 1.5 to 3.5 inches behind connector.
2. Make a window in the outer jacket .35 inches maximum in length. See
figure 15.

.35”

Figure 5
Figure 15

3. Place solder sleeve over shield, and shrink using approved heat gun.

NOTE: Instructions For Right Angle Backshell See Fab Aid A72 For
16VE049.

ACCEPT/REJECT CRITERIA:

1. Reference FZM-8027, and/or requirements specified in this procedure.

2. Reference 16PR145 paragraph 3.4.9.5 for solder sleeve termination

procedure.

3. After termination, cable support tubing will overlap cable by .07 inches
nominal.

A120-9
F. A. C11788-9
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C11788-9 CONTACTS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LM Aero) production operations for terminating C11788-9
contacts.
2. This Fabrication Aid is applicable for all programs.

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
4. Reference 16PR145 paragraph 3.4.9.5 for Solder Sleeve Terminations

SOLDER SLEEVE FOR TERMINATION OF SECOND SHIELD

1. Slide solder sleeve onto cable for termination after contact completed.

CABLE PREPARATION FOR C8898-1

Figure 2
1. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

A121-1
.15” .05” .350” .250”

Figure 1

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.

INSERTING PREPARED C8898-1 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in Figure 2

.070 inch

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.
Note: After termination, the cable support tubing will overlap cable by .07
inches nominal.

CABLE PREPARATION FOR C8898-2:

1. Strip the cable in accordance with Figure 3. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.
.05” .15” .4” .3”
.110”

Figure 13
Figure

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C8898-2 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
4.

A121-2
.1”

Figure 4

CABLE PREPARATION FOR C20826-1:

.15” .05” .10” .25”

Figure
Figure 1 5
4. Tin center conductor to insure proper installation into contact.
INSERTING PREPARED C20826-1 CABLE INTO CONTACT.
1. Push conductor into the contact until it is fully seated as shown in Figure
6.

.070 inch

Figure 6

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.
NOTE: After termination, the cable support tubing will approximately
overlap cable by .07 inches.
CABLE PREPARATION FOR C8811-1 & C8811-2:
1. Strip the cable in accordance with Figure 7. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

A121-3
Figure 1 7
Figure
2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C8811-1 & -2 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
8.
.05”

Figure 8

CABLE PREPARATION FOR C20910-1:

1. Strip the cable in accordance with Figure 9. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.
.025” .1” .4”
.15”

Figure
Figure1 9

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

A121-4
CABLE PREPARATION FOR C20910-1 COAX CABLE WITH C8865-2 or -3
BUS
1. Strip the cable in accordance with Figure 10. All the cuts shall be square.
Precautions shall be taken against nicks of conductor.

.025” .1” 1.5” .4”

.15”

Figure
Figure1 10

2. Make sure that stranded conductors are twisted into their normal lay,
retwist and smooth the strands if necessary.
3. Pretin stranded wire.

INSERTING PREPARED C20910-1 CABLE INTO CONTACT.

1. Push conductor into the contact until it is fully seated as shown in Figure
11.

.05”

Figure 11

2. If the conductor cannot be positioned correctly, remove then and check for
improper strip dimensions, splayed or bent conductor.
NOTE: The distance from the rear end of the contact body to the wire
insulation must not exceed .05 inch.
CABLE PREPARATION FOR M17/152-00001 & P998-1:
1. Strip the cable in accordance with Figure 12. All the cuts shall be square.
Precautions shall be taken against nicks of conductor. Overlapping shield
needs to be cut back to expose underneath shield to dimensions shown.

A121-5
Figure 1
Figure 12
2. Tin center conductor to insure proper installation into contact.

INSERTING PREPARED M17/152-00001 & P998-1 CABLE INTO CONTACT

1. Push conductor into the contact until it is fully seated as shown in Figure
13.
.07 inch

Figure 13

HEATING PROCEDURES:
1. Select the appropriate holding fixture and adapter for the contact to be
terminated.
NOTE: Tools required for a suitable fixture to be used, to prevent damage
to the contacts.
A. Insert the contact/cable assembly into the appropriate end of the
adapter.
B. Clamp the cable in the AD-1319 holding fixture.
1. The cable must remain fully inserted in the contact.
2. The contact must be fully inserted in the adapter.
3. The cable must be straight between the contact and the cable
clamp.
C. Attach the appropriate reflector and other applicable accessories to
the heating tool.

A121-6
1. For AA-400 SuperHeater: No. 979663 Mini-Solder Sleeve
reflector.
2. For CV-5300 MiniGun: MG-1 reflector.
3. For PH-1200 Proheat Variemp heat gun: No. 50379 and No.
51598, or No. 35027 reflectors.
D. Turn heating tool on and allow to warm up.

E. Heat the contact as follows:

1. Using the holding fixture, position the contact in the heating
tool reflector as shown in Figure 14, with the forward
inspection window centered in the reflector, the inspection
windows aimed for good visibility, and the side with the ground
conductor facing down.
2. Continue heating until the smaller solder preform on the
forward inspection window has melted and flowed. The large
solder preform in the rear inspection window should have
melted and flowed by this time, if it has not, direct hot air at the
rear inspection window until the preform melts.
F. Allow the contact to cool for at least 19 seconds, remove the
contact and cable from the holding fixture.
G. Verify proper termination according to accept/reject criteria.

A121-7
Figure 3
Figure 14

A121-8
SOLDER SLEEVE TERMINATION
1. Solder sleeve should be placed 1.5 to 3.5 inches behind connector.
2. Make a window in the outer jacket .35 inches maximum in length. See
figure 15.

.35”

Figure
Figure 515

3. Place solder sleeve over shield, and shrink using approved heat gun.

NOTE: Instructions For Right Angle Backshell See Fab Aid A72 For
16VE049.

ACCEPT/REJECT CRITERIA:

1. Reference FZM-8027, and/or requirements specified in this procedure.

2. Reference 16PR145 paragraph 3.4.9.5 for solder sleeve termination

procedure.

3. After termination, cable support tubing will overlap cable by .07 inches
nominal

A121-9
F.A. C8828-2-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8828-2-1 CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for installation of
C8828-2-1 connector, manufactured by Phoenix Logistics, Inc., for coaxial
cables.
2. This Fabrication Aid is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MTPA-002
3. LMAero Soldering Process J-STD-001, Class III.
4. Workmanship Standards for Electrical Assemblies – FZM-8027.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 and M22520/5-25 dies.
2. Soldering iron or hot air gun
3. Torque wrench

CABLE PREPERATION:
1. Parts are identified in Figure 1.
A. Connector Housing
B. Contact
C. Rear Dielectric
D. Braid terminator
E. Rear Nut
F. Crimp Sleeve
G. Shrink Sleeve

A122-1
2. Load the shrink sleeve onto the cable.
3. Load the crimp sleeve with the internal taper and hole positioned towards
the end of the cable.
4. Trim the cable jacket to the dimension shown in Figure 2. All cuts shall be
square, being careful not to cut through underlying layers

INSTALLATION OF REAR ASSEMBLY:

1. Load the rear nut onto the braid terminator; gently slide the tapered end of
the braid terminator over the dielectric and under the braid until it butts
against the jacket.
2. Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
3. Crimp the crimp sleeve in place using tool #M22520/5-01 with #M22520/5-
25 die Closure ―A.‖
4. Apply heat to the crimp sleeve using soldering iron or hot air gun, and feed
solder into the holes insuring adequate evidence of wetting. Caution
should be exercised when using the hot air gun to avoid damage to the
outer jacket of the cable.

INSTALLATION OF CONTACT:
1. Trim the dielectric flush with the face of the braid terminator, being careful
not to nick the center conductor.
2. Trim the center conductor to the dimension shown in Figure 3.

3. Pre-tin center conductor and the rear of contact.

4. Solder the contact flush with cable dielectric, until it seats.

A122-2
INSTALLATION OF CABLE ASSEMBLY:
1. Insert cable into the connector housing; see Figure 4.

2. Torque the rear nut to 25-35 in. lbs.

3. Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:
1. Reference J-STD-001, Class III and/or FZM-8027 for accept/reject criteria.

A122-3
F. A. C8832-2
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8832-2 CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LM Aero) production operations for installation of
C8832-2 connectors.
2. This Standard is applicable to all programs.

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. LMAero Soldering Process J-STD-001, Class III.
3. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
4. Manufacturer‘s Operating Procedures or equivalent document (reference
only).

APPROVED TOOLS:
1. Soldering iron

CABLE PREPARATION:
1. Different Parts are identified in Figure 1.
A. Contact and Molding Assembly
B. Hood
C. Male and Female Guide
D. Lever
E. Pivot

FIGURE 1

A123-1
2. Route wires through cable clamp of connector hood and strip wires with
appropriate stripping tool. See Figure 2.
3. Solder wires to solder cups on molding assembly. See Figure 2.

FIGURE 2
4. Place lever/pivot between hood and molding assembly. See Figure 3.

FIGURE 3

A123-2
5. Insert molding assembly into hood. See Figure 4.

FIGURE 4

6. Line up pivot holes with molding assembly holes, and insert male and
female guides. See figure 5.

FIGURE 5

7. Tighten male and female guides.

8. Tighten cable clamp on back of Connector.

ACCEPT/REJECT CRITERIA:
1. Reference J-STD-001, Class III and FZM-8027, and/or requirements
specified in this procedure.

A123-3
F. A. C20348
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C20348 CONNECTOR

SCOPE:
1. This Fabrication Aid contains requirements applicable to LM Aero
production operations for terminating C20348 connector for twin axial
cables. Cable preparation varies for the different suppliers and for the –1
and –2 connectors.
2. This Standard is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document.
2. FZM 8027 –Workmanship Standards for Electrical Assemblies.

TOOLS REQUIRED:
1. Soldering iron.
2. Torque wrench.

CABLE PREPARATION FOR C20348-1 MANUFACTURED BY DELTA.

1. Different parts are identified in Figure 1.
A. Clamp Nut
B. Flat Washer
C. Rubber Gasket
D., E Shield Clamp
F. White Spacer
G. Small Insulating Sleeve
H. Center Contact
J. Insulating Sleeve for Center Contact
K. Insulating Sleeve For Center Contact
L. Large White Insulating Sleeve For Outer Contact
M. Connector Body

A124-1
2. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of braid, insulation, and
conductors.

3. Pre-tin the center conductors, making sure that there is no excess solder.
Note that the white wire is signal wire and is the center conductor.

A124-2
4. Slip the following listed items on the twin axial cable:

Item Length Qty

(inches)
P5381-3 (ID Tubing A/R 1
Clamp Nut (A) N/A 1
Washer (B) N/A 1
Gasket © N/A 1
P5381-1 1.25 1
M23053/5-105-0 1.0 1
1.5 2
M23053/5-104-0 1.0 1

5. Slide the piece of M23053/5-104-0 shrink tubing up to the edge of the

jacket trim-line, and shrink it in place. Use the remaining pieces of shrink
tubing to build up the cable o.d. to match the i.d. of the clamp nut, being
sure to finish up with the
6. Place part D on the cable, then comb out the braid from the shield and fold
it over part D of the shield clamp. Place shrink tubing over the center
conductor (white wire) in the order shown in the following listing:
Item Length Qty
(inches)
M23053/8-001-C .40 1

7. Slide the E part of the shield clamp then the white spacer (item F) over the
two conductors.
8. Slide the small insulating sleeve (item G) over the white conductor.
9. Solder the white conductor to the center contact (item H). Insert the
contact into the insulating sleeve for the center contact (item J0.
10. Insert items G, H, and J into the outer contact K. Dress the purple
conductor such that it can be soldered to the outer contact (item K). Trim if
necessary.
11. Solder the purple conductor to the outer contact (item K). The soldered
wire shall not protrude out of the ―well‖ of the contact such that the outer
insulating sleeve (item L) cannot be installed (Figure 3). Trim the shield
flush with outer surfaces of items D and E.

A124-3
12. Slide the outer insulating sleeve (item L) on the outer contact (item K).
Insert the assembly into the body of the connector (item M).
13. Insert the connector parts (items B and C) into the body, and tighten the
clamp nut (Item A) to 13-15 inch-pounds.
14. Install the last piece of shrink tubing (P5381-3) over the connector body to
provide strain relief between the connector body and the built-up cable.
NOTE: For braided harnesses, add P5372 Teflon over tubing to stop
braid.
15. VERIFICATION POINTS:
16. Verify soldered connection for the purple conductor (at the outer contact –
item K). Cold connection or excess solder shall not be accepted (Figure
3).
17. The final assembly shall be examined for correct installation.
18. FZM 8027 shall be referenced for accept/reject criteria.

CABLE PREPARATION FOR C20348-1 MANUFACTURED BY SPECIALTY

CONNECTOR CO:
1. Different parts are identified in Figure 4.

A124-4
2. Slip the following listed items on the twin axial cable before stripping:

Item Length Qty

(inches)
P5381-3 (ID Tubing) A/R 1
Gasket (C) N/A 1
P5381-1 1.25 1
M23053/5-105-0 1.0 1
1.5 2
M23053/5-104-0 1.0 1

3. Strip the twin axial cable per the dimensions shown in Figure 5. Tin the
white and purple wires.

A124-5
4. Comb out the braid and place shrink tubing over the center conductor in
the order shown in the following listing:
Item Length Qty
(inches)
M23053/8-001-C 60 1

5. Build up the diameter of the wires to approximately 0.16‖, that is, to fit
inside the tapered clamp/insulator combination in the order shown in the
following listing:
Item Length Qty
(inches)
M23053/5-104-C .35 2
M23053/5-105-0 .35 1

6. Place slotted insulator in position with slot facing back towards the cable.
The shorter wire (white) goes through the slot and center hole, and the
longer wire (purple) lays in the slot. Place center contact in position and
solder. Note: The center contact shall butt up against the slotted insulator,
and the slotted insulator shall butt up against the tapered clamp and
insulator.
7. Slip on the inner insulator and middle contact. Place the purple wire
through the slot of the middle contact, and wrap it around between the two
shoulders. Solder in place.
NOTE: Neither the solder not the wire shall extend above the o.d. of the
shoulder.
8. Push the tapered clamp/insulator over the tubing, and bring the shield
braid back over the tapered clamp. Slide the piece of M23053/5-106-0 up
over the shield, and shrink in place. Trim off the shield even with the outer
diameter (o.d.) of the tapered clamp.
9. Continue adding the shrink to build up the o.d. of the cable to match the
i.d. of the nut. Be sure to finish up with M23053/5-106-0 covered with
P5381-1. Snip off any unused tubing.
10. Slide the outer insulator in the body, and place these on the middle
contact assembly. Tighten the back nut to 13-15 inch-pounds. Install the
last piece of shrink tubing (P5381-3) over the connector body to provide
strain relief between the connector body and the built-up cable.
11. VERIFICATION POINTS:
12. Braid termination on tapered clamp.
13. Soldered connection for the purple wire within shoulder height.
14. Outer shrink snug on connector body.

A124-6
CABLE PREPARATION FOR C20348-2 MANUFACTURED BY DELTA.
1. Different parts are identified in Figure 6.

2. Slide the following listed items on the twinaxial cable before stripping:

Item Length Qty

(inches)
P5381-3 (ID Tubing) A/R 1
Clamp Nut N/A 1
Washer N/A 1
Gasket (C) N/A 1
P5381-1 1.25 1
M23053/5-105-0 1.0 1
1.5 2
M23053/5-104-0 1.0 1

3. Strip the twin axial cable per the dimensions shown in Figure 7. Tin the
stripped portion of the white and purple wires.

A124-7
4. Slide a piece of the small diameter shrink tubing up to the edge of the
jacket trim-line, and shrink it in place. Use the remaining pieces of shrink
tubing to build up the cable o.d. to match the i.d. of the clamp nut, being
sure to finish up with the P5381-1. Snip off any unused tubing.
5. Comb out the braid, install the braid clamp over the braid and squarely
against the build-up jacket. Form the braid wire smoothly back over the
clamp, and trim off excess braid wire.
6. Insert assembly into connector body, and tighten clamp nut to 13-15 inch-
pounds.
7. Solder the white wire to the center contact.
8. Route the purple wire around the center contact, and solder it to the
middle (concentric) contact.
9. Ensure that the purple wire is not fouling the center contact, and install the
cap. Tighten the cap to 15-20 in.-lbs.
10. Install the last piece of shrink tubing (P5381-3) over the connector body to
provide strain relief between the connector body and the built-up cable.
11. VERIFICATION POINTS:
12. Braid termination on braid clamp.
13. Solder connections to correct contacts.
14. Outer shrink tubing snug on connector body.

TERMINATION OF C20348-2 MANUFACTURED BY SPECIALTY CONNECTOR CO.:

1. Different parts are identified in Figure 8.

2. Slip the following listed items on the twin axial cable before stripping:

A124-8
Item Length Qty
(inches)
P5381-3 (ID Tubing) A/R 1
Hex Nut N/A 1
P5381-1 1.25 1
M23053/5-105-0(C) 1.0 1
1.5 1
M23053/5-104-0 1.0 2

3. Strip the twin axial cable per the dimensions shown in Figure 9. Tin the
white and purple wires.

4. Comb out the braid.

5. Build up the diameter of the wires to approximately 0.16‖, that is, to fit
inside the taper clamp/insulator combination.
6. Push the tapered clamp/insulator over the tubing, and bring the shield
braid back over the tapered clamp. Slide the piece of M23053/5-104-0 up
over the shield, and shrink in place. Trim off the shield even with the outer
diameter (o.d.) of the tapered clamp.
7. Continue adding the shrink tubing to build up the o.d. of the cable to match
the i.d. of the nut. Be sure to finish up with M23053/5-105-0 covered with
P5381-1. Snip off any unused tubing.
8. Insert assembly into connector body, and tighten clamp nut to 13 to 15
inch-pounds.
9. Solder white wire to the center contact.
10. Route the purple wire around the center contact, and solder it to the
middle (concentric) contact.
11. Ensure that the purple wire is not fouling the center contact, and install the
cap. Tighten to 15 to 20 inch-pounds.

A124-9
12. Install the last piece of shrink tubing (P5381-3) over the connector body to
provide strain relief between the connector.
13. VERIFICATION POINTS:
14. Braid termination on tapered clamp.
15. Solder connections to correct contacts.
16. Outer shrink tubing snug on connector body.
NOTE: Engineering has stated that P5034-28, -29 may be used (until
stock is depleted) in place of M23053/5-104, -105, -0.

A124-10
F. A. C20783
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C20783 CONNECTOR ASSEMBLY

SCOPE
1. This connector will accept M39029/76, M39029/78 coaxial contacts and/or
M39029/57,M39029/58 contacts.
2. C20783 is supplied as a kit, i.e., the plug/receptacle housing and insert
are separated.
REFERENCES
1. Manufacturer‘s Operating Procedures or equivalent document.
2. FZM-8027 – Workmanship Standard For Electrical Assemblies
WIRE TERMINATION
1. Coaxial Cable Termination to M39029/76 and M39029/78 contacts:
a. Strip cable to dimensions according to figure 1.
b. Crimp contact onto wire using approved tool with approved
positioner.
2. Wire termination to M39029/57 and M39029/58 contacts:
a. Strip wire and crimp contact onto wire using approved tool with
approved positioner.
b. The gap between the insulation and the crimp barrel shall not
exceed past 0.03 inches.
NOTE: Reference Fabrication Aid MIL-C-39029/58 for stripping dimensions
of M39029/58 contacts.
CONTACT INSERTION/EXTRACTION
1. Using approved insertion tool for the application, position wire in the tip of
the tool so that the shoulder of the contact butts against the tool tip.
2. Insert the contact with firm and even pressure into connector by pressing
the tool against the contact shoulder. A slight click may be felt as the tines
snap into place behind the contact shoulder. The contacts may be wet
with isopropyl alcohol (for lubricating purposes).
CAUTION: CRACKED, SPLIT, OR DULL TOOLS WILL DAMAGE CONNECTOR
SEALING GROMMET.

A125-1
INSERT INSTALLATION
1. Align the insert keyway with the key in housing.
2. Align inserts with housing according to figure 2. Inserts are identified by
housing orientation identification according to figure 3. Push in insert until
flush, then push insert with insertion tool* (―extract‖ word facing up) until
housing tabs click. Repeat for second insert.
3. Check for proper insert location.
4. To extract, insert tools (―insert‖ words facing up) between the top and
bottom of an insert and the housing. Bottom out tools in the housing, pinch
tabs together and extract insert.

Reference Insert/Extraction tool for connector is PN 06090/CTA-0161

.33 .30

A125-2
A125-3
F. A. C20773-4
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C20773-1/-4 TRIAX CABLE SOLDER SPLICE

SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company Vendor/Supplier Operations for the assembly of
C20773-1/-4 Triax Cable Solder Splices.
2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS
1. Manufacturer‘s operating procedures or equivalent document (reference
only).
2. Workmanship standard for electrical assemblies FZM 8027.

TOOLS REQUIRED
1. Heat Gun CV500 Mini Gun Heater with MG-1 or MG-7 reflector

WIRE/CABLE PREPARATION
1. Slide tubing (for -1) and large solder sleeve over double Triax end. (Side
with 2 Triax cables)
2. Slide medium solder sleeve over single Triax cable.
3. Cut & remove outer insulation 1.25 in from end of each of the three cables
to be joined. Comb and trim the 1st. shield. Fold back the 1st. shield over
the Outer insulation.

A126- 1
Outer Insulation

Dielectric

1st shield (Will extend 1.25 in)

Center
Conductor

2nd. Insulation

2nd Shield
(Will extend .7in)

.22in.

.4in
.55in.
3rd. cut

2nd. cut .7in.

1.25in.

1st. cut

4. Cut and remove 2nd. insulation .70 in from end of each of the three cables
to be joined. Comb and fold the 2nd shield back over the 2nd insulation.
5. Strip the dielectric .4 in from cable end exposing the center conductor.
Twist the dielectric while removing from the center conductor.
6. Pre-tin center conductor and clean.
7. Place the small solder sleeve over the dielectric of the single cable.
8. Mate all three-center conductors: sandwiched the single center conductor
between the center conductors of the other two cables. The center
conductors can be tacked in place to hold until the small solder sleeve is
centered over all three conductors and heated to shrink and seal.
9. Comb 2nd shield over small solder sleeve ensuring that they overlap at the
center.

A126- 2
10. Center medium solder sleeve over shields and heat sleeve until ends are
sealed and solder is melted. Make sure the larger end of the solder
sleeve is toward the double Triax end. (Be careful not to pull cable ends
while heating)
11. Comb and trim all three outer shields so that they reach the midpoint of
the medium sleeve.
12. Cover the outer shields/sleeves with copper foil. Perforations of the foil
should be over outer shield. Keep foil smooth with no creases or
protrusions. Shield protrudes through foil if not properly combed.
13. Center large solder sleeve over foil (make sure solder rings are over foil
perforations) heat sleeve until end seals and solder rings melt completely.

14. Center tubing over large solder sleeve and heat to shrink for -1.

NOTE: All component dimension figures represent -4.

1in.
2in.

H-M-2-06 for the small solder sleeve:

L=19mm (+-1mm); Midpoint to Midpoint of Thermoplastic=13mm (+-1mm); Large
Diameter Side=6.65mm (+-1mm); small side diameter=5mm(+-1mm).
L=19mm=. 75in. .75in
L=13mm=. 51in.
L=6.65mm=. 26in. .51in
L=5mm=. 19in

.19in .26in

A126- 3
H-M-4-06 for the middle solder sleeve
L=36mm(+-3mm); Midpoint to Midpoint of Thermoplastic=30mm(+3mm, -2mm);
Large Diameter Side=9mm(+-1mm); small side diameter=8mm(+-1mm).
L=36mm=1.4in 1.18in
L=30mm=1.18
L=9mm=. 35in 1.4in
L=8mm=. 31in

.31in . .3 .35in

.16in Thermo-Plastic .16in

Solder Ring .24in

H-M-5-O6 for the large solder sleeve

L=63mm(+2mm, -2mm); Midpoint to Midpoint of Thermoplastic=56.5(+-1mm);
Large Diameter Side=11mm(+2mm, -1mm); small side diameter=8.5mm(+-
1mm).
L=36mm=1.4in
L=56.5=2.22in.
L=11mm=. 43in. 1.4in
L=8.5mm=. 33in.
.09in 1.03in .16in

.33in .43in

Solder Ring .11in

2.22in

Midpoint-to-Midpoint of solder rings=47mm(+-2mm). The foil should be 1inch X 2

inch
L=47mm1.85in.

A126- 4
F. A. 16VE141
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

PREPARATION OF HARNESS FOR TERMINATION AT 16VE141

INTERPHONE FILTER ASSEMBLY
SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LMAero) Vendor/Supplier operations for preparing end of
wiring harnesses for termination at 16VE141 interphone filter assembly,
opposite end onto which C192 Interphone jack connectors are installed.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction

Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.

TOOLS REQUIRED:

1. An approved crimping tool.

2. An approved heating gun.

ASSEMBLY PROCEDURES:

1. Cut cable end square and remove outer shield 10.00 inches. Place the
1.60 inch piece of P5381-2 Heat Shrink Tubing as shown. Place the
NAS1744-8 Solder Sleeve and wire and the 1.35 inch piece of P5381-2
Heat Shrink Tubing as shown. Secure all per approved methods. Remove
remainder of shield to expose wires. Place .40 inch piece of Heat Shrink
Tubing as shown and secured as required.

A127-1
2. Place C8844-1 sleeving as shown and secure one end with the 1.00 inch
piece of P5381-2 Heat Shrink Tubing. Secure per approved methods.

A127-2
F.A. M39029/75
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/75 CONTACTS

(MIL-C-39029/75 Contacts, Electrical Connector, Socket, Crimp, Removable,
Shielded, Size 12)
SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/75 contacts on F-16 wire harnesses.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS

1. Manufacturer‘s Operating Procedures or equivalent document (reference

only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F16 Wiring Harnesses and Other Authorized Programs – MTPA-
002.
3. Workmanship Standard for Electrical Assemblies – FZM 8027.
TOOLS REQUIRED
1. For proper crimping tool see MTPA-002.
CABLE/WIRE PREPARATION
1. Cut the wire to the correct length as defined by the Engineering/Tool
ensuring that there is enough slack to allow re-termination as defined by
Engineering requirements.
2. All cuts shall be square. (Perpendicular to the centerline of the conductor)
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and
shall have no more than 0.03 inch exposed bare conductor at rear of
crimp barrel.
4. Position the contact in the jaws of the crimping tool to hold the contact
while the wire is inserted in the barrel of the contact.
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.
6. Crimp the contact on to the wire fully and release the crimping tool.

A128-1
ACCEPT/REJECT CRITERIA

1. Barrel cracking or peeled plating shall be a cause for rejection.

2. Stripped wire shall be visible through inspection holes (when an inspection
hole exists).
3. As visually determined, the depth and configuration of the crimp
impression shall be consistent with impressions made by the tool
approved for this particular application.
4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable
provided:
a) Cracking does not occur.
b) The conductor termination meets wire pull requirements (found in
the applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.

5. Maximum acceptable insulation gap from the rear of the contact barrel is
0.03 inch.
6. Minimum acceptable insulation gap – flush with the contact barrel. Under
no circumstances is the wire to be bent sharply at the contact to verify
insulation gap. A gentle bend (approximately 15 degrees) is allowable
when the insulation end cannot be located otherwise.
7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A128-2
F.A. M39029/76
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/76 CONTACTS

(MIL-C-39029/76 Contacts, Electrical Connector, Pin, Crimp, Removable,
Shielded, Size 16)
SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/76 contacts on F-16 wire harnesses.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS
1. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Workmanship Standard for Electrical Assemblies – FZM 8027.
TOOLS REQUIRED
1. For proper crimping tool see MTPA-002.
CABLE/WIRE PREPARATION
1. Cut the wire to the correct length as defined by the Engineering/Tool
ensuring that there is enough slack to allow re-termination as defined by
Engineering requirements.
2. All cuts shall be square. (Perpendicular to the centerline of the conductor)
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and
shall have no more than 0.03 inch exposed bare conductor at rear of
crimp barrel.
4. Position the contact in the jaws of the crimping tool to hold the contact
while the wire is inserted in the barrel of the contact.
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.
6. Crimp the contact on to the wire fully and release the crimping tool.

A129-1
ACCEPT/REJECT CRITERIA
1. Barrel cracking or peeled plating shall be a cause for rejection.
2. Stripped wire shall be visible through inspection holes (when an inspection
hole exists).
3. As visually determined, the depth and configuration of the crimp
impression shall be consistent with impressions made by the tool
approved for this particular application.
4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable
provided:
a) Cracking does not occur.
b) The conductor termination meets wire pull requirements (found in
the applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.
5. Maximum acceptable insulation gap from the rear of the contact barrel is
0.03 inch.
6. Minimum acceptable insulation gap – flush with the contact barrel. Under
no circumstances is the wire to be bent sharply at the contact to verify
insulation gap. A gentle bend (approximately 15 degrees) is allowable
when the insulation end cannot be located otherwise.
7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A129-2
F.A. M39029/77
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/77 CONTACTS

(MIL-C-39029/77 Contacts, Electrical Connector, Socket, Crimp, Removable,
Shielded, Size 16)
SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/77 contacts on F-16 wire harnesses.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS
1. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Workmanship Standard for Electrical Assemblies – FZM 8027.
TOOLS REQUIRED
1. For proper crimping tool see MTPA-002.
CABLE/WIRE PREPARATION
1. Cut the wire to the correct length as defined by the Engineering/Tool
ensuring that there is enough slack to allow re-termination as defined by
Engineering requirements.
2. All cuts shall be square. (Perpendicular to the centerline of the conductor).
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and
shall have no more than 0.03 inch exposed bare conductor at rear of
crimp barrel.
4. Position the contact in the jaws of the crimping tool to hold the contact
while the wire is inserted in the barrel of the contact.
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.
6. Crimp the contact on to the wire fully and release the crimping tool.

130-1
ACCEPT/REJECT CRITERIA
1. Barrel cracking or peeled plating shall be a cause for rejection.
2. Stripped wire shall be visible through inspection holes (when an inspection
hole exists).
3. As visually determined, the depth and configuration of the crimp
impression shall be consistent with impressions made by the tool
approved for this particular application.
4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable
provided:
a) Cracking does not occur.
b) The conductor termination meets wire pull requirements (found in
the applicable Mil-Spec for the contact).
c) The crimp tool indentation does not extend to the barrel end.
5. Maximum acceptable insulation gap from the rear of the contact barrel is
0.03 inch.
6. Minimum acceptable insulation gap – flush with the contact barrel. Under
no circumstances is the wire to be bent sharply at the contact to verify
insulation gap. A gentle bend (approximately 15 degrees) is allowable
when the insulation end cannot be located otherwise.
7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

130-2
F.A. M39029/78
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF M39029/78 CONTACTS

(MIL-C-39029/78 Contacts, Electrical Connector, Socket, Crimp, Removable,
Shielded, Size 16)
SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/78 contacts on F-16 wire harnesses.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS
1. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Workmanship Standard for Electrical Assemblies – FZM 8027.
TOOLS REQUIRED
1. For proper crimping tool see MTPA-002.
CABLE/WIRE PREPARATION
1. Cut the wire to the correct length as defined by the Engineering/Tool
ensuring that there is enough slack to allow re-termination as defined by
Engineering requirements.
2. All cuts shall be square. (Perpendicular to the centerline of the conductor)
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and
shall have no more than 0.03 inch exposed bare conductor at rear of
crimp barrel.
4. Position the contact in the jaws of the crimping tool to hold the contact
while the wire is inserted in the barrel of the contact.
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.
6. Crimp the contact on to the wire fully and release the crimping tool.

131-1
ACCEPT/REJECT CRITERIA
1. Barrel cracking or peeled plating shall be a cause for rejection.
2. Stripped wire shall be visible through inspection holes (when an inspection
hole exists).
3. As visually determined, the depth and configuration of the crimp
impression shall be consistent with impressions made by the tool
approved for this particular application.
4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable
provided:
a) Cracking does not occur.
b) The conductor termination meets wire pull requirements (found in
the applicable Mil-Spec for the contact)
c) The crimp tool indentation does not extend to the barrel end.
5. Maximum acceptable insulation gap from the rear of the contact barrel is
0.03 inch.
6. Minimum acceptable insulation gap – flush with the contact barrel. Under
no circumstances is the wire to be bent sharply at the contact to verify
insulation gap. A gentle bend (approximately 15 degrees) is allowable
when the insulation end cannot be located otherwise.
7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A131-2
F.A. M39029/90
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

.TERMINATION OF M39029/90 CONTACTS

(MIL-C-39029/90 Contacts, Electrical Connector, Concentric Twinax, Pin, Size 8)
SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) Vendor/Supplier operations for terminating
M39029/90 contacts on F-16 wire harnesses.
2. This Fabrication Aid is applicable for all F-16 programs.
APPLICABLE DOCUMENTS
1. Manufacturer‘s Operating Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs –
MTPA-002.
3. Workmanship Standard for Electrical Assemblies – FZM 8027.
TOOLS REQUIRED
1. For proper crimping tool see MTPA-002.
CABLE/WIRE PREPARATION
1. Cut the wire to the correct length as defined by the Engineering/Tool
ensuring that there is enough slack to allow re-termination as defined by
Engineering requirements.
2. All cuts shall be square. (Perpendicular to the centerline of the conductor)
3. Strip the wire/cable so that the stripped portion of the conductor shall be at
least long enough to reach the bottom of the crimp barrel minimum, and
shall have no more than 0.03 inch exposed bare conductor at rear of
crimp barrel.
4. Position the contact in the jaws of the crimping tool to hold the contact
while the wire is inserted in the barrel of the contact.
5. Ensure the wire touches the bottom of the contact barrel (should be visible
through the inspection hole in the contact barrel if hole exists), before
executing the crimp.
6. Crimp the contact on to the wire fully and release the crimping tool.

A132-1
ACCEPT/REJECT CRITERIA
1. Barrel cracking or peeled plating shall be a cause for rejection.
2. Stripped wire shall be visible through inspection holes (when an inspection
hole exists).
3. As visually determined, the depth and configuration of the crimp
impression shall be consistent with impressions made by the tool
approved for this particular application.
4. ―Squaring‖ (deformation of the barrel end due to crimping) is acceptable
provided:
a. Cracking does not occur.
b. The conductor termination meets wire pull requirements (found in
the applicable Mil-Spec for the contact)
c. The crimp tool indentation does not extend to the barrel end.
5. Maximum acceptable insulation gap from the rear of the contact barrel is
0.03 inch.
6. Minimum acceptable insulation gap – flush with the contact barrel. Under
no circumstances is the wire to be bent sharply at the contact to verify
insulation gap. A gentle bend (approximately 15 degrees) is allowable
when the insulation end cannot be located otherwise.
7. For contacts with ―support wells‖, bare wire outside the support well is
unacceptable.

A132-2
F.A. C9718-1 and -2
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C9718-1, -2 CONNECTORS

SCOPE:
1. This Process Standard contains requirements applicable to Lockheed
Martin Aeronautics Company (LMAero) production operations for
installation of C9718-1,-2 connectors, manufactured by Trompeter
Electronics, Inc., for twinax cables.
2. This Process Standard is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MPTA-002.
3. LMAero Soldering Process J-STD-001, Class III.
4. Workmanship Standards for Electrical Assemblies – FZM-8027.

TOOLS REQUIRED:
1. Basic crimping tool M22520/2-01 with Trompeter 010-0041(Daniels
K815s) positioner for center contact.
2. Trompeter crimp tool NO CT3 withCD3-4 die set for crimp shield and
crimp sleeve.
3. Soldering iron (optional).

CABLE PREPARATION:
1. Parts are identified in Figure 1.
A. Body assembly
B. Contact
C. Ferrule
D. Dielectric & Shield assy.
E. Dual entry dielectric
F. Nut
G. Crimp Sleeve
H. Shrink tubing

A133-1
2. In order, install clamp nut, crimp sleeve, and shrink tubing onto cable.
3. Using approved tool, strip cable to dimensions in Figure 2a and 2b.Tin
(optional) conductors.

4. Flare end of braid to allow free entry of ferrule.

INSTALLATION OF FERRULE:
1. Push ferrule fully under braid until white conductor protrudes beyond
ferrule to dimension shown in figure 3.

a) Hold ferrule in place while positioning shrink tubing over braid and
seating it against ferrule shoulder.
b) Shrink tubing into place, and allow it to cool before moving on; See
figure 4.

A133-2
Shrink sleeve

2. Slide the crimp sleeve over shrink tubing and seat against ferrule shoulder
and crimp in place using Trompeter crimping tool CT3 with a Trompeter
positioner CD3-4 Closure ―B;‖ see figure 5.

INSTALLATION OF DUAL ENTRY DIELECTRIC AND CONTACT

1. Bend blue/purple conductor outward as illustrated in figure 5.
2. Install the dual entry dielectric onto the conductors with the white
conductor through the center hole and the blue/purple conductor through
the side hole; see Figure 6.

3. Position the pin over the white conductor and crimp in place using basic
tool M22520/2-01 with Daniels positioner K815S.

INSTALLATION OF DIELECTRIC & SHIELD/SHIELD ASSY:

1. Install the crimp shield assembly over the pin.
2. Insert blue/purple conductor into the small hole at rear of the crimp shield
assembly, assuring that the crimp shield assembly bottoms against the
dual entry dielectric; see figure 7.

A133-3
3. Crimp the crimp shield assembly in place using Trompeter CT3 tool with
CD3-4 die closure ―A.‖

INSTALLATION OF CONNECTOR BODY ASSEMBLY:

1. Insert entire cable assembly into body assembly, bring up clamp nut and
engage threads; see figure 8.

2. Wrench tighten clamp nut to 25-35 IN LBS Torque.

ACCEPT/REJECT CRITERIA:
1. Reference J-STD-001, Class III and FZM-8027, and/or requirements
specified in this procedure.

A133-4
F. A. C9718-3, -4
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C9718-3, -4 CONNECTORS

SCOPE
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for installation of
C9718-3,-4 connectors, manufactured by Trompeter Electronics, Inc., for
twinax cables.
2. This Process Standard is applicable to all programs.

APPLICABLE DOCUMENTS
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MPTA-002.
3. LMAero Soldering Process J-STD-001, Class III.
4. Workmanship Standards for Electrical Assemblies – FZM-8027.

TOOLS REQUIRED:
1. Basic crimping tool M22520/2-01 with Trompeter 010-0041 positioner.
2. Basic crimping tool M22520/5-01 tool with Trompeter CD5-9 (Daniels
Y687) die set.
3. Soldering iron (optional).

CABLE PREPARATION:
Parts are identified in Figure 1.
A. Body assembly
B. Shield/dielectric assembly
C. Pin/Dual Entry Dielectric assembly
D. Crimp bushing
E. Shrinkable strain relief

A134-1
1. Remove outer jacket of cable to dimensions in Figure 2, being careful not
to cut or nick the underlying shield braid.

2. Fold back the outer shield braid and remove extraneous materials (Mylar,
mu-metal, etc.) as far back as possible in Figure 3.

3. Fold shield braid(s) back over cable jacket.

4. Trim the conductors to the dimensions shown in Figure 4; then, (optional)
lightly tin.

INSTALLATION OF CRIMP BUSHING AND CRIMP RING:

1. Bring shield braid(s) forward over the conductor wires and twist the
braid(s) around the conductors; see Figure 5A.

2. Load the shrinkable strain relief onto the cable.

3. Push the cable through the crimp bushing until the jacket bottoms inside
the bushing.

A134-2
4. Fold the braid(s) back over the crimp bushing; see Figure 5B.

INSTALLATION OF DUAL ENTRY DIELECTRIC & CONTACT

1. Bring the blue/purple conductor outward, and position the white conductor
to the center of the cable.
2. Install the pin/dual entry dielectric onto the conductors with the white
conductor through the center hole and the blue/purple conductor through
the side hole; see Figure 6.

3. Position the pin over the white conductor and crimp in place using basic
tool M22520/2-01 with TEI positioner 010-0041.

INSTALLATION OF DIELECTRIC & SHIELD/SHIELD ASSY:

A134-3
3. Crimp the crimp shield assembly in place using basic tool M22520/5-
01with a TEI CD5-9 die set, closure B; see Figure 7B.

INSTALLATION OF CONNECTOR BODY ASSEMBLY

1. Push entire assembly into body assembly until bottomed. Hold assembly
firmly bottomed until fully hex crimped as shown using M22520/5-01 with
TEI die set CD5-9, closure A.
2. Bring up shrinkable strain relief to (approx) dim, See Figure 8, and shrink
in place.

ACCEPT/REJECT CRITERIA
1. Reference J-STD-001, Class III, and FZM-8027, and/or requirements
specified in this procedure.

A134-4
F.A. C20857-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C20857-1 SOCKET CONTACT

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C20857-1
contacts, manufactured by Astrolab, Inc, for C20826-1 coax cable.
2. The standard is applicable for all programs.

APPROVED TOOLS:
1. Basic crimping tool Astrolab AT-1007-1.5 with 1.5 die.
2. Solder iron

CABLE PREPARATION:
1. Different parts are identified in Figure 1.
A. Connector subassembly
B. Contact
C. Ferrule

2. Insert the ferrule over the jacket.

A135-1
3. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

4. Remove Kapton between inner and outer cable shield. Flare inner and
outer cable shield to expose dielectric. See figure 3a.

5. When installing the outer contact over the center pin, if undue resistance
is met which impedes the dielectric from entering the contact, it will be
necessary to remove a small portion of the white inner dielectric. If this is
necessary, retract the contact and remove 1.5 to 2 turns of the center
conductor dielectric to allow for cable insertion into the contact. Remove
only the minimum amount of dielectric required to allow for insertion into
the contact. See figure 3b.

6. Tin center contact and install inner pin contact onto conductor, verifying
that the conductor is visible in the inspection window. Contact butts
against rear insulator. Solder contact onto center conductor. See figure 4.

A135-2
7. Install the outer socket contact over inner pin contact assembly until the
contact is fully seated. See figure 5.

8. Slide Ferrule over the cable shields. Trim the excess shields between the
shield crimp sleeve and the outer socket contact. See figure 5.
9. Crimp the crimp sleeve with approved tool.

ACCEPT/REJECT CRITERIA:
1. There shall be no gap between the inner pin contact and the inner
insulator.
2. The center conductor shall be visible in the inspection window of the inner
pin contact.
2. Gap between outer jacket of the cable and shield crimp sleeve shall not
exceed 0.06 inch.
3. Reference FZM-8027, and/or requirements specified in this procedure.

A135-3
F.A. C20858-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C20858-1 PIN CONTACT

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C20858-1
contacts, manufactured by Astrolab, Inc, for C20826-1 coax cable.
2. The standard is applicable for all programs.

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.
3. Manufacturer's Operating Procedures or equivalent document (reference
only).

APPROVED TOOLS:
1. Basic crimping tool Astrolab AT-1007-1.5 with 1.5 die.
2. Solder iron

CABLE PREPARATION:
1. Different parts are identified in Figure 1.
A. Connector subassembly
B. Contact
C. Ferrule

2. Insert the ferrule over the jacket.

A136-1
3. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

4. Remove Kapton between inner and outer cable shield. Flare inner and
outer cable shield to expose dielectric. See figure 3a.

A136-2
7. Install the outer socket contact over inner pin contact assembly until the
contact is fully seated. See figure 5.

8. Slide Ferrule over the cable shields. Trim the excess shields between the
shield crimp sleeve and the outer socket contact. See figure 5.
9. Crimp the crimp sleeve with approved tool.

ACCEPT/REJECT CRITERIA:
1. There shall be no gap between the inner pin contact and the inner
insulator.
2. The center conductor shall be visible in the inspection window of the inner
pin contact.
3. Gap between outer jacket of the cable and shield crimp sleeve shall not
exceed 0.06 inch.
4. Reference FZM-8027, and/or requirements specified in this procedure.

A136-3
F.A. C20895-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C20895-1 SOCKET CONTACT

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics (LMAero) production operations for terminating C20895-1
contacts, manufactured by Astrolab, Inc, for C20826-1 coax cable.
2. The standard is applicable for all programs.

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.
3. Manufacturer's Operating Procedures or equivalent document (reference
only).

APPROVED TOOLS:
1. Basic crimping tool Astrolab AT-1007-1.5 with 1.5 die.
2. Solder iron

CABLE PREPARATION:
1. Different parts are identified in Figure 1.
D. Connector subassembly
E. Contact
F. Ferrule

2. Insert the ferrule over the jacket.

A137-1
3. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

4. Remove Kapton between inner and outer cable shield. Flare inner and
outer cable shield to expose dielectric. See figure 3a.

A137-2
7. Install the outer socket contact over inner pin contact assembly until the
contact is fully seated. See figure 5.

8. Slide Ferrule over the cable shields. Trim the excess shields between the
shield crimp sleeve and the outer socket contact. See figure 5.
9. Crimp the crimp sleeve with approved tool.

ACCEPT/REJECT CRITERIA:
1. There shall be no gap between the inner pin contact and the inner
insulator.
2. The center conductor shall be visible in the inspection window of the inner
pin contact.
3. Gap between outer jacket of the cable and shield crimp sleeve shall not
exceed 0.06 inch.
4. Reference FZM-8027, and/or requirements specified in this procedure.

A137-3
F.A. C20896-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

TERMINATION OF C20896-1 PIN CONTACT

APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.
3. Manufacturer's Operating Procedures or equivalent document (reference
only).

APPROVED TOOLS:
1. Basic crimping tool Astrolab AT-1007-1.5 with 1.5 die.
2. Solder iron

CABLE PREPARATION:
1. Different parts are identified in Figure 1.
A. Connector subassembly
B. Contact
C. Ferrule

2. Insert the ferrule over the jacket.

A138-1
3. Strip the cable in accordance with Figure 2. All the cuts shall be square.
Precautions shall be taken against nicks of insulation and conductors.

4. Remove Kapton between inner and outer cable shield. Flare inner and
outer cable shield to expose dielectric. See figure 3a.

A138-2
7. Install the outer socket contact over inner pin contact assembly until the
contact is fully seated. See figure 5.

8. Slide Ferrule over the cable shields. Trim the excess shields between the
shield crimp sleeve and the outer socket contact. See figure 5.
9. Crimp the crimp sleeve with approved tool.

ACCEPT/REJECT CRITERIA:
1. There shall be no gap between the inner pin contact and the inner
insulator.
2. The center conductor shall be visible in the inspection window of the inner
pin contact.
3. Gap between outer jacket of the cable and shield crimp sleeve shall not
exceed 0.06 inch.
4. Reference FZM-8027, and/or requirements specified in this procedure.

A138-3
F.A. C8804-12
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

INSTALLATION OF C8804-12 CONNECTOR

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for installation of
C8804-12 connector, manufactured by Phoenix Logistics, Inc.
2. This Fabrication Aid is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MTPA-002
3. LMAero Soldering Process J-STD-001, Class III.
4. Workmanship Standards for Electrical Assemblies – FZM-8027.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 with M22520/5-11 dies.
2. Soldering iron or hot air gun (AA-400 SuperHeater).
3. Torque wrench.

GENERAL
1. Parts for Phoenix Logistics are identified in Figure 1.

A139-1
CABLE PREPERATION:
1. Load the shrink sleeve onto the cable.
2. Load the crimp sleeve with the internal taper and hole positioned towards
the end of the cable.
3. Trim the cable jacket to the dimension shown in Figure 2. All cuts shall be
square, being careful not to cut through underlying layers

INSTALLATION OF REAR ASSEMBLY:

1. Load the rear nut onto the braid terminator;
2. Gently slide the tapered end of the braid terminator over the dielectric and
under the braid until it butts against the jacket.
3. Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.
4. Crimp the crimp sleeve in place using tool number M22520/5-01 with die
number M22520/5-11 Closure A.
NOTE: After crimping – a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum gap is .05 inch.
5. Apply heat to the crimp sleeve using a soldering iron or hot air gun, and
feed solder into the holes insuring adequate evidence of wetting. Caution
should be exercised when using the hot air gun to avoid damage to the
outer jacket of the cable.

3. Pre-tin center conductor and the rear of contacts

A139-2
4. Slide the match sleeve and rear dielectric onto the center conductor until it
stops against the braid terminator..
5. Solder the contact onto the center conductor, fully bottomed against the
rear dielectric.

INSTALLATION OF CABLE ASSEMBLY:

1. Slide the front dielectric over the contact; see Figure 4.
2. Insert the cable into the connector housing; see Figure 4.

3. Torque the rear nut to 25-35 in. lbs.

4. Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:
1. Reference J-STD-001, Class III and/or FZM-8027 for accept/reject criteria
- for exceptions to this criteria see paragraph INSTALLATION OF REAR
ASSEMBLY note (for Phoenix Logistics connectors only).

A139-3
F.A. C8825-2-4
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-2-4 CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for installation of
C8825-2-4 connector, manufactured by Automatic Connectors, Inc., for
coaxial cables
2. This Fabrication Aid is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MTPA-002
3. Workmanship Standards for Electrical Assemblies – FZM-8027.

TOOLS REQUIRED:
1. Basic crimping tool M22520/1-01 and M22520/1-12 dies.
2. Basic crimping tool M22520/5-01 and M22520/5-19 die, closure B.
3. Hot air gun.

CABLE PREPERATION:
1. Parts are identified in Figure 1.
A. Connector Housing
B. Contact
C. Crimp Ferrule
D. Shrink sleeve

A140-1
2. Load the shrink sleeve onto the cable.
3. Load the crimp sleeve onto the cable.
4. Trim the cable to the dimension shown in Figure 2. All cuts shall be square,
being careful not to cut through underlying layers.

INSTALLATION OF CONTACT:
1. Install contact onto center conductor. See Figure 3.
2. Crimp contact with appropriate tool and die.

INSTALLATION OF CABLE ASSEMBLY:

1. Insert the cable into the connector housing; see Figure 4.

A140-2
2. Slide the crimp ferrule forward and crimp in place with appropriate tool. See
Figure 5.

3. Slide shrink sleeve until butts against connector assembly, and shrink into
place. See Figure 6.

ACCEPT/REJECT CRITERIA:
1. Reference FZM-8027 for accept/reject criteria.

A140-3
F.A. C8825-3-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8825-3-1 CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for installation of
C8825-3-1 connector, manufactured by Automatic Connectors, Inc., for
coaxial cables
2. This Fabrication Aid is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MTPA-002
3. Workmanship Standards for Electrical Assemblies – FZM-8027.
4. LMAero Soldering Process J-STD-001, Class III.

TOOLS REQUIRED:
1. Basic crimping tool M22520/5-01 and M22520/5-25 die, closure A.
2. Soldering Iron
3. Hot air gun.

CABLE PREPERATION:
1. Parts are identified in Figure 1.
A. Connector Housing
B. Contact
C. Crimp Ferrule
D. Shrink sleeve

A141-1
2. Load the shrink sleeve onto the cable.
3. Load the crimp sleeve onto the cable.
4. Trim the cable to the dimension shown in Figure 2. All cuts shall be
square, being careful not to cut through underlying layers

INSTALLATION OF CONTACT:
1. Install contact onto center conductor. See Figure 3.
2. Solder contact into place.

INSTALLATION OF CABLE ASSEMBLY:

1. Insert the cable into the connector housing; see Figure 4.

A141-2
2. Slide the crimp ferrule forward and crimp in place with appropriate tool. See
Figure 5.

3. Slide shrink sleeve until it covers crimped ferrule, and shrink into place. See
Figure 6.

ACCEPT/REJECT CRITERIA:
1. Reference J-STD-001, Class III and/or FZM-8027 for accept/reject criteria.

A141-3
F.A. MS27488
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

INSERTION OF MS27488
SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for terminating
MS27488 sealer plugs into connectors.
2. This Fabrication Aid is applicable to all programs.

APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document (reference
only).

GENERAL
1. MS27488 Sealer Plug

FIGURE 1
SOCKET RELAY TERMINATION
1. Install sealer plug into grommet of relay socket larger end first.
2. Sealer plug shall be installed as far as the last sealing ring of the
grommet. Plug shall not be inserted past connector contact locks. See
Figure 2.

A142-1
SEALER PLUG
GROMMET

LOCKS

RELAY SOCKET

FIGURE 2

ROUND CONNECTOR TERMINATION:

1. Insert sealer plug into grommet of connector larger end first.
2. Sealer plug shall go in as far as the last sealing ring of the grommet. Plug
shall not be inserted past connector contact locks. See Figure 3.

LOCK
PLUG

ROUND CONNECTOR

FIGURE 3

ACCEPT/REJECT CRITERIA:
1. Sealer plugs are to be installed larger end first.
2. Plugs shall not be pushed past contact locks.

A142-2
Seal Plug Tool Part Number
MS27488-22-X M81969/14-01
MS27488-20-X M81969/14-11
MS27488-16-X M81969/14-03
MS27488-12-X M81969/14-04
MS27488-16-X M81969/14-03
MS27488-12-X M81969/14-04

A142-3
F.A. C20777
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C20777 BACKSHELL

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for terminating
C20777-1-15 connectors with C20778-1 and C20778-3 ferrules.
2. This Fabrication Aid is applicable to all programs.
APPLICABLE DOCUMENTS:
1. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.
2. Manufacturer's Operating Procedures or equivalent document (reference
only).
CONNECTOR PARTS:

Figure 1

A143-1
CONNECTOR ASSEMBLY:
1. Pass the clamping nut (1), the conic ring (3), and then the body (4) over the
cable bundles (as shown). For adapters containing drilled stars, route the
wires that pass through the center hole of the star before inserting the contacts
into the connector.

Figure 2

2. Insert contacts (7) into connector (6).

3. Tighten the body (4) onto the connector (6).
4. Clip the ferrules (8) into the star (2). For star-in-star or split star configurations,
install the ferrules starting from the inner star or ferrule slot.
5. Position the conic ring (3) on the star (2), according to note B*.

Figure 3

6. Position the sub-assemblies (stars+conic rings+ferrules) into the body by

carefully twisting the cables.
7. Tighten the clamping nut (1) on the body (4).

A143-2
TIGHTEN THE BODY AND CLAMPING NUT:
1. It is essential for reliable electrical performance to adequately tighten the
adaptor onto the connector.
2. Apply a suitable liquid lock compound (e.g. vibratite) to the first thread, also
acts as a lubricant when tightening Hexashield adaptors
3. Hand tighten the body onto the connector ensuring that anti-rotation teeth are
properly mated. It is recommended that the connector is mated to a receptacle
or connector wrench before final tightening takes place.
4. Wrap strap around the body. See figure 4.
5. Turn the handle clockwise until the strap becomes tight on the body. Assure
that the strap is centered on the knurled section of the body and that the metal
handle of the strap wrench does not come in contact with the surface of the
body. See figure 4.
6. Continue to turn the handle until clamping nut is tight. Slippage of the strap on
the body suggests that body cannot be tightened anymore
7. Remove the strap from the hole and body. Verify that the body cannot be
loosened by hand. Repeat procedure with clamping nut.

APPLICATION OF STRAP WRENCH

LEVER MOVEMENT

BACKSHELL

STRAP
DIRECTION

Figure 4

ACCEPT/REJECT CRITERIA:
1. Refer to C20778 fab-aid for termination of C20778-1 and C20778-3 ferrules.
2. Verify Body and Clamping nut can not be loosened by hand.

A143-3
F.A. C20778-1 & -3
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C20778-1 & -3 FERRULES

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for terminating
C20778-1 and C20778-3 ferrules for shield cables.
2. This Fabrication Aid is applicable to all programs.
APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.
3. Manufacturer's Operating Procedures or equivalent document (reference
only).

TOOLS REQUIRED:
1. Approved heating source for shrinking of solder sleeves.

CABLE PREPARATION:
1. Cable accommodation dimensions
Table 1 Table 2
Envelope Diameters for C20778-1 Envelope Diameters for C20778-3*
Jacket Shield Conductor Jacket Shield Conductor
Min. Max. Min. Max. Max. Min. Max. Min. Max. Max.
.122 .271 .094 .208 .165 .170 .350 .094 .244 .165

2. Strip the cable(s) in accordance with the Figure 1 below. All the cuts shall
be square. Precautions shall be taken against nicks of conductor.

A144-1
.3 ‖ 1.6 ‖

Figure 1

INSERTING SOLDER SLEEVE AND FERRULE ONTO CABLE:

1. Slide Solder sleeve and ferrule onto cable(s) as shown in figure 2.

TUBING INSTLD

Figure 2

2. If primary wire(s) are less than .039‖ in diameter, use a short piece of shrink
tubing butted against the cable braid(s). Heat shrink sleeve into place.
3. The gap between the end of the sleeve and shoulder of the ferrule must not
exceed .05 in.

TERMINATION PROCEDURE
1. Allow the hot air tool to warm up for at least 1 minute to its operating
temperature before heating assembly.
2. Position the solder preform in the center of the reflector.
3. Heat until the solder performs are completely melted and solder fillets are
formed between the ferrule and solder sleeve, and between the cable
braids and solder sleeve. If necessary, continue to heat the device moving
towards the cable until the tubing is fully shrunk onto the cable jackets(s)
4. Verify proper termination according to accept/reject criteria.

ACCEPT/REJECT CRITERIA:
1. Reference FZM-8027, and/or requirements specified in this procedure.
2. The maximum number of shielded cables per ferrule specified for this
product is 4.

A144-2
F.A. C20928-1
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C20928-1 CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) vendor/supplier operations for
terminating C20928-1 connectors for RG 316 coax cables.
2. This Fabrication Aid is applicable to all programs.
APPLICABLE DOCUMENTS:
1. FZM 8027, Workmanship Standards for Electrical Assemblies.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-
002.
3. Manufacturer's Operating Procedures or equivalent document (reference
only).

TOOLS REQUIRED:
1. Solder Iron
2. Basic crimping tool M22520/5-01 with M22520/5-03 die
3. Approved torque wrench

CABLE PREPARATION:
1. Parts are identified in Figure 1.
A. Connector housing
B. Contact
C. Insulator
D. Ferrule
E. Back Nut

A145-1
2. Slide Shrink tubing onto cable.
3. Slide Ferrule onto cable.
4. Strip the cable in accordance with Figure 1. All the cuts shall be square.
Precautions shall be taken against nicks of conductor. See Figure 2.

INSTALLATION OF REAR ASSEMBLY:

1. Slide tapered end of back nut onto cable underneath braided shield until it
butts against jacket. See Figure 3.

2. Slide crimp ferrule forward and crimp into place with appropriate tool.
3. Slide insulator onto cable until it butts against back nut. See Figure 4.
4. Slide contact onto inner conductor. Conductor shall be visible in inspection
hole. See Figure 4.

A145-2
5. Solder contact flush to the cable dielectric.

INSTALLATION OF CABLE ASSEMBLY:

1. Insert cable assembly into connector housing. See Figure 5.

2. Tighten back nut with torque wrench with a torque of 90-100 inch ounces.
3. Slide shrink tubing over crimped ferrule and shrink into place.

ACCEPT/REJECT CRITERIA
1. Reference FZM-8027, and/or requirements specified in this procedure.

A145-3
F.A. C9718-6
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C9718-6 CONNECTORS

SCOPE:
1. This Fabrication Aid contains requirements applicable to Lockheed Martin
Aeronautics Company (LMAero) production operations for installation of
C9718-6 connectors, manufactured by Trompeter Electronics, Inc., for 20807-
26-1P cables.
2. This Fabrication Aid is applicable to all programs.
APPLICABLE DOCUMENTS:
1. Manufacturer‘s Assembly Procedures or equivalent document.
2. Authorized Tool List of Electrical Crimping and Insertion and Extraction
Tools for F-16 Wiring Harnesses – MPTA-002.
3. Workmanship Standards for Electrical Assemblies – FZM-8027.

TOOLS REQUIRED:
1. Basic crimping tool M22520/2-01 with Trompeter 010-0041(Daniels K815S)
positioner.
2. Basic crimping tool M22520/5-01 tool with Trompeter CD5-9 (Daniels Y687)
die set.
3. Soldering iron (optional).

CABLE PREPARATION:
1. Parts are identified in Figure 1.
A. Body assembly
B. Shield/dielectric assembly
C. Pin/Dual Entry Dielectric assembly
D. Crimp bushing
E. Shrinkable strain relief

A146-1
2. Remove outer jacket of cable to dimensions in Figure 2, being careful not
to cut or nick the underlying shield braid.

3. Fold back the outer shield braid and remove extraneous materials (Mylar,
mu-metal, etc.) as far back as possible in Figure 3.

4. Fold shield braid(s) back over cable jacket.

5. Trim the conductors to the dimensions shown in Figure 4; then, (optional)
lightly tin.

INSTALLATION OF CRIMP BUSHING AND CRIMP RING:

1. Bring shield braid(s) forward over the conductor wires and twist the
braid(s) around the conductors; see Figure 5A.

2. Load the shrinkable strain relief onto the cable.

3. Push the cable through the crimp bushing until the jacket bottoms inside
the bushing.

A146-2
4. Fold the braid(s) back over the crimp bushing; see Figure 5B.

5. Bring the blue/purple conductor outward, and position the white conductor
to the center of the cable.
6. Install the pin/dual entry dielectric onto the conductors with the white
conductor through the center hole and the blue/purple conductor through
the side hole; see Figure 6.

7. Position the pin over the white conductor and crimp in place using basic
tool M22520/2-01 with TEI positioner 010-0041 (Daniels K815S).

INSTALLATION OF DIELECTRIC & SHIELD/SHIELD ASSY:

A146-3
3. Crimp the crimp shield assembly in place using basic tool M22520/5-01
with a TEI CD5-9 die set (Daniels Y687), closure B; see Figure 7B.

INSTALLATION OF CONNECTOR BODY ASSEMBLY

1. Push entire assembly into body assembly until bottomed. Hold assembly
firmly bottomed until fully hex crimped as shown using M22520/5-01 with
TEI die set CD5-9(Daniels Y687), closure A.
2. Bring up shrinkable strain relief to (approx) dim, See Figure 8, and shrink
in place.

ACCEPT/REJECT CRITERIA

1. Reference FZM-8027, and/or requirements specified in this procedure.

A146-4
F.A. C8952-1-5
DATED: 30 March 2011

FABRICATION AID

IMPORTANT NOTICE: A hard copy of this document may not be the document currently in
effect. The current version is ALWAYS the version on the Lockheed Martin Network.

ASSEMBLY OF C8952-1-5 COAX CONNECTORS

SCOPE:

1. This Fabrication Aid contains requirements applicable to Lockheed Martin

Aeronautics (LM Aero) Vendor/Supplier operations for assembling C8952-1-3
coax connector, manufactured by Phoenix Logistics, Inc. For connectors
produced by manufactures other than Phoenix Logistics, Inc., see Paragraph
3.4.5.3.1, General Coax Assembly Instructions.

2. This Fabrication Aid is applicable for all F-16 programs.

APPLICABLE DOCUMENTS:

1. Manufacturer's Operating Procedures or equivalent document (reference

only).

2. Workmanship Standard for Electrical Assemblies - FZM 8027.

3. Authorized Tool List of Electrical Crimping and Insertion and Extraction Tools
for F-16 Wiring Harnesses and Other Authorized Programs - MTPA-002.

4. LMTAS Soldering Process J-STD-001, CLASS III.

TOOLS REQUIRED:

1. Basic crimping tool M22520/5-01 with M22520/5-25 die.

2. Approved torque wrench.

3. Approved soldering iron or hot air gun (AA-400 Super Heater).

ASSEMBLY PROCEDURES:

1. CABLE PREPARATION:
a) Parts are identified in Figure 1.
Shrink sleeve
Crimp sleeve

A147-1
Rear nut
Braid terminator
Rear Dielectric
Contact
Connector housing

b) Load shrink sleeve onto cable.

c) Load the crimp sleeve onto the cable with the internal taper and hole
positioned towards the end of the cable.

d) Trim the cable jacket and braid to the dimensions shown in Figure 2. All
cuts shall be square. Precautions shall be taken to avoid cutting the
underlying layers.

2. INSTALLATION OF REAR ASSEMBLY:

a) Load the rear nut onto the braid terminator.

b) Gently slide the tapered end of the braid terminator over the cable
dielectric and under the braid until it butts against the jacket.

c) Slide the crimp sleeve forward over the braid and braid terminator until it
stops behind the rear nut.

d) Crimp the crimp sleeve in place using tool number M22520/5-01 with die
M22520/5-25 Closure A.

NOTE: After crimping - a gap between the cable jacket and the crimp
sleeve is acceptable. The maximum allowable gap is 0.05 inch.

3. INSTALLATION OF CONTACT:
a) Trim the dielectric flush with the face of the braid terminator, being careful
not nick the center conductor.

b) Trim the center conductor to the dimension shown in Figure 3.

c) Pre-tin center conductor and the rear of contact.

d) Slide the rear dielectric onto the center conductor until it butts against the
braid terminator. Ensure that the dielectric counter bore faces the braid
terminator.
A147-2
e) Solder the contact onto the center conductor, ensuring that the contact
shoulder is fully bottomed against the rear dielectric.

NOTE: Contact may be crimped using a M22520/1-01 Setting M22520/1-

14.

4. INSTALLATION OF CABLE ASSEMBLY:

a) Insert the cable into the connector housing - see Figure 4.

b) Torque the rear nut to 25-35 inch lbs.

c) Slide the shrink sleeve forward and shrink in place.

ACCEPT/REJECT CRITERIA:

1. Reference FZM 8027 for accept/reject criteria.

2. For exceptions to this criteria see 2.d - NOTE (above).

A147-3
A147-4

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