INSTALLATION AND REPAIR PRACTICES VOLUME III AIRCRAFT .
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-31 September 2007TECHNICAL MANUALINSTALLATION AND REPAIR PRACTICESVOLUME IIIAIRCRAFT RECTANGULAR ELECTRICALCONNECTORS AND ACCESSORIESThis manual is incomplete without volume 1 (NAVAIR 01-1A-505-1)For U.S. Air Force Users Only- It is incomplete without T. O. 1-1A-14For U.S. Army Users Only - It is incomplete without 1-1500-323-24-1This manual supersedes: NAVAIR 01-1A-505.15, 01-1A-505.16, 01-1A-505.17, 01-1A-505.18,01-1A-505.19, 01-1A-505.20, 01-1A-505.22, 01-1A-505.23 and Air Force T.O. 00-25-255-2, dated15 February 1993.DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.DESTRUCTION NOTICE - For unclassified, limited documents, destroy by any method that willprevent disclosure of contents or reconstruction of the document.PUBLISHED BY DIRECTION OF COMMANDER, NAVAL AIR SYSTEMS COMMAND0801LP1068153
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-31 September 2007Page ANUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGESList of Current ChangesOriginal .0 .1 September 2007Only those work packages/pages assigned to the manual are listed in this index. Insert Change , dated .Dispose of superseded and deleted work packages/pages. If changed pages are issued to a work package, insert thechanged pages in the applicable work package. The portion of text affected in a changed or revised work package isindicated by change bars or the change symbol “R” in the outer margin of each column of text. Changes toillustrations are indicated by point hands or change bars, as applicable. Changes to wiring diagrams and schematicsare indicated by shading.WPNumberTitlePage ATPDRHMWS001 00WP 002 00WP 003 00WP 003 01WP 003 02WP 003 03WP 004 00WP 004 01WP 004 02WP 004 03WP 005 00WP 005 01WP 005 02TitleWPNumberWP 005 03Numerical Index of Effective WorkPackages/PagesList of Technical PublicationsDiscrepancy Reports IncorporatedWarnings Applicable to HazardousWaste materialsAlphabetical IndexIntroductionAlphabetical Index for ConnectorsMIL-C-24308Introduction to Connectors MILDTL-24308Connectors MIL- DTL-24308Connector Accessories MIL- DTL24308Alphabetical Index for ConnectorsMIL-DTL-28731Introduction to Connectors MILDTL-28731Connectors MIL-DTL-28731Connector Accessories MIL-DTL28731Alphabetical Index for ConnectorsMIL-DTL-28748Introduction to Connectors MILDTL-28748Connectors MIL-DTL-28748WP 006 00WP 006 01WP 006 02WP 006 03WP 007 00WP 007 01WP 007 02WP 007 03WP 008 00WP 008 01WP 008 02WP 008 03WP 009 00WP 009 01WP 009 02TitleConnector Accessories MIL-DTL28748Alphabetical Index for ConnectorsMIL-DTL-28804Introduction to Connectors MILDTL-28804Connectors MIL-DTL-28804Connector Accessories ConnectorsMIL-DTL-28804Alphabetical Index for ConnectorsMIL-C-81659Introduction to Connectors MIL-C81659Connectors MIL-C-81659Connector Accessories forConnectors MIL-C-81659Alphabetical Index for ConnectorsMIL-DTL-83733Introduction to Connectors MILDTL-83733Connectors MIL-DTL-83733Connector Accessories forConnectors MIL-DTL-83733Alphabetical Index for ConnectorsMIL-C-21617Introduction to Connectors MIL-C21617Connectors MIL-C-21617
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-3Page BWPNumberWPNumberTitleWP 011 03WP 009 03WP 010 00WP 010 01WP 010 02WP 010 03WP 011 00WP 011 01WP 011 02Connector Accessories forConnectors MIL-C-21617Alphabetical Index for ConnectorsMIL-DTL-26518Introduction to Connectors MILDTL-26518Connectors MIL-DTL-26518Connector Accessories forConnectors MIL-DTL-26518Alphabetical Index for ConnectorsMIL-DTL-83513Introduction to Connectors MILDTL-83513Connectors MIL-DTL-83513WP 012 00WP 012 01WP 012 02WP 012 03WP 013 00WP 013 01WP 013 02AppendixTitleConnector Accessories forConnectors MIL-DTL-83513Alphabetical Index for ConnectorsMIL-C-85028Introduction to Connectors MIL-C85028Connectors MIL-C-85028Connector Accessories forConnectors MIL-C-85028Alphabetical Index for ConnectorsMTC SeriesIntroduction to Connectors MTCSeriesConnectors MTC SeriesPart Numbers StatusTotal number of pages in this publication is 396 consisting of the following:WP/Page No.Change No.Title .0A-B .0C Blank.0TPDR-1 .0TPDR-Blank .0HMWS-1 – HMWS-4.0001 001.02 Blank .0002 001 - 4.0003 001.02 Blank .0003 011.02 Blank .0003 021 - 38.0003 031 - 8.0004 001.02 Blank .0004 011.02 Blank .0WP/Page No.Change No.004 021 - 28. 0004 031 - 6. 0005 001 . 02 Blank. 0005 011 . 02 Blank. 0005 021 - 39. 040 Blank. 0005 031 - 5. 06 Blank. 0006 001 . 02 Blank. 0006 011 . 02 Blank. 0006 021 - 10. 0006 031 - 2. 0007 00WP/Page No.Change No.1 . 02 Blank . 0007 011 . 02 Blank . 0007 021 - 31 . 032 Blank . 0007 031 - 5 . 06 Blank . 0008 001 . 02 Blank . 0008 011 . 02 Blank . 0008 021 - 21 . 022 Blank . 0008 031 - 4 . 0009 001 . 02 Blank . 0009 011 . 0
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-3Page CWP/Page No.Change No.2 Blank .0009 021 - 10.0009 031 - 2.0010 001.02 Blank .0010 011.02 Blank .0010 021 – 21.022 Blank .0010 031 - 3.04 Blank .0011 001.02 Blank .0011 011.02 Blank .0011 021 - 8.0011 031 - 10.0012 001.02 Blank .0012 011.02 Blank .0012 021 - 16.0012 031 - 3.04 Blank .0013 001.02 Blank .0013 011.02 Blank .0013 021 - 24.0AppendixA-1 – A-13.0WP/Page No.Change No.A-14 Blank. 0WP/Page No.Change No.
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-3TPDR-1/(2 Blank)1 September 2007LIST OF TECHNICAL PUBLICATION DEFICIENCY REPORTS INCORPORATEDINSTALLATION PRACTICESCONNECTORS MIL-DTL- 28731Identification No/QA Sequence No.ServiceNoneRecord of Applicable Technical DirectivesType/No.DateTitle and ECP No.NoneDate Inc.Remarks
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3HMWS-11 September 2007HAZARDOUS MATERIAL WARNING AND SAFETYRecord of Applicable Technical DirectivesCode of Federal Regulations . 49 CFR, Parts 171-179OPNAVINST . 5100 SeriesNavy Occupational Safety and Health . 5100.23Hazardous Material Handling. 5100.28Air Force Occupational Safety & Health Program.AFOSH 161-17Hazard Communication Program .AFOSH 161-21Alphabetical IndexSubjectPage No.General Safety Precautions. 1Introduction . 1Explanation of Hazardous Symbols . 5Specific Hazardous Material Warnings . 6Hazardous Material Warnings . 3General Warnings and Cautions . 2Support Equipment RequiredNoneMaterials RequiredNone1. INTRODUCTION. This work package (WP)addresses hazardous materials precautions(HAZMAT).2.HAZARDOUS MATERIAL WARNINGS.3. Warnings for hazardous materials listed inthis manual are designed to warn personnel ofhazards associated with such items when theycome in contact with them by actual use.Additional information related to hazardousmaterials is provided in OPNAVINST 5100.23,Navy Occupational Safety and Health(NAVOSH) Program Manual, NAVSUPINST5100.27, Navy Hazardous Material ControlProgram, and the DOD 6050.5, HazardousMaterials Information System (HMIS) seriespublications. For each hazardous material usedwithin the Navy, a material safety data sheet(MSDS) is required to be provided and availablefor review by users. Consult your local safety andhealth staff concerning any question onhazardous chemicals, MSDS’s, personalprotective equipment requirements, andappropriate handling and emergency proceduresand disposal guidance.4. Complete warnings for hazardous materialsreferenced in this manual are identified by use ofan icon, nomenclature and specification or partnumber of the material, and a numeric identifier.The numeric identifiers have been assigned to the
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3hazardous materials in the order of theirappearance in the manual. Each hazardousmaterial is assigned only one numeric identifier.Repeated use of a specific hazardous materialreferences the numeric identifier assigned at itsinitial appearance.6.EXPLANATION OF HAZARDOUS SYMBOLSHMWS-25. In the text of the manual, the captionWARNING will not be used for hazardousmaterials. Such warnings will be identified by anicon and numeric identifier. The materialnomenclature will also be provided. The user isdirected to refer to the corresponding numericidentifier listed below for the complete warningapplicable to the hazardous materials
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3BiologicalChemicalExplosionEye ProtectionFireHMWS-3The abstract symbol bug shows that a materialmay contain bacteria or viruses that present adanger to your life or health.The symbol of drops of a liquid onto a handshows that the material will cause burns orirritation of human skin or tissue.The rapidly expanding symbol shows that thematerial may explode if subjected to hightemperatures, sources of ignition, or highpressure.The symbol of a person wearing goggles showsthat the material will injure your eyes.The symbol of a flame shows that a material canignite and burn you.PoisonThe symbol of a skull and crossbones shows that amaterial is poisonous or is a danger to life.RadiationVaporThe symbol of three circular wedges shows thatthe material emits radioactive energy and caninjure human tissue or organs.The symbol of a human figure in a cloud showsthat vapors of a material present a danger to yourlife or health.CryogenicThe symbol of a hand in a block of ice shows thatthe material is extremely cold and can injurehuman skin or tissue.
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-37.HMWS-4SPECIFIC HAZARDOUS MATERIALS WARNINGS1. Isopropyl Alcohol (TT-I-735). Flammable and mildly toxic to eyes, skin, and respiratory tract.Skin and eye protection is required. Avoid repeated and/or prolonged contact. Use only in wellventilated areas. Keep away from open flames or other sources of ignition. Poison by ingestion.2. Flux (Mil-F-14256). Flux fumes during soldering may cause irritation to the eyes. Soldering fluxmay also cause irritation to the skin and respiratory system. Containers may burst at elevatedtemperatures. Avoid breathing vapors. Avoid skin and eye contact. Use only in well ventilatedareas. Keep away from heat, sparks, flames, and incompatible materials.3. Lead, Solder (SNGOWRMAP3, or SN63WRMAP3). Poison by unspecified route. Skin, eye, andrespiratory irritant. Skin and eye protection required. Do not breathe smoke during soldering.High temperatures may produce heavy metal fumes, dust, and/or vapor.
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3001 001 September 2007Page 1/(2 Blank)ALPHABETICAL INDEXINSTALLATION AND REPAIR PRACTICESAIRCRAFT RECTANGULAR ELECTRICAL CONNECTORS AND ACCESSORIESTitleWP NumberAlphabetical Index .001 00Components Part Number Index . AppendixIntroduction .002 00Connectors MIL-DTL-24308 .003 00Connectors MIL-DTL-28731 .004 00Connectors MIL-DTL-28748 .005 00Connectors MIL-DTL-28804 .006 00Connectors MIL-C-81659 .007 00Connectors MIL-DTL-83733 .008 00Connectors MIL-DTL-21617 .009 00Connectors MIL-DTL-26518 .010 00Connectors MIL-DTL-83513 .011 00Connectors MIL-C-85028 .012 00Connectors MTC Series .013 00Hazardous Material Waste Safety . HMWSList of Technical Publication Discrepancy Reports Incorporated.TPDR
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3002 001 September 2007Page 1INTRODUCTIONINSTALLATION AND REPAIR PRACTICESAIRCRAFT RECTANGULAR ELECTRICAL CONNECTORS AND ACCESSORIES1.PURPOSE AND SCOPE.4.2. This manual was prepared for the followingreasons:ARRANGEMENT AND USE.5. This manual is divided into work packages(WPs) which are self–contained procedures that maybe used to support specific tasks.a. To gather under one cover the recommendedpractices and techniques to be used for installing,repairing, and maintaining aircraft rectangularelectrical connectors and accessories.b. To standardize these techniques andmethods so that electrical installations will be done ina uniform manner.c. To indoctrinate all personnel with theimportance of good workmanship.d. To point out the failures which, may resultfrom poor workmanship.e. To promote safety by pointing out andprohibiting unsafe practices.3. This manual provides updated data andprocedures on the most commonly encountered,general and special purpose rectangular electricalconnectors and accessories employed on militaryaircraft. It also includes applicable tooling,consumables and equipment required to maintainthese rectangular connectors, cables and accessories.6. Each WP is maintained separately. The WPs areidentified by five–digit numbers in the upper rightcorner of each page. This number aids in rapidassembly of a complete manual and is used forreferencing within a manual.7. This manual was prepared using Navy seriesmanual numbers throughout the text as references toreduce the amount of text required. When otherservices are using this joint service manual refer toTable 1 for an explanation of their correspondingmanual number (i.e. 01–1A–505–1 Navy, is 1–1A–14Air Force, or 1–1500–323–24–1 Army). When aconflict exists between this series of manuals andother manuals the precedence is as follows:a.OEM drawingsb.Platform Specific Manualsc.SAE AS50881d.NAVAIR 01–1A–505 (series)Table 1. Joint Services ManualsServiceManual TopicNavyAir ForceArmyGeneral �24–1Circular 00–323–24–2Rectangular 00–323–24–3
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3002 00Page 28.REQUISITIONING AND AUTOMATICDISTRIBUTION.21. Warnings, Cautions, and Notes are usedthroughout this manual. They are defined as follows:9.Procedures to be used by Naval activities andother Department of Defense activities requiringNAVAIR technical manuals are defined in NAVAIR00-25-100.10.QUALITY ASSURANCE.11. Maintenance procedure steps, essential toequipment performance or to the safety of personnel,are highlighted by the addition of the abbreviation(QA) following the procedure. Quality Assuranceaction shall be taken on all steps designated (QA)priorto proceeding to the next step.12.SUPPORT EQUIPMENT REQUIRED.13.Each individual WP identifies the supportequipment required to maintain the componentscovered within it. When alternate repair proceduresexist, different tools may be required. Wherepossible, the alternate tools are identified.14. CONSUMABLE MATERIALSREQUIRED.An operating or maintenance procedure, practice,condition, statement, etc., which, if not strictlyobserved, could result in injury to, or death ofpersonnel.An operating or maintenance procedure, practice,condition, statement, etc., which, if not strictlyobserved, could result in damage to, ordestruction of, equipment or loss of missioneffectiveness.NOTEAn essential operating or maintenanceprocedure, condition, or statement, which mustbe highlighted.15.Each individual WP identifies the consumablematerials required to maintain the componentscovered within it. The materials required for eachmaintenance task are listed in the corresponding WP.When alternate repair procedures exist, differentmaterials may be required. Where possible, thealternate materials are identified.22. GENERAL SAFETY PRECAUTIONS. Thefollowing general safety precautions shall apply:16.b. Observe and adhere to allWarning/Caution/Advisory signs on equipment andmaterials.REFERENCE MATERIAL.17. Each WP identifies the applicable list ofreference material required to install, maintain orrepair the applicable rectangular connector and/oraccessory.18.TECHNICAL DIRECTIVES.19. A record of applicable technical directives willalso appear in each WP in this manual, but will listonly technical directives that affect the text andillustrations of that particular WP.20.WARNINGS, CAUTIONS, AND NOTES.a. Observe and follow all written safetyprecautions while performing procedures given in themethods of this and other work packages containedwithin this manual.c. Observe and adhere to all Warning/Caution/Advisories/Notes in the applicableType/Model/Series aircraft manuals for repair of, andoperational verification of wiring and interconnectsystems.d. The following are general safety precautionswhich are not related to any specific procedure andtherefore do not appear elsewhere in this publication.These are recommended precautions that personnel
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3002 00Page 3shall understand and apply during many phases ofoperation and maintenance.23. KEEP AWAY FROM LIVE CIRCUITS.Operating personnel shall observe all safetyregulations at all times. Do not replace componentsinside the equipment when potentially lethal voltagesare present. Turn off system power beforemaking/breaking electrical connections. Regard anyexposed connector, terminal board, or circuit boardsas a possible shock hazard. Components that retain acharge shall be discharged only when such groundingdoes not result in equipment damage. If a testconnection to energized equipment is required, makethe test equipment ground connection before probingthe voltage or signal to be tested. Adhere to all lockout/tag out requirements.24. DO NOT SERVICE OR ADJUST ALONE.Personnel shall not under any circumstance reach intoor enter any enclosure for the purpose of servicing, oradjusting the equipment alone, without immediatepresence, or assistance of another person capable ofrendering aid.25.RESUSCITATION. Personnel working with,or near high voltages or hazardous materials shall befamiliar with modern methods of resuscitation. Moreinformation may be obtained by consulting with: theOffice of Bioenvironmental Health (Air Force), NavySafety Center, Activity HAZMAT Officer (Navy), orthe local Red Cross organization.26. DO NOT WEAR JEWELRY. Remove rings,watches, and other metallic objects which may causeelectric shock, or burn hazard.27. GENERAL WARNINGS ANDCAUTIONS.Do not perform hot work without specificauthorization of activity Aviation Gas FreeEngineer (AVGFE) or Gas Free Engineer(GFE).The HT-900B, HT-920B, HT-71002 andMCH-100-A heat guns are the onlyauthorized heat guns to be used whenworking on aircraft that have not beendefueled and purged. The aircraft must bedefueled and purged before using any otherheat guns listed in this manual. Aircraft withopen fuel cells or broken or open fuel linesshall be certified gas free in accordance withNAVAIR 01-1A-35, or AF T.O. 1-1-3.Only the HT-900B/HT-920B, HT-71002,MCH-100-A heating tools are authorized foruse on any aircraft whenever AVGAS, JP-4or the presence of any type of fuel isimposing an immediate danger.When using heat guns with electric motors,re-certification may be required as workprogresses, as directed by the Aviation GasFree Engineering Technician (AVGFET).The MCH-100-A heat gun has been Electromagnetic interference (EMI) qualified forflight line or flight deck use. All otherelectric motor type heat guns are notauthorized for flight line or flight deck usedue to electro-magnetic interference (EMI).hangar deck/flight line environment,provided the aircraft meets the gas-freeenvironment criteria (NAVAIR 01-1A-35,or AF T.O. 1-1-3), and there are no EMIrestrictions.
NAVAIR 01-1A-505-3TO 00-25-255-2TM 1-1500-323-24-3002 00Page 4preferred. Inspect tool tips for damage ordistortion before use.Do not perform wire repair while usingexplosive solvent /paint products on theaircraft. When using a heat tool, do notuse electrical power from the aircraftbeing repaired. Use electrical power froma ground power unit. Use of nitrogen withthe HT-900B/HT-920B heat gun in anenclosed area can be hazardous.Discharge of nitrogen into a poorlyventilated area can result in asphyxiation.Be careful if using metal tools (M81969).These tools can damage the wire sealinggrommet in the connector. Plastic tools areDamage to the connector wire sealinggrommet can occur. Avoid using metal toolingto remove and install backshells. These toolscan damage the backshell and connector. Nonmetallic tools are designed to wear beforedamaging connector or backshell.Do not remove a contact attached to a brokenwire with an unwired contact removal tool.The tool and connector may be damaged. Wirestrands may be encountered at any point up to5 16 inch of tool insertion. Do not force tool ifwire strands are encountered. Withdraw toolany time it cannot be advanced into connector.Inspect tool tip for nicks, cracks,mushrooming, and other damage that willprevent proper functioning. Replace removaltool and repeat procedure if required.
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-31 September 2007003 00Page 1/(2 Blank)ALPHABETICAL INDEXINSTALLATION PRACTICESCONNECTORS MIL-DTL- 24308TitleWP NumberConnector Accessories MIL-DTL-24308.003 03Connectors MIL- DTL-24308 .003 02Introduction .003 01
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-3003 011 September 2007Page 1/(2 Blank)INTRODUCTIONINSTALLATION PRACTICESCONNECTORS MIL-DTL-243081.PURPOSE AND SCOPE.2. This Work Package (WP) covers allconnectors manufactured in accordance withGeneral Specification MIL-DTL-24308. Itincludes: power, thermocouple, coaxial contactsand all associated tooling and accessories.3. SPECIFICATION UPDATES (ASSISTSEARCH).4. The most up to date government specificationsand Qualified Products Lists (QPLs) can beobtained from the Quick Search section of theASSIST website, the address ishttp://assist.daps.mil/quicksearch. Non-governmentstandards can be obtained through a license with adocument service such as Information HandlingServices (IHS) or purchased individually from theSociety of Automotive Engineers (SAE).5.QUALIFIED PRODUCTS LIST (QPL).6. The Qualified Products List (QPL) is a list ofproducts which have met the qualificationrequirements stated in the applicable specification.These requirements include appropriate productidentification and perform-ance/testing parameters.The list contains the government part number andthe manufacturer’s part number. The name of themanufacturer, office and manufacturing plantaddress, CAGE (Commercial and GovernmentEntity) code, assembly plant, or distributor asapplicable, is also included in the back of the QPL.The component specification will identify theappropriate quality assurance provisions such asQPL, First Article testing, or user verified testresults. NAVAIR Patuxent River(http://www.navair.navy.mil/qpl/) now has anoperational website where the latest QPL revisioncan be accessed, along with all outstanding QPLchange letters as they are written. This enables allusers to have access to the latest procurementinformation without relying on the publication of anew QPL revision. When the QPL is revised, alloutstanding QPL change letters are incorporated inthe latest revision.
NAVAIR 01-1A-505-3T.O. 00-25-255-2TM1-1500-323-24-3003 021 September 2007Page 1CONNECTORSMIL-DTL-24308Reference MaterialConnectors, Electric, Rectangular, Non-Environmental,Miniature, Polarized Shell, Rack and Panel . MIL-DTL-24308Installation Practices, Aircraft Electric and Electronic Wiring . NAVAIR 01-1A-505-1Alphabetical IndexPage No.SubjectConnector Buildup . 32Contact Crimping . 32Connector Sealing . 33Contact Insertion . 33Contact Removal . 34Wire Stripping.
MIL-DTL-28748 WP 005 01 Introduction to Connectors MIL-DTL-28748 WP 005 02 Connectors MIL-DTL-28748 WP 005 03 Connector Accessories MIL-DTL-28748 WP 006 00 Alphabetical Index for Connectors MIL-DTL-28804 WP 006 01 Introduction to Connectors MIL-DTL-28804 WP 006 02 Conne
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