021c99s2c12

021c99s2c12
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
SECTION 2
CHAPTER 12
RF CONNECTORS AND CABLING
INTRODUCTION
1.
Coaxial cable assemblies are used to carry radio
frequency (RF) power from one point to another with a
known rate of loss. An assembly consists of RF
connectors attached to coaxial cable. The coaxial cable
described in this chapter is of the flexible, solid
dielectric type, relatively small to medium size. The
characteristic impedance of most of the cable is 50
ohms, but several of the cables listed have a
characteristic impedance of 48, 53, 75 or 93 ohms.
2.
This chapter describes and illustrates the Military
Standard RF connectors and coaxial cable most
commonly used in aircraft and the recommended
methods for assembling coaxial cable to the
connectors. This section also describes and gives
instructions for assembly of miniature RF connectors to
coaxial cable, and for RF connectors used in fuelquantity-indicating systems. General procedures for
installation of coaxial cable assemblies into aircraft are
given in Section 2, Chapter 4.
REFERENCE SPECIFICATIONS
MIL-DTL-22520
Crimping Tools, Wire
Termination, General
Specification For
MIL-DTL-25516
Connectors, Electrical,
Miniature, Co-axial, Environment
Resisting Type, General
Specification For
MIL-PRF-39012
Connectors, Coaxial, Radio
Frequency, General
Specification for
DESCRIPTION
RF Connectors
4.
RF connectors are available as pin-contact or
socket-contact plugs. (See Figure 12–1.) All plugs are
cabled and are for attaching to the ends of coaxial
cables. Receptacles are designed for mounting to
panels or chassis. Receptacles are either cabled or
uncabled. The following categories of RF connectors
are used for replacement purposes, with Category D
being the preferred.
3.
The following specifications are applicable to RF
connectors and cabling:
J-STD-004
Requirements for Soldering
Fluxes
J-STD-005
Requirements for Soldering
Pastes
J-STD-006
Requirements for Electronic
Grade Solder Alloys and
Fluxed and Non-Fluxed Solid
Solders for Electronic
Soldering Applications.
MIL-C-17
MIL-C-3607
MIL-C-3643
a.
Category A - Braid clamp and solder contact.
b.
Category C - Solder centre pin or socket crimp
ferrule. See Figure 12–2.
c.
Category D - Crimp centre pin or socket, crimp
ferrule. See Figure 12–2.
5.
The following series of RF connectors are used:
a.
Cables, Radiofrequency,
Flexible and Semi-rigid, General
Specification For
BNC Series. A small, lightweight, bayonet type,
quick-connect/disconnect connector, used with
small coaxial cables, where peak voltage is not
more than 500 volts. (See Figure 12–2.)
b.
Connectors, Coaxial,
Radiofrequency, Series Pulse,
General Specification For
HN Series. A high voltage (up to 5,000 volts),
threaded coupling connector used with medium
size coaxial cables. (See Figure 12–3.)
c.
Connectors, Coaxial,
Radiofrequency, Series HN,
General Specification For
N Series. A general purpose, threaded coupling
connector used with medium size coaxial cables.
(See Figure 12–4.)
d.
C
Series.
A
bayonet
type,
quickconnect/disconnect connector used with medium
size coaxial cables. It is electrically similar to the
N series. (See Figure 12–5.)
SAE AS 8660
Silicone Compound NATO Code
Number S-736 FSC 6850
MIL-S-22473
Sealing, Locking and Retaining
Compounds, Single-Component
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
e.
Pulse Series. A high-voltage connector for pulse
or DC applications. (See Figure 12–6.) Designed
to be used with rubber dielectric pulse cables but
may be used with equivalent-size cables of other
constructions where high voltage is not required.
With ceramic inserts, peak voltage is 15,000
volts at sea level. With rubber inserts, peak
voltage is 5,000 volts at 50,000 feet, but higher
voltages may be used at lower altitudes.
f.
TNC Series. A small lightweight connector
similar to the BNC series, but having a threaded
coupling, used where a positive coupling under
vibration and a low noise level is desirable. See
Figure 12–7.)
g.
SC Series. A connector used with medium size
coaxial cables; similar to the C series, but having
a threaded coupling. (See Figure 12–8.)
Figure 12–1 RF Connectors
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–2 Typical BNC Connectors
Figure 12–4 Typical N Connectors
Figure 12–3 Typical HN Connectors
Figure 12–5 Typical C Connectors
Coaxial Cable
6.
Coaxial cable consists of an inner (centre)
conductor separated from the outer conductor, usually
called a shield, by an insulating dielectric. The cable is
protected against moisture and abrasion by a tough
outer jacket (sometimes called a sheath). See Figure
12–9 for typical coaxial cables. The inner conductor is
usually copper, either solid or stranded, and may be
bare, tin plated, or silver plated. The outer conductor
(shield) is usually a copper braid, bare, tin plated, or
silver plated, woven over the dielectric. Some coaxial
cables have a double outer conductor (double shield)
to provide extra shielding. The dielectric has two
functions: (1) it provides low loss insulation between
the inner conductor and the outer conductor, and (2) it
maintains the relative position of the inner conductor
inside the outer conductor and therefore keeps the
capacitance between the two at a constant value. The
maximum operating temperature of cables with
polyethylene dielectric is 85C. The maximum
operating temperature of cables with teflon dielectric is
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
200C. Teflon dielectric coaxial cables can replace
polyethylene dielectric cables of the same physical and
electrical characteristics.
Figure 12–8 Typical SC Connectors
Figure 12–6 Typical Pulse Connectors
Figure 12–9 Typical Coaxial Cables
GENERAL PRECAUTIONS AND PROCEDURES
Figure 12–7 Typical TNC Connectors
General Precautions
7.
A good connection depends on holding coaxial
cable and connectors to the design dimensions. Any
change in these dimensions will cause added losses to
the RF power being carried, and may also cause
radiation interference. It is important that the assembly
directions given for each connection be followed
carefully to avoid problems. The following precautions
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
are common to all assemblies of the coaxial cable and
RF connectors:
a.
When working with coaxial cable, never step on
the cable, set anything heavy on it, or bend it
sharply. This will flatten the cable and will
change its electrical characteristics. Handle
coaxial cable carefully at all times. Anything
which damages it, or which might lead to its
being damaged later, reduces the efficiency of
the system.
b.
Do not use pliers to assemble or disassemble
RF connectors.
c.
Pins and sockets for RF connectors are usually
packed unassembled. Do not misplace them.
d.
Use care in starting the braid clamp nut into a
plug or jack body, in order to prevent cross
threading.
e.
Keep soldering iron clean, smooth, and well
tinned at all times. See Section 2, Chapter 7 for
care of soldering iron.
f.
RF connectors should be physically tight on their
coaxial cable. Improperly fitting connectors will
allow movement that degrades the electrical
connection by bending, nicking, and breaking the
braided shield wires. This can cause premature
failure or equipment damage if the cable is used
in a transmitting system. Degraded signal
carrying capability can occur in a receiving or
data transfer system. If any rotational movement
is found between the RF connector and cable,
the connector shall be replaced.
g.
In areas where RF connectors are subject to
mechanical or physical strain that would tend to
break connections or braided shields, strain
relieving cable clamps may be installed to
prevent damage
General Procedures
8.
During the preparation of coaxial cable
assemblies, observe the following general procedures:
a.
Cut coaxial cable to length with long handled
cable cutters or pruning shears, making sure cut
is clean and square.
b.
Identify cable by using the methods described in
Section 2, Chapter 2.
c.
Strip outer jacket from cable by first making a cut
carefully around circumference with a sharp
knife. Then make a lengthwise slit, and peel off
jacket. Take care not to nick, cut, or damage
shield.
d.
For connectors using braid clamps comb out the
braid by using a pointed wooden dowel or a
scriber.
CAUTION
Do not damage dielectric or break shield strands.
Figure 12–10 Tinning Centre Conductor
WARNING
Failure to ensure that the centre conductor is not
shorted may result in equipment damage, personal
injury or death.
h.
Check assembled coaxial connectors with an
ohm-meter to ensure that the centre conductor is
not shorted to the shield. This can be
accomplished by placing the ohm-meter on its
highest scale, ensuring that the other end of the
coaxial cable is disconnected from the
equipment, then placing the ohm-meter leads on
the centre pin and the connector shell. The
reading should be infinite ohms. An optional
check can be performed using a time domain
reflectometer (TDR).
Figure 12–11 Tinning Inside of Contact
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
e.
To remove dielectric, cut with sharp knife around
circumference, not quite through to centre
conductor, taking care not to nick or cut strands
or otherwise damage conductor. Pull off
dielectric.
f.
For connectors using solder pins or sockets, tin
centre conductor with soldering iron as shown in
Figure 12–10.
g.
h.
Tin inside of solder type pins and sockets with a
soldering iron, as shown in Figure 12–11. (Use
untinned face of tip to prevent depositing solder
on outside of contact.)
Solder pins and sockets to centre conductor with
clean well tinned soldering iron using solder per
standard J-STD-006.
CAUTION
Contact must butt flush against dielectric before and
after soldering.
i.
When assembling the connector, always start
the clamping nut into the body by hand, then
hold the body assembly in a vice using lead or
neoprene jaw protectors. (See Figure 12–13.)
Hold body only on the flats. Do not use
excessive pressure, since the body can be easily
distorted. Tighten nut with end spanner.
SOLDERING COAXIAL CABLE TO RF
CONNECTORS
Preparation of Work
9.
The work to be soldered must be clean and free
from oxides. Remove grease by cleaning with
Stoddard’s solvent or other approved cleaner. Oxides,
if not too heavy, are removed by the action of the rosin
flux during the soldering operation. Heavily oxidised
wire cannot be cleaned by the rosin flux and should be
discarded.
Selection of Soldering Iron
10. For good soldering, it is important to select a
soldering iron of the proper size and heat capacity. For
soldering coaxial cable to RF connectors, use an iron
with a heating element rated at 65 to 100 watts, and a
tip of about 0.25 inch (6.3mm) in diameter. The
soldering tip should be shaped as shown in Figure 12–
14. Maintain this shape by dressing the tip with a mill
smooth file. Make sure the soldering iron is clean,
smooth, and well tinned. See Section 2, Chapter 7 for
detailed instructions on care and maintenance of the
soldering iron.
Figure 12–12 Soldering Contact to Coaxial Cable
Figure 12–14 Correct Shape for Soldering Iron Tip
NOTE
For soldering coaxial cable to RF connectors, tin only
one face of the tip so that areas adjacent to that being
soldered will not be coated with solder by accident.
Figure 12–13 Tightening Braid Clamp Nut into Plug
or Jack Body
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Soldering Procedure
BNC AND TNC SERIES CONNECTORS
11. See Section 2, Chapter 7 for general soldering
procedures and precautions. For soldering cable to RF
connectors, use only 60/40 tin-lead solder with a core
of rosin flux. Heat the parts to be joined, and apply the
solder at the junction of the soldering iron tip and the
work as shown in Figure 12–12. Do not apply heat
longer than is necessary to melt the solder; excessive
heat will swell the dielectric and make it difficult to
insert into the body shell. Do not allow solder to flow
over the outside of the contact. After the joint has
cooled, remove excess flux by wiping with a clean
cloth, using denatured alcohol as a solvent if
necessary.
BNC and TNC Connector Types
12. There are three versions of connectors, differing
in the method of attaching coaxial cable to the
connector body. (See Figure 12–15.)
a.
“Crimp Ferrule, Crimp Centre Pin or Socket”
consists of connector body, crimp outer ferrule,
and crimp centre pin or socket.
b.
“Crimp Ferrule, Solder Centre Pin or Socket”
consists of connector body, crimp outer ferrule,
and solder centre pin or socket.
c.
“Braid Clamp, Solder Centre Pin or Socket”
consists of connector body, nut, gasket clamp,
bushings, and solder centre pin or socket.
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–15 Attaching BNC & TNC (M39012) Crimp Connectors to Coaxial Cable
8
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–16 M22520/5-01 Crimping Tool and Hex Dies
9
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–17 M22520/1-01 Crimping Tool and Turret
10
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–18 M22520/1-01 Crimping Tool Turrets
11
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–1 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17)
Cable
Connector
Centre
or Socket
Pin
Tool
Ferrule
Crimp
Tool
Alternate
BNC (Cabled) Plug, Pin, Contact
RG-58
M39012/16-0504
RG-141
M39012/16-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/16-0013
Solder
RG-223
M39012/16-0014
Solder
RG-142
M39012/16-0503
RG-59
M39012/16-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/16-0015
Solder
RG-140
M39012/16-0015
Solder
RG-210
M39012/16-0015
Solder
RG-122
M39012/16-0501
RG-71
M39012/16-0017
Positioner
M22520/1-12
Solder
RG-302
M39012/16-0020
Solder
RG-400
M39012/16-0503
RG-180
M39012/16-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
A
B
B
B
A
A
A
A
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
B
A
A
A
B
A
A
A
A
B
A
A
B
B
BNC (Cabled) Plug, Socket, Contact
RG-58
M39012/17-0504
RG-141
M39012/17-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/17-0013
Solder
RG-223
M39012/17-0014
Solder
RG-142
M39012/17-0503
RG-59
M39012/17-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/17-0015
Solder
RG-140
M39012/17-0015
Solder
RG-210
M39012/17-0015
Solder
RG-122
M39012/17-0501
RG-71
M39012/17-0017
Positioner
M22520/1-12
Solder
RG-302
M39012/17-0020
Solder
12
B
B
B
A
A
A
A
A
B
A
A
A
A
A
B
A
A
A
A
B
A
A
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–1 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre
or Socket
RG-400
M39012/17-0503
RG-180
M39012/17-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Pin
Tool
Ferrule
Cavity
M22520/5-05
Cavity
M22520/5-05
Crimp
A
B
Tool
Alternate
Cavity
M22520/5-19
Cavity
M22520/5-41
B
B
BNC (Cabled) Receptacle, Socket, Contact, Flange Mounted
RG-58
M39012/18-0504
RG-141
M39012/18-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/18-0013
Solder
RG-223
M39012/18-0014
Solder
RG-142
M39012/18-0503
RG-59
M39012/18-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/18-0015
Solder
RG-140
M39012/18-0015
Solder
RG-210
M39012/18-0015
Solder
RG-122
M39012/18-0501
RG-71
M39012/18-0017
Positioner
M22520/1-12
Solder
RG-302
M39012/18-0020
Solder
RG-400
M39012/18-0503
RG-180
M39012/18-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
A
B
B
B
A
A
A
A
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
B
A
A
A
B
A
A
A
A
B
A
A
B
B
BNC (Cabled) Receptacle, Socket, Contact, Jam Nut Mounted
RG-58
M39012/19-0504
RG-141
M39012/19-0013
Positioner
M22520/1-12
Solder
RG-303
M39012/19-0013
Solder
RG-223
M39012/19-0011
Solder
RG-142
M39012/19-0503
RG-59
M39012/19-0015
Positioner
M22520/1-12
Solder
RG-62
M39012/19-0015
Solder
RG-140
M39012/19-0015
Solder
RG-210
M39012/19-0015
Solder
RG-122
M39012/19-0501
Positioner
M22520/1-12
Solder
RG-71
M39012/19-0017
B
B
B
A
A
A
A
A
B
A
A
A
A
B
A
A
A
A
B
A
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–1 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre
or Socket
RG-302
M39012/19-0020
Solder
RG-400
M39012/19-0503
RG-180
M39012/19-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Pin
Tool
Ferrule
Crimp
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
A
B
Tool
Alternate
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
A
Cavity
M22520/5-19
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
B
B
BNC (Cabled) Plug, Pin, Contact, Right Angle
RG-58
M39012/20-0504
RG-141
M39012/20-0006
Positioner
M22520/1-12
Solder
RG-303
M39012/20-0006
Solder
RG-223
M39012/20-0007
Solder
RG-142
M39012/20-0503
RG-122
M39012/20-0501
RG-302
M39012/20-0010
Positioner
M22520/1-12
Positioner
M22520/1-12
Solder
RG-400
M39012/20-0503
RG-180
M39012/20-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
B
B
B
A
B
A
A
B
A
A
A
B
B
A
B
B
TNC (Cabled) Plug, Pin, Contact
RG-58
M39012/26-0504
RG-316
M39012/26-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/26-0010
Solder
RG-223
M39012/26-0011
Solder
RG-142
M39012/26-0503
RG-59
M39012/26-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/26-0012
Solder
RG-174
M39012/26-0022
Solder
RG-210
M39012/26-0012
Solder
RG-122
M39012/26-0501
RG-71
M39012/26-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/26-0021
Solder
RG-400
M39012/26-0503
RG-180
M39012/26-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
14
B
B
B
A
A
A
B
A
B
A
A
A
B
A
A
A
B
A
A
B
A
B
A
A
B
B
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–1 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre
or Socket
Pin
Tool
Ferrule
Crimp
Tool
Alternate
TNC (Cabled) Plug, Socket, Contact
RG-58
M39012/27-0504
RG-316
M39012/27-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/27-0010
Solder
RG-223
M39012/27-0011
Solder
RG-142
M39012/27-0503
RG-59
M39012/27-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/27-0012
Solder
RG-174
M39012/27-0022
Solder
RG-210
M39012/27-0022
Solder
RG-122
M39012/27-0501
RG-71
M39012/27-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/27-0021
Solder
RG-400
M39012/27-0503
RG-180
M39012/27-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
B
B
B
A
A
A
B
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
B
A
A
B
A
A
B
A
B
A
A
B
B
TNC (Cabled) Receptacle, Socket, Contact, Jam Nut Mounted
RG-58
M39012/28-0504
RG-316
M39012/28-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/28-0010
Solder
RG-223
M39012/28-0011
Solder
RG-142
M39012/28-0503
RG-59
M39012/28-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/28-0012
Solder
RG-174
M39012/28-0022
Solder
RG-210
M39012/28-0012
Solder
RG-122
M39012/28-0501
RG-71
M39012/28-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/28-0021
Solder
RG-400
M39012/28-0503
RG-180
M39012/28-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
B
B
B
A
A
A
A
A
B
A
A
A
B
B
A
A
B
A
A
B
A
B
A
A
B
B
15
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–1 BNC & TNC Series M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre
or Socket
Pin
Tool
Ferrule
Crimp
Tool
Alternate
TNC (Cabled) Receptacle, Socket, Contact, Flange Mounted
RG-58
M39012/29-0504
RG-316
M39012/29-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/29-0010
Solder
RG-223
M39012/29-0011
Solder
RG-142
M39012/29-0503
RG-59
M39012/29-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/29-0012
Solder
RG-174
M39012/29-0022
Solder
RG-210
M39012/29-0012
Solder
RG-122
M39012/29-0501
RG-71
M39012/29-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/29-0021
Solder
RG-400
M39012/29-0503
RG-180
M39012/29-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
Cavity
M22520/5-05
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-63
Cavity
M22520/5-19
Cavity
M22520/5-05
Cavity
M22520/5-05
A
B
B
B
A
A
A
B
A
B
A
A
A
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
Cavity
M22520/5-19
Cavity
M22520/5-41
Cavity
M22520/5-11
Cavity
M22520/5-11
Cavity
M22520/5-19
Cavity
M22520/5-13
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-13
Cavity
M22520/5-41
Cavity
M22520/5-15
Cavity
M22520/5-13
Cavity
M22520/5-19
Cavity
M22520/5-41
B
B
A
A
B
A
A
B
A
B
A
A
B
B
TNC (Cabled) Plug, Pin, Contact, Right Angle
RG-58
M39012/30-0504
RG-316
M39012/30-0022
Positioner
M22520/1-12
Solder
RG-303
M39012/30-0010
Solder
RG-223
M39012/30-0011
Solder
RG-142
M39012/30-0503
RG-59
M39012/30-0012
Positioner
M22520/1-12
Solder
RG-62
M39012/30-0012
Solder
RG-174
M39012/30-0022
Solder
RG-210
M39012/30-0012
Solder
RG-122
M39012/30-0501
RG-71
M39012/30-0014
Positioner
M22520/1-12
Solder
RG-302
M39012/30-0021
Solder
RG-400
M39012/30-0503
RG-180
M39012/30-0502
Positioner
M22520/1-12
Positioner
M22520/1-12
16
B
B
B
A
A
A
B
A
B
A
A
A
B
B
A
A
B
A
A
B
A
B
A
A
B
B
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Attaching Improved BNC Connectors to Coaxial
Cable
13. When attaching improved BNC connectors to
coaxial cable (see Figure 12–19), use the following
procedure:
NOTE
i.
Push cable assembly into connector body as far
as it will go. Make sure gasket is properly
seated, with sharp edge of sleeve clamp
entering gasket groove. Slide nut into connector
body and fasten in vice. Start nut by hand and
tighten with end spanner until enough pressure
is applied to make a good seal by splitting the
gasket. (See Figure 12–13.)
While attaching connector, observe all general
precautions and procedures listed in paragraphs 7
and 8.
CAUTION
Do not nick or damage shield.
a.
Remove 7.8mm of outer jacket, exposing shield.
b.
Slide nut and gasket (V-groove away from nut),
in that order, onto jacket. Slide sleeve clamp
over tapered shield until inside shoulder of clamp
butts flush against cut end of jacket.
c.
Comb out shield. Use care to prevent breaking
shield strands.
d.
Strip dielectric 4.7mm from edge of jacket to
edge of dielectric exposing centre conductor.
CAUTION
Do not nick or damage centre conductor.
e.
Comb shield back smoothly over sleeve clamp,
and trim to 2.3mm with scissors.
f.
Trim dielectric to 3mm from shield, and cut off
centre conductor to 3mm from edge of dielectric.
g.
Tin centre conductor as shown in Figure 12–10.
Tin inside of pin or socket as shown in Figure
12–11.
h.
Slip contact over centre conductor so that
contact butts flush against dielectric. For RG62/U and 71/U, add bushing. Solder, using a
clean, well tinned, soldering iron. Contact must
still be flush against dielectric after solder has
cooled; if it is not, remake the joint. (See Figure
12–12.)
CAUTION
Ensure that correct contact is used. a male contact
always goes into a plug body, and a female contact
always goes into a jack body.
Figure 12–19 Attaching Improved BNC Connectors to
Coaxial Cable
17
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Attaching BNC Connectors with Captivated Contacts
to Coaxial Cable
14. When attaching BNC connectors with captivated
contacts to coaxial cable (see Figure 12–20), follow
this procedure:
NOTE
While attaching connector, observe all general
precautions and procedures listed in paragraphs 7
and 8.
a.
Remove 9.5mm of outer jacket, exposing shield,
for all except plugs 31-301 and 31-304; strip
jacket for these plugs 10.7mm. Disassemble nut,
grooved gasket, and sleeve clamp from plug or
jack body. Slide nut and grooved gasket (Vgroove away from nut), in that order, over shield
onto jacket.
CAUTION
Do not nick or damage shield.
b.
Comb out shield. Use care to prevent breaking
shield strands.
c.
Cut off cable dielectric to 4.7mm for cables RG55/U, 58/U, 59/U, 140/U, 141/U, and 142/U. Cut
to 0.156 inch (4mm) for cables RG-62/U and
RG-71/U.
CAUTION
Do not nick or damage centre conductor.
d.
Comb shield back smoothly over sleeve clamp
and trim to proper length; form evenly over
clamp. Tin centre conductor as shown in Figure
12–10. Slide on contact. These parts must butt
as shown. When attaching to cables RG-62/U
and RG-7l/U, add insulator bushing.
e.
Solder pin or socket to centre conductor (see
Figure 12–14). Remove excess flux and solder
from outside of contact.
f.
Slide front insulator over contact and butt against
contact shoulder. Do not reverse direction of
insulator.
g.
Insert cable assembly into connector body. Make
sure that the sharp edge of the clamp seats
properly in the gasket. Tighten the nut, holding
the body stationary. (See Figure 12–13.)
18
Figure 12–20 Attaching BNC Connectors With
Captivated Contacts to Coaxial Cable
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
C AND SC SERIES CONNECTORS
15. There are three versions of C and SC
connectors, differing in the method of attaching coaxial
cable to the connector body.
c.
As shown, (see Figure 12–22) flare end of cable
braid slightly to facilitate insertion onto inner
ferrule. Do not comb out braid.
d.
Place contact on cable centre conductor so that
it butts against cable dielectric. Centre conductor
should be visible through inspection hole. Crimp
or solder the pin or socket in place as follows:
e.
Crimp Method. Select appropriate tool from
Table 12–2. Crimp centre pin or socket. (See
Figure 12–16.)
f.
Solder Method. Soft solder contact to cable
centre conductor. Do not get any solder on
outside surfaces of contact. Avoid excessive
heat to prevent swelling of dielectric.
g.
Install cable assembly into body assembly so
that inner ferrule portion slides under braid. Push
cable assembly forward until contact snaps into
place in insulator. Slide outer ferrule over braid
and up against connector body. Crimp outer
ferrule using cavity of die set specified in Table
12–2. (See Figure 12–16.)
Attaching Series C and SC Crimp Connectors to
Coaxial Cable
16. When attaching C and SC connectors to coaxial
cable (see Figure 12–21), use the following procedure:
a.
Select correct connector for cable. See Table
12–2.
CAUTION
Do not nick or damage braid, dielectric, or centre
conductor.
b.
Strip cable jacket, braid, and dielectric to
dimensions shown 0.25mm (see Figure 12–22).
All cuts are to be sharp and square. Tinning of
centre conductor is not necessary if contact is to
be crimped. For solder method, tin centre
conductor avoiding excessive heat. Slide outer
ferrule onto cable as shown.
Figure 12–21 Attaching Series C and SC Connectors to Coaxial Cable
Table 12–2 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
C (Cabled) Plug, Pin, Contact
RG-212
M39012/06-0027
Solder
RG-304
M39012/06-0027
Solder
RG-213
M39012/06-0028
Solder
RG-214
M39012/06-0029
Solder
RG-165
M39012/06-0028
Solder
RG-225
M39012/06-0030
Solder
RG-11
M39012/06-0031
Solder
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
A
A
A
A
A
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
A
A
A
A
A
A
19
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–2 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
C (Cabled) Plug, Socket, Contact
RG-212
M39012/07-0014
Solder
RG-304
M39012/07-0014
Solder
RG-213
M39012/07-0011
Solder
RG-214
M39012/07-0012
Solder
RG-165
M39012/07-0011
Solder
RG-225
M39012/07-0013
Solder
RG-11
M39012/07-0015
Solder
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
A
A
A
A
A
A
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
A
A
A
A
A
A
A
C (Cabled) Receptacle, Socket, Contact, Flange Mounted
RG-212
M39012/08-0013
Solder
RG-304
M39012/08-0013
Solder
RG-213
M39012/08-0010
Solder
RG-214
M39012/08-0011
Solder
RG-165
M39012/08-0010
Solder
RG-225
M39012/08-0012
Solder
A
A
A
A
A
A
A
A
A
A
C (Cabled) Pin, Contact, Right Angle
RG-213
M39012/10-0006
Solder
RG-214
M39012/10-0007
Solder
RG-165
M39012/10-0006
Solder
RG-225
M39012/10-0008
Solder
A
A
A
A
A
A
C (Cabled) Socket, Contact, Receptacle, Jam Nut Rear Mounted
RG-212
M39012/11-0012
Solder
RG-304
M39012/11-0012
Solder
RG-213
M39012/11-0013
Solder
RG-214
M39012/11-0014
Solder
RG-165
M39012/11-0013
Solder
RG-225
M39012/11-0015
Solder
RG-11
M39012/11-0016
Solder
20
A
A
A
A
A
A
A
A
A
A
A
A
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–2 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
SC (Cabled) Plug, Pin, Contact
RG-212
M39012/35-0010
Solder
RG-304
M39012/35-0010
Solder
RG-213
M39012/35-0502
M22520/1-14
RG-214
M39012/35-0501
M22520/1-14
RG-165
M39012/35-0011
Solder
RG-225
M39012/35-0501
M22520/1-14
RG-11
M39012/35-0013
Solder
RG-144
M39012/35-0013
Solder
RG-400
M39012/35-0503
M22520/1-14
RG-142
M39012/35-0503
M22520/1-14
RG-393
M39012/35-0501
M22520/1-14
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
SC (Cabled) Plug, Socket, Contact
RG-212
M39012/36-0009
Solder
RG-304
M39012/36-0009
Solder
RG-213
M39012/36-0502
M22520/1-14
RG-214
M39012/36-0501
M22520/1-14
RG-165
M39012/36-0007
Solder
RG-225
M39012/36-0501
M22520/1-14
RG-11
M39012/36-0010
Solder
RG-144
M39012/36-0010
Solder
RG-400
M39012/36-0503
M22520/1-14
RG-142
M39012/36-0503
M22520/1-14
RG-393
M39012/36-0501
M22520/1-14
A
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
A
A
A
21
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–2 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
SC (Cabled) Receptacle, Socket, Contact, Flange Mounted Rear
RG-212
M39012/38-0008
Solder
RG-304
M39012/38-0008
Solder
RG-213
M39012/38-0502
M22520/1-14
RG-214
M39012/38-0501
M22520/1-14
RG-165
M39012/38-0006
Solder
RG-225
M39012/38-0501
M22520/1-14
RG-400
M39012/38-0503
M22520/1-14
RG-142
M39012/38-0503
M22520/1-14
RG-393
M39012/38-0501
M22520/1-14
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
A
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-19
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-57
A
A
A
A
A
A
A
A
A
SC (Cabled) Plug, Pin, Contact, Right Angle
RG-213
M39012/39-0502
M22520/1-13
RG-214
M39012/39-0501
M22520/1-13
RG-165
M39012/39-0004
Solder
RG-225
M39012/39-0501
M22520/1-13
RG-400
M39012/39-0503
M22520/1-13
RG-142
M39012/39-0503
M22520/1-13
RG-393
M39012/39-0501
M22520/1-13
A
A
A
B
B
A
A
A
A
A
A
A
SC (Cabled) Receptacle, Socket, Contact, Jam Nut Rear Mounted
RG-212
M39012/40-0014
Solder
RG-304
M39012/40-0014
Solder
RG-213
M39012/40-0502
M22520/1-14
RG-214
M39012/40-0501
M22520/1-14
RG-217
M39012/40-0018
Solder
RG-165
M39012/40-0015
Solder
RG-225
M39012/40-0501
M22520/1-14
RG-11
M39012/40-0021
Solder
RG-144
M39012/40-0021
Solder
RG-216
M39012/40-0017
Solder
RG-400
M39012/40-0503
M22520/1-14
22
A
A
A
A
A
A
A
B
A
A
A
A
A
A
A
A
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–2 Series C and SC M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
SC (Cabled) Receptacle, Socket, Contact, Jam Nut Rear Mounted (Continued)
RG-142
M39012/40-0503
M22520/1-14
RG-393
M39012/40-0501
M22520/1-14
Cavity
M22520/5-19
Cavity
M22520/5-61
B
A
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
HN SERIES CONNECTORS
HN Connector Types
17. There are two versions of HN connectors with
differing methods of attaching coaxial cable to the
connector body. See Figure 12–3 for typical examples
of HN connectors. Table 12–3 lists the more common
connectors in the HN series and shows the coaxial
cables associated with each.
NOTE
The HN series of RF connectors are used for
replacement purposes only.
a.
Improved Version. Consists of a plug or jack
body assembled to coaxial cable with nut,
gasket, and braid clamp (see Figure 12–23).
Plug UC-59E/U and jack UG-60E/U are typical of
this version.
b.
Captivated Contact Version Consists of a plug
or jack body assembled to coaxial cable with nut,
gland, gasket, clamp, sleeve, and front and rear
insulators (see Figure 12–24). Plug UG-l213/U
and jack UG-l214/U are typical of this version.
Attaching Improved HN Connectors to Coaxial Cable
18. When attaching improved HN connectors to
coaxial cable (see Figure 12–25), use the following
procedure:
NOTE
While attaching connector, observe all general
precautions and procedures listed in paragraphs 7
and 8.
a.
b.
Disassemble nut, grooved gasket and braid
clamp from plug or jack body. (See Figure 12–
23.)
Remove 17.5mm from outer jacket, exposing
shield. Slide nut and gasket, in that order, over
shield onto jacket. Make sure that groove in
gasket faces away from the nut.
Figure 12–22 Cable Crimping Instructions
CAUTION
Do not nick or damage shield or centre conductor
c.
Comb out shield and strip dielectric 6.3mm.
23
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
d.
Slide clamp over shield until inside shoulder of
clamp butts flush against cut end of jacket.
e.
Fold shield strands back over clamp without
overlaps. Trim strands with scissors, so that all
strands end at end of clamp taper.
f.
Tin centre conductor as shown in Figure 12–10.
g.
Tin inside of contact (male or female) as shown
in Figure 12–11.
h.
Slip pin or socket over centre conductor so that
contact butts flush against dielectric. Solder,
using a clean, well tinned, soldering iron.
Contact must still be flush against dielectric after
solder has cooled; if not, remake the joint. (See
Figure 12–12).
a.
Disassemble nut, gland, gasket, clamp, sleeve,
and front and rear insulators front plug or jack
body. (See Figure 12–24.)
b.
Slide nut and gland onto jacket. Make sure that
sharp edge of gland is toward end of cable. Then
slide gasket onto jacket, with "V" groove toward
gland. Remove 4cm from outer jacket, exposing
shield. Slide clamp over the braid until inside
shoulder of clamp butts flush against end of
jacket.
CAUTION
Take care not to nick or damage shield or centre
conductor
c.
Comb out shield and cut off dielectric 23mm
from end of jacket.
d.
Fold shield strands back over clamp without
overlaps. Trim strands with scissors so that all
strands end at end of clamp taper.
e.
Tin centre conductor as shown in Figure 12–10,
using minimum amount of heat.
f.
Slide sleeve and rear insulator over cable
dielectric. Slip contact over centre conductor.
Rear insulator must seat against cable dielectric,
and contact shoulder must be flush with insulator
face. Solder contact to centre conductor. (See
Figure 12–12.)
g.
For jacks only, install front insulator.
CAUTION
Ensure correct pin or socket is used. a male pin
always goes into a plug body, and a female socket
always goes into a jack body.
i.
Push cable assembly into connector body as far
as it will go. Slide gasket into connector body;
make sure gasket is properly seated with sharp
edge of braid clamp entering groove in gasket.
Slide nut into connector body and fasten body in
vice (see Figure 12–13). Start nut by hand and
tighten with spanner until moderately tight.
NOTE
Gasket should be cut in half during tightening.
CAUTION
Attaching HN Connectors with Captivated Contacts
to Coaxial Cable
19. When attaching HN connectors with captivated
contacts to coaxial cable (see Figure 12–26), use the
following procedure:
NOTE
While attaching connector, observe all general
precautions and procedures listed in paragraphs 7
and 8.
Ensure that correct pin or socket is used. a male pin
always goes into a plug body, and a female socket
always goes into a jack body.
h.
Push cable assembly carefully into connector
body as far as it will go. Make sure that sharp
edge of gland remains in the gasket groove,
Tighten nut with spanner, holding body
stationary. (See Figure 12–13.)
NOTE
Gasket should be cut in half during tightening.
24
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–23 Improved HN Connectors - Exploded View
Table 12–3 HN Series Connectors (MIL-C-3643) with Associated Cables
Plug
Jack
Panel Jack
*UG-59E/U
**UG-1213/U
*UG-60E/U
**UG-1214/U
*UG-61E/U
**UG-1215/U
*Improved Version
For Use With
Cable Types
RG8/U,
213/U AND 214/U
9/U,
**Captivated Contact Version
Figure 12–24 HN Connectors with Captivated Contacts - Exploded View
25
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
N SERIES CONNECTORS
N Connector Types
20. There are three versions of N connectors,
differing in method of attaching coaxial cable to the
connector body. Refer to paragraph 4.
Attaching N Type Crimp Connectors, M39012, to
Coaxial Cables
21. N Type Crimp Connectors are attached as
follows:
a.
Figure 12–25 Attaching Improved HN Connectors to
Coaxial Cable
Select correct connector for cable Table 12–4.
Figure 12–27 N Crimp Connectors
CAUTION
The 50 ohm N type RF connectors are not compatible
and should not be mated.
NOTE
Some 70 ohm coaxial cables do not have suitable 70
ohm
connectors
and
therefore
equipment
manufacturers may have substituted compatible 50
ohm connectors. This practice is accepted, but
physical matching of male and female connectors is
essential.
Figure 12–26 Attaching HN Connectors with
Captivated Contacts to Coaxial Cable
26
b.
Strip cable jacket, braid, and dielectric to
dimensions shown (see Figure 12–28). All cuts
are to be sharp and square. Important: Do not
nick braid, dielectric, and centre conductor.
Tinning of centre conductor is not necessary if
contact is to be crimped. For solder method, tin
centre conductor avoiding excessive heat.
c.
Slide outer ferrule onto cable as shown. Flare
slightly end of cable braid as shown to facilitate
insertion onto inner ferrule.
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
h.
Slide outer ferrule over braid and up against
connector body. Crimp outer ferrule using cavity
of Die Set specified in Table 12–4. (See Figure
12–16.)
Attaching N Type Connectors with Captivated
Contacts to Coaxial Cables
22. When attaching captivated contact N Type
connectors to coaxial cable (see Figure 12–29), use
the following procedure:
NOTE
While attaching connector, observe all general
precautions and procedures listed in paragraphs 7
and 8.
CAUTION
Do not nick shield or centre conductor.
a.
Remove 9.1mm of outer jacket, exposing shield.
b.
Comb out shield and cut off cable dielectric
3.1mm from end of jacket.
c.
Disassemble nut, gasket, clamp, washer, and
insulator from plug or jack body.
d.
Place contact on cable centre conductor so it
butts against cable dielectric. Centre conductor
should be visible through inspection hole in
contact. Crimp or solder centre pin or socket in
place as follows:
Taper shield toward centre conductor, and wrap
with tape. Slide nut and gasket, in that order,
over tapered shield onto jacket. Make sure
grooved side of gasket faces away from nut.
Then slide clamp over tapered shield and push
back against cable jacket.
e.
Remove tape and fold shield strands back over
clamp taper without overlaps. Trim shield with
scissors so that strands end at end of clamp
taper.
e.
Crimp Method. Select appropriate tool from
Table 12–4. Crimp centre pin or socket (see
Figure 12–16).
f.
Check that exposed dielectric is 1.1mm beyond
shield.
f.
Solder Method. Soft solder contact to cable
centre conductor. Do not get any solder on
outside surface of contact. Avoid excessive heat
to prevent swelling of dielectric.
g.
Tin centre conductor as shown in Figure 12–10,
using minimum amount of heat.
h.
Slide on washer, rear insulator, and contact, so
that the counter-bored end of the rear insulator
butts flush against the dielectric, and the pin or
socket shoulder butts flush against the rear
insulator, Solder the contact to centre conductor.
(See Figure 12–12.)
Figure 12–28 Cable Stripping Instructions
NOTE
Do not comb out braid.
d.
g.
Install cable assembly into body assembly so
inner ferrule portion slides under braid. Push
cable assembly forward until contact snaps into
place in insulator.
27
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–4 Series N M39012 Connectors and Associated Cables (MIL-C-17)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
N (Cabled) Plug, Pin, Contact
RG-212
M39012/01-0016
Solder
RG-222
M39012/01-0016
Solder
RG-213
M39012/01-0502
M22520/1-13
RG-214
M39012/01-0501
M22520/1-13
RG-217
M39012/01-0019
Solder
RG-165
M39012/01-0021
Solder
RG-225
M39012/01-0501
M22520/1-13
RG-11
M39012/01-0023
Solder
RG-144
M39012/01-0023
Solder
RG-216
M39012/01-0024
Solder
RG-6
M39012/01-0027
Solder
RG-400
M39012/01-0503
M22520/1-13
RG-142
M39012/01-0503
M22520/1-13
RG-393
M39012/01-0501
M22520/1-13
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
A
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
A
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
A
B
B
B
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
A
N (Cabled) Plug, Socket, Contact
RG-212
M39012/02-0019
Solder
RG-222
M39012/02-0019
Solder
RG-213
M39012/02-0502
M22520/1-13
RG-214
M39012/02-0501
M22520/1-13
RG-217
M39012/01-0022
Solder
RG-165
M39012/02-0024
Solder
RG-225
M39012/02-0501
M22520/1-13
RG-11
M39012/02-0026
Solder
RG-144
M39012/02-0026
Solder
RG-216
M39012/02-0039
Solder
RG-6
M39012/02-0040
Solder
RG-400
M39012/02-0503
M22520/1-13
RG-142
M39012/02-0503
M22520/1-13
RG-393
M39012/02-0501
M22520/1-13
28
A
A
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
A
A
A
A
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–4 Series N M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
N (Cabled) Receptacle, Socket, Contact, Flange Mounted
RG-212
M39012/02-0027
Solder
RG-222
M39012/02-0027
Solder
RG-213
M39012/02-0512
M22520/1-13
RG-214
M39012/02-0511
M22520/1-13
RG-165
M39012/02-0041
Solder
RG-225
M39012/02-0511
M22520/1-13
RG-11
M39012/02-0042
Solder
RG-144
M39012/02-0042
Solder
RG-216
M39012/02-0030
Solder
RG-6
M39012/02-0043
Solder
RG-400
M39012/02-0513
M22520/1-13
RG-142
M39012/02-0513
M22520/1-13
RG-393
M39012/02-0511
M22520/1-13
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
M22520/5-27
A
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
A
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
A
A
N (Cabled) Receptacle, Socket, Contact Jam Nut, Mounted
RG-212
M39012/03-0013
Solder
RG-222
M39012/03-0013
Solder
RG-213
M39012/03-0502
M22520/1-14
RG-214
M39012/03-0501
M22520/1-14
RG-217
M39012/03-0016
Solder
RG-165
M39012/03-0018
Solder
RG-225
M39012/03-0501
M22520/1-14
RG-11
M39012/03-0020
Solder
RG-144
M39012/03-0020
Solder
RG-216
M39012/03-0021
Solder
RG-6
M39012/03-0023
Solder
RG-400
M39012/03-0503
M22520/1-14
RG-142
M39012/03-0503
M22520/1-14
RG-393
M39012/03-0501
M22520/1-14
A
A
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
A
A
A
A
29
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–4 Series N M39012 Connectors and Associated Cables (MIL-C-17) (Continued)
Cable
Connector
Centre Pin
or Socket
Tool Crimp
Ferrule
Tool
Alternate
N (Cabled) Plug, Right Angle
RG-212
M39012/05-0016
Solder
RG-222
M39012/05-0016
Solder
RG-213
M39012/05-0502
M22520/1-13
RG-214
M39012/05-0501
M22520/1-13
RG-165
M39012/05-0015
Solder
RG-225
M39012/05-0501
M22520/1-13
RG-11
M39012/05-0014
Solder
RG-144
M39012/05-0014
Solder
RG-216
M39012/05-0017
Solder
RG-6
M39012/05-0013
Solder
RG-400
M39012/05-0503
M22520/1-13
RG-142
M39012/05-0503
M22520/1-13
RG-393
M39012/05-0501
M22520/1-13
30
Cavity
M22520/5-35
Cavity
M22520/5-35
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-61
Cavity
M22520/5-35
Cavity
M22520/5-19
Cavity
M22520/5-19
Cavity
M22520/5-61
A
A
A
A
A
A
A
A
A
A
B
B
A
Cavity
M22520/5-29
Cavity
M22520/5-29
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-25
Cavity
M22520/5-29
Cavity
M22520/5-57
Cavity
M22520/5-57
Cavity
M22520/5-25
A
A
A
A
A
A
A
A
A
A
A
A
A
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
k.
CAUTION
Ensure that the correct pin or socket is used. a pin
always goes into a plug body, and a socket always
goes into a jack body.
i.
j.
Slide front insulator over pin or socket; make
sure the counter-bored end of the insulator is
toward the mating end of the contact.
Push the cable assembly into the connector
body. Make sure that the sharp edge of the
clamp seats properly in the gasket. Tighten the
nut, holding the body stationary. (See Figure
12–13.)
WARNING
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft.
PULSE SERIES CONNECTORS
Pulse Connector Types
23. There are two versions of pulse connectors.
These versions differ in the material of the inserts,
and in the method of attaching the coaxial cable to
the connector body. See Figure 12–6 for typical
examples of pulse connectors. Table 12–5 lists the
more common connectors in the pulse series and
shows the coaxial cables associated with each.
a.
WARNING
Use of nitrogen with hot air gun in an enclosed area
can be hazardous. Ensure area is well ventilated.
Cut two lengths of heat shrink, one 7cm and
one 8cm. Slide the 7cm piece of heat shrink
over the connector covering only the back
15.8mm of it. Heat the heat shrink until it is
secure on the cable and connector. Repeat the
same procedure with the 8cm piece of heat
shrink.
Ceramic Insert Version. Consists of a plug or
jack body assembled to coaxial cable with nut,
cable clamp, washer, and corona shield. (See
Figure 12–30). Plug UG-174/U is typical of this
version.
Rubber Insert Version consists of a plug or
jack body assembled to coaxial cable with
clamp, washer, gasket, sleeve, and ferrule.
(See Figure 12–31). Plug UG-l80A/U and jack
UG-182A/U are typical of this version.
Figure 12–29 Attaching N Connectors with Captivated Contacts to Coaxial cable
31
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–30 Pulse Connector - Ceramic Insert
32
Figure 12–31 Pulse Connector - Rubber Insert
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–5 Pulse Series Connectors (MIL-C-3643) with Associated Cables
Plug
Jack
Panel Jack
For Use With
Cable Types
Ceramic Insert:
UG-34/U
UG-174/U
RG-25/U
RG-28/U
Rubber Insert:
UG-180A/U
UG-182A/U
UG-1086/U
UG-181A/U
Attaching Ceramic Insert Pulse Connectors to
Coaxial Cable
NOTE
first shield. Trim shield strands 1.5mm below
diameter of cable clamp flange.
e.
Slide brass washer carefully over second shield
against fanned-out shield. Remove second
shield to 4.7mm from brass washer for RG-281U
cable, and 31mm for RG-25/U cable, exposing
conducting rubber.
f.
Remove layer of conducting rubber to 9.5mm
from face of brass washer for RG-28/U cable
and 4.7mm for RG-25/U cable by making small
slit at end of cable core and removing
conducting rubber with dull knife. Scrape
insulating rubber underneath to remove any
traces of conducting rubber.
The following procedure is for assembling UG-l74/U
plug to RG-28/U cable, and UG-34/U plug to RG-25/U
cable. Both assemblies differ in dimensions. Both
cables have a double shield.
24. When attaching ceramic insert pulse connectors
to coaxial cable (see Figure 12–32), use the following
procedure:
NOTE
Observe all general precautions and procedures
listed in paragraphs 7 and 8.
a.
b.
Disassemble nut, cable clamp, washer, and
corona shield from plug or jack body. (See
Figure 12–30.)
Slide nut and cable clamp, in that order, onto
cable jacket. Remove 9.2cm of outer jacket of
RG-28/U cable and 7cm of RG-2S/U cable,
exposing first shield.
CAUTION
Do not damage insulating rubber.
g.
Slide corona shield over conducting rubber and
under second shield until straight part of corona
shield enters hole in brass washer approximately
1.5mm.
h.
Solder second shield to brass washer and to
corona shield. Remove excess flux. Remove
insulating rubber and conducting rubber
underneath it to 6.7cm from face of brass
washer for RG-28/U cable and 27mm for RG25/U cable, exposing centre conductor. Taper
rubber down to conductor 9.5mm for RG-28/U or
6.3mm for RG-25/U. Tin centre conductor.
Remove excess flux.
i.
Scrape nickel plating from recess of plug into
which brass washer fits. Remove set screws.
CAUTION
Do not nick shield.
c.
Remove first shield to 0.76mm from cut edge of
outer jacket exposing insulating tape.
d.
Comb out shield and bend at right angles, as
shown. Remove insulating tape even with cut
edge of outer jacket, exposing second shield.
Slide cable clamp forward against fanned-out
RG-25/U, 64/U, 77/U,
78/U & 88/U
33
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–32 Assembly of Ceramic Insert Pulse Connector
34
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
j.
Slide cable assembly into plug body, allowing
cable clamp to slide back on cable. Solder brass
washer to recess in plug by flowing solder into
space between washer and groove. Remove
excess flux.
k.
Slide cable clamp against washer, and nut onto
plug body. Start nut by hand and tighten with
spanner. Hold plug with strap wrench to prevent
it from turning.
l.
Cut off excess conductor protruding beyond
contact pin. Solder conductor to contact by
flowing solder down into hole. Leave a drop of
solder on end of contact and file smooth.
Remove excess flux.
m. Insert bleeder tube in top hole so it is vertical.
Insert pressure gun in lower hole and fill plug
cavity with SAE AS 8660 compound until
material oozes from bleeder tube. Replace set
screws and stake with prick punch.
Attaching Rubber Insert Pulse Connectors to
Coaxial Cable
e.
NOTE
Cable RG-25A/U, 64A/U, 78/U, and 88A/U have a
thin layer of red insulating rubber over the cable core.
Do not remove this layer. Cables RG-25/U and RG64/U have a thin layer of black conducting rubber
over the cable core. Remove this layer to 1.5mm from
ferrule very carefully with a sharp knife.
f.
25. When attaching rubber insert pulse connectors
to coaxial cable (see Figure 12–33), use the following
procedure:
NOTE
While attaching connector, observe all general
precautions and procedures listed in paragraphs 7
and 8.
a.
Disassemble nut, washer, gasket, sleeve, and
ferrule from plug or jack body. (See Figure 12–
31.)
Ensure correct pin or socket is used. a pin always
goes into a plug body, and a socket always goes into
a jack body.
g.
Push cable core into plug or jack body as far as
it will go. Insert sleeve and tighten as far as it will
go against ferrule, holding body with spanner so
it will not turn. (See Figure 12–13.)
h.
Insert gasket, then washer into sleeve. Install nut
on sleeve and tighten until gasket deforms
around cable to hold it securely.
Do not nick shield or cut cable core.
Slide nut, washer, gasket, and sleeve, in that
order onto cable jacket. Remove 6.7cm of outer
jacket exposing shield.
c.
Cut shield to 9.5mm from cut edge of outer
jacket, exposing cable core.
d.
Push ferrule over cable core and under shield.
Tin inside of pin or socket as shown in Figure
12–11. Slip contact over centre conductor so
that contact butts flush against cable cow.
Solder, using a clean well tinned soldering iron.
Pin or socket must still be flush against cable
core after solder has cooled; if it is not, remake
this joint. (See Figure 12–12.) Remove excess
flux.
CAUTION
CAUTION
b.
Solder shield carefully to ferrule all around its
circumference. Ensure solder flows through to all
shields. If it is necessary to solder shields
separately, fold back outer shield. Solder inner
shield, then bring forward outer shield and solder
separately on top of inner shield. After solder
has cooled, grasp cable in left hand, ferrule in
right hand, and give several quick pulls to
remove' any slack in shield. Remove excess
flux. Remove cable core with sharp square cut
leaving 28.5mm from ferrule for connection to
UG-180A/U and 25mm from ferrule for
connection to UG-181A or 182A/U. Trim centre
conductor to 4.7mm and tin.
35
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
connectors consist of a plug or jack body assembled to
coaxial cable with clamp nut, braid clamp, and insulator
bushing. (See Figure 12–34.)
Attaching MB Connectors to Coaxial Cable
27. The assembly procedure differs according to the
cable used. For assembly to cables RG-58/U and RG141/U, the procedure is as follows (see Figure 12–35):
a.
Remove cable jacket to A dimension given in
Table 12–7. Insert clamp nut over cable jacket
and braid clamp over braid wire.
b.
Comb out braid wire, fold back over braid clamp,
and trim to length. Cut off cable dielectric to
dimension C in Table 12–7, and tin exposed
conductor. If solderless contact is used, omit
tinning.
c.
Insert contact over conductor. The end of the
solderless contact with the shortest slot is
inserted over the conductor. If a solder contact is
used, solder it to the conductor, and remove
excess solder from the outside of the contact.
d.
Insert assembly minus clamp nut into body and
rotate slightly to make sure braid clamp is
seated. When assembling straight plugs, insert
insulator over contact before assembly into
body. Thread clamp nut into body and tighten
nut, holding body stationary.
28. For assembly into cables RG-59/U and 62/U, the
procedure is as follows:
a.
Remove cable jacket to dimension A in Table
12–7. Insert clamp nut over cable so that internal
shoulder seats against end of cable jacket. Insert
braid clamp over wire.
b.
Comb out braid wires, fold back over braid
clamp, and trim to length. Cut off cable dielectric
to dimension C in Table 12–7, and tin exposed
conductor. If solderless contact is used, omit
tinning.
c.
Insert contact over conductor. The end of the
solderless contact with the shortest slot is
inserted over the conductor. Insert insulator
bushing over contact if cable RG-62/U is being
used. If solder contact is used, solder it to the
conductor, and remove excess solder from the
outside of the contact.
d.
Insert insulator over contact. Insert assembly
minus clamp nut into body and rotate slightly to
make sure braid clamp is seated. Thread clamp
nut into body and tighten nut, holding body
stationary.
Figure 12–33 Assembly of Rubber Insert Pulse
Connector
MINIATURE RF CONNECTORS
MB Miniature Connector Series
26. These are small, lightweight, bayonet type, quick
connect/disconnect connectors, used with small RF
cables where peak voltage is not more than 500 volts.
These connectors do not carry a military number. No
soldering is required in the assembly of plugs to solid
centre conductors, such as RG58/U, 59/U, 62/U, 71/U,
and 141/U. All jacks require soldering. Table 12–6 lists
the more common connectors in the MB series and
shows the coaxial cables associated with each. These
36
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
e.
Right angle jacks or plugs: Strip cable jacket and
dielectric, install parts, and form braid as
instructed in steps a and b above.
f.
Tin conductor, and insert assembly into body.
g.
With cap removed, solder the conductor in slot of
angle plug contact.
h.
Insert cap, and spot solder or spot stake.
Figure 12–34 MB Connectors - Exploded View
Figure 12–35 Attaching MB Connectors to Coaxial Cable
37
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–6 MB Series Connectors with Associated Cables
Plug
Jack
Panel Jack
IPC
King
IPC
King
IPC
King
Cable RG-
79875
79525
KA51-03
KA51-02
79600
79500
KA31-02
KA31-03
79425
79925
KA11-04
KA11-03
55/U,
59/U
58/U
Table 12–7 Stripping Dimensions for Coaxial Cable Assembled to MB Connectors
Stripping Dimensions
Connector
Part (IPC)
RG- /U Cable
A
(mm)
C
(mm)
Plugs
45000
45025
45050
45550
58,
59,
58,
59, 62
141
62
141
161.1
282.0
161.1
282.0
51.0
51.0
51.0
51.0
Jacks
46300
46325
46700
46775
58,
59,
58,
59, 62
141
62
141
161.1
322.6
161.1
322.6
61.0
61.0
61.0
61.0
Angle Plugs
53000
53500
58,
59, 62
141
241.3
241.3
71.0
71.0
SUBMINIATURE RF CONNECTORS
Subminiature RF Connectors (Amphenol #27 Series)
29. These connectors are very small, lightweight
connectors designed for use with RG-l74/U
miniaturized coaxial cable, where peak voltage does
not exceed 500 volts. Coupling is either of the screw
thread type or the push-on type. The connectors
consist of a plug or jack body assembled to coaxial
cable with a sleeve and an insulator. (See Figure 12–
36.) The assembly is crimped into the body, and a vinyl
boot shrunk on for cable strain relief. Table 12–8 lists
types of Amphenol #27 series connectors commonly
used in aircraft.
CAUTION
Do not nick braid.
b.
Trim jacket to dimension A in Table 12–8.
c.
Slip sleeve over braid against cable jacket. Fold
braid back over the sleeve and comb out so it
lays even without overlapping.
CAUTION
Avoid overheating during soldering, excessive heat
may deform dielectric.
d.
Trim dielectric to dimension B in Table 12–8. Tin
exposed centre conductor, and clean off excess
solder.
e.
Straight plugs and jacks. Slip contact over
centre conductor so that it butts flush against cut
end of dielectric. Solder contact to conductor,
and remove excess solder from outside of
contact.
f.
Slip cable assembly into body and trim off
excess braid protruding beyond body end. Crimp
the assembly securely (see paragraph 31 for
detailed crimping instructions), and pull boot
over body as shown.
Attaching Subminiature RF Connectors to Coaxial
Cable
30. When attaching subminiature RF connectors to
coaxial cable, follow this procedure (see Figure 12–37):
a.
38
Dilate the boot and slip it over the cable. The
boot will remain dilated for approximately five
minutes.
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
g.
Angle plugs. Unscrew front part of body. Follow
procedure of steps a through d above. Then
thread cable through back part of body as shown
and crimp. Thread female insulator over
conductor and insert into body. Holding the
female insulator in place in the body, pull the
cable as far forward as possible to remove all
slack. Trim conductor to 2.1mm minimum.
a.
Open jaws of tool 227-900 by loosening nut and
pulling down lock screws (see Figure 12–38).
Place the connector assembly in jaws, and set
optimum distance between jaws for each
assembly by means of the travel limit screw.
Refer to connector placement Figure 12–38, A,
B and C for straight plugs and jacks, and Figure
12–38, D for angle plugs.
h.
Slip contact over conductor and butt contact
flush against the female insulator. Solder contact
to conductor, and remove excess solder.
b.
Lock jaws by pulling lock screws up, and tighten
nut.
c.
Squeeze handles to crimp.
i.
Place male insulator over the contact, and screw
the front body part into back body arid tighten
with end spanner.
d.
Release handles to open jaws, and remove
crimped assembly. Trim off any excess braid
protruding beyond end of body.
e.
Slip boot over body end.
Crimping Procedure for Subminiature Connectors
31.
Crimp subminiature connector bodies as follows:
Figure 12–36 Subminiature RF Connector - Exploded View
Table 12–8 Stripping Dimensions and Crimping Tool Positions for Subminiature RF Connectors
A
(mm +0 –0.4)
B
(mm Max)
Position in
Tool 27-900
Figure No.
Straight Plug
231.1
40.6
11-38 A
Jack, Push-on
241.3
40.6
11-38 B
Jack, Screw-on
241.3
53.3
11-38 C
Bulkhead Jack
241.3
53.3
11-38 C
Angle Plug
503.0
53.3
11-38 D
Body Type
39
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–37 Attaching Subminiature RF Connectors
to Coaxial Cable
40
Figure 12–38 Crimping Subminiature RF
Connectors
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
RF CONNECTORS USED IN FUEL-QUANTITY
INDICATING SYSTEMS
32. Because of their transmission line efficiency, RF
connectors are often used in aircraft fuel-quantityindicating systems. The connectors most commonly
used for this purpose are of two types. One is similar to
the standard BNC connector; typical of this type are the
163 series made by Avien, and the Liquidometer 9100
series. The second type is the miniature RF connector;
the Nu-Line 1200 series (MIL-DTL-25516) and
Liquidometer S62 and S63 are typical. These
connectors are designed to be used with coaxial cable,
but they are also frequently used with standard
shielded or unshielded wire. They do not carry a
military number.
Assembling BNC Type Fuel-Quantity-Indicating
Connectors
33. For assembly of Avien 163-088 and 163-089
connectors to RG-58A/U coaxial cables, (see Figure
12–39), use the following procedures:
a.
Slide nut, washer, and gasket onto cable. Strip
outer jacket 11mm, taking care not to nick the
braid. Slide the clamp over the braid so it rests
flush against the cut end of the jacket.
b.
Comb out braid and fold it back over the clamp,
and trim the braid even with edge of clamp.
c.
Strip dielectric 2.4mm from edge of clamp.
d.
Cut exposed conductor to 2.8mm.
e.
Slide contact onto conductor, and check that
there is no exposed conductor between the
insulation and the contact solder hole. Check
that the distance from the braid to the end of the
contact is 12.7mm, as shown in Figure 12–39.
f.
Tin conductor and solder hole, and solder
contact to conductor. Remove any excess
solder.
g.
Push assembly into connector body, screw nut
into body, and tighten.
Figure 12–39 Attaching Avien 163-088 and 163-089
Connectors to Coaxial Cable
34. For assembly of Avien 163-07 and 163-027
connectors to AN No. 20 unshielded wire, (see Figure
12–40), use the following procedure:
a.
Strip wire to expose 6.3mm of conductor, and tin
the stripped wire. Tin inside of contact.
b.
Slide nut, washer, and gasket over the wire.
Install TFE clamp over the wire so that the inside
shoulder of the clamp butts against the cut
insulation.
Figure 12–40 Attaching Avien 163-088 and 163089 Connectors to Unshielded Wire
41
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
c.
Slide contact over the wire so that it butts
against end of the clamp. While doing this, hold
the insulation firmly in place against the clamp
shoulder.
d.
Solder the contact to the conductor, and remove
any excess solder.
e.
Insert the assembly into the connector body. The
contact end should be flush with the end of the
TFE clamp, but a recess of 0.8mm maximum is
acceptable.
f.
Tighten nut while holding the body stationary.
35. For assembly of Liquidometer 9100 series
connectors to RG-58/U coaxial cable, (see Figure 12–
41), use the following procedure:
a.
Slide nut, washer, and gasket over the cable;
strip outer jacket 9.5mm, taking care not to nick
the braid. Slide the large eyelet over the braid so
that it butts against the cut end of the jacket.
b.
Comb out the braid up to the large eyelet, and
slide the smaller eyelet over the dielectric.
c.
Clamp the braid between the two eyelets with
special slotted pliers, as shown in Figure 12–43.
Trim off excess braid.
d.
Cut dielectric 3.0mm from the small eyelet, and
cut off the exposed conductor to 3.0mm.
e.
Tin the exposed conductor and the inside hole of
the contact.
f.
Slide the contact onto the conductor and solder.
Remove any excess solder.
g.
Seat contact and eyelets into connector body
and install the gasket firmly against the eyelets.
Insert washer firmly against the gasket.
h.
Screw nut into connector body and tighten,
holding connector body stationary. Tighten to 40
– 47 Newton metres (Nm) torque.
Figure 12–41 Attaching Liquidometer 9100 Series
Connectors to Coaxial Cable
e.
Slide braid clamp sleeve (large ID toward
gasket) over braid, and trim off excess braid with
scissors. Install O-ring as shown.
f.
Place contact retainer firmly over dielectric, and
strip off dielectric flush with contact retainer,
exposing centre conductor.
g.
Cut off centre conductor 2.0mm from cut end of
dielectric.
Assembling Miniature RF Fuel-Quantity-Indicating
Connectors
36. For assembly of Nu-Line 1200 Series coaxial
connectors to coaxial cable, (see Figure 12–42), use
the following procedure:
a.
Remove 12.7mm of outer jacket, exposing
shield.
b.
Slide nut, washer, and gasket, in that order, onto
outer jacket.
c.
Screw threaded braid clamp over jacket as
shown.
d.
Comb out braid, and fold braid back over braid
clamp, without overlap.
42
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
NOTE
When connector is properly torqued, the gap between
nut and body assembly should not exceed 1.0mm.
37. For assembly of Liquidometer S62 and S63
series connectors to RG-58/U coaxial cable (see
Figure 12–43), use the following procedure:
a.
Slide nut and bushing back over cable. Cut outer
jacket to dimension A in Table 12–9, being
careful not to nick braid.
b.
Place the two halves of the cable clamp over the
cable, lining up front (large) end of clamp with
cut end of outer jacket. Slide bushing over
tapered end of clamp. Compress bushing over
cable clamp with special pliers as far as it will go.
NOTE
Special pliers No. TJF-107 are available from
connector manufacturers.
c.
Comb braid back over clamp and trim braid
around edge of clamp.
NOTE
Omit step (d) when using connectors S624 and S634.
Figure 12–42 Attaching Nu-Line 1200 Series
Connectors to Coaxial Cable
h.
Slide contact, male or female, over centre
conductor so that contact butts flush against
dielectric.
i.
Solder contact to centre conductor; contact must
still be flush against dielectric after soldering.
j.
Slide cable assembly into connector body as far
as it will go. Apply (MIL-S-22473, Grade C,
sealing compound completely around the hex
nut threads. Torque nut to approximately ten
inch pounds.
d.
Slide washer, gasket, and second washer over
dielectric and push up to cable clamp. Cut off
dielectric to expose 2.4mm of conductor, and tin
conductor.
e.
Slide contact over conductor
Remove any excess solder.
f.
Slide assembly into plug or jack body until
contact shoulder seats on insulator. Screw
clamp nut into body, using a torque of 20Nm.
and
solder.
Table 12–9 Stripping Dimensions for Coaxial Cable
Assembled to Liquidometer S62 and S63 Series
Connectors
Connector
(Liquidometer Number)
Stripping
Dimension A
S62-1 and -4
8.7mm
S62-2 and -3
7.9mm
S63-1 and -4
7.9mm
S63-2 and -3
3.9mm
43
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
c.
Flair the ends of the wire braid to facilitate
insertion of inner ferrule of body assembly. (See
Figure 12–44.) Do not comb out the braid.
d.
Place the stripped centre conductor into the
contact until the cable dielectric butts against it.
End of the wire must show through the
inspection hole. (See Figure 12–44.)
e.
Insert the contact into the crimping tool until it is
fully seated in the contact locator. Crimp with
one full stroke. (See Table 12–10 for crimping
tool information.)
Table 12–10 Crimping Tool Details
Crimp on Centre Contact
Figure 12–43 Attaching Liquidometer S62 and S63
Series Connectors to Coaxial Cable
ASSEMBLY PROCEDURE FOR SUBMINIATURE CONNECTOR, ONO89558
b.
44
Install the sealing boot and slide the outer ferrule
onto cable prior to stripping the cable. (See
Figure 12–44.)
Strip cable jacket, braid, and dielectric to
dimensions indicated. (See Figure 12–44.) All
cuts are to be square and sharp. Do not nick
braid, dielectric or centre conductor when
cutting. If the wire ends of the centre conductor
are frayed, twist them to normal lay.
Basic Tool
Setting
Contact Locator
M22520/2-01
No. 5
M22520/2-24
f.
Install the centre contact in the body assembly
while sliding the inner ferrule underneath the
wire braid. (See Figure 12–45.) The centre
contact shall be inserted until it is locked into
place in the body assembly. A 1.5 kilogram min
to 2.3 kilogram max pull shall be exerted on the
cable to assure that the contact is securely
locked in place.
g.
Slide the outer ferrule over the wire braid and up
against the body assembly. No slack shall exist
in the wire braid.
h.
Crimp the outer ferrule with M22520/5-01 tool
and M22520/5-10 die. See Figure 12–46.
i.
The shielded contact now assembled shall be
inserted into the connector assembly with
insertion tool ONO89564.
j.
Push the sealing boot forward into the grommet
of the connector until the O-ring riser of the boot
has effected its snap-in seal. (See Figure 12–
47). The installation of the shielded contact is
complete.
38. For assembly of connector to RG-l95/U coaxial
cable, use the following procedure:
a.
Basic Tool
39. For assembly of connector to twisted pair of 26
or 24 A.W.G. wires, use the following procedure:
a.
Install the sealing boot onto the untwisted wire
prior to stripping the wires. (See Figure 12–48.)
b.
Strip the wires to the dimensions indicated. (See
Figure 12–48.) All cuts are to be square and
sharp. Do not nick the conductors when stripping
the insulation.
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–44 Stripping Dimensions, Scaling Boot, Ferrule and Contact Before Crimping the Contact
Figure 12–45 Final Assembly and Outer Ferrule Crimping
c.
Fold the longer stripped wire to a 5.5mm
dimension. (See Figure 12–48.)
d.
Place the insulator and the contact onto the
shorter stripped wire. The wire which is now the
centre conductor must be visible through the
contact inspection hole (See Figure 12–49.)
e.
Insert the contact into the crimping tool until it is
fully seated in the contact locator. Crimp with
one full stroke. (See Table 12–11 for crimping
tool information.)
Table 12–11 Crimping Tool Details
f.
Slide the outer ferrule onto the cable prior to
installing the centre contact in the body
assembly. (See Figure 12–50.)
g.
Position the folded wire on top of the inner
ferrule. (See Figure 12–50.) The centre contact
shall be inserted until it is locked in place in the
body assembly. A 1.5kg min to 2.3kg maximum
pull shall be exerted on the cable to assure that
the contact is securely locked in place.
h.
Slide the outer ferrule over the folded wire and
against the body assembly. Crimp the outer
ferrule with crimp tool ONO89140.
i.
The shielded contact now assembled shall be
inserted into the connector assembly with
insertion tool ONO89564.
j.
Push the sealing boot forward into the grommet
of the connector until the O-ring riser of the boot
has effected its snap-in seal. (See Figure 12–
49). The installation of the shielded contact is
complete.
Crimp on Centre Contact
Basic Tool Setting
Basic
Tool
26 A.W.G.
24 A.W.G.
Contact
Locator
M22520/2-01
No. 6
No. 7
M22520/2-24
45
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–46 Crimping Tool for Shielded Outer Ferrule
b.
Slide cable nut and bushing over cable. Do not
nick, braided shield or conductor.
c.
With a knife cut through and remove 9.5mm of
outer jacket.
d.
Comb out braid and cut inner dielectric 2.5mm
from end of cable.
e.
Place cable clamp in place making sure end of
clamp is flush with end of outer jacket. (See
Figure 12–51.)
f.
Slide nut into place to hold cable clamp in
position.
g.
Carefully fold back braid over cable clamp,
position first washer and gasket in place and trim
excess braid flush with washer.
h.
Place second washer in place, tin centre
conductor and contact hole.
i.
Solder contact on centre conductor flush with
inner dielectric. Place insulator in place.
CAUTION
Turn nut only. Do not rotate body of cable.
j.
Insert cable assembly into connector, push firmly
in place and tighten nut until flush with body of
connector.
k.
Place front gasket in place.
Figure 12–47 Final Connection Assembly
40. For assembly of Dage Type Connectors, use the
following procedure:
a.
Cut off end of cable even and square.
Figure 12–48 Stripping Dimensions and Sealing Boot Before Crimping the Contact
46
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
c.
Position 2.8mm to 3.3mm thick jeweller’s saw in
slot of fixture, and carefully cut through cable
shield while rotating cable and maintaining
pressure against fixture.
d.
Remove cable from fixture.
CAUTION
Do NOT nick or score centre conductor with blade.
Figure 12–49 Assembly Before Crimping
e.
Using a razor blade, cut and remove dielectric to
expose centre conductor.
f.
Using the trimmer tool, smooth copper shield
and dielectric (Figure 12–53). This is
accomplished as follows:
(1) Slip correct end of tool over exposed end of
cable.
(2) Push lightly against cable while slowly
revolving tool clockwise two or three times.
(3) Remove tool and clean any chips from end
of cable.
g.
Re-insert cable into cable dressing fixture for
pointing. Keep pressure against fixture and
rotate cable slowly while filing on 45 surface
(Figure 12–54) with a small pillar file or mill file.
Continue filing until conductor offers no
resistance to the file.
h.
Remove cable and brush off any chips.
Figure 12–50 Final Assembly and Outer Ferrule
Before Crimping the Outer Ferrule
ASSEMBLY PROCEDURE FOR SMA
TERMINATION OF SEMI-RIGID CABLE USING
HAND TOOL M22520/36
41. SMA connectors, Category F, designed for use
with RG-402/U (3.6mm OD) and RG405/U (2.2mm OD)
semi-rigid cable, consist of a plug (with or without a
centre contact) or jack body. The plug (or jack) is
assembled and terminated to the semi-rigid cable by
means of an integrated grip sleeve. See Figure 12–52.
A plug couples to a jack by means of screw threading.
Tooling for Preparing Semi-Rigid Cable
42. Before terminating the SMA connectors to the
semi-rigid cable, the cable must be prepared using the
components of the preparation tooling listed in Figure
12–53.
Selection of Cable, Connector, and Tool
Components
44. Refer to Figure 12–55, and select the correct
combination of cable, connector, hand tool locator, and
die set from Table 12–12.
Tool Setup Procedure
45. Before the connector can be terminated to the
prepared cable the hand tool must be set up with an
appropriate locator and dies as follows:
a.
Having selected the proper locator die set for the
selection chart (see Table 12–12), loosen locator
locking screw on tool (see Figure 12–56).
b.
Insert locator into cavity of ram, making sure
locator bottoms on top surface of ram.
c.
Re-tighten locking screw.
d.
Position each die of the die set on its respective
tool jaw, orienting chamfer on die as shown in
Figure 12–57. Die chamfers positioned
improperly will result in an unacceptable
termination.
Preparing the Semi-Rigid Cable
43.
Prepare both cable ends as follows:
a.
Place cable dressing fixture in vice.
b.
Insert end of cable into cable size-designated
hole (see Figure 12–53).
47
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
e.
Secure, without tightening, the dies to jaws with
the die-holding screws.
f.
Align dies by placing cable inside locator and
squeezing the handles to dose tool. After
ensuring that the dies are aligned with each
other, tighten the die-holding screws (see Figure
12–58).
e.
When terminating PANEL JACK to cable, align
sides of panel jack with tool jaws as shown in
Figure 12–60.
f.
Support cable connector assembly and close
tool handles until ratchet releases to complete
termination.
Cable Bending Procedures
Cable Termination
46. Refer to Figure 12–59 (plug termination) or
Figure 12–60 (jack termination), then proceed as
follows:
a.
Slide connector over cable, flange end first.
b.
Place connector and cable inside locator of tool.
c.
Ensure that centre conductor or centre contact
enters hole in locator if applicable.
d.
Ensure that connector is seated squarely on
locator.
47. The 90° bending fixture assembly makes precise
right-angle bends on the cable adjacent to the flange
end of the plug. Refer to Figure 12–61 for tangent-ofradius to end-of-connector dimensions. Bends can
have a radius of either 3.1mm on RG-402/U or RG405/U cable, or 6.3mm on RG-402/U cable only. The
spacer shown in Figure 12–62 must be positioned
behind the dummy jack when bending the following:
RC-402/U cable to either radius when cable is
terminated with either plug M39012/79-3308 or plug
M39012/79-3208; RG-405/U cable to 3.2mm radius
when cable is terminated with plug M39012/79-3307 or
plug M39012/79-3207. Simply loosen dummy jack to
insert spacer, and retighten jack before proceeding.
Figure 12–51 Assembly of Dage Type Connectors
48
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–52 SMA Connectors M39012, Category F
Table 12–12 Cable, Connector and Tool Component Selection
Connector Part Number
For RG-402/U
(3.6mm OD.) Cable Using
Dies
M22520/36-02
For RG-405/U
(2.2mm OD.) Cable Using
Dies
M22520/36-03
M39012/79-3308
M39012/79-3307
Plug with centre contact
M22520/36-04
M39012/79-3208
M39012/79-3207
Plug with centre contact, with safety wire
holes
M22520/36-04
M39012/92-3301
Plug without centre contact
M22520/36-06
M39012/92-3201
Plug without centre contact, with safety
wire holes
M22520/36-06
Connector
Description
Locator
Part Number
M39012/81-3208
M39012/81-3207
Jack
M22520/36-05
M39012/82-3208
M39012/82-3207
Panel Jack
M22520/36-05
M39012/83-3208
M39012/83-3207
Bulkhead Jack
M22520/36-05
49
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–53 Tooling to Prepare Semi-rigid Cable
6.3mm Bends on RG-402/U Cable or 3.2mm Bends
on RG-405/U Cable
48.
Refer to Figure 12–63, and proceed as follows:
a.
Screw terminated plug onto dummy jack of
holder.
b.
Refer to Table 12–13, and slip appropriate bend
segment under cable.
NOTE
Figure 12–54 Pointing the Cable End
50
TOP marking is not designated on bend segment
M22520/36-12.
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
d.
Re-attach plug to dummy jack of holder.
e.
Place conforming block over cable with tongue
of block in slot of holder (see Figure 12–64).
0.125-Inch Radius Bends on RG-402/U Cable
f.
Insert limiting pin through hole in conforming
block, and slide block against holder.
49.
g.
Place assembly in a vice with a 7cm opening
and tighten vice to force conforming block into
holder slot. Continue to tighten vice until legs of
holder prevent further movement of vice jaws.
c.
Using finger pressure, bend cable around
segment to desired angle, 90 maximum.
d.
Unscrew plug from dummy jack on holder.
Refer to Figure 12–64, and proceed as follows:
a.
Form a 6.3mm radius bend as described in
paragraph 48.
b.
Remove plug from dummy jack on holder.
h.
c.
Replace 6.3mm bend segment with the 3.2mm
segment for RG402/U cable.
Remove assembly from vice, and unscrew plug
from dummy jack on holder.
i.
Remove conforming block and bend segment
from holder.
Figure 12–55 Termination Tooling
51
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Table 12–13 Bend Segment Selection
Cable
Bend
Number
RG-402/U
RG-405/U
Segment
Radii Dimension
Plug Number
M22520/36-12
6.3mm
M39012/79-3308
M22520/36-11
3.2mm
M39012/79-3208
M39012/92-3301
M39012/92-3201
M22520/36-13
3.2mm
M39012/79-3307
M39012/79-3207
Figure 12–56 Locator and Locking Screw
Figure 12–58 Die Alignment
Figure 12–57 Orientation of Die Chambers
52
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Daily Maintenance
good SAE No. 20 motor oil. Do NOT oil
excessively.
50. Each operator of the hand tool shall be made
aware of, and responsible for, the following four steps
of daily maintenance.
a.
d.
When tool is not in use, keep handles closed to
prevent objects from becoming lodged in the
dies; store tool in a clean, dry area.
Remove dust, moisture, and other contaminants
with a clean brush, or a soft, lint-free cloth. Do
NOT use objects that could damage the tool.
Periodic Inspection
b.
Make sure proper retaining pins are in place and
secured with proper retaining rings.
51. Regular periodic inspection and testing of hand
crimping tools shall be performed in accordance with
the requirements of Section 2 Chapter 6.
c.
Make certain all pins, pivot points and bearing
surfaces are protected with a THIN coat of any
Figure 12–59 Plug Termination
Figure 12–60 Jack Termination
53
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–61 Radii Dimensions for Semi-Rigid Cable Bending
Figure 12–62 Spacer on Dummy Jack
Figure 12–63 0.025 Inch Radius Bends on RG-402/U Cable and 0.125 Inch Radius Bends on RG-405/U Cable
54
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
Figure 12–64 3.2mm Radius Bends on RG-402/U Cable
Figure 12–65 Triaxial Connector Assembly - Exploded View
TRIAXIAL CONNECTORS
Assembling Triaxial Cable Connectors
52. MIL-PRF-49142 triaxial connectors and other
such related connectors and fittings are intended for
use with triaxial cable and can be used for radio
frequency application when more shielding is required.
It can be used in video circuits and for serial digital
transfer.
53. When assembling triaxial cable connectors to
wire or cable, refer to Figure 12–65 through to Figure
12–68.
a.
Remove 12.7mm of outer insulation.
b.
Comb outer shield. Taper the shield over end
middle insulation.
55
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 12
c.
Slide nut over outer insulation.
d.
Slide washer ‘A’ over tapered shield. Press the
washer firmly against outer insulation.
e.
Cut outer shield to dimension shown in Figure
12–66.
f.
Flare outer shield. Install washer B firmly against
shield. If necessary, trim shield flush with
circumference of washers ‘A’ and ‘B’.
g.
Install gasket firmly against washer ‘B’.
h.
Cut middle insulation to dimension shown in
Figure 12–67.
i.
Install teflon washer firmly against gasket.
j.
Install washer C firmly against teflon washer.
k.
Cut middle shield to dimension shown in Figure
12–67.
l.
Flare middle shield. Install washer firmly against
shield. If necessary, trim shield flush with
circumference of washers ‘C’ and ‘D’.
Figure 12–66 Attaching Triaxial Connector to Cable
m. Cut inner insulation and inner conductor to
dimensions shown in Figure 12–68.
n.
Tin inner conductor. Solder contact to inner
conductor (do not over heat). Remove excess
solder.
o.
Install items ‘E’, ‘F’, ‘G’ and ‘H’. Tighten nut to
14+1 inch-pounds while holding outer shell and
outer
insulation
fixed.
Figure 12–67 Attaching Gasket to Middle Insulation
Figure 12–68 Attaching Outer Shell to Gasket
56
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