TM 1-1520-240-BD•Bundle forming and protection.•Circular and flat connector repair.•Terminal board replacement.•Terminal lug installation.Prior to performing any of the listed repairs, the repairtechnician must be knowledgeable in the application ofthe basic repair procedures, and proficient in the use ofwiring repair tools and materials. The techniquesillustrated, when applicable, duplicate the "short-form"instruction for each repair material that are affixed to thestorage box cover.(1)UnshieldedPrimaryWireSplicing. Therepair set provides wire splice capability for all 24 to 12AWG wiring used on Army helicopters, regardless of thewire temperature ratings. Splices are provided for wiresrated at 1050C or below (wires identified as M5086,MS26313, M7078/3, 5, 7, and M27500 A, B, C, P, AA,AB, or AD); TM 1-1520-240-BD and for wires rated at125° C or above (wire identified as M22759/16, 18, 32,34, 43 and M81381/7, 11). All primary wire stocked inthe repair set is M22759/43, rated at 200°C. This wiremay be spliced to any existing aircraft wiring providedthat the splice selected is appropriate for the existingaircraft wiring temperature rating. Wire bundle repairsshould be accomplished using the splicing techniquesdescribed in this section. Care should be exercised tostagger splices. Where possible, splices in adjacentwires in a bundle should be separated by at least onesplice length. This may require the use of the pre-madesplice segments (Figure 9-10) or locally manufacturedjumper wires made from the kit primary wire stockspliced into the existing aircraft wiring. Figures 9-4, 9-5,and 9-6 illustrate the technique for the splicing of 125°Cor above rated wires of the sizes indicated. Figures 9-7,9-8, and 9-9 illustrate the technique for splicing wiresrated at 105oC or below for the wire size indicated.Figure 9-10 illustrates the use of the premade wirerepair segments on primary wires rated at 125°C orabove. Adherence to these techniques results in apermanent, environmentally sealed primary wire splice.Figure 9-4. Item B15 Crimp Splice9-9
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