SPECIFICATION CONTROL DRAWING MATERIALS 1. INSULATION SLEEVE: Heat-shrinkable, transparent blue, radiation cross-linked modified polyvinylidene flouride. 2. SINGLE-WIRE SEAL: Immersion resistant thermoplastic. 3. THREE-WIRE SEAL: Immersion resistant thermoplastic. 4. CRIMP SPLICE: Base metal: Copper Alloy 101 or 102 per ASTM B-75. Plating: Tin per MIL-T-10727, Type 1. Color code: See table below. Dimensions of Crimp Splice : Part Prod. Crimp Splice Name Rev. Size A B D E Color Code D-436-52 C 16 2.69 (0.106) 1.75 (0.069) 14.86 (0.585) 7.11 (0.280) Blue 2.56 (0.101) 1.63 (0.064) 14.35 (0.565) 6.60 (0.260) D-436-53 C 12 3.91 (0.154) 2.59 (0.102) 14.86 (0.585) 7.11 (0.280) Yellow 3.73 (0.147) 2.46 (0.097) 14.35 (0.565) 6.60 (0.260) Installation Data: Wire Size Range of Crimp Splice Splicer One Wire Two wires Three wires Size Minimum Maximum Minimum Maximum Minimum Maximum 16 20 16 24 20 24 22 12 16 12 22 16 22 18 TITLE : TE Connectivity Raychem 305 Constitution Drive IN-LINE SPLICE SEALING SYSTEM, Menlo Park, CA 94025, USA Products 2 OR 3 TO 1 SPLICE: Tin Plated, Color Coded, with Inspection Slots UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS. DOCUMENT NO.: D-436-52/-53 INCHES DIMENSIONS ARE BETWEEN BRACKETS. TOLERANCES: ANGLES: N/A TE Connectivity reserves the right to amend this DATE: DOC ISSUE: 0.00 N/A drawing at any time. Users should evaluate the 15-Apr-11 2 0.0 N/A ROUGHNESS IN suitability of the product for their application. 0 N/A MICRON DRAWN BY: REPLACES: DCR NUMBER: PROD. REV. SCALE: SIZE: SHEET: M. FORONDA N/A D001302 SEE TABLE None A 1 of 2 Print Date: 9-May-11 If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION CONTROL DRAWING APPLICATION 1. These parts are designed to provide an immersion resistant in-line splices of 2 or 3 to 1 wires falling within the size range listed on sheet 1, having insulations rated for at least 135C. 2. Parts are available only as an assembly of one of each Item 1 and Item 2. 3. Parts are to be installed per Thermofit Assembly Procedure, see below. 4. Inside diameter and outside diameter of splice are to be measured in crimp areas, 2.54 to 5.08 (0.100 to 0.200) from ends of part. Slight burr permitted on parted surfaces. 5. Acceptance sampling shall be in accordance with Paragraph 4.6.1 of MIL-T-7928. 6 . Packing and packaging shall be in accordance with Section 5, Level C, of MIL-T-7928. 7. This document takes precedence over documents referenced herein. THERMOFIT ASSEMBLY PROCEDURE 1.0 SCOPE This document outlines the procedure to be followed to obtain immersion resistant 3 or 2 to 1 in-line splices using Thermofit In-Line Splice Sealing System D-436-52/-53. 2.0 PROCEDURE: a) Strip all wires 7.92 (0.312) to 8.74 (0.344). b) Attach the single lead to the appropriate size crimp splice using a Raychem AD-1377 Crimp Tool. c) Pass the wires to be attached to other barrel through the sealing sleeve from the three-hole insert end. d) Insert wires into barrel and crimp. Care must be taken that the wires remain untwisted between the crimp splice and the three wire seal or the sealing sleeve cannot be positioned properly. e) Apply heat, using the recommended heat source, first to the three-hole insert and then the other. Heat should be applied until insert melts and flows axially along the wires. 3.0 RECOMMENDED RAYCHEM HEATING TOOLS Heater Reflector Thermogun 500A TG-14 Shop Air Heater CV-4504 991180 Mini-Gun CV-5300 991319 TITLE : TE Connectivity Raychem 305 Constitution Drive IN-LINE SPLICE SEALING SYSTEM, Menlo Park, CA 94025, USA Products 2 OR 3 TO 1 SPLICE: Tin Plated, Color Coded, with Inspection Slots UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS. DOCUMENT NO.: D-436-52/-53 INCHES DIMENSIONS ARE BETWEEN BRACKETS. TOLERANCES: ANGLES: N/A TE Connectivity reserves the right to amend this DATE: DOC ISSUE: 0.00 N/A drawing at any time. Users should evaluate the 15-Apr-11 2 0.0 N/A ROUGHNESS IN suitability of the product for their application. 0 N/A MICRON DRAWN BY: REPLACES: DCR NUMBER: PROD. REV. SCALE: SIZE: SHEET: M. FORONDA N/A D001302 SEE TABLE None A 2 of 2 Print Date: 9-May-11 If this document is printed it becomes uncontrolled. Check for the latest revision.