01 March 2005
Change 1
NAVAIR 01-1A-509-3
15 July 2008
TM 1-1500-344-23-3
TO 1-1-689-3
i. The replacement of conformal coatings shall be
a. Protect open connectors with plastic/metal caps
in accordance with NAVAIR 01-1A-23 (Navy) or TO
or pressure sensitive tape in accordance with paragraph
00-25-234 (Air Force).
6-3.10. ALUMINUM ELECTROLYTIC CAPACITORS.
b. If connector boots are installed and water intrusion
Aluminum Electrolytic Capacitors, MIL-C-62, that utilize
cannot be prevented due to design, a small drain hole
(1/4 inch minimum, 3/8 inch maximum) may be cut in the
s y n t h e t i c rubber seals (some rubber/plastic
combination seals) are susceptible to damage during
low point of the connector boot to allow water to escape.
cleaning. Inspect Aluminum Electrolytic Capacitor,
MIL-C-62, for end seal deterioration. If seals look
c. Special attention should be given to connectors
bulged or uneven, the capacitor must be replaced and
using replaceable pins. These connectors use a
all adjacent areas cleaned to prevent further corrosion.
self-sealing gasket that automatically seals the
connector against water intrusion. "Dog bones" (plastic
a. Clean area in accordance with paragraph 6-3.9.e.
inserts) are used to fill unused contactor cavities. The
repeated removal and replacement of the pins or
b. Dry area in accordance with paragraph 6-3.9.g.
omission of the "dog bones" may cause the watertight
seal to lose its effectiveness. The use of potting
c. Preserve area in accordance with paragraph
compounds may be required to prevent water intrusion
in extreme cases when the connector cannot be
replaced (refer to paragraph 5-4.2.).
d. The replacement of conformal coating shall be in
accordance with NAVAIR 01-1A-23 (Navy) or TO
d. Connectors mounted on avionic equipment that
00-25-234 (Air Force).
are susceptible to the same environment as aircraft
wire harness connectors shall be treated with the
6-3.11. MULTIPIN ELECTRICAL CONNECTORS,
same corrosion removal/preservation techniques.
CLEANING AND PRESERVATION. Multipin electrical
Mounting plates normally contain a gasket that acts as
connectors require special attention, especially in areas
a watertight seal. These gaskets should be inspected
exposed to salt water, such as speed brake, wing fold,
each time a connector is dismantled for cleaning or
and landing gear. The following techniques will assist
repair.
in limiting corrosion attack:
6-3.11.1. External Corrosion Removal and Cleaning.
WARNING
a. Disassemble the connector back shell, if possible,
and inspect for corrosion damage. If the damage is too
Ensure that all electrical power is disconnected
severe, the connector may require replacement.
from the aircraft and all systems in the aircraft
are deactivated. Disconnect all batteries.
b. Remove corrosion on unplated surfaces with
Abrasive Mat, A-A-58054 Type I Grade A (Volume IV
CAUTION
or V, Chapter 2), as appropriate. Ensure connector
mating surfaces, threads, shell and mounting plate
Cleaning compounds and solvents identified
(if used) are cleaned.
in Volume IV or V may react with some
encapsulants or plastics used to form wire
c. Corrosion on cadmium plated connectors appears
harness tubing, wire coatings, conformal
as white to light grey powdery deposits. A smooth dark
coatings, gaskets, or seals. Test on a small
grey surface indicates tarnish but does not affect the
area for softening or other adverse reactions
function of the connector or clamp. Removal of a dark
prior to general application. Refer to Table 2-4
grey finish is not required; proceed to step e. below.
for further restrictions on these materials.
White/light grey deposits, heavy pitting, or red rust
indicates the presence of corrosion and shall be removed
NOTE
by the least aggressive method described below.
Continuity test does not preclude a visual
inspection of connectors because corrosion
can still occur externally.
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