munications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
Subject: Assembly
Procedures
APPROVED BY
Manager, Hardware Engineering
STATUS Maintenance
Revision
PURPOSE
Defines the requirements for assembly techniques and procedures that
cannot be categorized in other specific L-3 Communications Corporation,
Link Simulation & Training Division (hereafter referred to as Link)
Manufacturing Instructions. Establishes procedures for part exchanges
(by Manufacturing) without formal authorization. Part exchanges for
nonreparable parts specified within this instruction may be made without
initiation of a Class I or Class II engineering change. This instruction
shall be followed by personnel involved in assembly of Link designed
equipment.
AFFECTED Hardware
Engineering
FUNCTIONS Manufacturing
REFERENCES
LMS 11-3


Hand Soldering, Electrical
LMS 11-13

Electrical
Bonding
DOD-STD-480
Configuration Control - Engineering Changes,



Deviations and Waivers
MIL-STD-188/124
Grounding, Bonding and Shielding
MIL-STD-280
Definitions of Item Levels, Item Exchangeability,



Models, and Related Items
MIL-HDBK-419
Grounding Bonding and Shielding for Electronic



Equipments and Facilities
MIL-STD-454
General Requirements for Electronic Equipment
MIL-STD-1857
Grounding, Bonding and Shielding Design


Practices
MS3400

Connector, Receptacle, Electric, Wall Mounting,



Front Release, Crimp Contact, AN Type
MS3452

Connector, Receptacle, Electrical, Box Mounting,



Rear Release, Crimp Contact, AN Type
MIL-B-5087
Bonding, Electrical, and Lighting Protection,



for Aerospace Systems
MIL-T-7928
Terminals, Lug: Splices, Conductors: Crimp



Style, Copper, General Specification for Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
2 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
MS27212

Terminal Board Assembly, Molded-In Stud,


Electric
MIL-T-23991
Training Devices, Military; General Specification



cation for
MIL-T-55164
Terminal Boards; Molded, Barrier, Screw and



Stud Types, Associated Accessories, General



Specification for
1. Requirements
1.1 Assembly
procedures.
a.
Masking tape and electrical tape. The use of masking tape in equipment
is permissible for such purposes as temporary identification of wires or
other items of equipment during the test phase. Electrical tape may be
used to provide temporary electrical insulation or protection of terminal
ends of wires that are disconnected for testing, etc. Any masking or
electrical tape used for the above purposes shall be removed and the
equipment returned to an acceptable condition prior to customer
acceptance.
b.
Wiring potentiometers (2inch diameter and larger). Wire lead length
shall be approximately 4 inches from the main trunk of the harness and
shall be routed as shown in Figure 1. Figure 1 may be considered as a
top, side, or bottom view, depending upon the orientation of the
potentiometer terminals when mounted.
00111301
Main trunk
Trunk in middle alternate method.
Main trunk
Trunk on side preferred method.

Figure 1 Wiring Potentiometers Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
3 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
c. Shims,
shafts. Shafts with snaprings shall be shimmed at assembly to
prevent undue axial motion due to tolerance buildup between ring
grooves. Laminated shims may be selected from the following:
Link PN 479419 (for 1/8inch shaft)
Link PN 479420 (for 3/16inch shaft)
Link PN 451137 (for 1/4inch shaft)
d. Solderless
lugs.
(1)
Assembly arrangement of solderless lugs and their attaching
hardware shall be as shown in the following paragraphs, unless
otherwise specified on the engineering drawings.
(a)
Terminal strip connection (Figure 2).
(b)
Chassis ground connection, tapped mounting hole
(Figure 3).
NOTE:
Mounting surface prepared in accordance with MIL-B-5087
LMS 11-13

Electrical
Bonding).
(c)
Chassis ground connection, untapped hole (Figure 4).
NOTE:
Mounting surface prepared in accordance with MIL-B-5087

(
LMS 11-13
Electrical
Bonding).
(d)
Chassis ground connection, untapped hole - with
secured mounting. During assembly and subsequent
wiring of assemblies, it may be necessary to
disassemble parts to gain access and mount lugged
wires at E1 ground positions. To avoid this
disassembly, an additional flat washer, lockwasher,
and nut may be used with the existing hardware
(Figure 5).
NOTE:
Mounting surface prepared in accordance with MIL-B-5087

(
LMS 11-13
Electrical
Bonding). Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
4 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
00111302
Terminal lug
Nut
Flat washer
Flat washer
Flat washer
Terminal strip
Nut
Split lock washer
Stud
Terminal lug
Nut
Terminal strip
Stud shoulder
Lock washer
Stud
WITHOUT STUD SHOULDER
WITH STUD SHOULDER

Figure 2 Typical Terminal Strip Connection
00111303
Screw or bolt
Term lug
A. STEEL SURFACE
Screw or bolt
Flat washer
(ALCLAD)
Flat washer
Split lock washer
Term lug
B. ALUMINUM SURFACE
Mounting surface
(Aluminum)
Split lock washer
Mounting surface
(Plated steel,
CRES steel)
Flat Washer

Figure 3 Chassis Ground Connection (Tapped Hole) Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
5 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
Screw or bolt
Nut
Flat washer
Split lock washer
Term lug
A. STEEL SURFACE
Mounting surface
(Plated steel,
CRES steel)
Screw or bolt
Nut
Flat washer
Split lock washer
Term lug
B. ALUMINUM SURFACE
Mounting
surface
(Aluminum)
Flat washer
(ALCLAD)
Flat washer
00111304

Figure 4 Chassis Ground Connection (Untapped Hole)
00111305
Term lug
Stud
Flat washer
Nut
Mounting surface
(Plated steel,
CRES steel)
A. STEEL SURFACE
Split lock
washer
Split lock washer
Nut
Nut
Bolt or screw
Mounting
surface
(Aluminum)
B. ALUMINUM SURFACE
Split lock
washer
Split lock
washer
Flat washer
Bolt or screw
Flat washer
Flat washer
(ALCLAD)
Stud
Nut
Term lug

Figure 5 Chassis Ground Connection
(Untapped Hole Secured Mounting)
(e)
Chassis ground connection, feedthru stud (Figure 6).
NOTE:
Mounting surface prepared in accordance with MIL-B-5087

(
LMS 11-13
Electrical
Bonding).
(f)
Bus bar, tapped mounting hole (Figure 7). For voltage
and power return connections.
(g)
Bus bar, untapped mounting hole (Figure 8). For
voltage and power return connections. Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
6 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
00111306
Stud
Flat washer
Nut
Nut
Nut
Mounting surface
(Plated steel, CRES steel)
Split lock washer
Split lock washer
Split lock washer
Flat washer
Flat washer
Terminal lug

Figure 6 Chassis Ground Connection (Feedthru Stud)
00111307
Screw or bolt
Flat washer
Split lock washer
Term lug
A. COPPER SURFACE
Screw or bolt
Aluminum bus bar
Flat washer
B. ALUMINUM SURFACE
Split lock washer
Term lug
Flat washer
(ALCLAD)
Copper bus
bar

Figure 7 Bus Bar Connection (Tapped Hole) Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
7 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
00111308
Copper bus
bar
Screw or bolt
Nut
Flat washer
Flat washer
Split lock washer
Term lug
A. COPPER SURFACE
Screw or bolt
Flat washer
(ALCLAD)
B. ALUMINUM SURFACE
Flat washer
(ALCLAD)
Nut
Flat washer
Split lock washer
Term lug
Aluminum bus bar

Figure 8 Bus Bar Connection (Untapped Hole)
(2)
Unless otherwise specified by the Engineering drawing, the
hardware supplied with the purchase material shall be used.
e.
Mounting nylon or plastic parts. When specified on the engineering
drawing, a flat washer shall be used with a lockwasher and nut to mount
plastic or nylon parts, spacers, or connectors to prevent distortion or
damage. When an existing engineering drawing does not specify a flat
washer, Manufacturing shall utilize the hardware called out. (See Figure 9.)
00111309
Nut
Stud
Mounting surface
Split lock washer
Flat washer
Plastic or Nylon
part

Figure 9 Plastic or Nylon Part Mounting
f.
Terminal markers (mylar).
(1)
When mylar terminal markers are specified on the engineering
drawing, the markers (Link PN 858492) shall be ink stamped
with the appropriate terminal numbers as indicated on the
assembly drawings. Numbers shall read as shown in Figure 10. Link Simulation & Training


Instruction


Hardware Engineering
No. LMS 13-1

6-14-04
8 of 27
Rev. BE
Copyright
2004
L-3 Communications Corporation, Link Simulation & Training Division

UNSIGNED HARDCOPY
NOT CONTROLLED
00111310
5
3
1