Lesson 4/Learning Event 1
Solderless Terminals
Solderless terminals come in a variety of designs. Some of the more common recommended
terminals are the ring-tongue, rectangular-tongue, and flag types. One of the major sources of
trouble when a terminal is connected to a wire has always been the breakage of the wire near its
junction with the terminal. Wire failures have been decreased by adding a sleeve to the basic
terminal. The inside diameter of the sleeve is slightly larger than the outside diameter of the wire
insulation. In the crimping operation, when the barrel is fastened to the end of the wire, the
insulation-supporting sleeve is fastened around the insulation. This additional support prevents
excessive bending of the wire at the point where it enters the barrel of the terminal, and also
prevents fraying of the insulation or braid that is over the wire. A special water seal terminal,
designed to fit MIL-C-13486 cable and grip the insulation to prevent water from reaching the
conductor, also is provided. This terminal should be used wherever MIL-C-13486 interconnecting
wire is terminated in an area subject to bilge water, road splash, or corrosive spills. If water seal
terminals are not used in such circumstances, the stranded conductor will absorb moisture, and
rapid corrosion of the individual strands will occur.
Solder-Type Terminals
Solder-type terminals come in most of the configurations. Although they are considered to make
more positive, permanent connections, they are not used as widely as solderless connectors because
of the difficulty involved with installing them.
WIRE CONNECTORS
Connectors have evolved to facilitate the coupling and uncoupling of electrical equipment for
replacement or service. The typical connectors used on military vehicles permit the elements of a
system to be fabricated and serviced as individual assemblies or components so that the final
system configuration is built and maintained more easily. The interconnection generally is
accomplished using multiconductor or single-conductor cable assemblies or wiring harnesses, which
permit convenient placement of the system components. Connectors and receptacles also are
attached directly to individual components to permit the easy removal of items that are connected
to mating parts without the use of interconnecting cables (circuit boards and relays). A compatible
connection system consists of a plug assembly, a mating receptacle assembly, and the wires or
cables leading to them. Connector assemblies exist in a variety of configurations, each of which is
intended for a particular environmental and/or mounting condition.
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