Garmin Avionics Wiring Termination

ID: 157628

Description: This is a guide on the technique on how to...

Steps:

  1. DMC crimpers with appropriate turret
  2. Wire strippers
  3. Flush cuts
  4. Razor
  5. Fine tip sharpie, or label printer for wires
  6. Heat gun
    7. Step image
  7. Wire
  8. Shield braid
  9. Heat shrink (2 pieces), at least one piece white
  10. Environmental splice
  11. Pins
    12. Step image
  12. Interior wires- where the signal is passed through
  13. Outer layer of insulation
  14. Shielding- a braid inside the wire over the interior wires. This protects the signal from interference or interfering with other signals. The shielding is terminated to a ground
    15. Step image
  15. Expose about 1.5" of shield by removing outer layer of wire.
    16. Step image Step image
  16. Remove shielding to expose wires
  17. Option 1: unbraid shield and the cut away from wire
  18. Option 2: carefully cut shield away without nicking the interior wires
    19. Step image Step image
  19. Cut a 0.25" long section from outer layer of the wire about 2.5" from the end of the wire.
  20. This accomplished with a razor. A new razor will cut more easily through the insulation but can also cut through the shielding. A dull razor is harder to cut with but also more forgiving to mistakes.
  21. If the shielding is cut through and the interior wires nicked there is a high potential for a short to ground and that section of wire must be cut off and the wire must be restarted.
    22. Step image
  22. Insert the environmental splice over the cut shielding block and insert the shield braid into it. The solder ring must go over both the exposed shield and the braid.
  23. Insert a piece of heat shrink over the end of the wire where the shield and outer insulation is cut. This will protect the end of the wire
  24. Heat the splice and heat-shrink with a heat gun. Ensure the solder flows in the splice soldering the braid to the shield.
    25. Step image Step image
  25. Strip wires appropriate length - detailed in next step
  26. Crimp terminals to wire
    27. Step image Step image
  27. The wire strip length should by just barely longer than the barrel (where the wire goes) of the crimped contact
  28. First picture shows a correct termination
  29. Second picture shows to long of strip on wire
  30. To make sure the wire is stripped long enough the conductor strands should be visible in the witness hole circled in the third picture
    31. Step image Step image Step image
  31. Add heat-shrink with wire number added to it to identify wire after install
    32. Step image
  32. Push pins into connector, the should lock into place and need a special tool for removal
    33. Step image
  33. Crimp ring terminal to shield braid
  34. Install ring terminal to designated grounding location. Often the connector back-shell.
  35. This step is done last after all wires for a connector are installed and back-shell is assembled on connector. Sometimes a separate ground lug needs to be installed onto the back-shell.
    36. Step image
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