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AC 43.13-1B CHG 1 9/27/01 diameter should be placed on the bottom and the smallest diameter on top. Tightening ter minal connections should not deform the ter minal lugs or the studs. Terminal lugs should be so positioned that bending of the terminal lug is not required to remove the fastening screw or nut, and movement of the terminal lugs will tend to tighten the connection. d. Copper Terminal Lugs. Solderless crimp style, copper wire, terminal lugs should be used and conform to MIL-T-7928. Spacers or washers should not be used between the tongues of terminal lugs. e. Aluminum Terminal Lugs. The alu minum terminal lugs conforming to MIL-T-7099 (MS-25435, MS-25436, MS-25437, and MS-25438) should be crimped to aluminum wire only. The tongue of the aluminum terminal lugs or the total number of tongues of aluminum terminal lugs when stacked, should be sandwiched between two MS-25440 flat washers when terminated on terminal studs. Spacers or washers should not be used between the tongues of terminal lugs. Special attention should be given to aluminum wire and cable installations to guard against conditions that would result in excessive volt age drop and high resistance at junctions that may ultimately lead to failure of the junction. Examples of such conditions are improper in stallation of terminals and washers, improper torsion (“torquing” of nuts), and inadequate terminal contact areas. f. Class 2 Terminal Lugs. The Class 2 terminal lugs conforming to MIL-T-7928 may be used for installation, provided that in such installations, Class1 terminal lugs are ade quate for replacement without rework of in stallation or terminal lugs. Class 2 terminal lugs should be the insulated type, unless the conductor temperature exceeds 105 °C. In that case uninsulated terminal lugs should be used. Parts’ lists should indicate the appropriate Class 1 terminal lugs to be used for service re placement of any Class 2 terminal lugs in stalled. g. Termination of Shielded Wire. For termination of shielded wire refer to MIL-DTL-27500. 11-175. ATTACHMENT OF TERMI- NALS TO STUDS. Connectors and terminals in aircraft require special attention to ensure a safe and satisfactory installation. Every possi bility of short circuits, due to misinstallation, poor maintenance, and service life, should be addressed in the design. Electrical equipment malfunction has frequently been traced to poor terminal connections at terminal boards. Loose, dirty, or corroded contact surfaces can produce localized heating that may ignite nearby combustible materials or overheat adja cent wire insulation. (See paragraph 11-178) 11-176. STUDS AND INSULATORS. The following recommendations concerning studs also apply to other feed-through conductors. a. Current Carrying Stud Resistance. Due to heat loss arising from wire-to-lug and lug-to-stud voltage drop, the resistance per unit length of a current carrying stud should not be greater than that of the wire. b. Size of Studs. In designing the stud for a feed-through connection, attention should be given to the higher resistance of brass, as com pared to copper. A suggested method of de termining the size is to use a current density in the stud equivalent to that of the wire, com pensating for the difference of resistance of the metals. Consideration should also be given to mechanical strength. c. Support for Studs. The main stud support in the feed-through insulation should be independent of the attachment of the lugs to the stud. Therefore, loosening of the insula tion support of the stud will not affect the Page 11-68 Par 11-179PDF Image | AFS-640
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