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Training for Electrical Harness Equipment and Their Usage by Derya Milner
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Training for Electrical Harness Equipment and Their Usage by Derya Milner

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The training that I have given when working at TAI about electrical harness equipment, their usage and standards.

The training that I have given when working at TAI about electrical harness equipment, their usage and standards.


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  • 1. GENERAL ELECTRICAL EQUIPMENT USED FOR HARNESS JOBS Made By Derya (Durmus) Milner Senior Electrical Design Engineer, Project Manager, PMP
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  • 4. Electrical cables must be stripped before they are fitted with contacts, terminals etc. to form a conductive connection. The respective stripping length is defined in the relevant process specification depending on the contact, terminal etc. to be used. Cables of the sizes 26 AWG (0,15 mm2 ) to 10 AWG (5 mm2 ) are stripped with hand–held pliers or automatic stripping tools. Cables with larger cross–sections, coaxial cables and shielded cables are stripped with cable–stripping knives, special tools or automatic stripping tools. STRIPPING OF ELECTRICAL CABLES TAS-304
  • 5. LACING TAPE Lacing Tape makes bundling wires or wrapping a large cable harness possible Used to wrap wire bundles where other harness material is not practical, not suitable or simply will not fit. Strong braided Nylon lace with a waxed finish is the solution. MIL T-43435B
  • 6. SPIRAL WRAP SPIRAL WRAP TOOL Black spiral wrapping to bundle wires, make a harness etc. Great for computer cables, telephone cables, automotive and marine use. Easily applied and removed. Just wrap around your wires For temporary or permanent applications. Materials: Polyethylene, Nylon and PTFE. Helps apply spiral wrapping up to 1/2 inch to bundle wires, harness's etc.
  • 7. ELECTRIC WIRE AND WIRE BUNDLES IDENTIFICATION Electrical cables can be marked according to the hot stamp and UV-laser procedures. Also, identification sleeves, cable ties and marking tapes can be used to mark the electrical cables.
  • 8. CM-SCE Military grade tie-on cable marker tags CM-SCE markers are flat, rigid, non-adhesive labels that can be used to identify large cables and wire bundles in environments such as military and aerospace. Marker tags are applied to cables or wire bundles with cable ties. Print performance meets or exceeds the requirements of SAE AS81531 4.6.2 and MIL-STD-202.
  • 9.  
  • 10. Nylon Cable Ties – Tie Wrap Cable Tie Installation Tool
  • 11. TERMINI Fiber optic termini utilize constant pressure from a specially designed coil spring to help prevent termini separation resulting from shock, vibration or thermal cycling. The M29504 termini "float" within the connector and self-align to provide precise mating every time due to the unique shape of the ferrule and alignment sleeve hood.
  • 12. EXAMPLE of A CIRCULAR CONNECTOR TAS-305 Circular, rectangular and flat connectors consist of a ”PLUG”, the movable part, and a ”RECEPTACLE”, the fixed part.The receptacle is attached with its flange to the structure, housing, etc. by means of screws. Most frequently, circular connectors are of the thread or bayonet locking type whereas rectangular connectors are connected either by threads or a special type of locking.
  • 13. Circular Connector NAS1599 TAS-305
  • 14. Circular Connector NAS1599 TAS-305
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  • 18. Tool with Inserted Cable
  • 19. Unlocked Contact (unlocking from the rear)
  • 20. Tightening of Knurled Nuts with Polygrip Pliers Hand–tighten the knurled nuts on the receptacles until a movement of the connector parts can no longer be felt. Then tighten the nut by another 1/8 thru 1/4 turn (corresponds to 45° thru 90°) using polygrip pliers (see Figure 26). The connector and its surface protection must not be damaged in the process. Circular connectors with screw–type locking: TAS-480
  • 21.  
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  • 23. TAS-480
  • 24. Strain Relief Installed with Cable Clamp
  • 25. Connector with Dust Cap
  • 26. ELECTRICAL WIRE BUNDLES FABRICATION TAS-302 Bundle Breakout and Crossover
  • 27. Bundle Breakout and Crossover ELECTRICAL WIRE BUNDLES FABRICATION TAS-302
  • 28. Tying Cables TAS-302
  • 29. Attachment of Draw Wires TAS-480
  • 30. The conduits shall protrude by 10–15 mm from the last support. Last Protective Conduit Support TAS-480
  • 31. Attachment of Diodes and Joints to Cable Harness/Route TAS-480
  • 32. Connection of Several Cables to One Bonding Point TAS-480 If several cables shall be connected to one bonding point, they must be routed to the bonding point from different directions so that the terminals do not hinder one another or become bent. A maximum of 4 cables may be connected to one bonding point. The cable with the greatest size should be connected lowermost and that with the smallest size uppermost
  • 33.  
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  • 35. Terminal Blocks
  • 36. Junction Terminal Block with Accessories TAS-306
  • 37. Identification of Terminal Connections TAS-306 Stud–type terminal blocks are available with one and two poles.
  • 38. LOAD ANALYSIS WORK
      • WORKING CONDITIONS
  • 39. Bus wiring diagram. The bus wiring diagram shall consist of a functional single-line diagram of the bus arrangement, with buses, power sources and interconnections identified
  • 40. 115VAC ESSENTIAL BUS AC and DC analyses.
  • 41. PIN TO PIN Konnektör No Pin No İşaret Yönü İşaret Tipi İşaret Tanımı Kablo Sarım Bilgisi --- --- Giriş Power 28VDC Twisted Pair --- --- Giriş Power Ground GND --- --- Giriş Power 28VDC Twisted Pair --- --- Giriş Power Ground GND Geldiği Birim Konnektör No Pin No İşaret Adı Gittiği Birim VTB J1 A 28VDC_IN Helikopter 28VDC VTB J1 C 28VDC_RTN Helikopter 28VDC_RTN VTB J1 B 28VDC_IN Helikopter 28VDC VTB J1 D 28VDC_RTN Helikopter 28VDC_RTN
  • 42. WIRING DIAGRAM
  • 43. WIRING DIAGRAM CLOSER
  • 44. HARNESS DIAGRAM
  • 45. HARNESS ROUTING
  • 46. HARNESS ROUTING