CONNECTOR, CONTACT AND BACKSHELL REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION

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1. General

This chapter gives the procedure for the replacement of a connector and backshell on a cable assembly. Refer to AWL and IPC for connectors, backshell part numbers and for pin numbers equipment list. Refer to Chapter 70-71-12 for the connector contact/insert arrangement.
Standard equipment and consumable material can be replaced with equivalent items.

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2. Standard equipment

-----------------------------------------------------------------------------

! ! Supplier ! ! !

! Part No. ! Code ! Nomenclature ! Application !

!------------------!----------!----------------------!------------------------!

! BT-BS-611 ! 11815 ! Strap Wrench !Removal and Installation!

! TG-70 ! 11815 ! Strap Wrench !of the backsshells !

! 600-004 ! 06324 ! Torque Wrench ! !

! ! 11851 ! ! !

! ! ! ! !

! M81969/8-05 ! 11851 ! Insertion Tool 20 ga.!Removal and Insertion of!

! M81969/8-06 ! 11851 ! Removal Tool 20 ga. !the contacts !

! M81969/14-03 ! F0225 ! Removal and Insertion! !

! ! 11851 ! Tool 16 ga. ! !

! ! 14283 ! ! !

! ! 49367 ! ! !

! M81969/14-02 ! F0225 ! Removal and Insertion!Removal and Insertion of!

! ! 11851 ! Tool 20 ga. !the contacts !

! ! 14283 ! ! !

! ! 49367 ! ! !

! MS27495A16 ! 11851 ! Insertion Tool 16 ga.!Removal and Insertion of!

! MS27495A20 ! 11851 ! Insertion Tool 20 ga.!the contacts !

! MS27495R16 ! 11851 ! Removal Tool 16 ga. ! !

! MS27495R20 ! 11851 ! Removal Tool 20 ga. ! !

! ! ! ! !

! Model 160B ! 80164 ! Digital Multimeter !Use to measure !

! ! ! !continuity and point-to-!

! ! ! !point circuits !

! ! ! ! !

! Model 1863 ! 24655 ! Megohmmeter !Use to measure !

! ! ! !insulation resistance !

! ! ! ! !

! HT210-16 ! 11851 ! Retention Test Toll !Use to test the 16 ga. !

! 67-016-02 ! 11851 ! Replacement Pin Tip !contact retention !

! 68-016-01 ! 11851 ! Replacement Socket ! !

! ! ! Tip ! !

! ! ! ! !

! HT210-20 ! 11851 ! Retention Test Tool !Use to test the 20 ga. !

! 67-020-02 ! 11851 ! Replacement Pin Tip !contact retention !

! 68-020-01 ! 11851 ! Replacement Socket ! !

! ! ! Tip ! !

!------------------!----------!----------------------!------------------------!

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3. Consumable Material

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! ! Supplier ! !

! Part No. ! Code ! Designation !

!--------------------!----------!-------------------------!

! Scotch No. 361 ! 04963 ! Tape, glass cloth !

! 20-90426-13 ! 0ABG9 ! Braid, Knit mesh !

! ! ! !

!--------------------!----------!-------------------------!

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4. Removal of the Backshell from the Connector

A. Procedure

Backshell Removal. ** ON A/C NOT FOR ALL

(1) Remove the lockwire from the shell, strain relief clamp and coupling nut, and the two screws.

(2) Make a mark on the connector backshell in relation to the connector master keyway if the backshell is other than a straight type.

(3) Remove or loosen the screws from the strain relief clamp and coupling nut.

(4) Remove the strain relief clamp and coupling nut from the backshell with a PN BT-BS-611 or BT-70 Strap Wrench.

(5) Move the strain relief clamp and coupling nut to the rear over the cables. If applicable, remove the glass cloth tape.

(6) Refer to figure for the correct backshell application.

(7) Move the grounding ferrule or the washer, ring, split ring, and tube to the rear over the cables enough to permit the shell to be removed.

(8) Remove the coupling nut from the connector with a strap wrench. Move the shell to the rear over the cables.

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5. Removal of the Contacts from the Connector

A. Procedure

Contact Removal. ** ON A/C NOT FOR ALL

(1) Apply a small piece of tape to each wire and write on the tape the number of the connector hole from which the wire came.

(2) Use the applicable contact removal tool that is listed in the standard equipment for the correct contact gage.

NOTE: All the power plant connector contacts (pin/socket) are released from the rear of the connector.

(3) Remove the contact (pin/socket) as follows:

(a) Place the contact removal tool on the wire.

(b) Move the tool back on the wire while you hold against the wire at the connector opening. The wire will move into the slot of the tool.

NOTE: When the tool touches the bottom of the connector it will expand the collet from the contact to permit the contact to be released from the connector.

(d) While you keep light pressure on the tool, hold the wire against the serrated shoulder of the tool and remove both the wired contact and tool.

(e) Do steps (a) thru (d) until you remove all the contacts.

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6. Replacement of the Connector or Backshell

NOTE: Refer to AWL Equipment List of IAE section for the Functional Item Number (FIN) and connector part number and the backshell part number.

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7. Installation of the Contacts into the Connector

A. Procedure

Contact Removal. ** ON A/C NOT FOR ALL

(1) If the backshell detail parts were removed install the parts on the cable assembly by the applicable illustration.

NOTE: The backshell detail parts cannot be installed on the connector after the contacts are installed in the connector.

(2) Move the backshell detail parts to the rear over the cable assembly to permit the contacts to be inserted in the connector.

(3) Use the applicable contact insertion tool given in the standard equipment for the correct contact gage.

(4) If the connector is replaced, examine the connector part number and make sure that it agrees with the correct FIN.

(5) When you install the contacts you must start with the wire in the center connector cavity.

(6) Install the insertion tool on the contact.

(a) Put the wire between the slot and squeeze the wire into the slot at the tool tip. Make sure the wire is in the slot at the tool tip.

(b) Pull the wire back through the tool until the tip seats on the rear shoulder of the crimp contact.

(7) Install the contact into the connector.

(a) Hold the connector in your hand.

(b) Use the mark on the wire to identify the correct contact (pin/socket) location in the connector.

NOTE: The detailed wiring data from Termination A to Termination B is found in the AWL 92-20 Hook-Up List/Plugs and receptacles.

CAUTION: IF TOO MUCH PRESSURE IS USED WHEN YOU INSTALL THE CONTACT INTO THE

CONNECTOR, DAMAGE TO THE CONNECTOR COLLET TINES CAN OCCUR.

(d) When the contact is properly locked in the connector, a light click sound can be heard.

NOTE: The click sound is made by the tines on the collet as they lock in position behind the contact shoulder. This locks the contact in the connector collet.

(e) Lightly pull back on the wire to feel if the contact is locked in the collet.

(f) Remove the tool.

(8) Do steps (6) and (7) until all the contacts are installed.

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8. Contact Retention Test

A. Procedure

(1) Do a test on each contact to make sure it has a retention force of between 31.1 N and 57.8 N (7 and 13 lbf.)

CAUTION: EXERCISE CARE WHEN TESTING CONTACTS TO PREVENT DAMAGE TO THE CONTACT,

CONNECTOR GROMMET OR RETENTION TEST TOOL.

(2) Use the applicable retention test tools and replacement pin and socket tools that are listed in the standard equipment for the correct contact gage.

(3) Put the 16 or 20 gage retention test tool and replacement tip on the contact so they are in a straight line.

(a) Use the pin replacement tips when you do a test of the socket contacts.

(b) Use the socket replacement tips when you do a test of the pin contacts.

(4) Hold this position when you do a test on each contact. This will give the most accurate retention force reading.

(5) With the retention test tool in position on the contact do the test that follows:

(a) Apply pressure on the tool until a minimum of half of the color-coded area is covered.

(b) At this point 44.5 N (10 lbf.) of pressure has been applied.

(6) Do steps (3) thru (5) until all the contacts are tested.

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9. Installation of the Backshell to the Connector

A. Procedure

Backshell Removal. ** ON A/C NOT FOR ALL

(1) Refer to figure for the correct backshell application.

(2) Move the coupling nut and shell forward over the cables.

(3) Align the mark you made before on the backshell with the connector master keyway.

NOTE: The mark on the connector backshell correctly aligns the connector and the backshell when you install the harness on the engine.

(4) Install the coupling nut to the connector and tighten with a PN BT-BS-611 or TG-70 Strap Wrench.

(5) Move the grounding ferrule or the tube, split ring, ring, and washer forward over the cables and into the shell. Make sure the wire braid is held under the grounding ferrule or split ring.

(6) Move the strain relief clamp and coupling nut forward over the cables to the shell.

(7) Install the coupling nut on the shell.

(8) TORQUE the coupling nut to 10 lbf.in. (1.13 Nm) with a strap wrench and a PN 600-004 GLENAIR Torque Wrench.

(9) Make sure all of the twists and bends are out of the cable.

(10) Wrap the cable with Scotch No. 361 Tape under the strain relief clamp for the correct build-up under the clamp.

(11) Tighten the two screws on the clamp.

(12) TORQUE the two screws to between 10 and 20 lbf.in. (1.13 and 2.26 Nm).

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10. Backshell Continuity Test

A. Procedure

(1) Do a continuity test on the backshell to the connector. Use a Model 160B Digital Multimeter or equivalent.

(2) The resistance must be no more than 0.01 ohm.

(3) Do a continuity test on the backshell of Termination A to the backshell of Termination B.

NOTE: The detailed wiring data from Termination A to Termination B is found in the AWL 92-20 Hook-Up Lists/Plugs and Receptacles.

(4) Each backshell must have continuity from Termination A to Termnation B

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11. Insulation Resistance Test

A. Procedure
Do an insulation resistance test on all the repaired circuits. Use Model 1863 Megohmmeter or equivalent.

CAUTION: YOU MUST DISCONNECT ALL THE CONNECTORS WHICH HAVE A RELATION TO THE

CIRCUITS IN THE CONNECTOR THAT IS TESTED. FAILURE TO DO THIS WILL

CAUSE UNSATISFACTORY RESISTANCE INDICATIONS AND POSSIBLE DAMAGE TO

THE CIRCUITS.

(1) Do the insulation resistance test between each pair of wires that have been repaired.

(2) Set the megohmmeter to the 100 volt DC scale.

(3) Connect one test lead of the megohmmeter to the contact (pin or socket) of one of the repaired wires. Connect the other test lead to the contact (pin or socket) of the other repaired wire.

(4) The resistance should be infinity.

(5) Do the insulation resistance test between each repaired wire and the braided shield.

(6) The resistance must be a minimum of 20 megohms.

(7) Do the insulation resistance test between each repaired wire and the backshell.

(8) Set the megohmmeter to the 500 volt DC scale.

(9) Connect one test lead of the megohmmeter to the backshell body of the connector. Connect the other test lead to the contact (pin or socket) of the connector.

(10) The resistance must be a minimum of 20 megohms.

(11) Safetying of the Backshell

Lockwire the backshell by the procedure given in Chapter 70-71-13.

[Rev.10 from 2021] 2026.04.01 02:19:57 UTC