DOC AIRBUS | AMM A320FCONTACT REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
1. General
** ON A/C NOT FOR ALL - This chapter gives the procedure for the replacement of a connector contact (pin or socket) on a cable assembly. Refer to AWL Engine Equipment List for connectors and backshell part numbers and ATA 92-20 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.
2. Standard equipment
** ON A/C NOT FOR ALL | ----------------------------------------------------------------------------- |
| ! ! Supplier ! ! ! |
| ! Part No. ! Code ! Nomenclature ! Application ! |
| !------------------!----------!----------------------!------------------------! |
| ! BT-BS-611 ! 11815 ! Strap Wrench !Removal and Installation! |
| ! TG-70 ! 11815 ! Strap Wrench !of the backshells ! |
| ! 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 ! |
| ! M81969/14-02 ! F0225 ! Removal and Insertion! ! |
| ! ! 11851 ! Tool 20 ga. ! ! |
| ! ! 14283 ! ! ! |
| ! ! 49367 ! ! ! |
| ! M81969/14-03 ! F0225 ! Removal and Insertion!Removal and Insertion of! |
| ! ! 11851 ! Tool 16 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 Tool !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 ! ! |
| ! ! ! ! ! |
| ! M22520/1-01 or ! 11851 ! Crimp tool frame !Use to crimp electrical ! |
| ! equivalent ! 58164 ! !contact on wire ! |
| ! ! ! ! ! |
| ! M22520/1-02 or ! 11851 ! Crimp tool locator !Use to crimp electrical ! |
| ! equivalent ! 58164 ! 16 ga. !contact on wire ! |
| ! ! ! ! ! |
| ! M22520/1-04 or ! 11851 ! Crimp tool locator !Use to crimp electrical ! |
| ! equivalent ! 58164 ! 20 ga. !contact on wire ! |
| !------------------!----------!----------------------!------------------------! |
3. Consumable Material
** ON A/C NOT FOR ALL | ----------------------------------------------------------- |
| ! ! Supplier ! ! |
| ! Part No. ! Code ! Designation ! |
| !--------------------!----------!-------------------------! |
| ! Scotch No. 361 ! 04963 ! Tape, glass cloth ! |
| ! 20-90426-13 ! 0ABG9 ! Braid, Knit mesh ! |
| ! ! ! ! |
| !--------------------!----------!-------------------------! |
4. Removal of the Backshell from the Connector
Backshell Removal(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.
5. Removal of the Contacts from the Connector
(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.
(c) Push the tool along the wire into the rear of the connector until it touches the bottom of the connector.
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.
6. Wire Preparation
** ON A/C NOT FOR ALL - Cut the wire at the rear edge of the damaged contact to remove the contact from each wire.
7. Stripping of the Wire
** ON A/C NOT FOR ALL - Strip the wire insulation 7 mm (0.27 in.),from the end of the wire with a PN 45092 Mechanical Wire Stripper.
NOTE: When the 20 gage wire is used in a size 16 gage contact crimp barrel, filler wire must be inserted along with the 20 gage wire conductor. Use enough filler wire to make sure you have a correct pull test when the barrel is crimped.
8. Crimping of the Contact
(1) Use the applicable crimp tool frame and locator given in the standard equipment for the correct wire gage.
(2) Install the crimp tool positioner to the crimp tool frame as follows:
(a) Remove the lock clip from the lock ring on the positioner.
(b) Use the correct positioner which agrees with the contact gage size to be crimped.
(c) Put the positioner on the tool frame lock plate with the positioner pins aligned with the lockplate ring slots.
(d) Push the positioner into the tool frame and turn the positioner 90 degrees in a clockwise direction until you get a positive lock.
(e) Install the lock clip to the positioner lock ring.
(3) Crimp the replacement contact to the wire as follows:
(a) Raise and turn the tool frame selector knob until the number of the knob agrees with the number on the positioner's data plate for the correct wire size. Align the number on the knob to the index mark on the tool frame and release the knob.
| CAUTION: IF THE TOOL FRAME SELECTOR KNOB IS PUT IN THE WRONG POSITION, DAMAGE |
| TO THE CONTACT AND WIRE CAN OCCUR. ALSO THE CONTACT CAN BE LOOSELY |
| CRIMPED ON THE WIRE. |
(b) Examine the wire to make sure the wire strands are not separated. Carefully twist the wire strands in their normal direction of twist to fit the contact wire hole.
(c) Install the stripped end of the wire into the contact wire hole.
(d) Push the wire into the contact wire hole until you feel it touch the bottom.
NOTE: If the wire was incorrectly stripped, the wire will not touch the bottom of the crimp barrel or there will be too much bare wire at the rear shoulder of the barrel.
(e) Install the contact and stripped wire end through the tool frame hole and into the positioner hole.
(f) Squeeze the tool frame handles together until the ratchet releases.
NOTE: If too much or too little force is needed to squeeze the tool frame handles together, the contact is not crimped correctly.
Look at the crimp tool for the correct position for the wire and contact size.
You cannot open the tool frame until the full crimp is completed.
Look at the crimp tool for the correct position for the wire and contact size.
You cannot open the tool frame until the full crimp is completed.
(g) Remove the crimped contact.
(h) Do steps (a) thru (g) until you crimp all the replacement contacts on the wires.
9. Contact Continuity Test
A. Procedure
- Do a continuity test on the replaced harness assembly contacts from point-to-point. Use a Model 160B Digital Multimeter or a Model 260 Ohmmeter or equivalent.
NOTE: The detailed wiring data from Termination A to Termination B is found in the AWL 92-20 Hook-Up Lists/Plugs and Receptacles.
- Each circuit must have continuity from Termination A to Termination B on each circuit.
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 Termination B
11. Install the Contact into the Connector
(1) Make sure the backshell detail parts were not removed from the cable assembly.
(2) If the detail parts were removed, install the parts on the cable assembly.
NOTE: The backshell detail parts cannot be installed on the connector after the contacts are installed in the connector.
(3) Use the applicable contact insertion tool that is listed in the standard equipment for the correct contact gage.
(4) Move the backshell detail parts to the rear over the cable assembly to permit the contacts to be inserted in the connector.
(5) 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.
(6) Install the contact into the connector.
(a) Hold the connector in your hand.
| CAUTION : IF TOO MUCH PRESSURE IS USED WHEN YOU INSTALL THE CONTACT INTO THE |
| CONNECTOR, DAMAGE TO THE CONNECTOR COLLET TINES CAN OCCUR. |
(b) Install the wired contact into the cavity at the rear of the connector with a strong and equal pressure.
(c) 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.
(d) Lightly pull back on the wire to feel if the contact is locked in the collet.
(e) Remove the tool.
(f) Do steps (a) thru (e) until you install all the contacts.
12. Contact Retention Test
A. Procedure
(1) Do a test on each contact to make sure it has a retention force of 3.11 daN (6.9915 lbf) to 5.78 daN (12.9939 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 4.45 daN (10.0039 lbf) of pressure has been applied.
(c) If the contact is still firmly held in the same position, the contact retention is satisfactory.
(6) Do steps (3) thru (5) until all the contacts are tested
13. Installation of the Backshell to the Connector
(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 knit mesh strip goes outside the tube and split ring, but under the ring, washer and strain relief clamp and coupling nut. Make sure the wire braid is held under the grounding ferrule.
(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) If applicable, wrap the cable with Scotch No. 361 Tape around the cables under the strain relief clamp for the correct build-up under the clamp.
(9) TORQUE the coupling nut to 10 lbf.in (1,13 Nm) with a strap wrench and a PN 600-004 Torque Wrench.
(10) Make sure all of the twists and bends are out of the cable.
(11) Tighten the two screws on the clamp.
(12) TORQUE the two screws 10 to 20 lbf.in (1,13 to 2,26 Nm).
14. 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 Termination B
15. 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 megohm.
(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.
16. Safetying of the Backshell
- Lockwire the backshell by the procedure given in Chapter 70-71-13.