58389253 Standard Wiring Practices Manual

PARAGRAPH DESCRIPTION PAGE

1. Part Numbers and Description 11.A. Switch Part Numbers 12. Switch Disassembly 12.A. Connector Separation 13. Switch Assembly 13.A. Plug and the Receptacle Connection 1

1.Part Numbers and Description

A. Switch Part Numbers

Janco AD45-() switches have these technical features:

- Cory or Tri-Star CSLT2-21R() receptacle connectors mounted on the rear- Connect to Cory or Tri-Star CSLT2-21P() plug connectors.

Refer to Subject 20-61-29 for assembly of Cory and Tri-Star CSLT2-21P()connectors.

TABLE ISWITCH PART NUMBERS

Part

NumberDescription Supplier

AD45-() Switch, Rotary Janco

2.Switch Disassembly

A. Connector Separation

Refer to Subject 20-61-29.

3.Switch Assembly

A. Plug and the Receptacle Connection

Refer to Subject 20-61-29.

b

STANDARD WIRING PRACTICES MANUAL

JANCO AD45-() SWITCHES

MANUAL NO: D6-54446 PAGE 1NOV 01/200520-84-17

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1. Part Numbers and Description 11.A. Connector Clamp Part Numbers 12. Connector Clamp Disassembly 12.A. Clamp Removal 13. Connector Clamp Assembly 13.A. Clamp Installation 1


A. Connector Clamp Part Numbers

TABLE ICONNECTOR CLAMP PART NUMBERS

Part Number Supplier

G2636-() Glenair

G2918-() Glenair

2.Connector Clamp Disassembly

A. Clamp Removal

(1) Remove the screws from the clamp assembly.

(2) Spread the clamp assembly to remove it from the connector.

3.Connector Clamp Assembly

A. Clamp Installation

(1) Install the connector clamp assembly. Refer to Figure 1.

(2) Tighten the clamp assembly.

Make sure that the torque on the screws is from 10 inch-pounds to 12inch-pounds.

b


ASSEMBLY OF GLENAIR G2636-() AND G2918-() CONNECTOR CLAMPS


CONNECTOR CLAMP ASSEMBLYFigure 1

b


ASSEMBLY OF GLENAIR G2636-() AND G2918-() CONNECTOR CLAMPS

MANUAL NO: D6-54446PAGE 2AUG 01/1996 20-85-11

This Subject gives the procedures to assemble the landing gear cables for these Model 747,Model 767, and Model 777 systems:

- Anti-Skid- Brake Cooling- Tire Pressure- In-Axle.


1. Part Numbers and Description 11.A. Necessary Parts and Materials 11.B. Configuration of Cable Assemblies 22. Landing Gear Cable Assembly: 747-100,

747-200, 747-3002

2.A. Anti-Skid Cable Assembly 32.B. Brake Cooling Cable Assembly 53. Landing Gear Cable Assembly: 747-400 73.A. Anti-Skid Cable Assembly 73.B. Brake Cooling Cable Assembly 103.C. Tire Pressure Cable Assembly 114. Landing Gear Cable Assembly: 767 134.A. Anti-Skid Cable Assembly 134.B. Brake Cooling and Tire Pressure Cable

Assembly16

5. Landing Gear In-Axle Cable Assembly: 777 195.A. Wire Preparation 195.B. Connector Assembly 23


A. Necessary Parts and Materials

TABLE ICABLE ASSEMBLY COMPONENT PART NUMBERS

Component Part Number Supplier

Adapter G1504-() Glenair

Lanyard G70259T77-() Glenair

b


ASSEMBLY OF LANDING GEAR CABLES


TABLE IINECESSARY MATERIALS

Material Part Number Supplier

Sleeve, Teflon TFE 2XChemplast

Zeus Industrial Products

SPIRAP, Teflon 500024 AMP

B. Configuration of Cable Assemblies

TABLE IIICONFIGURATION OF LANDING GEAR CABLE ASSEMBLIES

System ModelG1504-()

AdapterLanyard

Length

(inch) Reference

TFE 2X SPIRAP

Anti-Skid

747-100

Yes - - 55 Paragraph 2.A.747-200

747-300

747-400 No - 58 - Paragraph 3.A.

767 No - 39 - Paragraph 4.A.

Anti-SkidWith BrakeCooling

747-200Yes - - 33 Paragraph 2.A.

747-300

Anti-SkidWith TirePressure

747-400 No - 58 - Paragraph 3.A.

767 No - 39 - Paragraph 4.A.

BrakeCooling

747-200Yes G70259T77-35 - 33 Paragraph 2.B.

747-300

747-400 No G70259T77-38 41 41 Paragraph 3.B.

767 No G70259T77-38 40 40 Paragraph 4.B.

TirePressure

747-400 No - 58 - Paragraph 3.C.

767 No - 39 - Paragraph 4.B.

In-Axle 777 No -Refer toTable IV

- Paragraph 5.

2.Landing Gear Cable Assembly: 747-100, 747-200, 747-300

This Paragraph gives the procedures to install Glenair G1504-() cable adapters onlanding gear cables for the anti-skid system.

b



MANUAL NO: D6-54446PAGE 2FEB 01/2002 20-85-12

A. Anti-Skid Cable Assembly

ANTI-SKID CABLE ASSEMBLYFigure 1

(1) Cut the length of SPIRAP. Refer to Table III.

(2) Put the SPIRAP on the cable.

(3) Remove 2.0 inches ±0.1 inch of the outer jacket of the cable. Refer toFigure 2.

CABLE SHIELD TERMINATIONFigure 2

(4) Terminate the shield so that it is a dead end. Refer to Figure 2 andSubject 20-10-15.

(a) Cut the shield so that the end of the shield is 0.25 inch ±0.06 inchfrom the end of the jacket.

(b) Fold the shield back over the jacket.

(c) Shrink a 3 inch length of heat shrinkable sleeve over the shield.

(5) Put these sleeves in this sequence over the cable:

(a) A 1-3/4 inch length of 1/2 inch diameter yellow heat shrinkable sleeve

(b) A 2-1/4 inch length of 3/8 inch diameter yellow heat shrinkable sleeve

(c) A 2-3/4 inch length of 3/8 inch diameter yellow heat shrinkablesleeve.

(6) Put the Glenair G1504-() cable adapter over the cable.

Make sure to put the clamp end first.

b




(7) Remove the cable clamp from the G1504-() adapter.

(8) Put one drop of Vibratite thread lock compound:

- On a minimum of two threads of the internal threads of the adapterbody

- On a minimum of two threads of the external threads of the adapterbody.

Refer to Figure 3.

LOCATION OF THE VIBRATITEFigure 3

(9) Put the edge of the SPIRAP so that it is approximately flush with the cablejacket. Refer to Figure 4.

POSITION OF THE SPIRAPFigure 4

(10) Install the cable diameter buildup sleeves. Refer to Figure 5 and Subject20-10-14.

CABLE DIAMETER BUILDUP SLEEVESFigure 5

(a) Slide the 2-3/4 length of 3/8 inch diameter sleeve to the end of thecable until it extends between 1/8 inch and 1/4 inch farther than theforward edge of the SPIRAP.

b



MANUAL NO: D6-54446PAGE 4NOV 01/2000 20-85-12

(b) Shrink the sleeve into position. Refer to Subject 20-10-14.

(c) Put the 2-1/4 inch length of 3/8 inch diameter sleeve over the firstsleeve.

(d) Shrink the sleeve into position. Refer to Subject 20-10-14.

(e) Put the 1-3/4 inch length of 1/2 inch diameter sleeve over the secondsleeve.

(f) Shrink the sleeve into position. Refer to Subject 20-10-14.

(11) Assemble the connector. Refer to Subject 20-61-11.

(12) Hold the two conductors immediately forward of the buildup sleeves and pushthem to the connector to make the wires bend.

The wires should remain bent after they are released.

CAUTION: DO NOT GRIP THE BUILDUP SLEEVES TO MAKE THE WIRES BEND. THESLEEVES CAN MOVE OUT OF POSITION.

(13) Move the adapter body forward.

(14) Engage the threads of the adapter and the connector.

(15) Torque the adapter hand tight plus 1/8 of a turn.

(16) Hold the cable and put the forward edge of the buildup sleeves so that theyare flush to 1/8 inch in the end of the adapter body.

Make sure that:

- The sleeve remains in position when the cable is released- The wires have slack in the adapter.

(17) Engage the threads of the cable clamp and the adapter.

(18) Torque the cable clamp hand tight plus 1/8 of a turn.

(19) Tighten the clamp saddle screws.

(20) If the cable clamp does not hold the cable tightly:

(a) Remove the cable clamp from the adapter.

(b) Remove the adapter from the connector.

(c) Remove the contacts from the connector. Refer to Subject 20-61-11.

(d) Put the necessary number of 1 inch lengths of RT-876 or equivalentheat shrinkable sleeves on the cable.

Make sure that each sleeve has the smallest diameter that can moveeasily on the cable.

(e) Align the forward edge of each sleeve with the forward edge of the2-3/4 inch length of heat shrinkable sleeve.

(f) Shrink each sleeve in position. Refer to Subject 20-10-14.

(g) Do Step (11) thru Step (19) again.

Make sure that the clamp holds the cable tightly.

(21) Install safety wires on the saddle screws.

B. Brake Cooling Cable Assembly

(1) Assemble the brake cooling cable but do not tighten the saddle clampscrews. Refer to Paragraph 2.A.

b




(2) Make a selection of a lanyard from Table III.

(3) Install the lanyard. Refer to Figure 6.

INSTALLATION OF THE LANYARDFigure 6

(4) Attach the forward lanyard fitting below one of the clamp saddle screws.

Make sure:

- That the forward lanyard mounting hole is approximately centered overthe rear sleeve

- To keep the lanyard as straight as possible.

A bend in the cable results after the lanyard has been secured to theGlenair adapter.



(a) Remove the lanyard from the clamp.

(b) Remove the clamp from the connector.

(c) Remove the adapter from the connector.

(d) Remove the contacts from the connector. Refer to Subject 20-61-11.

(e) Put the necessary number of 1 inch lengths of RT-876 or equivalentheat shrinkable sleeves on the cable.


(f) Align the forward edge of each sleeve with the forward edge of the2-3/4 inch length of heat shrinkable sleeve.

(g) Shrink each sleeve in position. Refer to Subject 20-10-14.

(h) Do Step (1) thru Step (5) again.



b



MANUAL NO: D6-54446PAGE 6NOV 01/2000 20-85-12

3.Landing Gear Cable Assembly: 747-400



(1) Make a selection of the necessary length of TFE 2X teflon sleeve. Refer toTable II and Table III.

(2) Put the sleeve on the cable.



(4) Assemble a shield dead end. Refer to Figure 8.




Make sure the end of the sleeve extends 0.25 inch farther than the endof outer jacket.

b



MANUAL NO: D6-54446 PAGE 7FEB 01/200220-85-12

(5) Push a 1.0 inch ±0.1 inch length of 3/16 inch diameter heat shrinkablesleeve on the cable until the rear end of the sleeve is against the shielddead end. Refer to Figure 9.

POSITION OF THE FORWARD SLEEVEFigure 9

(6) Shrink the sleeve into position. Refer to Subject 20-10-14.

(7) Push a 2.75 inch ±0.10 inch length of 3/16 inch diameter heat shrinkablesleeve on the cable until the forward end is aligned with the forward endof the 1 inch sleeve. Refer to Figure 10.

POSITION OF THE REAR SLEEVEFigure 10


(9) Push the TFE 2X sleeve on the wire end of the cable, over the forward andrear heat shrinkable sleeves until the forward end of the TFE 2X sleeveextends 0 inch to 0.2 inch farther than the end of the heat shrinkablesleeves.


(a) A 1.5 inch ±0.1 inch length of 1/2 inch diameter yellow heatshrinkable sleeve

(b) A 2.0 inch ±0.1 inch length of 3/8 inch diameter yellow heatshrinkable sleeve

(c) A 2.5 inch ±0.1 inch length of 3/8 inch diameter yellow heatshrinkable sleeve.

(11) Install the cable diameter buildup sleeves. Refer to Figure 11.

b





(a) Push the 2.5 inch length of 3/8 inch diameter sleeve forward until theforward edge is 0 inch to 0.2 inch behind the forward edge of the TFE2X sleeve.


(c) Align the forward end of the 2.0 inch length of 3/8 inch diametersleeve with the forward end of the 2.5 inch sleeve.


(e) Align the forward end of the 1.5 inch length of 1/2 inch diametersleeve with the forward end of the 2.0 inch sleeve.



(13) Put one drop of Vibratite thread lock compound on the internal threads ofthe saddle clamp.

Make sure that each drop of Vibratite covers a minimum of two threads.

(14) Engage the threads of the cable clamp and the connector.



Make sure that the distance from the forward edge of the clamp bar to theforward edge of the heat shrinkable sleeves is 0.13 inch minimum. Refer toFigure 7.


(a) Remove the cable clamp from the connector.

(b) Remove the contacts from the connector. Refer to Subject 20-61-11.

(c) Put the necessary number of 1 inch lengths of RT-876 or equivalentheat shrinkable sleeves on the cable.


(d) Align the forward edge of each sleeve with the forward edge of the 1.5inch length of heat shrinkable sleeve.

(e) Shrink each sleeve into position. Refer to Subject 20-10-14.

(f) Do Step (12) thru Step (16) again for each sleeve.


b




(18) Install safety wires the saddle screws.

B. Brake Cooling Cable Assembly

(1) Cut the length of the TFE 2X sleeve. Refer to Table III.

(2) Put the TFE 2X sleeve on the cable so that it is 0.9 inch from the cableend.

(3) Put a 2-1/2 inch length of 3/8 inch diameter heat shrinkable sleeve overthe TFE 2X sleeve.



(6) Put the SPIRAP on the cable over the TFE 2X sleeve.

(7) Put a 2 inch length of 1/2 inch diameter heat shrinkable sleeve over theSPIRAP.


(9) Put a 1-1/2 inch length of 1/2 inch diameter heat shrinkable sleeve overthe SPIRAP and the first sleeve.











Make sure:



b




A bend in the cable will result after the lanyard has been secured to theGlenair adapter.



(a) Remove the lanyard from the clamp.

(b) Remove the clamp from the connector.








(20) Install safety wires the on the saddle screws.

C. Tire Pressure Cable Assembly


(2) Put the TFE 2X on the cable.

(3) Remove 1.85 inches ±0.1 inch of cable outer jacket.(4) Make a shield ground wire with the solder sleeve procedure. Refer to

Figure 13 and Subject 20-10-15.


(5) Put a 1 inch ±0.06 inch length of 3/16 inch diameter heat shrinkable sleeveagainst the shield termination.

(6) Put a 2.75 inch ±0.06 inch length of 3/16 inch diameter heat shrinkablesleeve over the 1 inch sleeve. Refer to Figure 14.

b



MANUAL NO: D6-54446 PAGE 11AUG 01/200120-85-12

POSITION OF THE SLEEVEFigure 14

(7) Put the TFE 2X sleeve over the cable and heat shrinkable sleeves so that itis flush with the end of the sleeves.



(b) A 2 inch length of 3/8 inch diameter yellow heat shrinkable sleeve




(a) Put the 2-1/2 length of 3/8 inch diameter sleeve forward until it isflush with the forward edge of the TFE 2X sleeve.

(b) Shrink the sleeve into position. Subject 20-10-14.

(c) Put the 2 inch length of 3/8 inch diameter sleeve over the firstsleeve.

(d) Shrink the sleeve into position. Subject 20-10-14.


(f) Shrink the sleeve into position. Subject 20-10-14.




b












(d) Align the forward edge of each sleeve with the forward edge of the1-1/2 inch length of heat shrinkable sleeve.

(e) Shrink each sleeve in position. Refer to Subject 20-10-14.

(f) Do Step (10) thru Step (14) again.



4.Landing Gear Cable Assembly: 767



(1) Make a selection of the necessary length of TFE 2X teflon sleeve. Refer toTable II and Table III.

(2) Put the sleeve on the cable.


b





(4) Assemble a shield dead end. Refer to Figure 17.




Make sure the end of the sleeve extends 0.25 inch farther than the endof outer jacket.

(5) Push a 1.0 inch ±0.1 inch length of 3/16 inch diameter heat shrinkablesleeve on the cable until the rear end of the sleeve is against the shielddead end. Refer to Figure 18.



(7) Push a 2.75 inch ±0.10 inch length of 3/16 inch diameter heat shrinkablesleeve on the cable until the forward end is aligned with the forward endof the 1 inch sleeve. Refer to Figure 19.


b





(9) Push the TFE 2X sleeve on the wire end of the cable, over the forward andrear heat shrinkable sleeves until the forward end of the TFE 2X sleeveextends 0 inch to 0.2 inch farther than the end of the heat shrinkablesleeves.


(a) A 1.5 inch ±0.1 inch length of 1/2 inch diameter yellow heatshrinkable sleeve

(b) A 2.0 inch ±0.1 inch length of 3/8 inch diameter yellow heatshrinkable sleeve

(c) A 2.5 inch ±0.1 inch length of 3/8 inch diameter yellow heatshrinkable sleeve.



(a) Push the 2.5 inch length of 3/8 inch diameter sleeve forward until theforward edge is 0 inch to 0.2 inch behind the forward edge of the TFE2X sleeve.


(c) Align the forward end of the 2.0 inch length of 3/8 inch diametersleeve with the forward end of the 2.5 inch sleeve.


(e) Align the forward end of the 1.5 inch length of 1/2 inch diametersleeve with the forward end of the 2.0 inch sleeve.








b




Make sure that the distance from the forward edge of the clamp bar to theforward edge of the heat shrinkable sleeves is 0.13 inch minimum. Refer toFigure 16.






(d) Align the forward edge of each sleeve with the forward edge of the 1.5inch length of heat shrinkable sleeve.

(e) Shrink each sleeve into position. Refer to Subject 20-10-14.

(f) Do Step (12) thru Step (16) again for each sleeve.



B. Brake Cooling and Tire Pressure Cable Assembly


(2) Put the TFE 2X on the cable.


(4) Put the SPIRAP on the cable over the TFE 2X sleeve.

(5) Remove 2.0 inches ±0.1 inches of the outer jacket of the cable.(6) Terminate the shield so that it is a dead end. Refer to Figure 21 and

Subject 20-10-15.





(7) Put a 1 inch ±0.06 inch length of 3/16 inch diameter heat shrinkable sleeveagainst the shield dead end. Refer to Figure 22.

b






(9) Put a 2.75 inch ±0.06 inch length of 3/16 inch diameter heat shrinkablesleeve over the 1 inch sleeve. Refer to Figure 23.



(11) Put the TFE 2X sleeve on the wire end of the cable, over the forward andrear heat shrinkable sleeves.

Make sure that the sleeve extends 0.125 inch farther than the end of theheat shrinkable sleeves.



(b) A 2 inch length of 3/8 inch diameter yellow heat shrinkable sleeve




b




(a) Put the 2-1/2 length of 3/8 inch diameter sleeve forward until it isflush with the forward edge of the TFE 2X sleeve.


(c) Put the 2 inch length of 3/8 inch diameter sleeve over the firstsleeve.













Make sure:



A bend in the cable will result after the lanyard has been secured to theGlenair adapter.


(a) Remove the lanyard from the cable clamp.

(b) Remove the cable clamp from the connector.



b









(22) If the cable clamp does not hold the cable tightly, install the necessarynumber of 1 inch heat shrinkable sleeves.


5.Landing Gear In-Axle Cable Assembly: 777

A. Wire Preparation

(1) Put the sleeves with connector and wire identification on the cable. Referto Figure 26.

LOCATION OF THE CONNECTOR AND WIRE IDENTIFICATION SLEEVESFigure 26

(a) Put the sleeve with the connector identification on the wire harness.

(b) Put the sleeve with the wire identification on the cable so that it is4.0 inches ±0.2 inches from the end of the cable.

(c) Shrink the wire identification sleeve into position. Refer to Subject20-10-14.

(2) Remove 2.0 inches ±0.13 inch of the outer jacket of the cable.(3) If the wiring diagram shows that the end of the shield has a shield ground

wire, install the shield ground wire with a solder sleeve.

Refer to Figure 27 and Subject 20-10-15.

SHIELD TERMINATION WITH A SHIELD GROUND WIREFigure 27

(4) If the wiring diagram shows that the end of the shield is not terminated,terminate the shield so that it is a dead end.

b





SHIELD DEAD ENDFigure 28

(5) Put a 1.0 inch ±0.1 inch length of heat shrinkable sleeve on the cable sothat it is adjacent to the solder sleeve of the shield ground wire oragainst the insulation sleeve of the insulated shield.

NOTE: Use a sleeve with the smallest diameter that can move easily on thewires.

Refer to Figure 29.


(6) Put a 2.75 inch ±0.1 inch length of heat shrinkable sleeve over the shieldend and the first sleeve so that the edge is aligned with the edge of thefirst sleeve.

NOTE: Use a sleeve with the smallest diameter that can move easily on thewires.

Refer to Figure 30.

b




OUTER CABLE END SLEEVE POSITIONFigure 30


(8) Cut a length of TFE 2X sleeve. Refer to Table IV.

This sleeve goes on the sleeves 1.0 inch and 2.75 inch lengths of sleeve.

TABLE IVTFE 2X SLEEVE LENGTH

Landing Gear Sleeve Length

(inch)Axle Truck Location

Nose - 46

Left Main

Front 82

Center 88

Rear 73

Right Main

Front 82

Center 88

Rear 73

(9) Put the TFE 2X sleeve on the cable so that the end of the sleeve extends0.20 inch ±0.05 inch farther than the aligned end of the other sleeves.Refer to Figure 31.

b




POSITION OF THE TFE 2X SLEEVEFigure 31


These sleeves are installed so that the backshell cable clamps hold thecable tightly.


(a) Put a 2.5 inch ±0.2 inch length of heat shrinkable sleeve on the cableso that the edge of the sleeve aligns with the end of the TFE 2Xsleeve.



(c) Put a 2.0 inch ±0.2 inch length of heat shrinkable sleeve on the cableso that the edge of the sleeve aligns with the end of the TFE 2Xsleeve.



(e) Put a 1.5 inch ±0.2 inch length of heat shrinkable sleeve on the cableso that the edge of the sleeve aligns with the end of the TFE 2Xsleeve.



b




(11) Install more sleeves for cable diameter buildup so that the cable assemblycannot move when the screws of the strain relief clamp are tightened.


(a) Put a 1.0 inch ±0.2 inch length of heat shrinkable sleeve on the cableso that the edge of the sleeve aligns with the end of the TFE 2Xsleeve.



B. Connector Assembly

(1) Put the strain relief backshell on the cable.

(2) Remove the wire insulation. Refer to Subject 20-61-11.

(3) Assemble the contacts. Refer to Subject 20-61-11.

(4) Insert the contacts. Refer to Subject 20-61-11.

(5) Use the procedures in the Subject 20-25-12 to do these three tasks:

(6) Attach the strain relief backshell to the connector. Refer to Subject20-25-12.

(7) Attach the shield ground wire terminals to the strain relief backshell.

(8) Tighten the cable clamps on the cable. Refer to Subject 20-25-12.

b





1. Part Numbers And Description 11.A. Connector Part Numbers 11.B. Contact Part Numbers 11.C. Insert Configuration 22. Connector Disassembly 22.A. Contact Removal 23. Connector Assembly 33.A. Contact Assembly 33.B. Contact Insertion 44. Approved Tool Suppliers 44.A. Contact Crimp Tools 44.B. Contact Insertion Tools 54.C. Contact Removal Tools 5

1.Part Numbers And Description

A. Connector Part Numbers

TABLE ICONNECTOR PART NUMBERS


MT17R-1 Burndy

B. Contact Part Numbers

TABLE IICONTACT PART NUMBERS

Contact Size

Part Number SupplierEngaging

End

Crimp

Barrel

20 20MS24255-20S QPL

BACC47CP1T Boeing

20 16 48-100-5007S-02 Amphenol

b


ASSEMBLY OF BURNDY MT17R-1 CONNECTORS


C. Insert Configuration

BURNDY MT17R-1 RECEPTACLE CONTACT CONFIGURATIONFigure 1

2.Connector Disassembly

A. Contact Removal

TABLE IIICONTACT REMOVAL TOOLS

Crimp

Barrel

Size

Removal Tool Supplier

20

ST2220-3-13 Boeing

MS24256-R20 QPL

294-89 Amphenol

16 ST2220-3-13 Boeing

(1) Make a selection of a removal tool from Table III.

(2) Align the removal tool with the contact on the front side of the connector.

(3) Press firmly until the contact is loosened.

(4) Gently pull on the wire from the rear of the receptacle until the contactis completely removed.

b




3.Connector Assembly

A. Contact Assembly

TABLE IVINSULATION REMOVAL LENGTH

Crimp

Barrel

Size

Removal Length

(inch)

Target Tolerance

20 3/16 1/16

16 5/16 1/16

TABLE VCONTACT CRIMP TOOLS

Contact Size Crimp Tool

Engaging

End

Crimp

Barrel

Basic Unit Locator

Part Number Setting Die Set Part Number Color

20 20

ST2220-1-Y - - ST2220-1-1 -

M10S - S-6 SL-3 -

MS3191-1 - - MS3191-20() Red

20 16ST2220-1-Y - - ST22220-1-45 -

MS3191-1 - - 294-1140 -

NOTE: A maximum of two AWG 20 wires may be terminated in a size 16 wire barrel.

(1) Make a selection of a contact from Table II.

(2) Remove the wire insulation to the length given in Table IV.

(3) Make a selection of a crimp tool from Table V.

(4) Insert the wire into the contact crimp barrel.

(5) Crimp the contact.

b




B. Contact Insertion

TABLE VICONTACT INSERTION TOOLS

Crimp

Barrel

Size

Insertion Tool

Handle Supplier Bit Supplier

20

ST2220-2 Boeing ST2220-2-8 Boeing

MS24256-A20 QPL - -

294-88 Burndy - -

16 ST2220-2 Boeing ST2220-2-8 Boeing

(1) Make a selection of an insertion tool from Table VI.

(2) Slide the contact into the tool tip.

(3) Place the contact into the grommet hole at the rear of the receptacle.

(4) Hold the tool straight and push forward until the contact is fully seated.

4.Approved Tool Suppliers

A. Contact Crimp Tools

TABLE VIICRIMP TOOL SUPPLIERS


294-1140 Amphenol

M10S Burndy

MS3191-1 QPL

MS3191-20() QPL

S-6 Burndy

SL-3 Burndy

ST2220-1-1 Boeing

ST22220-1-45 Boeing

ST2220-1-Y Boeing

b




B. Contact Insertion Tools

TABLE VIIIINSERTION TOOL SUPPLIERS


294-88 Burndy

MS24256-A20 QPL

ST2220-2 Boeing

ST2220-2-8 Boeing

C. Contact Removal Tools

TABLE IXREMOVAL TOOL SUPPLIERS


294-89 Amphenol

MS24256-R20 QPL

ST2220-3-13 Boeing

b




This Subject gives the procedures to assemble the 69B41500 HF antenna lead assembly to the69-54481 HF probe antenna receptacle.


1. Part Numbers and Description 11.A. HF Antenna Part Numbers 12. HF Antenna Lead To HF Probe Antenna

Receptacle Assembly1

2.A. Terminal Assembly 1


A. HF Antenna Part Numbers

TABLE IHF ANTENNA PART NUMBERS

Description Part Number Supplier

HF Antenna Lead Assembly 69B41500 Boeing

HF Probe Antenna Receptacle 69-54481 Boeing

Terminal 69B41501-() Boeing

2.HF Antenna Lead To HF Probe Antenna Receptacle Assembly

A. Terminal Assembly

(1) Slide the clamp nut and terminal on the lead. Refer to Figure 1.

CLAMP NUT AND TERMINAL POSITIONFigure 1

(2) Put the 69B41501-() terminal into the 69-54481 antenna receptacle. Referto Figure 2.

Make sure that the terminal is against the bottom of the receptacle.

b


HF ANTENNA LEAD ASSEMBLY AND PROBE RECEPTACLES


TERMINAL AND RECEPTACLE ASSEMBLYFigure 2

(3) Turn the clamp nut on the receptacle.

(4) Tighten the clamp nut on the receptacle.

Make sure that the clamp nut is torqued to 95 inch-pounds ±5 inch-pounds.

b


HF ANTENNA LEAD ASSEMBLY AND PROBE RECEPTACLES



1. Part Numbers and Description 11.A. Terminal Block Module Part Numbers 11.B. Resistor and Diode Terminal Block Part

Numbers4

1.C. Terminal Block Module Accessory PartNumbers

6

1.D. Contact Part Numbers for the StandardDensity Terminal Block

7

1.E. Contact Part Numbers for the High DensityTerminal Block

8

2. Terminal Block Module Location Codes 92.A. Terminal Block Module Identification 93. Terminal Block Module Removal 103.A. Removal of the Module from the Track 104. Terminal Block Module Disassembly 104.A. Contact Removal from Standard Density

Terminal Block Modules10

4.B. Contact Removal from High Density TerminalBlock Modules

12

5. Standard Density Terminal Block ModuleAssembly

12

5.A. Contact Assembly 125.B. Contact Insertion 156. High Density Terminal Block Module Assembly 166.A. Contact Assembly 166.B. Contact Insertion 177. Terminal Block Module Installation 177.A. Installation of the Module on the Track 17


A. Terminal Block Module Part Numbers

TABLE ITERMINAL BLOCK MODULES

Block Type

(Reference)

Boeing

Standard

Terminal Block Module

Part Number Density Supplier

F BACM15C1A YHLZ-22 Standard Burndy

G BACM15C1B YHLZ-44 Standard Burndy

H BACM15C2A YHLZ-8 Standard Burndy

X BACM15C3A

YHLZ16-2 High Burndy

421120-450 HighPrecision ConnectorDesign

b


ASSEMBLY OF BACM15C AND BURNDY YHLZD-() AND YHLZR-() TERMINAL BLOCK MODULES


Block Type

(Reference)

Boeing

Standard

Terminal Block Module

Part Number Density Supplier

Y BACM15C3B



Z BACM15C3C



TYPE F TERMINAL BLOCKFigure 1

TYPE G TERMINAL BLOCKFigure 2

b




TYPE H TERMINAL BLOCKFigure 3

TYPE X TERMINAL BLOCKFigure 4

TYPE Y TERMINAL BLOCKFigure 5

b




TYPE Z TERMINAL BLOCKFigure 6

B. Resistor and Diode Terminal Block Part Numbers

TABLE IIBURNDY RESISTOR TERMINAL BLOCK MODULES

Part

Number

Resistance

(ohm)

Watts

(W)

Tolerance

(percent)

ColorSupplier

Side A Side B

YHLZR-1 27K 0.5 2 Blue Natural Burndy

YHLZR-2 4.3K 0.5 2 Blue Black Burndy

YHLZR-3 5.6K 0.5 2 Black Black Burndy

YHLZR-4 6.2K 0.5 2 Yellow Yellow Burndy

YHLZR-5 9.1K 0.5 2 Black Orange Burndy

YHLZR-6 10 0.25 2 Yellow Black Burndy

YHLZR-7 120 0.25 5 Yellow Green Burndy

YHLZR-8 51.1K 0.25 1 Yellow Blue Burndy

YHLZR-9 12K 0.5 2 Yellow Red Burndy

YHLZR-10 11K 0.25 1 Yellow Natural Burndy

YHLZR-11 24K 0.5 2 Brown Brown Burndy

YHLZR-13 240 0.25 2 Brown Brown Burndy

YHLZR-14 1K 0.5 2 Green Green Burndy

YHLZR-15 2.7K 0.5 2 Black Red Burndy

YHLZR-16 71.5 0.5 1 Red Orange Burndy

YHLZR-17 2.0K 2 1 Green Brown Burndy

YHLZR-18 4.3K 0.5 2 Brown Brown Burndy





b



MANUAL NO: D6-54446PAGE 4MAY 01/2003 20-90-11

Part

Number

Resistance

(ohm)

Watts

(W)

Tolerance

(percent)

ColorSupplier

Side A Side B






YHLZR-28 1.8K 0.1 0.5 Brown Brown Burndy


YHLZR-30 3K 0.125 0.5 Brown Brown Burndy







YHLZR-37 15 2 1 Brown Brown Burndy








YHLZR-47 150 1 2 Brown Brown Burndy

TABLE IIIBURNDY DIODE TERMINAL BLOCK MODULES

Part NumberColor

Diode Type Supplier NotesSide A Side B

YHLZD-9 Red Red JAN 1N3613 Burndy YHLZD-32 is Preferred

YHLZD-11 Red Green JAN 1N3022 Burndy -

YHLZD-14 Red Blue R4615 BurndyNo Longer Available,No Alternate

YHLZD-15 Red Natural 1N5552 Burndy Obsolete, Use YHLZD-33

b



MANUAL NO: D6-54446 PAGE 5MAY 01/200320-90-11

Part NumberColor

Diode Type Supplier NotesSide A Side B

YHLZD-23 Green Blue UZ1325 BurndyNo Longer Available,No Alternate

YHLZD-24 Green Orange UDZ860 Burndy -

YHLZD-26 Green Black 1N5061 Burndy -

YHLZD-28 Brown Black JANTX 1N4965 Burndy -

YHLZD-29 Brown Yellow JANTX 1N5551 Burndy -

YHLZD-30 Brown Orange JANTX 1N5618 Burndy -

YHLZD-31 Green Yellow JANTX 1N4971 Burndy -

YHLZD-32 Blue Yellow JANTX 1N3613 Burndy -

YHLZD-33 Red Yellow JANTX 1N5552 Burndy -

YHLZD-34 Red Brown JANTX 1N5553 Burndy -

YHLZD-35 Red Black JANTX 1N4148-1 Burndy -

YHLZD-38 Blue Blue JANTX 1N4972 Burndy -

YHLZD-39 Natural Red JANTX 1N6467 Burndy -

TYPE F RESISTOR OR DIODE TERMINAL BLOCKFigure 7

C. Terminal Block Module Accessory Part Numbers

NOTE: A BACS18AR1 identification spacer is not necessary when the BACC29A2 endclamp is used.

b




TABLE IVTERMINAL BLOCK MODULE ACCESSORIES

Accessory Boeing StandardModule Accessories


End Clamp

BACC49A1

AMMC-6 Burndy

H-28-1 Harper

UP103 Metal Forms

BACC49A2H-49-2 Harper

MF104-2 Metal Forms

BACC49A3H-49-3 Harper

MF104-3 Metal Forms

Spacer

BACS18AR1

YHLZ1C-2 Burndy

FAB276-A Fabricators

H-21-1 Harper

UP300-1 Metal Forms

BACS18AR6

YHLZ1C-7 Burndy

FAB276-0 Fabricators

H-21-6 Harper

UP300-6 Metal Forms

Track BACT44() AMY()T() Burndy

TERMINAL BLOCK MODULE ACCESSORIESFigure 8

D. Contact Part Numbers for the Standard Density Terminal Block

NOTE: The contacts with the suffix A are recommended over the contacts withoutthe suffix A.

b




TABLE VSTANDARD DENSITY CONTACT PART NUMBERS

Boeing

Standard

Contact


BACC47DE1AYHMM16-6D28 Burndy

417-1215-332 Tri-Star

BACC47DE1 YHMM16-1F50 Burndy


417-1223-332 Tri-Star

BACC47DE3 YHMM22-1DB8 Burndy


417-1222-332 Tri-Star



417-1216-332 Tri-Star



417-1218-332 Tri-Star



417-1220-332 Tri-Star



417-1224-332 Tri-Star


E. Contact Part Numbers for the High Density Terminal Block

TABLE VIHIGH DENSITY CONTACT PART NUMBERS

Part Number Crimp Barrel Color Code Supplier

M39029/11-145 Brown Yellow Green QPL

b




THE M39029/11-145 CONTACTFigure 9

2.Terminal Block Module Location Codes

A. Terminal Block Module Identification

Terminal block modules are identified on the wire diagrams by a code that gives:

- The block type- The location.

Refer to Figure 10.

TERMINAL BLOCK MODULE LOCATION CODEFigure 10

The location code is the position of the block in relation to the horizontal rowidentifier and the vertical column identifier.

Refer to Figure 11.

The vertical column identifier:

- Can be located on the T bar or on the block mount rail- Gives the column of the cavities that is directly adjacent to the number.

The horizontal row identifier:

- Can be located on the end clamp, on a spacer, or on the block mount rail- Gives the row of the cavities in all the blocks in the rail that is

directly adjacent to the letter.

NOTE: If the block module identification code does not have a horizontal rowidentifier:

- All the cavities in that column are bussed together- The horizontal location is not important.

b




LOCATION OF A MODULEFigure 11

3.Terminal Block Module Removal

A. Removal of the Module from the Track

(1) Loosen the clamp screw until the clamp can be moved.

(2) Turn the clamp 90 degrees and lift from the track.

NOTE: A satisfactory alternative is to slide the clamp out of the track.

(3) Move or remove any terminal block modules next to the specified module.

(4) To remove the block module, turn the module 90 degrees and lift from thetrack.

NOTE: A satisfactory alternative is to slide the block module out of thetrack.

4.Terminal Block Module Disassembly

A. Contact Removal from Standard Density Terminal Block Modules

TABLE VIICONTACT REMOVAL TOOLS

ContactRemoval Tool

Handle Tip Supplier

BACC47DE()

ATB3062-2 - Astro

DHK21 - Daniels

J-1276-1 - Burndy

ST2220-3-34-1 ST2220-3-34A-3 Boeing

ST2220-3-34-2 ST2220-3-34A-8 Boeing

b




(1) Make a selection of a contact removal tool from Table VII.

CAUTION: USE ONLY THE REMOVAL TOOLS THAT ARE GIVEN IN TABLE VII. OTHERTOOLS CAN CAUSE DAMAGE TO THE MODULE.

(2) Put the removal tool into the contact removal tool slot in the module.

The contact removal tool slot is adjacent to the contact.

(3) Push the tool into the slot of the module until it stops.

This releases the lock spring that locks the contact in position.

CAUTION: IF A CONTACT IS REMOVED WHEN THE LOCK SPRING IS NOT RELEASED,DAMAGE TO ANY OF THESE COMPONENTS OCCURS:

- THE CONTACT- THE MODULE- THE WIRE.

(4) Carefully, pull the wire and the contact from the cavity of the module.Refer to Figure 12.

CONTACT REMOVALFigure 12

(5) After the wired contact is removed, pull the removal tool out of the slot.

b




B. Contact Removal from High Density Terminal Block Modules

TABLE VIIICONTACT REMOVAL TOOLS

Contact Removal Tool Supplier

M39029/11-145

CIET20HDL Cannon

DRK-269 Daniels

M81969/1-02 QPL

MS3156-20 QPL

(1) Make a selection of a removal tool from Table VIII.

NOTE: The DRK-269 contact removal tool is recommended for high densityterminal blocks.

(2) Put the removal tool on the wire.

(3) Push the tool on the wire and into the module block until it stops.

(4) Hold the wire against the tool.

(5) Pull the tool and the wired contact out of the module at the same time.

5.Standard Density Terminal Block Module Assembly

A. Contact Assembly

TABLE IXCONTACT SELECTION

Wire

Size

(AWG)

Wire Insulation Diameter

(inch)Contact

Minimum MaximumBoeing

StandardFinish Color Band

24

0.032 0.045BACC47DE8A Gold Violet

BACC47DE8 Silver Green

0.041 0.065BACC47DE4A Gold Green

BACC47DE4 Gold Green

0.070 0.080BACC47DE3A Gold None

BACC47DE3 Gold None

b




Wire

Size

(AWG)

Wire Insulation Diameter

(inch)Contact

Minimum MaximumBoeing

StandardFinish Color Band

22

0.047 0.065BACC47DE7A Gold Red

BACC47DE7 Gold Red

0.041 0.065BACC47DE4A Gold Green

BACC47DE4 Gold Green

0.070 0.080BACC47DE3A Gold None

BACC47DE3 Gold None

20

0.047 0.065BACC47DE7A Gold Red

BACC47DE7 Gold Red

0.056 0.069BACC47DE6A Gold Black

BACC47DE6 Silver Black

0.063 0.083BACC47DE5A Gold Blue

BACC47DE5 Silver Red

0.080 0.110BACC47DE1A Gold Brown

BACC47DE1 Silver None

18

0.056 0.069BACC47DE6A Gold Black

BACC47DE6 Silver Black





16





TABLE XCONTACT CRIMP TOOLS

ContactCrimp Tool

Basic Unit Die Locator Supplier

BACC47DE() M10S-1 S-1 SL-53 Burndy

b




(1) Measure the diameter of the insulation of the wire.

(2) Make a selection of a contact from Table IX.

(3) Remove 0.22 inch ±0.03 inch of the insulation from the end of the wire.Refer to Figure 13.

WIRE PREPARATIONFigure 13

(4) Put a 0.5 inch ±0.13 inch length of RT-876 heat shrinkable sleeve that hasthe smallest diameter that can be moved on the wire.

Make sure that the end of the sleeve:

- Is not on the conductor- Is within 0.03 inch of the end of the insulation.

(5) Shrink the sleeve in position. Refer to Subject 20-10-14.

(6) Make a selection of a crimp tool from Table X.

(7) Put the conductor into the wire barrel of the contact. Refer to Figure 14.

Make sure that:

- The conductor can be seen in the inspection hole of the contact- The wire insulation is against the bottom of the insulation grip of

the contact.

POSITION OF THE CONTACTFigure 14

(8) Crimp the contact. Refer to Figure 15.

Make sure that there are four crimp indents on:

- The contact crimp barrel- The wire insulation grip.

b




CONTACT CRIMP DETAILFigure 15


TABLE XICONTACT INSERTION TOOLS

Contact Insertion Tool Supplier

BACC47DE()ST2220-3-34A-1 Boeing

ST2220-3-34A-2 Boeing

(1) Make a selection of a contact insertion tool from Table XI.

(2) Put the tip of the wired contact into the contact cavity of the module.

(3) Put the tip of the tool on the contact until it makes a click and thecontact stops.

(4) Push the contact in position. Refer to Figure 16.

Make sure that the contact is locked in the module.

b




CONTACT INSERTIONFigure 16

6.High Density Terminal Block Module Assembly

A. Contact Assembly

TABLE XIICONTACT CRIMP TOOLS

Wire

Size

(AWG)

Crimp

Barrel

Size

Crimp Tool

Basic Unit Locator

Part Number Setting Supplier Part Number Supplier

24 20

612916 6 Buchanan - -

M22520/2-01 5 QPL M22520/2-08 QPL

M22520/7-01 4 QPL M22520/7-02 QPL

ST2220-1-Y - Boeing ST2220-1-43 Boeing

WA22 5 Daniels M22520/2-08 QPL

22 20

612916 7 Buchanan - -

M22520/2-01 6 QPL M22520/2-08 QPL

M22520/7-01 5 QPL M22520/7-02 QPL



b




Wire

Size

(AWG)

Crimp

Barrel

Size

Crimp Tool

Basic Unit Locator

Part Number Setting Supplier Part Number Supplier

20 20

612916 8 Buchanan - -

M22520/2-01 7 QPL M22520/2-08 QPL

M22520/7-01 6 QPL M22520/7-02 QPL



(1) Make a selection of a contact from Table VI.

(2) Remove 3/16 inch ±1/32 inch of the wire insulation.(3) Make a selection of a crimp tool from Table XII.

(4) Put the conductor into the wire barrel of the contact.



TABLE XIIICONTACT INSERTION TOOLS

Contact Insertion Tool Supplier

M39029/11-145M81969/1-02 QPL

MS3156-20 QPL

(1) Make a selection of an insertion tool from Table XIII.

NOTE: Manual insertion of the contact is a satisfactory alternative.

(2) Insert the wired contact into the contact cavity.

7.Terminal Block Module Installation

A. Installation of the Module on the Track

(1) Install the block module. Refer to Figure 17.

NOTE: A satisfactory alternative is to slide the block module into thetrack from the end.

b




INSTALLATION OF A MODULEFigure 17

(a) Put the the block module in the track.

Make sure that the sides of the terminal blocks and the end clampsthat have the part numbers are turned toward the open side of thetrack assembly.

(b) Turn the block 90 degrees.

(2) When all the terminal blocks and fillers are aligned correctly in thetrack, push the end clamp tightly against the last block or filler.

NOTE: The A side of the end clamp is on the closed side of the trackassembly.

(3) Tighten the clamp screw so that:

- The lockwasher is fully compressed- The end clamp does not move or turn when pressure is applied.

NOTE: Only a split lockwasher is permitted under the screw head.

b





1. Part Numbers and Description 11.A. Terminal Block Part Numbers 11.B. Contact Part Numbers 21.C. Seal Plug Part Numbers 21.D. Terminal Block Mounting Track Part Number 32. Terminal Block Disassembly 32.A. Terminal Block Removal 32.B. Contact Removal 33. Terminal Block Assembly 33.A. Contact Assembly 33.B. Contact Insertion 43.C. Seal Plug Installation 43.D. Terminal Block Installation 5


A. Terminal Block Part Numbers

TABLE ITERMINAL BLOCK PART NUMBERS

Terminal BlockContact


TBS20-8-1 Burndy YTB20-2





TBS1620-8-1 BurndyYTB16-1

YTB20-2


YTB20-2


YTB20-2







b


ASSEMBLY OF BURNDY SEALOK SEALED TERMINAL BLOCKS



TABLE IITERMINAL BLOCK CONTACT PART NUMBERS


YTB20-2 Burndy

YTB16-1 Burndy

YTB12-1 Burndy

C. Seal Plug Part Numbers

TABLE IIISEAL PLUG PART NUMBERS

Terminal BlockSeal Plug

Part Number Color Supplier

TBS20-8-1 TBP20-1 Red Burndy





TBS1620-8-1TBP16-1 Blue Burndy

TBP20-1 Red Burndy


TBP20-1 Red Burndy


TBP20-1 Red Burndy

TBS16-8-1 TBP16-1 Blue Burndy



TBS12-8-1 TBP12-1 Yellow Burndy



b




D. Terminal Block Mounting Track Part Number

TABLE IVTERMINAL BLOCK MOUNTING TRACK PART NUMBERS

Mounting Track Supplier

TBT7200-() Burndy

2.Terminal Block Disassembly

A. Terminal Block Removal

(1) Make a selection of the removal tool from Table VIII.

(2) Remove the terminal block from the mounting track.

Refer to the instructions on the tool.

B. Contact Removal

(1) Make a selection of the contact removal tool from Table VII.

(2) Remove the contact from the module block with the removal end of the tool.

3.Terminal Block Assembly

A. Contact Assembly

TABLE VINSULATION REMOVAL LENGTH

Wire

Size

(AWG)

Contact

Removal Length

(inch)

Target Tolerance

24 YBT20-2 3/16 ±1/3222 YBT20-2 3/16 ±1/32

20YBT20-2 3/16 ±1/32YBT16-1 3/16 ±1/32

18 YBT16-1 3/16 ±1/3216 YBT16-1 3/16 ±1/3214 YBT12-1 1/4 ±1/3212 YBT12-1 1/4 ±1/32

b




TABLE VICONTACT CRIMP TOOLS

ContactCrimp Tool

Basic Unit Die Locator Supplier

YBT12-1 M10S-1 S-8 SL-2 Burndy

YBT16-1 M10S-1 S-7 SL-3A Burndy

YBT20-2 M10S-1 S-6A SL-3A Burndy

(1) Remove the necessary length of insulation from the end of the wire.

Refer to Table V and Subject 20-00-15.

(2) Make a selection of a crimp tool from Table VI.

(3) Put the wire in the crimp barrel of the contact.

Make sure that:

- All the strands of the conductor are in the crimp barrel- The strands of the conductor are can be seen in the inspection hole.



TABLE VIICONTACT INSERTION AND REMOVAL TOOLS

ContactInsertion and

Removal ToolSupplier

YBT20-2 NAS1664-20 Burndy



NOTE: Each tool is both an insertion tool and a removal tool.

(1) Make a selection of an insertion tool from Table VII.

(2) Put the contact in the module block with the insertion end of the tool.

C. Seal Plug Installation

A sea plug must be installed in all unused contact cavities.

(1) Make a selection of a seal plug from Table III.

(2) Manually install a seal plug in the contact cavity.

b




D. Terminal Block Installation

TABLE VIIITERMINAL BLOCK INSTALLATION AND REMOVAL TOOLS

Installation and

Removal ToolSupplier

TBTS-1 Burndy

NOTE: The tool is both an installation tool and a removal tool.

(1) Make a selection of an installation tool from Table VIII.

(2) Install the terminal block in the mounting track.

Refer to the instructions on the tool.

b





1. Part Numbers and Description 11.A. Jiffy Junction Splice Part Numbers 11.B. Contact Part Numbers 12. Module Disassembly 22.A. Contact Removal 23. Module Assembly 23.A. Contact Assembly 23.B. Contact Insertion 44. Approved Tool Suppliers 54.A. Contact Removal Tools 54.B. Contact Crimp Tools 54.C. Contact Insertion Tools 5


A. Jiffy Junction Splice Part Numbers

TABLE IJIFFY JUNCTION SPLICE PART NUMBERS


TSE-20-01 Deutsch

TSE-16-01 Deutsch

TSE-12-01 Deutsch


TABLE IICONTACT PART NUMBERS

Contact Size

Part Number SupplierEngaging

End

Crimp

Barrel

20 20 1841-1-5620 Deutsch

16 16 1841-1-5616 Deutsch

12 12 1841-1-5612 Deutsch

b


ASSEMBLY OF DEUTSCH JIFFY JUNCTION SPLICES


2.Module Disassembly

A. Contact Removal

TABLE IIICONTACT REMOVAL TOOLS

Crimp Barrel

SizeRemoval Tool Supplier

20

M15570-20 Deutsch

M81969/14-02 QPL

M83723/31-20 QPL

16

M15570-16 Deutsch

M81969/14-03 QPL

M83723/31-16 QPL

12

M15570-12 Deutsch

M81969/14-04 QPL

M83723/31-12 QPL

(1) Make a selection of a contact removal tool from Table III.

(2) Slide the tip of the removal tool over the wired contact and into themodule until the tool releases the contact retention clip.

(3) Hold the wire against the tool and pull the wired contact and the tool outat the same time.

3.Module Assembly

A. Contact Assembly

TABLE IVINSULATION REMOVAL LENGTH

Wire

Size

(AWG)

Contact SizeRemoval Length

(inch) Special Instructions

Engaging

End

Crimp

BarrelTarget Tolerance

24 20 20 13/64 1/64 -

22 20 20 13/64 1/64 -

2020 20 13/64 1/64 -

16 16 13/64 1/64 -

18 16 16 19/64 1/64 -

b




Wire

Size

(AWG)

Contact SizeRemoval Length


Engaging

End

Crimp

BarrelTarget Tolerance

16 16 16 19/64 1/64 -

14 12 12 19/64 1/64 -

12 12 12 19/64 1/64 -

TABLE VCONTACT CRIMP TOOLS

Wire

Size

(AWG)

Crimp

Barrel

Size

Crimp Tool

Basic Unit Locator

Part Number Setting Part Number Color

24 20 M22520/2-01 5 M22520/2-02 -

22 20 M22520/2-01 6 M22520/2-02 -

20 20 M22520/2-01 7 M22520/2-02 -

20 16 M22520/1-01 4 M22520/1-02 Blue

18 16 M22520/1-01 5 M22520/1-02 Blue

16 16 M22520/1-01 6 M22520/1-02 Blue

14 12 M22520/1-01 7 M22520/1-02 Yellow

12 12 M22520/1-01 8 M22520/1-02 Yellow


Refer to Table IV and Subject 20-00-15.

(2) Put the wire in the contact crimp barrel. Refer to Figure 1.

Make sure that the wire is inserted completely into the crimp barrel.

WIRE POSITION IN THE CONTACT CRIMP BARRELFigure 1

b




(3) Make a selection of a crimp tool from Table V.


(5) Remove the crimped contact from the tool.

Make sure that:

- All the wire strands are in the contact crimp barrel- The wire strands are visible in the inspection hole.


TABLE VICONTACT INSERTION TOOLS

Crimp Barrel

SizeInsertion Tool Supplier

20

M15570-20 Deutsch

M81969/14-02 QPL

M83723/31-20 QPL

16

M15570-16 Deutsch

M81969/14-03 QPL

M83723/31-16 QPL

12

M15570-12 Deutsch

M81969/14-04 QPL

M83723/31-01 QPL

(1) Make a selection of an insertion tool from Table III.

NOTE: As an option, the contact can be inserted by hand.

(2) Push the contact into the contact cavity. Refer to Figure 2.

Make sure the contact snaps into the retention clip.

CONTACT INSERTIONFigure 2

b





A. Contact Removal Tools

TABLE VIIREMOVAL TOOL SUPPLIERS


M15570-20 Deutsch

M15570-16 Deutsch

M15570-12 Deutsch

M81969/14-02 QPL

M81969/14-03 QPL

M81969/14-04 QPL

M83723/31-20 QPL

M83723/31-16 QPL

M83723/31-12 QPL

B. Contact Crimp Tools

TABLE VIIICRIMP TOOL SUPPLIERS

Crimp Tool Supplier

M22520/1-01 QPL

M22520/1-02 QPL

M22520/2-01 QPL

M22520/2-02 QPL

C. Contact Insertion Tools

TABLE IXINSERTION TOOL SUPPLIERS

Insertion Tool Supplier

M15570-20 Deutsch

M15570-16 Deutsch

M15570-12 Deutsch

M81969/14-02 QPL

M81969/14-03 QPL

M81969/14-04 QPL

b





M83723/31-20 QPL

M83723/31-16 QPL

M83723/31-12 QPL

b





1. Part Numbers and Description 11.A. Terminal Junction System Description 11.B. Terminal Module Part Numbers 21.C. Ground Module Part Numbers 41.D. Terminal Module Track Part Numbers 51.E. Diode Module Part Numbers 81.F. Resistor Module Part Numbers 91.G. Contact Part Numbers 102. Terminal Module and Ground Module

Configurations11

2.A. Terminal Module Configurations 112.B. Ground Module Configurations 123. Disassembly of the Terminal Junction System 133.A. Removal of a Terminal Module from a Track 133.B. Removal of a Diode or a Resistor Module 143.C. Contact Removal 153.D. Unwired Contact Removal 163.E. Seal Plug or Seal Rod Removal 164. Assembly of the Terminal Module 174.A. Contact Assembly 174.B. Contact Insertion 194.C. Seal of an Empty Contact Cavity 225. Installation of the Terminal Junction

System23

5.A. Installation of a Terminal Module on aTrack

23

5.B. Installation of the Diode or ResistorModule

24

5.C. Installation of a Track on an Assembly orthe Structure

26

6. Approved Tool Suppliers 266.A. Contact Removal Tools 266.B. Terminal Module Removal Tools 276.C. Contact Insertion Tools 276.D. Contact Crimp Tools 27


A. Terminal Junction System Description

The terminal junction system has these components:

- Terminal modules- Ground modules- Tracks- Tracks with ground modules- Diode modules- Resistor modules.

b


S280W555-() TERMINAL JUNCTION SYSTEM


S280W555-() TERMINAL JUNCTION SYSTEM PART NUMBER STRUCTUREFigure 1

BURNDY TERMINAL JUNCTION SYSTEM PART NUMBER STRUCTUREFigure 2

B. Terminal Module Part Numbers

TABLE ITERMINAL MODULE PART NUMBERS

Boeing Standard Description

S280W555-102 Feedback





b




TABLE IISUPPLIER PART NUMBERS OF BOEING S280W555-() TERMINAL MODULES

Boeing Standard Part Number Supplier

S280W555-102 RBTB20-2 Burndy





TABLE IIIALTERNATIVE TERMINAL MODULE PART NUMBERS

Specified

Module

Alternative Module


S280W555-104 MDTB20-4 Framatome Connectors International

S280W555-108 MDTB20-8 Framatome Connectors International

S280W555-() TERMINAL MODULEFigure 3

b




C. Ground Module Part Numbers

TABLE IVGROUND MODULE PART NUMBERS

Boeing Standard Description Mount Type

S280W555-16 Ground Module Panel

S280W555-16S Ground Module Panel

S280W555-20 Ground Module Panel

S280W555-401 Electronic Rack Ground Module Electronic Rack

S280W555-402 Electronic Rack Ground Module Electronic Rack

TABLE VSUPPLIER PART NUMBERS OF BOEING S280W555-() GROUND MODULES


S280W555-16 RBGB16-1 Burndy

S280W555-20 RBGB20-1 Burndy

S280W555-401 RBG516-1 Burndy

S280W555-402 RBG532-1 Burndy

S280W555-() GROUND MODULEFigure 4

b




S280W555-() GROUND MODULE WITH A PROTECTIVE SEALFigure 5

S280W555-4() ELECTRONIC RACK GROUND MODULEFigure 6

D. Terminal Module Track Part Numbers

TABLE VITERMINAL MODULE TRACK PART NUMBERS

Boeing Standard DescriptionLength

(inch)

S280W555-502 Track with Ground Module 2





b




Boeing Standard DescriptionLength

(inch)





S280W555-602 Track 2

S280W555-604 Track 4

S280W555-606 Track 6

S280W555-608 Track 8

S280W555-610 Track 10

S280W555-614 Track 14

S280W555-616 Track 16

S280W555-622 Track 22

S280W555-626 Track 26

TABLE VIISUPPLIER PART NUMBERS OF BOEING S280W555-() TERMINAL MODULE TRACKS


S280W555-502 RBGT2 Burndy









S280W555-602 RBMT2 Burndy








b






S280W555-6() TRACKFigure 7

S280W555-5() TRACK WITH A GROUND MODULEFigure 8

b




E. Diode Module Part Numbers

TABLE VIIIDIODE MODULE PART NUMBERS

Boeing StandardDiode Current

(amp)

S280W555-751 1

S280W555-753 3

TABLE IXSUPPLIER PART NUMBERS OF BOEING S280W555-() DIODE MODULES


S280W555-751 RBD20-1 Burndy

S280W555-753 RBD20-2 Burndy

S280W555-7() DIODE MODULEFigure 9

b




F. Resistor Module Part Numbers

TABLE XRESISTOR MODULE PART NUMBERS

Boeing StandardResistance

(ohm)

S280W555-702 4300

S280W555-703 12000

S280W555-704 49900

S280W555-705 71.5

S280W555-706 10000

S280W555-707 1800

TABLE XISUPPLIER PART NUMBERS OF BOEING S280W555-() RESISTOR MODULES


S280W555-702 RBR20-2 Burndy






b




S280W555-7() RESISTOR MODULEFigure 10

G. Contact Part Numbers

The contacts have these technical properties:

- A pin configuration- A gold finish.

NOTE: The Burndy RBM18M-1DJ5 contact does not have a gold finish.

TABLE XIICONTACT PART NUMBERS

Contact SizeContact

TypePart Number

Color Code

SupplierEngaging

End

Crimp

BarrelBand Color

16

20 Pin

M39029/1-101

1 Brown

QPL2 Black

3 Brown

S280W555-920

1 Red

Tri Star2 Red

3 Red

18 Pin

RBM18M-1DJ5 - - Burndy

S280W555-918

1 Red

Tri Star2 White

3 Red

b




Contact SizeContact

TypePart Number

Color Code

SupplierEngaging

End

Crimp

BarrelBand Color

14 16 Pin

M39029/1-102

1 Brown

QPL2 Black

3 Red

S280W555-916

1 Blue

Tri Star2 Blue

3 Blue

EXAMPLE OF A CONTACT SIZEFigure 11

PIN CONTACTFigure 12

2.Terminal Module and Ground Module Configurations

A. Terminal Module Configurations

TABLE XIIITERMINAL MODULE CONFIGURATIONS

Boeing Standard

Contact Bus Configuration

Engaging End

SizeQuantity Sets Contact Cavities

S280W555-102 16 16 8 2

b




Boeing Standard

Contact Bus Configuration

Engaging End

SizeQuantity Sets Contact Cavities

S280W555-104 16 16 4 4

S280W555-108 16 16 2 8

S280W555-203 14 12 4 3

S280W555-206 14 12 2 6

TERMINAL MODULE BUS CONFIGURATIONSFigure 13

B. Ground Module Configurations

TABLE XIVGROUND MODULE CONFIGURATIONS

Boeing Standard

Contact

Engaging End

SizeQuantity

S280W555-16 14 12

S280W555-16S 14 12

S280W555-20 16 16

S280W555-401 16 16

b




Boeing Standard

Contact

Engaging End

SizeQuantity

S280W555-402 16 32

S280W555-502 16 16

S280W555-504 16 32

S280W555-506 16 48

S280W555-508 16 64

S280W555-510 16 80

S280W555-514 16 112

S280W555-516 16 128

S280W555-522 16 176

S280W555-526 16 208

3.Disassembly of the Terminal Junction System

A. Removal of a Terminal Module from a Track

(1) Push the latch of the terminal module to release the latch from the latchretainer on the track. Refer to Figure 14.

LOCATION OF THE LATCH ON THE TERMINAL MODULEFigure 14

(2) Pull the front of the module from the front of the track. Refer to Figure15.

b




REMOVAL OF THE TERMINAL MODULE FROM THE TRACKFigure 15

(3) Carefully pull the module to the front of the track until the key isdisengaged from the keyway.

(4) Pull the module from the track.

B. Removal of a Diode or a Resistor Module

TABLE XVMODULE REMOVAL TOOLS

Module Removal Tool

Diode RDW20-4

Resistor RDW20-4

b




DIODE OR RESISTOR MODULE REMOVALFigure 16

Refer to Figure 16.

(1) Make a selection of a removal tool from Table XV.

(2) Put the fork of the tool behind the latch of the module to release thelatch retention tab.

(3) Pull the tool up to remove the resistor or diode module from the terminalmodule.

C. Contact Removal

For the procedure to remove an unwired contact, refer to Paragraph 3.D.

TABLE XVICONTACT REMOVAL TOOLS

Crimp Barrel

Size

Removal Tool

Part Number Color

20

ATR 2080 BAC -

ATR 2079 BAC -

DRK83-20 Red

M81969/14-11 White

RRX20B -

18

ATR 2080 BAC -

ATR 2079 BAC -

M81969/14-11 White

16

ATR 2112 BAC -

ATR 2106 BAC -

M81969/14-03 White

RRX16B -

b




(1) Make a selection of a contact removal tool from Table XVI.

(2) Put the end of the tool on the wire near the rear grommet.

(3) Carefully push the tool straight into the contact cavity until it stops.

CAUTION: DO NOT TURN THE TOOL WHILE IT IS IN THE CONTACT CAVITY. DAMAGE TOTHE CONTACT RETENTION CLIPS CAN OCCUR.

(4) Carefully pull the wire and the tool out of the contact cavity at the sametime.

(5) If the contact does not come out of the contact cavity:

(a) Pull the tool out of the contact cavity.

(b) Turn the tool 90 degrees.

(c) Do Step (2) through Step (4) again.

D. Unwired Contact Removal

TABLE XVIIUNWIRED CONTACT REMOVAL TOOLS

Contact Size Removal Tool

Engaging

End

Crimp

BarrelHandle

Bit

Part Number Color

16

20 DRK-110-1SA DRK-20-2 Red

18 DRK-110-1SA DRK-20-2 Red

16 DRK-110-1SA DRK-16-2 Blue

(1) Make a selection of a contact removal tool from Table XVII.

(2) Align the tool axially with the contact.

(3) Pull the plunger back until it stops.

(4) Hold the plunger in position.

(5) Carefully push the end of the tool straight into the contact cavity untilit stops.

(6) Carefully pull the tool straight out of the contact cavity.

(7) Push the plunger forward to release the contact from the tool.

E. Seal Plug or Seal Rod Removal

(1) Make a selection of a pair of needle nose pliers that has:

- Jaws with smooth surfaces- No sharp edges.

CAUTION: ROUGH SURFACES OR SHARP EDGES CAN CAUSE DAMAGE TO THE REARGROMMET.

(2) Hold the end of the seal plug or seal rod tightly in the jaws of thepliers.

(3) Pull the plug or rod straight out of the rear grommet.

b




4.Assembly of the Terminal Module

A. Contact Assembly

TABLE XVIIIINSULATION REMOVAL LENGTH

Wire

Size

(AWG)

Crimp

Barrel

Size

Removal Length L


Target Tolerance

2420 0.15 ±0.02 -

16 0.54 ±0.04 Fold the conductor back

2220 0.15 ±0.02 -

16 0.54 ±0.04 Fold the conductor back

2020 0.15 ±0.02 -

16 0.27 ±0.02 -

1818 0.15 ±0.02 -

16 0.27 ±0.02 -

16 16 0.27 ±0.02 -

TABLE XIXCONTACT CRIMP TOOLS

Wire

Size

(AWG)

Crimp

Barrel

Size

Crimp Tool

Basic Unit Locator


24

20

M22520/1-01 2 M22520/1-02 Red

M22520/2-01 5 M22520/2-11 -

WA22 5 M22520/2-11 -

WA22LC 5 M22520/2-11 -

WA27 2 M22520/1-02 Red

16

M22520/1-01 5 M22520/1-02 Blue

ST2220-1-Y - ST2220-1-2 -

WA27F 5 M22520/1-02 Blue

b




Wire

Size

(AWG)

Crimp

Barrel

Size

Crimp Tool

Basic Unit Locator


22

20

M22520/1-01 3 M22520/1-02 Red

M22520/2-01 6 M22520/2-11 -

WA22 6 M22520/2-11 -

WA22LC 6 M22520/2-11 -

WA27 3 M22520/1-02 Red

16

M22520/1-01 6 M22520/1-02 Blue

ST2220-1-Y - ST2220-1-2 -

WA27F 6 M22520/1-02 Blue

20

20

M22520/1-01 4 M22520/1-02 Red

M22520/2-01 7 M22520/2-11 -

WA22 7 M22520/2-11 -

WA22LC 7 M22520/2-11 -

WA27 4 M22520/1-02 Red

16

M22520/1-01 4 M22520/1-02 Blue

ST2220-1-Y - ST2220-1-2 -

WA27F 4 M22520/1-02 Blue

18

18M22520/1-01 5 M22520/1-02 Red

WA27 5 M22520/1-02 Red

16M22520/1-01 5 M22520/1-02 Blue

WA27 5 M22520/1-02 Blue

16 16M22520/1-01 6 M22520/1-02 Blue

WA27 6 M22520/1-02 Blue


Refer to:

- Figure 17- Table XVIII- Subject 20-00-15 for the insulation removal procedures.

WIRE PREPARATIONFigure 17

b




(2) If it is specified, fold the conductor back. Refer to Figure 18.

CONDUCTOR FOLDED BACKFigure 18

(3) Make a selection of a crimp tool from Table XIX.

(4) Put the end of the wire into the crimp barrel of the contact. Refer toFigure 19.

Make sure that:

- All of the strands of the conductor are in the crimp barrel- The strands of the conductor can be seen in the inspection hole- The distance from the end of the insulation to the end of the crimp

barrel is a maximum of 0.03 inch.

POSITION OF THE WIRE IN THE CRIMP BARRELFigure 19


(6) Examine the contact assembly for these types of damage:

- Broken strands of the conductor- Strands of the conductor on which the base metal can be seen- Cracks in the crimp barrel of the contact.

(7) If the contact or the wire has damage, replace the contact.


TABLE XXCONTACT INSERTION TOOLS

Crimp Barrel

Size

Insertion Tool

Part Number Color

20

DAK83-20 -

M81969/14-11 Red

ST2220-2-28 -

b




Crimp Barrel

Size

Insertion Tool

Part Number Color

18

91039-1 -

DAK83-20 -

M81969/14-11 Red

16

DAK83-16 -

M81969/14-03 Blue

ST2220-2-4 -

ST2220-2-11A -

(1) Make a selection of a contact insertion tool from Table XX.

CAUTION: DO NOT USE A TOOL WITH A TIP THAT:

- IS BENT- IS FLARED- IS BROKEN- HAS A CRACK.

WARNING: A DEFECTIVE TOOL CAN CAUSE INJURY TO THE OPERATOR.

CAUTION: A DEFECTIVE TOOL CAN CAUSE DAMAGE TO THE GROMMET OF THE CONNECTOROR THE CONTACT RETENTION CLIPS.

(2) Put the contact in the insertion end of the insertion tool. Refer toFigure 20.

POSITION OF THE CONTACT IN THE INSERTION TOOLFigure 20

(3) Axially align the contact and the tool with the contact cavity. Refer toFigure 21.

b




POSITION OF THE CONTACT INSERTION TOOL AND THE CONTACT CAVITYFigure 21

(4) Carefully push the tool straight into the contact cavity until it stops.

CAUTION: DO NOT TURN THE TOOL WHEN IT IS IN THE CONTACT CAVITY. DAMAGE TOTHE CONTACT RETENTION CLIPS CAN OCCUR.

(5) Carefully pull the tool straight out of the contact cavity.

(6) Lightly pull the wire to make sure that the contact is locked in position.

CAUTION: DO NOT PULL THE WIRE WITH A STRONG OR A SUDDEN FORCE. THE FORCECAN CAUSE DAMAGE TO THE TERMINAL MODULE OR THE CONTACT.

CAUTION: DO NOT MAKE A DENT IN THE WIRE INSULATION WITH THE FINGERNAILS.DAMAGE TO THE WIRE INSULATION CAN CAUSE UNSATISFACTORY PERFORMANCEAND RELIABILITY OF THE WIRE.

(7) If the contact is not locked in the contact cavity:

(a) Pull the contact out of the cavity.

(b) Do Step (2) through Step (6) again.

(8) Examine the grommet for these types of damage:

- Damage between the bus sets; refer to Figure 22- Damage of the contact cavity that has a depth that is more than the

outer seal web in the grommet; refer to Figure 23.

b




TYPES OF DAMAGE OF THE MODULE GROMMETFigure 22

DAMAGE OF THE GROMMET IN RELATION TO THE OUTER SEAL WEBFigure 23

C. Seal of an Empty Contact Cavity

These conditions are applicable:

- For a ground module, an empty contact cavity cannot be sealed- For a terminal module in the pressurized area, the seal of an empty

contact cavity is not necessary- For a terminal module in the unpressurized area, an empty contact cavity

must be sealed with a seal plug or a seal rod.

(1) If it is applicable, install a seal plug or a seal rod in each emptycontact cavity of the terminal module. Refer to Subject 20-60-08.

If a seal rod is installed, make sure that the length of the seal rod is0.5 inch ±0.1 inch.

b




5.Installation of the Terminal Junction System

A. Installation of a Terminal Module on a Track

(1) Align the key of the module with the applicable keyway on the track. Referto Figure 24.

POSITION OF THE TERMINAL MODULE ON THE TRACKFigure 24

(2) Push the top of the module until it makes a click and the latch is lockedin the latch retainer. Refer to Figure 25.

TERMINAL MODULE INSTALLED ON THE TRACKFigure 25

b




(3) Examine the terminal module for these types of damage:

- A latch that is bent or broken- A latch that has a crack- A latch retention tab that is broken- A module shell that has a crack- A key that is broken.

B. Installation of the Diode or Resistor Module

(1) Refer to the Wiring Diagram to find the position of the diode or theresistor module in the terminal module.

(2) Examine the module. Refer to Figure 26.

Make sure that the terminal pins and the alignment pins are straight.

CONFIGURATION OF THE DIODE MODULE OR THE RESISTOR MODULEFigure 26

(3) Align the pins of the diode or resistor module with the sockets of theterminal module. Refer to Figure 27.

Make sure that:

- Latch A is aligned with side A of the terminal module- Terminal Pin A is aligned with the outer socket on Side A- Latch B is aligned with side B of the terminal module- Terminal Pin B is aligned with the outer socket on Side B- The two filler pins of the module are aligned with the corresponding

inner sockets in the terminal module.

CAUTION: IF THE LATCHES ARE NOT ALIGNED WITH THE APPLICABLE SIDE OF THETERMINAL MODULE, INCORRECT OPERATION OF THE SYSTEM CAN OCCUR.

b




ALIGNMENT OF THE DIODE OR RESISTOR MODULE AND THE TERMINAL MODULEFigure 27

(4) Push the module down into the terminal module. Refer to Figure 28.

Make sure that:

- The two terminal pins engage the two sockets- The two latches are fully engaged with the two latch retention tabs.

POSITION OF THE DIODE OR RESISTOR MODULE IN THE TERMINAL MODULEFigure 28

b




(5) Examine the diode or resistor module for these types of damage:

- A module shell that has a crack- A latch that has a crack or a bend- A latch that is broken- A pin that is bent.

C. Installation of a Track on an Assembly or the Structure

CAUTION: A RIVET MUST NOT BE INSTALLED IN AN OLD HOLE IN THE STRUCTURE. THEELECTRICAL BOND BETWEEN THE RIVET IN AN OLD HOLE AND THE STRUCTURE CANCAUSE UNSATISFACTORY PERFORMANCE.

(1) Make a selection of a rivet that:

- Is aluminum- Has an alodine finish- Has a 0.125 inch diameter- Has the necessary length for the installation.

(2) Drill a hole in the assembly or the structure for each hole in the track.

Make sure that the hole has the correct diameter for the rivet.

(3) Install a rivet in each hole of the track and the assembly or structure.


A. Contact Removal Tools

TABLE XXICONTACT REMOVAL TOOL SUPPLIERS


ATR 2079 BAC Astro

ATR 2080 BAC Astro

ATR 2106 BAC Astro

ATR 2112 BAC Astro

DRK83-20 Daniels

DRK-110-1SA Daniels

DRK-20-2 Daniels

DRK-16-2 Daniels

M81969/14-03 QPL

M81969/14-11 QPL

RRX16B Russtech

RRX20B Russtech

b




B. Terminal Module Removal Tools

TABLE XXIIMODULE REMOVAL TOOL SUPPLIERS


RDW20-4 Russtech

C. Contact Insertion Tools

TABLE XXIIICONTACT INSERTION TOOL SUPPLIERS


91039-1 AMP

DAK83-16 Daniels

DAK83-20 Daniels

M81969/14-03 QPL

M81969/14-11 QPL

ST2220-2-4 Boeing

ST2220-2-11A Boeing

ST2220-2-28 Boeing

D. Contact Crimp Tools

TABLE XXIVCONTACT CRIMP TOOL SUPPLIERS

Crimp Tool Supplier

M22520/1-01 QPL

M22520/1-02 QPL

M22520/2-01 QPL

M22520/2-11 QPL

ST2220-1-2 Boeing

ST2220-1-Y Boeing

WA22 Daniels

WA22LC Daniels

WA27 Daniels

WA27F Daniels

b




This Subject gives the procedures to assemble, connect, disconnect, and install the BurndyRBDSC-() Program Switch Module.


1. Part Numbers and Description 11.A. Program Switch Module Part Numbers 11.B. Security Cover Assembly Part Numbers 41.C. Contact Part Numbers 51.D. Necessary Materials 51.E. Recommended Tools 62. Disassembly of the Program Switch Module 62.A. Security Cover Removal 62.B. Switch Seal Plug Removal 62.C. Switch Module Removal from the Structure 72.D. Contact Removal 73. Assembly of the Program Switch Module 83.A. Contact Assembly 83.B. Contact Insertion 103.C. Installation of Spare Contacts 123.D. Installation of Seal Plugs or Seal Rods 123.E. Configuration of the Switches 124. Installation of the Program Switch Module 134.A. Installation of the Security Cover on the

Module13

4.B. Installation of the Switch Module on theStructure

14

5. Approved Tool Suppliers 145.A. Contact Removal Tools 145.B. Contact Insertion Tools 155.C. Contact Crimp Tools 15


A. Program Switch Module Part Numbers

TABLE IPROGRAM SWITCH MODULE ASSEMBLY PART NUMBERS

Part Numbers Configuration Supplier

RBDSC-126 Size 16 Contacts with 24Switched Outputs

Burndy

b


BURNDY RBDSC-() PROGRAM SWITCH MODULE


BURNDY RBDSC-() PROGRAM SWITCH MODULE PART NUMBER STRUCTUREFigure 1

BURNDY RBDSC-1 PROGRAM SWITCH MODULEFigure 2

b




BURNDY RBDSC-1 PROGRAM SWITCH MODULE WITH A SECURITY COVERFigure 3

ELECTRICAL CONFIGURATION OF THE SWITCH MODULEFigure 4

b




The Burndy RBDSC-() program switch module have these technical features:

- 24 switched outputs- Captive switch seal plugs- Security covers to protect switch positions- Standard MIL-C-39029/1-101 size 1620 contacts.

B. Security Cover Assembly Part Numbers

TABLE IISECURITY COVER ASSEMBLY PART NUMBERS

Description Part Number Supplier Note

Security Cover RBDSC-1P15 BurndyHeld in position by the RBDSC-1P12threaded stud

Threaded Stud RBDSC-1P12 BurndyHolds the security cover on theprogram switch module and the moduleon the structure

BURNDY RBDSC-1P15 SECURITY COVERFigure 5

The Burndy RBDSC-1P15 security cover:

- Gives protection from accidental change of the position of the switch- Locks the switch seal covers into position- Prevents the contamination of the switches.

b




C. Contact Part Numbers

TABLE IIICONTACT PART NUMBERS

Contact SizeContact

TypePart Number

Color Code

SupplierEngaging

End

Crimp

BarrelBand Color

16 20 Pin MIL-C-39029/1-101

1 Brown

QPL2 Black

3 Brown

EXAMPLE OF A CONTACT SIZEFigure 6

MIL-C-39029() PIN CONTACTFigure 7

The contacts have these technical features:

- A size 20 crimp barrel- A gold finish.

D. Necessary Materials

TABLE IVNECESSARY MATERIALS FOR ASSEMBLY

Material Specification Supplier Note

Seal Plug MS27488-16 QPL Blue

Seal Rod AMS 3656 QPL Cut to the necessary length

b




E. Recommended Tools

NOTE: The satisfactory alternatives to the tools in Table V are:

- In Table VI for contact removal tools- In Table VIII contact crimp tools- In Table IX contact insertion tools.

TABLE VRECOMMENDED TOOLS

Procedure

Contact Size Tool

Engaging

End

Crimp

BarrelType Part Number

Contact Removal 16 20 Removal M81969/14-11

Contact Assembly 16 20Crimp M22520/1-01

Locator M22520/1-02

Contact Insertion 16 20 Insertion M81969/14-11

Switch Configuration 16 20 Insertion M81969/14-02

2.Disassembly of the Program Switch Module

A. Security Cover Removal

(1) Loosen the screws that hold the cover to the module.

(2) Remove the cover.

B. Switch Seal Plug Removal

(1) Carefully pull the tab of the applicable switch seal plug up and away fromthe module. Refer to Figure 8.

Make sure to pull the tab lightly so that the nylon lanyard at the otherend of the plug does not break.

CAUTION: THE NYLON LANYARD AT THE ONE END OF THE SWITCH SEAL PLUG KEEPS THESEAL PLUG ATTACHED TO THE MODULE SO THAT THE PLUG IS ALWAYSAVAILABLE TO GIVE PROTECTION TO THE SWITCHES. DO NOT DISCONNECTTHIS END OF THE PLUG.

b




58389253 Standard Wiring Practices Manual

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