THAKUR INSTITUTE OF AVIATION TECHNOLOGY

PRACTICAL PROCEDURE SHEET

TASK NO: TIAT/P-66/B2/PRAC-14
Time: 6 hrs.
MODULE: 7A
CATEGORY: B2
TITLE:DisassembleandassembleanaircraftcomponentIAWManufacturer’s overhaul manual.

TASK: Disassembly and Assembly of Dadc Used In Boeing 747-200/300 Aircraft UsingManufacturer Component Overhaul Manual
OBJECTIVES:
 To familiarize the student about the procedure to be followed to disassemble and assembly of an LRU used in aircraft and
while doing so what are the safety precaution to be followed.
 If an LRU found unserviceable during its operation, maintenance personal will do a BITE test before sending it workshop and
he will record the fault BITE to log it. It will give a shop personal an idea to rectify the fault.
AREAS TO PERFORM THE TASK: Shop floor (Instrument)
REFERENCES: AMM reference – ATA Chapter –34 (34-13-01),
CMM - Honeywell -Component Maintenance Manual Part No. 3757183-2
PREPARATION FOR THE PROCEDURE: Use conductive plastic mat to the component and its parts
SAFETY PRECAUTION/NOTES:
1. Follow ESDS procedure
2. General workshop safety procedure
CONSUMABLE MATERIALS: Tying chord and Tie strap
TOOLS/EQUIPMENTS: General tools

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PROCEDURE:
DISASSEMBLY(Ref. IPL Figures 1 and 2) Component Maintenance Manual Part No. 3757183-2
A. General
(1) Test the DADC before disassembly, as specified in Section 3, to determine if repair is required. If the unit does not meet
the requirements of Section 3, and repair is required, disassemble only to the extent necessary to effect repairs.
Complete disassembly (and subsequent maintenance/overhaul and reassembly) is impractical and undesirable at the
field level. The DADC houses some modules that contain metal oxide semiconductor (MOS) devices. These modules
require special handling.
DISASSEMBLY TASK WILL BE ONLY UPTO THE CARD MODULE ASSEMBLY REMOVAL

WARNING: Avoid exposure to possible electric shock when observing the special grounding requirements for MOS devices.
Do not perform maintenance procedures requiring static grounding of personnel in the presence of exposed electrical power
sources.
(2) During disassembly, refer to the order of key index numbers given in IPL Figures 1 and 2. Note that the attaching parts
immediately follow the parts which they attach.
CAUTION: EXERCISE CARE WHEN UNSOLDERING FROM TERMINALS ON THE ELECTRICAL COMPONENT
ASSEMBLIES TO AVOID DAMAGE TO LEADS AND TERMINALS.
(3) Tag all disconnected leads to facilitate reassembly. Refer to Figure Table 603 and 604, and Figure 601 and 602 for point-
to-point wiring designations.
B. Plug-In Modules
(1) Loosen eight captive screws (8, IPL Figure 2) and remove top cover (10) from DADC chassis assembly.
CAUTION: MODULES OF THE DADC THAT CONTAIN MOS DEVICES CAN BE DAMAGED BY STATIC
DISCHARGE. IT IS MANDATORY THAT SUCH MODULES BE HOUSED IN A CONDUCTIVE CONTAINER
(CONDUCTIVE BAG, CLOSED METAL TRAY, ETC.) DURING TRANSPORTATION, STORAGE, OR SHIPMENT. IN
ADDITION, A CONDUCTIVE-PLASTIC SHUNT BAR MUST BE PLACED OVER THE PINS OF THE MODULE
CONNECTOR WHENEVER THE MODULE IS NOT IN USE. DO NOT HANDLE THE MODULE OR THE MOS

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DEVICES UNLESS YOUR ARE PROPERLY GROUNDED. THE FOLLOWING REQUIREMENTS MUST BE STRICTLY
ADHERED TO:
1) Work benches must be covered with conductive-plastic matting.
2) Personnel must wear properly ground wrist straps at all times when handling modules or mos devices.

3) Whenever module is not in use, ensure that conductive- plastic shunt bar is in place, and module is placed in
conductive-plastic bag.

4) Soldering irons must be posi-ground type, identified by neck band or handle or white band above colored band on wire.
Tip of iron must be secured by set screw; a loose soldering tip could cause a grounding failure.

(2) Remove module assemblies [10 through 20 and 23 (as applicable), IPL Figure 1] by lifting up the card extractors at the upper
corners of each module assembly to separate the module connector from its mating chassis connector, and then sliding the module up
and out of DADC chassis assembly (22).
NOTE: Maintenance procedures for plug-in modules are covered in separate publications. Refer to Table 101 for details.
C. Transducer Module Assembly A2
(1) Remove top cover as described in Section 4B(1).
(2) Unscrew captive fasteners which mechanically connect electrical plug connector P8, located on transducer mother board
assembly, to electrical receptacle connector J20 (58, IPL Figure 2).
(3) Disconnect electrical plug connector P8 from electrical receptacle connector J20.
(4) Support transducer module assembly A2 (3, IPL Figure 1) while performing the following steps.
(a) Remove two screws V4) that secure air manifold assembly located on transducer module assembly to the front of
DADC chassis assembly (22, IPL Figure 1).
(b) Remove two screws (5) that secure support bracket located on transducer module assembly to the side of DADC
chassis assembly (22, IPL Figure 1).
(c) Remove two screws (6), two lock washers (7), and two flat washers (8) that secure posts located on transducer
module assembly to the front of DADC chassis assembly (22, IPL Figure 1).

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 (d) Remove transducer module assembly A2 (3, IPL Figure 1) from DADC chassis assembly (22).
NOTE: The transducer module assembly is not to be tested or repaired in the field. If the transducer module assembly is faulty, return
it to the manufacturer for repairs.

D. Front Panel and Connector Assembly A1

(1) Remove transducer module assembly as described in Section 4C.
(2) Remove eight screws (12, IPL Figure 2) that secure bottom cover assembly (11) to sides of DADC chassis assembly (-1),
and two screws (13) that secure the bottom cover assembly to the front panel and connector assembly A1 (-24).
Remove the bottom cover assembly from the DADC chassis assembly.
(3) Remove two screws (17) and two lock washers (18) that attach handle assemblies (16), and the front panel and connector
assembly A1 to the DADC chassis assembly.
(4) Remove screw (21), clamp washer (22), nut (23), and loop clamp (20).
(5) Remove two screws (26) and two lock washers (21) securing connector assembly P11 (44) to connector J4 of wire wrap
tray and connector assembly (-51). Separate the connectors.
(6) Remove four screws (25) that attach the front panel and connector assembly A1 to the DADC chassis assembly. Then
remove the front panel and connector assembly A1.
E. Chassis and Mounted Components
 Do not disassemble chassis and mounted components (51 through 135, IPL Figure 2) unless it is necessary to make structural,
connector, or wiring repairs. Refer to Section 7B through 5G for repair procedures.
ASSEMBLY
A. General
(1) The DADC houses some modules that contain metal oxide semiconductor (MOS) devices. These modules require special
handling.
WARNING: Avoid exposure to possible electric shock when observing the special grounding requirements for MOS devices.
Do not perform maintenance procedures requiring static grounding of personnel in the presence of exposed electrical power
sources.
B. Front Panel and Connector Assembly A1

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 (1) With transducer assembly A2 (3, IPL Figure 1) removed for access to components, position front panel and connector
assembly A1 (-24, IPL Figure 2) onto DADC chassis assembly (-1) and secure it with screws (25).
(2) Secure connector assembly P4 (44) to connector J4 of wire wrap tray and connector assembly (-51) using two screws (26)
and two lock washers (27).
(3) Install loop clamp (20) on the wiring harness of the front panel and connector assembly A1 and secure the clamp to
chassis assembly (122) using screw (21), clamp washer (22) and nut (23).
(4) Place handle assemblies (16) in position on the front panel and connector assembly A1 and secure the assemblies using
two screws (17) and two lock washers (18).
(5) Position bottom cover assembly (11) and secure with screws (12 and 13).
C. Transducer Module Assembly A2
If transducer module assembly A2 (3, IPL Figure 1) has been removed for repairs and subsequent testing and calibration, or for access
to internal chassis part, install the assembly in DADC chassis assembly (22) as follows:
NOTE Support transducer assembly A2 (3, IPL Figure 1) while performing steps (1) through (3).
(1) Place transducer assembly A2 (3) into DADC chassis assembly (22). Install two screws (6) and two lock washers (7), and
two flat washers (8) securing posts located on transducer module assembly to the front of DADC chassis assembly (22,
IPL Figure 1).
(2) Install support bracket (26, IPL Figure 2) to the side of DADC chassis assembly (22, IPL Figure 1) and secure with two
screws (5).
(3) Install two screws (4) securing air manifold assembly located on transducer module assembly to the front of DADC
chassis assembly (22, IPL Figure 1).
(4) Connect electrical plug connector P8 (10, IPL Figure 4) to electrical receptacle connector J20 (58, IPL Figure 2).
(5) Install top cover (10) on DADC chassis assembly (-1) and tighten captive screws (8).
D. Plug-In Modules
CAUTION: DO NOT USE FORCE TO SEAT A MODULE. IF RESISTANCE IS FELT, FIRST CHECK THAT THE
MODULE BEING INSTALLED IS IN THE CORRECT LOCATION. THEN CHECK MODULE CONNECTOR(S) ON
DADC CHASSIS ASSEMBLY (22, IPL FIGURE 1) FOR DAMAGE OR OBSTRUCTIONS. IF WIRE WRAP TRAY AND
CONNECTOR ASSEMBLY (-51, IPL FIGURE 2) HAD BEEN REMOVED AND THEN REINSTALLED, IT MAY BE

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NECESSARY TO REALIGN THE TRAY FOR PROPER MODULE CONNECTOR AND TRAY CONNECTOR
ENGAGEMENT. SEE FOLLOWING STEPS FOR PROCEDURE.
(1) To install module assemblies (10 through 20, IPL Figure 1) into DADC chassis assembly (22), proceed as follows:

CAUTION: MODULES OF THE DADC THAT CONTAIN MOS DEVICES CAN BE DAMAGED BY STATIC
DISCHARGE. IT IS MANDATORY THAT SUCH MODULES BE HOUSED IN A CONDUCTIVE CONTAINER
(CONDUCTIVE BAG, CLOSED METAL TRAY, ETC.) DURING TRANSPORTATION, STORAGE, OR SHIPMENT. IN
ADDITION, A CONDUCTIVE-PLASTIC SHUNT BAR MUST BE PLACED OVER THE PINS OF THE MODULE
CONNECTOR WHENEVER THE MODULE IS NOT IN USE. DO NOT HANDLE THE MODULE OR THE MOS
DEVICES UNLESS YOU ARE PROPERLY GROUNDED. THE FOLLOWING REQUIREMENTS MUST BE STRICTLY
ADHERED TO:
1. Work benches must be covered with conductive plastic matting.
2. Personnel must wear properly grounded wrist straps at all times when handling modules or mos devices.
3. Whenever module is not in use, ensure that conductive-plastic shunt bar is in place and module is placed in conductive-
plastic bag.
4. Soldering irons must be posi-ground type, identified by neck band on handle or white band above colored band on
wire. Tip of iron must be secured by set screw; a loose soldering tip could cause a grounding failure.
(a) Hold the card extractor at the upper corner of a module assembly and place the module assembly into the DADO
chassis assembly such that the connector on the module assembly is aligned with its mating connector on the
DADC chassis assembly.
(b) Slide the module assembles downwards into the DADC chassis assembly until the connector on the module
assembly is in firm contact with its mating connector on the DADC chassis assembly.
(2) Install top cover (10, IPL Figure 2) on DADC chassis assembly (1) and tighten captive screws (8).
E. Chassis and Mounted Components
(1) If an electrical component was replaced, solder the new component in place with the solder specified in Section 7A.
(Materials Required).

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 (2) If wire wrap tray and connector assembly (-51, IPL Figure 7) is being reinstalled, leave screws (52) loose. Install correct
plug- in module at each end of tray and align the tray so module connectors engage properly. With tray positioned
properly, tighten screws (52). Recheck for correct module disengagement and engagement.
(3) If transformer and bracket assembly A18 (73, IPL Figure 2) is being replaced, test the new assembly in accordance with
Section 8F (below) prior to installation.
F. Transformer and Bracket Assembly A18 Preassembly Test
(1) Perform a continuity test of the transformer and bracket assembly using a volt-ohmmeter set to RX1 scale. See Figure 701
for terminal locations. Test points and required readings are, as follows:
Ohmmeter
Terminals Indication
E7 to E37 Less than 0.5 ohm
E8 to E38 Less than 0.5 ohm
E11 to E39 Less than 0.5 ohm
E13 to E40 Less than 0.5 ohm
(2) Perform a polarity check of the transformer and bracket assembly using an oscilloscope and a 7-volt ac, 400-Hz power
source connected as shown in Figure 701. Apply 7 volts ac, 400 Hz to each pair of input terminals in turn, while
observing the output at each corresponding pair of output terminals with the oscilloscope. For each input application,
the resulting no load output voltage shall have the same instantaneous polarity as indicated below
Aerospace Electronic Systems Boyne City, MI Component Maintenance Manual Part No. 3757183-1/2/3/4/5 Input Output
(Lo) E18 to (Hi) E17 (Lo) E20 to (Hi) E19
(Lo) E10 to (Hi) E9 (Lo) E13 to (Hi) E11
(Lo) E14 to (Hi) E12 (Lo) E16 to (Hi) E15
(Lo) E6 to (Hi) E5 (Lo) E8 to (Hi) E7
(Lo) E2 to (Hi) E1 (Lo) E4 to (Hi) E3
(Lo) E32 to (Hi) E31 (Lo) E29 to (Hi) E30
(Lo) E36 to (Hi) E35 (Lo) E33 to (Hi) E34

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(Lo) E22 to (Hi) E21 (Lo) E23 to (Hi) E24
(Lo) E28 to (Hi) E27 (Lo) E25 to (Hi) E26

Transformer and Bracket Assembly Test Diagram

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ASSESMENT POINTS:

1 - Check -conductive plastic mat to the component and its parts were used

2 -Is the student is wearing properly ground wrist straps at all times when handling modules ?

3 – Ensure module is placed in conductive-plastic bag.

4 - Is the student is using CMM /procedure sheet during the task

5 – Ask student to remove A7 and A9 module & check correct modules were removed

6 –Ask student to install A7 and A9 module & check correct modules were installed in correct place after checking the part number

7 - Observe whether correct post job completion Procedure followed

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ASSESMENT POINTS:

1 - Check -conductive plastic mat to the component and its parts were used

2 -Is the student is wearing properly ground wrist straps at all times when handling modules ?

3 – Ensure module is placed in conductive-plastic bag.

4 - Is the student is using CMM /procedure sheet during the task

5 – Ask student to remove A7 and A9 module & check correct modules were removed

6 –Ask student to install A7 and A9 module & check correct modules were installed in correct place after checking the part number

7 - Observe whether correct post job completion Procedure followed

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ANSWER -

1 – YES NO

He must use conductive plastic mat to the component and its parts

2 – YES NO

Check student is wearing properly ground wrist straps at all times when handling modules

3– YES NO

Check module is placed in conductive-plastic bag.

4 – YES NO

Yes , he should make use of CMM /procedure sheet during the task

5 – YES NO

Check for correct module(A7 & A9)removal

6 – YES NO

Check for correct module (A7&A9)installation

7 – YES NO

He should return all tools and kept the area cleaned

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