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FORM TC-15

PRACTICAL EXERCISE SHEET


PHIẾU BÀI TẬP THỰC HÀNH
Title Electric Cables & Connectors - Exercise 01 - Rev 00

Code AMB-M7.7-01 Applicable for: Cat A,B1,B2,B1+B2

Compliance with Electric Cables & Connectors, code: AMB-M7.7

Description This exercise is designed for new technical engineer/technician in accordance


with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 4 hours  Level: 1

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.


 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Electric Cables & Connectors - Exercise 01 Code: AMB-M7.7-01

Type Cable

WARNING: - Do not use cable ties can be dangerous if not operated properly.
CAUTION: - Loose cable tying will make cable loose and rubbed
1. JOB SET-UP INFORMATION
A. Fixtures, Tools, Test and Support Equipment
REFERENCE QTY UNIT DESIGNATION
N/A N/A N/A N/A

B. Consumable Material
REFERENCE QTY UNIT DESIGNATION
Cable Wires (8 Wires) Cable 6 2 Meters
Coaxial cables (4 wire cores) 2 Meters
Cable Tie (3x100, length: 10cm) 16 EA
Board Electrical (40x40) 8 EA
Face mask (1 time use) 8 EA
Industrial rags 0.5 Kg
Industrial glasses 8 EA

C. Expendable Parts
REFERENCE QTY UNIT DESIGNATION
Rubber 8 EA N/A

D. Referenced Information
REFERENCE DESIGNATION
N/A N/A

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 1 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 01 Code: AMB-M7.7-01


2. JOB SET-UP
+ Prepare 6 Cable ties.
+ Prepare 6 rubber.
+ Ensure the cable is in good condition before using the equipment.
3. PROCEDURE
Knot Number 1 Tying procedure:
1. Chose Cable ties.
2. Chose rubber.
3. Knot 1 is the standard knot and can be used anywhere.

Knot Number 1 Tying Sequence (Figure 1)


Knot Number 2 Tying procedure:
Knot 2 is used in areas which are not easily accessible.

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 2 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 01 Code: AMB-M7.7-01

Knot Number 2 Tying Sequence (Figure 2)


4. PRODUCTION REQUIREMENTS/ ASSESSMENT
A. Trainee understands the warning and caution of tool (1 pts).
B. Assess the practical training Knot Number 1 Tying Sequence of trainee (5 pts)
C. Assess the practical training Knot Number 2 Tying Sequence of trainee (5 pts)
Final assessment: Passed / Not passed
A. Trainee understands the warning and caution of tool as required (1 pts).
B. Trainee prepares the material for practice as required (1 pts).
C. Trainee understands and answer the process of Knot Number 1 Tying Sequence as required Figure
1 (2 pts).
D. Trainee the practical training process of Knot Number 1 Tying Sequence as required Figure 1 (2
pts).
E. Trainee understands and answer the process of Knot Number 2 Tying Sequence as required Figure
2 (2 pts).
F. Trainee the practical training process of Knot Number 2 Tying Sequence as required Figure 2 (2 pts).
Final assessment: Passed 5/10 / Not passed 4/10

5. CLOSE-UP
A. Make sure that the work area is clean and clear of tools and other items.
B. Clean Workshop
C. Put Workshop to Its usual condition

Prepared by: Trương Công Tuấn Date: 01/01/2022

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 3 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 01 Code: AMB-M7.7-01

Evaluated by: Hoàng Ngọc Thưởng Date: 01/01/2022

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 4 / 4


FORM TC-15

PRACTICAL EXERCISE SHEET


PHIẾU BÀI TẬP THỰC HÀNH
Title Electric Cables & Connectors - Exercise 02 - Rev 00

Code AMB-M7.7-02 Applicable for: B1,B2,B1+B2

Compliance with Electric Cables & Connectors, code: AMB-M7.7

Description This exercise is designed for new technical engineer/technician in accordance


with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 6 hours  Level: 1

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.


 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Electric Cables & Connectors - Exercise 02 Code: AMB-M7.7-02

Manual multimeter meter

WARNING: - Make sure that no AC or DC power source is connected to the aircraft


electrical circuits. There is a risk of electrocution if the AC or DC power
stays connected.
- When you put the cable and contact assembly into the connector, do not
apply too much force, specially if you use a metal insertion tool. If you
apply too much force, you will cause damage to the cable insulation or to
the cable.
CAUTION: - Only do this test for the electrical items specified in this procedure. You
can cause damage if you do this procedure for other items.
1. JOB SET-UP INFORMATION
A. Fixtures, Tools, Test and Support Equipment
REFERENCE QTY UNIT DESIGNATION
Isolation Tester 01 EA N/A

Milliohm-meter 01 EA N/A

B. Comsumable Material
REFERENCE QTY UNIT DESIGNATION
Cable Wires (8 Wires)
1 Meter N/A
Cable 6
Connector 01 EA N/A
Pin/socket 8 EA N/A

Fabric Gloves 8 EA N/A


Face mask (1 time
8 EA N/A
use)

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 5 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 02 Code: AMB-M7.7-02


Industrial rags 0.5 Kg N/A
C. Expendable Parts
REFERENCE QTY UNIT DESIGNATION
N/A N/A N/A N/A

D. Referenced Information
REFERENCE DESIGNATION
N/A N/A

2. JOB SET-UP
I.1 Trainee number: Group 8 persons
I.2 Document Handout: Refer to ESPM 20-52-21/22/24
I.3 Tools/Equipment: 8 set of Milliohm-meter, Isolation Tester
I.4 Consumable Material/ Parts:
Wires/ Relays/ Diots/ Componants …
3. PROCEDURE
A Continuity Test of an Aircraft Wire
.
There are two methods for this test:
(1) Continuity test with aircraft wire connected to a grounding point
(a) Disconnect the connectors at the two ends of the aircraft wire.
(b) Connect one end of the aircraft wire to a grounding point.
(c) Connect one of the ohmmeter probes to a contact at the other end of the wire.
(d) Connect the second ohmmeter probe to a grounding point.
(e) Make sure that the current flows through the conductor (the indication on the ohmmeter
changes).
EN standards have a copyright and Airbus cannot copy the data in the Standard Manual.
NOTE: The
Thus,resistance valueresistance
for the normal of the wirevalues
is shown.
of EN wires, refer to the applicable EN standards.
For calculation of the normal resistance value, refer to the Standard Manual (resistance
per meter).
For circuits without lamps, relay coils or diodes, continuity resistance takes into account
the maximum length of the harness, the maximum cable gauge used in the harness and
the cable type used (copper or aluminum).
NOTE:
(f) Repeat the procedure for each contact of the wire and the shielding.
NOTE: To do the test successively on each section of a circuit, operate the control components
(switches, pushbuttons, etc.).
NOTE:You must do a continuity check of all types of conductors. This includes dual and shunted circuits
(e.g.: shunting of standby circuit-breaker power supply). For dual and shunted circuits, you must
open the circuit at one point before the test.
NOTE:After this procedure, we recommend that you do a short circuit detection test or an insulation test,
as applicable for the type of wire.
(2) Continuity test with an extension wire
(a) Disconnect the connectors at the two ends of the aircraft wire.

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 6 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 02 Code: AMB-M7.7-02


(b) Connect one end of the extension wire to one end of the aircraft wire.
(c) Connect the other end of the extension wire to one probe of the ohmmeter.
(d) Connect the second ohmmeter probe to the second end of the aircraft wire.
(e) Make sure that the current flows through the conductor (the indication on the ohmmeter changes).
NOTE:The resistance value of the wire is shown.
For calculation of the normal resistance value, refer to the Standard Manual (resistance per
meter).
For circuits without lamps, relay coils or diodes, continuity resistance takes into account the
maximum length of the harness, the maximum cable gauge used in the harness and the cable
type used (copper or aluminum).
NOTE:EN standards have a copyright and Airbus cannot copy the data in the Standard Manual. Thus,
for the normal resistance values of EN wires, refer to the applicable EN standards.
(f) Repeat the procedure for each contact of the wire and the shielding.
NOTE:After this procedure, we recommend that you do a short circuit detection test or an insulation test,
as applicable for the type of wire.
B. Test for short-circuit of an Aircraft Wire
Disconnect the aircraft wire at the two ends.
(1) Test between the conductor and the structure

(a) Connect one of the ohmmeter probes to one contact of the aircraft wire.

(b Connect the second ohmmeter probe to a grounding point.

(c) Make sure that the current does not flow from the conductor to the structure (the indication on the
ohmmeter does not change).

NOTE The resistance must not be less than 5 MOhm in all temperature and relative humidity
: conditions.

(d) Do this procedure for each contact (including unused contacts) of the wire.

(2) Test between two conductors

(a) Connect one of the ohmmeter probes to a contact of one the connector of the wire to be tested.

(b) Connect the second ohmmeter probe to another contact of the connector.

(c) Make sure that the current does not flow through the conductors (the indication on the ohmmeter
does not change).

NOTE
The resistance must not be less than 5 MOhm in all temperature and relative humidity conditions.
:

(d) Do this procedure again as many times as necessary to make sure that there is no defect.

NOTE
Shielding of shielded or coaxial cables must be tested as single wires.
:
For example:

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 7 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 02 Code: AMB-M7.7-02

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 8 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 02 Code: AMB-M7.7-02

4. PRODUCTION REQUIREMENTS/ ASSESSMENT


01. Use multimeter to check components: Diode, transitor, wire connec: (5 pts)
- Continuity test with aircraft wire connected to a grounding point (2 pts)
- Insulation test (2 pts).
- Test between two conductors. ( 1 pts).
02. How to use common tools as multimeter, crimping tools? (5 pts)
- Multimeter with short-circuit of an Aircraft Wire. (2.5 pts)

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 9 / 4


FORM TC-15

Electric Cables & Connectors - Exercise 02 Code: AMB-M7.7-02


- Test for criming tools. (2.5 pts)
5. CLOSE-UP
- Give the tools back to store
- Set all equipment in workshop back to initial configuration
Clean up the workshop

Prepared by: Trương Công Tuấn Date: 01/01/2022

Evaluated by: Hoàng Ngọc Thưởng Date: 01/01/2022

ISS. 01, REV. 00 - DATE: 16 JUN 2017 PAGE 10 / 4


FORM TC-20

PRACTICAL EXERCISE SHEET


PHIẾU BÀI TẬP THỰC HÀNH
Title Electric Cables & Connectors - Exercise 03 - Rev 00

Code AMB-M7.7-03 Applicable for: Cat B1,B2,B1+B2

Compliance with Electric Cables & Connectors, code: AMB-M7.7

Description This exercise is designed for new technical engineer/technician in accordance


with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 6 hours  Level: 2

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.


 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Electric Cables & Connectors - Exercise 03 Code: AMB-M7.7-03

Clean and Protection of the Cable & Wire

WARNING: Wear gloves when you touch the cables


CAUTION: Do not soak the cables with the solvent when the solvent tools the cable core it
removes the lubricant. this causes corrosion and the cables wear fast
1. JOB SET-UP INFORMATION
A. Fixtures, Tools, Test and Support Equipment
REFERENCE QTY UNIT DESIGNATION
N/A N/A N/A N/A
B. Comsumable Material
REFERENCE QTY UNIT DESIGNATION
(Material No. 03HBD9 ) 1 EA Synthetic Ester base Grease-General Purpose Low Temp
(Material No. 08BBB1 ) 1 EA Non Aqueous Cleaner-- Petroleum Based
(Material No. 12AGC2) 1 EA Corrosion Preventive Compound-- Soft Film System
C. Expendable Parts
REFERENCE QTY UNIT DESIGNATION
N/A N/A N/A N/A
D. Referenced Information
REFERENCE DESIGNATION
A_M06_M07 EWIS_2010.09.28
ESPM 20-54-55 AirN@v

2. JOB SET-UP
I.5 Trainee number: Group of 6 persons
I.6 Document Handout: Refer to ESPM 20-54-55
I.7 Tools/Equipment:
3. PROCEDURE

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 1 / 4


FORM TC-20

Electric Cables & Connectors - Exercise 03 Code: AMB-M7.7-03


A . Cleaning of the Cables
(1) Soak a cloth with Non Aqueous Cleaner
-- Petroleum Based
- (Material No. 08BBB1 ) and remove the unwanted material. Clean the surface of the
cable.
NOTE: Remove the unwanted material from the cloth to make sure that it does not go into the cable
core. This removes the lubricant around each strand.

(2) Fully dry the cables.


Subtask 20-24-11-916-050-A

B. Protection of the Cables


(1) Apply Corrosion Preventive Compound-- Soft Film System
(Material No. 12AGC2 ) with :
· a GUN - SPRAY or with a BRUSH - BRISTLED .
NOTE: These conditions are applicable for each procedure:
- the ambient temperature must be between 5 deg.C (41.00 deg.F) and 35 deg.C (95.00
deg.F),
- if you use a spray gun, the air pressure must be at least 4 bar (58.0151 psi),
- the protective coat that gives protection must be 0.05 mm (0.0020 in.) thick,
- the protective film must be even along the length of the cable. There must be no unwanted
thickness caused by drops or runs,
(2) Let the cable dry between 1h30 and 2h00 (this time is related to the ambient temperature).
(3) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No. 03HBD9 )
on the rear THS control cables (between FR71 and the THS actuator) to prevent corrosion in
this area.
Close-up

ESPM 20-54-55
Sealing of contacts and terminals
(Ref. Fig. Protection and Stowage for Terminals, Contacts and Cables - Plastic Bags and Shrinkable
Sleeves SHEET 1)
(Ref. Fig. Protection and Stowage for Terminals, Contacts and Cables - Shrinkable Sleeves for
Connected Contacts SHEET 1)
A. With plastic bags
- For the description of plastic bags and related procedures,
(Ref. ESPM D/O 20-54-51-02)
- Protection and Stowage for Circular Connectors.
B. With heat-shrinkable sleeves
- On end fittings without special protection (for example splices, terminal lugs, etc.), make sure that a
heat-shrinkable sleeve is installed to protect the connection.
- For items connected to equipment, terminal lugs and the contacts must be protected to each before
delivery of the racks or harnesses by a sleeve (shrunk or not) to avoid short-circuit on aircraft start.
- Soldered connections must be protected with a heat-shrinkable sleeve.
This sleeve must be adapted to the diameter of the connection and lightly force fitted. It must be
possible to slide the sleeve to do a check of the solder (not applicable to rotary type selectors).
- On harnesses where the diameter of the insulation is small or smaller than the cavities of the
connector, it is permitted to use a heat-shrinkable sleeve with a minimum length of 15 mm (0.59 in.) to
agree with the diameter and make sure that the sealing is correct. This also prevents folding and gives

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 2 / 4


FORM TC-20

Electric Cables & Connectors - Exercise 03 Code: AMB-M7.7-03


better strength to the harness at the end and at tin soldering.
Close-up ESPM 20-54-55

Make sure that the work area is clean and clear of tools and other items.
4. PRODUCTION REQUIREMENTS/ ASSESSMENT
1. Prepair Material & Tool (3 Score):
- Prepair Tool equitments (1.5 Sore).
- Prepair consumable (1.5 Sore).

2. Cleaning of the Cables (3 Score):


- Soak a cloth with Non Aqueous Cleaner (1.5 Sore).
- Fully dry the cables. (1.5 Sore).

3. Sealing of contacts and terminals (4 Score):


- With plastic bags (2 Score):
+ For the description of plastic bags and related procedures,
(Ref. ESPM D/O 20-54-51-02) (1 Score).
+ Protection and Stowage for Circular Connectors (1 Score)
- With heat-shrinkable sleeves (2 Score):
+ For items connected to equipment, terminal lugs and the contacts must be protected to each
before delivery of the racks or harnesses by a sleeve (shrunk or not) to avoid short-circuit on aircraft
start (0.5 Score).
+ Soldered connections must be protected with a heat-shrinkable sleeve (0.5 Score).
This sleeve must be adapted to the diameter of the connection and lightly force fitted. It must be
possible to slide the sleeve to do a check of the solder (not applicable to rotary type selectors).
+ On harnesses where the diameter of the insulation is small or smaller than the cavities of the
connector, it is permitted to use a heat-shrinkable sleeve with a minimum length of 15 mm (0.59 in.) to
agree with the diameter and make sure that the sealing is correct. This also prevents folding and gives
better strength to the harness at the end and at tin soldering (1 Score).

5. CLOSE-UP
A. Make sure that the work area is clean and clear of tools and other items.
B. Clean Workshop
C. Put Workshop to Its usual condition

Prepared by: Trương Công Tuấn Date: 01/01/2022

Evaluated by: Hoàng Ngọc Thưởng Date: 01/01/2022

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 3 / 4


FORM TC-20

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 4 / 4


FORM TC-20

PRACTICAL EXERCISE SHEET


PHIẾU BÀI TẬP THỰC HÀNH
Title Electric Cables & Connectors - Exercise 04 - Rev 00

Code AMB-M7.7-04 Applicable for: Cat A,B1, B2,B1+B2

Compliance with Electric Cables & Connectors, code: AMB-M7.7

Description This exercise is designed for new technical engineer/technician in accordance


with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 2 hours  Level: 2

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.


 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Electric Cables & Connectors - Exercise 04 Code: AMB-M7.7-04

Stripping tools

WARNING: - Any piece of equipment can be dangerous if not operated properly.


- You are responsible for the safe operation of this equipment
- The operator must carefully read and follow any warnings, safety signs and
instructions provided with or located on the equipment.
CAUTION: - Check machine periodically for loose-bolt and nuts
- Do not use tools that have V-shapes or Shear-type knives.
- This type of knife can cause damage to cables.
- Be very careful when you use these tools, they are sharp and can cut you.
1. JOB SET-UP INFORMATION
A. Fixtures, Tools, Test and Support Equipment
REFERENCE QTY UNIT DESIGNATION
N/A 1 EA Stripping tools

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 1 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 04 Code: AMB-M7.7-04

Stripping Tools

Content of Jaws Set (Figure 1)

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 2 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 04 Code: AMB-M7.7-04

Stripping Tools (Figure 2)


B. Consumable Material
REFERENCE QTY UNIT DESIGNATION
Cable Wires (8 Wires) Cable 6 1 Meters
Face mask 8 EA
Industrial rags 0.5 Kg
Industrial glasses 8 EA

C. Expendable Parts
REFERENCE QTY UNIT DESIGNATION
N/A N/A N/A N/A

D. Referenced Information
REFERENCE DESIGNATION
N/A N/A
2. JOB SET-UP
+ Prepare Stripping tools, Stripping Dies P/N 45-1952-1.
+ Prepare Stripping tools, Stripping Dies P/N 45-1939-1.
+ Prepare Wire Blue size 26 to 16.
+ Prepare Wire Red size 14 to 10.
+ Ensure the tools are in good condition before using the equipment.
+ Ensure the cable is in good condition before using the equipment.

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 3 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 04 Code: AMB-M7.7-04


3. PROCEDURE
Stripping procedure:
4. Chose Wire Blue size.
5. Chose Strip master
6. To strip the wire, it must be placed into the matching notch of the Strip master stripping tool.
7. Then the handles must be pressed until stop.
8. When releasing the handles, the clamping jaws open first so that the wire can be removed smoothly.

Stripping procedure (Figure 3)


After the stripping process, inspect the wire for any signs of damage.

Damages caused by Stripping (Figure 4)

4. PRODUCTION REQUIREMENTS/ ASSESSMENT


A. Trainee understands the warning and caution as required (1 pts).
B. Trainee prepares the material for practice and the tools are in good condition (1 pts).

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 4 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 04 Code: AMB-M7.7-04


C. Trainee must recognize content of Jaws Set as required Figure 1 (2 pts).
D. Trainee must recognize types P/N and color and size of tools as required Figure 2 (2 pts).
D. Trainee the practical training process of Stripping Sequence as required Figure 1 (4 pts).
Answer:
+ Trainee understands and answer steps the process of Stripping Sequence as required.
Trainee the practical training process:
+ Chose Wire Blue size 26 to 16.
+ Chose Stripping Dies P/N 45-1952-1.
+ To strip the wire, it must be placed into the matching notch of the Strip master stripping tool.
+ Then the handles must be pressed until stop.
+ When releasing the handles, the clamping jaws open first so that the wire can be removed smoothly.
+ Trainee inspects the wire for any signs of damage as required Figure 4.
5. CLOSE-UP
A. Make sure that the work area is clean and clear of tools and other items.
B. Clean Workshop
C. Put Workshop to Its usual condition

Prepared by: Trương Công Tuấn Date: 01/01/2022

Evaluated by: Hoàng Ngọc Thưởng Date: 01/01/2022

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 5 / 5


FORM TC-20

PRACTICAL EXERCISE SHEET


PHIẾU BÀI TẬP THỰC HÀNH
Title Electric Cables & Connectors - Exercise 05 - Rev 00

Code AMB-M7.7-05 Applicable for: Cat A, B1, B2,B1+B2

Compliance with Electric Cables & Connectors, code: AMB-M7.7

Description This exercise is designed for new technical engineer/technician in accordance


with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 2 hours  Level: 2

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.


 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05

Crimping Tools

WARNING: - Any piece of equipment can be dangerous if not operated properly.


- You are responsible for the safe operation of this equipment
- The operator must carefully read and follow any warnings, safety signs and
instructions provided with or located on the equipment.
CAUTION: - Check machine periodically for loose-bolt and nuts
- did you choose the appropriate tool for the terminal?
- for cleanliness
- for damages
- for corrosion
- for abrasion
1. JOB SET-UP INFORMATION
A. Fixtures, Tools, Test and Support Equipment
REFERENCE QTY UNIT DESIGNATION
N/A 2 EA Crimping Tools

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 1 / 7


FORM TC-20

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05

Crimping Tools
B. Consumable Material
REFERENCE QTY UNIT DESIGNATION
N/A 16 EA Terminals
N/A 16 EA Splices
N/A 2 Meter Wire size 26 to 24
N/A 2 Meter Wire size 22 to 18
N/A 8 EA Fabric Gloves
N/A 8 EA Face mask (1 time use)
N/A 0.5 Kg Industrial rags
N/A 8 EA Industrial glasses

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 2 / 7


FORM TC-20

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05

Terminals & splices (PIDG)


C. Expendable Parts
REFERENCE QTY UNIT DESIGNATION
N/A N/A N/A N/A

D. Referenced Information
REFERENCE DESIGNATION
N/A N/A
2. JOB SET-UP
+ Prepare Crimping Tools.
+ Prepare terminals.
+ Prepare splices.
+ Prepare Wire Yellow size 26 to 24
+ Prepare Wire Red size 22 to 18.
+ Ensure the tools are in good condition before using the equipment.
+ Ensure the cable is in good condition before using the equipment.
3. PROCEDURE
Crimping procedure:
1.In the crimping procedure both the conductor and the insulation are connected to the terminal.
2.The insulation sleeve is also identified with dot coding (dot matrix).
3.These dots indicate whether the terminal has been pressed with the correct matrix size.
Color Code:
To avoid errors when selecting terminals and corresponding crimping tools, the terminals come with
colored insulation sleeves and the crimping tools have colored handles, too. Different colors are
assigned to corresponding wire sizes.

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 3 / 7


FORM TC-20

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05

Color Coding (Figure 1)

Crimping for Pidg terminals procedure:


1.Selecting the right crimping tool, the insulation crimp has to be adjusted to match the wire insulation.
2.Set insulation crimp to position 4, insert terminal, insert non−stripped wire into the insulation crimping
jaws, crimp.
3.Examine whether the wire is held well by the insulation crimp, as a test bend the wire 90 degrees at
the terminal twice.
4. If this isn’t the case, choose the next smaller position and repeat the procedure until the desired
insulation support is achieved (the smaller the position/ number, the stronger the crimp of the
insulation).
5. Strip wire to desired length insert terminal into tool until stop and insert the stripped end of the wire.
6.The strand should stick out approx. 1 mm from the terminal barrel.
7.Crimp tool until security ratchet is unblocked.
8.Finally, check if:
− the crimping is on the correct position of the terminal
− all strands have been included
− the imprinted dots are visible
− the insulation crimp is as desired
− the strands are visible at the side with the terminal.

PIDG terminal Crimping (Figure 2)


Crimping for PIDG Splices:
1.The same crimping tool as described for terminals is used.

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 4 / 7


FORM TC-20

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05


2.Insert stripped wire into splice and begin with first crimping procedure.
3.When finished, check if done properly. Insert other side of the splice into the tool for the second
crimping procedure. Second check as described for terminals.

PIDG Splice Crimping (Figure 3)

Possible Damages in Crimping Procedures (Figure 4)

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 5 / 7


FORM TC-20

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05

Crimping Damages (Figure 5)


4. PRODUCTION REQUIREMENTS/ ASSESSMENT
A. Trainee understands the warning and caution of tool as required (1 pts).
B. Trainee prepares the material for practice as required (1 pts).
C. Trainee must recognize wire sixe color code as required Figure 1 (1 pts).
D. Trainee the practical training process of PIDG terminal Crimping as required Figure 1 (3 pts).
Answer:
+ Selecting the right crimping tool, the insulation crimp has to be adjusted to match the wire insulation.
+ Set insulation crimp to position 4, insert terminal, insert non−stripped wire into the insulation crimping
jaws, crimp.
+ Examine whether the wire is held well by the insulation crimp, as a test bend the wire 90 degrees at
the terminal twice.
+ If this isn’t the case, choose the next smaller position and repeat the procedure until the desired
insulation support is achieved (the smaller the position/ number, the stronger the crimp of the
insulation).
+ Strip wire to desired length insert terminal into tool until stop and insert the stripped end of the wire.
+The strand should stick out approx. 1 mm from the terminal barrel.
+ Crimp tool until security ratchet is unblocked
+ Finally, check if:
− the crimping is on the correct position of the terminal
− all strands have been included
− the imprinted dots are visible
− the insulation crimp is as desired
− the strands are visible at the side with the terminal.
E. Trainee the practical training process of PIDG Splice Crimping as required Figure 2 (2 pts).
Answer:

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 6 / 7


FORM TC-20

Electric Cables & Connectors - Exercise 05 Code: AMB-M7.7-05


+ The same crimping tool as described for terminals is used.
+ Insert stripped wire into splice and begin with first crimping procedure.
+ When finished, check if done properly. Insert other side of the splice into the tool for the second
crimping procedure. Second check as described for terminals.
F. Trainee must recognize damages in Crimping Procedures as required (Figure 4) (1 pts).
G. Trainee must recognize Crimping Damages as required (Figure 5) (1 pts).
5. CLOSE-UP
A. Make sure that the work area is clean and clear of tools and other items.
B. Clean Workshop
C. Put Workshop to Its usual condition

Prepared by: Trương Công Tuấn Date: 01/01/2021

Evaluated by: Hoàng Ngọc Thưởng Date: 01/01/2021

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 7 / 7


FORM TC-20

PRACTICAL EXERCISE SHEET


PHIẾU BÀI TẬP THỰC HÀNH
Title Electric Cables & Connectors - Exercise 06 - Rev 00

Code AMB-M7.7-06 Applicable for: Cat A, B1B2,B1+B2

Compliance with Electric Cables & Connectors, code: AMB-M7.7

Description This exercise is designed for new technical engineer/technician in accordance


with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 2 hours  Level: 2

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.


 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Electric Cables & Connectors - Exercise 06 Code: AMB-M7.7-06

Insertion and removal of contacts tools

WARNING: - The operator must carefully read and follow any warnings, safety signs and
instructions provided with or located on the equipment.
CAUTION: - Be very careful when you use these tools.
- The selected tool is the correct tool for the type and size of contact.
- The tool is in the correct condition:
+ Tools, specially tools for small contacts, are easily damaged.
+ Do a visual check of their condition: broken ends, gouges, wearing.
1. JOB SET-UP INFORMATION
A. Fixtures, Tools, Test and Support Equipment
REFERENCE QTY UNIT DESIGNATION
N/A 8 EA Insertion and removal of contacts tools

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 1 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 06 Code: AMB-M7.7-06

Insertion and removal of contacts Plastic tools (Figure 1)


B. Consumable Material
REFERENCE QTY UNIT DESIGNATION
N/A 3 EA PIN/Socket (PN:NSA938152SA2000)
N/A 1 Wire size: 22,24,26
Meter
N/A 1 Meter Wire size: 18,20
N/A 2 EA Connector
N/A 8 EA Fabric Gloves
N/A 8 EA Face mask
N/A 0.5 Kg Industrial rags
N/A 8 Kg Industrial glasses

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 2 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 06 Code: AMB-M7.7-06

Connectors with pin


C. Expendable Parts
REFERENCE QTY UNIT DESIGNATION

D. Referenced Information
REFERENCE DESIGNATION

2. JOB SET-UP
+ Prepare Insertion and removal of contacts tools
+ Prepare Wire with difference size
+ Prepare 06 connectors
+ Prepare 06 pin
+ Ensure the cable is in good condition before using the equipment.
+ Ensure the tools are in good condition before using the equipment.
3. PROCEDURE
Insertion of Contacts procedure:
1. Chose Insertion of Contacts tool.
2. Chose connectors with pin.
3. Place wire through opening in tool.
4. Press wire until it snaps into place in the slot.
5. Slide tool down the wire until it bottoms against contact shoulder.
6. Press wire against serrations, push forward with a straight line motion until contact seats and locks.

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 3 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 06 Code: AMB-M7.7-06

Insertion of Contacts Sequence (Figure 2)


After insertion:
Make sure that:
1. The contact is correctly locked in the cavity.
2. After tool/cable separation, do a check to make sure that the cable is not damaged.
Rear Removal of Contacts procedure:
When removing contacts from the rear, the tool is inserted above the wire and then into the connector
until the locking clip releases the contact. Then, together with the tool, the wire is removed from the
contact cavity.
1. Place wire through opening in tool.
2. Press wire until it snaps into place in the slot.
3. Slide tool down the wire and into grommet until it bottoms.
4. Press wire against. Pull tool and contact wire assembly to remove.

Rear Remove of Contacts Sequence (Figure 3)

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 4 / 5


FORM TC-20

Electric Cables & Connectors - Exercise 06 Code: AMB-M7.7-06


4. PRODUCTION REQUIREMENTS/ ASSESSMENT
A. Trainee understands the warning and caution as required (1 pts).
B. Trainee prepares the material for practice and the tools are in good condition (1 pts).
C. Trainee must recognize types MIL P/N and color and size of tools as required Figure 1 (2 pts).
D. Trainee the practical training process of Insertion of Contacts Sequence as required Figure 1 (3 pts).
Answer:
+ Trainee understands and answer steps the process of Insertion of Contacts as required.
Trainee the practical training process:
+ Place wire through opening in tool.
+ Press wire until it snaps into place in the slot.
+ Slide tool down the wire until it bottoms against contact shoulder.
+ Press wire against serrations, push forward with a straight line motion until contact seats and locks.
+ Trainee make sure that the contact is correctly locked in the cavity, the cable is not damaged.
E. Trainee the practical training process of Remove of Contacts as required Figure 2 (3 pts).
Answer:
+ Trainee understands and answer steps the process of Remove of Contacts as required.
Trainee the practical training process:
+ Place wire through opening in tool.
+ Press wire until it snaps into place in the slot.
+ Slide tool down the wire and into grommet until it bottoms.
+ Press wire against. Pull tool and contact wire assembly to remove.

5. CLOSE-UP
A. Make sure that the work area is clean and clear of tools and other items.
B. Clean Workshop
C. Put Workshop to Its usual condition

Prepared by: Trương Công Tuấn Date: 01/01/2022

Evaluated by: Hoàng Ngọc Thưởng Date: 01/01/2022

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 5 / 5


FORM TC-20

ISS. 01, REV. 00 - DATE: 15 MAY 2018 PAGE 6 / 5

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