Manual Number 9019161 Revision C, August 18, 2023 13
3.3.3 CABLE HARNESS ASSEMBLY
To assemble the aircraft cable harness, refer to the following instructions and Figure 3.2:
1) Install a pin/socket as supplied in the Connector Kit using an appropriate crimping tool for
each wire in the aircraft cable harness. Be sure to make the harness long enough to remove
the unit from the panel without stressing the harness.
a. Crimp and insertion/removal tool references can be found in Table 3.1.
2) Wire shields should be exposed and peeled back from the pin/socket termination
approximately 2”.
3) Insert the pins of the cable harness into the rear of the 26-pin D-Sub connector (Item 1, as
applicable, per Table 3.2 or Table 3.3 and Figure 3.1 using an appropriate pin insertion tool
per Table 3.1 or similar.
4) Select one (recommended), two or three locations for routing the wire harness bundle into the
Backshell (Item 2) and slide the Blanking Plates (Item 3) into the unused entry points.
5) Install the Backshell Spring Clip (Item 4) into the thin slot of the Backshell as shown.
6) Place the Backshell Slide Lock (Item 5) over the D-Sub connector.
7) Install the D-Sub connector with Slide Lock and cable harness attached into the Backshell and
secure with (2) screws (Item 6). Verify that the Backshell Leaf Spring is between the Slide
Lock and Backshell. Move the Slide Lock back and forth to verify free movement.
8) Bundle the exposed shields and wrap them around the harness for the length of the cable
clamp.
9) Add a grounding wire or braid to the bundled shields which can be attached to nearby aircraft
chassis ground.
10) Route the aircraft wire harness (with exposed shield bundle and chassis ground wire) between
the two halves of the Cable Strain Relief Clamp (Item 7).
11) Connect the two halves of the Cable Strain Relief Clamp with (2) screws (Item 8).
12) Place the Cable Strain Relief Clamp in the Backshell as shown.
13) Secure the Backshell Cover (Item 9) onto the Backshell using (4) Screws (Item 10).
14) The completed assembly should look as shown. Verify that the Slide Lock operates freely and
that no wires are pinched, nicked, or otherwise damaged.
15) Verify that power and ground signals are installed properly before connecting power.
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