N27/P27 Aircraft Connector

Instruction to replacement of LPA plug

Distributed By:
Mark C. Pope Associates, Inc.
4910 Martin Court
Smyrna, GA 30082
800-299-2999
info@[Link]
 Introduction

For further information about the chemicals look at following safety sheet:
- “RS Dark Grey Polyurethane, Part A & Part B” and “LOCTITE SI 5660 GY TB100ML EGFD”

(Enclosed as separate document)

Drawing No. 974.005 Rev. A/CFR Page 2 of 26

 Introduction

Tools and parts needed to replace the aircraft connector:

Part overview
Quantity Part. No. (US) Description
1 44472 (lev.) Cold Shrink (42,6-93,7mm)
1 MO0032 Resistor
1 SC0532 400Hz connector
1 SC0520 ON/OFF plate assy w/LED
1 SC0521 IN/OUT plate assy w/LED
4 SR0647 M4*8mm Screw (A2)
Small parts
8 KF0030 Heat Shrink 6-2mm
7 KF0031 Heat Shrink Ø3/1mm
3 KB0049 Cable ties
1 TP5051 Insulation tape
2*140mm KB6003 Black wire (2,5mm2)
1*170mm KB6003 Black wire (2,5mm2)
2*420mm KB6005 Red wire (0,75mm2)
Chemicals
1 tube PK0014 Locktite SI5660 – Grey Silicone
1 pk. PK0013 Dark Grey Polyurethane (RS 199-1395)

Tools
Crimping tool Measuring tape
Large crimp tool (page 8) 7mm Socket wrench insert
Torque Wrench (6Nm) Self-adjusting insulation stripper
Heat gun Power drill
Lock ring tool HOP 4×152mm
HOP 6×50mm HOP 5×89mm
Screwdriver PH0 Stanley knife
Soldering station Torx 20
Hammer
Special tool
Two pin adaptor socket kit (LPA ref. no: 50872 and 50871)
Special made split

Drawing No. 974.005 Rev. A/CFR Page 3 of 26

 Assembly instruction

Step 1
1.1 Kindly follow the procedure in “Replacement of Aircraft Cable 2400 Power Coil (AXA) series revAB”
step 1-7 for this task. Carry the cable to a dry and clean workshop.
1.2 Cut off the plug (picture 0- red line), and remove the cold shrink.
1.3 Measure 250mm on the cable and remove the orange insulation (picture 1).
1.4 Take the cold shrink (44472) and lead on the orange cable (picture 2)
1.5 Remove the white insulation around the cable.
1.6 Take the connector (SC0532) and turn with the “In-Out” side up and make white dotes as
illustrated at picture 2.
1.7 Loosen the clamp in the top of the connector (7mm socket wrench insert) (picture 2 – red arrow).

Drawing No. 974.005 Rev. A/CFR Page 4 of 26

 Assembly instruction

Step 2
2.1 Loosen the six screws to separate the rear part and main body together (HOP 4) (picture 3-4).
2.2 Turn the plug around and loosen the two screws in the front piece (HOP 5) (picture 5).
2.3 Separate the front piece from the main body, push the pins out to separate the inner connection from
the main body (picture 6).

Drawing No. 974.005 Rev. A/CFR Page 5 of 26

 Assembly instruction

Step 3
3.1 Take the small screwdriver and use to loosen the five pins (A, B, C, N and E) by inserting it into the pin
hole (picture 7).
3.2 Remove the loose pins (picture 8).
3.3 Take the lock ring tool and remove the five lock rings at pin A, B, C, N and E (picture 9).
3.4 At pin F, place the lock ring near the black O-ring (picture 10).

Drawing No. 974.005 Rev. A/CFR Page 6 of 26

 Assembly instruction

Step 4
4.1 Prepare the following wires:
 Two 430mm pieces of red 0,75mm2 wire (KB6005).
 Two 140mm pieces of black 2,5mm2wire (KB6003).
 One 170mm black 2,5mm2wire (KB6003).
4.2 Picture 11 creates an overview of where the different wires and cables are going.
 Pin E: One black 140mm wire.
 Pin F: One black 140mm wire.
 Pin A, B and C: Black Cables.
 Pin N: Three Blue cables + One 170mm black wire.
4.3 Press the pins up (picture 12) and pull pin F half way out. Remove the rest of the pins from the inner
connection (picture 13).

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 Assembly instruction

Step 5
5.1 Take a 140mm black wire, strip 15mm in one end and insert into pin E (picture 14). The stripped wire
must be visible in the sight hole (picture 14 – red arrow).
5.2 Press the wire in the pin E using the crimp tool (picture 15.1 – 15.2).
5.3 Take a 140mm black wire, strip 15mm in one end and insert into pin F (picture 16). The striped wire
must be visible in the sight hole!
5.4 Press the wire in the pin F using the crimp tool (picture 17).
 Be careful not to brake the two grey wires already attached to the F pin!

Drawing No. 974.005 Rev. A/CFR Page 8 of 26

 Assembly instruction

Step 6
6.1 Push pin F back in place and mount the E pin into the E hole at the inner connection.
6.2 Mount the two lock rings back on pin F and E (picture 18).
6.3 Take the rear part and cut as illustrated at picture 19 – with red lines.
6.4 Mount the rear part on the cable, as illustrated at picture 20.

18 19

20

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 Assembly instruction

Step 7
7.1 Measure from the orange insulation and cut the white wires at 250mm (picture 21).
7.2 Measure from the orange insulation and cut the blue cables at 190mm (picture 21).
7.3 Measure from the orange insulation and cut the black cables at 170mm (picture 21).
7.4 Cut off white wire no. 15 to 24 at the orange insulation (picture 21).
7.5 Insert white wire 1, 2, 3 and 8 in the IN/OUT side (picture 22).
7.6 Insert white wire 14, 4, 5, 6 and 7 in the ON/OFF side (picture 22).

21

22

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 Assembly instruction

Step 8
8.1 Take the three black cables, strip 25mm, and remove all the white insulation around the cobber
threads (picture 23, 24 and 25).
8.2 Insert the stripped ends into pin A, B and C (picture 26), make sure the cobber threads is visible in the
sight hole (picture 26 – red arrow).
8.3 Press twice in the crimp tool, once close to the top (picture 27) and once next to the first one.

Drawing No. 974.005 Rev. A/CFR Page 11 of 26

 Assembly instruction

Step 9
9.1 Take the three blue cables and strip 25mm (picture 28).
9.2 Take the 170mm black wire (2,5mm2) (KB6003) and strip 25mm.
9.3 Place the black wire in the center of the three blue cables and insert into the N pin (picture 29), make
sure the cobber threads is visible in the sight hole.
9.4 Press the N pin twice in the large crimp tool, once close to the cables (picture 30) and once press once
close by.

Drawing No. 974.005 Rev. A/CFR Page 12 of 26

 Assembly instruction

Step 10
10.1 Take the Loctite SI5660 (PK0014) and apply around the A, B, C and N pins before mounting in the inner
connection (picture 31).

10.2 Attach the lock rings to the pins (picture 32) and mount the pins using the torque wrench (6Nm) with
the two pin adaptor socket kit (picture 33).

10.3 Take the two grey wires from pin F and the black wire from pin E and cut to match the shortest wire
(picture 34). Strip 15mm of the three wires.

Drawing No. 974.005 Rev. A/CFR Page 13 of 26

 Assembly instruction

Step 11
11.1 Strip 15mm of the following wires: One black wire from pin F, One black wire from pin N, two red
420mm wires (0,75mm2) (KB6005), white wire 9 to 13

11.2 Connect by twisting the following wires (picture 35):

 Two red 420mm wires (0,75mm2) and combine with one grey wire (pin F) and white wire
no. 9.
 The white wire no. 13 and one grey wire from pin F.
 The white wire no. 11 and the black wire from pin F.
 The white wire no. 10 and the black wire from pin E.
 The white wire no. 12 and the black wire from pin N.

11.3 Sold the wires together (picture 36).

Drawing No. 974.005 Rev. A/CFR Page 14 of 26

 Assembly instruction

Step 12
12.1 Cut four 40mm heat shrink (KF0031) and place over all soldered ends.

12.2 Crimp the heat shrink with a heat gun and close the ends as illustrated at picture 37-38.

12.3 Make sure that the glue from heat shrink is visible at the wire (picture 37 – green arrow).

12.4 Fasten all the heat shrink tips with a cable tie (KB0049) at pin A and fold a rubber band around the
loose wires (picture 39 – red arrows, Page 16).

12.5 Lead one red wire through the hole in the IN/OUT side and the other through the ON/OFF side (picture
39 – green arrow, page 16).

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 Assembly instruction

39

Drawing No. 974.005 Rev. A/CFR Page 16 of 26

 Assembly instruction

Step 13
13.1 Apply the Loctite SI5660 – grey silicone (PK0014) at the inner connections recess all around the inner
connection (picture 40).

13.2 Insert the inner connection into the body (picture 41)

13.3 Place the nose piece over the pins and fasten two bolts in the nose-piece (HOP 5) (picture 42).

Drawing No. 974.005 Rev. A/CFR Page 17 of 26

 Assembly instruction

Step 14
14.1 Start at the ON/OFF side at take the ON/OFF switch plate (SC0520). Strip 15mm of the switch wires.

14.2 If two blue wires are present cut them off and throw out. Connect the following wires by twisting
them (picture 43):

1) White wire no. 4 with black wire from green button.

2) White wire no. 5 with black wire from red button.
3) White wire no. 6 with thin black wire from red diode.
4) White wire no. 7 and thin black wire from green diode.
5) Wire from green button, wire from red button, the two thin red wires from the
diodes and the red wired from pin F.

14.3 Take a resistor (MO0032) and twist one end around the white wire no. 7 assembly (4) and the other
end over the large wire assembly (5) (picture 43).

14.4 Sold the ends of all the wire assemblies (picture 44).

14.5 Add 40mm of heat shrink (KF0031) over the two wire assemblies combined with a resistor. Make sure
the resistor is covered! Add 40mm heat shrink (KF0030) on the remaining wire ends, crimp with a heat gun
and squeeze the tips flat (picture 45).

14.6 Use a cable tie (KB0049) to keep the heat shirk tips together (picture 46 – blue arrow).

Drawing No. 974.005 Rev. A/CFR Page 18 of 26

 Assembly instruction

Step 15
15.1 Turn to the IN/OUT side at take the IN/OUT switch plate (SC0521). Strip 15mm of the switch wires.

15.2 Combine the following wires (picture 47):

1. White wire no.2 with black wire from IN button.

2. White wire no.3 with black wire from OUT button.
3. White wire no.8 with black wire from yellow diode.
4. Black wire from IN, Black wire from OUT, red wire from yellow diode and red wire
from pin F.

15.3 Sold the ends of all the wire assemblies (picture 48).

15.4 Add 40mm of heat shrink (KF0030) on the three wire assemblies with white wires. Add 40mm of heat
shrink (KF0031) on the last wire assembly, crimp with a heat gun and squeeze the tips flat (picture 49).

15.5 Use a cable tie (KB0049) to keep the heat shirk tips together (picture 49).

Drawing No. 974.005 Rev. A/CFR Page 19 of 26

 Assembly instruction

Step 16
16.1 Make a continuity test of A, B, C, 90% switch, E and F to verify that the installation is correctly
executed.

16.2 Place the tester in the plug and place the other end at the matching cable lug from the back of the
cable (picture 50).

16.3 Test the switches as well.

Drawing No. 974.005 Rev. A/CFR Page 20 of 26

 Assembly instruction

Step 17
17.1 Place the plug as illustrated at picture 50, fasten the horizontal piece of wood with two screws in each
end (picture 51 – green arrows).

17.2 The plug must face down. Make sure that the cable is pointing straight down into the plug! Make sure
the set-up is stable enough to stand this way the next 24 hours.

17.3 Take the Polyurethane (PK0013) and open the package (picture 52).

17.4 Before continuing take on rubber gloves, protection glasses and apron and read “RS Dark Grey
Polyurethane, Part A & Part B” and “LOCTITE SI 5660 GY TB100ML EGFD”, which is enclosed as separate
document.

17.5 Remove the plastic divider (picture 52 – green arrow) and mix thoroughly for 3-4 min. (picture 53). The
content must be uni-colored!

Drawing No. 974.005 Rev. A/CFR Page 21 of 26

 Assembly instruction

Step 18
18.1 Picture 54 illustrates well-mixed content!

18.2 Cut a small hole in the plastic bag (picture 54) and pour gently the entire content into the plug (picture
55).

18.3 Let the Polyurethane dry for 24 Hours before continuing.

Drawing No. 974.005 Rev. A/CFR Page 22 of 26

 Assembly instruction

Step 19
19.1 Press the top piece down to the body and gently fasten (2-4Nm) the six screws in the top piece
combining the top to the bottom (HOP 4) (picture 56).

19.2 Fasten the top clamp with 2,5Nm (7mm socket wrench insert) (picture 57)

19.3 Fasten (1Nm) the two switch plates with two M4*8mm screws (SR0647) (Torx 20) (picture 58 – green
circles).

19.4 Take the insulation tape (TP5051) and apply four layers over the metal strip (picture 59).

Drawing No. 974.005 Rev. A/CFR Page 23 of 26

 Assembly instruction

Step 20 – Optional
Some cables come with the following clamp. If the clamp was not at the cable before please
continue to step 21.2
20.1 Take the M8*45mm bolt (SR0453) and fasten the M8 nut (SR0196) on. Place the nut in the cable clamp
(277456) hole and hammer into the hole (picture 60). Repeat this in the other side as well (picture 61).

20.2 Remove the bolt. Take the two M8*45mm bolts and apply Foodlube multipaste (LI0045) at the ends
(picture 62).

20.3 Place the two bolts in the other cable clamp (picture 63).

Drawing No. 974.005 Rev. A/CFR Page 24 of 26

 Assembly instruction

Step 21
21.1 Optional - Fasten the cable clamp just above the top of the plug (picture 64) and tighten the bolts
alternately (HOP 6).

21.2 Place the cold shrink over the top and the cable clamp. Lead the plastic end up through the cold shrink
(picture 65- red arrows).

21.3 Fasten the cold shrink by pulling the plastic strip (picture 65 – red arrow). Make sure to hold the cold
shrink in place when fastening!

21.4 Picture 66 illustrated the correctly mounted cold shrink.

Drawing No. 974.005 Rev. A/CFR Page 25 of 26

 Assembly instruction

Step 22 – Re-assembly of the strain relief

22.1 Measure 500mm from the start of the plug and up and make a line (picture 67).

22.2 Assemble the stop ring by placing the M8 bolt into the stop ring hole with the recess. Place the strain
relief on the bolt (picture 68).

22.3 Inset another M8 bolt next to the first and assemble the stop ring around the cable, with the bottom
just covering the 500mm line (picture 69).

22.4 Fasten the stop ring to the cable by placing a locking brick on the opposite side of the two M8 bolts
and fastening the two bolts (HOP 6). Next place another locking brick on the opposite side of the first and
fasten with two M8 bolts (picture 69).

22.5 Check that the label on the strain relief points away from the cable (picture 69 –red arrow)!

22.6 Go back to “Replacement of Aircraft Cable 2400 Power Coil (AXA) series revAB” instruction and follow
step 8 – 17 of how to install the cable correctly in the Power Coil again.

Drawing No. 974.005 Rev. A/CFR Page 26 of 26