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9/27/01 AC 43.13-1B CHG 1 SECTION 19. UNUSED CONNECTORS AND UNUSED WIRES 11-260. GENERAL. Connectors may have one or more contact cavities that are not used. Depending on the connector installation, un- used connector contact cavities may need to be properly sealed to avoid damage to the con- nector, or have string wire installed. Unused wires can be secured by tying into a bundle or secured to a permanent structure; individually cut with strands even with insulation; or pre- insulated closed end connector or 1 inch piece of insulating tubing folded and tied back. 11-261. QUICK REFERENCE CHART. A quick reference chart of unused connector contact cavity requirements is given in ta- ble 11-25. These requirements apply to har- ness manufacturing or connector replacement only. 11-262. UNPRESSURIZED AREA CON- NECTORS. Connectors may be installed in unpressurized areas of the aircraft. Unused connector contact cavities installed in unpres- surized areas should be properly sealed as fol- lows: a. Firewall Connectors Installations. Firewall unused connector contact cavities should be filled with spare contacts and stub wires. (See figure 11-39.) (1) Construct stub wires using high temperature wire (260 oC). Ensure that stub wires are of the same type of wires in the bun- dle. (2) Crimp the proper contact, for the connector and cavity being used, onto the wire. Install the crimped contact into the unused cavity. (3) Extend stub wires beyond the back of the connector clamp from 1.5 to 6 inches. Feather trim stub wires to taper wire bundle. (4) Secure wire ends with high tem Par 11-260 perature (greater than 250oC) lacing cord. Nylon cable ties are not allowed for this in- stallation. NOTE: Both connectors mating through the engine fire-seal are con- sidered firewall connectors. Connec- tors mounted on or near, but not through, the engine fire-seal are not considered firewall connectors. b. Non-firewall Connector Installations. In this type of installation all unused connector cavities must also be filled with spare contacts. It is not required, however, to crimp stub wires on filling contacts. Fill unused contact cavities with spare contacts and Teflon sealing plugs or rods. (See fig- ure 11-40.) Rods shall be cut so that they ex- tend 1/8 to 1/4 inch beyond the surface of the grommet when bottomed against the end of the spare sions.) contact. (See table 11-26 for dimen- 11-263. PRESSURIZED AREAS. Con- nectors installed in pressurized areas of the aircraft may be divided into two main installa- tion categories, sealed and unsealed. a. Sealed connector installations. Sealed connectors installed in pressurized areas must have their unused contact cavities filled with Teflon sealing plugs or rods. (See fig- ure 11-40.) Installation of spare contacts is optional, except for future wiring addition re- quirements. (See paragraph 11-234). No stub wires are required. b. Unsealed Connector Installations. It is not required to fill unused contact cavities of unsealed connectors installed in pressurized areas with Teflon sealing plugs or rods. In- stallation of spare contacts is optional, except for future wiring addition requirements. (See paragraph 11-234.) Page 11-103PDF Image | AFS-640
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