American Airlines Logo Light Harness Troubleshooting

Competitors Required:

1

Description:

Competitors will troubleshoot electrical Harness of an inoperable logo light

References:

• Fluke 77/75/23/21 Series III Multimeter Instruction Sheet
• Electrical schematic (provided at the event)

Tools, Equipment, and Materials Provided:

Digital Fluke Multimeter with leads

Snap-on provided tooling (qty one in each of two pallets unless otherwise indicated):

Cannon plug pliers with grips (ATI508KG)

Procedures:

1. Deactivate logo light system Select LOGO LIGHT SWITCH TO OFF, PULL AND COLLAR LOGO LIGHT CIRCUIT BREAKER.
2. Remove electrical wiring harness.
3. With electrical schematic and multimeter provided, perform the following wire check steps in order to determine the status of each wire of the electrical logo light harness (These are the possible conditions, resistance, continuity, Open)
4. Find the wire termination data. Refer to the Electrical Schematic.

WARNING: EACH CONNECTOR ON THE CIRCUIT THAT MUST HAVE A TEST MUST BE DISCONNECTED. IF THE CONNECTORS ARE NOT DISCONNECTED, UNSATISFACTORY RESISTANCE INDICATIONS OR DAMAGE TO THE CONNECTOR CAN OCCUR.

WARNING: DO NOT BEND OR PUT STRESS ON THE CONTACTS. DAMAGE TO THE CONNECTOR OR THE CONTACTS CAN OCCUR.

1)     Wire Continuity / Resistance Check

1. 1. Select multimeter.

WARNING: DO NOT USE A MEGOHMETER FOR THE INSULATION RESISTANCE TEST OF THE ON-WING WIRING REPAIR. INJURY TO PERSONNEL OR DAMAGE TO THE AIRPLANE CAN OCCUR.

1. 2. Set the meter to the proper selection. (REF. Multimeter instruction)
   3. Attach one meter test lead to WIRE PIN 1 on the “A” connector plug assembly.

WARNING: DO NOT BEND OR PUT STRESS ON THE CONTACTS. DAMAGE TO THE CONNECTOR OR THE CONTACTS CAN OCCUR.

1. 4. Check continuity on all pins on the “B” plug. WARNING: DO NOT BEND OR PUT STRESS ON THE CONTACTS. DAMAGE TO THE CONNECTOR OR THE CONTACTS CAN OCCUR.
   5. Using the wiring diagram and the meter readings to record any discrepancies/faults found on worksheet.

NOTE: Use the discrepancy codes that are listed on the score sheet to describe the faults that are found in the harness. Which plug (A or B) and which pin (1 thru 7) with the corresponding code (1 thru 3) Example: (A5 to B3 #3, Plug A Pin 5 to Plug B pin 3 fault #3 CONTINUITY)

1. 6. Continue Continuity Check Repeat steps c) through e) for the remaining WIRE PIN contact on the “A” connector plug. Continue PIN 2 through 7

1. 7. Attach one meter test lead to WIRE PIN 1 on the “B” connector plug assembly.

WARNING: DO NOT BEND OR PUT STRESS ON THE CONTACTS. DAMAGE TO THE CONNECTOR OR THE CONTACTS CAN OCCUR.

1. 8. Check continuity on all pins on the “A” plug. WARNING: DO NOT BEND OR PUT STRESS ON THE CONTACTS. DAMAGE TO THE CONNECTOR OR THE CONTACTS CAN OCCUR.
   9. Using the wiring diagram and the meter readings to record any discrepancies/faults found on worksheet.

NOTE: Use the discrepancy codes that are listed on the score sheet to describe the faults that are found in the harness. Which plug (A or B) and which pin (1 thru 7) with the corresponding code (1 thru 3) Example: (A5 to B3 #3, Plug A Pin 5 to Plug B pin 3 fault #3 CONTINUITY)

1. 10. Repeat steps g) through i) for the remaining WIRE PIN contact contacts (pins 2 through 7) on the “B” connector plug and record any discrepancies/faults found on worksheet.

2)     Plug Integrity check.

1. 11. Attach one meter test lead to WIRE PIN 1 on the “A” connector plug assembly.
   12. Connect the other meter test lead to all other WIRE PIN contacts on the “A” connector plug.
   13. Continue with integrity Check to include pins 2 to all other pins, pin 3 to all other pins and so on until all pins have been checked for integrity.
   14. Using the wiring diagram and the meter readings to record any discrepancies/faults found on worksheet.

NOTE: Use the discrepancy codes that are listed on the score sheet to describe the faults that are found in the harness. Which plug (A or B) and which pin (1 thru 7) with the corresponding code (1 thru 3) Example: (A5 to B3 #3, Plug A Pin 5 to Plug B pin 3 fault #3 CONTINUITY)

1. 15. Repeat steps a) through c) for the “B” connector plug and record any discrepancies/faults found on worksheet.

3)     Back shell Check

1. 16. Attach one meter test lead to the back shell.
   17. Use the other meter test lead on the WIRE PIN assemblies in the same connector plug.

WARNING: DO NOT BEND OR PUT STRESS ON THE CONTACTS. DAMAGE TO THE CONNECTOR OR THE CONTACTS CAN OCCUR.

1. 18. Read the meter. Make sure that the resistance shown on the meter is open or 100 megohms.
   19. Repeat steps a) through c) for each WIRE PIN assemblies in the connector plug.
2. Record PASS or FAIL on the work sheet if Backshell test fails, record discrepancy on worksheet.

1. 1. Request and Replace harness with new one provided BY THE JUDGE
   2. Reactivate Logo light system.
   3. Verify Logo light operates.
   4. Return tools to shadow board and cleanup work area.
   5. Tell Judge when you are completed

There will be an Optional bonus questions on the work sheet that can be answered for a time deduction if the contestant chooses to answer with the time remaining.