TECHNICAL BULLETIN 206-11-198 13 November 2012 MODEL AFFECTED: 206A/B and TH-67 SUBJECT: DAVTRON DIGITAL CLOCK M800-5-BATT, INTRODUCTION OF HELICOPTERS AFFECTED: Serial numbers 154 through 4310 and 5101 through 5284. COMPLIANCE: At customer s option. DESCRIPTION: This bulletin provides instructions for installing a new Davtron Digital Clock M800-5- BATT Retrofit Kit P/N 206-704-738-101S to replace the Eight Day Wind-up Clock P/N 206-070-275-001 and -005. APPROVAL: The engineering design aspects of this bulletin are Transport Canada Civil Aviation (TCCA) approved. CONTACT INFO: For any questions regarding this bulletin, please contact: MANPOWER: Bell Helicopter Product Support Engineering - Light Helicopters Tel: 450-437-2862 / 1-800-363-8023 / pselight@bh.com Approximately 6.0 man-hours are required to complete this bulletin. This estimate is based on hands-on time, and may vary with personnel and facilities available. WARRANTY: There is no warranty credit applicable for parts or labor associated with this bulletin. Page 1 of 20
MATERIAL: Required Material: The following material is required for the accomplishment of this bulletin and may be obtained through your Bell Helicopter Textron Supply Center. The following parts are contained in retrofit kit P/N 206-704-738-101S Part Number Nomenclature Qty 206-704-738-121 Cover 1 MS3367-4-9 Strap Tiedown 12 MS35214-15 Screw 4 M800-5-BATT Clock 1 MS25036-102 Terminal 2 MS25036-149 Terminal 1 M39029/1-101 Contact 2 M81824/1-1 Splice 3 1-480303-0 Connector 1 1-480305-0 Connector 1 3502 Plug 1 60619-1 Contact 3 60620-1 Pin 3 130-065-22-1 Terminal Junction 1 30-266-1 End Cap 1 100-075-5W Plate Marking 2 RLR32C10R0GS Resistor 1 130-005-4-2 S/S by Insul Tubing 2 M23053/18-304-0 130-005-6N2 Tubing 1 130-061-03W2 S/S by Tubing Id Heat 1 130-061-03W2MA 130-045-3-0-6 Insul Tubing 3 inches (Note 1) 130-045-4-0-6 Insul Tubing 3 inches (Note 1) 130-045-5-0-6 Insul Tubing 3 inches D400A22 Wire & I.D. 120 inches L402A22 Wire & I.D 60 inches L402B22 Wire & I.D 60 inches L401A22N Wire & I.D. 60 inches Note 1: To protect soldering the correct I.D. size of insulation, tubing must be determined at installation. Spare Parts Requirement: Spare parts may be obtained by ordering P/N 206-704-738-101S through your Bell Helicopter Textron Supply Center. Page 2 of 20
Consumable Material: The following material is required to accomplish this bulletin, but may not require ordering, depending on the operator s consumable material stock levels. This material may be obtained through your Bell Helicopter Textron Supply Center. Part Number Nomenclature Qty Reference * Solder Electronic Grade Solder A/R C-538 Primer, Epoxy Polyamide Primer A/R C-204 High-Solids MILC85285TYI-36307 Spray paint Flat Gray A/R C-245 # 36307 MILC85285TYI-37038 Spray paint Gunship Black #37038 A/R C-245 * C-XXX number refers to the consumables list in BHT-ALL-SPM Standard Practices Manual SPECIAL TOOLS: Soldering iron. Heat gun. For the M39029/1-101 contact use M22520/1-01 crimp tool with M22520/1-02 turret or M22520/2-01 crimp tool with M22520/2-11 turret installation /removal tools M81969/14-02 and M81969/14-10. For the M81824/1-1 splice use AD1377 crimp tool. For the MS25036-102, -149 AMP terminal use APM S-9824-1 crimp tool or T&B terminal use WT 145C crimp tool. For the 130-065-22-1 in line terminal junction use M22520/7-01 crimp tool with M22520 /7-11 turret. For the 30-266-1 end cap use a regular heat gun. For the 60619-1 and 60620-1 contact pin use AMP 90124-2 crimp tool with insert / removal tools 91002-1 and 1-305183-1. For the 3502 connector plug use soldering iron to solder the 2 wires and use as required appropriate size of 130-045-3-0-6,-4-0-6 and -5-0-6 shrinkable tubing to isolate solder terminations and protect wires. Page 3 of 20
WEIGHT AND BALANCE: Not affected. ELECTRICAL LOAD DATA: Not affected. REFERENCES: BHT-206A/B-SERIES-IPB Illustrated Parts Breakdown. BHT-206A/B-SERIES-MM-10 Maintenance Manual, Chapter 95. BHT-206A/B-SERIES-MM-12 Chapter 98, Wiring diagram. BHT-ALL-SPM, Chapter 3. BHT-ELEC-SPM. PUBLICATIONS AFFECTED: None affected. ACCOMPLISHMENT INSTRUCTIONS: PART I: Installation of Digital Clock Kit P/N 206-704-738-101S 1. Prepare the helicopter for maintenance. 2. Ensure all electrical power is removed from the helicopter. 3. Disconnect the helicopter battery. 4. Remove console shroud assembly from top of instrument panel and prepare to open front of instrument panel for rear access by removing caution/warning panel and screws. (Refer to BHT-206A/B-SERIES-MM-10, Chapter 95) 5. Remove windshield centre post fairing. 6. Lower circuit breaker panel to gain access to circuit breakers. 7. Remove the Eight Day Wind-up Clock P/N 206-070-275-001 / -005. a. Refer to Figure 1. Tilt instrument panel to gain access behind the wind-up clock (3). b. Remove the screws (1) and nuts (2). Remove the clock (3) from the instrument panel (4) and discard or return to inventory. 8. Install the Davtron digital clock. Page 4 of 20
a. A clock hole modification will be required depending on the instrument position on the instrument panel. (Refer to Figure 2) Using as a template, position the cover (6) in front of the instrument panel and mark the hole to be drilled for the screw (7) in upper right corner of the cover (6) and mark lower left hand hole position to be trimmed. Remove cover and drill a 0.125 inch hole in the upper right corner of instrument panel. Trim the existing cut out in the instrument panel in lower left corner to provide clearance for the screw. Refer to BHT-All-SPM, Chapter 3 to refinish bare metal surfaces, apply primer (C-204). b. Touch up instrument panel with paint color(c-245). c. (Refer to Figure 1) Position the digital clock (5) behind the instrument panel (4). d. Position the cover (6) in front of the instrument panel (4). e. Install the screws (7) through the cover (6) and attach the clock (5) behind the instrument panel (4). f. Fabricate clock power supply harness referencing the appropriate step for your aircraft's serial number. (1) for aircraft s/n 154 through 253, see step 9. (2) for aircraft s/n 254 through 583, see step 10. (3) for aircraft s/n 584 through 4216, see step 11. (4) for aircraft s/n 4217 through 4310 and TH-67 serial numbers 5101 through 5284, see step 12. 9. (Refer to Figure 3) Wire harness instructions for 206A serial numbers 154 through 253. a. Crimp terminal P/N MS25036-149 to wire D400A22 and connect to circuit breaker CB2 (INST LT). Route wire from circuit breaker panel to instrument panel digital clock location. b. Terminate wire D400A22 using P/N 60620-1 contact. Insert into position 2 on P/N 1-480305-0 connector. c. Crimp contact P/N MS25036-102 to wire L402A22 and connect to position 4 on terminal block TB6 and route to instrument panel digital clock location. Page 5 of 20
d. Terminate wire L402A22 to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 3 on 1-480305-0 connector. e. Crimp contact MS25036-102 to wire L401A22N and connect to position 2 on terminal block TB6 and route to instrument panel digital clock location. f. Terminate wire L401A22N to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 1 on 1-480305-0 connector. g. Cap and stow yellow wire furnished on the digital clock using 30-266-1 cap and shrink using heat gun. h. Crimp contact 60619-1 contact to orange wire and insert into position 2 on P400 (1-480303-0 connector). i. Assemble resistor as shown in View A using the following instructions: (1) Insert on one lead of resistor a reference designator 130-061-03W2. Prior to shrinking with heat gun, identify with permanent marker as 8R6 and shrink. (2) Insert along blue wire located on the digital clock a 4 inch piece of 130-005- 6N2 insulation tubing and a 1.5 inch piece of 130-005-4-2 insulation tubing (do not shrink with heat gun), crimp blue wire to resistor lead using splice M81824/1-1. (3) Insert along wire L402B22 a 1.5 inch piece of 130-005-4-2 insulation tubing and crimp wire L402B22 to other end of resistor lead using splice M81824/1-1, recover insulation tubing along wires from both sides. Shrink with heat gun the two 1.5 inch pieces of 130-005-4-2 insulation tubing over splices and leads on each side of resistor, place the 4 inch piece of 130-005-6N2 insulation tubing over complete resistor assembly and shrink with heat gun. j. Terminate opposite end of wire L402B22 using 60619-1 contact and insert into position 3 on P400 (1-480303-0 connector). k. Crimp 60619-1 contact to black wire and insert into position 1 of P400 (1-480303-0 connector). l. Attach plate marking 100-075-5W with a strap tie down around wire bundle at connector end 1-480305-0 and identify with permanent marker as J400. Attach second plate marking around wire bundle at connector end 1-480303-0 and identify as P400. 10. Refer to Figure 4, wire harness instruction for 206A serial numbers 254 through 583. Page 6 of 20
a. Crimp terminal lug MS25036-149 to wire D400A22 and connect to circuit breaker CB2 (INST LT). Route wire from circuit breaker panel to instrument panel digital clock location. b. Terminate wire D400A22 to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 2 on 1-480305-0 connector. c. Crimp contact MS25036-102 to wire L402A22 and connect to position 8 on terminal block TB25 and route to instrument panel digital clock location. d. Terminate wire L402A22 to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 3 on 1-480305-0 connector. e. Crimp contact MS25036-102 to wire L401A22N and connect to position 2 on terminal block TB25 and route to instrument panel digital clock location. f. Terminate wire L401A22N to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 1 on 1-480305-0 connector. g. Cap and stow yellow wire furnished on the digital clock using 30-266-1 cap and shrink using heat gun. h. Crimp contact 60619-1 to orange wire and insert into position 2 on P400 (1-480303-0 connector). i. Assemble resistor as shown in View A using the following instructions: (1) Insert on one lead of resistor a reference designator 130-061-03W2, prior to shrinking with heat gun identify with permanent marker as 8R6 and shrink. (2) Insert along blue wire located on the digital clock a 4 inch piece of 130-005- 6N2 insulation tubing and a 1.5 inch piece of 130-005-4-2 insulation tubing ( do not shrink with heat gun),crimp blue wire to resistor lead using splice M81824/1-1. (3) Insert along wire L402B22 a 1.5 inch piece of 130-005-4-2 insulation tubing and crimp wire L402B22 to other end of resistor lead using M81824/1-1 splice, recover insulation tubing along wire from both side, shrink with heat gun the two 1.5 inch pieces of 130-005-4-2 insulation tubing over splices and leads on each side of the resistor, place the 4 inch piece of 130-005-6N2 insulation tubing over complete resistor assembly and shrink with heat gun. j. Terminate opposite end of wire L402B22 using 60619-1 contact and insert into position 3 on P400 (1-480303-0 connector). k. Crimp 60619-1 contact to black wire and insert into position 1 of P400 (1-480303-0 connector). Page 7 of 20
l. Attach plate marking 100-075-5W with a strap tie down around wire bundle at connector end 1-480305-0 and identify with permanent marker as J400. Attach second plate marking around wire bundle at connector end 1-480303-0 and identify as P400. 11. Refer to Figure 5, wire harness instructions for 206A/B serial numbers 584 through 4216. a. Crimp terminal lug MS25036-149 on wire D400A22 and install on circuit breaker CB2 (INST LT). b. Route wire D400A22 from circuit breaker panel to instrument panel at digital clock location. c. Terminate wire D400A22 using terminal junction 130-065-22-1 to orange wire at digital clock. d. Cap and stow yellow wire using end cap 30-266-1 and shrink using heat gun. e. Assemble resistor as shown in View B using the following instructions: (1) Insert on one lead of resistor a reference designator 130-061-03W2, prior to shrinking with heat gun identify with permanent marker as 8R6 and shrink. (2) Insert along blue wire located on the digital clock a 4 inch piece of 130-005- 6N2 insulation tubing and a 1.5 inch of 130-005-4-2 insulation tubing ( Do not shrink with heat gun), crimp blue wire to one end of resistor lead using M81824/1-1splice. (3) Insert along wire L402A22 a 1.5 inch piece of 130-005-4-2 insulation tubing and crimp wire L402A22 to other end of resistor lead using M81824/1-1 splice, recover insulation tubing along wires from both side, shrink the two 1.5 inch pieces of 130-005-4-2 insulation tubing over splices and leads on each side of the resistor, place the 4 inch of 130-005-6N2 insulation tubing over complete resistor assembly and shrink with heat gun. (4) Install and crimp splice M81824/1-1 to the black wire of clock assembly and wire L401A22N. (5) Route wires L401A22N and L402A22 to location P189. f. (Refer to View A in Figure 5) In preparation for steps below, remove backshell from connector assembly 3502. Page 8 of 20
(1) Route both wires L402A22 and L401A22N through the backshell and insert both wires through 130-045-5-0-6 insulation tubing. (2) Insert on L401A22N and L402A22 wires the appropriate size of 130-045-3-0- 6 or 130-045-4-0-6 insulation tubing to isolate solder terminations and protect wires. (3) Solder the wire L402A22 to the center post of the 3502 plug as shown in View A. (4) Solder the wire L401A22N to the case of the 3502 plug as shown in View A. (5) Place insulating tubing installed in step 2 above over the solder joint and shrink in place with heat gun. (6) Place insulating tubing installed in step 1 above as close as possible to the solder joints performed above and shrink in place with heat gun. (7) Install backshell to the 3502 connector. (8) Install 3502 connector to J189 position. 12. Refer to Figure 6, wire harness instruction for 206B serial numbers 4217 through 4310 and TH-67 serial numbers 5101 through 5284. a. Crimp terminal lug MS25036-149 to wire D400A22 and connect to circuit breaker CB2 (Inst Light). Route wire from circuit breaker panel to instrument panel digital clock location. b. Terminate wire D400A22 to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 3 on 1-480305-0 connector. c. Crimp contact M39029/1-101 to wire L402A22 and connect to position B1 on terminal block TB8 and route to instrument panel digital clock location. d. Terminate wire L402A22 to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 2 on 1-480305-0 connector. e. Crimp contact M39029/1-101 to wire L401A22N and connect to position B2 on terminal block TB8 and route to instrument panel digital clock location. f. Terminate wire L401A22N to J400 (1-480305-0 connector) using 60620-1 contact and insert into position 1 on 1-480305-0 connector. g. Cap and stow yellow wire furnished on the digital clock using 30-266-1 cap and shrink using heat gun. Page 9 of 20
h. Crimp contact 60619-1 contact to orange wire and insert into position 3 on P400 (1-480303-0 connector). i. Assemble resistor as shown in View A using the following instructions: (1) Insert on one lead of resistor a reference designator 130-061-03W2, prior of shrinking with heat gun identify with permanent marker as 8R6 and shrink. (2) Insert along blue wire located on the digital clock a 4 inch piece of 130-005- 6N2 insulation tubing and a 1.5 inch piece of 130-005-4-2 insulation tubing ( do not shrink with heat gun), crimp blue wire to one end of resistor lead using M81824/1-1splice. (3) Insert along wire L402B22 a 1.5 inch piece of 130-005-4-2 insulation tubing and crimp wire L402B22 to other end of resistor lead using M81824/1-1 splice, recover insulation tubing along wires from both side, shrink with heat gun the two 1.5 inch pieces of 130-005-4-2 insulation tubing over splices and leads on each side of the resistor, place the 4 inch piece of 130-005-6N2 insulation tubing over complete resistor assembly and shrink with heat gun. j. Terminate opposite end of wire L402B22 using 60619-1 contact and insert into position 2 on P400 (1-480303-0 connector). k. Crimp 60619-1 contact to black wire and insert into position 1 of P400 (1-480303-0 connector). l. Attach plate marking 100-075-5W with a strap tiedown around wire bundle at connector end 1-480305-0 and identify with permanent marker as J400. Attach second plate marking around wire bundle at connector end 1-480303-0 and identify as P400. 13. Once installation is done, secure wire harness and connector to the existing wire bundle using MS3367-4-9 strap. 14. Close instrument panel and circuit breaker panel. Reinstall center post fairing and console shroud on top of instrument panel. Connect battery. 15. Apply power. Proceed to Part II to set up and operate clock. CAUTION Compatibility of this installation with previously installed equipment must be determined by the installer. Page 10 of 20
16. Make an entry in the helicopter logbook and historical service records indicating compliance with this Technical Bulletin. PART II: Operating Instructions of Digital Clock Model M800-5-BATT: The SELECT button selects what is to be displayed on the four digit window and the CONTROL button controls what is being displayed. Pressing SELECT sequentially selects Universal Time (UT), Local Time (LT) and Elapsed Time (ET) and back to UT. The CONTROL button starts, stops, and resets Elapsed Time (ET) when momentarily pushed. Normal operation of the M800 cannot accidentally reset time. 1. Clock Universal Time (UT) Set: a. Push the SELECT button to select the Universal Time (UT) indication on the clock. b. Push the SELECT and CONTROL buttons together to select the set mode. Make sure that the farthest left digit starts to flash. c. Push the CONTROL button to set the digit that flashes. d. Push the SELECT button to select the next digit to be set. Make sure that the next digit starts to flash. e. Push the CONTROL button to set the digit that flashes. f. When the last digit is set with the CONTROL button, push the SELECT button and exit the set mode. 2. Clock Local Time (LT) Set: Page 11 of 20
-NOTE- The minute digits of the Local Time (LT) mode are synchronized with the minutes of the Universal Time (UT) and cannot be set in local time. Minutes can only be set when in the UT time set mode. -NOTE- When there is no power applied to the clock, the CONTROL and SELECT buttons are disabled. a. Push the SELECT button to select the Local Time (LT) indication on the clock. b. Push the SELECT and CONTROL buttons together to select the set mode. Make sure that the digit starts to flash. LT may be switched from 12 to 24 hour format by pressing SELECT button for 5 seconds while in LT mode. The display will show current hour format. c. Push the CONTROL button to set the digit that flashes. d. Push the SELECT button to select the next digit to be set. Make sure that the next digit starts to flash. e. Push the CONTROL button to set the digit that flashes. f. When the last digit is set with the CONTROL button, push the SELECT button and exit the set mode. 3. Elapsed Time (ET) Count Up: a. Push the SELECT button to select the ET on the display. b. Push the CONTROL button to start ET counting. -NOTE- Elapsed time counts up to 59 minutes, 59 seconds, and then switches to hours and minutes. It continues counting up to 99 hours and 59 minutes. c. Push the CONTROL button to stop ET. d. Another press resets ET to zero. Page 12 of 20
4. Elapsed Time (ET) Count Down: a. Push the SELECT button to select ET on the display and enter set mode by pressing both SELECT and CONTROL buttons. b. Entering the time is identical to UT time setting. When the time is entered and the last digit is no longer flashing, the clock is ready to start the countdown. c. Momentarily pressing the CONTROL button starts the countdown. When the count reaches zero the displays flash and the external alarm is activated. d. Pressing either SELECT or CONTROL will deactivate the alarm. e. ET will continue counting up. f. Pressing CONTROL again will stop counting. g. Another press will reset to zero. 5. Clock Test Mode: a. Hold the SELECT button down for 3 seconds. b. The display indicates 88:88 and the clock mode indicators all come on and show underlined UT/LT/ET. PART III: Clock Battery Replacement 1. The M800-5-BATT Davtron Digital Clock needs to be verified for functionality before each start. It has a Keep Alive feature using a regular AA size battery captured in a plastic holder located in the back of the digital clock. 2. Replace the battery every 12 months. The time settings on the clock are maintained by one alkaline type battery of 1.5 volts, size AA. To replace the battery do the following steps: a. Gain access to the back of the clock indicator. b. Remove the existing battery from its mount. c. Place a new battery in the mount. Place the positive terminal of the battery towards the end marked positive (red). d. Refer to Part II operating instructions of digital clock to time setting after battery replacement. Page 13 of 20
Figure 1: Installation of the Digital Clock Page 14 of 20
Figure 2. Clock Hole Modification Page 15 of 20
WIRING INSTRUCTION TABLE ACTION WIRE # LENGTH (INCH) FROM HARDWARE TO CONNECTOR HARDWARE TOOLS ADD D400A22 120 CB2 MS25036-149 1-480305-0 (J400) PIN 2 60620-1 Note 3,4 TERMINATE ORANGE CUT TO LENGTH CLOCK 1-480303-0 (P400) PIN 2 60619-1 Note 4 ADD L402A22 60 TB6 (Pos 4) MS25036-102 1-480305-0 (J400) PIN 3 60620-1 Note 3,4 ADD L402B22 60 P400 (PIN 3) 60619-1 SPLICE (8R6) M81824/1-1 Note 2,4 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR (8R6) Note 2 TERMINATE BLUE CUT TO LENGTH CLOCK SPLICE (8R6) M81824/1-1 Note 2 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR (8R6) Note 2 ADD L401A22N 60 TB6 (Pos 2) MS25036-102 1-480305-0 (J400)PIN1 60620-1 Note3,4 TERMINATE BLACK CUT TO LENGTH CLOCK 1-480303-0 (P400) PIN1 60619-1 Note 4 TERMINATE YELLOW CUT TO LENGTH CLOCK 30-266-1 CAP Note 1 Notes: 1) For the 30-266-1 end cap use a regular heat gun. 2) For the M81824/1-1splice use AD1377 crimp tool. 3) For the MS25036-102, -149 AMP terminal use the following tool; APM S-9824-1 crimp tool or T&B terminal use WT 145C crimp tool. 4) For the 60619-1 and 60620-1 contact pin use AMP 90124-2 crimp tool with insert / removal tools 91002-1 and 1-305183-1. Figure 3: Wire Harness Instruction for 206A S/N 154 through 253 Page 16 of 20
WIRING INSTRUCTION TABLE ACTION WIRE # LENGTH (INCH) FROM HARDWARE TO CONNECTOR HARDWARE TOOLS ADD D400A22 120 CB2 MS25036-149 1-480305-0 (J400) PIN 2 60620-1 Note 3,4 TERMINATE ORANGE CUT TO LENGTH CLOCK 1-480303-0 (P400) PIN 2 60619-1 Note 4 ADD L402A22 60 TB25 (Pos 8) MS25036-102 1-480305-0 (J400) PIN 3 60620-1 Note 3,4 ADD L402B22 60 P400 (PIN 3) 60619-1 SPLICE (8R6) M81824/1-1 Note 2,4 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR (8R6) Note 2 TERMINATE BLUE CUT TO LENGTH CLOCK SPLICE (8R6) M81824/1-1 Note 2 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR (8R6) Note 2 ADD L401A22N 60 TB25 (Pos 2) MS25036-102 1-480305-0 (J400)PIN1 60620-1 Note 3,4 TERMINATE BLACK CUT TO LENGTH CLOCK 1-480303-0 (P400) PIN1 60619-1 Note 4 TERMINATE YELLOW CUT TO LENGTH CLOCK 30-266-1 CAP Note 1 Notes: 1) For the 30-266-1 end cap use a regular heat gun. 2) For the M81824/1-1 splice use AD1377 crimp tool. 3) For the MS25036-102, -149 AMP terminals use the following tool; APM S-9824-1 crimp tool or T&B terminal use WT 145C crimp tool. 4) For the 60619-1 and 60620-1 contact pin use AMP 90124-2 crimp tool with insert / removal tools 91002-1 and 1-305183-1. Figure 4: Wire Harness Instruction for 206A S/N 254 through 583 Page 17 of 20
WIRING INSTRUCTION TABLE ACTION WIRE # LENGTH (INCH) FROM HARDWARE TO HARDWARE Tools ADD D400A22 120 CB2 MS25036-149 INSTRUMENT PANEL 130-065-22-1 Note 3,4 TERMINATE ORANGE CUT TO LENGTH CLOCK TERM. JONCTION 130-065-22-1 Note 4 ADD L402A22 60 P189 3502 PLUG SPLICE (8R6) M81824/1-1 Note 2,5 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR ( 8R6) Note 2 TERMINATE BLUE CUT TO LENGTH CLOCK SPLICE (8R6) M81824/1-1 Note 2 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR ( 8R6) Note 2 ADD L401A22N 60 P189 3502 PLUG INSTRUMENT PANEL M81824/1-1 Note 2,5 TERMINATE BLACK CUT TO LENGTH CLOCK SPLICE M81824/1-1 Note 2 TERMINATE YELLOW CUT TO LENGTH CLOCK 30-266-1 CAP Note 1 Figure 5. Wire Harness instruction for 206A/B S/N 584 through 4216 Page 18 of 20
Notes for Figure 5: 1) For the 30-266-1 end cap use a regular heat gun. 2) For the M81824/1-1 splice use AD1377 crimp tool. 3) For the MS25036-149 AMP terminal use the following tool; APM S-9824-1 crimp tool or T&B terminal use WT 145C crimp tool. 4) For the 130-065-22-1 in line terminal junction use M22520/7-01 crimp tool with M22520 /7-11 turret. 5) For the 3502 connector plug use a soldering iron to solder the 2 wires and use as required appropriate size of 130-045-3-0-6,-4-0-6 and -5-0-6 shrinkable tubing to isolate solder terminations and protect wires. Page 19 of 20
WIRING INSTRUCTION TABLE ACTION WIRE # LENGTH (INCH) FROM HARDWARE TO CONNECTOR HARDWARE TOOLS ADD D400A22 120 CB2 MS25036-149 1-480305-0 (J400) PIN 3 60620-1 Note 3,4 TERMINATE ORANGE CUT TO LENGTH CLOCK 1-480303-0 (P400) PIN 3 60619-1 Note 4 ADD L402A22 60 TB8 (B1) M39029/1-101 1-480305-0 (J400) PIN 2 60620-1 Note 5,4 ADD L402B22 60 P400 (PIN 2) 60619-1 SPLICE (8R6) M81824/1-1 Note 2,4 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR (8R6) Note 2 TERMINATE BLUE CUT TO LENGTH CLOCK SPLICE (8R6) M81824/1-1 Note 2 TERMINATE SPLICE N/A N/A M81824/1-1 RESISTOR (8R6) Note 2 ADD L401A22N 60 TB8 (B2) M39029/1-101 1-480305-0 (J400)PIN1 60620-1 Note 5,4 TERMINATE BLACK CUT TO LENGTH CLOCK 1-480303-0 (P400) PIN1 60619-1 Note 4 TERNIMATE YELLOW CUT TO LENGTH CLOCK 30-266-1 CAP Note1 Notes: 1) For the 30-266-1 end cap use a regular heat gun 2) For the M81824/1-1 splice use AD1377 crimp tool. 3) For the MS25036-102, -149 AMP terminal use the following tool; APM S-9824-1 crimp tool or T&B terminal use WT 145C crimp tool. 4) For the 60619-1 and 60620-1 contact pin use AMP 90124-2 crimp tool with insert / removal tools 91002-1 and 1-305183-1. 5) For the M39029/1-101 contact use the following tool:m22520/1-01 crimp tool with M22520/1-02 turret or M22520/2-01 crimp tool with M22520/2-11 turret.installation /removal tools M81969/14-02 and M81969/14-10. Figure 6: Wire Harness Instruction for 206B S/N 4217 through 4310, TH67 S/N5101 through 5284 Page 20 of 20