(e)
Position outer sleeve over ground wire connection and center over inner sleeve. Hexagonal swage outer sleeve to make a secure connection.
(3)
On rod end assemblies without wire rope hole, connect switch leads to connector plug and install rod end (Detail B).
(a)
Cut switch lead and ground wire as required to provide overall length of 7.00 to 8.00 inches from rod end to outer end of connector plug, when connected.
(b)
Using connector pin insertion tool, connect switch lead to pin 2 of connector plug and ground wire to pin 1.
(c)
Compress switch and hold switch leads firmly against rod end.
(d)
Screw rod end into piston until distance between centerlines of actuator support fitting bolt and rod end bolt is 12.69 to 12.71 inches. Use inside calipers to measure distance. Ensure that switch assembly turns with rod end and seats correctly in piston.
(e)
If inside calipers are not available, or clearance prevents their use, screw rod end into piston until distance between centerline of rod end bolt and point marked on actuator housing during rod end removal is exactly as that recorded in step 3.L. Ensure that switch assembly turns with rod end and seats correctly in piston.
(f)
Tighten locknut 220 to 300 pound-inches. Lockwire nut and locking key.
(g)
Release switch lead wire.
(h)
Using tying braid, secure switch lead to rod end. Apply a clove hitch firmly around rod end at lead wire hole. Tie a square knot firmly over the clove hitch and cut off free ends to a length of 0.25 to 0.50 inch.
(4)
On rod end assemblies with wire rope hole, connect switch leads to connector plug and install rod end (Detail C).
(a)
Compress spring in rod end with switch and hold. Cut switch lead wire and ground wire as required to provide overall distance of 7.5 to 8.0 inches from rod end to outer end of connector plug, when connected.
(b)
Cut wire rope 0.30 inches shorter than switch wire length from rod end and trim 1/8-inch tubing at least 0.75 inches away from rod end.
NOTE: Wire rope length is such that after installation, load between connector plug and rod end will be carried by wire rope and not switch wire.
(c)
Release hold on spring.
(d)
Using connector pin insertion tool, connect switch lead wire to pin 2 of connector plug and ground wire to pin 1.
(e)
Slide heat shrink tubing, RT-876-3/16, over wire rope (near connector end). Loop end of wire rope through hole in connector and ferrule. Swage ferrule. Position tubing over swage. Do not shrink.
(f)
With switch compressing spring in rod end, hold switch wire and wire rope firmly against rod end and screw rod end into piston until distance between centerlines of actuator support fitting bolt and rod end bolt is 12.69 to 12.71 inches. Use inside calipers to measure distance. Ensure that switch assembly turns with rod end and seats correctly in piston.
(g)
If inside calipers are not available, or clearance prevents their use, screw rod end into piston until distance between centerline of rod end bolt and point marked on actuator housing during rod end removal is exactly as that recorded in step 3.L. Ensure that switch assembly turns with rod end and seats correctly in piston.
(h)
Tighten locknut 220 to 300 pound-inches. Lockwire nut and locking key.
(i)
Release switch wire and wire rope and insert end of wire rope through hole in rod end. Swage terminal ball cable on end of wire rope that projects through.
(5)
Check that 3/16-inch tubing is covering ferrule and that 1/8-inch tubing allows space for free switch wire movement near rod end. Shrink tubing.
NOTE: Do not exert enough pressure to cause deformation of the wire insulation.
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27-81-111 Page 406 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. Oct 20/85
F. Attach connector plug to mounting bracket.
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Oct 20/85 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 27-81-111 Page 407
G. Apply silicone sealant around rod end assembly and lockout. Ensure that sealant is applied to tying braid and wire rope, if present, and point where switch lead wire enters rod end.
CAUTION: SEAL OFF ALL ACCESS AREA TO ROD END THREADS AND GLAND NUTS. SWITCH WIRE IS HELD PERPENDICULAR TO ROD END DURING APPLICATION AND CURING OF SEALANT.
H. Remove all leading edge slat actuator locks.
I. Provide system A hydraulic power (Ref 27-81-0).
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