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18080 NE 68th Street, Redmond, WA 98052

USA
425.883.8008

ACS CrystalTint LCD Monitor


Manufacturing Procedures Manual

P/N: DLD-2602D-01

Prepared by Hironori Katoh Date 3/6/2015

Approved by Yukio Sugimoto Date 3/9/2015

QA Approval Dan Landin Date 3/9/2015

ACS P/N: ACS S/N: ACS Manufacture Date:

DLD-2602D-01 AD

Proprietary Notice: The information contained herein is proprietary to Aircraft Cabin Systems, LLC., and shall not be
disclosed or reproduced in part or in whole or used for any purpose without written authorization from Aircraft Cabin
Systems, LLC.,

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Revision Historical Records

Revision Description Revision Prepared Section


Symbol (Revision Sheet No./ Content) Date Prepared Approval

New Initial release 3/13/12 H. Katoh Y. Sugimoto


Copper tape added to hold cable Assy
A Copper plate added 8/3/12 H. Katoh Y. Sugimoto

B EMI and current harmonics fix 3/22/13 H. Katoh Y. Sugimoto

C Part quantity corrected 8/9/13 H. Katoh Y. Sugimoto

D LVDS cable change to FPC version for EMI fix 2/20/14 H. Katoh Y. Sugimoto

E Adjusted wire lead lengths 11/4/14 B. Cooper H. Katoh

F Part numbers corrected requested by Purchasing 3/6/15 H. Katoh Y. Sugimoto


Sec D, pg 30 - Added Silicon Sealant step for
LVDS cabling. Figure D-1 reflects the change.
G 6/23/15 J.Hoo B.Cooper
Added Silicon Sealant to Appendix 1, page 31-32,
Item 13
Updated the following:
-AW-2602-01PH2-40A
-AW-2602D-01-LVA
H 2/23/16 J.Hoo B.Cooper
-AS-DLD-2602D-01
- DLD-2602D-01-101
-DLD-2602D-01-202-Assy
Sec 1.6:- parts corrected to Molex from RF parts
-corrected PHDR-10VS From: PHDR-10
Sec 1.12: Added step to apply silicone sealant to
cable assembly after completion
Sec 2.1: Added S/N & C/N to item #1
J 6/22/16 J. Hoo B. Cooper
-Updated EMI Gaskets To: IMG-01007GP From:
82-122-74038
Sec C: revised parts list
Sec D: Added silicone foam blocks to assembly
and updated view for placement
PER ECR-181029-03 Prepared by Checked by Approved by
Corrected wire lengths
- Page 4. PN: AW-2602-01-J11-10
- Page 5, PN: AM-2602-01-LF-09
- Page 6, PN: AW-2602-01-PH1-09
K - Page 8, PN: AW-2602-01-PH2-40A H. NAKAMURA /
- Page 10, PN: AW-2602-01-DDC-16 12/13/18
- Page 12, PN: AW-2602-01-ERC-13
- Page 15, PN: AW-2602-01-VP-13
- Page 17, PN: AW-2602D-01-SH-07
- Page 21, PN: AW-2602D-01-LVA

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DLD-2602D-01 LCD Monitor
Manufacturing Procedures Manual
(A) Cable Assembly
1.1 J1 Assy to MOXA BD Cable (P/N: AW-2602-01-J11-10)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
PH connector plug PHR-6 1
( 6 pin)
PH connector contact SPH-002T-P.0.5S 4

AWG 24 Teflon Wire M22759/11-24-3 AR


(Orange)
AWG 24 Teflon Wire M22759/11-24-5 AR
(Green)
AWG 24 Teflon Wire M22759/11-24-8 AR
(Gray)
Molex connector housing 90123-0105 1
Molex connector contact 901190109 4

Step 1
Prepare Cables as required.
Step 2
Strip wires as required with Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A1).
Use AP-K2N Crimping Machine Applicator #: MKDSSPH002P05S for SPH002T-P0.5S

Step 3
Insert and Strand wire/contact assemblies to Connector Plugs per drawing (Figure-A1).

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Figure-A1

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.2 Line Filter Assy (P/N: AM-2602-01-LF-09)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
Line Filter 3VB1 1
Electrolytic Capacitor ECA-1HM101 1
(50V,100 uF)
JST VH series connector plug VHR-3N 2
(3 pin)
JST VH series connector contact SVH-21T-P1.1 4
AWG 22 Teflon Wire M22759/11-22-0 AR
(Black)
AWG 22 Teflon Wire M22759/11-22-2 AR
(Red)

Step 1
Prepare Cables as required.

Step 2
Strip wires as required with Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A2).
Use AP-K2N Crimping Machine Applicator #: MKSL17993 for SVH-21T-P1.1

Step 3
Insert and Strand wire/contact assemblies to Connector Plug per drawing (Figure-A2).

Step 4
Solder electrolytic capacitor (P/N: ECA1HM101) to line filter terminals.
Refer J-STD-001 standard book for soldering process.

Figure-A2

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.3 Backup Power Assy to DC/DC Cable (P/N: AW-2602-01-PH1-09)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
JST HR series connector plug VHR-6N 2
(6 pin)
JST HR series connector contact SVH-21T-P1.1 12

AWG 22 Teflon Wire M22759/11-22-1 AR


(Brown)
AWG 22 Teflon Wire M22759/11-22-2 AR
(Red)
AWG 22 Teflon Wire M22759/11-22-3 AR
(Orange)
AWG 22 Teflon Wire M22759/11-22-4 AR
(Yellow)
AWG 22 Teflon Wire M22759/11-22-5 AR
(Green)
AWG 22 Teflon Wire M22759/11-22-6 AR
(Blue)

Step 1
Prepare Cables as required.

Step 2
Strip wires as required with Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A3).
Use AP-K2N Crimping Machine Applicator #: MKSL17993 for SVH-21T-P1.1

Step 3
Insert and Strand wire/contact assemblies to Connector Plugs per drawing (Figure-A3).

Figure-A3

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Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

1.4 Backup Power Assy to LCD Power Cable (P/N: AW-2602-01-PH2-40)


Parts List
Parts Description Part Number Qty Cert/ Lot Number
JST HR series connector plug VHR-4N 1
(4 pin)
JST HR series connector contact SVH-21T-P1.1 4

PHR connector plug PHR-14 1


(14 pin)
PHR connector plug PHR-7 1
(7 pin)
PH connector contact SPH-002T-P.0.5S 12

AWG 22 Teflon Wire M22759/11-22-0 AR


(Black)
AWG 22 Teflon Wire M22759/11-22-2 AR
(Red)
AWG 24 Teflon Wire M22759/11-24-0 AR
(Black)
AWG 24 Teflon Wire M22759/11-24-5 AR
(Green)
AWG 24 Teflon Wire M22759/11-24-8 AR
(Gray)

Step 1
Prepare Cables as required.

Step 2
Strip wires as required with Wire Stripper (Tool #: 45-125) and crimp or solder contacts per drawing (Figure-A4).
Use AP-K2N Crimping Machine Applicator #: MKSL17993 for SVH-21T-P1.1
Use AP-K2N Crimping Machine Applicator #: MKDSSPH002P05S for SPH002T-P0.5S
Refer J-STD-001 standard book for soldering process.

Step 3
Insert and Strand wire/contact assemblies to Connector Plugs per drawing (Figure-A4).

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Figure-A4

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.4 DCDC to G5A BD Cable (P/N: AW-2602-01-DDC-16)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
XHP connector plug XHP-4 1
(4 pin)
XHP connector contact SXH-001T-P0.6 4

JST PHD connector plug PHDR-12VS 1


(10 pin)
JST PHD series contact SPHD-001T-P0.5 4

AWG 24 Teflon Wire M22759/11-24-1 AR


(Brown)
AWG 24 Teflon Wire M22759/11-24-2 AR
(Red)
AWG 24 Teflon Wire M22759/11-24-3 AR
(Orange)
AWG 24 Teflon Wire M22759/11-24-4 AR
(Yellow)

Step 1
Prepare Cables as required.
Step 2
Strip wires as required with using Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A5).
Use AP-K2N Crimping Machine Applicator #: MKSL15671 for SXH-001T-P0.6
Use Crimp Tool #: WC-610 for SPHD-001T-P0.5
Step 3
Insert and Strand wire/contact assemblies to Connector Plug per drawing (Figure-A5).

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Figure-A5

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.6 Ethernet 232C Converter to G2D BD Cable (P/N: AW-2602-01-ERC-13)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
Molex connector plug 901420010 1
(10 pin)
Molex connector plug 901430014 1
(14 pin)
Molex connector contact 901190109 5

PHR connector plug PHR-2 1


(2 pin)
PHR connector plug PHR-3 1
(3 pin)
PHR connector plug PHR-10 1
(10 pin)
PH connector contact SPH-002T-P.0.5S 6

PHDR connector plug PHDR-10VS 1


(10 pin)
JST PHD series contact SPHD-001T-P0.5 3

AWG 24 Teflon Wire M22759/11-24-0 AR


(Black)
AWG 24 Teflon Wire M22759/11-24-1 AR
(Brown)
AWG 24 Teflon Wire M22759/11-24-2 AR
(Red)
AWG 24 Teflon Wire M22759/11-24-3 AR
(Orange)

Step 1
Prepare Cables as required.
Step 2
Strip wires as required with using Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A6).
Use AP-K2N Crimping Machine Applicator #: MKDSSPH002P05S for SPH002T-P0.5S
Use 010427-300 for RF-SC2210
Step 3
Insert and Strand wire/contact assemblies to Connector Plug per drawing (Figure-A6).

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Figure-A6

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.7 J1 Connector Assy (P/N: AB-2602-01-J1)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
PWB bare board APW-2601-17W2 1

15 pin D-sub conncetor solder 17W2P 1


cup and 75 ohms coax
VH series connector post B3PS-VH 1
(3 pin)
PH connector post B2B-PH-K-S 1
(3 pin)
PH connector post B6B-PH-K-S 1
(6 pin)
Dual common cathode rectifier UH20FCT 1

Silicon rectifier 1N4004 3

Surface Mount Fuse 7A TR2/6125FA7A 1

P-channel 40V MOS FET Si4401BDY 1

400W SMD Voltage suppressor SMAJ33CA 1


(33V)
SMT Capacitor (0.1 uF) 12065C104MAT2A 2

1/8 W SMT resistor RC2012J473CS 1

1/8 W SMT resistor RC2012J223CS 1

Coax cable RG-179 AR

Alignment Ring 4000-4025-020 2

Coaxial Conn. (Male) 131J200229X 1

Step 1
Gather parts as required (P/N: RG-179 & 131J200229X).
Step 2
Expose one end of RG-179 for crimping to Coax Connector
Step 3
Attached and crimp coax and connector together.

Step 4
Expose end for soldering purposes later on.

Step 5
Assemble PWB and insert the coax plugs into the connector. (Figure A7). Note to add and secure Alignment Ring
(P/N: 400-4025-020)

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A1 A2

Note:
A1 → J3 (ACSC2H01)
A2 → J5 (ACSC2H01)

Figure-A7

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.8 G5A to HDSDI/HDMI CNV BD Cable (P/N: AW-2602-01-VP-13)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
PHR connector plug PHR-2 2
(2 pin)
PH connector contact SPH-002T-P.0.5S 4

AWG 24 Teflon Wire M22759/11-24-0 AR


(Black)
AWG 24 Teflon Wire M22759/11-24-2 AR
(Red)

Step 1
Prepare Cables as required.
Step 2
Strip wires as required with Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A8).
Use AP-K2N Crimping Machine Applicator #: MKDSSPH002P05S for SPHD-001T-P0.5

Step 3
Insert and Strand wire/contact assemblies to Connector Plugs per drawing (Figure-A8).

Figure-A8

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.9 HDSDI/HDMI Converter to G5A BD Cable (P/N: AW-2602-01-SH-07)

Parts List
Parts Description Part Number Qty Cert/ Lot Number
SHDR series plus 20 pin SHDR-20V-S-B 1
SHDR series Contact SSH-003T-P0.2 20
Header 2 x 14 pin P: 2.54 mm 0901420028 1
Female
Header connector contact 0901190109 20

AWG 28 Teflon Wire M22759/11-28-0 AR


(Black)
AWG 28 Teflon Wire M22759/11-28-1 AR
(Brown)
AWG 28 Teflon Wire M22759/11-28-2 AR
(Red)
AWG 28 Teflon Wire M22759/11-28-3 AR
(Orange)
AWG 28 Teflon Wire M22759/11-28-4 AR
(Yellow)
AWG 28 Teflon Wire M22759/11-28-5 AR
(Green)
AWG 28 Teflon Wire M22759/11-28-6 AR
(Blue)
Copper Tape CCH-36-101-0100 AR

Kapton Tape KPT-1-1/4 AR

Step 1
Prepare Cables as required.
Step 2
Strip wires as required with using Wire Stripper (Tool #: 45-125) and crimp contacts per drawing (Figure-A9).
Use AP-K2N Crimping Machine Applicator #: MKDSSPH002P05S for SPH002T-P0.5S
Use 010427-300 for RF-SC2210
Step 3
Insert and Strand wire/contact assemblies to Connector Plug per drawing (Figure-A9).
Step 4
Cover whole wiring with copper tape (P/N: CCH-36-101-0100). Install kapton tape on the header connector so
the copper does not touch contacts.

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Figure-A9

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.10 Power Backup Assy (P/N: AB-2601-01-PH)
Parts List
Parts Description Part Number Qty Cert/ Lot Number
PWB bare board APW-2601-1 1
Rev. D
Surface mount rectifier S3G-E3/57T 2

Electrolytic capacitor ECA-1VHG472 4


(4700 uF, 35 V)
Resistor (22 ohms, 2W) RHC2512 FT22R0 1

Capacitor (0.1 uF, 100V) CB037E0104-JBA 3

EMI filter BNX012-01 1

VH series connector post B3PS-VH 1


(3 pin)
VH series connector post B4PS-VH 1
(4 pin)
VH series connector post B6PS-VH 1
(6 pin)

Figure-A10
Step 1

Insert part and solder them. Refer to the Figure-A10


Refer J-STD-001 standard book for soldering process.

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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1.11 DC-DC Converter Assy (P/N: AB-2601-DDC)
Parts List
Ref.
Parts Description Part Number Qty Cert/ Lot Number
#
Bare PWB APW-2601-PS 1 1
(Rev. C)
VH series connector post B6PS-VH 1 2
(6 pin)
XH connector post B4B-XH-A 1 3
(4 pin)
DC/DC converter VHB100W-Q24-S24 1 4

DC/DC converter UHE-12/2500-Q12-C 1 5

Electrolytic Capacitor ECA-1VM101 2 6


(35V,100 uF)
Electrolytic Capacitor ECA-1HM101 2 7
(50V,100 uF)
Schottky Diode SD103B-F 2 9

AWG 22 Teflon Wire M22759/11-22-0 AR 10


(Black)
Rag Terminal RG179 1 11

3 2

4
10
11
A

9
To “A”
To “C”
To “B”
B

2"/ AWG 22

Figure-A11

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Step 1

Insert part and solder them. Refer to the Figure-A9.


Refer J-STD-001 standard book for soldering process.

Step 2

Solder 11” black and red cable (need to be twisted) between leads of capacitors and DC to DC converter inputs (In
+, In-). Refer to Figure-A9.
Refer J-STD-001 standard book for soldering process.

Step 3

Lay down the capacitors on the chassis with side adhesive tape.

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

1.12 LVDS Interconnect Cable Assy (P/N: AW-2602D-01-LVA)


Parts List
Parts Description Part Number Qty Cert/ Lot Number
DF13 series connector 40 pin DF13-40DS-1.25C 1

DF13 series connector 30 pin DF13-30DS-1.25C 1

DF13 series contact DF13-2630SCF 60

AWG 28 Teflon Wire M22759/11-28-0 AR


(Black)
AWG 28 Teflon Wire M22759/11-28-2 AR
(Red)
AWG 28 Teflon Wire M22759/11-28-4 AR
(Yellow)
AWG 28 Teflon Wire M22759/11-28-5 AR
(Green)

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Figure-A12

Step 1
Apply Silicone (P/N: KE3494) sealant on top of the wires after they are installed to each connector housing.

Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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(B) Front Case Assembly (P/N: DLD-2602D-01-101)
2.1 LCD Panel Assembly (P/N: DLD-2602D-01-101)
Parts List
Ref
Parts Description Part Number Qty Cert/ Lot Number
#
26 INCH LCD Panel G260JJE-L07
S/N
1 1
C/N
LCD Bracket Left DLD-2602D-301
2 1
LCD Bracket right DLD-2602D-311
3 1
LCD Bracket Bottom DLD-2601D-321
4 1
LCD Bracket Top DLD-2601D-331
5 1
Screw, SEMS, M3 XMS3S-8-C
6 8
ACS Certification / identification ACS-NP0001-102
label 7 1
Soft Shield Gasket IMG-01007GP
8 80

Figure-B3
Step 1
Mount brackets as shown in Figure B3
Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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(C) Back Case Assembly (P/N: DLD-2602D-01-202-ASSY )
Parts List
Parts Description Part Number Ref # Qty Cert/ Lot Number
Back Case DLD-2602D-01-202 1 1

J1 Connector Assy AB-2602-01-J1 2 1 See paragraph 1.7

Line Filter Assy AM-2602-01-LF-09 3 1 See paragraph 1.2

Power Hold Up Assy AB-2601-01-PH 4 1 See paragraph 1.10

DC-DC Converter Assy AB-2601-DDC 5 1 See paragraph 1.11


Video Processor Assy 90ADG5A202L2 1 S/N
6
C/N
Ethernet to RS232C Converter
NE4120S 7 1
board
D-SUB Screw set / Screw,
5205817-1 8 2
washer, Spring Washer

EMI Shield Assembly DLD-2602D-01-106 9 1

Screw, SEMS, M3 XMS3-6-C 10 20

Rag Terminal RIN-1N 11 1

Washer, Spring, M3 91202A222 12 26

NUT, HEX, M3 92497A200 13 26

Washer, Flat, M3 91166A210 14 2

Screw, Flat Head, M3 91420A118 15 4


Power backup assy to DC/DC
converter cable
AW-2602-01-PH1-09 16 1 See paragraph 1.3

DCDC Converter to G5A cable AW-2602-01-DDC-16 17 1 See paragraph 1.5


Power backup assy to LCD panel AW-2602-01-PH2-
power
18 1 See paragraph 1.4
40A
LVDS Interconnect Cable AW-2602D-01-LVA 19 1 See paragraph 1.12
Ethernet to RS232C Converter
board to G5A BD cable
AW2602-01-ERC-13 20 1 See paragraph 1.6
G5A Board to HDSDI/HDMI CNV
BD cable
AW-2602-01-VP-13 21 1 See paragraph 1.8
J1 assy To MOXA converter cable
(Ethernet)
AW-2602-01--J11-10 22 1 See paragraph 1.1

HDSDI/HDMI Conversion Board ACS-C2H01 23 1

Copper Tape CCH-36-101-0100 24 AR

HDSDI BD to G5A Board cable AW2602-01-SH-07 25 1 See paragraph 1.9

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Figure-C1

Step 1
Install J1 connector assy (P/N: AB-2602-01-J1).

Step 2
Place the following assemblies on to the back case (P/N: DLD-1701D-200) with screws shown in Figure-C1 and
the part list.
- Line Filter Assy (P/N: AB-2602-01-LF-09)
- Power Hold UP Assy (P/N: AB-2601-01-PH)
- DC-DC Converter Assy (P/N: AB-2601-DDC)
- Video Processor Board (P/N: 90ADG5A202L2)
o Set the jumpers to the settings below (Figure-C1.1)
- Ethernet 232C Converter (P/N: NE-4120S)

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Figure-C1.1

Step 3
Install the following cable assemblies as instructed in Figure-C1.
- AW-2602-01-PH1-09
- AW-2602-01-DDC-16
- AW-2602-01-PH2-40A
- AW-2602-01-ERC-12
- AW-2602-01-J11-10
- AW-2602D-01-LVA

For EMI improvements, FPC LVDS should be copper taped showing below.

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Assembler Signatures
Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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(D) Final Assembly (P/N: AS- DLD-2602D-01)
Parts List
Ref
Parts Description Part Number Qty Cert/ Lot Number
#
Front Case DLD-2602D-100 1
1
Rev. C
Rear Case ASSY DLD-2602D-01-202- 1
2 See paragraph (C)
ASSY
LCD Panel Assembly DLD-2602D-01-101 1
3 See paragraph 2.2
Screw, Flat Head, Number 4 96640A056 9
4
Screw, Flat Head, Number 4 90273A108 10
5
XMS3S-8-C XMS3S-8-C 8
6
NAME PLATE / PLACARD ACS-NP0001-101 1
7
Silicone Selant KE3494 AR
8
Access Hole Cover DLD-2602D-01-109 1
9
Silicon foam 1” Thick (2” X 5”) AS-DLD-2602D-100 2
10
Silicon foam 1” Thick (2” X 8”) AS-DLD-2602D-101 1
11
Silicone foam ½” Thick (2” X 8”) AS-DLD-2602D-102 1
12

Figure-D1

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Figure-D2

Step 1
Combine the front case assembly and back case assembly with screws shown in the Figure-D2.

Assembler Signatures

Assembler Signatures Date Mech QA Remarks

Assemble per drawing

Inspect Complete

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Appendix 1- TOOL LIST
Item Tool Number Manufacture Description
01 100 P.2-100 Vessel 3mm Screw Driver
02 100 P.1-75 Vessel 4-40 Screw Driver
03 41964 Craftsman 3mm Nut Driver
04 4100 7-125 Vessel 4mm Nut Driver
05 41963 Craftsman Nut Driver for D-Sub Screw
06 K042850 Molex Crimp Tool for Molex Connector
07 45-125 Ideal Industries Inc. Wire Strip Tool
08 0283864 Wagner Heat Gun
09 WES50 Weller Soldering Tool
10 010427-300 N/A Crimp Tool for Molex 0800108 contact pin

M22520/2-09 Crimp Tool for D-Sub socket (Female)


11 DMC
M22520/2-06 Crimp Tool for D-Sub pin (Male)
12 AP-K2N JST Crimping Machine
13 KE3494 ShinEtsu Silicon Sealant
* Tool may be alternated with equivalent tool.

Item 01

Item 10

Item 02 Item 07

Item 03
Item 11
Item 08

Item 04

Item 05

Item 09

Item 12
Item 06

Item 13

Document: AMPM-2602D-01 Revision: K


Date: 12/13/2018 Page: 29/29

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