Narrative:

B757 automatic fuel pump shutoff modification. I was notified that there was a problem with the section of the modification in question that I have been doing to help. I was asked by composite shop manager what contact I had been installing in the left side cannon plug D40612P-AP0011 at position #4. I told shop manager that I had been putting a male contact in that position. I was then told that mr X who I had trained had inadvertently installed the contact in the wrong hole of the cannon plug of the aircraft that he was working on and that when it was troubleshot by the second shift right/east it was discovered that we had been installing the wrong contact in D40612P-AP0011 position #4 at location 37. I was told that I would be helping with the automatic fuel boost pump shutoff modification and that I would be sitting in with one of their technicians for a couple aircraft for training. On aircraft X I assisted mr Y. He did the PL11-4 side and I did the PL11-3 side which is the left side. Another of the technicians; mr Z; was to check in on us to see how we were doing. At the point where I was to install the contact on wire 0022-22; I went to get mr Z to instruct me on finding the correct hole on D40612P-AP0011 position #4 and installing the connector on the wire. Mr Z then told us that a female contact was to be installed on the right side and a male contact was to be installed on the left side. At that time he took the male pin from the parts kit that he had put together for us and showed me how to crimp it on the wire. Mr Z then showed me how to count the holes in the back side of the cannon plug to install the pin in the right position. I did read through the paperwork but was not aware that the part #BACC47CPIS on flag note 3 on page 47 was a female connector. I then performed the modification on aircraft with the same male contact at position #4 at location 37. I also trained mr X to do the modification starting with aircraft X.

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Original NASA ASRS Text

Title: A B757 TECHNICIAN RPTS WHILE WORKING ON AN AUTO FUEL PUMP SHUTOFF MODIFICATION INSTALLED AN INCORRECT ELECTRICAL CONNECTOR PIN AT POS #4.

Narrative: B757 AUTO FUEL PUMP SHUTOFF MODIFICATION. I WAS NOTIFIED THAT THERE WAS A PROB WITH THE SECTION OF THE MODIFICATION IN QUESTION THAT I HAVE BEEN DOING TO HELP. I WAS ASKED BY COMPOSITE SHOP MGR WHAT CONTACT I HAD BEEN INSTALLING IN THE L SIDE CANNON PLUG D40612P-AP0011 AT POS #4. I TOLD SHOP MGR THAT I HAD BEEN PUTTING A MALE CONTACT IN THAT POS. I WAS THEN TOLD THAT MR X WHO I HAD TRAINED HAD INADVERTENTLY INSTALLED THE CONTACT IN THE WRONG HOLE OF THE CANNON PLUG OF THE ACFT THAT HE WAS WORKING ON AND THAT WHEN IT WAS TROUBLESHOT BY THE SECOND SHIFT R/E IT WAS DISCOVERED THAT WE HAD BEEN INSTALLING THE WRONG CONTACT IN D40612P-AP0011 POS #4 AT LOCATION 37. I WAS TOLD THAT I WOULD BE HELPING WITH THE AUTO FUEL BOOST PUMP SHUTOFF MODIFICATION AND THAT I WOULD BE SITTING IN WITH ONE OF THEIR TECHNICIANS FOR A COUPLE ACFT FOR TRAINING. ON ACFT X I ASSISTED MR Y. HE DID THE PL11-4 SIDE AND I DID THE PL11-3 SIDE WHICH IS THE L SIDE. ANOTHER OF THE TECHNICIANS; MR Z; WAS TO CHK IN ON US TO SEE HOW WE WERE DOING. AT THE POINT WHERE I WAS TO INSTALL THE CONTACT ON WIRE 0022-22; I WENT TO GET MR Z TO INSTRUCT ME ON FINDING THE CORRECT HOLE ON D40612P-AP0011 POS #4 AND INSTALLING THE CONNECTOR ON THE WIRE. MR Z THEN TOLD US THAT A FEMALE CONTACT WAS TO BE INSTALLED ON THE R SIDE AND A MALE CONTACT WAS TO BE INSTALLED ON THE L SIDE. AT THAT TIME HE TOOK THE MALE PIN FROM THE PARTS KIT THAT HE HAD PUT TOGETHER FOR US AND SHOWED ME HOW TO CRIMP IT ON THE WIRE. MR Z THEN SHOWED ME HOW TO COUNT THE HOLES IN THE BACK SIDE OF THE CANNON PLUG TO INSTALL THE PIN IN THE R POS. I DID READ THROUGH THE PAPERWORK BUT WAS NOT AWARE THAT THE PART #BACC47CPIS ON FLAG NOTE 3 ON PAGE 47 WAS A FEMALE CONNECTOR. I THEN PERFORMED THE MODIFICATION ON ACFT WITH THE SAME MALE CONTACT AT POS #4 AT LOCATION 37. I ALSO TRAINED MR X TO DO THE MODIFICATION STARTING WITH ACFT X.

Data retrieved from NASA's ASRS site as of January 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.