TASK 70-35-25-300-001-A01 Replace The Contact Pin(s) Or Socket(s) In The Electrical Connector Or Receptacle Of The Electrical Harness, Repair-001 (VRS7002)

DMC:V2500-00-70-35-25-00A-920A-D|Issue No:004.00|Issue Date:2021-08-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 70-35-25-300-001-A01 Replace The Contact Pin(s) Or Socket(s) In The Electrical Connector Or Receptacle Of The Electrical Harness, Repair-001 (VRS7002)

General

This TASK details the procedure for the replacement of electrical contact pins or sockets.

Refer to Repair, VRS7002 SPM TASK 70-35-25-300-001 (REPAIR-001) for the following:

Effectivity

Equipment and materials

General

All illustrations/Figs

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 3J12704 Wrench and holderLOCALIAE 3J12704

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-146 LOCKWIRELOCALCoMat 02-146
CoMat 08-013 COLD CURING SILICONE COMPOUNDX222XCoMat 08-01375 ml

Silicoset 152, optional for BiFi connectors (point 11 of the procedure)

CoMat 02-148 ADHESIVE TAPE (ELECTRICAL)LOCALCoMat 02-148

Optional for 90deg backshell (point 11 of the procedure)

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 70-35-25-350-001 Prepare the Harness Adjacent to the Electrical Connector or Receptacle

    1. Refer to Figure and Figure.

      2. Remove the clamp bar, black rubber sleeve and cable tie(s) adjacent to the electrical connector or receptacle.

      1. Remove the safety wire, two screws, and clamp bar. Carefully push the black rubber sleeve rearwards and remove only the cable tie(s) necessary to do this repair.

    2. SUBTASK 70-35-25-350-002 Disassemble the Backshell Assembly from the Electrical Connector or Receptacle

    1. NOTE

      If the backshell to be removed is angular make a mark on the backshell to show position of the key-way.
      If the backshell to be removed is a connector or receptacle make a mark on the backshell to show position of the key-way.

      Refer to Figure and Figure.

      2. Remove the backshell nut.

      1. Install the electrical connector assembly to the IAE 3J12704 Wrench and holder, 1 off. Disconnect the backshell nut and move it along the cables.

      3. Remove the backshell.

      1. Remove the upper ring, sleeve, and split ring. Disconnect the backshell with the IAE 3J12704 Wrench and holder and move the backshell along the cables. Discard the knitmesh. Remove the electrical connector or receptacle from the IAE 3J12704 Wrench and holder.

    3. SUBTASK 70-35-25-350-059 Remove the Sealant from the BiFi Connectors of EEC Core Harness And Voltage Divider Harness Assembly

      NOTE

      This subtask to be used only if following conditions applied:
      If repairing BIFI CONNECTOR (4008VC or 4009VC) of EEC Core Harness And Voltage Divider Harness Assembly (6A8171 or 6A8172) please check if the connector is filled with sealant and if there is a mark VRS9906/A on the identification sleeve of the harness adjacent to the connector. If so, use blunt-edge tool to remove the sealant.

      1. CAUTION

        BE CAREFUL NOT TO DAMAGE THE INSULATION OF CABLES WHEN REMOVING THE SEALANT FROM CONNECTOR

        Remove all the sealant from the connector to completely uncover all cables and connector's surface.

      1. Use a clean blunt-edge tool.

    4. SUBTASK 70-35-25-350-060 Remove the Anti-chafing Tape from the 90deg Backshells

      NOTE

      This subtask to be used only if following conditions applied:
      If repairing connector with 90deg backshell please check if the wires in the connector are wrapped by anti-chafing tape and if there is a mark VRS9907/A or VRS9908/A on the identification sleeve of the harness adjacent to the connector. If so, use blunt-edge tool to remove the anti-chafing tape.

      1. CAUTION

        BE CAREFUL NOT TO DAMAGE THE INSULATION OF CABLES WHEN REMOVING THE ANTI-CHAFING TAPE FROM CONNECTOR

        Remove all the anti-chafing tape from the connector to completely uncover all cables.

      1. Use a clean blunt-edge tool.

    5. SUBTASK 70-35-25-350-003 Remove the Contact Pin (s) or Socket(s) from the Electrical Connector or Receptacle

    1. Refer to Figure and Figure.

      2. Remove the contact pin(s) or socket(s).

      1. Use the extraction/insertion tool, remove the contacts from the holes in the electrical connector or receptacle.

      3. Cut off the damaged contact pin(s) or socket(s).

      1. Cut the cable adjacent to the damaged contact pin(s) or socket(s).

    6. SUBTASK 70-35-25-350-004 Prepare the Cable Termination

    1. Refer to Figure and Figure.

      2. Make sufficient cable length for the termination.

      1. Carefully pull the cable from the harness loom to get the same length of termination (as before the cut back of the cable).

    7. SUBTASK 70-35-25-350-005 Install the New Contact Pin(s) or Socket(s) to the Cable

      1. Remove the conductor insulation.

      1. Use the thermo stripper and remove sufficient conductor insulation from the cable end.

      2. Install the new contact pin(s) or socket(s).

      1. Put the new contact pin(s) or socket(s) into the crimping tool. Put the core lead into the contact pin(s) or socket(s) and crimp it.

      3. Examine the core lead.

      1. Do a visual examination of the core lead. Make sure the contact pin(s) or socket(s) is correctly attached and crimped.

    8. SUBTASK 70-35-25-350-006 Assemble the Sheath to the Cable

    1. Refer to Figure and Figure.

      2. Cut the cable jacket.

      1. Cut the end of the jacket to get the same length of the termination (as before the cut back of the cable).

      3. Unknit the screen braid.

      1. Unkit the screen braid to get the same unknitted length (as before the cut back of the cable).

      4. Wrap the new knitmesh braid.

      1. Wrap the knitmesh braid on each cable screen braid and put the split tube over it.

      5. Install the backshell on the cable loom.

      1. Turn and fold the unknit screen braid tails and temporarily tape the ends to the cables. Make sure the backshell, upper ring, washer, and nut are installed on the cable loom.

    9. SUBTASK 70-35-25-350-007 Install the Contact Pin(s) or Socket(s) into the Electrical Connector or Receptacles

      1. Install the contact pin(s) or socket(s).

      1. Bend the core lead slightly to slide it into the insertion tool slot. Move the core lead and the tool in opposite directions, so that the core lead slides into the tabular area of the tool. Pull the core lead rearwards through the tool until the tip of the tool seats against the contact pin(s) or socket(s) shoulder. Slowly press the contact pin(s) or socket(s) and the tool into the insert hole by hand so they are vertical with the electrical connector or receptacle surface. When the contact pin(s) or socket(s) is in the correct position in the insert hole, release the cable and remove the tool. Lightly pull the cable to make sure the contact pin(s) or socket(s) is engaged correctly in the insert hole.

    10. SUBTASK 70-35-25-350-008 Install the Backshell to the Electrical Connector or Receptacle

    1. NOTE

      Make sure the key-way of the connector or receptacle aligns with the mark you made on the backshell.

      Refer to Figure and Figure.

      2. Install the backshell.

      1. Install the electrical connector or receptacle assembly to the IAE 3J12704 Wrench and holder, 1 off. Attach the backshell to the electrical connector or receptacle and tighten the nut by hand. Tighten the backshell nut through 90 degrees with the IAE 3J12704 Wrench and holder.

      3. Install the other backshell parts.

      1. Remove the temporary tape and put the screen tails equally around the split ring cone surface and through the ID of the upper ring and washer. Attach and tighten the backshell nut to the backshell so the different parts hold the screen braid tails. Trim the tails and shrink the sleeve over them.

    11. SUBTASK 70-35-25-350-009 Finish the Harness Adjacent to the Electrical Connector or Receptacle

      NOTE

      If repairing BIFI CONNECTOR (4008VC or 4009VC) of EEC Core Harness And Voltage Divider Harness Assembly (6A8171 or 6A8172) and if the connector before repair was filled with sealant and marked VRS9906/A on the identification sleeve of the harness adjacent to the connector please perform TASK 71-52-43-300-006 EEC Core Harness And Voltage Divider Harness Assembly - ADDING SEALANT TO BIFI CONNECTORS TO AVOID MOISTURE INGRESS, REPAIR-006 (VRS9906) before continue the assembly of electrical connector.

      NOTE

      If you find the repairing connector with 90deg backshell and also before you do repair to the connector, if it has anti-chafing tape applied and marked VRS9907/A or VRS9908/A on the identification sleeve of the harness adjacent to the connector. You must do TASK 71-51-41-300-009 THE 90DEG BACKSHELL ANTI CHAFING TAPE REPAIR - WRAPPING TAPE AROUND WIRES INSIDE 90DEG BACKSHELL, REPAIR-009 (VRS9907) or TASK 71-52-43-300-008 THE 90DEG BACKSHELL ANTI CHAFING TAPE REPAIR - WRAPPING TAPE AROUND WIRES INSIDE 90DEG BACKSHELL, REPAIR-008 (VRS9908) accordingly before you do with the assembly of electrical connector.

      1. Install the cable ties, black rubber sleeve and clamp bar adjacent to the electrical connector or receptacle.

      1. Use the applicable color lacing tape and lace ties. The lacing positions are the same as the previous positions. Refer to SPM TASK 70-35-25-300-001-H01. Push the black rubber sleeve forward so it packs the cables at the forward clamp bars. Attach the clamp bars together with the two screws, tighten the screws.

      2. Safety the parts.

      1. Safety the backshell, nuts, and screws with CoMat 02-146 LOCKWIRE.

    12. SUBTASK 70-35-25-750-001 Test the Electrical Harness Assembly

      1. Test the harness.

      1. Refer to (TESTING P.B. 1301) of the appropriate Chapter/Section/Subject for details and tool set up, as necessary.

    13. SUBTASK 70-35-25-550-001 Do the Harness Preservation Procedure

      1. Put the harness assembly in storage.

      1. Refer to (STORAGE P.B. 1201) of the appropriate Chapter/Section/Subject for details, as necessary.

    14. SUBTASK 70-35-25-350-051 Identify the Repair

      1. Make a mark VRS7002/A on the identification sleeve of the harness adjacent to the part number.

      1. Use permanent marker.

    15. Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the note. (21VC136)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:LOCAL
Supply Number:CoMat 02-146
Type:sp01
Supply Short Name:CoMat 02-146 LOCKWIRE
Supply Name:CoMat 02-146 LOCKWIRE
Specification Groups:
Doc NumberType
AIA/NAS NASM20995 Part Number MS20995C20 (0,5 MM)
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 02-148
Type:sp01
Supply Short Name:CoMat 02-148 ADHESIVE TAPE (ELECTRICAL)
Supply Name:CoMat 02-148 ADHESIVE TAPE (ELECTRICAL)
Specification Groups:
Doc NumberType
OMAT: 296SCOTCH NO. 69 (WHITE)
Suppliers:
ManufacturerRemarks
LOCAL
76381
94960
K0993
K6835
Manufacturer Code:X222X
Supply Number:CoMat 08-013
Type:sp01
Supply Short Name:CoMat 08-013 COLD CURING SILICONE COMPOUND
Supply Name:CoMat 08-013 COLD CURING SILICONE COMPOUND
Specification Groups:
Doc NumberType
If CoMat 08-013 is specified without an asterisk or a letter suffix, use one of the letter suffix alternative materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:IAE 3J12704
Tool Name:IAE 3J12704 Wrench and holder