TASK 71-51-44-300-004 Ignition Supply Harness - Replace The Cable, Repair-004 (VRS1044)

DMC:V2500-A0-71-51-4400-02A-920A-C|Issue No:002.00|Issue Date:2018-05-01

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

5A9305

Common Information

TASK 71-51-44-300-004 Ignition Supply Harness - Replace The Cable, Repair-004 (VRS1044)

Effectivity

FIG/ITEM

PART NO.

01-005

5A9305

01-005

6A5668

General

This TASK gives the procedure to replace an unserviceable cable in the ignition supply harness. It is not necessary to remove this cable length completely, only a specified length at each end. A new length of cable is then attached to the assembly with lacing.

To identify the consumable materials refer to the PCI.

Special tools are identified in the procedure by the tool primary number.

Repair Parts

FIG/ITEM

PART NO.

PART IDENT

QTY

03-848

5A9248

Marker

A/R

03-915

5A9215

Lacing tape (White)

A/R

03-916

5A9216

Lacing tape (Black)

A/R

04-015

5A9269

Contact, socket

A/R

04-035

5A9269

Contact, socket

A/R

04-055

5A9271

Contact, socket

A/R

04-075

5A9271

Contact, socket

A/R

04-095

5A9271

Contact, socket

A/R

04-115

5A9271

Contact, socket

A/R

04-475

5A9271

Contact, socket

A/R

04-487

5A9304

Contact, socket

A/R

04-488

5A9303

Contact, socket

A/R

04-535

5A9271

Contact, socket

A/R

04-548

5A9304

Contact, socket

A/R

04-548

5A9303

Contact, socket

A/R

04-595

5A9269

Contact, socket

A/R

04-615

5A9269

Contact, socket

A/R

04-635

5A9271

Contact, socket

A/R

04-655

5A9271

Contact, socket

A/R

04-889

5A9189

Knitmesh

A/R

04-894

5A9194

Cable

A/R

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Contact crimping toolLOCALContact crimping tool
Contact extraction/insertion toolLOCALContact extraction/insertion tool
Thermo stripperLOCALThermo stripper
IAE 3J12704 Wrench and holder0AM53IAE 3J127041 Off

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-146 LOCKWIRELOCALCoMat 02-146
CoMat 02-148 ADHESIVE TAPE (ELECTRICAL)LOCALCoMat 02-148
CoMat 06-069 MARKERIE207CoMat 06-069

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 71-51-44-350-091 Prepare the Harness Adjacent to the Electrical Connector/Receptacle

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

      1. Remove the safety wire, two screws and clamp bar.

      2. Carefully push the black rubber sleeve rearwards and remove only the cable tie(s) necessary to do this Repair.

      3. Make a mark on the cable to show the position of the clamp with CoMat 06-069 MARKER.

    2. SUBTASK 71-51-44-350-092 Disassemble the Backshell Assembly from the Electrical Connector/Receptacle

    1. Refer to Figure.

      2. Remove the backshell nut

      1. Install the electrical connector/receptacle assembly to the IAE 3J12704 Wrench and holder 1 off.

      2. Disconnect the backshell nut and move it rearwards along the cables.

      3. Remove the backshell

      1. Remove the upper ring, sleeve and split ring.

      2. Disconnect the backshell with the IAE 3J12704 Wrench and holder and move the backshell along the cables.

      3. Discard the knitmesh.

      4. Remove the electrical connector/receptacle from the IAE 3J12704 Wrench and holder.

    3. SUBTASK 71-51-44-350-093 Remove the Unserviceable Cable

      1. Identify the unserviceable cable

      1. Test the cable. Refer to Testing-001 TASK 71-51-44-750-301.

      2. Mark the cut back position on the unserviceable cable

      1. Make the mark 3.5 in. (90 mm) from the cable clamp position with CoMat 06-069 MARKER.

      3. Cut back the cable

      1. Cut the cable at the marked position.

    4. Install a heat shrink sleeve over each cut end to prevent the frettage of adjacent wires. Tie these cut ends to the loom with lacing tape.

    4. SUBTASK 71-51-44-350-094 Remove the Receptacle

    1. Refer to Figure.

      2. Remove the contact (previously attached to the unserviceable cable)

      1. Use the Contact extraction/insertion tool, remove the contact from the hole in the electrical connector/receptacle

    5. SUBTASK 71-51-44-350-095 Prepare the New Cable for Assembly

    1. Make sure the cable is of the correct type to replace the unserviceable cable.

    6. SUBTASK 71-51-44-350-096 Install the New Contact to the New Cable

      1. Remove the conductor insulation

      1. Use the Thermo stripper and remove 3 in. (76.2 mm) of the conductor insulation from the cable end. Refer to Figure.

        2. Install the new contact

        1. Put the new contact into the Contact crimping tool. Put the core lead into the contact and crimp it.

        3. Examine the core lead

        1. Do a visual examination of the core lead.

        2. Make sure the contact is correctly attached and crimped.

    7. SUBTASK 71-51-44-350-097 Assemble the Sheath to the Cable

    1. Refer to 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 unserviceable cable).

      3. Unknit the screen braid

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

      4. Temporarily attach the new cable to the loom

      5. Wrap the new knitmesh braid

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

      6. Install the backshell on the cable loom

      1. Turn and fold the unknit screen braid tails and temporarily tape the ends to the cables.

      2. Make sure the backshell, upper ring, washer and nut are installed on the cable loom.

    8. SUBTASK 71-51-44-350-098 Install the Contact into the Electrical Connector/Receptacle

      1. Install the contact

      1. Bend the core lead slightly to slide it into the insertion tool slot.

      2. 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 shoulder.

      3. Slowly press the contact and the tool into the insert hole by hand so they are vertical with the electrical connector/receptacle surface.

    9. SUBTASK 71-51-44-350-099 Install the Backshell to the Electrical Connector/Receptacle

    1. Refer to Figure.

      2. Install the backshell

      1. Install the electrical connector/receptacle assembly to the IAE 3J12704 Wrench and holder 1 off.

      2. Attach the backshell to the electrical connector/receptacle and tighten the nut by hand.

      3. 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.

      2. Attach and tighten the backshell nut to the backshell so the different parts hold the screen braid tails.

      3. Trim the tails and shrink the sleeve over them.

    10. SUBTASK 71-51-44-350-100 Finish the Harness Adjacent to the Electrical Connector/Receptacle and Install the Cable Ties

      1. Install the cable ties, black rubber sleeve and clamp bar adjacent to the electrical connector/receptacle. Attach the new cable to the outside of the harness.

      1. Use the applicable color lacing tape and lace the ties. The lacing positions are the same as the previous positions.

      2. Refer to VRS1043 (Repair-003) TASK 71-51-44-300-003.

      3. Push the black rubber sleeve forward so it packs the cables at the clamp bars.

      4. 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.

    11. SUBTASK 71-51-44-750-059 Test the Ignition Supply Harness Assembly

      1. Test the harness

      1. Refer to Testing-001 TASK 71-51-44-750-301.

    12. SUBTASK 71-51-44-550-056 Do the Harness Preservation Procedure

      1. Put the harness assembly in storage.

      1. Refer to Storage-001 TASK 71-51-44-550-301.

    13. Figure: Repair the Ignition Supply Harness

    Repair the Ignition Supply Harness

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the effectivity table to add part number 6A5668. (17VC589)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:IE207
Enterprise Name:DELETED, REFER TO 16956
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:IE207
Supply Number:CoMat 06-069
Type:sp01
Supply Short Name:CoMat 06-069 MARKER
Supply Name:CoMat 06-069 MARKER
Specification Groups:
Doc NumberType
OMAT:262TMARKS-A-LOT
JCR-085MARKS-A-LOT
Suppliers:
ManufacturerRemarks
IE207
Manufacturer Code:LOCAL
Tool Number:Contact crimping tool
Tool Name:Contact crimping tool
Manufacturer Code:LOCAL
Tool Number:Contact extraction/insertion tool
Tool Name:Contact extraction/insertion tool
Manufacturer Code:0AM53
Tool Number:IAE 3J12704
Tool Name:IAE 3J12704 Wrench and holder
Manufacturer Code:LOCAL
Tool Number:Thermo stripper
Tool Name:Thermo stripper