DOC AIRBUS | AMM A320FSHIELDED WIRE REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
1. Shielded Wire Replacement Procedure
A. General
(1) This chapter gives the procedure for a shielded wire replacement on the power plant electrical wire harness. This does not include externally braided harnesses and IDG power cables.
(2) This is a group of words that is shown in this procedure.
(a) Harness - A single bundle of two or more branched group of bundles terminated by connectors or terminal lugs.
(b) Bundle - A group of cables tied together with lacing tape.
(c) Cable - A group of unterminated wires enclosed by a metal shield and insulated jacket.
(d) Wire - A single metallic strand that is insulated.
(3) Replace the repaired cables when the harness is removed or during the next shop visit of the engine.
(4) Standard equipment and consumable materials can be replaced with equivalent items.
(5) Refer to the AWL for the wire type, gauge, length, and Termination A to Termination B.
2. Standard Equipment
** ON A/C NOT FOR ALL | -----------------------------------------------------------------------------! |
| ! !Supplier! ! ! |
| ! Part No. ! Code ! Nomenclature ! Application ! |
| !------------- -!--------!------------------------!--------------------------! |
| ! ! ! ! ! |
| ! BT-BS-611 ! 11851 ! Strap Wrench ! Removal and Installation ! |
| ! TG-70 ! 11851 ! Strap Wrench ! of the backshells ! |
| ! 600-400 ! 06324 ! Torque Wrench ! ! |
| ! ! 11851 ! ! ! |
| ! ! ! ! ! |
| ! M81969/8-05 ! 11851 ! Insertion Tool 20 ga. ! Removal and Insertion of ! |
| ! M81969/8-06 ! 11851 ! Removal Tool 20 ga. ! the contacts ! |
| ! M81969/14/02 ! F0225 ! Removal and Insertion ! ! |
| ! ! 11851 ! Tool 16 ga. ! ! |
| ! ! 14283 ! ! ! |
| ! ! 49367 ! ! ! |
| ! ! ! ! ! |
| ! M81969/14/03 ! F0225 ! Removal and Insertion ! Removal and Insertion of ! |
| ! ! 11851 ! Tool 20 ga. ! the contacts ! |
| ! ! 14283 ! ! ! |
| ! ! 49367 ! ! ! |
| ! MS27495A16 ! 11851 ! Insertion Tool 16 ga. ! Removal and Insertion of ! |
| ! MS27495A20 ! 11851 ! Insertion Tool 20 ga. ! the contacts ! |
| ! MS27495R16 ! 11851 ! Removal Tool 16 ga. ! ! |
| ! MS27495R20 ! 11851 ! Removal Tool 20 ga. ! ! |
| ! ! ! ! ! |
| ! 45092 ! 30119 ! Strip Master Wire ! Manually remove the ! |
| ! ! ! Stripper 16 thru 20 ga.! insulation from the ! |
| ! ! ! ! cable and wire ! |
| ! ! ! ! ! |
| ! M22520/1-01 ! 11851 ! Crimp Tool Frame ! Crimp the contacts to ! |
| ! ! 58164 ! ! wires ! |
| ! M22520/1-02 ! 11851 ! Crimp Tool Locator, ! Crimp the contacts to ! |
| ! ! 58164 ! 16 ga. ! wires ! |
| ! M22520/1-04 ! 11851 ! Crimp Tool Locator, ! ! |
| ! ! 58164 ! 20 ga. ! ! |
| ! ! ! ! ! |
| ! Model 160B ! 80164 ! Digital Multimeter ! Use to measure ! |
| ! Model 260 ! 16902 ! Ohmmeter ! continuity and point-to- ! |
| ! ! ! ! point circuits ! |
| ! ! ! ! ! |
| ! Model 1863 ! 24655 ! Megohmmeter ! Use to measure ! |
| ! ! ! ! insulation resistance ! |
| ! ! ! ! ! |
| ! HT210-16 ! 11851 ! Retention Test Tool ! Use to test the 16 ga. ! |
| ! 67-016-02 ! 11851 ! Replacement Pin Tip ! contact retention ! |
| ! 68-016-01 ! 11851 ! Replacement Socket Tip ! ! |
| ! ! ! ! ! |
| ! HT210-20 ! 11851 ! Retention Test Tool ! Use to test the 20 ga. ! |
| ! 67-020-02 ! 11851 ! Replacement Pin Tip ! contact retention. ! |
| ! 68-020-01 ! 11851 ! Replacement Socket Tip ! ! |
| ! ! ! ! ! |
| !_______________!________!________________________!__________________________! |
3. Consumable Material
** ON A/C NOT FOR ALL | _________________________________________________________ |
| ! ! Supplier ! ! |
| ! Part No. ! Code ! Designation ! |
| !________________________!__________!_____________________! |
| ! ! ! ! |
| ! Scotch No. 361 ! 04963 ! Tape, glass cloth. ! |
| ! 20-90426-13 ! 0ABG9 ! Braid, Knit mesh. ! |
| !________________________!__________!_____________________! |
4. Shielded Wire Replacement
A. Procedure
(1) You can replace a damaged or an open circuit cable with a new unshielded or shielded cable that you can put along the outer edge of the harness assembly. This can be used to replace a 2-wire and 3-wire cable.
(2) Refer to the AWL for the correct repair wire gauge, length, and type.
(3) Install the new cable.
(a) Put one end of the new wire so it extends up to 152.4 mm (6 in.) more than the end of the connector.
(b) Tape the wire to the connector.
(c) Put the wire along the outer edge of the harness assembly to the connector at the other end of the damaged wire.
(d) Extend the wire up to 152.4 mm (6 in.) more than the end of the connector and cut the wire.
(e) Apply a small piece of tape to the wire at each end. Write on the tape the connector contact number of the wire to be replaced.
(f) Install the new cable in all the clamps which holds the harness to the engine. If the clamp will not hold the new wire, tie the new wire to the harness assembly with lacing tape.
(4) Disconnect the two harness connectors that contain the damaged wire
Backshell Removal.(a) Remove the lockwire from the shell, strain relief clamp and coupling nut, and the two screws.
(b) Remove or loosen the screws from the strain relief clamp and coupling nut.
(c) Remove the strain relief clamp and coupling nut from the backshell with a PN BT-BS-611 or TG-70 Strap Wrench.
(d) Move the strain relief clamp and coupling nut to the rear over the cables. If applicable, remove the glass cloth tape under the strain relief clamp.
(e) Refer to figure for the correct backshell application.
(f) Move the grounding ferrule or the washer, ring, split ring, and tube to the rear over the cables enough to permit the shell to be removed.
(g) Make a mark on the connector backshell in relation to the connector master keyway if the backshell is other than a straight type.
(h) Remove the coupling nut from the connector with a strap wrench. Move the shell to the rear over the cables.
(a) Use the applicable contact removal tool that is listed in the standard equipment for the correct contact gage.
NOTE: All the power plant connector contacts (pin/sockets) are released from the rear of the connector.
(b) Remove the contact (pin/socket) as follows:
1 Place the contact removal tool on the wire.
2 Move the tool back on the wire while you hold against the wire at the connector opening. The wire will move into the slot of the tool.
3 Push the tool along the wire into the rear of the connector until it touches the bottom of the connector.
NOTE: When the tool touches the bottom of the connector it will expand the collet from the contact to permit the contact to be released from the connector.
4 While you keep light pressure on the tool, hold the wire against the serrated shoulder of the tool and remove both the wired contact and tool.
5 Do steps 1_ thru 4_ until you remove the contact from the other connector.
(7) Put the new wire into and through the backshell detail parts.
(8) If applicable, unwrap the knit mesh braid strip as necessary to install the new wire under the knit mesh. Wrap the cable with the PN 20-90426-13 Mesh Braid Strip by the figure.
(9) Cut the new wire egual with the damaged wire length and the braided shield length.
(10) Cut the contacts from the two ends of the damaged cable. Cut the old cable so that the ends of the cable are outside of the first cable clamps.
(11) Strip the wire insulation 7. mm (0.276 in.) from the end of the new wire with a PN 45092 Mechanical Wire Stripper.
NOTE: When the 20 gage wire is used in a size 16 gage contact crimp barrel, filler wire must be inserted along with the 20 gage wire conductor. Use enough filler wire to make sure you have a correct pull test when the barrel is crimped.
(a) Use the applicable crimp tool frame and locator given in the standard equipment for the correct wire gage.
NOTE: Refer to AWL Engine Equipment List for connectors and backshell part numbers and ATA 92-20 for pin numbers equipment list. Refer to Chapter 70-71-12 for the connector contact/insert configuration.
(b) Install the crimp tool positioner to the crimp tool frame as follows:
1 Remove the lock clip from the lock ring on the positioner.
2 Use the correct positioner which agrees with the contact gage size to be crimped.
3 Put the positioner on the tool frame lock plate with the positioner pins aligned with the lockplate ring slots.
4 Push the positioner into the tool frame and turn the positioner 90 degrees in a clockwise direction until you get a positive lock.
5 Install the lock clip to the positioner lock ring.
(c) Crimp the contact to the wire as follows:
1 Raise and turn the tool frame selector knob until the number of the knob agrees with the number on the positioner's data plate for the correct wire size. Align the number on the knob to the index mark on the tool frame and release the knob.
| CAUTION: IF THE TOOL FRAME SELECTOR KNOB IS PUT IN THE WRONG POSITION, DAMAGE |
| TO THE CONTACT AND WIRE CAN OCCUR. ALSO THE CONTACT CAN BE LOOSELY |
| CRIMPED ON THE WIRE. |
2 Examine the wire to make sure the wire strands are not separated. Carefully twist the wire strands in their normal direction of twist to fit the contact wire hole.
3 Install the stripped end of the wire into the contact wire hole.
4 Push the wire into the contact wire hole until you feel it touch the bottom.
NOTE: If the wire was incorrectly stripped, the wire will not touch the bottom of the crimp barrel or there will be too much bare wire at the rear shoulder of the barrel.
5 Install the contact and stripped wire end through the tool frame hole and into the positioner hole.
6 Squeeze the tool frame handles together until the ratchet releases.
NOTE: If too much or too little force is needed to squeeze the tool frame handles together, the contact is not crimped correctly.
Look at the crimp tool for the correct postion for the wire and contact size.
You cannot open the tool frame until the full crimp is completed.
Look at the crimp tool for the correct postion for the wire and contact size.
You cannot open the tool frame until the full crimp is completed.
7 Remove the crimped contact.
8 Do steps 1_ thru 7_ until you crimp the contact on the other end of the wire.
(13) Contact continuity test.
(a) Do a continuity test on the replaced harness assembly contacts from point-to-point. Use a Model 160B Digital Multimeter or a Model 260 Ohmmeter or equivalent.
NOTE: The detailed wiring data from Termination A to Termination B is found in the AWL 92-20 Hook-Up Lists/Plugs and Receptacles.
(b) Each circuit must have continuity from Termination A to Termination B on each contact.
(a) Make sure the backshell detail parts were not removed from the cable assembly.
(b) If the detail parts were removed, install the parts on the cable assembly by the applicable illustration.
NOTE: The backshell detail parts cannot be installed on the connector after the contacts are installed in the connector.
(c) Use the applicable contact insertion tool given in the standard equipment for the correct contact gage.
(d) Move the backshell detail parts to the rear over the cable assembly to permit the contacts to be inserted in the connector.
1 Put the wire between the slot and squeeze the wire into the slot at the tool tip. Make sure the wire is in the slot at the tool tip.
2 Pull the wire back through the tool until the tip seats on the rear shoulder of the crimp contact.
1 Hold the connector in your hand.
| CAUTION : IF TOO MUCH PRESSURE IS USED WHEN YOU INSTALL THE CONTACT INTO THE |
| CONNECTOR, DAMAGE TO THE CONNECTOR COLLET TINES CAN OCCUR. |
2 Install the wired contact into the cavity at the rear of the connector with a strong and equal pressure.
3 When the contact is properly locked in the connector, a light click sound can be heard.
NOTE: The click sound is made by the tines on the collet as they lock in position behind the contact shoulder. This locks the contact in the connector collet.
4 Lightly pull back on the wire to feel if the contact is locked in the collet.
5 Remove the tool.
6 Do steps 1_ thru 5_ to install the contact in the other connector.
(15) Contact retention test.
(a) Do a test on each contact to make sure it has a retention force of 7 to 13 lbs (31.1 to 57.8N).
| CAUTION : EXERCICE CARE WHEN TESTING CONTACTS TO PREVENT DAMAGE TO THE CONTACT, |
| CONNECTOR GROMMET OR RETENTION TEST TOOL. |
(b) Use the applicable retention test tools and replacement pin and socket tools that are listed in the standard equipment for the correct contact gage.
(c) Put the 16 or 20 gage retention test tool and replacement tip on the contact so they are in a straight line.
1 Use the pin replacement tips when you do a test of the socket contacts.
2 Use the socket replacement tips when you do a test of the pin contacts.
(d) Hold this position when you do a test on each contact. This will give the most accurate retention force reading.
(e) With the retention test tool in position on the contact do the test that follows:
1 Apply pressure on the tool until a minimum of half of the color-coded area is covered.
2 At this point, 10 lbs (44.5 N) pressure has been applied.
3 If the contact is still firmly held in the same position, the contact retention is satisfactory.
(f) Do steps (a) thru (e) to test the other contact.
(a) Refer to figure for the correct backshell application.
(b) Move the coupling nut and shell forward over the cables.
(c) Align the mark you made before on the backshell with the connector master keyway.
NOTE: The mark on the connector backshell correctly aligns the connector and the backshell when you install the harness on the engine.
(d) Install the coupling nut to the connector and tighten with a PN BT-BS111 or TG-70 Strap Wrench.
(e) Move the grounding ferrule or the tube, split ring, and washer forward over the cables and into the shell. Make sure the knit mesh strip goes outside the tube and split ring, but under the ring, washer and strain relief clamp and coupling nut. Make sure the wire braid is held under the grounding ferrule.
(f) Move the strain relief clamp and coupling nut forward over the cables to the shell.
(g) Install the coupling nut on the shell.
(h) If applicable, wrap a piece of Scotch No. 361 Tape around the cable under the strain relief clamp and coupling nut.
(i) Torque the coupling nut to 10 lbf.in. (1.13 Nm) with a strap wrench and a PN 600-400 Torque Wrench.
(j) Make sure all of the twists and bends are out of the cable.
(k) Wrap the cable under the strain relief clamp with PN Scotch No. 361 Tape for the correct build-up under the clamp.
(l) Tighten the two screws on the clamp.
(m) Torque the two screws 10 to 20 lbf.in. (1.13 to 2.26 Nm).
(17) Backshell continuity test.
(a) Do a continuity test on the backshell to the connector and the backshell to the shield termination point. Use a Model 160B Digital Multimeter or equivalent.
(b) The resistance must be no more than 0.01 ohm.
(18) Do an insulation resistance test on all the repaired circuits. Use Model 1863 Megohmmeter or equivalent.
| CAUTION : YOU MUST DISCONNECT ALL THE CONNECTORS WHICH HAVE A RELATION TO THE |
| CIRCUITS IN THE CONNECTOR THAT IS TESTED. FAILURE TO DO THIS WILL |
| CAUSE UNSATISFACTORY RESISTANCE INDICATIONS AND POSSIBLE DAMAGE TO |
| THE CIRCUITS. |
(a) Do the insulation resistance test between each pair of wires that have been repaired.
(b) Set the megohmmeter to the 100 volt DC scale.
(c) Connect one test lead of the megohmmeter to the contact (pin or socket) of one of the repaired wires. Connect the other test lead to the contact (pin or socket) of the other repaired wire.
(d) The resistance should be infinity.
(e) Do the insulation resistance test between each repaired wire and the braided shield.
(f) The resistance must be a minimum of 20 megohms.
(g) Do the insulation resistance test between each repaired wire and the backshell.
(h) Set the megohmmeter to the 500 volt DC scale.
(i) Connect one test lead of the megohmmeter to the backshell body of the connector. Connect the other test lead to the contact (pin or socket) of the connector.
(j) The resistance must be a minimum of 20 megohms.
(19) Lockwire the backshell by the procedure given in Chapter 20-71-13.
(20) Replace the wire harness lacing that was removed by the procedure given in Chapter 70-71-14.