Replacement of The Terminal Lug Replacement [IAE]

TASK 70-71-26-960-801-A
Replacement of The Terminal Lug Replacement

1. Reason for the Job

This chapter gives the procedure for the replacement of a terminal lug. The length of the cables is insufficient to let you replace the terminal lug two times only. If it becomes necessary to replace the terminal lug a third time, disassemble the harness and replace the applicable cable. Refer to Chapter 70-71-24.
Standard equipment and consumable material can be replaced with equivalent items.

2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	CRIMPING TOOL 25-3085
No specific	1	MULTIMETER MODEL 160B
No specific	1	OHMMETER MODEL 260
No specific	AR	WARNING NOTICE(S)

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451AL, 452AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461AL, 462AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 71-13-00-010-010-A	Opening of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 71-13-00-410-010-A	Closing of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 78-30-00-040-012-A	Deactivation of the Thrust Reverser Hydraulic Control Unit (HCU) for Ground Maintenance
TASK 78-30-00-440-012-A	Re-activation of the Thrust Reverser Hydraulic Control Unit (HCU) after Ground Maintenance
TASK 78-32-00-010-010-A	Opening of the Thrust Reverser Halves
TASK 78-32-00-410-010-A	Closing of the Thrust Reverser Halves
Terminal Lug Replacement
Heat Tool

3. Job Set-up
Subtask 70-71-26-941-050-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) On the center pedestal, on the ENG panel 115VU:
(a) Put a WARNING NOTICE(S) in position to tell persons not to start the engine.
(2) Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do this procedure.
(3) On the maintenance panel 50VU:
(a) Make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) in position to tell persons not to energize the FADEC 1(2).

Subtask 70-71-26-010-050-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Open the fan cowls (Ref. AMM TASK 71-13-00-010-010)
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.

Subtask 70-71-26-040-050-A ** ON A/C NOT FOR ALL

C. Deactivate the thrust reverser.

WARNING: MAKE SURE THAT THE THRUST REVERSER HYDRAULIC CONTROL UNIT (HCU) IS DEACTIVATED BEFORE YOU DO WORK ON OR AROUND THE THRUST REVERSER. IF THE HCU IS NOT DEACTIVATED, THERE IS A RISK OF UNWANTED THRUST REVERSER OPERATION WHICH CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Deactivate the thrust reverser hydraulic control unit (HCU) (Ref. AMM TASK 78-30-00-040-012).

Subtask 70-71-26-010-051-A ** ON A/C NOT FOR ALL

D. Open the thrust reverser halves (Ref. AMM TASK 78-32-00-010-010):
(1) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(2) FOR [1000EM2] (ENGINE-2)
461AL 462AR.

4. Procedure
Subtask 70-71-26-020-050-A ** ON A/C NOT FOR ALL

A. Prepare the Cable End
(1) Cut the cable adjacent to the terminal lug and discard the terminal lug.
(a) Remove 0.39 in. (10 mm) of the outer installation sheath of the cable.
(b) Pull back the ground screen from the cable end.
(c) Remove 0.28 in. (7 mm) of the inner cable insulation sheath.
(d) Pull the ground screen over the cable inner conductors and twist together the screen and the inner conductors.
(2) Install the new terminal lug.
(a) Install the terminal lug on the cable end.
(b) Make sure that the terminal lug barrel is fully around the outer sheath of the cable.

WARNING: DO NOT USE ANY HEAT GUN IF THERE ARE FUEL OF FUEL VAPORS AS DETERMINED BY A COMBUSTIBLE INDICATOR. HEAT GUNS ARE A SOURCE OF COMBUSTION. FUEL OR FUEL VAPORS CAN CAUSE INURY OR DEATH TO THE PERSON. DO NOT USE ANY HEAT GUN ON AN AIRPLANE WHEN PASSENGERS ARE ABOARD, WHEN THE AIRPLANE IS IN THE AIRPORT TERMINAL AREA OR IN A HANGAR. DO NOT BREATHE THE FUMES RELEASED FROM THE HEAT SHRINK SLEEVE WHEN YOU DO THE SHRINKING PROCESS. THE FUMES CAN CAUSE INJURY TO THE PERSON. USE SUFFICIENT VENTILATION TO REMOVE FUMES RELEASED FROM THE HEAT SHRINK SLEEVE AND TO KEEP THE ENGINE COMPARTMENT AND SURROUNDING AREA FREE OF FUEL VAPORS.

(c) Crimp the terminal lug in place on the cable. Use CRIMPING TOOL 25-3085 or (Heat Tool Compressed Air and Nitrogen) HT900B or HT920B.

Subtask 70-71-26-750-050-A ** ON A/C NOT FOR ALL

B. Fuel Vapor Test
(1) Do a fuel vapor test and use a combustible gas indicator Model 160B or Model 260 or Model D-16 or Model M-6 or Model 2A or Model 40.

Subtask 70-71-26-420-050-A ** ON A/C NOT FOR ALL

C. Install the Heat Shrink Sleeve
(1) Cut a 0.78 in. (20 mm) length of the heat shrink sleeve.
(2) Install the heat shrink sleeve on the cable and the barrel of the terminal lug.
(3) Install the reflector on the heat tool (Compressed Air and Nitrogen) HT900B or HT920B.
(4) Set the heat tool to give air at a temperature of 620 deg.F (326.67 deg.C).
(5) Use the heat tool to heat-shrink the sleeve onto the cable and terminal lug barrel.

Subtask 70-71-26-720-050-A ** ON A/C NOT FOR ALL

D. Do a continuity test on the repaired circuit from the terminal lug to the connector contact. Use a MULTIMETER MODEL 160B or a OHMMETER MODEL 260, or equivalent.
(1) Each circuit must have continuity from one end of the wire to the other end of the wire.

5. Close-up
Subtask 70-71-26-410-050-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser halves (Ref. AMM TASK 78-32-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR.

Subtask 70-71-26-440-050-A ** ON A/C NOT FOR ALL

B. Activate the thrust reverser HCU (Ref. AMM TASK 78-30-00-440-012).

Subtask 70-71-26-410-051-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowls (Ref. AMM TASK 71-13-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 02:20:03 UTC