Installation of the Ignition Cables [PW11]

TASK 74-21-61-400-802-A
Installation of the Ignition Cables

WARNING: USE NECESSARY PRECAUTIONS WHEN YOU DO WORK ON THE ENGINE IGNITION SYSTEM. THIS SYSTEM HAS HIGH ENERGY AND CAN CAUSE INJURY OR DEATH BY ELECTRICAL SHOCK.

WARNING: BEFORE YOU REMOVE/INSTALL IGNITION COMPONENTS:

WAIT FOR SOME MINUTES AFTER THE IGNITION SYSTEM IS USED
MAKE SURE THAT THE ENG/MODE SELECTOR SWITCH IS IN THE NORM POSITION.

AFTER YOU REMOVE THE IGNITER LEAD FROM THE IGNITER PLUG, IMMEDIATELY PUT THE IGNITION LEAD TERMINAL IN CONTACT WITH A GOOD GROUND TO LET ALL OF THE ELECTRICAL ENERGY OUT OF THE SYSTEM. THE IGNITION SYSTEM VOLTAGE IS VERY HIGH. IF YOU DO NOT OBEY THESE INSTRUCTIONS, INJURY OR DEATH CAN OCCUR.

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: IGNITION SYSTEM VOLTAGE IS DANGEROUSLY HIGH. THE IGNITION SWITCH MUST BE IN THE "OFF" POSITION BEFORE REMOVING OR INSTALLING ANY IGNITION COMPONENTS. AFTER DISCONNECTING CABLE FROM IGNITER PLUG, DISCHARGE CURRENT BY GROUNDING IGNITION CABLE TERMINAL TO ENSURE COMPLETE DISSIPATION OF ENERGY FROM THE SYSTEM. FAILURE TO FOLLOW THIS PROCEDURE COULD RESULT IN SEVERE INJURY TO PERSONNEL.

ZONE: 400
FIN: 4038JH ** ON A/C NOT FOR ALL
FIN: 4039JH ** ON A/C NOT FOR ALL

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	Torque wrench: range to between 160 and 140 lbf.in (1.81 and 1.58 m.daN )
No specific	Torque wrench: range to between 250 and 225 lbf.in (2.83 and 2.54 m.daN )

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 72-21-11-400-801-A	Installation of the Lower BiFi
TASK 74-00-00-710-802-A	Operational Test of the Ignition System with the CFDS
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
Installation of the Ignition Cables

3. Job Set-up
Subtask 74-21-61-941-056-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).

Subtask 74-21-61-865-054-A ** ON A/C NOT FOR ALL

B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	ENGINE/1 AND 2/IGN/SYS A	1JH	A03
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENG 1)
121VU	ENGINE/IGN/ENG1/SYS B	3JH1	P41
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENG 2)
121VU	ENGINE/IGN/ENG2/SYS B	3JH2	P42

Subtask 74-21-61-010-056-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR

Subtask 74-21-61-040-053-A ** ON A/C NOT FOR ALL

D. Deactivation of the Thrust Reverser for Ground Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Make sure that you did the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 74-21-61-010-057-A ** ON A/C NOT FOR ALL

E. Get Access
(1) Make sure that the thrust reverser cowl-doors are open (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR

4. Procedure
Subtask 74-21-61-420-051-A ** ON A/C NOT FOR ALL

A. Installation of the Ignition Cables

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

(1) Removal of the protection covers:

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Make sure that you remove all the necessary COVER - PROTECTION to prevent damage to the engine.
(2) Rout the ignition cables (1) along the engine. See the sheet 1, sheet 2 and sheet 3 of the figure.
(3) Look to see if SB C-74-00-0001A has been incorporated before you perform the maintenance steps below.

NOTE: This Service Bulletin changes the igniter to exciter plug cable routing at the igniter plug end so that the igniter plug (upper) will be connected to ignition system B and the igniter plug (lower) will be connected to ignition system A.

(4) If the Service Bulletin is used, the cables should be routed per the Service Bulletin.

NOTE: The figures in this procedure show the pre Service Bulletin configuration.

(5) Install the ignition cable (1) as follows:

CAUTION: DO NOT BEND OR TWIST THE IGNITION CABLES. INSTALL THE CABLE ENDS STRAIGHT INTO THE IGNITER PLUG RECEPTACLES. IF NECESSARY, UNCLIP THE IGNTION CABLE FROM THE SPRING CLIPS TO REMOVE TENSION FROM THE CABLE. IF YOU DO NOT OBEY THIS CAUTION, YOU CAN CAUSE DAMAGE TO THE CABLE ENDS AND/OR IGNITER PLUG CERAMIC.

CAUTION: USE A SECOND WRENCH TO HOLD THE MATING PARTS WHEN YOU LOOSEN OR TIGHTEN THE TUBE OR HOSE NUTS. IF YOU DO NOT OBEY THIS CAUTION, YOU CAN TWIST OR CAUSE DAMAGE TO THE TUBES OR HOSES.

(a) Connect the ignition cable nut to the igniter plug.
(b) TORQUE the ignition cable (1) nut to between 250 and 225 lbf.in (2.83 and 2.54 m.daN )

.
(c) Connect the ignition cable nut to the ignition exciter.
(d) TORQUE the ignition cable (1) nut to between 160 and 140 lbf.in (1.81 and 1.58 m.daN )

.
(6) Install the ignition cables (1) to the lower BiFi (Ref. AMM TASK 72-21-11-400-801).
(7) Engage the ignition cable (1) into the spring clips as follows. See the sheet 6 of the figure.
(a) Start at the middle of the ignition cable (1).
(b) Press the ignition cable (1) into the spring clips.
(c) Make sure that all the spring clips are engaged with the ignition cable (1).
(d) Make sure that the tension in the ignition cable (1) is sufficient to prevent loose or tight conditions.
(8) Examine the assembly for foreign objects, damage and correct assembly.

5. Close-up
Subtask 74-21-61-860-054-A ** ON A/C NOT FOR ALL

A. Put the aircraft back to its initial configuration.
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR

Subtask 74-21-61-440-051-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 74-21-61-410-050-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR
(2) Remove the WARNING NOTICE(S).

Subtask 74-21-61-865-055-A ** ON A/C NOT FOR ALL

D. Remove the safety clip(s) and tag(s) and close this (these) circuit breaker(s) (circuit breaker(s) with orange extension caps) :

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	ENGINE/1 AND 2/IGN/SYS A	1JH	A03
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENG 1)
121VU	ENGINE/IGN/ENG1/SYS B	3JH1	P41
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENG 2)
121VU	ENGINE/IGN/ENG2/SYS B	3JH2	P42

Subtask 74-21-61-720-051-A ** ON A/C NOT FOR ALL

E. Tests
(1) Do the operational test of the ignition system (Ref. AMM TASK 74-00-00-710-802).

[Rev.10 from 2021] 2026.04.01 13:02:02 UTC