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G. Do the Cable Splice Repair.
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WARNING: DO NOT USE HEAT GUNS, SOLDERING GUNS, AND SOLDERING IRONS FOR
_______
THE ON-WING REPAIRS. THEY ARE NOT RESISTANT TO EXPLOSION AND
CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.
(1)
Remove the lacing tape and the harness clamps from the wire harness
to get sufficient access to the damaged cable.
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(2)
Cut, remove, and discard the damaged part of the cable from the wire harness.
NOTE: Repair one cable at a time.
____
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(3) Do these steps to prepare the two ends of the remaining engine cable (Fig. 801):
(a)
Clean the cable 12 inches (300 mm) from the ends.
(b)
Cut and remove the insulation jacket 6 inches (150 mm) from the end of the cable to show the braided shield.
(c)
Cut and remove the braided shield so that 0.75 inch (19 mm) of the shield shows.
(d)
Cut one wire 4 inches (100 mm) from the insulation jacket.
(e)
Cut the other wire 2 inches (50 mm) from the end of the first wire.
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(4)
Cut a piece of the replacement cable 12 inches (300 mm) longer than
the distance between the two ends of the remaining cable.
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(5)
Do the steps above to prepare one end of the replacement cable as
you did for the remaining engine cable.
NOTE: Align the insulation colors on the replacement cable wires
____ with the engine cable wires. Cut the wires such that the long engine wire aligns with the short replacement wire.
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(6) Do these steps to install the replacement cable:
(a)
Get the correct size inner and outer termination ferrules (Ref Consumable Materials).
(b)
Install one outer termination ferrule on each end of the cable. 1) Move the ferrules away from the splice area.
(c)
Cut a length of tubular braid to put on the splice area.
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////////////////////////A / PW4000 SERIES /747-400 / ENGINES /MAINTENANCE MANUAL ////////////////////////
BRAIDED SHIELD
INSULATION
CRIMPED WIRE SPLICE
Wire Splice
Figure 801
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C20075
(d)
With the tubular braid expanded, install it on one end of the cable. 1) Move the braid away from the splice area.
(e)
Install one inner termination ferrule on each end of the cable. 1) Move the ferrules away from the splice area.
(f) Make a splice on each of the wires as follows (Fig. 801): 1) Use the wire stripper to remove sufficient insulation to make it easy to put the conductor into the splice correctly.
2) Put the wires into each end of the wire splice to make an overlap.
NOTE: This is a parallel splice and not a butt splice.
____ The ends of the wires show at each end of the splice.
3) Use the correct crimp tool to attach the splice.
4) Pull on the splices to make sure they will not come off the wires.
5) Remove all the sharp edges from the splices.
NOTE: The splice will not have sharp edges if you install
____
it correctly.
6) Wind two layers of the red rubber tape (Moxness 620-3/4) directly around the splice with a 50% overlap on each turn of the tape (Fig. 802).
NOTE: Wind the second layer in the opposite direction
____ to the first layer. The tape wrap must be sufficiently tight to give a moisture-resistant seal.
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