TEMPORARY REVISION MM-TR-MDC-E4-439a · co cover. The wiring harness branch which runs to the gearbox side of the engine, has to be placed in parallel to the high pressure rail and

Maintenance Manual

E4 Series

E4.08.04 MM-TR-MDC-E4-439a

Issue Date: 10.Dec.2018 Electrical Harness COVERPAGE

TEMPORARY REVISION

MM-TR-MDC-E4-439a supersedes MM-TR-MDC-E4-439

Electrical Harness

This Temporary Revision MM-TR-MDC-E4-439a is approved in conjunction with the Design Change Advisory MDC-E4-439a and is valid in conjunction with the latest revision of the Maintenance Manual (MM) until this Temporary Revision has been incorporated into the MM. The limitations and information contained herein either supplement or, in the case of conflict, override those in the MM. The technical information contained in this document has been approved under the authority of DOA ref. EASA.21.J.399

Doc. Nr. Affected Section(s) Affected Page(s)

E4.08.04 71

28a

29a 30a-c

31a-c 32a-b

34a

35a-d 36a-b

37a 38a

39a

40a 41a

42a 43a

44a 45a

46a

Instruction:

- Print this document on yellow paper (single-sided)

- Insert this cover page as the first page of the MM

- Insert the other pages of this Temporary Revision adjacent to or in front of the corresponding MM pages

Maintenance Manual

E4 Series

E4.08.04 MM-TR-MDC-E4-439a

Issue Date: 10.Dec.2018 Electrical Harness 71-28a

71-50-140 Description Plug Connector Wiring Harness

This section is amended to read:

Connector Abbr.

Description English Description German

FPS Fuel Pressure Sensor Kraftstoffdrucksensor

RPS Rail Pressure Sensor Raildrucksensor

MOK Oil Combination Sensor Temperature/ Oil Level

Kombinierter Ölsensor Temperatur/ Ölstand

BPS1 Boost Pressure Sensor 1 Ladedrucksensor 1

BPS2 Boost Pressure Sensor 2 Ladedrucksensor 2

OPS Oil Pressure Sensor Öldrucksensor

IAT 1 Intake Air Temperature 1 Ladelufttemperatursensor 1

IAT 2 Intake Air Temperature 2 Ladelufttemperatursensor 2

CTS Coolant Temperature Sensor Kühlwassertemperatur

GBTS Gearbox Temperatur Sensor Getriebetemperatursensor

CTS_GPC GPC Coolant Temperature Kühlwassertemperatursensor GPC

FTS Fuel Temperature Sensor Kraftstofftemperatursensor

CAS 1 Camshaft Sensor 1 Nockenwellensensor 1 X)

CAS 2 Camshaft Sensor 2 Nockenwellensensor 2

ECU A ECU A Connector ECU A Stecker

ECU PWR ECU Power Connector ECU Power Stecker

ECU B ECU B Connector ECU B Stecker

GEN Alternator Excatation Generator Erreger Leitung

GPC GPC Connector GPC Stecker

CRS 1 Crankshaft Sensor 1 Kurbelwellensensor 1

CRS 2 Crankshaft Sensor 2 Kurbelwellensensor 2

GOV Governor Actuator Governor

GPC Glow Plug Control Glühsteurergerät

GP 1 Glow Plug 1 Glühkerze 1




W11 / 1 Ground Connection GPC Masse Verbindung für GPC

W11 / 2 Ground Connection Governor Masse Verbindung für Governor

X1/1 CPC 1 A/C Interface 1 CPC 1 Zellenanbindung

X1/2 CPC 2 A/C Interface 2 CPC 2 Zellenanbindung

BPA Boost Pressure Actuator Ladedrucksteller Elektrisch Pneumatischer Wandler (EPW)

PCV Pressure Control Valve Druckregelventil High Pressure Rail

INJ 1 Fuel Injector 1 Kraftstoff Injektor 1 X)




FMU Fuel Metering Unit Zumesseinheit

X) This sensor and the injector can only be checked all 300h if the Injector cover is removed.

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71-50-150 Material and saving material for the E4A/E4B Engine Wiring Harness

This section is amended to read:

Pos Teilenummer Bezeichnung St Drehmoment in Nm Werkzeug Sicherung

01 E4A-95-000-000 (for E4A engines)/ E4B-95-000-000 (for all other engines)

LU Kabelbaum 1

02 DIN3016-W1-DM28-20

Schelle 28 1

03 DIN3016-W1-DM 22x15

Schelle 22 2

04 DIN3016-W3-DM 8x15

Schelle 8 1

05 PLT4S-M30 Kabelbinder 25

06 E4A-90-100-808 Edge Clip 2

07 E4A-90-100-809 Edge Clip 4

08 50266513 Edge Clip 3

09 E4A-90-100-801 Schraube 1 5

10 E4A-95-100-000 Assy Shielding Fuel Pressure 1

71-50-160 [removed]

Maintenance Manual

E4 Series

E4.08.04 MM-TR-MDC-E4-439a


71-50-170 E4 Engine Wiring Harness mounting instruction

This page is amended to read:

Before the harness is mounted on the engine block, read chapter 71-50-03.

Harness routing overview

The main fixation point of the harness is realized with a rubberized metal clamp. This clamp is located on the belt drive side and connected to the cylinder head. Additional rubberized metal clamps and cable

ties are used to mount the wiring harness on the engine. After the main fixation clamp, the harness is divided into several branches.

One of this branch is bent by appr. 90° degrees and routed in the direction of the turbo charger and

connects the BPA, CAS2, RPS. The other branches are bent by appr. 90° degrees and routed in parallel to the cylinder head. The injector branch is routed beneath the injector cover to the Injectors and CAS1.

One of the branches is routed to the intake manifold and connects the related sensors. The thickest branch which is running to the gearbox side of the engine, is routed along the high pressure rail to

reach the sensors and actuators on the high pressure pump and further, with a bent, to the GPC,

alternator and sensors mounted on the engine block. Cable ties are used for bundling the branches and fixation on the engine. The installer is responsible for

the routing of the aircraft interface side of the harness (CPC- and EECU-Connector).

The installation material for the wiring harness is referenced with the numbers according to the table in chapter 71-50-150.

Maintenance Manual

E4 Series

E4.08.04 MM-TR-MDC-E4-439a

Issue Date: 10.Dec.2018 Electrical Harness 71-30b

Harness routing detailed

On the following pages the mounting of the engine wiring harness is described in detail. Unless otherwise described the mounting instruction is identical for all versions of E4 engine wiring harness.

Harness installation starts with harness fixation on the main clamp see Figure 71-34b. The harness is then bent by 90° degrees and runs in parallel to the cylinder head / rail.

To ensure an adequate distance between the wiring harness and the cylinder head to avoid cafing of

the wiring harness in this area, the wiring harness provides red markings as an installation aid.

These markings are realized with a red tape and indicate the optimal fixation points of the harness in

this area.

Figure 71-34a

Maintenance Manual

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Issue Date: 10.Dec.2018 Electrical Harness 71-30c

) Position A (Main Clamp) -> red tape wrapped over the three common routed wiring harnesses ) Position B (High pressure Rail)-> red tape wrapped over the single wiring harness routed parallel the

rail. (see Figure 71-36)

Position A (Main clamp):

This position indicates the area on the harness where the main cable clamp must be mounted. As an general guidline the angle of the clamp shall be parallel to the fins of the engine head (see Figure

71-34b). The main clamp is bolted with the mounting screw of the lifting eyelet (Torque 12 Nm). Additional, the

pig tail from the rail pressure sensor, is also mounted with this screw. (see Figure 71-35)

Figure 71-34b

The red marking of the harness should be fully covered by the cable clamp. If the red marking is clearly visible caused by a shifted wiring harness, the position of the harness must be corrected to ensure

enough space between harness and cylinder head. The different harness branches are divided as shown in Figure 71-35.

Position A Clamp

Engine Head Fin

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Figure 71-35

Position B (Rail): After the mounting of the main clamp the wiring harness is bent by 90° degree and is mounted parallel

to the high pressure rail in that way that the second red marking is placed at the end of the high pressure rail (Area of high pressure rail / rail pressure sensor). With a cable tie, the wiring harness must

be fixed on the rail. (see Figure 71-36 Pos B)

Figure 71-36

RPS

A B

No. [02]

RPS

Pigtail RPS

Lifting Eyelet

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Connection for BPA, CAS2 and RPS are on the belt drive side of the engine.

The branch of CAS2 wire has to be placed as shown at Figure 71-36a. Pigtail of CAS2 and BPA has to be connected to the CAS2 mounting screw (Torque 12 Nm), as shown at Figure 71-36a.

Make sure that the clearance between the harness and the turbocharger is more than 25mm.

Figure 71-36a

The branch of EPW and CAS2 has to be fixed with edge clip No. [06] and cable tie [05] to the BPA bracket (see Figure 71-36b). BPA filter has to be fixed with a cable tie No. [05] (see Figure 71-36b).

Only the connector adapter (of BPA filter) is allowed to be used for fixation with the cable tie.

Constriction of the BPA hose is not allowed.

Pigtail CAS 2

Pigtail BPA

CAS 2 Branch

BPA Branch

CAS 2 mounting screw

min 25mm distance

Maintenance Manual

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E4.08.04 MM-TR-MDC-E4-439a


Figure 71-36b

Fix the BPA branch with a cable tie No.[05] on the BPA connector housing as shown in Figure 71-36c.

Figure 71-36c

Edgeclip No.[06] 2x Cable tie No.[05]

Cable Tie No. [05]

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Ensure sufficient space between the wiring harness and the cylinder head as shown in

Figure 71-37 and Figure 71-38 to avoid chafing of the engine harness.

Figure 71-37

Figure 71-38

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The wiring harness branch for the injectors has to be placed above the injector pipes (see Figure 71-39). CAS1 pigtail has to be connected to the fastening screw of CAS1 (Torque 10 Nm). Use Loctite 243

for securing the screw. Refer chapter 76-00-40 for details of sensor fixation.

The wiring harness branches for the injectors has to be fixed with cable ties No.[05] in the near of

injector plugs.

Figure 71-39

After installing the injector cover, ensure that the wiring harness is not chafing on the

co cover.

The wiring harness branch which runs to the gearbox side of the engine, has to be placed in parallel to the high pressure rail and fixed with 3 cable ties No. [05] as shown in Figure 71-43.

It has to be ensured that the branches and cable ties do not constrain the mounting of the injector cover.

No.[05]

CAS1

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Figure 71-43

Rail

No.[05]

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This page is amended to read: For E4-A engines: use the screw of BPS2 (Torque: 5 Nm) to connect the combined pigtails of IAT1 &

BPS1 and IAT2 & BPS2.

For all other engines: use the screw BPS1 (Torque: 5 Nm) to connect the combined pigtails of BPS1 &

IAT1 and use the screw BPS2 (Torque: 5 Nm) to connect the combined pigtails of BPS2 & IAT2.

Figure 71-44 For E4-A engines Figure 71-45 For all other engines

Pigtails BPS1 & IAT2 Pigtails BPS2 & IAT2 Pigtails BPS1 & IAT2 Pigtails BPS2 & IAT2

Maintenance Manual

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E4.08.04 MM-TR-MDC-E4-439a


The cable branch, for IAT1 and IAT2 Sensors, shall be fixed with cable tie on the connector of the according sensor as shown in Figure 71-45a.

Figure 71-45a

The branch for the glow plugs shall be placed behind the thermostat as shown in Figure 71-45b and

Figure 71-45c.

Figure 71-45b

Cable Tie No.[05]

Glow Plug Branch

Maintenance Manual

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E4.08.04 MM-TR-MDC-E4-439a


Figure 71-45c

Sensor and actuator connections on the gearbox side of the engine are shown in Figure 71-46.

It has to be insured that the engine wiring branch has to be placed as shown at Figure 71-46. Avoid unnecessary crossing of the single cable branches! Cable branches shall run as long as possible

parallel to each other. Use cable ties to bundle the single cable branches. Wires shall not be outside of the green marked area as shown in Figure 71-46 to avoid any conflict with other customer installation.

Figure 71-46

Glow Plug Branch

Maintenance Manual

E4 Series

E4.08.04 MM-TR-MDC-E4-439a

Issue Date: 10.Dec.2018 Electrical Harness 71-35d

The engine harness has to be fixed with a clamp No. [03] to the EGR cover on the engine block (Torque 9 Nm) see Figure 71-46a. The bending radius before the clamp shall not be harsh.

Figure 71-46a

The rest of the branch, located in the area beneth the intake manifold, are fixed after starter, gearbox

and GPC are mounted.

Figure 71-46b

The next pictures describe the routing of the harness on the gearbox side of the engine, in more detail.

Coolant temperature cable branch shall be bundled with cable tie directly to CTS connector as shown at Figure 71-46c.

EGR Cover

No.[03]

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Figure 71-46c

The pigtails of FTS and PCV have to be screwed with the bolt mounted on the cylinder head (Torque 12 Nm) as shown at Figure 71-47.

Figure 71-47

Cable Tie No.[05]

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The pigtails of FMU and CTS have to be bolted with the mounting screw of the lifting eyelet. (Torque 12 Nm) see (Figure 71-48)

Figure 71-48

Maintenance Manual

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Fuel pressure sensor and the fuel pressure sensor cable have to be equipped with an additional shielding as shown in Figure 71-49. Therefore cover the fuel pressure sensor and fuel pressure sensor cable with

a netting, with the length of appr. 180 mm. At each end of the netting a cable tie is used to fix the

netting. At each end of the netting a tape should be used to avoid splicing of the netting. Netting, tape and cable ties are included in Kit E4A-95-100-000 No. [10]

Figure 71-49

The pigtail connector of FPS has to be connected to the mounting screw of the FMU as shown in Figure

71-50. Torque the M5 screw with 6,5 Nm. Use Loctite 243.

Figure 71-50

Pigtail FPS

Branch FPS

Netting

Cable Tie Tape

FMU

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For fixation the branch of CRS1 sensor the edge clips No.[08] has to be placed as shown at Figure 71-51.

Figure 71-51

The position of the Edge Clip is just a guideline for installer and no absolute position.

Fig. 71-52

The pigtail of CRS1 has to be connected to the screw of EGR cover on the cylinder head side. (Torque 21 Nm). The edge clips shall be used to fix the branch of CRS1.

No.[08]

Pigtail CRS1

Pigtail CRS1

EGR Cover

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This page is removed.

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This page is removed.

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The harness routing on the engine block is shown in Figure 71-58 (Prop. Governor not mounted). The harness branch running to GPC, MOK, OPS, GBTS, GEN and CRS2 has to be fixed with a clamp No.

[03] bolted with the oil filter housing screw (Torque 8 Nm). Additional the harness is fixed with a cable

tie on the starter motor.

Figure 71-58

GPC

GEN

MOK

No.[03]

Oil filter housing

CRS2

GPC_CTS

GBTS

OPS

Starter

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The next pictures describe the routing, on the engine block (Oil filter housing side), in more detail.

The pigtail of OPS has to be connected to the heat exchanger screw (Torque 9 Nm) see Figure 71-59.

The engine harness has to be fixed with cable tie [05] to the starter.

Figure 71-59

A clamp No.[04] is used for fixation the GEN branch. The screw of MOK-Sensor which is used for

mounting of the clamp No.[04] shall also be used to connect the pigtail of GEN connector (Torque 5 Nm).

W11/1 ring terminal and pigtail of MOK Sensor have to be connected to the screw No.[09] on the oil sump (Torque 5 Nm).

Figure 71-60

Pigtail OPS

OPS

Heat exchanger

No.[05]

No.[09]

W11/1

No.[04] Pigtail GEN

Oil sump

Pigtail MOK

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Two edge clips No.[07] have to be mounted to the GPC holder. The edge clips shall be used for fixation the branch of GBTS and W11/2 as shown at Figure 71-61.

Figure 71-61

The pigtail of GBTS and W11/2 terminal has to be connected to the GPC holder screw (Torque 10 Nm)

as shown at Figure 71-62

Figure 71-62

No.[07

GBTS

GBTS Pigtail

GPC Holder W11/2

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One edge clip No.[08] has to be mounted on the fin of the engine block as shown at Figure 71-63. It shall be used to fix the branch of CRS2 with Cable tie No.[05].

Figure 71-63

The branch of CRS2 is routed in the space between GPC and engine block. To fix this branch two edge

clips are mounted on the GPC holder as described next. One edge clip No. [07] has to be mounted on the GPC holder as shown at Figure 71-64.

Figure 71-64

No.[08]

Branch CRS2

GPC Holder No.[07]

Branch CRS2

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The second edge clip No. [06] has to be mounted on the other side of the GPC holder, shown at Figure 71-65. The pigtail of CRS2 has to be connected to the CRS2 fixation screw (Torque 11 Nm).

Figure 71-65

Figure 71-66 shows the connection of the Governor. The shrink boot or wiring branch should not contact other parts (installer equipment, eg. expansion tank) to avoid abraison.

Figure 71-66

Branch CRS2

No.[06] CRS2

Pigtail CRS2

Governor

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Figure 71-67

The installer of the engine harness is allowed to use cable ties No.[05] and Edge Clips No.[06], No.[07],

No.[08] to fix the engine harness additional. It has to be ensured by installer that the additional cable ties do not contact hot or driven parts of the engine. Tension on the wiring harness respectively tension

on the single wires on the connector entry should be avoided

Documents

TEMPORARY REVISION MM-TR-MDC-E4-439a · co cover. The wiring harness branch which runs to the gearbox side of the engine, has to be placed in parallel to the high pressure rail and