AC 21-99 Aircraft Wiring and Bonding Copyright Materials

Sect 2 Chap 5

SECTION 2

CHAPTER 5

REPAIRING WIRE AND CABLE

INTRODUCTION d. Cut out the segment of wire with
conductor or insulation damage. If a
1. Aircraft wiring is sometimes damaged during jumper wire is required, cut out at least
normal operation and maintenance. This chapter 15cm of the damaged wire to allow
provides information on repairing various types of wire room for splicing (Figure 5–2).
and cable.

NOTE

Where practicable, damaged wire or cable should

be replaced from one termination to the next.

SINGLE WIRE REPAIR

2. If an aircraft wire is damaged at a single point Figure 5–2 Removing Damaged Area
and there is sufficient slack in the wire, the damaged
wire should be repaired with a single splice. If a wire is e. If more than one jumper wire is to be
damaged along its length, the damaged segment must be installed, stagger splice positions by
cut out and replaced with a jumper wire and two splices varying lengths of sections that are cut
(Figure 5–1). out of the damaged wires.

f. Determine type and gauge of wire to be

replaced from wire identification code or
wiring diagram.

g. Cut replacement wire 12.7mm longer

than removed segment.

h. From Table 5–1, select applicable splice

for wire being replaced.
Figure 5–1 Damage Assessment

3. Carry out repairs as follows:

a. Cut cable ties and remove cable clamps DRY CLEANING SOLVENT P-D-680, TYPE II IS
as required to access wire damage. FLAMMABLE. AVOID EYE AND SKIN
CONTACT OR BREATHING OF VAPOURS.
b. Work damaged wires to outside of wire APPROPRIATE PROTECTIVE EQUIPMENT IS
bundle. Pull slack in wire toward REQUIRED.
damaged area to prevent strain on splice.
i. Clean 50mm of insulation, at wire ends
c. If more than one wire is to be spliced to be spliced, with dry cleaning solvent.
and wires are not colour coded or
otherwise identified, tag wires before j. Strip wire insulation appropriate length
proceeding. for selected splice.

k. Slide splice sealing sleeve over one end

of stripped wire (Figure 5–3).

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Table 5–1 Splice Selection

Wire Gauge Splice Part Number Colour Band Crimp Tool Crimp Die

26, 24, 22, 20 M81824/1-1 Red M22520/5-01 M22520/5-103

or or
M22520/10-01 M22520/10-104

20, 18, 16 M81824/1-2 Blue M22520/5-01 M22520/5-103

or or
M22520/10-01 M22520/10-104

16, 14, 12 M81824/1-3 Yellow M22520/5-01 M22520/5-102

or or
M22520/10-01 M22520/10-103

USE ONLY HOT AIR GUN M83521/5-01 OR

EQUIVALENT ON FUELLED AIRCRAFT

Figure 5–3 Sealing Sleeve placed on One

Wire End
USE OF NITROGEN WITH HOT AIR GUN
l. Using appropriate crimping tool and M83521/5-01 IN AN ENCLOSED AREA CAN
die (Table 5–1) crimp splice to wire BE HAZARDOUS. ENSURE AREA IS WELL
ends (Figure 5–4) VENTILATED.

n. Shrink sealing sleeve using hot air gun

with small termination reflector.
Shrink middle first and move heat
towards one end until sealant melts and
begins to flow out of sleeve (Figure 5–
6). Repeat for other end. Allow to
cool.
Figure 5–4 Correctly Installed Crimp Barrel

m. Centre sealing sleeve over crimp barrel

(Figure 5–5).

Figure 5–5 Sealing Sleeve Centred over

Crimp Barrel
Figure 5–6 Splice Sealing

o. If installing a jumper wire, repeat steps

i to n.

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p. Work repaired wires into the bundle

ensuring splices remain staggered
(Figure 5–7).

Figure 5–8 Scored Jacket on Multi-

Conductor Cable

Figure 5–7 Completed Splices

q. Replace cable clamps and cable ties

removed for access.

MULTI-CONDUCTOR CABLE REPAIR Figure 5–9 Damage Assessment

4. The following paragraphs provide details of e. If more than one wire is to be spliced
procedures, components and tooling for the repair of and wires are not colour coded or
multi-conductor cables. otherwise identified, tag wires before
proceeding.
NOTE
f. Cut out the segment of wire with
Where practicable, damaged cable should be conductor or insulation damage. If a
replaced from one termination to the next. jumper wire is required, cut out at least
15cm of the damaged wire to allow
5. Unshielded Cable Repair. Carry out repairs room for splicing (Figure 5–10).
as follows:

a. Cut cable ties and remove cable

clamps as required to access cable
damage.

WHEN SCORING CABLE JACKET,

ENSURE CONDUCTOR INSULATION IS
NOT DAMAGED. Figure 5–10 Removing Damaged Area
b. Using a sharp blade or knife, score g. If more than one jumper wire is to be
cable jacket around the cable and along installed, stagger splice positions by
the length of the damaged area (Figure varying lengths of sections that are cut
5–8). out of the damaged wires.
c. Flex cable at score marks until jacket h. Determine type and gauge of wire to
separates. be replaced from wire identification
code or wiring diagram.
d. Remove jacket to gain access to
damaged wires (Figure 5–9). i. Cut replacement wire 12.7 mm longer
than removed segment.

j. Select applicable splice for wire being

replaced from Table 5–2.

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AC 21-99 Aircraft Wiring and Bonding Copyright Materials
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Table 5–2 Splice Selection

Wire Gauge Splice Part Number Colour Band Crimp Tool Crimp Die
26, 24, 22, 20 M81824/1-1 Red M22520/5-01 M22520/5-103
or or
M22520/10-01 M22520/10-104
20, 18, 16 M81824/1-2 Blue M22520/5-01 M22520/5-103
or or
M22520/10-01 M22520/10-104
16, 14, 12 M81824/1-3 Yellow M22520/5-01 M22520/5-102
or or
M22520/10-01 M22520/10-103

DRY CLEANING SOLVENT P-D-680, TYPE II

IS FLAMMABLE. AVOID EYE AND SKIN
CONTACT AND BREATHING OF VAPOURS.
APPROPRIATE PROTECTIVE EQUIPMENT IS
REQUIRED.
Figure 5–13 Sealing Sleeve Centreed Over
Crimp Barrel
k. Using dry cleaning solvent, clean
50 mm of insulation at wire ends to be
spliced.

l. Strip wire insulation appropriate length

for selected splice. USE ONLY HOT AIR GUN M83521/5-01 OR
EQUIVALENT ON FUELLED AIRCRAFT.

USE OF NITROGEN WITH HOT AIR GUN

M83521/5-01 IN AN ENCLOSED AREA CAN
BE HAZARDOUS. ENSURE AREA IS WELL
Figure 5–11 Sealing Sleeve Placed on One VENTILATED.
Wire End

m. Slide splice sealing sleeve over one

end of stripped wire (Figure 5–11).

n. Using appropriate crimping tool and

die (Table 5–2) crimp splice to wire
ends (Figure 5–12).

o. Centre sealing sleeve over crimp barrel

(Figure 5-13).

Figure 5–14 Splice Sealing

Figure 5–12 Correctly Installed Crimp Barrel

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p. Shrink sealing sleeve using hot air gun NOTE

with small termination reflector.
Shrink the middle first and heat When applying insulating tape, hands should be
towards one end until sealant melts and free of dirt and oil.
begins to flow out of sleeve (Figure 5–
14). s. Apply insulating tape starting 12.7 mm
before repaired area. Wrap tape one
q. Repeat for other end. Allow to cool. complete turn around cable parallel to
If installing a jumper wire, repeat steps jacket cut line (Figure 5–16).
l. to p.
t. Keeping tape stretched firmly, begin
wrapping around cable in a single
layer, spiral wrap, using a 50%
overlap.

u. Continue wrapping until cable is

wrapped 12.7 mm beyond repair area.

v. Terminate tape by wrapping one

complete turn around cable, keeping
Figure 5–15 Completed Splices tape at a right angle to axis of bundle.

r. Work repaired wires into the bundle w. Spot tie both ends of insulating tape
ensuring splices remain staggered (Figure 5–16).
(Figure 5–15).
x. Replace cable clamps and cable ties
removed for access.

Figure 5–16 Taping Cable Jacket

6. Shielded Cable Repair. Carry out repairs as

follows:

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NOTE

This procedure calls for cutting all conductors

in the cable to allow installation of the repair
braid and insulation tubing.

a. Cut cable ties and remove cable

clamps as required to access cable
damage. Figure 5–19 Wire With Damaged Section
Removed
b. Select shield repair kit according to the
outside diameter of the damaged cable i. Cut undamaged wires at staggered
jacket (Table 5–3). locations (Figure 5–20).
c. Using a sharp blade, score cable jacket
around the cable and along the length
of the damaged area (Figure 5–17).

Figure 5–20 Undamaged Wires Cut at

Staggered Locations

j. Slide tubing and braid from shield

Figure 5–17 Scored Jacket repair kit, over one cable end (Figure
5–21). Tape tubing and braid away
d. Flex cable at score marks until jacket from repair area.
separates.

e. Remove jacket.

f. Using small scissors or diagonal cutter,

remove shield, taking care not to
damage underlying wire insulation
(Figure 5–18).

Figure 5–21 Tubing and Braid Located on

Cable End

k. If damaged sections of wire have been

removed ensure that the removed
sections are at least 50 mm long, to
allow room for splicing.
Figure 5–18 Damaged Multi-conductor Cable
l. If more than one jumper wire is to be
g. If wires are not colour coded or installed, stagger splice positions by
otherwise identified, tag all wires varying lengths of sections that are cut
before proceeding. out of the damaged wires.

h. Cut wires to remove damage. If a m. Determine type and gauge of wire to

segment of damaged wire must be cut be replaced from cable identification
out, remove at least 50 mm total code or wiring diagram.
length. (Figure 5–19). If damage is at
a single point, damaged wire can be n. Cut replacement wire appropriate
cut at the point of damage. length to match removed segment
(Figure 5–22).

Table 5–3 Shield Repair Kit Selection

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Repair Kit Cable Parameters Kit Components

Part Number Number of Conductor Conductor Splice Splice Shield Splice

Conductors Size Range Part Number Quantity Part Number

M81824/5-1 or 1 26-24-22-20 M81824/1-1 1 M81824/4-1

D-150-0168

M81824/5-2 or 1 20-18-16 M81824/1-2 1 M81824/4-2

D-150-0169

M81824/5-3 or 1 16-14-12 M81824/1-3 1 M81824/4-3

D-150-0170

M81824/5-4 or 2 26-24-22-20 M81824/1-1 2 M81824/4-4

D-150-0174

M81824/5-5 or 2 18-16 M81824/1-2 2 M81824/4-5

D-150-0175

M81824/5-6 or 2 14 M81824/1-3 2 M81824/4-6

D-150-0176

M81824/5-7 or 2 12 M81824/1-3 2 M81824/4-7

D-150-0177

M81824/5-8 or 3 or 4 26-24 M81824/1-1 4 M81824/4-4

D-150-0178

M81824/5-9 or 3 or 4 22-20 M81824/1-1 4 M81824/4-5

D-150-0179

M81824/5-10 or 3 or 4 18-16 M81824/1-2 4 M81824/4-6

D-150-0180

M81824/5-11 or 3 or 4 14-12 M81824/1-3 4 M81824/4-7

D-150-0181

o. Carry out wire splicing procedure as

detailed in paragraph 3, steps i to n.

p. When all wires have been reconnected,

remove 12.7 mm of cable jacket at
each end by carefully scoring around
cable and along length to be stripped
(Figure 5–17).

Figure 5–22 Jumper Wire Cut to Match

Removed Segment

Figure 5–23 Jacket Removed

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q. Slide repair braid along cable and

centre over repaired area (Figure 5–
24).

Figure 5–24 Repair Braid Centred Over

Repair Area
Figure 5–25 Heating Repair Braid

USE ONLY HOT AIR GUN M83521/5-01 OR

EQUIVALENT ON FUELLED AIRCRAFT.

Figure 5–26 Tubing Centred Over Repaired

Area
USE OF NITROGEN WITH HOT AIR GUN
M83521/5-01 IN AN ENCLOSED AREA CAN MIL-STD-1553 DATA BUS CABLE REPAIR
BE HAZARDOUS. ENSURE AREA IS WELL
VENTILATED. 7. The following paragraphs provide general
information on MIL-STD-1553 data bus system and
r. Heat one end of the repair braid using the tooling, materials, and procedures for repair of the
hot air gun fitted with appropriate size data bus.
reflector. Apply heat to the
overlapping shield area until the solder 8. The 1553B Data Bus is a computerized and
melts and the sleeve shrinks onto the multiplex digital data distribution system for the many
cable. Continue heating until solder functions of command, control, communications, and
flows into braid strands. Allow to cool intelligence designed for military aircraft. A twinax
undisturbed until solder solidifies cable of 78 ohms was selected to provide the
(Figure 5–25). transmitted digital information with the required
protection from magnetic and electrostatic interference
s. Repeat step r. for opposite end. including nuclear electromagnetic pulse. Therefore,
complete shielding of the pair along the transmission
t. Slide heat shrink tubing over repaired path as well as within the multi-pin connector must be
area and centre (Figure 5–26). maintained.

u. Heat tubing using hot air gun fitted NOTE

with appropriate size reflector. Start in
the middle and heat until tubing While the information and procedures
shrinks moving out to one end. Repeat contained in this supplement are appropriate for
for other end. repairing MIL-STD-1553 data bus cables,
aircraft specific repair procedures take
precedence.

Single Shield Cable with Solder Sleeve Primary

Splice.

9. Prepare the cable using the following

procedure:

a. Remove 31mm of cable jacket (Figure

5–27).

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