DOC AIRBUS | AMM A320FWIRE SPLICE REPAIR PROCEDURE - DESCRIPTION AND OPERATION
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
** ON A/C NOT FOR ALL
1. Wire Splice Repair Procedure
A. General
(1) This chapter gives the procedure for the wire splice repair on the power plant electrical wire harness.
(2) This is a group of words that is shown in this procedure.
(a) Harness - A single bundle of two or more branched group of bundles terminated by connectors or terminal lugs.
(b) Bundle - A group of cables tied together with lacing tape.
(c) Cable - A group of unterminated wires enclosed by a metal shield and insulated jacket.
(d) Wire - A single metallic strand that is insulated.
(3) Wires which cannot meet the wire splice repair limits or if the open circuit cannot be found, the cable can be replaced by the procedure given in Chapter 70-71-24.
(4) Replace the repaired cables when the harness is removed or during the next shop visit of the engine.
(5) Standard equipment and consumable materials can be replaced with equivalent items. The size of the shielded inner and outer ferrules will change with the different wire gages and the number of conductors.
(6) Refer to the AWL for the wire type, gauge, length, and Termination A to Termination B.
(7) This procedure is written for a 2-wire cable. If you need to put a splice in a 3-wire cable, put the third splice in the cable so that the insulation edges of the splices are at least 31,75 mm (1.25 in.) apart.
2. Standard Equipment
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| ! !Supplier! ! ! |
| ! Part No. ! Code ! Nomenclature ! Application ! |
| !------------- -!--------!------------------------!--------------------------! |
| ! ! ! ! ! |
| ! 45092 ! 30119 ! Strip Master Wire ! Manually remove the ! |
| ! ! ! Stripper 16 thru 20 ga.! insulation from the ! |
| ! ! ! ! cable and wire ! |
| ! ! ! ! ! |
| ! 46673 ! 00779 ! Crimp Tool ! Crimp all types of ! |
| ! ! ! ! splices ! |
| ! ! ! ! ! |
| ! WT440 ! 56501 ! Crimp Tool ! Crimp the GSC series ! |
| ! or ! ! ! shielded outer ferrules ! |
| ! WT540 ! ! ! ! |
| ! or ! ! ! ! |
| ! WT1540 ! ! ! ! |
| ! ! ! ! ! |
| ! Model 260 ! 16902 ! Ohmmeter ! Used to measure ! |
| ! ! ! ! continuity and point-to- ! |
| ! ! ! ! point circuits ! |
| ! ! ! ! ! |
| ------------------------------------------------------------------------------ |
3. Consumable material
** ON A/C NOT FOR ALL | ------------------------------------------------------------------------------ |
| ! ! Supplier ! ! |
| ! Part No. ! Code ! Designation ! |
| ------------------------------------------------------------------------------ |
| ! ! ! ! |
| ! Scotch ! 76381 ! Masking Tape ! |
| ! No. 62 ! 81348 ! ! |
| ! ! ! ! |
| ! Moxness ! 07099 ! Tape, red rubber, self-bonding ! |
| ! 620-3/4 ! ! ! |
| ! ! ! ! |
| ! 322822 ! 00779 ! Wire Splice (alumel, for alumel thermocouple ! |
| ! or ! ! wires) ! |
| ! NAS1387-4 ! ! ! |
| ! or ! ! ! |
| ! NAS1387-5 ! ! ! |
| ! ! ! ! |
| ! 2-323876-2 ! 00779 ! Wire Splice (chromel, for chromel thermocouple! |
| ! or ! ! wires) ! |
| ! 1-322325-1 ! ! ! |
| ! ! ! ! |
| ! Gudebrod ! 82110 ! Lacing Tape ! |
| ! 718Z ! ! ! |
| ! ! ! ! |
| ! NEQ241636SP ! 74116 ! Tubular Braid, silver plate copper ! |
| ! ! ! ! |
| ! GSB Series ! 56501 ! Shielded Inner Ferrule ! |
| ! ! ! ! |
| ! GSC Series ! 56501 ! Shielded Outer Ferrule ! |
| ! ! ! ! |
| ------------------------------------------------------------------------------ |
4. Wire Harness Splice Repair Limits.
A. General
(1) Do not splice the wires less than 152.4 mm (6 in.) from the connector baskshell strain relief clamp.
(2) The wire splice repairs must not have a concentration at any one location. The splice repair must not change the clamping or routing of the wire harness.
(3) Do not splice the generator feeders or cables with the steel outer braid.
(4) Splices must be moisture and abrasion resistant. Use a moisture resistant tape wrap that is covered with an abrasion resistant sleeve or tape when you do the repair.
(5) You must see the wire splice to do a visual inspection. do not put the wire splices under the clamps or drip loops.
(6) Shielding where used is very important and must be continuous across all the wire splices.
5. Unshielded Wire Repair
A. Procedure
(1) Remove the lacing tape from the wire harness to get access to the damaged cable.
(2) Refer to the AWL for the correct wire type, wire gage and wire color.
(3) Strip the insulation from each wire so the conductor can be inserted into the splice correctly.
Wire Splice(4) Install the wire into the correct wire splice and crimp the splice. Use the PN 46673 Crimp Tool.
(5) Wrap three layers of the Scotch No. 92 Electrical Silicone Tape directly around the splice.
(6) Use two layers of Scotch No. 92 Electrical Silicone Tape and spiral wrap beyond the insulation. Use a 50 percent overlap with the second layer wrapped opposite to the first layer and tight enough to produce a moisture resistant seal.
(7) Wrap the splice for abrasion protection as follows :
(a) Wrap the splice with two spiral layers of Scotch No. 62 Electrical Silicone Tape. Use a 50 percent overlap with the second layer wrapped opposite to the first layer and extend the wrap 25.4 mm (1.000 in.) beyond each of the initial tape wrap.
(b) Tie each end of the tape in place with PN Gudebrod 718Z Lacing Tape. Use a clove hitch and square knot. Tighten the clove hitch firmly before you tiethe square knot. Cut off the free ends to 6.35 to 12.7 mm (0.250 to 0.500 in.).
(8) Do a continuity test on the repaired wires point to point.
Each circuit must have continuity. Use a PN Model 260 Ohmmeter.
Each circuit must have continuity. Use a PN Model 260 Ohmmeter.
(9) Replace the wire harness lacing that was removed by the procedure given in chapter 70-71-14.
6. Shielded Wire Repair
A. Procedure
(1) Remove the lacing tape from the wire harness to get access to the damaged cable.
(2) Refer to the AWL for the correct wire type, wire gage and wire color.
(3) Trim the cable jacket and shield. Make sure 19.05 mm (0.750in.) of the shield is shown. Cut each wire so that individual wire splices are not opposite of each other.
(4) Use the correct size GSB Inner Shield Termination Ferrules and GSC Outer Shield Termination Ferrules. Move one pair of the inner and outer ferrules over each end of the cable. Move the ferrules clear of the splice area.
(5) Select the correct size tubular braid for the shield splice.
Cut a lenght of the braid to cover the splice repair area.
Cut a lenght of the braid to cover the splice repair area.
(6) Expand the tubular braid and install over one end of the cable. Move the braid clear of the splice repair area.
(7) Splice the individual wires as follows :
(a) Strip the insulation from each wire so the conductor can be inserted into the splice correctly.
(b) Install the wire into the correct wire splice and crimp the splice. Use the PN 46673 Crimp Tool.
(c) Wrap two layers of the Moxness 620-3/4 Red Rubber Tape directly around the splice.
(d) Use two layers of Scotch No. 92 Electrical Silicone Tape and spiral wrap beyond the insulation. Use a 50 percent overlap with the second layer wrapped opposite to the first layer and tight enough to produce a moisture resistant seal.
(8) Straighten out the metal strands of the braided shield that are shown on each side of the spliced area.
(9) Position the inner ferrule near the end of the cable jacket and fold the straighten out shielding back over the ferrule.
Make sure the metal strands of the braided shield are equally spaced around the ferrule.
Make sure the metal strands of the braided shield are equally spaced around the ferrule.
(10) Position one end of the tubular braid over the metal strands of the shieldand move the outer ferrule over the tubular braid and inner ferrule. Crimp the outer ferrule with the PN WT440, WT540 or WT1540 Crimp Tool and use the correct tool die for the outer ferrule.
(11) Pull the tubular braid tight across the splice area.
(12) Position the inner ferrule near the end of the cable jacket and fold the straighten out shielding back over the ferrule.
Make sure the metal strands of the braided shield are equally spaced around the ferrule.
Make sure the metal strands of the braided shield are equally spaced around the ferrule.
(13) Position the end of the tubular braid over the metal strands of the shield and move the outer ferrule over the tubular braid and inner ferrule. Crimp the outer ferrule with the PN WT440, WT540 or WT1540 Crimp Tool and use the correct tool die for the outer ferrule.
(14) Trim the excess braid near with the outer end of the two outer ferrules.
(15) Use two layers of Scotch No. 92 Electrical Silicone Tape and spiral wrap the entire area 12.7 mm (0.500in.) beyond the ferrules. Use a 50 percent overlap with the second layer wrapped opposite to the first layer and tight enough to produce a moisture resistant seal.
(16) Wrap the spliced cable for the abrasion protection as follows :
(a) Wrap the spliced section of the cable with two spiral layers of Scotch No. 62 Electrical Silicone Tape. Use a 50 percent overlap with the second layer wrapped opposite to the first layer and extend the wrap 25.4 mm (1.000in.) beyond each of the initial tape wrap.
(b) Tie each end of the tape in place with PN Gudebrod 718Z Lacing Tape. Use a clove hitch and square knot. Tighten the clove hitch firmly before you tie the square knot. Cut off the free ends 6.4 to 12.7 mm (0.250 to 0.500in.).
(17) Do a continuity test on the repaired wires point to point.
Each circuit must have continuity. Use a PN Model 260 Ohmmeter.
Each circuit must have continuity. Use a PN Model 260 Ohmmeter.
(18) Replace the wire harness lacing that was removed by the procedure given in chapter 70-71-14.