POWER PLANT WIRE SPLICE REPAIR PROCEDURE - DESCRIPTION AND OPERATION

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1. General

This repair procedure has been prepared to define wire repair limits for temporary on-wing repairs to damaged electrical harnesses. The procedure also defines the repair methods for the various type of harness contruction.
When it is not possible to remove a damaged wire from a harness this procedure may be used to join the damaged wire by splicing.
This procedure has been prepared as a temporary on wing repair. The repair must be monitored at 750 Flight Hours / 750 Flight Cycles / 4 calendar months (whichever the earliest) and a permanent repair must be incorporated at the next available time period, but not later than the next 7500 Flight Hours / 5000 Flight Cycles / 24 calendar months (whichever the earliest) check.
Wire splice repairs are considered allowable temporary repairs. The defective wire or wires must be replaced as specified in the repair limits shown in step 5. Wires which cannot be repaired within the limits of step 5 must be replaced.

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2. Tools and Equipment

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| REFERENCE | DESIGNATION | VENDOR |

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! MR-8-89-1 ! Crimp tool, regular wire splice ! V09922 !

! 46447 ! Crimp tool, thermocouple splice ! V00779 !

! 45092 ! Stripper, master wire ! V30119 !

! No specific ! Scissors ! Commercial !

! No specific ! Knife, utility ! Commercial !

! No specific ! Cutter, wire ! Commercial !

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3. Consumable Material

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| REFERENCE | DESIGNATION | VENDOR |

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! CP1041 ! Alcohol, isopropyl ! Commercial !

! 322325 ! Splice, regular insulated 16-22 AWG wire! V00779 !

! 322326 ! Splice, thermocouple, parallel type ! V00779 !

! ! nickel ! !

! 323876 ! Splice, thermocouple ! V00779 !

! HM352 ! Tape, insulating, high temperature ! V71643 !

! P423 ! Tape, insulating, high temperature ! V99742 !

! NSA8420-7 ! Tape, tying fiberglass MIL-T-43435 ! V00768 !

! ! type 4 ! !

! 23 X TZ ! Tape, tying fiberglass MIL-T-43435 ! V82110 !

! ! type 4 ! !

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4. Reference Information

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REFERENCE DESIGNATION

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70-71-16 Engine Harness Continuity and Resistance Tests

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5. Splice Repair Limits

A. Procedure

(1) A permanent repair must be incorporated at the next available time period, but not later than the next C-Check.

(2) Splices are not allowed in the Generator Power Feeder Circuits.

(3) Splices are not allowed in both primary and backup system circuits:
If one circuit is spliced the other circuit must not be spliced.

(4) Splices in critical engine circuits

(a) Splices in critical engine circuits are not recommended.

(b) If it becomes necessary to splice a wire in critical engine circuits, use these repair limits.

1 Channels A and B of the Engine Control Unit.

2 Engine Fire Dectection System.

3 All Fuel Control and Monitoring circuits.

4 All Oil Metering and Monitoring circuits.

5 All Hydraulic Fluid Metering and Monitoring circuits.

(5) Maximum number of splices

(a) Single conductor wire:

one splice per conductor.

(b) Two conductor cable:

one splice per conductor.

one splice per conductor.

(d) Four conductor cable:

one splice per conductor.

(6) Splices may not be closer than 6 in. (152.3997 mm) to a connector backshell.

(7) Splices must be offset from each other by at least 0.12 in. (3.0480 mm) when splicing more than one wire in a bundle.

(8) The splice must not change the clamping or routing of the wire harness.

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6. Preparation for wire repair

Harness Outer Jacket and Overbraid Removal ** ON A/C NOT FOR ALL

A. Procedure

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY

INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE

INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA SHEET

(MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU

OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS

GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD

CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY

USE, KEEP, AND DISCARD CHEMICALS.

(1) Clean the repair area with isopropyl alcohol.

(2) If installed, remove a piece of the harness outer jacket to access the damaged wire.

(a) Measure an equal distance on each side of the damaged area and mark it.

(b) Use a utility knife or scissors to cut around the outer jacket at the marks. Do not damage the metal overbraid.

(3) If installed, remove a piece of the metal overbraid to access the damaged wire.

(a) Mesure an equal distance on each side of the damaged area and mark it.

(b) Use scissors or wire cutters to cut the metal overbraid around the harness at the marks. Do not damage the inner protective sleeve.

(4) Remove a section of the inner protective sleeve to access the damaged wire.

(a) Measure an equal distance on each side of the damaged area and mark it.

(b) Use scissors to cut the inner protective sleeve around the harness at the marks.

(c) Cut the inner protective sleeve down the center from one mark to the other and remove the section of the protective sleeve.

(5) If required, remove any tape which is wound around the wires to access the damaged wire.

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7. Unshielded Wire Repair

Single Conductor Unshielded Wire Repair ** ON A/C NOT FOR ALL

A. Procedure

(1) Determine the size of the damaged area

(a) If the wire is damaged or broken in one place, cut the wire at the center of the damaged area and repair as shown below.

(b) If a section of the wire/cable is damaged:

1 Cut and remove the damaged section from the harness.

NOTE: See AWL Section 92-90 for wire type, gage and length.

2 Cut a piece of replacement wire/cable to extend to both ends of the damaged area and repair as shown below.

(2) Select the correct type of splice for the wire to be repaired:

322325 Splice, regular insulated for 16-22 AWG wire,
322326 Splice, thermocouple, parallel type, nickel,
3238762 Splice, thermocouple.

(3) Select the correct crimp tool for the wire to be spliced:

MR8-89-1 Crimp tool, regular wire splices,
46447 Crimp tool, thermocouple wire splices.

(4) Prepare the wire to be spliced

(a) Measure the splice crimp barrel for the correct wire strip length.

(b) Examine the wire stripper to make sure the blades are sharp and aligned.

(d) Cut the conductor to the correct length.

NOTE: The maximum space allowed between the splice and the wire insulation is 0.12 in. (3.0480 mm).

(5) Crimp the splice onto the wire.

(a) Put the splice into the crimp tool.

(b) Put one end of the wire into the splice, the wire must be visible through the inspection hole in the splice.

(d) Examine the splice to make sure the wire is correctly attached.

(6) Repeat steps 7.A.(2) thru 7.A.(5) for other end wire.

(7) Do a continuity test on the repaired wire. Refer to 70-71-16.
The wire must have continuity from end to end.

(8) Wrap the splice with insulating tape until the tape is level with the wire insulation.

(9) Wrap the splice area again for abrasion protection and to produce a moisture resistant seal.

(a) Wrap the splice area with a layer of insulating tape.

(b) Each wrap must overlap the last wrap by 50 percent.

(d) The wrap should extend 1 in. (25.4000 mm) beyond the end of the splice on both sides.

(e) Tie the ends of the insulating tape with the tying tape. For the tie use a clove hitch and a square knot.

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8. Single Conductor Shielded Wire Repair

Single Conductor Shielded Wire Repair ** ON A/C NOT FOR ALL

A. Procedure

(1) Determine the size damaged area

(a) If the wire is damaged or broken in one place, cut the wire at the center of the damaged area and repair as shown below.

(b) If a section of the wire/cable is damaged:

1 Cut and remove the damaged section from the harness.

NOTE: See AWL Section 92-90 for wire type, gage and length.

2 Cut a piece of replacement wire to extend to both ends of the damaged area and repair as shown below.

(2) Remove the insulated jacket for 2.5 in. (63.4999 mm) from the end of the wire to make the wire shield show.

(3) Cut a piece of the wire shield to cover the damaged area:

(a) Use the wire shield from the same type of wire.

(b) Cut a piece of repair wire shield to cover the splice area and extend 1 in. (25.4000 mm) beyond on both sides.

(4) Make the repair wire shield large and install it over one end of the damaged wire. Then move it away from the splice repair area.

(5) Select the correct type of splice for the wire to repaired:

322325 Splice, regular insulated for 16-22 AWG wire,
322326 Splice, thermocouple, parallel type, nickel,
323876 Splice, thermocouple.

(6) Select the correct crimp tool for the wire to be spliced:

MR8-89-1 Crimp tool, regular wire splices,
46447 Crimp tool, thermocouple wire splices.

(7) Prepare the wire to be spliced

(a) Measure the splice crimp barrel for the correct wire strip length.

(b) Examine the wire stripper to make sure the blades are sharp and aligned.

(d) Cut the conductor to the correct length.

NOTE: The maximum space allowed between the splice and the wire insulation is 0.12 in. (3.0480 mm).

(8) Crimp the splice onto the wire:

(a) Put the splice into the crimp tool.

(b) Put one end of the wire into the splice, the wire must be visible through the inspection hole in the splice.

(d) Examine the splice to make sure the wire is correctly attached.

(9) Repeat steps 8.A.(5) thru 8.A.(8) for other end of the wire.

(10) Do a continuity test on the repaired wire. Refer to 70-71-16.
The shield must have continuity from end to end.

(11) Cut the wire jacket and shied. Make sure that 1 in. (25.4000 mm) of the wire shield is shown.

(12) Move the piece of the repair wire shield over the splice area.

(13) Make sure the repair wire shield touches the shield of the wire.

(14) Wrap the repaired wire shield for abrasion and moisture protection.

(a) Wrap the repair wire shield with a layer of insulating tape.

(b) Each wrap must overlap the last wrap by 50 percent.

(d) The wrap should extend 1 in. (25.4000 mm) beyond the end of the repair area on both sides.

(e) Tie the ends of the insulating tape with the tying tape. For the tie use a clove hitch and a square knot.

(15) Do a continuity test on the repaired wire shield. Refer to 70-71-16.
The shield must have continuity from end to end.

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9. Multi-Conductor Shielded Wire Repair

How to Strip Wire and Position Splices ** ON A/C NOT FOR ALL

Multi-conductor Wire Repairs ** ON A/C NOT FOR ALL

NOTE: Multi-conductor means wires with more than one conductor. Two, three, and four conductor cables are multi-conductor wires.

A. Procedure

(1) Determine the size of the damaged area

(a) If the wire is damaged or broken in one place, cut the wire at the center of the damaged area and repair as shown below.

(b) If a section of the wire/cable is damaged:

1 Cut and remove the damaged section from the harness.

NOTE: See AWL Section 92-90 for wire type, gage and length.

2 Cut a piece of replacement wire to extend to both ends of the damaged area and repair as shown below.

(2) For both the damaged and replacement cables

(a) Remove the insulated jacket from the wires for 4 in. (101.5998 mm) to 6 in. (152.3997 mm) from the ends.

(b) Cut the wires 3.75 in. (95.2498 mm) from the insulated jacket.

(3) Cut a piece of wire shield to cover the damaged area

(a) Use the shield from the same type of wire.

(b) Cut a piece of repair wire shield to cover the splice area and extend 1 in. (25.4000 mm) beyond on both sides.

(4) Make the repair wire shield large and install it over one end of the damaged wire. Then move it away from the splice repair area.

(5) Select the correct type of splice for the wire to repaired:

322325 Splice, regular insulated for 16-22 AWG wire,
322326 Splice, thermocouple, parallel type, nickel,
323876 Splice, thermocouple.

(6) Select the correct crimp tool for the wire to be spliced:

MR8-89-1 Crimp tool, regular wire splices,
46447 Crimp tool, thermocouple wire splices.

(7) Prepare the wires to be spliced:

(a) Measure the splice crimp barrel for the correct wire strip length.

(b) Examine the wire stripper to make sure the blades are sharp and aligned.

(d) Cut the conductor to the correct length.

NOTE: The maximum space allowed between the splice and the wire insulation is 0.12 in. (3.0480 mm).

(8) At both ends of the damaged cable crimp one splice on to each of the wires.

(a) Put the splice into the crimp tool.

(b) Put one end of the wire into the splice, the wire must be visible through the inspection hole in the splice.

(d) Examine the splice to make sure the wire is correctly attached.

(9) At both ends of the replacement cable crimp the colored wire to the wire of the same color on the damaged cable.

(a) Put the splice into the crimp tool.

(b) Put one end of the wire into the splice, the wire must be visible through the inspection hole in the splice.

(d) Examine the splice to make sure the wire is correctly attached.

(10) Do a continuity test on the repaired wire. Refer to 70-71-16.
Each wire must have continuity from end to end.

(11) Wrap the splices witch insulating tape until the tape is level with the wire insulation.

(12) Double wrap the splice area with insulating tape:

(a) Wrap the splice area with a layer of insulating tape.

(b) Each wrap must overlap the last wrap by 50 percent.

(d) The wrap should extend 1 in. (25.4000 mm) beyond the end of the splice on both sides.

(13) Move the piece of repair wire shield over the splice area. Make sure the repair wire shield touches the shield of the wire.

(14) For abrasion protection and to provide a moisture proof seal. Wrap the repair area with two layers of insulating tape.

(a) Wrap the repair wire shield area with two layers of tape.

(b) Each wrap must overlap the last wrap by 50 percent.

(d) The wrap should extend 1 in. (25.4000 mm) beyond the end of the repair area on both sides.

(e) Tie the ends of the insulating tape with the tying tape. Use a clove hitch and a square knot.

(15) Do a continuity test on the repaired wire. Refer to 70-71-16.
The shield must have continuity from end to end.

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10. Metal Overbraid Repair

A. Procedure

(1) Cut a piece the metal overbraid to cover the splice area.

(a) The overbraid should extend 1.5 in. (38.0999 mm) beyond the end of the splice area on each side.

(b) Cut the metal overbraid down the center and fold the edges under.

(c) Remove any loose wires from the metal overbraid so that they will not go into the wire shield or the wire insulation.

(2) Wrap the piece of metal overbraid around the splice area:

(a) The overbraid should be wrapped around the harness so that the end of the wrap overlaps the strat.

(b) Tie the ends of the piece of overbraid with tying tape:

1 Make two ties 0.5 in. (12.7000 mm) apart.

2 For the ties use a clove hitch and a square knot.

(3) Do a continuity test on the repaired metal overbraid. Refer to 70-71-16.
The overbraid must have continuity from end to end.

(4) Wrap the piece of the metal overbraid with insulating tape.

(a) Wrap the metal overbraid with a layer of insulating tape.

(b) Each wrap must overlap the last wrap by 50 percent.

(d) The wrap should extend 1 in. (25.4000 mm) and 1.5 in. (38.0999 mm) beyond the end of the repair area on both sides.

(5) Tie the insulating tape with tying tape.

(a) The ties should be spaced 0.5 in. (12.7000 mm) apart and extend across the repair area.

(b) For the tie use clove hitch and a square knot.

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11. Harness Outer Jacket Repair

How to Wrap the Repair Area ** ON A/C NOT FOR ALL

A. Procedure

(1) Tie the harness outer jacket at the open end near the repair area with tying tape

(2) Add at least two ties at each end.

(3) The ties should be spaced 0.5 in. (12.7000 mm) apart.

(4) For the tie use clove hitch and a square knot.

[Rev.10 from 2021] 2026.04.01 12:55:05 UTC