PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES

Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

MODULE 7A
Sub Module 7.7

ELECTRICAL WIRING INTERCONNECTION SYSTEM

(EWIS)

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Contents

ELECTRICAL SAFETY PRACTICES ----------------------------------------------- 1

CONTINUITY TESTING ----------------------------------------------------------- 4
BONDING TECHNIQUES AND TESTING--------------------------------------- 8
CRIMPING ------------------------------------------------------------------------ 18
CRIMPING TOOLS --------------------------------------------------------------- 18
HAND AND HYDRAULIC CRIMING TOOL ------------------------------------ 18
TESTING OF CRIMP JOINTS ---------------------------------------------------- 21
CONNECTOR PIN REMOVAL AND INSERTION ----------------------------- 24
COAXIAL CABLES ---------------------------------------------------------------- 26
WIRING PROTECTION TECHNIQUES ----------------------------------------- 32
CABLE LOOM --------------------------------------------------------------------- 32
CABLE LOOP SUPPORT --------------------------------------------------------- 34
WIRE AND CABLE CLAMPING ------------------------------------------------- 39
EWIS INSTALLLATIONS --------------------------------------------------------- 43
INSPECTION ---------------------------------------------------------------------- 45
MODIFICATION AND REPAIR-------------------------------------------------- 45

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

ELECTRICAL SAFETY PRACTICES Electrical safety practices

General Before you start work: open, safety and tag the circuit
breaker(s) related to the system/equipment to prevent the
To work on the electrical system is necessary: supply of electrical power to the system/equipment during the
maintenance work.
 To know and obey the standard safety practices,
This prevents the risk of:
 To have a good knowledge of the electrical standard
practices,  Electric shocks that can occur if you touch energized
wiring connections, terminals, etc...
 To have a good knowledge of requirements (processes,
WARNINGS, CAUTIONS etc..) before you start the  Short circuits that can occur if metal tools or parts
work. accidentally touch energized wiring, terminals, contacts,
etc...
This is necessary to prevent injury to persons and/or damage to
equipment. Note:

These safety practices do not replace regulations specified by Some circuit breakers (A320 family only) have a red threaded
manufacturers and authorities. bush. This bush prevents reset of the circuit breaker in flight
(the crew cannot pull it).
Maintenance
If, for maintenance safety reasons, it is necessary to open such
Warning: a circuit breaker, you can remove the red threaded bush with a
standard wrench.
Make sure that no ac or dc power source is connected to the
aircraft electrical circuits. There is a risk of electrocution if the ac
or dc power stays connected.

Do not look into the end of a fiber-optic cable. There is a risk of

laser radiation, which you will not see. Laser radiation is
dangerous for your eyes.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Tools

Never use electric tools which deliver energy of more than 0.02
mill joule in fuel tanks or in areas where there are flammable
vapors.

Never use heat-generating tools in the fuel tanks or in areas

where there are flammable vapors.

Use only crimp-type contacts, terminals, splices, sleeves (non-

heat shrinkable sleeves) in these areas.

Warning:

Be careful when you use electric tools on the aircraft because

there are risks of electrocution or explosion. If there are local
regulations related to electric tools, make sure that you obey
them.

Be careful when you use electric tools in areas where there are
risks of explosion (fuel tanks, fuel vapor areas, etc.). Refer to
your local regulations and make sure that you obey them. Some
electric tools such as heat guns, soldering irons and tools
without intrinsic protection are not permitted in these areas.

Materials

Use only the materials that are specified by the manufacturer,

also refer to the applicable manufacturer’s documentation.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

CONTINUITY TESTING Millivolt drop test

A concealed break in a cable core or at a connection may be Excessive resistance in high-current carrying circuits can be
found by using a continuity tester, which normally consists of a caused by loose terminal connections, poorly swaged lead
low voltage battery (2.5 volts is satisfactory) and a test lamp or ends, etc. Faults of this kind are indicated by low terminal
an ohmmeter. voltage at the connections to the service load and by heating at
a conductor joint. If such faults are suspected, a millivolt drop
NOTE: In some testers incorporating a test lamp, test as described below is recommended, but it is also
semiconductors are included in the test lamp circuit and. To acceptable to check along progressive sections of the system
prevent damage, the currents should be limited to 120 with an accurately calibrated voltmeter: -
milliamps.

Before testing, the main electrical supply should be switched off a) For continuously rated circuits, the test should,
or disconnected. A check should be made that all fuses are whenever possible, be made with the normal operating
intact and that the circuit to be tested is not disconnected at any current flowing, the power being derived from an
intermediate point. All switches and circuit breakers, as external source. For short-rated circuits, a suitable
appropriate, should be closed to complete the circuit. resistance or other dummy load should be used in lieu
of the normal load and the current should be scaled
When carrying out a low voltage continuity check, it is essential down to avoid overheating.
to work progressively through the circuit, commencing from the
relevant fuse or circuit breaker and terminating at the NOTE: The test voltage may be reduced for safety
equipment. reasons.

Large circuits will probably have several parallel paths and b) The millivolt-meter should be connected to each side of
these should be progressed systematically, breaking down as the suspected joint and a note made of the volt drop
little as possible at plug and socket or terminal block indicated. The indicated reading should be compared
connections. In testing of this nature, it is valueless to check with the figures quoted in the relevant publication (an
several low resistance paths in parallel. approximate guide is 5 mV /10 amps flowing).

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Insulation resistance testing Preparations prior to test

In the following paragraphs general test procedures are Before beginning an insulation test on a system, the following
outlined; however, as a result of the wide variation in electrical preparations should be made, details of which will depend on
installation and equipment, which exists with different aircraft, the installation concerned: -
the routing charts and Approved Test Schedule for the aircraft
concerned must be consulted. All ancillary equipment should be The aircraft battery and any external supply should be
tested separately in accordance with the appropriate disconnected.
manufacturer’s publications.
 Where applicable, circuit breakers should be closed.
After installation and where specified in the Approved
Maintenance Schedule or Test Schedule, aircraft circuits should  The power selector switch should be switched to the
be tested by means of a 250-volt insulation tester which should position appropriate to that required for normal in-flight
have its output controlled so that the testing voltage cannot operation.
exceed 300 volts. In all systems having nominal voltages over
30 volts, cables forming circuits essential to the safety of the  All switches in the circuit concerned should be ‘ON',
aircraft should be tested individually. Other circuits may be dimmer-switches should be set at the minimum
connected in groups for test. However, the numbers of circuits, resistance position and micro-switches operated to the
which may be grouped for test, is governed by the test results; ‘ON' position.
where the insulation resistance so measured is found to be less
than the appropriate minimum value stated (in the last  All items of ancillary equipment, which are supplied by
paragraph under Test Results), the number of circuits grouped the system concerned, should be disconnected. This
together should be reduced. includes all rotary equipment (e.g. generators, motors,
actuator units, etc.), radio equipment, capacitors,
Immediately after an insulation test, functioning checks should semiconductors, voltage regulator coils, electrical
be made on all the services subjected to the test. If the instruments, fire extinguishers, etc.
insulation test or subsequent functioning tests should reveal a
fault, the fault should be rectified and the insulation and  In cases where the insulation resistance with the items
functioning tests should be repeated in that sequence on the concerned is not less than 2 mega ohms, the
affected circuits. disconnection may be made by the earth lead, leaving
the item connected to the circuit. NOTE: Bonded earth
connections to the airframe structure should, if possible,
remain undisturbed for the purpose of these tests.
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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

 Components such as cutouts and relays, which are Test results

normally open, should have their terminals bridged to
ensure continuity of the circuit and disconnected leads The results of insulation tests are of little significance unless
from suppressors should also be bridged for similar they are related to test results obtained on other occasions. The
reasons. Where a suppressor cannot be bridged and insulation resistance values are likely to vary with changes in
plug and socket connections are used, the capacitors the temperature and humidity of the local atmosphere, e.g. if the
should be discharged before the circuit is re-connected, aircraft has been in damp conditions for some time before the
otherwise arcing and burning of the pins may occur. test, low readings can be expected. Results of tests and the
Items in series, which are disconnected, should also be temperature and humidity conditions at the time of the test
bridged so that part of the circuit is not omitted. should be recorded, so that any pronounced drop in resistance
found on subsequent tests can be checked and rectified as
Testing the system necessary.

Double-pole systems on some older types of aircraft can be Functioning tests

tested by connecting the leads of the insulation tester to each of
the battery leads and measuring the resistance between them Before conducting any tests, all precautions for aircraft and
and, afterwards, checking the resistance between each battery personnel safety should be taken. Whenever possible,
lead and earth; fuses should be left in position for this test. On functioning tests should be carried out using an external supply
some large aircraft with double-pole systems, cables may be coupled to the ground supply connector. Tests must ensure
grouped as for single-pole systems, the earthing checks being proper functioning of individual and integrated section of circuits
made between bunched positive and earth and bunched and should be in accordance with schedules established by
negative and earth. reference to details in the relevant Maintenance Manual, Wiring
Diagram Manual or, where appropriate, instructions relating to
the incorporation of a modification or any substantial rewiring.
To test single-pole systems, one lead of the tester should be
connected to earth and the other to the cable or bunch of cables NOTE: Where applicable, when one or more engines are
to be tested. When cables are bunched together, it is advisable running, the power supply can be obtained from the associated
to limit the number to the smallest convenient figure. If the generators, due reference being made to the functioning of any
insulation resistance is less than the appropriate value quoted isolating relays.
(in the last paragraph under Test Results), the number of
circuits should be reduced. Testing should continue until, by For certain circuits (e.g. standby lighting), functioning tests can
process of elimination, any defective cables have been only be carried out using the aircraft battery system, but this
identified. battery should be used as little as possible.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

After the normal functioning test of an individual circuit has been

completed and the circuit switched off, the fuse should be
removed or the circuit breaker tripped and the circuit again
switched on to check the isolation of the circuit concerned.

When the operation of a circuit (e.g. generator equalizer circuit)

depends on the inherent resistance value of the circuit, the
resistance should be measured with a low reading ohmmeter
(such as that used in a bonding tester) to determine that the
resistance is within the specified limits.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

BONDING TECHNIQUES AND TESTING Bonding connections

Bonding is the electrical interconnection of metallic aircraft parts When a bonding connection is to be made or renewed, it is
(normally at earth potential) for the safe distribution of electrical essential that the conductor has the specified current-carrying
charges and currents. capacity, since the bond may have been designed to carry
relatively high electrical loads, e.g. under circuit fault conditions.
Bonding techniques
The manufacturers of solid bonding strip and braided bonding
Primary and secondary conductors cord usually quote the cross-sectional area on the relevant data
sheet. However, in the case of renewal or repair, if the original
Primary conductors are those required to carry lightning strikes, conductor cannot be matched exactly, a replacement
whilst secondary conductors are provided for other forms of manufactured of the same type of material, but of greater cross-
bonding. The current British Civil Airworthiness Requirements sectional area, should be selected.
(BCAR) for bonding paths are as follows: -
Braided copper or aluminium cords fitted at each end with
1) The cross-sectional area of Primary Conductors made connecting tags or lugs (usually referred to as 'bonding
from copper shall be not less than ¼ inch by 26 s.w.g. jumpers'), should be used for bonding connections between
wire, except that, where a single conductor is likely to moving parts or parts subjected to vibration and these are
carry the whole discharge from an isolated section, the suitable both as primary and secondary conductors.
cross-sectional area shall be not less than ½ inch by 26
s.w.g. wire. Aluminium conductors shall have a cross- The tags or lugs on bonding jumpers are generally fitted by the
sectional area giving an equivalent surge carrying 'Crimping method’; and only the correct form of crimp and
capacity. crimping tools should be used for the particular connection.
During assembly of the connections to aluminium cords, anti-
2) The cross-sectional area of secondary conductors made oxidant (crimping) compound consisting of 50% by weight of
from copper must not be less than 44 strands of 39 zinc oxide in white petroleum jelly and complying with DTD
s.w.g. for braided conductors. Where a single wire is 5503 should be applied to the connections.
used its size must be not less than 18 s.w.g.
All bonding connections should be properly locked to prevent
intermittent contact, which may be caused by vibration.

NOTE: Intermittent contact is worse than no contact at all.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Bonding connections should not interfere mechanically or

electrically with any associated or adjacent equipment and  In the case of bearings for control surface hinges it
bonding jumpers should not be excessively tight or slack. should be ascertained which bearings are classified as
self-bonding, e.g. metal-to-metal, nylon with conducting
The run of all primary conductors should be as straight as grease.
possible; sharp bends must be avoided.
 Where applicable, bonding jumpers for control surfaces
The number and location of bonding connections to the various should be as flexible and as short as possible, of as low
components is important and this should be checked and impedance as is practicable and should not be tinned.
verified by reference to the relevant drawing, e.g. where an The possibility of a jumper jamming the controls must be
engine is not in direct electrical contact with its mounting it avoided.
should be bonded with at least two primary conductors, one on
each side of the engine.

In most instances the following joints are considered self-

bonding, provided that all insulating materials (e.g. anodic finish,
paint, storage compounds, etc.), are removed from the contact
faces before assembly, but if any doubt exists regarding the
correctness of the bonds, a bonding test should be carried out: -

1) Metal-to-metal joints held together by threaded devices,

riveted joints, structural wires under appreciable tension
and bolted or clamped fittings.

2) Most cowling fasteners, locking and latching

mechanisms.

3) Metal-to-metal hinges for doors and panels and metal-

to-metal bearings (including ball bearings).

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Bonding flexible hose connections

Flexible hose connections used for joining rigid pipes should be After a non-conducting protective coating has been removed
bonded by fitting clips around the pipes approximately 13 mm from the connecting area, the preferred sealing and anti-oxidant
(0.5 inch) away from the hose and bridging with a corrugated treatment as specified on the relevant drawing and specification
bonding strip or jumper; the practice of tucking the ends of should be carried out.
bonding strips between the hose and the pipe is not
recommended. To obtain good electrical contact the area under NOTE: Non-conducting protective treatments include all
each clip should be cleaned and, after the clip has been fitted, generally used priming and finishing paints, varnishes and
protection should be restored. temporary protective, chromic, anodic and phosphate coatings.
Metallic coatings, such as cadmium and tin, are satisfactory
Not only must the flexible hose connection be bridged, but each conductors and should not be removed. If a poly sulphide
pipe run should be bonded to earth at each end, particularly compound is used for sealing the earth or bonding point, it must
within a radius of 2.42 meters (8 feet) of any unscreened radio be ensured that the anti-oxidant to be subsequently applied will
equipment or aerial lead, where earthling bonds should not be not have a detrimental effect on the sealing; e.g. DTD 5503
more than 1.5 meters (5 feet apart), or less distance apart, if should not be used.
called for by the manufacturer. These provisions also apply to
any long electrically conducting parts (including metallic When the connection has been made any excess compound
conduits and metal braiding), which are not insulated from should be wiped off, using a rag damped in methyl ethyl ketone
earth. (MEK) and the connection and adjacent area re-protected by
the specified method, this depending on the materials
If bridging strips or bonding cords are fractured a new conductor concerned and the position of the connection.
should be fitted. The soldering of broken ends is prohibited.
When a 'corrosion washer' forms part of the connecting
High-pressure flexible pipe assemblies are usually self-bonding, assembly, it should be correctly fitted and be of the correct
but a bonding test should be made between the assembly end- material for the type of connection concerned.
couplings to prove the integrity of the bonding.
NOTE: A corrosion washer is plated, or manufactured of a
Where any bonding or earth connection is made to the structure material having a potential such that when placed between
or equipment, the specified standard of protection against materials of widely differing potentials it reduces the risk of
corrosion should be provided. corrosion caused by electrolytic action.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Earth terminals Resistance values

When earth-return terminal assemblies are fitted or replaced, The maximum resistance values for the various conditions of
the correct method of fitting to the structure, the corrosion bonding are summarized in the Table (CAA Requirements).
protection required and the exact location on the structure
should be carefully checked. The procedure for fitting and the Bonding carrying the main electrical supply
number of terminations to be attached will vary with the design
of the terminal assembly and the type of structure, therefore The cross-sectional area of the main earth system, or any
reference should be made to the relevant drawings and connection to it, must be such that without overheating or
instructions to ensure both electrical and structural integrity. causing excessive voltage drop, it will carry any electrical
currents, which may pass through it normally or under fault
All earth terminal assemblies should be checked for resistance conditions.
between the lug attachment point(s) and the surrounding
structure and this must not exceed the figure specified for the If, under fault conditions, it should form part of a short-circuit,
aircraft concerned (e.g. 0.025 ohm). When earth terminal not provided against by a protective device, it should be capable
assemblies are also used to carry electrical supplies, a mill volt of carrying the full short-circuit current which can pass, without
drop test, must be carried out. risk of fire or damage to the bonding system.

If the resistance in either case is unsatisfactory, the terminal NOTE: For example, the above paragraph may apply to
assembly should be removed, the contacting faces cleaned with bonding which under fault conditions becomes part of a starter
a fine abrasive (e.g. aluminium wool) and reassembled using, or other heavy current circuit. Particular attention should be
where applicable, new corrosion washers. The connecting area given to non-metallic aircraft fitted with a double-pole wiring
should be sealed and treated with anti-oxidant compound as system to which single-pole equipment has subsequently been
specified in the relevant drawing and specification. added.

NOTE: Leads connected to earth terminal assemblies should be

of insulated cable with terminal tags fitted by the crimping
method. It is important that the cable is of the specified gauge
for the service concerned and is kept as short as possible.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Bond testing

Special test equipment, comprising a meter and two cables NOTE: When connecting the 60-foot lead to an earthling point,
each of specific length, is required for checking the resistance of any protective treatment (e.g. strippable lacquer) should be
bonding. A meter widely used, consists of an ohmmeter removed at the point of contact.
operating on the current ratio principle and a single 1.2-volt
nickel-alkaline cell housed in a wooden carrying case. The The 6-foot test lead should be used to check the resistance
associated cables are 60 feet and 6 feet in length and are fitted between selected points; these are usually specified in the
with a single-spike probe and a double-spike probe respectively. bonding test schedule or the Maintenance Manual for the
Plug and socket connectors provide for quick-action connection aircraft concerned. When the two spikes of the test lead probe
of the cables to the instrument. are brought into contact with the aircraft part, the test- meter will
indicate, in ohms, the resistance of the bond.
Prior to carrying out a bonding test, a check should be made on
the state of the nickel-alkaline cell of the tester by observing; As an alternative to the above, the four-terminal method of
resistance measurement may be adopted with the appropriate
a) That a full-scale deflection of the meter is obtained when milliohm meter (see Figure on next page). With this type of
the two spikes of the 6-foot cable probe are shorted by a instrument, a test current (approximately 2 amps) is supplied by
suitable conductor; and the internal batteries and passed through the resistance via
cables C1 and C2. The voltage drop across the resistance is
b) That the meter reads zero when the two spikes of the 6- measured (P1 and P2) and compared with the current flowing.
foot probe are shorted by the single spike of the 60-foot The resultant value is then displayed (normally digitally) on the
probe.
meter. The test leads may be in the form of duplex spikes (see
Figure on next page) or when used in association with crocodile
The 60-foot lead of the test equipment should be connected to
the main earth (also known as the bond datum point) at the type test leads, single spikes. In order to check that the
terminal points, which are usually shown diagrammatically in the instrument is functioning correctly, the two handspikes should
relevant Aircraft Maintenance Manual. Since the length of a be placed on a low resistance conductor with the potential
standard bonding tester lead is 60 feet, the measurement spikes (P1 and P2) closely together (see Figure on next page).
between the extremities of the larger types of aircraft may have The result of this test should be a zero reading on the meter.
to be done by selecting one or more main earth points
successively, in which event the resistance value between the To ensure good electrical contact at the probe spikes, it may be
main earth points chosen should be checked before proceeding necessary to penetrate or remove a small area of a non-
to check the remote point. conducting protective coating. Therefore, after test, any damage
to the protective coating must be restored.
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Meter and test leads

Meter schematic and test circuit

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

If the resistance at a bond connection is excessive, rectification NOTE: After carrying out tests, all areas where the protective
action will depend on the type of connection. The following coating has been removed should be re-protected using the
action should be taken for the more common types of appropriate scheme.
connections: -
Bonding tester servicing
(a) In the case of bonding jumpers, the connecting tag or
lugs should be removed and the contacting faces A tester requires little in the way of servicing, apart from periodic
thoroughly cleaned, using a slight abrasive if attention to the alkaline cell, which should be removed at
necessary. The bare metal thus exposed should be prescribed intervals for routine servicing. When replacing the
only just large enough to accept the palm of the tag or cell, it is most important that the polarity of connection is correct.
lug. The connecting area should be sealed and treated The ohmmeter is normally sealed in its case and no attempt
with anti-oxidant as specified in the relevant drawing should be made to open it; if a fault should develop, then the
and specification. complete instrument should be withdrawn from use and
overhauled.
NOTE: Where an abrasive has been used it is
important to ensure that all traces of it are removed. The leads are an integral part of the tester and being carefully
matched to the meter unit must not be modified or altered in any
(b) Where equipment is bonded through a holding bolt, the way. All contact surfaces of plug pins and probes must be kept
bolt should be removed and the area under the bolt scrupulously clean and the points of the probe spikes should be
head, or nut, thoroughly cleaned and protected as reasonably sharp to give effective penetration of protective
recommended in above paragraph. The correct washer finishes, etc., on metal surfaces.
(both with regard to size and material) should be fitted
before the bolt is replaced and tightened. The accuracy of the tester should be checked periodically by
using it to measure the resistance of standard test resistors.
(c) Where the required bond value cannot be obtained at a Normally, three such resistors are supplied for testing purposes
structural joint the advice of the manufacturer should be and the readings obtained should be within 10% of the standard
sought. ohmic values.

NOTE: Corrosion tends to form at a bonding or earth

connection and is often the cause of excessive
resistance.

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Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

CRIMPING HAND AND HYDRAULIC CRIMING TOOL

Crimping ensures electrical and mechanical connection of the Hydraulic crimping tools are often used on wire gauge sizes 0
wire to an item of equipment or to a connecting system by through 0000 because of the force required to properly crimp
means of the end fitting. the wire. Like the ratchet-type crimper, a hydraulic crimper must
be calibrated periodically.

CRIMPING TOOLS

Special crimping tools are needed to crimp a connecting device

onto a wire. A properly crimped terminal provides a joint
between the wire and the terminal as strong as the wire itself.
The preferred crimping tool is a ratchet-type crimper that is
periodically calibrated to ensure a consistent and proper crimp.

When using a ratchet-type crimping tool, the handles of the tool

will not release until the jaws have moved close enough
together to properly compress the terminal barrel.

Many crimping tool manufacturers are available (AMP,

Buchanan, Burndy, Cannon, Daniels, Hughes, Raychem, etc.),
who provide different types of crimping tools to be used with
different types of connecting devices.

Some have fixed locators, and the tools come in different sizes
indicated by the color coding on the handle. Some tools have
removable dies with different part numbers for different
connecting devices. Another type has an adjustable locator.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 18 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 19 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Testing of crimping tools

Test intervals

 Each new tool before use shall be submitted for

gauging, where applicable, and specimen checks.

 Each tool shall be submitted for gauging at 1000 and

2000 crimps and only if successful, returned for use. The
checking at 3000 crimps shall be by gauging and
specimen checks. This procedure shall be followed at
subsequent 1000 crimp checks.

 All tools not in regular use shall be similarly checked

every 12 months to the gauging requirements.

 When a tool becomes due for a 1000 crimp or yearly

check it shall not be used again, until the results of the
test interval are known and the tool certified for use.

Gauging of tools:

Each tool or die shall be tested by the insertion of GO/NO GO

gauge.

When tool handles are squeezed, the GO element must pass

through the dies, the NO-GO element must not pass.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 20 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

TESTING OF CRIMP JOINTS

Pre-crimping checks

1. Wire shall be correctly stripped. (See Wire Stripping)

2. Check correct combination of cable, tool, terminal end or

connector.

a) Crimping tool and locator shall be correctly

selected (See Crimping Tools tables).

b) Before use, every tool shall be checked for:

 Identification (Tool Serial No.) with its own

particular history card. (Tool used will not
have exceeded 1000 crimps on an
interval of 12 months without being
tested, unless otherwise stated)

 Cleanliness of die faces.

 Freedom from damage.

 Freedom from corrosion.

 Freedom from wear. (Tools in regular use

shall be cleaned daily to avoid buildup of
dirt and plating on die faces and care
shall be taken not to damage the die
faces.)

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 21 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Post-crimping checks
 Adequate insertion of conductor strands in barrel where
All crimped joints shall conform with the following visual checks: it is possible to check without damaging conductor,

 Correctness of form and location of crimp.  Absence of damage to the conductor.

 Freedom from facture and rough or sharp edges.

 Burrs are inherent in some forms of crimping.

 These burrs should not be excessive to the extent that

they cannot be removed without the use of a tool.

 Crimping indents away from inspection hole

 Crimping indent correctly centered on the barrel.

 No damage caused on the attaching system, or to the

female contact pressure system (removable contacts).

 Acceptable geometrical distortion, correct die mark.

 Wire visible through inspection hole, if applicable.

 Position of insulation after crimping (see Figure).

 Position of wire after crimping (see Figure).

 No strands outside the crimping barrel (and/or extending

out the inspection hole).

 No cut strands
ISO 9001:2008 Certified For Training Purpose Only
PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 22 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

On completion of the crimping operation, the wire insulation

must not be pushed back out of end fitting and sealing system. The maximum distance tolerated for the extension of the wire
core out of the crimping barrel, connection side is 1.5mm.

Crimped Contact

The distance between the crimping barrel and the wire

insulation must be less then 1mm.
Note: It is recommended that each crimp has a gentle manual
pull applied in order to establish there is no movement of
conductor within the crimp.

In specific cases where, by construction, the distance between

rear face of the hard insulation is less then 3mm, this value is
brought to 0.3mm max.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 23 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

CONNECTOR PIN REMOVAL AND INSERTION

There are two methods commonly used to install a contact into

a connector housing; front release and rear release. The front-
release contact is held in place by a relatively complex
combination of retainers molded into the connector housing. A
special tool is used to install a front-release contact in the front
of the connector housing. A rear-release contact is installed in
the rear of the connector housing and is secured with two or
more small tines as shown in Figure 1. The rear-release method
provides better front-end support for the contact; therefore, the
contact is less likely to bend during reassembly of the
connector.

Contact removal

To remove a contact from a connector assembly, the technician

must first remove any outer-shell components to expose the
wire and contact to be removed. A special removal tool is slid
gently into the connector housing; it releases the locking tabs
holding the contact in place. In many cases a double-ended tool
is used for both contact installation and removal. This helps to
eliminate confusion when repairing defective connections. To
remove a rear-release contact, simply slide the tool over the
wire and onto the contact. Once the tool has reached the end of
its travel, the locking tabs have been depressed and the contact
can be removed. A similar procedure is used for the removal of
front-release contacts; however, extra care must be taken not to
damage front-release components. Figure 2 shows the removal
of front- and rear-release pins.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 24 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 25 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

COAXIAL CABLES

Antennas are connected to most of the radio receivers and Coaxial cables have several advantages over standard cables.
transmitters with a special type of shielded wire called “Coaxial Firstly, they are shielded against electrostatic and magnetic
Cable”. Coaxial cables contain two or more separate fields. An electrostatic field does not extend beyond the outer
conductors. The inner most conductor may be solid or stranded conductor and the magnetic fields due to current flow in the
copper wire, and may be plain, tinned, silver plated or even gold inner and outer conductors cancel each other out. Secondly,
plated. The remaining conductors are in the form of tubes, since coaxial cables do not radiate, then likewise they will not
usually of fine braid. The insulation is usually teflon or pick up any energy or be influenced by magnetic fields. Thirdly,
polyethylene. Outer coverings or jackets serve to weatherproof coaxial cables have specific values of; impedance, capacitance
the cables and protect them from fluids, and mechanical and per unit length and attenuation per unit length.
electrical damage. Figure shows a typical coaxial cable.
Coaxial stripping procedures

OUTER JACKET – Once the outer jacket has been removed,

the following should be checked:
OUTER
SOLID INNER INSULATOR
INSULATOR  The outer jacket must not be chafed or incised.
CENTER JACKET
CONDUCTOR
 The outer jacket must have been cut off flat all round
and at right angles to the longitudinal direction of the
cable.

 The outer jacket must not be frayed.

 The strands of the underlying shield must not be

BRAID OUTER notched or cut off.
CONDUCTOR

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PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

SHIELD – After stripping the shield the following must be

checked: FRAYED
OUTER JACKET
REMOVAL

 The shield must have been cut off evenly all round.
CHAFED
OR CUT FLAT &

 The braiding of the shield must not be damaged. STRAIGHT

INCORRECT

 The underlying dielectric must not be chafed,

compressed or incised.
CORRECT
DAMAGED
DIELECTRIC – After stripping the dielectric the following must
be checked:

 The dielectric must not be chafed, incised or UNEVEN

INCORRECT
compressed.
SHIELD
 The dielectric must have been cut off flat all round the REMOVAL
cable. CORRECT

 The dielectric must not be frayed.

COMPRESSED
 The core wires must not be notched or cut off. & INCISED

NOTCHED

Figure shows the process of stripping a coaxial cable.

INCORRECT

DIELECTRIC
REMOVAL

CORRECT

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 27 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Coaxial cable testing

The relationship to the length of a coaxial cable and its

impedance is critical. If the impedance of the line does not
match the load impedance, not all the energy fed down the line
flows into the load. Some of the energy is reflected back to the
source, forming standing waves on the line. Every half wave
along the line, high V and Low I points appear, also between
these points will be Low V and High I. The ratio of the voltage
across the line at the High V points to that at the Low V points is
known as the “Voltage Standing-Wave Ratio” (VSWR).

If a coaxial cable is damaged (either crushed, pinched or cut), it

will affect the impedance of the cable; this in turn will result in
low power transmissions. Measuring the VSWR on the line will
identify the position of the damage. To measure the VSWR a
“Time Domain Meter” (TDM) is used.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 28 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

IDENTIFICATION OF WIRE TYPES

Wire number prefix
A modern aircraft contains miles and miles of wire and cable. It
is therefore important that we can identify individual wires The first part of the identification code is known as the wire
easily. number prefix. This has the special job of determining in which
Nowadays most aircraft manufacturers have adopted a method system on the aircraft the wire or cable is located. Let's use the
of coding wires and cables which conform to the ATA 100 first activity to determine how this wire number prefix is derived.
specification. This method is often referred to as ‘series coding'.
The code number appears on the wiring diagrams, Wire lists Wire number
and other electrical or electronic drawings. The code number is
imprinted at regular intervals on the wire or cable itself. A dash separates the ATA number prefix from the wire number.
Alternatively, an identification sleeve may be used. A wire number consisting of a maximum of 5 digits is used to
differentiate between wires, cables or co-axial cables in a
Construction of the series code particular sub system. A different wire number is used for each
conductor not sharing a common connection. Notice that both
wires shown below in Fig. have the same wire number. This is
because there· is a permanent connection between the two
wires. If there was a switch or relay contact between the two
wires then the wire number would change because in this case
there would not be a permanent connection between them.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Parallel or identical systems are identified with a 5-digit wire Wire Segment Letter
number, as shown in Fig. The first digit indicates the specific
parallel or identical system unit identification number such as In the case where two wires were permanently connected, such
Number 1 AC generation System. as in a terminal block, or a splice, the wire number didn't hang.
We still need to discriminate between these two wires. We use
a letter for this purpose. A different letter is used for each
segment sharing a common terminal or connection and having
the same 4-digit ATA number. See Fig. Where practicable
segments are lettered in alphabetical sequence and the letter A
identifies the first segment starting at the signal and/or power
source.

The letters I and 0 are not used. Double letters AA, AB, AC, BA,
BB, BC, etc., are used when more than 24 segments are
required. Segments joined by a permanent splice have different
segment letters assigned to them.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 30 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Wire Gauge

The wire or cable size number is used to identify the American

wire gauge (AWG) size of the wire or cable. The wire size
number is not normally included for co-axial cables. For INSULATION
CLEARANCE
thermocouple wires a dash is used instead of the wire size 1 - 2.5 mm

number. The wire gauge is not shown on a wiring diagram if a

POINT OF
note similar to the following appears. ENTRY

NOTE: All wires are 20 gauges unless otherwise specified." WIRE MUST BE
INSERTED
TO THE END
Ground, Phase or Thermocouple Letter OF THE CUP

The letter N (ground or earth) is used as a suffix to the wire

identification code to identify a segment of a wire or cable that is
a part of the ground network. The phase letters 'A', 'B' and 'c'
are used as suffixes to the wire or cable identification code on
all wire segments carrying three phases a.c. power from the
source of power up to and including the aircraft item using the
three phase a.c. power. The phase letter 'V' is used as a suffix
to the identification code to identify all segments of the high
voltage side of a single-phase power circuit.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 31 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

WIRING PROTECTION TECHNIQUES CABLE LOOM

The quantity of wires and cables required for a distribution In this method, wires or cables to be routed to and from
system depends on the size and complexity of the systems. consumer equipment in the specific zones of the aircraft are
However, regardless of quantity, it is important that wires and grouped parallel to each other in a bundle and bound together
cables be routed through an aircraft in a manner, which is safe, with waxed cording or p.v.c. strapping. A loom is supported at
avoids interference with the reception and transmission of intervals throughout its run usually by means of clips secured at
signals by such equipment as radio and compass systems, and relevant parts of the aircraft structure. An application of the
which also permits a systematic approach to their identification, method to an aircraft junction box is shown.
installation and removal, and to circuit testing.
The composition of a cable loom is dictated by such factors as
Various methods, dependent also on size and complexity, are
adopted but in general, they may be grouped under three 1 Overall diameter.
principal headings:
2 Temperature conditions, i.e. temperature rise in cables
 Open loom when operating at their maximum current carrying
 Ducted loom capacity in varying ambient temperature conditions.
 Conduit
3 Type of current, i.e. whether alternating, direct, heavy
duty or light duty.

4 Interference resulting from inductive or magnetic effects.

5 Type of circuit with which cables are associated; this

applies particularly to circuits in the essential category,
the cables of which must be safe-guarded against
damage in the event of short circuits developing in
adjoining cables.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Magnetic fields exist around cables carrying direct current and

where these cables must interconnect equipment in the vicinity
of a compass magnetic detector element, it is necessary for the
fields to be cancelled out. This is achieved by routing the
positive and earth return cables together and connecting the
earth-return cable at an earthing point located at a specific safe
distance from the magnetic detector element of a compass
system.

Requirements for open wiring

When wires or wire bundles are routed through the aircraft

without the mechanical protection of conduit, it is called open
wiring. Most aircraft use the open wiring system and mechanical
protection is provided in critical areas by routing wires behind
decorative or structural panels.

Open wiring is more vulnerable to wear, abrasion, and damage

from liquids than wiring installed in conduits; hence care must
be taken to see that it is installed where it is not exposed to
these hazards and in a manner to prevent damage. The number
of wires grouped in a bundle should be limited in order to
reduce the problems of maintenance and to limit damage in
case a short circuit should occur and burn one of the wires in
the bundle. Shielded cable, ignition cable, and wire that is not
protected by a circuit breaker or fuse should be routed
separately. The bending radius of a wire bundle should not be
less than 10 times the outer diameter of the bundle. This is
required to avoid excessive stresses on the installation.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

CABLE LOOP SUPPORT

Particular care in the supporting of cables is

necessary at the following points: -

 Adjacent to cable terminations.

 Where relative movement is likely to occur
between adjacent parts of the structure to which
the cables are fitted.
 Where cables are in proximity to moving parts, At
bends, especially where several small cables are
run together to form a relatively heavy group.

Ducted loom

This method is basically the same as that of the open loom

except that the bundles are supported in ducts, which are
routed through the aircraft and secured to the aircraft structure.
Ducts may be of aluminium alloy resin impregnated asbestos or
molded fiber-glass-reinforced plastic. In some applications of
this method, a main duct containing several channels may be
used, each channel supporting a cable loom corresponding to a
specific consumer system. For identification purposes, each
loom is bound with appropriately colored waxed cording.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Electrical conduits

Electrical conduit consists of thin-walled aluminium tubing, Installation of conduit should be such that it is protected from
braided metal tubing called flexible conduit, and non-metallic damage of all types. It should be securely attached to the
tubing. The purpose of conduit is to provide mechanical structure with metal clamps so there can be no movement or
protection, and metal conduit is often used as a means of vibration. A clean metal-to-metal contact will assure good
shielding electric wiring to prevent radio interference. bonding to aid in shielding. The installed conduit should not be
under appreciable stress and should not be located where it
Approved flexible conduit is covered by specification MIL-C- may be stepped upon or used as a hand support by a member
6136 for aluminium and specification MIL-C-7931 for brass. The of the crew. Drain holes must be provided at the lowest point in
aluminium conduit is made in two types. Type I is bare, and type any conduit run.
II is rubber-covered.
Rigid conduit that is cut or has appreciable dents should be
The size of conduit should be such that the inside diameter is replaced to prevent damage to the electric cable. Bends in the
about 25 percent larger than the largest diameter of the cable conduit must not be wrinkled and must not be flattened to the
bundle. To obtain the correct inside diameter of a conduit, extent that the minor diameter is less than 75 percent of the
subtract twice the wall thickness from the outside diameter. nominal tubing diameter. Table 1 shows the minimum tubing
Typically, conduits are specified according to their outside bend radii for rigid conduit.
diameter.
Flexible conduit cannot be bent as sharply as rigid conduit. This
The inside of the conduit should be clean and free of burrs, is indicated by Table 2, which gives the minimum bending radii
sharp edges, or obstructions. When conduit is being cut and for flexible aluminium or brass conduit.
prepared, all edges and holes should be deburred to assure a
smooth surface that will not damage the cable. The conduit When sections of flexible conduit are being replaced and it is
should be inspected carefully after the end fittings are installed necessary to cut the conduit, the operation can be greatly
to assure that the interior is clean and smooth. If a fitting is not improved by wrapping the area of the cut with transparent
installed on the end of a conduit section, the end should be adhesive tape. Frying of the end will be greatly reduced
flared to prevent the edge of the tubing from rubbing and because the tape will hold the fine wires in place as the cut is
wearing the insulation of the cable. made with a hacksaw. Before a wire or cable bundle is placed in
a conduit, the bundles should be liberally sprinkled with tale.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 35 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 36 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Cable lacing

The lacing of wire bundles should be performed according to Wire bundles may be laced with a continuous series of loops
accepted specifications. Approved lacing cord complying with around the bundle as shown in Figure 4 or with single ties as in
specification MIL-C-5649 or twine specification JAN-T-713 may Figure 5. When the continuous lacing is applied, the first loop is
be used for wire lacing. If wire bundles will not be exposed to a clove hitch locked with a double overhand knot as shown in
temperatures greater than 248°F [120°C], cable tie straps Figure 4(a). The knot is pulled tight as shown in Figure 4(b) and
the continuing end is then looped around the wire bundle with
complying with specification MS-17821 or MS-17822 can be
the cord brought over and under the cord from the previous loop
used. Typical tie straps are shown in Figure 1. Tie straps have to form the type of loop shown in Figure 4(b). These loops are
replaced lacing cord in many aircraft installations; but always continued at suitable intervals, and the series is then terminated
consult the current maintenance data to ensure that straps can with another clove hitch. The free end is wrapped twice around
be substituted for lacing cord. As seen in Figure 2, many aircraft the cord from the previous loop and is then pulled right to lock
have certain areas subject to high vibration or excessive heat the loop. The terminating ends of the cord are trimmed to
where tie straps are not acceptable. To install a tie strap, simply provide a minimum length of 3/8 in.[0.95 cm]. The method for
wrap the tie around the wire bundle, being sure not to twist the making the terminal loop is illustrated in Figure 4(c).
strap. Insert the strap through the locking eyelet, and tighten the
strap, using the proper tool. The tool is also used to cut off any When it is desired to use single ties to secure a wire bundle, the
excess trap, leaving a flush edge. Figure 3 illustrates the use of locked clove hitch is used. The clove hitch is formed as shown,
a typical tie strap installation tool. and it is then locked with a square knot. Single ties are
sometimes used to separate a group of wires from a bundle for
Single-cord lacing is used for cable bundles 1 in. [2.5 cm] in identification purposes, as shown in Figure 7. This helps
diameter or less. For larger bundles, double-cord lacing should maintenance technicians locate particular circuit wiring.
be employed. Cable bundles inside a junction box should be
laced securely at frequent intervals to assure that a minimum of When double-cord lacing is required for large cable bundles, the
movement can take place. In open areas, the bundles should be first loop is made with a special type of slipknot similar to the
laced or tied if supports for the cable are more than 12 in. [30.5 bowline-on-a-bight. This is shown in Figure 6. The double cord
cm] apart. is then used to make additional loops as required in the same
manner as the single cord is used. The terminal lock knot is
made by forming two single loops around the bundle and then
tying the two ends with a square knot.

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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Figure 2

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PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

WIRE AND CABLE CLAMPING Cable seals

Electric cables or wire bundles are secured to the aircraft In pressurized cabin aircraft it is essential for many cables to
structure by means of metal clamps lined with synthetic rubber pass through pressure bulkheads without a "break" in them and
or a similar material. Specification MS-21919 cable clamp without causing leakage of cabin air. This is accomplished by
meets the requirement for civil aircraft use. Such a clamp is sealing the necessary apertures with either pressure bungs or
illustrated in Figure 1. pressure proof plugs and sockets. An example of a pressure
bung assembly is shown in Figure 3. It consists of a housing,
In the installation of cable clamps, care must be taken to assure perforated synthetic rubber bung, anti-friction washer and
that the stress applied by the cable to the clamp is not in a knurled clamping nuts; the housing is flanged and threaded,
direction that will tend to bend the clamp. When a clamp is having a tapered bore to accept the bung. The holes in the bung
mounted on a vertical member, the loop of the clamp should vary in size to accommodate cables of various diameters, each
always be at the bottom. Correct methods for installing clamps hole being sealed by a thin covering of synthetic rubber at the
are shown in Figure 2. smaller diameter end of the bung. The covering is pierced by a
special tool when loading the bung with cables.
When a wire bundle is routed through a clamp, the bundle must
be held within the rubber lining of the clamp and no wires must The cables are a tight fit in the holes of the bung, which when
be pinched between the flanges of the clamp. Pinching of the fully loaded and forced into the housing by the clamping nut, is
wire could cause the insulation to be damaged, and a short compressed tightly into the housing and around the cables. The
circuit could result. anti-friction washer prevents damage to the face of the bung
when the clamping nut is turned. On assembly, holes not
In installing electric wiring in a particular make and model of occupied by cables are plunged with plastic plugs.
aircraft, it is the best practice to make the installation in
accordance with the manufacturer’s original design unless a In instances where cable "breaks" are required at a pressure
specific change has been ordered. The clamps, wiring, and bulkhead, the cables at each side of the bulk-head are
connectors should be of the same types specified and used by terminate by specially-sealed plug or socket assemblies of a
the manufacturer. type similar to those shown in Figure 4.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 39 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Figure 3 Figure 4

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 40 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Routing of wire bundles

The routing of electric wire should be done in a manner that will Particular care must be used in installing electric wire on and in
provide the protection previously mentioned, namely protection the vicinity of landing gear, flaps, and other moving structures.
against heat, liquids, abrasion, and wear. Clamps should be Slack must be allowed for required movement, but the wire
installed in such a manner that the wires do not come in contact must not be too loose. Routing of the wire must be such that it is
with other parts of the aircraft when subjected to vibration. not rubbed or pinched by moving parts during operation of the
Sufficient slack should be left between the last clamp and the mechanism. An examination of the wire during a ground check
electric equipment to prevent strain at the wire terminals and to of the operation of the mechanism will usually reveal any
minimize adverse effects on shock mounted equipment. Where hazards.
wire bundles pass through bulkheads or other structural
members, a grommet or suitable clamping device should be
provided to prevent abrasion as shown. lf a wire bundle is held Electric wiring must be protected from excessive heat. As noted
by a clamp in the center of a hole through a bulkhead, and the previously, electric wiring is insulated and protected with various
clearance between the edge of the hole and the bundle is more types of materials, some of which can withstand temperatures
than ¼ in. (0.64 cm), a grommet is not required. as high as 392°F [200°C). In areas where a wire must be
subjected to high temperatures, it is necessary to use wiring
At points in an installation where electric wire may be exposed with insulation made of asbestos or some other heat-resistant
to oil, hydraulic fluid, battery acid, or some other liquid, the material. Wires should not be routed near exhaust pipes,
cable should be enclosed in a plastic sleeve. At the lowest point resistors, or other devices that produce high temperatures
in the sleeve, a hole 1/8 in. [0.32 cm] in diameter should be cut except as required for special purposes and then only if the
to provide for drainage. The sleeve can be held in place by wires are protected with adequate heat-resistant insulation.
clamps or by lacing.

If a hot wire terminal should come into contact with a metal line
carrying a flammable fluid, the line might be punctured and the
fluid ignited. This, of course, would result in a serious fire and
probable loss of the airplane. Consequently, every effort should
be made to avoid this hazard by physical separation of the
cables from lines carrying oil, fuel, hydraulic fluid, or alcohol.

When separation is impractical, the electric wire should be

placed above the flammable-fluid line and securely clamped to
the structure.
ISO 9001:2008 Certified For Training Purpose Only
PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 41 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 42 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

EWIS INSTALLLATIONS Prevention of Chafing

Fig. below shows correctly routed loom cables, as well as some When it is impossible to prevent cable loom contact with the
common mistakes. aircraft structure, then wrapping is the recommended method of
protection.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
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 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

Routing Through Bulkheads Slack between Loom Supports

When a loom has to pass through a bulkhead, cable clamps The slack or droop of a loom between loom supports should be
and grommets are used to keep the cables clear of the not more than 1/2 inch when moderate hand pressure is applied
bulkhead structure. at the midpoint between clamps, as shown in Fig.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 44 Nov 2017
 PIA TRAINING CENTRE (PTC) Module 7A - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.7 – Electrical wiring Interconnection System

INSPECTION

Ensure that the conduit used is properly assembled and is to

the requirements of the drawing.

MODIFICATION AND REPAIR

Cables used as replacements, or used for modifications of an

aircraft, should be of a type approved by the constructor for that
particular aircraft type unless an approved design authority
selects an alternative. This selection should recognize the
various factors detailed in this Information Leaflet. This is most
readily achieved by obtaining a Declaration of Design and
Performance (DPP) from the manufacturer if that manufacturer
is suitably CAA Approved. The user should also take steps to
ensure that the quality of cable is satisfactory and the preferred
method of achieving this is by obtaining a CAA Approved
Certificate from the manufacturer.

ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7A/05 Rev. 01
7.7 - 45 Nov 2017