AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5
SECTION 2
CHAPTER 5
WIRING MAINTENANCE PRACTICES – INCLUDING REPAIRING
WIRE AND CABLE
INTRODUCTION
1. All wiring should be maintained so that it is
mechanically and electrically sound and neat in
appearance. It is imperative to prevent or significantly
reduce potential contamination or debris from coming
into contact with the wiring and components during all
maintenance, repairs and modifications. This begins
with an awareness of potential wiring contamination,
and remembering to install appropriate protection
(e.g., plastic sheeting), as necessary, to cover
avionics/electrical wiring and components.
2. A "clean-as-you-go" process helps to maintain
the integrity of the installation. Care should be taken to
protect wire bundles and connectors during work, and
to ensure that all shavings, debris and contamination
are cleaned up after work is completed.
3. Aircraft wiring is sometimes damaged during
normal operation and maintenance. This chapter
provides information on general maintenance
techniques and the methods that may be relevant in
repairing various types of wire and cable.
4. Always follow the manufacturer’s repair process
but for those aircraft that do not have repair processes
for the wiring installations then an acceptable methods
of maintaining the original electrical and mechanical
integrity are set out in in this document and FAA A.C.
43-13 –1B & 2A.
NOTE
Where practicable, damaged wire or cable should
be replaced from one termination to the next.
WIRING MAINTENANCE PRACTICES
5. Following maintenance, care should be taken to
ensure the routing is in accordance with
manufacturers’ documentation. The wiring must be
adequately supported throughout its length. A
sufficient number of supports must be provided to
prevent undue vibration of the unsupported lengths. All
wires and wire groups should be maintained and be
routed or installed to protect them from:
a. Chafing or abrasion
b. High temperature
c. Being used as handholds
d. Damage by personnel moving within the aircraft
e. Damage from cargo stowage or shifting
f. Damage from battery acid fumes, spray, or
spillage
g. Damage from solvents and fluids.
6. Specific routing and installation procedures are
described in the aircraft maintenance/wiring diagram
manuals. In general terms, the following items can be
considered guidelines when conducting wiring
maintenance:
7. Protection Against Chafing. Wires and wire
groups should be protected against chafing or
abrasion in those locations where contact with sharp
surfaces or other wires would damage the insulation.
Cable clamps should be used to support wire bundles
and maintain spacing at each hole through a
bulkhead. If wires come closer than 3/8 inch (10mm)
to the edge of the hole, a suitable grommet should be
used in the hole Sometimes it is also necessary to cut
nylon or rubber grommets to facilitate installation. In
these instances, after insertion, the grommet can be
secured in place with general-purpose cement. The
cut should be at the top of the hole, and made at an
angle of 45 degrees to the axis of the wire bundle
hole.
8. Protection Against High Temperature. To
prevent insulation deterioration, wires should be kept
separate from high-temperature equipment, such as
resistors, exhaust stacks, or pneumatic ducts. The
amount of separation is normally specified by
engineering drawings. Some wires must invariably be
run through hot areas. These wires must be insulated
with high temperature material. A low-temperature
insulation wire should never be used to replace a high-
temperature insulation wire. Many coaxial cables have
soft plastic insulation, such as polyethylene, which is
especially subject to deformation and deterioration at
elevated temperatures. All high temperature areas
should be avoided when installing cables insulated
with plastic or polyethylene.
9. Protection Against Solvents and Fluids. One
frequently encountered hindrance to inspections is dirt
and grime. Consult the manufacturer’s maintenance
instructions for recommendation on materials suitable
for cleaning electrical connectors and wires. For wire
inspections, a soft cloth, such as a cotton glove, can
be used to clean individual wires. With any cleaning
process, care should be taken not to remove wire
markings and ID tape. In addition, airplanes are often
pressure washed with a general purpose detergent.
Moderate pressure and a general purpose detergent
are not harmful to wiring, but water under high
pressure can penetrate components such as
connectors and splices. Moisture penetration into
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5
components tends to increase with elevated water
temperatures.
10. Engine and APU Wire Harnesses.
Consideration should be given to the refurbishment of
engine and APU wire harnesses during engine and
APU maintenance visits due to the harsh environment.
11. Protection of Wires in the Wheel Well Area.
Typically, wire bundles in this area should be
mechanically protected. These wires and their
protective devices should be inspected carefully at
frequent intervals. There should be no strain on
attachments when parts are fully extended, slack
should not be excessive.
12. Routing Precautions. When wiring must be
routed parallel to combustible fluid or oxygen lines for
short distances, as much fixed separation as possible
should be maintained. Specific separation standards
should be available in manufacturer documentation.
However, when such information is unavailable, a six-
inch minimum separation may be used as a guideline,
and no wire should be routed nearer than ½ inch to a
plumbing line. The wires should be on the level with,
or above, the plumbing lines. Clamps should be
spaced so that if a wire is broken at a clamp, it will not
contact the line. When a specified separation is not
possible, both the wire bundle and the plumbing line
can be clamped to the same structure to prevent any
relative motion. A wire or wire bundle should not be
supported from a plumbing line that carries flammable
fluids or oxygen. Wiring should be routed to maintain a
manufacturer recommended minimum clearance from
control cables. When a manufacturer-specified
clearance is not given, coordinate with the Original
Equipment Manufacturer.
13. Connectors. A connector should be
disconnected from a receptacle in the following
manner:
a. Use connector pliers to loosen coupling rings,
which are too tight to be loosened by hand.
b. Alternately pull on the plug body and unscrew
the coupling ring until the connector is
separated.
c. Protect disconnected plugs and receptacles to
keep contamination from entering and causing
faults.
d. Do not use excessive force, and do not pull on
attached wires.
e. Use only approved contact cleaners do not use
oil based water displacement products unless
the connector is properly cleaned prior to re-
installation
f. When reconnecting, special care should be
taken to ensure the connector body is fully
seated, the jam nut is fully secured, and no
tension is on the harness.
14. Conduits are used in aircraft installation for
protection of wires and cables. Conduits are available
in metallic and non-metallic material, both in rigid and
flexible form. When selecting conduit size, a general
2
recommendation is to select the inside diameter of the
conduit to be about 25% larger than the maximum
diameter of the conductor bundle. Conduits are
vulnerable to abrasion at the ends. Suitable fittings are
affixed to the conduit ends in such a manner that a
smooth surface comes in contact with the conductor
within the conduit. When fittings are not used, the
conduit ends should be flared to prevent wire
insulation damage. The conduit should be supported
by clamps along its run. Many of the common conduit
problems can be avoided by proper attention to the
following details:
15. Do not use a conduit as a handhold or footstep.
16. Ensure drain holes are provided at the lowest
point in a conduit run and are clear. Drilling burrs
should be carefully removed from the drain holes.
17. Ensure that the conduit is supported to prevent
chafing against the structure and to avoid stressing its
end fittings. Damaged conduit sections should be
repaired to prevent damage to the wires or wire
bundle. The minimum acceptable tube bend radii for a
rigid conduit as prescribed by the manufacturer’s
instructions should be followed. Kinked or wrinkled
bends in a rigid conduit are normally not acceptable.
Transparent adhesive tape is recommended when
cutting flexible tubing with a hacksaw to minimize
fraying of the braid.
18. Cleaning. Care must be taken whenever wiring
is being cleaned, especially as the aircraft and its
wiring age. In general, wire insulation may become
brittle, so displacement or moving of wiring during
cleaning must be kept to the absolute minimum.
Careful identification of the most appropriate cleaning
methodology is very important. Vacuuming, perhaps in
combination with light sweeping of wiring and wire
bundles with soft brushes, to remove dirt and debris
may be preferred. Additionally, significant damage can
be done to wire insulation and other electrical system
components with the inappropriate use of cleaning
solvents.
19. Wire Marking. Some wiring, due to either or
both gauge and wire type is unsuitable for “Hot Stamp”
marking as defect reporting has identified a significant
number of insulation failures due to damage from this
process. Care must be used and the recommended
temperatures, pressures and dwell time for hot
stamping must be followed. After marking an insulation
test should be carried out to determine the integrity of
the insulation. Preferentially the alternate process of
inkjet and UV laser marking should be used.
SINGLE WIRE REPAIR
20. If an aircraft wire is damaged at a single point
and there is sufficient slack in the wire, the damaged
wire should be repaired with a single splice. If a wire
is damaged along its length, the damaged segment
must be cut out and replaced with a jumper wire and
two splices (Figure 5–1).

WIRE DAMAGED
AT SINGLE POINT
WIRE DAMAGED
AT ALONG LENGTH
Figure 5–1 Damage Assessment
2. Carry out repairs as follows:
a. Cut cable ties and remove cable clamps as
required to access wire damage.
b. Work damaged wires to outside of wire bundle.
Pull slack in wire toward damaged area to
prevent strain on splice.
c. If more than one wire is to be spliced and wires
are not colour coded or otherwise identified, tag
wires before proceeding.
d. Cut out the segment of wire with conductor or
insulation damage. If a jumper wire is required,
cut out at least 15cm of the damaged wire to
allow room for splicing (Figure 5–2).
CUT OUT DAMAGED AREA
CUT MINIMUM 150 mm
Figure 5–2 Removing Damaged Area
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5
e. If more than one jumper wire is to be installed,
stagger splice positions by varying lengths of
sections that are cut out of the damaged wires.
f. Determine type and gauge of wire to be
replaced from wire identification code or wiring
diagram.
g. Cut replacement wire 12.7mm longer than
removed segment.
h. From Table 5–1, select applicable splice for wire
being replaced.
WARNING
Dry cleaning solvent P-D-680, type II is flammable.
Avoid eye and skin contact or breathing of vapours.
Appropriate protective equipment is required.
i. Clean 50mm of insulation, at wire ends to be
spliced, with dry cleaning solvent.
j. Strip wire insulation appropriate length for
selected splice.
k. Slide splice sealing sleeve over one end of
stripped wire (Figure 5–3).
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Table 5–1 Splice Selection

Wire Gauge Splice Part Number Colour Band Crimp Tool Crimp Die

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

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

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

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

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

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

WARNING
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft

WARNING
Use of nitrogen with hot air gun M83521/5-01 in an
Figure 5–3 Sealing Sleeve placed on One Wire End
enclosed area can be hazardous. Ensure area is
well ventilated.
l. Using appropriate crimping tool and die (Table
5–1) crimp splice to wire ends (Figure 5–4) n. Shrink sealing sleeve using hot air gun with
small termination reflector. Shrink middle first
and move heat towards one end until sealant
melts and begins to flow out of sleeve (Figure
5–6). Repeat for other end. Allow to cool.

Figure 5–4 Correctly Installed Crimp Barrel

m. Centre sealing sleeve over crimp barrel (Figure

5–5).

Figure 5–5 Sealing Sleeve Centred over Crimp

Barrel Figure 5–6 Splice Sealing

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

o. If installing a jumper wire, repeat steps i to n.

p. Work repaired wires into the bundle ensuring

splices remain staggered (Figure 5–7).

Figure 5–8 Scored Jacket on Multi-Conductor Cable

Figure 5–7 Completed Splices

q. Replace cable clamps and cable ties removed

for access.

Figure 5–9 Damage Assessment

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

22. Unshielded Cable Repair. Carry out repairs

as follows:

a. Cut cable ties and remove cable clamps as

required to access cable damage.

CAUTION
When scoring cable jacket, ensure conductor
insulation is not damaged.
Figure 5–10 Removing Damaged Area
b. Using a sharp blade or knife, score cable jacket
around the cable and along the length of the
damaged area (Figure 5–8). g. If more than one jumper wire is to be installed,
stagger splice positions by varying lengths of
c. Flex cable at score marks until jacket separates. sections that are cut out of the damaged wires.
d. Remove jacket to gain access to damaged h. Determine type and gauge of wire to be
wires (Figure 5–9). replaced from wire identification code or wiring
diagram.

i. Cut replacement wire 12.7 mm longer than

removed segment.

j. Select applicable splice for wire being replaced

from Table 5–2.

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Table 5–2 Splice Selection

Wire Gauge Splice Part Number Colour Band Crimp Tool Crimp Die

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

or or
M22520/10-01 M22520/10-104
20, 18, 16 M81824/1-2 Blue M22520/5-01 M22520/5-103
or or
M22520/10-01 M22520/10-104
16, 14, 12 M81824/1-3 Yellow M22520/5-01 M22520/5-102
or or
M22520/10-01 M22520/10-103

WARNING
Dry cleaning solvent P-D-680, Type II is flammable.
avoid eye and skin contact and breathing of
VAPOURS. appropriate Protective equipment is
required.

k. Using dry cleaning solvent, clean 50 mm of

insulation at wire ends to be spliced.
Figure 5–13 Sealing Sleeve Centred Over Crimp
l. Strip wire insulation appropriate length for Barrel
selected splice.

WARNING
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft.

WARNING
Figure 5–11 Sealing Sleeve Placed on One Wire Use of nitrogen with hot air gun M83521/5-01 in an
End enclosed area can be hazardous. Ensure area is
well ventilated.
m. Slide splice sealing sleeve over one end of
stripped wire (Figure 5–11).

n. Using appropriate crimping tool and die (Table

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

o. Centre sealing sleeve over crimp barrel (Figure

5-13).

Figure 5–12 Correctly Installed Crimp Barrel Figure 5–14 Splice Sealing

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

p. Shrink sealing sleeve using hot air gun with NOTE

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

t. Keeping tape stretched firmly, begin wrapping

around cable in a single layer, spiral wrap, using
a 50% overlap.

u. Continue wrapping until cable is wrapped

12.7 mm beyond repair area.

v. Terminate tape by wrapping one complete turn

around cable, keeping tape at a right angle to
axis of bundle.
Figure 5–15 Completed Splices w. Spot tie both ends of insulating tape (Figure 5–
16).
r. Work repaired wires into the bundle ensuring x. Replace cable clamps and cable ties removed
splices remain staggered (Figure 5–15). for access.

Figure 5–16 Taping Cable Jacket

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

23. Shielded Cable Repair. Carry out repairs as

follows:

NOTE
This procedure calls for cutting all conductors in the
cable to allow installation of the repair braid and
insulation tubing.

a. Cut cable ties and remove cable clamps as Figure 5–19 Wire With Damaged Section Removed
required to access cable damage.

b. Select shield repair kit according to the outside i. Cut undamaged wires at staggered locations
diameter of the damaged cable jacket (Table 5– (Figure 5–20).
3).

c. Using a sharp blade, score cable jacket around

the cable and along the length of the damaged
area (Figure 5–17).

Figure 5–20 Undamaged Wires Cut at Staggered

Locations

j. Slide tubing and braid from shield repair kit,

over one cable end (Figure 5–21). Tape tubing
Figure 5–17 Scored Jacket and braid away from repair area.

d. Flex cable at score marks until jacket separates.

e. Remove jacket.

f. Using small scissors or diagonal cutter, remove

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

Figure 5–21 Tubing and Braid Located on Cable

End

k. If damaged sections of wire have been removed

ensure that the removed sections are at least
50 mm long, to allow room for splicing.

l. If more than one jumper wire is to be installed,

stagger splice positions by varying lengths of
Figure 5–18 Damaged Multi-conductor Cable sections that are cut out of the damaged wires.

m. Determine type and gauge of wire to be

g. If wires are not colour coded or otherwise
replaced from cable identification code or wiring
identified, tag all wires before proceeding. diagram.
h. Cut wires to remove damage. If a segment of n. Cut replacement wire appropriate length to
damaged wire must be cut out, remove at least match removed segment (Figure 5–22).
50 mm total length. (Figure 5–19). If damage is
at a single point, damaged wire can be cut at
the point of damage.

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Table 5–3 Shield Repair Kit Selection

Repair Kit Cable Parameters Kit Components

Part Number Number of Conductor Conductor Splice Splice Shield Splice
Conductors Size Range Part Number Quantity Part Number

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

D-150-0168

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

D-150-0169

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

D-150-0170

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

D-150-0174

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

D-150-0175

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

D-150-0176

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

D-150-0177

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

D-150-0178

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

D-150-0179

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

D-150-0180

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

D-150-0181

o. Carry out wire splicing procedure as detailed in

paragraph 3, steps i to n.

p. When all wires have been reconnected, remove

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

Figure 5–22 Jumper Wire Cut to Match Removed

Segment

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5
Figure 5–23 Jacket Removed
q. Slide repair braid along cable and centre over
repaired area (Figure 5–24).
Figure 5–24 Repair Braid Centred Over Repair Area
WARNING
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft.
WARNING
Use of nitrogen with hot air gun M83521/5-01 in an
enclosed area can be hazardous. Ensure area is
well ventilated.
r. Heat one end of the repair braid using hot air
gun fitted with appropriate size reflector. Apply
heat to the overlapping shield area until the
solder melts and the sleeve shrinks onto the
cable. Continue heating until solder flows into
braid strands. Allow to cool undisturbed until
solder solidifies (Figure 5–25).
s. Repeat step r. for opposite end.
t. Slide heat shrink tubing over repaired area and
centre (Figure 5–26).
u. Heat tubing using hot air gun fitted with
appropriate size reflector. Start in the middle
and heat until tubing shrinks moving out to one
end. Repeat for other end.
10
Figure 5–25 Heating Repair Braid
Figure 5–26 Tubing Centred Over Repaired Area
MIL-STD-1553 DATA BUS CABLE REPAIR
24. The following paragraphs provide general
information on MIL-STD-1553 data bus system and
the tooling, materials, and procedures for repair of the
data bus.
25. The 1553B Data Bus is a computerized and
multiplex digital data distribution system for the many
functions of command, control, communications, and
intelligence designed for military aircraft. A twinax
cable of 78 ohms was selected to provide the
transmitted digital information with the required
protection from magnetic and electrostatic interference
including nuclear electromagnetic pulse. Therefore,
complete shielding of the pair along the transmission
path as well as within the multi-pin connector must be
maintained.
NOTE
While the information and procedures contained in
this supplement are appropriate for repairing MIL-
STD-1553 data bus cables, aircraft specific repair
procedures take precedence.
 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Single Shield Cable with Solder Sleeve Primary c. Overlap conductors under solder preforms.
Splice. d. Use a holding fixture to hold wires in alignment.

26. Prepare the cable using the following

procedure: WARNING
Use only hot air gun M83521/5-01 or equivalent on
a. Remove 31mm of cable jacket (Figure 5–27). fuelled aircraft.
b. Trim shield to 9mm from cable jacket.

c. Strip primary conductors 12.7mm and pre-tin.

d. Trim fillers flush with shield. WARNING

Use of nitrogen with hot air gun M83521/5-01 in an
27. Assemble as follows: enclosed area can be hazardous. Ensure area is
well ventilated.
a. Place D-150-0124-01 outer sleeve and
D150-0124-02 shield splice (small end first)
onto one cable. e. Heat solder preforms until they melt and form a
fillet along wires.
b. Insert primary conductors in D-150-0124-03
primary splice assembly.

Figure 5–27 Single Shield Cable Strip Dimensions

Table 5–4 Tooling

Name Part Number

Crimp Tool AD-1377

or
M22520/10-01
with die
M22520/10-104

Holding Fixture AD-1319

Hot Air Gun M83521/5-01

Databus Harness Tester S2476N

(Aircraft specific test leads
required)

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Table 5–5 Materials

Name Part Number

Splice Kit D-150-0124

Solder Sleeve
24-22 AWG
Single Shield

Splice Kit D-150-0133

Mini-Seal Crimp
24-22 AWG
Double Shield

Splice Kit D-150-0134

Solder Sleeve
24-22 AWG
Double Shield

Splice Kit D-150-0167

Mini-Seal Crimp
24-22 AWG
Single Shield

p. Apply heat in centre of sleeve and move it

NOTE through the heat until it has recovered onto the
The thermal indicator will lose its colour when assembly.
sufficient heat has been applied to make the joint.
q. Perform inspection (Paragraph 20).
f. Heat ends of sleeves until inserts melt and flow
along wires. Double Shield Cable With Solder Sleeve Primary
Splice
g. Perform inspection (Paragraph 17).

h. Centre D-150-0124-02 shield splice sleeve over 28. Prepare the cable using the following
splice and exposed cable shields. procedure:

i. Using heat gun, heat centre of sleeve until a. Remove 43mm of cable jacket (Figure 5–28).
solder melts and shield and tube recover.
b. Trim shield to 18mm from cable jacket, then trim
j. Move sleeve slowly through heat to one end of outer shield to 9mm from cable jacket.
shield to keep sleeve recovering.
c. Strip primary conductors 12.7mm and pre-tin
k. Apply additional heat for 5 to 10 seconds to final primaries.
12.7mm of sleeve shield to ensure sufficient
d. Trim fillers flush with shields.
heat transfer to the cable to make a good joint.

l. Apply heat to end of sleeve until ring melts and

flows along cable jacket. 29. Assemble as follows:

m. Repeat for other end of sleeve. a. Place D-150-0134-01 outer sleeve and
D150-0134-02 shield splice (small end first)
n. Perform inspection (Paragraph 19). onto one cable.
o. Centre D-150-0124-01 strain relief sleeve over b. Insert primary conductors in D-150-0134-03
completed splice. primary splice assembly.

c. Overlap conductors under solder preforms.

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

d. Use a holding fixture to hold wire in alignment.

NOTE
The thermal indicator will lose its colour when
WARNING sufficient heat has been applied to make the joint.
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft. f. Heat ends of sleeves until inserts melt and flow
along wires

g. Perform inspection (Paragraph 17).

WARNING h. Centre D-150-0134-02 shield splice sleeve over

splice and exposed cable shields.
Use of nitrogen with hot air gun M83521/5-01 in an
enclosed area can be hazardous. Ensure area is i. Using heat gun, heat centre of sleeve until
well ventilated. solder melts and shield and tube recover.

j. Move sleeve slowly through heat to one end of

e. Using heat gun, heat solder preforms until shield to keep sleeve recovering.
melted and form a fillet along the conductors.

Figure 5–28 Double Shield Cable Strip Dimensions

k. Apply additional heat for 5 to 10 seconds to final q. Perform inspection (Paragraph 20).
12.7mm of sleeve to ensure sufficient heat
transfer to the cable shield to make a good joint. Single Shield Cable with Miniseal Crimp Primary
Splice
l. Apply heat to end of sleeve until rings melt and
flow along cable jacket.
30. Prepare the cable using the following
m. Repeat for other end. procedure:

n. Perform inspection (Paragraph 19). a. Remove 56mm of cable jacket (Figure 5–29).

o. Centre D-150-0134-01 strain relief sleeve over b. Trim shield to 9mm from cable jacket.
completed splice.
c. Cut one primary 23mm from cable jacket.
p. Apply heat in centre of sleeve and move it
d. Strip both primaries 7mm.
through the heat until it has recovered onto the
assembly. e. Trim fillers flush with shield.

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Figure 5–29 Single Shield Cable Strip Dimensions for Mini-Seal Crimp

31. Assemble as follows: h. Centre D-150-0167-01 shield splice sleeve over

splice and exposed cable shield.
a. Place D-150-0167-04 outer sleeve and D-
150-0167-01 shield splice (small end first) onto i. Heat centre of sleeve until solder melts and
one of the cables. shield and tube recover.

b. Place one D-150-0167-03 sealing sleeve onto j. Move sleeve slowly through heat to one end of
longer lead of each cable. shield to keep sleeve recovering.

c. Crimp matching primaries into opposite ends of k. Apply additional heat for 5 to 10 seconds to final
D-150-0167-02 crimp splice. 0.5 inch (12.7mm) of sleeve to ensure sufficient
heat transfer to cable shield to make a good
d. Centre D-150-0167-03 sleeves over splices. joint.

l. Apply heat to end of sleeve until rings melt and

WARNING flow along cable jacket.
Use only hot air gun M83521/5-01 or equivalent on m. Repeat for other end of sleeve.
fuelled aircraft.
n. Perform inspection.

o. Centre D-150-0167-04 strain relief sleeve over

completed splice.
WARNING
Use of nitrogen with hot air gun M83521/5-01 in an p. Starting at centre of sleeve, move sleeve
enclosed area can be hazardous. Ensure area is through heat until it has recovered onto
well ventilated. assembly.

q. Perform inspection.
e. Using heat gun, apply heat to centre of sleeves
until recovered and then heat ends until sealing Double Shield Cable with Miniseal Crimp Primary
rings melt and flow along wires. Splice

NOTE 32. Prepare the cable using the following

The thermal indicator will lose its colour when procedure:
sufficient heat has been applied to make the joint.
a. Remove 71mm of cable jacket (Figure 5–30).

b. Trim shield to 19mm from cable jacket, then trim

f. Heat ends of sleeves until inserts melt and flow
outer shield to 9mm from cable jacket.
along wires.
c. Cut one primary 32mm from cable jacket.
g. Perform inspection (Paragraph 18).
d. Strip primaries 7mm.

e. Trim fillers flush with shield.

14
 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

33. Assemble as follows: c. Crimp matching primaries into opposite end of

D-150-0133-03 crimp splice.
a. Place D-150-0133-04 outer sleeve and D-
150-0133-02 shield splice (small end first) onto d. Centre D-150-0133-04 sleeves over splices.
one cable.

b. Place one D-150-0133-04 sealing sleeve onto

longer lead of each cable.

Figure 5–30 Double Shield Cable Strip Dimensions for Mini-Seal Crimp

h. Centre D-150-0133-02 shield splice sleeve over

WARNING splice and exposed cable shield.
Use only hot air gun M83521/5-01 or equivalent on
fuelled aircraft. i. Apply heat to centre of sleeve until solder melts
and shield and tube recover.

j. Move sleeve slowly through heat to one end of

WARNING
Use of nitrogen with hot air gun M83521/5-01 in an
enclosed area can be hazardous. Ensure area is
well ventilated.
shield to keep sleeve recovering.
k. Apply additional heat for 5 to 10 seconds to final
12.7mm of sleeve to ensure sufficient heat
transfer to cable shield to make a good joint.

l. Apply heat to end of sleeve until rings melt and

e. Using heat gun, apply heat to centre of sleeves flow along cable jacket.
until recovered and then heat ends until sealing
rings melt and flow along wires. m. Repeat for other end of sleeve.

n. Perform inspection.
NOTE
The thermal indicator will lose its colour when o. Centre D-150-0133-01 strain relief sleeve over
sufficient heat has been applied to make the joint. completed splice.

f. Heat ends of sleeves until inserts melt and flow p. Starting from centre of sleeve, move sleeve
along wires. through heat until it has recovered onto
assembly.
g. Perform inspection (Paragraph 18).
q. Perform inspection.

15
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 5

Inspection 36. Shield splices must be inspected for the

following:
34. Solder sleeve splices must be inspected for the
following: a. Sleeve/shield must be recovered along its entire
length.
a. Conductors must be overlapped a minimum
9mm. b. Sleeve must be recovered tightly around cable
jacket.
b. Fillet length must be a minimum 6mm.
c. Sealing rings must have flowed along cable
c. Sealing rings must have flowed along the wire. jacket.
d. Sleeve must not have discoloured to the degree d. Sleeve must not have discoloured to the degree
that joint cannot be inspected. that the joint cannot be inspected.
e. Sleeve must not be cut or split. e. Sleeve must not be cut or split.
f. Strands of conductor must not be sticking f. Strands must not be sticking through of sleeve.
through the sleeve.
37. Outer sleeves must be inspected for the
35. Mini-Seal splices must be inspected for the following:
following:
a. Sleeves must be recovered tightly onto
a. Conductors must be visible at point where they assembly along its full length.
enter crimp barrel.
b. An adhesive bead should be visible at ends of
b. Both indentations of crimp, must be on crimp sleeve.
barrel.
c. Sleeve must not be cut or split.
c. Sealing sleeve inserts must have flowed along
wire insulation. Testing
d. Sleeve must not have discoloured to the degree
that crimp barrel cannot be inspected. 38. On completion of the inspection procedure the
data bus should be tested to ensure there are no short
e. Sleeve must not be cut or split. circuits, shorts to shield, open circuits or crossovers,
using test equipment detailed in Table 5–4, or
equivalent.

16