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should be considered for aged aircraft if these precautions have not been taken.
Current clamping practices should be evaluated and alternative methods investigated to minimize
damage to wire in aerospace applications.
Routine inspection schedules for aged aircraft should include wire-to-wire wear inspections for
XPI wire. In addition, PI and PTFE/glass wire types should be routinely inspected for wire-towire
wear in fluid-contaminated areas.
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Routine inspection schedules for aged aircraft should include clamp to wire tightness
inspections. Building up bundles to the clamp diameter should be considered as needed.
The following additional testing options should be considered to further understand the
degradation characteristics of mixed wire in the EWIS:
• Subject test bundles to both fluid and metal shavings contamination
• Test bundles with and without twisted pairs
• Actively monitor during vibration testing
• Use tape wrap inside the cushion clamp if it does not fit snugly on the wire bundle
• Heat aging of wires prior to testing
• Crush test at elevated temperature
• Abrasion cut through testing
• Flex bending of bundles
• Alternative clamping practices
7. RELATED DOCUMENTATION.
a. Industry Standards
• AS50881, SAE Aerospace Standard, Wiring, Aerospace Vehicle
• AS22759, SAE Aerospace Standard, Wire, Electrical, Fluoropolymer-Insulated,
Copper or Copper Alloy
• AC 43.13-1B, Department of Transportation, Federal Aviation Administration,
Advisory Circular: Acceptable Methods, Techniques, and Practices. Aircraft
Inspection and Repair
• ANM-01-04, Department for Transportation, Federal Aviation Administration,
Policy Statement, System Wiring Policy for Certification of 14 CFR Part 25
Airplanes
• Advancement Handbook for Aviation Electricians Mate of 15 October 2001
• SAE ARP4404A, Aerospace Recommended Practice, Aircraft Electrical
Installation
• 14 CFR Part 25, Department of Transportation, Federal Aviation Administration
• SAE AS4373, Test Methods for Insulated Electric Wire
b. Military Standards
• MIL-W-81044, Military Specification, Wire, Electric, Crosslinked Polyalkene,
Crosslinked Alkene-Imide Polymer, or Polyarylene Insulated, Copper or Copper
Alloy
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• MIL-W-5086, Military Specification, Wire, Electric, Polyvinyl Chloride
Insulated, Copper or Copper Alloy
• ITSS (MATMEP) F/A-18 Duty Area (MOS 6337), Aircraft Electrical Technician
• MIL-HDBK-5400, Electronic Equipment, Aerospace, General Specification For
• MIL-HDBK-454, General Guidelines for Electronic Equipment
• MIL-W-5088L, Military Specification, Wiring, Aerospace Vehicle
• NAVAIR 01-1A-505, Technical Manual, Installation Practices, Aircraft Electric
and Electronic Wiring
• Air Force T.O. 1-1A-14, Technical Manual, Installation Practices, Aircraft
Electric and Electronic Wiring
• NAVWAG Guideline D5-GI-1188
c. Aircraft Manufacturer Specifications
• Airbus Industrie Manual 20-33-10, Electrical Standard Practices
• Boeing Standard D6-54446, 20-00-14, Wiring Practices Manual
• Boeing Specification Support Standard BSS 7324F, Procedure for Testing
Electrical Wire and Cable
d. Miscellaneous Documentation
• Raytheon—Indianapolis and FAA report Aircraft Wire System,
Recommendations for a TSO to Address Minimum Safety Performance of 30
June 2003
• Naval Avionics Center Report TR-2333, Testing of Selected Aircraft Electrical
Wire Insulations
• McDonnell Douglas Corporation report MDC J1530: 09/73, Engineering Report,
Vibration of DC-10 Wire Bundles
• McDonnell Douglas Corporation report MDC J1530/01: 08/74, Engineering
Report, Vibration of DC-10 Wire Bundles
• McDonnell Douglas Corporation report MDC J6573: 04/76, Interim Engineering
Methods Authorization Report
• McDonnell Douglas Corporation report MDC J6998: 09/76, Final Engineering
Methods Authorization Report, Aircraft Wire Containment
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• ASTRAC HWG ESWPM 10/31/02
• McDonnell Aircraft Company Report MDC B0482, Performance Comparison of
M81381/9, M22759/19, M22759/33, and Non-MIL Spec Wire and Cable
• ASTRAC Task 6: Wire Systems Certification Requirements Harmonization
Working Group Final Report
• ASTRAC Transport Aircraft Intrusive Inspection Project, An Analysis of the
Wire Installations of Six Decommissioned Aircraft
8. REFERENCES.
1. ATSRAC Transport Aircraft Intrusive Inspection Project (An Analysis of the Wire
Installations of Six Decommissioned Aircraft), section, Research Recommendations of
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