B767-300 and 300 ER
Maintenance Airframe; Maintenance Avionics; Maintenance Powerplant
Maintenance Avionics 23; Maintenance Technician 10
Communication Breakdown
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural FAR
General Maintenance Action
Incorrect / Not Installed / Unavailable Part; Staffing; Procedure; Human Factors; Company Policy; Aircraft
I have been an Avionics Technician at Air Carrier X for 20-plus years and am currently on the B767 Maintenance Dock in ZZZ. Lately; while working the Emergency Battery Airworthiness Directive (AD) Engineering Order (EO) Modification (MOD); I have noticed [electrical] wires that appear not to be in accordance with the Standard Wiring Practices Manual (SWPM). The majority of wiring concerns are located inside and around the P36 Power Panel; as well in the Overhead P5 Panel in the flight deck. What I have seen and repaired are clamps jumped; missing tie-wraps; clamping too large and/or missing; wires rubbing on structure and not routed in bundles. On one airplane; a small bundle of wires appear to be banjoed across a section of the E/E compartment in midair. I have documented these issues with pictures and used the resources available to me including Lead Mechanics; Technical Support; Union Representative contacts and Company Engineering. As I am assigned the work; I have been repairing what I can see; but wonder if I may have missed some other issues within and beyond the scope of the AD MOD we are currently doing. The last few airplanes that have been through our Maintenance Dock have had wire issues of one form or another. I am not sure of the exact state of these airplanes and am worried that if left alone the rubbing and chafing could get worse. My other concern is how many of our B767 fleet has similar issues related to the P36 panel and the pilot's overhead areas. I strongly feel this is a serious issue and it's not getting the support and attention warranted.
Reporter stated the Airworthiness Directive (A/D) 2013-24-10 he referenced; requires making wiring changes; running new wires and installing a new Air/Ground Relay to the Battery Charger System. The Engineering Order (E/O) incorporates the A/D requirements for Avionics Technicians to accomplish the necessary Modifications. The A/D requires major opening up of the cockpit ceiling; sidewalls and lower E/E compartment to accomplish the installation of two wires that run from the P33 Panel to the P36 Power Panel in the lower E/E Compartment up through the cockpit floor sidewall to the P61 Maintenance Panel and a new Air/Ground Relay behind the First Officer; then a single wire run from the P61 Panel up the cockpit sidewall and across the cockpit ceiling to the P5-Overhead Panel and the Battery switch. Reporter stated the extensive open-up required by the A/D he was working; exposed areas that were previously opened about four or five years ago to accomplish a major cockpit electrical wiring and electronics upgrade modification. That work was accomplished by mechanics who were upgraded to an Avionics Technician's position with little to no training about Standard Wiring Practices and Procedures. That particular modification involved the installation of many wire bundles without any Quality Assurance (Q/A) or Inspections required; or called out for in their work documents. They are the same areas he has been accomplishing the current A/D wiring modifications.Reporter stated he has been finding previously installed wire bundles in the P36 Power Panels that are missing all kinds of Tie-wraps with open looms of wires that are loose and not secured. Electrical wires inside the cockpit Overhead P5 electrical panel and adjacent ceiling panels are not secured to the Tie-wraps that are anchored to the upper fuselage. As a result; the same wire bundles sag over time lay across the metal supports for the ceiling and P5 Panel and start chaffing and fretting because they do not even have protective nylon spiral wraps installed around the bundles. The potential for an electrical fire developing in the cockpit of their B767-300 becomes even more of a concern because these are over water ETOPS aircraft. He hopes his Air Carrier will initiate a Fleet Campaign to check all of their B767s.
An Avionics Maintenance Technician (AMT) reports finding improper and unsafe routing installations of wire bundles in P36 power panels and cockpit overhead P5 panels on numerous B767-300 aircraft. Technician also raises concerns about aircraft safety; the potential for electrical fires from unsecured and chaffing wire bundles; especially on over water ETOPS aircraft.