Date: 201205
Local time of day: 0001-0600
Location: ZZZ.Airport, US
Weather elements / visibility: Rain
Light: Night
Aircraft: B757-200
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Parked
Aircraft component: Recirculation Fan
Reporter organization: Air Carrier
Reporter function: Inspector
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Confusion
Second reporter function: Technician
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Maintenance
When detected: Routine Inspection
Result: General Maintenance Action
Contributing factors: Aircraft; Equipment / Tooling; Human Factors; Chart Or Publication; Procedure; Manuals
Primary problem: Chart Or Publication

Narrative: I was assigned to accomplish the Final Inspection of an Engineering Order callout and Fleet Campaign Directive Revision-B; to inspect the Right Recirculation (Recirc) Fan Wiring Check; after Aircraft Maintenance Technician (AMT) X accomplished his task; which was to untie the wire bundle; reroute wire bundle and used filler strip provided. He tried to use the filler strip provided in the [Part's] Kit; but was not enough [filler] to secure the wire bundle on the clamp. He opted to use electrical Guideline tape by which in the Standard Wiring Practices Manual (SWPM) 20-10-12 is allowed. Also the SWPM was pointed out on Revision-B of the FCD. During my Inspection; the Guideline tape was not part of the Fleet Campaign Directive and was rejected by Maintenance Control. It should [have] been filler material totally inside the clamp between the wire bundles. Air Carrier Revision that came later clearly stated that no tape allowed at all.


Second narrative: I was assigned to accomplish an Engineering Order for a Right Recirculation (Recirc) Fan Check with an Inspector on a B757-200 aircraft. In the process; we found the wire bundle was looped. I untied the wire bundle and rerouted it according to the instruction stated in the Engineering Order callout pictorial figure. When I installed the wire bundle into one of the clamps; I realized there was a lot of slack in the clamp. To rectify the problem; I went to the Part's Kit provided by the Engineering Order callout. I was looking for a filler rubber rod to reduce the slack in the clamp. I found a black rubber rod; long in length and small in diameter and a clamp that was the same size as the one installed on the aircraft. I wasn't able to use the clamp provided in the kit. I needed a smaller clamp. As a result; I took the black rubber rod and cut into three short pieces and placed inside the clamp of the wire bundle and secured with a tie wrap. The result of the security of the wire bundle was still loose and materials provided for me caused a sloppy result. It would have been better if I was provided with a rubber rod at least four times (4X) thicker than the black rubber rod or proper size of clamp. With my past experience as Avionic Technician; I wasn't satisfied with the result; I decided to remove the rubber rods and use guideline tape to secure the wires into one solid bundle. This is a common past practice that I have used and it is in the Standard Wiring Practices Manual (SWPM) 20-10-12. I used Revision-B of the paperwork. When I returned from my days off; the newer Revision-E stated no tape is allowed as filler material. I placed the wire bundle into the clamp and secured with Tie wrap. The resulting bundle was not loose. In addition; the number of lacing tape used on the sleeve should be more than just both ends of the sleeve per Engineering Order callout. There should be lacing tape in the middle of sleeve for security. By trying to comply with the objective of the Airworthiness Directive (AD); I deviated from the material used in the kit provided by the Engineering Order callout. This event taught me a big lesson: Do not deviate from the AD and if resources or materials are not provided; STOP THE JOB.


Synopsis: A Line Mechanic describes his efforts to accomplish an Engineering Order and Fleet Campaign Directive (FCD) to untie; reroute and use filler material for a Right Recirculation Fan Wiring bundle. A Line Inspector also notes the confusion involving the use of Guideline tape in the FCD to secure the wire bundles.