Crimping
Interpreting information
September 2002, Revision 02
Interpreting information related
to crimping operations
Interpreting the wire coding system.
Making the distinction between various types
of terminals.
Interpreting the terminal coding system.
Selecting the terminal according to the information given in the
work documents.
Selecting the crimping tool depending on the terminal.
COMPETENCE
1
Wire codes
D230-110 2 EA 141 AA 20 CR W7-8 FF255-61
Wire starting area D230
Wire connection 110
Wire number 2 EA 141 AA 20 CR
Electrical bonding, Phase, Thermocouple, Colour
Wire Gauge
Letter Segment
Wire number
Circuit Function Code
System Number
Routing on the jig board W7 – 8
Destination area FF 255
Wire connection 61
Wire codes
FAA J 0001 W-22
F A A J 0001 W - 22
Dimension
Wire Gauge(Wire Gauge)
Mise à la masse,
Electrical phase,
bonding, thermocouple,
Phase, couleur
Thermocouple, Colour
Numéro du conducteur
Letter Segment
Fonction
Operationoptionnelle
function code
Système
System
Position
Localisation
Localisation
Refer to : D230-110 FAA J 0001 W-22 FF 255-61
2
Jig board
The jig board allows us to establish the position of each wire on
a predetermined path.
Jig board
Several hundreds of wires are positioned
on this board.
3
Installing wiring in the aircraft
Interpreting information related
to crimping operations
Distinguish various types of terminals.
COMPETENCE
4
Terminals
Insulated lug
Uninsulated lug
Splice
End cap
Contacts
Male contact
Female contact
Contact with insulating support
Y-type contact
5
Colour code
Coloured insulation on terminals indicates the size of wire to be
installed:
Insulation;
Red Size 2 wire
Yellow Size 4 wire
Blue Size 6 wire
Red Size 8 wire
Yellow Size 10-12 wire
Blue Size 14-16 wire
Red Size 18-20-22 wire
Yellow (small size) Size 24 wire
Colour code Nickel plating
A different colour code is used for nickel plating :
Insulation;
Green Size 20-22 wire
Orange Size 16-18 wire
White Size 14 wire
Black Size 10-12 wire
6
Colour code for contacts
M39029 / XX series
Colour code for contacts:
0 – Black 5 - Green
1 – Brown 6 - Blue
2 – Red 7 - Violet
3 – Orange 8 - Grey
4 – Yellow 9 – White
First colour (2)
Second colour (4)
Third colour (7)
Interpreting information related
to crimping operations
Select the terminal according to the
information given in the work documents.
Select the appropriate crimping tool
depending on the terminal.
COMPETENCE
7
Terminal
Lugs, splices and end caps
Search for the terminal number in the work document.
Example of lug number:
SGC
Crimping tool
Terminal with insulation
Select the crimping tool depending on the supplier, number and
colour code of the terminal.
8
Crimping tool
Uninsulated clip
The tool used to crimp an uninsulated lug has no colour code:
The crimping tools are listed in the “Crimping Tool Selection Guide”
and they are selected based on the lug number.
Crimping tool
Pneumatic / hydraulic
The pneumatic / hydraulic tools used are:
AMP
T&B
Burndy
9
Crimping tool
Colour code
The colour of the terminal insulation must match the colour of the
crimping tool label.
Crimping tool
Contacts
Search for the tool number in the work document.
Select the basic tool corresponding to the number given in the work
document.
Select the “Die” depending on the type of contact and wire thickness.
10
Searching for the tool number
When the tool number is not mentioned in the work document:
Refer to the “Crimping Tool Selection Guide”;
Selection guide
Crimping tools
11
Crimping
Terminals
Stripping a wire
Terminals
Determine the length of wire to be stripped:
12
Stripping tool
Position the wire in the appropriate opening and press the
handles until the wire is stuck in the tool.
Check the wire length on the side opposite to the pliers holding
the wire.
Stripping of a wire
Press the tool handles until the jaws are open.
Strands broken by a tool
with damaged blades,
or by using a non authorized tool
13
Checking the stripping
Terminals with insulation
Check the length of the stripped wire using the appropriate
terminal.
Checking the stripping
Terminals without insulation
Check the length of the wire to be stripped using the appropriate
terminal.
14
Adjusting the tool
The dowel pin is positioned depending on the wire thickness:
Red tool Size 18, 20 and 22 wires;
Small wire Position 1 (as illustrated),
Medium wire Position 2
Large wire Position 3
The tool is adjusted depending on the total thickness of
the wire (strands + insulation)
Red = 1
Blue = 2
Green = 3
Inserting a lug
Insert the lug into the tool, so that the insulation is flush with the
tool guide.
15
Crimping a lug
Insert the wire into the lug up to the mechanical stop of the tool.
Mechanical stop
Checking the crimping
Insulated lug
Check whether the installation conforms to the specifications:
Bending of lug for wire gauge 22 to 10 AWG
Bending angle = 90°
Frequency = 1 time
Bending of lug for wire gauge 8 and higher diameter
Bending angle = 30°
Frequency = 1 time
Bend radius of lug = thickness of the lug
16
Tool selection for a T&B lug
Inspection
Make sure the crimping tools correspond to the numbers given in
the work documents.
Mounting T&B tools
Equipment preparation
Install the male and female components.
17
Crimping a T&B lug
Pneumatic equipment
Crimp the T&B lug:
Place the lug on the stop plate;
Press the pedal that activates crimping;
Make sure the required pressure is reached.
Checkpoints
T&B lug
Make sure that:
the wire braid coincides with the end of the electrical crimping area;
the figure is visible on the electrical crimping area of the lug;
the insulation is not damaged.
18
Inserting a lug
Insert the lug into the tool so that the secondary crimping area is
flush with the tool guide.
Crimping a splice
Insert the wire into the splice until it becomes visible in the
inspection opening.
19
Checking crimping of a splice
Make sure it is installed in accordance
with the specifications:
Raychem Splice
Always use « Raychem » tools for « Raychem » splice
20
Inserting an end cap
Position the end cap in the crimping tool, so that the end cap
rests against the mechanical stop.
Press the handles together to keep the terminal in place.
Inserting the wire
Insert the wire until it touches the insulation on the bottom of the
end cap.
Firmly press the tool handles together.
21
Checking an end cap
Check the installation of the end cap:
Crimping
Uninsulated lug
Place the uninsulated lug properly in the crimping tool.
22
Checking the crimping
Uninsulated lug
The tool marks on an uninsulated lug must be on the right side,
so that the lug is not folded.
Number of wires per uninsulated lug
Lug Number of wire
Uninsulated Diameter 22 AWG 20 AWG 18 AWG
M7928/7-3, 22-18 1à2 1 1
-1, -2, -4, -5, -6
M7928/7-7, 16-14 4 ou 5 2 ou 3 2
-8, -9, -10, -11
MS 20659-165, 12-10 9 à 13 4à8 3à5
-105, -106, -128, -166
Uninsulated lugs
Assembling
Eight lugs maximum can be installed on this type of cable holder
Six lugs maximum can be installed on this type of connector
23
Crimping a terminal
You are able to...
Select the crimping tools according to the instructions in the work
documents.
“Cahier de montage”;
Crimping tools selection guide;
Etc.
Check the position of the stripped wire in the terminal:
in a lug, up to the mechanical stop;
in a splice, up to the inspection opening;
in an end cap, up to the insulator.
Crimping a terminal
You are able to...
Check the crimping :
the wire position in the terminal;
the inspection mark (point or figure) on the terminal insulation;
the absence of cracks on the insulation;
the flattening of the secondary crimping area on the wire insulation ;
tool marks left on the uninsulated lug;
The tool marks must be on the front side of the lug.
24
Crimping
Contacts
Stripping a wire
Contacts
Determine the length of wire to be stripped:
25
Checking the stripping
Contacts
Check the length of the stripped wire using the appropriate
contact.
Installation of a positioner
Install the appropriate positioner in the basic tool, according to
the gathered information.
26
Finding information
Read the information on the positioner in order to place the
selector in the appropriate position.
In the example below, the selector, for a size 22 wire, has to
be placed at 5.
Installation of the die
Install the appropriate die and screw it into the basic tool for
crimping contacts.
27
Finding information
Die
Read the information given in the metallic label of the tool.
Position the red barrel for a size 20 contact;
Adjusting the tool
“Selector”
Adjust the selector placed on the tool handle, depending on the
information given in the metallic label of the die.
In the example bellow, the “Red barrel” must be selected for a size
22 wire and the”Selector” must be positioned at 2.
28
Crimping a contact
Before crimping a contact, make sure the wire length is correct.
Crimping a contact
Insert the contact and the wire into the tool opening.
29
Crimping a contact
Firmly press the tool handles.
Crimping a contact
Pneumatic tool
The length of wire stripping for “large size” contacts is checked in
the same way as for small size wires.
30
Crimping tool
Pneumatic/hydraulic
Inserting a locator
Pneumatic/hydraulic - Locator
Place the locator correctly.
Make sure the locator number corresponds to the number mentioned
in the work documents.
31
Die operation
Make sure the number on the die corresponds to the number
mentioned in the work documents.
Inserting the die
Pneumatic/hydraulic - Die
Make sure to align the tool PLUNGER with the die OPENING.
32
Crimping tool
Pneumatic/hydraulic - Crimping
Screw the cover on the tool by hand .
Insert the wire and contact in the locator opening:
Press the button to start the tool.
Checking the crimping
Contact
Check the conformity of crimping:
the wire is visible through the inspection opening;
the crimping marks are visible and centered;
the wire insulation is equal to or 1/32" away from the contact;
the contact is straight and without any deformation.
33
Crimping a contact
You are able to...
Select the tool and its accessories according to the information
given in the working documents or the tool label.
Adjust the die and selector depending on the type of contact and
thickness of the wire.
Insert the wire in the contact so that it is visible through the
inspection opening.
Crimping a contact
You are able to...
Insert the wire and the contact into the tool opening, then firmly
squeeze the handles.
Activate the calibrated pneumatic tool, while checking the
maximum pressure.
Check the crimping marks, the wire in the inspection opening and
the distance between the wire insulation and the contact.
34
