In the copalum splice section I've schetched a scenario where a generator power feeder wire was shorted out and a piece of the wire has been damaged on a outstation.
The damaged wire was a gauge #6 copper wire and it was damaged between a copalum splice and a wing disconnect receptacle.
In this scenario we have to go there and repair the aircraft. We have decided to make a permanent repair on the wire.
In the copalum splice section we've seen how to check if we are allowed to repair the wire with a splice and how to repair the wire with a splice.
We have chosen to replace a length of wire, splice it in with the copalum splice and crimp a pin on it to connect the wire to the wing disconnect receptacle.
For this example I will use a hydraulic hex tool to crimp the contact.
If we are going to an outstation it is very important to bring the correct materials and tools so first of all, like with the copalum splice, we need to find the correct procedure and equipment and tools partnumbers for this job.
By looking at the wiring diagram we know the receptacle number D5124J.
We take this number to the equipment list to find the receptacle's partnumber.
Now that we know the partnumber of the receptacle (BACC63CD28A22P) we go to the SWPM (Standard Wire Practices Manual), we go to the chapter cross reference index to find the chapter for this partnumber.
We go to this chapter, we have the partnumber of the receptacle so let's look at the partnumber breakdown for this receptacle.
Because our partnumber is BACC63CD28A22P that apart from the fact that it is a receptacle, it has a straight BACC10HV cable strain relief clamp, the insert configuration is 28-22, the contacts are pins and the index position is normal.
With the insert configuration we can find the layout of the connector's contacts, the number of contacts and the contact sizes.
For our receptacle we have 3 gauge #4 size holes in the receptacle and 3 gauge 16 size holes.
We go to figure 25 for a look at the contact cavity layout.
From the wiring diagram we know that it was contact B that had the damaged wire so it is this contact that we will replace.
We will need to crimp a pin on the new cable that we've spliced in using the copalum crimptool and insert it into this receptacle.
This connector and receptacle are known to have caused problems in the past, high resistance in this connector or improper installation (not fully engaged) has led to overheated and burned out contacts.
This type of defect is usually accompanied with a feeder fault and/or popping 3 phase circuitbreakers.
Removing this connector however is not an easy task, the access to this connector is terrible.
This connector is in good shape.
If u take the effort to disconnect and inspect the pylon disconnect and invent some new curse words trying to manhandle this connector off and on, it is almost obvious that u take a look inside the firewall disconnect connector on the engine wich in comparison to the pylon disconnect connector is a walk in the park.
This connector and receptacle is also in good shape.
To remove the contact from the receptacle we need a extractor tool wich is found under contact removal in the chapters index.
In our case the contact cavity size is gauge #4 so the removal tool will have to be this size.
For inserting the new contact once it's finished we also need a insertion tool.
We know that the contact cavity is gauge #4 so we need to order a gauge #4 pin to connect to the power feeder wire.
The crimp barrel is a gauge #4 wich is larger than the gauge #6 wire that we want to connect to it.
For the preparation of the wire we find that we need to increase the conductor size.
For a gauge 8 and larger wire we don't use filler wires but a adapter sleeve.
We now have the partnumbers for the receptacle, the extractor tool, the pin and the adapter sleeve, we now need to know wich tool to use to make the crimp.
We find that the SWPM states 2 types of crimptool for this job, a indent crimp tool (8 indent) and a hex crimp tool.
For this demonstration we will use the hex crimptool. If u want to use the indent tool see the Pico 400B tool section.
The basic unit's are partnumbers of crimp heads that hold the Die Set, the Die Set is the hexagonal shape crimp block that we will press to make the crimp.
We use the Thomas&Betts 13642 crimp head.
The 13642 crimp head allready holds a Die Set but for our contact this is not the correct one.
To remove a Die Set from this crimping head we simply twist the top off.
And the Die Set comes right out.
We find the correct Die Set 11734.
I put the Die Set in the crimping head, close the head back up and put the metal guard around the crimping head.
For the crimping head we now connect a hydraulic power pump.
I would allways make a test crimp before I'd go to an outstation because if there are any discrepancies it is best to find out at main base than somewhere on some small airfield standing under the wing with horizontal rain and heavy wind gusts beating into you.
Here's my colleague Erik triumphantly waving his screwdriver after we found a faulty fire detection element after a good hour troubleshooting in the rain on an outstation.
So for the testcrimp, here is a bit of gauge #6 wire, the pin and the adapter sleeve.
With the wire in the adapter sleeve the strands of the conductor stick out a bit.
So that when we insert the wire with the adapter sleeve into the pin, we can see the conductor through the inspection hole.
I put the pin into the Die Set and pressurise the crimping head.
And the contact is crimped.
But the crimp is not finished, there are two flanges on the sides of the contact that need to be dealt with.
So we rotate the contact 60 degrees and put it back into the crimptool. This time the crimp comes out with a proper hex crimp.
The difference between the first crimp and the second crimp is pretty clear.
We now have the crimptool, the extractor, the insert tool, the pin, the adapter sleeve, the new wire, some standard tools, the procedures on paper, the copalum splice equipment and tools that we've seen in the copalum splice section so now we only need passports, tickets and some clean clothes and we are ready to go to the outstation.
To read about the copalum splice in the power feeder wire go to the copalum splice section, to read about making this same contact on the same receptacle by using a indentor tool go to the picotool section.