Pins and sockets crimptool (gauge 20-32)
This tool is used to crimp the lower ranges of pins and sockets. The wire gauges that can be crimped with this tool range from 20 trough 32.
The tool's military specification is the M22520/2-01, the Daniels Manufacturing Corperation makes one called the DMC AFM8 and Astro makes one called the Astro 615717.
It's bigger brother the M22520/1-01 uses a turret that can (in most cases) be selected to three diameters color coded to be red, blue and yellow.
The M22520/2-01 tool however does not use a turret that can be selected to different diameters, it uses so called 'locators' to accept the contact.
They both use a selector that sets the depth of the indents allowing a range of wire gauges to be crimped.
The locators often have information printed onto them for quick reference.
Like some other crimptools on this page I have created a scenario in wich we need to look to the books to find the right tool and the step by step procedure to arrive at the proper tool and parts that need to be ordered.
The scenario I made up is that some wires, pins, sockets and both the receptacle and the EADI connector have burned out at a Electronic Attitude Direction Indicator in the cockpit.
So the EADI stops working and the captains complains that his main instrument is not working anymore.
We come in and take the display out and see that the connector is burned.
At this point it is probably best to send it straight to the hangar because this is not a quick fix on the line.
Looking at wich contacts have damaged we go to the Wiring Diagram Manual and find that these three contacts are damaged.
Firstly, we need to order the new EADI wich we can find easily through the IPC (Illustrated Parts Catalogue)or through the equipment number of the EADI.
The EADI has the receptacle on the backside of the unit itself therefore we don't need to order a new receptacle.
The plug in this case however is the part that is fitted to the aircraft and is the part that the receptacle on the backside of the EADI slides onto.
This one is damaged and needs to be ordered.
For this we need the equipment number of the plug, this equipment number can be found at the bottom side of the receptacle in the Wiring Diagram.
I order the plug wich is a DPXBMB-67-33S-0001, at this point we could also decide to order the mounting plate and the filler that are used to install this receptacle. At this time I'll assume that they are still in good condition.
Now it's time to find the details about this receptacle from the Standard Wire Practices Manual.
I go to the chapter cross reference index to find wich chapter I need to look under.
Turns out to be chapter 20-71-11
In this chapter I first go to the partnumber breakdown.
Our partnumber was DPXBMB-67-33S-0001 so the DPX is the ITT CANNON DPX series, arinc style shell is B, the class is MB wich means that the receptacle has crimp type contacts (as opposed to soldered) and a wire separator.
The contact configuration is 67, the 33S means that this is the plug side and the S means that this side incorperates sockets (So the receptacle side incorperates pins).
Further partnumber breakdown translates that the arinc style B is a single insert shell that has polarization.
The class MB is further described also.
The single insert means that there is only one plug and receptacle pair and the polarized is a attempt of making this connection fool proof, by selecting different key and post positions on both sides we can exclude the connector or receptacle to accept only their polarization.
A double insert polarized would look like this.
And a single insert non-polarized like this.
The SWPM states a alternative partnumber for if we don't have this plug on stock.
We can use a ITT Cannon DPXBMA-67-33S-00() or a Radiall DSX1H23S00() instead.
We take the partnumber to the insert configuration table and find that the insert configuration is A-67.
At the insert configuration table we find that this insert configuration is made up of 3 1616 sockets and 64 2020High Density sockets.
We know that they are sockets because of the partnumber breakdown (DPXBMB-67-33S(ockets)-0001).
The insert configurations table refers us to figure 46 for a closer look at the plug.
Our damaged contacts were on positions 30, 31 and 32, we found that the other contacts were not damaged by the overheat.
Positions 30, 31 and 32 are the 2020HD type sockets so now we can go to the contact partnumbers list.
These are approved sockets to be used for our purpose.
If we haven't already removed the contacts from the plug and were not sure about the proper removal tool, this is also specified in the SWPM.
This removal tool is standard red.
To know wich side of the 2020HD is the crimp barrel and wich is the engaging end we take a further look at the contact partnumbers section.
We now have found the required partnumbers and as soon as we have them we can start repairing the burned contacts. For this scenario I will not order wire because the wiring is still in good shape and is lengthy enough to shorten it a bit (by putting a new contact on it).
So now it's time to strip the wire, the wire stripping details are stated in the SWPM also.
The wiring diagram showed us that we will have only 1 wire in each of the three contacts, the wire gauge size is 24.
The insert configuration tells us that we have a gauge 20 crimp barrel size so now we know that we need to strip 0.19 inch of insulation off with a tolerance of 0.03 inch and that we do not need to fold the conductor back to increase the thickness of the wire.
Then we go to the finishing information, for one gauge 24 wire to be crimped onto a 2020HD contact we need to use the M22520/2-01 tool with a setting of 5 (wich selects the crimp depth) and locator M22520/2-08 (wich selects the position on the contact where the crimp is made).
When the new plug comes in it needs to be set at the proper polarization.
A look at the double insert partnumber breakdown informs us that the -0001 dashnumber at the end of the partnumber refers to the modification status and the polarization code.
Our partnumber DPXBMB-67-33s-0001 can therefore be further broke down in a modification status 00 and a polarization code 01.
The polarization code 01 means for our plug that the posts are to be alligned upwards (position 1 in the drawing).
For the M22520/2-01 we use a Astro 615717 tool with the M22520/2-08 locator installed on it.
The locator is connected by a simple bayonet connection so removing it just requires a quarter turn.
When the contact is inserted into the crimp opening the locator should hold it at the proper crimp length. (In this example I use a contact with a insulation jacket and not the contact that we are about to crimp).
I strip the wires to the required length (gauge 24 is quite a thin wire).
On a contact without a insulation jacket the insulation should never be flush with the contact, a small space is required between the end of the insulation and the contact.
Also the wire must be visible through the inspection hole on the contact.
U can see that this gauge 24 wire is quite a bit thinner than it's gauge 20 crimp barrel.
I put the contact in the crimptool.
I crimp the contact and I inspect the crimp.
There are several different locators available.
So far this example of using the M22520/2-01 crimptool.