AC 21-99 Aircraft Wiring and Bonding

Sect 2 Chap 6

SECTION 2
CHAPTER 6

SOLDERLESS TERMINATIONS AND SPLICES

INTRODUCTION
splices. Terminal lugs and splices are crimped to wires by
1. Electric wires are terminated with solderless terminal means of hand or power crimping tools. Power tools may
lugs to permit easy and efficient connection to and be portable or stationary (bench-mounted). Typical
disconnection from terminal boards, busbars, and other crimping tools are illustrated where they are mentioned in
electrical equipment. Solderless splices join electric wires the procedures. Environmental sealed splices (MIL-S-
to form permanent continuous runs. 81824) are the only permanent splices that should be used
on aircraft. Potted non-environmental splices may be used
2. This chapter describes recommended methods for as a temporary/emergency repair and shall be replaced as
terminating copper and aluminium wires, using solderless soon as practicable.
terminal lugs. It also describes recommended methods for
permanently joining (splicing) wires, using solderless End Caps, Splices, Terminal Lugs and Crimp Tools
splices. (Termination of thermocouple wires is covered in 6. Only Class I end caps, splices, terminal lugs and
Section 2, Chapter 16.) crimping tools qualified to SAE AS 70991, SAE AS 7928,
REFERENCE SPECIFICATIONS MIL-S-81824 or MIL-DTL-22520 are recommended for use
on aircraft unless otherwise authorised by an appropriate
3. The following specifications are applicable to engineering authority. Class I terminations are approved
solderless terminations and splices: for the replacement of Class II terminations or non-
qualified terminations fitted by the manufacturer or
MIL-DTL-22520 Crimping Tools, Wire Termination, specified in the aircraft/equipment IPB.
General Specification For 7. Terminal Lugs, splices, end caps and tooling are
MIL-S-81824 Splice, Electric, Permanent, Crimp classified as follows:
Style, Copper, Insulated, a. Class I Terminal Lugs and Splices and End Caps –
Environment Resistant Lugs, splices and end caps that conform to all the
requirements of the applicable specification when
MIL-T-81714 Terminal Junction System (TJS), installed with the specified crimping tools.
Environment Resistant General
Specification For b. Class I Tools are those which meet all the
requirements of the applicable specification.
SAE AS70991 Terminals, Lug and Splice, Crimp c. Class II Terminal Lugs, Splices and End Caps -
Style, Aluminium, for Aluminium lugs, splices and end caps that conform to the
Aircraft Wire material and marking requirements of the
specification and are replaceable by Class I
SAE AS7928 Terminals, Lug: Splices, Conductor:
terminals. They conform to the performance
Crimp Style, Copper, General
requirements of the specification when crimped with
Specification For
a tool having crimping dies and motion conforming
DESCRIPTION to the terminal manufacturer’s drawing.
d. Class II tools, terminal lugs, end caps and splices
4. Solderless terminal lugs and splices are plated copper should not to be used on aircraft.
or aluminium, and are pre-insulated or uninsulated, e. The types and styles of terminal lugs, splices and
depending on the application. Terminal lugs and splices for end caps are listed in Annex A, Table 6–A–1.
high temperature applications are silver or nickel plated
copper and are insulated with TFE (or a similar material). TERMINATING SMALL COPPER WIRES WITH
PRE-INSULATED TERMINAL LUGS
NOTE
Use only copper terminations on copper wire and 8. Small copper wires (sizes No. 26 thru No. 10) are
aluminium terminations on aluminium wire. Only terminated with solderless pre-insulated straight copper
environment resistant sealed splices shall be used as terminal lugs conforming to SAE AS 7928. (See Annex A,
permanent electrical wire splices on aircraft. Table 6–A–1.) As shown in Figure 6–2, the insulation is
part of the terminal lug and extends beyond its barrel, so
that it will cover a portion of the wire insulation; this makes
5. Terminal lugs are available in four styles: straight, 90 the use of an insulation sleeve unnecessary. In addition,
degree upright, angle, and flag, for use under different pre-insulated terminal lugs have an insulation support (a
applications. Figure 6–1 shows typical terminal lugs and metal reinforcing sleeve) beneath the insulation for extra

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

supporting strength on the wire insulation. Most pre-

insulated terminals accommodate more than one size of
wire. The insulation is colour coded and the range of wire
sizes is marked on the tongue to identify the wire sizes that
can be terminated with each of the terminal lug sizes.

Figure 6–1 Solderless Terminal Lugs and Splices

CAUTION
Using tin plated terminals on nickel plated wire may not achieve appropriate voltage drop and tensile strength
requirements. Refer to SAE AIR 1263.

High Temperature Terminal Lugs

9. Appropriately rated high temperature terminal lugs shall be used on high temperature wire where the termination is
located in a high temperature area. Where wire termination is in a low temperature area, standard crimp terminals may be
used. Table 6–2 provides details of tools and terminations that are considered suitable for use on high temperature wire.

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

Colour of Terminal Lug To Be Used On Wire

Installation Size(s)
Yellow with Black Stripe 26
Yellow with Blue Stripe 24
Yellow 26 or 24
Red with Green Stripe 22
Red with Red Stripe 20
Red with White Stripe 18
Red 22, 20 or 18
Blue with Blue Stripe 16
Blue with Green Stripe 14
Blue 16 or 14
Yellow with Yellow Stripe 12
Figure 6–2 Preinsulated Terminal Lug – Cut-Away Yellow with Brown Stripe 10
Yellow 12 or 10
Table 6–1 Colour Coding of Copper Terminal Lug
Insulation
Gold Plated PIDG Ring Tongue Insulated Terminals Rated to 260C (500F)
Terminal Part Number Stud Size Wire Size Tool Part Number (AMP)
1-332433-0 6 22-20
332434 8 22-20 69692-1
1-332434-0 10 22-20
332453 6 18-16
332454 8 18-16 69693-1
1-332454-0 10 18-16
Nickel Plated Ring Tongue Terminals Rated to 343C (650F) Uninsulated with Insulation Support
323151 6 22-16
323152 8 22-16 46673
323153 10 22-16
Nickel Ring Tongue Terminals Rated to 649C (1200F) Uninsulated with Insulation Support
321892 6 22-16
321893 8 22-16 46673
321894 10 22-16

Crimping Tools Hand Tool Description

10. Only tools qualified to MIL-DTL-22520 are to be used 11. All approved hand crimping tools have a self-locking
for crimping terminal lugs. These tools crimp the barrel to ratchet, which prevents the tool from opening until crimp is
the conductor, and simultaneously form the insulation complete. This mechanism must never be disassembled
support to the wire insulation. since it ensures proper crimping closure. The M22520/5
and M22520/10 tools are the approved tools to be used in
crimping sizes 26 through 10, end caps, splices and
CAUTION terminal lugs. The M22520/5-01 and M22520/10-01 crimp
With some of the smaller gauge thin wall wires, tools have removable dies for crimping 26 through 10
insulation can be inadvertently inserted and crimped in terminal (wire barrel) sizes see Figure 6–3.
the terminal barrel.
Hand Tool Inspection
12. Dies and other working parts of crimping tools used
for electrical terminations become worn in service and this
can result in unsatisfactory terminations. An effective
means to ensure a serviceable termination is to monitor
the condition of the tool by regular testing. The standard

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

tools are checked by means of a GO/NOGO gauge for tool jaws and the shafts of the gauge are clean and free of
assurance of quality crimps. For good crimping results, damage.
gauging should be carried out prior to each series of
crimping operations. Replace or repair hand tools, which Millivolt Drop and Tensile Strength Test
are out of tolerance. The details contained in Table 6–3
are provided for in-service inspection gauging of 13. When gauging tools are unavailable, testing can be
M22520/5-01 and M22520/10-01 tools and dies. Prior to accomplished by carrying out a millivolt drop and tensile
performing the gauging test, ensure that both the crimping strength test on a completed crimp (Refer to Annex D).
Table 6–3 Gauging Tools

Die Part Number Die Cavity Size Gauge Part Number

M22520/5-100 12 – 10 M22520/3-9
M22520/5-100 26 – 14 M22520/3-10
M22520/5-101 26 – 20 M22520/3-11
M22520/5-102 16 – 12 M22520/3-12
M22520/5-103 20 – 16 M22520/3-13
M22520/5-103 26 – 20 M22520/3-14
M22520/10-100 12 – 10 M22520/3-9
M22520/10-101 26 – 14 M22520/3-10
M22520/10-102 26 – 20 M22520/3-11
M22520/10-103 16 – 12 M22520/3-12
M22520/10-104 20 – 16 M22520/3-13
M22520/10-104 26 – 20 M22520/3-14

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 AC 21-99 Aircraft Wiring and Bonding
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Figure 6–3 Crimp Tools and Dies (Sheet 1 of 2)

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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

Figure 6–3 Crimp Tools and Dies (Sheet 2 of 2)

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

Table 6–4 Dies and Gauges for Power Tool MS25441

Terminal Lug Size Die Part Number MS Gauge Part Number

(For Head MS25441-1)
Insulated Terminals
8 MS23002-8 MS23003-8
6 MS23002-6 MS23003-6
4 MS23002-4 MS23003-4
2 MS23002-2 MS23003-2
1 MS23002-1 MS23003-1
1/0 MS23002-01 MS23003-01
2/0 MS23002-02 MS23003-02
3/0 MS23002-03 MS23003-03
4/0 MS23002-04 MS23003-04
Uninsulated Terminals
8 MS90485- 8 MS90486-8
6 MS90485-6 MS90486-6
4 MS90485-4 MS90486-4
2 MS90485-2 MS90486-2
1 MS90485-1 MS90486-1
1/0 MS90485-01 MS90486-01
2/0 MS90485-02 MS90486-02
3/0 MS90485-03 MS90486-03
4/0 MS90485-04 MS90486-04
Aluminium Terminals
8 MS25442-8A MS25472- 1
6 MS25442-6A MS25472-2
4 MS25442-4A MS25472-3
2 MS25442-4A MS25472-4
1 MS25442-1A MS25472-5
1/0 MS25442-01A MS25472-6
2/0 MS25442-02A MS25472-7
3/0 MS25442-03A MS25472-8
4/0 MS25442-04A MS25472-9

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AC 21-99 Aircraft Wiring and Bonding
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Crimping Procedure for M22520/5 and M22520/10 Hand

Tools

14. Hand crimp pre-insulated copper terminal lugs in the

No. 26 - No. 10 wire size range with M22520/5 or
M22520/10 hand tools as follows:

a. Strip wire insulation using one of the recommended

stripping procedures detailed in Section 2, Chapter
3. (Stripping lengths are provided in Table 6–4).
b. Check tool for correct adjustment in accordance
with paragraph 12. Tools out of adjustment must be
returned to the manufacturer for repair.
c. Insert terminal lug, tongue first, into wire side of
hand tool barrel crimping jaws, until terminal lug
barrel butts flush against tool stop on the locator.
(See Figure 6–3 for correct insertion method).
Figure 6–4 Proper Insertion of Stripped Wire in
d. Squeeze tool handles slowly until tool jaws hold Insulated Terminal Lug for Crimping
terminal lug barrel firmly in place, but without
denting it.
e. Insert stripped wire into terminal lug barrel until wire
insulation butts flush against near end of wire barrel.
(See Figure 6–2 or Figure 6–4.)

f. Squeeze tool handles until ratchet releases.

g. Remove completed assembly and examine it for
proper crimp in accordance with paragraph 36.

CAUTION
With some of the smaller gauge thin wall wires,
insulation can be inadvertently inserted and crimped in
the terminal wire barrel. Figure 6–5 Insulating Sleeves

Insulating Sleeves
Table 6–5 Wire Stripping Lengths for Small Copper
Terminal Lugs 16. Uninsulated straight flag terminal lugs are insulated
(after assembly to wire) with heat shrinkable tubing (see
Wire Size Stripping Length (mm) Section 2, Chapter 4) or with lengths of transparent tubing.
26 and 24 4.0 These methods of insulation provide electrical and
mechanical protection at the connection. When the size of
22 and 20 4.7 sleeving used is such that it will fit tightly over the terminal
18, 16 and 14 6.4 lug, the sleeving need not be tied; otherwise, it is to be tied
12 and 10 7.0 with lacing cord. (See Figure 6–5.)
Crimping Tools for Sizes 8 through 4/0 Terminals
TERMINATING LARGE COPPER WIRES
17. Manual and/or power crimping tools are available for
15. Copper terminal lugs of two styles (straight and flag) crimping M7928/4 and MS25036 insulated terminals,
are used to terminate copper wires sizes No. 8 through No. MS20659 uninsulated terminals and MS25189 flag type
4/0. The style to be used depends on existing space terminals. The tools are the MS25441-5 hydraulic pedal
conditions. These terminal lugs are available uninsulated pump and the MS25441-4 electric hydraulic pump used
in both types and pre-insulated in the straight type. Straight with the MS25441-1 hydraulic head and the MS25441-3
pre-insulated terminal lugs conform to SAE AS 7928 (see hose (or an adaption - without the control cable), and the
Annex A, Table 6–A–1). As shown in Figure 6–2, pre- proper dies.
insulated terminal lugs have the insulation extending MS25441 Tool Adjustment
beyond the wire barrel, so that it will cover a portion of the
wire insulation. This makes the use of a separate 18. The MS25441 tools can be checked for proper
insulating sleeve unnecessary. Straight uninsulated adjustment. For good crimping results, this must be done
terminal lugs conform to SAE AS 7928 and MS20659. Flag before each series of crimping operations. When tool is
uninsulated terminal lugs conform to SAE AS 7928 and adjustable, proper correction must be made; otherwise, the
MS25189. tool must be returned to manufacturer for repair. Gauge
the dies of the MS25441 tool in the closed position with the
appropriate GO/NO GO gauges listed in Table 6–5.

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 AC 21-99 Aircraft Wiring and Bonding
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Millivolt Drop and Tensile Strength Test

19. When gauging tools are unavailable, testing can be

accomplished by carrying out a millivolt drop and tensile
strength test on a completed crimp (Refer to Annex D).

CRIMPING PROCEDURE FOR MS25441 TOOLS

20. Crimp large Military Standard copper terminals as

follows:

a. Select proper die for terminal and wire size from

Table 6–5 and install die in tool.

WARNING
ALWAYS disconnect power tool from its pressure
source BEFORE installing or removing dies.

NOTE
Do not use any crimping tool beyond its rated capacity.

b. Strip wire insulation, using recommended practices

described in Section 2, Chapter 3. Stripping lengths
for copper wire shall be conductor barrel length plus
1.6mm.

c. Insert stripped wire into terminal barrel until wire Figure 6–6 Power Crimping Tools – Large Copper
insulation butts flush against end of barrel. Terminal Lugs

d. Insert wire and terminal lug assembly into die.

e. Actuate the crimp tool. Press button on handle for

electrically operated tool. Do not release the button
until the dies open automatically. Actuate handle for Aluminium Terminal Lugs
manual hydraulically operated tool.
22. Only aluminium terminal lugs conforming to SAE AS
f. Remove the crimped assembly, and examine it for 70991 are used to terminate aluminium wires. See Figure
proper crimp, in accordance with paragraph 36. 6–1 for typical connections. Aluminium terminal lugs are
available in four types; straight (MS25435), 90 degrees
upright (MS25436), left angle (MS25437), and right angle
TERMINATING ALUMINIUM WIRE (MS25438). The barrels of aluminium terminal lugs are
filled with a petroleum-base abrasive compound. This
21. Aluminium wire is used in aircraft because of its compound, by a grinding process during the crimping
weight advantage over copper. Aluminium, however, has operation, removes the oxide film from the aluminium. The
the disadvantage of being softer than copper. Further, compound also prevents oxide from reforming in the
bending aluminium wire will cause “work hardening” of the completed connection. All aluminium terminals have an
metal that makes it more brittle. This will result in failure or inspection hole to allow checking the depth of wire
breakage of strands much sooner than in copper wire. insertion (see Figure 6–1). This inspection hole is sealed
Aluminium also forms a high resistance oxide film with a removable plastic plug, which also serves to retain
immediately upon exposure to air. To compensate for the oxide-inhibiting compound. Each aluminium terminal
these disadvantages it is important to follow carefully the lug is marked with the letters “AL” indicating it is for use
recommended installation procedures. with aluminium wire, and also with the wire size it will
accommodate.
CAUTION
CAUTION
Do not use any aluminium wire which has nicked or
broken strands. Damaged strands will fail in service. Do not remove the inspection plug until the crimp has
been completed and the wire insertion is to be
inspected. Replace plug after inspection.

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AC 21-99 Aircraft Wiring and Bonding
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Insulating Sleeves i. Check visually to see that the correct wire size is
imprinted on the barrel.
23. Aluminium terminal lugs are not pre-insulated;
therefore, it is necessary to insulate them, after assembly, j. Remove the inspection plug and check visually or
with lengths of transparent flexible tubing or heatshrink with the aid of a probe to see that wire is fully
sleeves. The sleeve provides mechanical and electrical inserted. Replace the plug after inspection.
protection at the connection. (See Figure 6–5). k. Slide insulating sleeve over the terminal lug barrel
and secure in accordance with paragraph 16 and
Crimping Tools Figure 6–5.

24. Use the MS25441 tool to install MS aluminium Table 6–6 Stripping Lengths for Aluminium Wire
terminal lugs. See paragraph 18 for tool adjustment.
MS25435, MS25436,
Crimping Procedure for Aluminium Terminal Lugs Wire Size
MS25437, MS25438

25. Crimp MS aluminium terminal lugs as follows: 8 17.5

a. Using MS25441 tool, select proper die for wire size.
6 20.6
Die is stamped with the wire size on both upper and
lower faces and with the letters AL. Install die in tool
head. 4 21.5

2 2.6.0
CAUTION
Use care when stripping wire insulation. do not nick or 1 26.0
damage aluminium wire strands.
1/0 25.0
b. Strip wire insulation carefully, using recommended
stripping practices for aluminium wire described in 2/0 31.0
Section 2, Chapter 3. Stripping lengths are listed in
Table 6–6.
3/0 32.5
c. Install insulating sleeve over wire insulation, well
back from crimping area. 4/0 36.5

d. Inspect to see that inner barrel is well coated with

compound.

CAUTION
Do not remove the inspection plug as this keeps the
compound in the barrel. When the wire is inserted to the
full depth of the barrel, the compound is forced between
and around the conductor strands.

e. Insert wire into terminal barrel.

f. Wipe off any excess compound squeezed out of

terminal lug barrel with a clean soft cloth.

g. Insert assembly into the die and position as shown

in Figure 6–7.

h. Actuate the crimp tool. On electrically operated tool,

press the button on the control handle. Do not
release the button until the dies open automatically.
Actuate handle for manual hydraulically operated
tool.

NOTE
Wire sizes No. 8 thru No. 2/0 require only one crimp.
Wire sizes No. 3/0 and No. 4/0 require two crimps.
Locate the second crimp centrally on the portion of the
barrel remaining after the first crimp. See Figure 6–8.

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 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

SPLICING SMALL COPPER WIRES

26. Environmental permanent splices conforming to MIL-

S-81824 are used to join small copper wire sizes No. 26
through No. 10. Typical splices are shown in Figure 6–1.
The splice insulation extends over the wire insulation.
Each splice size can be used for more than one wire size.
Splices are colour coded in the same manner as insulated
copper terminal lugs; refer to paragraph 8 and Table 6–1
for details.

27. Permanent wire splices may be used to assemble

sub-assemblies, to incorporate changes or to facilitate
repairs. The use of permanent splices shall be subject to
the following restrictions:

a. There shall not be more than one splice in any one

wire segment between any two connectors or other
disconnect points, except as allowed by sub-paras
e, g and h below.

b. Installation of splices in bundles shall not increase

the size of the bundle so as to prevent the bundle
from fitting in its designated space or cause
congestion that will adversely affect maintenance.

c. Splices shall not be used to salvage scrap lengths

of wire.

d. Splices shall not be used within 30cm of a

termination device, except for sub-para e, below.

e. Splices may be used within 30cm of a termination

device when attaching to the pigtail spare lead of a
potted termination device, or to splice multiple wires
to a single wire, or to adjust the wire sizes so that
they are compatible with the contact crimp barrel
sizes.

f. The application of splices shall be under design

control and shall be authorised by engineering
drawings.

Figure 6–7 Positioning Aluminium Terminal Lugs in Die g. Splices may be used to repair manufactured
Nests harnesses or installed wiring when approved by an
appropriate engineering authority.

h. Splices shall not be used on firing or control circuits

associated with ordnance or explosive sub-systems.

i. Splices shall not be used on fire resistant wire.

28. When practicality conflicts with the intent of these

restrictions refer to local engineering authority.

Crimping Tools

29. The M22520/5 and M22520/10 crimp tools with

appropriate dies are the approved tools for crimping sizes
26 through 10 splices.
Figure 6–8 Single Crimp on Aluminium Terminal Lugs

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AC 21-99 Aircraft Wiring and Bonding
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Single Conductor Wire Splicing And Repair Procedure

30. The following text is the repair procedure for a single 33. If a wire is damaged at a single point and there is
conductor, non-shielded copper wire of 6 to 26 AWG. sufficient slack in the wire, as shown in Figure 6-9, the
damaged wire can be repaired with a single splice.
31. To carry out the repair on a single conductor, a MIL-S-
81824 splice is used. The splice is a two piece; 34. If a wire is damaged along its entire length, as shown
environmentally resistant, copper crimp type splice used at the bottom of Figure 6-10, the damaged segment must
on 12 to 26 AWG copper wire. They may be used with tin be cut out and replaced with a jumper wire installed using
plated and silver plated conductors, where the total two splices
temperature of the wire insulation does not exceed 150°C.
Restrictions 35. To perform a single conductor wire splicing and repair:

32. The following restrictions apply when carrying out a a. Cut ties and remove support clamps as required to
repair of a single conductor, non-shielded copper wire of 6 access wire damage.
to 26 AWG:
b. Work damaged wires to outside of wire bundle.
a. Repairs requiring multiple splices must be Carefully pull slack in wire toward damaged area to
staggered. Splices should not increase the size of prevent strain on the splice.
the bundle enough to prevent it from fitting into its
designated place or cause congestion that will c. If more than one wire is to be spliced, and the wires
adversely affect maintenance. are not colour coded or otherwise identified, tag the
wires to be spliced with an identification before
b. Splices should not to be used within 300 mm of a proceeding.
termination device except as follows:
d. Cut out any wire with damaged conductor or
(1) When attaching to the pigtail spare lead of a insulation. If a jumper is required, proceed as
potted termination device; follows:
(2) To splice multiple wires to a single wire; or
(3)To adjust wire sizes so they are compatible with contact
crimp barrel sizes.

Figure 6-9 - Wire Damaged Along Its Entire Length

36. Figure 6-10 illustrates, that at least 130 mm of the damaged wire must be removed to allow room for splicing.

FOR WIRES DAMAGED ALONG LENGTH THAT REQUIRE A JUMPER A

MINIMUM CUT GAP OF 130MM IS REQUIRED

Figure 6-10 Removal of the Damaged Section

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 AC 21-99 Aircraft Wiring and Bonding
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37. If more than one jumper is to be installed, stagger splice positions by varying lengths of sections that are cut out of
damaged wires. This prevents bunching of the splices, keeping the diameter of the loom to a minimum. Then:

a. Determine type and gauge of wire being repaired from applicable aircraft wiring data manual.

b. Select a jumper wire of the same type and gauge, cutting a 12.5mm longer section than removed.

c. Select applicable splice for gauge of wire being repaired from the Table 6-6.

Wire Gauge Splice Part No. Colour Band

20 - 26 M81824/1-1 RED

16 - 18 M81824/1-2 BLUE

12 - 14 M81824/1-3 YELLOW

8 D-436-0081 N/A

Table 6-6

Warning
Dry cleaning solvent P-D-680, Type 2 is flammable. Avoid eye and skin contact or breathing of vapours. Protective
equipment consisting of goggles and gloves is required.

d. Clean the last 5 cm of both ends of the wire’s insulation, to be spliced, with dry cleaning solvent.

e. Strip wire insulation to dimensions specified in the table shown below.

Splice Part No. Strip Dimension (mm)

1.5, -0

M81824/1-1 6.0

M81824/1-2 8.0

M81824/1-3 8.0

D-436-0081 11.0

Table 6-7
f. Slide sealing sleeve over one end of the stripped wire, as shown in Figure 6-11.

Figure 6-11 Procedure for Installing Sealing Sleeve

g. Choose the corresponding crimping tool, die set, and inspection gauge specified in the table below for the splice
selected. Insert die set into the crimping tool and ensure correct die closure using the specified inspection gauge.

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AC 21-99 Aircraft Wiring and Bonding
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Splice Part No. Strip Dimension (mm) Crimp Tool

1.5, -0

M81824/1-1 6.0 AD-1377

M81824/1-2 8.0 AD-1377

M81824/1-3 8.0 AD-1377

D-436-0081 11.0 H20

Table 6-8
h. Insert crimp barrel into correct cavity of crimping tool as shown in Figure 6-12. For wire gages 12 through 26, the
cavity colour code will match the colour of the stripe on the crimp barrel. Ensure that the end of the crimp barrel is
against the of the tool and the inspection hole is visible.

Figure 6-12 Insert Crimp Barrel into Correct Cavity of Crimping Tool
i. Insert end of wire into end of crimp barrel opposite stop. The wire must be visible through inspection hole. A gap of
0.8 to 1.5 mm for wire gages 10 through 26, or 1.5 to 3.0 mm for wire gages six and eight, must exist between wire
insulation and crimp barrel as illustrated in Figure 6-13. Trim conductor or insulation as required.

1.5 to 3.0 mm MAXIMUM GAP

Figure 6-13 Crimping the Wire

j. Squeeze handles of the crimping tool through complete crimp cycle.

k. Reverse crimp barrel in cavity. The attached wire will fit in the slot of the stop. Ensure end of crimp barrel is against
stop of tool and inspection hole is visible.

l. Repeat the two steps above.

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 AC 21-99 Aircraft Wiring and Bonding
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m. Examine crimped connection for the following:

(1) Indent centred on splice barrel,

(2) Indent in line with barrel,
(3) Barrel not cracked,
(4) Wire cannot be pulled out of splice, and
(5) A gap of 0.8 to 1.5 mm for wire gages 10 through 26, or 1.5 to 3.0 mm for wire gages 6 and 8, should exist
between wire insulation and crimp barrel.

n. Centre the sealing sleeve over crimp barrel as shown in Figure 6-14.

Figure 6-14 Positioning the Sealing Sleeve

o. Shrink sealing sleeve using a heat gun with a small termination sleeve reflector as shown in Figure 6-15. Start by
shrinking the middle then heat towards each end until sealant melts and begins to flow out of both ends. Allow time
for sleeve to cool before handling.

Figure 6-15
Shrinking the Sealing Sleeve
p. If installing a jumper, repeat steps six to 17 for the other end.

q. If wire identification is no longer within 75 mm of a termination the wire will require remarking.

r. As illustrated by Figure 6-16, position repaired wires into a bundle ensuring the splices remain staggered.

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AC 21-99 Aircraft Wiring and Bonding
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Figure 6-16
Re-Positioning the Wires within the Loom
s. 21. Reinstall any support clamps removed for access.

SPLICING PROCEDURE FOR M81824

ENVIRONMENTAL SPLICES WARNING
Use of nitrogen with hot air gun M83521/5-01 in an
38. Splice in accordance with the following: enclosed area can be hazardous. Ensure area is well
ventilated.
a. Check the M22520/5 or /10 crimp tool for wear in
accordance with paragraph 12. If the tool is worn
j. Slide the sealing sleeve over the crimp barrel,
out of tolerance, it must be replaced.
centre it and heat with hot air to shrink the sleeve.
b. Identify the correct size splice Heat the middle first to lock the sleeve in place, then
heat the ends until the sealing rings melt and ooze
c. Identify the correct size die that will accommodate out around the wire. To ensure a good seal; allow to
the wire(s) to be crimped and install in M22520/5 or cool before handling.
/10 crimp tool.

d. Strip 0.79mm to 0.86mm of insulation from wires,

CAUTION
following one of the procedures in Section 2, Fire resistant wire shall not be spliced. When fire
Chapter 3. resistant wire is damaged or deteriorated replace the
entire length of wire from one permanent termination to
e. Position the crimp barrel in the die of the M22520/5 the next.
or /10 crimp tool, so that one end of the crimp barrel
butts against the crimp locator. Lock in place by
partially closing the handles without denting the
crimp barrel.
CAUTION
f. Insert the wire fully into the crimp barrel, and crimp
Fusing tin plated splices on nickel plated wire may not
by closing the handles until the ratchet releases.
achieve appropriate voltage drop and tensile strength
g. Before completing the splice, slide the sealing requirements. Refer to SAE AIR 1263.
sleeve, which will be shrunk later, back over one of
the wires.
SPLICING HIGH TEMPERATURE WIRES
h. Reverse the position of the crimp barrel in the crimp
tool die. The attached wire will extend through the
slot in the crimp locator. 39. Splices for high temperature applications are available
in the same wire size ranges as terminal lugs. The tools
i. Lock the crimp barrel in place by partially closing the and crimping procedures are the same for splices as for
handles. Insert the other wire(s) and crimp as terminal lugs. Crimp splice at both ends. Appropriately
before. rated high temperature splices shall be used on high
temperature wire where the splice is located in a high
temperature area. Where wire splice is in a low
WARNING temperature area, standard splices may be used. See
Use only hot air gun M83521/5-01 or equivalent on Table 6–9 for details of splices suitable for use on high
fuelled aircraft. temperature wire.

16
 AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

Table 6–9 Splices and Tooling – High Temperature Wire

Nickel Plated Splices Rated to 343C (650F) Uninsulated with Insulation Support
Splice Pt No AWG Tool Pt No.
322823 22-16 46673
322825 16-14 46988
Nickel Splices Rated to 649C (1200F) Uninsulated with Insulation Support
322325 22-16 46673
322346 16-14 46988

Table 6–10 Circular Mil Area (CMA) of Wires and Splices

Wire AWG Circular Mils Splice Part Number Circular Mils

(Nominal) (Nominal)
26 304 M81824/1-1 2025
24 475 M81824/1-2 3969
22 754 M81824/1-3 9025
20 1216
18 1900
16 2426
14 3831
12 5874

SPLICING ALUMINIUM WIRES complying with MS27488 shall be installed in unused

grommet holes. Annex C contains details of SAE
40. Splice large aluminium wires sizes No. 8 through No. AS81714/11 and SAE AS81714/12 environment proof,
4/0 with splice MS25439. Use the MS25441 power tool disconnect, wire splices and associated tooling.
with the correct dies from MS25442. Follow the same
procedure as for aluminium terminal lugs outlined in SPLICING TO REDUCE WIRE SIZE
paragraph 25, positioning the splice in the tool. Crimp 43. Splices may be used to reduce wire sizes. This is a
splice at both ends. special application and may be used only when called for
on the applicable engineering drawing or otherwise
NOTE authorised by an appropriate authority.
The sealing properties of environmental splices may be
compromised when multi-splicing. CAUTION
Do not use any connection which is found defective as
MULTI-SPLICING a result of the visual inspection. Cut off defective
connection and remake using a new terminal lug or
41. Multi-splicing is the crimping together of three or more splice.
wires in a single splice. This is a special application and
may be used only when called for on the applicable
engineering drawing or otherwise authorised by an INSPECTION OF CRIMPED CONNECTIONS
appropriate authority. Where more than one wire is to be 44. Examine the crimped connection carefully for the
crimped into one end of a splice the technician must following:
ensure that the combined size (circular mil area) of the
conductors is compatible with the selected splice. a. Crimp indent centred on terminal lug barrel or splice
Additionally, the wires must fit into the splice insulation barrels
support without altering their insulation. Refer to Table b. Crimp indent in line with barrel.
610 for circular mil area (CMA) of common wires and
c. Terminal lug or splice barrel not cracked.
splices.
d. Terminal lug or splice insulation not cracked.
ENVIRONMENT RESISTANT WIRE e. Insulation support on lugs crimped.
DISCONNECT SPLICES
f. Spliced wires are butted against the stop.
42. When splices are used for inline connections of two or g. Splices for correct environmental sealing.
more wires, where disconnection is required, disconnect
h. Splices for evidence of overheating.
splices complying to SAE AS81714/11 and SAE
AS81714/12 are approved for use. Sealing plugs

17
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 6

TERMINAL JUNCTION SYSTEMS Annexes:

A. Terminations and Tooling
45. See Section 2, Chapter 4, Electrical Wiring B. Stud Size and Corresponding Terminal Lug
Installation, for terminal junction systems. Dimension Reference Chart
C. Disconnect Splices and Tooling
D. Crimp Tool Testing

18
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

TERMINATIONS AND TOOLING

1. The following is a list of tables contained in d. Table 6–A–4. SAE AS81824/1 - Splice,
this annex: Electric, Permanent, Crimp Style,
Copper, Insulated, Environment
a. Table 6–A–1. MS25036 - Terminal Lug, Resistant, Class 1, For 150ºC Total
Crimp Style, Copper, Insulated, Ring Conductor Temperature.
Tongue, Bell Mouthed, Type II, Class 1,
For 105ºC Total Conductor e. Table 6–A–5. MS25274 - Cap,
Temperature. Electrical, Wire End, Crimp Style, Type
II, Class 1, For 105ºC Total Conductor
b. Table 6–A–2. SAE AS7928/1 - Terminal Temperature.
Lug, Crimp Style, Copper, Insulated,
Ring Tongue, For Thin Wall Wire, Type 2. Appropriate crimping tool details are provided
II, Class 1, For 105ºC Total Conductor in each table.
Temperature.

c. Table 6–A–3. SAE AS7928/4 - Terminal

Lug, Crimp Style, Copper, Insulated,
Ring Tongue, Bell Mouthed, Type II,
Class 1, For 150ºC Total Conductor
Temperature.

6A–1
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

Table 6–A–1 MS25036 – Terminal Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell Mouthed,
Type II, Class 1, For 105C Total Conductor Temperature

MS25036
Stud Size Dash Number Tooling

Wire Gauge 26-24 AWG (Lug Colour Yellow)

2 143 Tool M22520/5-01 with
4 144 Die M22520/5-100
6 145 or
8 146 Tool M22520/10-01 with
10 147 Die M22520/10-101
Wire Gauge 22-18 AWG (Lug Colour Red)
2 159
4 148
6 101
Tool M22520/5-01 with
6 102
Die M22520/5-100
8 149
or
10 103
Tool M22520/10-01 with
0.250 inch 150
Die M22520/10-101
0.312 inch 104
0.375 inch 105
0.500 inch 151
Wire Gauge 16-14 AWG (Lug Colour Blue)
4 152
6 106
6 107 Tool M22520/5-01 with
8 153 Die M22520/5-100
10 108 or
0.250 inch 154 Tool M22520/10-01 with
0.312 inch 109 Die M22520/10-101
0.375 inch 110
0.500 inch 155
Wire Gauge 12-10 AWG (Lug Colour Yellow)
6 111
8 156 Tool M22520/5-01 with
10 112 Die M22520/5-100
0.250 inch 157 or
0.312 inch 113 Tool M22520/10-01 with
0.375 inch 114 Die M22520/10-100
0.500 inch 158
Wire Gauge 8 AWG (Lug Colour Red)
10 115
0.250 inch 116 Hydraulic Tooling MS25441
0.312 inch 117 Head MS25441-1
0.375 inch 118 Die MS23002-8
Wire Gauge 6 AWG (Lug Colour Blue)
10 119
0.250 inch 120 Hydraulic Tooling MS25441
0.312 inch 121 Head MS25441-1
0.375 inch 122 Die MS23002-6

6A–2
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

MS25036
Stud Size Dash Number Tooling

Wire Gauge 4 AWG (Lug Colour Yellow)

0.250 inch 123 Hydraulic Tooling MS25441
0.312 inch 124 Head MS25441-1
0.375 inch 125 Die MS23002-4
Wire Gauge 2 AWG (Lug Colour Red)
0.250 inch 126 Hydraulic Tooling MS25441
0.375 inch 127 Head MS25441-1
0.500 inch 128 Die MS23002-2
Wire Gauge 1 AWG (Lug Colour Clear to White)
0.250 inch 129 Hydraulic Tooling MS25441
0.375 inch 130 Head MS25441-1
0.500 inch 131 Die MS23002-1
Wire Gauge 0 AWG (Lug Colour Blue)
0.250 inch 132 Hydraulic Tooling MS25441
0.375 inch 133 Head MS25441-1
0.500 inch 134 Die MS23002-01
Wire Gauge 00 (2/0) AWG (Lug Colour Yellow)
0.312 inch 135 Hydraulic Tooling MS25441
0.375 inch 136 Head MS25441-1
0.500 inch 137 Die MS23002-02
Wire Gauge 000 (3/0) AWG (Lug Colour Red)
0.375 inch 138 Hydraulic Tooling MS25441
0.500 inch 139 Head MS25441-1
Die MS23002-03
Wire Gauge 0000 (4/0) AWG (Lug Colour Yellow)
0.375 inch 140 Hydraulic Tooling MS25441
0.500 inch 141 Head MS25441-1
Die MS23002-04
Example: MS25036-119 is a terminal lug for wire size 6 AWG suitable for stud size 10

6A–3
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

Table 6–A–2 SAE AS7928/1 Terminal Lug, Crimp Style, Copper, Insulated, Ring Tongue, Type II,
Class 1, For Thin Wall Wire For 105C Total Conductor Temperature
M7928/1
Stud Size Dash Number Tooling

Wire Gauge 26 AWG (Lug Colour Yellow with Black Stripe)

2 1
4 2 Tool M22520/10-01 with
6 3 Die M22520/10-101
8 4
10 5
Wire Gauge 24 AWG (Lug Colour Yellow with Blue Stripe)
2 6
4 7 Tool M2520/10-01 with
6 8 Die M22520/10-101
8 9
10 10
Wire Gauge 22 AWG (Lug Colour Red with Green Stripe)
2 70
4 11 Tool M22520/5-01 with
6 12 Die M22520/5-100
6 13 or
8 14 Tool M22520/10-01 with
10 15 Die M22520/10-101
0.250 inch 16
0.312 inch 17
0.375 inch 18
0.500 inch 19
Wire Gauge 20 AWG (Lug Colour Red)
2 71
4 20
6 21
Tool M22520/5-01 with
6 22
Die M22520/5-100
8 23
or
10 24
Tool M22520/10-01 with
0.250 inch 25
Die M22520/10-101
0.312 inch 26
0.375 inch 27
0.500 inch 28
Wire Gauge 18 AWG (Lug Colour Red with White Stripe)
4 72
6 29
6 30
Tool M22520/5-01 with
8 31
Die M22520/5-100
10 32
or
0.250 inch 33
Tool M22520/10-01 with
0.312 inch 34
Die M22520/10-101
0.375 inch 35
0.500 inch 36
37

6A–4
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

M7928/4
Stud Size Dash Number Tooling

Wire Gauge 16 AWG (Lug Colour Blue)

4 38
6 39
6 40 Tool M22520/5-01 with
8 41 Die M22520/5-100
10 42 or
0.250 inch 43 Tool M22520/10-01 with
0.312 inch 44 Die M22520/10-101
0.375 inch 45
0.500 inch 46
Wire Gauge 14 AWG (Lug Colour Blue with Green Stripe)
4 47
6 48
6 49 Tool M22520/5-01 with
8 50 Die M22520/5-100
10 51 or
0.250 inch 52 Tool M22520/10-01 with
0.312 inch 53 Die M22520/10-101
0.375 inch 54
0.500 inch 55
Wire Gauge 12 AWG (Lug Colour Yellow)
6 56
8 57 Tool M22520/5-01 with
10 58 Die M22520/5-100
0.250 inch 59 or
0.312 inch 60 Tool M22520/10-01 with
0.375 inch 61 Die M22520/10-100
0.500 inch 62
Wire Gauge 10 AWG (Lug Colour Yellow with Brown Stripe)
6 63
8 64 Tool M22520/5-01 with
10 65 Die M22520/5-100
0.250 inch 66 or
0.312 inch 67 Tool M22520/10-01 with
0.375 inch 68 Die M22520/10-100
0.500 inch 69
Example: M7928/1-30 is a terminal lug for wire size 18 AWG suitable for stud size 6

AL 1 6A–5
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

Table 6–A–3 SAE AS7928/4 Terminal Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell
Mouthed, Type II, Class 1, For 150C Total Conductor Temperature

M7928/4
Stud Size Dash Number Tooling

Wire Gauge 26-24 AWG (Lug Colour Transparent with Yellow Stripe)
2 143
4 144 Tool M22520/10-01 with
6 145 Die M22520/10-101
8 146
10 147
Wire Gauge 22-18 AWG (Lug Colour Transparent with Red Stripe)
2 159
4 148
6 101 Tool M22520/5-01 with
6 102 Die M22520/5-100
8 149 or
10 103 Tool M2520/10-01 with
0.250 inch 150 Die M22520/10-101
0.312 inch 104
0.375 inch 105
0.500 inch 151
Wire Gauge 16-14 AWG (Lug Colour Transparent with Blue Stripe)
4 152
6 106
6 107 Tool M22520/5-01 with
8 153 Die M22520/5-100
10 108 or
0.250 inch 154 Tool M22520/10-01 with
0.312 inch 109 Die M22520/10-101
0.375 inch 110
0.500 inch 155
Wire Gauge 12-10 AWG (Lug Colour Transparent with Yellow Stripe)
6 111
8 156 Tool M22520/5-01 with
10 112 Die M22520/5-100
0.250 inch 157 or
0.312 inch 113 Tool M22520/10-01 with
0.375 inch 114 Die M22520/10-101
0.500 inch 158
Wire Gauge 8 AWG (Lug Colour Transparent with Red Stripe)
10 115 Hydraulic Tooling MS25441
0.250 inch 116 Head MS25441-1
0.312 inch 117 Die MS23002-8
0.375 inch 118
Wire Gauge 6 AWG (Lug Colour Transparent with Blue Stripe)
10 119 Hydraulic Tooling MS25441
0.250 inch 120 Head MS25441-1
0.312 inch 121 Die MS23002-6
0.375 inch 122

6A–6 AL 1
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

M7928/4
Stud Size Dash Number Tooling

Wire Gauge 4 AWG (Lug Colour Transparent with Yellow Stripe)

0.250 inch 123 Hydraulic Tooling MS25441
0.312 inch 124 Head MS25441-1
0.375 inch 125 Die MS23002-4
Wire Gauge 2 AWG (Lug Colour Transparent with Red Stripe)
0.250 inch 126 Hydraulic Tooling MS25441
0.312 inch 127 Head MS25441-1
0.375 inch 128 Die MS23002-2
Wire Gauge 1 AWG (Lug Colour Transparent with White Stripe)
0.250 inch 129 Hydraulic Tooling MS25441
0.312 inch 130 Head MS25441-1
0.375 inch 131 Die MS23002-1
Wire Gauge 0 (1/0) AWG (Lug Colour Transparent with Blue Stripe)
0.250 inch 132 Hydraulic Tooling MS25441
0.312 inch 133 Head MS25441-1
0.375 inch 134 Die MS23002-01
Wire Gauge 00 (2/0) AWG (Lug Colour Transparent with Yellow Stripe)
0.312 inch 135 Hydraulic Tooling MS25441
0.375 inch 136 Head MS25441-1
0.500 inch 137 Die MS23002-02
Example: M7928/4-149 is a terminal lug for wire size 22-18 AWG suitable for stud size 8

6A–7
AC 21-99 Aircraft Wiring and Bonding Annex A to
Sect 2 Chap 6

Table 6–A–4 SAE AS81824/1 Splice, Electric, Permanent Crimp Style, Copper, Insulated,
Environment Resistant, Class 1, For 150C Total Conductor Temperature

M81824/1 Tool Die

Dash Number

Wire Gauge 26-20 AWG (Splice Colour Code Red)

M22520/5-01 and M22520/5-103
-1 or
M22520/10-01 and M22520/10-104
Wire Gauge 20-16 AWG (Splice Colour Code Blue)
M22520/5-01 and M22520/5-103
-2 or
M22520/10-01 and M22520/10-104
Wire Gauge 16-12 AWG (Splice Colour Code Yellow)
M22520/5-01 and M22520/5-102
-3 or
M22520/10-01 and M22520/10-103
Example: M81824/1-3 is a splice for wire size 16-12 AWG
Note
Following the crimping procedure, use suitable heat source to
shrink the insulation sleeve on the splice for environmental sealing

Table 6–A–5 MS25274 Cap, Electrical, Wire End, Crimp Style, Class 1, For 105C Total Conductor
Temperature

MS25274
Dash Number Tool Die

Wire Gauge 26-24 AWG (Cap Colour Yellow)

M22520/5-01 and M22520/5-100
-1 or
M22520/10-01 and M22520/10-101
Wire Gauge 22-18 AWG (Cap Colour Red)
M22520/5-01 and M22520/5-100
-2 or
M22520/10-01 and M22520/10-101
Wire Gauge 16-14 AWG (Cap Colour Blue)
M22520/5-01 and M22520/5-100
-3 or
M22520/10-01 and M22520/10-101
Wire Gauge 12-10 AWG (Cap Colour Yellow)
M22520/5-01 and M22520/5-100
-4 or
M22520/10-01 and M22520/10-100
Example: M25274-3 is an end cap for wire size 16-14 AWG

6A–8
AC 21-99 Aircraft Wiring and Bonding Annex B to
Sect 2 Chap 6

STUD SIZE AND CORRESPONDING TERMINAL LUG DIMENSIONS

The table below provides information on various terminal studs and the corresponding terminal lug ‘stud hole’
size. Terminal lugs may be selected by comparing with the silhouettes provided. (Approximate size only).


Stud Size Code Stud Terminal
US Metric Dia (in) Minimum Hole 1/2 M12 0.500
Cust Dia (in)
0 0.060 
0.064
1 0.073 
0.077 0.510



2 M2 0.086
0.090 M16 0.625
5/8
3 0.099 
0.103
4 0.112 
0.116
5 M3 0.125
 0.651
0.129


6 M3.5 0.138
 3/4 0.750
0.142
8 M4 0.164

0.168
10 0.190

0.194
0.776

12 0.216


7/8 0.875
0.220


14 0.242

0.247

1/4 M6 0.250

0.260
0.901


5/16 M8 0.312
1 1.000

0.323


3/8 0.375

0.385


7/16 0.437
1.026

0.448

6B–1
AC 21-99 Aircraft Wiring and Bonding Annex B to
Sect 2 Chap 6

Blank Page

6B–2
AC 21-99 Aircraft Wiring and Bonding Annex C to
Sect 2 Chap 6

DISCONNECT SPLICES AND TOOLING

SAE AS81714/11 DISCONNECT SPLICE AND TOOLING

Figure 6–C–1 Single Wire In-Line Junction Body

Table 6–C–1 Single Wire In-Line Junctions

In-Line Junction

Splice Body Contacts Crimping Tool Positioner Installing/Removal

(Note 1) (Note 2) Tool (Note 3)

Part Number A Dia B Dia L Part Number Part Number Part Number Part Number
 .025 Max Max

M81714/11-22D .250 .225 1.552 M39029/1-100 M22520/2-01 M22520/2-11 M81969/14-02

M81714/11-20D .250 .225 1.552 M39029/1-101 M22520/1-01 M22520/1-02 M81969/14-02

M81714/11-16D .281 .256 1.922 M39029/1-102 M22520/1-01 M22520/1-02 M81969/14-03

M81714/11-12D .344 .319 1.922 M39029/1-103 M22520/1-01 M22520/1-02 M81969/14-04

Notes:
1. Only Class D splices are approved for use.
2. Dimensions are in inches.
3. Tools for contact insertion/removal shall be ordered separately.

6C–1
AC 21-99 Aircraft Wiring and Bonding Annex C to
Sect 2 Chap 6

SAE AS81714/12 - DOUBLE DISCONNECT SPLICE AND TOOLING

Figure 6–C–2 Double Wire In-Line Junction Body

Table 6–C–2 Double Wire In-Line Junctions

In-Line Junction
Splice Body Contacts Crimping Tool Positioner Installing/
(Note 3) Removal Tool
Part Number A B C L Part Number Part Number Part Number Part Number
(Note 1) (Note 2) Max Max  .01 Max (Note 4)

M81714/12-22D-* .400 .275 .13 1.552 M39029/1-100 M22520/2-01 M22520/2-11 M81969/14-02

M81714/12-20D-* .400 .275 .13 1.552 M39029/1-101 M22520/1-01 M22520/1-02 M81969/14-02

M81714/12-16D-* .500 .300 .18 1.922 M39029/1-102 M22520/1-01 M22520/1-02 M81969/14-03

M81714/12-12D-* .620 .370 .25 1.922 M39029/1-103 M22520/1-01 M22520/1-02 M81969/14-04

Notes:
1. Only Class D splices are approved for use.
2. Insert 1 or 2 at * to indicate Type 1 or Type 2 splice.
3. Dimensions are in inches.
4. Tools for contact insertion/removal shall be ordered separately.

6C–2
AC 21-99 Aircraft Wiring and Bonding Annex D to
Sect 2 Chap 6

CRIMP TOOL TESTING

Introduction 5. Gauging Test. Prior to performing the
gauging test ensure that both the crimping tool jaws
1. Dies and other working parts of crimping and the shafts of the gauge are clean and undamaged,
tools used for electrical terminations become worn in then carry out the following:
service and this can result in unsatisfactory
terminations. An effective means to ensure a a. Select gauges as follows:
serviceable termination is to monitor the condition of
the tool by regular testing. (1) Military Specification (Mil
Spec) Tools. Gauges for Mil
Description Spec (Class 1) tools are
specified in Section 2 Chapter
2. General Use. Before a tool is used, it should 6.
be checked for completeness and signs of wear or
corrosion. Check also for correct operation of the (2) Proprietary Tools. Units are
ratchet mechanism. After crimping, check the terminal encouraged to locally
for: manufacture gauges for use
with propriety tools.
a. correct location of the jaw indentation
on the terminal wire barrel;

b. damage to insulation or conductors;

c. all conductor strands fully inserted and DO NOT INSERT THE GAUGE PRIOR TO
secure in the wire barrel of the FULLY CLOSING THE TOOL
terminal.
NOTE
Testing
The tool is fully closed when the ratchet
3. In-service testing of crimping tools should be releases and the handles are able to return to the
carried out: fully open position.

a. at 12 month intervals, and b. Actuate the crimping tool to the fully

closed position and hold.
b. at any time the serviceability of a tool
is suspect. c. Insert the GO end of the gauge into the
die cavity - no restriction should be
4. The test is to be performed using either: felt.

a. the appropriate GO, NO-GO gauge d. Attempt to insert the NO-GO end of
which will determine the correct the gauge into the die cavity - the
closure distance of the crimping jaws; gauge may enter partially but must not
or pass completely through the die cavity.

b. a millivolt drop and tensile strength e. The crimping tool is unserviceable if it

test of a completed 'test piece' fails either of the above tests and
termination, if a gauging tool is not should be repaired or replaced as
available. appropriate.

NOTE Millivolt Drop Testing

Testing of the crimping tool barrel (wire) die 6. Perform the millivolt drop test of Terminal
and braid die (if applicable) is mandatory and Lugs, Splices and Connector Contacts as follows:
testing of the crimping tool insulation die is
advisable to ensure complete serviceability of a. Prepare one sample of the largest and
the crimping tool. smallest termination for the crimping
tool. Sample crimps are to be prepared

6D–1
AC 21-99 Aircraft Wiring and Bonding Annex D to
Sect 2 Chap 6

as detailed in Figure 6-D-1, 6-D-2 or c. Connector contact millivolt drop

6-D-3. measurements shall be made across the
entire mated length of the two contacts.
b. Connect the test sample across a 28 Connect the voltmeter probes to the
VDC variable power supply. Adjust conductors approximately 6 inches
the current to attain the specified test (150mm) apart and equidistant from
current detailed in Table 6-D-1 for the end of each contact. See Fig 6-D-
copper splices and terminal lugs, Table 3.
6-D-2 for aluminium splices and
terminal lugs, and Table 6-D-3 for d. Measure the millivolt drop across the
electrical connector pins and sockets. crimped terminations while the
specified test current is being applied
7. Terminal lugs, conductor splices and and after the temperature of the
connector contacts shall be tested as follows: termination has stabilised.

a. Terminal lug millivolt drop 8. Tensile Strength Test. If the millivolt drop
measurements shall be made by across the crimped joint/s is within limits, attach the
puncturing the insulation of the current test pieces to a static test rig using a suitable adaptor.
carrying conductor 0.062 in (1.6 mm) Add weights to ensure the minimum tensile strength
from the wire receiving end of the figure in Tables 6-D-1, 6-D-2 or 6-D-3 is reached
terminal, for one test point and using without failure of the crimp joint. Alternatively, a
the intersection of the tongue and spring balance may be used for this test.
barrel for the other test point. The
distance between the two tested points
shall be noted. See Fig 6-D-1.

b. Conductor splice millivolt drop

measurements shall be made by
puncturing the insulation of the current
carrying conductor 0.062 in (1.6 mm)
from each wire receiving end of the
splice. The distance between the two
tested points shall be noted. See Fig 6-
D-2.

6D–2
AC 21-99 Aircraft Wiring and Bonding Annex D to
Sect 2 Chap 6

Figure 6–D–1 Terminal Lug

Figure 6–D–2 Splice

Figure 6–D–3 Connector Contacts

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AC 21-99 Aircraft Wiring and Bonding Annex D to
Sect 2 Chap 6

Table 6–D–1 Copper Terminal Lugs and Splices (SAE AS7928 and SAE AS81824)

Maximum Voltage Drop (mV) in

Addition to the Voltage Drop of an
Equivalent Length of Wire
Wire Size Test Current Terminal Lug Splice Minimum Tensile Strength
(AWG) (Amps) (SAE AS7928) (SAE AS81824) lb (kg)
26 3 5 10 7 (3.18)
24 4.5 4 8 10 (4.53)
22 9 3 4 15 (6.80)
20 11 3 4 19 (8.62)
18 16 3 4 38 (17.24)
16 22 3 4 50 (22.68)
14 32 3 4 70 (31.75)
12 41 3 4 110 (49.90)
10 55 3 – 150 (68.04)
8 73 3 – 225 (102.06)
6 101 3 – 300 (136.08)
4 135 3 – 400 (181.44)
2 181 3 – 550 (249.48)
1 211 3 – 650 (294.83)
0 245 4 – 700 (317.51)
00 283 4 – 750 (340.19)
000 328 4 – 825 (374.21)
0000 380 4 – 875 (396.89)

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AC 21-99 Aircraft Wiring and Bonding Annex D to
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Table 6–D–2 Aluminium Terminal Lugs and Splices (SAE AS70991)

Maximum Voltage Drop (mV) in

Addition to the Voltage Drop of an
Equivalent Length of Wire
Wire Size Test Current Terminal Lug Splice Minimum Tensile Strength
(AWG) (Amps) (SAE AS70991) (SAE AS70991) lb (kg)
8 60 11 22 130 (58.97)
6 83 11 22 200 (90.72)
4 108 8 16 300 (136.08)
2 152 8 16 500 (226.80)
1 174 7 14 700 (317.52)
0 202 7 14 900 (408.23)
00 235 7 14 1100 (498.96)
000 266 7 14 1300 (589.67)
0000 303 7 14 1500 (680.40)
Note: MS25441 crimping tool with MS25442 dies are to be used with aluminium lugs and splices

Table 6–D–3 Electrical Connector Contacts (MIL-C-39029)

Wire Size Test Current Maximum Voltage Drop (mV) Minimum Tensile Strength
(AWG) (Amps) (Across Mated Contacts) lb (kg)
26 2 52 5 (2.27)
24 3 45 8 (3.63)
22 5 73 12 (5.44)
20 7.5 55 20 (9.07)
16 13 49 50 (22.68)
14 17 40 70 (31.75)
12 23 42 110 (49.89)
10 33 33 150 (68.04)
8 46 26 225 (102.06)
6 60 25 300 (136.08)
4 80 23 400 (181.44)
2 100 17 550 (249.48)
1 125 19 650 (294.83)
0 150 21 700 (317.51)
00 185 19 750 (340.19)
0000 225 21 875 (396.89)

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AC 21-99 Aircraft Wiring and Bonding Annex D to
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6D–6