In the field of avionics, contact crimping tools are vital for the secure and reliable termination of electrical wires to connector contacts, ensuring electrical continuity, mechanical strength, and long-term durability in demanding aerospace environments.
Contact crimping tools are used to deform a connector contact (pin or socket) around a wire conductor to establish a gas-tight, vibration-resistant mechanical and electrical bond. Proper crimping is essential in avionics to withstand:
- High vibration
- Temperature extremes
- Electromagnetic interference (EMI)
- Moisture and corrosion
All aerospace and military-grade crimping must adhere to MIL-SPEC standards, such as:
- MIL-DTL-22520: The overarching specification for crimping tools and accessories.
- IPC/WHMA-A-620: Industry standard for cable and wire harness assemblies.
Proper calibration, periodic inspection, and test crimps (pull tests) are essential to maintain tool accuracy and compliance.
CONTACT CRIMPING TOOLS
| TOOL PART NUMBER | PIN SIZE | IMAGE |
| AF8 OR M22520/1-01 | 12-20 |    |
BEFORE USING AF8 OR AFM8, MAKE SURE YOU USE GO/NO-GO GAUGE CHECK:
P/N: M22520/3-1 TOOL NAME: GO/NO-GO
| TOOL PART NUMBER | PIN SIZE | IMAGE |
| AFM8 OR M22520/2-01 | 20-32 |  |
COAX CRIMPING TOOLS: (20-51-00)
| TOOL PART NUMBER | PIN PART NUMBER (TOOL CODE) | IMAGE |
| M22520/5-01HX4 | FROM CONNECTOR PART NUMBER |  |
NOTE: THE SELECTION COAX CRIMPING OF TOOLS DEPENDS ON THE PIN OR SLEEVE PART NUMBER, USED AS A TOOL CODE.
JACKET REMOVAL TOOLS (20-00-15)
| TOOL PART NUMBER | WIRE TYPE CODE | DESCRIPTION | COLOR CODE | IMAGE |
| 45-401 | REFER SWPM | JACKET REMOVAL | ORANGE |  |
| 45-402 | REFER SWPM | JACKET REMOVAL | YELLOW |  |
| 45-403 | REFER SWPM | JACKET REMOVAL | PINK |  |
| 45-404 | REFER SWPM | JACKET REMOVAL | GREEN |  |
REFERENCE: FOR 20-00-15
NOTE: THE SELECTION JACKET AND INSULATION REMOVAL OF TOOLS DEPENDS ON WIRE TYPE CODE (WTC).
INSULATION REMOVAL TOOLS
| TOOL PART NUMBER | AWG | WIRE TYPE CODE | DESCRIPTION | COLOR CODE | IMAGE |
| 45-173 ST2222-30 | 10-14 | REFER SWPM | INSULATION REMOVAL | DMC BOEING |  |
| 45-174 ST2222-29 | 16-26 | REFER SWPM | INSULATION REMOVAL | DMC BOEING |   |
Conversion Chart (Military to DMC)
In many aviation maintenance settings, technicians often face the challenge of cross-referencing military part numbers with commercial equivalents, particularly when using tools from manufacturers like Daniels Manufacturing Corporation (DMC).
What is a Conversion Chart?
A conversion chart is a reference tool that maps:
- MIL-SPEC part numbers (e.g., M22520/1-01)
- To their DMC commercial counterparts (e.g., DMC AF8 tool)
This allows avionics personnel to:
- Identify compatible DMC tooling based on the MIL-spec requirement
- Avoid procurement errors
- Maintain traceability for compliance and auditing
Example Conversion Table:
| MIL-SPEC Tool No. | DMC Equivalent | Description |
|---|---|---|
| M22520/1-01 | AF8 | Standard adjustable hand crimper |
| M22520/2-01 | AFM8 | Miniature adjustable hand crimper |
| M22520/7-01 | HX4 | Heavy-duty crimper for coaxial contacts |
| M22520/5-01 | WA22 | Pneumatic crimp tool |
Likewise, positioners and turrets also follow this mapping, for example:
| MIL-SPEC Positioner | DMC P/N | Connector Family |
|---|---|---|
| M22520/1-02 | TH1A | General circular contacts |
| M22520/2-06 | K42 | Size 20 M39029 contacts |
These charts are typically provided in:
- Tooling catalogues
- DMC documentation
- Aerospace wiring standards libraries
To conclude in avionics, precision and repeatability are non-negotiable, contact crimping tools are foundational to these principles. By integrating the correct tools and leveraging conversion charts between MIL-SPEC and DMC, technicians can ensure compatibility, compliance, and consistent quality in aircraft electrical systems. Whether maintaining a military platform or commercial airliner, using approved and calibrated crimp tools in accordance with standards is critical for mission and flight safety.
