11.2, 11.3 & 11.4CRIMPING, TESTING, AND CONNECTOR PIN PROCEDURES

Hand crimp tools are mainly used for:

• Large terminals

• Small terminals

• Hydraulic fittings

Answer explanation

Hand crimpers are designed for small aircraft terminals and precise, repeatable crimps.

A hand crimp tool used in aviation must have a:

• Grip handle

• Calibration tag

• Rubber cover

Answer explanation

Tools must be calibrated and tagged with valid test dates for aviation use.

A hydraulic crimp tool is used when:

• The terminal is small

• Speed is more important than accuracy

• High crimping pressure is required

Answer explanation

Hydraulic or pneumatic crimpers apply the force needed for large terminals.

If the wrong crimp tool is selected, the result can be:

• Cosmetic issues only

• Poor electrical contact and tool damage

• Stronger connection

Answer explanation

Incorrect tooling causes bad crimps and may damage the crimper before next calibration.

The correct crimp tool and locator are determined by:

• The terminal part number

• Engineer’s preference

• Wire colour

Answer explanation

Manuals list approved crimpers and locators for each terminal part number.

Before crimping, verify the tool has:

• Current calibration

• Rubber handles

• Clean jaws

Answer explanation

Always confirm valid calibration before use to ensure repeatable crimp performance.

After crimping, the engineer should perform a:

• Voltage test

• Pull test

• Resistance test

Answer explanation

A light pull test checks that the conductor is securely held by the crimp barrel.

A proper crimp should show wire strands:

• Hidden inside the barrel

• Clearly visible through the inspection hole.

• Covered by insulation

Answer explanation

Visible wire strands confirm full conductor insertion and proper positioning.

Over-crimping causes:

• Stronger joints

• Elongated and weakened conductors

• Improved conductivity

Answer explanation

Excess pressure damages and thins the wire, increasing resistance and fatigue risk.

Under-crimping results in:

• Loose strands and corrosion

• High mechanical strength

• Perfect low resistance

Answer explanation

Gaps from under-crimping let in moisture and oxygen, causing corrosion and high resistance.