(2)
When using AMP part No. 52524 for 4 gage copper wire, remove insert from end and mate this side with copper wire.
B. Crimp splice-wire assembly using proper tooling (Fig. 801). Position splice in stationary die with crimp mark aligned with edge of die. Then reposition splice in stationary die for uncrimped half with splice rotated approximately 180 degrees.
C. Inspect splice
(1)
The edge of transition must be within 1/16 inch from crimp index mark.
(2)
A certification mark must be centrally located and visible in the bottom of the crimp impression. The mark is a well formed cylindrical button having a symmetrical fully formed pap protruding from its exact center.
(3)
The crimp impressions on each end of the wire splice termination must be on opposing sides.
(4)
Check that splice is aligned such that copper and aluminum conductors are mated to proper end.
(a)
For AMP part No. 53527-1, check that copper wire is inserted into blue band side of splice.
(b)
For AMP part No. 52524, when used with 4 gage copper wire, check that copper wire is inserted into side of splice that insert was removed from.
501
24-00-09 Page 802 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. Jun 20/87
ALUMINUM INSPECTION HOLE PLUG P/N: 269-31499-0
STRIP LENGTH ±1/16 ALUM WIRE SIZE COPPER WIRE SIZE SPLICE P/N (AMP) AMP POWER UNIT 3
A B DIE SET TOOL HEAD
3/4 3/4 7/16 7/16 1-3/8 1-1/4 1 1 0 2 4 4 4 14 4 16 277163-1 53528-1 4 277159-1 52525 4 277165-1 53527-1 4 277158-1 2 52524-1 2 277158-1 52524 4 59877-1 68009 68008 68008 AMP 69066 (MOD Z) OR 69993
A - CONDUCTOR STRIP LENGTH B - TOTAL STRIP LENGTH, CONDUCTOR PLUS OUTER
INSULATION FOR MULTI-LAYER INSULATED WIRE 1/8-INCH BLUE BAND ON COPPER SIDE OF SPLICE OPTIONAL - REMOVE INSERT AND USE FOR 4 GAGE COPPER NO. 69120-1, 115 VOLTS (60HZ)
NO. 69120-2, 230 VOLTS (60HZ) NO. 1-69120-0, 220 VOLTS (50HZ) ALTERNATIVE
501 Splices and Crimping Tools
Oct 20/88 Figure 801 24-00-09
Page 802A/802B
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
T52181
501 Wire Stripping Methods
Jun 20/87 Figure 802 24-00-09
Page 803
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
6. Insulation of Splice Assembly
A. Method 1: Tape Wrap Method (Fig. 803)
(1)
Clean splice and at least 1-1/2 inches of outer wire insulation, using general purpose cleaning solvent and a clean cloth. Allow to air dry.
(2)
Build up all voids between splice and wire insulation to prevent abrupt step or sharp edge using Type B film.
(3)
Spiral wrap splice area with Type B film. Three layers of film are required, each with 50% overlap, and extending 1-1/4 +1/4 inches over outer insulation.
(4)
Apply 3 layers of Polymide tape (preferred) or bondable TFE fluorocarbon film or polymide (H-film) over Type B film. Wrap each layer spirally with 50% overlap. Reverse direction of spiral with each layer. Extend tape 1/4 to 3/8 inch beyond each end of Type B film.
B. Method 2: Potted Splice Method (Fig. 804)
(1)
Select transparent TFE-R sleeve that is large enough to allow 1/8 to 1/4 inch of potting compound to encompass largest portion of splice area.
(2)
Cut sleeve to length that will allow potting compound to extend 1-1/4 +1/4 inch over outer insulation including any jacket.
(3)
Slide sleeve over wire and out of the way. Complete splice assembly.
(4)
Center sleeve over splice area and tie one end with Type IV tying material.
(5)
Pot splice with PR-1933 compound.
(6)
When potting operation is completed, tie other end of sleeve.
C. Method 3: Tape and Sleeve Method (Fig. 805)
(1)
Select two heat shrinkable sleeves that are large enough to fit over taped wire areas and that will fit tightly over wires when shrunk into place. Cut sleeves long enough to extend 1 +1/4 inch beyond taped area, when shrunk in place per step (5) below.
(2)
Select third heat shrinkable sleeve that is large enough to fit over taped splice and that will fit tightly when shrunk into place. Cut sleeve to length that will extend to within 1/4 +1/8 inch of ends of two sleeves (step (1) above).
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