the military specification m22520/5-01 is a crimptool made by several companies, as far as i know, these companies are dmc, astro and kings. the hx4 is the equivalent by the daniels manufacturing corp (dmc), the 620175 or ak100 by the astro tool corp and the kth-1000 by kings electronics inc.

for this demonstration let’s assume that a marker beacon antenna cable and coaxial connector were damaged and we needed to repair it.
first we find the schematic in the wiring diagram manual.

 

before we take any information from the manuals we must first ensure that we have the correct airline effectivity number. different aircraft have different systems installed, different options, different wiring, some have been modified to a different status than others etc etc etc.
we use effectivity numbers to identify systems, if a specific wire is in a range of aircraft that range of aircraft’s effectivity numbers is displayed on the drawing of that specific wire. for the purpose of this demonstration we’ll take effectivity number 001

 

we have the wire number (w193-451-ba5903) and the connector equipment number (d57). with this information we go to the wire list and the equipment list. first i find the connector partnumber in the equipment list (kd-59-161).

 

after that i find the wire type code in the wirelist.

 

we go to the standard wire practices manual (swpm) chapter 20-00-13 to get the partnumber for this wire type code.

 

we order up the length of wire, allways order a little bit more offcourse because different suppliers and storemen have different measurement skills and we can cut the wire shorter but not longer.
we find the required length in the wire list.

u must have heard the murphy rule that a wire that is cut to length is allways too short.

 

we also order the the connector and we go to the cross reference chapter in the standard wire practices manual (swpm) to find the chapter on this connector.

we learn that the chapter is 20-51-15 and that the connector is a kings electronics connector.

 

in this chapter we can find the wire preparation, the finishing instructions, the tools etc etc.

 

in this chapter, we first find the tool that we need, for this connector we need to have a crimp for the center contact and a crimp to connect the outer conductor to the outer ring of the connector.
therefore we find a toolcode for the center contact and a toolcode for the k-grip sleeve (the sleeve is a ferrule with rubber on each side to environmentally seal the crimp).

 

we find the toolcode in the tool list and we see a couple of options.
i’ve red circled the tools that we have equivalents for in our hangar (allways a good idea to make a list of the electrical crimptools that u have available in your toolstore, makes looking for a tool much easier).

 

we will use a daniels (dmc) electrical cable repair kit so we need to use the daniels equivalents to the kings electronics tools.

 

we see that there are different dies possible, the kings kth-1079 is equivalent to the daniels y630p, the kings kth-2211 is equivalent to the daniels y889, the kings kth-2212 is equivalent to the daniels y890 and the military spec m22520/5-57 daniels equivalent is y209p.
all these die sets have a hex opening that is 0.100 inch across.

 

we the y630p as our center contact die.

 

the bottom die can be removed just by pulling it, for the top one u need to press this button.

 

there is a groove that sticks out to allign the die set properly in the tool.

 

some dies have two allignment pins also that need to mate.

 

for the k-grip sleeve we found the 213hs toolcode and for the kth-1000 tool, these are the dies we can use.
we have the kth-2061 die by the kings corporation but we also have its equivalent from daniels the y572 and since we are using the daniels electrical cable repair kit we use the daniels tool so we only have to carry one toolset out of the toolstore.

 

with the y630p we use the small hole for the center contact and with the y572 we use the large hole to crimp the k-grip sleeve.

 

the strip lengths for the coax cable are found in this swpm chapter also, the connector number with 4 dimensions next to it.
further down in the cable preperation we will find were these dimensions are.

 

also note that these are in inches, we calculate them to metric because that is much easier to measure.

 

now we know what the dimensions a, b, c and d must be and the tolerance, we go to the cable preperation and find the dimensions a and b on the cable.

 

and here are the dimensions c and d.

 

i strip the coax cable according to the specifications.

 

don’t forget to put the k-grip sleeve and the heatshrinkable sleeve over the wire.

 

we put the center contact onto the center conductor.

 

the crimp is made between the side and the inspection hole.

 

the center contact can now be locked into the coax connector.

 

when the coax connector is pushed over the cable, the center contact locks into the connector and the metal ring on the back of the connector slides between the outer conductor and the dielectric.

 

then the k-grip sleeve is shoved into place.

 

the k-grip sleeve fits snugly into the die set.

 

the hexagonal crimp should be environmentally sealed by the rubber on both sides.

 

the heatshrinkable sleeve is shoved over the k-grip sleeve and crimped with a heatgun.

 

this connector is now ready to be connected to the marker beacon antenna.