FAA Aviation Mechanic Airframe (AMA)Airframe Electrical and InstrumentsHard
A technician crimps a new terminal lug onto a wire and inspects the connection before installation. Which inspection finding would require the technician to reject the crimped terminal and remake the connection?
- AThe crimp indent is centered on the barrel with no visible strand damage
- BSeveral wire strands are visibly cut or broken at the point where they enter the terminal barrel
- CThe terminal barrel color-codes correctly for the wire gauge used
- DThe wire insulation is visible slightly inside the terminal's insulation grip, with no bare copper exposed beyond the barrel
Show answer & explanationAnswer & explanation
Correct answer: B. Several wire strands are visibly cut or broken at the point where they enter the terminal barrel
Cut or broken strands at the crimp point significantly reduce the current-carrying capacity and mechanical strength of the termination, creating a high-resistance connection prone to failure; this defect requires the terminal to be cut off and remade with a new, properly sized terminal.
Why the other options are wrong
- A. A centered, undamaged crimp is a correct, acceptable installation, not a defect.
- C. Correct color-coding for wire gauge match confirms proper terminal selection, which is acceptable.
- D. Proper insulation support with no exposed bare copper beyond the barrel is the correct, acceptable condition.
Crimped Terminal Inspection
Visual and mechanical inspection of a crimped wire terminal to verify proper strand condition, indent location, and insulation support before installation.
- Terminal barrel size must match wire gauge (color-coded)
- No cut, broken, or missing strands allowed at crimp point
- No bare copper should extend beyond the terminal barrel
Memory trick: Broken strands = broken connection — cut it off and start over.