Crimping Tools for HD002, HD485 & HD442 Dies (MS5259/1)
HD120 – Replaces HH80C
The HD120 is a hand-actuated hydraulic crimp tool designed to use interchangeable MS23002-XX dies (for insulated lugs), MS90485-XX dies (for un-insulated lugs) and MS25442-XX dies (for aluminum lugs). This heavy-duty crimper delivers 12 tons of die force necessary to crimp large conductors. The two-stage pump minimizes the number of handle closures needed to complete the crimp and the padded handles provide a comfortable advantage. The tool’s hydraulic pump is filled with biodegradable hydraulic fluid at the factory and does not need to be bled or primed.
The HD120 is a hand-operated hydraulic equivalent to the Mil-Qualified, TBHD1M (MS25441-1) remote hydraulic crimp head. DMC also offers a battery version of this tool, HDE120B. All dies are able to be interchanged throughout these 3 tools.
- 360 degrees rotating head
- Automatic relief valve
- Crimp force: 12 tons
- Length: 21.3 inches
- Weight: 14.6 pounds
- Hydraulic Oil : .1pt (50ml) Biodegradable Hydraulic Fluid
- Crimping Range: 8 AWG to 4/0 AWG
HH80C – Discontinued – Replaced by HD120
Historical Information on HH80C.
The HH80C Heavy Duty Hydraulic Crimper delivers the die force necessary to crimp large conductors, but still in a hand operated hydraulic crimper. The HH80C produces 7 tons with the two stage pump that minimizes the number of handle closures needed to complete the crimp.
The utilization of the HD002 (MS23002), HD485 (MS90485), and HD442 (MS25442) dies extends the range of crimping capabilities to 2/0 AWG conductors in insulated military/aerospace applications and 4/0 AWG conductors in uninsulated Military/aerospace applications. (Verification available upon request. Contact/terminal samples required.) Boeing ST 2354 Series Dies are also available from DMC.
The HH80C Hydraulic Crimper is fitted with comfortable handle grips for the best ergonomic advantage.
Other features are the following:
- Crimp force: 7.0 tons (62.28kN)
- Length: 24 inches (610 mm)
- Weight 13.0 pounds (5.9kg)
- Automatic relief valve to prevent over-compression
- Release lever for relaxing crimp pressure and opening dies
- 360º rotating head for ease in confined work areas
- Advance closing to crimp position is achieved by rotating the handle
TBHD1M REMOTE HYDRAULIC CRIMP HEAD (MS2544-1)
The TBHD1M Remote Hydraulic Crimp Head (MS25441-1) exerts 12 tons of crimp force and extends the range of crimping capabilities to 4/0 AWG conductors in military/aerospace applications, and 750 MCM applications on commercial systems.
The TBHD1M accepts the HD002 (MS23002), HD485 (MS90485), HD442 (MS25442) and Boeing ST 2354 Die combinations. In some cases the tool can be used as a hand-held crimper, but the tool weight (9.6 lbs) and force means mounting it in a stationary position with a bench mount (BM-2A) is the preferred mode of operation. The recommended hydraulic pump is the HPU11M air over hydraulic powered pump and consult DMC for other hydraulic pump options.
Other Specifications that apply to the TBHD1M are the following:
- Crimp force: 12.0 tons (107kN)
- Length: 10.0 inches (254 mm)
- Width: 6.0 inches (152.4 mm)
- Weight: 9.6 pounds (6.9 kg)
HD485 Dies
MS90485* DIES & GAGES for MS20659 UNINSULATED TERMINALS |
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MIL DIE P/N* |
DMC P/N |
COMMENTS |
MIL Gage P/N * |
DMC GAGE P/N |
MS90485-8 | HD485-8 | For Uninsulated Size 8 | MS90486-8 | G720 |
MS90485-6 | HD485-6 | For Uninsulated Size 6 | MS90486-6 | G721 |
MS90485-4 | HD485-4 | For Uninsulated Size 4 | MS90486-4 | G722 |
MS90485-2 | HD485-2 | For Uninsulated Size 2 | MS90486-2 | G833 |
MS90485-1 | HD485-1 | For Uninsulated Size 1 | MS90486-1 | G834 |
MS90485-01 | HD485-01 | For Uninsulated Size 1/0 | MS90486-01 | G835 |
MS90485-02 | HD485-02 | For Uninsulated Size 2/0 | MS90486-02 | G836 |
MS90485-03 | HD485-03 | For Uninsulated Size 3/0 | MS90486-03 | G837 |
MS90485-04 | HD485-04 | For Uninsulated Size 4/0 | MS90486-04 | G838 |
HD002 Dies
MS23002* DIES & GAGES for MS25036 INSULATED TERMINALS |
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MIL DIE P/N * |
DMC P/N |
COMMENTS |
MIL Gage P/N * |
DMC GAGE P/N |
MS23002-8 | HD002-8 | For Insulated Size 8 | MS23003-8 | G723 |
MS23002-6 | HD002-6 | For Insulated Size 6 | MS23003-6 | G724 |
MS23002-4 | HD002-4 | For Insulated Size 4 | MS23003-4 | G725 |
MS23002-2 | HD002-2 | For Insulated Size 2 | MS23003-2 | G281 |
MS23002-1 | HD002-1 | For Insulated Size 1 | MS23003-1 | G726 |
MS23002-01 | HD002-01 | For Insulated Size 1/0 | MS23003-01 | G727 |
MS23002-02 | HD002-02 | For Insulated Size 2/0 | MS23003-02 | G728 |
MS23002-03 | HD002-03 | For Insulated Size 3/0 | MS23003-03 | G282 |
MS23002-04 | HD002-04 | For Insulated Size 4/0 | MS23003-04 | G729 |
HD442 Dies
MS25442* DIES & GAGES for AS70991 UNINSULATED TERMINALS |
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MIL DIE P/N * |
DMC P/N |
COMMENTS |
MIL Gage P/N * |
DMC GAGE P/N |
MS25442-8A | HD442-8A | For Uninsulated Size 8 | MS25472-1 | G1129 |
MS25442-6A | HD442-6A | For Uninsulated Size 6 | MS25472-2 | G1130 |
MS25442-4A | HD442-4A | For Uninsulated Size 4 | MS25472-3 | G1131 |
MS25442-2A | HD442-2A | For Uninsulated Size 2 | MS25472-4 | G1132 |
MS25442-1A | HD442-1A | For Uninsulated Size 1 | MS25472-5 | G1133 |
MS25442-01A | HD442-01A | For Uninsulated Size 1/0 | MS25472-6 | G1134 |
MS25442-02A | HD442-02A | For Uninsulated Size 2/0 | MS25472-7 | G1135 |
MS25442-03A | HD442-03A | For Uninsulated Size 3/0 | MS25472-8 | G1136 |
MS25442-04A | HD442-04A | For Uninsulated Size 4/0 | MS25472-9 | G1137 |
DESCRIPTION |
PART NO. |
MIL DIE P/N * |
Manual Hydraulic Tool (7 ton force) | HH80C | |
Remote Crimp Head (12 ton force) (Requires Air to Hydraulic Pump) |
TBHD1M* | MS25441-1* |
Air to Hydraulic Pump | HPU11M | |
Hose Assembly (6 Ft. Length) | 12-4040 | MS25441-3* |
In-Line Pressure Gauge | HPU11-PG | |
*Qualified to MS5259/1 Large Gage Crimp Tool Specification
DMC1948 TOOL KIT
The DMC1948 Tool Kit contains the TBHD1M Crimp Tool, HPU11M Pump, Hose Assembly, and all the HD002 (MS23002) and HD485 (MS90485) dies for crimping insulated and uninsulated terminals and splices size 8 through 4/0.
This tool kit is contained in a molded, high-density plastic case with foam inserts that have contoured tool cavities, laminated instruction sheets permanently attached on a ring binder, and contents charts identifying the location of each tool.
DMC1966 TOOL KIT
The DMC1966 Tool Kit contains the TBHD1M Crimp Tool, HPU11M Pump, Hose Assembly, and all the HD442 (MS25442) dies for crimping uninsulated aluminum terminals and splices size 8 through 4/0.
This tool kit is contained in a molded, high-density plastic case with foam inserts that have contoured tool cavities, laminated instruction sheets permanently attached on a ring binder, and contents charts identifying the location of each tool.
The HPU11-PG In-Line Hydraulic Pressure Gauge is recommended for cycle control monitoring, when using Remote Crimp Heads. It installs into either end of the hydraulic line to monitor the hydraulic pressure. The gauge will indicate to the operator when the required hydraulic pressure is achieved.