Common Dies Tooling Guide – CRiMP-TECH AUSTRALIA

PRODUCTS
- Backshell ToolingThe evolution of circular connectors has produced a multitude of configurations which have more precise dimensional tolerances and electrical characteristics than any other mechanical component used in modern electrical systems. The associated tooling must meet the same level of precision to apply the connector to its intended purpose. Until now, very little attention has been focused on the tooling which is used to mount strain-relief backshells and other accessories to wired connector assemblies. This is why the BETA® system was developed.
- Banding ToolsThe termination of EMI/RFI shielding materials is a specialised science in today’s aerospace wiring systems. Application tooling is a critical factor in the overall performance of the wiring system components. DMC has worked closely with the world’s leading connector accessory manufacturers and standards organisations to develop the necessary tooling and accessories to meet the stringent demands of aerospace and defence system contractors. The resulting products afford the user a repeatable and reliable means of terminating shielding on aerospace wiring systems. Tooling is available for all bands qualified to AS85049/128
- Battery Crimp ToolsCrimp-Tech Australia has a range of battery operated crimp tools to crimp a wide range of contacts, terminals and splices . We believe the following information and data will answer your questions. If not please contact us for personalized service. Working on today’s electrical connections calls for increased mobility and repeatable, consistent crimping force so we offer a wide range of battery powered crimp tools designed to integrate with your current tooling systems. These battery powered tools offer the mobility of a hand tool without sacrificing the power of pneumatic tools. In the field or on the factory floor, every tool crimps with the consistency and precision you expect from DMC products. The ergonomic tool body helps reduce workplace injuries and eases operator fatigue keeping costs low and production high. DMC battery powered tools have been engineered to work with our existing die series and compliment our established crimp tool lines. And, as always, if we don’t have a die to meet your needs, we will engineer and manufacture it for you. So if your workload is too much for hand tools, or pneumatic hoses and power cables are unwelcome, unsafe or impractical for the work environment, a battery powered…
- Connectors
- Crimp Tool GaugesWith the need to ensure that your tooling die sets, positioners, turret heads and also the indent crimp tools is in calibration and conforms to the required standards, DMC have a large range of GO NO-GO Gauges available for a variety of applications. If you do not know the required GO NO-GO gauge please contact us for assistance.
- Cutting & Stripping ToolsCable preparation is an essential part of wiring system practices, and have the right tool to prepare our cable for crimping of contacts, terminals or lugs is critical. It is important not to damage the insulation on conductors, cable shielding or damage the copper or fibre that will be transmitting the signal down you cable.
- DMC Tool KitsBuilding a tool kit to service an entire wiring system involves extensive research to select to correct tooling and ensure all serviceable connectors, terminals, splices and contacts are covered. Technicians who are responsible for the maintenance or production of entire systems cannot be expected to know all the answers, nor do they have the time to do the necessary research or locate tooling. Crimp-Tech and DMC has this knowledge and does the technical research for them.
- Hand Crimp ToolsCrimp-Tech Australia offers a range of Military and Commercial Hand Crimp Tools. Here you will find a range of these products, if the particular tool you are looking for is not listed please contact us.
- Harting Tool Kits
- Heat GunsHeat Guns and Hot Air Hand Tools
- Hydraulic Crimp Tools
- Insertion/Removal ToolsDMC is dedicated to serving the connector tooling needs of the electronics industry. We, therefore, top off our product package with a wide variety of installing and removal tools. Although we supply both plastic and metal tools, we recommend the use of the metal tools because of their durability. When used properly they are more cost effective in that they withstand thousands of contact insertion and removal cycles. The trend to all metals tools is being actively encouraged by most departments of the government. DMC installing and removal tools are of proven high quality and reliability. In addition to the tools listed in these reference table, we have many more for other connector applications. Please contact us for more details.
- LaceLok®LaceLok® Cable Lacing Fasteners are used as secondary support for cable and wire bundling. Developed to replace cable ties and hand tied lacing tape, LaceLok® provides an ergonomic solution for consistent bundling with unrivaled strength and superior performance.
- Misc Tools
- Pneumatic Crimp Tools
- Safe-T-CableSafe-T-Cable™ is constructed of high tensile strength, stranded cable. It is more flexible than its Safety Wire counterpart, although the working diameters are equivalent. This provides a stronger assembly which has greater strength and lighter weight. The cable ends are electrically fused to form an easy threading end.
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Many die configurations for crimping terminals and splices are required for OEM and maintenance operations. Interchangeable dies eliminate the need for separate fixed die crimp tools for each and every different application.

Many die configurations for crimping terminals and splices are required for OEM and maintenance operations. AWG size is one determining factor, but each die configuration has a designated tool series. The hand tool is the basis of each tool series and suitable for the low volume of prototype or repair work. For higher volume production and intermediate/depot maintenance, a tool series might include pneumatic tools, hydraulic tools, battery hydraulic tools, or electric hydraulic tools.

Common Dies for HX4, HXE4B, HX23 & HD37

MILITARY P/N	DMC P/N	NSN	A. HEX	LENGTH	B. HEX	LENGTH	MILITARY GAGE P/N	DMC GAGE P/N
M22520/5-02	Y200P	5120-01-335-8244	.091	.090	.068	.270	M22520/6-030	G207
M22520/5-03	Y196	5120-01-335-8245	.128	.325	.105	.325	M22520/6-001	G150
M22520/5-04	Y152	5120-01-335-8246	.138	.090	.118	.270	M22520/6-002	G186
M22520/5-05	Y197	5120-01-335-8247	.213	.325	.178	.325	M22520/6-006	G185
M22520/5-06	Y203	5120-01-335-8248	.128	.094			M22520/6-003	G155
M22520/5-07	Y195	5120-01-335-8249	.255	.325			M22520/6-011	G170
M22520/5-08	Y215	5120-01-335-8250	.128	.375			M22520/6-003	G155
M22520/5-09	Y204P	5120-01-335-8251	.178	.400	.068	.093	M22520/6-006	G185
M22520/5-10	Y189	5120-01-335-8252	.160	.400			M22520/6-005	G188
M22520/5-11	Y205P	5120-01-335-8253	.213	.400	.068	.093	M22520/6-008	G180
M22520/5-13	Y206P	5120-01-335-8254	.255	.400	.068	.093	M22520/6-011	G170
M22520/5-15	Y207P	5120-01-335-8255	.263	.400	.068	.093	M22520/6-012	G192
M22520/5-17	Y193	5120-01-335-8256	.118	.375			M22520/6-002	G186
M22520/5-19	Y142	5120-01-335-8257	.255	.400	.213	.400	M22520/6-008	G180
M22520/5-21	Y149	5120-01-335-8258	.475	.400			M22520/6-025	G203
M22520/5-23	Y145	5120-01-335-8259	.384	.400			M22520/6-020	G199
M22520/5-25	Y110P	5120-01-335-8260	.429	.400	.100	.120	M22520/6-031	G208
M22520/5-27	Y151	5120-01-335-8261	.532	.400			M22520/6-027	G205
M22520/5-29	Y109P	5120-01-335-8262	.324	.400	.100	.120	M22520/6-031	G208
M22520/5-31	Y150	5120-01-335-8263	.501	.400			M22520/6-026	G204
M22520/5-33	Y136	5120-01-335-8264	.343	.400	.105	.400	M22520/6-018	G175
M22520/5-35	Y137	5120-01-335-8265	.324	.400	.128	.400	M22520/6-017	G197
M22520/5-37	Y138	5120-01-335-8266	.314	.400	.151	.400	M22520/6-016	G196
M22520/5-39	Y139	5120-01-335-8267	.309	.400	.160	.400	M22520/6-015	G195
M22520/5-41	Y140	5120-01-335-8268	.290	.400	.178	.400	M22520/6-014	G194
M22520/5-43	Y141	5120-01-335-8269	.268	.400	.197	.400	M22520/6-013	G193
M22520/5-45	Y143	5120-01-335-8270	.231	.400	.218	.400	M22520/6-009	G190
M22520/5-47	Y144	5120-01-335-8271	.359	.400			M22520/6-019	G198
M22520/5-49	Y146	5120-01-335-8292	.401	.400			M22520/6-021	G200
M22520/5-51	Y147	5120-01-335-8293	.431	.400			M22520/6-023	G201
M22520/5-53	Y148	5120-01-335-8294	.454	.400			M22520/6-024	G202
M22520/5-55	Y102	5120-01-335-8295	.324	.400			M22520/6-017	G197
M22520/5-57	Y209P	5120-01-335-8296	.213	.400	.100	.120	M22520/6-031	G208
M22520/5-59	Y208P	5120-01-335-8297	.255	.400	.100	.120	M22520/6-031	G208
M22520/5-61	Y178	5120-01-335-8298	.429	.400			M22520/6-022	G165
M22520/5-63	Y314P	5120-01-335-8299	.263	.400	.091	.091
M22520/5-100	Y501	5120-01-335-8300	Pre-Insulated Terminal Crimp 26-10 AWG
M22520/5-101	Y527	5120-01-335-8301	Pre-Insulated Splice Crimp 26-20 AWG
M22520/5-102	Y539	5120-01-335-8302	Splice Crimp 12-16 AWG
M22520/5-103	Y540	5120-01-335-8303	Splice Crimp 16-26 AWG
M22520/5-104	Y692
M22520/5-105	Y631	5120-01-361-9554	.218	.307				G465
M22520/5-106*	Y1115		Adjustable Insulation Terminal Crimp for Red 18-22 AWG					G1369
M22520/5-107*	Y1116		Adjustable Insulation Terminal Crimp for Blue 14-16 AWG
M22520/5-108*	Y1117		Adjustable Insulation Terminal Crimp for Yellow 10-12 AWG

*QPL is progress

* Additional dies available, consult DMC

Dies for HD51 5.5 Ton Crimping Tool

The HD51 Medium Duty Hydraulic Crimper is the most popular hand operated hydraulic crimper.

The HD51 is still lightweight at 4.6 pounds, but the 5.5 tons of die force and the larger die configuration extends the range of crimping capabilities to 2/0 AWG* conductors in many applications.

MILITARY P/N	DMC P/N	A. CAVITY	A. LENGTH	B. CAVITY	B. LENGTH	APPLICATION	MILITARY GAGE P/N	DMC GAGE P/N
N/A	HD51-101	.325	.125	.216	.187	.325 / .216, Hexes	N/A
N/A	HD51-105	.170	.250			For Insulated Terminals Size 8	N/A	G682
N/A	HD51-106	.202	.312			For Insulated Terminals Size 6	N/A	G683
N/A	HD51-107	.254	.375			For Insulated Terminals Size 4	N/A	G684
N/A	HD51-110	.530	.365			.530, Hex	N/A
N/A	HD51-112	.440	.358	.538	.358	.440 / .538, Hexes	N/A
N/A	HD51-113	.312	.470			For Insulated Terminals Size 2	N/A	G801
N/A	HD51-114N	.135	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 8 (Single Indent)	N/A	G1150
N/A	HD51-115N	.126	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 6 (Single Indent)	N/A	G1151
N/A	HD51-116N	.131	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 4 (Single Indent)	N/A	G1152
N/A	HD51-117N	.190	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 2 (Single Indent)	N/A	G1153
N/A	HD51-118N	.135	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 8 (Double Indent)	M5259/6-001	G1150
N/A	HD51-119N	.126	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 6 (Double Indent)	M5259/6-002	G1151
N/A	HD51-120N	.131	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 4 (Double Indent)	M5259/6-003	G1152
N/A	HD51-121N	.190	.312			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 2 (Double Indent)	M5259/6-004	G1153
N/A	HD51-122N	.275	.470			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 1/0 (Single Indent)	N/A	G1154
N/A	HD51-123N	.275	.470			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 1/0 (Double Indent)	M5259/6-005	G1154
N/A	HD51-124N	.320	.470			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 2/0 (Double Indent)	M5259/6-006	G1155
N/A	HD51-125N	.320	.470			For Uninsulated AS7928 Copper Terminals and AS7974 Contacts Size 2/0 (Single Indent)	N/A	G1155
N/A	HD51-127	.445	.250	.395	.200	.445 / .395, Hexes	N/A
N/A	HD51-130-1	R .100 H .300				#2 – #8 Uninsulated Needs HD51-131-2 or HD51-132-2	N/A
N/A	HD51-131-2	R .275		R .145		#2 & #8 Uninsulated Needs HD51-130-1	N/A	G744 G747
N/A	HD51-132-1	R .219		R .188		#4 & #6 Uninsulated Needs HD51-130-1	N/A	G745 G746
N/A	HD51-133-2	.312		.170		#2 & #8 Insulated Needs HD51-113-1 for #2 & HD51-105-1 for #8	N/A	G801 (#2) G682 (#8)
N/A	HD51-134-2	.202		.254		#4 & #6 Insulated Needs HD51-106-1 for #6 & HD51-107-1 for #4	N/A	G683 (#6) G684 (#4)
N/A	HD51-138	.377	.435			#2 Uninsulated .377, Hex MS90485-2 Equiv.	N/A
N/A	HD51-139	.587	.400			.587 Hex	N/A
N/A	HD51-140	.956		.500		.956 & .500 Hex	N/A
N/A	HD51-144	.140	.470			.140 Hex	N/A
N/A	HD51-148	.216				.216 Hex	N/A
N/A	HD51-149	.660	.400			.660 Hex	N/A
N/A	HD51-150	.352	.470			AB Twinax Pin & Socket Contacts Hex	N/A
N/A	HD51-152	.304	.470			Packard Hughes .437 Ferrules Gage	N/A
N/A	HD51-154	.339	.437			For Insulated Terminals Size 1 MS23002-1 Equiv.	N/A	G726
N/A	HD51-157					#10 Flag Terminal	N/A
N/A	HD51-159	.312	.470			#2 AWG Insulated Hex	N/A
N/A	HD51-160	.500	1.300			#2 Uninsulated For Aluminum Wire, Hex	N/A
N/A	HD51-162	.218	.470			.218, Hex	N/A
N/A	HD51-163P	.210	.310			For Uninsulated Terminals Size 8, Functional Equiv MS90485-8	N/A	G720
N/A	HD51-164P	.240	.310			For Uninsulated Terminals Size 6, Functional Equiv MS90485-6	N/A	G721
N/A	HD51-165P	.299	.372			For Uninsulated Terminals Size 4, Functional Equiv MS90485-4	N/A	G722
N/A	HD51-166P	.417	.435			For Uninsulated Terminals Size 1, Functional Equiv MS90485-1	N/A	G834
N/A	HD51-167P	.456	.435			For Uninsulated Terminals Size 1/0, Functional Equiv MS90485-01	N/A	G835
N/A	HD51-168P	.500	.470			For Uninsulated Terminals Size 2/0, Functional Equiv MS90485-02	N/A	G836
N/A	HD51-169P	.562	.470			For Uninsulated Terminals Size 3/0, Functional Equiv MS90485-03	N/A	G837
N/A	HD51-170P	.618	.470			For Uninsulated Terminals Size 4/0, Functional Equiv MS90485-04	N/A	G838

* Additional dies available, consult DMC

Dies for EMC3300 Electro Mechanical Crimp Tool

The scissor action EMC 3300 offers advanced Ergonomic Tool Design with “Safe Distance” Trigger Closing Control. Dies for the EMC3300 crimp splices, insulated, and uninsulated terminals. Ask DMC for information regarding requivilant dies for our popular “Y” die series.

DMC P/N	A. CAVITY	A. LENGTH	B. CAVITY	B. LENGTH	C. CAVITY	C.LENGTH	D. CAVITY	D. LENGTH	APPLICATION
EMC-101D	.072		.089		.116		.142		W, R, B, Y Insulated Spare Wire Caps
EMC-102D	.082		.096		.132				R, B, Y Insulated Terminals (TE58423-1)
EMC-102DL	.082		.096		.132				Same as EMC-102D plus Locator
EMC-105D	.079		.092		.124				EQUIV. TO DCT4-105
EMC-106D	.042 SQ	.090	.128	.400	.178	.400			.042 sq, .128 hex, .178 hex
EMC-108D	.068	.095	.213	.400	.255	.400			.068 sq, .213 hex, .255 hex
EMC-117D	.128	.500	.178	.500	.213	.500	.255	.500	.128 hex, .178 hex, .213 hex, .255 hex (AMPHENOL SOCAPEX SX660-0062)
EMC-129D	.028 GAGE		.047 GAGE		.068 GAGE				M81824/1-X splices (comparable to M22520/37-01, GMT 232)
EMC-199D	.062/.067 GAGE	.236	.084/.089 GAGE	.236	.110-.115 GAGE	.236			Equivalent to T & B ERG4002
EMC-204D	.095 GAGE	.250	.100 GAGE	.250					Equivalent to TE 58630-1 tool for ULTRA-FAST 12-10 Terminals
EMC-277D	.114-.120	.215	.148-.154	.215	.030-.050	.215	.075-.095	.215	Equivalent to GMT277
EMC-1005D	.049		.057		.079				Uninsulated Terminals 10-22 AWG (Equiv to GMT1005, comparable to TE49935)
EMC-1006D	.054		.062		.086				High Temp Uninsulated Terminals 10-22AWG (Equiv to GMT1006, comparable to TE46447)

* Additional dies available, consult DMC

**Dies for TBHD1M and HD120* 12 Ton Crimping Tool**

The TBHD1M Remote Hydraulic Crimp Head (MS25441-1) and HD120 exert 12 tons of crimp force and extends the range of crimping capabilities to 4/0 AWG conductors.

* The HD120 is currently not on QPL. Request for Qualification has been sent to the QA and is in progress

MS23002* Dies & Gages for MS25036 Insulated Terminals

MILITARY P/N	DMC P/N	APPLICATION	MILITARY GAGE P/N	DMC GAGE P/N
MS23002-8	HD002-8	For Insulated Terminals Size 8	MS23003-8	G723
MS23002-6	HD002-6	For Insulated Terminals Size 6	MS23003-6	G724
MS23002-4	HD002-4	For Insulated Terminals Size 4	MS23003-4	G725
MS23002-2	HD002-2	For Insulated Terminals Size 2	MS23003-2	G281
MS23002-1	HD002-1	For Insulated Terminals Size 1	MS23003-1	G726
MS23002-01	HD002-01	For Insulated Terminals Size 1/0	MS23003-01	G727
MS23002-02	HD002-02	For Insulated Terminals Size 2/0	MS23003-02	G728
MS23002-03	HD002-03	For Insulated Terminals Size 3/0	MS23003-03	G282
MS23002-04	HD002-04	For Insulated Terminals Size 4/0	MS23003-04	G729

*Qualified to AS5259/1 (Tool Head) and AS5259/7 (Crimp Dies). Additional dies available, consult DMC

MS90485* Dies & Gages for MS20659 Uninsulated Terminals

MILITARY P/N	DMC P/N	APPLICATION	MILITARY GAGE P/N	DMC GAGE P/N
MS90485-8	HD485-8	For Uninsulated Terminals Size 8	MS90486-8	G720
MS90485-6	HD485-6	For Uninsulated Terminals Size 6	MS90486-6	G721
MS90485-4	HD485-4	For Uninsulated Terminals Size 4	MS90486-4	G722
MS90485-2	HD485-2	For Uninsulated Terminals Size 2	MS90486-2	G833
MS90485-1	HD485-1	For Uninsulated Terminals Size 1	MS90486-1	G834
MS90485-01	HD485-01	For Uninsulated Terminals Size 1/0	MS90486-01	G835
MS90485-02	HD485-02	For Uninsulated Terminals Size 2/0	MS90486-02	G836
MS90485-03	HD485-03	For Uninsulated Terminals Size 3/0	MS90486-03	G837
MS90485-04	HD485-04	For Uninsulated Terminals Size 4/0	MS90486-04	G838

*Qualified to AS5259/1 (Tool Head) and AS5259/7 (Crimp Dies). Additional dies available, consult DMC

MS25442* Dies & Gages for AS70991 (MS25435) Uninsulated Terminals

MILITARY P/N	DMC P/N	APPLICATION	MILITARY GAGE P/N	DMC GAGE P/N
MS25442-8A	HD442-8A	For Uninsulated Terminals Size 8	MS25472-1	G1129
MS25442-6A	HD442-6A	For Uninsulated Terminals Size 6	MS25472-2	G1130
MS25442-4A	HD442-4A	For Uninsulated Terminals Size 4	MS25472-3	G1131
MS25442-2A	HD442-2A	For Uninsulated Terminals Size 2	MS25472-4	G1132
MS25442-1A	HD442-1A	For Uninsulated Terminals Size 1	MS25472-5	G1133
MS25442-01A	HD442-01A	For Uninsulated Terminals Size 1/0	MS25472-6	G1134
MS25442-02A	HD442-02A	For Uninsulated Terminals Size 2/0	MS25472-7	G1135
MS25442-03A	HD442-03A	For Uninsulated Terminals Size 3/0	MS25472-8	G1136
MS25442-04A	HD442-04A	For Uninsulated Terminals Size 4/0	MS25472-9	G1137

*Qualified to AS5259/1 (Tool Head) and AS5259/7 (Crimp Dies). Additional dies available, consult DMC