Attachment 2 - Generator Lug Crimping System - TO-1-1A-14 Snip.pdf
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This is a technical specification table from military maintenance documentation (NAVAIR 01-1A-505-1, T.O. 01-1A-14, TM 1-500-323-24-1, Change 1 dated June 1, 2021) detailing uninsulated copper terminal lugs and associated crimp tools. Table 14 presents specifications for AS20659 and AS7928/11 terminal lugs across multiple wire size ranges (1/4 inch through 7/8 inch) and stud sizes (ranging from -115 through -160 dash numbers). For each configuration, the table specifies required crimp tools (primarily MS25441-1 models), crimp dies (MS90485 and MS90486 series with various suffixes), and corresponding inspection gages and gage tips.
Key specifications include: MS20659 nickel-plated terminal lugs offering a 260°C temperature rating (identified by green color paint stripe) and M7928/11 tin whisker resistant lugs (identified by blue dot on tongue); MS25441-1 is the standard crimp tool used across configurations; hydraulic operation requires M5259/2-01 hose and M5259/2-02 foot pump or equivalent 10,000 PSI pumps; sizes designated 000 and 0000 require two crimp cycles; M7928/11 terminal lugs can substitute for MS20659 lugs using identical dash numbers, but reverse substitution is prohibited. The document references supplementary materials (SUPP J) and cross-references to other technical manuals for additional guidance on stud sizes and tool specifications.
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013 00
NAVAIR 01-1A-505-1
T.O. 01-1A-14
TM 1-1500-323-24-1
Change 1 - 1 June 2021
Table 14. AS20659 and AS7928/11 Uninsulated Copper Terminal Lug and Crimp Tool (Cont.)
Part No.
MS20659
M7928/11 4/
Wire Size
Range Stud Size Crimp Tool Crimp Die Inspection
Gage Inspection Gage Tip
-115
1/4
MS25441-1
M5259/3-01
M5259/4-01 3/ M5259/5-01
MS90485-1
MS90485-1
M5259/7-005 M5259/7-005
MS90486-1
MS90486-1
MS90486-1
MS90486-1
N/A
-149 5/16 -116 3/8 -150 7/16 -134 1/2 -117
1/4
MS25441-1
M5259/3-01
M5259/4-01 3/ M5259/4-01 3/ M5259/5-01 M5259/5-01
MS90485-01
MS90485-01
M5259/7-006 M5259/7-014 M5259/7-006 M5259/7-014
MS90486-01
MS90486-01
MS90486-01
M5259/6-005
MS90486-01
M5259/6-005
-151 5/16 -118 3/8 -152 7/16 -135 1/2
-153
1/4
MS25441-1
M5259/3-01
M5259/4-01 3/ M5259/4-01 3/ M5259/5-01 M5259/5-01
MS90485-02
MS90485-02
M5259/7-007 M5259/7-015 M5259/7-007 M5259/7-015
MS90486-02
MS90486-02
MS90486-02
M5259/6-006
MS90486-02
M5259/6-006
-119 5/16 -120 3/8 -154 7/16 -136 1/2
-155
5/16
MS25441-1 MS90485-03 MS90486-03
-121 3/8 -156 7/16 -122 1/2 -157
0000 /5
5/16
MS25441-1 MS90485-0 MS90486-04
-123 3/8 -158 7/16 -124 1/2 -159 5/8 -160 3/4 -137 7/8
1/ See M22520/38-01 tool and M22520/39-02 inspection gage.
2/ M22520/24-01 is superseded by M22520/38-01.
3/ Crimp tool requires a hydraulic M5259/2-01 hose and a M5259/2-02 foot pump or other hydraulic 10,000 PSI pumps (see WP 013 01).
4/ The MS20659 nickel plated terminal lugs o er 260_C temperature rating. The dash number changes from ”- 1XX” to ”- 2XX”. Remaining size, t and tool remain the same as the “- 1XX”. This type lug is identi ed by a green color paint stripe around the wire barrel. The M7928/11 tin whisker resistant nish has a blue dot on the tongue next to the sleeve.
5/ Two crimp cycles are required for the 000 and 0000 sizes.
Notes:
1. MS20659- XX terminal lugs can be substituted with M7928/11- XX ”Tin Whisker Resistant” terminal lugs using same dash numbers, but the M7928/11- XX terminal lugs cannot be substituted with the MS20659_XX terminal lugs. The M7928/11 tin plated whisker resistant terminal lug is identi ed with a blue color paint dot on the ring tongue.2. Refer to NAVAIR 01-1A-8 for explanation of stud size, or WP 017 00, Table 3 this manual.
2. See Table 20 for stud sizes.
See SUPP J See SUPP J
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