Generator Lug Crimping System

Other / Unclassified

This document is a Brand Name Justification for the acquisition of a specific tool setup for crimping generator lugs on PN 35-8255-801 used with TF33-P103 left-hand assemblies. The justification is based on the need for a tool compatible with existing depot-level crimping dies to ensure reliable electrical and mechanical connections, as governed by Technical Orders (T.O.) 1B-52H-2-23 and 1-1A-14.

• Sole Source Justification: The document asserts that only a specific brand's tool setup can ensure exact die-to-tool alignment and compliance with technical orders without extensive and costly requalification or redesign.
• Compatibility Requirement: The tool must be compatible with the depot's existing crimping dies and integrated into depot-level maintenance processes.
• Market Research: Limited market research was conducted, identifying only one responding small business out of four contacted, and one additional potential vendor. This led to the determination that proceeding with a small business set-aside is in the Government's best interest.
• Contact Information: For further information or clarification, bidders can contact Mark Todd at OC-ALC/OBCA, (405) 739-8311.

Form / Attachment / Pricing Sheet

This document provides detailed instructions and specifications for the installation and repair of electrical terminals and cables, specifically focusing on copper and aluminum components. It serves as a technical guide for personnel performing these tasks.

• Section 1-3.17 & 1-3.18: Covers general repair of terminals and cables, emphasizing the use of like materials and replacement of damaged segments.
• Section 1-3.19: Details the installation of copper terminals and splices, including procedures for inserting conductors, using splices as connectors, and handling three-way splices. It also lists specific splice sizes, adapter of filler types, and recommended tools.
• Section 1-3.20: Outlines the procedure for installing aluminum terminals, including the application of insulating sleeves, stripping insulation from cables, and the use of specific compounds. It provides tables for insulating sleeve lengths and insulating strip lengths based on wire size and terminal type.

This document is crucial for bidders who will be responsible for performing electrical termination and repair work as part of the opportunity. It specifies the exact procedures, materials, tools, and measurements required, ensuring compliance with technical standards. Bidders should review this document to understand the performance expectations and potential costs associated with these tasks.

Form / Attachment / Pricing Sheet

This document, Table 14, provides a detailed listing of uninsulated copper terminal lugs and the corresponding crimp tools and dies required for their application. It serves as a reference for selecting the correct components for specific wire sizes and stud sizes.

• Part Numbers: Lists MS20659 and AS7928/11 part numbers for terminal lugs.
• Wire Size Range: Specifies the applicable wire gauge for each lug.
• Stud Size: Indicates the required stud size for connection.
• Crimp Tool & Die: Identifies the specific crimp tool (e.g., MS25441-1) and crimp die (e.g., MS90485-01) needed for each lug.
• Inspection Gage & Tip: Details the inspection gage (e.g., MS90486-1) and tip used to verify the crimp quality.
• Notes: Provides important supplementary information, including:
  • References to specific tools and inspection gages (SUPP J).
  • Details on hydraulic requirements for certain crimp tools.
  • Information on the temperature rating and identification of MS20659 and M7928/11 lugs.
  • Requirements for two crimp cycles for specific lug sizes (000 and 0000).
  • Guidance on substituting terminal lugs and identifying them by color markings.
  • References for stud size explanations.

This attachment is crucial for bidders to understand the specific hardware and tooling required for any work involving electrical connections. It directly impacts material procurement, labor requirements, and quality assurance processes related to the installation of terminal lugs. Bidders must ensure they can procure and utilize the specified tools and lugs to meet the opportunity's technical requirements.

Form / Attachment / Pricing Sheet

This document provides a detailed item description and specifications for equipment required for a generator lug crimping system.

• Crimpers Kits (Quantity 2):
  • Compliant with TO 1-1A-14 for 3/0 Copper wiring lugs.
  • Requires TBHD1M Remote Hydraulic Crimp Head Assembly or equivalent (Mil PN: MS25441-01).
  • Crimp Force: 12.0 Tons.
  • Crimping Range: 8 AWG to 4/0 AWG.
  • Weight: 9.6 Pounds.
  • Dimensions: 10.0" (L) X 6.0" (W).
  • Die Compatibility: Accepts MS90485-03 dies.
  • Capable of crimping both insulated and uninsulated terminals.
  • Preferred Power Source: HPU11M air-powered hydraulic pump.
  • Mounts to a BM-2A bench mount.
• Air Powered Hydraulic Pump (Quantity 2):
  • HPU11M or equivalent.
  • Foot-actuated and pneumatically powered.
  • Capable of fully powering the specified crimper.
  • Requires 1/4-inch industrial style female pneumatic quick disconnect.
  • Maximum Output Pressure: 10,000 PSI.
  • Input air pressure: 30-125 PSI.
  • Hydraulic / Air Ratio: 100:1.
  • Weight: 19.4 Pounds (with hose and fluid).
  • Dimensions: 11.5" (Depth) X 13.75" (Width) X 6.25" (Height).
• Adjustable Base Mount (Quantity 2):
  • BM-2A or equivalent.
  • Fully adjustable with 3-axis adjustments.
  • Locks tool securely with a single knob.
  • Material: Heavy-duty machined high grade cast steel.
  • Base Dimensions: 4" X 8".
  • Weight: 3.68 pounds.
• Go-No-GO Gages (Quantity 2):
  • Two gauges required per system.
  • Equivalent to PN G837 (corresponds to MS90485-03 die set).
• Air Hose Assembly (Quantity 2):
  • 12-4040 or equivalent.
  • Pre-installed hydraulic lines, ready for air supply connection.
  • Length: 10 Feet.
  • Construction: Heavy duty hydraulic hose and couplings.
  • Fittings: Screw-on MS fittings with dust covers.

This document details the specific technical requirements and specifications for a crimping system. Bidders must ensure their proposed equipment meets or exceeds these detailed specifications to be considered compliant.

Solicitation / RFP / RFQ

This is a combined synopsis/solicitation for commercial products or services for the GENERATOR LUG CRIMPING SYSTEM at Tinker AFB, OK. The Air Force Sustainment Center's Maintenance Contracting Branch anticipates awarding a Firm Fixed Price (FFP) contract. This announcement is the only solicitation, and a separate written solicitation will not be issued.

• The solicitation is for the "GENERATOR LUG CRIMPING SYSTEM".

• Specific items include:

  • TBHD1M REMOTE HYDRAULIC CRIMP HEAD ASSEMBLY OR EQUIVALENT (2 units)
  • HPU11M AIR POWERED HYDRAULIC PUMP OR EQUIV (2 units)
  • BM-2A ADJUSTABLE BASE MOUNT OR EQUIV (2 units)
  • GO-NO-GO GAGES MS90485-03 OR G837 (2 units)
  • 12-4040 AIR HOSE ASSEMBLY OR EQUIVALENT (2 units)

• Deliveries are FOB Destination to Tinker AFB, OK 73145.

• Contract Type: Firm Fixed Price (FFP)

• This is a one-time Purchase Order.

• Quote Submission Deadline: 21 April 2026, 12:00 PM (Noon) Central Standard Time.

• Quotes must be submitted to the Point of Contact (POC) listed on page 1.

• Evaluation Factors: Technical Acceptability and Price.

• Award will be made to the technically acceptable vendor with the lowest Total Evaluated Price (TEP).

• The Government intends to award without interchanges.

• This acquisition is a 100% Small Business Set-aside.

• Large businesses are not eligible for award.

• NAICS Code: 333991

• The Non-Manufacturing Rule does not apply.

• Offerors must be registered in the System for Award Management (SAM) prior to quoting. Failure to be registered in SAM by the time of award will result in ineligibility.

• Vendors must complete annual representations and certifications electronically via SAM.

• The solicitation incorporates provisions and clauses by reference, accessible at https://www.acquisition.gov/far-overhaul/far-part-deviation-guide and https://www.acq.osd.mil/dpap/dars/dfars_far_overhaul_class_deviations.html.

• Attachments referenced include "Item Description", "TO-1-1A14 Snip", and "TO-1B-52H-2-23 Snip".