(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 97 Terminal Products and Tools Terminals Overview ................................................... 98 - 101 Nylon Insulated Ring............................... 102 - 106 Vinyl Insulated Ring ................................ 107 - 109 Non-Insulated Ring ................................. 110 - 112 Heavy Duty Ring .............................................. 113 High Temperature Non-Insulated..................... 114 TEFZEL(R) Insulated Ring .................................. 115 Rectangular Rings .................................... 116-117 Flag Terminals .................................................... 118 Fork Terminals Nylon Insulated Fork............................... 119 - 120 Vinyl Insulated Fork ......................................... 121 Non-Insulated Fork .......................................... 122 Locking Fork Terminals Nylon Insulated Fork ........................................ 123 Vinyl Insulated Fork ......................................... 124 Heat Shrinkable Fork ....................................... 125 Non-Insulated Fork .......................................... 125 Pin Terminals ...................................................... 126 Insulated Ferrules ...................................... 127 - 128 Non-Insulated Ferrules ....................................... 129 Heat Shrinkable Terminals, Splices, Disconnects ............................................ 130 - 131 Splice Connectors...................................... 132 - 134 Parallel Splices ................................................... 135 Disconnects Female (250 Series) ............................... 136 - 137 Piggy Back (250 Series) .................................. 137 Female (187 Series) ........................................ 138 Male (250 Series)............................................. 139 Male (187 Series and 110 Series) ................... 140 250 Series Adapters and Coupler.................... 141 Wristlock Disconnects ...................................... 141 Pin Terminals/Vinyl Terminals (Mini-Pack) ....................................................... 142 Wire Joints - Nylon Insulated ............................. 143 Installation Kits.................................................... 144 Stripping/Cutting Tools .............................. 145 - 146 Application Tools Plier Tools............................................... 147 - 148 Comfort Crimp(R) ........................................149 - 150 Rachet Hand Tools ................................. 151 - 154 Toggle Type.............................................154 - 155 Flag Terminal Type Hand Tool .........................154 TBM60RS Short Handle .................................. 155 Shure-Stake(R) Auto Feed .................................. 156 BAT22-6 Battery-Powered Crimping Tool. 157 - 158 Air Operated ........................................... 159 - 160 Air Hydraulic..................................................... 160 Twelve Ton Crimping ...................................... 161 Installation Dies................................................ 162 Electric Hydraulic Pump ................................... 163 Tool Charts ............................................. 164 - 165 Stud Size and Clearance Hole Chart .................. 165 Wire Guide Tables ..................................... 166 - 169 Military Cross Reference..................................... 170 Cross Reference for Packaging................. 171 - 174 (ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 147 Application Tools Plier Type Tools Cat. No. Description A, B, C non-insulated terminal and splices and A, B noninsulated terminals with insulation grip A, B, C, PT non-insulated terminal and splices RA, RB, A, B, C, non-insulated and RC insulated nylon and vinyl terminal and splices WT110M WT110M WT111M WT112M Std. Pkg. Wt. Each 1 1 1 lb 1 lb 1 1 lb 9-19/32" AB C WT111M 4-01 520/2 M22 (R) G ON LU STA-K TO 18 A 22 TO 14 B 18 TO 10 C 12 NOTE: ONLY THIS HANDLE PAINTED GREEN INSTALLS "C" "C" STA-KON STA-KON(R)(R)TERMINALS-GAUGING TERMINALS-GAUGING.075-.095 .075-.095 INSTALLS WT112M These tools are designed in a variety of styles--some with wire cutters and strippers-- for installation of the various STA-KON terminal series. #22-10 AWG wire range. (R) INSTALLS .030-.050 INSTALLS"A "A&&B" B"STA-KON STA-KON(R) TERMINALS-GAUGING TERMINALS-GAUGING .030-.050 (R) CLOSING CLOSINGINSULATION INSULATIONGRIP GRIPON ONSTA-KON STA-KON(R)"B" "B"SIZE SIZETERMINALS TERMINALS AND ANDDISCONNECT DISCONNECTTIPS. TIPS. (R) CLOSING SIZE TERMINALS TERMINALS CLOSING INSULATION INSULATION GRIP GRIP ON ON STA-KON STA-KON(R) "A" "A" SIZE AND AND DISCONNECT DISCONNECT TIPS. WT110M TIPS. Installs "C" Sta-Kon(R) terminals-gauging .075-.095 Installs "A" & "B" Sta-Kon(R) terminals-gauging .030-.050 Closing Insulation Grip on Sta-Kon(R) "B" size terminals and disconnect tips. Closing Insulation Grip on Sta-Kon(R) "A" size terminals and disconnect tips. 9 19/32" 2 15/16" Wire WIRE Cutter CUTTER ORANGE 1 1/4" STA-KON(R) LUG A 22 TO 18 B 18 TO 14 C 12 TO 10 WT111M PLASTISOL HANDLES 1 1/4" 1 1/4" TTS AS & BE THOM B&C FOR A, MINALS N TER STA-KO M WT 112 2-15/16" 2- 15/16" BLACK CUTTERS Wire Cutter (R) INSTALLS "A" & "B" STA-KON TERMINALS GAUGING .027-.053 INSTALLS "C" STA-KON TERMINALS GAUGING .072-.098 WT111M Cutters Installs "A" & "B" Sta-Kon(R) terminals gauging .027-.053. Installs "C" Sta-Kon(R) terminals gauging .072-.098. CRIMPING NEST FOR Crimping Nest INSULATED STA-KONS(R) for insulated Sta-Kons(R) CRIMPING NEST FOR Crimping Nest for NON-INSULATED STA-KONS(R) non-insulated Sta-Kons(R) PLASTISOL HANDLE GRIPS GRIPS PLASTISOL HANDLE COLOR: BLACK & ORANGE COLOR: BLACK & ORANGE WT112M Installs insulated and non-insulated Sta-Kon(R) terminals, splices, disconnects, and wire joints 22-10 AWG. 147 (ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 148 Application Tools Plier Type Tools - (Continued) Cat. No. Description A, B, C, PT non-insulated terminal and splices A, B, C: AB, PT, RA, RB, RC insulated and non-insulated terminal and splices WT161M WT2000 WT161M Std. Pkg. Wt. Each 1 1 lb 1 1 lb WT2000 These tools are designed in a variety of styles--some with wire cutters and strippers-- for installation of the various STA-KON terminal series. #22-10 AWG wire range. CUTTERS Cutters Insulation INSULATIONCrusher CRUSHER Wire Stripper WIRE STRIPPER Handle RETURN Return HANDLE SPRINGS Spring WIRE Wire CUTTER Cutter Handle GRIPS Grips HANDLE LATCH Latch 8 10 SOL 18 16 14 12 10 STR 22-20 18 16 14 AB C 12 6-32 10-24 10-32 2-3/16" 8-32 4-40 INSUL Cushion CUSHIONGrip GRIPHandle HANDLE NON INSUL Plier CRIP Grip PLIER 22-10 .070 .070 .080 .080 22-10 BLACK PLASTISOL COATED HANDLE ORANGE PLASTISOL COATED HANDLE (R) STA-KONNest Installing INSTALLING NEST WireCUTTER Cutter WIRE CrimpINDICATOR Indicator GAUGE Gauge CRIMP CRIMPING NEST FOR INSULATED Crimping Nest for insulated WT161M Installs "A," "B," and "C" size (#18-#10 wire) Sta-Kon terminals, splices, and wire joints (PT-60M and PT-70). 148 WT2000 Wire Cutter--No. 10 AWG and smaller solid or stranded wire. Crimping Nests--Insulated and non-insulated Sta-Kon terminals, splices and wire joints on No. 22 to No. 10 AWG, solid or stranded wire. Cutters--Chasing feature for screws, sizes 4-40, 6-32, 8-32, 10-24, 10-32. Wire Stripper--Removes most types of insulation from No. 22-10 AWG stranded wire and No. 18-8 AWG solid wire. (ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 149 Application Tools For easy visual verification of crimps, integrity dots are embossed on the top and bottom of the terminal. Color-coded die nests on both the right and left sides of the tool are included for insulated terminals. toggle action increases mechanical gain, which dramatically reduces handle force - and the stress on your hands. Advanced ergonomic design of handle distributes the force more evenly across the hand. Shure-Stake(R) mechanism helps to ensure a complete crimp cycle before it releases the tool. Rubberized thermoplastic handle combines maximum friction with a soft, comfortable feel that reduces muscle tension. Comfort Crimp (R) Terminal Tool Concerned about safety? Down time? Health care costs? Thomas & Betts' ergonomically designed Comfort Crimp(R) tool helps reduce the risk of Carpal Tunnel Syndrome, the cause of almost one out of every two industrial injuries. This tool's unique design delivers the same reliable crimp with up to 60% less handle force than other terminal hand tools. So you won't have to sacrifice your hand to make a successful crimp. We've researched the tool components to provide maximum comfort to the operator while assuring a complete crimp. Just wrap your hands around our Comfort Crimp(R) terminal tool. It's such a relief you won't want to handle any other tool ever again. ERG-2001 ERG-2002 SURE STAKE RELEASE ON BOTH SIDES (22-18) A NEST (16-14) B NEST (12-10) C NEST 149 (ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 150 Application Tools Comfort Crimp Terminal Tool (R) Cat. No. ERG-2001 NEW Std. Pkg. Description ERG-2001 ERG-2002 RA, RB, RC Nylon & vinyl terminals, splices & disconnects A, B, C Non-insulated terminals, splices, disconnects 1 1 ERG-2004 C and C Flag terminal AB Flag terminal and A, B, C noninsulated terminals, splices, disconnects 1 ERG-2005 B, C, D Non-insulated terminals, splices, (D tubular only) 1 ERG-2007 RD & RE Insulated terminals (Except Brazed Seam) 1 ERG-2008 Non-insulated terminals #8 AWG - 1/0 AWG 1 ERG-2008 Shure-Stake(R) release on ON BOTH SIDES both sides Terminal locator Tool Gaging Requirements* Nest Gaging Min.-Max. ERG-2001 RA RB RC .100--.106 .116--.124 .148--.156 ERG-2002 A B C .062--.067 .084--.089 .110--.115 ERG-2004 AB C .062--.067 .110--.115 ERG-2005 B C D .082--.090 .117--.125 .145--.153 ERG-2007 8 (RED) 6 (BLUE) .190--.196 .212--.218 ERG-2008 Self-Contained Rotating Die 8AWG - 1/0 AWG Cat. No. (22-18) A NestT (16-14) B NestT (12-10) C NestT Installs nylon and vinyl insulated terminals, disconnects, and splices 22-10/22-14 AWG. The force required to release the Shure-Stake(R) mechanism should be no less than 15 lbs. Shure-Stake(R) release on both sides (12-10) C NestT (16-14) B NestT (22-18) A NestT STA -KON (R) NO. CAT. ERG -200 2 * Gauges available from T&B Tool Service Installs Non-insulated Terminals, Disconnects, and Splices 22 - 10 AWG. The force required to release the Shure-Stake(R) mechanism should be no less than 15 lbs. PUSH ERG-2001 Nest Gaging Min.-Max. Red Blue Yellow .100 - .106 .116 - .124 .148 - .156 ERG-2002 Installs Non-insulated Terminals #8 AWG 1/0 AWG. UL Listed crimp per UL standard 486C on tubular D, E, F, G, and H style Sta-Kon(R) Terminals. 150 Nest Gaging Min.-Max. A B C .067 - .062 .089 - .084 .115 - .110 (ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 151 Application Tools Rachet Hand Tools Cat. No. Description RA, RAX, RB, RBC, RC, RAA, RBB, RBC, RCC nylon terminal WT145A UPPER NEST LOWER NEST ABECFSDJ LJSALSDKL JKSDA ASDFJJAFLL KLKLJ WT145A LOCATOR Locator SCREW Installs RA, RB, RBC, RC nylon terminals. Correct compression every time-the ShureStake(R) mechanism principle prevents opening of the handles until full staking action is completed. Installs self-insulated and non-insulated Sta-Kon(R) terminal series in the #26-10 AWG wire range. With the "Lower" gage (683-G-398) placed into the rectangular side of the lower nest, the force required to release the Shure-Stake(R) mechanism should be 10-40 lbs. WT145A Upper UPPER Nest NEST Load LOAD BAR Bar Nest Gaging Min.-Max. Upper Lower .097 - .106 .121 - .128 LOAD Lower BAR Nest Go, GO,No-Go NO-GO GAGE Gage Rachet Hand Tools - (Continued) Cat. No. WT145C Description RA, RB, RC, RAA, RBB, RCC, RBC nylon and vinyl terminals, splices and disconnects 1 Nest Gaging Min.-Max. Upper Lower .118 - .122 .169 - .173 WT145C Correct compression every time-the Shure-Stake(R) mechanism principle prevents opening of the handles until full staking action is completed. Installs self-insulated and non-insulated StaKon(R) terminal series in the #26-10 AWG wire range. Installs RA, RB, RC nylon terminals, disconnects, splices and RA, RB, RC vinyl terminals, disconnects, splices. The force required to release the ShureStake(R) mechanism should be 10 lbs. minimum. Upper Nest UPPER NEST Lower Nest LOWER NEST Go, No-Go GO. NO GO Gage GAGE LOCATOR 151 (ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 152 Application Tools Rachet Hand Tools - (Continued) Cat. No. WT1377 WT1377 Std. Pkg. Description NW Ring Terminals 1 Use Front Nest to install NW18 series term., NW20 series term., NW22 series term., NW50 series term. Use Rear Nest to install NW10 series term., NW14 series term., NW80 series term., 675-14716 series term. Installs NW Series Heater Wire Terminals Correct compression every time-the ShureStake(R) mechanism principle prevents opening of the handles until full staking action is completed. Installs self-insulated and non-insulated Sta-Kon(R) terminal series in the #26-10 AWG wire range. CAUTION: HANDLES ARE CAUTION: NON-INSULATIONG. HANDLES ARE NON-INSULATING. DO NOT CRIMP DO NOT CRIMP ENERGIZED WIRES. ENERGIZED WIRES. W20, NW50 SERIES TERMINALS SEE GAGING TABLES NW80 NW20 NW50 NW20, NW50 series terminals NW80 series terminals SERIESgaging TERMINALS .064 - .069 gaging .047 - .054 NW80 SEE GAGING TABLES SHURE STAKE(R) MECHANISM (R) SHURE-STAKE MECHANISM RELEASE OPPOSITE SIDE RELEASE OPPOSITE SIDE Ratchet Hand Tools - (Continued) Cat. No. Std. Pkg. Description WT1452 Installs RZ, RV Terminals/Splices Installs RZ, RV Terminals (26-22 AWG wire) and Splices. 1 Min. Gage "Go" Max. Gage "No-Go" BT .039 .049 RZ, RV #26-#22 .063 .073 Nest Thomas & Betts BT BT GAGING Gaging 152 #26-#22 #26-#22 GAGING Gaging WT14 52 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 153 Application Tools Rachet Hand Tools - (Continued) Cat. No. Std. Pkg. Description RA, RB .110 insulated disconnects WT465 1 WT465 N1 Installs .110 RA, RB disconnects. Pre-load requirement: 20-50 lbs. A FORCE N9 N9 .102 .098 .116 .112 .032 .078 .098 .094 1 3/4 FORCE Rachet Hand Tools - (Continued) Cat. No. Description Std. Pkg. WT1255 RA, RB, RC Heat Shrinkable nylon insulated terminals, butt splices and disconnects 1 Pre-load 35 to 45 pounds. WT1255 CONDUCTOR CRIMP AREA STRIPPING LENGTH RED & BLUE = 1/4" YELLOW = 11/32" WT1255 12-10 16-14 22-16 Nest Gaging 22-18 098/086 16-14 .113/.101 12-10 .161/.149 STRIPPED WIRE Rachet Hand Tools - (Continued) Cat. No. WT2130A WT2130A Installs RBC, RC, RD, Sta-Kon(R) terminals and RC6 and RP7 wire joints. The force required to release the Shure-Stake(R) mechanism should be 20 lbs. minimum. Std. Pkg. Description RC, RBC, and RD insulated terminal #14-#8 1 WT2130A Nest 2130A LATED SU RE NO. WT ER WI CAT. NG SELF-IN COPP TALLIINALS ON GRIP ION (R) RM FOR INS ING ON TEN-INSULATCORPORAT STA-K NO BETTS & AS THOM 12-1 Gaging Min.-Max. 12-10 .147 - .157 8 .185 - .195 0 153 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 154 Application Tools Ratchet Hand Tools - (Continued) Cat. No. WT3185 For Use With Sta-Kon(R) Series Std. Pkg. Wt. Each 1 6 For 8 AWG to 250 MCM non-insulated Sta-Kon(R) terminals Installation and Gaging Procedure - Adjustable Crimper WT3185 Gaging Procedure 1. Close the tool jaws until they bottom. 2. Select the side of tool to be gaged (Tubular or Brazed seam) 3. Move indentor until the pointer slot aligns (click) with the selected cable size: For brazed seam connector use 6 AWG. For tubular connectors use 2/0. 4. Gage the crimping area with a suitable pin gage. The gage diameter must fall within .4056010 tubular and .215.010 for 6 AWG. brazed product. Checking Handle Pre-load 1. Lay the tool on a flat surface as shown in figure 3. Open handle and release it so that it will close of its own weight. 2. Measure the handle spread distance at the inner surface of the handle tips as shown in figure 3. 3. If the distance is 14"1/2" the tool is adjusted properly. If not, the tool should be adjusted. Pre-load Adjustment Procedure 1. Turn Adjustment screw clockwise to increase handle spread and counterclockwise to decrease handle spread. (refer to figure 3.) Toggle Type Hand Tools Cat. No. Installs Thomas & Betts Sta-Kon(R) terminals series D, E, F, and G. WT115A For Use With Sta-Kon(R) Series D, E, F, & G non-insulated terminals Std. Pkg. Wt. Ea. 1 4 DOWEL PIN FRAME DOWEL PIN DOWEL PIN HANDLE INDENTOR WT115A Flag Terminal Type Hand Tool Cat. No. Installs Thomas & Betts Sta-Kon(R) terminals series D, E, F, and G flag terminals. WT129 Std. Pkg. Description D, E, F, & G non-insulated flag terminals 1 WT115A & WT129A Nest D, E, F, G Nests D.E.F.G. NESTS 154 D E F G Gaging .138 .005 .170 .005 .192 .005 .222 .005 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 155 Application Tools Toggle Type Hand Tools - (Continued) Cat. No. TBM6 TBM6S TBM6 For Use With Sta-Kon(R) Series D thru M (Dies not included) RD thru RM D thru M (Dies not included) RD thru RM with Shure-Stake(R) Installs D thru M non-insulated terminals and splices, RD thru RM nylon insulated terminals and splices Close handles until lower die touches upper die. Measure distance between ends of handles. Distance must be 11" min. and 14" max. If it is less than 11" or more than 14", the tool needs adjustment. Std. Pkg. Wt. Ea. 1 1 9 9 Std. Pkg. Wt. Ea. 1 6 LOWER DIE MOVABLE JAW TBM6, TBM6S UPPER DIE TOOL HEAD Installing Dies for Non-Insulated Code and Aircraft Sta-Kon(R) Terminals Cat. No. NEST Nest Nest Stationary Die Indentor INDENTOR GAGING Gaging Use in installing tool Cat. No. TBM6 and TBM6S. Gaging GAGING Use in installing tool Cat. No. TBM6 & TBM6S. 11803 11803 11805 11806 11807 11808 11809 11810 11811 Indentor Movable Die 11802 Term. Size Gaging .010 D E (Tubular) E (Brrazed), F (Tubular) F (Brazed), G H J K L M .152 .152 .167 .206 .234 .272 .250 .266 .312 Installing Dies for Nylon Insulated Sta-Kon(R) Terminals TBM6 & TM6S Tool Cat. No. Die Set Term. Size Gaging .010 11821 11822 11823 11824 11825 11826 11827 11828 11829 RD RE RF RG RH RJ RK RL RM .170 .202 .254 .321 .339 .370 .382 .456 .554 TBM60RS Short Handle Ratchet Tool Cat. No. TBM60RS For Use With Sta-Kon Series D thru M (Uninsulated terminals) RD thru RM (Insulated terminals) For more information, see page K5. Gaging Procedure 1. Ratchet handles until jaws are fully closed. 2. Insert GO, NO-GO gage into nest. GO gage should enter freely. NO-GO gage should not enter. 155 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 156 Application Tools Shure-Stake(R) Auto-Feed Tool Cat. No. 12050 Std. Pkg. Description Compact, pneumatically operated unit for crimping tape-mounted STA-KON(R) terminals; equipped with a Shure-Stake(R) mechanism which ensures a full compression each time 1 Space Requirement - 30" W x 20" H x 20" D Weight - 55 lbs. Wire Range - #26 - #10 AWG Air Pressure 90-125 psi input air supply 12050 Safety Features * Fully guarded foot pedal. * Dies color matched to terminals. * Clear plastic safety guard over die area. * Automatic tool shut-down when safety guard is removed. * "Ram UP" emergency switch. Crimping tape-mounted STA-KON(R) terminals. Wire Range - #26 - #10 AWG. GAGING Gaging Installing Dies for 12050 Sta-Kon(R) Terminal Type Insulated Terminals Gaging RA - Nylon RA - Vinyl RB - Nylon RB - Vinyl RC - Nylon and Vinyl Insulated A - Non-Insulated B - Non-Insulated C - Non-Insulated C Disconnect, Non-Insul RV - RZ AWG Wire Size Die Cat. No. Gaging Min.-Max. Max. Insul. Dia. 22-18 12-10 12051 12054* 12052 12055* 12056 .108/.114 .117/.121 .133/.139 .122/.126 .149/.157 .136 .150 .162 .170 .210 22-18 16-14 12-10 12-10 26-24 12057 12058 12059 12060 683-54335 .061/.068 .083/.090 .126/.134 .103/.111 .075/.081 - - - - - 16-14 * Can also be used on nylon. RA Series requires a 12061 Die. Non-insulated Terminals 156 RB Series requires a 12062 Die. (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 157 Battery-Powered Crimping Tool BAT22-6 1 1 /2 Tons of Grip for Less than Three Pounds! T&B's newest battery-powered tool is fast and portable for making high volume and difficult-to-reach terminal installations in a snap. The Sta-Kon(R) BAT22-6 delivers 1.5 tons of crimping force with an easy, push-button trigger. The lightweight, ergonomic design minimizes the risk of repetitive motion injuries that can occur with traditional hand crimping tools. And at less than three pounds, one-hand operation is easy while still packing enough power to crimp up to 6 AWG terminals in seconds. BAT22-6 Advantages * Interchangeable Dies The BAT22-6 uses the exact dies from the Thomas & Betts Comfort Crimp line of ergonomic tools for Sta-Kon(R), Spec-Kon(R), and Dragon Tooth(R) terminals. These can be quickly changed to crimp non-insulated and insulated terminals up to 6 AWG. And because the dies are the same as our hand tools, crimps will be exactly the same between StaKon(R) hand tools such as our ERG-2001 and the new BAT22-6. * 360 Rotating Head The BAT22-6 head rotates 360 giving the user the added flexibility when crimping hard- to-reach connections. * Short Cycle Time With crimping times of less than two seconds, this tool brings speed to the workplace. Quick, lightweight and manuverable, the new BAT22-6 makes installing terminals faster and easier than ever. Easy to handle, it delivers fast and effective crimping power. * NiCd Battery Operation The NiCd battery provides longlasting battery life to complete up to 150 crimps on a single charge. An extra battery and charger are included with the tool ensuring round-the-clock operation. The battery charger provides full battery life in under sixty minutes. * Powerful and Precise The BAT22-6 tool delivers 1.5 tons of linear crimping force, enough power to crimp up to 6 AWG terminals. The linear crimping motion gives a symmetric, high quality crimp every time. * Accessories Each BAT22-6 tool is equipped with a sturdy, plastic carrying case for using the tool on the move. Case includes two 9.6 Volt NiCd batteries and battery charger along with a sturdy tray for convenient storage of crimp dies. Utilizes the exact dies of the Comfort Crimp line of ergonomic tools for Sta-Kon(R), Spec-Kon(R), and Dragon Tooth(R). 157 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 158 Specifications Crimping force: 2900 lbs max. Wire crimping range: Up to 6 AWG Crimp cycle time: 2 seconds Power supply: 9.6 Volt NiCd battery Recharging time: 1 hour Number of crimps per charge: 150 Dimensions: 25.4" (645 mm) Length 3.1" (79 mm) Width 2.1" (53 mm) Height 3 2 /4 lbs. Tool weight (with battery): Sta-Kon(R) BAT22-6 Ordering Information Cat. No. Description UPC BAT22-6 Battery Crimping Tool 1.5 Tons with 120 VAC Charger 78621092214 DIE2001 DIE2002 DIE2005 DIE2007 DIE2500 Crimp Dies* Insulated 22-10 AWG Sta-Kon(R) Terminals Non-insulated 22-10 AWG Sta-Kon(R) and Spec-Kon(R) Terminals Non-insulated 16-6 AWG Sta-Kon(R) Terminals Insulated 8-6 AWG Sta-Kon(R) Terminals Insulated 22-10 AWG Spec-Kon(R) Terminals 78621092215 78621092216 78621093172 78621092546 78621092217 Tool purchase includes crimping tool, two 9V batteries, charger and case. *Dies sold separately. 158 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 159 Application Tools Air Operated - Bench Mounted Tools Cat. No. 25000 Std. Pkg. Description This compact heavy duty air tool installs nylon and TEFZEL(R) insulated Sta-Kon(R) terminals on wire sizes from 8 AWG to 250 MCM; non-insulated styles are also installed just as quickly and dependably; to crimp a terminal, you simply insert the stripped wire into the terminal barrel, position it in the crimping nest, and depress the foot pedal actuating the crimping dies - it's that easy 1 Tefzel(R) is a registered trademark of DuPont. * Convenience and Economy The tool accepts a full range of interchangeable dies, the same as used in the TBM6 or 6S tools. To install the dies, simply pull the spring-loaded pin and remove the indentor die. Then, flex the retaining spring and remove the die nest. * Shure-Stake(R) Mechanism Means Quality Connections The Shure-Stake(R) mechanism senses inlet air pressure, and if insufficient is designed to prevent the tool from cycling. Thus you avoid "undercrimping." An 8590 psi air pressure source is required. Nest NEST INDENTOR Indentor * Safety Features Increase Productivity, Reduce Downtime GAGING Gaging Safety features include a guard over the die area, an air shutdown switch activated by a slight push with the finger, and an enclosed foot pedal designed to prevent unwanted tool operation. In additiion, the tool may be bench mounted for stability and control. For convenience when crimping large size terminals on heavy wire, the head assembly may overhang the workbench. Installing Dies for Non-Insulated Code and Aircraft Sta-Kon(R) Terminals for 25000 tool Gaging GAGING Cat. No. Nest Stationary Die 11803 11803 11805 11806 11807 11808 11809 11810 11811 Cat. No. Indentor Movable Die 11802 Term. Size Gaging .010 D E F G H J K L M .152 .152 .167 .206 .234 .272 .250 .266 .312 Installing Dies for Nylon Insulated Sta-Kon(R) Terminals for 25000 tool Cat. No. Die Set Term. Size Gaging .010 11821 11822 11823 11824 11825 11826 11827 11828 11829 RD RE RF RG RH RJ RK RL RM .170 .202 .254 .321 .339 .370 .382 .456 .554 159 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 160 Application Tools Air Operated - Bench Mounted Tools Cat. No. 13500 Std. Pkg. Description Heavy duty, high speed production tool installs a wide range of Sta-Kon(R) terminals, from 26-10 gauge; uses the 100-1 air tool dies for both non-insulated and insulated terminals; is supplied complete with foot pedal, air hose-air/lubricator STA-KON(R) Installing Dies for 13500 Tool, 11901A-11904A 13500 STA-KON(R) terminals, insulated and non-insulated #22 thru #10 ire range. Die Cat. No. Wire Range Gaging Type Crimp Installs Term. Type 11951 10, 22 AWG .062/.070, .081/.089, .106/.114 Double Indent A, AA, AIA, B, BB {BIB, C, CC, CIC 11958 11959 11960 11994 11995 - - - 14, 22 AWG 10, 12 AWG .086/.096 .112/.120 .086/.096, 112/.120 .105/.109, 125/.129 .160/.166 Elliptical Elliptical Elliptical Elliptical Elliptical RB4 Wire Joint RC6 Wire Joint RB4, RC6 RB, RB Nylon & Vinyl RC Nylon & Vinyl Air Hydraulic Tool Cat. No. 11901A 11902A 11903A 11904A 11903A 160 Description Closed yoke; hand actuated Closed yoke; foot actuated Open "C" yoke; hand actuated Open "C" yoke; foot actuated Cat. Nos. 11902A and 11904A also require two (2) Cat. No. 11913 air hoses and one (1) Cat. No. 11930 foot valve. Cat. Nos. 11901A and 11903A require one (1) Cat. No. 11913 air hose. 1 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 161 Application Tools Twelve Ton Crimping Tool Cat. No. 13400 Std. Pkg. Description Twelve ton crimping tool for installing both insulated and noninsulated Sta-Kon(R) terminals #8 to 250 MCM (dies ordered separately) 1 FORGED STEEL 13400 Twelve Ton Crimping Tool (Military Spec. MS25441-1) Cat. No. 13642M Std. Pkg. Description Hydraulic operated 12 to press installs "D" size through "M" size Sta-Kon(R) terminals on "AN" copper wire 1 Hex Dies for 13642M & 13400 13642M Die Cat. No. For For Tubular Brazed Term Seam A 11732 - 11733 - 11734 - 11736 11737 11738 11739 11740 11771 - 11733 - 11734 - 11735 - - - - - - Sta-Kon(R) Size Wire Size D 8 E 6 F 4 G H J K L M 2-1 1/0 2/0 3/0 4/0 250 MCM Hex Die Code A Gaging 21 24 24 29 29 33 37 42 45 50 54 62 .197 .005 .228 .005 .228 .005 .288 .005 .288 .005 .332 .005 .376 .005 .415 .005 .453 .005 .500 .005 .544 .009 .623 .004 Hex Dies for 13642M (Military Listed) Die Cat. No. 11781M 11782M 11783M 11784M 11785M 11786M 11787M 11788M 11789M Sta-Kon(R) Size Wire Size A Gaging D E F G H J K L M 8AN 6AN 4AN 2AN 1AN 1/0AN 2/0AN 3/0AN 4/0AN .208 - .212 .238 - .242 .297 - .301 .375 - .379 .415 - .419 .454 - .458 .488 - .502 .560 - .564 .616 - .620 161 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 162 Installation Dies COLOR CODE IN COUNTERBORE Installing Dies for Insulated Terminals to fit 13642M (Military Listed) Cat. No. 1-29/32" A REF. 2" REF. AN-WIRE SIZE IS ENGRAVED ON THIS SURFACE 21707M 21708M 21709M 21710M 21711M 21712M 21713M 21714M 21715M A Gaging .168 - .172 .200 - .204 .252 - .256 .310 - .314 .337 - .341 .368 - .372 .406 - .402 .436 - .440 .471 - .475 Gaging for Installing Dies Used to Install Flag Type Sta-Kon(R) Terminals - Use With 13642M & 13400 Nest Cat. No. 21733 21734 21735 21736 21737 21738 21739** 21740** 21741** Indentor Cat. No. Sta-Kon(R) Size Min. Max. 21731 8 6 4 .147 .171 .194 .153 .177 .200 2 1 1/0 2/0 3/0 4/0 .262 .278 .309 .356 .382 .434 .269 .284 .315 .362 .388 .440 21732 Gage ** Cat. Nos. 21739, 21740 and 21741 dies must be left in 13642 head with 21732 indentor when gauging. CAT. NO. STAMPED ON BOTH HALVES Nest and Indentor for Installing One Piece - Non-insulated Terminals to Fit 13642M & 13400 Indentor Cat. No. Nest Cat. No. A Gaging Terminal Series 13650 13650 13650 13650 13650 13650 13654 13655 13656 13657 13658 13659 .202-.210 .230-.238 .268-.276 .246-.254 .262-.270 .308-.316 G H J K L M Nest and Indentors for Installing Sta-Kon(R) Brazed Seam Type Non-insulated Terminals to Fit 13642M & 13400 162 Nest Cat. No. Indent. Cat. No. Sta-Kon(R) Size Code Wire Dia. 13643 13644 13645 13650 D E F 8 6 4 .153/.161 .183/.191 .214/.222 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 163 Application Tools Electric Hydraulic Pump Cat. No. 13810A 13611 13612 13613 13614 13619 13600 13810A 13620 13589A 13619 13618 Description Electric hydraulic pump, 10000 psi with Shure-Stake(R) mechanism feature; this is a heavy duty OEM pump with high flow rate; 115V, 60Hz, 112 HP, 23 Amps; requires hand or foot control Hand Switch for 13810A Foot Switch for 13810A High Pressure, steel reinforced hydraulic hose; 6 ft. High Pressure, steel reinforced hydraulic hose; 10 ft. High Pressure, plastic hydraulic hose; 10 ft. Std. Pkg. 1 1 1 1 1 1 This electric hydraulic pump is for use with all T&B hydraulic heads - consists of pump with pressure gage and Pioneer type male coupler; add suffix WG to eliminate gage; output pressure 9800 PSI; order switch and hose separately Hand Switch - 10 ft Foot Switch - 10 ft 10 ft. Non Metallic Hose 20 ft. Non Metallic Hose A remote control switch is required. Order Cat. No. 13620 for hand operation or Cat. No. 13589A for foot operation. All pumps are supplied with a metal carrying case. 13610A 13611 13612 13797 Shure-Stake(R) electric hydraulic pump has same features as 13600, but includes the Shure-Stake(R) control mechanism; prevents under crimping; (pump pressure must reach 9,800 psi before recycling); requires hand or foot control; order switch and hose separately Hand Switch - 10 ft Foot Switch - 10 ft In line hydraulic pressure inspection gage with male and female pioneer type coupler A remote control switch is required to operate this unit. Use either a #13611 (hand) or #13612 (foot) switch. 13610A 163 (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 164 Tool Charts Rachet Ergonomic Hand Tools Plier Description Terminal Series Nylon Terminal RZZ RA, RAX RB, RBC, RC * * * * * * * * * RA RB RC * * * * * * * * * Nylon/ Butt Splice Nylon/ Parallel Splices Rachet Hand Tool * * * * * * * * * * * * * RA, RAA RB, RBB RC, RCC, RBC Bare Terminal, Splices A, AA B, BB C, CC Wire Joints RB RC RP PT Hi-Temp Terminals NW-Rings NW-Splice Insulation Grip A B * * 110 Disconnects A, B RA, RB * Flag Terminal AB C D, E, F, G * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * Tefzel(R) is a registered trademark of DuPont. * * * * * * * * RD, RE * * * RA RB RC Self contained rotating die 8 AWG - 1/0 AWG * * * * * * * * * * * * * * * * * * * * * * * * Vinyl Disconnects Tepzel 164 * * * Tefzel(R) Terminal RAT, RBT, RCT (R) * * * * Vinyl Terminal, Splices RAAT RBBT RCCT * * * * * * Heat Shrinkable RAS Nylon Terminal, RBS Butt Splice, RCS Disconnects Tefzel(R) Butt Splices * * * * * Nylon RA Disconnect/ RB Fully Insul. RC Disconnects (except 110 Disconnects A B C 11901A - 11904A 13500 Die Numbers * RAA RBB RCC Bare Disconnects 12050 Die Numbers WT110M WT111M WT112M WT161M WT2000 ERG-2001 ERG-2002 ERG-2003 ERG-2004 ERG-2005 ERG-2007 ERG-2008 WT1377 WT129 WT145A WT145C WT1452 WT465 WT1255 WT2130A 12051 12052 12054 12055 12056 12057 12058 12059 12060 11951 11958 11959 11960 11994 11995 Tool * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * (ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 165 Tool Charts Description Term. Terminal Tubular ERG2005 WT3185 Brazed WT3185 D E NonInsulated Terminals and Splices TEFZEL Nylon Insulated Terminals and Splices (R) NonInsulated Flag Terminals 25000 Air Tool TBM6 - Toggle Hand Tool TBM6S - Toggle Hand Tool Die Cat. Nos. Nest (Stationary) Indentor (Movable) Hand Tool With Dies Tubular WT3185 Brazed WT3185 11803 11805 Tubular WT3185 F Brazed WT3185 G H Tubular Tubular WT3185 WT3185 11807 J Tubular WT3185 11808 K Tubular 11809 L Tubular 11810 M Tubular 11811 RD Tubular Brazed Tubular Brazed Tubular Brazed Tubular Tubular Tubular Tubular Tubular Tubular RE RF RG RH RJ RK RL RM D E F G H J K L M 11806 11802 ERG2007 ERG2007 13642M (MS25441-1) and 13400 Hydraulic Tool Hex Dies Nest 11781M* 11732 11733 11733 11782M* 11734 11734 11783M* 13651 11735 11784M*/11736 11785M* 11737 11786M* 11738 11787M* 11739 11788M* 11740 11789M* 11771 13645 13654 13655 Indentor 13652 13652 13653 13653 13650** 13656 13657 13658 13659 11821 (Set) 21707M* (Set) 11822 (Set) 21708M* (Set) 11823 (Set) 21709M* (Set) 11824 (Set) 21710M* (Set) 11825 (Set) 11826 (Set) 11827 (Set) 11828 (Set) 11829 (Set) 21711M* (Set) 21712M* (Set) 21713M* (Set) 21714M* (Set) 21715M* (Set) WT129 WT129 WT129 WT129 N E S T 21733 21734 21735 21736 21737 21738 21739 21740 21741 I 21731 N D E N T 21732 O R * Indicates military listed die. ** To order the military version suffix the indentor catalog number with an M (13650M). Nest catalog number does not change. Tefzel(R) is a registered trademark of DuPont. Stud Size and Clearance Hole Chart Stud Size 2 4 6 8 10 1 4 5 16 3 8 7 16 1 5 3 2 8 4 Min. hole diam. - in. 0.92 .116 .143 .169 .196 .262 .323 .388 .453 .516 .650 .775 Min. hole diam. - mm. 2.337 2.946 3.632 4.292 4.978 6.655 8.204 9.855 11.506 13.106 16.510 19.685 165