21737 - ABB - Datasheet.Live

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®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®........................................149 - 150

Rachet Hand Tools ................................. 151 - 154

Toggle Type.............................................154 - 155

Flag Terminal Type Hand Tool .........................154

TBM60RS Short Handle .................................. 155

Shure-Stake®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

Terminal Products

and Tools

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 97

147

CRIMPING NEST FOR

INSULATED STA-KONS®

CRIMPING NEST FOR

NON-INSULATED STA-KONS®

1 1/4"

WIRE CUTTER

2- 15/16"

PLASTISOL HANDLE GRIPS

COLOR: BLACK & ORANGE

THOMAS & BETTS

FOR A, B & C

STA-KON TERMINALS

WT 112M

Application Tools

WT112M

Installs insulated and non-insulated Sta-Kon

terminals, splices, disconnects, and wire joints

22-10 AWG.

WT111M

Cutters

Installs “A” & “B” Sta-Kon

terminals

gauging .027-.053.

Installs “C” Sta-Kon

terminals

gauging .072-.098.

STA-KON® LUG

A 22 TO 18

B 18 TO 14

C 12 TO 10

WT 111M

1 1/4"

9 19/32" 2 15/16"

ORANGE

BLACK

PLASTISOL

HANDLES

CUTTERS

INSTALLS “A” & “B” STA-KON® TERMINALS

GAUGING .027-.053

INSTALLS “C” STA-KON TERMINALS

GAUGING .072-.098

Crimping Nest for

insulated Sta-Kons®

Crimping Nest for

non-insulated Sta-Kons®

Wire Cutter

Plier Type Tools

Cat. Std. Wt.

No. Description Pkg. Each

WT110M A, B, C non-insulated terminal and splices and A, B non- 1 1 lb

insulated terminals with insulation grip 1 1 lb

WT111M A, B, C, PT non-insulated terminal and splices

WT112M RA, RB, A, B, C, non-insulated and RC insulated nylon and 1 1 lb

vinyl terminal and splices

INSTALLS "C" STA-KON

® TERMINALS-GAUGING .075-.095

INSTALLS "A & B" STA-KON

® TERMINALS-GAUGING .030-.050

CLOSING INSULATION GRIP ON STA-KON

® "B" SIZE TERMINALS

AND DISCONNECT TIPS.

CLOSING INSULATION GRIP ON STA-KON

® "A" SIZE TERMINALS

AND DISCONNECT TIPS.

NOTE: ONLY THIS HANDLE

PAINTED GREEN

M22520/24-01

A B

STA-KON

® LUG

A 22 TO 18

B 18 TO 14

C 12 TO 10

9-19/32"

INSTALLS “C” STA-KON®TERMINALS-GAUGING .075-.095

INSTALLS “A & B” STA-KON®TERMINALS-GAUGING .030-.050

CLOSING INSULATION GRIP ON STA-KON®“B” SIZE TERMINALS

AND DISCONNECT TIPS.

CLOSING INSULATION GRIP ON STA-KON®“A” SIZE TERMINALS

AND DISCONNECT

TIPS. WT110M

Installs “C” Sta-Kon

terminals-gauging .075-.095

Installs “A” & “B” Sta-Kon

terminals-gauging .030-.050

Closing Insulation Grip on Sta-Kon

“B” size

terminals and disconnect tips.

Closing Insulation Grip on Sta-Kon

“A” size

terminals and disconnect tips.

PLASTISOL HANDLE GRIPS

COLOR: BLACK & ORANGE

2-15/16”

1 1/4”

WT111M

WT110M

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.

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 147

Application Tools

Plier Type Tools – (Continued)

Cat. Std. Wt.

No. Description Pkg. Each

WT161M A, B, C, PT non-insulated terminal and splices 1 1 lb

WT2000 A, B, C: AB, PT, RA, RB, RC insulated and non-insulated

terminal and splices 1 1 lb

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 insula-

tion from No. 22-10 AWG stranded wire and No.

18-8 AWG solid wire.

WT161M

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.

PLIER CRIP

WIRE CUTTER

STA-KON®

INSTALLING NEST

ORANGE PLASTISOL

COATED HANDLE

.070

.080

INSULATION CRUSHER

BLACK PLASTISOL

COATED HANDLE

CUSHION GRIP HANDLE

WIRE CUTTER

CUTTERS

HANDLE RETURN

SPRINGS

WIRE STRIPPER

LATCH

HANDLE GRIPS

CRIMP INDICATOR GAUGE

CRIMPING NEST FOR INSULATED

2-3/16"

22-10

22-10 INSUL

NON

INSUL

4-40

8-32

10-32

10-24

6-32

ABC

STR SOL

22-20

Cushion Grip Handle

Insulation Crusher

.070

.080 Plier Grip

Wire Cutter

Installing Nest

Wire Cutter

Handle Return

Spring

Wire Stripper

Latch

WT161M

Installs “A,” “B,” and “C” size (#18-#10 wire)

Sta-Kon terminals, splices, and wire joints

(PT-60M and PT-70).

Cutters

Handle Grips

Crimp Indicator Gauge

Crimping Nest for insulated

148

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 148

149

Application Tools

Comfort Crimp

Terminal Tool

Concerned about safety? Down

time? Health care costs?

Thomas & Betts’ ergonomically

designed Comfort Crimp®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 sacri-

fice 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®terminal tool. It’s such

a relief you won’t want to handle any

other tool ever again.

For easy visual

verification of

crimps, integrity

dots are

embossed on the

top and bottom

of the terminal.

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.

ERG-2001

Rubberized thermoplastic

handle combines

maximum friction with a

soft, comfortable feel that

reduces muscle tension.

Shure-Stake®

mechanism helps

to ensure a

complete crimp

cycle before it

releases the tool.

Color-coded die nests

on both the right and

left sides of the tool

are included for

insulated terminals.

SURE STAKE RELEASE

ON BOTH SIDES

(22-18) A NEST

(16-14) B NEST

(12-10) C NEST

ERG-2002

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 149

Application Tools

ERG-2001

Gaging

Nest Min.-Max.

Red .100 – .106

Blue .116 – .124

Yellow .148 – .156

ERG-2002

Gaging

Nest Min.-Max.

A .067 – .062

B .089 – .084

C .115 – .110

BOTH

SIDES

STA-KON

CAT. NO. ERG-2002

Terminal locator

(22-18) A Nest

(16-14) B Nest

(12-10) C Nest

Installs nylon and vinyl insulated terminals,

disconnects, and splices 22-10/22-14 AWG.

The force required to release the Shure-Stake

mechanism should be no less than 15 lbs.

(12-10) C Nest

(16-14) B Nest

(22-18) A Nest

Installs Non-insulated Terminals, Disconnects,

and Splices 22 - 10 AWG.

The force required to release the Shure-Stake

mechanism should be no less than 15 lbs.

Comfort Crimp®Terminal Tool

Cat. Std.

No. Description Pkg.

ERG-2001 RA, RB, RC Nylon & vinyl terminals, splices & disconnects 1

ERG-2002 A, B, C Non-insulated terminals, splices, disconnects 1

ERG-2004 C and C Flag terminal AB Flag terminal and A, B, C non- 1

insulated terminals, splices, disconnects

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

Shure-Stake®

release on

both sides

Shure-Stake®

release on

both sides

Tool Gaging Requirements*

Gaging

Cat. No. Nest Min.-Max.

ERG-2001 RA .100—.106

RB .116—.124

RC .148—.156

ERG-2002 A .062—.067

B .084—.089

C .110—.115

ERG-2004 AB .062—.067

C .110—.115

ERG-2005 B .082—.090

C .117—.125

D .145—.153

ERG-2007 8 (RED) .190—.196

6 (BLUE) .212—.218

ERG-2008 Self-Contained 8AWG - 1/0 AWG

Rotating Die

* Gauges available from T&B Tool Service

150

ERG-2001

ERG-2008

PUSH

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

Terminals.

NEW

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 150

151

Rachet Hand Tools

Cat.

No. Description

WT145A RA, RAX, RB, RBC, RC, RAA, RBB, RBC, RCC nylon terminal

Rachet Hand Tools – (Continued)

Cat.

No. Description

WT145C RA, RB, RC, RAA, RBB, RCC, RBC nylon and vinyl terminals, splices and disconnects 1

Application Tools

WT145A

Installs RA, RB, RBC, RC nylon terminals.

Correct compression every time-the Shure-

Stake

mechanism principle prevents opening

of the handles until full staking action is com-

pleted. Installs self-insulated and non-insulated

Sta-Kon

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

mecha-

nism should be 10-40 lbs.

WT145C

Correct compression every time-the

Shure-Stake

mechanism principle pre-

vents opening of the handles until full

staking action is completed. Installs

self-insulated and non-insulated Sta-

Kon

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 Shure-

Stake

mechanism should be 10 lbs.

minimum.

Gaging

Nest Min.-Max.

Upper .118 – .122

Lower .169 – .173

UPPER NEST LOWER NEST

GO. NO GO

GAGE

LOCATOR

Upper Nest Lower Nest

Go, No-Go

Gage

UPPER NEST

LOWER NEST

ABECFSDJ LJSALSDKL JKSDA

ASDFJJAFLL KLKLJ

WT145A

Gaging

Nest Min.-Max.

Upper .097 – .106

Lower .121 – .128

UPPER

NEST

LOCATOR

SCREW

GO, NO-GO

GAGE

LOAD

BAR

LOAD

BAR

Locator

Upper

Nest

Go, No-Go

Gage

Load

Bar

Lower

Nest

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 151

Application Tools

WT1377

Installs NW Series Heater Wire Terminals

Correct compression every time-the Shure-

Stake

mechanism principle prevents opening

of the handles until full staking action is com-

pleted. Installs self-insulated and non-insulated

Sta-Kon

terminal series in the #26-10 AWG

wire range.

Installs RZ, RV Terminals (26-22 AWG wire)

and Splices.

Rachet Hand Tools – (Continued)

Cat. Std.

No. Description Pkg.

WT1377 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.

Ratchet Hand Tools – (Continued)

Cat. Std.

No. Description Pkg.

WT1452 Installs RZ, RV Terminals/Splices 1

Min. Gage Max. Gage

Nest “Go” “No-Go”

BT .039 .049

RZ, RV #26-#22 .063 .073

SHURE STAKE® MECHANISM

RELEASE OPPOSITE SIDE

NW80 SERIES TERMINALS

SEE GAGING TABLES

W20, NW50 SERIES TERMINALS

SEE GAGING TABLES

NW80

NW50

NW20

CAUTION: HANDLES ARE

NON-INSULATING.

DO NOT CRIMP

ENERGIZED WIRES.

#26-#22

GAGING

Thomas & Betts

WT1452

#26-#22

Gaging

NW80 series terminals

gaging .064 – .069

NW20, NW50 series terminals

gaging .047 – .054

CAUTION: HANDLES ARE

NON-INSULATIONG.

DO NOT CRIMP

ENERGIZED WIRES.

SHURE-STAKE®MECHANISM

RELEASE OPPOSITE SIDE

152

(ang part 4) Stakon.qxd 8/18/05 3:32 PM Page 152

153

WT2130A

Installs RBC, RC, RD, Sta-Kon

terminals and

RC6 and RP7 wire joints.

The force required to release the Shure-Stake

mechanism should be 20 lbs. minimum.

Rachet Hand Tools – (Continued)

Cat. Std.

No. Description Pkg.

WT2130A RC, RBC, and RD insulated terminal #14-#8 1

CAT. NO. WT2130A

FOR INSTALLING SELF-INSULATED

STA-KON ® TERMINALS ON COPPER WIRE

NON-INSULATING GRIP

THOMAS & BETTS CORPORATION

12-10

WT2130A

Gaging

Nest Min.-Max.

12-10 .147 – .157

8 .185 – .195

Application Tools

Installs .110 RA, RB disconnects.

Pre-load requirement: 20-50 lbs.

WT465

Rachet Hand Tools – (Continued)

Cat. Std.

No. Description Pkg.

WT465 RA, RB .110 insulated disconnects 1

FORCE

1 3/4

N9 N9

N1 A

.116

.112

.102

.098

.032

.078

.098

.094

WT1255

Nest Gaging

22-18 098/086

16-14 .113/.101

12-10 .161/.149

Rachet Hand Tools – (Continued)

Cat. Std.

No. Description Pkg.

WT1255 RA, RB, RC Heat Shrinkable nylon insulated terminals, butt splices and disconnects 1

Pre-load 35 to 45 pounds.

CONDUCTOR

CRIMP AREA

STRIPPING LENGTH

RED & BLUE = 1/4"

YELLOW = 11/32"

STRIPPED

WIRE

22-16

16-14

12-10

WT1255

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 153

Application Tools

WT115A

D.E.F.G. NESTS

Installs Thomas & Betts Sta-Kon

terminals

series D, E, F, and G.

Toggle Type Hand Tools

Cat. Std. Wt.

No. For Use With Sta-Kon®Series Pkg. Ea.

WT115A D, E, F, & G non-insulated terminals 1 4

DOWEL PIN

FRAME

HANDLE

DOWEL PIN

DOWEL PIN INDENTOR

WT115A & WT129A

Nest Gaging

D .138 ± .005

E .170 ± .005

F .192 ± .005

G .222 ± .005

D, E, F, G Nests

WT3185

Ratchet Hand Tools – (Continued)

Cat. Std. Wt.

No. For Use With Sta-Kon®Series Pkg. Each

WT3185 For 8 AWG to 250 MCM non-insulated Sta-Kon®terminals 1 6

Installation and Gaging Procedure – Adjustable Crimper

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

.405

010 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.)

Flag Terminal Type Hand Tool

Cat. Std.

No. Description Pkg.

WT129 D, E, F, & G non-insulated flag terminals 1

154

Installs Thomas & Betts Sta-Kon

terminals

series D, E, F, and G flag terminals.

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 154

155

Application Tools

TBM6

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.

GAGING

INDENTOR

NEST

Nest

Indentor Gaging

Use in installing tool Cat. No. TBM6 and

TBM6S.

GAGING

Gaging

Use in installing tool Cat. No. TBM6 & TBM6S.

Toggle Type Hand Tools – (Continued)

Cat. Std. Wt.

No. For Use With Sta-Kon®Series Pkg. Ea.

TBM6 D thru M (Dies not included) RD thru RM 1 9

TBM6S D thru M (Dies not included) RD thru RM with Shure-Stake®19

Installing Dies for Non-Insulated Code and Aircraft Sta-Kon®Terminals

Cat. No.

Nest Indentor

Stationary Movable Term. Gaging

Die Die Size ± .010

11803 D .152

11803 E (Tubular) .152

11805 E (Brrazed), F (Tubular) .167

11806 11802 F (Brazed), G .206

11807 H .234

11808 J .272

11809 K .250

11810 L .266

11811 M .312

Installing Dies for Nylon Insulated Sta-Kon®Terminals TBM6 & TM6S Tool

Cat. No. Term. Gaging

Die Set Size ± .010

11821 RD .170

11822 RE .202

11823 RF .254

11824 RG .321

11825 RH .339

11826 RJ .370

11827 RK .382

11828 RL .456

11829 RM .554

LOWER DIE

UPPER DIE

MOVABLE JAW

TOOL HEAD

TBM6, TBM6S

TBM60RS Short Handle Ratchet Tool

Cat. Std. Wt.

No. For Use With Sta-Kon Series Pkg. Ea.

TBM60RS D thru M (Uninsulated terminals) 1 6

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.

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 155

Application Tools

GAGING

Gaging

Insulated Terminals

Non-insulated Terminals

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

terminals.

Wire Range – #26 - #10 AWG.

Shure-Stake®Auto-Feed Tool

Cat. Std.

No. Description Pkg.

12050 Compact, pneumatically operated unit for crimping tape-mounted STA-KON®terminals; 1

equipped with a Shure-Stake®mechanism which ensures a full compression each time

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

Installing Dies for 12050

Max.

Sta-Kon®AWG Die Gaging Insul.

Terminal Type Wire Size Cat. No. Min.-Max. Dia.

RA – Nylon 22-18 12051 .108/.114 .136

RA – Vinyl 12054* .117/.121 .150

RB – Nylon 16-14 12052 .133/.139 .162

RB – Vinyl 12055* .122/.126 .170

RC – Nylon and 12-10 12056 .149/.157 .210

Vinyl Insulated

A – Non-Insulated 22-18 12057 .061/.068 –

B – Non-Insulated 16-14 12058 .083/.090 –

C – Non-Insulated 12-10 12059 .126/.134 –

C Disconnect, Non-Insul 12-10 12060 .103/.111 –

RV – RZ 26-24 683-54335 .075/.081 –

* Can also be used on nylon.

156

RA Series requires a

12061 Die.

RB Series requires a

12062 Die.

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 156

157

Battery-Powered Crimping Tool

BBAATT2222--66

1111//22 TToonnss ooff GGrriipp ffoorr LLeessss tthhaann TThhrreeee PPoouunnddss!!

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® 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.

BBAATT2222--66 AAddvvaannttaaggeess

•Interchangeable Dies The BAT22-6 uses the exact dies

from the Thomas & Betts Comfort Crimp line of ergonomic tools

for Sta-Kon®, Spec-Kon®, and Dragon Tooth®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 Sta-

Kon® hand tools such as our ERG-2001 and the new BAT22-6.

•360° Rotating Head The BAT22-6 head rotates 360° giv-

ing 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, light-

weight and manuverable, the new BAT22-6 makes installing

terminals faster and easier than ever.

•NiCd Battery Operation The NiCd battery provides long-

lasting 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.

Easy to handle, it delivers fast and effective crimping power.

Utilizes the exact dies of the Comfort Crimp line of ergonomic tools for Sta-Kon

Spec-Kon

, and Dragon Tooth

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 157

158

Sta-Kon®BAT22-6 Ordering Information

Cat. No. Description UPC

BAT22-6 Battery Crimping Tool 1.5 Tons with 120 VAC Charger 78621092214

Crimp Dies*

DIE2001 Insulated 22-10 AWG Sta-Kon®Terminals 78621092215

DIE2002 Non-insulated 22-10 AWG Sta-Kon®and Spec-Kon®Terminals 78621092216

DIE2005 Non-insulated 16-6 AWG Sta-Kon®Terminals 78621093172

DIE2007 Insulated 8-6 AWG Sta-Kon®Terminals 78621092546

DIE2500 Insulated 22-10 AWG Spec-Kon®Terminals 78621092217

Tool purchase includes crimping tool, two 9V batteries, charger and case.

*Dies sold separately.

SSppeecciiffiiccaattiioonnss

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

Tool weight (with battery): 2 3/4 lbs.

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 158

Application Tools

GAGING

INDENTOR

NEST

GAGING

Nest

Indentor Gaging

Gaging

Air Operated – Bench Mounted Tools

Cat. Std.

No. Description Pkg.

25000 This compact heavy duty air tool installs nylon and TEFZEL®insulated Sta-Kon®1

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

Tefzel®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

Mechanism Means Quality Connections

The Shure-Stake®mechanism senses inlet air pressure, and if insufficient is

designed to prevent the tool from cycling. Thus you avoid “undercrimping.” An 85-

90 psi air pressure source is required.

• Safety Features Increase Productivity, Reduce Downtime

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®Terminals for 25000 tool

Cat. No. Cat. No.

Nest Indentor

Stationary Movable Term. Gaging

Die Die Size ±.010

11803 D .152

11803 E .152

11805 F .167

11806 11802 G .206

11807 H .234

11808 J .272

11809 K .250

11810 L .266

11811 M .312

Installing Dies for Nylon Insulated Sta-Kon®Terminals for 25000 tool

Cat. No. Term. Gaging

Die Set Size ±.010

11821 RD .170

11822 RE .202

11823 RF .254

11824 RG .321

11825 RH .339

11826 RJ .370

11827 RK .382

11828 RL .456

11829 RM .554

159

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Application Tools

Air Operated – Bench Mounted Tools

Cat. Std.

No. Description Pkg.

13500 Heavy duty, high speed production tool installs a wide range of Sta-Kon®terminals, from 1

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®Installing Dies for 13500 Tool, 11901A–11904A

Die Wire Type Installs

Cat. No. Range Gaging Crimp Term. Type

{A, AA, AIA, B, BB

11951 10, 22 AWG .062/.070, .081/.089, .106/.114 Double Indent BIB, C, CC, CIC

11958 – .086/.096 Elliptical RB4 Wire Joint

11959 – .112/.120 Elliptical RC6 Wire Joint

11960 – .086/.096, 112/.120 Elliptical RB4, RC6

11994 14, 22 AWG .105/.109, 125/.129 Elliptical RB, RB Nylon & Vinyl

11995 10, 12 AWG .160/.166 Elliptical RC Nylon & Vinyl

Air Hydraulic Tool

Cat. No. Description

11901A Closed yoke; hand actuated

11902A Closed yoke; foot actuated

11903A Open “C” yoke; hand actuated

11904A 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.

11903A

13500

STA-KON

terminals, insulated and

non-insulated #22 thru #10 ire range.

160

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Application Tools

Twelve Ton Crimping Tool

Cat. Std.

No. Description Pkg.

13400 Twelve ton crimping tool for installing both insulated and noninsulated Sta-Kon®terminals 1

#8 to 250 MCM (dies ordered separately)

Twelve Ton Crimping Tool (Military Spec. MS25441-1)

Cat. Std.

No. Description Pkg.

13642M Hydraulic operated 12 to press installs “D” size through “M” size Sta-Kon®terminals on “AN” 1

copper wire

Hex Dies for 13642M & 13400

Die Cat. No.

For For Hex

Tubular Brazed Sta-Kon®Wire Die A

Term Seam Size Size Code Gaging

11732 – D 8 21 .197 ± .005

– 11733 24 .228 ± .005

11733 – E 6 24 .228 ± .005

– 11734 29 .288 ± .005

11734 – F 4 29 .288 ± .005

– 11735 33 .332 ± .005

11736 – G 2-1 37 .376 ± .005

11737 – H 1/0 42 .415 ± .005

11738 – J 2/0 45 .453 ± .005

11739 – K 3/0 50 .500 ± .005

11740 – L 4/0 54 .544 ± .009

11771 – M 250 MCM 62 .623 ± .004

Hex Dies for 13642M (Military Listed)

Die Sta-Kon®Wire A

Cat. No. Size Size Gaging

11781M D 8AN .208 – .212

11782M E 6AN .238 – .242

11783M F 4AN .297 – .301

11784M G 2AN .375 – .379

11785M H 1AN .415 – .419

11786M J 1/0AN .454 – .458

11787M K 2/0AN .488 – .502

11788M L 3/0AN .560 – .564

11789M M 4/0AN .616 – .620

FORGED

STEEL

13642M

13400

161

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Installation Dies

AN-WIRE SIZE IS ENGRAVED

ON THIS SURFACE

2" REF.

COLOR CODE

IN COUNTERBORE

1-29/32"

REF. A

CAT. NO.

STAMPED ON

BOTH HALVES

Installing Dies for Insulated Terminals to fit 13642M (Military Listed)

Cat. No. Gaging

21707M .168 – .172

21708M .200 – .204

21709M .252 – .256

21710M .310 – .314

21711M .337 – .341

21712M .368 – .372

21713M .406 – .402

21714M .436 – .440

21715M .471 – .475

Gaging for Installing Dies Used to Install Flag Type Sta-Kon®Terminals –

Use With 13642M & 13400

Nest Indentor Sta-Kon®Gage

Cat. No. Cat. No. Size Min. Max.

21733 8 .147 .153

21734 21731 6 .171 .177

21735 4 .194 .200

21736 2 .262 .269

21737 1 .278 .284

21738 21732 1/0 .309 .315

21739** 2/0 .356 .362

21740** 3/0 .382 .388

21741** 4/0 .434 .440

** Cat. Nos. 21739, 21740 and 21741 dies must be left in 13642 head with 21732 indentor when gauging.

Nest and Indentor for Installing One Piece – Non-insulated Terminals to Fit 13642M &

13400

Indentor Nest A Terminal

Cat. No. Cat. No. Gaging Series

13650 13654 .202-.210 G

13650 13655 .230-.238 H

13650 13656 .268-.276 J

13650 13657 .246-.254 K

13650 13658 .262-.270 L

13650 13659 .308-.316 M

Nest and Indentors for Installing Sta-Kon®Brazed Seam Type Non-insulated Terminals to

Fit 13642M & 13400

Nest Indent. Sta-Kon®Code

Cat. No. Cat. No. Size Wire Dia.

13643 D 8 .153/.161

13644 13650 E 6 .183/.191

13645 F 4 .214/.222

162

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Application Tools

13810A

13610A

Electric Hydraulic Pump

Cat. Std.

No. Description Pkg.

13810A Electric hydraulic pump, 10000 psi with Shure-Stake®mechanism feature; 1

this is a heavy duty OEM pump with high flow rate; 115V, 60Hz, 11⁄2HP,

23 Amps; requires hand or foot control

13611 Hand Switch for 13810A 1

13612 Foot Switch for 13810A 1

13613 High Pressure, steel reinforced hydraulic hose; 6 ft. 1

13614 High Pressure, steel reinforced hydraulic hose; 10 ft. 1

13619 High Pressure, plastic hydraulic hose; 10 ft. 1

13600 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

13620 Hand Switch – 10 ft

13589A Foot Switch – 10 ft

13619 10 ft. Non Metallic Hose

13618 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 Shure-Stake®electric hydraulic pump has same features as 13600,

but includes the Shure-Stake®control mechanism; prevents under

crimping; (pump pressure must reach 9,800 psi before recycling);

requires hand or foot control; order switch and hose separately

13611 Hand Switch – 10 ft

13612 Foot Switch – 10 ft

13797 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.

163

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Tool Charts

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

Rachet Ergonomic 11901A – 11904A

Tool Plier Hand Tools Rachet Hand Tool 12050 Die Numbers 13500 Die Numbers

Description Terminal Series

Nylon RZZ •

Terminal RA, RAX • • • • • • • • •

RB, • • • • • • • • •

RBC, RC • • • • • • • •

Nylon/ RA • • • • •

Butt Splice RB • • • • •

RC • • • • •

Nylon/ RAA •

Parallel RBB •

Splices RCC •

Nylon RA • • • • • • •

Disconnect/ RB • • • • • • •

Fully Insul. RC • • • • • • •

Disconnects (except 110 Disconnects

Heat Shrinkable RAS •

Nylon Terminal, RBS •

Butt Splice, RCS •

Disconnects

Vinyl RA, RAA • • • • • • •

Terminal, RB, RBB • • • • • • •

Splices RC, RCC, RBC • • • • • • •

Bare A, AA • • • • • • • •

Terminal, B, BB • • • • • • • • •

Splices C, CC • • • • • • • • •

Wire RB • • • •

Joints RC • • • • •

RP • •

PT • • •

Hi-Temp NW-Rings •

Terminals NW-Splice •

Insulation A •

Grip B •

110 A, B • • •

Disconnects RA, RB •

Flag AB •

Terminal C • •

D, E, F, G

Tefzel®Terminal RAT, RBT, RCT • •

Vinyl RA • • • • • • • •

Disconnects RB • • • • • • • •

RC • • • • • • •

Bare A • • • • • • • •

Disconnects B • • • • • • • •

C•••••••• •

Tefzel®RAAT • • •

Butt Splices RBBT • • •

RCCT • • • •

Tepzel®RD, RE •

Self contained rotating die

8 AWG - 1/0 AWG •

Tefzel®is a registered trademark of DuPont.

164

(ang part 4) Stakon.qxd 8/18/05 3:33 PM Page 164

25000 Air Tool 13642M (MS25441-1)

Hand TBM6 – Toggle Hand Tool and

Tool TBM6S – Toggle Hand Tool 13400 Hydraulic Tool

With Die Cat. Nos. Hex

Description Term. Terminal Dies Nest (Stationary) Indentor (Movable) Dies Nest Indentor

Tubular ERG2005 11781M* 13651

DWT3185 11732

Brazed 11803 11733 13652

WT3185 11733 13652

Tubular WT3185 11782M*

EBrazed 11734 13653

WT3185 11805 11734 13653

Tubular WT3185 11783M*

Non- F Brazed

Insulated WT3185 11806 11735 13645

Terminals G Tubular WT3185 11802 11784M*/11736 13654 13650**

and H Tubular WT3185 11807 11785M* 13655

Splices 11737

J Tubular WT3185 11808 11786M* 13656

11738

K Tubular 11809 11787M* 13657

11739

L Tubular 11810 11788M* 13658

11740

M Tubular 11811 11789M* 13659

11771

RD Tubular ERG2007 11821 (Set) 21707M* (Set)

Brazed 11822 (Set) 21708M* (Set)

RE Tubular ERG2007

TEFZEL®† Brazed 11823 (Set) 21709M* (Set)

Nylon RF Tubular

Insulated Brazed 11824 (Set) 21710M* (Set)

Terminals RG Tubular

and RH Tubular 11825 (Set) 21711M* (Set)

Splices RJ Tubular 11826 (Set) 21712M* (Set)

RK Tubular 11827 (Set) 21713M* (Set)

RL Tubular 11828 (Set) 21714M* (Set)

RM Tubular 11829 (Set) 21715M* (Set)

D WT129 21733 I

E WT129 21734 N

21731

F WT129 N21735 D

Non- G WT129 E21736 E

Insulated H S21737 N

Flag J T21738 T21732

Terminals K 21739 O

L21740 R

M21741

* 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®is a registered trademark of DuPont.

Tool Charts

Stud Size and Clearance Hole Chart

Stud Size 2 4 6 8 10 1⁄45⁄16 3⁄87⁄16 1⁄25⁄83⁄4

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

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