Terminal Products and Tools

Transcription

1 Terminal Products and Tools Terminals Overview Nylon Insulated Ring Vinyl Insulated Ring , 18 Non-Insulated Ring Heavy Duty Ring...16 High Temperature Non-Insulated...17 TEFZEL Insulated Ring...19 Rectangular Rings Flag Terminals...22 Fork Terminals Nylon Insulated Fork Vinyl Insulated Fork...25 Non-Insulated Fork...26 Locking Fork Terminals Nylon Insulated Fork...27 Vinyl Insulated Fork...28 Heat Shrinkable Fork...29 Non-Insulated Fork...29 Pin Terminals...30 Insulated Ferrules Non-Insulated Ferrules...33 Heat Shrinkable Terminals, Splices, Disconnects Splice Connectors Disconnects Female (250 Series) Piggy ack (250 Series)...40 Female (187 Series)...41 Male (250 Series)...42 Male (187 Series and 110 Series) Series dapters and Coupler...44 Wristlock Disconnects...44 Pin Terminals/Vinyl Terminals (Mini-Pack)...45 Wire Joints Nylon Insulated...46 Installation its...47 pplication Tools Plier Tools Comfort Crimp Rachet Hand Tools Toggle Type Flag Type...55 TM60RS Short Handle...56 Shure-Stake uto Feed...57 ERG ir Operated ir Hydraulic...60 Twelve Ton Crimping...61 Installation Dies Electric Hydraulic Pump...63 Tool Charts Stud Size and Clearance Hole Chart...65 Wire Guide Tables Military Cross Reference...70 Cross Reference for Packaging

2 Terminals Why Sta-on Terminals re etter Sta-on Chamfered Funnel arrel Entry. Selectively annealed long barrel. Longer barrel design. Color-code Tefzel, Nylon or Vinyl Insulators. razed or overlapping seams. nti-rotational tongue. Hardened tongue. Complete wire and stud size identification. Thomas & etts developed the first tool-applied solderless terminals and connectors over 60 years ago in response to industry awareness of the need for better performance of electrical systems. Chamfered/Funneled Terminal arrel Entry This feature makes wire insertion faster and easier. Chamfering eliminates wire strand hang up and departure upon insertion into the terminal s barrel. The loss of even a couple of wire strands can have negative results on electrical efficiency and resistance to mechanical strain. Deep Internal Serrations fter the insertion of a wire into the terminal s barrel, a deep serrated interior insures a large area of contact which lowers the resistance of a connection. With the mechanical force of the tool, the wire strands cold flow into the serrated interior. This guarantees electrical resistance lower than the wire to which it is applied. This feature also prevents pullout from vibration and mechanical strain. Deep internal serrations can be compared to the effective holding power of a well treaded tire on a wet highway. Sta-on s Long arrel Design If lowering electrical resistance, preventing wire pullout, eliminating a missed crimp and an insulator that stays on the barrel during installation are your goals, then you must design a terminal with a long barrel. Most competitive barrel lengths range from 20%- 50% shorter than Sta-on terminals. The results are usually a stream of electrical failure, rework and added expense. This also provides the insulator with additional surface area, holding tight to the barrel. Many competitive insulators come off during crimping due to a limited barrel length. razed or Overlapped Seam long barrel design is of little value unless it is one solid piece. That is why Thomas & etts brazes the seam on our vinyl insulated Sta-on and overlaps the seam on nylon insulated terminals. Many competitive terminals have butted seams. This means increased chances for wirestrand loss, poor resistance, wire pullout and electrical failure. If the installer doesn t position the tool exactly on the correct spot on the barrel, there s likely going to be an improper termination. The butted seam can also fold due to tool-applied pressure piercing the terminals insulation from the inside out. With a brazed or overlapped seam the installer can crimp anywhere along the barrel s surface providing up to 2.5 times the tensile strength of a butted seam terminal, guaranteeing proper electrical flow, void free. Strands enter as a homogeneous group and compact tightly under compression due to fully brazed seam Thomas & etts Corporation. Specifications are subject to change without notice.

3 Terminals Why Sta-on Terminals re etter continued Deep Internal Serrations. Flat bottom box. Electro-tin plating. Center reinforced spring detent for minimum insertion force. Compound Spring Rails provide positive contact after repeated insertions. Selective nnealing ecause of the mechanical strength of copper, an installer can experience fatigue associated with repeated installations. For this reason Thomas & etts puts our terminals through one more step called selective annealing. This process leaves the barrel soft enough to crimp and form around the wire. However, we cold form the tongue during the manufacturing process so it remains strong. This is done so the tongue can withstand repeated bends and bolt tightening strain common in most electrical installations. Many competitors attempt to accomplish similar goals by removing valuable material or using a softer copper which has lower conductivity. This increases electrical resistance as well as the odds for shorting and downtime. nti-rotational Tongues This is a unique feature to the Thomas & etts ring tongue terminal. This design prevents terminal shorting by keeping the terminal secure in the terminal block. The installer can place a greater number of terminals closer together without worry. Proper Identification We identify all terminals with Thomas & etts initials, T &. We also indicate wire and stud sizes. These markings are clearly visible on the surface of the tongue, taking any guesswork out of replacing or reordering additional parts. Our superior bright plating also assists in visibility. ll Sta-on Terminals are Deburred and Degreased To insure a Sta-on terminal is properly plated and insulated, all our parts are put through a process which cleans and smooths the terminal of any manufacturing by-products, mainly grease, oils and sharp edges. Many competitive products do not put their product through such rigorous finishing. Platings/Finish Electroplated-Tin is standard. ll others require minimum order quantities and are generally not stocked. lternative platings as follows: Gold, Silver, Tinalloys, Nickel, etc. The following finishes are available on most one-piece Sta-on terminals: Finish Suffix Spec. Gold Plate GP MIL-G Type II, Grade, C, D, Class O Nickel Plate NP QQ-N-290 Class 2, Grade G Plain Finish PF None Silver Plate SP MIL-T Type I or II, 400 F, 204 C Tin Plate TP MIL-T Type I To order add the indicated suffix to the regular catalog number. Underwriters Laboratories Listing Sta-on Rings, Fork, and Locking Forks are tested and listed to U.L. 486, two-way splices to U.L. 486C, disconnects to U.L. 310 and all applicable products to CS Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 3

4 Terminals Sta-on Ring, Fork & Locking Fork Complete line of installing tools engineered to match tool with terminal. First to gain military approval for pressure connections many styles available for military applications. Sta-on products exceed test specification requirements of military, U.L. and CS. TEFZEL & Nylon Terminals provided with extra metal sleeve to grip insulation. Vinyl insulated and bare Sta-on terminals feature brazed seam wire barrels which can be crimped at any place on the barrel circumference. Sta-on Disconnects Internal barrel serrations and long barrel provide for maximum tensile strength. Complete line of installing tools, engineered to match tool with terminal. Funnel entry insulators allow for easier inserting of wire into barrel. Color-coded for easy installation. ERG-2001 The Shure-Stake Tools are Matched to Terminals The Shure-Stake mechanism prevents the dies from releasing the terminal until the proper compression has been completed. With this method, an operator achieves a reliable crimp everytime. Thomas & etts tooling techniques correctly match tools, wire size and terminal to produce optimum mechanical and electrical performance. Sta-on Technical Data Sta-on Terminals & Splices U.L. 94 Insulation Rating Flammability Voltage Temperature Nylon V-2 600V** 105 C Vinyl V-0 600V** 105 C TEFZEL V-0 600V** 150 C **1000V fixture or sign Disconnects 300V 105 C The Sta-on Terminal Numbering System Distributor Package 100/50 ulk O.E.M. Packaged 1000/500 Common to oth Packages Letter denotes WG wire range Letter denotes WG wire range Letter C denotes WG wire range Letter R preceding the above letters indicates the terminal is insulated No letter R no insulation no exception! Distributor Packaged Part numbers are very descriptive indicating insulation and type, stud size, tongue style and the largest maximum wire that can be put inside. If the letter R precedes the number the part is nylon insulated R18-6 If the letter R follows the number the part is vinyl insulated 14R-8 EXMPLE: 10RC-8F C Indicates WG 10RC Vinyl Insulated 8 Indicates stud size F means a fork tongue terminal FL would indicate locking fork EXMPLE: 2R18X 2 Indicates a 2 way or butt style connector X means expanded insulation. Tefzel is a registered trademark of DuPont Thomas & etts Corporation. Specifications are subject to change without notice.

5 Terminals Performance Data Voltage Drop Test 500 Cycles Thomas & etts terminals show consistently lower millivolt drops than those allowed by NEM specification. Voltage Drop (mv) CODE Typical test value of T& Terminals NEM requirement MPS WG Wire Pullout Tension Test Thomas & etts terminals show consistently higher wire retention forces than those required by NEM specification. The Proper Installation Procedure for the Quality ssured Connection The proper installation of terminals, splices and connectors is very important to the efficient performance of an electrical system. The properly installed connector will allow good conductivity through the termination. poor termination results in a high resistance connection. poor connector installation may cause damage or failure of an entire system. Certain basic requirements must be met to make a good termination. 1. efore the connector or terminal is installed on the conductor, follow these recommended practices: Strip the insulation carefully so as to avoid nicking or cutting conductor strands Strip the insulation to the proper length so that the conductors can be inserted fully into the connector barrel; the wire/cable should be visible in the inspection hole of the lug; the proper strip length can be found on page Thomas & etts wire strippers will help eliminate these problems by properly gaging and measuring the depth and length requirements for the conductor. See page 49 for wire strippers. Wire Pullout Force (lbs.) CODE Typical test value of T& Terminals NEM requirement Wire Size (WG) stripped wire rest stripping length terminal orient tongue as shown indentor The terminal must be properly installed. Installation Procedure 1. Train the wires to eliminate fanning of strands. 2. Open handles fully. 3. Insert terminal in proper die nest and locate it as shown above. When crimping a butt splice, position in proper die nest with window facing indentor. 4. Close handles slightly to secure terminal. Do not deform terminal. 5. Insert properly stripped wire into terminal. 6. Complete crimp by closing handles. Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 5

6 Terminals Sta-on Self-insulated with high dieletric-strength nylon sleeves, these ring terminals are recommended for temperatures up to 105 C. n inner bronze insulation grip sleeve lengthens the flexing radius of the conductor and eliminates conductor creep. The nylon jacket is colorcoded: Color Code Wire Range yellow red blue yellow Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) RZ & RX stock thickness:.02 R & R stock thickness:.03 RC stock thickness:.04 Nylon Insulated Ring Insulation Grip Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M RZ22-2** # RZ22-4** # RZ22-6** # RZ22-8** # RZ22-10** # RX23* # RX43* # RX63* # RX83* # RX103* # R # R # R # R # R # R # R # R # R # R # R b" R b" R j" R j" R c" R c" R d" R d" R # R # R # R # R # R # R # R # R # R b" R b" R j" R j" R c" R c" R d" R d" RC # RC # RC # RC # RC # RC # RC b" RC b" RC j" RC j" RC c" RC c" RC d" RC d" * Not Listed y U.L. CS ** CS Listed only U.L. Listed E9809 Installing tools: WT2000, WT112M, WT145C, ERG-2001, ERG-2003, WT145 Installing tool: WT1452 (RZ series only) M C Thomas & etts Corporation. Specifications are subject to change without notice.

7 Terminals Catalog numbers with the suffix X indicate an expanded insulation grip. This means a wider wire entry to accommodate heavy wall insulation. Ring terminals won t fall free even if the mounting screw loosens. R stock thickness:.03 RC stock thickness:.04 Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Nylon Insulated Ring Expanded Insulation Grip Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M R14-4X # R # R14-6X # R # R14-8X # R # R14-10X # R # R14-14X b" R b" R14-516X j" R j" R14-38X c" R c" RC10-6X # RC # RC10-8X # RC # RC10-10X # RC # RC10-14X b" RC b" RC10-516X j" RC j" RC10-38X c" RC c" RC10-12X d" U.L. Listed E9809 Installing tools: WT2000, WT112M, WT145C, ERG-2001, ERG-2003, WT145 M C Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 7

8 Terminals Heat Shrinkable Ring Terminals Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M RS18-6X # RS18-8X # RS18-10X # RS14-6X # RS14-8X # RS14-10X # These ring terminals are self-insulated with heat shrinkable polyolefin and internally coated sealant. Upon completed installation, a fully sealed connection is achieved to protect the joint against the degrading effects of galvanic action, corrosion, and environmental exposure. RCS10-6X # RCS10-8X # RCS10-10X # RCS10-14X b" U.L. Listed E9809 Installing tool: WT1255 Note: Not available on Mylar Tape. RS & RS stock thickness:.03 RCS stock thickness:.04 M C Sta-on Thomas & etts Corporation. Specifications are subject to change without notice.

9 Terminals RD, RE, RF stock thickness:.04 RG stock thickness:.05* *razed Seam, Lolly-Pop Style Tongue. Nylon Insulated Ring Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M RD # RD # RD # RD b" RD b" RD j" RD j" RD c" RD c" RD d" RD757* d" RD N.270 # RD N.270 # RD N.270 b" RD N.270 j" RD N.270 c" RE # RE # RE b" RE b" RE j" RE j" RE c" RE c" RE d" RE757* d" RE N.315 # RE N.315 b" RE N.315 j" RE N.315 c" RF # RF # RF b" RF b" RF j" RF j" RF c" RF c" RF757* d" RF N.380 # RF N.380 b" RF N.380 j" RF N.380 c" RG # RG # RG b" RG b" RG j" RG j" RG c" RG c" RG d" RG d" RG N 453 b" RG N.453 c" RG N.453 d" N ircraft Wire. U.L. Listed E9809. Installing tools: TM6/TM6S, ERG-2007, (RD & RE Except razed Seam) Note: Not available on Mylar Tape. Sta-on M C 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 9

10 Terminals Sta-on Stock Thickness: RH =.05 RJ =.06 R =.06 RL =.07 RM =.07 Nylon Insulated Ring continued Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M RH N.500 b" RH N.500 c" RH N.500 d" RJ /0N.550 b" RJ /0N.550 c" RJ /0N.550 d" RH /0.629 b" RH /0.629 j" RH /0.629 c" RH /0.629 d" R /0N.610 c" R /0N.610 d" RJ /0.675 b" RJ /0.675 j" RJ /0.675 c" RJ /0.675 d" RL /0N.680 c" RL /0N.680 d" R /0.765 b" R /0.765 j" R /0.765 c" RM /0N.750 c" RM /0N.750 d" RL /0.785 c" RL /0.785 d" RM MCM.868 c" RM MCM.868 k" RM MCM.868 d" N ircraft Wire U.L. Listed E9809 Installing tools: TM6/TM6S, ERG-2007, (RD & RE Except razed Seam) Note: Not available on Mylar Tape. M C Thomas & etts Corporation. Specifications are subject to change without notice.

11 Terminals These ring terminals are self-insulated with a PVC insulation sleeve of extra length to give protection and relieve bending stress at wire s flex point. razed seam barrel is serrated to obtain high pull-out value. Terminal is made of high conductivity electrolytic copper, electro-tin plated. Insulation material is color-coded: Color Code Wire Range red blue yellow Stock Thickness: R & R =.03 RC =.04 Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Vinyl Insulated Ring Insulation Grip Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M 18R # R # R # R # R # R # R # R # R b" R b" R j" R j" R c" R c" R # R # R # R # R # R # R # R # R b" R b" R j" R j" R c" R c" RC # RC # RC # RC # RC # RC # RC b" RC b" RC j" RC j" RC c" RC c" U.L. Listed E9809 Installing tools: WT145C, WT2000, WT112M, ERG-2001, ERG-2003 Sta-on M C 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 11

12 Terminals Sta-on Catalog numbers with the suffix X indicate an expanded insulation support. This means a wider wire entry to accommodate heavy wall insulation. Ring terminals won t fall free even if the mounting screw loosens. Stock Thickness: R & R = 03 RC =.04 Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Vinyl Insulated Ring Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M 18R-6X # R-8X # R # R-10X # R # R-14X b" R j" R-4X # R-6X # R # R-8X # R # R-10X # R # R-14X b" R b" R-516X j" R-38X c" RC-6X # RC # RC-8X # RC # RC-10X # RC # RC-14X b" RC b" RC-516X j" RC-38X c" RC c" U.L. Listed E9809 Installing tools: WT145C, WT2000, WT112M, ERG-2001, ERG-2003 M C Thomas & etts Corporation. Specifications are subject to change without notice.

13 Terminals These non-insulated ring terminals are made of electrolytic copper for high conductivity. They can be installed with crimping tools having a single indentor or double indentor (recommended for solid wire). Serrated barrel increases grip on wire. Wire range identification is stamped on the tongue of each terminal. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and applicaton dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Stock Thickness: & =.03 C =.05 C =.04 Non-Insulated Ring Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M # # # # # # # b" b" j" j" c" c" d" d" # # # # # # # # b" b" j" j" c" c" d" d" # # C heavy duty # C use C tooling # C heavy duty # C use C tooling # C heavy duty # C use C tooling # C heavy duty b"" C use C tooling b" C heavy duty j" C use C tooling j" C heavy duty c" C use C tooling c" C heavy duty d" C use C tooling d" C # C # C # C # C # C # C # C b" C b" C j" C j" C j" C c" C c" C d" C d" U.L. Listed E9809 Installing tools: WT111M, WT112M, WT110M, ERG-2002, WT2000 Sta-on M C 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 13

14 Terminals Sta-on These non-insulated ring terminals are made of electrolytic copper for high conductivity. They can be installed with crimping tools having a single indentor or double indentor (recommended for solid wire). Serrated barrel increases grip on wire. Wire range identification is stamped on the tongue of each terminal. Stock Thickness: D & E =.06 F =.07 D10, E10, F10 =.04 D975 & F975 =.04 Non-Insulated Ring razed Seam Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M D8-10* 25 8 # D36* # D8-14* 25 8 b" D71* b" D8-516* 25 8 j" D72* j" D8-38* 25 8 c" D73* c" D8-12* 25 8 d" D75* d" E6-10* 20 6 # E26* # E6-14* 20 6 b" E71* b" E6-516* 20 6 j" E72* j" E6-38* 20 6 c" E73* c" E6-12* 20 6 d" E75* d" F4-10* 20 4 # F26* # F4-14* 20 4 b" F71* b" F4-516* 20 4 j" F72* j" F4-38* 20 4 c" F73* c" F4-12* 20 4 d" F75* d" Installing tools: ERG-2005 (D Series only), WT115 D, E, F and G, TM6/TM6S, WT3185 Installing dies: INDENTOR (D-E-F-G), D NEST, E NEST, F NEST (all ordered separately) Not available on Mylar Tape. M C Thomas & etts Corporation. Specifications are subject to change without notice.

15 Terminals Non-Insulated Ring Tubular Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M D # D # D b" D j" D c" D975* d" These non-insulated ring terminals are made of electrolytic copper for high conductivity. They can be installed with crimping tools having a single indentor or double indentor (re commended for solid wire). Serrated barrel increases grip on wire. Wire range identification is stamped on the tongue of each terminal. Stock Thickness: G & H =.05 J & =.06 L & M =.07 E # E b" E j" E c" F # F b" F j" F c" F975* d" G b" G j" G c" G d" G # G b" G j" G c" G d" H N-1/0 b" H N-1/0 j" H N-1/0 c" H N-1/0 d" H /0 b" J /0N-2/0 b" J /0N-2/0 j" J /0N-2/0 c" J /0N-2/0 k" J /0N-2/0 d" J /0 c" /0N-3/0 b" /0N-3/0 j" /0N-3/0 c" /0N-3/0 k" /0N-3/0 d" /0 c" L /0N-4/0 c" L /0N-4/0 k" L /0N-4/0 d" L /0 c" M /0N-250MCM j" M /0N-250MCM c" M /0N-250MCM k" M /0N-250MCM d" M MCM c" N ircraft Wire Installing tools: TM6/TM6S, WT3185 (G, H, J Series only) Note: Not available on Mylar Tape. Sta-on M C 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 15

16 Terminals Nylon #16-14 WG Heavy Duty Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M Stud Size Marked In This rea C M Nylon or Vinyl Insulated RC heavy duty.210 # RC use RC tooling.210 # RC heavy duty.210 # RC use RC tooling.210 # RC heavy duty.210 # RC use RC tooling.210 # RC heavy duty.210 b RC use RC tooling.210 b RC heavy duty.210 j RC use RC tooling.210 j RC heavy duty.210 c RC use RC tooling.210 c RC heavy duty.210 d RC use RC tooling.210 d WT2000, WT145C, and power tools as recommended crimp in the nest (yellow) Vinyl #16-14 WG Heavy Duty Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M Sta-on Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Material: copper.050 thk. Finish: electro tin-plate Wire Range: #16-14 Color Code: green vinyl or nylon insulator 14RC heavy duty.210 # RC use RC tooling.210 # RC heavy duty.210 # RC use RC tooling.210 # RC heavy duty.210 # RC use RC tooling.210 # RC heavy duty.210 b" RC use RC tooling.210 b" RC heavy duty.210 j" RC use RC tooling.210 j" RC heavy duty.210 c" RC use RC tooling.210 c" RC heavy duty.210 d" R use RC tooling.210 d" Stud Size Marked In This rea C M Non-Insulated Non-Insulated #16-14 WG Heavy Duty Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M C heavy duty # C use RC tooling # C heavy duty # C use RC tooling # C heavy duty # C use RC tooling # C heavy duty b C use RC tooling b" C heavy duty j C use RC tooling j" C heavy duty c C use RC tooling c" C heavy duty d C use RC tooling d" WT111M, WT2000, and power tools as recommended, crimp in the nest Thomas & etts Corporation. Specifications are subject to change without notice.

17 Terminals High Temperature Non-Insulated Ring 1200 F Max. Terminals for nichrome wire NW Series Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M For easily installed, permanent terminations of solid, round, or stranded nichrome wires as used in toasters, irons, heaters, etc. High temperature non-insulated ring terminals and splices are designed for use with solid or stranded resistance wires as used in appliances such as toasters, irons, and heaters. Stock Thickness: ga. = ga. = ga. = ga. =.040 NW # NW # NW # NW # NW # NW # NW # NW # NW # NW #12* NW #12* NW # NW # NW #12* * #12 stud is approximate 1 4" stud. Installing tool: WT1377 Note: Not available on Mylar Tape. M C Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 17

18 Terminals Vinyl Insulated Ring Max. Cat. Stud Ins. Wire No. Size Dia. Range C M Sta-on Stock Thickness:.04 *razed Seam, Lolly-Pop Style Tongue Series RDV ircraft Wire N RDV10161 # RDV10361 # RDV10711 b" RDV10721 j" RDV10731 c" Code Wire WG RDV167 # RDV367 # RDV717 b" RDV727 j" RDV737 c" RDV757* d" Series REV ircraft Wire N REV10261 # REV10711 b" REV10721 j" REV10731 c" Code Wire WG REV267 # REV717 b" REV727 j" REV737 c" REV757* d" Note: Not available on Mylar Tape. Installing tool: ERG-2007 (RD & RE Except razed Seam), TN6/65 M C Thomas & etts Corporation. Specifications are subject to change without notice.

19 Terminals Stock Thickness: RT & RT =.03 RCT =.04 Package Quantities: RT & RT = 1000 pcs. RCT = 500 pcs. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Tefzel Insulated Ring Insulation Grip Max. Cat. Stud Ins. Wire No. Size Dia. Range C M Series RT For U.L. 94V-O Flammability Rating/High Temperature and Chemical Resistance. RT853 # RT863 # RT873 # RT713 b" Series RT RT853 # RT863 # RT873 # RT713 b" Series RCT RCT333 # RCT863 # RCT363 # RCT713 b" RCT703 j" RCT733** c" ** Not available on tape. U.L. Listed E9809 Installing tool: WT145C, WT112M M C Sta-on Tefzel is a registered trademark of DuPont Thomas & etts Corporation. Specifications are subject to change without notice. 19

20 Terminals Nylon Insulated Rectangular Rings u-ships Cat. Stud Wire Tongue No. Size Range C M Shape Stock Thickness: R & R =.03 RC =.04 Note: ga. = 1-2 Navy ga. = Navy ga. = 6-9 Navy Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Series R R486 # L86P-1 R485 # L85P-1 R483 # L83P-1 R484 # L84P-1 R481 # L81P-1 R482 # L82P-1 R480** # L80P-1 Series R R486 # L86P-2 R485 # L85P-2 R483 # L83P-2 R484 # L84P-2 R481 # L81P-2 R482 # L82P-2 R480** # L80P-2 Series RC RC486 # L86P-3 RC485 # L85P-3 RC483 # L83P-3 RC484 # L84P-3 RC481 # L81P-3 RC482 # L82P-3 RC480** # L80P-3 Sta-on ** Not available on tape. Note: R, R, RC486 for use with U-Ships terminal board types 26T. R, R, RC485 for use with 25T and 27T. R, R, RC483 for use with 8T. R, R, RC484 for use with 10T and 11T. R, R, RC481 for use with 6T, 7T and 9T. R, R, RC482 for use with 15T. R, R, RC480 for use with 3T, 4T, 5T, 16T, 17T and 18T. Note: When ordering terminals on tape add the suffix M, example: (R250M), to the catalog number. U.L. Listed E9809 Installing tools: ERG2001, WT145C C M Thomas & etts Corporation. Specifications are subject to change without notice.

21 Terminals Non-Insulated Rectangular Rings u-ships Cat. Stud Wire Tongue No. Size Range C M Shape Stock Thickness: & =.03 C =.04 Note: ga. = 1-2 Navy ga. = Navy ga. = 6-9 Navy Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Series 486 # L # L # L # L # L # L82 480** # L80 Series 486 # L # L # L # L # L # L82 480** # L80 Series C C486 # L86 C485 # L85 C483 # L83 C484 # L84 C481 # L81 C482 # L82 C480** # L80 ** Not available on tape. Note:,, C486 for use with u-ships terminal board types 26T.,. C485 for use with 25T, 27T.,, C483 for use with 8T.,, C484 for use with 10T and 11T.,, C481 for use with 6T, 7T and 9T.,, C482 for use with 15T.,, C480 for use with 3T, 5T, 16T, 17T and 18T. Note: When ordering terminals on tape add the suffix M, example: (R250M), to the catalog number. U.L. Listed E9809 Installing tool: ERG 2002 C M Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 21

22 Terminals Non-Insulated Flag Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M M C Flag terminals allow a 90 connection to the terminal block without bending the wire. Stock Thickness: =.03 C =.04 D =.06 E =.06 F =.07 G = # # # # # # C # C # C # C # C # D ,8,7 # D ,8,7 # D ,8,7 1 4" E ,5 # E ,5 b" E ,5 j" F ,3 # F ,3 b" F ,3 j" F ,3 c" G b" G j" G c" U.L. Listed E9809 Installing tools: ERG-2004 Note: Not available on Mylar Tape. Sta-on Thomas & etts Corporation. Specifications are subject to change without notice.

23 Terminals Nylon Insulated Fork Insulation Grip Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M Fork terminals with nylon insulation sleeves, recommended for temperatures up to 105 C. Inner bronze insulation grip sleeve lengthens flex radius of conductor and eliminates conductor creep. Nylon jacket is color-coded. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) R18-6F # R # R18-8F # R # R18-10F # R # R18-14F b" R b" R14-6F # R # R14-8F # R # R14-10F # R # R14-14F b" R b" R # R # R # RC10-6F # RC # RC10-8F # RC # RC10-10F # RC # RC10-14F b" RC b" RC # RC # U.L. Listed E9809 Installing tools: WT145C, WT2000, WT112M, ERG-2001, ERG-2003, WT145 M C Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 23

24 Terminals Nylon Insulated Fork Flanged Tongue Insulation Grip Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M R18-6FS # R # R18-8FS # R # R18-10FS # R # Fork terminals allow easy installation because screw needs only to be loosened. Suffix S indicates a flanged-tongue fork with turned up tips for extra holding protection. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) R14-6FS # R # R14-8FS # R # R14-10FS # R # R # R # RC10-8FS # RC # RC10-10FS # RC # RC # RC # U.L. Listed E9809 Installing tools: WT145C, WT2000, WT112M, ERG-2001, ERG-2003, WT145 M C Sta-on Thomas & etts Corporation. Specifications are subject to change without notice.

25 Terminals Vinyl Insulated Fork Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M 18R-6F # R # R-8F # R # R-10F # R # These fork terminals have extra-long PVC insulation sleeve for protection and stress relief at wire s flex point. razed seam barrel is serrated for high pull-out value. Terminal is high conductivity electrolytic copper, electro-tin plated. Insulation is color-coded. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) 14R-6F # R # R-6FS # R-8F # R # R-10F # R # R-14F b" R b" RC-6F # RC # RC-8F # RC # RC-10F # RC # RC-14F b" RC b" U.L. Listed E9809. Installing tools: WT145C, WT2000, WT112M, ERG-2001, ERG-2003 M C Vinyl Insulation Fork Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M Sta-on Fork terminals allow easy installation since the mounting screw does not have to be completely removed. Catalog numbers with the suffix X indicate an expanded insulation support. This means a wider wire entry to accommodate heavy wall insulation. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) 18R-6FX # R # R-8FX # R # R-10FX # R # R-6FX # R # R-8FX # R # R-10FX # R # RC-8FX # RC # RC-10FX # RC # RC-14FX b" U.L. Listed E9809. Installing tools: WT145C, WT2000, WT112M, ERG2001, ERG2003 M C 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 25

26 Terminals These non-insulated fork terminals are made of electrolytic copper for high conductivity. They can be installed with crimping tools having a single indentor or double indentor (recommended for solid wire). Serrated barrel increase grip on wire. Wire range identification is stamped on the tongue of each terminal. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Non-Insulated Fork Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M 18-6F # # F # # F # # F # # # F # # F # # F b" C10-6F # C # C10-8F # C # C10-10F # C # C10-14F b" C b" U.L. Listed E9809 Installing tools: WT111M, WT112M, WT110M, WT2000, ERG-2002 M C Sta-on Thomas & etts Corporation. Specifications are subject to change without notice.

27 Terminals Locking fork terminals have a specially designed tongue that lets them go on like a fork and stay on like a ring. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Nylon Insulated Locking Fork Insulation Grip Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M R18-6FL # R # R18-8FL # R # R18-10FL # R # R14-6FL # R # R # R14-8FL # R # R14-10FL # R # R # RC10-6FL # RC # RC # RC10-8FL # RC # RC10-10FL # RC # RC # RC10-14FL b" RC b" U.L. Listed E9809 Installing tools: ERG-2001, ERG-2003, WT145C, WT2000, WT112M, WT145 M C Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 27

28 Terminals Vinyl Insulated Locking Fork Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) 18R-6FL # R # R # R-8FL # R # R-10FL # R # R-6FL # R # R # R-8FL # R # R-10FL # R # RC-6FL # RC # RC-8FL # RC # RC-10FL # RC # RC-14FL b" RC b" U.L. Listed E9809. Installing tools: ERG-2001, ERG-2003, WT145C, WT2000, WT112M M C Sta-on Vinyl Insulated Locking Fork Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M 18R-6FLX # R-8FLX # R-10FLX # R # Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) 14R-6FLX # R # R # R-8FLX # R # R-10FLX # R # RC-6FLX # RC # RC-8FLX # RC-10FLX # RC # RC-14FLX b" U.L. Listed E9809. Installing tools: ERG-2001, ERG-2003, WT145C, WT2000, WT112M M C Thomas & etts Corporation. Specifications are subject to change without notice.

29 Terminals Heat Shrinkable Locking Fork Terminals Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 RS18-6FLX # RS18-8FLX # RS18-10FLX # RS14-6FLX # RS14-8FLX # RS14-10FLX # RCS10-6FLX # RCS10-8FLX # RCS10-10FLX # RCS10-14FLX " U.L. Listed E9809 Installing tool: WT1255 Note: Heat Shrinkable terminals not available on Mylar Tape. Stock thickness same as ring terminal of same size. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Non-Insulated Locking Fork Cat. Pkg. Wire olt Per No. Qty. Range Hole 1000 C M 18-6FL #6 4f #6 4f FL #8 4f #8 4f FL #10 4f #10 4f FL #6 4f #6 4f FL #8 4f #8 4f FL #10 4f #10 4f C10-6FL #6 7f C #6 7f C10-8FL #8 7f C #8 7f C10-10FL #10 7f C #10 7f C10-14FL " 7f U.L. Listed E9809 Installing tools: WT110M, WT111M, WT112M, WT2000, ERG-2002 Sta-on M C 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 29

30 Terminals Pin Terminals Nylon Insulated Terminals Cat. Pkg. Wire D Recommended No. Qty. Range (Dia.) L Tools Provides an easy and effective way to terminate stranded wire into European/metric-style terminal blocks. Designed to prevent shorting, wire strand loss and/or wire pullout resulting from improper termination of stranded wire. Designed to meet emerging global standards which require wire-to-metric style terminal block installations be terminated with a pin style terminal. vailable in vinyl insulated, nylon insulated, and non-insulated styles. ll styles offered in 22 WG to 10 WG and compatible with existing Sta-on tooling. Voltage Rating Vinyl 600V Nylon 300V Non-Insulated 47PT WT111M 47PT ERG-2002 C55PT Vinyl 18R-47PT ERG-2003 R47PT R-47PT R47PT RC-55PT RC55PT ERG-2001 Nylon R18-47PT ERG-2003 R147PT WT2000 R14-47PT R147PT RC10-55PT RC155PT ERG-2001 Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Non-Insulated Vinyl/Nylon Sta-on Thomas & etts Corporation. Specifications are subject to change without notice.

31 Insulated Ferrules Features Ferrules ensure reliable electrical connections when terminating conductors in screw clamp terminal blocks. Fraying and breaking of wire strands is prevented and the possibility of an unreliable connection is minimized. Insulated ferrules prevent conductor breakage due to bending, wire stress or vibration, while facilitating wire insertions into the terminal block clamp. Ferrules are the preferred alternative to twisting wire stands or tinning the wire end before terminating into a terminal block. Ferrules are thin-walled copper tubes, which are mechanically crimped onto the ends of stranded wires. They are easy to use simply strip the wire, slide the ferrule onto the end of the wire and crimp. How to pply a Ferrule Strip the insulation from the end of the wire and insert into the insulated end of the ferrule. Using the designated crimping tool, place the metal shaft into the tool s appropriate slot. Compress the tool to make a crescent-shape depression along the length of the ferrule. Insert the crimped ferrule into the terminal block. Tighten the ferrule and wire into the terminal block. Materials High conductivity copper Tin plating Insulated Ferrules Conductor Section Color Inches/MM Installation Tooling Cat. No. WG MM 2 øc ød E F WHITE.453 / / / / / 0.15 T1, T3 & ERG F WHITE.531 / / / / / 0.15 T1, T3 & ERG F WHITE.610 / / / / / 0.15 T1, T3 & ERG F GREY.472 / / / / / 0.15 T1, T3 & ERG F GREY.551 / / / / / 0.15 T1, T3 & ERG F GREY.630 / / / / / 0.15 T1, T3 & ERG F GREY.709 / / / / / 0.15 T1, T3 & ERG F RED.492 / / / / / 0.15 T1, T3 & ERG F RED.571 / / / / / 0.15 T1, T3 & ERG F RED.650 / / / / / 0.15 T1, T3 & ERG F RED.728 / / / / / 0.15 T1, T3 & ERG F LC.571 / / / / / 0.15 T1, T3 & ERG F LC.650 / / / / / 0.15 T1, T3 & ERG F LC.728 / / / / / 0.15 T1, T3 & ERG F LC.965 / / / / / 0.15 T1, T3 & ERG F LUE.591 / / / / / 0.15 T1, T3 & ERG F LUE.748 / / / / / 0.15 T1, T3 & ERG F LUE.984 / / / / / 0.15 T1, T3 & ERG F GREY.889 / / / / / 0.20 T3 & ERG F GREY.787 / / / / / 0.20 T3 & ERG F GREY / / / / / 0.20 T3 & ERG F YELLOW.787 / / / / / 0.20 T3 & ERG F YELLOW.984 / / / / / 0.20 T3 & ERG F RED.827 / / / / / 0.20 T3 & ERG F RED / / / / / 0.20 T3 & ERG F LUE.906 / / / / / 0.20 ERG F LUE / / / / / 0.20 ERG F YELLOW / / / / / 0.20 ERG F YELLOW / / / / / 0.20 ERG F YELLOW / / / / / 0.20 ERG F RED / / / / / 0.20 ERG F RED / / / / / 0.20 ERG F RED / / / / / 0.20 ERG F2053 1/ LUE / / / / / 0.35 ERG F2054 1/ LUE / / / / / 0.35 ERG F Grey.413/ / / / /.25 T3, ERG ,000 F Grey.492/ / / / /.25 T3, ERG ,000 F Yellow.413/ / / / /.25 T3, ERG ,000 F Yellow.492/ / / / /.25 T3, ERG ,000 F Purple.413/ / / / /.25 T3, ERG ,000 F Purple.492/ / / / /.25 T3, ERG ,000 ag Pkg. Qty. Case Pkg. Qty. Sta-on Ferrule conform to DIN Part Thomas & etts Corporation. Specifications are subject to change without notice. 31

32 Insulated Ferrules Insulated Twin Ferrules Conductor Section Color Inches/MM Installation Tooling Cat. No. WG MM 2 øc ød E ag Pkg. Qty. Case Pkg. Qty. F8000 2x 20 2x 0.50 WHITE.591 / / / / / 0.25 T F8001 2x 18 2x 0.75 GREY.591 / / / / / 0.25 T F8002 2x 18 2x 0.75 GREY.669 / / / / / 0.15 T F8003 2x 17 2x 1.00 RED.591 / / / / / 0.15 T F8005 2x 17 2x 1.00 RED.669 / / / / / 0.15 T F8006 2x 16 2x 1.50 LC.630 / / / / / 0.15 T F8007 2x 16 2x 1.50 LC.787 / / / / / 0.15 T F8008 2x 14 2x 2.50 LUE.728 / / / / / 0.15 T F8009 2x 14 2x 2.50 LUE.846 / / / / / 0.15 T F8010 2x 12 2x 4.00 GREY.906 / / / / / 0.15 ERG-2 / 6MM DIE F8011 2x 10 2x 6.00 YELLOW.984 / / / / / 0.20 ERG-2 / 10MM DIE Ferrule conform to DIN Part 4. Insulated Ferrules (Old DIN and French Standards) Conductor Style Section Color Inches/MM Installation Tooling Cat. No. WG MM 2 øc ød E ag Pkg. Qty. Case Pkg. Qty. Sta-on F4000 OLD DIN ORNGE.571 / / / / / 0.15 T1, T3 & ERG F4001 OLD DIN WHITE.571 / / / / / 0.15 T1, T3 & ERG F4002 OLD DIN YELLOW.571 / / / / / 0.15 T1, T3 & ERG F4003 OLD DIN RED.571 / / / / / 0.15 T1, T3 & ERG F Grey.413/ / / / /.25 T3, ERG ,000 F Grey.492/ / / / /.25 T3, ERG ,000 F Yellow.413/ / / / /.25 T3, ERG ,000 F Yellow.492/ / / / /.25 T3, ERG ,000 F Purple.413/ / / / /.25 T3, ERG ,000 F Purple.492/ / / / /.25 T3, ERG ,000 F4020 OLD DIN LUE.571 / / / / / 0.15 T1, T3 & ERG F4021 FRENCH WHITE.571 / / / / / 0.15 T1, T3 & ERG F4023 FRENCH Lt LUE.571 / / / / / 0.15 T1, T3 & ERG F4024 FRENCH RED.571 / / / / / 0.15 T1, T3 & ERG F4027 FRENCH LC.571 / / / / / 0.15 T1, T3 & ERG F4028 FRENCH GREY.571 / / / / / 0.15 T1, T3 & ERG Ferrule conform to DIN Part 4. Tooling for Sta-on Insulated Ferrules Cat. No. Description Std. Pkg. T1 Sta-on Crimp tool for wire ferrules #20-14 WG insulated handle 1 T3 Sta-on Crimp tool for wire ferrules #26-10 WG insulated handle 1 ERG-2 Comfort Crimp Sta-on Crimp Tool with Shure-Stake mechanism, for installing wire ferrules #26-1 WG. 1 4 interchangeable die sets included. Insulated handle. Packaged in sturdy plastic carrying case. ERG3000 Dies available. See page 58. T1 T3 ERG-2 T& Part No. ERG2014F ERG128F ERG6F ERG4F ERG2F ERG1F Description ERG3000 Die for ferrules, size WG ERG3000 Die for ferrules, size 12-8 WG ERG3000 Die for ferrules, size 6 WG ERG3000 Die for ferrules, size 4 WG ERG3000 Die for ferrules, size 2 WG ERG3000 Die for ferrules, size 1 WG Thomas & etts Corporation. Specifications are subject to change without notice.

33 Non-Insulated Ferrules Uninsulated Ferrule Terminals Conductor (Inches / MM) Section Installation Pkg. Cat. No. WG MM 2 C D E Tooling Qty. F / / / / 0.15 T1, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG2 100 F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.15 T1, T3, ERG F / / / / 0.2 T3, ERG F / / / / 0.2 T3, ERG F / / / / 0.2 T3, ERG F / / / / 0.2 T3, ERG F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / / 0.2 T3, ERG2 250 F / / / /.25 ERG F / / / /.25 ERG F / / / /.25 ERG F / / / /.25 ERG F / / / /.25 ERG2 100 F / / / /.25 ERG2 100 F / / / /.25 ERG2 100 F9037 1/ / / / / 0.3 ERG2 100 F9038 1/ / / / / 0.3 ERG2 100 F9039 1/ / / / / 0.3 ERG2 100 Sta-on D C E 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 33

34 Heat Shrinkable Terminal, Splices, Disconnects Heat Shrinkable These ring terminals, butt splices and disconnects are self-insulated with heat shrinkable polyolefin and internally coated sealant. Upon completed installation, a fully sealed connection is achieved to protect the joint against the degrading effects of galvanic action, corrosion, and environmental exposure. These ring terminals are self-insulated with heat shrinkable polyolefin and internally coated sealant. Upon completed installation, a fully sealed connection is achieved to protect the joint against the degrading effects of galvanic action, corrosion, and environmental exposure. RS & RS stock thickness:.03 RCS stock thickness:.04 Heat Shrinkable Ring Terminals Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 C M RS18-6X # RS18-8X # RS18-10X # RS14-6X # RS14-8X # RS14-10X # RCS10-6X # RCS10-8X # RCS10-10X # RCS10-14X b" U.L. Listed E9809 Installing tool: WT1255 Note: Not available on Mylar Tape. M C Sta-on Heat Shrinkable Locking Fork Terminals Expanded Insulation Support Cat. Pkg. Wire Max. olt Per No. Qty. Range Ins. Hole 1000 RS18-6FLX # RS18-8FLX # RS18-10FLX # RS14-6FLX # RS14-8FLX # RS14-10FLX # RCS10-6FLX # RCS10-8FLX # RCS10-10FLX # RCS10-14FLX " U.L. Listed E9809 Installing tool: WT1255 Note: Heat Shrinkable terminals not available on Mylar Tape Thomas & etts Corporation. Specifications are subject to change without notice.

35 Heat Shrinkable Terminal, Splices, Disconnects Heat Shrinkable-Fully Insulated 250 Disconnects Female Cat. Pkg. Wire Max. Tab Per No. Qty. Range Ins Size 1000 RS18-250X x RS14-250X x RCS10-250X x Installing tool: WT1255 Heat Shrinkable-Fully Insulated 250 Disconnects Male Cat. Pkg. Wire Max. Tab Per No. Qty. Range Ins Size RS-251TX x RS-251TX x RCS-251TX x Installing tool: WT1255 Sta-on Heat Shrinkable Splices utt Type Expanded Insulation Cat. Pkg. Wire Max. Per No. Qty. Range Ins RS18X RS22X RS14X RS22X RCS10X RCCS22X These butt splices are self-insulated with heat shrinkable polyolefin and internally coated sealant. Upon completed installation, a fully sealed connection is achieved to protect the joint against the degrading effects of galvanic action, corrosion, and environmental exposure. Installing tool: WT Thomas & etts Corporation. Specifications are subject to change without notice. 35

36 Splices Connectors utt Type Splices In butt splices, the wires are butted together and crimped at each end of the splice. They are available either non-insulated, or insulated with nylon or PVC. Nylon insulated splices meet or exceed the requirements of MIL-T These splices are color-coded according to wire size. Nylon Insulated Splices ircraft Systems Splices Cat. Pkg. Wire Per No. Qty. Range RZZ R R R R RCC RCC Not U.L. Listed Installing tools: WT145C, ERG-2001, ERG-2003, WT1452(R22) Sta-on Nylon Insulated Splices utt Type Insulation Support Max Cat. Pkg. Ins. Wire Per No. Qty. Dia. Range R R R R RC RCC RD RDD RE REE RF U.L. Listed E9809 Installing tools: ERG-2001, ERG-2003, WT145C, WT112M, TM6/TM6S (D-F) Note: Not available on Mylar Tape Thomas & etts Corporation. Specifications are subject to change without notice.

37 Splice Connectors Vinyl Insulated Splices utt Type Expanded Insulation Cat. Pkg. Wire Max. Per No. Qty. Range Ins R18X R R R14X R R RC10X RCC RCC U.L. Listed E9809 Installing tools: WT145C, WT2000, WT112M, ERG-2001, ERG-2003 ulk No's:R22X R22X RCC22X These butt splices are self-insulated with heat shrinkable polyolefin and internally coated sealant. Upon completed installation, a fully sealed connection is achieved to protect the joint against the degrading effects of galvanic action, corrosion, and environmental exposure. Heat Shrinkable Splices utt Type Expanded Insulation Cat. Pkg. Wire Max. Per No. Qty. Range Ins RS18X RS22X RS14X RS22X RCS10X RCCS22X Installing tool: WT1255, & C bulk numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) Non-Insulated Splices utt Type Cat. Pkg. Wire Per No. Qty. Range C CC D DD E EE F FF G GG Sta-on U.L. Listed E9809 Installing tools,, C: WT111M, WT110M, WT2000, ERG-2002, WT112M Installing tools D, E, F, G: WT115, TM6/TM6S 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 37

38 Splice Connectors Overlap Type Splices Wires are laid side by side in the connector, and the connection is made in one crimp. These splices offer advantages in simplicity of installation, and small size. One crimp completes the splice. Nylon Insulated Splices Overlap Type (Parallel) Cat. Pkg. Wire Per No. Qty. Range R R C RCC U.L. Listed E9809 Installing tools: WT2000, WT112M High-Tech Splice-Overlap Type (Parallel) Cat. Pkg. Wire Per No. Qty. Range Sta-on Non-Insulated Splices Overlap Type Cat. Pkg. Wire Per No. Qty. Range C C1C D D1D E E1E F F1F G G1G H1H Not U.L. Listed. U.L. Listed E9809 Installing tools,, C: WT110M, WT2000, WT111M, WT112M Installing tools D, E, F, G: WT115, TM6/TM6S Tefzel Insulated utt Splice Max. Cat. Pkg. Wire Per Ins No. Qty. Range 1000 Dia. RT RT RCCT Installing tool WT-145C Tefzel is a registered trademark of DuPont Thomas & etts Corporation. Specifications are subject to change without notice.

39 Disconnects Disconnect terminals provide a quick, reliable method of connection to terminal blocks and boards without the use of tools. They are supplied in a variety of styles to meet virtually all quick-disconnect requirements. Female disconnect terminals and matching male tabs accommodate a range of WG, and are available in non-insulated, partially insulated, and fully insulated styles, in both nylon and vinyl. They are available in various tab widths including.250",.187", and.110", and a combination size. unique construction of the female disconnect offers long-term dependability. The brazed seam serrated barrel provides maximum tensile strength Series Female Disconnects 2 R18-250F nylon self-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M 1 Cat. Pkg. Wire Max. Tab Per No. Qty. Range Ins. Size 1000 R18-250F x R x R14-250F x R x RC10-250F x RC x R-250F vinyl self-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M 18R-2577 nylon fully-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M R-250F x R x R x R-250F x R x R x RC-250F x RC x R x R x R x R x RC x RC x RS18-250X x RS14-250X x RCS10-250X x Sta-on 4 Material: brass Finish: tin plated U.L. Listed E66716 RS18-250X heat-shrinkable fully insulated disconnects installing tool WT1255 Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages for description of tooling. Please add the suffix M for Mylar Tape (i.e. R2573-M) Thomas & etts Corporation. Specifications are subject to change without notice. 39

40 Disconnects Series Female Disconnects continued Cat. Pkg. Wire Max. Tab Per No. Qty. Range Ins. Size R nylon open top insulated 90 flag installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M non-insulated installing tools WT111M, WT1110M, WT2000, ERG-2002, WT112M R x R2577F x R x R2577F x RC x RC2577F x x x x x C10-250F x C x F x G x x G x x G x C x C252G x U.L. Listed E F non-insulated/insulation grip installing tool WT110M Sta-on non-insulated 90 flag installing tools WT110M, WT111M, WT2000, ERG-2002, WT112M 250 Series Piggy ack Disconnects Nylon Insulated Cat. Pkg. Wire Max. Tab Per No. Qty. Range Ins. Size 1000 C 5 5 R18-250FP x R250P x R14-250FP x R250P x For stacking applications Installing Tool WT112M Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages for description of tooling. Please add the suffix M for Mylar Tape (i.e. R2573-M). C 30 O Thomas & etts Corporation. Specifications are subject to change without notice.

41 Disconnects Series Female Disconnects 2 RD nylon self-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M 1 Max. Cat. Pkg. Tab Wire Ins. No. Qty. Size Range Dia. RD x RD x RD x RD x RD x RD x RD x RD x RD-183 vinyl self-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M 18RD nylon fully-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x RD x D non-insulated installing tools WT111M, ERG-2002, WT2000, WT112M, D x D x D x D x D x D x D x RD x RD1877F x RD x RD1887F x RD x RD1877F x RD x RD1887F x Sta-on RD nylon fully-insulated 90 flag installing tools WT1145C, WT2000, ERG-2001, ERG-2003, WT112M U.L. Listed E66716 Material: brass Finish: tin plated Disconnect terminals provide a quick, reliable method of connection to terminal blocks and boards without the use of tools. They are supplied in a variety of styles to meet virtually all quick-disconnect requirements. Female disconnect terminals and matching male tabs accommodate a range of WG, and are available in non-insulated, partially insulated, and fully insulated styles, in both nylon and vinyl. They are available in various tab widths including.250",.187", and.110", and a combination size. unique construction of the female disconnect offers long-term dependability. Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages for description of tooling. Please add the suffix M for Mylar Tape (i.e. R2573-M) Thomas & etts Corporation. Specifications are subject to change without notice. 41

42 Disconnects Series Male Tabs 18R-250T vinyl self-insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M 1 Cat. Pkg. Wire Max. Tab Per No. Qty. Range Ins. Size R-250T x R x R-250T x R x RC-250T x RC x R-251T nylon fully insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M R-251T x R x R-251T x R x RC-251T x RC x RS-251TX x RS-251TX x RCS-251TX x T x T x T x x T x x C10-251T x RS-251TX heat shrinkable nylon fully insulated installing tool WT Material: brass Finish: tin plated Sta-on T Non-insulated/insulated grip installing tool WT110M Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages for description of tooling. Please add the suffix M for Mylar Tape (i.e. R2573-M) T Non-insulated installing tools WT110M, WT111M, WT2000, WT112M, ERG-2002, WT112M Thomas & etts Corporation. Specifications are subject to change without notice.

43 Disconnects 1 18RD-187 vinyl insulated installing tools WT145C, WT2000, ERG-2001, ERG-2003, WT112M Series Male Tabs Cat. Pkg. Tab Wire Max Per Dia. No. Qty. Size Range Ins RD x RD x RD x RD x U.L. Listed E66716 Material: brass Finish: tin plated Series Disconnects* Cat. Pkg. Tab Wire Max Per No. Qty. Size Range Ins R18-111F nylon-insulated installing tool WT465 2 R18-110F x R x R18-111F x R x R14-110F x R x R14-111F x R x F non-insulated installing tools WT111M, WT2000, WT112M F x x F x x F x x F x x Sta-on *Not U.L. Listed or CS approved. Material: brass Finish: tin plated Most standard bulk catalog numbers can be put on Mylar Tape for reel fed applications (i.e tool and application dies). See pages Please put the suffix M for Mylar Tape R2573M. (ulk number 1000 and 500 packages.) 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 43

44 Disconnects 1 2 R insulated coupler no tool required Male Series dapters & Coupler Cat. Pkg. Tab Per No. Qty. Size 1000 F250T x FT x R x R x Not U.L. Listed Cat. No. F250T Cat. No. R Material: brass Finish: tin plated Material: brass Finish: none Insulation: vinyl 1 2 Sta-on R18D Nylon-insulated wire barrels installing tool WT2000 (Not U.L.) 14-D non-insulated/insulation grip installing tool WT110M (Not U.L.) Wristlock Disconnects Cat. Pkg. Wire Max. Per No. Qty. Range Ins R18D R R14D R D Not U.L. Listed Note: Not available on Mylar Tape. Nylon Insulated and Non-insulated Picture shows wristlock assemblied as 2 pieces. Parts are sold by the piece not assemblies Thomas & etts Corporation. Specifications are subject to change without notice.

45 Pin Terminals/Vinyl Terminals (Mini-Pack) Sta-on Mini-Pack Terminals Cat. Unit Std. Wire olt No. Qty. Pack. Range Hole Convenient 20-count packaging. Wire ranges from 22 WG to 10 WG. Vinyl Insulated Ring and forked-tongued terminals, female disconnects, butt-type splice connectors. Note: CP designates mini-pack quantities. Refer to other catalog pages for description and dimensional information. 18R-6FCP #6 18R-8CP #8 18R-10CP #10 14R-6CP #6 14R-8CP #8 14R-10CP #10 10RC-10CP #10 10RC-14CP R-8FCP #8 18R-10FCP #10 14R-6FCP #6 14R-8FCP #8 14R-10FCP #10 10RC-8FCP #8 10RC-10FCP R18XCP R14XCP RC10XCP R-250FCP R-250FCP RC-250FCP U.L. Listed E9809 Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 45

46 T& T& Wire Joints Nylon Insulated one piece nylon self-insulated Installing tool WT2000, WT2130 (RC & RP) two piece nylon insulator Installing tool WT161M one piece non-insulated Installing tool WT161M Sta-on wire joints come in one-piece nylon, self-insulated and non-insulated, and a twopiece nylon insulator. Tool applied Crimp on Wire Joints Tool pplied Wire Range Cat. Pkg. Per No. Qty. Min. Max R #18 2# R RC #18 2# RC RP #14 4# RP PT66M 100 2#18 3#12 combination 4 PT6M 100 Insulator only PT60M 100 2#14 3#12 Connector only PT #14 3# PT70M 200 3#18 4# PT #16 4# U.L. Listed E9809 Items on this page sold in multiples of unit packages only. Installation Procedure for PT Connectors Twist wires, insert through serrated barrel of wire joint. (PT60M, PT70, PT70M, PT80). Sta-on Crimp and trim off excess wire with WT161M hand tool Screw PT6 insulator firmly onto PT160M barrel. Cat. llowable Wire Combinations No. #22 #20 #18 #16 #14 #12 # R4/R Cat. llowable Wire Combinations No. #22 #20 #18 #16 #14 #12 # RC6/RC Cat. llowable Wire Combinations No. #22 #20 #18 #16 #14 #12 # RP7/RP Thomas & etts Corporation. Specifications are subject to change without notice.

47 Installing its Wiring Organizer Cat. Std. No. Description Pkg. Wt. ORG2 Heavy Duty Steel Drawer with (17) compartments to hold Sta-on terminals, Color-eyed 1 4 lugs, Ty-Rap cable ties, and other small parts Drawer does not include Thomas & etts products. ORG-2 Sta-it For residential or light commercial installations we recommend this proven assortment of popular Sta-on vinyl terminals. This kit includes a WT112M criming tool. Cat. Std. No. Description Pkg. Wt. STIT 100 2R18X butt splices for WG, R14X butt splices for WG, 50 2RC10X butt splices for WG, 50 10RC-10 ring terminals for WG, 50 10RC-10FL locking fork terminals for WG, 50 10RC-250F disconnects for WG, R-10 ring terminals for WG, R-8FL locking fork terminals for WG, R-250F disconnects for WG, R-8F Fork Terminals for WG, R-6FL locking fork terminals for WG, R-250F disconnects for WG 1 WM-0-9 wire marker book 1 WT112M crimping tool and 100 TY525M Ty-Rap cable ties (approx. length ) (ll splices, terminals and disconnects are vinyl insulated). Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 47

48 pplication Tools Plier Type Tools Cat. Std. Wt. No. Description Pkg. Each WT110M WT110M,, C non-insulated terminal and splices and, non- 1 1 insulated terminals with insulation grip 1 1 WT111M,, C, PT non-insulated terminal and splices WT112M R, R,,, C, non-insulated and RC insulated nylon and 1 1 vinyl terminal and splices WT111M 9-19/32" C ST-ON LUG 22 TO TO 14 C 12 TO 10 M22520/24-01 NOTE: ONLY THIS HNDLE PINTED GREEN WT112M These tools are designed in a variety of styles some with wire cutters and strippers for installation of the various ST-ON terminal series. #22-10 WG wire range. INSTLLS C "C" ST-ON TERMINLS-GUGING INSTLLS " & " ST-ON TERMINLS-GUGING CLOSING INSULTION GRIP ON ON ST-ON "" SIZE TERMINLS ND ND DISCONNECT TIPS. CLOSING INSULTION GRIP ON ST-ON "" SIZE TERMINLS ND DISCONNECT TIPS. TIPS. WT110M Sta-on 1 1/4" CUTTERS ST-ON LUG 22 TO TO 14 C 12 TO 10 WT111M 9 19/32" 2 15/16" PLSTISOL HNDLES INSTLLS & ST-ON TERMINLS GUGING INSTLLS C ST-ON TERMINLS GUGING ORNGE LC 1 1/4 1 1/4" Wire WIRE Cutter CUTTER Wire Cutter Installs C Sta-on terminals-gauging Installs & Sta-on terminals-gauging Closing Insulation Grip on Sta-on size terminals and disconnect tips. Closing Insulation Grip on Sta-on size terminals and disconnect tips. THOMS & ETTS FOR, & C ST-ON TERMINLS WT 112M CRIMPING Crimping NEST FOR Nest for INSULTED ST-ONS insulated Sta-ons CRIMPING Crimping NEST FOR Nest for NON-INSULTED ST-ONS non-insulated Sta-ons 2-15/16 15/16" PLSTISOL HNDLE HNDLE GRIPS GRIPS LC & ORNGE COLOR: LC & ORNGE WT111M WT112M Cutters Installs & Sta-on terminals gauging Installs C Sta-on terminals gauging Installs insulated and non-insulated Sta-on terminals, splices, disconnects, and wire joints WG Thomas & etts Corporation. Specifications are subject to change without notice.

49 8 pplication Tools Plier Type Tools (Continued) Cat. Std. Wt. No. Description Pkg. Each WT161M WT161M,, C, PT non-insulated terminal and splices 1 1 WT2000,, C:, PT, R, R, RC insulated and non-insulated terminal and splices 1 WT2000 These tools are designed in a variety of styles some with wire cutters and strippers for installation of the various ST-ON terminal series. #22-10 WG wire range. LC PLSTISOL COTED HNDLE Insulation INSULTION Crusher CRUSHER PLIER Plier CRIP Grip CUTTERS Cutters HNDLE Handle RETURN Return WIRE CUTTER SPRINGS Spring Wire Cutter Wire WIRE STRIPPER Stripper Latch LTCH HNDLE Handle GRIPS Grips Cushion CUSHION Grip GRIP Handle HNDLE NON INSUL INSUL C STR SOL /16" ORNGE PLSTISOL COTED HNDLE Installing ST-ON Nest INSTLLING NEST WIRE Wire CUTTER Cutter CRIMP Crimp INDICTOR Indicator GUGE Gauge CRIMPING Crimping NEST Nest FOR for INSULTED insulated Crimping Nest for non-insulated WT161M Installs,, and C size (#18-#10 wire) Sta-on terminals, splices, and wire joints (PT-60M and PT-70). WT2000 Wire Cutter No. 10 WG and smaller solid or stranded wire. Crimping Nests Insulated and non-insulated Sta-on terminals, splices and wire joints on No. 22 to No. 10 WG, solid or stranded wire. Cutters Chasing feature for screws, sizes 4-40, 6-32, 8-32, 10-24, Wire Stripper Removes most types of insulation from No WG stranded wire and No WG solid wire. Sta-on 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 49

50 pplication 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. Shure-Stake mechanism helps to ensure a complete crimp cycle before it releases the tool. dvanced ergonomic design of handle distributes the force more evenly across the hand. Rubberized thermoplastic handle combines maximum friction with a soft, comfortable feel that reduces muscle tension. Comfort Crimp Terminal Tool Concerned about safety? Down time? Health care costs? Thomas & etts 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 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 terminal tool. It s such a relief you won t want to handle any other tool ever again. ERG-2001 Sta-on ERG-2002 ERG-2003 Our ERG-2003 WG two-nest model is designed to perform 85% of your terminations with even less handle force than our ERG For the additional WG range, specify our three-nest insulated or non-insulated Comfort Crimp tool Thomas & etts Corporation. Specifications are subject to change without notice.

51 pplication Tools NEW ERG-2001 Comfort Crimp Terminal Tool Cat. Std. No. Description Pkg. ERG-2001 R, R, RC Nylon & vinyl terminals, splices & disconnects 1 ERG-2002,, C Non-insulated terminals, splices, disconnects 1 ERG-2004 C and C Flag terminal Flag terminal and,, C non- 1 insulated terminals, splices, disconnects ERG-2005, C, D Non-insulated terminals, splices, (D tubular only) 1 ERG-2007 RD & RE Insulated terminals (Except razed Seam) 1 ERG-2008 Non-insulated terminals #8 WG - 1/0 WG 1 ERG-2008 Terminal locator Shure-Stake release on ON OTH SIDES both sides Tool Gaging Requirements Gaging Cat. No. Nest Min.-Max. (22-18) Nest T (16-14) Nest T T (12-10) C Nest Installs nylon and vinyl insulated terminals, disconnects, and splices 22-10/22-14 WG. The force required to release the Shure-Stake mechanism should be no less than 15 lbs. (12-10) C Nest T (16-14) Nest T (22-18) Nest T ST-ON CT. NO. ERG-2002 Shure-Stake release on both sides Installs Non-insulated Terminals, Disconnects, and Splices WG. The force required to release the Shure-Stake mechanism should be no less than 15 lbs. ERG-2001 R R RC ERG C ERG C ERG C D ERG (RED) (LUE) ERG-2008 Self-Contained 8WG - 1/0 WG Rotating Die Gauges available from T& Tool Service ERG-2001/ERG-2003 Sta-on Nest Gaging Min.-Max. PUSH Red lue Yellow Installs Non-insulated Terminals #8 WG - 1/0 WG. UL Listed crimp per UL standard 486C on tubular D, E, F, G, and H style Sta-on Terminals. ERG-2002 Nest Gaging Min.-Max C Thomas & etts Corporation. Specifications are subject to change without notice. 51

52 pplication Tools Rachet Hand Tools Cat. No. Description WT145 R, RX, R, RC, RC, R, R, RC, RCC nylon terminal UPPER NEST LOWER NEST ECFSDJ LJSLSDL JSD SDFJJFLL LLJ WT145 Installs R, R, RC, RC nylon terminals. Correct compression every time-the Shure- Stake mechanism principle prevents opening of the handles until full staking action is completed. Installs self-insulated and non-insulated Sta-on terminal series in the #26-10 WG 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 mechanism should be lbs. LOCTOR SCREW Locator Go, GO, No-Go NO-GO Gage GGE Load LOD ar R UPPER Upper NEST Nest Lower LOD Nest R WT145 Nest Gaging Min.-Max. Upper Lower Sta-on Rachet Hand Tools (Continued) Cat. No. Description WT145C R, R, RC, R, R, RCC, RC nylon and vinyl terminals, splices and disconnects 1 Nest Gaging Min.-Max. Upper Lower WT145C Correct compression every time-the Shure-Stake mechanism principle prevents opening of the handles until full staking action is completed. Installs self-insulated and non-insulated Sta- on terminal series in the #26-10 WG wire range. Installs R, R, RC nylon terminals, disconnects, splices and R, R, RC vinyl terminals, disconnects, splices. The force required to release the Shure-Stake mechanism should be 10 lbs. minimum. Upper Nest UPPER NEST Lower Nest LOWER NEST LOCTOR Go, No-Go Gage GO. NO GO GGE Thomas & etts Corporation. Specifications are subject to change without notice.

53 pplication Tools Rachet Hand Tools (Continued) Cat. Std. No. Description Pkg. WT1377 NW Ring Terminals 1 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 completed. Installs self-insulated and non-insulated Sta-on terminal series in the #26-10 WG wire range. 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., series term. CUTION: HNDLES RE CUTION: NON-INSULTIONG. HNDLES RE DO NON-INSULTING. NOT CRIMP ENERGIZED DO NOT CRIMP WIRES. ENERGIZED WIRES. NW20, NW50 SERIES TERMINLS SEE GGING TLES NW20, NW50 series terminals NW80 series terminals NW80 SERIES gaging TERMINLS gaging SEE GGING TLES NW20 NW50 NW80 SHURE STE MECHNISM SHURE-STE MECHNISM RELESE OPPOSITE SIDE RELESE OPPOSITE SIDE Installs RZ, RV Terminals (26-22 WG wire) and Splices. Ratchet Hand Tools (Continued) Cat. Std. No. Description Pkg. WT1452 Installs RZ, RV Terminals/Splices 1 Min. Gage Max. Gage Nest Go No-Go T RZ, RV #26-# Sta-on Thomas & etts T GGING Gaging #26-#22 GGING Gaging WT Thomas & etts Corporation. Specifications are subject to change without notice. 53

54 pplication Tools Rachet Hand Tools (Continued) Cat. Std. No. Description Pkg. WT465 R, R.110 insulated disconnects 1 WT465 N1 Installs.110 R, R disconnects. Pre-load requirement: lbs. FORCE 1 3/4 N9 N FORCE Rachet Hand Tools (Continued) Cat. Std. No. Description Pkg. WT1255 R, R, RC Heat Shrinkable nylon insulated terminals, butt splices and disconnects 1 Pre-load 35 to 45 pounds. WT WT1255 Nest Gaging /086 Sta-on CONDUCTOR CRIMP RE / /.149 STRIPPING LENGTH RED & LUE = 1/4" YELLOW = 11/32" STRIPPED WIRE Rachet Hand Tools (Continued) Cat. Std. No. Description Pkg. WT2130 Installs RC, RC, RD, Sta-on terminals and RC6 and RP7 wire joints. The force required to release the Shure-Stake mechanism should be 20 lbs. minimum CT. NO. WT2130 FOR INSTLLING SELF-INSULTED ST-ON TERMINLS ON COPPER WIRE NON-INSULTING GRIP THOMS & ETTS CORPORTION WT2130 RC, RC, and RD insulated terminal #14-#8 1 WT2130 Gaging Nest Min.-Max Thomas & etts Corporation. Specifications are subject to change without notice.

55 pplication Tools Ratchet Hand Tools (Continued) Cat. Std. Wt. No. For Use With Sta-on Series Pkg. Each WT3185 For 8 WG to 250 MCM non-insulated Sta-on terminals 1 WT3185 Installation and Gaging Procedure djustable Crimper Gaging Procedure 1. Close the tool jaws until they bottom. 2. Select the side of tool to be gaged (Tubular or razed seam) 3. Move indentor until the pointer slot aligns (click) with the selected cable size: For brazed seam connector use 6 WG. For tubular connectors use 2/0. 4. Gage the crimping area with a suitable pin gage. The gage diameter must fall within tubular and for 6 WG. 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 If the distance is 14" 1/2" the tool is adjusted properly. If not, the tool should be adjusted. Pre-load djustment Procedure 1. Turn djustment screw clockwise to increase handle spread and counterclockwise to decrease handle spread. (refer to figure 3.) Installs Thomas & etts Sta-on terminals series D, E, F, and G. Toggle Type Hand Tools Cat. Std. Wt. No. For Use With Sta-on Series Pkg. Ea. WT115 D, E, F, & G non-insulated terminals 1 4 FRME DOWEL PIN Sta-on DOWEL PIN HNDLE DOWEL PIN INDENTOR WT115 Flag Terminal Type Hand Tool Cat. Std. No. Description Pkg. Installs Thomas & etts Sta-on terminals series D, E, F, and G flag terminals. WT129 D, E, F, & G non-insulated flag terminals 1 WT115 & WT129 Nest Gaging D.E.F.G. D, E, NESTSF, G Nests D.138 ±.005 E.170 ±.005 F.192 ±.005 G.222 ± Thomas & etts Corporation. Specifications are subject to change without notice. 55

56 pplication Tools Toggle Type Hand Tools (Continued) Cat. Std. Wt. No. For Use With Sta-on Series Pkg. Ea. TM6 TM6 D thru M (Dies not included) RD thru RM 1 9 TM6S D thru M (Dies not included) RD thru RM with Shure-Stake 1 9 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. MOVLE JW LOWER DIE UPPER DIE TM6, TM6S TOOL HED Sta-on Nest NEST Indentor INDENTOR GGING Gaging Use in installing tool Cat. No. TM6 and TM6S. Gaging GGING Use in installing tool Cat. No. TM6 & TM6S. Installing Dies for Non-Insulated Code and ircraft Sta-on Terminals Cat. No. Nest Indentor Stationary Movable Term. Gaging Die Die Size ± D E (Tubular) E (rrazed), F (Tubular) F (razed), G H J L M.312 Installing Dies for Nylon Insulated Sta-on Terminals TM6 & TM6S Tool Cat. No. Term. Gaging Die Set Size ± RD RE RF RG RH RJ R RL RM.554 TM60RS Short Handle Ratchet Tool Cat. Std. Wt. No. For Use With Sta-on Series Pkg. Ea. TM60RS D thru M (Uninsulated terminals) 1 6 RD thru RM (Insulated terminals) For more information, see page 5. 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 Thomas & etts Corporation. Specifications are subject to change without notice.

57 pplication Tools Shure-Stake uto-feed Tool Cat. Std. No. Description Pkg Compact, pneumatically operated unit for crimping tape-mounted ST-ON 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 WG ir Pressure psi input air supply Safety Features Fully guarded foot pedal. Dies color matched to terminals. Clear plastic safety guard over die area. utomatic tool shut-down when safety guard is removed. Ram UP emergency switch. Crimping tape-mounted ST-ON terminals. Wire Range #26 - #10 WG. GGING Gaging Installing Dies for Insulated Terminals Gaging Max. Sta-on WG Die Gaging Insul. Terminal Type Wire Size Cat. No. Min.-Max. Dia. R Nylon / R Vinyl 12054*.117/ R Nylon / R Vinyl 12055*.122/ RC Nylon and / Vinyl Insulated Non-Insulated /.068 Non-Insulated /.090 C Non-Insulated /.134 C Disconnect, Non-Insul /.111 RV RZ /.081 * Can also be used on nylon. Sta-on Non-insulated Terminals 2002 Thomas & etts Corporation. Specifications are subject to change without notice. 57

58 pplication Tools Sta-on Die release knob cuts power to the tool head and protects fingers when changing die sets. Quickly interchangeable dies accommodate Sta-on terminals from 22 to 6 WG series connectors. LEDs on tool head indicate when a work cycle is complete and the tool head is ready. Low force actuating button initiates and completes the crimping work cycle. Swiveling tool head allows positioning for maximum comfort and convenience. Control lever opens the dies, allowing terminal to be inserted for crimping. Tough PanaVise benchmount clamp holds tool head securely. ase power unit houses the hydraulic pump, fluid reservoir, and electronic control unit. Closed system for low maintenance. Easy-to-see lamps indicate when the ERG 3000 is ready to operate. Separate C adapter can be used for bench mount or stationary application. Foot pedal allows for hands-free crimping, resting wrists and allowing for increased speed. Power Operated Installing Tools There s a portable crimping tool that is designed to reduce the stress traditional hand tools put on wrist muscles. Thomas & etts ERG 3000 uses battery-powered hydraulics instead of muscle power to install Dragon Tooth terminals safely and securely. In addition, our power crimping tool is engineered to substantially reduce the weight in the tool head, which is in the user s hand, to further reduce fatigue. ecause the ERG 3000 is constructed with the battery in the separate base unit, the tool head itself is very light and compact enabling it to operate in tight quarters other power tools can t reach. ecause there is no manual or physical force required, the ERG 3000 s ergonomic design dramatically reduces the risk of carpal tunnel syndrome that can occur with repetitive handcrimping. nd, by significantly reducing muscle fatigue, the ERG 3000 can lead to increased productivity over traditional hand crimping tools. Tests conducted showed that the ERG 3000 increased productivity more than 50% when used in actual working situations. Short cycle times help speed work. Depending on the size of the terminal being installed, the ERG 3000 has an exceptionally fast cycle time of just one to three seconds. dd this to its ergonomic design and convenient portability, and you have a tool that makes installing Dragon Tooth connectors terminals faster and easier than ever. Standard Components Cat. No. Description Wt. (lb.) ERG-3001* ase Unit 11.0 ERG-3002* Hose & Tool Head ssembly 3.5 ERG-3003 NiCd attery 1.3 ERG min. attery Charge 3.0 ERG-3005 Carrying Case 6.3 ERG-3006 C dapter 7.0 ERG-3007 enchmount 1.0 ERG-3008 Foot Switch 2.5 ERG-3000 Complete it (see note below) 26.4 *Cannot be purchased separately. Technical data for the ERG 3000 ase Unit Working pressure 3625 psi Power supply NiCd attery 12 V DC or C/DC converter 110 V 60 Hz Work cycle 1-3 seconds Weight (with battery) 11 lb. (without tool/hose pack) 13.77" L x 7.28" W x 5.12" D Temperature range -4 to 122 F Tool Head ssembly Press force 3372 lb. Weight (tool only) 1.65 lb. Diameter of handle 1.61 in. Length of handle 8.86 in. Length of hose 7.22 ft. attery Type NiCd 12 V, rechargeable Recharging time 15 min. Number of recharges 1000 Dies for ERG-3000 Cat. No. Description ERG-86 Die Set for Non-insulated 8 and 6 WG ERG-86i Die Set for Insulated 8 and 6 WG ERG-2214 Die Set for Non-insulated WG ERG-2214i Die Set for Insulated WG ERG-1210 Die Set for Non-insulated WG ERG-1210i Die Set for Insulated WG Thomas & etts Corporation. Specifications are subject to change without notice.

59 pplication Tools ir Operated ench Mounted Tools Cat. Std. No. Description Pkg This compact heavy duty air tool installs nylon and TEFZEL insulated Sta-on 1 terminals on wire sizes from 8 WG 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 TM6 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. n psi air pressure source is required. Nest NEST Indentor INDENTOR GGING Gaging 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. Gaging GGING Installing Dies for Non-Insulated Code and ircraft Sta-on Terminals for tool Cat. No. Cat. No. Nest Indentor Stationary Movable Term. Gaging Die Die Size ± D E F G H J L M.312 Sta-on Installing Dies for Nylon Insulated Sta-on Terminals for tool Cat. No. Term. Gaging Die Set Size ± RD RE RF RG RH RJ R RL RM Thomas & etts Corporation. Specifications are subject to change without notice. 59

60 pplication Tools ir Operated ench Mounted Tools Cat. Std. No. Description Pkg Heavy duty, high speed production tool installs a wide range of Sta-on terminals, from gauge; uses the air tool dies for both non-insulated and insulated terminals; is supplied complete with foot pedal, air hose-air/lubricator ST-ON terminals, insulated and non-insulated #22 thru #10 ire range. ST-ON Installing Dies for Tool, Die Wire Type Installs Cat. No. Range Gaging Crimp Term. Type , 22 WG.062/.070,.081/.089,.106/.114 Double Indent,, I,, I, C, CC, CIC /.096 Elliptical R4 Wire Joint /.120 Elliptical RC6 Wire Joint /.096, 112/.120 Elliptical R4, RC , 22 WG.105/.109, 125/.129 Elliptical R, R Nylon & Vinyl , 12 WG.160/.166 Elliptical RC Nylon & Vinyl { ir Hydraulic Tool Cat. No. Description Closed yoke; hand actuated Closed yoke; foot actuated Open C yoke; hand actuated Open C yoke; foot actuated Cat. Nos and also require two (2) Cat. No air hoses and one (1) Cat. No foot valve. Cat. Nos and require one (1) Cat. No air hose. Sta-on Thomas & etts Corporation. Specifications are subject to change without notice.

61 pplication Tools Twelve Ton Crimping Tool Cat. Std. No. Description Pkg Twelve ton crimping tool for installing both insulated and noninsulated Sta-on terminals 1 #8 to 250 MCM (dies ordered separately) FORGED STEEL Twelve Ton Crimping Tool (Military Spec. MS ) Cat. Std. No. Description Pkg M Hydraulic operated 12 to press installs D size through M size Sta-on terminals on N 1 copper wire Hex Dies for 13642M & M Die Cat. No. For For Hex Tubular razed Sta-on Wire Die Term Seam Size Size Code Gaging D ± ± E ± ± F ± ± G ± H 1/ ± J 2/ ± / ± L 4/ ± M 250 MCM ±.004 Sta-on Hex Dies for 13642M (Military Listed) Die Sta-on Wire Cat. No. Size Size Gaging 11781M D 8N M E 6N M F 4N M G 2N M H 1N M J 1/0N M 2/0N M L 3/0N M M 4/0N Thomas & etts Corporation. Specifications are subject to change without notice. 61

62 Installation Dies 1-29/32" REF. COLOR CODE IN COUNTERORE 2" REF. N-WIRE SIZE IS ENGRVED ON THIS SURFCE Installing Dies for Insulated Terminals to fit 13642M (Military Listed) Cat. No. Gaging 21707M M M M M M M M M Gaging for Installing Dies Used to Install Flag Type Sta-on Terminals Use With 13642M & Nest Indentor Sta-on Gage Cat. No. Cat. No. Size Min. Max / ** 2/ ** 3/ ** 4/ Sta-on CT. NO. STMPED ON OTH HLVES ** Cat. Nos , and dies must be left in head with indentor when gauging. Nest and Indentor for Installing One Piece Non-insulated Terminals to Fit 13642M & Indentor Nest Terminal Cat. No. Cat. No. Gaging Series G H J L M Nest and Indentors for Installing Sta-on razed Seam Type Non-insulated Terminals to Fit 13642M & Nest Indent. Sta-on Code Cat. No. Cat. No. Size Wire Dia D 8.153/ E 6.183/ F 4.214/ Thomas & etts Corporation. Specifications are subject to change without notice.

63 pplication Tools Electric Hydraulic Pump Cat. Std. No. Description Pkg Electric hydraulic pump, psi with Shure-Stake mechanism feature; 1 this is a heavy duty OEM pump with high flow rate; 115V, 60Hz, HP, 23 mps; requires hand or foot control Hand Switch for Foot Switch for High Pressure, steel reinforced hydraulic hose; 6 ft High Pressure, steel reinforced hydraulic hose; 10 ft High Pressure, plastic hydraulic hose; 10 ft This electric hydraulic pump is for use with all T& 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 ft. Non Metallic Hose ft. Non Metallic Hose remote control switch is required. Order Cat. No for hand operation or Cat. No for foot operation. ll pumps are supplied with a metal carrying case 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 Hand Switch 10 ft Foot Switch 10 ft In line hydraulic pressure inspection gage with male and female pioneer type coupler remote control switch is required to operate this unit. Use either a #13611 (hand) or #13612 (foot) switch. Sta-on Thomas & etts Corporation. Specifications are subject to change without notice. 63