Page 1
3M
™
Cold Shrink QT-III Silicone
Rubber Skirted Termination Kit
With High-K Stress Relief
For Tape Shielded, Wire Shielded and UniShield® Cable
7685-S-8
Instructions
IEEE Std. No. 48
Class 1 Termination
35 kV Class
200 kV BIL
F CAUTION
Working around energized systems may cause serious injury or death. Installation should
be performed by personnel familiar with good safety practice in handling electrical
equipment. De-energize and ground all electrical systems before installing product.
January 2013
78-8119-6018-2 Rev C 3
Page 2
1.0 Kit Contents
3 High-K, Tracking Resistant, Silicone Rubber Terminations
3 Pre-formed Ground Braids
3 Constant Force Springs
3 3M™ EMI Copper Foil Shielding Tape 1181 Strips, 1/2" x 10"
6 Strips Scotch® Mastic Strip 2230 (black with white release liners, bagged)
1 3M™ Cable Cleaning Preparation Kit CC-2
1 Instruction Sheet
NOTE: Do Not use knives to open plastic bags.
Kit Selection Table
NOTE: Final Determination Factor is cable insulation diameter.
Kit Number
7685-S-8
Primary Insulation
O.D. Range
1.05" - 1.80"
(26,7 - 45,7 mm)
Jacket O.D. Range
1.39" - 2.40"
(35,3 - 61,0 mm)
Table 1
Conductor Size Range (AWG & kcmil)
15 kV 25/28 kV 35 kV
500 - 1000 kcmil
(240 - 500 mm2)
250 - 800 kcmil
(125 - 400 mm2)
3/0-600 AWG
(95 - 325 mm2)
2 78-8119-6018-2 Rev C
Page 3
Instructions For Tape Shielded Cable
2.0 Prepare Cable
2.1 Check to be sure cable size fits within kit size range as shown in Table 1.
2.2 Prepare cable using dimensions shown in Figure 1. Refer to Table 2 for semi-con cutback dimension.
BE SURE TO ALLOW FOR DEPTH OF TERMINAL LUG. If necessary to prevent tape shield from
unrolling, hold down edge with a single wrap of 3M™ EMI Copper Foil Shielding Tape 1181.
NOTE: Provide additional exposed conductor distance to account for growth during crimping of ALUMINUM
lugs or connectors as follows:
Aluminum Connector
Growth Allowance
NOTE: It is imperative to remove all remnants of the semi-con layer, even if the semi-con layer comes off as one
layer. There should not be any remaining black areas, or particles, on the cable insulation layer.
Kit Number Insulation 0.D.
1.05" -1.46"
7685-S-8
(26,7 - 37,1 mm)
1.24" - 1.80"
(31,5 - 45,7 mm)
2 - 350
1/4” (6 mm)
15 kV
AWG / kcmil
500-700
(240 - 400 mm2)
750-1000
(400 - 500 mm2)
3” (76 mm)
400 - 650
1/2" (13 mm)
25/28 kV
AWG / kcmil
250-500
(125 - 250 mm2)
600-800
(300 - 400 mm2)
Table 2
Jacket Removal Length
Depth Of Terminal Lug + Growth Allowance
Semi-Con Cutback
35 kV
AWG / kcmil
3/0-350
(95 - 150 mm2)
500-600
(185 - 325 mm2)
750–1000
3/4" (19 mm)
Semi-con
Cutback
13.5"
(342,9 mm)
13.0"
(330,2 mm)
1 1/ 2”
(38 mm)
Semi-Con
Tape Shield
Cable Jacket
Figure 1
78-8119-6018-2 Rev C 3
Page 4
3.0 Install Ground Braid
3.1 Select a Scotch® Mastic Strip 2230 from kit and remove white release liners. Using light tension, apply a
SINGLE WRAP of mastic around the cable jacket 1/4" (6 mm) from cut edge (Figure 2). Cut off excess.
1/4” (6 mm)
Semi-Con
Tape Shield
1ST Scotch® Mastic Strip 2230
Cable Jacket
Figure 2
3.2 Position pre-formed ground braid with short tail over tape shield directly adjacent to cable jacket cut edge.
PLEASE NOTE: The ground braid needs to make full contact with the metallic shield. Position long tail of
ground braid, extending over cable jacket with solder block over mastic strip (Figure 3). Secure ground braid to
cable jacket 4 l/2" (114 mm) from cable semi-con edge using vinyl tape (Figure 3).
NOTE: Position vinyl tape with care, it also serves as a marker for positioning the termination.
4 1/2 (1
Vinyl Tape Marker
14 mm)
Semi-Con Edge
Tape Shield
Ground Braid
Cable Jacket Edge
Solder Block
1ST Scotch® Mastic Strip 2230
Figure 3
4 78-8119-6018-2 Rev C
Page 5
3.3 Wrap ground braid around cable tape shield one complete wrap, trim excess to prevent overlap and secure in
place with constant force spring. Wrap spring in same direction as ground braid (Figure 4). Cinch (tighten) the
spring after wrapping the final winding.
3.4 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE
WRAP of mastic over solder block on ground braid and previously applied mastic (Figure 4). Cut off excess.
Constant Force Spring
Tape Shield
Ground Braid
1ST Scotch® Mastic Strip 2230
Solder Block
2ND Scotch® Mastic Strip 2230
Trim
Cable
Tape
Shield
Ground Braid Leg
Figure 4
3.5 Wrap two highly stretched half-lapped layers of electrical grade vinyl tape around mastic seal, constant force
spring and exposed tape shield (Figure 5).
NOTE: Take care not to cover exposed semi-con insulation shield. A minimum of 1" (25 mm) must be exposed.
SPECIAL NOTE FOR CLOTH OR PAPER SEMI-CON INSULATION SHIELD
In cables with cloth or paper semi-conductive shields, it is recommended the shield be over wrapped with one halflapped layer of highly stretched semi-conductive rubber tape such as Scotch® Electrical Semi-Conducting Tape 13.
Semi-Con
Tape Shield
Constant Force Spring
Two Half-Lapped Layers of Electrical Grade Vinyl Tape
Scotch® Mastic Strip 2230
ape Marker
Vinyl T
Figure 5
78-8119-6018-2 Rev C 5
Page 6
4.0 Install Lug or Connector
4.1 Check to insure 3M™ Cold Shrink QT-III Silicone Rubber Termination assembly fits over the selected lug
or connector. If lug or connector (Figure 6) will not fit through the termination core, clean the insulation
(per Step 5.0) and slide termination on cable before installing lug or connector.
DO NOT REMOVE CORE AT THIS TIME.
Clearance
Connector/Lug
Figure 6
NOTE: Refer to pages 19-21 for 3M™ Connector and Lug crimping information.
NOTE: For Aluminum Conductors - Thoroughly wire brush conductor strands to remove aluminum oxide layer.
Immediately insert conductor into lug or connector barrel as far as it will go.
4.2 Position connector or lug and crimp according to manufacturer's directions. Remove excess oxide inhibitor and
sharp crimp flashings following crimping.
5.0 Clean Cable Insulation and Lug or Connector Barrel Using Standard Practice
5.1 Wipe the cable insulation with one of the solvent saturated pads from the 3M™ Cable Cleaning Preparation Kit
CC-2. DO NOT ALLOW SOLVENT TO TOUCH SEMI-CON INSULATION SHIELD!
5.2 If abrasive must be used:
a. Use on insulation only. DO NOT USE ABRASIVE ON SEMI-CON INSULATION SHIELD!
b. Use only aluminum oxide abrasive; grit 120 or finer, included in the 3M™ Cable Cleaning Preparation Kit
CC-2.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.
6 78-8119-6018-2 Rev C
Page 7
6.0 Install Termination
6.1 Slide the termination body onto the cable and remove core. Pull while unwinding, counter-clockwise, starting
with the loose end (Figure 7). Make sure the termination body (not the core) is butted up to the edge of the
vinyl tape marker previously applied (Figure 7).
NOTE: Once the termination body makes contact over the mastic seal area, there is no need to continue
supporting the assembly. DO NOT PUSH OR PULL ON THE TERMINATION ASSEMBLY WHILE UNWINDING
THE CORE.
Counter-Clockwise
Vinyl Tape Marker
The material being removed at this step is mixed polymersNOTE:
waste.and can be recycled with
Figure 7
6.2 Connect ground braid to system ground according to standard practice.
Correct Installation of Termination on Tape Shielded Cable
Vi nyl Tape
Marker
Ridge at End
of High-K Tube
Semi-Con Insulation Shield
Stress Controlling Compound
Ridge at End of Cable
Insulation Shield (Semi-Con)
Cable
Insulation
Conductor
Envioronmental
Seal
High-K Stress
Relief Tube
Top
78-8119-6018-2 Rev C 7
Page 8
Instructions for Wire Shielded Cable
7.0 Prepare Cable
7.1 Check to be sure cable size fits within kit size range as shown in Table 1.
7.2 Prepare cable using dimensions shown in Figure 8 and 9. Refer to Table 3 for semi-con cutback dimension.
BE SURE TO ALLOW FOR DEPTH OF TERMINAL LUG.
NOTE: Provide additional exposed conductor distance to account for growth during crimping of ALUMINUM
lugs or connectors as follows:
Aluminum Connector
Growth Allowance
2 - 350
1/4” (6 mm)
400 - 650
1/2" (13 mm)
750–1000
3/4" (19 mm)
NOTE: It is imperative to remove all remnants of the semi-con layer, even if the semi-con layer comes off as one
layer. There should not be any remaining black areas, or particles, on the cable insulation layer.
Kit Number Insulation 0.D.
1.05" -1.46"
7685-S-8
(26,7 - 37,1 mm)
1.24" - 1.80"
(31,5 - 45,7 mm)
15 kV
AWG / kcmil
500-700
(240 - 400 mm2)
750-1000
(400 - 500 mm2)
Table 3
Depth Of Terminal Lug + Growth Allowance
3 (76 mm)
25/28 kV
AWG / kcmil
250-500
(125 - 250 mm2)
600-800
(300 - 400 mm2)
Jacket Removal Length
Semi-Con Cutback
35 kV
AWG / kcmil
3/0-350
(95 - 150 mm2)
500-600
(185 - 325 mm2)
Semi-con
Cutback
13.5"
(342,9 mm)
13.0"
(330,2 mm)
Semi-Con
Shield Wires
Cable Jacket
Figure 8
7.3 Bend leading 1 1/2" (38 mm) of exposed shield wires back upon themselves to jacket edge (Figure 9).
3 (76 mm)
1 1/2 (38 mm)
Semi-Con
Cable Jacket
Figure 9
8 78-8119-6018-2 Rev C
Shield Wires
Page 9
8.0 Install Ground Braid
8.1 Select a Scotch® Mastic Strip 2230 from kit and remove white release liners. Using light tension, apply a
SINGLE WRAP of mastic around the cable jacket 1/4" (6 mm) from cut edge (Figure 10). Cut off excess.
1/4" (6 mm)
Semi-Con
1ST Scotch® Mastic Strip 2230
Cable Jacket
Figure 10
8.2 Position pre-formed ground braid with short tail over wire shield directly adjacent to cable jacket cut edge.
Position long tail of ground braid, extending over cable jacket with solder block over mastic strip (Figure 11).
Secure ground braid to cable jacket 4 1/2" (114 mm) from cable semi-con edge using vinyl tape (Figure 11).
NOTE: Position vinyl tape with care, it also serves as a marker for positioning the termination.
4 1/2
Vinyl Tape Marker
(114 mm)
Cable Jacket Edge
Solder Block
1ST Scotch® Mastic Strip 2230
Semi-Con Edge
Shield Wire
Ground Braid
Figure 11
78-8119-6018-2 Rev C 9
Page 10
8.3 Wrap ground braid around cable shield wires one complete wrap, trim excess to prevent overlap and secure in
place with constant force spring. Wrap spring in same direction as ground braid (Figure 12). Cinch (tighten) the
spring after wrapping the final winding.
8.4 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE
WRAP of mastic over solder block on ground braid and previously applied mastic (Figure 12). Cut off excess.
Constant Force Spring
Shield Wires
Ground Braid
1ST Scotch® Mastic Strip 2230
Solder Block
2ND Scotch® Mastic Strip 2230
Ground Braid Leg
Trim
Cable
Wire
Shield
Figure 12
8.5 Wrap two highly stretched half-lapped layers of electrical grade vinyl tape around mastic seal, constant force
spring and exposed shield wires (Figure 13).
NOTE: Take care not to cover exposed semi-con insulation shield. A minimum of 1" (25 mm) must be exposed.
1 1/2 (38 mm)
Semi-Con
Shield Wires
Constant Force Spring
Two Half-Lapped Layers of Electrical Grade Vinyl Tape
Scotch® Mastic Strip 2230
Vinyl Tape Marker
Figure 13
10 78-8119-6018-2 Rev C
Page 11
9.0 Install Lug or Connector
9.1 Check to insure 3M™ Cold Shrink QT-III Silicone Rubber Termination assembly fits over the selected lug or
connector. If lug or connector (Figure 14) will not fit through the termination core, clean the insulation (per
Step 10.0) and slide termination on cable before installing lug or connector. DO NOT REMOVE CORE AT
THIS TIME.
Figur e 14 Clearance
Connector/Lug
Figure 14
NOTE: Refer to pages 19 -21 for 3M™ connector and lug crimping information.
NOTE: For Aluminum Conductors - Thoroughly wire brush conductor strands to remove aluminum oxide layer.
Immediately insert conductor into lug or connector barrel as far as it will go.
9.2 Position connector or lug and crimp according to manufacturer's directions. Remove excess oxide inhibitor and
sharp crimp flashings following crimping.
10.0 Clean Cable Insulation and Lug or Connector Barrel Using Standard Practice
10.1 Wipe the cable insulation with one of the solvent saturated pads from the 3M™ Cable Cleaning Preparation Kit
CC-2. DO NOT ALLOW SOLVENT TO TOUCH SEMI-CON INSULATION SHIELD!
10.2 If abrasive must be used:
a. Use on insulation only. DO NOT USE ABRASIVE ON SEMI-CON INSULATION SHIELD!
b. Use only aluminum oxide abrasive; grit 120 or finer, included in the 3M™ Cable Cleaning Preparation Kit CC-2.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.
78-8119-6018-2 Rev C 11
Page 12
11.0 Install Termination
11.1 Slide the termination body onto the cable and remove core. Pull while unwinding, counter-clockwise, starting
with the loose end (Figure 15). Make sure the termination body (not the core) is butted up to the edge of the
vinyl tape marker previously applied (Figure 15).
NOTE: Once the termination body makes contact over the mastic seal area, there is no need to continue
supporting the assembly. DO NOT PUSH OR PULL ON THE TERMINATION ASSEMBLY WHILE
UNWINDING THE CORE.
Counter-Clockwise
Vinyl Tape Marker
The material being removed at this step is mixed polymersNOTE:
waste.and can be recycled with
Figure 15
11.2 Connect ground braid to system ground according to standard practice.
Correct Installation of Termination on Wire Shielded Cable
Vi nyl Tape
Marker
Ridge at End
of High-K Tube
Semi-Con Insulation Shield
Stress Controlling Compound
Ridge at End of Cable
Insulation Shield (Semi-Con)
Cable
Insulation
Conductor
Envioronmental
Seal
High-K Stress
Relief Tube
Top
12 78-8119-6018-2 Rev C
Page 13
Instructions for UniShield® Shielded Cable
12.0 Prepare Cable
12.1 Check to be sure cable size fits within kit size range as shown in Table 1.
12.2 Prepare cable using dimensions shown in Figure 16, 17 and 18. Refer to Table 4 for dimension [A]. BE SURE
TO ALLOW FOR DEPTH OF TERMINAL LUG.
NOTE: Provide additional exposed conductor distance to account for growth during crimping of ALUMINUM lugs or
connectors as follows:
Aluminum Connector
Growth Allowance
Kit Number Insulation 0.D.
1.05" -1.46"
7685-S-8
12.3 Install constant force spring as shown in Figure 16. Pull shield wires through semi-conductive jacket to leading
edge of constant force spring (Figure 16).
(26,7 - 37,1 mm)
1.24" - 1.80"
(31,5 - 45,7 mm)
2 - 350
1/4” (6 mm)
15 kV
AWG / kcmil
500-700
(240 - 400 mm2)
750-1000
(400 - 500 mm2)
Table 4
400 - 650
1/2" (13 mm)
25/28 kV
AWG / kcmil
250-500
(125 - 250 mm2)
600-800
(300 - 400 mm2)
Depth Of T
erminal Lug + Growth Allowance
750–1000
3/4" (19 mm)
35 kV
AWG / kcmil
3/0-350
(95 - 150 mm2)
500-600
(185 - 325 mm2)
Dimension [A]
13.5"
(342,9 mm)
13.0"
(330,2 mm)
Constant Force Spring
Shield Wires
Figure 16
78-8119-6018-2 Rev C 13
[A] + 1 1/2” (38 mm)
Semi-Conductive Jacket
Page 14
12.4 Remove constant force spring. Carefully bend shield wires back upon cable jacket 1 1/2" (38 mm). Cut excess
shield wire and discard (Figure 17).
Depth Of T erminal Lug + Growth Allowance
[A] + 3” (76 mm)
1 1/2 (38 mm)
Semi-Conductive Jacket
Fold Back Shield Wires
Figure 17
12.5 Remove semi-conductive jacket to dimension shown in Figure 18.
NOTE: To ease jacket removal, install constant force spring as shown in Figure 18 and ring cut 80% through
jacket. Remove jacket sections by pulling against constant force spring. DO NOT BELL SEMI-CON JACKET.
Remove constant force spring.
NOTE: It is imperative to remove all remnants of the semi-conductive jacket, even if the semi-conductive jacket
comes off as one layer. There should not be any remaining black areas, or particles, on the cable insulation layer.
1 1/2
(38 mm)
Depth Of Terminal Lug + Growth Allowance
[A]
1 1/2 (38 mm)
Semi-Conductive Jacket
Cut Line
Constant Force Spring
Fold Back Shield Wires
Figure 18
14 78-8119-6018-2 Rev C
Page 15
13.0 Install Ground Braid
13.1 Select a Scotch® Mastic Strip 2230 from kit and remove white release liners. Using light tension, apply a
SINGLE WRAP of mastic around the cable semi-conductive jacket 1/4" (6 mm) from shield wires (Figure 19).
Cut off excess.
(6 mm)
1/4
Semi-Con
Shield Wires
1ST Scotch® Mastic Strip 2230
Figure 19
13.2 Position pre-formed ground braid with short tail directly over cut edge of folded back shield wires. Position
long tail of ground braid, extending over cable semi-conductive jacket with solder block over mastic strip
(Figure 20). Secure ground braid to cable semi-conductive jacket 4 1/2" (114 mm) from cable semi-con edge
using vinyl tape (Figure 20).
NOTE: Position vinyl tape with care, it also serves as a marker for positioning the termination.
4 1/2 (114 mm)
Solder Bloc k
1ST Scotch® Mastic Strip 2230
Vinyl Tape Marker
Semi-Con Edge
Shield Wire
Ground Braid
Figure 20
78-8119-6018-2 Rev C 15
Page 16
13.3 Wrap ground braid around cable shield wires one complete wrap, trim excess to prevent overlap and secure in
place with constant force spring. Wrap spring in same direction as ground braid (Figure 21). Cinch (tighten) the
spring after wrapping the final winding.
13.4 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE
WRAP of mastic over solder block on ground braid and previously applied mastic (Figure 21). Cut off excess.
Constant Force Spring
Shield Wires
Ground Braid
1ST Scotch® Mastic Strip 2230
Solder Bloc k
2ND Scotch® Mastic Strip 2230
Ground Braid Leg
Trim
Cable
Wire
Shield
Figure 21
13.5 Wrap two highly stretched half-lapped layers of electrical grade vinyl tape around mastic seal, constant force
spring and exposed shield wires (Figure 22).
NOTE: Take care not to cover exposed semi-con insulation shield. A minimum of 1" (25 mm) must be exposed.
1 1/2 (38 mm)
Semi-Con
Shield Wires
Constant Force Spring
Two Half-Lapped Layers of Electrical Grade Vinyl Tape
Scotch® Mastic Strip 2230
Vinyl Tape Marker
Figure 22
16 78-8119-6018-2 Rev C
Page 17
14.0 Install Lug or Connector
14.1 Check to insure 3M™ Cold Shrink QT-III Silicone Rubber Termination assembly fits over the selected lug or
connector. If lug or connector (Figure 23) will not fit through the termination core, clean the insulation (per
Step 15.0) and slide termination on cable before installing lug or connector. DO NOT REMOVE CORE AT
THIS TIME.
Clearance
Connector/Lug
Figure 23
NOTE: Refer to pages 19 - 21 for 3M™ connector and lug crimping information.
NOTE: For Aluminum Conductors - Thoroughly wire brush conductor strands to remove aluminum oxide layer.
Immediately insert conductor into lug or connector barrel as far as it will go.
14.2 Position connector or lug and crimp according to manufacturer's directions. Remove excess oxide inhibitor and
sharp crimp flashings following crimping.
15.0 Clean Cable Insulation and Lug or Connector Barrel Using Standard Practice
15.1 Wipe the cable insulation with one of the solvent saturated pads from the 3M™ Cable Cleaning Preparation Kit
CC-2. DO NOT ALLOW SOLVENT TO TOUCH SEMI-CON INSULATION SHIELD!
15.2 If abrasive must be used:
a. Use on insulation only. DO NOT USE ABRASIVE ON SEMI-CON INSULATION SHIELD!
b. Use only aluminum oxide abrasive; grit 120 or finer, included in the 3M™ Cable Cleaning Preparation Kit CC-2.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.
78-8119-6018-2 Rev C 17
Page 18
16.0 Install Termination
16.1 Slide the termination body onto the cable and remove core. Pull while unwinding, counter-clockwise, starting
with the loose end (Figure 24). Make sure the termination body (not the core) is butted up to the edge of the
vinyl tape marker previously applied (Figure 24).
NOTE: Once the termination body makes contact over the mastic seal area, there is no need to continue
supporting the assembly. DO NOT PUSH OR PULL ON THE TERMINATION ASSEMBLY WHILE UNWINDING
THE CORE.
Counter-Clockwise
Vinyl Tape Marker
The material being removed at this step is mixed polymersNOTE:
Figure 24
16.2 Connect ground braid to system ground according to standard practice
Correct Installation of Termination on UniShield® Shielded Cable
Vinyl Tape
Marker
Ridge at End
of High-K Tube
Ridge at End of Cable
Insulation Shield (Semi-Con)
waste.and can be recycled with
Semi-Con Insulation Shield
Stress Controlling Compound
18 78-8119-6018-2 Rev C
Cable
Insulation
Conductor
Environmental
Top Seal
High-K Stress
Relief Tube
Page 19
Tooling Index
30014 thru 30045
One hole
Cable
Size AWG/
kcmil
6
4
2
1
1/0
2/0
3/0
4/0
250
300
350
400
500
600
Stud
Size
(in.)
10
1/4
5/16
10
1/4
3/8
1/4
5/16
3/8
5/16
3/8
5/16
3/8
3/8
3/8
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
5/8
1/2
1/2
1/2
3M™
Scotchlok™
Copper Lug
Number
30014
30015
30016
30018
30019
30021
30022
30023
30024
30027
30028
30031
30032
30036
31036
30041
31041
30045
31045
31145
31049
31149
31053
31153
31056
31156
31060
31160
31066
31067
31166
31068
31168
Lug and Crimping Information for 3M™ Scotchlok™ Copper Lugs
31145 thru 31178
31036 thru 31068
Two hole — long barrel
One hole-long barrel
Crimping Tool-Die Sets (Minimum Number Of Crimps)
Burndy Corporation Thomas & Betts Corporation
MD6 MY29 Y34A
– 6AWG(1) – U5CRT(1) Blue(1) Blue(1) – (1)
W161(1) 4AWG(1) A4CR(1) U4CRT(1) Grey(1) Grey(1) – (1)
W162(2) 2AWG(1) A2CR(1) U2CRT(2) Brown(1) Brown(1) 33(1) (2)
– 1AWG(1) A1CR(1) U1CRT(2) Green(1) Green(1) 37(1) (2)
W163(2) 1/0(1) A25R(1) U25RT(1) Pink(2) Pink(2) 42H(2) (1)
W241(2)
W241(3)
W243(2)
W243(3)
BG(3)
BG(4)
BG(4)
W166(4) 250(2) A29R(2) U29RT(3) Yellow(2) Yellow(2) 62(2) (2)
– – A30R(2) U30RT(3) – White(3) 66(3) (3)
– – A31R(2) U31RT(3) – Red(4) 71H(4) –
– – A32R(2) U32RT(3) – Blue(4) 76H(4) –
– – A34R(2) U34RT(3) – Brown(4) 87H(4) –
– – – U36RT(3) – Green(4) 94H(4) –
2/0(1)
2/0(2)
3/0(1)
3/0(2)
4/0(1)
4/0(2)
4/0(2)
A26R(1)
A26R(2)
A27R(1)
A27R(2)
A28R(2)
Y35, Y39,
Y45*, Y46*
U26RT(2)
U26RT(3)
U27RT(2)
U27RT(3)
U28RT(2)
U28RT(3)
U28RT(3)
TBM 5 TBM 8 TBM 15
Black(2)
Black(3)
Orange(2)
Orange(3)
Purple(2)
Purple(3)
Purple(3)
Black(2)
Black(3)
Orange(2)
Orange(3)
Purple(2)
Purple(3)
Purple(3)
45(1)
45(2)
50(1)
50(2)
54H(2)
54H(3)
54H(3)
Square D Co.
Anderson Div.
VC6–3,
VC6–FT**
(1)
(2)
(2)
(3)
(2)
(3)
(3)
Y39, Y45,
750 1/2 31172 – – –
1000 1/2 31178 – – –
* Y45 and Y46 accept all Y35 dies (“U” series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter.
** Anderson VC6–3 and VC6–FT require no die set.
78-8119-6018-2 Rev C 19
Y46
U39RT(5)
Y45:
S44RT(6)
Y46:
P44RT(6)
– – 106H(4) –
– – 125H(4) –
Page 20
Tooling Index
Lug and Crimping Information for 3M™ Scotchlok™ Copper/Aluminum Lugs
40016 thru 40079
One hole
40132 thru 40178
Two hole
™
Burndy Corporation Thomas & Betts Corporation
kcmil
Stud Size (in.)
Cable Size AWG/
6 5/16 40016 W161(1) 6AWG(1) A6CAB(1) U6CABT(1) (1) Grey(1) Grey(1) – 29(1) (1) – BY19(3) J(3)
4 5/16 40020 W162(3) 4AWG(1) A4CAB(1) U4CABT(1) (1) Green(2) Green(2) – 37(1) (1) – BY53(3) P(3)
3/8
2
1/2
3/8
1
1/2
3/8
1/0
1/2
3/8
1/2
2/0
1/2
1/2
3/0
1/2
1/2
4/0
5/8
1/2
1/2
250
5/8
1/2
1/2
300
1/2
1/2
350
5/8
1/2
400 1/2 40160 – – – U32ART(4) (1) – – 94H(4) 94H(4) – (2) – –
5/8
500
1/2
600 1/2 40170 – – – U36ART(4) (1) – – – 115H(3) – (3) – –
5/8
750
1/2
5/8
1000
1/2
Lug Number
3M™ Scotchlok
40024
40025
40028
40029
40032
40033
40132
40037
40137
40041
40141
40045
40046
40145
40049
40050
40149
40053
40153
40056
40057
40156
40067
40166
40073
40172
40079
40178
W163(3)
W163(3)
W163(3)
W163(3)
W241(3)
W241(3)
W241(3)
W166(4)
W166(4)
W660(4)
W660(4)
W660(4)
W249(3)
W249(3)
W249(3)
MD6 MY29 Y34A
2AWG(1)
2AWG(1)
1AWG(1)
1AWG(1)
1/0(1)
1/0(1)
1/0(1)
BG(4)
BG(4)
2/0(1)
2/0(1)
3/0(1)
3/0(1)
4/0 (2)
4/0 (2)
4/0 (2)
– –
– – –
– – –
– – –
– – –
A2CAB(1)
A2CAB(1)
A1CAR(1)
A1CAR(1)
A25AR(1)
A25AR(1)
A25AR(1)
A26AR(2)
A26AR(2)
A27AR(2)
A27AR(2)
A28AR(2)
A28AR(2)
A28AR(2)
A29AR(2)
–
A29AR(2)
A29AR(2)
A30AR(2)
A30AR(2)
* Y45 and Y46 accept all Y35 dies (“U” series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter.
** Anderson VC6–3, VC6–FT, VC8C and Burndy Y1000 require no die set.
Crimping Tool-Die Sets (Minimum Number Of Crimps)
Y35, Y39,
Y45*, Y46*
U2CABT(1)
U2CABT(1)
U1CART(1)
U1CART(1)
U25ART(1)
U25ART(1)
U25ART(1)
U26ART(2)
U26ART(2)
U27ART(2)
U27ART(2)
U28ART(2)
U28ART(2)
U28ART(2)
U29ART(2)
U29ART(2)
U29ART(2)
U30ART(2)
U30ART(2)
U31ART(2)
U31ART(2)
U31ART(2)
U34ART(4)
U34ART(4)
U39ART(4)
U39ART(4)
S44ART(4)
S44ART(4)
Y1000** TBM 5 TBM 8 TBM 12 TBM 15
(1)
Pink(2)
Pink(2)
(1)
Pink(2)
Pink(2)
(1)
Gold(2)
Gold(2)
(1)
Gold(2)
Gold(2)
(1)
Tan(2)
Tan(2)
(1)
Tan(2)
Tan(2)
(1)
Tan(2)
Tan(2)
(1)
Olive(2)
Olive(2)
(1)
Olive(2)
Olive(2)
(1)
Ruby(2)
Ruby(2)
(1)
Ruby(2)
Ruby(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
White(4)
–
White(4)
White(4)
– –
– –
– –
– –
– – –
– – –
106H(4)
106H(4)
–
–
–
–
–
–
71H(4)
71H(4)
71H(4)
76H(4)
76H(4)
87H(4)
87H(4)
87H(4)
42H(2)
42H(2)
45(1)
45(1)
50(1)
50(1)
50(1)
54H(2)
54H(2)
60(2)
60(2)
66(4)
66(4)
66(4)
71H(2)
71H(2)
71H(2)
76H(2)
76H(2)
87H(3)
87H(3)
87H(3)
106H(3)
106H(3)
125H(4)
125H(4)
140H(4)
140H(4)
Square D Co.
Anderson Div.
VC6–3**
VC6–FT**
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
(3)
(3)
(3)
(3)
(3)
(3)
–
–
–
ITT
Blackburn
Co.
VC8C** OD58 TYPE O
BY23(3)
–
BY23(3)
BY23(3)
–
BY23(3)
BY25(3)
–
BY25(3)
BY25(3)
BY31C(3)
–
BY31C(3)
– –
BY35C(4)
–
BY35C(4)
BY35C(4)
– – –
– – –
– – –
(2)
(2)
(3)
(3)
(3)
(3)
– –
– –
– –
Kearny
Nat’l
Div.
1/2(3)
1/2(3)
1/2(3)
1/2(3)
5/8–1(3)
5/8–1(3)
5/8–1(3)
5/8–1(3)
5/8–1(3)
737(3)
737(3)
840(4)
840(4)
840(4)
20 78-8119-6018-2 Rev C
Page 21
Tooling Index
Crimping Information for
3M™ Stem Connectors
Copper/Aluminum
Conductor Size
AWG & kcmil
Stranded Solid Manufacturer Mech. Tool
2, 1
4
1/0
2/0
3/0
4/0
* Y45 and Y46 accept all Y35 dies (“U” series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter.
** Anderson VC6 is dieless and does not require a die set.
1, 1/0
2
2/0
3/0
4/0
–
3M™ Connec-
tor
Number
SC0001
SC0002
SC0010
SC0020
SC0030
SC0040
Burndy MD6 BG(4), W243(4) Y35, Y39, Y45* U25ART(2), U243(2)
Kearny 0–51, 0–52 5/8–1 (4) 12, 20, 40, Ton 5/8–1(4)
T & B TBM 5 Tan(2) – –
T & B TBM 8 Olive(2) TBM 15 50(2)
Anderson – – VC6 (2)
Burndy MD6 W669(0) 840(5) Y35, Y39, Y45* U28ART(2)
Kearny 0–51, 0–52 840(5) WH–1, WH–2 840(2)
T & B TBM 8 White(4) TBM 15 66H(3)
Anderson – – VC6 (2)
Crimping Table For 3M™ Stem Type Connector
Recommended Crimping Tools
Die (Minimum No.
Crimps)
Hydraulic
Die (Minimum No.
Crimps)
78-8119-6018-2 Rev C 21
Page 22
3M, Scotch and Scotchlok are trademarks of 3M Company.
UniShield is a registered trademark of General Cable Technologies Corporation.
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but the accuracy or completeness is not guaranteed. Before using this product, you must evaluate it and determine if it is suitable for
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This product will be free from defects in material and manufacture at the time of purchase. 3M MAKES NO OTHER WARRANTIES
INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
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3
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78-8119-6018-2 Rev C
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