Installation Manual
Cat. No.
60800
60801
60802
60803
60804
Bolt Size
1/4
5/16
3/8
1/2
5/8
Max. O.D.
11/16
13/16
1
1-3/16
1-1/2
FLAT
WASHER
COMPRESSION
WASHER
TO INSTALL: Turn bolt until
compression washer is flat.
1st COMPRESSION
LAST COMPRESSION
Figure 3
Figure 2
Figure 1
ALUMINUM COLOR-KEYED
®
LUGS
GENERAL INFORMATION
• Made of high conductivity aluminum, electro-tin plated.
• Wire barrel contains oxide inhibiting compound for minimum connection resistance.
• UL and CSA listed for either stranded aluminum or stranded copper code cables.
• Color coded to assist in the matching of installing die and connector.
• Maximum Temperature rating 90°C.
WARRANTY: Thomas & Betts sells this product with the understanding that the user will perform all necessary tests to determine the suitability of this
product for the user's intended application. Thomas & Betts warrants that this product will be free from defects in materials and workmanship for a
period of two (2) years following the date of purchase. Upon prompt notification of any warranted defect, Thomas & Betts will, at its option, repair or
replace the defective product or refund the purchase price. Proof of purchase is required. Misuse or unauthorized modification of the product voids all
warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY FOR BREACH OF THE ABOVE WARRANTY IS LIMITED TO COST OF
REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE FOR ANY INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES.
INSTALLATION INSTRUCTIONS
1. Strip the insulation from cable length found in table (on reverse side). Be careful not to nick cable strands which may
later result in strands breaking.
2. Remove the plastic protective cap from the end of the wire barrel.
WARNING
Do not remove compound from barrel. Exact amount was installed. Insufficient compound will result in
an increase in connection resistance. This compound contains petroleum distillates and small metal
particles - avoid prolonged skin contact (wash with soap and water). Consult a physician if swallowed
or if contact is made with eyes.
3. Aluminum cable: Smear a thin layer of joint compound onto the cable and brush it with a wire brush or emery cloth and
insert cable into connector until it stops. The insertion length must be approximately the length of the stripped cable.
4. Table on reverse side contains installing die and the number of compressions required for each die connector
combination. Insert connector in die and compress between marking beginning near the tongue of the connector.
CAUTION
Using improper installing die may result in a defective connection.
5. After crimping, remove all sharp edges, flash, burrs due to crimping dies.
6. Insulating using one of the methods found in table on
reverse side.
IMPORTANT NOTE:
The compressions of COLOR-KEYED
®
Lugs are only
one half of a good aluminum wire connection. The other
half is bolting the lugs to a pad. Expansion &
contraction due to temperature changes will affect the
tension of the connection. A Belleville compression
washer should be used to compensate for these
connection changes. T&B Belleville compression
washers (see table on the right) maintain tension on the
lug through many cycles of heating and cooling.
WARNING
RISK OF SHOCK, DISCONNECT
POWER BEFORE INSTALLATION.
TA00880 J pg 1 of 2
140B