Cables y Poleas PDF

Precision Cable Assemblies Miniature & Small Cables Small MIL-SPEC Wire Rope Push-Pull Controls Plastic &
Steel Idler Pulleys Wire Rope Terminals Fittings & Hardware Ferrous & Nonferrous Alloys
Design Guide for Cable Solutions
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IS.EN.ISO 9001:2008 Certified
For Over 35 YearsCarl Stahl Sava Industries

has been developing and manufacturing high quality precision miniature and small cables, fittings, assemblies, and pulleys for an increasing diverse range of customers and applications. Founded as a garage-based business in the 1970s, Sava has steadily grown into a company with sales in excess of $21 million, more than 120 employees and four operational subsidiaries in the United States. In 1988, Sava Industries was acquired by Carl Stahl GmbH of Sssen, Germany. As a member of the Carl Stahl group of companies, Sava is now part of an international network of over 50 sister companies with sales, manufacturing operations, and customers in more than 70 countries. SAVAS CORE BUSINESSis high quality, value-added precision cable assembliesparticularly in applications requiring small, delicate miniature cables. We manufacture standard cable to nominal diameters as small as .006, with extremely tight tolerances. Sava also applies the same high level of quality to cables and cable assemblies in all sizes, constructions, and materials up to a nominal diameter of 3/8. While many cables and assemblies are produced using common stainless steel alloys or galvanized steel, Sava specializes in working with exotic materials such as Vitallium, Tungsten, and Inconel. Cable is also available in bulk and can be coated with a variety of materials including nylon, vinyl, and Teflon. Sava also stocks pulleys in nylon, Delrin or steel, with or without bearings; a large inventory of MIL Spec and other fittings to complement our bulk cable such as eyelets, threaded plugs, balls, loop sleeves, and turnbuckles; and a variety of tools, cutters, and kits for prototype assemblies.
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Comprehensive In-House Capabilitiesinclude complete engineering and manufacturing services backed by highly experienced sales professionals with extensive industry experience. Our engineering team is available to assist with recommendations that enable our customers to achieve their performance goals in the most cost-effective manner possible. Experienced Personnel...our key manufacturing staff have extensive, industry-specific experience and expertise in the areas of Stranding, Assembly, Extrusion, and Molding. All work product is carefully monitored by a skilled Quality Assurance group highly trained in metrology. Our knowledgeable technical sales team provides advice and guidance to help our customers meet their requirements most effectively. Our sales staff is complemented by numerous independent manufacturers representatives throughout the United States. Savas Customersrange from sole proprietors to Fortune 100 companies engaged in a wide range of businesses inclusive of medical/surgical devices, electronics, computers, telecommunications, aerospace, automotive, marine, and construction equipment, consumer goods, industrial machinery, lighting, vending and gaming machines, and many others. Regardless of the size of your company or the extent of your needs, Sava has a cable solution to meet your exact application requirements. ISO 9001 Certificationis your assurance Sava is committed to providing products of the highest quality that meet or exceed our customers requirements and expectations. Our extensive Quality Assurance Team employs rigorous standards in examining product samples during the manufacturing process, and in final inspection, to guarantee the finished product you receive conforms to all specifications. Sava continues to invest in the latest, most sophisticated testing equipment and is an industry leader in meeting the more stringent IS.EN.ISO 9001:2008 standard. Our Headquarters and Operational Subsidiaries are situated in various locations throughout the United States to serve and support our current and growing customer base. Carl Stahl Sava Industries is headquartered in Riverdale, NJ and occupies 75,000 square feet in two company-owned buildings. Carl Stahl Dcor Cable Innovations, based in Chicago, IL, distributes stainless steel rope products and connectors for a wide range of architectural, decorative, and structural applications. Carl Stahl American Lifting, based in Waukesha, WI, distributes a variety of lifting and material handling equipment inclusive of complex overhead crane systems, chain hoists, wire rope, and fabric slings. Jordan Mfg and Metaport Mfg, based in Lafayette, NJ, manufacture a diverse variety of stampings and machined components.
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P.O. Box 30 4 North Corporate Drive, Riverdale, New Jersey 07457- 0030 973.835.0882 Fax: 973.835.0877 www.savacable.com
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TABLE OF CONTENTS
APPLICATION INFORMATION Cable Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Guidelines for Cable Selection, Cable Fatigue Life Chart, Stretch Characteristics Chart . . . . . . . . . . . . . . . . . . . . 4 Tolerances, Prolonging Cable Life, Swaged Cables, Custom Stranding and Coating, Electric Cutting . . . . . . . . . . 5 Relative Costs, Proof LoadingPrestressing, Special Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tips on Designing, Self-Coiling Applications, Cable Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PRECISION MINIATURE and SMALL CABLES Stainless Steel Cable, Nylon, and Vinyl Coated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Low Stretch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Teflon Coated Cable, Dacron Cord Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Galvanized Steel Cable, Nylon, Vinyl Coated, and Safety Orange Vinyl Coated . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FITTINGS, TOOLS, CUTTERS, AND PROTOTYPE KIT PACKAGE Cable FittingsEye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cable FittingsThreaded Plug, Ball-End Plug, Straight Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cable FittingsBall, Ball and Shank, Strap Fork, Strap Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cable FittingsLoop Sleeve, Stop Sleeve, Wire Rope Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cable FittingsTurnbuckle, Super Strength Turnbuckle, Hook, Rod, and Clevis End . . . . . . . . . . . . . . . . . . . . . . 16 Safety Snap Hook, Wire Snap Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Tools, Cutters, and Thimbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Prototype Assemblies, Kit Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MIL SPEC CABLE AND FITTINGS CableMIL-DTL-83420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cable FittingsMS-20664 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 21 Cable FittingsMS-20663, MS-20667, and MS-20668 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cable FittingsMS-21259 and MS-21260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 PUSH-PULL CONTROL ASSEMBLIES Construction, Loss of Motion, Travel, Bend Radii and Life, Input Load Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Available Casing and Cores, Lubrication, End Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25 Other Types of Controls Available, Design Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PULLEYS PulleysNylon, with Precision Ground Ball Bearings, 38 - 134 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PulleysNylon, with Precision Machined Open Ball Bearings 12 - 134 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 PulleysNylon, with Bronze Bushings, 34 - 134 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 PulleysZinc Plated Steel, 12 - 312 O.D.
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PulleysBlack Delrin , 8 - 2 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PulleysMD Nylon, 212 - 6 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 32 Sintered Bronze Bushings, Roller Bearings, and Ball Bearings for Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 PulleysBracket Mounted, Stainless Steel, Plated Steel, Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pulley Size vs. Cable Strength, Recommended Pulley Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SALES POLICY AND TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Strand, wire rope or cable, is a uniform helical arrangement of wires concentrically stranded together for a variety of operating conditions. These constructions have different properties which are designed for specific applications. The STRAND constructions have larger wires, increased abrasion resistance, and less flexibility. In small sizes, they are useful as fishing lines and leaders, light guying
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APPLICATION INFORMATION
LAY = DISTANCE OF ONE COMPLETE REVOLUTION OF A STRAND COATING WIRE
PREFORMED STRAND
CABLE DIAMETER
CORE OR CENTER STRAND
CABLE CONSTRUCTION
and lanyards; in larger sizes, as guy strand, standard rigging on boats and other applications where flexibility of the cable is not essential. The CABLE constructions have more wires and are consequently more flexible with less abrasion resistance. This type of construction has applications in automotive, appliances, boating, instrumentation, aviation, agriculture, hobbies, medicine, recreation, etc.
BASIC CONSTRUCTIONS
Two or more wires laid together the construction is normally referred to as 1 x the number of wires involved; i.e., 1x7, 1x19, etc. 1x7 (7 WIRES) This is the basic strand construction which is used in different combinations to construct another strand or other cables. It is somewhat stiff in larger diameters. 1x19 (19 WIRES) Stronger than 1x7 and more symmetrical in configuration, affording still better properties than 1x7.
Three or more strands laid together the construction is normally referred to as number of strands x number of wires in each strand (for example7x7see below). 3x7 (21 WIRES) A combination of three 1x7 strands. Very flexible in small diameters. 7x7 (49 WIRES) A combination of seven 1x7 strands, affording abrasion resistance and flexibility through a wide range of diameters.
7x7
7x19 (133 WIRES) A combination of seven 1x19 strands, producing a fine combination of strength and flexibility in a wide range of sizes.
7x49 (343 WIRES) A combination of seven 7x7 strands, making a cable with extraordinary flexibility for use over small pulleys.
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GUIDELINES FOR CABLE SELECTION

TO OPTIMIZE LIFE 1. Select a cable that has a minimum breaking strength of 10 times the working load. 2. Should a pulley be utilized, see chart on page 35, for proper pulley diameter. AFTER you have determined the maximum tension on the cable and selected the cable diameter and pulley for your system, apply the numbers to the formula on the right to determine the cable load factor. Read anticipated cycle life from chart. NOTE: A system frequently cannot be designed for optimum conditions. The formula and chart show that a trade-off can be made between cable size, pulley size and life. FORMULA (see example) Cable Factor = Tension on Cable Bare Cable dia. x Pulley Root dia. Curve for part nos. 2014SN, 2018SN, 2027SN, 2031SN, 2036SN, 2048SN, 3048GN, 2064SN, 2094SN, 3064GN, 3094GN Curve for part nos. 2009SN, 2012SN, 2030SN 3X7 Construction Nylon Coated Curve for part nos. 2019SN, 2024SN, 2032SN, 2037SN, 2038SN, 2046SN, 2047SN, 2050SN, 2054SN, 2065SN, 2095SN, 3065GN, 3095GN Curve for part nos. 2018, 2027, 2031, 2036, 2046, 2048, 2064, 2094, 3048, 3064, 3094
7x7 Construction Nylon Coated
CABLE FATIGUE LIFE CHART

1000 900 800
7x19 or 7x49 Construction Nylon Coated 7x7 Construction Uncoated
CABLE FACTOR
700 600 500 400 300 200 100
Example: Determine the cable size, pulley diameter, and cycle life for a counterweight system working with a load of 15 lbs. Anticipated life of cable should be 2,000,000 cycles. Step 1 Select a cable from page 8 which has a breaking strength of 10 times the load. Cables 2036, 2037, and 2038, .036 diameter, qualify. Step 2 Multiply cable diameter .036 by 40 for pulley groove diameter. .036 x 40 = 1.44 Step 3 Cable Factor = 15 = 289 .036 x 1.44 Applying this factor to the Cable Fatigue Life Chart, it is seen that a 7x7 bare cable will have an expected cycle life of only 400,000 cycles, which is not sufficient. When a nylon-coated cable (2036-SN) is selected, the Cable Factor line will not intersect the curve on the cable for a 7x7 or 7x19 coated. The 7x7 coated cable (2036SN) is less expensive and would be the logical choice.
.2
.4
.6
.8
1.0
1.2
1.4
1.6
CYCLE LIFE MILLIONS (TO FAILURE)

NOTE: The numbers on this chart were determined under laboratory conditions and are intended to serve as a guide. Since there is considerable variation in application, we recommend actual life tests for your intended use. DATA ON STRETCH OF CABLE AND STRAND Two kinds of stretch occur in cable constructional stretch and elastic stretch. They are due to two different causes. Constructional Stretch When strand and cable are made, the load at the closing head is light. Therefore, there are small clearances between the wires and strands, and between the strand and the core. The application of initial load causes wires and strands to seat properly, and a slight overall elongation of the strand or cable accompanies this section. The amount of constructional stretch is not constant for all cables it depends on such variables as type of construction, length of lay, and other factors, including the load applied. Elastic Stretch Elastic stretch is the actual elongation of the wires of a strand or a cable. This is caused by the application of a load, up to the yield point of the metal, and the stretch is approximately proportional to the load applied. When the load is released, strand or cable subjected to elastic stretch returns to its approximate original length, providing the stretch has not reached the yield point of the metal. Removal of Stretch Where the elimination of as much stretch as possible is important, the cables or assemblies can be proof loaded to remove most of the constructional stretch. For assemblies, this process also verifies the holding power of the terminals. Proof loading is usually done by applying a 60% load to the cable or assemblies. This load is based on the minimum breaking strength of the cable or fittings, whichever is lower. Handling the cable as little as possible after prestretching helps eliminate putting constructional stretch back in.
ELASTIC STRETCH CHARACTERISTICS OF SAVA CABLE

.100 .090
AMOUNT OF STRETCH PER 10 OF LENGTH
.080 .070 .060 .050 .040 .030 .020 .010 10 20 30 40 50
% LOAD OF CABLE BREAKING STRENGTH

NOTE: For construction of 7x7, 7x19, 8x19, and 7x49. The chart represents close approximates.
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.010 - .035 .036 - .065 .066 - .130 .131 - .260 .261 - .380 .381 - .500
NOTES:
The following notes are common to both the stainless steel cables shown on pages 8 and 9 and the galvanized steel cables shown on page 11. 1. Coating for cables up to 1/16 diameter is our No. 194 Nylon which is designed for superior fatigue life in thin wall applications in both high and low temperature ranges and has excellent abrasion resistance. Our No. 195 Nylon is used on cables 3/32 and larger. This is also a superior grade resin, slightly less expensive yet has good flexibility, excellent abrasion resistance, and works well with larger diameter cables with greater bearing surfaces. 2. The vinyl coating part numbers refer to clear vinyl only. Color choices are available for a nominal additional charge. Vinyl is the most commonly used coating in cables over 3/32 in diameter. It is more flexible than most coatings, has excellent resistance to sunlight, and is less expensive. 3. The most common coating diameters are shown. Contact SAVA if you have a special application.
PROLONGING CABLE LIFE

LUBRICATION Nylon coated miniature stainless steel cables, P/N 2018SN through 2065SN (see pg. 8) are impregnated with our specially formulated lubricant which results in substantially improved fatigue life. For other lubricated cables, please consult with our sales office. PLASTIC COATINGS The coating of cables with nylon, vinyl, Teflon, or other plastics offers a number of advantages. The plastic protects the wire from abrasion and chemical attack. It seals in the lubrication and seals out moisture, dirt, and grit. It cushions the cable from shock and pressure, protects pulleys from abrasion, and is easy to clean. Generally, in fatigue applications, using nylon, working life is increased 300% to 1000%. STRENGTH AND SAFETY FACTORS To arrive at the working load of a cable, the normal load as well as additional stresses caused by acceleration, shock, and bending must be considered. A safety factor should be applied, taking into consideration both the cost and the dangers which could result from failure. Where cable is stationary, a factor of 312 is usually safe. In a hoisting application, the factor could be as high as 8 or 12 under special conditions. However, additional testing is highly recommended, with final decision and acceptance by the customer.
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SAVAS STANDARD COATING TOLERANCES

NOMINAL COATING DIAMETER inches mm .25 - .90 .91 - 1.65 1.66 - 3.30 3.31 - 6.60 6.61 - 9.65 9.66 - 12.70 COATING O.D. TOLERANCE inches +.004 -.000 +.008 -.000 +.012 -.000 +.018 -.000 +.024 -.000 +.032 -.000 mm +.10 -.00 +.20 -.00 +.30 -.00 +.45 -.00 +.60 -.00 +.80 -.00
SAVAS STANDARD CABLE O.D. TOLERANCES

NOMINAL CABLE DIAMETER inches .006 - .020 .021 - .035 .036 - .065 .066 - .095 .096 - .130 .131 - .260 .261 - .380 mm .15 - .50 .51 - .90 .91 - 1.65 1.66 - 2.40 2.41 - 3.30 3.31 - 6.60 6.61 - 9.65 CABLE O.D. TOLERANCE inches +.002 -.000 +.004 -.000 +.008 -.000 +.010 -.000 +.014 -.000 +.018 -.000 +.026 -.000 mm +.05 -.00 +.10 -.00 +.20 -.00 +.25 -.00 +.35 -.00 +.45 -.00 +.65 -.00
SWAGED CABLES
For applications requiring increased wear resistance and lower friction in a given size cable, particularly push-pull types, swaging provides a good answer. The average diameter decrease by swaging without appreciable loss in performance is approximately 10%. In swaging, the outer wires are flattened to provide greater wear area and smoother surface. The breaking-strength-to-cable-diameter ratio remains constant, without appreciable loss of flexibility.
CUSTOM STRANDING
Our stranding equipment is available for manufacture of cables using your material or a material of your specifications. We have successfully manufactured cables from very unusual materials, some of which were also plastic coated.
CUSTOM PLASTIC COATINGS

SAVAs modern extrusion equipment and expertise lend themselves very well to extruding other plastic materials such as polypropylene, polyethylene, polyurethane, and many types of nylon. Also, we will be pleased to quote on coating more than one cable in a common jacket in either a flat or round shape. Colored plastic is possible in most plastics. Many of the cables are available in black nylon or vinyl coating.
ELECTRIC CUTTING
Electric cutting of uncoated cable is a process by which the ends of the cable are fused (sealed) to prevent fraying and to allow easy application of a fitting. It is particularly desirable to specify electric cutting where only one end of an assembly has a fitting. SAVA is equipped with automatic electric cutting machinery which is also available to cut your bulk cable to desired lengths. Unless you are similarly equipped, you will find this service particularly advantageous.
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RELATIVE COSTS
CABLE CONSTRUCTION Fewer number of wires in a cable will result in lower cost and less flexibility. Hence, a 1x19 (19 wires) will be less expensive than a 7x7 (49 wires) and a 7x7 will be less expensive and less flexible than a 7x19 (133 wires) in the same diameter. MATERIAL Stainless steel cable using standard 302/304 stainless, will cost approximately 1.5 to 3 times more than galvanized steel cable, depending on the size and construction. Galvanized steel cable with a plastic coating will generally cost less than stainless steel cable, particularly in sizes over 3/32. Vinyl coating is less expensive than nylon, and Teflon is the most expensive. Contact factory for other types of cable and coating materials available. STRENGTH RECOMMENDATIONS Specifying less than full strength on your cable assembly prints will usually result in lower pricing, usually accomplished by crimping the fitting over the cable coating (a loss of strength of approximately 35%). However, to obtain full breaking strength, the cable coating would then be stripped and the fittings swaged directly onto the cable. Also note that cables with 1x19 construction have less holding strength, consult factory. LENGTH TOLERANCES Length tolerances are an important cost consideration. Close tolerances require more expensive cutting processes and increased inspection criteria. Cable sizes and fittings used often determine attainable tolerances. Assemblies specifying precision tolerances must state under what load the length is to be measured. Please, do not overspecify. Confirm your desired tolerances with SAVA Industries prior to production. Standard tolerances will be used unless otherwise agreed upon. FITTINGS The following is a ranking of the relative cost of fittings starting from the least expensive. The ranking is predicated on the cost of the fitting and its cost of attachment to the cable based on the assembly being manufactured by SAVA INDUSTRIES, INC. 1. EYE 2. BALL-END PLUG 3. BALL 4. THREADED PLUG 5. BALL & SHANK 6. LOOP 7. MS TERMINALS
RECOMMENDED LENGTH TOLERANCES

LENGTH (IN. FT.) 0.1 - 2.0 2.1 - 5.0 5.1 - 10.0 10.1 - 20.0 20.1 - 40.0 40.1 - 60.0 60.1 - 80.0 80.1 - 100.0 TOLERANCE (IN INCHES) PRECISION TIGHT CLOSE STANDARD 1/64 1/32 1/16 1/8 1/4 1/2 7/8 1-1/2 1/32 1/16 1/8 1/4 1/2 1 2 3 .5% of length 1/16 1/8 1/4 1/2 1 2 4 6 .8% of length 1/8 1/4 1/2 1 2 4 8 12 1.5% of length
100.1 AND ABOVE
PROOF LOADINGPRESTRESSING
Proof loading of cable assemblies serves two purposes. First, it ensures the efficiency of the assemblies; and second, it prestresses the cable, removing some of the constructional stretch. Proof loading is generally done at 60% of rated breaking strength. The removal of constructional stretch means that frequent adjustments are not necessary to maintain proper tension in a control system. After assemblies are proof loaded, subsequent handling should be held to a minimum, otherwise the prestressing effect will be partially removed. If stretch is critical in your application, we suggest contacting SAVAs Engineering Department for further information.
SPECIAL FITTINGS
It is always preferable to use a standard fitting shown in the catalog for cost effectiveness and prompt shipping schedule. Terminals other than those shown in this catalog can be applied for those requiring special or unusual fittings. Our engineers will be pleased to assist you in the most reliable and economical design. If you wish to supply your own terminal for SAVA to apply, please be certain to contact us regarding the design in order to eliminate special tooling charges. The bonding strength between cables and special or unusual fittings cannot be predicted beforehand. It is established only after testing a number of samples. The customer should check with our Engineering Department for the strength that can be achieved on the parts before going into full-scale production.
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The following procedure offers a checklist on the information needed for SAVA to quote on your cable assembly. Please complete as much information as possible. If in doubt contact the factory for any design assistance. The following information is required: A . . . is the cable part number from the catalog. B . . . identify the fittings. Remember, the least expensive fitting by far is the eye, followed in order of least cost by the ball end or straight plug, ball, threaded plug, ball and shank, loop and MS terminals. C . . . for length, refer to fitting diagrams in the catalog to see where the standard measuring point is. D . . . is length tolerance. Remember, close tolerances add to cost. Refer to page 6 for tolerance recommendations. E . . . be sure to specify the strength requirements. Some fittings, such as the ball, do not provide full strength and these are noted in the catalog. Also, specifying less than full strength of the fitting will frequently result in lower pricing. For example, if you select a cable with a breaking strength of 480 lbs., have a load of 50 lbs. with a safety factor of 6-1, then a 300 lb. minimum cable assembly strength would be sufficient.
A B D C E B
SAVAs self-coiling cables are manufactured from high tensile, aircraft grade steel cable. A vinyl coating is extruded to form a secure bond into the interstices of the cable wires. The coating gives the cable a soft, clean finish which protects the area of use. The cut-through resistance is determined by the size and construction of the inner steel cable. For example, a 3/16 7x7 construction with a vinyl coating to 1/4 is extremely difficult to cut through with a hack saw. A very large bolt cutter would be necessary. Other features are: Compact, stores easily Returns to original shape Clean Strengths 500-5000 lbs. Lengths can be varied Colored vinyl available on special order
CABLE APPLICATIONS
Cable and cable assemblies are designed to be a reliable and economical means of transmitting motion or controlling an item mechanically. Typically their usage falls into two broad applications listed here.
USED IN THESE TYPICAL TYPES OF PRODUCTS Aircraft Appliances Automotive Bicycles Boats Carts Computers Copy Machines Dental Equipment Drafting Equipment Farm Equipment Floor Sweepers Hospital Beds Lawn Equipment Material Handling Medical Equipment Models Office Equipment Plotters Power Tools Printers Pumps Scales Ski Equipment Tape Drives Throttles Timers Toys and Games Vending Machines Washing Machines X-Ray Equipment
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TIPS ON DESIGNING AND ORDERING CABLE ASSEMBLIES
Typical Cable Assembly Layout
Other information: 1. If a center fitting is required, the same principles apply. 2. If a loop fitting is required, be sure to list the P and D dimensions as shown on page 15 in the catalog. Be sure to add tolerances. 3. If 100% prestressing or prooftesting is required, please specify. 4. Full dimensions and strengths of special fittings must be given.
SELF-COILING CABLES FOR SECURITY APPLICATIONS
ACTUATING DEVICES
LANYARDS
Adjustment Alignment Braking Connecting Controlling Counterbalancing Cycling Driving Hoisting Traversing
Capturing Connecting Grounding Hanging Restraining Securing Stopping Supporting Tripping
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PRECISION MINIATURE AND SMALL CABLES

STAINLESS STEEL CABLE, NYLON, AND VINYL COATED
UNCOATED PART NO. 2006 2009 2010 2011 2012 2014 2015 2016 2017 2018 2019 2020 2023 2024 2027 2030 2031 2032 2033 2035 2036 2037 2038 2039 2045 2046 2047 2048 2049 2050 2054 2063 2064 2065 2080 2081 2082 2093 2094 2095 2096 2124 2125 2126 2158 2188 2252 2315 2375 NOMINAL DIAMETER in. .006 .009 .010 .012 .013 .014 .016 .017 .019 .018 .018 .018 .024 .024 .027 .032 .032 .032 .032 .036 .035 .038 .038 .038 .044 .046 .044 3/64 3/64 3/64 .054 1/16 1/16 1/16 5/64 5/64 5/64 3/32 3/32 3/32 3/32 1/8 1/8 1/8 5/32 3/16 1/4 5/16 3/8 mm .152 .229 .254 .305 .305 .356 .406 .432 .483 .457 .457 .457 .610 .610 .686 .813 .813 .813 .813 .914 .914 .965 .965 .965 1.12 1.17 1.12 1.19 1.19 1.19 1.37 1.59 1.59 1.59 1.98 1.98 1.98 2.38 2.38 2.38 2.38 3.18 3.18 3.18 3.97 4.76 6.35 7.94 9.53 CON- MIN. BREAKING STRENGTH STRUCTION lbs. kg 1x7 3x7 7x7 1x7 3x7 7x7 1x7 3x3 1x7 7x7 7x19 1x19 7x7 7x19 7x7 3x7 7x7 7x19 7x49 3x49 7x7 7x19 49+(8x19) 1x19 7x19 7x7 7x49 7x7 1x19 7x19 7x49 1x19 7x7 7x19 7x19 7x49 7x7 1x19 7x7 7x19 7x49 1x19 7x7 7x19 7x19 7x19 7x19 7x19 7x19 5 10 15 20 18 26 30 26 40 40 40 45 70 70 90 110 120 120 100 120 160 160 160 160 220 225 170 270 335 270 250 500 480 480 700 550 800 1200 920 920 800 2100 1700 1760 2400 3700 6400 9000 12000 2.3 4.5 6.8 9.1 8.2 11.8 13.6 11.8 18.1 18.1 18.1 20.5 31.8 31.8 40.8 49.9 54.4 54.4 45.4 54.4 72.6 72.6 72.6 72.6 100 100 77.1 122 152 122 113 227 218 218 318 250 360 544 417 417 360 953 771 798 1089 1678 2903 4082 5443 WITH NYLON COATING (See Notes 1 & 3 on pg. 5) PART NO. 2006SN 2009SN 2010SN 2011SN 2012SN 2014SN 2015SN 2016SN 2017SN 2018SN 2019SN 2020SN 2023SN 2024SN 2027SN 2030SN 2030SN1 2031SN 2032SN 2033SN 2035SN 2036SN 2037SN 2038SN 2039SN 2045SN 2046SN 2047SN 2048SN2 2049SN2 2050SN2 2054SN2 2063SN3 2064SN3 2064SN4 2065SN3 2080SN3 2081SN3 2082SN3 2093SN4 2094SN4 2094SN5 2094SN6 2095SN4 2096SN4 2124SN6 2125SN6 2126SN6 2158SN7 2188SN8 2252SN10 2315SN13 2375SN15 COATING DIAMETER in. .010 .014 .014 .019 .019 .019 .024 .024 .024 .024 .024 .024 .030 .030 .034 .037 3/64 .037 .037 .037 .044 .044 .046 .046 .046 .052 .052 .052 1/16 1/16 1/16 1/16 3/32 3/32 1/8 3/32 3/32 3/32 3/32 1/8 1/8 5/32 3/16 1/8 1/8 3/16 3/16 3/16 7/32 1/4 5/16 13/32 15/32 mm .254 .356 .356 .483 .483 .483 .610 .610 .610 .610 .610 .610 .762 .762 .864 .940 1.19 .940 .940 .940 1.12 1.12 1.17 1.17 1.17 1.32 1.32 1.32 1.59 1.59 1.59 1.59 2.38 2.38 3.18 2.38 2.38 2.38 2.38 3.18 3.18 3.97 4.76 3.18 3.18 4.76 4.76 4.76 5.56 6.35 7.94 10.32 11.91 2093SV4 2094SV4 2094SV5 2094SV6 2095SV4 1/8 1/8 5/32 3/16 1/8 3.18 3.18 3.97 4.76 3.18 2063SV3 2064SV3 2064SV4 2065SV3 3/32 3/32 1/8 3/32 2.38 2.38 3.18 2.38 2048SV2 1/16 1.59 WITH VINYL COATING (See Notes 2 & 3 on pg. 5) PART NO. COATING DIAMETER in. mm APPROXIMATE WEIGHT PER 100 FEET UNCOATED lbs. 0.01 0.02 0.02 0.03 0.03 0.03 0.04 0.04 0.06 0.05 0.05 0.05 0.12 0.12 0.13 0.16 0.16 0.16 0.16 0.16 0.23 0.23 0.23 0.23 0.23 0.35 0.37 0.35 0.42 0.55 0.55 0.55 0.85 0.75 0.75 0.75 1.42 1.42 1.42 2.00 1.60 1.60 1.60 1.74 1.74 3.50 2.80 2.90 4.50 6.50 11.00 17.30 24.30 kg 0.00 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.03 0.02 0.02 0.02 0.05 0.05 0.06 0.07 0.07 0.07 0.07 0.07 0.10 0.10 0.10 0.10 0.10 0.16 0.17 0.16 0.19 0.25 0.25 0.25 0.39 0.34 0.34 0.34 0.64 0.64 0.64 0.91 0.73 0.73 0.73 0.79 0.79 1.59 1.27 1.32 2.04 2.95 4.99 7.85 11.02 COATED lbs. 0.01 0.02 0.02 0.04 0.04 0.04 0.05 0.05 0.07 0.06 0.06 0.06 0.14 0.14 0.15 0.22 0.31 0.22 0.22 0.22 0.24 0.26 0.26 0.26 0.26 0.39 0.41 0.39 0.49 0.65 0.65 0.65 1.10 0.93 1.50 0.93 1.60 1.60 1.60 2.20 1.85 2.18 2.67 1.99 1.99 4.30 3.60 3.62 5.40 8.60 13.50 20.40 28.00 kg 0.00 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.03 0.03 0.03 0.03 0.06 0.06 0.07 0.10 0.14 0.10 0.10 0.10 0.11 0.12 0.12 0.12 0.12 0.18 0.19 0.18 0.22 0.29 0.29 0.29 0.50 0.42 0.68 0.42 0.73 0.73 0.73 1.00 0.84 0.99 1.21 0.90 0.90 1.95 1.63 1.64 2.45 3.90 6.12 9.25 12.70
2018SV
.024
.610
2030SV 2030SV1
.037 3/64
.940 1.19
2125SV6 2126SV6 2158SV7 2188SV8 2252SV10 2315SV13 2375SV15
3/16 3/16 7/32 1/4 5/16 13/32 15/32
4.76 4.76 5.56 6.35 7.94 10.32 11.91
NOTES: All coatings are extruded with natural plastic. Many are available in black and other colors for a nominal cost. NOTE: 2030SN1 cable was previously 2030SN2, 2158 cable was 2168.
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ISO 9001 CERTIFIED
Low-stretch cables solve the problem of tension loss in small cable drive systems. Stretch reduction of up to 300% compared to standard cables under dynamic working conditions can be
UNCOATED PART NO. 1021 1023 1024 1027 1031 1032 1036 1037 1048 1050 1064 1065 NOM. DIA. in. .021 .024 .024 .027 .032 .032 .036 .036 .048 .048 .063 .063 mm .534 .610 .610 .686 .813 .813 .914 .914 1.19 1.19 1.59 1.59 NYLON COATED COATING PART O.D. NO. in. mm 1021SN .027 .686 1023SN .030 .762 1024SN 1027SN 1031SN 1032SN 1036SN 1037SN 1048SN 1050SN 1064SN 1065SN .030 .034 .037 .037 .046 .046 .063 .063 .094 .094 .762 .864 .940 .940 1.17 1.17 1.59 1.59 2.38 2.38
STRETCH/FT. IN INCHES
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SAVA LOW-STRETCH HIGH-FATIGUE MINIATURE STAINLESS STEEL CABLE

realized. These newly developed cables are designed to reduce to practical insignificance the loss of resolution caused by stretch.
APPROX. WT. (100 FT.) UNCOATED lbs. 0.11 0.12 0.12 0.13 0.16 0.16 0.23 0.23 0.42 0.55 0.75 0.75 kg 0.04 0.05 0.05 0.06 0.07 0.07 0.10 0.10 0.19 0.25 0.34 0.34 COATED lbs. 0.12 0.14 0.14 0.15 0.22 0.22 0.26 0.26 0.49 0.65 0.93 0.93 kg 0.05 0.06 0.06 0.07 0.10 0.10 0.12 0.12 0.22 0.29 0.42 0.42
CONSTRUCTION 7x7 7x7 7x19 7x7 7x7 7x19 7x7 7x19 7x7 7x19 7x7 7x19
MIN. BREAKING STRENGTH lbs. 50 70 60 90 120 100 160 150 270 270 450 450 kg 22.7 31.8 27.2 40.8 54.4 45.4 72.6 68.0 122.5 122.5 204.1 204.1
LOW-STRETCH vs STANDARD MINIATURE STEEL CABLE

.0250 .0200
Standard Cable
.0150 .0100
Low-Stretch Cable
.0050
.2
.4
.6
.8
1.0
1.2
1.4
1.6
1.8
2.0
NUMBER OF CYCLES (Millions)
Test data were obtained by cycling both standard and low-stretch cables under tension loads to 2,000,000 cycles while continuously monitoring the stretch.
TYPICAL APPLICATIONS INCLUDE Computer Printers
Plotters Typewriters Instrumentation Robotics Other Precision Drive Mechanisms

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ISO 9001 CERTIFIED
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TEFLON FEP COATED STAINLESS STEEL CABLE

PART NO. UNCOATED NOMINAL DIAMETER in. 2014ST 2018ST 2023ST 2024ST 2027ST 2031ST 2032ST 2036ST 2037ST 2048ST2 2050ST2 2054ST2 2064ST3 2065ST3 2095ST4 2126ST6 2188ST8 .014 .018 .024 .024 .027 .032 .032 .036 .038 3/64 3/64 .054 1/16 1/16 3/32 1/8 3/16 mm .356 .457 .610 .610 .686 .813 .813 .914 .914 1.19 1.19 1.37 1.59 1.59 2.38 3.18 4.76 OUTSIDE DIAMETER OF COATING in. .021 .026 .032 .032 .036 .040 .040 .049 .049 .062 .062 .062 .084 .084 1/8 3/16 1/4 mm .53 .66 .813 .813 .914 1.02 1.02 1.24 1.24 1.59 1.59 1.59 2.13 2.13 3.18 4.76 6.35 7x7 7x7 7x7 7x19 7x7 7x7 7x19 7x7 7x19 7x7 7x19 7x49 7x7 7x19 7x19 7x19 7x19 CONSTRUCTION MINIMUM BREAKING STRENGTH lbs. 26 40 70 70 90 120 120 160 160 270 270 250 480 480 920 1760 3700 kg 12 18 32 32 41 54 54 73 73 122 122 113 218 218 417 798 1678 APPROXIMATE WEIGHT PER 100 FEET lbs. 0.04 0.06 0.14 0.14 0.15 0.22 0.22 0.26 0.26 0.49 0.49 0.65 0.85 0.85 2.25 4.35 9.60 kg 0.02 0.03 0.06 0.06 0.07 0.10 0.10 0.12 0.12 0.22 0.22 0.29 0.39 0.39 1.02 1.98 4.36
NOTE: All coatings are extruded with natural Teflon. Many are available in black, blue or other colors. Check with factory.
TEFLON FEP OFFERS THE FOLLOWING EXCELLENT COMBINATION OF PROPERTIES
Nonaging characteristics Low coefficient of friction Chemical inertness Exceptional dielectric properties
Toughness and flexibility Continuous service temperature +400F Heat resistance Nonstick characteristics
Negligible moisture absorption

(less than .01%)
Weather resistance Nonflammable
DACRON CORD AND ASSEMBLIES*

Natural (white) in color. For additional colors in black, olive drab, etc. contact factory. Dacron is a low stretch fiber with excellent abrasion and ultraviolet resistance, highly recommended for outdoor use.
Braided Low stretch fiber All weather Inexpensive Great flexibility Nonconductive
PART NO. DC033 DC042 DC060
NOMINAL DIAMETER (REF.) .033 .042 .060
TEST OF CORD 50 lb. 90 lb. 180 lb.
SAVA FITTINGS WHICH CAN BE APPLIED TO FORM ASSEMBLY #305 EYE, #307 EYE, #7030 LOOP #305 EYE, #307 EYE, #7047 LOOP #310 EYE, #315 EYE, #318 EYE, #7062 LOOP
MINIMUM STRENGTH OF ASSEMBLY 25 lb. 40 lb. 90 lb.
*Hand tools are not available to crimp eyelets. It is recommended you have SAVA assemble eyelets for you to obtain proper breaking strength.
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ISO 9001 CERTIFIED
PART NO.
3030* 3048 3049 3063 3064 3065 3093 3094 3095 3124 3125 3126 3157 3158 3187 3188 3219 3252 3315 3375
NOTES: All coatings are extruded with natural plastic. Many are available in black and other colors for a nominal cost. 3030 cable was previously 3032, 3030GN1 and GV1 cables were 3030GN2 and GV2, 3158 cable was 3168. *3030 is being replaced with 2030 stainless steel, 1/32, 3x7 cable when current stock is depleted. See page 8, consult factory.
NOTES: *3030 is being replaced with 2030 stainless steel, 1/32, 3x7 cable when current stock is depleted. See page 8, consult factory.
Nylon coating is available on request. Other diameters and constructions are also available on request. These cables are coated with a highly visible bright orange vinyl coating and used as safety cables, lanyards, and on assemblies. 11
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GALVANIZED STEEL CABLE, NYLON, AND VINYL COATED

UNCOATED WITH NYLON COATING (See Notes 1 & 3 on pg. 5) MINIMUM BREAKING STRENGTH lbs. kg 110 270 375 500 480 480 1200 920 1000 2100 1700 2000 2600 2800 3700 4200 5600 7000 9800 14400 50 122 170 227 218 218 544 417 454 953 771 907 1179 1270 1678 1905 2540 3175 4445 6531 PART NO. 3030GN 3030GN1 3048GN2 3049GN2 3063GN3 3064GN3 3064GN4 3065GN3 3093GN4 3094GN4 3094GN5 3094GN6 3095GN4 3124GN6 3125GN6 3126GN6 3157GN7 3158GN7 3187GN8 3188GN8 3219GN9 3252GN10 3315GN13 3375GN15 OUTSIDE DIAMETER OF COATING in. mm .037 3/64 1/16 1/16 3/32 3/32 1/8 3/32 1/8 1/8 5/32 3/16 1/8 3/16 3/16 3/16 7/32 7/32 1/4 1/4 9/32 5/16 13/32 15/32 .940 1.19 1.59 1.59 2.38 2.38 3.18 2.38 3.18 3.18 3.97 4.76 3.18 4.76 4.76 4.76 5.56 5.56 6.35 6.35 7.14 7.94 10.32 11.91 WITH VINYL COATING (See Notes 2 & 3 on pg. 5) PART NO. 3030GV 3030GV1 3048GV2 3049GV2 3063GV3 3064GV3 3064GV4 3065GV3 3093GV4 3094GV4 3094GV5 3094GV6 3095GV4 3124GV6 3125GV6 3126GV6 3157GV7 3158GV7 3187GV8 3188GV8 3219GV9 3252GV10 3315GV13 3375GV15 OUTSIDE DIAMETER OF COATING in. mm .037 3/64 1/16 1/16 3/32 3/32 1/8 3/32 1/8 1/8 5/32 3/16 1/8 3/16 3/16 3/16 7/32 7/32 1/4 1/4 9/32 5/16 13/32 15/32 .940 1.19 1.59 1.59 2.38 2.38 3.18 2.38 3.18 3.18 3.97 4.76 3.18 4.76 4.76 4.76 5.56 5.56 6.35 6.35 7.14 7.94 10.32 11.91 APPROXIMATE WEIGHT PER 100 FEET UNCOATED lbs. 0.16 0.16 0.42 0.55 0.85 0.75 0.75 0.75 2.00 1.60 1.60 1.60 1.74 3.50 2.80 2.90 4.30 4.50 6.50 6.50 8.60 11.00 17.30 24.30 kg 0.07 0.07 0.19 0.25 0.39 0.34 0.34 0.34 0.91 0.73 0.73 0.73 0.79 1.59 1.27 1.32 1.95 2.04 2.95 2.95 3.90 4.99 7.85 11.02 COATED lbs. 0.22 0.31 0.49 0.65 1.10 0.93 1.50 0.93 2.20 1.85 2.18 2.67 1.99 4.40 3.60 3.62 5.20 5.40 8.60 8.60 9.76 13.50 20.4 28.0 kg 0.10 0.14 0.22 0.29 0.50 0.42 0.68 0.42 1.00 0.84 0.99 1.21 0.90 2.00 1.63 1.64 2.35 2.45 3.90 3.90 4.43 6.12 9.25 12.7
NOMINAL DIAMETER in. 1/32 3/64 3/64 1/16 1/16 1/16 3/32 3/32 3/32 1/8 1/8 1/8 5/32 5/32 3/16 3/16 7/32 1/4 5/16 3/8 mm .813 1.19 1.19 1.59 1.59 1.59 2.38 2.38 2.38 3.18 3.18 3.18 3.97 3.97 4.76 4.76 5.56 6.35 7.94 9.53
CONSTRUCTION 3x7 7x7 1x19 1x19 7x7 7x19 1x19 7x7 7x19 1x19 7x7 7x19 7x7 7x19 7x7 7x19 7x19 7x19 7x19 7x19
GALVANIZED STEEL CABLE, SAFETY ORANGE VINYL COATED

PART NO. UNCOATED NOMINAL DIAMETER in. 3030GSV2* 3048GSV3 3064GSV4 3094GSV6 3094GSV8 3126GSV6 3188GSV8 3252GSV10 1/32 3/64 1/16 3/32 3/32 1/8 3/16 1/4 mm .813 1.19 1.59 2.38 2.38 3.18 4.76 6.35 OUTSIDE DIAMETER OF COATING in. 1/16 3/32 1/8 3/16 1/4 3/16 1/4 5/16 mm 1.59 2.38 3.18 4.76 6.35 4.76 6.35 7.94 3x7 7x7 7x7 7x7 7x7 7x19 7x19 7x19 CONSTRUCTION MINIMUM BREAKING STRENGTH lbs. 110 270 480 920 920 2000 4200 7000 kg 50 122 218 417 417 907 1905 3175 APPROXIMATE WEIGHT PER 100 FEET lbs. 0.46 0.68 1.50 2.67 3.00 3.62 8.60 13.50 kg 0.21 0.31 0.68 1.21 1.36 1.64 3.90 6.12
Orange vinyl-coated cables are frequently used as pull cords for operating safety switches to stop machines in an emergency.
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CABLE FITTINGS
AVAILABLE IN BULK OR FACTORY APPLIED
SAVAs miniature to small cable fittings are designed to be RELIABLE, PRECISE, EFFICIENT, and ECONOMICAL. These fittings were planned for use with SAVAs miniature and small cable. However, they can be applied to other cables which fall into the same size range. The combination of our miniature cable and fittings gives engineers a precise, economical, and reliable operating mechanism which can be the ideal solution to space problems.
J H C MEASURING POINT FOR ASSEMBLY
SAVAs precision-designed dies and modern equipment are used to manufacture cable assemblies. However, we offer most of these fittings loose and some can be crimped with pliers, vise, etc., for prototype applications. Although it can be an unreliable method of attaching, it is frequently convenient and necessary. We offer our prototype package on page 19 primarily for this purpose.
EYE (EYELET)
H + .010 -.005 .100 .377 .142 .171 .190 .220 .251 .157 .190 .157 .190 .190 .219 .260 .142 .190 .219 .260 .219 .315 .376 .438 .315 .376 .438 .204 .251 .204 .251 .376 .501 .376 .501 .251 .316 .251 .316 .376 .501 .376 .501 .313 .380 .501 .313 .380 .501 .512 .635 .512 .635 W .020 .190 .530 .260 .375 C REF. .130 .340 .150 .230 As REF. .100 .100 .120 .120 J + .010 -.005 .030 .030 .040 .040 Ls REF. .300 .550 .5805 (or 460) 11/16 MATERIAL Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Stainless Steel Stainless Steel
PART NO. 302S1001 303S377 305S142 305S171
FOR CABLE DIA. .010 - .034 .010 - .034 .014 - .044 .014 - .044
BEFORE CRIMPING
W
307S190 307S220 307S250 310P156 310P190 310S156 310S190
1/32 - 1/167
.330
.260
.140
.047
3/4
EYE CAN BE BENT6 Ls
315P190 315P218 315P2602 315S142 315S190 315S218 315S2602 315PSL218 315SSL218 318P315 318P375 318P438 318S315 318S375 318S438 320P203 320P250 320S203 320S250 321P375 321P500 321S375 321S500 330P2503 330P3163 330S250 330S316 331P375 331P500 331S375 331S500 340P313 340P380 340P5004 340S313 340S380 340S500 350P510 350P635 350S510 350S635
3/64 - 1/16
.420
.340
.210
.060
As
3/64 - 1/16
.410
.410
.210
.060
15/16
AFTER CRIMPING
W H J
3/64 - 1/16
.625
.370
.210
.060
.375 C MEASURING POINT FOR ASSEMBLY
3/32
.500
.470
.280
.090
1-5/16
PART NO. 315PSL218 PART NO. 315SSL218
3/32
.750
.470
.280
.090
1-3/16
BEFORE CRIMPING
This type can be developed for other cable sizes also.
NOTES: 1. 302 eye holds 85 lbs. max. 2. 315x260 holds 350 lbs. max. 3. 330P eye holds 1600 lbs. max. 4. 340P500 holds 3500 lbs. max. 5. .580 dimensions will be furnished unless otherwise specified. 6. When designing a cable assembly with a bent eyelet, the angle must be specified with a standard tolerance of 5 7. 310 eyelets hold 300 lbs. max.for 1/16 cable.
1/8
.580
.530
.350
.125
1-15/16
1/8
.850
.600
.350
.125
1-13/16
5/32 - 3/16
1.000
.630
.500
.190
2-3/8
1/4
1.250
.750
.700
.250
2-7/8
GENERAL NOTES: Dimensions shown are after swaging. Before swaging, the legs on the shank of the fittings are in a straight-up position. StrengthThese eye fittings require special tooling and considerable tonnage to crimp. Eyelet fittings generate the full rated breaking strength when swaged by Sava on 7x7 or 7x19 cables, except as noted above. Please note, to obtain rated breaking strength, any plastic coating must be removed from cable prior to swaging these fittings. Stainless steel material for eyes is AISI Type 302/304. Hand swaging tools are not available. We recommend that you have these fittings factory applied by Sava.
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455B0500 455B1000* 458B0750 460B0500 460B1000* 465B0500 465B1000* 468B1250 470B0750
GENERAL NOTES: *Old part no. 457 is now 455, 462 is now 460, 467 is now 465. StrengthThreaded plug fittings generate the full rated breaking strength when swaged by Sava on 7x7 or 7x19 cables. Please note, to obtain rated breaking strength, any plastic coating must be removed from cable prior to swaging these fittings. Hand swaging tool availability is limited (see note 5). We recommend that you have these fittings factory applied by Sava. MEASURING POINT FOR ASSEMBLY BALL-END F6 PLUG STRAIGHT PLUG MEASURING POINT FOR ASSEMBLY
PART NO. 401B1* 401B2* 401B3* 401B4* 403B1 403B2 403B3 403B4* 405B1 405B2 405B3 405B4 410B1 410B2 415B
NOTES: *Fittings hold 50% of cable strength. Hand tool T185 available for prototype work on P/N 401, 403, 405, 410 only.
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THREADED PLUG
PART NO. & MATERIAL BRASS STAINLESS STEEL 455S0500 455S1000* 458S0750 460S0500 460S1000* 465S0500 465S1000* 468S1250 470S0750 475S0750 475S1250 475S1500 476S1375 477S1000 477S2000 478S1500 480S1250 480S2250 481S1500 482S1500 483S2000 485S1750 490S2000 CARBON STEEL PLATED 468P1250 470P0750 475P07507 475P12507 475P15003, 7 476P1375 477P1000 477P20003 478P1500 480P1250 480P22503 481P1500 482P1500 483P2000 485P1750 490P2000 FOR CABLE DIA. .010 - .048 .010 - .048 .010 - .048 .028 - .048 .028 - .048 3/64 - 1/16 3/64 - 1/16 3/64 - 1/16 1/16 - 3/32 3/32 - 1/8 3/32 - 1/8 3/32 - 1/8 1/16 - 1/8 1/8 - 5/32 1/8 - 5/32 1/8 - 5/32 3/32 - 3/16 3/32 - 3/16 1/8 - 3/16 1/4 1/4 5/16 3/8 DIMENSIONS (AFTER SWAGING) THREAD SIZE T #5 - 40 #5 - 40 #6 - 32 #8 - 32 #8 - 32 #10 - 24 #10 - 24 #10 - 32 1/4 - 20 1/4 - 20 1/4 - 20 1/4 - 20 1/4 - 28 5/16 - 18 5/16 - 18 5/16 - 24 3/8 - 16 3/8 - 16 3/8 - 24 1/2 - 13 1/2 - 20 5/8 - 11 3/4 - 10 THREAD LENGTH B 1/2 1 3/4 1/2 1 1/2 1 1-1/4 3/4 3/4 1-1/4 1-1/2 1-3/8 1 2 1-1/2 1-1/4 2-1/4 1-1/2 1-1/2 2 1-3/4 2 F 6 .010 7/64 7/64 1/8 9/64 9/64 5/32 5/32 5/32 7/32 7/32 7/32 7/32 7/32 9/32 9/32 9/32 5/16 5/16 5/16 7/16 7/16 9/16 11/16 Ls REF. 1 1-1/2 1-1/4 1 1-1/2 1-1/8 1-5/8 1-7/8 1-5/16 1-9/16 2-1/16 2-5/16 2-3/16 1-15/16 2-15/16 2-7/16 2-1/4 3-1/4 2-1/2 2-13/16 3-5/16 3-5/8 4 NOTES: 1. If you order threaded plugs loose, the cable diameter must be given so that the proper hole can be furnished for the cable you intend to use. 2. Unless stated, all threads are right hand. 3. Available with left hand threads to fit super strength turnbuckles #810, 811, and 812. See page 16. 4. Rolled threads can be made available if requested. 5. Hand tool T185 available for prototype work on parts 455B; 458B; 460B; 465B; and 468B. 6. After swage dimensions. Before swage, the fitting is round. 7. 475P plugs hold 1600 lbs. max.
THREADED PLUG T
MEASURING POINT FOR ASSEMBLY
B Ls
F6
F6 Ls
Ls
BALL-END PLUG
FOR CABLE SIZES .010 - 3/32 FOR CABLE DIA. .010 - .027 .028 - .037 .038 - .046 3/64 .010 - .027 .028 - .037 .038 - .046 3/64 .010 .028 .038 .049 .027 .037 .048 .065 Ls REF. F6 .010 MATERIAL PART NO. 420P 420S 422P 422S 425P 425S 430P 430S 3/8 1/8 Brass 435P 435S 440P 440S 1/2 9/16 5/32 7/32 Brass Brass
STRAIGHT PLUG
FOR CABLE SIZES 1/8 - 3/8 FOR CABLE DIA. 1/8 5/32 3/16 1/4 5/16 3/8 Ls REF. 5/8 11/16 3/4 1 1-1/4 1-9/16 F 6 .010 5/16 7/16 7/16 9/16 11/16 7/8 MATERIAL Plated Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Stainless Steel
5/32
7/64
Brass
1/4
7/64
Brass
3/64 1/16 3/32
NOTES: StrengthStraight plug fittings generate the full rated breaking strength when swaged by Sava on 7x7 or 7x19 cables. Please note, to obtain rated breaking strength, any plastic coating must be removed from cable prior to swaging these fittings. Hand swaging tools are not available. We recommend that you have these fittings factory applied by Sava.
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BALL
PART NO. 552S 553S
FOR CABLE DIA. .006 - .014 .006 - .024 .006 - .024 .009 - .036 .014 - .050 .034 - 1/16 .034 - 1/16 .036 - 3/32 3/32 1/8 5/32 3/16 1/4 5/16
B .005 .035 .060 .080 .090 .125 .156 .190 .250 .250 .310 .380 .440 .570 .690
MATERIAL Stainless Steel Stainless Steel Brass Brass or Stainless Steel Brass or Stainless Steel Brass or Stainless Steel Brass or Stainless Steel Plated Steel Stainless Steel Plated or Stainless Steel Stainless Steel Stainless Steel Plated or Stainless Steel Stainless Steel
AFTER SWAGE SPHERICAL DIA. B
.062 MAX.
555B 557B or 557S 560B or 560S
BALL
GENERAL NOTES: Dimensions shown are after swaging. StrengthBalls swaged by Sava on 1/16 and 3/32 cables with constructions of 7x7 or 7x19, ball fittings hold 80% of rated breaking strength. All others over 3/32 develop 60% of rated cable strength on 7x7 or 7x19 constructions. For 3/64 and below consult factory for breaking strength. For other ball sizes, or for strength of fittings swaged over plastic, consult factory. Balls can be swaged along the length of the cable. Before swage, ball fittings are oval in shape. If ball is ordered loose, please state cable diameter you intend to use. Hand swaging tools are not available. We recommend that you have these fittings factory applied by Sava.
562B or 562S 565B or 565S 570P 570S 573P or 573S 575S 578S 580P or 580S 582S
NOTE: 562 Balls with 1/16 cable hold min. 200 lbs.
BALL AND SHANK*

AFTER SWAGE SPHERICAL DIA. B
A .062 MAX.
PART NO. 505B 505S
FOR CABLE DIA. .012-.036 3/64 1/16 3/32 1/8 5/32 3/16 1/4 5/16
A .010 .075 .112 .143 .190 .222 .255 .348 .413
B .010 .125 .190 .253 .315 .379 .442 .567 .694
Ls REF .085 .156 .234 .313 .391 .470 .625 .810
MATERIAL Brass Stainless Steel Stainless Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Stainless Steel Stainless Steel Stainless Steel
Ls
510S1 510S2* 515P 515S* 520P 520S* 522S* 525P 525S* 530S* 535S* NOTE: *Per MS-20664
BALL AND SHANK

GENERAL NOTES: Dimensions shown are after swaging. StrengthBall and shank fittings generate the full rated breaking strength when swaged by Sava on 7x7 or 7x19 cables, except for the 505 which is capable of holding 80%. Please note, to obtain rated breaking strength, any plastic coating must be removed from the cable prior to swaging these fittings. Hand swaging tools are not available. We recommend that you have these fittings factory applied by Sava.
STRAP FORK (REF. NAS 1435-K)*

C D F E
PART NO. SF2 SF3 SF4
STAINLESS STEEL REF. NAS PART NO. NAS 1435K-2 NAS 1435K-3 NAS 1435K-4
CABLE DIA. 1/16 3/32 1/8
A REF. 1-1/16 1-1/2 1-5/8
B REF. .454 .616 .638
C .010 .188 .188 .188
D REF. .042 .049 .093
E REF. 3/8 7/16 1/2
F REF. .093 .108 .195
LBS. PER PIECE .006 .013 .030
B A MEASURING POINT FOR ASSEMBLY
STRAP FORK
STRAP EYE (REF. NAS 1435-E)*

C D B A MEASURING POINT FOR ASSEMBLY E
PART NO. SE2 SE3 SE4
STAINLESS STEEL REF. NAS PART NO. NAS 1435E-2 NAS 1435E-3 NAS 1435E-4
CABLE DIA. 1/16 3/32 1/8
A REF. 1-1/16 1-1/2 1-5/8
B REF. .454 .616 .638
C .010 .188 .188 .188
D REF. .088 .103 .190
E REF. 3/8 7/16 1/2
LBS. PER PIECE .006 .013 .030
STRAP EYE
NOTE: *Ball and Shank is always recommended for use with strap terminals (noted above).
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FOR CABLE PART NO. DIAMETERS 7000B 7000S (S1) 7020B (B1) 7020S 7025B 7025S 7030C (C1) 7030S 7047C (C1) 7047S (S1) 7062A 7062C (C1) 7062S 7092A 7092C 7092S 7125A 7125C 7125S 7156A 7156C 7156S 7187A (A1) 7187C 7187S 7218A 7218C 7250A 7250C 7250S 7312A (A1) 7312C 7375A (A1) 7375C .006 - .014 .016 - .022 .023 - .026 .027 - .038 .039 - .054
NOTES: For large diameter cable sleeves, different lengths or finishes, consult factory. Loop sleeves per MS51844 also available, consult factory.
Thimbles, used with loop sleeves or malleable wire clips, protect cable from wear and tear. They help to distribute the load on the cable over a larger area, thereby increasing the life of the cable. Thimbles come in either cold-rolled steel (zinc plated) or stainless steel (natural finish).
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LOOP SLEEVES
MATERIAL Brass Stainless Steel Brass Stainless Steel Brass Stainless Steel Ls REF. AFTER SWAGE .19 .25 (.06) .28 (.11) .25 .28 .28 USE TOOL & CAVITY NO. Pliers Factory Applied T185-A Factory Applied T185-A Factory Applied T185-D Factory Applied T185-B or T188-1 Factory Applied T185-C or T188-2 T185-C or T188-2 T188-1 T188-3 T188-3 51-C-887 or T188-2 T188-4 T188-4 51-G-887 or T188-3 T188-5 T188-5 51-M-850 or T188-4
When ordering assemblies, specify P pin dia. and D distance from bearing point to fitting. P should be at least five (5) times the cable diameter for guaranteed breaking strength and D should be at least 2.5 times P.
NOTES: 1. Although the stainless steel loop sleeves are available loose, they are usually factory applied. 2. Wherever possible, thimbles should be used with loop sleeves to protect the cable. 3. Specify pin P diameter. Strengthwhen crimped over bare cable, standard length loop sleeves generate full breaking strength of cable. For shorter loop sleeves with suffix 1 or sleeves swaged over plastic, consult factory. Stainless steel sleeves generate a minimum of 85% of cable rated breaking strength. Depending on size and material, loop sleeves may have round, oval or figure eight shape. Call factory for details, if required. Copper may be substituted for brass, depending on availability.
Zinc-Plated Copper .28 (.16) Stainless Steel .28 Zinc-Plated Copper .44 (.18) Stainless Steel .38 (.18) Aluminum .46 Zinc-Plated Copper .42 (.32) Stainless Steel .45 Aluminum Zinc-Plated Copper Stainless Steel Aluminum Zinc-Plated Copper Stainless Steel Aluminum Zinc-Plated Copper Stainless Steel .63 .50 .44 .81 .75 .42 1.03 .88 .78
1/16
3/32
1/8
5/32
LOOP CRIMPS
Loop crimps are factory applied splices, which are very economical and hold approximately 50% of cable breaking strength dependent on cable size and type used. Not sold in bulk.
PART NO. 7010B 7010S 7015B* 7015S* 7050B 7050P 7050S FOR CABLE DIAMETERS .009 - .027 .024 - .038 3/64 - 3/32 MATERIAL Brass Stainless Steel Brass Stainless Steel Tin-Plated Brass Tin-Plated Steel Stainless Steel Ls REF. AFTER SWAGE .09 .17 .26
3/16
Aluminum 1.19 (.55) T188-6 Zinc-Plated Copper 1.25 T188-6 Stainless Steel 1.10 51-P-850 or T188-5 Aluminum Zinc-Plated Copper Aluminum Zinc-Plated Copper Stainless Steel 1.50 1.06 1.63 1.50 1.50 Factory Applied 51-F2-850 3-F6-950 3-F6-950 Factory Applied Factory Applied Only Factory Applied Only
7/32
1/4
5/16 3/8
Aluminum 1.70 (.86) Zinc-Plated Copper 1.38 Aluminum 2.38 (.95) Zinc-Plated Copper 1.63
NOTE: *7015B was 7010B2 and 7015S was 7010S2
THIMBLES
C
TO FIT CABLE DIA. IN INCHES COLD ROLLED STEEL ZINC PLATED Military Spec. STAINLESS STEEL Military Spec. A Ref. B Ref. DIMENSIONS WT.
C Ref.
D Ref.
E Ref.
F Ref.
Per 1000 2 1.5 4.3 6 9.8 15
F A E D
.015 - 3/64 AN100-C1* .190 1/4 1/8 3/32 .015 3/64 3/64 - 1/16 - 5/64 AN100-3 AN100-C3 .350 45/64 3/16 3/32 .032 5/64 3/32 - 7/64 - 1/8 AN100-4 AN100-C4 .350 45/64 7/32 9/64 .032 5/64 5/32 AN100-5 AN100-C5 .400 51/64 7/32 11/64 .032 7/64 3/16 AN100-6 AN100-C6 .500 1 5/16 13/64 .032 9/64 7/32 - 1/4 AN100-8 AN100-C8 .700 1-13/32 13/32 17/64 .032 11/64 The following thimbles are hot galvanized, heavy-duty type. D dimension on these thimbles is the overall thickness. FF-T-276b 5/16 1 1-7/8 1/2 Type III FF-T-276b 3/8 1-1/8 2-1/8 3/4 Type III
140 250
NOTES: Some thimbles may have open and/or uneven ends. Thimbles are recommended with loop sleeves above or with wire rope clips, see page 18. *AN100-C1 is a miniature stainless steel thimble which has no applicable military specification.
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TURNBUCKLES
THREAD T L F END A E END B PART NO. 0801TB 0802TB 0803TB 0804TB CABLE DIA. .010 - 3/64 1/32 - 3/64 3/64 - 1/16 3/32 - 1/8 THREAD T #5 - 40 #8 - 32 #10 - 24 1/4 - 28 LENGTH L .015 1.00 1.12 1.25 2.13 LENGTH FLATS E F REF .010 .68 .80 .79 1.19 .187 .218 .250 .375 MATING PARTS END A END B #403 Ball End Plug #455 Threaded Plug (Factory Applied) #403 Ball End Plug #460 Threaded Plug (Factory Applied) #405 Ball End Plug #465 Threaded Plug (Factory Applied) #415 Ball End Plug #476 Threaded Plug (Factory Applied)
LOOP ASSEMBLY
(Fittings Can Be Made Shorter to Conserve Space) Note 3
THRU BULKHEAD
NOTES: Standard Turnbuckle material is brass. See page 13 for ball end plug and thread plug dimensions and materials. Specify if nut is required. If applicable consult factory for breaking strength limits.
MINIATURE PRECISION TURNBUCKLES

Groove Signifies Left Hand Thd. No 11 R.H. 1-1/4 No 11 L.H. .142 .250 1-7/8 PART NO. 0011TB00 0011TB01 0011TB02 CABLE DIA. ** .010-.048 .010-.048 TURNBUCKLE MATERIAL Brass Brass Brass MATING PARTS* (BRASS, PLATED STEEL, OR S.S.) Eye (No. 11 L.H.) + Eye (No. 11 R.H.) Eye (No. 11 L.H.) + Plug (455B0500 R.H.) Plug (455B0500 L.H.) + Plug (455B0500 R.H.)
Length Open
Length 2-1/2
2-1/2 Max. Closed
(Eyes 3 turns in)
(Eyes fully in)
NOTES: Maximum pull strength 150 lbs. Check cable strength limit. Each turnbuckle furnished with #5-40 R.H. and L.H. nut for locking purposes. *Mating parts may vary pending availability **Cable diameter must not exceed 3/32 through eyelet hole.
SUPER STRENGTH TURNBUCKLES

Super strength turnbuckles are engineered for heavy-duty use and are designed to compete with drop forged strength at less cost. Bodies are made from a high-density aluminum alloy. Eyes are welded and bright zinc plated. Meet federal specifications for strength tests. Jam nuts are available, if required. Eye shape may vary, pending stock availability.
EYE & EYE

PART NO. EYE & THREADED PLUG 0810TB01 0811TB01 0812TB01 THREADED PLUG & THREADED PLUG 0810TB02 0811TB02 0812TB02
THREADED PLUG & THREADED PLUG

CABLE DIA. 3/32 - 1/8 5/32 3/16 THREAD SIZE 1/4 - 20 5/16 - 18 3/8 -16 TAKE UP REF. 2-1/8 2-5/8 3 BARREL LENGTH REF. 2-7/8 3-1/2 4
THREADED PLUG & EYE

EYE & EYE LENGTH CLOSED REF. 5-1/4 6-1/2 8 SAFE WOKING LOAD LBS. 310 540 820
EYE & EYE 0810TB00 0811TB00 0812TB00
NOTES: Threaded plug for 0810 is 475P1500, threaded plug for 0811 is 477P2000, threaded plug for 0812 is 480P2250; see page 13 for reference. Ultimate load is 5 times safe working load.
DROP FORGED END FITTINGS

SAVA is equipped to manufacture cable assemblies utilizing various drop forged fittings, as shown below. For availability of different types and dimensions, contact SAVA.
HOOK WITH OR WITHOUT SAFETY LATCH ROD END YOKE END
FOR CABLE SIZES 1/8 TO 3/8
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SAVA is offering several designs of ruggedly built safety snap hooks. These hooks come with a spring-loaded safety snap which rests against the inside of the hook preventing accidental dislodgement of the cable. Safety snap hooks can be incorporated in an assembly by us or sold separately.
PLATED STEEL SSH5P SSH6P SSH8P
NOTE: *Maximum safe working load is determined by the end user. At least 5:1 safety factor is generally advised.
NOTES: Designed for smaller cables, these hooks are made of stainless steel wire. The swivel is nickel-plated brass.
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SAFETY SNAP HOOKS

PART NO. SH0750
Material Eye size Overall length Snap opening Ultimate breaking strength Safe working load Galvanized Steel 3/4 Ref. 4 Ref. 3/4 Ref. 3750 lbs. 750 lbs.
PART NO. SH2000

Material Eye size Overall length Snap opening Ultimate breaking strength Safe working load Galvanized Steel 11/16 Ref. 4-3/8 Ref. 7/8 Ref. 9000 lbs. 2000 lb.
PART SSHE
PART NO. SSH PART NO. SSHE
PART SSH
MINIMUM BREAKING STRENGTH LBS.* PLATED STEEL 400 600 1200 STAINLESS STEEL 600 800 1500
STAINLESS STEEL PLATED STEEL SSH5S SSH6S SSH8S SSHE5P SSHE6P SSHE8P
STOCK SIZE REF. .200 .240 .310
OVERALL LENGTH REF. 2.10 2.40 3.10
SNAP OPENING REF. .250 .312 .375
WIRE SNAP HOOKS

WITHOUT SWIVEL
P H W
WITH SWIVEL
P T
L PART NO. WITHOUT SWIVEL SS2 SS3 SS4 SS5 SS6 SS7 WITH SWIVEL SSB2 SSB3 SSB4 SSB5 SSB6 SSB7 APPROX. TEST LBS. WITHOUT SWIVEL 50 75 150 200 250 450 WITH SWIVEL 30 75 100 150 225 350 L REF. 5/8 13/16 1-1/8 1-3/8 1-3/4 2 S REF. 1-1/16 1-5/16 1-13/16 2-1/8 2-3/4 3-1/4
W REF. 3/16 3/16 1/4 5/16 7/16 9/16
P REF. .052 .060 .084 .097 .134 .170
H REF. .087 .125 .140 .170 .190 .250
T REF. .075 .120 .140 .168 .190 .237
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TOOLS AND CUTTERS*

T185 COMPOUND CRIMPING TOOL
This four-nested precision crimping tool gives compound leverage of at least 15-1. Crimped properly, it will give full strength on copper and aluminum loop sleeve fittings 7020, 7025, 7030, 7047, and 7062. On ball end plug part nos. 401, 403, 405, and 410 and on threaded plug part nos. 455B, 458B, 460B, 465B, and 468B, it will give approximately 50% of rated cable strength when swaged over the nylon. Strip nylon for best swaging bond. This tool is designed for use on 7x7 or 7x19 construction cables. The scissor-action plier-type tool has jaws which are made of a tough chrome alloy steel. All component parts of the tool are hardened and tempered. The handles have nonslip plastic grips. Easy to use. Overall length 8-1/2. Shipping weight: 1 lb.
T188 COMPOUND CRIMPING TOOL

T188 is a six-cavity multiple-sleeve crimping tool and is made of high carbon steel, heat treated and hardened with centerless ground shoulder bolts. It is used on loop sleeves and stop sleeves from 3/643/16 as indicated on page 15. It covers a range of cable strengths from 270 lbs. to 4200 lbs. in both galvanized and stainless steel cables. Each tool is clearly size-coded, is shipped with full instructions and includes a go gauge for after crimping. Tool length: 20. Shipping weight: 5 lbs.
NOTE: We have determined through testing that the copper, aluminum, and stainless steel loop sleeves will hold in excess of 90% of nominal strength of galvanized or stainless steel cables manufactured to the fabrication requirements of MIL-DTL-83420 for 7x7 or 7x19 cables. See page 15 for strengths of stop sleeves. The holding power of sleeves on your cable should be checked by pull testing since the diameter and fabrication can vary from cable to cable. For cables of 1x7 or 1x19 construction, the use of two sleeves is recommended as well as thorough testing.
T-185
The T185/T188 tool is designed primarily for prototype or short-run applications. The strength of the crimp depends mainly upon the amount of pressure applied to the handles. For consistency, the same pressure should be applied when making more than one assembly. We recommend that all assemblies made with the T185/T188 be tested before use.
T-188 *NOTE: Select tool or cutter carefully; follow recommendations indicated. Consult factory if in doubt. Tools and cutters are not returnable. Strength of joint is a responsibility of the tool user.
A cable, when crushed or deformed in cutting, is difficult to use with fittings. These Swiss made, precision cable cutters, with unique triangular jaws, are designed to prevent frayed ends.
C07 CABLE CUTTER Capacity 3/16 diameter, length 8, weight 10 oz.
C09 CABLE CUTTER Capacity 1/4 diameter, length 13, weight 2 lbs.
C12 CABLE CUTTER Capacity 3/8 diameter, length 20, weight 3 lbs. NOTE: Other tools may be available, consult our office with your requirements
STOP SLEEVES
STOP SLEEVE
MALLEABLE WIRE ROPE CLIPS, STAINLESS STEEL AND GALVANIZED

Standard wire rope clipsdesigned for maximum holding stength. Heavy-duty construction throughout. For in-between sizes, use next larger size clip.
PART NO. WRC02G WRC02S WRC04G WRC04S WRC06G WRC05S WRC08G WRC06S WRC10G WRC08S WRC12G MATERIAL Malleable Steel Stainless Steel Malleable Steel Stainless Steel Malleable Steel Stainless Steel Malleable Steel Stainless Steel Malleable Steel Stainless Steel Malleable Steel FOR CABLE DIA. 1/16-3/32 1/8 - 5/32 3/16 - 7/32 1/4 - 9/32 5/16 3/8 - 7/16 RECOMMENDED NO. OF CLIPS 2 2 3 3 3 3 EST. WT. 100 PCS. IN LBS. 1.5 4.5 6.5 13.2 6.5 12.1 13.2 25.5
SAVA ITEM 8030C 8047C 8062C 8092C 8125C 8156C 8187C 8218C 8250C
REF. OLD PART NO. 803C 804C 805C 806C 807C 808C 809C 810C 811C
FOR Ls REF. TYPICAL TOOL & CABLE AFTER HOLDING GROOVE DIAMETERS CRIMPED STRENGTH LBS. CAVITY 1/32 3/64 1/16 3/32 1/8 5/32 3/16 7/32 1/4 .22 .28 .30 .38 .38 .41 .41 .75 .82 110 240 325 400 900 1200 1600 2500 3500 T185-D T188-1 T188-2 T188-3 T188-3 T188-4 T188-4 51-MJ 3-F6-950
NOTES: Std. material is copper. Cables with 1x19 construction have less holding strength, consult factory. Please note, to obtain typical holding strength above, any plastic coating must be removed from cable prior to swaging these fittings. To obtain proper breaking strength with T188 tool, crimp once, rotate stop sleeve 30 and crimp again or allow factory to swage onto cable. Unless specified, cable will protrude beyond crimped stop sleeve or cable can be ground flush. Also available in aluminum and other alloys, consult factory.
NOTE: Thimbles are recommended with wire rope clips, see page 15.
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ISO 9001 CERTIFIED
Make your own prototype cable assemblies, lanyards, control cabling, etc. Use the finest, most flexible, most durable materialSAVAS Miniature Cablea multiplicity of fine STAINLESS STEEL wires, internally lubricated and coated with a tough abrasion-resistant nylon. When your design is completed, inquire with SAVA about production quantities.
CABLE PART NO. 2009SN 2012SN 2014SN 2018SN 2024SN 2027SN 2031SN 2032SN 2036N 2037SN 2038SN 2047SN 2048 2048SN2 2050SN2 2054SN2 2064 2064SN3 2065 2065SN3
1The nylon must be stripped off to use fitting. 2All threaded plugs will be brass.
NOTE: Tool No. T185 is designed to give full cable strength for the loop sleeves. The ball end plugs and the threaded plugs, crimped over the nylon, will give approximately 50% of the rated breaking strength of the cable when properly applied. All above fittings, when factory applied, will give full rated strength of the cable. To get maximum crimping bond, strip nylon from cable. The T185 is designed for prototype or short-run applications by attaching fittings to cables and is to be used only on brass and copper fittings. We recommend that all assemblies made with the T185 be tested for strength before use.
SO
PROTOTYPE ASSEMBLIES
This package consists of: Precision Crimping Tool No. T185 2 choices of the following 20 cable sizes 4 choices (15 pcs. ea.) of the following fittings
KIT PACKAGE MK 48
SIZE OF SPOOL OR COIL 25 25 25 25 10 25 25 10 25 10 10 10 15 15 15 10 15 15 15 15 OUTSIDE DIAMETER (INCL. COATING) .014 .019 .019 .024 .030 .034 .037 .037 .044 .046 .046 .052 3/64 1/16 1/16 1/16 1/16 3/32 1/16 3/32 CONSTRUCTION BREAKING STRENGTH 10 18 26 40 70 90 120 120 160 160 160 170 270 270 270 250 480 480 480 480 LOOP SLEEVE 7000B 7020B 7020B 7025B 7030C 7030C 7030C 7030C 7047C 7047C 7047C 7047C 7047C 7062A 7062A 7062A 7062A 7062A1 7062A 7062A1 BALL END PLUG 401B1 or 403B1 401B1 or 403B1 401B1 or 403B1 401B1 or 403B1 403B2 or 405B2 403B2 or 405B2 403B2 or 405B2 403B2 or 405B2 403B3 o 405B3 403B3 or 405B3 403B3 or 405B3 405B4 or 410B2 405B3 or 410B1 405B31 or 410B11 405B31 or 410B11 405B41 or 410B21 405B4 or 410B2 405B41 or 410B21 405B4 or 410B2 405B41 or 410B21 THREADED2 PLUG 455B0500 455B0500 455B0500 455B0500 455B0500 or 460B0500 455B0500 or 460B0500 455B0500 or 460B0500 455B0500 or 460B0500 455B0500 or 460B0500 455B0500 or 460B0500 455B0500 or 460B0500 465B0500 465B0500 465B05001 465B05001 465B05001 465B0500 465B05001 465B0500 465B05001
3x7 3x7 7x7 7x7 7x19 7x7 7x7 7x19 7x7 7x19 49+(8x19) 7x49 7x7 7x7 7x19 7x49 7x7 7x7 7x19 7x19
SAVA recommends the use of a thimble when using loop sleeves. Miniature thimble part no. AN100-C1 should be used for cables 2009SN 2048; Part AN100-C3 for cables 2048SN2 2064 and 2065, 2064SN3 and 2065SN3.
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MIL SPEC CABLE AND FITTINGS

MIL-DTL-83420 CABLE
MIL-DTL-83420 cables are primarily used with MS-type terminals for both commercial aircraft and military applications. SAVA sells this cable in bulk or will quote your cable assembly design in compliance with MIL-T-6117 or MIL-T-781. We are fully equipped
SAVA Part No. S030 S048 S064 S065 S094 S095 S126 S158 S188 S252 S315 S375 SAVA Part No. Nominal Cable Dia. in. mm 1/32 3/64 1/16 1/16 3/32 3/32 1/8 5/32 3/16 1/4 5/16 3/8 .79 1.19 1.59 1.59 2.38 2.38 3.18 3.97 4.76 6.35 7.94 9.53
to proof load or prestress your assemblies to reduce constructional stretch and provide fitting reliability. For commercial grades of the equivalent cables at greatly reduced price, please refer to pages, 8, 9, 10 and 11 of this catalog.
Construction Tolerance on Diameter (Plus Only) in. mm .006 .008 .010 .010 .012 .012 .014 .016 .018 .018 .022 .026 .152 .203 .254 .254 .305 .305 .356 .406 .457 .457 .559 .660 Allowable Increase of Dia. at Cut End in. mm .006 .008 .009 .009 .010 .010 .011 .017 .019 .021 .024 .027 .152 .203 .229 .229 .254 .254 .279 .432 .483 .533 .610 .686 Minimum Breaking Strength Composition B lbs. kg 110 270 480 480 920 920 1,760 2,400 3,700 6,400 9,000 12,000 50 122 218 218 418 418 798 1089 1678 2903 4082 5443 Approximate Weight per 100 Feet lbs. kg 0.16 0.42 0.75 0.75 1.60 1.74 2.90 4.50 6.50 11.00 17.30 24.80 0.07 0.19 0.34 0.34 0.72 0.79 1.31 2.04 2.95 4.99 7.85 11.00
TYPE I NON-JACKETED WIRE ROPE

MIL-DTL-83420, LATEST AMENDMENT COMPOSITION B, CORROSION RESISTANT STEEL
3x7 7x7 7x7 7x19 7x7 7x19 7x19 7x19 7x19 7x19 7x19 7x19
Nominal Cable Dia. in. mm 1/32 3/64 1/16 1/16 1/16 1/16 3/32 3/32 3/32 3/32 1/8 5/32 3/16 1/4 5/16 3/8 .79 1.19 1.59 1.59 1.59 1.59 2.38 2.38 2.38 2.38 3.18 3.97 4.76 6.35 7.94 9.53
Construction
Outside Diameter of Jacket in. mm 3/64 1/16 3/32 1/8 3/32 1/8 1/8 5/32 1/8 5/32 3/16 7/32 1/4 5/16 7/16 1/2 1.19 1.59 2.38 3.18 2.38 3.18 3.18 3.97 3.18 3.97 4.76 5.56 6.35 7.94 11.11 12.7
Tolerance on Jacket O.D. (Plus Only) in. mm .008 .010 .012 .014 .012 .014 .014 .016 .014 .016 .018 .018 .018 .020 .024 .027 .203 .254 .305 .356 .305 .356 .356 .406 .356 .406 .457 .457 .457 .508 .610 .686
Jacket Wall Thickness (Reference) in. mm .008 .008 .016 .031 .016 .031 .016 .031 .016 .031 .031 .031 .031 .031 .063 .063 .203 .203 .406 .787 .406 .787 .406 .787 .406 .787 .787 .787 .787 .787 1.60 1.60
Approximate Weight per 100 Feet lbs. kg 0.22 0.49 0.93 1.18 0.93 1.18 1.85 2.18 1.99 2.32 3.62 6.10 7.75 12.30 19.80 27.20 0.10 0.22 0.42 0.53 0.42 0.53 0.84 0.99 0.90 1.05 1.64 2.77 3.51 5.58 8.98 12.34
TYPE II JACKETED WIRE ROPE

MIL-DTL-83420, LATEST AMENDMENT COMPOSITION B, CORROSION RESISTANT STEEL WITH NYLON JACKET
S030N047 S048N063 S064N094 S064N125 S065N094 S065N125 S094N125 S094N156 S095N125 S095N156 S126N188 S158N218 S188N250 S252N313 S315N438 S375N500 SAVA Part No.
3x7 7x7 7x7 7x7 7x19 7x19 7x7 7x7 7x19 7x19 7x19 7x19 7x19 7x19 7x19 7x19
TYPE I NON-JACKETED WIRE ROPE

MIL-DTL-83420, LATEST AMENDMENT COMPOSITION A, CARBON STEEL, TIN OR ZINC COATED
Nominal Cable Dia. in. mm 1/32 3/64 1/16 1/16 3/32 3/32 1/8 5/32 3/16 1/4 5/16 3/8 .79 1.19 1.59 1.59 2.38 2.38 3.18 3.97 4.76 6.35 7.94 9.53
Construction
Tolerance on Diameter (Plus Only) in. mm .006 .008 .010 .010 .012 .012 .014 .016 .018 .018 .022 .026 .152 .203 .254 .254 .305 .305 .356 .406 .457 .457 .559 .660
Allowable Increase of Dia. at Cut End in. mm .006 .008 .009 .009 .010 .010 .011 .017 .019 .021 .024 .027 .152 .203 .229 .229 .254 .254 .279 .432 .483 .533 .610 .686
Minimum Breaking Strength Composition A lbs. kg 110 270 480 480 920 1,000 2,000 2,800 4,200 7,000 9,800 14,400 50 122 218 218 418 453 907 1270 1905 3175 4445 6532
Approximate Weight per 100 Feet lbs. kg 0.16 0.42 0.75 0.75 1.60 1.74 2.90 4.50 6.50 11.00 17.30 24.30 0.07 0.19 0.34 0.34 0.72 0.79 1.31 2.04 2.95 4.99 7.85 11.00
G030 G048 G064 G065 G094 G095 G126 G158 G188 G252 G315 G375 SAVA Part No.
3x7 7x7 7x7 7x19 7x7 7x19 7x19 7x19 7x19 7x19 7x19 7x19
Nominal Cable Dia. in. mm 1/32 3/64 1/16 1/16 1/16 1/16 3/32 3/32 3/32 3/32 1/8 5/32 3/16 1/4 5/16 3/8 .79 1.19 1.59 1.59 1.59 1.59 2.38 2.38 2.38 2.38 3.18 3.97 4.76 6.35 7.94 9.53
Construction
Outside Diameter of Jacket in. mm 3/64 1/16 3/32 1/8 3/32 1/8 1/8 5/32 1/8 5/32 3/16 7/32 1/4 5/16 7/16 1/2 1.19 1.59 2.38 3.18 2.38 3.18 3.18 3.97 3.18 3.97 4.76 5.56 6.35 7.94 11.11 12.7
Tolerance on Jacket O.D. (Plus Only) in. mm .008 .010 .012 .014 .012 .014 .014 .016 .014 .016 .018 .018 .018 .020 .024 .027 .203 .254 .305 .356 .305 .356 .356 .406 .356 .406 .457 .457 .457 .508 .610 .686
Jacket Wall Thickness (Reference) in. mm .008 .008 .016 .031 .016 .031 .016 .031 .016 .031 .031 .031 .031 .031 .063 .063 .203 .203 .406 .787 .406 .787 .406 .787 .406 .787 .787 .787 .787 .787 1.60 1.60
Approximate Weight per 100 Feet lbs. kg 0.22 0.49 0.93 1.18 0.93 1.18 1.85 2.18 1.99 2.32 3.62 6.10 7.75 12.30 19.80 27.20 0.10 0.22 0.42 0.53 0.42 0.53 0.84 0.99 0.90 1.05 1.64 2.77 3.51 5.58 8.98 12.34
TYPE II JACKETED WIRE ROPE

MIL-DTL-83420, LATEST AMENDMENT COMPOSITION A, CARBON STEEL TIN OR ZINC COATED WITH NYLON JACKET
G030N047 G048N063 G064N094 G064N125 G065N094 G065N125 G094N125 G094N156 G095N125 G095N156 G126N188 G158N218 G188N250 G252N313 G315N438 G375N500
3x7 7x7 7x7 7x7 7x19 7x19 7x7 7x7 7x19 7x19 7x19 7x19 7x19 7x19 7x19 7x19
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ISO 9001 CERTIFIED
MS PART NO. STAINLESS STEEL MS-20663-C1* MS-20663-C2 MS-20663-C3 MS-20663-C4 MS-20663-C5 MS-20663-C6 MS-20663-C7 MS-20663-C8 MS-20663-C9 MS-20663-C10
NOTES: *SAVAs P/N MS-20663-C1 has no applicable military specification. All measurements in inches. Dimensions shown are after swaging. Unless otherwise specified, decimal tolerances are .010. STRENGTH: Generates full rated breaking strength of wire rope. USAGE: Swaged to wire rope at ends or in center as control point.
MS PART NO. STAINLESS STEEL MS-20667-2 MS-20667-3 MS-20667-4 MS-20667-5 MS-20667-6 MS-20667-7 MS20667-8 MS-20667-9 MS-20667-10 MS-20667-12
NOTES: All measurements in inches. Dimensions shown are after swaging. Unless otherwise specified, decimal tolerances are .010. STRENGTH: Generates full rated breaking strength of wire rope.
MS PART NO. STAINLESS STEEL MS-20668-2 MS-20668-3 MS-20668-4 MS-20668-5 MS-20668-6 MS-20668-7 MS-20668-8 MS-20668-9 MS-20668-10 MS-20668-12
NOTES: All measurements in inches. Dimensions shown are after swaging. Unless otherwise specified, decimal tolerances are .010. STRENGTH: Generates full rated breaking strength of wire rope.
SO
MS-20663 BALL AND DOUBLE SHANK

FOR CABLE DIA. 1/32 - 3/64 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 .075 .112 .143 .190 .222 .255 .302 .348 .382 .413 As DIA. REF. + .000 - .003 + .000 - .004 + .000 - .005 + .000 - .007 Bs SPHERICAL DIA. .125 .190 .253 .315 .379 .442 .505 .567 .632 .694 .003 + .000 - .003 + .000 - .004 + .000 - .005 + .000 - .007 Ls APPROX. .180 .390 .578 .765 .953 1.140 1.328 1.515 1.719 1.875 Rs MAX RAD. .012 .014 .019 .023 .028 .033 .038 .042 .046 .046
Rs Bs Ls
As
MS-20664 SINGLE BALL AND SHANK

See page 14.
MS-20667 FORK
FOR CABLE DIA. 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 3/8 As DIA. .138 .190 .219 .250 .313 .375 .438 .500 .563 .625 D DIA. F + .010 - .005 .218 .254 .383 .406 .543 .625 .688 .719 .765 .830 G .003 .093 .108 .195 .202 .260 .296 .313 .327 .348 .380 H .500 .670 .735 .800 .880 .970 1.070 1.170 1.268 1.525 LS APPROX. 1.75 2.06 2.61 3.00 3.24 3.74 4.10 4.48 4.86 5.74 U DIA. .344 .438 .547 .688 .781 .906 .969 1.156 1.265 1.500
U D H
.190 + .000 - .005 + .000 - .007 + .000 - .008 .250 + .002 - .000 .375 .438 +.005 - .000
G F
As
Ls MEASURING POINT FOR ASSEMBLY
.500
MS-20668 EYE
FOR CABLE DIA. 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 3/8 As DIA. .138 .190 .219 .250 .313 .375 .438 .500 .563 .625 C .020 .523 .707 .738 .831 .903 1.007 1.133 1.257 1.373 1.688 D DIA. .088 .103 .190 .197 .255 .291 .307 .322 .343 .375 J LS APPROX. 1.809 2.160 2.593 3.029 3.187 3.678 4.062 4.512 4.969 5.968 U + .025 - .010 DIA. .359 .438 .500 .640 .781 .813 .968 1.109 1.218 1.500
As U
.190 .250 .313 .375 .438 +.005 -.000 +.002 - .000
+.000 -.005 +.000 -.007 +.000 -.008
+.000 - .005
Ls
.500
+.000 -.015
C MEASURING POINT FOR ASSEMBLY
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ISO 9001 CERTIFIED
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MS-21259 THREADED TERMINALS

MS PART NO. STAINLESS STEEL LH THREAD MS-21259-2-LH MS-21259-3-LH MS-21259-4-LH MS-21259-5-LH MS-21259-6-LH MS-21259-7-LH MS-21259-8-LH MS-21259-9-LH MS-21259-10-LH MS-21259-12-LH RH THREAD MS-21259-2-RH MS-21259-3-RH MS-21259-4-RH MS-21259-5-RH MS-21259-6-RH MS-21259-7-RH MS-21259-8-RH MS-21259-9-RH MS-21259-10-RH MS-21259-12-RH FOR CABLE DIA. 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 3/8 THREAD B* NF-3A UNF-3A # 6-40 #10-32 1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 .138 .190 .219 .250 .313 .375 .438 .500 .563 .625 + .000 - .007 + .000 - .008 + .000 - .005 As DIA. D REF. .188 .250 .313 .375 .438 .500 .625 .688 .750 E REF. .156 .187 .250 .312 .375 .438 .563 .625 .688 Ls APPROX. 2.65 3.00 3.59 3.97 4.17 4.81 5.24 5.75 6.27 7.06
DRILL R CSK 90 x U BOTH SIDES
R + .005 .000 DIA.
U DIA.
Y + .063 .000 1.045
.063
.094
1.204 1.376 1.376 1.453 1.625
.098
.125
1.750 1.875 2.000 2.250
NOTES: All measurements in inches. Dimensions shown are after swaging. Unless otherwise specified, decimal tolerances are .010. STRENGTH: Generates full rated breaking strength of wire rope. *THREADS: Right-hand (RH) and left-hand (LH) threads available; unless otherwise specified, right-hand threads will be furnished. These terminals are not to be used with turnbuckle barrels.
MEASURING POINT FOR ASSEMBLY D Y
As
OR E THREAD B* Ls APPROX.
MS-21260 THREADED TERMINALS

MS PART NO. STAINLESS STEEL LH THREAD MS-21260-L2-LH MS-21260-S2-LH MS-21260-L3-LH MS-21260-S3-LH MS-21260-L4-LH MS-21260-S4-LH MS-21260-L5-LH MS-21260-S5-LH MS-21260-L6-LH MS-21260-S6-LH MS-21260-7-LH MS-21260-8-LH MS-21260-9-LH MS-21260-10-LH MS-21260-12-LH RH THREAD MS-21260-L2-RH MS-21260-S2-RH MS-21260-L3-RH MS-21260-S3-RH MS-21260-L4-RH MS-21260-S4-RH MS-21260-L5-RH MS-21260-S5-RH MS-21260-L6-RH MS-21260-S6-RH MS-21260-7-RH MS-21260-8-RH MS-21260-9-RH MS-21260-10-RH MS-21260-12-RH 7/32 1/4 9/32 5/16 3/8 7/16-20 1/2-20 9/16-18 3/8-24 .375 .438 .500 .563 .625 + .000 - .008 + .000 - .007 .361 .406 .476 .306 .438 .500 .625 .668 .750 .375 .438 .563 .625 .688 3/16 5/16-24 .313 .245 .375 .312 5/32 1/8 1/4-28 .250 .219 + .000 - .005 .195 .313 .250 3/32 #10-32 .190 .133 .250 .187 FOR CABLE DIA. 1/16 THREAD B* NF-3A UNF-3A # 6-40 .138 As DIA. C + .006 - .000 DIA. .092 D REF. E REF. F REF. 2.172 1.297 2.157 1.282 2.157 1.282 2.157 1.282 2.157 1.282 2.157 2.157 2.157 2.157 2.327 Ls APPROX. 3.67 2.79 3.86 2.98 4.28 3.40 4.66 3.78 4.78 3.90 5.21 5.52 5.90 6.30 7.01 1.125 1.000 .750 .098 .125 .875 .625 .563 .063 .094 .500 R + .005 .000 DIA. U DIA. Y .047
.188
.156
.375
THREAD B*
NOTES: All measurements in inches. Dimensions shown are after swaging. Unless otherwise specified, decimal tolerances are .010. STRENGTH: Generates full rated breaking strength of wire rope. D *THREADS: Right-hand (RH) and left-hand (LH) threads available; unless otherwise specified, right-hand threads will be furnished. Normally used in conjunction with turnbuckle barrel MS-21251. OR L and S designation refers to long and short shanks on threaded end.
E
DRILL R CSK 90O x U BOTH SIDES Ls F
C Y MEASURING POINT FOR ASSEMBLY
As
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ISO 9001 CERTIFIED
Push-pull and pull-pull cable controls offer a reliable method of transmitting motion between two fixed points or between points which are changing their relative position. Because of flexibility, they can be routed up, down, over obstacles and around corners without intermediate links or pulleys. Fewer working parts increase operational dependability of cable controls. They
CONSTRUCTION
The basic component of a push-pull control consists of a solid wire with a casing of plastic tube or spirally wrapped wire. See Figure 1. Substituting a flexible cable for the solid wire allows the control system to be bent to facilitate routing. Different fittings as shown in the following text can be attached to the ends of the casing and cable for ease of operation. Figure 1
LOSS OF MOTION
The principal elements of lost motion in a control system are backlash and deflection. See Figure 2. Backlash is caused by the core member moving inside the casing with the change in direction of motion. It is a function of the clearance between the core and casing and total number of degrees of bend in the cable. This can be reduced by careful design. The other cause of loss of motion is deflection of the core wire under compressive load. Elastic strain in the core member due to compressive or tensile force also contributes to the loss of motion. The casing must be anchored securely to keep it from responding to the compression or tension modes of input loading. Lost Motion Tension Load Compression Load Figure 2
TRAVEL
Travel of the core inside the casing should be kept to a minimum since longer travel increases friction and decreases output. In the push-pull type of application, the chance of buckling of the core becomes greater. The travel should be limited to less than 5 if possible. The linear speed of operation should be relatively low.
INPUT LOAD FACTOR

INPUT LOAD FACTOR
Friction between the core and the casing causes a loss in output force for a certain amount of input force. Friction is a function of the degrees of bend in the system. The ratio of the input force to the output force is called the Input Load Factor. The Input Load Factor has been plotted against the degrees of bend in the system and is shown in the accompanying graph. For selecting the right control system, the input load has to be determined by multiplying the output load with the Input Load Factor obtained from the graph using the following formula: I = Input Load P = Output Load F = Input Load Factor (from graph) I=PxF Example: Consider a push-pull assembly with metal-lined casing requiring an output load of 6 lbs. Total degrees of bend in the system270. Input Load Factor from chart2.05. Input Load = 6 x 2.05 = 12.30 lbs.
3.0 2.8 2.6 2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0 0
O
SO
PUSH-PULL CONTROL ASSEMBLIES

are virtually maintenance free as no periodic adjustments are necessary due to wear and tear of worn connections. Cable controls do not transmit noise and vibration. SAVA is flexible enough to handle small as well as large volume orders for cable controls. A wide variety of end fittings are available to the designer for use with the casings and core cables.
BEND RADII AND LIFE

Cable bend radii should always be as generous as possible for maximum cable life and efficiency. Smaller bends cause reduced service life because of added friction. Depending on the size of the casing and the construction of the moving core member, the minimum recommended radius can vary from 2 to 8 inches.
METAL-LINED CASING
PLASTIC-LINED CASING 90
O
180
270
360
450
DEGREES OF BEND IN SYSTEM
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PUSH-PULL CASING AND CORES

For light load applications casing made from nylon can be used. For heavier loads casing made from a round or half round wire tightly wound to resemble a closed spring is good for most applications. This type of casing is flexible, resists kinking and can be clamped or terminated without distortion of the wall. The casing can be ordered with a plastic coating. Casing with a plastic liner offers reduced friction and less start-up inertia.
PART NO. C0901 C130N1 C070 C070VC C096 C132 C132VC C187 CASING O.D. REF. 0.09 0.13 0.07 .070 w/Black PVC to .090 0.096 0.132 .132 w/Black PVC to .170 0.187 .187 w/Black HDPE to .225 0.187 .187 w/Black HDPE to .225 0.277 .277 w/Black HDPE to .305 0.277 .277 w/Black HDPE to .305 CASING I.D. REF. 0.040 0.060 0.035 0.035 0.050 0.060 0.060 0.080 0.080 0.080 0.080 0.140 0.140 0.140 0.140 STANDARD CASING MATERIAL Nylon Nylon Galv. Steel Galv. Steel Galv. Steel Galv. Steel Galv. Steel Galv. Steel Galv. Steel Galv. Steel w/HDPE Lining Galv. Steel w/HDPE Lining Galv. Steel Galv. Steel Galv. Steel w/HDPE Lining Galv. Steel w/HDPE Lining SOLID CORE WIRE SIZE .020 S.S. .032 S.S. .020 S.S. .020 S.S. .032 S.S. .036 S.S. .036 S.S. .054 S.S. .054 S.S. .054 S.S. .054 S.S. N/A N/A N/A N/A 1x7, 1x19 7x7 CORE CABLE RANGE .015 - .027 .024 - .040 .018 - .027 .018 - .027 .027 - .037 .036 - .050 .036 - .050 .045 - .063 .045 - .063 .045 - .063 .045 - .063 3/32 3/32 3/32 3/32
LUBRICATION
Generally, lubrication is not advised in the casing. Lubricant tends to collect dirt, which impedes the movement of the core inside the casing. The core cable can perform efficiently with little or no lubrication. If lubricant is desired for a particular application, it must be specified by the customer which lubricant to be applied to the core cable prior to the assembly.
C187PC C187PL C187PLPC C2772 C277PC2 C277PL C277PLPC
NOTES: 1 Nylon casing is molybdenum disulfide impregnated for friction reduction. 2 C277 and C277PC casing may be provided with HDPE lining, based on availability.
Casings available from stock are shown in the chart above. For other types of casing such as stainless steel and other sizes consult factory.
END TERMINALS FOR CORE WIRES

The simplest core is a solid wire which is adequate for low input loads and minimum bends. If the force is only in the pull direction, a stranded cable can be used with much tighter bends. Simple terminations can be provided on a solid core wire by forming the high tensile steel wire in the typical shapes shown below. Some catalog fittings, such as eyes, end plugs, etc. can be used on solid wire. Please consult factory.
CENTERED LOOP
OFFSET LOOP
U BEND
Z BEND
L BEND
END TERMINALS FOR CORE CABLES

At right are shown typical cable fittings used as push-pull cable core terminals. The dimensions for these should be taken from our catalog using the proper cable core size. Special terminals can also be manufactured.
BALL (PG. 14)
STOP SLEEVE (PG. 15) OR END PLUG (PG. 13)
THREADED PLUG (PG. 13)
LOOP SLEEVE (PG. 15)

24
EYELET (PG. 12)
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ISO 9001 CERTIFIED
For many applications simply clamping the casing close to the end of the control is acceptable. However, casing fittings can be applied directly to the ends. Special fittings developed for this purpose are shown below.
GROOVED TERMINAL 6005 6006 6008 6013 6014
NOTES: 1State material required by suffix - B (Brass) - S (S.S.) - P (Plated Steel). 2This dimension can be modified for special snap rings.
NOTES: 1Part no. 6465 is available in brass and stainless steel; the rest of the terminals are available in plated or stainless steel. State material required by suffix B (Brass), S (S.S.), P (Plated Steel). Other thread lengths and specials are available; see page 13. Jam nuts and washers furnished unless otherwise specified. To complete part no., add casing no. desired. (such as 6475S096)
2Hole
PART NO. 951N 952N 953P1 954P1 955P1 956P1
NOTE: 1The steel clamps are vinyl lined.
SO
END TERMINALS FOR CORE CASING
CAP AND GROOVE TERMINALS

PART NO.1 CAP TERMINAL 6105 6106 6108 6113 6114 AVAILABLE WITH CASING NO. C070,C070VC,C096 C132, C132VC C187, C187PC C187PLPC C187PL C277, C277PC A REF. .98 .98 1.00 1.25 1.50 B REF. .74 .74 .76 .87 1.12 C REF. .19 .25 .25 .38 .44 D REF. .125 .180 .180 .250 .344 E2 REF. .090 .090 .090 .130 .130 F REF.
SHOWN AFTER CRIMPING
.047 .063 .080 .125 .125
CAP TERMINAL
GROOVE TERMINAL
BULKHEAD TERMINALS
PART NO. AVAILABLE WITH CASING NO. C070, C070VC C070, C070VC, C096 C096, C132, C132VC C132, C132VC, C187, C187PC, C187PL, C187PLPC C187, C187PC, C187PL, C187PLPC C277, C277PC G REF. 1.62 2.06 1.94 2.25 2.81 3.38 H REF. 1.00 1.25 1.00 1.25 1.50 1.75 J REF. .19 .25 .31 .38 .50 .63 T REF. #10-24 1/4-20 5/16-18 3/8-16 1/2-13 5/8-11
64651
6475 6477 6480 6482 6485
BULKHEAD TERMINAL
size will match inside diameter of casing.
CLAMP TERMINAL
WIRE CLAMP
PART NO. WC-1 MATERIAL: PLATED STEEL
CLAMP TERMINALS FOR CASING

MATERIAL Nylon Nylon Plated Steel Plated Steel Plated Steel Plated Steel USED FOR CASING C130N C070 C132 C132VC C187, C187PLPC C187PL, C187PC C277 C277PC A REF. 5/16 9/32 11/32 13/32 7/16 5/8 B REF. 13/64 5/32 3/16 7/32 7/32 3/8 C REF. 1/2 3/8 3/8 1/2 1/2 5/8 D REF. 3/16 1/8 11/64 13/64 13/64 11/32
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ISO 9001 CERTIFIED
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OTHER TYPES OF CONTROLS AVAILABLE

PART NO. PPC1 AND PPC11
PUSH-PULL CONTROL
This type of push-pull assembly is ideal for choke or damper control. Fits wire size .054 or cable diameter .045-.063 with C187 series casing (see pg. 24).
ITEM PPC1 PPC11
A REF. 31/32 3/4
B REF. 3-9/16 3-1/8
D REF. 1-1/16 7/8
T REF. 2-1/4 1-1/2
LOCKING PUSH-PULL CONTROL

This control provides infinite adjustment for its entire travel. The operator can position the control where desired and then lock it in place by turning it clockwise. Specially suited for applications where spring tension or vibration causes ordinary controls to creep. Fits wire size .054 or cable diameter .045-.063 with C187 series casing (see pg. 24). All PPC part numbers will consist of the following: 1 knob with plunger 1 sleeve with face plate 1 lock washer 1 jam nut
ITEM PPC2 PPC22
PART NO. PPC2 AND PPC22
For assembly order please specify length of casing and wire. Part numbers PPC11 and PPC22 are less expensive, have shorter travel, and are intended for lighter duty applications.
A REF. 1-3/4 1-5/8
B REF. 4-1/8 2-15/16
T REF. 3 2
NOTE: PPC2 may not be available in small quantity. Consult factory.
DESIGN PROCEDURE
1. Select a cable suitable to withstand the load. Keep in mind, the more wires in a cable the more flexible the cable will be. For push-pull types of application the solid core wire will be most suitable. Next to that a 1x7 or 1x19 construction cable may be used where the movement is small and the casing is adequately constrained. Select a casing and make a scale layout drawing. Try to keep the number of bends to a minimum and the radii of bends to a maximum. The radius should not be less than 100 times the core diameter. Remember, the lighter casing with a light load will be more flexible. 2. Build a prototype of the design in its final configuration. Apply loads to determine performance characteristics. 3. Determine exact dimensions of the assembly from the prototype. Check tolerances on all components to keep the length at a minimum so extra bends are not necessary. Indicate the movement of the core inside the casing. 4. Prepare a drawing and indicate the distance moved by the core inside the casing. Include lengths, tolerances, end fittings, casing, core, quantities, and send to SAVA with a request for quote.
TYPICAL APPLICATIONS INCLUDE Dampers
Releases Valves Vents Doors Connectors Linkages Shutoffs Reset Devices
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ISO 9001 CERTIFIED
GENERAL INFORMATION
SAVAs Bearing Mounted Nylon Pulleys are primarily engineered and designed for use with small cables and cords. They offer greatly increased mechanical efficiency over plastic pulleys and are considerably less expensive than bearing mounted pulleys now available. SAVA pulleys are being used on recorders, metering equipment, indicators, control mechanisms, drive systems, etc.
SP SERIES PULLEYS
The SP series pulleys below incorporate a precision, double shielded, lubricated single row ball bearing which is ABEC3 precision built to give all the accuracy needed to satisfy the load, speed, and life expectancy requirements of many applications now using more expensive ultra-precise bearings. Please note that pulleys with extended inner races are more expensive than those without extensions.
SAVA ITEM SP2031 SP2031E SP2044 SP2044E SP2050 SP2050E SP2063 SP2063E SP3050E SP3088 SP3106 SP4088 SP4088E SP4125 SP4138 REF. OLD PART NO. SP-231 SP-231-E SP-243 SP-243-E SP-250 SP-250-E SP-263 SP-263-E SP-248-E SP-387 SP-310 SP-487 SP-487-E SP-613 SP-614 DIMENSIONS A .0005 .125 .125 .125 .125 .1875 .1875 .1875 .250 .250 .250 .250 B .020 .310 .437 .500 .625 .500 .885 1.063 .885 1.250 1.375 C .020 .375 .500 .625 .750 .625 1.070 1.250 1.070 1.500 1.750 D .010 .110 .156 .156 .156 .125 .250 .250 .281 .188 .281 .281 E .010 .093 .125 .125 .156 .125 .219 .219 .219 .188 .281 .281 F1 + .000 - .005 N/A .141 N/A .188 N/A .188 N/A .188 .156 N/A N/A N/A .219 N/A N/A R REF. .015 .025 .015 .025 .015 .025 .035 .025 .050 .065 CABLE SIZES TO 1/32 3/64 1/32 3/64 1/32 3/64 1/16 3/64 3/32 1/8 LOAD2 (LBS) 10 10 10 10 10 90 90 90 90 90
NOTES: 1Where F dimension is not applicable (N/A) on the chart, the bearing does not have an extended inner race. 2Dynamic Load Rating is given in lbs. at 500 RPM.
BEARING LIFE
The load ratings shown on the dimensional tables give the approximate dynamic capacity of the bearings under normal operating conditions of constant load and speed of 2500 hours average life. These figures assume that the bearings are properly mounted, operate under clean conditions, and are properly lubricated. For load ratings at speeds other than 500 PM shown in the dimensional table, multiply the rating at 500 RPM by the following factors:
50 RPM _______ 2.50 100 RPM ________ 1.90
The above figures are estimates based on statistical evidence and are intended to serve as a guide. The nylon pulley is a press fit over the bearing. Improper alignment of cable or cord may cause premature failure of the bearing or in certain installations cause the pulley sleeve to 27
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PULLEYS
SMALL NYLON PULLEYS BEARING MOUNTED
Two basic types of bearing mounted pulleys are offered. The SP series is used where a more precise shielded bearing is required and the UP series where a commercial type bearing is adequate. These are described in more detail with the charts. In addition to the pulleys shown, SAVA can manufacture special diameters and shapes to fit your requirements. In all cases where CABLE SIZES TO are noted, it should be understood that this includes the coating, if any.
It is frequently necessary to determine what life a bearing will have when operating under a known or mean radial load at some constant or average speed. The Load-Life Formula may be written as follows:
LIFE (UNKNOWN) @ = Load Rating at 2500 hours Actual Radial Load
300 RPM ________ 1.23
800 RPM ________ .83
1000 RPM _________ .76
come off. Since there is considerable variation in application, we recommend actual life tests for your intended use.
NOTE: Most pulleys can be supplied with metric bearings; please inquire. Pulleys can be manufactured out of other plastics for an additional cost.
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SMALL NYLON PULLEYS BEARING MOUNTED (Cont.) UP SERIES PULLEYS

SAVAs inexpensive UP series pulleys are used for moderate load and speed application not requiring the use of more precise ground bearings. The bulk of all applications falls into this category. The UP series pulleys are furnished with an open-type precision machined ball bearing, which is lightly lubricated. UP2044, UP2050, and UP2063 are also available with open-type, ABEC1 precision ground bearings with ball retainers and are very free turning. If you wish to purchase a precision ground brearing for these pulleys, specify the pulley part followed by R2X1 Bearing; e.g., UP2044R2X1.
SAVA ITEM UP2044 UP2050 UP2063 UP20811 UP3088 UP3106 UP4088 UP4106 UP4125 UP4138 UP6125 UP6138 REF. OLD PART NO. UP-243 UP-250 UP-263 UP-281 UP-387 UP-310 UP-487 UP-410 UP-413 UP-414 UP-613 UP-614 A + .005 - .001 .125 .125 .125 .125 .187 .187 .250 .250 .250 .250 .375 .375 B .020 .437 .500 .625 .813 .885 1.063 .885 1.063 1.250 1.375 1.250 1.375 C .020 .500 .625 .750 1.000 1.070 1.250 1.070 1.250 1.500 1.750 1.500 1.750 D .010 .156 .156 .156 .171 .250 .250 .250 .250 .312 .312 .312 .312 E .010 .125 .125 .156 .156 .219 .219 .219 .219 .281 .281 .281 .281 R REF. .025 .015 .025 .025 .025 .035 .025 .035 .050 .065 .050 .065 CABLE SIZES TO 3/64 1/32 3/64 3/64 3/64 1/16 3/64 1/16 3/32 1/8 3/32 1/8 LOAD2 (LBS) 10 10 10 35 35 45 35 45 80 80 70 70
UP PULLEY
NOTES: 1UP2081 contains an ABEC1 precision ground shielded bearing with bore tolerance .0005. 2Dynamic Load Rating is given in lbs. at 500 RPM.
MP SERIES PULLEYS
MP PULLEY
This line of nylon pulleys offers an oil-impregnated bushing of porous, sintered, selflubricating bronze. This vacuum impregnated oil, equivalent to SAE 30, supplements the pure bronze structure and forms a hydraulic cushion which absorbs unusual shock and permits the bushing to carry heavier loads than the SP of UP series pulleys. This nylon pulley is also highly corrosion and wear resistant.
SAVA ITEM MP2063 MP3088 MP3106 MP4088 MP4106 MP4125 MP4138 MP6125 MP6138 REF. OLD PART NO. MP-263 MP-387 MP-310 MP-487 MP-410 MP-413 MP-414 MP-613 MP-614 A .002 .127 .189 .189 .252 .252 .252 .252 .377 .377 B .020 .625 .885 1.063 .885 1.063 1.250 1.375 1.250 1.375 C .020 .750 1.070 1.250 1.070 1.250 1.500 1.750 1.500 1.750 D .010 .187 .250 .250 .250 .250 .313 .313 .313 .313 E .010 .156 .219 .219 .219 .219 .281 .281 .281 .281 R REF. .025 .025 .035 .025 .035 .050 .065 .050 .065 CABLE SIZES TO 3/64 3/64 1/16 3/64 1/16 3/32 1/8 3/32 1/8 STATIC LOAD LBS MAX. 20 70 90 70 90 160 180 160 180
STORAGE
SAVAs nylon pulleys with oil-impregnated sintered bronze bushings can be stored indefinitely in suitable containers using plastic bags, wax paper, metal, glass, etc. Woods, ordinary paper and cardboard are not suitable since they absorb oil from the bushings. Properly stored SAVAs oil-impregnated bushings retain their oil supply indefinitely.
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CP SERIES PULLEYS
This economical line of precision machined ball bearing pulleys is grooved for small cables. They offer precision steel balls, case-hardened steel races, light lube, machined raceways, and are zinc plated. For shielded pulleys, which are internally lubricated and have plastic seals, add S after CP prefix, such as CPS2038.
SAVA ITEM CP(S)2038 CP(S)3075 CP(S)3088 CP(S)4088 CP(S)6125 CP(S)6150 REF. OLD PART NO. CP(S)-243 CP(S)-375 CP(S)-387 CP(S)-487 CP(S)-413 CP(S)-650 + .005 - .000 .125 .187 .187 .250 .375 .375
NOTES: *The sum of the radial and thrust load on any installation should not exceed the radial load capacity. To obtain the radial capacity at other speeds, multiply the radial capacity above with the following conversion factors: 100 RPM - .75; 300 RPM - .39; 600 RPM - .28; 900 RPM - .22; 1,000 RPM - .19.
OP SERIES PULLEYS
This line of OP Pulleys is a continuation of the CP Series, except this pulley allows for larger cable up to 3/8. The OP Series also offers a more economical and optional bronze bushing or roller bearing.
SAVA ITEM OP0150 OP0200 OP0250 OP0281 REF. OLD PART NO. OP-163 OP-200 OP-250 OP-298 CABLE SIZES TO 3/16 1/4 5/16 3/8
NOTE: For availability of bushings and bearings, please refer to page 33.
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ZINC PLATED STEEL PULLEYS

WITH SHIELDED & UNSHIELDED BALL BEARING
SHIELDED
UNSHIELDED
B .010 C .010 D .005 .380 .750 .875 .875 1.250 1.500 .500 1.000 1.060 1.250 1.750 2.000 .188 .375 .281 .437 .500 .500
E .005 .156 .312 .250 .375 .437 .437
H .005 .096 .219 .190 .250 .315 .315
R REF. .025 .065 .050 .095 .125 .125
CABLE RADIAL SIZES CAPACITY TO AT 50 RPM* 3/64 1/8 3/32 3/16 1/4 1/4 36 lbs. 145 lbs. 175 lbs. 175 lbs. 290 lbs. 410 lbs.
ZINC PLATED STEEL PULLEYS

WITH BRONZE BUSHINGS OR ROLLER BEARINGS*
B .015 1-1/2 2 2-1/2 2-13/16
C + .015 2 2-1/2 3 3-1/2
E .010 .440 .440 .625 .625
H .010 .345 .345 .530 .530
R REF. .125 .150 .215 .240
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BLACK DELRIN PULLEYS

BP SERIES PULLEYS
The chemical composition, regular structure, and high crystallinity of Delrin give SAVA Black Delrin pulleys a combination of physical properties not available with either metals or other plastics such as: High mechanical strength and rigidity Fatigue endurance unmatched by other plastics Excellent resistance to moisture, gasoline, sunlight, solvents, and many other neutral chemicals
SAVA ITEM BP2031 BP2044 BP2050 BP2063 BP3081 BP3088 BP3106 BP4122 BP4125 BP4138 BP5158 REF. OLD PART NO. BP-231-2 BP-243 BP-250 BP-263 BP-381 BP-387 BP-310 BP-416 BP-413 BP-414 BP-516 OTHER BORES ARE AVAILABLE A .005 .128 .128 .128 .128 .190 .190 .190 .254 .254 .254 .316
Good electrical insulating characteristics Excellent dimensional stability and wide useful temperature range (+347F melt point) Resiliency Natural lubricity
B .020 .310 .438 .500 .625 .813 .885 1.063 1.225 1.250 1.375 1.580 C .020 .375 .500 .625 .750 1.000 1.070 1.250 1.575 1.500 1.730 1.950 E .010 .093 .125 .125 .156 .170 .219 .219 .330 .281 .281 .405 R REF. .015 .025 .015 .025 .025 .025 .035 .095 .050 .065 .125 CABLE SIZES TO 1/32 3/64 1/32 3/64 3/64 3/64 1/16 3/16 3/32 1/8 1/4
The following pulleys are manufactured from nylon. They are primarily used for fiber rope; however, in many cases they function well with cables. BP4061 BP4100 BP4118 BP-406 BP-411 BP-412 .254 .254 .268 .615 1.000 1.175 .960 1.375 1.750 .400 .400 .440 .170 .135 .130 1/4-5/16 1/4 1/4
NOTE: BP4100 and BP4118 have extended hubs of .025 per side.
STEEL INSERTS
BI SERIES INSERTS
These inexpensive steel inserts can be used to reduce bore diameters. They are made wider than our pulley bearings so that the pulley can rotate freely while the insert is held on the sides. The inserts are case-hardened and black oxide finished. USED PRIMARILY ON OP AND LP SERIES PULLEYS
SAVA ITEM BI192531 BI255050 B1315050 B1385050 B1387575 B1507575
REF. OLD PART NO. BI-45 BI-50 BI-55 BI-60 BI-65 BI-70
A .002 3/16 1/4 5/16 3/8 3/8 1/2
C .002 1/4 1/2 1/2 1/2 3/4 3/4
D REF. 5/16 1/2 1/2 1/2 3/4 3/4
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LP SERIES PULLEYS
SAVA LP Pulleys utilize a high strength molded nylon containing finely divided particles of molybdenum disulfide (MD) solid lubricant.
CONSIDER THESE ADVANTAGES

Reduced cost 6-1 weight savings over steel Corrosion resistant Self lubricating Nongalling Low friction High tensile strength Abrasion-resistant properties Runs quietly and smoothly Low coefficient of thermal expansion Lower H2O absorption Excellent impact resistance Less heat-generating friction Excellent vibration and fatigue resistance
...ALSO
The improved strength of the molybdenum disulfide (MD)impregnated nylon enables it to support bearing loads greater than other thermoplastic materials. The inherent resiliency of this material enables it to return to original dimension after deformation because of unusual extreme loading.
PHYSICAL PROPERTIES Tensile Strength Elongation at Break Shear Strength Flexural Strength (Yield) Hardness, Rockwell Compressive Strength Deflection Temperature F (264 PSI)
NOTE: This information, based on our experience, is in line with accepted engineering practice and is believed to be reliable. However, we do not warrant the conformity of our materials to the listed properties or the suitability of our materials for a particular purpose.
How to Order:
For pulleys without bushings or bearings, select pulley number from table on page 32, and add size of bore if you wish SAVA to bore the pulley; e.g., LP0438-.625. For pulleys with bushings or bearings, select pulley number from table on page 32, and add bushing or bearing number from respective tables on page 33; e.g., LP0338-RB385650.
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MD NYLON PULLEYS
...AND
Bare wire rope used in conjunction with this type of LP pulleys has shown 450% improvement in the endurance life of bare wire rope when tested at 10%, and 220% improvement when tested at 20% of wire rope breaking strength.
SAVA LP pulleys can also be molded from the basic plastics listed in the chart below. MD nylon, we feel, has properties which offer overall advantages. However, it cannot be offered in colors as other plastics. Polyethylene and polypropylene offer significant cost advantages but with considerable loss of physical properties as indicated on the chart.
PHYSICAL PROPERTIES OF BASIC PLASTICS

ASTM D638 D638 D732 D790 D785 D695 D648 UNIT PSI % PSI PSI R PSI F MD NYLON 13,500 15 10,500 16,500 119 13,000 210 NYLON 6/6 9,000-12,000 20-200 9,600 12,500-14,000 110-120 5,000 200-450 ACETAL 8,800-12,000 12-75 7,700-9,500 13,000-15,500 119-122 16,000 230-255 154-158 5,000-7,000 50-96 3,500-8,000 115-140 HIGH-DENSITY POLYETHYLENE 2,500-4,300 170-180 POLYPROPYLENE 4,000-5,500 200-700
GENERAL NOTES: For volume customers, your name or logo can be substituted for the SAVA logo. Custom-designed pulleys can be made to your specific size requirements. Please provide a drawing showing the dimensions as outlined in the sketch on page 32. These pulleys can also be assembled with the bore inserts shown on page 30 of our catalog. Pulley and cable alignment is very important in preventing premature failure and attaining long life in working or in static load conditions. Any application which has inherent pulley-cable misalignment should be thoroughly tested for the application.
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LP SERIES PULLEYS
SAVA
ITEM LP0220 LP0188 LP0200 LP0250 LP0256 LP0300 LP0338 LP0388 LP0438 LP0463 LP0513 LP0525 REF. OLD PART NO. LP-22 LP-18 LP-20 LP-25 LP-26 LP-30 LP-33 LP-38 LP-43 LP-46 LP-51 LP-52 PLAIN BORE SIZE RANGE
A1
.375 .375 .375 .375 .375 .375 .375 .375 .500 .500 .500 .500 -
+.002 - .001
B REF. 2.200 1.875 2.000 2.500 2.563 3.000 3.375 3.875 4.375 4.625 5.125 5.250
C REF. 2.500 2.440 2.500 3.000 3.000 3.500 4.000 4.500 5.000 5.500 6.000 6.000
E REF. .250 .687 .438 .438 .625 .438 .500 .500 .500 .625 .625 .625
R REF. .050 .160 .110 .110 .190 .110 .140 .140 .140 .170 .200 .170
FOR CABLE SIZES 1/16 - 3/32 1/8 - 5/16 1/8 - 3/16 1/8 - 3/16 1/8 - 3/8 1/8 - 3/16 3/16 - 1/4 3/16 - 1/4 3/16 - 1/4 1/4 - 5/16 1/4 - 3/8 1/4 - 5/16
TYPE A B B B B B B B B C C C
MAX. LOAD3 (LBS.) 200 1600 800 800 1600 800 1400 1400 1400 1600 1600 1600
APPROX. WT. EA. OZ. .7 1.3 .9 1.2 1.5 1.4 2.5 2.8 3.5 4.3 5.6 5.9
C A B BORE
1.000 .625 .625 .625 .625 .625 1.000 1.000 1.000 1.000 1.000 1.000
NOTES: For availability of bushings and bearings, please refer to page 33. Pulleys in the above chart are sold with an incomplete hole (cored). When machining these, care should be taken to make the bore concentric with the outside diameter. This is normally done in a lathe. Completing the bore in a drill press is not recommended because of possible misalignment and loss of concentricity. SAVA has semi-automated equipment to perform this according to your specifications. Maximum load indicates allowable load for pulleys furnished with bearings under static load conditions. For long pulley fatigue life, a load equal to 25% or less of the maximum load column is recommended.
Type A
BORE WEAR ON LP PULLEYS WITHOUT BEARINGS

On lightly loaded applications where the working load is less than 10% of the maximum load, as shown above, it is possible to use these pulleys without bushings or antifriction bearings. Analyzing the wear characteristics, it was found that two factors directly affect the wear on bearings: pressure (P) and surface velocity (V). Working with these two factors, a relationship with the bearing wear has been developed. Tests were run on our Pulley Testing Machine with different sizes of pulleys under various load conditions. Results obtained so far are depicted in the graph below. Shafts and mating parts made from hardened and ground steel perform best, while unhardened steel surfaces will wear quickly in many applications, particularly if unlubricated. Our tests for pulley wear were run on ground shafts with no lubrication. Lubrication will reduce wear. It is difficult to estimate wear rates for lubricated bearing surfaces, since this depends, to a great extent, on the lubricant and the efficiency of its application to the bearing surface. The following formula will predict the approximate bore wear on LP pulleys without bushings or bearings.
PV Factor = P x V P= W dxL P = Pressure in p.s.i. W = Load on bearing in pounds d = Diameter of bearing in inches L = Width of bearing in inches n = r.p.m. V = Velocity in feet/min.
Type B
V= xdxn 12
Type C
Wear at 100,000 cycles
I.D. CODE 1 2 3 4 5 6 7 8 9
RECOMMENDED BORE DIMENSIONS FOR LP PULLEYS W/O BEARINGS

SHAFT DIA. INCHES 3/8 7/16 1/2 9/16 5/8 11/16 3/4 7/8 1 BORE DIMENSIONS + .002 - .001 .376 .439 .501 .564 .626 .689 .751 .876 1.002
.005
.000 2000
3000
4000
5000
6000
7000
8000
PV FACTOR
GROOVE WEAR
All of our tests show insignificant groove wear when used with coated cable at the end of 500,000 cycles. 32
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MP253825 MP253844 MP253850 MP253869 MP324425 MP324444 MP324450 MP385025 MP385044 MP385050 MP385063 MP385069 MP506325 MP506944 MP506350 MP506363 MP506369 MP638850 MP631063 MP751050 MP751063
RB254425 RB254444 RB325044 RB385644 RS385644 RB385650 RB385663 RS385663 RB506944 RS506944 RB506950 RB506963 RS506963 RB638150 RB638163 RB751050 RS751050 RB751063 RS751063
NOTE: Unsealed roller bearings are protected from rust only. These should be grease lubricated before use. We suggest that bearings should be wiped with grease before installation. Sealed bearings are prelubricated.
SAVA ITEM SP38 UP38 UP48
UP50E
NOTES: 1Includes extended inner race of .060 each side. For LP0463, LP0513, LP0525, OP0250, and OP0281, the inner race will be flush with the hub. Bearings can be ordered as separate items if you prefer to install them or use them in another application.
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SINTERED BRONZE BUSHINGS

SAVA ITEM DIMENSIONS I.D. LENGTH 1/4 1/4 7/16 1/2 11/16 1/4 7/16 1/2 1/4 7/16 1/2 5/8 11/16 1/4 7/16 1/2 5/8 11/16 1/2 5/8 1/2 5/8 USED ON NYLON PULLEY PART NOS. LP0220 LP0200, LP0250, LP0300 LP0338, LP0388 LP0188 LP0220 LP0200, LP0250, LP0300 LP0338, LP0388 LP0220 LP0200, LP0250, LP0300 LP0338, LP0388, LP0438 LP0256, LP0463, LP0513, LP0525 LP0188 LP0220 LP0200, LP0250, LP0300 LP0338, LP0388, LP0438 LP0256, LP0463, LP0513,LP0525 LP0188 LP0338, LP0388, LP0438 LP0463, LP0513, LP0525 LP0338, LP0388, LP0438 LP0463, LP0513, LP0525 USED ON STEEL PULLEY PART NOS. OP0150, OP0200 OP0150, OP0200 OP0150, OP0200 OP0250, OP0281 OP0150, OP0200 OP0250, OP0281 OP0250, OP0281 OP0250, OP0281
5/16
3/8
LP pulleys are available with a variety of sintered, oil-impregnated, bronze bushings and with ball and needle roller bearings. The following tables show the standard sizes. For specials, please contact the factory. With bearings, these pulleys offer excellent wear properties and prolonged life using loads not exceeding the recommended limits (see note 3 on page 32). Pulleys should not be allowed to move from side to side without restraints, because the bearing might work sideways out of the bore.
1/2
5/8 3/4
STANDARD NEEDLE ROLLER BEARINGS

SAVA ITEM TYPE
Unsealed Unsealed Unsealed Unsealed Sealed Unsealed Unsealed Sealed Unsealed Sealed Unsealed Unsealed Sealed Unsealed Unsealed Unsealed Sealed Unsealed Sealed
DIMENSIONS I.D. LENGTH

1/4 1/4 5/16 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 1/2 1/2 5/8 5/8 3/4 3/4 3/4 3/4 1/4 7/16 7/16 7/16 7/16 1/2 5/8 5/8 7/16 7/16 1/2 5/8 5/8 1/2 5/8 1/2 1/2 5/8 5/8
USED ON NYLON PULLEY PART NOS.

LP0220 LP0200, LP0250, LP0300 LP0200, LP0250, LP0300 LP0200, LP0250, LP0300 LP0200, LP0250, LP0300 LP0338, LP0388, LP0438 LP0256, LP0463, LP0513, LP0525 LP0256, LP0463, LP0513, LP0525 LP0200, LP0250, LP0300 LP0200, LP0250, LP0300 LP0338, LP0388, LP0438 LP0256, LP0463, LP0513, LP0525 LP0256, LP0463, LP0513, LP0525 LP0338, LP0388, LP0438 LP0463, LP0513, LP0525 LP0338, LP0338, LP0463, LP0463, LP0388, LP0388, LP0513, LP0513, LP0438 LP0438 LP0525 LP0525
USED ON STEEL PULLEY PART NOS.

OP0150, OP0200 OP0150, OP0200 OP0150, OP0200 OP0150, OP0200 OP0250, OP0281 OP0250, OP0281 OP0150, OP0200 OP0150, OP0200 OP0250, OP0281 OP0250, OP0281 OP0250, OP0281 OP0250, OP0281 OP0250, OP0281
BALL BEARINGS
BEARING DESCRIPTION Ground and Shielded Unground and Open Unground and Open Unground and Shielded DIMENSIONS I.D. LENGTH .1875 +.0005 -.0000 .188 .250 +.004 -.000 +.004 -.000 +.004 -.000 1/4 1/4 1/4 USED ON NYLON PULLEY PART NOS. LP0220 LP0220 LP0220 LP0338, LP0388 LP0438, LP0463 LP0513, LP0525 USED ON STEEL PULLEY PART NOS. OP0150, OP0200 OP0250, OP0281
Theoretical Load Rating on ball bearings is 53 lbs. at 600 RPM. For other speeds use the conversion factor below: 3.6 @ 50 RPM 2.7 @ 100 RPM 1.4 @ 300 RPM .8 @ 900 RPM .7 @ 1000 RPM .6 @ 1200 RPM
.375
5/81
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BRACKET PULLEYS
These inexpensive brackets offer the option of different size pulleys, materials, and eyes as depicted. They can be top, side or eye mounted. How to Order: Select and list from chart 1 pulley no., 2 bracket style, and 3 material; e.g. BP4061APS.
EYE MOUNT (Swivel Type)

Bracket Style A
PULLEY NO (SIZE O.D.) BP4100 (1.375) PULLEY TYPE (MAXIMUM CABLE DIA.) N (1/4) P (3/16) N (3/16) P (1/4) EYE SIZE
SIDE MOUNT
OR
TOP MOUNT
Bracket Style B
3 MATERIAL
AVAILABLE FOR BRACKET Stainless Steel (SS)1 or Plated Steel (PS)1 Plated Steel (PS) A B C D E F G H J K L M N
1
BP4061 (.960)
CP4088 CPS4088 (1.250) LP0200 (2.50) LP0250 (3.00)
1.65
1.00
.70
.66
.78
1.15
.37
.22
.05
.21
CP6125 CPS6125 CP6150 CPS6150 (1.75) (2.00)
3.00
2.00
1.50
.78
.88
2.00
.50
.25
.53
.08
.23
(2x) .19
NOTES: 1 If the material ordered is stainless steel (SS), then the bracket, eye, and rivet will be furnished in 300 Series SS Otherwise, for plated steel (PS), rivet and eye will be plated steel and the bracket will be stainless steel. For volume customers, your name and logo can be substituted for the SAVA logo. See catalog for pulley details.
PULLEY TYPE
EYE SIZE
.214 .375 .187 WELDED WELDED .500
MATERIAL - NYLON TYPE N
MATERIAL - PLATED STEEL TYPE P
SIZE 2
500 LBS. MIN. BREAKING STRENGTH
SIZE 3
700 LBS. MIN. BREAKING STRENGTH
G G
SPECIAL BRACKETS
2.39 .95 .95 .20 .06 L J J E
H K
1.31 .61 .34
C A TOP VIEW
F N
.47
SIDE MOUNT BRACKET STYLE C PART NO. BP4122CAL ALUMINUM BRACKET WITH PULLEY BP4122
MIN. STRENGTHS NOTED ABOVE ARE FOR THE BRACKET PULLEY ASSEMBLY.
NOTE: Maximum safe working load is determined by the end user. At least a 3:1 safety factor is generally advised. This is exclusive of any shock load. For volume customers, specially designed brackets can be manufactured. All dimensions are for reference only.
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(1x) .19
(2x) .19
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When cable is used over pulleys, the cable life can be significantly prolonged by proper groove design. Laboratory tests prove that improper groove design reduces cable bending life to 90%. These same tests show that doubling a pulley diameter can increase cable bending life up to thirteen times. Also, pulley diameters less than fifteen rope diameters fall into a range in which cable life is relatively low. Cable life is reduced as the groove radius changes from the contour of the cable to a flat surface. For maximum cable life, the groove should make contact with the cable on at least 1/3 of the cable circumference.
RECOMMENDED MINIMUM PULLEY DIAMETERS To Maximize Life
CABLE CONSTRUCTION 3x7 7x7 7 x 19 7 x 49 PULLEY DIAMETERS (ROOT) 50 times rope (uncoated dia.) 40 times rope (uncoated dia.) 25 times rope (uncoated dia.) 15 times rope (uncoated dia.)
FITTINGSMost cable fittings shown in this catalog are available in prototype packages of 25 pieces for those who wish to make their own initial assemblies. However, many require special tooling which is expensive to develop. We recommend that you ask SAVA to quote you on your requirements. PULLEYSPulleys are available from stock. Some are sold in prototype packages. CABLEMost cables shown are in stock and are sold in minimum quantities of 250 feet. Some cables are made to order since the demand is infrequent. For cables made to order, the minimum order quantity is normally 1000 feet and SAVA will ship the yield of the manufacturing run.
WARRANTY
All products sold by Carl Stahl Sava Industries, Inc. are guaranteed against manufacturing defects. Any item found to be defective will be replaced or an adjustment made provided that we are notified promptly upon receipt. An item is considered defective only if it fails to meet specifications set forth in the purchasers Purchase Order or other specifications published by the Company. We reserve the right to request that an item be returned to us for examination; we are not responsible for any labor or other charges incurred in replacement of any item. In no event shall our liability for any defective product exceed its replacement cost to us. THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL RESPONSIBILITY OR LIABILITY FOR THE PERFORMANCE OF ANY PRODUCT INTO WHICH THE COMPANYS PRODUCTS ARE INTEGRATED OR ASSEMBLED AND PURCHASER AGREES TO HOLD THE COMPANY HARMLESS AGAINST ANY SUCH LIABILITY. THE COMPANY MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THE COMPANY SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES. CERTIFICATIONSUnless specified on the quotation, prices do not include the preparation of certifications or any other documentation that may be required by purchaser. Please contact factory, as additional fees may apply.
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PULLEYS
HOW PULLEY SIZE AFFECTS CABLE STRENGTH
The radius of bend has an affect on the strength of cable. In order to take this into account in selecting the size pulley to be used with a given diameter cable, the following table can be used as a guide:
RATIO A = 40 30 20 15 10 8 6 4 2 1 PULLEY DIA. CABLE DIA. STRENGTH EFFICIENCY COMPARED TO CATALOG STRENGTH IN % 95 93 91 89 86 83 79 75 65 50
FOR EXAMPLE: Using a .030 dia. cable with a .600 dia. pulley. Ratio A = .600 .030 = 20 and the strength efficiency = 91% as compared to the catalog strength of the cable.
SALES POLICY AND TERMS

CREDIT AND PAYMENT TERMSNet 30 payment terms will be extended to firms with a satisfactory commercial rating. To avoid delay in servicing an order, we will ship COD when proper credit information is not available. Unless otherwise noted, prices are quoted FOB shipping point. MINIMUM BILLING$150.00 domestic, $200.00 non-domestic. RETURNED CHECK CHARGE$25.00 RETURNED MERCHANDISEAll material that is not the subject of a request for return authorization within thirty (30) days of shipment shall be deemed accepted by the customer. Credit will not be issued for material returned without authorization from us. All returned std. items in satisfactory condition are subject to a handling charge of 20%. Contact factory for a return authorization number. Items manufactured to customers specifications may not be returned. TOOLS AND CUTTERSAre not returnable. SPECIFICATIONSThe dimensions, weights, lengths, strengths, and other specifications shown in this catalog are for reference only and subject to variation within reasonable tolerances and subject to change without notice. ACCEPTANCE OF ORDERSAll orders are subject to acceptance by our home office. We are not responsible for delays or nonfulfillment due to riot, fire, floods, strikes or other causes beyond our control. Prices are based on costs and conditions existing on the date of quotation and are subject to change by the seller before final acceptance by seller. Unless otherwise agreed upon, purchaser agrees to accept and pay for quantities 5% of the total quantity ordered. Quoted delivery is subject to prior sales. BLANKET ORDERSA blanket order is a firm contract for acceptance of the total quantity ordered, to be delivered over time. All blanket orders are to be shipped complete and accepted within one year of the date of the order. In the event that the complete order is not accepted by purchaser within one year, the price may revert to that for the quantity taken and the purchaser will be responsible for the difference, along with cancellation charges and charges for material and work in process and/or in final inventory.
35
Sales Representative
Savas Medical Brochure is available online or in print. www.savacable.com/medical
P.O. Box 30, 4 North Corporate Drive Riverdale, NJ 07457-0030 973.835.0882 Fax: 973.835.0877 www.savacable.com
Copyright, Carl Stahl Sava Industries, Inc. 2006, Rev. 6/10 All Rights Reserved Printed in USA Neither this manual as a whole nor any part of it may be reproduced for any purpose whatsoever without written permission. This catalog supersedes all previous editions. Vitallium is a registered trademark of Howmedica Osteonics Corp. Inconel is a registered trademark of Special Metals Corporation Teflon, Delrin, and Dacron are registered trademarks of E.I. DuPont DG1007 5K

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Precision Cable Assemblies Miniature & Small Cables Small MIL-SPEC Wire Rope Push-Pull Controls Plastic &

Design Guide for Cable Solutions

ISO 9001 CERTIFIED

IS.EN.ISO 9001:2008 Certified

For Over 35 YearsCarl Stahl Sava Industries

IS.EN.ISO 9001:2008 Certified

ISO 9001 CERTIFIED

ISO 9001 CERTIFIED

CORE OR CENTER STRAND

ISO 9001 CERTIFIED

GUIDELINES FOR CABLE SELECTION

7x7 Construction Nylon Coated

CABLE FATIGUE LIFE CHART

7x19 or 7x49 Construction Nylon Coated 7x7 Construction Uncoated

700 600 500 400 300 200 100

CYCLE LIFE MILLIONS (TO FAILURE)

ELASTIC STRETCH CHARACTERISTICS OF SAVA CABLE

AMOUNT OF STRETCH PER 10 OF LENGTH

.080 .070 .060 .050 .040 .030 .020 .010 10 20 30 40 50

% LOAD OF CABLE BREAKING STRENGTH

ISO 9001 CERTIFIED

PROLONGING CABLE LIFE

SAVAS STANDARD COATING TOLERANCES

SAVAS STANDARD CABLE O.D. TOLERANCES

CUSTOM PLASTIC COATINGS

ISO 9001 CERTIFIED

RECOMMENDED LENGTH TOLERANCES

100.1 AND ABOVE

ISO 9001 CERTIFIED

TIPS ON DESIGNING AND ORDERING CABLE ASSEMBLIES

Typical Cable Assembly Layout

SELF-COILING CABLES FOR SECURITY APPLICATIONS

Capturing Connecting Grounding Hanging Restraining Securing Stopping Supporting Tripping

ISO 9001 CERTIFIED

PRECISION MINIATURE AND SMALL CABLES

2125SV6 2126SV6 2158SV7 2188SV8 2252SV10 2315SV13 2375SV15

3/16 3/16 7/32 1/4 5/16 13/32 15/32

4.76 4.76 5.56 6.35 7.94 10.32 11.91

ISO 9001 CERTIFIED

SAVA LOW-STRETCH HIGH-FATIGUE MINIATURE STAINLESS STEEL CABLE

LOW-STRETCH vs STANDARD MINIATURE STEEL CABLE

NUMBER OF CYCLES (Millions)

TYPICAL APPLICATIONS INCLUDE Computer Printers

Plotters Typewriters Instrumentation Robotics Other Precision Drive Mechanisms

ISO 9001 CERTIFIED

TEFLON FEP COATED STAINLESS STEEL CABLE

TEFLON FEP OFFERS THE FOLLOWING EXCELLENT COMBINATION OF PROPERTIES

Negligible moisture absorption

Weather resistance Nonflammable

DACRON CORD AND ASSEMBLIES*

PART NO. DC033 DC042 DC060

NOMINAL DIAMETER (REF.) .033 .042 .060

TEST OF CORD 50 lb. 90 lb. 180 lb.

MINIMUM STRENGTH OF ASSEMBLY 25 lb. 40 lb. 90 lb.

ISO 9001 CERTIFIED

GALVANIZED STEEL CABLE, NYLON, AND VINYL COATED

GALVANIZED STEEL CABLE, SAFETY ORANGE VINYL COATED

PART NO. 302S1001 303S377 305S142 305S171

307S190 307S220 307S250 310P156 310P190 310S156 310S190