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BLUE - 6 GA
BROWN - 2 GA
GREEN - 1 GA
BLACK - 2/0
PURPLE - 4/0
8 GA - RED
4 GA - GRAY
1/0 - PINK
3/0 - ORANGE
250 MCM - YELLOW
ADJUSTABLE CRIMPER
INSTALLATION AND GAUGING PROCEDURE
For Battery Cables 4 GA to 4/0
Catalog Number BCT840 and BCT840S
WARNING
HANDLES ARE NON-INSULATING.
DO NOT CRIMP ON ENERGIZED WIRES.
01
1. Strip cable without cutting or nicking the strands.
2. Select the side of the tool according to the type of
connector to be installed: casting or tubing.
3. Move indenter by turning the adjusting wheel until
the pointer slot aligns with the selected cable size
line. The wheel should be in a positive detented
INSTALLING PROCEDURE
5. Locate connector in the tool between the die nest
and indenter so that the die is between the color
code marks (See Figure 2).
6. Crimp connector by closing the handles.
NOTE: Some connectors require more than one
crimp. Refer to instructions packed with connectors.
position (See figure 1).
4. Insert cable into connector barrel until it bottoms.
Nest
Connector
Cable Size
Indenter
Adjusting
Wheel
Pointer Slot
Cable
Tubing Connector
Line
BCT840S is equipped with th SHURE-STAKE® Full Stroke
Type of
Connector
Compelling Mechanism. Keep fingers and other body
parts clear of die nest during operation of this tool.
Figure 1 Figure 2
Die Nest
Connector
Die Indentor
WARNING
Casting Connector
TA01063 C page 1 of 2
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02
HANDLE ADJUSTMENT PROCEDURE
CHECKING HANDLE ADJUSTMENT
1. Lay the tool on a flat surface as shown in Figure 3.
Open handle and release it so that it will close of its
own weight.
2. Measure the handle spread distance at the inner
surface of the handle tips as shown in Figure 3.
3. If the distance is 14”±1/2” the tool is adjusted
properly. If not, the tool should be adjusted.
HANDLE ADJUSTMENT PROCEDURE
1. Turn Adjustment screw clockwise to increase
handle spread and counterclockwise to decrease
handle spread (Refer to Figure 3).
Adjustment Screw
14” ±1/2”
Figure 3
03
1. Close the tool jaws until they bottom.
2. Select the side of the tool to be gauged (Casting and/or Tubing).
3. Move indenter until the pointer slot aligns with the selected cable size. The adjusting wheel should be in a
positive detented position. For cast connector select 1/0. For tubular connectors select 2/0.
4. Gauge the crimping area with a suitable pin gauge. The gauge diameter must fall within .405 ±.010.
GAUGING PROCEDURE
For Parts or Service, contact the tool service center at 1-800-284-TOOL (8665).
WARRANTY: Thomas & Betts sells this product with the understanding that the user will perform all necessary tests to determine
the suitability of this product for the user’s intended application. Thomas & Betts warrants that this product will be free from defects
in materials and workmanship for the period stated on the enclosed warranty card. Upon prompt notification of any warranted
defect, Thomas & Betts will, at its option, repair or replace the defective product or refund the purchase price. Proof of purchase is
required. Misuse or unauthorized modification of the product voids all warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY CONCERNING THIS PRODUCT, AND IS IN
LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY
FOR BREACH OF THE ABOVE WARRANTY IS LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT,
AND UNDER NO CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
Thomas & Betts Corporation
Memphis, Tennessee
© 2007 Thomas & Betts. All Rights Reserved.
www.tnb.com
TA01063 C page 2 of 2
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