Instruction Sheet MATE-N-LOK* Terminal 411-1040 Crimping Tools 27 JAN 16 Rev B PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume applications. A wide selection of powered application equipment for extended-use, production operations is available. Pin Crimp Symbol Stamped Here Locator Slot 5.2 [.205] Insulation Crimping Adjustment Pin in No. 3 Position Socket Wire Barrel 5.2 [.205] CERTI-CRIMP* Hand Crimping Tool Insulation Barrel Ratchet Control TOOL CRIMP WIRE SIZE INSULATION DIAMETER TERMINAL TERMINAL NO. SYMBOL mm [CMA] mm [in.] NO. H.P. NO. 163240 163242 0.3-0.75 1.39-2.54 A [600-1500] [.065-.100] 163241 163243 575937 160495 160565 0.5-1.0 1.65-2.79 B [1000-2000] [.065-.110] 160496 160566 160497 160567 1.0-1.5 MM 2.28-3.3 A [2000-3000] [.090-.130] 160498 160568 575938 160497 160567 1.5-2.5 2.54-3.8 B [3000-5000] [.110-.150] 160498 160568 Figure 1 1. INTRODUCTION Crimping tools 575937 and 575938 are used to crimp the MATE-N-LOK Terminals listed in the table in Figure 1. Use this table to select the proper tool for the wire size to be used. NOTE Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are for reference only and are not drawn to scale Reasons for reissue are provided in Section 5, REVISION SUMMARY. 2. WIRE STRIPPING Strip the wire 5.2 mm [.200 in.] for both the pin and socket terminals. 3. INSULATION CRIMPING ADJUSTMENT 1. The insulation crimping jaws have three adjustments. 2. Place the insulation crimping adjustment pin in the No. 3 position. See Figure 1. 3. Place the terminal in the tool according to Paragraph 4, and insert the unstripped wire into only the insulation barrel. © 2016 TE Connectivity family of companies PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 2 All Rights Reserved For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 411-1040 4. Crimp the terminal. Bend the wire back and forth once. If the wire pulls out, set pin in No. 2 position and repeat the test until the desired grip is obtained. 4. CRIMPING PROCEDURE 1. These tools is equipped with a CERTI-CRIMP Ratchet (see Figure 1) to ensure proper crimping. To open the tool handles, squeeze them until the ratchet releases. NOTE Once the ratchet is engaged, the handles cannot be opened until they are fully closed. 2. Place the terminal in the tool so that the locator fits in the slot between the terminal insulation barrel and the wire barrel. See Figure 2. Close Crimping Jaws Just End of Insulation Butts Enough to Retain Terminal Against Locator When Wire is Inserted in Terminal Locator Fits into Slot See Crimping Procedure Between Wire Barrel in Paragraph 4.6 and Insulation Barrel Figure 2 3. Close the handles until the crimping jaws close just enough to retain the terminal. See Figure 2. CAUTION Do not deform the terminal. Damaged product should not be used. If damaged product is evident, it should be replace with a new one. Terminals should not be re-terminated. 4. Insert the stripped wire into the terminal until the end of the insulation butts against the locator. 5. Close the tool handles until the CERTI-CRIMP Ratchet releases. Remove the crimped terminal from the tool. 6. For wire with insulation diameter 3.5 mm [.138 in.] and larger, first insert the wire into the terminal. The insulation barrel will be fixed around the insulation. 7. Then follow steps 2 and 5. 5. GAGE DIMENSIONS To ensure the tool is dimensionally correct, check the tool dimensions with a gage. See Figure 3. TOOL NO. 575937 TOOL NO. 575938 Insulation Nest Gage Height Insulation Nest Gage Height Wire Nest Gage Height Wire Nest Gage Height Adjuster Set At #1 Adjuster Set At #1 A B A B A B A B 1.04-1.14 1.17-1.27 1.83-2.24 2.08-2.49 1.32-1.42 1.75-1.85 2.72-3.12 3.15-3.56 [.041-.045] [.046-.050] [.072-.088] [.082-.098] [.052-.056] [.069-.073] [.107-.123] [.124-.140] Figure 3 6. MAINTENANCE Lubricate all pins, pivot points, and bearing surfaces as needed with any good S.A.E. No. 2 Motor Oil. 7. REVISION SUMMARY  Updated document to corporate requirements. Added new gage dimension information in new Figure 3. 2 of 2 Rev B