MCT-8200 Hand Crimp Tool Hand Crimp Tool Operating Instruction Sheet and Specifications Order No. 64001-3900 Engineering No. MCT-8200 (Replaces 19284-0035) FEATURES Heavy-duty cable crimping tool with hand held precision Tool can be used with insulated and non-insulated terminals in wire sizes 2 to 8 AWG A ratchet feature is standard Perfect for maintenance and lower volume crimping Long handles provide maximum mechanical advantage which reduces operator fatigue SCOPE Perma-Seal, InsulKrimp, NylaKrimp, VersaKrimp Terminals and Splices 2–8 AWG. Fully insulated and non-insulated Ring Tongue terminals also Step Down Butt and Parallel Splices. Testing Mechanical The tensile test, or pull test is, a means of evaluating the mechanical properties of the crimped connections. The following charts show the UL and Government specifications (MIL-T-7928) for various wire sizes. The tensile strength is shown in pounds. It indicates the minimum acceptable force to break or separate the terminal from the conductor. Wire Size (AWG) 8 6 4 2 *UL - 486 A 90 100 140 180 *UL – 486 C 45 50 N/A N/A **Military 225 300 400 550 *UL - 486 A - Terminals (Copper conductors only) *UL - 486 C - Butt Splices, Parallel Splices **Military – Military Approved Terminals only as listed The following is a partial list of the product part numbers and their specifications that this tool is designed to run. We will be adding to this list and an up to date copy is available on www.molex.com Wire Size: 8 8.50mm² Terminal Terminal No. Eng No. (REF) 19067-0003 19067-0006 19067-0008 19067-0012 19067-0016 19067-0018 19067-0022 D-950-08 D-950-10 D-950-14 D-950-56 D-951-10 D-951-14 D-951-38 Doc. No: ATS-640013900 Revision: K Wire Strip Length In .375 .375 .375 .375 .375 .375 .375 mm 9.53 9.53 9.53 9.53 9.53 9.53 9.53 Wire Size: 8 8.50mm² Insulation Diameter Maximum In mm .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 Release Date: 09-26-03 Revision Date: 05-06-08 Terminal Terminal No. Eng No. (REF) 19067-0025 19067-0028 19067-0030 19067-0031 19067-0032 19067-0033 19067-0034 D-951-56 D-952-12 D-952-38 D-952-76 D-953-12 D-953-34 D-953-58 UNCONTROLLED COPY Wire Strip Length In .375 .375 .375 .375 .375 .375 .375 mm 9.53 9.53 9.53 9.53 9.53 9.53 9.53 Insulation Diameter Maximum In mm .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 Page 1 of 9 MCT-8200 Hand Crimp Tool Wire Size: 8 8.50mm² Terminal Terminal No. Eng No. (REF) 19067-0037 19067-0039 19067-0041 19067-0128 19067-0129 19071-0134 19071-0136 19071-0140 19071-0144 19071-0146 19071-0148 19071-0153 19071-0162 19071-0164 19071-0166 19071-0173 19071-0176 19071-0178 19071-0180 19071-0182 19071-0334 19154-0041 19154-0044 19154-0047 19164-0079 19164-0080 19164-0081 19164-0082 19164-0083 19164-0457 19164-0458 19164-0459 19164-0833 19193-0146 19193-0149 19193-0157 19193-0159 19193-0163 19193-0184 19193-0186 19193-0187 19193-0192 19193-0195 19193-0198 19193-0204 19205-0004 19215-0034 19215-0037 19215-0042 D-956-08 D-956-10 D-956-14 D-951-76 D-952-58 D-650-08X D-650-10X D-650-14X D-650-56X D-651-10X D-651-14X D-651-56X D-652-38X D-652-58X D-652-76X D-653-58X D-656-06X D-656-08X D-656-10X D-656-14X D-652-12X D-654X DC-654X ED-662X SD-8 SD-656-10 SD-651-14 SD-652-38 SD-651-56 SD-652-12 SD-253-58 SD-253-34 SDC-354 D-350-08X D-350-10 D-350-56 D-351-10 D-351-14 D-352-38 D-352-56 D-352-76 D-353-34 D-353-58 D-356-06 D-356-14 D-355 D-354 DC-354 ED-362 Doc. No: ATS-640013900 Revision: K Wire Strip Length In .375 .375 .375 .375 .375 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .315 .432 .420 .500 .387 .300 .300 .300 .300 .300 .300 .300 .300 .315 .315 .315 .320 .320 .330 .330 .330 .330 .330 .358 .358 .408 .387 .400 .500 mm 9.53 9.53 9.53 9.53 9.53 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 10.97 10.66 12.70 9.83 7.60 7.60 7.60 7.60 7.60 7.60 7.60 7.60 8.00 8.00 8.00 8.13 8.13 8.38 8.38 8.38 8.38 8.38 9.08 9.08 10.36 9.83 10.16 12.70 Wire Size: 6 16.0mm² Insulation Diameter Maximum In mm .350 8.89 .350 8.89 .350 8.89 .350 8.89 .350 8.89 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .385 9.78 .380 9.65 .435 11.05 .370 9.40 .375 9.54 .375 9.54 .375 9.54 .375 9.54 .375 9.54 .375 9.54 .375 9.54 .375 9.54 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Release Date: 09-26-03 Revision Date: 05-06-08 Terminal Terminal No. Eng No. (REF) 19063-0050 19063-0052 19063-0062 19063-0066 19063-0069 19067-0045 19067-0047 19067-0052 19067-0055 19067-0059 19067-0061 19067-0063 19067-0065 19067-0067 19067-0069 19067-0071 19067-0073 19071-0188 19071-0190 19071-0193 19071-0196 19071-0201 19071-0208 19071-0218 19071-0221 19071-0225 19071-0229 19154-0047 19193-0209 19193-0212 19193-0229 19193-0230 19193-0233 19193-0234 19193-0238 19193-0243 19193-0251 19202-0055 19205-0006 19215-0040 19215-0042 E-757-10 E-757-14 E-758-12 E-758-58 E-760-08 E-957-10 E-957-14 E-957-38 E-957-56 E-957-76 E-958-12 E-958-38 E-958-76 E-960-08 E-960-10 E-960-14 E-960-56 E-657-10X E-657-14X E-657-38X E-657-56X E-658-12X E-658-76X E-660-08X E-660-10X E-660-14X E-660-56X ED-662X E-357-10 E-357-14 E-358-14 E-358-38 E-358-58 E-358-76 E-359-34 E-360-08 E-360-56 E-762 E-361 E-362 ED-362 Wire Strip Length In .368 .368 .368 .368 .368 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .469 .500 .395 .395 .375 .375 .375 .375 .375 .392 .392 .493 .477 .500 .500 mm 9.35 9.35 9.35 9.35 9.35 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 11.91 12.7 9.65 9.65 9.52 9.52 9.52 9.52 9.52 9.96 9.96 12.51 12.12 12.70 12.70 Insulation Diameter Maximum. In mm .345 8.76 .345 8.76 .345 8.76 .345 8.76 .345 8.76 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .428 10.87 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .440 11.18 .435 11.05 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A .345 8.76 N/A N/A N/A N/A N/A N/A Wire Size: 4 25.0mm² Terminal Terminal No. Eng No. (REF) 19063-0078 19063-0079 19063-0080 F-766-10 F-766-12 F-766-14 UNCONTROLLED COPY Insulation Diameter Maximum In mm In mm .432 10.97 .432 10.97 .432 10.97 .432 10.97 .432 10.97 .432 10.97 Wire Strip Length Page 2 of 9 MCT-8200 Hand Crimp Tool Wire Size: 4 25.0mm² Terminal Terminal No. Eng No. (REF) 19063-0086 19063-0089 19067-0076 19067-0077 19067-0078 19067-0079 19067-0080 19067-0081 19067-0082 19067-0084 19067-0085 19067-0087 19067-0088 19071-0231 19071-0234 19071-0237 19071-0240 19071-0243 19071-0250 19071-0253 19154-0048 19193-0254 19193-0258 19193-0261 19193-0278 19193-0283 19193-0285 19193-0289 19193-0293 19202-0056 19205-0007 19215-0045 F-767-56 F-770-34 F-966-12 F-966-14 F-966-38 F-966-56 F-966-76 F-967-10 F-967-14 F-967-56 F-969-12 F-969-58 F-970-34 F-666-10X F-666-12X F-666-14X F-666-38X F-666-56X F-667-10X F-667-14X F-664X F-366-10 F-366-12 F-366-14 F-367-56 F-369-38 F-369-58 F-370-34 F-370-58 F-764 F-365 F-364 Wire Strip Length In .438 .432 .501 .501 .501 .501 .501 .501 .501 .501 .501 .501 .501 .425 .425 .425 .425 .425 .425 .425 .745 .447 .447 .447 .447 .447 .447 .447 .447 .547 .547 .547 mm 11.11 10.97 12.73 12.73 12.73 12.73 12.73 12.73 12.73 12.73 12.73 12.73 12.73 10.80 10.80 10.80 10.80 10.80 10.80 10.80 19.15 11.35 11.35 11.35 11.35 11.35 11.35 11.35 11.35 13.89 13.89 13.89 Wire Size: 2 35.0mm² Insulation Diameter Maximum In mm .432 10.97 .432 10.97 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .510 12.95 .515 13.08 .515 13.08 .515 13.08 .515 13.08 .515 13.08 .515 13.08 .515 13.08 .605 15.37 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A .432 10.97 N/A N/A N/A N/A Wire Size: 2 35.0mm² Terminal Terminal No. Eng No. (REF) 19063-0094 19063-0097 19067-0090 19067-0092 19067-0093 19067-0094 19067-0095 19067-0096 19067-0097 19067-0098 19067-0099 19067-0100 G-774-14 G-774-58 G-974-12 G-974-38 G-974-56 G-974-76 G-975-10 G-975-14 G-975-38 G-975-56 G-977-34 G-977-58 Doc. No: ATS-640013900 Revision: K Wire Strip Length In .495 .495 .559 .559 .559 .559 .559 .559 .559 .559 .559 .559 mm 12.57 12.57 14.20 14.20 14.20 14.20 14.20 14.20 14.20 14.20 14.20 14.20 Insulation Diameter Maximum In mm .512 13.00 .512 13.00 .600 15.24 .600 15.24 .600 15.24 .600 15.24 .600 15.24 .600 15.24 .600 15.24 .600 15.24 .600 15.24 .600 15.24 Release Date: 09-26-03 Revision Date: 05-06-08 Terminal Terminal No. Eng No. (REF) 19071-0272 19071-0273 19071-0277 19071-0279 19071-0281 19071-0283 19071-0285 19154-0049 19193-0297 19193-0298 19193-0299 19193-0320 19205-0008 19215-0046 G-674-12X G-674-14X G-674-58X G-675-10X G-675-14X G-675-38X G-675-56X G-672X G-374-14 G-374-38 G-374-56 G-377-34 G-373 G-372 Wire Strip Length In .490 .490 .490 .490 .490 .490 .490 .640 .505 .505 .505 .490 .680 .610 mm 12.45 12.45 12.45 12.45 12.45 12.45 12.45 16.25 12.83 12.83 12.83 12.45 17.27 15.49 Insulation Diameter Maximum In mm .650 16.51 .650 16.51 .650 16.51 .650 16.51 .650 16.51 .650 16.51 .650 16.51 .650 16.51 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A MILITARY Wire Size: 8 8.50mm² Terminal Terminal No. Eng No. (REF) 19193-0152 19193-0167 19193-0171 19193-0179 19193-0200 19193-0202 D-350-14 D-351-38 D-351-56 D-352-12 D-356-08 D-356-10 Wire Strip Length In .315 .320 .320 .330 .358 .358 mm 8.00 8.13 8.13 8.38 9.08 9.08 Insulation Diameter Maximum In mm N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A MILITARY Wire Size: 6 16.0mm² Terminal Terminal No. Eng No. (REF) 19063-0054 19063-0056 19063-0071 19063-0073 19193-0216 19193-0219 19193-0226 19193-0245 19193-0248 E-757-38 E-757-56 E-760-10 E-760-14 E-357-38 E-357-56 E-358-12 E-360-10 E-360-14 Wire Strip Length In .368 .368 .368 .368 .395 .395 .375 .392 .392 mm 9.35 9.35 9.35 9.35 9.65 9.65 9.52 9.96 9.96 Insulation Diameter Maximum. In mm .345 8.76 .345 8.76 .345 8.76 .345 8.76 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A MILITARY Wire Size: 4 25.0mm² Terminal Terminal No. Eng No. (REF) Wire Strip Length In UNCONTROLLED COPY mm Insulation Diameter Maximum In mm Page 3 of 9 MCT-8200 Hand Crimp Tool MILITARY Wire Size: 4 25.0mm² Terminal Terminal No. Eng No. (REF) 19063-0081 19063-0082 19063-0085 19193-0264 19193-0267 19193-0273 19193-0275 19193-0281 F-766-38 F-766-56 F-767-14 F-366-38 F-366-56 F-367-10 F-367-14 F-369-12 Wire Strip Length In .447 .447 .438 .470 .470 .470 .470 .470 mm 11.35 11.35 11.13 11.94 11.94 11.94 11.94 11.94 MILITARY Wire Size: 2 35.0mm² Insulation Diameter Maximum In mm .432 10.97 .432 10.97 .432 10.97 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Terminal Terminal No. Eng No. (REF) 19063-0093 19063-0100 19063-0101 19193-0302 19193-0303 19193-0305 19193-0307 19193-0309 OPERATION Wire Strip Length In .495 .495 .495 .505 .505 .505 .505 .505 G-774-12 G-775-14 G-775-38 G-374-76 G-375-10 G-375-14 G-375-38 G-375-56 mm 12.57 12.57 12.57 12.83 12.83 12.83 12.83 12.83 Insulation Diameter Maximum In mm .512 13.00 .512 13.00 .512 13.00 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A JAWS OPEN Open the tool by first closing the jaws sufficiently for the ratchet mechanism to release. Crimping Terminals 1. Insert the terminal in the proper nest (for insulated or bare terminals) as marked on the tool with the barrel up and centered in the nest. 2. Partially close the tool to hold the terminal securely in place. See Figure 1. 3. Insert the properly stripped wire into the terminal barrel. See Figure 2. Cycle the tool. WIRE TERMINAL Figure 1 Note: The tamper-proof ratchet action will not release the tool until it has been fully closed. 4. Remove the crimp and inspect for proper crimp location. Molex offers a Crimp Inspection Handbook for closed barrel industrial product. See our website or contact your sales engineer. CONDUCTOR PUNCH/ANVIL TERMINAL WIRE CONDUCTOR PUNCH/ANVIL VISUALLY CENTER SPLICE BUTT SPLICE WIRE CONDUCTOR PUNCH/ANVIL Figure 2 Doc. No: ATS-640013900 Revision: K Release Date: 09-26-03 Revision Date: 05-06-08 CONDUCTOR PUNCH/ANVIL Figure 3 UNCONTROLLED COPY Page 4 of 9 MCT-8200 Hand Crimp Tool 5. When crimping butt splices, insert the wire into the butt splice. Position the splice and the wire in proper nest 2ND WIRE with conductor crimp on the conductor barrel of the splice. The splice should be approximately centered inside the tooling nests. See Figure 3. Cycle the tool. 6. When crimping parallel splices, Insert the 1st wire into one end of splice then insert the 2nd wire into the PARALLEL SPLICE opposite end of the parallel splice. This procedure will crimp both wires at the same time. Make sure the wires are fully seated into the parallel splice. Position the splice and the wires in proper nest with conductor crimp Figure 4 on the conductor barrel of the splice. The splice should be approximately centered inside the tooling nests. See Figure 4. Cycle the tool. CONDUCTOR PUNCH/ANVIL VISUALLY CENTER SPLICE 1ST WIRE CONDUCTOR PUNCH/ANVIL Note: Whenever crimping without the locator, make sure the seam of the terminal is oriented up or down in the tool if using unbrazed product, as this will provide higher pull force values. Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: 1. Remove dust, moisture and other contaminants with a clean brush, or soft, lint-free cloth. 2. Do not use any abrasive materials that could damage the tool. 3. Make certain all pins; pivot points and bearing surfaces are protected with a thin coat of high quality machine oil. Do not oil excessively. This hand tool was engineered for durability, but like any fine piece of equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. A light oil, such as 30 weight automotive oil used at the oil points shown in Figure 6, every 5,000 crimps or 3 months will significantly enhance the tool life and ensure a stable calibration. 4. When tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping dies, and store the tool in a clean, dry area. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) Figure 5 Doc. No: ATS-640013900 Revision: K Release Date: 09-26-03 Revision Date: 05-06-08 UNCONTROLLED COPY Page 5 of 9 MCT-8200 Hand Crimp Tool Miscrimps or Jams Should this tool ever become stuck or jammed in a partially closed position, Do Not force the handles open or closed. The tool will open easily by pushing the ratchet release lever forward. See Figure 6. PRELOAD ADJUSTMENT SCREW RATCHET RELEASE LEVER PUSH FORWARD TO RELEASE Figure 6 How to Adjust Tool Preload (See Figure 6 and 7) Over the life of the tool, it may be necessary to adjust tool handle preload force. Listed below are the steps required to adjust the crimping force of the hand tool to obtain proper crimp conditions: 1. Close the tool handles until jaws are fully closed and not under pressure. Put one handle grip on a weight scale and apply pressure downward against opposite handle. Observe the highest-pressure reading. 2. If tool needs adjustment, turn the preload adjustment screw. To increase preload setting, tighten (CW) the screw slightly, to decrease loosen (CCW) the screw. The preload should be 30-35 LBS. 3. Recheck the preload after making a crimp. Check the crimp specifications after tool handle preload force is adjusted. JAWS FULLY CLOSED PRELOAD ADJUSTMENT SCREW Figure 7 HANDLE GRIPS Tool Calibration A Certificate of Calibration (see last page) was supplied with the tool. To recalibrate this tool, pin gauge measurements should be taken in each conductor nest and compared to this chart. The tool should be lubricated before recalibration to ensure consistent measurements. Handle preload is factory set to 30-35 LBS. See How to Adjust Tool Preload, see Figure 7 to recalibrate. Wire Range AWG mm² 8 10.00 6 16.00 4 25.00 2 35.00 PIN GAUGE IN CONDUCTOR CRIMP X “CONFINING” CRIMP “X” Dimension Conductor Crimp Mean Go No Go .170 .165 .176 .240 .235 .246 .330 .325 .336 .378 .373 .384 AWG pin gauge readings are taken from nests marked “INS.” Doc. No: ATS-640013900 Revision: K Release Date: 09-26-03 Revision Date: 05-06-08 UNCONTROLLED COPY Page 6 of 9 MCT-8200 Hand Crimp Tool Warranty This tool is for electrical terminal crimping purposes only. This tool is made of the best quality materials. All vital components are long-life tested. All tools are warranted free of manufacturing defects for a period of 30 days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange will not be applicable to alter, misused or damaged tools. This tool is designed for hand use only. Any clamping, fixturing, or use of handle extensions voids this warranty. Hand held crimping tools are intended for low volume, prototyping, or repair requirements only. Caution: Repetitive use of this tool should be avoided. Doc. No: ATS-640013900 Revision: K Release Date: 09-26-03 Revision Date: 05-06-08 UNCONTROLLED COPY Page 7 of 9 MCT-8200 Hand Crimp Tool PARTS LIST Item 1 2 Order No 64001-3900 63810-0600 64001-3970 3 4 5 6 7 8 9 64001-3901 64001-3902 64001-3910 64001-3911 63700-3374 63700-3375 N/A Description Hand Crimp Tool 17” Handle (OPT #HS-HAND-432) Tooling Kit Tooling Kit Only Conductor Punch/Anvil Conductor Punch/Anvil Link Rocker Stripper Bolt Nut 5/16” - Washer Quantity Figure 8 1 1 1 1 2 1 2 2 2** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270). 1 9 8 (2) (2) 3 2 4 6 5 7 (2) Figure 8 Doc. No: ATS-640013900 Revision: K Release Date: 09-26-03 Revision Date: 05-06-08 UNCONTROLLED COPY Page 8 of 9 MCT-8200 Hand Crimp Tool Certificate of Calibration Tool Order Number ____________________________ Tool Eng. Number_____________________________ Tool Revision________________________________ Serial Number_______________________________ Date of Manufacture___________________________ Handle Load Range; see Tool Preload (page 6). =______________ Actual =_______________ Pin Gauge of Conductor Nest/Nests or Slug height if the nest is the “F” Crimp style. Range Conductor Nest # 1 =______________Actual =_____________ Range Conductor Nest # 2 =______________Actual =_____________ Range Conductor Nest # 3 =______________Actual =_____________ Range Conductor Nest # 4 =______________Actual =_____________ Technician________________________ Date of Calibration ___________________ Calibration should be done every 5,000 cycles or 3 months. Tools should be lubricated during this operation. Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX [email protected] Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 [email protected] Far East South Headquarters Jurong, Singapore 65-6-268-6868 [email protected] European Headquarters Munich, Germany 49-89-413092-0 [email protected] Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Doc. No: ATS-640013900 Revision: K Release Date: 09-26-03 Revision Date: 05-06-08 UNCONTROLLED COPY Page 9 of 9