mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 1 of 9 revision: k revision date: 05-06-08 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 preci sion tool can be used with insulated and non-insulated t erminals 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 w hich reduces operator fatigue scope perma-seal ? , insulkrimp ? , nylakrimp ? , versakrimp ? terminals and splices 2?8 awg. fully insulated an d non-insulated ring tongue terminals also step down butt and parallel splices. testing mechanical the tensile test, or pull test is, a means of evalu ating the mechanical properties of the crimped conn ections. the following charts show the ul and government specifi cations (mil-t-7928) for various wire sizes. the t ensile strength is shown in pounds. it indicates the mini mum acceptable force to break or separate the termi nal from the conductor. wire size (awg) *ul - 486 a *ul ? 486 c **military 8 90 45 225 6 100 50 300 4 140 n/a 400 2 180 n/a 550 *ul - 486 a - terminals (copper conductors only) *ul - 486 c - butt splices, parallel splices **military ? military approved terminals only as li sted 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 co py is available on www.molex.com wire size: 8 8.50mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19067-0003 d-950-08 .375 9.53 .350 8.89 19067-0006 d-950-10 .375 9.53 .350 8.89 19067-0008 d-950-14 .375 9.53 .350 8.89 19067-0012 d-950-56 .375 9.53 .350 8.89 19067-0016 d-951-10 .375 9.53 .350 8.89 19067-0018 d-951-14 .375 9.53 .350 8.89 19067-0022 d-951-38 .375 9.53 .350 8.89 wire size: 8 8.50mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19067-0025 d-951-56 .375 9.53 .350 8.89 19067-0028 d-952-12 .375 9.53 .350 8.89 19067-0030 d-952-38 .375 9.53 .350 8.89 19067-0031 d-952-76 .375 9.53 .350 8.89 19067-0032 d-953-12 .375 9.53 .350 8.89 19067-0033 d-953-34 .375 9.53 .350 8.89 19067-0034 d-953-58 .375 9.53 .350 8.89
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 2 of 9 revision: k revision date: 05-06-08 wire size: 8 8.50mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19067-0037 d-956-08 .375 9.53 .350 8.89 19067-0039 d-956-10 .375 9.53 .350 8.89 19067-0041 d-956-14 .375 9.53 .350 8.89 19067-0128 d-951-76 .375 9.53 .350 8.89 19067-0129 d-952-58 .375 9.53 .350 8.89 19071-0134 d-650-08x .315 8.00 .385 9.78 19071-0136 d-650-10x .315 8.00 .385 9.78 19071-0140 d-650-14x .315 8.00 .385 9.78 19071-0144 d-650-56x .315 8.00 .385 9.78 19071-0146 d-651-10x .315 8.00 .385 9.78 19071-0148 d-651-14x .315 8.00 .385 9.78 19071-0153 d-651-56x .315 8.00 .385 9.78 19071-0162 d-652-38x .315 8.00 .385 9.78 19071-0164 d-652-58x .315 8.00 .385 9.78 19071-0166 d-652-76x .315 8.00 .385 9.78 19071-0173 d-653-58x .315 8.00 .385 9.78 19071-0176 d-656-06x .315 8.00 .385 9.78 19071-0178 d-656-08x .315 8.00 .385 9.78 19071-0180 d-656-10x .315 8.00 .385 9.78 19071-0182 d-656-14x .315 8.00 .385 9.78 19071-0334 d-652-12x .315 8.00 .385 9.78 19154-0041 d-654x .432 10.97 .385 9.78 19154-0044 dc-654x .420 10.66 .380 9.65 19154-0047 ed-662x .500 12.70 .435 11.05 19164-0079 sd-8 .387 9.83 .370 9.40 19164-0080 sd-656-10 .300 7.60 .375 9.54 19164-0081 sd-651-14 .300 7.60 .375 9.54 19164-0082 sd-652-38 .300 7.60 .375 9.54 19164-0083 sd-651-56 .300 7.60 .375 9.54 19164-0457 sd-652-12 .300 7.60 .375 9.54 19164-0458 sd-253-58 .300 7.60 .375 9.54 19164-0459 sd-253-34 .300 7.60 .375 9.54 19164-0833 sdc-354 .300 7.60 .375 9.54 19193-0146 d-350-08x .315 8.00 n/a n/a 19193-0149 d-350-10 .315 8.00 n/a n/a 19193-0157 d-350-56 .315 8.00 n/a n/a 19193-0159 d-351-10 .320 8.13 n/a n/a 19193-0163 d-351-14 .320 8.13 n/a n/a 19193-0184 d-352-38 .330 8.38 n/a n/a 19193-0186 d-352-56 .330 8.38 n/a n/a 19193-0187 d-352-76 .330 8.38 n/a n/a 19193-0192 d-353-34 .330 8.38 n/a n/a 19193-0195 d-353-58 .330 8.38 n/a n/a 19193-0198 d-356-06 .358 9.08 n/a n/a 19193-0204 d-356-14 .358 9.08 n/a n/a 19205-0004 d-355 .408 10.36 n/a n/a 19215-0034 d-354 .387 9.83 n/a n/a 19215-0037 dc-354 .400 10.16 n/a n/a 19215-0042 ed-362 .500 12.70 n/a n/a wire size: 6 16.0mm2 wire strip length insulation diameter maximum. terminal no. terminal eng no. (ref) in mm in mm 19063-0050 e-757-10 .368 9.35 .345 8.76 19063-0052 e-757-14 .368 9.35 .345 8.76 19063-0062 e-758-12 .368 9.35 .345 8.76 19063-0066 e-758-58 .368 9.35 .345 8.76 19063-0069 e-760-08 .368 9.35 .345 8.76 19067-0045 e-957-10 .469 11.91 .428 10.87 19067-0047 e-957-14 .469 11.91 .428 10.87 19067-0052 e-957-38 .469 11.91 .428 10.87 19067-0055 e-957-56 .469 11.91 .428 10.87 19067-0059 e-957-76 .469 11.91 .428 10.87 19067-0061 e-958-12 .469 11.91 .428 10.87 19067-0063 e-958-38 .469 11.91 .428 10.87 19067-0065 e-958-76 .469 11.91 .428 10.87 19067-0067 e-960-08 .469 11.91 .428 10.87 19067-0069 e-960-10 .469 11.91 .428 10.87 19067-0071 e-960-14 .469 11.91 .428 10.87 19067-0073 e-960-56 .469 11.91 .428 10.87 19071-0188 e-657-10x .469 11.91 .440 11.18 19071-0190 e-657-14x .469 11.91 .440 11.18 19071-0193 e-657-38x .469 11.91 .440 11.18 19071-0196 e-657-56x .469 11.91 .440 11.18 19071-0201 e-658-12x .469 11.91 .440 11.18 19071-0208 e-658-76x .469 11.91 .440 11.18 19071-0218 e-660-08x .469 11.91 .440 11.18 19071-0221 e-660-10x .469 11.91 .440 11.18 19071-0225 e-660-14x .469 11.91 .440 11.18 19071-0229 e-660-56x .469 11.91 .440 11.18 19154-0047 ed-662x .500 12.7 .435 11.05 19193-0209 e-357-10 .395 9.65 n/a n/a 19193-0212 e-357-14 .395 9.65 n/a n/a 19193-0229 e-358-14 .375 9.52 n/a n/a 19193-0230 e-358-38 .375 9.52 n/a n/a 19193-0233 e-358-58 .375 9.52 n/a n/a 19193-0234 e-358-76 .375 9.52 n/a n/a 19193-0238 e-359-34 .375 9.52 n/a n/a 19193-0243 e-360-08 .392 9.96 n/a n/a 19193-0251 e-360-56 .392 9.96 n/a n/a 19202-0055 e-762 .493 12.51 .345 8.76 19205-0006 e-361 .477 12.12 n/a n/a 19215-0040 e-362 .500 12.70 n/a n/a 19215-0042 ed-362 .500 12.70 n/a n/a wire size: 4 25.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19063-0078 f-766-10 .432 10.97 .432 10.97 19063-0079 f-766-12 .432 10.97 .432 10.97 19063-0080 f-766-14 .432 10.97 .432 10.97
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 3 of 9 revision: k revision date: 05-06-08 wire size: 4 25.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19063-0086 f-767-56 .438 11.11 .432 10.97 19063-0089 f-770-34 .432 10.97 .432 10.97 19067-0076 f-966-12 .501 12.73 .510 12.95 19067-0077 f-966-14 .501 12.73 .510 12.95 19067-0078 f-966-38 .501 12.73 .510 12.95 19067-0079 f-966-56 .501 12.73 .510 12.95 19067-0080 f-966-76 .501 12.73 .510 12.95 19067-0081 f-967-10 .501 12.73 .510 12.95 19067-0082 f-967-14 .501 12.73 .510 12.95 19067-0084 f-967-56 .501 12.73 .510 12.95 19067-0085 f-969-12 .501 12.73 .510 12.95 19067-0087 f-969-58 .501 12.73 .510 12.95 19067-0088 f-970-34 .501 12.73 .510 12.95 19071-0231 f-666-10x .425 10.80 .515 13.08 19071-0234 f-666-12x .425 10.80 .515 13.08 19071-0237 f-666-14x .425 10.80 .515 13.08 19071-0240 f-666-38x .425 10.80 .515 13.08 19071-0243 f-666-56x .425 10.80 .515 13.08 19071-0250 f-667-10x .425 10.80 .515 13.08 19071-0253 f-667-14x .425 10.80 .515 13.08 19154-0048 f-664x .745 19.15 .605 15.37 19193-0254 f-366-10 .447 11.35 n/a n/a 19193-0258 f-366-12 .447 11.35 n/a n/a 19193-0261 f-366-14 .447 11.35 n/a n/a 19193-0278 f-367-56 .447 11.35 n/a n/a 19193-0283 f-369-38 .447 11.35 n/a n/a 19193-0285 f-369-58 .447 11.35 n/a n/a 19193-0289 f-370-34 .447 11.35 n/a n/a 19193-0293 f-370-58 .447 11.35 n/a n/a 19202-0056 f-764 .547 13.89 .432 10.97 19205-0007 f-365 .547 13.89 n/a n/a 19215-0045 f-364 .547 13.89 n/a n/a wire size: 2 35.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19063-0094 g-774-14 .495 12.57 .512 13.00 19063-0097 g-774-58 .495 12.57 .512 13.00 19067-0090 g-974-12 .559 14.20 .600 15.24 19067-0092 g-974-38 .559 14.20 .600 15.24 19067-0093 g-974-56 .559 14.20 .600 15.24 19067-0094 g-974-76 .559 14.20 .600 15.24 19067-0095 g-975-10 .559 14.20 .600 15.24 19067-0096 g-975-14 .559 14.20 .600 15.24 19067-0097 g-975-38 .559 14.20 .600 15.24 19067-0098 g-975-56 .559 14.20 .600 15.24 19067-0099 g-977-34 .559 14.20 .600 15.24 19067-0100 g-977-58 .559 14.20 .600 15.24 wire size: 2 35.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19071-0272 g-674-12x .490 12.45 .650 16.51 19071-0273 g-674-14x .490 12.45 .650 16.51 19071-0277 g-674-58x .490 12.45 .650 16.51 19071-0279 g-675-10x .490 12.45 .650 16.51 19071-0281 g-675-14x .490 12.45 .650 16.51 19071-0283 g-675-38x .490 12.45 .650 16.51 19071-0285 g-675-56x .490 12.45 .650 16.51 19154-0049 g-672x .640 16.25 .650 16.51 19193-0297 g-374-14 .505 12.83 n/a n/a 19193-0298 g-374-38 .505 12.83 n/a n/a 19193-0299 g-374-56 .505 12.83 n/a n/a 19193-0320 g-377-34 .490 12.45 n/a n/a 19205-0008 g-373 .680 17.27 n/a n/a 19215-0046 g-372 .610 15.49 n/a n/a military wire size: 8 8.50mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19193-0152 d-350-14 .315 8.00 n/a n/a 19193-0167 d-351-38 .320 8.13 n/a n/a 19193-0171 d-351-56 .320 8.13 n/a n/a 19193-0179 d-352-12 .330 8.38 n/a n/a 19193-0200 d-356-08 .358 9.08 n/a n/a 19193-0202 d-356-10 .358 9.08 n/a n/a military wire size: 6 16.0mm2 wire strip length insulation diameter maximum. terminal no. terminal eng no. (ref) in mm in mm 19063-0054 e-757-38 .368 9.35 .345 8.76 19063-0056 e-757-56 .368 9.35 .345 8.76 19063-0071 e-760-10 .368 9.35 .345 8.76 19063-0073 e-760-14 .368 9.35 .345 8.76 19193-0216 e-357-38 .395 9.65 n/a n/a 19193-0219 e-357-56 .395 9.65 n/a n/a 19193-0226 e-358-12 .375 9.52 n/a n/a 19193-0245 e-360-10 .392 9.96 n/a n/a 19193-0248 e-360-14 .392 9.96 n/a n/a military wire size: 4 25.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 4 of 9 revision: k revision date: 05-06-08 terminal jaws open figure 1 wire figure 2 wire conductor punch/anvil terminal conductor punch/anvil butt splice figure 3 wire conductor punch/anvil visually center splice conductor punch/anvil military wire size: 4 25.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19063-0081 f-766-38 .447 11.35 .432 10.97 19063-0082 f-766-56 .447 11.35 .432 10.97 19063-0085 f-767-14 .438 11.13 .432 10.97 19193-0264 f-366-38 .470 11.94 n/a n/a 19193-0267 f-366-56 .470 11.94 n/a n/a 19193-0273 f-367-10 .470 11.94 n/a n/a 19193-0275 f-367-14 .470 11.94 n/a n/a 19193-0281 f-369-12 .470 11.94 n/a n/a military wire size: 2 35.0mm2 wire strip length insulation diameter maximum terminal no. terminal eng no. (ref) in mm in mm 19063-0093 g-774-12 .495 12.57 .512 13.00 19063-0100 g-775-14 .495 12.57 .512 13.00 19063-0101 g-775-38 .495 12.57 .512 13.00 19193-0302 g-374-76 .505 12.83 n/a n/a 19193-0303 g-375-10 .505 12.83 n/a n/a 19193-0305 g-375-14 .505 12.83 n/a n/a 19193-0307 g-375-38 .505 12.83 n/a n/a 19193-0309 g-375-56 .505 12.83 n/a n/a operation open the tool by first closing the jaws sufficientl y for the ratchet mechanism to release. crimping terminals 1. insert the terminal in the proper nest (for insulat ed or bare terminals) as marked on the tool with the barrel up and center ed in the nest. 2. partially close the tool to hold the terminal secur ely in place. see figure 1. 3. insert the properly stripped wire into the terminal barrel. see figure 2. cycle the tool. note: the tamper-proof ratchet action will not rel ease the tool until it has been fully closed. 4. remove the crimp and inspect for proper crimp locat ion. molex offers a crimp inspection handbook for closed barrel industrial product. see our website or cont act your sales engineer.
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 5 of 9 revision: k revision date: 05-06-08 lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 5 5. when crimping butt splices, insert the wire into th e butt splice. position the splice and the wire in proper nest with conductor crimp on the conductor barrel of the splice. the splice should be approximately centere d inside the tooling nests. see figure 3. cycle the tool. 6. when crimping parallel splices, insert the 1 st wire into one end of splice then insert the 2 nd wire into the opposite end of the parallel splice. this procedur e will crimp both wires at the same time. make sure the w ires are fully seated into the parallel splice. positio n the splice and the wires in proper nest with conductor crimp on the conductor barrel of the splice. the splice should be approximately centered inside the tooling nests. see figure 4. cycle the tool. 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 pr ovide 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 sur faces are protected with a thin coat of high qualit y machine oil. do not oil excessively. this hand tool was e ngineered for durability, but like any fine piece o f equipment, it needs cleaning and lubrication for a maximum ser vice life of trouble-free crimping. a light oil, s uch 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 st able calibration. 4. when tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimpi ng dies, and store the tool in a clean, dry area. figure 4 1 st wire conductor punch/anvil parallel splice 2 nd wire visually center splice conductor punch/anvil
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 6 of 9 revision: k revision date: 05-06-08 miscrimps or jams should this tool ever become stuck or jammed in a p artially closed position, do not force the handles open or closed. the tool will open easily by pushing the ratchet re lease lever forward. see figure 6. how to adjust tool preload (see figure 6 and 7) over the life of the tool, it may be necessary to a djust tool handle preload force. listed below are the steps required to adjust the crimping force of the hand t ool 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 weigh t scale and apply pressure downward against opposite handle. observe the highest-pressure reading. 2. if tool needs adjustment, turn the preload adjustme nt screw. to increase preload setting, tighten (cw) t he screw slightly, to decrease loosen (ccw) the screw. the preload should be 30-35 lbs. 3. recheck the preload after making a crimp. check th e crimp specifications after tool handle preload forc e is adjusted. tool calibration a certificate of calibration (see last page) was su pplied with the tool. to recalibrate this tool, pin gauge measurements shoul d be taken in each conductor nest and compared to this chart. the too l should be lubricated before recalibration to ensure consistent measureme nts. handle preload is factory set to 30-35 lbs. see how to adjust tool p reload, see figure 7 to recalibrate. wire range ?x? dimension conductor crimp awg mm2 mean go no go 8 10.00 .170 .165 .176 6 16.00 .240 .235 .246 4 25.00 .330 .325 .336 2 35.00 .378 .373 .384 awg pin gauge readings are taken from nests marked ?ins.? ratchet release lever push forward to release figure 6 preload adjustment screw handle grips preload adjustment screw jaws fully closed figure 7 pin gauge in conductor crimp ?confining? crim p x
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 7 of 9 revision: k revision date: 05-06-08 warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long-life tested. all tools are war ranted free of manufacturing defects for a period o f 30 days. should such a defect occur, we will repair or excha nge the tool free of charge. this repair or exchan ge will not be applicable to alter, misused or damaged tools. thi s 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 volum e, prototyping, or repair requirements only. caution: repetitive use of this tool should be avoided.
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 8 of 9 revision: k revision date: 05-06-08 figure 8 2 7 1 9 8 5 6 4 3 (2) (2) (2) parts list item order no description quantity 64001-3900 hand crimp tool figure 8 1 63810-0600 17? handle (opt #hs-hand-432) 1 2 64001-3970 tooling kit 1 tooling kit only 3 64001-3901 conductor punch/anvil 1 4 64001-3902 conductor punch/anvil 1 5 64001-3910 link 2 6 64001-3911 rocker 1 7 63700-3374 stripper bolt 2 8 63700-3375 nut 2 9 n/a 5/16? - washer 2** ** the following purchased parts are available from an industrial supply company such as msc (1-800-64 5-7270).
mct-8200 hand crimp tool doc. no: ats-640013900 release date: 09-26-03 uncontrolled copy page 9 of 9 revision: k revision date: 05-06-08 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 amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com 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
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