HAND CRIMP TOOL M22520/2-01 Tool in open position Selector knob Safety clip Positioner guide This Hand Crimp Tool has been designed for use with the following Crimp Contacts: Datamate Signal Crimp Sockets (when used with Positioner T5747): M80-01100XX .................. Large bore Female crimp contact for 22 AWG wire (used in all L-Tek, J-Tek and Mix-Tek female crimp connectors). M80-01300XX .................. Small bore Female crimp contact for 24-28 AWG wire (used in all L-Tek, J-Tek and Mix-Tek female crimp connectors). M80-01900XX .................. Extra small bore female crimp for 28-32 AWG wire (used in all L-Tek, J-Tek and Mix-Tek female crimp connectors). M80-04000XX ................. Large bore Male crimp contact for 22 AWG wire (used in L-Tek male crimp connectors). M80-04100XX .................. Small bore Male crimp contact for 24-28 AWG wire (used in L-Tek male crimp connectors). Datamate Signal Crimp Pins can also be crimped (when used with Positioner Z80-193): M80-19400XX .................. Large bore Male crimp contact for 22 AWG wire (used in J-Tek and Mix-Tek male crimp connectors). M80-19500XX .................. Small bore Male crimp contact for 24-28 AWG wire (used in J-Tek and Mix-Tek male crimp connectors). Datamate and M300 Power Crimp Contacts can also be crimped (when used with Positioner Z80-058): M80-05500XX .................. Power Female crimp contact for 18-20 AWG (used in M80-716 and M80-719 series). M300-0010045 ................ Power Female crimp contact for 18-20 AWG M300-0020045 ................ Power Female crimp contact for 22 AWG M300-1010045 ................. Power Male crimp contact for 18-20 AWG M300-1020045 ................ Power Male crimp contact for 22 AWG K series Power Crimp Sockets can also be crimped (when used with Positioner ZK3609-00): K3606-46 ......................... Power Male crimp contact for 18 AWG. K3607-46 ......................... Power Female crimp contact for 18 AWG. Harwin North America T: +1 603 893 5376 F: +1 603 893 5396 E: [email protected] W: www.harwin.com IS-01 Issue: 6 Date: 03.10.14 C/Note: 12610 Harwin Europe T: +44 (0) 23 9231 4545 F: +44 (0) 23 9231 4590 E: [email protected] W: www.harwin.com Harwin Asia T: +65 6 779 4909 F: +65 6 779 3868 E: [email protected] W: www.harwinasia.com Page 1 of 3 GENERAL INFORMATION The Hand crimp tool M22520/2-01 consists of a basic hand tool, which should be used with a positioner. The contact is correctly crimped when the tool is free to open at the fully closed position, i.e., when the ratchet releases. The tool cannot be opened without completing the cycle. TOOL PREPARATION 1. Check that the tool is in the open position. Remove the safety clip from the positioner guide (do not discard). 2. Insert the Positioner into the positioner guide and turn it 90° in the direction shown on the tool, until the bayonet pins lock. 3. Install the safety clip back into the positioner guide (optional). 4. Check Table 1 for the correct crimp tool setting of the wire size you wish to crimp. 5. Remove the safety clip from the selector knob (do not discard). 6. Lift and turn the selector knob until the correct crimp tool setting is lined up with the “Sel. No.” arrow. Lower the selector knob, ensuring the locating peg lines up with a notch. 7. Install the safety clip back into the selector knob. CRIMPING PROCEDURE 1. Ensure that the wire to be crimped is within the specified range of sizes for the contact and the crimp tool. Failure to use the specified wire size will result in poor quality crimps and possible tool damage. Table 1 Contact M80-01100XX M80-04000XX M80-19400XX M80-01300XX M80-04100XX M80-19500XX M80-01900XX M80-05500XX M300-0010045 M300-1010045 M300-0020045 M300-1020045 K36XX-46 2. IS-01 Crimp Type Wire Gauge (AWG) Stranding (mm) Crimp Tool Setting Minimum pull-off force Datamate Large Bore 22 19/0.15 6 50N 24 26 28 28 30 32 20 18 20 18 7/0.2 7/0.15 7/0.12 7/0.12 1/0.25 7/0.08 19/0.2 19/0.26 19/0.2 19/0.25 6 6 6 5 4 4 8 8 8 8 44N 25N 12.5N 12.5N 7N 4N 85N 140N 80 140 22 19/0.15 8 50 18 Variable 8 142N Datamate Small Bore Datamate Extra small bore Datamate Power Crimp M300 series Large Bore M300 Series Small Bore K Series Power Crimp Cut the end of the cable to be terminated so that there is a clean cut end (Figure A). Strip the cable to the correct length (Figure B) using a PTFE Wire stripper, preferably with adjustable rotating cutter. This should result in all the strands lying together neatly. If the lay of the strands is disturbed, it may be re-imposed with a slight twist. Issue: 6 Date: 03.10.14 C/Note: 12610 Page 2 of 3 Clean cut RIGHT Ø0.75mm max 28-32 AWG Ø1.10mm max 22-28 AWG (M80) Ø1.40mm max 22 AWG (M300) Ø1.80mm max 18-20 AWG WRONG 2.00 ±0.15mm M80/300 Series 3.75 ±0.25mm K Series Figure A Figure B 3. Position the crimp contact fully into the positioner, with the crimp barrel uppermost. 4. Load the terminated end of the cable into the crimp barrel of the contact. Ensure the wire is fully inserted, with all strands in place (see Figure C). Figure C 5. Squeeze the handles of the crimp tool fully together, until ratchet releases. The handle will return to the open position. Remove the crimped contact and wire. Check that there is no exposed or stray wire, and that the insulation is fully within the end of the crimp barrel. Note: The cross hole on the crimp barrel, although not an inspection hole (it is designed to assist with plating processes) may give approximate guidance to the location of the conductor. After crimping the contact, the indent may overlap this hole. 6. Crimp joints should be checked for: a) Correct combination of cable, tool setting and crimp termination. b) Correctness of form and location of crimp. c) Freedom of fracture, rough edges and flash. d) Adequate insertion of all conductor strands in the crimp barrel. e) Absence of damage to the conductor or the insulation. CONTACT ASSEMBLY TO HOUSING PROCEDURE M80 Series parts are assembled using Assembly Tool Z80-280 and Instruction Sheet IS-25. M300 Series parts are assembled using Assembly Tool Z300-902 and Instruction Sheet IS-40. K Series parts are assembled using the Assembly Tool ZK3610-00 and Instruction Sheet IS-22. CARE OF TOOL There is virtually no maintenance required for the M22520/2-01 tool. However, it is good practice to keep the indenter tips free of residual colour band deposits and other debris. A small wire brush may be used for this purpose. We strongly recommend that you: 1. DO NOT immerse tools in any cleaning solution. 2. DO NOT spray oil into tool to lubricate. 3. DO NOT attempt to disassemble tool or make repairs. This is a precision crimp tool and should be handled as such. IS-01 Issue: 6 Date: 03.10.14 C/Note: 12610 Page 3 of 3