HAND CRIMP TOOLS Z80-292 & Z80-293 Tool in closed position Tool in open position Die Set Positioner Guide Selector Index Safety Clip Positioner Z80-292 Z80-293 These Hand Crimp Tools have been designed for use with the following Datamate Mix-Tek coax Crimp [when used with positioner Z80-291]: M80-305 to 307…………………………………..Straight female coax crimp contact (Used in Mix-Tek female crimp connectors) M80-308 & 309... (Z80-293 only)…………..90° female coax crimp contact (Used in Mix-Tek female crimp connectors) M80-315 to 317……………………….. ………….Straight male coax crimp contact (Used in Mix-Tek male crimp connectors) M80-318 & 319... (Z80-293 only)……………90° male coax crimp contact (Used in Mix-Tek male crimp connectors) Harwin North America Harwin Europe T: +1 603 893 5376 F: +1 603 893 5396 E: [email protected] W: www.harwin.com T: +44 (0) 23 9231 4545 F: +44 (0) 23 9231 4590 E: [email protected] W: www.harwin.com IS-34 Issue: 3 Date: 19.03.2013 C/Note: 11973 Harwin Asia T: +65 6 779 4909 F: +65 6 779 3868 E: [email protected] W: www.harwinasia.com Page 1 of 5 CONTENTS Contents ................................................................................................................................................... 2 General information ................................................................................................................................ 3 Tool preparation ...................................................................................................................................... 3 Wire stripping details .............................................................................................................................. 4 Crimping procedure Z80-292................................................................................................................... 4 Crimping procedure Z80-293................................................................................................................... 5 Care of tool .............................................................................................................................................. 5 IS-34 Issue: 3 Date: 19.03.2013 C/Note: 11973 Page 2 of 5 GENERAL INFORMATION The Hand crimp tools Z80-292 & Z80-293 consist of a basic hand tool, which should be used with a positioner or die set. 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. Table 1 Cable Type RG 178 PTFE cellular RG 174 RG 179 RG 316 Max. Insulation Diameter Ø2.0mm Ø2.4mm Ø2.7mm Ø2.7mm Ø2.7mm Compatible Contacts M80-305, M80-308, M80-315, M80-318 M80-306, M80-316 M80-307, M80-309, M80-317, M80-319 M80-307, M80-309, M80-317, M80-319 M80-307, M80-309, M80-317, M80-319 TOOL PREPARATION Z80-292 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 (Z80-291) 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 2 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. Z80-293 1. Align die rail slots in die halves with the rail in the crimp tool and push shank of dies into holes, dies will snap into place. 2. Close handle to make sure dies are properly seated. 3. The tool is now ready to use. IS-34 Issue: 3 Date: 19.03.2013 C/Note: 11973 Page 3 of 5 WIRE STRIPPING DETAILS Straight coax connector Fig A 90° coax connector Fig B CRIMPING PROCEDURE Z80-292 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. 2. See Figs. A & B for correct wire stripping dimensions for the appropriate contact. See also drawings M80-305 to 307 & M80-315 to 317 for cable diameter and type. 3. Place the prepared wire and contact into the positioner and squeeze the handles of the crimp tool fully together, until the ratchet releases. The handle will return to the open position. Remove the crimped contact and wire. Using the sight hole (Fig A) on the side wall of the contact, ensure that adequate insertion of strands into the crimp contact has been achieved. 4. For pull off forces for individual contacts see table 2. 5. Refer to component specification C005XX for details of coax assembly methods. Table 2 IS-34 Contact Inner Contact M80-305 M80-306 M80-307 M80-315 M80-316 M80-317 M80-393 M80-394 M80-395 M80-387 M80-388 M80-389 Issue: 3 Date: 19.03.2013 C/Note: 11973 Crimp Tool Setting (inner contact only) 4 4 4 4 4 6 Min’ Pull Off Force (N) 15 10 44 13 10 28 Page 4 of 5 CRIMPING PROCEDURE Z80-293 1. Ensure that the wire to be crimped is within the specified range of sizes for the contact and the crimp tool (see table 1). Failure to use the specified wire size will result in poor quality crimps and possible tool damage. 2. See Figs. A & B for correct wire stripping dimensions for the appropriate contact. The straight coax contact (Fig A) will need to be crimped to the wire before insertion into outer contact. For the 90° coax contact (Fig B) the wire is inserted into the coax body and soldered before assembly, see component specification C005XX for further details of coax assembly methods. 3. Check below table 3 to select which of the two hexagon sizes is correct to crimp contact with. Place contact with crimp sleeve in position into the above selected hexagon with the flat against the surface (the side with the manufacturers ID plate on), gently squeeze the handle until it will go no further the crimp is now complete, squeeze handle again to release completed crimp. 4. A correctly crimped contact & sleeve will achieve a pull off force of 30N minimum. Table 3 Cable Type Max. Insulation Diameter Compatible Contacts RG 178 Ø2.0mm M80-305, M80-308, M80-315, M80-318 PTFE cellular Ø2.4mm M80-306, M80-316 RG 174 Ø2.7mm RG 179 Ø2.7mm RG 316 Ø2.7mm M80-307, M80-309, M80-317, M80-319 M80-307, M80-309, M80-317, M80-319 M80-307, M80-309, M80-317, M80-319 Crimp Sleeve Hexagon Size Small 0.105” (2.67mm) A/F Small 0.105” (2.67mm) A/F Large 0.128” (3.25mm) A/F Large 0.128” (3.25mm) A/F Large 0.128” (3.25mm) A/F CARE OF TOOL There is virtually no maintenance required for the Z80-292 & Z80-293. 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-34 Issue: 3 Date: 19.03.2013 C/Note: 11973 Page 5 of 5