HAND CRIMP TOOL Z80-294 (M22520/1-01) Retainer Ring Tool in Closed Position Selector Index Selector Knob Spring Clip This Hand Crimp Tool has been designed for use with the following Datamate Mix-Tek Power Crimp Sockets [when used with Positioner Z80-295 (TP1663)]: M80-338 .......................... Male power crimp contact for 18 AWG wire (Used in Mix-Tek male crimp connectors). M80-328 .......................... Female power crimp contact for 18 AWG wire (Used in Mix-Tek female crimp connectors). M80-339 .......................... Male power crimp contact for 20 AWG wire (Used in Mix-Tek male crimp connectors). M80-329 .......................... Female power crimp contact for 20 AWG wire (Used in Mix-Tek female crimp connectors). GENERAL INFORMATION The Hand crimp tool M22520/1-01 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. 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-29 Issue: 4 Date: 16.12.2010 C/Note: 11057 Harwin Asia T: +65 6 779 4909 F: +65 6 779 3868 E: [email protected] W: www.harwin.com.sg Page 1 of 3 TOOL PREPARATION 1. Check that the tool is in the open position. 2. Place positioner assembly onto retainer ring with the 2 socket head screws lined up with tapped holes. 3. After positioner assembly is seated against retainer ring, tighten socket head screws with 9/64 Inch (3.57mm) hex key. 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. 2. 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 Crimp Type M80-338 M80-328 M80-329 M80-339 Power Crimp Power Crimp Power Crimp Power Crimp Wire Gauge (AWG) 18 18 20 20 Stranding (mm) 19/0.26 19/0.26 19/0.20 19/0.20 Crimp Tool Setting 7 7 7 7 Minimum pull-off force 50N 50N 50N 50N 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. Clean cut RIGHT Ø1.60mm Maxmax (20 AWG) Ø1.10mm (22-28 AWG) Ø1.80mm Maxmax (18 AWG) Ø1.80mm (18-20 AWG) Figure A IS-29 Issue: 4 Date: 16.12.2010 C/Note: 11057 WRONG 5.0 ±0.25mm 2.00 ±0.15mm (M80-XXX) 3.75 ±0.25mm (K36XX) Figure B Page 2 of 3 3. Position the crimp socket fully into the positioner, with the crimp barrel uppermost. 4. Load the terminated end of the cable into the crimp barrel of the socket. Ensure the wire is fully home, with all strands in place (see Figure C). Figure C 5. Squeeze the handles of the crimp tool fully together, until the ratchet releases. The handle will return to the open position. Remove the crimped socket and wire. Using the sight hole on the side wall of the socket, ensure that adequate insertion of strands into the crimp socket has been achieved. 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. CARE OF TOOL There is virtually no maintenance required for the Z80-294 (M22520/1-01) 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-29 Issue: 4 Date: 16.12.2010 C/Note: 11057 Page 3 of 3