Harwin Gecko Z125-900 User manual

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Instruction Sheet
IS-37
Gecko Hand Crimp Tool Z125-900
Safety clip
Tool in nearly
closed position
Positioner
Positioner
location guide
Crimp Setting
Selector knob

2
Issue:
6
Date:
01
11
20
2
3
C
Order
:
3210
2
IS
-
37
Instruction Sheet for Z125-900 Gecko Hand Crimp Tool
CRIMP CONTACT INFORMATION
This Hand Crimp Tool has been designed for use with the following Gecko Crimp Contacts (when
used with Positioner Z125-901):
 G125-0010005 ............... Large bore Female crimp contact for 26 AWG wire
 G125-0020005 .............. Small bore Female crimp contact for 28-32 AWG wire
 G125-1010005 ............... Large bore Male crimp contact for 26 AWG wire
 G125-1020005 ............... Small bore Male crimp contact for 28-32 AWG wire
GENERAL INFORMATION
The hand crimp tool Z125-900 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
locator (do not discard).
2. Insert the Positioner into the positioner locator 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 locator (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.
Contact Crimp Type
Wire Gauge
(AWG
Stranding
(mm
Crimp Tool
Setting
Minimum pull
-
off force
(N
G125
-
00100
G125
-
10100
Large Bore 26 7 0.15 6 18
G125-00200
G125-10200 Small Bore
28
7 0.
1
2
5
12.5
30
1 0.25
5
7
32
7 0.08
5
4
Table 1 - Crimp Tool Settings and Forces

3
Issue:
6
Date:
01
11
20
2
3
C
Order
:
3210
2
IS
-
37
Instruction Sheet for Z125-900 Gecko Hand Crimp Tool
2. 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). We recommend that when the wire is stripped, it
is clamped or supported close to the stripping area - this will prevent insulation slippage.
Suitable wire strippers (such as a PTFE wire stripper) must be used. 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
Ø
0.7
2
mm max
,
28
-
32 AWG
Ø0.80mm max, 26 AWG
RIGHT
WRONG
1.50m
m
to 1
.75mm
Figure A - Clean cut end Figure B - Strip wire
Caution: Wear Nitrile/Latex powder free gloves or Finger cots when handling contacts to
prevent hands from contaminating contacts.
3. Load the terminated end of the cable into the crimp barrel of the socket. Ensure the wire is
fully inserted, with all strands in place (Figure C).
Figure C - All strands in inner crimp bore
4. Apply pressure to the positioner plunger in the direction shown by the arrow (Figure D and
E). Release the plunger, to ensure it is moving freely and returns to the default position
without jamming. Once you are satisfied with plunger operation, re-apply pressure in
direction shown by the arrow (Figure D and E).
5. Maintain pressure on the plunger, and insert the crimp contact with cable fully into the
positioner (Figure F).
Figure D Figure E Figure F

4
Issue:
6
Date:
01
11
20
2
3
C
Order
:
3210
2
IS
-
37
Instruction Sheet for Z125-900 Gecko Hand Crimp Tool
6. Apply light pressure to the wire in the direction shown by arrow in Figure G. Slowly release
pressure on the plunger, and allow it to return to its default position as shown.
Figure G
7. Caution: Failure to allow the positioner plunger to return to its default position may
result in indentor damage during crimping.
If the plunger is not fully home, the indentors could crimp on the plunger, damaging both
the Z125-900 hand tool and the Z125-901 positioner {Figure H}.
Figure H – Damage risk if the positioner is not fully back to default position
8. 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.
9. Crimp joints should be checked for:
a) Correct combination of cable, tool setting and crimp termination.
b) Correct form of indents 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.

5
Issue:
6
Date:
01
11
20
2
3
C
Order
:
3210
2
IS
-
37
Instruction Sheet for Z125-900 Gecko Hand Crimp Tool
CONTACT ASSEMBLY TO HOUSING PROCEDURE
Contacts are assembled to housings using the Assembly Tool Z125-902. See Instruction Sheet
IS-38 for details on assembly.
CARE OF TOOL
There is virtually no maintenance required for the Z125-900 tool. However, it is good practice to
keep the indenter tips free of 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.