Harwin Z80-294 User manual

IS-29 Issue: 4 Date: 16.12.2010 C/Note: 11057 Page 1 of 3
HAND CRIMP TOOL Z80-294 (M22520/1-01)
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.
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Spring Clip
Tool in Closed Position
Retainer Ring
Selector Knob
Selector Index

IS-29 Issue: 4 Date: 16.12.2010 C/Note: 11057 Page 2 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. 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
Wire Gauge
(AWG)
Stranding
(mm)
Crimp Tool
Setting
Minimum
pull-off force
M80-338 Power Crimp 18 19/0.26 7 50N
M80-328 Power Crimp 18 19/0.26 7 50N
M80-329 Power Crimp 20 19/0.20 7 50N
M80-339 Power Crimp 20 19/0.20 7 50N
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) 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
Ø1.10mm max (22-28 AWG)
Ø1.80mm max (18-20 AWG)
RIGHT WRONG
2.00 ±0.15mm (M80-XXX)
3.75 ±0.25mm (K36XX)
Figure A Figure B
Ø1.60mm Max (20 AWG)
Ø1.80mm Max (18 AWG) 5.0 ±0.25mm

IS-29 Issue: 4 Date: 16.12.2010 C/Note: 11057 Page 3 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.