Owner's manual

ManualsBrandsHarwin ManualsToolsZ80-255

IS-27 Issue: 6 Date: 14.11.11 C/Note: 11542 Page 1 of 9

HAND CRIMP TOOL Z80-255

This Hand Crimp Tool has been designed for use with the following Datamate Trio-Tek Signal

Crimp Contacts:

M80-28300XX .............. Female crimp contact for 22-24 AWG wire, supplied loose

M80-28400XX .............. Female crimp contact for 26-28 AWG wire, supplied loose

M80-25300XX .............. Female crimp contact for 22-24 AWG wire, supplied reeled

M80-25400XX .............. Female crimp contact for 26-28 AWG wire, supplied reeled

Harwin recommend the use of BS 3G 210 Type A PTFE Equipment Wire or near equivalent.

Contact

Wire

Gauge

(AWG)

Typical Stranding

(no of strands/Ø

mm)

Conductor

cross-sectional

area (mm²)

Max Insulation

diameter (mm)

Crimp

height

(mm)

Minimum

pull-off

force

M80-25300XX

M80-28300XX

22 19/0.15 0.3358 1.10

0.76 –

0.82mm

45N

24 7/0.20 0.2199 0.95 29N

M80-25400XX

M80-28400XX

26 7/0.15 0.1237 0.80

0.50 –

0.56mm

18N

28 7/0.12 0.0792 0.71 9.8N

Harwin North America Harwin Europe Harwin Germany Harwin Asia

T: +1 603 893 5376 T: +44 (0) 23 9231 4545 T: +49 (0) 89 3791 9400 T: +65 6 779 4909

E: misboston@harwin.com E: mis@harwin.co.uk E: wpohl@harwin.com E: mis@harwin.com.sg

Summary of content (9 pages)

PAGE 1
HAND CRIMP TOOL Z80-255 This Hand Crimp Tool has been designed for use with the following Datamate Trio-Tek Signal Crimp Contacts: M80-28300XX .............. Female crimp contact for 22-24 AWG wire, supplied loose M80-28400XX .............. Female crimp contact for 26-28 AWG wire, supplied loose M80-25300XX .............. Female crimp contact for 22-24 AWG wire, supplied reeled M80-25400XX ..............
PAGE 2
general information The Hand crimp tool Z80-255 consists of a Rigidus Hand Crimp Tool with a die-set (Z80-244) designed for Trio-Tek crimp contacts. The tool is supplied with a locator (Z80-259), fitted to the rear of the tool, to ensure correct and consistent location of the crimp contacts within the tool.
PAGE 3
Rotate the locator down, snapping the lower tabs on the locator into the bottom slots on the tool. Correct position for the locator. WIRE PREPARATION 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. Cut the end of the cable to be terminated so that there is a clean cut end (Figure A).
PAGE 4
. Release the locator button, allowing the crimp contact to move back between the crimping jaws. 6. Load the stripped wire through the terminal, and against the wire stop inside the tool. 7. 5. Close the handle, until the second ratchet position engages. Whilst holding the wire against the wire stop, complete the crimp by squeezing the tool handles together through the rest of the ratchet clicks – another 3, to make 5 in total. The handles should then be free to open. Remove the crimped wire.
PAGE 5
CRIMP INSPECTION (CONT.) Crimp Inspection Areas 1 2 1. Insulation Inspection window 3 2. Bellmouth 3. Conductor Inspection window 4 5 6 4. Insulation crimp area 5. Conductor crimp area 6. Contact stop ear Target Insulation extends past Insulation crimp area, but does not enter Bellmouth. Insulation crimp does not cut or break Insulation. Insulation crimp is fully wrapped around and supporting insulation. Conductors extend past conductor crimp area, but not past contact stop ear.
PAGE 6
Deffects Insulation crimp incorrectly formed. Conductor trapped in Insulation crimp. Conductor outside of crimp area. Insulation not visible in Inspection window. Conductor not visible in Inspection window. Insulation enters bellmouth Conductor extends past stop ear IS-27 Issue: 6 Date: 14.11.
PAGE 7
ASSEMBLY – CRIMP INTO HOUSING The completed crimp can now be inserted into the appropriate Trio-Tek crimp housing. For larger wire sizes, no other tooling should be required for this operation; the crimps can be pushed in by hand. Crimps are assembled into the mould with the retaining tang towards the outer edge of the housing. With thinner wires, it may be helpful to push onto the back of the crimp with the Extraction Tool Z80-258.
PAGE 8
Rotate the setting wheel to a different setting – the higher the number displayed, the higher the preload force. Release the link to lock the wheel in place. If the wheel has been set to the maximum setting possible, then the tool is no longer capable of achieving the minimum pull-off force and should be replaced. TROUBLESHOOTING – REPLACING THE DIES If you need to remove the dies to clean the tool, or replace the dies due to damage, then this section will tell you how to remove the locator and the dies.
PAGE 9
CARE OF TOOL Although the Rigidus tool is engineered for durability, it is recommended that the following maintenance points are observed, to maximise the life of the tool. 1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint-free cloth. 2. Do not use any abrasive materials that could damage the tool. 3. All pins, pivot points and bearing surfaces should be covered with a thin coat of high quality machine oil – do not oil excessively.