Harwin Z80-255 User Manual

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.

Wire

Contact

Gauge
(AWG)

M80-25300XX

22 19/0.15 0.3358 1.10

or

M80-28300XX
M80-25400XX

24 7/0.20 0.2199 0.95 29N

26 7/0.15 0.1237 0.80

or

M80-28400XX

28 7/0.12 0.0792 0.71 9.8N

Harwin North America Harwin Europe Harwin Germany Harwin Asia

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Typical Stranding

(no of strands/Ø

mm)

Conductor

cross-sectional

area (mm²)

Max Insulation

diameter (mm)

Crimp

height

(mm)

0.76 –

0.82mm

0.50 –

0.56mm

Minimum

pull-off

force

45N

18N

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

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.

The Rigidus Hand Crimp Tool includes the following features:

Parallel action stroke for accurate and consistent crimp performance
Unique locator design for full visibility of contact and wire insertion
Symmetric crimp dies and locator allow assembly to suit right or left hand users
Lightweight and compact design for easy access
Ergonomic handles shaped for low effort crimping
Ratchet control to ensure completion of crimp cycles
Die closure adjustment function for tool calibration
Lifetime tests exceeding 50,000 cycles

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 – if the handles have not opened, squeeze the handles together to complete
the cycle.

TOOL PREPARATION – CHANGING FROM RIGHT TO LEFT HAND OPERATION

If the locator is fitted, please see section “Troubleshooting – Replacing the Dies” on page 6 for instructions on
removing the locator.

Ensure that the crimp

tool is at the fully open

position.

Remove the TX-10 TORX head screws

holding the die sets in place.

Reverse the die sets, ensuring that

the small locating marks line up and

are on the outside of the tool.

TOOL PREPARATION – ASSEMBLING THE LOCATOR

Ensure that the crimp

tool is at the fully open

position.

Push down the centre insert of the

locator, as far as it will go.

Insert the top hooks of the

locator into top slots of the tool

frame.

IS-27 Issue: 6 Date: 14.11.11 C/Note: 11542 Page 2 of 9

Rotate the locator down, snapping the lower tabs on the locator

Correct position for the

locator.

into the bottom slots on the tool.

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). 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 laying together neatly. If the
lay of the strands is disturbed, it may be re-imposed with a slight twist.

Clean cut

Ø1.10mm max

RIGHT WRONG

2.70 – 3.00mm

Figure A Figure B

CRIMPING PROCEDURE

1. Ensure that the crimp

tool is at the fully
open position.

Push the button on the back of the locator, which will

2.
move the locator forward between the crimp dies.

3. Whilst holding the locator in the forward

position, insert the crimp contact into the correct
locator nest. The wire size is marked on the
crimp die, above each location.

IS-27 Issue: 6 Date: 14.11.11 C/Note: 11542 Page 3 of 9