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Crimping Instructions
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Crimping Instructions 

These instructions cover the use of the following tools:

  • Hand Crimp Tool M22520/2-01
  • Positioners T5747 and Z80-193
  • Insertion/Extraction tool Z80-280

All crimp and insertion/extraction tools are supplied with instruction sheets. Before starting, assemble the positioner to the crimp tool
(instructions supplied with the crimp tool).

Crimping

  • Check that your selected cable size is correct to the following table – Harwin recommend PTFE insulated equipment wire to BS 3G 210 Type A:



Crimping Instructions
  • Cut the end of the cable to give a clean cut end. Strip the end of the cable by 2.00±0.15mm using a PTFE wire stripper, ideally with an adjustable rotating cutter. This should result in a clean edge to the insulation, and all the strands laying together neatly. If the strands are disturbed, they can be re-aligned by putting a slight twist into the strand bundle.
  • Assemble the crimp onto the end of the cable – make sure all the strands are within the crimp body. Look through the inspection hole in the side of the barrel, to check the ends of the strands are fully inside the barrel. The cable insulation should also go inside the crimp barrel – see Figure 1.
  • Position the crimp socket fully into the positioner, by inserting it clip-end first through the crimp tool jaws. Keep a small amount of pressure on the cable, to ensure it stays inserted in the crimp.

  • Squeeze the handles of the crimp fully together, until the ratchet releases. The handles will then return to the open position. Remove the crimped wire, and check the following:

    • The strands are still visible within the inspection hole
    • Evenness of crimp indentations, no fractures or rough edges around the crimp
    • No damage to the rest of the crimp or insulation
    • Regularly check a sample to ensure the minimum pull-off force is maintained
Crimping Instructions

Crimp Insertion

  • Attach the correct tool piece to the handle of Z80-280 for inserting your cable size(check the instruction sheet for further advice).
  • Place the crimped contact partially in the moulding – this should leave 1.5-2mm
    of crimp protruding from the moulding. It is important that the correct position is found (Figure 2), otherwise the retention shoulder inside the moulding will get removed when force is applied, and the crimp will not stay in the moulding (Figure 3).
  • Support the face of the moulding on a solid surface (do not rest the connector on any fitted latches). Place the insertion tool around the wire and onto the back of the crimp (Figure 4). Push firmly – there will be an audible click when the socket is correctly seated.
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