Harwin M22520/2-01 - User Manual

IS-01 Issue: 2 Date: 06.09.00 C/Note: 5393 Side 1
HAND CRIMP TOOL M22520/2-01
This Hand Crimp Tool has been designed for use with the following Datamate crimp
sockets (when used with Positioner T5747):
M80-0110001.........Large bore crimp socket (22 AWG), Tin shell/Gold clip
(used in M80-889XX01 and M80-899XX01)
M80-0110005.........Large bore crimp socket (22 AWG), Gold shell/Gold clip
(used in M80-889XX05 and M80-899XX05)
M80-0130001.........Small bore crimp socket (24-28 AWG), Tin shell/Gold clip
(used in M80-888XX01 and M80-898XX01)
M80-0130005.........Small bore crimp socket (24-28 AWG), Gold shell/Gold clip
(used in M80-888XX05 and M80-898XX05)
The following Datamate Power Crimp Sockets can also be crimped (when used with
Positioner Z80-058):
M80-0550001.........Power crimp socket (18-20 AWG), Tin shell/Gold clip
(used in M80-716XX01 and M80-719XX01)
M80-0550005.........Power crimp socket (18-20 AWG), Gold shell/Gold clip
(used in M80-716XX05 and M80-719XX05)
HARWIN Inc HARWIN plc HARWIN pte
U.S.A. U.K. Singapore
Tel: 812 285 0055 023 9231 4545 65 779 1304
Fax: 812 285 0056 023 9231 4590 65 779 3868
E-Mail: mis@harwin.com mis@harwin.co.uk mis@harwin.com.sg

Summary

Datamate Crimp Socket Compatibility

Datamate Crimp Sockets (Positioner T5747)

Lists Datamate crimp sockets compatible with Positioner T5747 for the M22520/2-01 tool.

Datamate Power Crimp Sockets (Positioner Z80-058)

Lists Datamate Power Crimp Sockets compatible with Positioner Z80-058 for the M22520/2-01 tool.

General Information

Tool Preparation

Crimping Procedure

Assembly Procedure

Care of Tool

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The Harwin Hand Crimp Tool M22520/2-01 is a precision instrument designed for crimping Datamate crimp sockets and Power Crimp Sockets. This tool ensures reliable electrical connections by securely attaching wires to contacts through a controlled crimping process. Its primary function is to provide a consistent and high-quality crimp, which is crucial for the performance and longevity of electronic assemblies. The tool operates on a ratchet mechanism, ensuring that a full crimp cycle is completed before the handles can be released, thereby preventing partial or inadequate crimps.

Function Description

The Hand Crimp Tool M22520/2-01 is a basic hand tool that must be used with a positioner to achieve optimal crimping results. The tool's core function is to mechanically deform a crimp barrel around a stripped wire, creating a gas-tight electrical connection. This process is critical for preventing corrosion and ensuring low electrical resistance. The tool features a selector knob that allows users to choose the correct crimp tool setting based on the wire gauge and contact type, ensuring that the crimp force is appropriate for the specific application.

For Datamate crimp sockets, the tool is used with Positioner T5747. It supports large bore crimp sockets (22 AWG) for both Tin shell/Gold clip (M80-0110001, used with M80-889XX01 and M80-899XX01) and Gold shell/Gold clip (M80-0110005, used with M80-889XX05 and M80-899XX05) configurations. Additionally, it handles small bore crimp sockets (24-28 AWG) for Tin shell/Gold clip (M80-0130001, used with M80-888XX01 and M80-898XX01) and Gold shell/Gold clip (M80-0130005, used with M80-888XX05 and M80-898XX05).

For Datamate Power Crimp Sockets, the tool is used with Positioner Z80-058. It is compatible with power crimp sockets (18-20 AWG) for Tin shell/Gold clip (M80-0550001, used with M80-716XX01 and M80-719XX01) and Gold shell/Gold clip (M80-0550005, used with M80-716XX05 and M80-719XX05). The tool also supports crimping of Power Crimp Pins (18 AWG, Tin plated) and Power Crimp Sockets (18 AWG, Tin shell/Tin clip) when used with Positioner ZK3609-00.

The crimping process involves several steps to ensure a proper connection. First, the cable end must be prepared with a clean cut and stripped to the correct length, ensuring all strands are neatly together. The crimp socket is then positioned fully into the positioner, with the crimp barrel facing upwards. The terminated end of the cable is loaded into the crimp barrel, ensuring the wire is fully home and all strands are in place. Finally, the handles of the crimp tool are squeezed together until the ratchet releases, signifying a complete crimp cycle. The tool will then return to the open position, allowing the crimped socket and wire to be removed. A sight hole on the side wall of the socket allows for visual inspection to confirm adequate insertion of strands.

Usage Features

The M22520/2-01 tool is designed for ease of use while maintaining precision. Its key usage features include:

• Ratchet Mechanism: This ensures that the tool cannot be opened until a full crimp cycle is completed, guaranteeing consistent and reliable crimps. This prevents incomplete crimps that could lead to poor electrical connections.
• Positioner Integration: The tool is designed to be used with specific positioners (T5747, Z80-058, ZK3609-00) that guide the contact into the correct crimping position, ensuring accurate alignment and preventing damage to the contact or wire. The positioner is inserted into the positioner guide and turned 90 degrees until its bayonet pins lock, securing it in place.
• Selector Knob for Crimp Settings: A selector knob allows the user to choose from different crimp tool settings, which are crucial for matching the wire gauge and contact type. This adjustability ensures that the correct crimp force is applied, preventing over-crimping (which can damage the wire) or under-crimping (which can result in a loose connection). To adjust, the selector knob is lifted and turned until the desired setting aligns with the "Sel. No." arrow, then lowered to engage the locating peg with a notch.
• Safety Clip: Safety clips are provided for both the positioner guide and the selector knob. These clips help secure the positioner and the selector knob setting, preventing accidental changes during operation. While the safety clip for the positioner guide is optional after installation, it is good practice to use it.
• Visual Inspection Aids: The crimp sockets themselves often include a sight hole, allowing for a visual check to confirm that the wire strands are adequately inserted into the crimp barrel after the crimp is made. This helps in quality control.
• Clear Crimp Procedure: The manual outlines a clear, step-by-step crimping procedure, from cable preparation to final inspection, making it accessible for users to achieve high-quality results. This includes instructions on stripping cable ends to specific lengths for different contact types.
• Crimp Joint Checks: The tool emphasizes the importance of checking crimp joints for correctness in terms of cable/tool/termination combination, form and location of crimp, freedom from fracture/rough edges/flash, adequate insertion of conductor strands, and absence of damage to conductor or insulation. These checks are vital for ensuring the integrity of the electrical connection.

Maintenance Features

The M22520/2-01 is designed to be a low-maintenance tool, but certain practices are recommended to ensure its longevity and continued precision:

• Minimal Maintenance Required: The tool generally requires very little maintenance, reflecting its robust design.
• Keeping Indenter Tips Clean: It is good practice to keep the indenter tips free of residual color band deposits and other debris. A small wire brush can be used for this purpose. Clean indenter tips ensure consistent crimp quality and prevent contamination of contacts.
• Avoid Immersion in Cleaning Solutions: Users are strongly advised not to immerse the tool in any cleaning solution. This can damage internal components or lubricants.
• No Spray Lubrication: Do not spray oil into the tool to lubricate it. The tool is designed with specific lubrication requirements, and external sprays may interfere with its proper functioning or attract debris.
• No Disassembly or Repairs by User: As a precision crimp tool, users are explicitly warned not to attempt to disassemble the tool or make repairs themselves. Any issues requiring repair should be handled by qualified personnel or returned to the manufacturer. This ensures that the tool's calibration and precision are maintained.
• Proper Handling: The tool should be handled with care, as it is a precision instrument. This helps prevent accidental damage that could affect its performance.

In summary, the Harwin Hand Crimp Tool M22520/2-01 is a specialized, precision tool essential for creating high-quality electrical connections with Datamate contacts. Its design incorporates features that ensure consistent crimping, user safety, and ease of operation, while its robust construction and minimal maintenance requirements contribute to its reliability in professional applications.

Harwin M22520/2-01 Specifications

General

Type	Hand Crimp Tool
M22520 Series	Yes
Manufacturer	Harwin
Model	M22520/2-01
Material	Steel
Weight	0.5 kg
Compatible Connectors	MIL-DTL-38999
Application	Crimp Contacts
For Use With	M22520 Series contacts