HT-0095 FCI-CONNECTOR | Alldatasheet
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FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 1 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals HT-0095 Mini PV Receptacles 22-32 AWG Crimping Hand Tool Tool P/N HT-0095 FCI MANUAL P/N 415988-001 PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 2 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals HT-0095 PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 3 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals Table of Contents Introduction Operation Service Parts Replacement Procedure Spare Parts Reference Documents Form # E-3246--Hand Tool Warranty Form # E-3247--FCI Electronics Address List TA –75 Latch Housing Mini PV Crimp/Appl. Data TA-146 Discrete Wire Mini PV Crimp/Appl. Data PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 4 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals INTRODUCTION Hand Tool Function The HT-0095 is a manually operated hand tool designed for crimping loose piece (individual) Mini PV™ terminals to various sizes of wire. Physical Description The major components, which make up the HT-0095, are identified in Figure 1. These components include a frame, lever, tooling and tooling holders, and terminal holding pins. The heart of the hand tool is the tooling. The tooling performs the crimping operation and is divided into top and bottom component groups. The top group consists of those parts, which remain stationary with the frame. The bottom group contains those parts, which move with the lever. The HT-0095 is equipped with tooling for crimping two different ranges of wire sizes. These are identified as "A" and "B" on a plate affixed to the hand tool frame. The "A" side tooling is for crimping terminals to wire sizes ranging from 28-32 AWG. The "B" side tooling is used for wire sizes from 22-26 AWG. Figure 1 PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 5 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals Principles of Operation The lever attaches to the lower tooling and provides the mechanical advantage to generate the necessary crimping pressure. As the lever is closed, a ratchet mechanism engages to prevent the lever from opening until the crimping cycle is complete. When the lever is pulled closed, the lower tooling and terminal are pushed up against the upper tooling. The crimp is formed between the wire and insulation barrel anvils and the wire and insulation crimpers. Once closed, the ratchet releases and allows a spring to pull the lever open. Specifications (See TA-75, TA-146) When crimping the Mini PV™ to wires, the following parameters must be met. Wire Length Requirements: Insulation Diameters of Wires: Strip Length of Insulation:
- Discrete and Latch
- Rod Housing Wire Barrel Crimp Height: (For All Applications)
- Single Wire 22-26 AWG or
- Single Wire 28-32 AWG or Insulation Barrel Crimp Height:
- Discrete Application …………………………2.84 mm (0. 112 in.) Max.
- Latch and Rod Housing Mini PV™ Receptacles: NOTE: Loose piece terminals have different part numbers than reeled terminals. PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
or with FCI Electronics to be sure that the new terminal number is compatible with your hand tool. between the lever and handle when closing hand tool.
- Hold the hand tool so that the lever is on the left. With your index finger, push and hold the
terminal holder in its forward position (see Figure 2).
- Insert the disconnect (box) portion of the terminal, with "U" shaped barrels up, onto the holding
Figure 2. Positioning Terminal
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 9 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals TROUBLESHOOTING The troubleshooting information provided in the following chart will help to isolate and identify crimping problems. Troubleshooting Chart, PV™ Receptacles Problem Possible Cause Corrective Action 1. Bellmouth(s) is deformed or improperly positioned on wire barrel. Terminal is not properly position in crimping area. Loosen the two 2-56 setscrews on the side of the anvil holder and reposition guide pins until proper bellmouth(s) is achieved. 2. Disconnect (box) portion of terminal is bent down. Terminal is sticking in wire barrel crimper Replace wire barrel crimpers 3. The sides of the terminal’s wire barrel are bent down. Wire barrel crimper is defective. Replace wire barrel crimpers 4. Flashings formed on the bottom of the wire barrel are unequal or abnormal. Anvil is worn or broken. Replace anvil 5. Insulation bulges between wire and insulation barrels. Wire is inserted too far into terminal. Position the end of the insulation so that it lies midway between the ends of the wire barrel and the insulation barrel. 6. Insulation bulges around insulation barrel. Wire size or insulation diameter is incorrect for the terminal being used. Refer to section “Specifications” for correct insulation diameter requirements. PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 13 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals 5. Remover the crimpers (2 and 3) and tonkers (18) from the crimper holder. 6. Remove the damaged crimper(s) (2 or-3). The top crimper is the wire barrel crimper (3). Wire and Insulation Barrel Crimpers and Tonker Installation NOTE: When replacing tooling, always be sure that the part number on the part(s) being replaced is the same as the number of the part that was removed. 1. Place the insulation crimper (2) onto the flat side of the crimper holder (1). Place the wire barrel crimper (3) on the insulation crimper (2) and install two 4-40 cap screws (9) and loosely tighten. 2. Insert tonkers (18), with the top tabs facing outward, into the slots between the wire and insulation crimpers. 3. Place and hold the crimper assembly into the hand tool on the same side as the anvil holder (4). Make sure that the tonkers (18) go into the holes in the top of the hand tool frame. 4. Place spring guides (20) into the holes in the top of the hand tool frame, then insert the springs (19) into the holes so that the springs slip over the shoulder of the spring guides. 5. Place spring retainer (21) over tonker springs (19). Make sure springs are fully compressed, then loosely attach the spring retainer (21) and the crimper holder (1) to the hand tool with a 6-40 cap screw (13). 6. To align the tooling, close hand tool completely and hold it in its closed position. Tighten the two 4-40 cap screws (9) to secure the crimpers to their holder. Then tighten the 6-40 cap screw (13), which secures the crimper holder to the hand tool frame. 7. Crimp a terminal to a proper-sized wire, and inspect the terminal as described in Section 11, paragraph B. Holding Pin Removal (See Figure 15) NOTE: When holding pins (14) become bent, it is necessary to replace them. NOTE: When removing the holding pin, the terminal holder (10) and guide pins (15) must also be removed. Prior to removal, note the position of the guide pins (15) in the anvil holder, so that they can be repositioned as they were before removal: the flat on the guide pin must face the setscrew (12) in the anvil holder (4). 1. Loosen the two 2-56 setscrews (12) in the anvil holder (4). Then remove the terminal holder assembly, which includes the terminal holder (10), guide pins (15), "0" rings (16), holding spring’s (17), and holding pins (14) attached. PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 14 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals 2. Remove the two holding spring’s (17) and the guide pins (15) from the terminal holder. 3. Loosen the two 2-56 setscrews (12) in the top of the terminal holder (10), which secure the holding pins (14). 4. Using needle-nose pliers, remove both holding pins (14) by pulling straight out from terminal holder (10). Discard the damaged holding pin(s). Holding Pin Installation CAUTION Over tightening the two 2-56 setscrews (12) in the top of the terminal holder (10) can flatten the holding pins (14), making them extremely difficult to remove. terminal holder (10) until pins are flush with the extended supports. Be sure that a flat side of each pin is at right angles to the two 2-56 setscrew holes on top of the terminal holder (10). 2. Lightly tighten the two 2-56 setscrews (12) into the terminal holder (10) to secure the holding pins (14). 3. Re-install the two guides pins (15), "0" rings (16), and the two holding spring’s (17). 4. Re-install the terminal holder (10) to the anvil holder (4), and tighten the two 2-56 setscrews (12) in the anvil holder (4) onto the flats of the guide pins (15). 5. Crimp a terminal to a proper-sized wire, and inspect the terminal as described in Section II, paragraph B. PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 16 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals Figure 14 4. Reinstall the anvil holder assembly onto the hand tool and loosely tighten the attaching cap screw. Then slowly close the hand tool all the way and tighten the cap screw. 5. Crimp a terminal to the proper size wire and check the wire barrel crimp height of the crimped terminal. If crimp height is not as specified, turn the adjusting collar an additional 5 degrees. Continue adjusting the collar in this same manner until the proper crimp height is achieved. 6. Remove the anvil holder assembly from the hand tool. Next, tighten the setscrew in the adjustable tool holder to lock the adjusting collar. Then reinstall the anvil holder assembly and tighten the attaching cap screw. PARTS Spare Parts These are parts that FCI considers practical for the user to stock for replacement. Recommended spare parts for the hand tool are specified in bold type in the parts list for Figure 15. Parts Ordering Information To obtain replacement parts, contact: FCI Electronics
825 Old Trail Road
Etters, PA. 17319-9769 Phone Toll Free 1-800-237-2374 Please provide the description of the part, FCI part number (if specified), quantity desired, and also the hand tool model and serial number. PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
FCI Electronics Manual Part No. 415988-001 Issued: Date (03/12/99) Page 17 of 18 Rev. 05/07/01 ECR V10337 Revision B K\\DCU\\Manuals Hand Tool Repair Policy FCI Electronics charges a standard rate to repair any hand tool not under warranty. Phone Toll Free 1-800-237-2374 to obtain a Return Material Authorization number (RMA), shipping instructions and the current cost of repair. FCI will repair the hand tool and return it to you by the fastest means possible. Parts List for Figure 15. HT-95 Hand Tool Parts Index Qty No. Part No. Description Per 1 155089-001 CRIMPER HOLDER 1 2* 104958-1 INSULATION BARREL CRIMPER, 22-26 and 28-32 Gauge Wire 1 3* 104959-1 WIRE BARREL CRIMPER, 22-26 AND 28-32 Gauge Wire 1 4 102466-1 ANVIL HOLDER 1 5* 104914-1 INSULATION BARREL ANVIL, 28-32 Gauge Wire (A SIDE) 1 6* 104914-2 INSULATION BARREL ANVIL, 22-26 AWG Wire (B SIDE) 1 7* 104960-1 WIRE BARREL ANVIL, 28-32 Gauge Wire (A SIDE) 1 8* 104960-2 WIRE BARREL ANVIL, 22-26 AWG Wire (B SIDE) 1 9 915305-224 SCREW, Cap, Socket Hd, 4-40 NF x 3/8” lg. 8 10 102467-5 TERMINAL HOLDER 1
11 A-856-1 TOOL HOLDER, Adjustable
12 915305-559 SETSCREW, Socket Hd. 2-56 NF x 1/8” lg. 4 13 915305-205 SCREW, Cap, Socket Hd, 6-40 NF x ½” lg. 2 14* 104756-1 HOLDING PIN (0.025" sq. BergPin™ Material 0.430" lg.) 2 15 102468-1 GUIDE PIN 2 16 900066-001 "O" RING, 01-004 2 17 102470-1 HOLDING SPRING 2 18 104964-1 TONKER 2
19 A-1153 SPRING TONKER 2
20 A-1155 SPRING GUIDE 2
21 155014-001 SPRING RETAINER 1 22 144547-001 GUIDE RAIL 2 * Recommended Spare Parts PDM: Rev:B Released STATUS: Printed: Dec 19, 2002
Figure 15. HT-95 Hand Tool Parts