FCI HT-0095 Manuel utilisateur

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 1 of 18

Rev. 05/18/06 EC V06-0481 Revision C

HT-0095

Mini PV Receptacles 22-32 AWG Crimping Hand Tool

Tool P/N HT-0095

FCI MANUAL P/N 415988-001

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 2 of 18

Rev. 05/18/06 EC V06-0481 Revision C

HT-0095

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 3 of 18

Rev. 05/18/06 EC V06-0481 Revision C

Table of Contents

Introduction

Hand Tool Illustration ................................................................................................................ 2

Table of Contents ....................................................................................................................... 3

Hand Tool Function.................................................................................................................... 4

Physical Description................................................................................................................... 4

Principles of Operation............................................................................................................... 5

Specifications ......................................................................................................................... 5

Operation

Operating Procedures ................................................................................................................. 6

Terminal Inspection.................................................................................................................... 7

Troubleshooting............................................................................................................................... 9

Service

Parts Replacement Procedure

Anvil Removal ............................................................................................................... 10

Anvil Installation ............................................................................................................ 11

Wire and Insulation Barrel Crimpers and Tonker Removal ........................................... 12

Wire and Insulation Barrel Crimpers and Tonker Installation ....................................... 13

Holding Pin Removal ..................................................................................................... 13

Holding Pin Installation .................................................................................................. 14

Crimp Height Adjustment ........................................................................................................ 15

Spare Parts

Parts Ordering Information ........................................................................................ 16

Hand Tool Repair Policy ............................................................................................ 17

Recommended Spare Parts ......................................................................................... 17

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:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 4 of 18

Rev. 05/18/06 EC V06-0481 Revision C

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:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 5 of 18

Rev. 05/18/06 EC V06-0481 Revision C

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:

• Minimum ……………………………………..19.05 mm (0.75 in.)

• Maximum …………………………………….As Required

Insulation Diameters of Wires:

• "A" Side (28-32 AWG) ………………………0.71-1.37 mm (0.028-0.054 in.) Dia.

• "B" Side (22-26 AWG) ………………………0.91-1.52 mm (0.036-0.060 in.) Dia.

Strip Length of Insulation:

• Discrete and Latch

Housing Applications ……………………….3.81-4.31 mm (0. 150- 0.170 in.)

• Rod Housing

Applications ………………………………….3.30-3.81 mm (0. 130-0.150 in.)

Wire Barrel Crimp Height:

(For All Applications)

• Single Wire 22-26 AWG or

Two Wires 26-28 AWG ……………………..0.81-0.86 mm (0.032-0.034 in.)

• Single Wire 28-32 AWG or

Two Wires 30-32 AWG ……………………..0.66-0.71 mm (0.026-0.028 in.)

Insulation Barrel Crimp Height:

• Discrete Application …………………………2.84 mm (0. 112 in.) Max.

• Latch and Rod Housing

Applications ………………………………….1.75 mm (0.069 in.) Max.

Mini PV™ Receptacles:

• Loose Piece ………………………………….22-32 AWG

NOTE: Loose piece terminals have different part numbers than reeled terminals.

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 6 of 18

Rev. 05/18/06 EC V06-0481 Revision C

CAUTION

If the terminal and the tooling are not compatible, damage to the tooling could result. If you wish to use

a terminal with a part number other than the one that was ordered for the HT-0095, check with your

distributor or with FCI Electronics to be sure that the new terminal number is compatible with your

hand tool.

OPERATION

Operating Procedures

WARNING

To prevent hand injury, keep fingers from between the upper and lower tooling and from

between the lever and handle when closing hand tool.

1. 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).

2. Insert the disconnect (box) portion of the terminal, with "U" shaped barrels up, onto the holding pin

and against the pin shoulder. While holding the terminal against the shoulder, release the terminal

holder. This ensures that the terminal remains in proper position while moving over the anvil.

Figure 2. Positioning Terminal

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 7 of 18

Rev. 05/18/06 EC V06-0481 Revision C

3. While grasping the lever and the handle portion of the frame, insert a wire so that the end of the

insulation is centered between the wire barrel and the insulation barrel of the terminal (see Figure 3),

and then close the hand tool lever completely. This will crimp the terminal to the wire(s).

Figure 3. Crimping Terminal to Wire

4. Release the lever to open the hand tool and remove the crimped terminal from the holding pin by

lightly pulling straight out on the wire.

CAUTION

The crimp height for this hand tool was factory adjusted. Any random changes to this

adjustment could cause a defective crimp or damage to the tooling.

Terminal Inspection

The crimped terminal should be inspected to ensure that the tooling is correctly aligned and that the

wire was correctly inserted. Make the following visual checks (see Figure 4).

NOTE: If inspection of the crimped terminal reveals any defects, the terminal has not been properly

crimped and should be discarded.

• Check that all wire strands were crimped within the wire barrel.

• Check that the edge of the wire insulation lies between the insulation and wire barrel.

• Check that the bell mouth(s) were formed correctly.

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 8 of 18

Rev. 05/18/06 EC V06-0481 Revision C

• Check that the spring was not dislodged from the disconnect (box) portion of the terminal.

• Check that the wire barrel seam is even and tightly closed.

Figure 4. Correctly Crimped Terminal

Next, obtain a crimp height micrometer and measure the areas of the terminal shown in Figure 5. If the

crimp heights do not meet the specifications listed in “Specifications” on page 5, refer to the section for

proper adjustment procedures of crimp height on page 15.

Figure 5. Measuring Crimp Height of Terminal

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 9 of 18

Rev. 05/18/06 EC V06-0481 Revision C

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:C Released .STATUS: Printed: Feb 09, 2009

FCI Electronics Manual Part No. 415988-001

Issued: (03/12/99) Page 10 of 18

Rev. 05/18/06 EC V06-0481 Revision C

PARTS REPLACEMENT PROCEDURE

Anvil Removal

NOTE: Replace anvils when they show excessive wear or become cracked or chipped.

1. Using a 3/32-inch Allen wrench loosen the attaching cap screw(s) for the defective anvil(s).

See Figure 6.

Figure 6

2. Using a 7/64-inch Allen wrench, remove the cap screw securing the anvil holder assembly to the

hand tool (see Figure 7). Then remove the anvil holder assembly.

Figure 7

3. Remove the cap screw(s) and defective anvil(s) from the anvil holder assembly (see Figure 8).

Figure 8

PDM: Rev:C Released .STATUS: Printed: Feb 09, 2009

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