FCI HT-0102 Bedienungsanleitung

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 1 of 10

Rev. 03/08/01 ECR V10318 Revision B

K\DCU\Manuals

HT-0102 Hand Tool Manual

Crimp-to-Wire Male Pin Terminals

(22-32 AWG)

Hand Tool P/N: HT-0102

FCI MANUAL P/N 144000-001

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 2 of 10

Rev. 03/08/01 ECR V10318 Revision B

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TABLE OF CONTENTS

I. INTRODUCTION..............................................................................................................................................3

A. Hand Tool Function ........................................................................................................................................3

B. Physical Description ........................................................................................................................................3

C. Principles of Operation ....................................................................................................................................3

D. Specifications .................................................................................................................................................3

II. OPERATION ...................................................................................................................................................4

A. Operating Procedures ......................................................................................................................................4

B. Terminal Inspection.........................................................................................................................................5

III. TROUBLESHOOTING ..................................................................................................................................6

IV. PARTS REPLACEMENT PROCEDURES.....................................................................................................7

A. Anvil Replacement .........................................................................................................................................7

B. Wire and Insulation Barrel Crimpers and Tonker Replacement (see Figure 13)....................................................8

V. ADJUSTMENT PROCEDURES ......................................................................................................................8

Crimp Height Adjustment.....................................................................................................................................8

VI. PARTS............................................................................................................................................................9

A. Spare Parts ....................................................................................................................................................9

B. Parts Ordering Information..............................................................................................................................9

C. Hand Tool Repair Policy.................................................................................................................................9

REFERENCE DOCUMENTS

TA-211 – CTW Male Pin Mini Latch Application Data

FORM # E-3246- - Hand Tool Warranty

FORM # E-3247- - FCI Electronics Address List

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 3 of 10

Rev. 03/08/01 ECR V103118 Revision B

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I. INTRODUCTION

A. Hand Tool Function

The HT-0102 is a manually operated hand tool

designed for crimping loose piece (individual)

Crimp-to-Wire Male Pin terminals to wire sizes of

22-32 AWG.

B. Physical Description

The major components that make up the HT-0102 are

identified in Figure 1. These include a frame, lever,

tooling, tooling holders and a terminal holder. 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 that

move with the lever. The HT-0102 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.

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

Figure 1. HT-0102 Hand Tool

D. Specifications

When crimping the Male Pin 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)

Latch Housing and

Discrete Applications ............0.81-1.37 mm

(0.032-0.054 in.) Dia.

•“B" Side (22-26 AWG)

Latch Housing and

Discrete Applications ..............0.96-1.52 mm

(0.038-0.060 in.) Dia.

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 4 of 10

Rev. 03/08/01 ECR V103118 Revision B

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D. Specifications (continued)

Strip Length of Insulation:

•Latch Housing and

Discrete Applications ................... 3.81-4.32 mm

(0.150-0.170 in.)

Wire Barrel Crimp Height:

•Single Wire (28-32 AWG)

Or Double Wires

(30-32 AWG) ............................... 0.61-0.66 mm

(0.024-0.026 in.)

•Single Wire (22-26 AWG)

Or Double Wires

(26-28 AWG) ............................... 0.76-0.81 mm

(0.030-0.032 in.)

Insulation Barrel Crimp Height:

•"A" Side (28-32 AWG)

Latch Housing and

Discrete Applications ................. 1.75 mm

(0.069 in.) Max. Dia.

•“B" Side (22-26 AWG)

Latch Housing and

Discrete Applications ................... 1.75 mm

(0.069 in.) Max. Dia.

Male Pin Terminals:

•Loose Piece....................................... 22-32 AWG

NOTE

Loose piece terminals have different part

numbers than reeled terminals

II. OPERATION

A. Operating Procedures

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).

NOTE

When inserting a terminal into the terminal holder

you will notice a slight drag (interference) on the

terminal. The drag is caused by the spring ball

plunger (see Figure 13 item no. 21) applying

downward pressure on the pin end of the terminal.

This downward pressure helps to orient and hold

the terminal in the terminal holder until crimped.

2. Insert the pin end of the terminal, with “U” shaped

barrels up, into the terminal holder and against the

pin shoulder. While holding the terminal against

the shoulder, release the terminal holder. This

ensures that the terminal remains in the proper

position while moving over the anvil.

Figure 2. Positioning Terminal for Crimping

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-0102 check with your

distributor or FCI Electronics to be sure that the new

terminal number is compatible with your hand tool.

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.

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 5 of 10

Rev. 03/08/01 ECR V103118 Revision B

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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). An

alternate method is to position the end of the insulation

against the tonker (see Figure 13, item no. 2) which

protrudes from between the crimpers (3 & 4). Then

close the hand tool lever completely. This will crimp

the terminal to the wire(s).

Figure 3. Crimping Terminal to Wire

3. Release the lever to open the hand tool and remove

the crimped terminal by lightly pulling straight out

on the wire.

B. 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 end of the wire insulation lies

between the insulation and the wire barrel.

•Check that the bellmouth(s) were formed correctly.

•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

Section I, Paragraph D, refer to Section V for proper

adjustment procedures.

Figure 5. Measuring Crimp Height of Terminal

CAUTION

The crimp height for this hand tool was factory

adjusted. Any changes to this crimp height

adjustment could cause a defective crimp or

damage to the tooling.

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 6 of 10

Rev. 03/08/01 ECR V103118 Revision B

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III. TROUBLESHOOTING

The troubleshooting information provided in the following chart will help isolate and identify crimping problems.

Troubleshooting Chart, Male Pin Terminal

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

1. Bellmouth(s) is deformed or

improperly positioned on wire

barrel.

Terminal is not properly positioned

in crimping area.

Insert terminal so its shoulder is

against the terminal holder.

Reposition guide pins until proper

bellmouth(s) is achieved.

2. Pin end of terminal is bent down Terminal is sticking in wire barrel

crimper.

Tooling is broken or cracked.

Replace wire barrel crimper as

described in Section IV, paragraph B.

3. The sides of the terminal’s wire

barrel are scored or scratched.

Wire barrel crimper is defective. Replace wire barrel crimper as

described in Section IV paragraph B.

4. Flashings formed on the bottom

of the wire barrel are unequal or

abnormal.

Anvil is worn or broken Replace anvil as described in

Section IV, paragraph A.

5. Insulation bulges between wire

and insulation barrels.

Wire strip length is incorrect, or wire

was inserted too far into the terminal.

Refer to Section I, Paragraph D

(specifications) for strip length

requirements.

6. Insulation bulges around

insulation barrel

Wire or insulation diameter is

incorrect for the terminal being used.

Refer to section I, paragraph D

(specifications) for correct insulation

diameter requirements.

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 7 of 10

Rev. 03/08/01 ECR V103118 Revision B

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IV. PARTS REPLACEMENT

PROCEDURES

A. Anvil Replacement

Replace anvils when they show excessive wear or become

cracked or chipped.

Removal

1Remove the cap screw securing the anvil holder assembly

to the hand tool (see Figure 6) and then remove the anvil

holder assembly.

Figure 6

2Loosen the two setscrews in the anvil holder and remove

the terminal holder (see Figure 7).

Figure 7

3Remove the cap screw and defective anvil(s) from the

anvil holder (see Figure 8).

Figure 8

Installation NOTE

When replacing the anvils, be sure that the part number for

the new anvil(s) is the same as the one being replaced.

1Loosely install the new anvils to the anvil holder

with the attaching cap screw (See Figure 8).

2Reinstall the anvil holder onto the hand tool and

tighten the attaching cap screw.

3Cut out two strips of paper. Then fold the strips in

half and place them over the anvils (see Figure 9).

Figure 9

4Slowly close the hand tool lever completely. This will

align the anvils to the crimpers. Then tighten the anvil

cap screw and release the lever. Next, remove the

paper from the anvils.

5Reinstall the terminal holder to the anvil holder. Make

sure that the flats on the end of the terminal holder

guide pins face the setscrews in the anvil holder. Then

tighten the anvil holder set screws.

6Crimp a terminal to the proper size wire. Then inspect

the terminal as described in section II, paragraph B.

CAUTION

To prevent the anvils from being

damaged during alignment, place a

piece of paper over the anvils.

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 8 of 10

Rev. 03/08/01 ECR V103118 Revision B

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B. Wire and Insulation Barrel Crimpers and

Tonker Replacement (see Figure 13)

Removal

1Loosen, but do not remove at this time, the two cap

screws (7) that secure the crimpers to the crimper holder

(1).

2Remove the cap screw (9) from the crimper holder (1).

Then remove the spring retainer (8) and the crimper

holder (1) with crimpers attached.

3Remove the two tonker springs (5) and the two spring

guides (6) from the hand tool frame. This can be

accomplished by tilting the hand tool down.

4Remove the two cap screws (7) that secure the crimpers to

the crimper holder (1).

5Remove the crimpers (3 and 4) and tonkers (2) from the

crimper holder (1).

6Remove the damaged crimper(s) (3) or (4). The top

crimper is the wire barrel crimper (4).

Installation NOTE

When replacing tooling, always be sure that the part

number of the new part is the same number that is on

the old part that was removed

7Place the insulation crimper (3) onto the flat side of the

crimper holder (1). Place the wire barrel crimper (4) on the

insulation crimper (3) and loosely install the two attaching

cap screws.

8Insert tonkers (2), with the top tabs facing outwards, into the

slots between the wire and insulation crimpers.

9Place and hold the crimper assembly into the hand tool with

crimper holder (1) on the same side as the anvil holder (11).

Make sure that the tonkers (2) go into the holes in the top of

the hand tool frame.

10 Place spring guides (6) into the holes in top of the hand tool

frame, then insert the springs (5) into the holes so that the

springs slip over the body of the spring guides.

11 Place spring retainer (8) over tonker springs (5). Make sure

springs are compressed, then loosely attach the spring

retainer (8) and the crimper holder (1) to the hand tool with

the attaching cap screw (9).

12 To align the tooling, close hand tool completely and hold it

in it’s closed position. Tighten the two cap screws (7) to

secure the crimpers to their holder. Then tighten the cap

screw (9), which secures the crimper holder to the hand tool

frame.

13 Crimp a terminal to a proper-size wire and inspect the

terminal as described in Section II, paragraph B.

V. ADJUSTMENT PROCEDURES

Crimp Height Adjustment

1Remove the cap screw securing the anvil holder

assembly to the hand tool (see Figure 10). Then

remove the anvil holder assembly.

Figure 10

2Insert a 3/32-inch Allen wrench into the hole in the

adjustable tool holder and into the socket head

setscrew (see Figure 11). Turn the setscrew ¼ turn

counterclockwise to unlock the adjusting collar.

Figure 11

3Close the hand tool lever one click to gain access to

the holes in the side of the adjusting collar. Next,

insert a pin approximately 1/16-inch in diameter, into

one of the holes in the collar (see Figure 12). Then

rotate the collar about 5 degrees counterclockwise to

increase crimp height or clockwise to decrease crimp

height.

Figure 12

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 9 of 10

Rev. 03/08/01 ECR V103118 Revision B

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4Reinstall the anvil holder assembly onto the hand tool

and tighten the attaching cap screw.

5Crimp 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, remove the anvil

holder assembly and turn the adjusting collar an

additional 5 degrees. Then reinstall the anvil holder

assembly and again check the crimp height. Continue

adjusting the crimp height in this manner until the

proper crimp height is achieved.

6Remove the anvil holder assembly and tighten the

setscrew clockwise in the adjustable tool holder. Then

reinstall the anvil holder assembly and tighten the

attaching cap screw.

VI. PARTS

A. Spare Parts

These are parts that FCI Electronics 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

13.

B. Parts Ordering Information

To obtain replacement parts, contact FCI Electronics, 825

Old Trail Road, Etters, PA 17319; Phone Toll Free 1-800-

237-2374. Provide the description of the part, FCI part

number (if specified), quantity desired, and also the hand

tool model and serial number.

C. 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 13, HT-0102 Hand Tool Parts

Index

no. Part No. Description Quantity

1 A-857-5 CRIMPER HOLDER 1

2* 104964-1 TONKER 2

3* 108175-1 INSULATION BARREL CRIMPER 22-32 GAUGE WIRE 1

4* 108176-1 WIRE BARREL CRIMPER 22-32 GAUGE WIRE 1

5 A-1153 TONKER SPRING 2

6 A-1155 GUIDE SPRING 2

7 915305-224 SHCS, 4-40 NF X ⅜” LONG 8

8 104963-1 SPRING RETAINER 1

9 915305-205 SHCS, 6-40 NF X ½” LONG 2

10 915305-559 SHSS(SET SCREW) 2-56 NC X 1/8” LONG 2

11 102466-1 ANVIL HOLDER 1

12* 108178-1 INSULATION BARREL ANVIL, SIDE “A”, 28-32 G WIRE 1

13* 108178-2 INSULATION BARREL ANVIL, SIDE “B”, 22-26 G WIRE 1

14* 108177-1 WIRE BARREL ANVIL, SIDE “A”, 28-32 G WIRE 1

15* 108177-2 WIRE BARREL ANVIL, SIDE “B”, 22-26 G WIRE 1

16 102470-1 TERMINAL HOLDER SPRING, 0.65” LONG 2

17 147070-1 TERMINAL HOLDER 1

18 900066-001 O-RING, 0.070” I.D., 01-004 2

19 102468-2 GUIDE PIN 2

20 144547-001 GUIDE RAIL 2

21 147071-1 TERMINAL CLAMP 1

22 147072-1 QUILL PUNCH 1

23 102470-2 PUNCH SPRING, 0.300” LONG 1

24 150564-1 COLLAR. NYLON@,PRESS-FIT, 0.0625” I.D. 1

*Recommended Spare Parts

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

ELECTRONICS

FCI Electronics Manual Part No. 144000-001

Issued: Date (10/24/94) Page 10 of 10

Rev. 03/08/01 ECR V103118 Revision B

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Figure 13. HT-0102 Hand Tool Parts

FOR TECHNICAL HELP ON THIS HAND TOOL PLEASE CALL 1

800

843

6911

PDM: Rev:B ReleasedSTATUS: Printed: Dec 20, 2002

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