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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

Содержание HT-0095

Страница 1: ...rt 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 ...

Страница 2: ...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 ...

Страница 3: ...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 ...

Страница 4: ...l 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 ...

Страница 5: ...rimping 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 1...

Страница 6: ... 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 aga...

Страница 7: ...aight 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 th...

Страница 8: ...l 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 STATU...

Страница 9: ...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 insert...

Страница 10: ...ed 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 Release...

Страница 11: ...Then turn the setscrew 1 4 turn counterclockwise to unlock the adjusting collar Figure 9 2 Insert the turned down end of the 3 32 inch Allen wrench or a pin approximately 1 16 inch in diameter into one of the holes in the adjusting collar see Figure 10 Then rotate the collar about 1 2 turn counterclockwise Figure 10 3 Reinstall the anvil holder onto the hand and tighten the attaching cap screw CAU...

Страница 12: ...d tool and remove the protective covering from the anvils NOTE The adjusting collar remains unlocked for further adjustment of the crimp height 6 Crimp a terminal to the proper size wire Then inspect the terminal and measure the wire barrel crimp height as described in Section II paragraph B Wire and Insulation Barrel Crimpers and Tonker Removal See Figure 15 1 Loosen but do not remove at this tim...

Страница 13: ...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 comp...

Страница 14: ...he 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 1 Install two new holding pins 14 0 025 in square BergPin material 0 430 in long into 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 h...

Страница 15: ...ole in the adjustable tool holder and into the socket head setscrew see Figure 13 Turn the setscrew 1 4 turn counterclockwise to unlock the adjusting collar Figure 13 3 Insert the turned down end of the 3 32 inch Allen wrench or a pin approximately 1 16 inch in diameter into one of the holes in the adjusting collar see Figure 14 Then rotate the collar about 5 degrees counterclockwise to increase c...

Страница 16: ...s 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 ...

Страница 17: ... 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 ...

Страница 18: ...FCI Electronics Manual Part No 415988 001 Issued 03 12 99 Page 18 of 18 Rev 05 18 06 EC V06 0481 Revision C Figure 15 HT 95 Hand Tool Parts PDM Rev C Released STATUS Printed Feb 09 2009 ...

Страница 19: ...Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery Lifecycle Information FCI Amphenol HT 0095 ...

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