FCI HT-1038A User manual

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 1of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
MANUAL FOR HT-1038A
WIRE INSERTION HAND TOOL
963T CONNECTOR 24 –28 AWG
P/N 412905-001
MANUAL P/N 412905-000
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 2of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
Table of Contents
Table of Contents……………………………………………………………….....…2
Introduction………………………………………………………………………..….3
Operation Instructions……………………………………………….……………..…4
Maintenance……………………………………………………………………….….6
Position Locator Adjustment……………………………………..…………...6
Punch Removal ………………………………………………….…………...6
Punch Installation…………………………………………………….………8
Service…………………………………………….…………………………..……. 9
Assembly Drawings and Warranty/Service Forms
412905-001
E-3246 Hand Tool Warranty
E-3247 Address Sheet
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 3of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
INTRODUCTION
The HT-1038A wire insertion pliers type hand tool is used to terminate the 963T connector with
24 – 28 awg wires. The HT-1038A hand tool (see Figure 1) is designed to terminate the contact
points of the connector using the IDC (Insulation Displacement Connector) system. By squeezing
on the pliers, the punch enters the contact area of the connector. The individual wire is pressed
into the tines, piercing the insulation and making contact with the wire. At the same time, the
upper portion of the punch gathers in the ears of the insulation wrap portion of the terminal and
securely wraps them around the insulation of the individual wires. This action results in each
wire having its own strain relief.
Figure 1
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 4of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
OPERATION INSTRUCTIONS
1. With the hand tool securely held, insert the connector into the lower-jaw guide of the hand
tool. Using your fingers, index the connector into position for wire termination (Figure 2).
Figure 2
2. Remove a section of the outer insulation jacket to expose the individual wires to a proper termination
length (see GS-20-004). It will not be necessary to strip the insulation from the individual wire
because the IDC section of the connector will make electrical contact with the wire causing
termination. If you have removed too much of the outer insulation it may be necessary to trim the
individual wires to length. Insert the individual wire into the slot in the top of the die along side the
position you wish to terminate. Keep pushing the wire into the slot until the wire bottoms out on the
tooling (Figure 3).
Figure 3
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 5of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
3. While holding the wire in place, slowly squeeze the pliers’ handles, until the upper and
lower jaws touch to insert the wire into the contact. This ensures the proper depth of wire
insertion into the contact. (See Figure 4).
Figure 4
4. Index the connector to the next insertion position, centering the connector position on the
insertion slot and repeat the previous operations.
5. Once all of the terminations have been made, remove the connector from the tool and
inspect for proper termination (see Figure 5).
Figure 5
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ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 6of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
MAINTENANCE
The HT-1038A style hand tool is designed to be maintenance free under normal operational
conditions. However, a need may arise to perform an adjustment or to replace the punch.
Position Locator Adjustment
Follow these procedures to adjust position locator (see Figure 6). Use a straight bladed
screwdriver to adjust the position locator (see Figure 7). Place a connector in the hand tool. Turn
the screw until the connector moves freely end to end without excessive play. The locator will
position the connector properly for wire termination.
Figure 6 Figure 7
Punch Removal
Following are the steps to remove the punch from the hand tool.
1. Using a straight-bladed screwdriver and holding the nut, remove the 0.8mm screw from the
hand tool (see Figure 8). This will allow the punch to rotate free of the hand tool (see Figure 9).
Figure 8 Figure 9
Punch Removal continued:
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 7of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
2. Using a 5/64 Allen wrench loosen the two 8-32 set screws that hold the punch in place (see
Figure 10).
Figure 10
3. Remove the punch from the hand tool (see Figures 11 and 12).
Figure 11 Figure 12
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ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 8of 9
Rev. 02/22/01 ECR V10315 Revision B
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Punch Installation
The following step are use to install the punch in the hand tool:
1. Re-install the punch making sure that the “U” up is at the front of the hand tool and the
shoulder of the punch is pushed up against the jaw of the pliers (see Figure 13). Tighten the
two 8-32 set screw on both sides of the tool (see Figure 14).
Figure 13 Figure 14
2. Using a straight-bladed screwdriver and holding the nut, tighten the 0.8mm screw. Do not over
tighten the screw, as this will cause the tool to work hard (see Figure 15). The hand tool is
again ready for operation.
Figure 15
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004

ELECTRONICS
FCI Electronics Manual Part No. 412905-000
Issued: 10/19/94 Page 9of 9
Rev. 02/22/01 ECR V10315 Revision B
K\DCU\Manuals
SERVICE
SERVICE
If you should require assistance in servicing this hand tool, please, in the USA, call
800-843-6911 or [phone].
The FCI fax line is available for manuals or product prints. For the FCI fax line call
800-237-2374.
PARTS REPLACEMENT
For part information please refer to assembly parts list.
PARTS ORDERING
In order to expedite the ordering process, please have the part numbers ready for the
part(s) you wish to order. The part numbers can be found on the assembly parts list
located on the pages following this section.
To order parts call 800-237-2374 and talk to one of our customer service representatives.
If you need help in obtaining a part number, our representatives will help you.
PDM: Rev:B ReleasedSTATUS: Printed: Jan 14, 2004