FCI HT-0102 User manual

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
K\DCU\Manuals
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.
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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.
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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.
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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.
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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
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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