HT102 User`s manual - Föhrenbach Application Tooling nv.
Contents
1. F hrenbach i Iie ariom Te A096 TAB LE TOOL HOLDER KE TSCHEW Figure 13 HT 0102 Hand Tool Parts The technical data in this publication has been carefully checked and assembled No liability from inaccuracies or errors is assumed The right to change or improve this document without notice is reserved Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 16 162. 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 Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 11 16 E F hrenbach ipplicgrian Te ling 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 Il paragraph B 5 ADJUSTMENT PROCEDURES 5 1 Crimp Height Adjustment 1 Remove the cap screw securing the anvil holder assembly to the hand tool see Figure 10 Then remove the anvil holder assembly el fi A ay i KEN Ta Hi ER ee z ae b EN Ai E Ai OR pe nd V Le Zeg a eT a di h Sc e a Pe Figure JO 2 Insert 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 1 4 turn
3. Then close the hand tool lever completely This will crimp the terminal to the wire s EDGE OF IM SLILA TKH WIRE BARRE Ki ki ks s i mm j MSULA TRON BAARE Figure 3 Crimping Terminal to Wire 4 Release the lever to open the hand tool and remove the crimped terminal by lightly pulling straight out on the wire 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 2 2 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 e Check that all wire strands were crimped within the wire barrel e Check that the end of the wire insulation lies between the insulation and the wire barrel e Check that the bellmouth s were formed correctly e Check that the wire barrel seam is even and tightly closed Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 6 16 E E F hrenbach REAR BELLI TS LEGE SF MER PHM 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
4. counterclockwise to unlock the adjusting collar wi Be e ae INN LIST EE a H THGL HIER I D et ae a aX E wi Su aA ee COLL SG Figure fl Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 12 16 E F hrenbach ippligzstim Teeaiina 3 Close 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 heigf n ENN Figure 2 Reinstall the anvil holder assembly onto the hand tool and tighten the attaching cap Screw Crimp 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 Remove 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 Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 13 16 E ee 6 PARTS 6 1 Spare Parts These are parts that F hrenbach A
5. 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 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 Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 5 16 E F hrenbach ipplicgreion Te ling 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 amp 4
6. AWG Latch Housing and Discrete Applications 0 81 1 37 mm 0 032 0 054 in Dia e B Side 22 26 AWG Latch Housing and Discrete Applications 0 96 1 52 mm 0 038 0 060 in Dia Strip Length of Insulation Latch Housing and Discrete Applications 3 81 4 32 mm 0 150 0 1 70 in Wire Barrel Crimp Height e Single Wire 28 32 AWG Or Double Wires 30 32 AWG 0 61 0 66 mm 0 024 0 026 in e 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 e A Side 28 32 AWG Latch Housing and Discrete Applications 1 75 mm 0 069 in Max Dia e B Side 22 26 AWG Latch Housing and Discrete Applications 1 75 mm 0 069 in Max Dia Male Pin Terminals e LOOSE bece nenn 22 32 AWG NOTE Loose piece terminals have different part numbers than reeled terminals Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 4 16 u E F hrenbach ippligzstim Te ling CAUTION lf 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 to be sure that the new terminal number is compatible with your hand tool 2 OPERATION 2 1 Operating Procedures WARNING To prevent hand injury keep
7. HT102 Handpistol to crimp male pin terminals User s Guide F hrenbach Application Tooling www foehrenbach be E F hrenbach ippligzstim Te ling CONTENTS De PENI EU GVO net ee ee ee E 3 1 1 Aana HOON e GUO IM EE 3 1 2 e WR edel E 3 1 32 Principles o DC OI EE 3 1 42 SCI CA ONS rennen een en an en nee een ee 4 SE E ee ee nn ne ee 5 2 1 Operating Hrocecdures nennen nnnnnnnnnennnnnn nenne E nennen nnnnnnnnnen nennen 5 2 2 LEI INA MISO EE 6 2 TROUBLE CHOO MNG E 8 4 TE WEE US CH Ee BUET 9 4 1 Anvil Replacement EE 9 4 2 Wire and Insulation Barrel Crimpers and Tonker Replacement Eischte 11 eo E ee 12 5 1 e done He te ln el Et E ee ee 12 Ee 14 SEN DE 0 210 ol Alle ee nee ee eee een ene eee eee 14 6 2 Parts Ordering Information ccccceeeecceseeceeceeceeeceeeceeeeeeeeseeceeseeeeeeseeeeeesgeeeseaeeees 14 8 3 Ee Lee le RE ee er 14 Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 2 16 E F hrenbach 1 INTRODUCTION 1 1Hand 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 1 2 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
8. 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 1 3 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 Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 3 16 E F hrenbach ippligzstim Telling 1 4Specifications When crimping the Male Pin to wires the following parameters must be met Wire Length Requirements e Minimum 19 05 mm 0 75 in e Maximum As Required Insulation Diameters of Wires e A Side 28 32
9. is Af Te Figure Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 9 16 E F hrenbach App licgreian Terlirg 3 Remove the cap screw and defective anvil s from the anvil holder see Figure 8 Dis ILS T b Kid D ef BW d Or w nn AN rl HOLDER cnn IL N ST WILS im Figure A 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 1 Loosely install the new anvils to the anvil holder with the attaching cap screw See Figure 8 2 Reinstall the anvil holder onto the hand tool and tighten the attaching cap screw CAUTION To prevent the anvils from being damaged during alignment place a piece of paper over the anvils 3 Cut out two strips of paper Then fold the strips in half and place them over the anvils see Figure 9 PAPER ARVILS Figure 9 Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 10 16 E F hrenbach ippligzstim Telling 4 9 Slowly 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 Reinstall 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 screw
10. pplication Tooling 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 6 2 Parts Ordering Information To obtain replacement parts contact F hrenbach Application Tooling 6 3 Hand Tool Repair Policy F hrenbach Application Tooling charges a standard rate to repair any hand tool not under warranty F hrenbach Application Tooling will repair the hand tool and return it to you by the fastest means possible Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 14 16 E F hrenbach ipplicgrion Terlirg Parts List for Figure 13 HT 0102 Hand Tool Parts Description Quantity 1 A 857 5 CRIMPER HOLDER 1 2 104964 1 TONKER 108175 1 INSULATION BARREL CRIMPER 22 32 GAUGE WIRE 1 ANVIL HOLDER 12 108178 1 INSULATION BARREL ANVIL SIDE A 28 32 G WIRE 13 108178 2 INSULATION BARREL ANVIL SIDE B 22 26 G WIRE 14 WIRE BARREL ANVIL SIDE A 28 32 G WIRE 15 WIRE BARREL ANVIL SIDE B 22 26 G WIRE 102470 1 TERMINAL HOLDER SPRING 0 65 LONG 147070 1 TERMINAL HOLDER 2 2 4 5 10 1 147072 1 QUILL PUNCH 2 102470 2 PUNCH SPRING 0 300 LONG 24 150564 1 COLLAR NYLON_ PRESS FIT 0 0625 I D 16 17 18 19 20 21 22 3 Recommended Spare Parts Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 15 16
11. r cracked Wire barrel crimper is defective Anvil is worn or broken Wire strip length is incorrect or wire was inserted too far into the terminal Wire or insulation diameter is incorrect for the terminal being used Documentrev 4 Insert terminal so its shoulder is against the terminal holder Reposition guide pins until proper bellmouth s is achieved Replace wire barrel crimper as described in Section IV paragraph B Replace wire barrel crimper as described in Section IV paragraph B Replace anvil as described in Section IV paragraph A Refer to Section Paragraph D specifications for strip length requirements Refer to section paragraph D specifications for correct insulation diameter requirements www foehrenbach be Page 8 16 E E F hrenbach 4 PARTS REPLACEMENT PROCEDURES 4 1 Anvil Replacement Replace anvils when they show excessive wear or become cracked or chipped Removal 1 Remove the cap screw securing the anvil holder assembly to the hand tool see Figure 6 and then remove the anvil holder assembly HAND THL ERARE ANVIL HOLDER ASSEMBLY GAP al a vi l G SCREW Se AI Lex i vi Ce D l may Tag z a ee Fa wc Mg a e Figure 6 2 Loosen the two setscrews in the anvil holder and remove the terminal holder see Figure 7 SETSOREWS BARIS GUDE PING PEF AMINAL D HOLDER E Pi C Ka 0 SEN ee te Ps ANIL d ud HOLDER Ba eg B
12. s Crimp a terminal to the proper size wire Then inspect the terminal as described in section Il paragraph B 4 2 Wire and Insulation Barrel Crimpers and Tonker Replacement see Figure 13 Removal 1 Loosen but do not remove at this time the two cap screws 7 that secure the crimpers to the crimper holder 1 2 Remove the cap screw 9 from the crimper holder 1 Then remove the spring retainer 8 and the crimper holder 1 with crimpers attached 3 Remove 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 4 Remove the two cap screws 7 that secure the crimpers to the crimper holder 1 5 Remove the crimpers 3 and 4 and tonkers 2 from the crimper holder 1 6 Remove 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 T Place 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 Insert tonkers 2 with the top tabs facing outwards into the slots between the wire and insulation crimpers Place and hold the crimper assembly into the hand tool with crimper holder 1 on the same side as the anvil holder 11
13. specifications listed in Section 1 Paragraph 2 4 refer to Section 5 for proper adjustment procedures SLNATION SARRI CAMP HEIGHT SEE DETAIL Di N a mal U V4 oe aee me fy zu PU m ns r LL WEE BARREL RP HEIGHT SEE DETAIL A Figure 5 Measuring Crimp Height of I Ko Terminal Le J d B er Lf DETAIL A DETAIL 8 WARE is ULATION BARREL BARREL WAS ET MEASUREMENT Instruction manual HT 102 www foehrenbach be Date August 2007 Documentrev 4 Page 7 16 E F hrenbach ippligzstim Te ling 3 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 Bellmouth s is deformed or improperly positioned on wire barrel DEFORMED BELL MCUTH ui A Gs Lie Co Pin end of terminal is bent down eee rd 19 The sides of the terminals wire barrel are scored or scratched SC AATOHES ON WIRE BARREL ue se sed C Flashings formed on the bottom of the wire barrel are unequal or abnormal ABNOR PL FLASHING Insulation bulges between wire and insulation barrels TIETE s i z a XC u i d D Insulation bulges around insulation barrel BULGES Instruction manual HT102 Date August 2007 Terminal is not properly positioned in crimping area Terminal is sticking in wire barrel crimper Tooling is broken o
Download Pdf Manuals
Related Search