HT95 user's guide V3 - Föhrenbach Application Tooling nv.
Contents
1. I WIRE BARREL CRIME HEIGHT SEE DETAIL Ap DEYAIL E vel INSULATION BARREL BA MEASUREMENT MEASUREMENT mod Mhe Figure 5 Measuring Crimp Height of Terminal Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 7 15 RA Fohrenbach Joplicatian Tooling 3 TROUBLESHOOTING The troubleshooting information provided in the following identify crimping problems Troubleshooting Chart PV Receptacles HT 95 chart will help isolate and PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1 Bellmouth s is deformed or improperly positioned on wire barrel NESOAMED LEII BIO FH Terminal is not properly positioned 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 WAS toys wie 7 Terminal is sticking in wire barrel crimper Tooling is broken or cracked Replace wire barrel crimper as described in Section 2 para graph 2 3 The sides of the terminals wire barrel are scored or scratched STRATCHES OM SAC BANE zf a Hi Jas _ it Sh E Wire barrel crimper is defective Replace wire barrel crimper as described in Section 4 para graph 2 4 Flashings formed on the bottom of the wire barrel are unequal or abnormal ANKOFMA FLASHINGE WEE aar N oe Mad EEE ad2. Anvil is worn or broken Replace anvil as described in Section 4 paragraph 1 5 Insulation bulges between wire and insulation barrels BULGES 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 BULGES meat Wire size or insulation diameter is incorrect for the terminal being used Refer to Section 1 paragraph 4 specifications for correct insulation diameter requirements Instruction manual HT95 Date August 2007 Documentrev 3 www foehrenbach be Page 8 15 is Fohrenbach 4 PARTS REPLACEMENT PROCEDURE 4 1 Anvil Replacement see figure 6 NOTE Replace anvils when they show excessive wear or are cracked or chipped 4 1 1 Removal When removing the anvil the terminal holder 10 and guide pins 15 must also be removed Prior to removal note the position of the guide pins in the anvil holder so that they can be positioned as they were before removal the flat on the guide pins must face the setscrews 12 in the anvil holder 4 1 Loosen the two 2 56 setscrews 12 in the anvil holder 4 and remove terminal holder assembly 10 2 Remove 4 40 cap screw 9 from the damaged anvil s 5 and 7 or 6 and 8 3 Remove damaged anvil 4 1 2 Installation NOTE When replacing tooling be sure that th
3. for this hand tool was factory adjusted Any random changes to this 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 Check that all wire strands were crimped within the wire barrel Check that the end of the wire insulation lies between the insulation and wire barrel Instruction manual HT95 Date August 2007 REAR BELLMOUTHS WIAE STRANDS SPRING EDGE OF INSULATION Va Ta am MTA Figure A Correctly Crimped Terminal www foehrenbach be Documentrev 3 Page 6 15 RA Fohrenbach Check that the bellmouth s were formed correctly Check that the spring was not dislodged from the disconnect box portion of the terminal Check that the ends of the wire strands form an angle not exceeding approximately 45 Check that the wire barrel seam is even and tightly closed 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 paragraph D refer to Section V for proper adjustment procedures INSULATION BARREL CALMP HEIGHT SEE DETAIL 8
4. HT95 Handpistol mini PV AWG 22 32 User s Guide Fohrenbach Application Tooling RA F hrenbach Joep lication Tooling CONTENTS se lee Innere er N EE EE EE 3 1 1 Hand 100 Iunellon ses EE EE oe ER RE EKE 3 1 2 Physical description essentielle 3 1 3 Principles of operalan ne 3 VA SS CMC AT OIG ses cca ea ee 4 2 3 MUNN RE EE EE EN acdsee tc ee EE EE OE 5 2 1 Operating procedures unse aa een ee ER Ge 5 2 2 Tetininalinspetiiafis ssssne see 6 3 TOURS SMOG essen eine 8 4 Parts replacement procedure iss ee ee AA ee eenn 9 4 AnviltEDlaEERENE ss Re RR Ke ee cede ba re ER EE er Se ee Se ee 9 4 2Wire and insulation barrel crimpers and tonker replacement 10 4 3 Holding pin replacement sesse ees ee ee ee ee ee ee ennn 11 5 Crimp height adjustment u seen ee 12 E P lle a nee ee OE TE OES EE 14 6 1 Spare panl Seen ee ee ee 14 6 2 Paris ordering information ana ae ee 14 6 3 Hand HOON repair poly ies een 14 Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 2 15 RA F hrenbach Joep lication Tool ing 1 INTRODUCTION 1 1 Hand Tool Function The HT 95 is a manually operated hand tool designed for crimping loose piece individual Mini PV terminals to various sizes of wire 1 2 Physical Description The major components which make up the HT 95 are identified in figure 1 These include a frame lever tooling and tooling ho
5. T95 www foehrenbach be Date August 2007 Documentrev 3 Page 4 15 3 Fohrenbach 2 OPERATION 2 1 Operating Procedures 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 against the pin shoulder While holding the terminal against the shoulder release the terminal holder This ensures that the terminal remains in proper position while moving over the anvil TERRA AL CISGONHMECT 160 OF TERMINAL won wire Figure 2 Positioning Terminal for Crimping 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 then close the hand tool lever completely This will crimp the terminal to the wire s Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 5 15 RA Fohrenbach Figure 3 Crimping Terminal to Wire 4 Release the lever to open the hand tool and remove the crimped terminal from the holding pin by lightly pulling straight out on the wire CAUTION The crimp height
6. e part number of the part being replaced is the same as the number of the part that was removed 1 Loosely install the new anvil s to the anvil holder 4 with the 4 40 cap screw 9 2 Close hand tool completely this aligns anvil to the crimper Tighten the 4 40 cap screw 9 and release the lever 3 Re install terminal holder 10 to the anvil holder 4 and tighten the two 2 56 setscrews 12 4 Crimp a terminal to a proper sized wire and inspect the terminal as described in Section Il paragraph B Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 9 15 RA Fohrenbach Application Tool ing 4 2 Wire and Insulation Barrel Crimpers and Jonker Replacement see figure 6 4 2 1 Removal 1 Loosen but do not remove at this time the two 4 40 cap screws 9 that secure the crimpers to the crimper holder 1 Remove the 6 40 cap screw 13 from the crimper holder 1 Then remove the spring retainer 21 and the crimper holder 1 with crimpers attached Remove the two tonker springs 19 and the two spring guides 20 from the hand tool frame This can be accomplished by tilting the hand tool down Remove the two 4 40 cap screws 9 that secure the crimpers to the crimper holder 1 Remove the crimpers 2 and 3 and tonkers 18 from the crimper holder 6 Remove the damaged crimper s 2 or 3 The top crimper is the wire barrel crimper 3 4 2 2 Installat
7. einstall terminal holder assembly and anvil holder as described in steps 5 through 7 above Parts List for Figure 6 HT 95 Hand Tool Parts Index Part No Description Oty Per No 1 A 857 5 Crimper holder 1 104958 1 Insulation barrel crimper 22 26 and 28 32 gauge wire 1 3 104959 1 Wire barrel crimper 22 26 and 28 32 gauge wire 1 4 102466 1 Anvil holder 1 5 104914 A Insulation barrel anvil 28 32 gauge wire 1 6 104914 B Insulation barrel anvil 22 26 awg wire 1 7 104960 A Wire barrel anvil 28 32 gauge wire 1 8 104960 B Wire barrel anvil 22 26 gauge Wire 1 9 Screw cap socket Hd 4 40 NF x 0 37 in lg 4 10 104961 1 Terminal holder 1 11 A 856 1 Tool holder adjustable 12 Setscrew socket Hd 2 56 NF x 0 12 in Ig 4 13 Screw cap socket Hd 6 40 NF x 0 50 in Ig 2 14 104756 1 Holding pin 0 025 sa Bergpin material 0 430 Ig 2 15 102468 1 Guide pin 2 16 O ring 01 004 2 17 102470 1 Holding spring 2 18 104964 1 Tanker 2 19 A 1153 Spring tanker 2 20 A 1155 Spring guide 2 21 104963 1 Spring retainer 1 Recommended Spare Parts Instruction manual HT95 Date August 2007 www foehrenbach be Documentrev 3 Page 13 15 3 Fohrenbach 6 PARTS 6 1 Spare Parts These are parts which F A Tooling NV considers practical for the user to stock for replacement Recommended spare parts f
8. ion NOTE When replacing tooling always be sure that the part number on the part s being replaced is the same as the number of the part that was removed 1 Place the insulation crimper 2 onto the flat side of the crimper holder 1 Place the wire barrel crimper 3 on the insulation crimper 2 and install two 4 40 cap screws 9 and loosely tighten 2 Insert tonkers 18 with the top tabs facing outward into the slots between the wire and insulation crimpers 3 Place and hold the crimper assembly into the hand tool on the same side as the anvil holder 4 Make sure that the tonkers 18 go into the holes in the top of the hand tool frame 4 Place spring guides 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 Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 10 15 RA Fohrenbach Jap lication Tooling 6 To align the tooling close hand tool completely and hold it in its closed position Tighten the two 4 40 cap screws 9 to secure the crimpers to their holder Then tighten the 6 40 cap screw 13 which secures the crimper holder to the hand tool frame 7 C
9. lders and terminal 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 95 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 SPRING aes CRIMPER HOLDER Ba ry N di GUIDE FIN Es TERMINAL HOLDER EET eB WISE IDENTIFICATION lt 3 PLATE f CSIMPERS ANMILS ANVIL HOLDER aw HPE Figure 1 HT 96 Hand Toal Instruction manual HT95 www foehrenbach be Date August 2007 Docu
10. mentrev 3 Page 3 15 a RA Fohrenbach 1 4 Specifications When crimping the Mini PV 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 32AWG 0 71 1 37mm 0 028 0 054 in Dia e B Side 22 26AWG 0 91 1 52mm 0 036 0 060 in Dia Strip length of Insulation e Discrete and latch Housing Applications 3 81 4 31 mm 0 150 0 170 in e Rod Housing 3 30 3 81 mm Applications 0 130 0 150 in Wire Barrel Crimp Height For All Applications e Single Wire 22 26 AWG or Two Wires 26 28 AWG 0 81 0 86 mm 0 032 0 034 in e Single Wire 28 32 AWG or Two Wires 30 32 AWG 0 66 0 71 mm 0 026 0 028 in Insulation Barrel Crimp Height e Discrete Application 2 84 mm 0 112 in Max e Latch and Rod Housing Applications 1 75 mm 0 069 in Max Mini PVTM Receptacles e loose Piece 22 32AWG NOTE Loose piece terminals have different part numbers than reeled terminals 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 HT95 check with your distributor or F hrenbach Application Tooling NV to be sure that the new terminal number is compatible with your hand tool Instruction manual H
11. or the hand tool are specified in bold type in the parts list for figure 6 6 2 Parts Ordering Information To obtain replacement parts contact F A Tooling NV Krijgsbaan 128 2640 Mortsel Belgium Provide the description of the part part number if specified quantity desired and also the hand tool model and serial number 6 3 Hand Tool Repair Policy The repair cost is according to expenses Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 14 15 RA Fohrenbach Application Tooling ADJUSTABLE TOOL HOLS H SETEGREN CHIN EFAHT ADJUSTING QULLAR 4 1 Aitah 16 ated Frye amp 7 95 Hend Tool Parts 3 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 HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 15 15
12. rimp a terminal to a proper sized wire and inspect the terminal as described in Section Il paragraph B 4 3 Holding Pin Replacement see figure 6 NOTE When holding pins 14 become bent it is necessary to replace them 4 3 1 Removal NOTE When removing the holding pin the terminal holder 10 and guide pins 15 must also be removed Prior to removal note the position of the guide pins 15 in the anvil holder so that they can be repositioned as they were before removal the flat on the guide pin must face the setscrew 12 in the anvil holder 4 1 Loosen the two 2 56 setscrews 12 in the anvil holder 4 Then remove the terminal holder assembly which includes the terminal holder 10 guide pins 15 0 rings 16 holding springs 17 and holding pins 14 attached 2 Remove the two holding springs 17 and the guide pins 15 from the terminal holder 3 Loosen the two 2 56 setscrews 12 in the top of the terminal holder 10 which secure the holding pins 14 4 Using needle nose pliers remove both holding pins 14 by pulling straight out from terminal holder 10 Discard the damaged holding pints 4 3 2 Installation CAUTION Overtightening the 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 un
13. th hand tool or a pin approximately 1 16 inch in diameter into one of the four holes in the adjusting collar Rotate the adjusting collar about 5 degrees to the right to increase the crimp height by 0 002 inch or to the left to decrease crimp height by 0 002 inch Re install anvil holder 4 with anvils and loosely tighten the 6 40 cap screw 13 Close hand tool completely so that the anvils align themselves to the crimpers While in the closed position tighten the cap screw 13 to lock anvils into position Open the hand tool Re install terminal holder assembly to the anvil holder 4 and tighten the two 2 56 setscrews 12 against the flats on the guide pins 15 Crimp a terminal to a wire and recheck the wire barrel crimp height If crimp height meets specifications remove terminal holder assembly and anvil holder 4 then lock the adjusting collar by tightening the setscrew in the adjustable tool holder 11 Reinstall terminal holder assembly and anvil holder as described in steps 5 through 7 above Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 12 15 if Fohrenbach b If crimp height does not meet specifications close the hand tool one click so that the adjusting collar is visible and rotate the adjusting collar as described in step 4 When correct crimp height is attained lock the adjusting collar by tightening the setscrew in the adjustable tool holder 11 R
14. til 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 holder 10 Instruction manual HT95 www foehrenbach be Date August 2007 Documentrev 3 Page 11 15 RA Fohrenbach Joplicatian Tooling 5 Lightly tighten the two 2 56 setscrews 12 into the terminal holder 10 to secure the holding pins 14 Re install the two guides pins 15 0 rings 16 and the two holding springs 17 Re install the terminal holder 1 0 to the anvil holder 4 and tighten the two 2 56 setscrews 12 in the anvil holder 4 onto the flats of the guide pins 15 Crimp a terminal to a proper sized wire and inspect the terminal as described in Section Il paragraph B CRIMP HEIGHT ADJUSTMENT see figure 6 Loosen the two 2 56 setscrews 12 in the anvil holder 4 Remove terminal holder assembly which includes the terminal holder 10 guide pins 15 O rings 16 holding springs 17 and holding pins 14 attached Remove the 6 40 cap screw 13 which secures the anvil holder 4 to the adjustable tool holder 11 Remove the anvil holder with anvils attached Insert a 3 32 inch Allen wrench into the hole in the adjustable tool holder 11 and into the socket head setscrew Turn screw to the right 1 4 turn to unlock the adjusting collar Insert the turned down end of the 3 32 inch Allen wrench supplied wi
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