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

K\DCU\Manuals

B. 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

7 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.

8 Insert tonkers (2), with the top tabs facing outwards, into the

slots between the wire and insulation crimpers.

9 Place 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

1

Remove the cap screw securing the anvil holder

assembly to the hand tool (see Figure 10). Then

remove the anvil holder assembly.

Figure 10

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 ¼ turn

counterclockwise to unlock the adjusting collar.

Figure 11

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 height or clockwise to decrease crimp

height.

Figure 12

PDM: Rev:B

Released

STATUS:

Printed: Dec 20, 2002