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Instruction manual HT119
Date : August 2007
Documentrev. : 4
Page : 11 / 15
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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
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.