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refer to application specification 11413183 or application and termination requirements for these contacts. figure 1 procrimper iii hand tool assembly 20632911 consists of die assembly 20632912 and procrimper iii hand tool frame 3549401. the die assembly consists of crimping dies and a locator assembly. read these instructions thoroughly before crimping any contacts.
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'4* the tool features a tool frame with a stationary jaw and handle, a moving jaw, a moving handle, and an adjustable ratchet that ensures full contact crimping. the tool frame holds a die assembly with three crimping sections. the die assembly features a wire anvil, an insulation anvil, a wire crimper, and an insulation crimper. attached to the outside of the frame is a locator assembly, which contains a locator, a spring retainer, and a contact support. die retaining pins and die retaining screws are used to position and secure the dies in the tool frame. a nut is used on the upper die retaining screw to hold the locator assembly in place.

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$" # "! "$ figure 2 " $ # $ "'# " #%$ & " & #$ " "!" " %$ $ " ##( #%$ "!" %" 1. open the tool handles and remove the two die retaining screws from the tool jaws. 2. place the wire anvil and insulation anvil so that their chamfered sides and their marked surfaces face outward, when mounted in the moving jaw of the tool frame. 3. insert the two die retaining pins. 4. insert the short die retaining screw through the jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. do not tighten the screw completely at this time. 5. place the wire crimper and insulation crimper so that their chamfered sides and their marked surfaces face outward, when mounted in the stationary jaw of the tool frame. 6. insert the two die retaining pins. 7. insert the long die retaining screw through the jaw and through both crimper dies, and tighten the screw just enough to hold the dies in place. do not tighten the screw completely at this time. 8. carefully close the tool handles, making sure that the anvils and crimpers align properly. continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both die retaining screws. 9. place the locator assembly over the end of the long screw, and position the locator assembly against the side of the tool jaw. 10. place the nut onto the end of the long screw and tighten the nut enough to hold the locator assembly in place, while still allowing the locator to slide up and down. 11. to disassemble, close the tool handles until the ratchet releases, remove the nut, the locator assembly, the two die retaining screws, and the four die retaining pins, and slide the anvils and crimpers out of the tool jaws. %"

1. make a sample crimp and determine if the contact is straight, bending upward, or bending downward. 2. if adjustment is required, loosen the screw that holds the contact support onto the locator assembly.

3. place a contact with wire into the proper nest and close the tool handles until the ratchet reaches the sixth click, or until the contact support touches the contact.
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" $ 4. slightly loosen the nut that holds the locator assembly onto the tool frame. 5. move the contact support as required to eliminate the bending of the contact. 6. tighten the nut and close the handles until the ratchet releases. 7. remove and inspect the contact. 8. make another sample crimp. if the contact is straight, tighten the contact support screw. if the contact is still being bent during crimping, repeat the adjustment procedure. "#, -))& #, *+)/# 0#-" +#'* $.,-'(- -.+ (#-#&&1 -" +#'* "#!"- ,").& /+# # , ,*# # #( #!.+ + -) -#)( ( -#)(
-) /+# 1 +#'* "#!"- )+ .,#(! -" -))& -) +#'* ,#+ )(--, ( 0#+ ,#2, refer to the table in figure 1 and select wire of the specified size and insulation diameter. strip the wire to the length indicated in figure 1, taking care not to nick or cut wire strands. select an applicable contact and identify the appropriate crimp section according to the wire size markings on the tool. refer to figure 3 and proceed as follows: 1. hold the tool so that the back (wire side) is facing you. squeeze tool handles together and allow them to open fully. 2. holding the contact by the mating end, insert the contact e insulation barrel first e through the front of the tool and into the appropriate crimp section. 3. position the contact so that the mating end of the contact is on the locator side of the tool, and so that the open auo of the wire and insulation barrels must face the top of the tool. place the contact up into the nest so that the movable locator drops into the slot in the contact. refer to figure 3. butt the front end of the wire barrel against the movable locator. % ,.+ -"- )-" ,#, ) -" #(,.&-#)( ++& + ,-+- /(&1 #(-) -" +#'*#(! ,-#)( ) --'*- -) +#'* ( #'*+)*+&1 *),#-#)( )(-- 4. hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. do not deform insulation barrel or wire barrel. 5. insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop, as shown in figure 3. 6. holding the wire in place, squeeze tool handles together until ratchet releases. allow tool handles to open and remove crimped contact. " +#'* )(-- '1 ,-#% #( -" +#'*#(! + .- -" )(-- ( ,#&1 +')/ 1 *.,"#(! )0(0+ )( -" -)* ) -" &)-)+ , #!.+ 7. check the contact's crimp height as described in section 6, crimp height inspection. if necessary, adjust the crimp height as described in section 7, crimp height adjustment. figure 3 $

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, & .& #*(&% ) &('&(* &% this inspection requires the use of a micrometer with a modified anvil. tyco electronics recommends the modified micrometer (crimp height comparator rs10195lp) which may be purchased from: shearer industrial supply co. 7177677575 or valco 6106913205 proceed as follows: 1. refer to figure 4 and select a wire (maximum size) for each crimp section listed. / &) * &% & %* &% %*( & ( ((# ''&) * $ & %, # # & # $ # & 1 ,,

figure 4 2. refer to section 5, crimping procedure, and crimp the contact(s) accordingly. 3. using a crimp height comparator, measure the wire barrel crimp height as shown in figure 4. if the crimp height conforms to that shown in the table, the tool is considered dimensionally correct. if not, the tool must be adjusted. refer to section 7, crimp height adjustment. ! +( 1. remove the lockscrew from the ratchet adjustment wheel. 2. with a screwdriver, adjust the ratchet wheel from the locator side of the tool. 3. observe the ratchet adjustment wheel. if a tighter crimp is required, rotate the adjustment wheel counterclockwise to a highernumbered setting. if a looser crimp is required, rotate the adjustment wheel clockwise to a lowernumbered setting. 4. replace the lockscrew. 5. make a sample crimp and measure the crimp height. if the dimension is acceptable, replace and secure the lockscrew. if the dimension is unacceptable, continue to adjust the ratchet, and again measure a sample crimp. figure 5 (-( ,( ** !+)*$%* # &")(- .' ensure that the tool and dies are clean by wiping them with a clean, soft cloth. remove any debris with a clean, soft brush. do not use objects that could damage the tool. when not in use, keep handles closed to prevent objects from becoming lodged in the crimping dies, and store in a clean, dry area. "! the crimping dies should be inspected on a regular basis to ensure that they have not become worn or damaged. inspect the crimp sections for flattened, chipped, worn, or broken areas. if damage or abnormal wear is evident, the tool must be replaced. see section 10, replacement. customerreplaceable parts are shown in figure 1. available separately, procrimper iii repair kit 6792211 includes a replacement nut and a variety of pins, rings, screws, and springs. if the dies are damaged or worn excessively, they must be replaced. order the repair kit and replaceable parts through your tyco electronics representative, or call 18005265142, or send a facsimile of your purchase order to 17179867605, or write to: customer service (3835) tyco electronics corporation p.o. box 3608 harrisburg, pa 171053608 " !% initial release of document

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