411-3236

Hand Crimping Tool 90035-3

3 of 5

Rev A

Tyco Electronics Corporation

Though recommendations call for at least one

inspection per month, the inspection frequency should

be based on the amount of use, working conditions,

operator training and skill, and established company

standards. These inspections should be performed in

the following sequence:

A. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the tool (handles partially closed) in a

suitable commercial degreaser that will not affect

paint or plastic material.

2. Make certain that all retaining pins are in place

and are secured with retaining rings. If

replacements are necessary, refer to the parts list

in Figure 6.

3. Inspect crimping areas for pitted or chipped

surfaces.

4. Close the tool handles until the ratchet releases,

then allow handles to open freely. If they do not

open quickly and fully, the spring is defective and

must be replaced. Refer to Section 5,

REPLACEMENT AND REPAIR.

B. Gaging Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions listed in Figure 4. To

gage the crimping chamber, proceed as follows:

1. Close the jaws by squeezing the tool handles

together until the jaws have bottomed, and then

HOLD the handles in this position. DO NOT force

the jaws beyond initial contact.

2. Align the GO element of the gage with the wire

barrel crimp section of the crimping chamber. Refer

to Figure 5. Push the element straight into the

crimping chamber without using force. The GO

element must pass completely through the

crimping chamber.

3. Align the NO–GO element of the gage with the

same crimp section, and try to insert the element.

The NO–GO element may start entry, but it must

not pass completely through the crimping chamber.

Refer to Figure 5.

4. Repeat the gage inspection for the insulation

crimp section of the crimping chamber, making

sure to use the correct plug gage.

If the crimping chamber conforms to the gage

inspection, the tool is considered dimensionally

correct. If the crimping chamber does not conform to

the inspection, the tool must be repaired. Refer to

Section 5, REPLACEMENT AND REPAIR.

For additional information concerning the use of the

plug gage, refer to Instruction Sheet 408–7424.

C. Ratchet Inspection

Obtain a .025–mm [.001–in.] shim that is suitable for

checking the clearance between the bottoming

surfaces of the jaws. To inspect the ratchet control,

proceed as follows:

1. Refer to Figure 2, and select a product and

maximum size wire.

2. Position the product in the crimping chamber.

3. While holding the wire in place, squeeze the tool

handles together until the ratchet releases. Holding

the tool in this position, maintain just enough

pressure to keep the jaws closed.

4. Check the clearance between the bottoming

surfaces of the jaws. If the clearance is .025 mm

[.001 in.] or less, the ratchet is satisfactory. If

clearance exceeds .025 mm [.001 in.], the ratchet

is out of adjustment and must be repaired. Refer to

Section 5, REPLACEMENT AND REPAIR. If the

tool conforms to this inspection procedure,

lubricate it with a THIN coat of any good SAE 20

motor oil, and return it to service.

5. REPLACEMENT AND REPAIR

Customer–replaceable parts are listed in Figure 6.

A complete inventory should be stocked and

controlled to prevent lost time when replacement of

parts is necessary. Parts other than those listed

should be replaced by Tyco Electronics to ensure

quality and reliability. Order replacement parts

through your representative, or call 1–800–526–5142,

or send a facsimile of your purchase order to

717–986–7605, or write to:

CUSTOMER SERVICE (038–035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105–3608

For customer repair service, call 1–800–526–5136.

6. REVISION SUMMARY