Tyco Electronics 871087 Reference guide

Customer Manual
Air Tools TERMI-POINT
(diverse types)
871087
Customer Manual No.: 412-18008 _Rev. D1
Language: en (Translation of the original German version)

Air Tools TERMI
-POINT
(diverse types)
©2013 Tyco Electronics AMP GmbH, a TE Connectivity company.
All rights reserved.
TE Connectivity, TE connectivity (logo), TERMI-POINT and Tyco
Electronics are Trademarks.
1/ 1
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
The data specified above only serve to describe the product. No statements concerning a
certain condition or suitability for a certain application can be derived from our information.
The information given does not release the user from the obligation of own judgment and
verification. It must be remembered that our products are subject to a natural process of wear and
aging
©2013 Tyco Electronics AMP GmbH, a TE Connectivity company.
All rights reserved.
The cover page shows a sample configuration. The delivered product may thus differ from the figure.
The original operation manual is written in German.

Air Tools TERMI
-POINT
(diverse types)
©2013 Tyco Electronics AMP GmbH, a TE Connectivity company.
All rights reserved.
TE Connectivity, TE connectivity (logo), TERMI-POINT and Tyco
Electronics are Trademarks.
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Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
1General information..................................................................................4
1.1 Copyrights, industrial property rights................................................................................. 4
2Using the operation manual......................................................................5
2.1 Abbreviations used............................................................................................................ 5
3General safety instructions.......................................................................6
3.1 Intended use...................................................................................................................... 6
3.2 Improper use..................................................................................................................... 6
3.3 Reasonably foreseeable misuse....................................................................................... 6
3.4 Qualification of personnel.................................................................................................. 7
3.5 Safety instructions in this document.................................................................................. 7
3.6 Pictograms used................................................................................................................ 8
3.7 Adhere to the following instructions .................................................................................. 9
3.7.1 General instructions.................................................................................................. 9
3.7.2 During operation........................................................................................................ 9
3.7.3 During maintenance and repair...............................................................................10
3.7.4 During disposal .......................................................................................................10
3.8 Obligations and Responsibility of the Operator...............................................................10
3.8.1 Obligations of the Operator.....................................................................................10
3.8.2 Responsibility of the Operator.................................................................................10
3.9 Obligations and Responsibility of the Carrier..................................................................10
3.9.1 Obligations of the Carrier........................................................................................10
3.9.2 Responsibility of the Carrier....................................................................................11
3.10 Residual Risks.................................................................................................................11
4Scope of delivery....................................................................................12
5Product description.................................................................................13
5.1 Identification of product...................................................................................................14
5.2 Tools, Mandrels and Clips...............................................................................................15
5.2.1 Introduction .............................................................................................................15
5.2.2 Per GP 1935 Rev. Germany 3/86...........................................................................16
5.2.3 Per GP 1944 Rev. Germany 3/86...........................................................................18

Air Tools TERMI
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6Commissioning.......................................................................................19
6.1 Tool Preparation..............................................................................................................20
6.2 Loading the Tool..............................................................................................................22
6.3 Unloading the Tool..........................................................................................................23
6.4 Installation of Mandrel.....................................................................................................23
6.5 Removal of Mandrel........................................................................................................23
7Transport and Storage............................................................................24
7.1 Transport.........................................................................................................................24
7.2 Storage............................................................................................................................24
8Operation................................................................................................25
8.1 General............................................................................................................................25
9Adjustment .............................................................................................28
9.1 Clip Positioning Adjustment ............................................................................................28
10 Maintenance and Repair ........................................................................29
10.1 Preventive Maintenance..................................................................................................29
10.1.1 Introduction .............................................................................................................29
10.1.2 Tool Check (weekly) ...............................................................................................30
11 Disposal.................................................................................................. 31
12 Troubleshooting......................................................................................32
13 Repairing / Replacement of Wear Parts................................................. 34
13.1 Push Rod and Saddle Spring Replacement ...................................................................35
13.2 Clip Guide Anvil Replacement ........................................................................................35
13.3 Post Pickups Replacement.............................................................................................36
13.4 Front / Rear Catch and Spring Replacement..................................................................37
13.5 Air Cylinder Replacement ...............................................................................................38
13.6 Replacement of Miniature Valve / Actuator.....................................................................39
13.7 Replacement of Air Filters...............................................................................................39
14 Technical Data .......................................................................................40
15 Appendix ................................................................................................41
15.1 List of spare parts............................................................................................................41
15.1.1 Air Tool TERMI-POINT 871087-1...........................................................................42
15.1.2 Air Tool TERMI-POINT 871087-2...........................................................................43
15.1.3 Air Tool TERMI-POINT 1-871087-1 (special model)..............................................44
15.1.4 Air Tool TERMI-POINT 1-871087-2 (special model)..............................................45
15.1.5 Air Tool TERMI-POINT 2-871087-1 (special model)..............................................46

Air Tools TERMI
-POINT
(diverse types)
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15.1.6 Air Tool TERMI-POINT 2-871087-2 (special model)..............................................47
15.1.7 Air Tool TERMI-POINT 2-871087-3 (special model)..............................................48
15.1.8 Air Tool TERMI-POINT 2-871087-4 (special model)..............................................49
15.1.9 Air Tool TERMI-POINT 4-871087-1 (special model)..............................................50
15.2 Operator’s Quality Check Procedure ..............................................................................53
15.2.1 Quality Control Procedure for TERMI-POINT Clip Applications.............................53
15.3 Pull Test Tool Part-No. 69358-2......................................................................................55
15.3.1 Introduction .............................................................................................................55
15.4 Operators’s Quality Check Procedure for TERMI-POINT...............................................58
15.4.1 Introduction .............................................................................................................58
15.4.2 Clip Application .......................................................................................................58
15.5 Extraction Tool Part No. 69357-3....................................................................................62
15.5.1 Introduction .............................................................................................................62
15.5.2 Extraction Procedure ..............................................................................................62
15.5.3 Clip Positioning Procedure......................................................................................63
15.6 Address After Sales Serviced .........................................................................................64

Air Tools TERMI
-POINT
(diverse types)
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All rights reserved.
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Customer
Manual
412-18008 Rev. D1
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1 General information
1.1 Copyrights, industrial property rights
© This document, as well as the data, specifications and other information set forth in it, are the
exclusive property of Tyco Electronics AMP GmbH.
It may not be reproduced or given to third parties without its consent.
This manual is exclusively meant for the carrier of the „Hand tool for AMP DUOPLUG 2.5™“
(in further course called “Hand tool”) and its personnel for internal use only.
The additional device-specific manual includes descriptions, engineering drawings, instructions and
references, that you may not copy, reproduce or distribute without written consent neither completely
nor in parts.
If the competition try for discover and inspect this manual, we do expect the same fairness, that you
may expect from your customers in that case.
All rights, including rights created by patent grant or registration of a utility model or design, are
reserved.
Subject to change without notice. Errors and omissions excepted.

Air Tools TERMI
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2 Using the operation manual
These instructions contain important information on the safe and appropriate operation and simple
troubleshooting of the hand tool.
Read these instructions completely, especially section 3 „General safety instructions”, before working
with the Hand tool.
Tyco Electronics AMP GmbH decline to accept any liability for damages that are incurred due to
the fact that the instructions in the operation manual have been disregarded.
The user is responsible for supplementing the operation manual with any instructions resulting from
current national regulations for accident prevention and protection of the environment.
Also observe the generally applicable, legal or otherwise binding regulations of the European or
national legislation and the rules for the prevention of accidents and for environmental protection
applicable in your country.
2.1 Abbreviations used
Abbreviation
Meaning
PN
Part
-
No.
RoHS Restriction of (the use of certain) hazardous substances

Air Tools TERMI
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3 General safety instructions
Das Druckluftwerkzeug wurde gemäß den allgemein anerkannten Regeln der Technik hergestellt. Trotzdem
besteht die Gefahr von Personen- und Sachschäden, wenn Sie die folgenden grundsätzlichen Sicherheits-
hinweise und die Warnhinweise vor Handlungsanweisungen in dieser Anleitung nicht beachten.
Read these instructions completely and thoroughly before working with the hand tool.
Keep these instructions in a location where they are accessible to all users at all times.
Always include the operating instructions when you pass the hand tool to third parties.
RoHS Information
Information on the presence and location of any substances subject to
RoHS (Restriction on Hazardous Substances) can be found at the following website:
http://www.tycoelectronics.com/customersupport/rohssupportcenter/
Click on “Find Compliance Status” and enter equipment part number.
3.1 Intended use
The tool is an electrically driven, manually tool: used to contact roll-fed clips with manually fed wire by means
of various tool kits.
Individual lead positions may be singled out and omitted within the processing sequence.
Only approved wires may used.
It is absolutely necessary to use the correct mandrels.
The air tool TERMI-POINT may used exclusively with clips lited in section 5.2 „Tools, Mandrels and Clips“
with appropriate wires.
The hand tool is not a product in terms of the EU-Machinery Directive 2006/42/EG.
Intended use includes having read and understood these instructions, especially
section 3 „General safety instructions“.
3.2 Improper use
Any attempt to use this hand tool other than described in section 3.1 „Intended use“.
3.3 Reasonably foreseeable misuse
Any attempt to use this hand tool with other than the specified connectors, described in
section 5.2 „Tools, Mandrels and Clips“.
Moreover, the hand tool may used exclusively within the limits of its intended use
(section 3.1 „Intended use“).

Air Tools TERMI
-POINT
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3.4 Qualification of personnel
In order to ensure operating safety, these activities may therefore only be carried out by qualified
technical personnel or an instructed person under the direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute the appropriate safety
measures due to their professional training, knowledge, and experience, as well as their understanding of
the relevant conditions pertaining to the work to be done. Qualified personnel must observe the rules
relevant to the subject area.
3.5 Safety instructions in this document
In these instructions, there are safety instructions before an instruction whenever there is a risk of personal
injury or damage to the equipment. The measures described to avoid these hazards must be observed.
Safety instructions are set out as follows:
SIGNALWORD
Type of risk
Consequences
Precautions
Listing
•Safety Sign: Draws attention to the hazard
•Signal word: Identifies the degree of hazard
•Type of danger: Identifies the type or source of the hazard
•Consequences: Describes the consequences of non-compliance
•Precautions: States how the hazard can be prevented
Signal Word Application
ApplicationApplication
Application
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will certainly result in serious injury or even
death.
WARNING
Indicates a potentially hazardous situation, which, if not
avoided, could result in serious injury or even death.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury or dam-
age to equipment.
NOTE
If this information is disregarded, it may result in machine
malfunction or breakdown.

Air Tools TERMI
-POINT
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3.6 Pictograms used
Pictogram
PictogramPictogram
Pictogram Meaning
MeaningMeaning
Meaning
These pictograms are placed on the Hand tool.
Fig. 1: Pictograms
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Wear ear proctection (see Fig. 1 / Pos. 1)
Wear proctective goggles (see Fig. 1 / Pos. 2)

Air Tools TERMI
-POINT
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3.7 Adhere to the following instructions
3.7.1 General instructions
Observe the regulations for accident prevention and environmental protection for the
country where the product is used and at the workplace.
Exclusively use the hand tool in good technical order and condition.
Check the hand tool for visible defects.
You must generally not modify or retrofit the product.
Only use the product appropriate to the intended use described in this manual.
Person who assemble, operate, disassemble or maintain the machine must not consume
any alcohol, drugs or pharmaceuticals that may affect their ability to respond.
Before putting the hand tool into operation, it is always important to check whether all de-
vices are at hand and functioning correctly.
The warranty only applies to the delivered configuration. The warranty will not apply if the
product is incorrectly assembled, not used as intended and/or handled improperly.
If the hand tool is apparently damaged or do not work proper, you must send it in for
repairs (section 15.6 „Address After Sales Serviced“).
The warranty only applies to the delivered configuration. The warranty will not apply if the
product is incorrectly assembled, not used as intended and/or handled improperly.
3.7.2 During operation
Only persons who have been authorized by the operator may work with the air tool within
the limits of the intended use.
Do not exceed maximum air line pressure of 6.5 bar or tool damage may occur. Ifair
pressure exceeds 6.5 bar use air regulator. For proper functioning of tool air line pressure
should never fall below 5.5 bar during terminating cycle.
Disconnect or turn off air pressure as instructed in procedures, when changing tooling or
performing any maintenance on tool.
Never hold nose of tool against hand or body when squeezing trigger. Being actuated,
tool nose must be clear of all objects or properly positioned on terminal post.
Never cycle tool without having side and top cover securely installed.
Before operating, make sure that compatible post, clip, wire and wire insulation are being
used.

Air Tools TERMI
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3.7.3 During maintenance and repair
It is absolutely essential that tool and equipment parts on which maintenance or service
jobs have to be carried out are disconnected from the air supply, unless anything to the
contrary is stated in the operating manual.
3.7.4 During disposal
For environmentally friendly disposal please observe the notes in section 11 “Disposal”.
3.8 Obligations and Responsibility of the Operator
3.8.1 Obligations of the Operator
The operator of the Tyco Electronics AMP GmbH products is bound to provide for personnel training on a
regular basis regarding the following subjects:
Observation and use of the operating instructions and the legal regulations.
Intended use and operation of the hand tool.
3.8.2 Responsibility of the Operator
The operator personnel is responsible that:
the machine is defended from unauthorized use
the machine is only operated full functional and reliable
the safety markers and instructions on the machine are in legible condition
the machine is protected against unauthorised use
wear the personal protective equipment;
be skilled and introduced in operating and cleaning the machine;
be familiar with and able to apply accident prevention regulations and safety instructions on the tool;
Repairs are discussed with the manufacturer;
to put the machine out of action, when there are established defects or abnormal operating states 0/
faults;
Operations on the machine only be carried out, when the machine is disconnected and secured
against resetting.
3.9 Obligations and Responsibility of the Carrier
3.9.1 Obligations of the Carrier
The service personnel has to:
be skilled and introduced in operating and cleaning the machine;
use the machine only conventional;
wear the personal protective equipment;
to put the machine out of action, when there are established defects or abnormal operating states 0/
faults;
to report established defects or abnormal operating states / faults immediately

Air Tools TERMI
-POINT
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3.9.2 Responsibility of the Carrier
The carrier is responsible that:
the tool is only used conventional
the tool is only operated full functional and reliable
the machine will be maintained as described under „Maintenance“.
3.10 Residual Risks
Attention must be paid to the following risks present when operating the machine and which cannot be re-
moved:
Risk of crushing due to insertion of the rod pushs
Risk of cutting damage due to sharp edges at the housing of nippers

Air Tools TERMI
-POINT
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4 Scope of delivery
The scope of delivery includes following parts:
1 Air Tool TERMI-POINT (type as ordered)
1 operating manual

Air Tools TERMI
-POINT
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5 Product description
TERMI-POINT air tools with interchangeable mandrels as listed in the tool and clip selection chart,
GP 1935 (section 5.2.2 ”Per GP 1935 Rev. Germany 3/86“), are used to terminate TERMI-POINT rectangu-
lar posts with AMP TERMI-POINT clips as follows.
The clips are automatically fed from a reel into the tool in continuous strip form. Unstripped wires, either
stranded or solid, is inserted into the tool mandrel and terminated to the post with a clip.
The hand-operated tools are typically illustrated in Fig. 2.
Fig. 2: Dimensional sheet
Post Size [mm]
Post Size [mm]Post Size [mm]
Post Size [mm] Clip / Pos
Clip / PosClip / Pos
Clip / Post
tt
t Part No.:
Part No.:Part No.:
Part No.:
0,8 x 1,6 x 22 3 max. 871087-2
0,8 x 2,4 x 26 3 max. 871087-1

Air Tools TERMI
-POINT
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5.1 Identification of product
Fig. 3: Identification of product
An identifikation label is placed on the hand tool (arrow).
There you find following informations:
1 Manufacturing date (MM.YYYY) 2 Work pressure [hPa]
3 Part No. 4 Product description
5 CE - label

Air Tools TERMI
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5.2 Tools, Mandrels and Clips
5.2.1 Introduction
TERMI-POINT mandrels, mandrel insert and clips are color coded to support the operator by matching clips
and mandrel assemblies (refer to table).
Aufkleber (1) und Kennzeichnungen
Code Location
The color code will appear on label, containing part number and quantity affixed to the clip reel (Fig. 4).
Fig. 4: Codification clip reel
The clip (1) is identified by a colored dot or stripe on the crown of the clip (Fig. 5).
Fig. 5: Codification Clip
Mandrels and mandrel inserts (1) are color coded as shown in Fig. 6.
Fig. 6: Codification mandrel

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5.2.2 Per GP 1935 Rev. Germany 3/86
Post Size 0.8 x 1.6 mm
Post Size 0.8 x 1.6 mmPost Size 0.8 x 1.6 mm
Post Size 0.8 x 1.6 mm
Mechanical Tool Part.
Mechanical Tool Part.Mechanical Tool Part.
Mechanical Tool Part.-
--
-No. 69526
No. 69526No. 69526
No. 69526-
--
-2 (Customer Manual CM2002)
2 (Customer Manual CM2002)2 (Customer Manual CM2002)
2 (Customer Manual CM2002)
Wire Size
solid or 7 strands Insulation-ø Mandreal Part-No. Clips (1000/Reel) Finish Part-No. Mandrel and Clip Color Code
AWG [mm²] [mm] hot dip tin. Gold plated Tin-ni. pl.
22 0.32 0.87-1.23 69551-8 1-330495-4 6-330495-2 6-330495-7 orange
1.14 – 1.65 1-69411-4
24 0.20 0.74 – 1.23 69551-9 5-330495-2 1-330495-9 6-330495-3 red
1.10 – 1.65 1-69411-3
26 0.12 0.56 – 1.14 69551-6 3-30495-4 9-330495-8 8-330495-6 brown
1.14 – 1.65 1-69411-9
28 0.08 0.56 – 1.14 69551-5 330495-3 9-330495-0 black
Pneumatic Tool Part.
Pneumatic Tool Part.Pneumatic Tool Part.
Pneumatic Tool Part.-
--
-No.
No.No.
No. 871087
871087871087
871087-
--
-2
22
2
Wire Size
solid or 7 strands Insulation -ø Mandreal Part-No. Clips (1000/Reel) Finish Part-No. Mandrel and Clip Color Code
22 0.32 0.91 – 1.65 871295-3 1-330495-2 4-330495-9 6-330495-8 orange
24 0.20 0.86 – 1.65 871295-4 2-330495-0 2-330495-2 6-330495-4 Red
26 0.12 0.76 – 1.40 871295-5 3-330495-3 1-330495-8 8-330495-4 brown

Air Tools TERMI
-POINT
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Post Size 0.8 x 2
Post Size 0.8 x 2Post Size 0.8 x 2
Post Size 0.8 x 2.4 mm
.4 mm.4 mm
.4 mm
Mechanical Tool Part.
Mechanical Tool Part.Mechanical Tool Part.
Mechanical Tool Part.-
--
-No. 69526
No. 69526No. 69526
No. 69526-
--
-1 (Customer Manual CM2002
1 (Customer Manual CM20021 (Customer Manual CM2002
1 (Customer Manual CM2002-
--
-1)
1)1)
1)
Wire Size
solid or 7 strands Insulation -ø Mandreal Part-No. Clips (250/Reel) Finish Part-No. Mandrel and Clip Color Code
AWG [mm²] [mm] hot dip tin.
20 0.56 1.17 – 1.65 69561-0 2-330854-5 yellow
1.68 – 2.16 69561-1
24 0.20 1.17 – 1.65 69561-4 3-330854-0 red
Pneumatic Tool Part.
Pneumatic Tool Part.Pneumatic Tool Part.
Pneumatic Tool Part.-
--
-No.
No.No.
No. 871087
871087871087
871087-
--
-1
11
1
Wire Size
solid or 7 strands Insulation -ø Mandreal Part-No. Clips (250/Reel) Finish Part-No. Mandrel and Clip Color Code
20 0.56 0.91 – 1.65 871295-1 2-330495-6 yellow
24 0.20 0.86 – 1.65 871295-2 2-330854-9 red
Accessories
AccessoriesAccessories
Accessories
Pull Test Tool
Pull Test ToolPull Test Tool
Pull Test Tool Clip Extraction Tool
Clip Extraction ToolClip Extraction Tool
Clip Extraction Tool
Test Force Color Indicator Ring Post Size Part-No. Part-No.
[N] [mm]
11 gelb 0.8 x 1.6 69358,2 69357-3

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5.2.3 Per GP 1944 Rev. Germany 3/86
Post Size 0.8 x 1.6 mm
Post Size 0.8 x 1.6 mmPost Size 0.8 x 1.6 mm
Post Size 0.8 x 1.6 mm
Wire Size
solid or 7 strands Mandrel and Clip Color Code
AWG [mm²]
22 0.32 orange
24 0.20 red
26 0.12 brown
28 0.08 black
Post Size 0,8 x 2,4 mm
Post Size 0,8 x 2,4 mmPost Size 0,8 x 2,4 mm
Post Size 0,8 x 2,4 mm
Querschnittsbereich
massiv oder Litze (7adr.)
Farbcodierung
Abisoliereinsatz und
Clip
AWG [mm²]
20 0,56 yellow
24 0,20 red