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.
1/ 64
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
-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.
2/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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)
©2013 Tyco Electronics AMP GmbH, a TE Connectivity company.
All rights reserved.
TE Connectivity, TE connectivity (logo), TERMI-POINT and Tyco
Electronics are Trademarks.
3/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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)
©2013 Tyco Electronics AMP GmbH, a TE Connectivity company.
All rights reserved.
TE Connectivity, TE connectivity (logo), TERMI-POINT and Tyco
Electronics are Trademarks.
4/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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
-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.
5/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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
-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.
6/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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
(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.
7/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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
(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.
8/ 64
Customer
Manual
412-18008 Rev. D1
* Other products, logos and company names mentioned herein may be trademarks of their respective owners
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)