59865-2

SAFETY PRECAUTIONS A. READ THIS FIRST ! Customer Manual 409-2908 21 SEP 11 Rev A ORIGINAL INSTRUCTIONS customer manual TERMI-POINT* Air Tools 59865-1, -2, -3, -7 and 59928-1, -2, -3, -7 ............................ 2 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1. Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.2. Precautionary Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. TERMI-POINT TOOL AND CLIP SELECTION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4. TERMI-POINT COMPONENT COLOR CODE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6. OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.1. Installation of Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.2. Removal of Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.3. Tool Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.4. Tool Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6.5. Clip Positioning Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.6. General Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 6.7. Tool Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7. PREVENTATIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 8. MAINTENANCE AND ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 8.1. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 8.2. General Disassembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 8.3. General Reassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 8.4. Pneumatic Assembly - Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 20 8.5. Push Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8.6. Clearing Jammed Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8.7. Hold-Down Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.8. Clip Guide Anvil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.9. Post Pickups Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8.10. Catch Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8.11. Front and Rear Catch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8.12. Clip Positioner Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8.13. Wire Funnel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 8.14. Air Line Filters and Lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 9. STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 10. DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 11. REPLACEMENT AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 12. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 13. PARTS LISTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ©2011 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names might be trademarks of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 32 LOC B 409-2908 DANGER STOP SAFETY PRECAUTIONS AVOID INJURY Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during equipment operation. However, certain safety precautions must be taken by the operator and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or hazardous environment. • • • • • • Carefully observe the following safety precautions before and during operation of the equipment: • • • NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment. ALWAYS wear appropriate ear protection. ALWAYS wear approved eye protection when operating powered equipment. ALWAYS keep guard(s) in place during normal operation. ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock. ALWAYS turn off the main power switch and disconnect electrical cord from the power source when performing maintenance on the equipment. NEVER insert hands into installed application equipment. NEVER alter, modify, or misuse the application equipment. TOOLING ASSISTANCE CENTER CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY) The Tooling Assistance Center offers a means of providing technical assistance when required. In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the application equipment when problems arise which your maintenance personnel are unable to correct. INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many difficulties can be avoided in this manner. When calling the Tooling Assistance Center, be ready with the following information: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Rev A Customer name Customer address Person to contact (name, title, telephone number, and extension) Person calling Equipment number (and serial number if applicable) Product part number (and serial number if applicable) Urgency of request Nature of problem Description of inoperative component(s) Additional information/comments that may be helpful 2 of 32 409-2908 Read this manual thoroughly before operating the machine. The performance of this machine will depend largely upon the intelligent use of the information contained in this manual. When reading this manual, pay particular attention to DANGER, CAUTION and NOTE statements. DANGER Denotes an imminent hazard which may result in moderate or severe injury. STOP CAUTION Denotes a condition which may result in product or equipment damage. ! NOTE Highlights special or important information. i CAUTION Do NOT use the power unit as a crushing device or for anything other than a crimping machine for the specified product. Inappropriate use of the unit could result in personal injury OR damage to the power unit. ! Always wear approved eye protection while operating the equipment. Always wear approved hearing protection while operating the equipment. Read and understand the entire manual. Moving parts can crush and cut. Do not operate the machine if the guards are removed. Always disconnect the air and lockout the tool when not in use, when performing maintenance on the tool, or when clearing a jammed tool. DANGER There is a risk of whipping if a hose is not properly installed or becomes detached. STOP Rev A 3 of 32 409-2908 NOTE Measurements are in metric units [followed by U.S. customary units in brackets]. Illustrations are for identification only and are not drawn to scale. i DANGER The unit should ONLY be operated by trained personnel. STOP DANGER If not using quick-disconnect fittings to connect the tool to the air supply, provide operators other means to easily disconnect the tool from the air supply. STOP DANGER Stored gas or fluid MAY be a hazard. STOP Rev A 4 of 32 409-2908 HAND OPERATED TOOLS SEMIAUTOMATIC TOOLS TOOL NO. POST SIZE CLIPS/POST (Max) TOOL NO. POST SIZE CLIPS/POST (Max) 59865-1 .022 x .036 3 59928-1 .022 x .036 3 59865-2 .031 x .062 3 59928-2 .031 x .062 3 59865-3 .031 x .093 3 59928-3 .031 x .093 3 59865-7 .031 x .062 3 59928-7 .031 x .062 3 Figure 1 1. INTRODUCTION This customer manual provides general information, operation, and maintenance information for TERMI-POINT Air Tools 59865-1, -2, -3, -7 and 59928-1, -2, -3, and -7. It includes instructional, adjustment, and repair information relating to the tools. The following instructions should be read carefully before attempting to use the tools. The performance of the tools will depend largely upon the use of the information contained in this manual. All tools and accessories are carefully tested and adjusted before shipment and, with proper maintenance and use, will give years of satisfactory service. All illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. If the information does not agree with the tool or product being used, contact your local TE Connectivity Representative or contact the Tooling Assistance Center number. 2. DESCRIPTION Termi-Point air tools, with interchangeable mandrels as listed in the tool and clip selection figures, (see Figures 2 through 16), are used to terminate TE rectangular posts with Termi-Point clips. See the table in Figure 1. The clips are automatically fed from a reel into the tool in continuous strip form. Unstripped wire, either stranded or solid, is inserted into the tool mandrel and terminated to the post with a clip. The hand-operated tool is shown in Figure 1. The semiautomatic tools are very similar to the hand-operated tools; however a small air cylinder assembled to a bracket on the right side of the tool is used to actuate the wire funnel lever. See Figure 33. Rev A 5 of 32 409-2908 2.1. Tool Specifications The following specifications are applicable for all tools: Air Supply Pressure - 551.6 kPa [80 psi] (min) to 655 kPa [95 psi] (max) Tool Weight - Approximately .9 kg [2 lb.], including mandrel, fully loaded reel, and air line Air Volume Required - 82 cu cm [5 cu in.] per cycle Noise Level -