Customer Manual
TERMI-POINT* Tools
409-2002
69526-2 and 654182-1
13 MAR 08 Rev E
SAFETY PRECAUTIONS
1. INTRODUCTION
READ THIS FIRST !
. . . . . . . . . . . . . . . . . . . . . . . . . .
2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. PRODUCT-TO-TOOLING CROSS-REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. OPERATING INSTRUCTIONS
3.1. Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2. Mandrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3. Product Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4. General Operating Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. ADJUSTMENTS
4.1. Clip Positioning Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2. Clip Positioning Assembly Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3. Insulation Stripping Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4. Push Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. PREVENTIVE MAINTENANCE AND INSPECTION
5.1. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2. Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. REPLACEMENT AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1. Mandrel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2. Push Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8. REVISION SUMMARY
E
2008 Tyco Electronics Corporation, Harrisburg, PA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
All International Rights Reserved
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
visit our website at www.tycoelectronics.com
*Trademark. Other products, logos, and company names used are the property of their respective owners.
1 of 21
LOC B
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
DANGER
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:
D ALWAYS wear appropriate ear protection.
D ALWAYS wear approved eye protection when operating powered equipment.
D ALWAYS keep guard(s) in place during normal operation.
D ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
D ALWAYS turn off the main power switch and disconnect electrical cord from the power source when
performing maintenance on the equipment.
D NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
D NEVER insert hands into installed application equipment.
D 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 Engineers 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.
2 of 21
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
Tyco Electronics Corporation
Rev E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Reel Bracket
Spindle
Insulation Stripping
Adjustment Screw
Alignment
Foot
ÒÒ
ÒÒ
Front of Tool
Ram Rod Loader
(In Storage Location)
Insulation
Ejector
Clip Positioning Adjustment
Thumbscrew
Handle Assembly
Trigger
Figure 1
1. INTRODUCTION
TERMI–POINT Tools 69526–2 and 654182–1 (shown in Figure 1) are designed to terminate wires onto
rectangular posts with TERMI–POINT clips. These clips are automatically fed from a reel into the tool in
continuous strip form.
Read this manual thoroughly before operating the tool. The performance of the tool will depend largely upon
the intelligent use of the information contained in this manual.
Reasons for revision to this manual are provided in Section 8, REVISION SUMMARY.
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.
CAUTION
Denotes a condition which may result in product or equipment damage.
!
NOTE
Highlights special or important information.
i
NOTE
Dimensions in this manual are in metric units [with U.S. customary units in brackets].
i
Rev
E
Tyco Electronics Corporation
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409-2002
TERMI-POINT Tools 69526-2 and 654182-1
When received, the tool should conform to the dimensions shown in Figure 2.
12.7 mm [.50 in.]
25.4 mm
ÕÕ
ŠŠ
ŠŠ
17.5 mm [.69 in.]
28.4 mm
[1.12 in.]
[1.0 in.]
Front of Tool
92.07 mm
[3.62 in.]
133.3 mm [5.25 in.]
ÒÒ
ÒÒ
168.1 mm
[6.62 in.]
25.4 mm
[1.0 in.]
82.5 mm
[3.25 in.]
104.8 mm [4.125 in.]
158.8 mm [6.25 in.]
193.5 mm [ 7.62 in.]
Figure 2
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Tyco Electronics Corporation
Rev
E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
2. PRODUCT-TO-TOOLING CROSS-REFERENCE
These tools use the interchangeable mandrels listed in Figure 3. For product–to–tooling cross–reference, refer
to Figure 3.
WIRE
CLIP
COLOR
TOOL
69526-2
SIZE (AWG)
INSULATION
SOLID OR
DIAMETER
Reel of 1000
RANGE
(7 Strands)
(mm [in.])
22
0.99-1.14
[.039-.045]
0-69551-8
1.14-1.65
[.045-.065]
1-69411-4
0.84-1.14
[.033-.045]
0-69551-9
1.14-1.65
[.045-.065]
1-69411-3
0.71-1.14
[.028-.045]
0-69551-6
1.14-1.40
[.045-.055]
1-69411-9
0.61-1.14
[.024-.045]
0-69551-5
1.17-1.65
[.046-.065]
69561
1.68-2.16
[.066-.085]
0-69561-1
1.40-1.65
[.055-.065]
0-69561-4
26
28
20
654182-1
24
(M
(Mandrel
d l
Reel of 250
STRANDED
24
CODE
MANDREL
Tin-Nickel
and Clip)
Tin Plated
Gold Plated
Ċ
6 330495 1
6-330495-1
6 330495 2
6-330495-2
6 330495 1
6-330495-1
Orange
Ċ
5 330495 3
5-330495-3
Ċ
5 330495 3
5-330495-3
Red
Ċ
5 330495 5
5-330495-5
Ċ
5 330495 5
5-330495-5
Brown
Ċ
5-330495-9
Ċ
5-330495-9
Black
2 330854 5
2-330854-5
Ċ
Ċ
Ċ
Yellow
3-330854-0
Ċ
Ċ
Ċ
Red
Plated
Figure 3
3. OPERATING INSTRUCTIONS
CAUTION
To prevent damage to the tool, avoid unnecessary cycling of an empty tool.
!
3.1. Pre-Operation Check
Prior to operation be sure to check the following items and make any necessary adjustments to the tool.
1. Be sure that the mandrel is properly installed as described in Paragraph 3.2.
2. Be sure that the tool is properly loaded with product as described in Paragraph 3.3.
3. Be sure that the clip positioning adjustment is set as described in Paragraph 4.1, and that the clip
positioning assembly adjustment is correct (refer to Paragraph 4.2).
4. Be sure that the insulation stripping adjustment is correct as described in Paragraph 4.3.
5. Be sure that the push rod adjustment is correct (refer to Paragraph 4.4) and the distance between the
clip and the mandrel is as specified in Figure 12.
Rev E
Tyco Electronics Corporation
5
of 21
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
3.2. Mandrel Installation
(See Figure 4)
1. Remove the mandrel holding screw and the alignment foot from the front of the tool.
2. Pull the insulation ejector away from the tool to permit installation of the mandrel.
3. Insert the mandrel into the front of the tool so that, when the clips are in the tool, the tail of the
mandrel enters the open portion of the first clip.
4. Re–install the the alignment foot and the mandrel holding screw.
CAUTION
Tighten the mandrel holding screw only enough to hold the mandrel in place. Excessive tightening may distort the front
of the tool.
!
5. Align the insulation ejector with the insulation slot of the mandrel.
Front of Tool
Mandrel Holding Screw
Mandrel
Insulation
Insulation
Insulation
Ejector
Ejector Slot
Slot
Alignment Foot
Figure 4
3.3. Product Loading and Unloading
A. Loading
1. Select a full reel of product that corresponds with the tool, mandrel, and wire size being used (refer to
Figure 3).
2. Free the exposed end of the clip train on the reel, and place the reel onto the reel bracket with the
clips feeding from the bottom of the reel. See Figure 5, Detail A. Ensure that the clips are straight and
the insulation supports (strain reliefs) of the clips are “up” and face toward the front of the tool. See
Figure 5, Detail B.
3. Insert the clips into the clip feed slot. The insulation support (strain relief) of the clip must be “up” and
facing toward the front of the tool. See Figure 5, Detail B.
4. Use the ram rod loader, attached to the cap on the back of the tool, to push clips into the clip feed
slot until the strip is visible in the hole in the side of the tool. DO NOT FORCE THE CLIPS. See
Figure 5, Detail A.
5. Squeeze the trigger, then use the ram rod loader to feed the clips forward until a clip snaps into
position behind the mandrel.
6. Return the ram rod loader to the ram rod storage location of the tool. See Figure 5, Detail B.
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Tyco Electronics Corporation
Rev
E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
Detail A
Reel Bracket
Reel
Insulation Support
(Strain Relief) of Clip
Clip Train
Front of Tool
Clip Feed Slot
Cap
Drive Block
Holding Screw
Ram Rod
Loader
Note: DO NOT force the clips.
Ram Rod
Loader
Push to Reset
Clip Feed Mechanism
Front of Tool
Insert Tip and Advance
Clip onto Mandrel
Detail B
Insulation Support
(Strain Relief) of Clip
Clip Feed Slot
Back of Tool
Ram Rod Loader
(In Storage Location)
Figure 5
B. Unloading
1. Remove the mandrel.
2. Partially depress the trigger, then push the cap (on the end of the ram rod loader) forward to reset the
clip feed mechanism.
NOTE
If the trigger is
fully
depressed, a clip will be cut from the clip train strip.
i
3. Repeat Step 2 as many times as necessary to remove the unused portion of the clip train from the
tool.
4. Re–install the mandrel.
Rev
E
Tyco Electronics Corporation
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409-2002
TERMI-POINT Tools 69526-2 and 654182-1
3.4. General Operating Procedure
1. Insert an unstripped wire into the hole in the top of the mandrel. Make sure the wire bottoms in the
mandrel. See Figure 6.
Wire
Wire Bottomed
Mandrel
Mandrel
Figure 6
2. Slowly squeeze the trigger until it bottoms against the handle, then release the trigger. The clip is now
ready to be applied to the post.
3. Hold the tool perpendicular to the panel, and slip the exposed clip over the end of the post. See
Figure 7.
NOTE
The alignment foot should rest on the post(s) to aid in maintaining both vertical and horizontal alignment of the tool
with the post(s).
i
4. Grip the tool lightly, then push, using a steady even pressure until the clip reaches the desired
position on the post.
CAUTION
Always complete a termination after the trigger has been depressed. If the tool is reset and the trigger is depressed a
second time without completing a termination, two clips will be fed onto the mandrel, causing a jam.
!
Alignment Foot
Resting on Post(s)
Clip
Panel (Ref)
Cap
Post
Grip Tool Lightly
Figure 7
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Tyco Electronics Corporation
Rev
E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
CAUTION
DO NOT attempt to terminate a post that has been previously terminated.
!
5. Remove the tool from the post. A properly terminated post should appear as shown in Figure 8. Be
certain that stripped conductor, not the insulation, is visible at the back end of the clip.
Stripped Conductor
(Insulation Should Not
Post
Be Visible Here)
Back End of Clip
Insulation Support
(Strain Relief) of Clip
Front End of Clip
Figure 8
6. With the trigger released, push the cap (refer to Figure 7) fully forward to reset the tool for the next
termination.
7. Push the insulation ejector to remove the stripped insulation from the tool before inserting the next
wire. Refer to Figure 9.
8. Repeat Steps 1 through 6 for the next termination.
Push Down to Eject Insulation
Insulation Ejector
Insulation Drops Out of This Side
Figure 9
Rev
E
Tyco Electronics Corporation
9 of 21
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
4. ADJUSTMENTS
4.1. Clip Positioning Adjustment (Figure 10)
The clip positioning assembly adjustment controls the position of the clip when it is applied to the post. When
applying three clips to a post, first set the positioning adjustment to “3”. This positions the first clip at the
bottom of the post. Then set the positioning adjustment to the “2” setting to place the second clip in the middle
of the post. Finally, set the positioning adjustment to “1” to position the third clip on the top of the post. When
applying two clips to a post, begin with the “2” setting, and when applying one clip to a post, use the “1” setting.
Use the following procedure to make an adjustment.
1. Refer to Figure 10 to determine the maximum number of clips to be applied to a post.
2. Rotate the clip positioning adjustment thumbscrew so that the desired setting appears, as shown in
Figure 10. Figure 10 indicates the maximum number of clips to be applied to a post. If less than the
maximum is desired (i.e., two clips on a three–clip post, allowing space at the bottom for wire routing),
adjust the setting to the number required. The tool is now ready to apply clips.
NOTE
If the clip positioning assembly requires adjustment, refer to Paragraph 4.2, Clip Positioning Assembly Adjustment.
i
Clip Positioning Adjustment Setting
ÚÚ
MINIMUM POST HEIGHT (mm [in.])
TOOL 69526-2
MAXIMUM NUMBER OF
TOOL 654182-1
CLIPS TO BE APPLIED
8.60 [.34]
12.70 [.50]
1
13.70 [.54]
19.05 [.75]
2
18.80 [.74]
25.40 [1.0]
3
Figure 10
4.2. Clip Positioning Assembly Adjustment
Each tool has an adjustment to control the the distance travelled by the first clip onto a post. These tools are
preset at the factory and should require no further adjustment. However, adjustment may be necessary when
replacing the push rod. Adjust the clip position as follows:
1. Loosen the clip positioning assembly adjustment screws. Refer to Figure 11.
2. Slide the clip positioning assembly toward the back of the tool to increase the distance travelled by
the clip or slide the clip positioning assembly toward the front of the tool to decrease the distance
travelled by the clip.
3. Gradually, move the clip positioning assembly, tighten the adjustment screws, and make test
terminations to check the clip position.
4. Repeat Steps 2 and 3 until the required position is achieved.
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Tyco Electronics Corporation
Rev E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
Clip Positioning
Adjustment Thumbscrew
Clip Must Not Bottom
on Panel or
Chamfer of Post
ÒÒ
ÒÒ
(Clearance Equal to
Wire Insulation
Diameter)
Back of Tool
Clip Positioning Assembly
Adjustment Screws
Figure 11
4.3. Insulation Stripping Adjustment
Each tool has an adjustment (shown in Figure 1) to control the stripping action provided when the push rod
forces the clip over the mandrel. These tools are set at the factory and should not require adjustment.
However, if the tool is not stripping the wire properly (i.e., nicked conductor strands or insulation not stripped
from the wire), adjust the tool as follows:
1. Turn the insulation stripping adjustment screw clockwise to increase the strip depth, or
counterclockwise to decrease the strip depth.
2. Make a test termination to check the stripping action.
3. Repeat Steps 1 and 2 until the desired stripping action is obtained.
4.4. Push Rod Adjustment
The push rod can be adjusted to control the amount of travel during clip application. The tools are set at the
factory and the push rod should not normally require further adjustment. However, if improper feed or
positioning occurs, or if the push rod has been replaced, perform the following check and make the adjustment
as required.
Check the push rod adjustment as follows:
1. With the tool loaded, squeeze and hold the handle to keep the push rod fully extended onto the
mandrel.
2. With the push rod fully extended, measure the distance from the front of the clip to the front of the
mandrel. If the dimension is not within the range specified in Figure 12, adjustment is required.
Rev
E
Tyco Electronics Corporation
11 of 21
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
Push Rod
Front of Clip
(Fully Extended)
A
Distance Between Clip and Mandrel
Front of Mandrel
TOOL
DIMENSION A (mm [in.])
69526-2
1.5-2.3 [.060-.090]
654182-1
2.7-3.5 [.105-.140]
Figure 12
Adjust the push rod as follows:
1. Remove the loading tool, break the clip train strip as it enters the back of the tool, and remove the
reel bracket.
2. Loosen the clip positioning assembly adjustment screw behind the clip positioning adjustment
thumbscrew. See Figure 11.
3. Move the push rod forward or backward as required to obtain the required dimension given in
Figure 12.
4. Tighten the clip positioning assembly adjustment screw behind the clip positioning adjustment
thumbscrew. See Figure 11.
5. Re–install the reel bracket and the loading tool.
6. Push the cap forward to reset the tool. The tool is now ready for operation. Use the clips remaining
on the strip inside the tool and reload the tool with a clip strip from the reel. Refer to Paragraph 3.3.
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Tyco Electronics Corporation
Rev E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
5. PREVENTIVE MAINTENANCE AND INSPECTION
5.1. Lubrication
A periodic lubrication schedule, using any good grade SAE 20 motor oil, should be maintained at the intervals
specified in Figure 13.
1. Squeeze the tool handles to expose the push rod.
2. Apply a light coat of lubricant to the top of the push rod.
CAUTION
DO NOT allow the lubricant to contact the clips or clip contact surfaces (such as the mandrel).
!
3. Lubricate the tool body in the areas shown in Figure 13.
ÒÒ
ÒÒ
AREA
LOCATION
LUBRICATION INTERVAL
Top of Push Rod
1
Every 500 Terminations
Both Side of Tool Body
2
Every 1000 Terminations
Top and Bottom of Tool Body
3
Every 1000 Terminations
Figure 13
Rev E
Tyco Electronics Corporation
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409-2002
TERMI-POINT Tools 69526-2 and 654182-1
5.2. Inspection
The following items should be checked periodically to ensure proper operating efficiency of the tooling.
1. Be certain the screws (Figure 17, Items 14, 15, 20, and 21) are tight.
2. Clean the tool and remove insulation scraps on a regular basis.
3. When the tool is cycled to apply clips, observe the operation of the tool. If binding of moving parts is
noted, lubricate the tool as described in Paragraph 5.1.
4. Check the mandrel for nicks and burrs. Refer to Figure 14. Nicks and burrs on the mandrel can cause
clip jams and damage to other related parts.
a. Remove the mandrel and mandrel tail or anvil clip from the tool.
b. Use a magnifying glass or a fingernail to detect the location of nicks and burrs.
No Burrs or Nicks Here
No Burrs Here
Mandrel
Assembly
CAUTION
Avoid the following causes for nicks and burrs on the mandrel:
Ċ Cycling the tool continuously without clips installed.
!
Ċ Inserting a scribe or sharp object in the stripping groove area to remove stripped insulation
Ċ Using a scribe or sharp object improperly to remove the jammed clips from the mandrel
Ċ Inserting a scribe or sharp object in the stripping groove area to remove the mandrel from the tool
Ċ Cycling the tool continuously with clips jammed on the mandrel
Figure 14
If necessary, remove the nicks and burrs using a suitable oil stone, grind the burrs off the exterior edges
of the mandrel. Then clean the repaired parts and install them in the tool.
CAUTION
Always move the oil stone lengthwise along the mandrel. See Figure 15.
!
Move Oil Stone in This Direction
Burrs
Nicks
Figure 15
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Tyco Electronics Corporation
Rev E
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
6. TROUBLESHOOTING
Every tool is thoroughly inspected before leaving the factory and should be in perfect operating condition when
it reaches the customer. If, at anytime, the tool does not function properly, refer to Figure 16.
SYMPTOM
Clips do not feed from the tool.
POSSIBLE CAUSE
REMEDY
Clips are not properly seated in the tool.
Refer to Paragraph 3.3.,A., Loading.
Incorrect clip or mandrel is being used.
Be certain that the proper clip, mandrel, and wire
combination is being used. Refer to Figure 3.
The push rod is broken or bent.
Refer to Paragraph 7.2., Push Rod Replacement
and Paragraph 4.4., Push Rod Adjustment.
The push rod is riding over the clips.
Correct the insulation stripping adjustment. Refer to
Paragraph 4.5.
Clips jam in the tool.
The clip train is broken.
Refer to Paragraph 3.3,A., Loading.
The clip is improperly inserted into the tool.
Refer to Paragraph 3.3,A., Loading.
Incorrect clip or mandrel is being used.
Be certain that the proper clip, mandrel, and wire
combination is being used. Refer to Figure 3.
Incorrect application is being used.
Refer to Paragraph 3.4., General Operating
Procedure.
The push rod is riding over the clips.
Correct the insulation stripping adjustment. Refer to
Paragraph 4.3.
Clips indexed onto the mandrel
There is an incomplete cycling of the tool.
in a continuous strip.
Clip is mangled or distorted
been depressed.
Incorrect clip or mandrel is being used.
when applied to the post.
Wire is not stripped cleanly or
Always complete a termination after the trigger has
Be certain that the proper clip, mandrel, and wire
combination is being used. Refer to Figure 3.
Incorrect clip or mandrel is being used.
completely.
Be certain that the proper clip, mandrel, and wire
combination is being used. Refer to Figure 3.
The mandrel is worn or broken.
Replace the mandrel as described in Paragraph 7.1.
The insulation stripping adjustment is incorrect.
Correct the insulation stripping adjustment Refer to
Paragraph 4.3.
Wire conductor is nicked or cut.
Incorrect clip, wire, or mandrel is being used.
Be certain that the proper clip, mandrel, and wire
combination is being used. Refer to Figure 3.
The mandrel is worn or broken.
Replace the mandrel as described in Paragraph 7.1.
The insulation stripping adjustment is incorrect.
Correct the insulation stripping adjustment. Refer to
Paragraph 4.3.
Clips do not stack properly.
The clip positioning adjustment is incorrect.
Refer to Paragraph 4.1., Clip Positioning
Adjustment.
Clip has low tensile strength.
Incorrect clip, wire, or mandrel is being used.
Be certain that the proper clip, mandrel, and wire
combination is being used. Refer to Figure 3.
The insulation stripping adjustment is incorrect.
Correct the insulation stripping adjustment. Refer to
Paragraph 4.3.
Figure 16
Rev
E
Tyco Electronics Corporation
15 of 21
409-2002
TERMI-POINT Tools 69526-2 and 654182-1
7. REPLACEMENT AND REPAIR
Customer–replaceable parts are listed in Figure 17. 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.
REPLACEMENT PARTS
PART NUMBER
ITEM
69526-2
654182-1
(Detail A)
(Detail B)
>
>
QTY PER
DESCRIPTION
TOOL
!
! -& 844357
! -&
! $
>
"
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Figure 17 (Continued)
16 3*
