15647&6,21 +((6 ""!$+).#$"!,,"’&0 )+%, +"-"%+"" "*- &","(8 2&$6,1* ((’ $9/ /,’( 15(46 275,1* #,4( 7%$55(0%/: (6$,1(4 2’15(46(4 ’-756(4 #,4(15(46(4 ,’’(1 Figure 1 Features of the head (shown in Figure 1) and functions are as follows: Feed–Through Head Assembly 58442–1 is used to terminate discrete wires onto MTA–100 Receptacles Wire inserter—forces the wire into the two slotted 640620–[ ] (for wire size 22 AWG) and Receptacles beams of the contact. Note that it provides support for 640623–[ ] (for wire size 28 AWG) with a maximum the contact beams when applying insertion force on insulation diameter of 1.52 mm [.060 in.]. Read these the wire. instructions thoroughly before using the head. Rod inserter adjuster—is a piston for the wire inserter The head must be mounted onto one of the following and regulates wire inserter travel. tools (for operating procedure for the tool, refer to the instructions packaged with the tool): Feed slide—automatically positions the receptacle after each termination. — Pistol Grip Manual Handle Assembly 58074–1 (408–6790) Locating pawl—aligns the receptacle for insertion, — Electric Power Unit 931800–1 (409–5746) and retains it during termination. The locating pawl is sometimes referred to as the “anti–backup pawl.” — Pistol Grip Pneumatic Handle Assembly 58075–1 (408–6789) Insert housing—holds the receptacle in place in — Pneumatic Power Bench Assembly 58338–1 relation to the wires. (408–9393) Wire subassembly retainer—holds the wires in place in relation to the receptacle. Reasons for reissue of this instruction sheet are ",-+%’* provided in Section 8, REVISION SUMMARY. 1. Make a termination according to Section 4, Steps 1 through 6. If the receptacle cannot be inserted into the head, or if the receptacle is too The head serves as a guide and support for the loose in the head, adjust the insert housing receptacle during termination. according to Paragraph 3.2. ! !!!+,5&21642//(’’2&70(16,557%-(&662&+$1*(:&2!/(&6421,&524324$6,21$44,5%74*2) //16(41$6,21$/,*+65(5(48(’"!!24/$6(564(8,5,21$1’(*,21$/75620(4 (48,&( !/2*2$1’:&2!/(&6421,&5$4(64$’(0$4.58,5,62749(%5,6($6-0 )"&" -+)(% , )’/// 4$’(0$4.!6+(4342’7&65/2*25$1’&203$1:1$0(575(’$4(6+(3423(46:2)6+(,44(53(&6,8(291(45 !)’, !**%$- 2. After making the test crimp, depress the locating")&*)+"’&(+!#,*+%&+ pawl and push the receptacle out of the RIGHT 1. Remove the head from the tool. side of the head. 2. If the wire is inserted too deep, turn the rod 3. Inspect the termination according to Section 5. If necessary, make the following adjustment: inserter adjuster clockwise one–sixth of a revolution (the wire insertion depth will be — For the manual handle assembly or electric decreased by approximately 0.20 mm [.008 in.]). power unit, if the wire is inserted too deep or not If the wire is not inserted deep enough, turn the rod deep enough in the contact slot, adjust the wire inserter adjuster counterclockwise one–sixth of a insertion depth according to Paragraph 3.3. Then, revolution (the wire insertion depth will be repeat the termination procedure and inspection. increased by approximately 0.20 mm [.008 in.]). — For the pistol grip pneumatic handle assembly Refer to Figure 4. or pneumatic power bench assembly, if the wire is inserted too deep in the contact slot, adjust the wire insertion depth according to Paragraph 3.3. If the wire is not inserted deep enough in the 1. Determine the wire size and select the contact slot, increase the air pressure by 69 kPa appropriate receptacle (receptacles are [10 psi], and repeat the termination and inspection color–coded according to wire size). procedure until either the proper insertion depth is obtained or the air pressure is set to 483 kPa 2. Install the head onto the tool according to the [70 psi]. If the proper insertion depth is not reached instructions packaged with the tool. at 483 kPa [70 psi], return the air pressure to 3. Refer to Figure 2, and: 276 kPa [40 psi], and adjust the wire insertion depth according to Paragraph 3.3. Then, repeat — for the electric power unit, insert the receptacle the termination procedure and inspection. into the LEFT side of head (in the direction of the arrow) until the first contact aligns with the wire &*)+’,*"& #,*+%&+ inserter. If the receptacle cannot be inserted into the head, or — for the manual handle assembly, pistol grip if the receptacle is too loose in the head, loosen the pneumatic handle assembly, and pneumatic power two screws on the insert housing, and adjust the bench assembly, depress and hold the trigger or insert housing until the receptacle fits properly in the foot pedal (the wire inserter should extend), and head. insert the receptacle into the LEFT side of head (in $#%#$ # $#%# !% ( & # )$! "% %!#&$$* % # % # % $%!#" & $$* "% Figure 2 !*!%#! $!#"!#%! ’ !’&* !(($#+ the direction of the arrow) until it stops, then release the trigger or foot pedal (the receptacle should advance so that the first contact aligns with the wire inserter). 4. Check that the locating pawl is resting between the index ribs of the receptacle. See Figure 2. If not, push the receptacle out of the RIGHT side of the head, and re–insert it. )’" #))()’"%),’ (*(("!-’)#’#*((($,## *’)$$!#!$)),’(*’# )’"#)$#(+$))’)#’!))$$%#) ’)#’ 5. Insert an unstripped wire into the funnel area between the contact and the wire inserter until it is in the desired location to be terminated. 6. Actuate the tool according to the instructions included with the tool. When the cycle is completed, the wire inserter will retract, and the feed slide will automatically advance the receptacle to the next contact position. !$)#%,!,!!"$+*%#$,#() ’%)!(*)$")!!-+#)’$*) $,+’"$+"#)($()’*)$’ Figure 3(’%’(()!$)#%,!#%*() ’%)!$*)$)($) 7. Repeat Steps 4 through 6 until all contacts have been terminated. 8. Inspect each termination according to Section 5. *’#!$ ,()$’( ’#(’)$#%) Refer to Figure 3, and inspect each termination to ensure the following: — the wire is terminated past the lead–in transition and is about halfway in the contact slot — the wire is from 1.78 to 2.16 mm [.070 to .085 in.] beyond the front of the contact beam *’#$*#)’!$ ,()$#’( — the wire is NOT bottomed in the contact slot’#(’)$#%) — the contact beams are NOT deformed (if Figure 4 damage is apparent, replace the contacts in accordance with the instructions packaged with the receptacle) — the wire is NOT nicked or cut in any area other The following procedures have been established to than the contact slot ensure the quality and reliability of the head. The head should be checked daily, and a more detailed — the wires extend beyond the strain–reliefs of the receptacle inspection should be performed by your quality control group on a regular basis. ’)$$’)!%%!)$# "#+"%)%% ’&*’"#)( Each operator should be aware of, and responsible for, the following steps of maintenance. ! "(’+!" )) %$, 1. Remove dust, moisture, and other contaminants 1. Remove any accumulated film with a suitable with a clean brush, or soft, lint–free cloth. DO NOT cleaning agent that will NOT affect plastic material. use objects that could damage the head. 2. Make sure all components are in place and are properly secured. 2. Make sure all components are in place and properly secured. 3. Make a few test terminations, and inspect the termination in accordance with Section 5. 3. Actuate the tool to ensure mechanisms inside the head move smoothly. 4. Check for chipped, cracked, worn, or broken areas. If damage is evident, repair is necessary. See Section 7. +$#*,’&*(’$#&* && Regular inspections should be performed by your quality control personnel. A record of quality control inspections should remain with the personnel Customer–replaceable parts are listed in Figure 5. responsible for the head. One inspection a month is A complete inventory should be stocked and recommended; however, operator skill, amount of controlled to prevent lost time when replacement of use, ambient working conditions, and your company’s parts is necessary. Parts other than those listed established standards are all factors in establishing should be replaced by Tyco Electronics to ensure frequency of inspections. quality and reliability. Order replacement parts Figure 5 (Cont’d) $$#&*),%&$!#++$("’- *-*1)&% .,/0&11*.- !.$"2*-( /*0"+/0*-( !*-*1)&%&&% .,/0&11*.- &&% 0"4&01&+*%& !*0& +.22&%/0*-( -1&02&0 .%-1&02&0 .,/0&11*.- -1&02 !"$)*-& &0,*-"+ -1&02 !3#"11&,#+5 Figure 5 (End) through your representative, or call 1–800–526–5142, or send a facsimile of your purchase order to Updated document to corporate requirements 717–986–7605, or write to: Corrected Section 1 CUSTOMER SERVICE (038–035)Corrected part number for item 17 and switched bubbles 17 and 18 in Figure 5 TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105–3608 For customer repair service, call 1–800–526–5136. &45$.+&$20.-*$1.0/.0"2*.-.’