Instruction Sheet Feed-ThroughHeadAssembly58443-1 408--9607 ForDiscreteWireMTA-156Receptacles 20DEC 10 RevC Locating Feed Pawl Slide Insert Housing Wire Subassembly Retainer Rod Inserter Adjuster Wire Inserter (Hidden) Figure 1 Features of the head assembly (shown in Figure 1) 1. INTRODUCTION and functions are as follows: Feed--Through Head Assembly 58443--1 is used to terminate discrete wires onto MTA--156 Receptacles Wire inserter—forces the wire into the two slotted 640599--[ ] (for wire size 18 AWG) and Receptacles beams of the contact. Note that it provides support for 640604--[ ] (for wire size 26 AWG) with a maximum the contact beams when applying insertion force on insulation diameter of 2.41 mm [.095 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 All numerical values in this instruction sheet are NOTE in relation to the receptacle. in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and i inches]. Figures are not drawn to scale. 3. TESTCRIMPANDHEADADJUSTMENTS Reasons for reissue of this instruction sheet are 3.1. TestCrimp provided in Section 8, REVISION SUMMARY. 1. Make a termination according to Section 4, Steps 1 through 6. If the receptacle cannot be 2. DESCRIPTION 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. E2010TycoElectronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlleddocument is subject tochange. 1 of 5 PRODUCT INFORMATION1--800--522--6752 Forlatest revisionandRegional CustomerService, All Rights Reserved visit ourwebsiteatwww.tycoelectronics.com TE logoandTycoElectronics aretrademarks. LOCB *Trademark. Otherproducts names, logos, orcompany names might betrademarks of theirrespectiveowners. ORIGINAL INSTRUCTIONS 408-9607 Feed-ThroughHeadAssembly58443-1 2. After making the test crimp, depress the locating 3.3. WireInsertionDepthAdjustment 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. inserter adjuster clockwise one--sixth of a If necessary, make the following adjustment: 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 toFigure4. or pneumatic power bench assembly, if the wire is inserted too deep in the contact slot, adjust the 4. TERMINATIONPROCEDURE 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 3.2. InsertHousingAdjustment 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 Discrete Wires Wire Inserter Locating (Hidden) Pawl Funnel Area Index Ribs of Receptacle Left Side of Head Wire Sub--Assembly Retainer Retainer Latch Pistol Grip Manual Handle Assembly (Ref) Feed Slide Receptacle Figure 2 2 of 5 TycoElectronicsCorporation RevC 408-9607 Feed-ThroughHeadAssembly58443-1 the direction of the arrow) until it stops, then Inspection ofProperly Terminated Wire release the trigger or foot pedal (the receptacle should advance so that the first contact aligns with Correct Contact the wire inserter). Slot Wire 4. Check that the locating pawl is resting between Front of the index ribs of the receptacle. See Figure 2. If Lead--In Contact Beam not, push the receptacle out of the RIGHT side of Transition the head, and re--insert it. After making the test crimp, the wire NOTE sub--assembly retainer can be used (as shown in Figure 2) to hold and locate the wires during i terminations. Pivot the retainer latch to open the retainer. 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. Incorrect 6. Actuate the tool according to the instructions Strain Relief 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. The locating pawl will move up and down as the NOTE Deformation Cut in Wire receptacle is automatically advanced through the head. However, if movement is obstructed, or if i desired, depress the locating pawl and push the Figure 3 receptacle out of the RIGHT side of the head. 7. Repeat Steps 4 through 6 until all contacts have Wire Insertion Depth Adjustment been terminated. 8. Inspect each termination according to Section 5. Turn Clockwise to Decrease 5. TERMINATIONINSPECTION Wire Insertion Depth Refer to Figure 3, and inspect each termination to ensure the following: —the wire is terminated past the lead--in transition Rod Inserter Adjuster and is about halfway in the contact slot —the wireis from 2.29to2.74mm [.090 to .108 in.] beyond the front of the contact beam Turn Counterclockwise to Increase —the wire is NOT bottomed in the contact slot Wire Insertion Depth —the contact beams are NOT deformed (if Figure 4 damage is apparent, replace the contacts in accordance with the instructions packaged with the receptacle) 6. MAINTENANCEANDINSPECTION —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 —the wires extend beyond the strain--reliefs of the head should be checked daily, and a more detailed receptacle inspection should be performed by your quality control group on a regular basis. Refer to 114--1020 for detailed application NOTE 6.1. DailyMaintenance requirements. Each operator should be aware of, and responsible i for, the following steps of maintenance. RevC TycoElectronicsCorporation 3 of 5 408-9607 Feed-ThroughHeadAssembly58443-1 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. 6.2. QualityControlMaintenance Regular inspections should be performed by your 7. REPLACEMENTANDREPAIR 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 TE to ensure quality and frequency of inspections. reliability. Order replacement parts 17 16 14 13 12 A A 15 18 Section A--A 2 3 4 5 6 7 8 9 10 11 1 Figure 5 (Cont’d) 4 of 5 TycoElectronicsCorporation RevC 408-9607 Feed-ThroughHeadAssembly58443-1 REPLACEMENTPARTS QTYPERHEAD ITEM PARTNUMBER DESCRIPTION ASSEMBLY 1 314487--2 HEAD,Finished 1 2 6--22278--5 SPRING,Compression 1 3 312147--1 PAWL,Locating 1 4 21041--7 PIN,SpiralSpring 1 5 312192--1 PAWL,FinishedFeed 1 6 1--23147--2 SPRING,Compression 1 7 312151--1 SLIDE,Feed 1 8 314491--1 CAM,TraverseSlide 1 9 312154--1 INSERTER,Wire 1 10 3--21028--2 PIN,SlottedSpring 1 11 312148--1 ROD,Inserter 1 12 312149--1 ADJUSTER,RodInserter 1 13 22488--5 SPRING,Compression 1 14 314489--1 HOUSING,Insert 1 15 4--22430--8 SCREW,Machine4--40¢.88in. 4 16 845053--2 GUIDE,Terminal 1 17 854179--1 HOUSING,Insert 1 18 314500--1 WIRE RETAINER,Subassembly 1 Figure 5 (End) through your representative, or call 1--800--526--5142, 8. REVISIONSUMMARY or send a facsimile of your purchase order to Revisions to this instruction sheet include: 717--986--7605, or write to: S Updated instruction sheet to corporate CUSTOMER SERVICE (038--035) requirements TYCO ELECTRONICS CORPORATION PO BOX 3608 S Added Original Instructions to page 1 HARRISBURG PA 17105--3608 For customer repair service, call 1--800--526--5136. RevC TycoElectronicsCorporation 5 of 5