Instruction Sheet Insertion Tools 59803-1 and 59804-1 for Mass Termination Assembly (MTA) 408-7907 Connectors 10 Mar 11 Rev A 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. Insertion Tool Handle (Ref) Lead-In Front Beam Centerline Slotted of Tool (Ref) Blade Connector Shoulder (Ref) Contact Slot Receptacle Contacts Inside Connector (Ref) Wire CONNECTOR TOOL NUMBER CONTACT TYPE CENTERLINE SPACING Receptacle .100 in. 59803-1 Contact Receptacle and Posted .156 in. 59804-1 Figure 1 1. INTRODUCTION 2. DESCRIPTION This instruction sheet covers the use of Insertion Tools The T-handle wire insertion tool is equipped with a 59803-1 and 59804-1 designed to terminate .100-in. slotted blade design which is used to insert the wire and .156-in. centerline MTA connectors. Read these into the MTA connector. The blade is designed to fit instructions thoroughly before using the tools to into the connector slot to terminate the wire using the ensure correct termination of the wire. Displacement Terminating Technique. Dimensions in this instruction sheet are in metric This technique requires inserting an unstripped wire NOTE units [with U.S. customary units in brackets]. into a slotted contact beam to form a reliable electrical Figures are not drawn to scale. connection between the conductor and contact. i ©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 3 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo is a trademark. visit our website at www.te.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B 408-7907 Insertion Tool Handle (Ref) Centerline of Tool Aligned with Contact Slotted Housing Blade (Ref) Centerline of Tool (Ref) Wire Contact Wire Contact Figure 2 The tool number is stamped on the tool side and a 3. Place appropriate tool on wire over contact so logo marking is molded on both sides. Insertion tool that the centerline of the tool matches the contact. 59803-1 is designed for connectors with contacts on The tool must be positioned as shown in Figure 2. .100-in. centers (MTA 100), and insertion tool 59804-1 4. Holding the tool handle perpendicular to the is designed for connectors with .156-in centers (MTA contact, apply a constant, direct pressure until the 156). wire is terminated with the contact. Exert pressure in such a manner as to avoid contact damage. 3. INSERTION PROCEDURES (Figure 2) 5. Remove tool and inspect contact for proper wire 1. Place the connector block on a flat surface or insertion. If necessary, repeat the operation. suitable support to prevent possible rocking when inserting the wire. 2. Position wire over the contact in the MTA connector. Make sure the end of the wire does not extend over the shoulder of the connector. Start the wire into contact with finger. Rev A 2 of 3 408-7907 50.3 [1.98] 16.0 [.63] 65.0 [2.56] A C B DIMENSIONS PRODUCT TOOL NUMBER DESIGNED FOR AB C 59803-1 2.67 [.105] 7.11 [.280] 1.02 [.040] MTA 100 Connector 59804-1 3.05 [.120] 9.53 [.375] 1.52 [.060] MTA 156 Connector Figure 3 4. TOOL INSPECTION 5. REVISION SUMMARY The insertion tools listed on this instruction sheet Revisions to this instruction sheet include: should be inspected with the information provided in • Updated document to corporate requirements. Figure 3. We recommend that you inspect the tools immediately upon arrival at your facility, and at regularly scheduled intervals, to ensure that the tools have not been damaged during handling. Additional tools can be purchased from: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 Rev A 3 of 3