5980(3,4)-1 Instr Sheet Datasheet

-:]'E nneclivily PROPER USE GUIDELINES lnserfion Tool
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©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
TE logo is a trademark.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
Instruction Sheet
TOOLING ASSISTANCE CENTER
1-800-722-1111
PRODUCT INFORMATION
1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
LOC B
408-7907
Insertion Tools 59803-1 and 59804-1
for Mass Termination Assembly (MTA)
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.
Figure 1
1. INTRODUCTION
This instruction sheet covers the use of Insertion Tools
59803-1 and 59804-1 designed to terminate .100-in.
and .156-in. centerline MTA connectors. Read these
instructions thoroughly before using the tools to
ensure correct termination of the wire.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
NOTE
i
2. DESCRIPTION
The T-handle wire insertion tool is equipped with a
slotted blade design which is used to insert the wire
into the MTA connector. The blade is designed to fit
into the connector slot to terminate the wire using the
Displacement Terminating Technique.
This technique requires inserting an unstripped wire
into a slotted contact beam to form a reliable electrical
connection between the conductor and contact.
CONNECTOR TOOL
NUMBER
CONTACT TYPE CENTERLINE SPACING
Receptacle .100 in. 59803-1
Receptacle and Posted .156 in. 59804-1
Insertion Tool
Handle (Ref)
Centerline
of Tool (Ref)
Connector
Shoulder
(Ref)
Wire
Contact
Receptacle Contacts
Inside Connector (Ref)
Contact Slot
Front
Beam
Lead-In
Slotted
Blade
‘355
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Rev A
Figure 2
The tool number is stamped on the tool side and a
logo marking is molded on both sides. Insertion tool
59803-1 is designed for connectors with contacts on
.100-in. centers (MTA 100), and insertion tool 59804-1
is designed for connectors with .156-in centers (MTA
156).
3. INSERTION PROCEDURES (Figure 2)
1. Place the connector block on a flat surface or
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.
3. Place appropriate tool on wire over contact so
that the centerline of the tool matches the contact.
The tool must be positioned as shown in Figure 2.
4. Holding the tool handle perpendicular to the
contact, apply a constant, direct pressure until the
wire is terminated with the contact. Exert pressure
in such a manner as to avoid contact damage.
5. Remove tool and inspect contact for proper wire
insertion. If necessary, repeat the operation.
Contact
Wire
Centerline
of Tool
(Ref)
Slotted
Blade
Insertion Tool
Handle (Ref)
Centerline of
Tool Aligned
with Contact
Housing
(Ref)
Contact
Wire
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Rev A
Figure 3
4. TOOL INSPECTION
The insertion tools listed on this instruction sheet
should be inspected with the information provided in
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
5. REVISION SUMMARY
Revisions to this instruction sheet include:
Updated document to corporate requirements.
TOOL NUMBER DIMENSIONS PRODUCT
DESIGNED FOR
ABC
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
50.3 [1.98]
65.0 [2.56]
A
B
C
16.0 [.63]