408-7907 TEC | Alldatasheet
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1 of 3©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 NUMBERCONTACT 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
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. ContactWire Centerline of Tool (Ref) Slotted Blade Insertion Tool Handle (Ref) Centerline of Tool Aligned with Contact Housing (Ref) ContactWire