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Instruction Sheet

TOOLING ASSISTANCE CENTER

1-800-722-1111



PRODUCT INFORMATION

1-800-522-6752

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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

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

Summary of content (3 pages)

PAGE 1
Instruction Sheet Insertion Tools 59803-1 and 59804-1 for Mass Termination Assembly (MTA) Connectors 408-7907 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.
PAGE 2
408-7907 Insertion Tool Handle (Ref) Centerline of Tool Aligned with Contact Slotted Blade Housing (Ref) Centerline of Tool (Ref) Wire Wire Contact Contact 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.
PAGE 3
408-7907 50.3 [1.98] 16.0 [.63] 65.0 [2.56] A C B DIMENSIONS A B C PRODUCT DESIGNED FOR 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 TOOL NUMBER Figure 3 4. TOOL INSPECTION 5. REVISION SUMMARY The insertion tools listed on this instruction sheet should be inspected with the information provided in Figure 3.