Insertion Tools 59803-1 and 59804-1
for Mass Termination Assembly (MTA)
Connectors
Instruction Sheet
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.
Insertion Tool
Handle (Ref)
Lead-In
Front
Beam
Centerline
of Tool (Ref)
Connector
Shoulder
(Ref)
Slotted
Blade
Contact Slot
Receptacle Contacts
Inside Connector (Ref)
Wire
CONNECTOR
CONTACT TYPE
Receptacle
CENTERLINE SPACING
.100 in.
.156 in.
TOOL
NUMBER
59803-1
59804-1
Contact
Receptacle and Posted
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
NOTE
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
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.
i
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
All Rights Reserved
TE logo is a trademark.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
1
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LOC B
408-7907
Insertion Tool
Handle (Ref)
Centerline of
Tool Aligned
with Contact
Slotted
Blade
Centerline
of Tool
(Ref)
Housing
(Ref)
Wire
Contact
Wire
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. 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.
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.
Rev
A
2
of 3
408-7907
50.3 [1.98]
16.0 [.63]
65.0 [2.56]
A
B
C
TOOL NUMBER
59803-1
59804-1
DIMENSIONS
A
2.67 [.105]
3.05 [.120]
B
7.11 [.280]
9.53 [.375]
Figure 3
C
1.02 [.040]
1.52 [.060]
PRODUCT
DESIGNED FOR
MTA 100 Connector
MTA 156 Connector
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.
Rev
A
3
of 3
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