ram insertion rod adjuster push rod locating pawl (hidden) wire inserter wire guide ? 2011 tyco electronics corporation, a te connectivity ltd. company ? all rights reserved *trademark te connectivity, te connectivit y (logo), and te (logo) are trademarks. other logos, product and/or company names may be tradem arks of their respective owners. 1 of 5 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 408-4406 mass insertion termin ating head 58644-1 ? for mta (mass termin ation assembly) 100 ? feed-through receptacle connectors 28 oct 11 rev c figure 1 1. introduction mass insertion terminating head 58644-1, shown in figure 1 , is designed to terminate mta 100 feed- through receptacle connectors (positions 2 through 1 2) onto discrete wire sizes 28 through 22 awg with a maximum insulation diameter of 1.27 mm [.050 in.]. refer to figure 2 for reference connector part numbers. note i this head is designed to terminate one connector at a time. note i a complete list of current connector part numbers cannot be maintained on this document. for all part numb ers and their description, refer to catalog 82056 or contact product information at the number at the bottom of this page. the head is used with pistol grip manual handle assemb ly 58074-1. for terminating head installation procedures, and setup and operation of the handle assembly, refer to instruction sheet 408-6790. read this and the referenced material before terminating any connectors. note i dimensions on this sheet are in metric units [with u.s. customary units in brackets]. figures are not drawn to scale. reasons for reissue are provided in section 8, revision summar y. 2. description (figure 1) the terminating head, when properly installed onto the handle assembly, serves as a guide for the connector during termination. features of the head and their functions are as follow s: wire inserter -s upports each wire in individual wire slots so that, during the insertion cycle, the wire forced into the two-slotted beam of the contact. wire guide - holds the wires in position over the wire inserter. ram - locates and holds the connector while pushing it down onto the wires. locating pawl -h olds connector in proper alignment to the wire inserter. push rod - used to push the terminated connector past the locating pawl for removal. insertion rod adjuster - is a piston for the ram and regulates the travel of the inserted wires.
wire size (awg) mta 100 feed-through receptacle connectors (with lo cking ramp) color code with polarizing tabs without polarizing tabs 22 red 644540 640620 24 white 644563 640621 26 blue 644564 640622 28 green 644565 640623 dash numbers indicate number of contact positions (-2 through -12 are applicable for this terminating head). 408-4406 2 of 5 rev c figure 2 each wire is terminated in a connector contact using the insulation displacement technique (a terminating technique which inserts unstripped wire into a slotted contact beam to form a reliable electrical connection between the wire and the contact). contact termination is complete when the handle assembly is actuated. 3. setup 3.1. installing head the head can be installed onto the handle assembly and used as a hand-held tool, or several tools can be mounted onto a board to be used as a low-level harness board fixture. the board must have two 6.36-mm [.250-in.] holes sp aced 44.45 mm [1.75 in.] apart for each head. secure each head with screws. see figure 3 . note i note i the handle assembly is not quick to install onto the head; therefore, each head should have its own handle assembly . 3.2. test termination at least one test termination should be performed and inspected before starting production. determine the wire size and select the appropriate color-coded connector. 1. using a small knife, cut off the wire retainers ( strain relief) from both si des of the test connector. see figure 4 . note i wire retainers must be removed from test connectors to provide a cl ear view for inspection-do not use test connectors for production applications. 2. terminate the test connector according to section 4 and inspect the connector following the requirements in step 6. make any insertion depth adjustments to the terminating head according to section 5 before starting production. handle assembly (ref) installing head as harness board fixture figure 3 4. terminating procedure 1. starting with the wire slot closest to the head frame, push one wire into one slot for each contact position of the connector being terminated. see figure 5 . 2. insert the connector into the ram with the contact insu lation barrels facing the wire slots. 3. using a screwdriver (or equivalent), push the con nector into the ram until the connector touches the surface of the frame. refer to figure 5. note i to ensure proper alignment in the head, all connector positions must touch the surface of the head frame.
terminated test connector wire retainers removed ? (both sides) contact partially removed for inspection lead-in ? transition no deformation of contact beam no cuts ? in wire terminated production connector contact slot 408-4406 3 of 5 rev c figure 4 wire inserted into wire slot ram handle assembly surface of head ? frame (connector ? must start here) figure 5 4. actuate the handle assembly according to the instructions packaged with the handle assembly. caution ! after the ram completes the stroke, no wires should be left in the wire slots. if any wires are still in the slots, pull them up and out of the slots before continuing. 5. depress the push rod to move the terminated connector beyond the loca ting pawl in the ram. 6. then grip the wires on both sides of the con nector and carefully guide the connector out of the ram. 7. refer to figure 4 and visually inspect the connector according to the following. if wire inse rtion depth is found to be improper, refer to section 5 for head adjustments. caution ! wire insulation tends to return to form after being compressed. it is important to inspect the connector within five minute s of termination; otherwise, an improper in spection may result. ? ? conductors are terminated past the lead-in transition and halfway into the contact slot. ? wires are not bottomed in contact slots. ? wire insulation is not ni cked or cut in any areas except in the contact slots. ? contact beams are not deformed. if damage is evident, replace the damaged contact according to the instructions pack aged with the connector. ? wire extends below the connector wire retainers. ? note i for detailed inspection information, refer to application specification 114-1019. 5. insertion d epth adjustment the terminating head is preset for nominal wire insertion depth; however, it may be necessary to make adjustments to the head, due to the wide range of cable sizes used, as follows: 1. remove the head from the handle assembly.
head removed from handle assembly insertion ? rod ? adjuster clockwise to decrease wire insertion depth counterclockwise to increase 408-4406 4 of 5 rev c figure 6 2. if the wires are too deep in the contact slots, turn the insertion rod adjuster clockwise. a 1/6- revolution will decrease the wire insertion depth by approximately 0.20 mm [.008 in.]. if the wires are not deep enough in the contact slots, turn the adjuster counterclockwise. a 1/6-revolution will increase the wire insertion depth by approximately 0.20 mm [.008 in.]. see figure 6 . 3. install the head onto the handle assembly; then ter minate and inspect a test connector. 4. repeat the adjustment as necessary until proper wire insertion depth is obtained. do not use a tighter setting than required. 6. maintenance and inspection te recommends that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. 6.1. daily maintenance 1. remove dust, moisture, and other contaminants with a clean, soft brush or a soft, lint-free cloth. do not use objects that could damage the head. 2. make sure that all pins, rings, and other com ponents are in place and secure. 3. when head is not in use, store it in a clean, dry ar ea. 6.2. periodic inspection regular inspections should be performed by quality control personnel. though recommendations call for at least one inspection a month, the frequency should be based on amount of use, working conditions, operator training and skill, and your established company policies. 1. remove all lubrication and accumulated film by imm ersing the head in a suitable commercial degreaser that will not affect paint or plastic. 2. make certain all components are in place. if re placements are necessary, refer to section 7. 3. check all bearing surfaces for wear. replace wor n or damaged parts. 4. inspect the head for flattened, chipped, or broken su rfaces. replace worn or damaged parts. 7. replacement and repair replacement parts are listed in figure 7 . a complete inventory can be stocked and controlled to prevent lost time whe n replacement of parts is necessary. order replacement parts through your te representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 1-717-986-7605, or write to: customer service (038-035) ? tyco electronics corporation ? po box 3608 ? harrisburg pa 17105-3608 for customer repair service, call 1-800-526-5136. 8. revision summary revisions to this instruction sheet include: ? changed company name and logo
item te part number description qty per as sy 1 904092-1 pawl, locating 1 2 23147-3 spring, compression 1 3 312149-1 adjuster, rod insertion 1 4 22488-5 spring, compression 1 5 904087-1 ram 1 6 2-22279-5 spring, compression 1 7 904093-1 rod, push 1 8 21003-1 screw, flat head cap, 0-80 x .12 1 9 1-23147-2 spring, compression 2 10 904086-1 clamp, wire guide 2 11 21949-1 pin, spiral wrapped 5 12 904129-1 block, wire 2 13 904085-1 guide, wire 1 14 1-21000-4 screw, socket head cap, 4-40 x .38 1 15 21028-2 pin, slotted spring 1 16 904084-1 block, inserter 1 17 1-21000-7 screw, socket head cap, 4-40 x .75 1 18 904083-1 head 1 408-4406 5 of 5 rev c figure 7
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