TE Connectivity 58644- 2 User manual

Instruction Sheet
Ribbon Cable Mass Insertion Terminating Head
58644- 2 for MTA (Mass Termination Assembly) 408--4440
1of 5
.2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
TOOLING ASSI STANCE 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
26 SEP 12 Rev B100 Feed- Through Receptacle Connectors
Figure 1
Insertion Rod
Adjuster
Push Rod
Ram
Wire Guide
Locating Pawl
(Hidden)
Wire Inserter
1. INTRODUCTION
Mass Insertion Terminating Head 58644--2, shown in
Figure 1, is designed to terminate MTA 100
feed--through receptacle connectors (positions 2
through 12) onto notched ribbon cable 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.
This head is designed to terminate one connector
at a time.
A complete list of current connector part numbers
cannot be maintained on this document. For all
part numbers 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
Assembly 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.
Dimensions on this sheet are in metric units [with
U.S. customary units in brackets]. Figures are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
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
follows:
Wire Inserter—supports 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—positions the ribbon cable over the wire
inserter.
Ram—locates and holds the connector while pushing
it down onto the wires.
Locating Pawl—holds 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.
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.
NOTE
i
NOTE
i
NOTE
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408- 4440
Rev B2 of 5
WIRE SIZE MTA 100 FEED--THROUGH RECEPTACLE CONNECTORS (With Locking Ramp)0
W
I
R
E
S
I
Z
E
(AWG) COLOR CODE WITH POLARIZING TABS WITHOUT POLARIZING TABS
28 Red 644540 640620
26 White 644563 640621
24 Blue 644564 640622
22 Green 644565 640623
Figure 2
0Dash numbers indicate number of contact positions (--2 through --12
are applicable for this terminating head).
The board must have two 6.36--mm [.250--in.] holes
spaced 44.45 mm [1.75 in.] apart for each head.
Secure each head with screws. See Figure 3.
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 sides of the test connector.
SeeFigure5.
Figure 3
Installing Head As
Harness Board Fixture
Handle
Assembly
(Ref)
Wire retainers must be removed from test
connectors to provide a clear 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.
4. TERMINATING PROCEDURE
1. Position the pre--notched ribbon cable so that
the first conductor goes into the wire guide slot
closest to the head frame. See Figure 6. (See
Figure 4 for ribbon cable limits and minimum notch
length.)
Figure 4
19.05 [.750]
Min.
Notch Length
2.54 [.100]
Typ.
1.63 [.064]
Typ. (Max.)
After Notching
1.27 [.050]
Dia (Max.)
For Mass Terminating
Insulation
Web
Conductor
NOTE
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NOTE
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408- 4440
3of 5Rev B
Figure 5
Terminated Test Connector Terminated Production Connector
Contact Partially
Removed for
Inspection
Wire Retainers Removed
(Both Sides)
Contact
Slot
Lead--In
Transition
No Deformation
of Contact Beam
No Cuts
in Conductor
2. Insert the connector into the ram with the
contact insulation barrels facing the wire slots.
3. Using a screwdriver (or equivalent), push the
connector into the ram until the connector touches
the surface of the frame. Refer to Figure 6.
To ensure proper alignment in the head, all
connector positions must touch the surface of the
head frame.
4. Actuate the handle assembly according to the
instructions packaged with the handle assembly.
After the ram completes the stroke, no
conductors should be left in the wire slots. If any
conductors 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 locating pawl in the ram.
Then grip the ribbon cable on both sides of the
connector and carefully guide the connector out of
the ram.
6. Refer to Figure 5 and visually inspect the
connector according to the following. If wire
insertion depth is found to be improper, refer to
Section 5 for head adjustments.
Wire insulation tends to return to form after being
compressed. It is important to inspect the
connector within five minutes of termination;
otherwise, an improper inspection may result.
:Conductors are terminated past the lead--in
transition and halfway into the contact slot.
:Conductors are not bottomed in contact slots.
:Insulation is not nicked 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 packaged with the
connector.
:Conductor extends below the connector wire
retainers.
For detailed inspection information, refer to
Application Specification 114--1019.
Figure 6
Ram
Handle
Assembly
(Ref)
First
Conductor Surface of Head
Frame (Connector
Must Start Here)
NOTE
i
CAUTION
!
CAUTION
!
NOTE
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408- 4440
Rev B4 of 5
5. INSERTION DEPTH 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.
2. If the conductors 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
conductors 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 7.
3. Install the head onto the handle assembly; then
terminate 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.
Figure 7
Insertion Rod
Adjuster
Clockwise to
Decrease
Counterclockwise
to Increase
Head Removed from
Handle Assembly
Wire Insertion Depth
6. MAINTENANCE AND INSPECTION
TE Connectivity 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
components are in place and secure.
3. When head is not in use, store it in a clean, dry
area.
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
immersing the head in a suitable commercial
degreaser that will not affect paint or plastic.
2. Make certain all components are in place. If
replacements are necessary, refer to Section 7.
3. Check all bearing surfaces for wear. Replace
worn or damaged parts.
4. Inspect the head for flattened, chipped, or
broken surfaces. Replace worn or damaged parts.
7. REPLACEMENT AND REPAIR
Replacement parts are listed in Figure 8. A complete
inventory can be stocked and controlled to prevent
lost time when 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 (38--35)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
For tool repair service, please contact a TE
representative at 1--800--526--5136.
8. REVISION SUMMARY
Since the previous version of this document, the
following changes were made:
:Updated document to corporate requirements

408- 4440
5of 5Rev B
Section A--A
Section B--B
AA
B
B
2 1 9
10
12 11
5 4 3
7
6
8
15
16
13
14
ITEM PART NUMBER DESCRIPTION QTY PER HEAD
1904092--1 PAWL, Locating 1
223147--3 SPRING, Compression 1
3312149--1 ADJUSTER, Rod Insertion 1
422488--5 SPRING, Compression 1
5904087--1 RAM 1
62--22279--5 SPRING, Compression 1
7904093--1 ROD, Push 1
821003--1 SCREW, Flat Head Cap, 0--80 x .12 1
921949--1 PIN, Spiral Wrapped 1
10 904129--1 BLOCK, Wire 2
11 904935--1 GUIDE, Wire 1
12 1--21000--4 SCREW, Socket Head Cap, 4--40 x .38 1
13 21028--2 PIN, Slotted Spring 1
14 904084--1 BLOCK, Inserter 1
15 1--21000--7 SCREW, Socket Head Cap, 4--40 x .75 1
16 904083--1 HEAD 1
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