designed to terminate discrete wire in MTA--156 IDC
closed--end receptacle connectors with or without lock
(ramp) and with or without polarizing tabs. Slotted
contacts for insulation displacement termination are
pre--assembled on 3.96--mm [.156--in.] centerlines in
each color--coded housing for a specific wire size.
The head must be installed in Pistol Grip Manual
Handle Assembly 58074--1 or Pistol Grip Pneumatic
Handle Assembly 58075--1. For head installation and
removal, refer to Instruction Sheet 408--6790 for the
manual handle assembly and 408--6789 for the
pneumatic handle assembly.
For detailed connector description and application
requirements, refer to Application Specification
114--1020.
Read these and all referenced instructions thoroughly
before using the head.
NOTE
All numerical values in this instruction sheet are
in metric units [with U.S. customary units in
brackets]. Dimensions are in millimeters [and
inches]. Figures are not drawn to scale.
Wire Inserter
— forces the wire into the two slotted
beams of the contact. Note that it provides support for
the contact beams when applying insertion force on
the wire.
Adjuster (Insertion Rod)
— is a piston for the wire
inserter and regulates wire inserter travel.
Feed Slide
— automatically positions the connector
after each termination.
Locating Pawl (or Anti-
-Backup Pawl)
— aligns the
connector for insertion, and retains it during
termination.
3. SETUP AND TEST INSPECTION
The adjuster (insertion rod) is preset for wire sizes
26 through 18 AWG. If the wire is being inserted too
deeply or not deeply enough inside the contact, it may
be necessary to adjust the depth of the wire inserter
or, in addition, if the pneumatic handle assembly is
being used, it may be necessary to adjust the air
pressure. Proceed as follows:
3.1. Setup
1. Determine the wire size, and select the
appropriate color--coded connector from Figure 2.
WIRE SIZE (AWG)
26
24
22
20
18
Figure 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
i
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
CONNECTOR COLOR CODE
Blue
Natural
Red
Yellow
Orange
2. DESCRIPTION
The head serves as a guide and support for the
connector during termination. Features of the head
(shown in Figure 1) and their function are as follows.
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
1
of 5
LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
ORIGINAL INSTRUCTIONS
Mass Termination Assembly (MTA)--156
Insulation Displacement Contact (IDC)
Closed--End Receptacle Connectors
408- 6930
2. Using a small knife, cut off the wire retainers
(strain relief) of the connector. This will provide a
clear view for inspecting the connector for a
properly terminated wire in the contact. See
Figure 3.
CAUTION
Wire retainers are removed in a connector for
testing only. DO NOT use such connectors for
production application.
For the pneumatic handle assembly, if the wire is
inserted too deeply (more than the required wire
insertion depth), refer to Section 4, WIRE
INSERTION DEPTH ADJUSTMENT. If the wire is
not inserted deeply enough (less than the required
wire insertion depth), increase the air pressure by
69 kPa [10 psi]. Repeat the termination procedure
and check the insertion depth. Continue in this
manner until either the proper insertion depth is
obtained or the air pressure is set to 483 kPa
[70 psi]. If the proper insertion depth is NOT
reached at 483 kPa [70 psi], return the air pressure
to 276 kPa [40 psi], and refer to Section 4.
6. Inspect the termination according to
Paragraph 3.2.
!
3. Make a test termination according to Steps 1
through 5 of Section 5, TERMINATING
PROCEDURE.
4. Push the connector out of the right side of the
head.
5. Check that the wire insertion depth is within the
dimension given in Figure 3.
NOTE
To obtain the wire insertion depth, measure from
the front of the contact beam to the center of the
wire as shown in Figure 3 - or - measure from
the front of the contact beam to the back of the
wire and subtract the wire diameter divided by 2.
3.2. Termination Inspection
(Refer to Figure 3)
NOTE
Refer to 114--1020 for detailed explanation of the
termination inspection requirements.
i
i
If it is not, proceed as follows:
For the manual handle assembly, refer to
Section 4, WIRE INSERTION DEPTH
ADJUSTMENT.
1 — The required wire insertion depth is within the
dimension given in Figure 3 (refer to Step 5 of
Paragraph 3.1 for measurement).
2 — The end of the wire extends past the contact
beam by at least 1.52 mm [.060 in.].
Test Connector
Termination Inspection
Contact (Partially
Removed)
Production Connector
Wire
5
Wire Extends Past Wire
Retainer (Strain Relief)
Wire Insulation
Not Nicked or Cut
4
Lock
(Ramp, Ref)
Wire Retainer
(Strain Relief)
Removed
1
2.41+0.46/-- 0.13 mm [.095+.018/-- .005 in.]
Wire Insertion Depth
(Front of Contact Beam to Center of Wire)
Figure 3
2
1.52 mm [.060 in.] Min
End of Wire Extends Past
Contact Beam
3
Contact Beams
Not Deformed
2
of 5
Rev F
408- 6930
3 — The contact beams are NOT deformed. If
damage is apparent, replace the contacts in
accordance with the instructions packaged with the
connector.
4 — The wire insulation is NOT nicked or cut in
any area other than the two contact slots.
5 — The wire extends past the wire retainer (strain
relief) of the connector.
5. TERMINATING PROCEDURE
(Refer to Figure 5)
NOTE
There is no wire preparation required.
i
1. Insert the connector into the left side of the
head.
2. Align the contact to be terminated with the wire
inserter of the head (shown in Figure 1). Make sure
that the locating pawl rests between the connector
index ribs.
3. Insert an unstripped wire into the funnel area
between the contact and the wire inserter until it
bottoms on the tool base.
4. Squeeze the cam handle (manual) or depress
the trigger (pneumatic) of the handle assembly,
and hold it until the ratchet releases (manual) or
the wire inserter bottoms (pneumatic).
5. Release the cam handle or trigger. The wire
inserter will retract and the feed slide will
automatically advance the connector to the next
contact position.
NOTE
The locating pawl will move up and down as the
connector is automatically advanced through the
head. However, if movement is obstructed, or if
desired, the locating pawl can be depressed and
the connector moved manually out of the RIGHT
side of the head.
4. WIRE INSERTION DEPTH ADJUSTMENT
(See Figure 4)
1. Remove the head from the handle assembly.
2. If the wire is inserted too deeply (more than the
required wire insertion depth), reduce the wire
insertion depth by turning the adjuster
1
/
6
of a
revolution
clockwise.
The wire insertion depth will
be reduced by approximately 0.20 mm [.008 in.].
CAUTION
If the wire is bottomed in the contact slot, this
indicates that the adjuster is set to the maximum
wire insertion depth — DO NOT turn the adjuster
counterclockwise; otherwise damage to the head
may occur.
!
If the wire is not inserted deeply enough (less than
the required wire insertion depth), increase the wire
insertion depth by turning the adjuster
1
/
6
of a
revolution
counterclockwise.
The wire insertion
depth will be increased by approximately 0.20 mm
[.008 in.].
CAUTION
When turning the adjuster counterclockwise,
make sure to check the wire insertion depth after
EACH
1
/
6
revolution. If the adjuster is set past the
maximum setting, damage to the head may
occur.
Wire Insertion Depth Adjustment
i
!
6. Repeat Steps 2 through 5 until all contacts have
been terminated.
7. Inspect each termination according to
Paragraph 3.2.
6. MAINTENANCE AND INSPECTION
6.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
with a clean, soft brush or lint--free cloth. DO NOT
use objects that could damage the head.
2. Make sure that all components are in place and
properly secured.
3. Actuate the tool to make sure that the
mechanisms inside the head function smoothly.
Turn CLOCKWISE to
Reduce Wire Insertion Depth
Adjuster
Turn COUNTERCLOCKWISE to
Increase Wire Insertion Depth
DO NOT Turn Past Maximum Setting
Refer to CAUTION
Note:
1
/
6
Revolution Equals 0.20 mm [.008 in.] Adjustment
Figure 4
6.2. Periodic Maintenance
1. Remove any accumulated film with a suitable
cleaning agent that will not affect plastic.
2. Make sure all components are in place and
properly secured.
3. Check for chipped, cracked, worn, or broken
areas on the head. If damage is evident, repair or
replace the head.
Rev F
3
of 5
408- 6930
Locating
Pawl
Feed Slide
Wire
Index Rib of
Connector
Funnel Area
Pistol Grip Handle
Assembly (Manual Shown)
Tool Base
Left Side
of Head
Figure 5
6.3. Inspection
Regular inspections should be performed by quality
control personnel with a record of quality control
inspections remaining with the personnel responsible
for the head. One inspection per month is the
recommended frequency; however, operator training
and skill, amount of use, working conditions, and
established company standards are all factors to be
considered in establishing inspection frequency.
quality and reliability. Order replacement parts
through your representative, or call 1--800--526--5142,
or send a facsimile of your purchase order to
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.
7. REPLACEMENT AND REPAIR
Customer--replaceable parts are listed in Figure 6.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
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