 Instruction Sheet

 408-7347
Insertion Tools 91002 and 91002-2 17 OCT 11 Rev A

Connector (Typ)

Tips
Insertion Tool

Handles
Wire Contact Wire

Figure 1

CAUTION To determine whether the insertion tool is needed in

an application, refer to the instruction sheet
1. INTRODUCTION ! packaged with the product or check with your local
TE representative.
This instruction sheet covers the use of insertion tools
91002-1 and 91002-2 which are designed to insert pin 3. INSERTION PROCEDURES (Figure 1)
and sockect contacts (which are crimped to small, fragile
wires) into connectors. Insert the contact as follows:
Read these instructions thoroughly before inserting 1. Place the insertion tool over the wire, with tool
any contacts. insertion tips behind the contact.

NOTE All dimensions on this instruction sheet are in 2. Squeeze tips together to hold the wire and
millimeters [with inch equivalents in brackets.] contact in position.
i 3. Align the contact with back of contact cavity in the
housing, and insert the contact into housing until it is
2. DESCRIPTION (Figure 1) fully seated.
This tweezer-shaped tool features two grooved NOTE Some contact cavities will not permit entry of the
insertion tips for grasping the wire connected to the tool tips. If the contact is not fully inserted, grasp
the wire further back from the contact and push the
contact and tool handles which assist in applying even
pressure to the insertion tips.
i contact in again until it is fully seated.
The tool is designed for 2.286 mm [.090-in.] maximum 4. Release pressure on tool tips and remove tool.
diameter insulation. but the tool can also be used with
other types of wire if caution is used during insertion.

© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 2
All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service,
*Trademark visit our website at www.te.com
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. LOC B
 408-7347

5. Pull back lightly on wire to make sure the contact is
locked in place.
4. TOOL INSPECTION
The tool listed in this instruction sheet should be 
inspected with the information provlded in Figure 2.
We recommend that you inspect the tool immediately
upon arrival in your factory and at regularly scheduled
intervals to ensure that the tooling has not been
damaged.

9.525 ± 3.175 [.375 ± .125]

7.9248 [.312]
76.2 [3.0]

44.45 
[1.75]
2.32 [.093]

Figure 2

5. REVISION SUMMARY
Revisions to this instruction sheet include:
• Changed company name and logo

Rev A 2 of 2