Instruction Sheet Modular Plug Hand Tool 4089767 (Premium Grade) 231652 07 JUN 02 Rev H 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 extendeduse, production operations is available. 1. INTRODUCTION Read and understand this instruction sheet before using the tool. For information on the modular Modular Plug Hand Tool (Premium Grade) 231652 interconnection system, see Catalog 82066. (shown in Figure 1) is designed to terminate modular Reasons for reissue of this instruction sheet are plug connectors onto stranded or solid, shielded or provided in Section 8, REVISION SUMMARY. unshielded flat oval cable or round cable. The tool also cuts and strips unshielded flat oval cable other cable must be prepared by separate tools. 2. DESCRIPTION (Figure 1) Each tool includes Die Set 853400 (see Figure 2), The die set consists of a nest and an indenter, each except Tool 22316520 which is available without a marked with a color code dot. The die set is held in die set. The die sets are also available separately. the tool by a single die holding screw. Each die set is unique to its purpose, but die sets can be Dimensions in this instruction sheet are in interchanged to accommodate any modular plug. NOTE millimeters with inches in brackets . Refer to Figure 2. The tool features a wire cutter and flat oval cable Die Holding stripper to prepare unshielded flat oval cable. The tool Screw handle ensures full crimping. Once engaged, the Nest (Die) Indenter (Die) ratchet will not release until the handles have been Color Code Dot Color Code Dot FULLY closed, unless the ratchet release (pawl) is Cable depressed to manually release the ratchet. When Cutter depressed, the pawl prevents crimping of an improperly positioned modular plug. The dies bottom before the ratchet releases. CAUTION This feature ensures maximum electrical and tensile performance of the crimp. DO NOT Ratchet readjust the ratchet. Flat Oval Cable CORRESPONDING DIE SET Stripper COLOR DESCRIPTION TOOOOL PART CODE (Modular Plug NUMBER DOT Type) 8Position 22316521 Line, Blue (Small 8534001 Black Conductor), Keyed, 22316522 Shielded Ratchet 22316523 8534003 Green 4Position Handset Release (Pawl) 6Position 22316526 8534006 Orange Offset Latch 6Position 22316527 8534007 Violet Long Body 2, 4, 6Position Handle 22316528 8534008 Blue Line, Blue (Small 22316524 Conductor) DO NOT cycle the tool without a CAUTION 32316520 8Position 18534000 White die in place otherwise, damage High Performance 32316521 to the stripping blades may occur. Same as preceding tool except packaged in clamshell for retail display. Figure 1 Figure 2 2002 Tyco Electronics Corporation, Harrisburg, PA. This controlled document is subject to change. TOOLING ASSISTANCE CENTER 18007221111 1 of 7 For latest revision call the AMP FAX* number. AMP FAX/PRODUCT INFO 18005226752 All International Rights Reserved. AMP and Tyco are trademarks. For Regional Customer Service, visit our website at LOC B *Trademark www.tycoelectronics.comModular Plug Hand Tool (Premium Grade) 231652 4089767 DO NOT squeeze handles together while pulling 3. CABLE PREPARATION NOTE cable out. Rather, with handles closed (but not Refer to Figure 3, and select the appropriate cable released) grip head of tool in one hand and cable and die set for the modular plug being used. Then in the other then pull cable straight out of tool. proceed as follows: 4. Check cable strip length as shown in Figure 4. 3.1. Unshielded Flat Oval Cable (Figure 4) 3.2. Shielded Flat Oval Cable and Round Cable 1. Insert cable squarely into CUT slot in tool cable Prepare the cable according to Application cutter. Squeeze handles until ratchet releases. Specification 1146016. 2. Insert trimmed cable into STRIP slot in tool flat 3.3. High Performance Cable oval cable stripper until cable butts against die Prepare the cable according to Application cable stop. Specification 1146053. 3. Close handles to last ratchet stop, but DO NOT DO NOT cut or remove insulation from individual CAUTION release them. Pull cable straight out of tool. Then conductors. This may result in shorted or open release tool handles. terminations within the terminated assembly. MODULAR PLUG CABLE DIEEE SET COLOR CODE DOTCO OR CO E O POSITION TYPE PART NUMBER TYPE STYLE 2 Line 56413332 Stranded Flat Oval Blue Handset 55562002 Solid Flat OOval GGreen Handset 56413342 Stranded 444 Line 56413352 Stranded Flat OOval Blue Blue (Small Conductor) 55579652 Solid Line 55690322 Solid Round Line 56413372 Stranded Blue Flat OOval Blue (Small Conductor) 55579702 Solid 6 Offset Latch 55552362 Solid Flat Oval Orange Long Body 55554262 Solid Flat Oval Long Body 55551772 Stranded Round VViolet Long Body (Shielded) 55551742 Stranded Flat Oval Line 55541692 Stranded Round Line 55547202 Solid Flat OOval Line 55547392 Stranded Line 55573152 Solid Round 8 Black Blue (Small Conductor) 55579722 Solid Keyed 55547432 Stranded Flat OOval Keyed 55554172 Solid Shielded 55695322 Stranded Round Line 55585302 Stranded Line 55692782 Solid 8 Round WWWhite (High Performance) Shielded 55695502 Solid Shielded 55695522 Stranded Standard modular plugs are designed to be used with cable having an outside diameter of 0.89 to 0.99 .035 to .039 . Use blue (small conductor) modular plugs with cable having an outside diameter of 0.74 to 0.86 .029 to .034 . Figure 3 2 of 7 Rev H