Instruction Sheet Modular Plug Hand Tools 408-9767 (Premium Grade) 231652- 12 JUN 14 Rev R 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 extended-use, production operations is available. 1. INTRODUCTION 2. DESCRIPTION (FIgure1) Modular Plug Hand Tools 231652- (shown in The die set consists of a nest and an indenter, each Figure 1) are designed to terminate modular plug marked with a color-code dot. The die set is held in the connectors onto stranded or solid, shielded or tool by a single die-holding screw. Each die set is unshielded flat oval cable or round cable. The tool also unique to its purpose, but die sets can be cuts and strips unshielded flat oval cable. Other cable interchanged to accommodate any modular plug. must be prepared by separate tools. Refer to Figure 2. Each tool includes Die Set (853400- ) (see Figure 2), The tool features a wire cutter and flat oval cable except Tool 2-231652-0 which is available without a stripper to prepare unshielded flat oval cable. The tool die set. The die sets are also available separately. handle ensures full crimping. Once engaged, the ratchet will not release until the handles have been All numerical values in this instruction sheet are in NOTE FULLY closed, unless the ratchet release (pawl) is metric units with U.S. customary units in brackets . depressed to manually release the ratchet. When Dimensions are in millimeters and inches . Figures depressed, the pawl prevents crimping of an i are not drawn to scale. improperly positioned modular plug. Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY. DIE SET TOOL PART COLOR DESCRIPTION NUMBER CODE DOT (Modular Plug Type) Nest (Die) 8-Position Line Die Holding Color Code Dot Indenter (Die) Blue (Small Conductor) Screw 2-231652-1 0-853400-1 Black Color Code Dot Keyed, Non-Keyed Shielded 4-Position 2-231652-3 0-853400-3 Green Handset Ratchet 6-Position 2-231652-6 0-853400-6 Orange Cable Cutter Offset Latch 6-Position 2-231652-7 0-853400-7 Violet Long Body 2-, 4-, 6-Position Line 2-231652-8 0-853400-8 Blue Blue (Small Conductor) 8-Position 3-231652-0 1-853400-0 White High Performance Flat Oval 8-Position Line Cable 3-231652-5 1-853400-3 Red Blue (Small Conductor) Stripper Non-Keyed Ratchet 8-Position Slimline Release 3-231652-6 1-853400-4 Gray Category 6/6A (Pawl) The BLACK color-coded tool and die set can be used for non-keyed modular plugs however, the RED color-coded tool and die set are Handle more durable when crimping non-keyed modular plugs. Includes 2119000-1 JacKnack Tool (408-10326). Figure 2 DO NOT cycle the tool CAUTION without a die in place The dies bottom before the ratchet releases. This CAUTION otherwise, damage to the feature ensures maximum electrical and tensile . stripping blades may occur performance of the crimp. DO NOT re-adjust the ratchet. Figure 1 2014 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 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. ORIGINAL INSTRUCTIONS408-9767 3. CABLE PREPARATION Proceed as follows: Refer to Figure 3, and select the appropriate cable and 3.1. Unshielded Flat Oval Cable (Figure 4) die set for the modular plug being used. 1. Insert cable squarely into CUT slot in tool cable cutter. Squeeze handles until ratchet releases. MODULAR PLUG CABLE DIE SET COLOR 2. Insert trimmed cable into STRIP slot in tool flat POSITION TYPE TYPE STYLE CODE DOT oval cable stripper until cable butts against die cable stop. 2 Line Stranded Flat Oval Blue 3. Close handles to last ratchet stop, but DO NOT Solid release them. Pull cable straight out of tool. Then Handset Flat Oval Green Stranded release tool handles. 4 Line Stranded DO NOT squeeze handles together while pulling NOTE Flat Oval Blue cable out. Rather, with handles closed (but not Blue Solid released) grip head of tool in one hand and cable in i Solid Round the other then pull cable straight out of tool. Line Blue Stranded Flat Oval 4. Check cable strip length as shown in Figure 4. Blue Solid Flat Oval Blue 3.2. Shielded Flat Oval Cable and Round Cable Offset Latch Solid Flat Oval Orange 6 Prepare the cable according to Application Solid Flat Oval Long Body Specification 114-6016. Violet Unshielded Stranded Round 3.3. High Performance Cable Long Body Stranded Flat Oval Violet Shielded Prepare the cable according to Application Specification 114-6053. Stranded Round DO NOT cut or remove insulation from individual Solid NOTE conductors. This may result in shorted or open Unshielded Flat Oval Stranded terminations within the terminated assembly. i Solid Round Black 8 Blue Solid Flat Oval 4. TERMINATION PROCEDURE Keyed, Before proceeding, make sure that the cable and Stranded Flat Oval Non-Keyed modular plug are compatible, and that cable polarity is correctly maintained for the specific application. Shielded Stranded Round Non-Keyed Stranded Flat Oval Red Before proceeding with high performance modular plugs, refer to 114-6053 for preparation techniques to Stranded ensure high performance levels. Unshielded 8 Solid Refer to Figure 5, and proceed as follows: (High Round White Stranded Performance) Shielded 1. Hold modular plug as shown (locking latch facing Solid UP). Insert cable into modular plug until fully bottomed. Stranded Unshielded 2. Open tool handles. Insert modular plug assembly Solid 8 Round Red fully into die cavity. When using a die set color (Slimline) Stranded coded with green, orange, or blue, make sure that Shielded Solid the modular plug locking latch snaps into position. When using a die set color coded with black, violet, The BLACK color-coded tool and die set can be used for non-keyed or white, make sure that the modular plug bottoms modular plugs however, the RED color-coded tool and die set are more in the die cavity but the locking latch does not snap durable when crimping non-keyed modular plugs. into position. Standard modular plugs are designed to be used with cable having an outside diameter of 0.89 to 0.99 mm .035 to .039 in Use blue (small Failure to fully seat the modular plug assembly in CAUTION conductor) modular plugs with cable having an outside diameter of 0.74 to the die cavity will cause the indenter to mis-align 0.86 mm .029 to .034 in with the internal strain reliefs of the modular plug, Figure 3 which may result in damage to the die set. 3. Hold the modular plug in the fully seated position, and squeeze tool handles until ratchet releases. Rev R 2 of 6