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- CABLE PREPARATION Refer to Figure 3, and select the appropriate cable and die set for the modular plug being used. 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 more durable when crimping non-keyed modular plugs. Standard modular plugs are designed to be used with cable having an conductor) modular plugs with cable having an outside diameter of 0.74 to Figure 3 Proceed as follows: 3.1. Unshielded Flat Oval Cable (Figure 4) 1. Insert cable squarely into CUT slot in tool cable cutter. Squeeze handles until ratchet releases. 2. Insert trimmed cable into STRIP slot in tool flat oval cable stripper until cable butts against die cable stop. 3. Close handles to last ratchet stop, but DO NOT release them. Pull cable straight out of tool. Then release tool handles. DO NOT squeeze handles together while pulling cable out. Rather, with handles closed (but not released) grip head of tool in one hand and cable in the other; then pull cable straight out of tool. 4. Check cable strip length as shown in Figure 4. 3.2. Shielded Flat Oval Cable and Round Cable Prepare the cable according to Application Specification 114-6016. 3.3. High Performance Cable Prepare the cable according to Application Specification 114-6053. DO NOT cut or remove insulation from individual conductors. This may result in shorted or open terminations within the terminated assembly. 4. TERMINATION PROCEDURE Before proceeding, make sure that the cable and modular plug are compatible, and that cable polarity is correctly maintained for the specific application. Before proceeding with high performance modular plugs, refer to 114-6053 for preparation techniques to ensure high performance levels. Refer to Figure 5, and proceed as follows: 1. Hold modular plug as shown (locking latch facing UP). Insert cable into modular plug until fully bottomed. 2. Open tool handles. Insert modular plug assembly fully into die cavity. When using a die set color coded with green, orange, or blue, make sure that the modular plug locking latch snaps into position. When using a die set color coded with black, violet, or white, make sure that the modular plug bottoms in the die cavity but the locking latch does not snap into position. Failure to fully seat the modular plug assembly in the die cavity will cause the indenter to mis-align with the internal strain reliefs of the modular plug, 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. MODULAR PLUG CABLE DIE SET COLOR CODE DOTPOSITION TYPE TYPE STYLE
2 Line Stranded Flat Oval Blue
Offset Latch Solid Flat Oval Orange Long Body Unshielded Solid Flat Oval Violet Stranded Round Long Body Shielded Stranded Flat Oval Violet Unshielded Stranded Round Black Solid Flat Oval Stranded Solid Round Blue Solid Flat Oval Keyed, Non-Keyed Stranded Flat Oval Shielded Stranded Round Non-Keyed Stranded Flat Oval Red (High Performance) Unshielded Stranded Round White Solid Shielded Stranded Solid (Slimline) Unshielded Stranded Round Red Solid Shielded Stranded Solid NOTE i NOTE i CAUTION
- MAINTENANCE AND INSPECTION Inspect the tool and die set immediately upon arrival at your facility and at regularly scheduled intervals thereafter to ensure that they have not been damaged. When not in use, store the tool with the handles closed in a clean, dry area. Failure to perform daily maintenance and periodic inspection can cause defective modular plug terminations leading to discontinuities on individual wire circuits. 6.1. Daily Maintenance Foreign particles should be cleaned from the tool using a soft, clean, lint-free cloth or brush. Make sure all pins, rings and other retaining hardware is in place, and that the die set is undamaged. Lightly lubricate all pins, pivot points, and bearing surfaces using a good grade SAE 20 motor oil. DO NOT lubricate excessively. DO NOT lubricate surfaces of the die set that contact the product. These areas must be kept clean to ensure a usable modular plug assembly. 6.2. Periodic Inspection It is recommended that the following inspections be conducted at least once a month by quality control personnel. More frequent inspections should be conducted if your work environment, company standards, or amount of tool use indicates the need. A. Visual Inspection 1. Remove the die set from the tool, then remove all lubrication, accumulated film, and debris by immersing the dies and tool head in a mild commercial degreaser. 2. Check for missing or defective pins, rings, or other retaining hardware. Replace parts as necessary. 3. Closely inspect dies for damage, giving special attention to bearing surfaces and surfaces that contact the product. Worn, cracked, pitted, or chipped indenter or nest surfaces, or other obvious wear or damage to the die set or tool head requires removal of the affected part from service. B. Die Closure Inspection The tool and die set is inspected for proper operation before shipment. To ensure uniform performance over the life of the tool, periodically inspect as follows: 1. Insert a properly stripped cable of appropriate type and size into a sample modular plug. Then insert the unterminated cable and plug into the die cavity. 2. Squeeze tool handles together slowly, while watching to ensure indenter bottoms against nest. 3. Release the handles to open the die set, and remove the terminated modular plug assembly. 4. Test the crimp for proper crimp height according to Step 4 in Section 4. If the plug crimp height is within acceptable limits, lightly lubricate the tool and die set. If the crimp height is not within acceptable limits, return the tool (with die set) for evaluation (refer to Section 7). 7. REPLACEMENT AND REPAIR Customer-replaceable parts are provided in Figure 9. A blade replacement kit and hand tool kits are available separately. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is necessary. 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 Adjusting Flat Oval Cable Stripper Movable Blade Assembly Screw (2 Places) Die Set Must Be Installed in Tool Blade Set-Up Gage (Ref) Replacing Blades in Flat Oval Cable Stripper 6.4 [.25] (Length) Screw (2 Places) Fixed Blade Assembly Beveled Edges of Blades Face Inward Movable Blade Assembly Fixed Blade Support Plate Cable (Ref) Movable Blade Support Plate 9.7 [.38] (Length) Screw (2 Places) CAUTION: DO NOT cycle the tool without the die set in place; otherwise, damage to the stripping blades may occur. CAUTION CAUTION
For tool evaluation and customer repair service, call 1-800-526-5136. 8. REVISION SUMMARY Revisions to this instruction sheet include:
- Updated tables in Figures 2 and 9 Available separately: Figure 9 ITEM PART NUMBER DESCRIPTION QTY PER TOOL 1 993314-1 SCREW, Pan Head (Die Holding) 4-40 x .250 Long 1 2 4-23619-8 PIN, Grooved 2 3 21045-3 RING, Retaining, Crescent 4 4 2-23620-5 PIN, Center, Straight 1 5 21045-6 RING, Retaining, Crescent 2 6 853400-[ ] † DIE SET 1 7 2-231652-0 TOOL ASSEMBLY FRAME (Without Die Set) 1 8 21045-1 RING, Retaining, Crescent 2 9 768522-1 PIN, Handle (Pawl) 2 100 231662-4 BLADE REPLACEMENT KIT 1 † Refer to Figure 2 for cross-reference of tool-to-die set part numbers. PART NUMBER DESCRIPTION 0-231662-4 BLADE REPLACEMENT KIT — Blade Set-Up Gage, 4 Pan Head Screws, 1 Cutter Blade Screw, 5 Wire Cutter Blades,
5 Fixed Blade Holders, 5 Slider Blade Assemblies
0-231666-9 HAND TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head Screws, and 2119000-1 JacKnack Tool 1-231666-0 HAND TOOL KIT — Same items as in Kit 231666-9 and: Modular Plug Hand Tool and the following Die Sets: 4-Position Line, 6-Position Line, and 8-Position 1-231666-1 HAND TOOL KIT — Same items as in Kit 231666-9 and: Modular Plug Hand Tool and the following Die Sets: 4-Position Line, 6-Position Line, 8-Position, and 4-Position Handset 1-231666-5 HAND TOOL KIT — Same items as in Kit 231666-9 and: Modular Plug Hand Tool and the following Die Sets: 4-Position Handset, 4-Position Line,6-Position Line, 8-Position, and 8-Position High Performance