Tyco Electronics 2-231652-1 Bedienungsanleitung

Instruction Sheet

Modular Plug Hand Tools 408--9767

LOC B

1of 7

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1--800--722--1111

PRODUCT INFORMATION 1--800--522--6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

22 JUL 09 Rev L(Premium Grade) 231652- [ ]

PROPER USE GUIDELINES

Cumulative Trauma Disorders can result from the prolonged use ofmanually 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

Modular Plug Hand Tools 231652--[ ] (shown in

Figure 1) are designed to terminate modular plug

connectors onto stranded or solid, shielded or

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.

Each tool includes Die Set 853400--[ ] (see Figure 2),

except Tool 2--231652--0 which is available without a

die set. The die sets are also available separately.

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.

Figure 1

Cable

Cutter

Indenter (Die)

Color Code Dot

Flat

Oval

Cable

Stripper

Die

Holding

Screw

Nest (Die)

Color Code

Dot

Ratchet

Release

(Pawl)

Handle

DO NOT cycle the tool

without a die in place;

otherwise, damage to the

stripping blades may occur.

CAUTION

Reasons for reissue of this instruction sheet are

provided in Section 8, REVISION SUMMARY.

2. DESCRIPTION (Figure 1)

The die set consists of a nest and an indenter, each

marked with a color code dot. The die set is held in

the tool by a single die holding screw. Each die set

is unique to its purpose, but die sets can be

interchanged to accommodate any modular plug.

RefertoFigure2.

The tool features a wire cutter and flat oval cable

stripper to prepare unshielded flat oval cable. The tool

handle ensures full crimping. Once engaged, the

ratchet will not release until the handles have been

FULLY closed, unless the ratchet release (pawl) is

depressed to manually release the ratchet. When

depressed, the pawl prevents crimping of an

improperly positioned modular plug.

CORRESPONDING DIE SET

TOOL PART

NUMBER

COLOR

CODE

DOT

DESCRIPTION

(Modular Plug

Type)

2--231652--1 853400--1 Black

8--Position

Line, Blue (Small

Conductor), Keyed,

Non--KeyedG,

Shielded

2--231652--3 853400--3 Green 4--Position Handset

2--231652--6 853400--6 Orange 6--Position

Offset Latch

2--231652--7 853400--7 Violet 6--Position

Long Body

2--231652--8 853400--8 Blue

2--, 4--, 6--Position

Line, Blue (Small

Conductor)

3--231652--0 1--853400--0 White 8--Position

High Performance

3--231652--5 1--853400--3 Red

8--Position

Line, Blue (Small

Conductor),

Non--KeyedG

3--231652--6 1--853400--4 Gray 8--Position Slimline

Cat6/6A

GThe 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.

Figure 2

NOTE

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408- 9767

Modular Plug Hand Tools (Premium Grade) 231652- [ ]

Rev L2 of 7 Tyco Electronics Corporation

The dies bottom before the ratchet releases.

This feature ensures maximum electrical and

tensile performance of the crimp. DO NOT

re--adjust the ratchet.

3. CABLE PREPARATION

Refer to Figure 3, and select the appropriate cable

and die set for the modular plug being used. Then

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 with the termination procedure,

check to make sure that the cable and modular plug

are compatible, and that cable polarity is correctly

maintained for the specific application.

Before proceeding with the termination procedure for

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.

MODULAR PLUG CABLEDDIE SET

COLOR

POSITION TYPEDTYPE STYLE

CODE

DOT

2Line Stranded Flat Oval Blue

Solid

Handset Stranded Flat Oval Green

4Line Stranded

Blue Solid Flat Oval Blue

Solid Round

Line Stranded

Blue

Blue Solid Flat Oval

Offset Latch Solid Flat Oval Orange

Lon

Bod

Solid Flat Oval

Unshielded Stranded Round

Long Body

Shielded Stranded Flat Oval

Stranded Round

Solid

Unshielded Stranded Flat Oval

Solid Round

8Blue Solid

Keyed,

Non--Keyed Stranded Flat Oval

Shielded Stranded Round

Non--Keyed Stranded Flat Oval RedG

Stranded

(

Unshielded Solid

(High

Per

ormance

)

Solid Round White

)

Shielded Stranded

Stranded

Unshielded Solid

8 Slimline

Stranded Round Gray

Shielded Solid

DStandard 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 conductor) modular plugs with cable having an outside

diameter of 0.74 to 0.86 mm [.029 to .034 in.].

GRefertoNote(G) at the bottom of Figure 2.

Figure 3

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.

CAUTION

NOTE

CAUTION

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408- 9767

Modular Plug Hand Tools (Premium Grade) 231652- [ ]

3of 7Rev LTyco Electronics Corporation

Figure 4

Unshielded Flat

Oval Cable

CUT Slot

Step 1

Cutt

dSt

ded

Step 2

STRIP Slot

Step 3

Handles Closed

Die Cable

Stop

Cable Strip Length

12.7--14.3 [.50--.56] (Ref)

Step 4

Note: Not to Scale

Figure 5

Modular Plug

Locking Latch

Cable Bottomed

in Modular Plug

odu

Step 1

Step 2

Step 3

Die

Cavity Modular Plug

Oriented as Shown

on Side of Tool Head

Modular Plug in

Fully Seated Position

Illustrations for termination procedure show

line modular plugs. Illustrations for other

types of modular plugs would be similar.

NOTE

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408- 9767

Modular Plug Hand Tools (Premium Grade) 231652- [ ]

Rev L4 of 7 Tyco Electronics Corporation

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.

When crimping, make sure to hold the modular

plug in the fully seated position to prevent the

modular plug from pushing out during the

termination procedure.

4. Depress the modular plug locking latch (if

applicable), and remove terminated modular plug

assembly from the tool.

5. Inspect the modular plug assembly for proper

crimp height using a dial indicator or digital

indicator with needle--point probes or Crimp Height

Gage 904170--1 according to 408--4389. Figure 6

shows a cross--section of a typical terminated

modular plug, proper crimp height dimension, and

required location of the conductors. A visual

inspection through the plastic housing of the

modular plug should reveal whether the conductors

are within acceptable range.

For specific information concerning inspection

requirements, refer to 114--6016 for standard and

blue (small conductor) modular plugs and

114--6053 for high performance modular plugs.

Terminated Modular Plug Inspection

6.02+0.13 [.237+.005]

Crimp Height

Cross--Section of Crimped Modular Plug

Terminal

A (See Table)B

(See Table) Note: Not to Scale

CONDUCTOR LOCATION

MODULAR PLUG

TYPE A

(Reference Zone)

(Preferred)

Standard and Blue

(Small Conductor)

0.00--0.64

[.000--.025] Conductors

ainst

High Performance 0.00--0.25

[.000--.010]

End of Wire Circuits

Figure 6

Once a termination has been made, DO NOT

re--terminate the modular plug. Replace damaged

modular plugs with new ones.

Crimp Height Gage 904170--1 is available to be

used as a quick verification of acceptable crimp

height as shown in Figure 7. Refer to 408--4389

for instructions on using the gage.

Note: The gage cannot be used for 4--position

handset and 6--position offset modular plugs.

Figure 7

Crimp Height

Gage (Ref)

Modular Plug

(See NOTE)

Checking Crimp Height

5. ADJUSTMENTS

5.1. Installing, Replacing, or Changing Die Set

1. Squeeze tool handles until ratchet releases.

2. Using a small flat blade screwdriver or

cross--recessed screwdriver, remove the die

holding screw (turn the screw counterclockwise).

3. Using the screwdriver, push the die set out of

the tool.

4. Insert the die set with the color dots facing

outward as shown in Figure 1.

5. Close the tool handles. Re--install the die

holding screw (turn the screw clockwise until tight).

5.2. Adjusting Flat Oval Cable Stripper (Figure 8)

If cable jacket is cut too shallow and does not strip

properly from the conductor bundle or if it is cut too

deeply and conductor insulation is also cut, adjust the

flat oval cable stripper on the tool according to the

following.

The die set must be in the tool when adjusting

the flat oval cable stripper.

1. Close tool handles until the dies bottom, but DO

NOT release the handles.

2. Loosen the two screws that hold the movable

blade assembly.

CAUTION

NOTE

CAUTION

NOTE

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408- 9767

Modular Plug Hand Tools (Premium Grade) 231652- [ ]

5of 7Rev LTyco Electronics Corporation

3. Insert Blade Set--Up Gage 231667--2 (available

separately and part of Blade Replacement Kit

231662--4) or a 1.02--mm [.040--in.] shim between

the stationary and movable blades. Slide the

movable blade against the gage or shim, and

tighten the screws.

The recommended shim thickness does not

account for larger than normal conductor

insulation. Adjust the blade gap according to your

specific needs.

Blade Set--Up

Gage (Ref)

Movable Blade

Assembly

Screw

(2 Places)

Adjusting Flat Oval Cable Stripper

Figure 8

6.4 [.25] (Length) Screw (2 Places)

Fixed Blade

Support Plate

Cable (Ref)

Movable Blade

Support Plate

9.7 [.38] (Length)

Screws (2 Places)

Movable Blade

Assembly

Beveled Edges

of Blades Face

Inward

Fixed Blade

Assembly

Replacing Blades in Flat Oval Cable Stripper

Die Set Must Be

InstalledinTool

CAUTION: DO NOT cycle the tool without a die in place.

5.3. Replacing Flat Oval Cable Stripper Blades (Figure 8)

If the flat oval cable stripper blades are worn or

damaged, replace the fixed blade assembly and

movable blade assembly according to the following.

1. Remove the four screws holding both blades in

place. Remove fixed blade assembly and movable

blade assembly from tool.

2. Position new blades onto tool with beveled

edges facing inward.

3. Install and tighten screws. Adjust flat oval cable

stripper according to Paragraph 5.2.

DO NOT cycle the tool without a die in place;

otherwise, damage to the stripping blades may

occur.

6. 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 tool with 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

Remove die set from the tool; then, remove all

lubrication and accumulated film and debris by

immersing the dies and tool head in a mild

commercial degreaser.

1. Check for missing or defective pins, rings, or

other retaining hardware. Replace parts as

necessary.

2. 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.

NOTE

CAUTION

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408- 9767

Modular Plug Hand Tools (Premium Grade) 231652- [ ]

Rev L6 of 7 Tyco Electronics Corporation

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 handles to open die set, and remove

terminated modular plug assembly.

4. Test for proper crimp height according to

Section 4, Step 4. If plug crimp height is within

acceptable limits, lightly lubricate the tool and die

set, and place it back into service. 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. The blade replacement kit and hand tool kits

are available separately. Refer to Figure 10 for a

description of each. 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

69.8 [2.75]

(Handles

Closed)

30.5 [1.20] 197 [7.75]

18 9 7

Weight: .3 kg [.75 lb] (Approx)

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

1993314--1 SCREW, Pan Head (Die Holding), 4--40¢.250 L 1

24--23619--8 PIN, Grooved 2

321045--3 RING, Retaining, Crescent 4

42--23620--5 PIN, Center, Straight 1

521045--6 RING, Retaining, Crescent 2

6853400--[ ]YDIE SET 1

72--231652--0 TOOL ASSEMBLY (Frame Without Die Set) 1

821045--1 RING, Retaining, Crescent 2

9768522--1 PIN, Handle (Pawl) 2

10 231662--4 BLADE REPLACEMENT KIT 1

YRefer to Figure 2 for a cross--reference of tool to die set part numbers.

Figure 9

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408- 9767

Modular Plug Hand Tools (Premium Grade) 231652- [ ]

7of 7Rev LTyco Electronics Corporation

KITS

PART NUMBER DESCRIPTION

231662--4

BLADE REPLACEMENT KIT

Blade Set--Up Gage, 4 Pan Head Screws,

1CutterBladeScrew,5WireCutter

Blades, 5 Fixed Blade Holders, 5 Slider

Blade Assemblies

231666--9

HAND TOOL KIT

Carrying Case, Screwdriver, Set of Strip

Blades, Cutoff Blade, 2 Support Plates,

and 4 Pan Head Screws

1--231666--0

HAND TOOL KIT

Carrying Case, Screwdriver, Set of Strip

Blades, Cutoff Blade, 2 Support Plates,

4 Pan Head Screws, Modular Plug Hand

Tool, 4-- and 6--Position Line Die Set, and

8--Position Die Set

1--231666--1

HAND TOOL KIT

Carrying Case, Screwdriver, Set of Strip

Blades, Cutoff Blade, 2 Support Plates,

4 Pan Head Screws, Modular Plug Hand

Tool, 4-- and 6--Position Line Die Set,

8--Position Die Set, and 4--Position

Handset Die Set

1--231666--2

HAND TOOL KIT

Carrying Case, Screwdriver, Set of Strip

Blades, Cutoff Blade, 2 Support Plates,

4 Pan Head Screws, Modular Plug Hand

Tool, 4-- and 6--Position Line Die Set,

8--Position Die Set, and 6--Position Long

Body Die Set

1--231666--3

HAND TOOL KIT

Carrying Case, Screwdriver, Set of Strip

Blades, Cutoff Blade, 2 Support Plates,

4 Pan Head Screws, Modular Plug Hand

Tool, 4-- and 6--Position Line Die Set,

8--Position Die Set, 6--Position Long Body

Die Set, and 4--Position Handset Die Set

1--231666--4

HAND TOOL KIT

Carrying Case, Screwdriver, Set of Strip

Blades, Cutoff Blade, 2 Support Plates,

4 Pan Head Screws, Modular Plug Hand

Tool, 4-- and 6--Position Line Die Set,

8--Position Die Set, 6--Position Long Body

Die Set, and 8--Position High--Performance

Die Set

Figure 10

For tool evaluation and customer repair service, call

1--800--526--5136.

8. REVISION SUMMARY

Revisions to this instruction sheet include:

SUpdated document to corporate requirements

SAdded new information to tables in Figures 2

and 3

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