AMP/TYCO ELECTRONICS 2-231652-8

Instruction Sheet Modular Plug Hand Tool 408–9767 (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 extended–use, 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 2–231652–0 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 re–adjust the ratchet. Flat Oval Cable CORRESPONDING DIE SET Stripper COLOR DESCRIPTION TOO OOL PART CODE (Modular Plug NUMBER DOT Type) 8–Position 2–231652–1 Line, Blue (Small 853400–1 Black Conductor), Keyed, 2–231652–2 Shielded Ratchet 2–231652–3 853400–3 Green 4–Position Handset Release (Pawl) 6–Position 2–231652–6 853400–6 Orange Offset Latch 6–Position 2–231652–7 853400–7 Violet Long Body 2–, 4–, 6–Position Handle 2–231652–8 853400–8 Blue Line, Blue (Small 2–231652–4 Conductor) DO NOT cycle the tool without a CAUTION 3–231652–0 8–Position 1–853400–0 White die in place; otherwise, damage High Performance 3–231652–1 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 1–800–722–1111 1 of 7 For latest revision call the AMP FAX* number. AMP FAX/PRODUCT INFO 1–800–522–6752 All International Rights Reserved. AMP and Tyco are trademarks. For Regional Customer Service, visit our website at LOC B *Trademark www.tycoelectronics.com Modular Plug Hand Tool (Premium Grade) 231652–[ ] 408–9767 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 114–6016. 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 114–6053. 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 CO COLOR CODE DOT OR CO E O POSITION TYPEPART NUMBER TYPE STYLE 2 Line 5–641333–2 Stranded Flat Oval Blue Handset 5–556200–2 Solid Flat O Oval G Green Handset 5–641334–2 Stranded 4 4 4 Line 5–641335–2 Stranded Flat O Oval Blue Blue (Small Conductor) 5–557965–2 Solid Line 5–569032–2 Solid Round Line 5–641337–2 Stranded Blue Flat O Oval Blue (Small Conductor) 5–557970–2 Solid 6 Offset Latch 5–555236–2 Solid Flat Oval Orange Long Body 5–555426–2 Solid Flat Oval Long Body 5–555177–2 Stranded Round V Violet Long Body (Shielded) 5–555174–2 Stranded Flat Oval Line 5–554169–2 Stranded Round Line 5–554720–2 Solid Flat O Oval Line 5–554739–2 Stranded Line 5–557315–2 Solid Round 8 Black Blue (Small Conductor) 5–557972–2 Solid Keyed 5–554743–2 Stranded Flat O Oval Keyed 5–555417–2 Solid Shielded 5–569532–2 Stranded Round Line 5–558530–2 Stranded Line 5–569278–2 Solid 8 Round W W White (High Performance) Shielded 5–569550–2 Solid Shielded 5–569552–2 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 408–9767 Modular Plug Hand Tool (Premium Grade) 231652–[ ] Cutting and Stripping Unshielded Flat Oval Cable 4. TERMINATION PROCEDURE Before proceeding with the termination procedure, Step 1 check to make sure that the cable and modular plug are compatible, and that cable polarity is correctly Unshielded maintained for the specific application. Flat Oval Cable Before proceeding with the termination procedure for high performance modular plugs, refer to 114–6053 for preparation techniques to ensure high CUT Slot 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 Step 2 Die Cable assembly fully into die cavity. When using a die set Stop 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 STRIP Slot does not snap into position. Failure to fully seat the modular plug assembly in CAUTION 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. Step 3 When crimping, make sure to hold the modular NOTE 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. Handles Closed 5. Inspect the modular plug assembly for proper crimp height using a dial indicator or digital indicator with needle–point probes, or a Crimp Height Gage 904170–1 according to 408–4389. Figure 6 shows a cross–section of a typical terminated modular plug, proper crimp height Step 4 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. Cable Strip Length For specific information concerning inspection 12.7–14.3 [.50–.56] (Ref) NOTE requirements, refer to 114–6016 for standard and blue (small conductor) modular plugs and Note: Not to Scale 114–6053 for high performance modular plugs. Once a termination has been made, DO NOT NOTE re–terminate the modular plug. Replace damaged Figure 4 modular plugs with new ones. Rev H 3 of 7 Modular Plug Hand Tool (Premium Grade) 231652–[ ] 408–9767 Terminating Modular Plug Terminated Modular Plug Inspection Cross–Section of Crimped Modular Plug Illustrations for termination procedure show NOTE 6.02+0.13 [.237+.005] line modular plugs. Illustrations for other Crimp Height types of modular plugs would be similar. Terminal Step 1 Modular Plug Locking Latch A (See Table) Note: Not to Scale B (See Table) Cable Bottomed CONDUCTOR LOCATION in Modular Plug MOA ODULARR PLUG A B TYPE (Reference Zone) (Preferred) Standard and Blue 0.00–0.64 (Small Conductor) [.000–.025] Conductors Against Step 2 End of Wire Circuits 0.00–0.25 High Performance [.000–.010] Modular Plug Die Oriented as Shown Figure 6 on Side of Tool Head Cavity 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. Modular Plug in Fully Seated 5. Close the tool handles. Re–install the die Step 3 holding screw (turn the screw clockwise until tight). Position 5.2. Adjusting Flat Oval Cable Stripper (Figure 7) 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 NOTE 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 Figure 5 blade assembly. 4 of 7 Rev H 408–9767 Modular Plug Hand Tool (Premium Grade) 231652–[ ] Adjusting Flat Oval Cable Stripper 1. Remove the four screws holding both blades in place. Remove fixed blade assembly and movable Die Set Must Be blade assembly from tool. Installed in Tool Movable Blade 2. Position new blades onto tool with beveled Assembly edges facing inward. 3. Install and tighten screws. Adjust flat oval cable Blade Set–Up stripper according to Paragraph 5.2. Gage (Ref) DO NOT cycle the tool without a die in place. CAUTION Damage to the stripping blades may occur. Screw 6. MAINTENANCE AND INSPECTION (2 Places) 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. Replacing Blades in Flat Oval Cable Stripper Failure to perform daily maintenance and periodic CAUTION inspection can cause defective modular plug 6.4 [.25] (Length) terminations, leading to discontinuities on Screw (2 Places) individual wire circuits. Fixed Blade 6.1. Daily Maintenance Assembly Foreign particles should be cleaned from the tool Fixed Blade using a soft, clean, lint–free cloth or brush. Make sure Support Plate all pins, rings and other retaining hardware is in place, and that the die set is undamaged. Lightly lubricate all Beveled Edges Cable (Ref) pins, pivot points, and bearing surfaces using a good of Blades Face grade SAE 20 motor oil. DO NOT lubricate Inward excessively. Movable Blade Support Plate DO NOT lubricate surfaces of the die set that CAUTION contact the product. These areas must be kept Movable Blade clean to ensure a usable modular plug assembly. Assembly 9.7 [.38] (Length) Screws (2 Places) 6.2. Periodic Inspection It is recommended that the following inspections be DO NOT cycle the tool without a die in place. CAUTION conducted at least once a month by quality control Damage to the stripping blades may occur. personnel. More frequent inspections should be conducted if your work environment, company Figure 7 standards, or amount of tool use indicates the need. 3. Insert Blade Set–Up Gage 231667–2 (available A. Visual Inspection separately and part of Blade Replacement Kit 231662–4) or a 1.02 [.040] shim between the Remove die set from the tool; then, remove all stationary and movable blades. Slide the movable lubrication and accumulated film and debris by blade against the gage or shim, and tighten the immersing the dies and tool head in a mild screws. commercial degreaser. 1. Check for missing or defective pins, rings, or The recommended shim thickness does not NOTE account for larger than normal conductor other retaining hardware. Replace parts as insulation. Adjust the blade gap according to your necessary. specific needs. 2. Closely inspect dies for damage, giving special attention to bearing surfaces and surfaces that 5.3. Replacing Flat Oval Cable Stripper Blades (Figure 7) contact the product. Worn, cracked, pitted, or If the flat oval cable stripper blades are worn or chipped indenter or nest surfaces, or other obvious damaged, replace the fixed blade assembly and wear or damage to the die set or tool head requires movable blade assembly according to the following. removal of the affected part from service. Rev H 5 of 7 Modular Plug Hand Tool (Premium Grade) 231652–[ ] 408–9767 set, and place it back into service. If the crimp B. Die Closure Inspection height is not within acceptable limits, return the tool The tool and die set is inspected for proper operation (with die set) to Tyco Electronics for evaluation before shipment. To ensure uniform performance over (refer to Section 7). the life of the tool, periodically inspect as follows: 1. Insert a properly stripped cable of appropriate 7. REPLACEMENT AND REPAIR type and size into a sample modular plug. Then Customer–replaceable parts are provided in Figure 8. insert the unterminated cable and plug into the die A complete inventory should be stocked and cavity. controlled to prevent lost time when replacement of parts is necessary. Order replacement parts through 2. Squeeze tool handles together slowly, while your representative, or call 1–800–526–5142, or send watching to ensure indenter bottoms against nest. a facsimile of your purchase order to 717–986–7605 3. Release handles to open die set, and remove or write to: terminated modular plug assembly. CUSTOMER SERVICE (038–035) 4. Test for proper crimp height according to TYCO ELECTRONICS CORPORATION Section 4, Step 4. If plug crimp height is within PO BOX 3608 acceptable limits, lightly lubricate the tool and die HARRISBURG PA 17105–3608 Weight: .3 kg [.75 lb] (Approx) 6 3 4 8 9 7 2 5 1 10 69.8 [2.75] (Handles Closed) 30.5 [1.20] 197 [7.75] REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY PER TOOL 1 993314–1 1 SCREW, Pan Head 4–40.250 L (Die Holding) 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 Refer to Figure 2 for a cross–reference of tool to die set part numbers. Figure 8 (cont’d) 6 of 7 Rev H 408–9767 Modular Plug Hand Tool (Premium Grade) 231652–[ ] KITS PART NUMBER DESCRIPTION BLADE REPLACEMENT KIT — Blade Set–Up Gage, 4 Pan Head Screws, 1 Cutter Blade Screw, 5 Wire 231662–4 Cutter Blades, 5 Fixed Blade Holders, 5 Slider Blade Assemblies TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, and 4 Pan 231666–9 Head Screws TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head 1–231666–0 Screws, Modular Plug Hand Tool, 4– and 6–Position Line Die Set, and 8–Position Die Set TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head 1–231666–1 Screws, Modular Plug Hand Tool, 4– and 6–Position Line Die Set, 8–Position Die Set, and 4–Position Handset Die Set TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head 1–231666–2 Screws, Modular Plug Hand Tool, 4– and 6–Position Line Die Set, 8–Position Die Set, and 6–Position Long Body Die Set TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head 1–231666–3 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 TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head 1–231666–4 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 8 (end) 8. REVISION SUMMARY Revisions to this instruction sheet per EC: 0990–0891–02 include: Changed title of document Modified Figure 2 Added Paragraph 5.1 Modified Paragraph 5.2, Step 3 Modified Figures 6 and 8 Rev H 7 of 7