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Instruction Sheet

TOOLING ASSISTANCE CENTER

1-800-722-1111

PRODUCT INFORMATION

1-800-522-6752

This controlled document is subject to change.

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LOC B

Modular Plug Hand Tools

(Premium Grade) 231652-[ ]

408-9767

08 APR 11 Rev M

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

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.

Reasons for reissue of this instruction sheet are

provided in Section 8, REVISION SUMMARY.

Figure 1

2. DESCRIPTION (FIgure1)

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.

Refer to Figure 2.

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.

Figure 2

NOTE

Flat Oval

Cable Stripper

Die Holding

Screw

Nest (Die)

Color Code

Dot

Ratchet

Release

(Pawl)

Handle

CAUTION: DO NOT cycle the

tool without a die in place;

otherwise damage to the

stripping blades may occur.

CAUTION

Cable Cutter

Indenter (Die)

Color Code Dot

Summary of content (7 pages)

PAGE 1
Instruction Sheet 408-9767 Modular Plug Hand Tools (Premium Grade) 231652-[ ] 08 APR 11 Rev M 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.
PAGE 2
408-9767 CAUTION ! The dies bottom before the ratchet releases. This feature ensures maximum electrical and tensile performance of the crimp. DO NOT re-adjust the ratchet. 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. 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.
PAGE 3
408-9767 Figure 4 Rev M Figure 5 3 of 7
PAGE 4
08-9767 3. Hold the modular plug in the fully seated position, and squeeze tool handles until ratchet releases. NOTE i 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. NOTE i 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.
PAGE 5
408-9767 NOTE i The recommended shim thickness does not account for larger than normal conductor insulation. Adjust the blade gap according to your specific needs. Adjusting Flat Oval Cable Stripper Die Set Must Be Installed in Tool Movable Blade Assembly 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.
PAGE 6
408-9767 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.
PAGE 7
408-9767 DESCRIPTION QTY PER TOOL ITEM PART NUMBER 1 993314-1 SCREW, Pan Head ((Die Holding) 4-40 X .250 L 1 2 4.