Instruction Sheet
408–9767
Modular Plug Hand Tool
(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
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
(shown in Figure 1) is 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.
NOTE
Dimensions in this instruction sheet are in
millimeters [with inches in brackets].
Die Holding
Screw
Nest (Die)
Color Code Dot
Indenter (Die)
Color Code Dot
Cable
Cutter
Read and understand this instruction sheet before
using the tool. For information on the modular
interconnection system, see Catalog 82066.
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.
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.
The dies bottom before the ratchet releases.
This feature ensures maximum electrical and
tensile performance of the crimp. DO NOT
re–adjust the ratchet.
CAUTION
Ratchet
Flat Oval
Cable
Stripper
CORRESPONDING DIE SET
COLOR
CODE
DOT
DESCRIPTION
(Modular Plug
Type)
853400–1
Black
8–Position
Line, Blue (Small
Conductor), Keyed,
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
Blue
2–, 4–, 6–Position
Line, Blue (Small
Conductor)
White
8–Position
High Performance
TOOL
OO
2–231652–1
2–231652–2
Ratchet
Release
(Pawl)
Handle
CAUTION
DO NOT cycle the tool without a
die in place; otherwise, damage
to the stripping blades may occur.
All International Rights Reserved.
AMP and Tyco are trademarks.
*Trademark
G
2–231652–8
2–231652–4
G
853400–8
3–231652–0
3–231652–1
G
1–853400–0
G Same as preceding tool except packaged in “clamshell” for retail display.
Figure 1
E2002 Tyco Electronics Corporation, Harrisburg, PA.
PART
NUMBER
Figure 2
This controlled document is subject to change.
For latest revision call the AMP FAX* number.
TOOLING ASSISTANCE CENTER 1–800–722–1111
AMP FAX/PRODUCT INFO 1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
1 of 7
LOC B
408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
3. CABLE PREPARATION
NOTE
Refer to Figure 3, and select the appropriate cable
and die set for the modular plug being used. Then
proceed as follows:
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.
3.1. 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
cutter. Squeeze handles until ratchet releases.
Prepare the cable according to Application
Specification 114–6016.
2. Insert trimmed cable into STRIP slot in tool flat
oval cable stripper until cable butts against die
cable stop.
3.3. High Performance Cable
3. Close handles to last ratchet stop, but DO NOT
release them. Pull cable straight out of tool. Then
release tool handles.
Prepare the cable according to Application
Specification 114–6053.
CAUTION
DO NOT cut or remove insulation from individual
conductors. This may result in shorted or open
terminations within the terminated assembly.
CABLED
MODULAR PLUG
POSITION
TYPED
PART NUMBER
TYPE
STYLE
DIE
E SET
E
COLOR
CO
OR CODE
CO E DOT
O
2
Line
5–641333–2
Stranded
Flat Oval
Blue
Handset
5–556200–2
Solid
Handset
5–641334–2
Stranded
Flat Oval
O
G
Green
Line
5–641335–2
Stranded
Blue (Small Conductor)
5–557965–2
Solid
Flat Oval
O
Blue
Line
5–569032–2
Solid
Line
5–641337–2
Stranded
Blue (Small Conductor)
5–557970–2
Solid
Offset Latch
5–555236–2
Solid
Flat Oval
Long Body
5–555426–2
Solid
Flat Oval
Long Body
5–555177–2
Stranded
Round
Long Body (Shielded)
5–555174–2
Stranded
Flat Oval
Line
5–554169–2
Stranded
Round
Line
5–554720–2
Solid
Line
5–554739–2
Stranded
Line
5–557315–2
Solid
Blue (Small Conductor)
5–557972–2
Solid
Keyed
5–554743–2
Stranded
Keyed
5–555417–2
Solid
Shielded
5–569532–2
Stranded
Line
5–558530–2
Stranded
Line
5–569278–2
Solid
Shielded
5–569550–2
Solid
Shielded
5–569552–2
Stranded
4
6
8
8
(High Performance)
Round
Flat Oval
O
Blue
Orange
V
Violet
Flat Oval
O
Round
Black
Flat Oval
O
Round
Round
W
White
D 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
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
Cutting and Stripping Unshielded Flat Oval Cable
408–9767
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.
Step 1
Unshielded
Flat Oval
Cable
Before proceeding with the termination procedure for
high performance modular plugs, refer to 114–6053
for preparation techniques to ensure high
performance levels.
CUT Slot
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.
Step 2
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.
Die Cable
Stop
STRIP Slot
CAUTION
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.
Step 3
NOTE
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.
Handles Closed
Step 4
Cable Strip Length
12.7–14.3 [.50–.56] (Ref)
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
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.
NOTE
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.
NOTE
Once a termination has been made, DO NOT
re–terminate the modular plug. Replace damaged
modular plugs with new ones.
Note: Not to Scale
Figure 4
Rev H
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408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
Terminated Modular Plug Inspection
Terminating Modular Plug
Cross–Section of Crimped Modular Plug
NOTE
Illustrations for termination procedure show
line modular plugs. Illustrations for other
types of modular plugs would be similar.
6.02+0.13 [.237+.005]
Crimp Height
Terminal
Step 1
Modular Plug
Locking Latch
A (See Table)
Note: Not to Scale
B (See Table)
Cable Bottomed
in Modular Plug
MODULAR
O
AR PLUG
TYPE
Die
Cavity
A
(Reference Zone)
Standard and Blue
(Small Conductor)
0.00–0.64
[.000–.025]
High Performance
0.00–0.25
[.000–.010]
Step 2
Modular Plug
Oriented as Shown
on Side of Tool Head
CONDUCTOR LOCATION
B
(Preferred)
Conductors Against
End of Wire Circuits
Figure 6
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.
Modular Plug in
Fully Seated
Position
Step 3
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 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.
NOTE
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.
Figure 5
4 of 7
2. Loosen the two screws that hold the movable
blade assembly.
Rev H
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
Adjusting Flat Oval Cable Stripper
Die Set Must Be
Installed in Tool
Movable Blade
Assembly
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.
Blade Set–Up
Gage (Ref)
3. Install and tighten screws. Adjust flat oval cable
stripper according to Paragraph 5.2.
CAUTION
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
CAUTION
6.4 [.25] (Length)
Screw (2 Places)
Fixed Blade
Support Plate
Beveled Edges
of Blades Face
Inward
Cable (Ref)
Movable Blade
Support Plate
Movable Blade
Assembly
9.7 [.38] (Length)
Screws (2 Places)
DO NOT cycle the tool without a die in place.
Damage to the stripping blades may occur.
Figure 7
3. Insert Blade Set–Up Gage 231667–2 (available
separately and part of Blade Replacement Kit
231662–4) or a 1.02 [.040] 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.
5.3. Replacing Flat Oval Cable Stripper Blades (Figure 7)
If the flat oval cable stripper blades are worn or
damaged, replace the fixed blade assembly and
movable blade assembly according to the following.
Rev H
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
Fixed Blade
Assembly
NOTE
DO NOT cycle the tool without a die in place.
Damage to the stripping blades may occur.
6. MAINTENANCE AND INSPECTION
Screw
(2 Places)
CAUTION
408–9767
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.
CAUTION
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.
5 of 7
408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
set, and place it back into service. If the crimp
height is not within acceptable limits, return the tool
(with die set) to Tyco Electronics for evaluation
(refer to Section 7).
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.
7. REPLACEMENT AND REPAIR
Customer–replaceable parts are provided in Figure 8.
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
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
Weight: .3 kg [.75 lb] (Approx)
6
1
2
4
3
5
8
9
7
10
69.8 [2.75]
(Handles
Closed)
30.5 [1.20]
197 [7.75]
REPLACEMENT PARTS
ITEM
PART NUMBER
1
993314–1
2
4–23619–8
3
21045–3
4
2–23620–5
5
21045–6
6
853400–[ ]Y
7
2–231652–0
8
21045–1
9
768522–1
DESCRIPTION
QTY PER TOOL
SCREW, Pan Head 4–40 .250 L (Die Holding)
1
PIN, Grooved
2
RING, Retaining, Crescent
4
PIN, Center, Straight
1
RING, Retaining, Crescent
2
DIE SET
1
TOOL ASSEMBLY (Frame Without Die Set)
1
RING, Retaining, Crescent
2
PIN, Handle (Pawl)
2
Y Refer to Figure 2 for a cross–reference of tool to die set part numbers.
Figure 8 (cont’d)
6 of 7
Rev H
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
408–9767
KITS
PART NUMBER
DESCRIPTION
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
231666–9
TOOL KIT — Carrying Case, Screwdriver, Set of Strip Blades, Cutoff Blade, 2 Support Plates, and 4 Pan
Head Screws
1–231666–0
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
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
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
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
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 8 (end)
8. REVISION SUMMARY
Revisions to this instruction sheet per
EC: 0990–0891–02 include:
S Changed title of document
S Modified Figure 2
S Added Paragraph 5.1
S Modified Paragraph 5.2, Step 3
S Modified Figures 6 and 8
Rev H
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