Instruction Sheet
408-9743
Terminating Modules 856196-[ ] for Use with
Modular Plug Dual Terminators 1320840-[ ]
17 NOV 16 Rev L
Terminating Module
Modular Plug Dual Terminator
Stacked Contact
Inserters and Strain
Relief Stuffers
Automatic Circuit
Tester (Terminators
1320840-1 and
1320840-2 Only)
Plastic Guard
Module Nests
Foot Switch
Cable Assembly
Release
Figure 1
The terminating module is designed to be used with the modular plug dual terminator (shown in Figure 1)
terminates the modular plugs listed in Figure 2 to create a cable assembly. During termination, terminators
1320840-1 and 1320840-2 are capable of testing the cable assembly for electrical circuit continuity. Terminator
1320840-3 will not provide electrical circuit continuity testing. Read these instructions completely before using
the module.
NOTE
Dimensions in this instruction sheet are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
For detailed information about the modular plug dual terminator, refer to customer manual 409-10010.
For information on modular interconnection system products, refer to Catalog 82066.
Refer to the applicable application specification for cable stripping and module plug crimp requirements:
114-6016 Modular Plug Connectors (Standard and Small Conductor)
114-6053 High Performance Modular Plug Connectors
When reading this document, pay particular attention to DANGER and CAUTION statements.
DANGER
Denotes an imminent hazard which may result in moderate or severe injury.
CAUTION
Denotes a condition which may result in product or equipment damage.
Reasons for re-issue of this instruction sheet are provided in Section 7, REVISION SUMMARY.
1. DESCRIPTION
These terminating modules fit interchangeably into the modular plug dual terminator. Each module features
dual nest areas for positioning the modular plugs, inserters for terminating the contacts, and stuffers for
terminating the primary and secondary strain reliefs. Since each feature is independently adjustable, crimp
heights can be adjusted to meet FCC specifications.
2. INSTALLATION
1. Install the modular plug dual terminator according to 409-10010.
To obtain information on CommScope® products,
contact your local CommScope® account
representative, PartnerPRO™ Network Partner
or visit our website at www.commscope.com
©2016 CommScope, Inc.
All Rights Reserved
This product is covered by one or more U.S.patents
or their foreign equivalents. For patents, see
www.commscope.com /ProductPatent/ProductPatent.aspx
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408-9743
MODULAR PLUG
TERMINATING
MODULE
POSITION
856196
DESCRIPTION
CABLE
BASE PART
NUMBER
TYPE
STYLE
Stranded
Flat Oval
0.89-0.99
[.035-.039]
6.35-7.14
[.25-.28]
Flat Oval
0.89-0.99
[.035-.039]
6.35-7.14
[.25-.28]
Flat Oval
0.74-0.86
[.029-.034]
6.35-7.14
[.25-.28]
Flat Oval
0.89-0.99
[.035-.039]
12.7-14.2
[.50-.56]
0.89-0.99
[.035-.039]
6.35-7.14
[.25-.28]
0.74-0.86
[.029-.034]
6.35-7.14
[.25-.28]
0.89-0.99
[.035-.039]
6.35-7.14
[.25-.28]
0.89-0.99
[.035-.039]
14.2
[.56]
0.89-0.99
[.035-.039]
12.7-14.2
[.50-.56]
0.74-0.86
[.029-.034]
12.7-14.2
[.50-.56]
641333
-1
2
Line
737743
737746
556200
CONDUCTOR
OUTSIDE STRIP LENGTH
DIAMETER
mm [in.]
mm [in.]
Solid
641334
-3
4
Handset
737628
737629
Stranded
737344
737335
556384
Solid
641335
Line
-1
4
737336
737742
Stranded
737345
737745
Blue—Small Conductor
-2
4
84 Long
Line
-1
6
557965
Solid
557967
Stranded
556586
Stranded
555042
Solid
641337
Stranded
554710
Stranded
Round
Stranded
Flat Oval
737744
737747
Blue—Small Conductor
-5
-4
6
6
Offset
Long—Unshielded
Solid
557971
Stranded
555238
Stranded
555236
Solid
555237
Stranded
555426
Solid
555176
555177
Long—Shielded
Line
-2
557970
8
Blue—Small Conductor
555174
Stranded
Stranded
554720
Solid
554739
Stranded
557315
Solid
554169
Stranded
557972
Solid
557973
Stranded
Flat Oval
Flat Oval
Round
Flat Oval
Flat Oval
Flat Oval
Round
Flat Oval
Flat Oval
Round
Flat Oval
Figure 2 (Cont’d)
Rev L
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408-9743
MODULAR PLUG
TERMINATING
MODULE
POSITION
856196
DESCRIPTION
Keyed
8
-2
Shielded
Shielded—Keyed
Line—High Performance
1-000000-1
8
Shielded—High Performance
1-000000-2
8
-6
100
-7
CABLE
BASE PART
NUMBER
TYPE
STYLE
555417
Solid
Flat Oval
554743
Stranded
Flat Oval
554170
Stranded
Round
569530
Solid
Round
569532
Stranded
Round
569542
Stranded
Flat Oval
569531
Solid
Round
569543
Stranded
Flat Oval
558530
Stranded
569278
Solid
569552
Stranded
569550
Solid
Round
CONDUCTOR
OUTSIDE STRIP LENGTH
DIAMETER
mm [in.]
mm [in.]
0.89-0.99
[.035-.039]
12.7-14.2
[.50-.56]
0.89-0.99
[.035-.039]
14.2
[.56]
0.89-0.99
[.035-.039]
Refer to
114-6053
0.89-0.99
[.035-.039]
12.7-14.2
[.50-.56]
Modular Plugs Without Secondary Strain Relief Other than CommScope
Call the number at the bottom of page 1 to ensure capability.
Line
557963
Stranded
Round
Allows Operator to Use 2 Different Modules Simultaneously (For Example: terminate product used on module 856196-2 on
Left Side and terminate product used on module 856196-1 on Right Side)
Figure 2 (End)
2. Disconnect the air supply.
DANGER
To avoid personal injury, always disconnect the air supply before attempting to install or remove the module from the
terminator. A lockout valve has been provided in the air line.
3. Remove the plastic guard from the module by removing four screws and two terminals from the limit
switch (refer to the module customer drawing for location).
4. For terminators -1 and -2 (only), refer to Figure 3, and:
a. Connect the cable from the automatic circuit tester to the back of the module, and tighten the
screws to secure cable.
b. Check that the two single-wire terminations on the limit switch to the left of the tester cable (viewing
from the back of the module) are firmly connected to the limit switch at the top-most and bottommost terminals (normally-closed position). Verify that the green wire of the tester cable is
connected to the terminator and to a suitable ground on an AC outlet.
c. Set up the automatic circuit tester according to 409-10010.
5. Position the module so that the T-slot at the top will slide onto the arm of the terminator so that the
module rests on the base plate of the terminator. Tighten the screws at the bottom front of the module,
securing the module to the base plate.
6. Re-connect the air supply to the terminator (regulated air supply of 551 to 689 kPa [80 to 100 psi] at
0.47 liters/sec [1.0 scfm]).
7. Re-install the plastic guard onto the module.
8. Run samples according to 409-10010 to inspect the crimp height and strain reliefs of each modular
plug.
Rev L
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408-9743
Using Terminators -1 and -2 Only
Tester Cable Connected to
Back of Module
Back of Terminator
Connect Green Wire of Tester Cable
to Suitable Ground on AC Outlet
Figure 3
9. Adjust the contact inserters (for proper crimp height measurement) and strain relief stuffers as follows
(refer to the applicable application specification for crimp height):
a. Lift the module ram mechanism off the module for ease in making adjustments.
NOTE
If adjustments must be made after module installation, first remove the module, and then remove the ram. See Figure 4.
b. Slightly loosen the two 8-32 socket head cap screws at the front of the ram (inserters and stuffers
are held to the ram by these screws) so that adjustments can be made.
10. Set the crimp height as follows:
a. Loosen the locking setscrews at the back of the ram head, and loosen the back-up setscrews
counterclockwise at least one full turn (one full turn equals approximately 0.18 mm [.007 in.]).
b. Rotate the contact inserter adjustment screws clockwise to adjust the inserter downward until the
inserters are at the correct crimp height for the modular plug. One full turn equals approximately
0.18 mm [.007 in.]. Refer to the application specification for the crimp height.
c. Tighten the locking setscrews and back-up setscrews.
Ram Head
Locking Setscrews
(At Back of Ram Head)
Primary Strain Relief Adjustment Screw
for 2-, 4-, and 6- (Excluding Long Body)
Position Modular Plugs
Contact Inserter
Adjustment Screw
Primary Strain Relief Adjustment Screw
for 6-Position Long Body and All 8- and
10-Position Modular Plugs
Setscrew for Back-Up
of Inserter Adjustment
Front of Ram
Secondary Strain Relief
Adjustment Screw
(Not Used on Module 1-856196-1)
8-32 Socket Head Cap Screws
(Hold Stacked Contact Inserters and
Strain Relief Stuffers to Ram)
Note: Adjustment for Left Side Inserter and
Stuffer are Mirrored for Right Side
Ram Mechanism
Stacked Contact Inserters
and Strain Relief Stuffers
Figure 4
Rev L
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408-9743
11. Adjust the primary strain relief stuffers as follows:
a. Loosen the 8-32 socket head cap screws enough to make the required adjustments.
b. Rotate the applicable primary strain relief adjustment screws (refer to Figure 4) clockwise to adjust
the primary strain relief stuffers downward. One rotation equals approximately 0.64 mm [.025 in.].
12. Adjust the secondary strain relief stuffers as follows:
a. Loosen the secondary strain relief adjustment screws enough to make the required adjustments.
b. Rotate the screws clockwise to adjust the secondary strain relief stuffers downward. One rotation
equals approximately 0.64 mm [.025 in.].
c. Hold all strain relief stuffers in their up-most position, and tighten the 8-32 socket head cap screws
(that hold the indenters and stuffers in place).
d. Re-position the ram on the module.
3. TERMINATING, TESTING, AND INSPECTING MODULAR PLUG
1. Strip the cable insulation outer jacket to the dimension given in Figure 2. Do not strip the insulation
from the individual conductors. Refer to the applicable application specification for shielded cable
stripping requirements.
2. Insert stripped cables into the modular plugs, and insert the cables and modular plugs into the module
nests. Make sure of the following:
— the cable conductors are oriented to the applicable contact slots before inserting the conductors
into the modular plugs,
— the cable conductors are bottomed in the contact slots of the modular plugs, and that they remain
bottomed throughout the cycling of the terminator, and
— the modular plugs bottom in the module nests; the modular plug release tab must snap firmly into
place.
3. Press the foot switch to cycle the terminator.
4. When termination is complete:
For terminators -1 and -2 (only), the tester will automatically examine the cable assembly and respond
with either a short tone or a long tone (refer to Figure 5). After the cable assembly is tested, hold the
cable assembly release down, and remove the cable assembly from the module.
CAUTION
Removing the cable assembly before a tone has sounded may cause good terminations to test as failures.
NOTE
Any coupled cable assembly may be tested or re-tested by inserting and latching the modular plugs into the nest areas and
pressing the TEST pushbutton.
For terminator -3, hold the cable assembly release down, and remove the cable assembly from the
module.
5. Inspect the crimps on the modular plugs using an indicator with a 0.25-mm [.010-in.] diameter needlepoint probe. Refer to the application specification for crimp height and other terminated modular plug
criteria.
Problems associated with bad cable assemblies should be recorded to aid in troubleshooting. Check
for the source of recurring problems in the following order:
a. Check the settings against the test cable.
b. Check that the correct combination of cable and plugs is being terminated.
c. Check crimp height and strain relief settings. If necessary, make corresponding adjustments to the
module.
d. Check that the spring plungers are all correctly resting on the contact probes.
e. Inspect and replace any defective mechanical tooling parts.
Rev L
5 of 7
408-9743
TESTING SUMMARY (Terminators -1 and -2 Only)
1:1/1:N ORIENTATION
TEST
CONDITION
TEST INDICATORS
The tester checks for open conductors.
There are one or more open conductors.
A long tone will sound and the OPEN LED will
light. The wire position LEDs will also light,
corresponding to the open conductors of the
plug located in the right-hand nest. Note that if
“opens” are found, the tester abandons further
testing; therefore, shorts that may have also
been present will not be indicated.
If there are no open conductors, the tester
checks for short circuits.
The cable assembly has two or more
shorted conductors.
A long tone will sound and the SHORT LED
will light. The wire position LEDs will also light,
corresponding to the shorted conductors of
the plug located in the right-hand nest.
No “opens” or “shorts” are found.
The cable assembly is considered good.
The tester will sound a short tone and the
GOOD LED will light.
CROSSED CONDUCTORS
TEST
CONDITION
TEST INDICATORS
With the position selector switch in the Learn
position, the tester compares the cable
assembly against a “learned” cable pattern.
When a cable assembly has a “learned”
cable pattern, open conductors, as well as,
crossed conductors, are noted.
Contacts that were “learned” as “open” are The tester will sound a long tone, light both
found to have continuity to other conductors the OPEN and SHORT LEDs, and light the
in the cable assembly.
wire position LEDs corresponding to the
connected conductors of the plug located in
the right-hand side of the nest.
If there are no connections where there
should be “opens”, the tester will conduct the
“opens” test.
The cable assembly has one or more open
conductors.
The tester will sound a long tone, the OPEN
LED will light, and the wire position LEDs will
light, corresponding to the open conductors of
the plug located in the right-hand side of the
nest.
If there are no opens present, the tester
performs the “shorts” test.
The cable assembly has two or more
shorted conductors.
The tester will sound a long tone, the SHORT
LED will light, and the wire position LEDs will
light, corresponding to the open conductors of
the plug located in the right-hand side of the
nest.
The cable assembly passes all three tests.
The cable assembly is considered good.
Tester will sound a short tone and GOOD LED
will light.
Figure 5
4. MAINTENANCE, INSPECTION, AND TROUBLESHOOTING
It is recommended that each module be inspected immediately upon arrival to ensure that the module has not
been damaged during shipping and at regularly scheduled intervals.
4.1. Daily Maintenance
1. At the end of each shift, clean the foreign particles from the module using a soft, clean, lint-free cloth
or brush. Make sure that the contact inserters and strain relief stuffers are secured in place. Check the
area under the base plate for foreign matter and debris.
2. For terminators -1 and -2 only, inspect the module for secure engagement of the connectors and cable
from the tester to the module and of the wires to the limit switch on the left at the back of the module.
3. Lubricate the module ram, if necessary, with a thin coat of high-pressure grease. Do not lubricate
excessively. Store the module in a clean, dry place.
4. Make sure to keep the terminating areas of the stuffers and nest areas especially clean. Do not oil or
grease the terminating areas of the stuffers or the contact slides.
Rev L
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408-9743
4.2. Periodic Inspection
Personnel responsible for the module should perform regular inspections, record the results, and keep a record
of inspections. It is recommended that inspections be performed at least once a month. Work environment,
company standards, or amount of module use may dictate more frequent inspections.
CAUTION
Failure to perform periodic inspection and cleaning can cause the module to make defective modular plug terminations leading
to discontinuities on individual wire circuits.
4.3. Troubleshooting
Refer to the troubleshooting section in 409-10010 (Modular Plug Dual Terminator Customer Manual).
5. REPLACEMENT AND REPAIR
Refer to the documentation package included with the module for a list of recommended customer-replaceable
spare parts. To order replacement parts or for customer evaluation and repair service, call:
Technical Support
Technical Assistance Center (TAC)
Tel.: 800.830.5056
Email: TAC.Americas@commscope.com
www.commscope.com
6. RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION
Information on the presence and location of any substances subject to RoHS can be found at
http://www.commscope.com/About-Us/Corporate-Responsibility-and-Sustainability/Environment/Product-Compliance/
7. REVISION SUMMARY
Revisions to this instruction sheet include:
Rebranded to CommScope
Added steps 3, 4c, and 7 to Section 2, dimension to step 10a of Section 2, and steps 1 and 2 to
Paragraph 4.1
Rev L
Added terminator part numbers to text that applies to tester
Replaced previous last 3 paragraphs of Section 2, step 1 of Section 3, Paragraph 5.1, and Figures 5 and
7 with reference to terminator customer manual
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