Tyco Electronics AMP 231652 Series User manual

Instruction Sheet
Modular Plug Hand Tool 408–9767
E 2002 Tyco Electronics Corporation, Harrisburg, PA.
AllInternationalRightsReserved.
AMP and Tyco are trademarks.
*Trademark LOC B
1 of 7
TOOLINGASSISTANCECENTER1–800–722–1111
AMP FAX/PRODUCT INFO1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
This controlled document is subject to change.
For latest revision call the AMP FAX* number.
07 JUN 02 Rev H
(Premium Grade) 231652–[ ]
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
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.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets].
Figure 1
Cable
Cutter
Indenter(Die)
Color Code Dot
Flat Oval
Cable
Stripper
DieHolding
Screw Nest (Die)
Color Code Dot
Ratchet
Ratchet
Release
(Pawl)
Handle
DO NOT cycle the tool without a
die in place; otherwise, damage
to the stripping blades may occur.
CAUTION
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–adjustthe ratchet.
OO
CORRESPONDING DIE SET
T
OO
LPART
NUMBER
COLOR
CODE
DOT
DESCRIPTION
(Modular Plug
Type)
2–231652–1
2–231652–2 G
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
2–231652–8
2–231652–4 G
853400–8 Blue 2–, 4–, 6–Position Line, Blue (Small
Conductor)
3–231652–0
3–231652–1 G
1–853400–0 White 8–Position
High Performance
Figure 2
G Same as preceding tool except packaged in “clamshell” for retail display.
NOTE
CAUTION

408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
Rev H2 of 7
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
terminationswithin the terminated assembly.
MODULAR PLUG CABLE
D
DI
E
S
E
T
CO OR CO E O
POSITION TYPE
D
PART NUMBER TYPE STYLE
EE
COLOR CODE DOT
2 Line 5–641333–2 Stranded Flat Oval Blue
4
Handset 5–556200–2 Solid
O
G
4
Handset 5–641334–2 Stranded Flat
O
val
G
reen
4
Line 5–641335–2 Stranded
O
Blue (Small Conductor) 5–557965–2 Solid Flat
O
val Blue
Line 5–569032–2 Solid Round
Line 5–641337–2 Stranded
O
Blue
Blue (Small Conductor) 5–557970–2 Solid Flat
O
val
6Offset Latch 5–555236–2 Solid Flat Oval Orange
Long Body 5–555426–2 Solid Flat Oval
V
Long Body 5–555177–2 Stranded Round
V
iolet
Long Body (Shielded) 5–555174–2 Stranded Flat Oval
Line 5–554169–2 Stranded Round
Line 5–554720–2 Solid
O
Line 5–554739–2 Stranded Flat
O
val
Line 5–557315–2 Solid Round
8Blue (Small Conductor) 5–557972–2 Solid
O
Black
Keyed 5–554743–2 Stranded Flat
O
val
Keyed 5–555417–2 Solid
Shielded 5–569532–2 Stranded Round
Line 5–558530–2 Stranded
W
8Line 5–569278–2 Solid
W
(High Performance) Shielded 5–569550–2 Solid Round
W
hite
Shielded 5–569552–2 Stranded
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
NOTE
CAUTION

408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
3of 7Rev H
Figure 4
Unshielded
Flat Oval
Cable
CUT Slot
Step 1
Cutting and Stripping Unshielded Flat Oval Cable
Step 2
STRIPSlot
Step 3
HandlesClosed
DieCable
Stop
CableStrip Length
12.7–14.3[.50–.56](Ref)
Step 4
Note: Not to Scale
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.
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.
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
terminationprocedure.
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 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.
Forspecific information concerning inspection
requirements, refer to 114–6016 for standard and
blue (small conductor) modular plugs and
114–6053 for high performancemodular plugs.
Once a termination has been made, DO NOT
re–terminatethe modular plug. Replace damaged
modular plugs with new ones.
CAUTION
NOTE
NOTE
NOTE

408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
Rev H4 of 7
Figure 5
ModularPlug
LockingLatch
CableBottomed
in Modular Plug
T
erminating Modular Plug
Step 1
Step 2
Step 3
Die
Cavity
ModularPlug
Orientedas Shown
on Side of Tool Head
Modular Plug in
FullySeated
Position
Illustrationsfor termination procedure show
line modular plugs. Illustrations for other
types of modular plugs would be similar.
NOTE
Terminated Modular Plug Inspection
6.02+0.13[.237+.005]
CrimpHeight
Cross–Sectionof Crimped Modular Plug
Terminal
A (See Table)
B (See Table) Note: Not to Scale
OAR
CONDUCTOR LOCATION
M
O
DUL
AR
PLUG
TYPE A
(Reference Zone) B
(Preferred)
Standard and Blue
(Small Conductor) 0.00–0.64 [.000–.025] Conductors Against
High Performance 0.00–0.25
[.000–.010] 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.
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.
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.
NOTE

408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
5of 7Rev H
BladeSet–Up
Gage(Ref)
MovableBlade
Assembly
Screw
(2Places)
Adjusting Flat Oval Cable Stripper
Figure 7
6.4 [.25] (Length)
Screw (2 Places)
FixedBlade
SupportPlate
Cable(Ref)
MovableBlade
SupportPlate
9.7 [.38] (Length)
Screws (2 Places)
MovableBlade
Assembly
BeveledEdges
of Blades Face
Inward
FixedBlade
Assembly
Replacing Blades in Flat Oval Cable Stripper
DO NOT cycle the tool without a die in place.
Damage to the stripping blades may occur.
CAUTION
Die Set Must Be
Installed in Tool
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
specificneeds.
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.
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.
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
individualwire 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
CAUTION
CAUTION

408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
Rev H6 of 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.
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) to Tyco Electronics for evaluation
(refer to Section 7).
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
69.8[2.75]
(Handles
Closed)
30.5[1.20] 197[7.75]
3
2
18 9 74 5
6
10
Weight: .3 kg [.75 lb] (Approx)
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1 993314–1 SCREW, Pan Head 4–40
 .250 L (Die Holding) 1
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–[ ] Y 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
Y Refer to Figure 2 for a cross–reference of tool to die set part numbers.
Figure 8 (cont’d)

408–9767
Modular Plug Hand Tool (Premium Grade) 231652–[ ]
7of 7Rev H
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