Termnatng Tools 2-231652- 5 Instructon Sheet and 2-231652- 9 for 408-9770 DEConnect Modular Plugs 29 NOV 10 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended -use, producton operatons s avalable. Indenter Color Code Dot Cable Cutter De Holdng Screw Nest Color Code Dot Flat Oval Cable Strpper Ratchet Ratchet Release (Pawl) : Do NOT cycle hand tool wthout a de n place. Damage to the strppng blades may occur. Handle TERMINATING CORRESPONDING DIE SET TOOL DIE NUMBER COLOR DOT DESCRIPTION 2-231652 -5 853400-6 ORANGE 6 -POSITION OFFSET LATCH 2-231652 -9 853400-9 BROWN 8 -POSITION PLUGS 1. INTRODUCTION Ths nstructon sheet covers Termnatng Tool 2--231652--5 whch ncludes de set 853400--6 for 6--poston DECconnect Modular Plug Connectors wth offset latch, and tool 2--231652--9 whch ncludes de set 853400--9 for 8--poston plugs. See Fgure 1. These tools also can cut and strp flat cables. Other cables pctured n Fgure 2 wll also termnate to the plugs, but must be cut and strpped by separate tools. Fgure 1 All dmensons are n mllmeters [followed by nches n brackets]. Fgures and llustratons are for dentfcaton only and are not drawn to scale. Read these nstructons completely and understand them before usng the termnatng tools. Reasons for ressue of ths nstructon sheet are provded n Secton 8, REVISION SUMMARY. These tools may accept other de sets (avalable separately) for other szes of the modular plug or to replace a worn or damaged de set. Refer to Instructon Sheet 408-9767. DEConnect s a trademark. 2. DESCRIPTION Each tool features a de set unque to ts purpose, but de sets can be replaced n ether tool to accommodate all modular plugs. A de set conssts of a nest and ndenter, each wth the same color dot code, one each on the nest and ndenter. The des E2010 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Rghts Reserved PRODUCT INFORMATION 1-800 -522-6752 TE logo and Tyco Electroncs are trademarks. *Trademark. Other product names, logos, or company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 6 LOC B
Termnatng Tools 2-231652- 5 and 2-231652- 9 are held n the tool by a sngle de holdng screw. The tools also ncludes a wre cutter and jacket nsulaton strpper to prepare the approprately szed cable. See Fgures 1 and 2. The tool handles ensures full crmpng. Once engaged, the ratchet wll not release untl the handles have been FULLY closed, unless the ratchet release (pawl) s depressed to manually release the ratchet. When depressed, the pawl prevents crmpng of an mproperly postoned connector. De sets may be purchased separately, ether for other szes of plugs or to replace a worn or damaged de set. (Refer to Paragraph 5.3). The des bottom before the ratchet releases. Ths desgn feature ensures maxmum electrcal and tensle performance of the crmp. Do NOT re -adjust the ratchet. Round Cable (Typ) Flat Oval Cable (Typ) Shelded Cable (Typ) Modular Plug Connector (Typ) (6 -Posn Shown) POSN MODULAR PLUG DESC CABLE PART NUMBER TYPE STYLE ASSEMBLY NUMBER HAND TOOL COLOR DOT DIE SET NUMBER 555019 SOLID ROUND 555020 STRANDED FLAT OVAL 6 OFFSET 555238 STRANDED ROUND 2-231652 -5 ORANGE 853400-6 555236 SOLID FLAT OVAL 555237 STRANDED FLAT OVAL 554169 STRANDED ROUND LINE 554720 SOLID FLAT OVAL 554739 STRANDED FLAT OVAL 557315 SOLID ROUND BLUE -SMALL CONDUCTOR 557972 SOLID FLAT OVAL 557973 STRANDED FLAT OVAL 555417 SOLID FLAT OVAL 8 KEYED 554743 STRANDED FLAT OVAL 2-231652 -9 BROWN 853400-9 554170 STRANDED ROUND 569530 SOLID ROUND SHIELDED 556179 STRANDED ROUND 569542 STRANDED FLAT OVAL 569531 SOLID ROUND SHIELDED -KEYED 556592 STRANDED FLAT OVAL 569543 STRANDED FLAT OVAL STRIP LENGTH 6.35-7.14 [.25 -.28] 12.7-14.2 [.50 -.56] : Small conductor products are for 0.74-0.86 mm [.029 -.034 n.] OD conductors. Regular products are for 0.89-0.99 mm [.035 -.039 n.] OD Conductors. Fgure 2 2 of 6 Tyco Electroncs Corporaton
Termnatng Tools 2-231652- 5 and 2-231652- 9 3. CABLE PREPARATION Refer to Fgure 2 and select the approprate 6--wre or 8--wre jacketed cable for the modular plug connector beng used. Then cut and strp the cable as follows: 3.1. Unshelded Flat Oval Cable 1. Refer to Fgure 3 and nsert cable squarely nto CUT slot n tool cable cutter. Squeeze handles untl ratchet releases. 2. Insert trmmed cable nto STRIP slot n tool flat oval cable strpper untl cable butts aganst de cable stop. 3. Close handles to last ratchet stop, but DO NOT release them. Pull cable straght out of tool. Then release tool handles. DO NOT squeeze handles together whle pullng cable out. Rather, wth handles closed (and not released0 grp head of tool n one hand and cable n other; then pull cable straght out of tool. 4. Check cable strp length as shown n Fgure 2. 3.2. Shelded Flat Oval and Jacketed Round Cable Prepare the cable accordng to Applcaton Specfcaton 114--6016. DO NOT cut or remove nsulaton from ndvdual conductors. Ths may result n shorted or open termnatons wthn the fnshed modular plug cable assembly. 4. TERMINATION PROCEDURE Step 1 Step 2 Step 3 Cuttng and Strppng Unshelded Flat Oval Cable Unshelded Flat Oval Cable CUT Slot STRIP Slot De Cable Stop All vews of termnatng procedures show 6 -poston offset modular plugs. Procedures are dentcal, and correspondng vews would be smlar for 8 -poston plugs. Before proceedng, double--check to be sure that the cable and plug are compatble, and that cable polarty s correctly mantaned for your specfc applcaton. Refer to Fgure 4 and proceed as follows: Handles Closed 1. Hold plug as shown (lockng tab facng UP). Insert cable nto plug untl fully bottomed. 2. Open tool handles. Insert plug assembly fully nto de cavty. Make sure that the plug bottoms nto place. Falure to fully seat the plug assembly n the cavty wll cause ndenter to msalgn wth plug stran -relef cavtes, whch may result n de set damage. Step 4 3. Squeeze handles untl ratchet releases. Depress lockng tab (f applcable) and remove termnated modular plug cable assembly. Fgure 3 Note: Not to Scale Cable Strp Length RefertoFgure2 Tyco Electroncs Corporaton 3 of 6
Termnatng Tools 2-231652- 5 and 2-231652- 9 4. After releasng the termnated plug, nspect for proper crmp heght usng a dal ndcator or dgtal ndcator wth needle--pont probes, or Crmp Heght Gage 904170--1 accordng to 408--4389. 5. Fgure 5 shows a cross--secton of a typcal termnated plug proper crmp heght dmenson and requred locaton of the conductors. A vsual nspecton through the plastc housng of the plug should reveal whether the conductors are wthn acceptable range. Step 1 Refer to 114-6016 for specfc nformaton concernng nspecton requrements. Termnatng Modular Plug Plug Lockng Tab CableBottomednPlug Crmped Modular Plug Inspecton 6.02+0.13 [.237+.005] Crmp Heght Fgure 5 5. TOOL ADJUSTMENTS 5.1. Adjustng the Cable Strpper If cable jacket s cut too shallow and does not strp properly from the conductor bundle, or f t s cut too deeply and conductor nsulaton s also cut, then refer to Fgure 6 and adjust the cable strpper on the hand tool as follows: 0.64 [.025] (Max) Conductor Locaton Cross -Secton of Crmped Modular Plug The de set must be n the tool when adjustng the flat cable strpper. Step 2 De Cavty Plug Orented as ShownonSde of Tool Head Do NOT cycle hand tool wthout a de n place. Damage to the strppng blades may occur. 1. Close tool handles untl the des bottom, but DO NOT release the handles. 2. Loosen the two screws that hold the movable blade assembly. 3. Insert the blade set--up gage (part of the blade replacement kt ncluded wth the tool) or a 1.02 mm [.040 n.] shm between the statonary and movable blades. Slde the movable blade aganst the gage (or shm) and tghten the screws. Step 3 Lockng Tab (Ref) The recommended shm thckness does not account for larger than normal conductor nsulaton. Adjust the blade gap accordng to your specfc needs. 5.2. Replacng Cable Strpper Blades If the cable strpper blades are worn or damaged, refer to Fgure 7 and replace the fxed blade assembly and movable blade assembly as follows: 1. Remove the four screws holdng both blades n place. Remove fxed blade assembly and movable blade assembly from tool. Fgure 4 2. Poston new blades onto tool wth beveled edges facng nward. 4 of 6 Tyco Electroncs Corporaton
Termnatng Tools 2-231652- 5 and 2-231652- 9 3. Install and tghten screws. Adjust cable strpper accordng to Paragraph 5.1. Screw (2 Places) Adjustng the Cable Strpper Movable Blade Assembly 6. MAINTENANCE AND INSPECTION Inspect the hand tool and de set mmedately upon arrval at your faclty and at regularly--scheduled ntervals thereafter to ensure that they have not been damaged. When not n use, store wth tool handles closed n a clean, dry area. 6.1. Daly Mantenance At the close of each shft, the responsble operator should clean foregn partcles from the tool usng a soft, clean, lnt--free cloth or brush. Make sure all pns, rngs and other retanng hardware s n place, and that the de set s undamaged. Lghtly lubrcate all pns, pvot ponts and bearng surfaces usng a good grade SAE 20 motor ol. Do not lubrcate excessvely. Blade Set -Up Gage (Ref) DO NOT lubrcate surfaces of the de set that contact the product. These areas must be kept clean to ensure a usable modular plug cable assembly. Fxed Blade Assembly Beveled Edges of Blades Face Inward Movable Blade Assembly Replacng Blades n Cable Strpper 6.4 [.25] (Length) Screw (2 Places) Fgure 6 5.3. Replacng or Changng the De Set Fxed Blade Support Plate Cable (Ref) Movable Blade Support Plate 9.7 [.38] (Length) Screws (2 Places) Replace worn de set, or change to another de set as follows: 1. Refer to Fgure 1 and remove de holdng screw. Slde de ndenter and nest out of tool. 2. Insert new de set and secure n place. To order replacement des, refer to the part numbers lsted n Fgure 2 and call 1-800 -526-5142. 6.2. Perodc Inspecton We recommend that the followng nspectons be conducted at least once a month by qualty control personnel. More frequent nspectons should be conducted f your work envronment, company standards, or amount of tool use ndcates the need. A. Vsual Inspecton Remove de set from the tool; then, remove all lubrcaton and accumulated flm and debrs by mmersng the des and tool head n a mld commercal degreaser. 1. Check for mssng or defectve pns, rngs, or other retanng hardware. Replace parts as necessary. 2. Closely nspect des for damage, gvng specal attenton to bearng surfaces and surfaces that contact the product. Worn, cracked, ptted, or chpped ndenter or nest surfaces, or other obvous wear or damage to the de set or tool head requres removal of the affected part from servce. B. De Closure Inspecton The hand tool and de set s nspected for correct operaton before shpment. To ensure unform performance over the lfe of the tool, perodcally nspect as follows: 1. Insert a properly strpped cable of approprate type and sze nto a sample modular plug. Then nsert the untermnated cable and plug nto the de cavty. 2. Squeeze tool handles together slowly, whle watchng to ensure ndenter bottoms aganst nest. Tyco Electroncs Corporaton 5 of 6
Termnatng Tools 2-231652- 5 and 2-231652- 9 3. Release handles to open de set and remove termnated cable assembly. 4. Test for proper crmp heght accordng to Secton 4, Step 4. If plug crmp heght s wthn acceptable lmts, lghtly lubrcate the tool and de set and place t back nto servce. If the crmp heght s not wthn acceptable lmts, return the tool (wth the de set) for evaluaton (refer to Secton 7). 7. REPLACEMENT AND REPAIR Customer--replaceable parts are provded n Fgure 7. A complete nventory should be stocked and controlled to prevent lost tme when replacement of parts s necessary. Order replacement parts through your Tyco Electroncs Representatve, or call 1--800--526--5142, or send a facsmle of your purchase order to 717--986--7605 or wrte to: CUSTOMER SERVICE (038--035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105--3608 8. REVISION SUMMARY Snce the prevous release of ths document, the followng changes were made: S Updated document to corporate requrements 6 1 2 3 4 5 8 9 7 Weght:.3 kg [.75 lb] (Approx) 69.8 [2.75] (Handles Closed) 10 30.5 [1.20] 197 [7.75] REPLACEMENT PARTS ITEM DESCRIPTION TOOLING PART NUMBER 2-231652-5 2-231652-9 QTY PER TOOL 1 SCREW, Pan Head 4-40 x.250 L (De Holdng) 993314-1 993314-1 1 2 PIN, Grooved 4-23619 -8 4-23619 -8 2 3 RING, Crescent Retanng 21045-3 21045-3 4 4 PIN, Center 2-23620 -5 2-23620 -5 1 5 RING, Crescent Retanng 21045-6 21045-6 2 6 DIE SET 853400-6 853400-9 1 7 TOOLING ASSEMBLY, (Wthout De Set) 2-231652 -0 2-231652 -0 1 8 RING, Crescent Retanng 21045-1 21045-1 2 9 PIN, Handle (Pawl) 768522-1 768522-1 2 10 KIT, Blade Replacement (Conssts of a blade set -up gage, 5 sets of strp blades, 5 cutoff blades, 2 support plates, and 5 pan head screws. Fgure 7 231662-4 231662-4 Not Included 6 of 6 Tyco Electroncs Corporaton