408-9767 Datasheet, PDF (2/6 Pages) TE Connectivity Ltd – Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.

408-9767
3. CABLE PREPARATION
Refer to Figure 3, and select the appropriate cable and
die set for the modular plug being used.
MODULAR PLUG
POSITION TYPE
CABLE
TYPE
STYLE
DIE SET
COLOR
CODE DOT
2
Line
Stranded Flat Oval
Blue
Solid
Handset _Stranded Flat Oval
Green
4
Line
Stranded
Flat Oval Blue
Blue
Solid
Solid
Round
Line
Blue
Stranded Flat Oval
Blue
Solid
Flat Oval
Blue
6
Offset Latch Solid
Flat Oval Orange
Long Body ^Solid
Unshielded _Stranded
Flat Oval
Round
Violet
Long Body
Shielded
Stranded
Flat Oval
Violet
Stranded Round
Solid
Unshielded
Stranded
Flat Oval
8
Solid
Round
Black
Blue
Solid
Flat Oval
Keyed,
Non-Keyed
Stranded
Flat Oval
Shielded Stranded Round
Non-Keyed Stranded Flat Oval Red
8
Unshielded
(High
Performance) _Shielded
Stranded
Solid
Stranded
Solid
Round
White
Stranded
Unshielded
8
(Slimline)
Solid
Round
Red
Stranded
Shielded
Solid
 The BLACK color-coded tool and die set can be used for non-keyed
modular plugs; however, the RED color-coded tool and die set are more
durable when crimping non-keyed modular plugs.
 Standard modular plugs are designed to be used with cable having an
outside diameter of 0.89 to 0.99 mm [.035 to .039 in.]. Use blue (small
conductor) modular plugs with cable having an outside diameter of 0.74 to
0.86 mm [.029 to .034 in.].
Figure 3
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.
NOTE
i
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.
NOTE
i
DO NOT cut or remove insulation from individual
conductors. This may result in shorted or open
terminations within the terminated assembly.
4. TERMINATION PROCEDURE
Before proceeding, make sure that the cable and
modular plug are compatible, and that cable polarity is
correctly maintained for the specific application.
Before proceeding with 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.
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.
Rev R
2 of 6