Instruction Sheet
Modular Plug Hand Tool
408–9767
E
2002 Tyco Electronics Corporation, Harrisburg, PA.
All International Rights Reserved.
AMP and Tyco are trademarks.
*Trademark
LOC B
1 of 7
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
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
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.
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
Die Holding
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–adjust the ratchet.
OO
CORRESPONDING DIE SET
TOOL
PART
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
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