Jan 2017, REV T

Transcription

1 Modular Plug Hand Tools (Premum Grade) [ ] Instructon Sheet Jan 2017, REV T 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. 1. INTRODUCTION Modular Plug Hand Tools [ ] (shown n Fgure 1) are desgned to termnate modular plug connectors onto stranded or sold, shelded or unshelded flat oval cable or round cable. The tool also cuts and strps unshelded flat oval cable. Other cable must be prepared by separate tools. Each tool ncludes De Set ( [ ]) (see Fgure 2), except Tool whch s avalable wthout a de set. The de sets are also avalable separately. All numercal values n ths nstructon sheet are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Fgures are not drawn to scale. Reasons for ressue of ths nstructon sheet are provded n Secton 8, REVISION SUMMARY. Cable Cutter Cable Strpper Indenter (De) Color Code Dot Fgure 1 De Holdng Screw Ratchet Release (Pawl) Handle Nest (De) Color Code Dot Ratchet DO NOT cycle the tool wthout a de n place; otherwse, damage to the strppng blades may occur. 2. DESCRIPTION (FIgure1) The de set conssts of a nest and an ndenter, each marked wth a color-code dot. The de set s held n the tool by a sngle de-holdng screw. Each de set s unque to ts purpose, but de sets can be nterchanged to accommodate any modular plug. Refer to Fgure 2. The tool features a wre cutter and flat oval cable strpper to prepare unshelded flat oval cable. The tool handle 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 modular plug. TOOL The BLACK color-coded tool and de set can be used for non-keyed modular plugs; however, the RED color-coded tool and de set are more durable when crmpng non-keyed modular plugs. Includes JacKnack Tool ( ). PART NUMBER Fgure 2 DIE SET COLOR CODE DOT Black Green Orange Volet Blue Whte Red Gray DESCRIPTION (Modular Plug Type) 8-Poston Lne Keyed, Non-Keyed Shelded 4-Poston Handset 6-Poston Offset Latch 6-Poston Long Body 2-, 4-, 6-Poston Lne 8-Poston Hgh Performance 8-Poston Lne Non-Keyed 8-Poston Slmlne Category 6/6A The des bottom before the ratchet releases. Ths feature ensures maxmum electrcal and tensle performance of the crmp. DO NOT re-adjust the ratchet. To obtan nformaton on CommScope products vst our webste at CommScope, Inc. All Rghts Reserved Ths product s covered by one or more U.S. patents or ther foregn equvalents. For patents, see 1 of 6

2 3. CABLE PREPARATION Refer to Fgure 3, and select the approprate cable and de set for the modular plug beng used. MODULAR PLUG CABLE DIE SET COLOR POSITION TYPE TYPE STYLE CODE DOT 2 Lne Blue (Hgh Performance) 8 (Slmlne) Handset Lne Blue Lne Green Blue Blue Blue Blue Offset Latch Orange Long Body Unshelded Long Body Shelded Unshelded Volet Volet Blue Keyed, Non-Keyed Shelded Black Non-Keyed Red Unshelded Shelded Unshelded Shelded Whte Red The BLACK color-coded tool and de set can be used for non-keyed modular plugs; however, the RED color-coded tool and de set are more durable when crmpng non-keyed modular plugs. Standard modular plugs are desgned to be used wth cable havng an outsde dameter of 0.89 to 0.99 mm [.035 to.039 n.]. Use blue (small conductor) modular plugs wth cable havng an outsde dameter of 0.74 to 0.86 mm [.029 to.034 n.]. Fgure 3 Proceed as follows: 3.1. Unshelded Cable (Fgure 4) 1. Insert 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 (but not released) grp head of tool n one hand and cable n the other; then pull cable straght out of tool. 4. Check cable strp length as shown n Fgure Shelded Cable and Cable Prepare the cable accordng to Applcaton Specfcaton Hgh Performance Cable Prepare the cable accordng to Applcaton Specfcaton DO NOT cut or remove nsulaton from ndvdual conductors. Ths may result n shorted or open termnatons wthn the termnated assembly. 4. TERMINATION PROCEDURE Before proceedng, make sure that the cable and modular plug are compatble, and that cable polarty s correctly mantaned for the specfc applcaton. Before proceedng wth hgh performance modular plugs, refer to for preparaton technques to ensure hgh performance levels. Refer to Fgure 5, and proceed as follows: 1. Hold modular plug as shown (lockng latch facng UP). Insert cable nto modular plug untl fully bottomed. 2. Open tool handles. Insert modular plug assembly fully nto de cavty. When usng a de set color coded wth green, orange, or blue, make sure that the modular plug lockng latch snaps nto poston. When usng a de set color coded wth black, volet, or whte, make sure that the modular plug bottoms n the de cavty but the lockng latch does not snap nto poston. Falure to fully seat the modular plug assembly n the de cavty wll cause the ndenter to ms-algn wth the nternal stran relefs of the modular plug, whch may result n damage to the de set. 3. Hold the modular plug n the fully seated poston, and squeeze tool handles untl ratchet releases. 2 of 6

3 Fgure 4 Fgure 5 3 of 6

4 When crmpng, make sure to hold the modular plug n the fully seated poston to prevent the modular plug from pushng out durng the termnaton procedure. 4. Depress the modular plug lockng latch (f applcable), and remove termnated modular plug assembly from the tool. 5. Inspect the modular plug assembly for proper crmp heght usng a dal ndcator or dgtal ndcator wth needle-pont probes. Refer to Fgure 6 for a typcal termnated modular plug, proper crmp heght dmenson, and requred locaton of the conductors. A vsual nspecton through the plastc housng of the modular plug should reveal whether the conductors are wthn acceptable range. 6.02±0.13 [.237±.005] B (See Table) MODULAR PLUG TYPE For specfc nformaton concernng nspecton requrements, refer to for standard and blue (small conductor) modular plugs and for hgh performance modular plugs. Termnated Modular Plug Inspecton (Cross-Secton Shown) CONDUCTOR LOCATION A (Reference Zone) Fgure 6 Crmp Heght Gage s avalable to be used as a quck verfcaton of acceptable crmp heght. Refer to for nstructons on usng the gage. See Fgure 7. The gage cannot be used for 4-poston handset or 6-poston offset modular plugs. Fgure 7 B (Preferred) Standard and [ ] Conductors Aganst End of Hgh Performance [ ] Wre Crcuts Modular Plug (Ref) Termnal A (See Table) Note: Not to Scale Crmp Heght Gage 5. ADJUSTMENTS Once a termnaton has been made, DO NOT re-termnate the modular plug. Replace damaged modular plugs wth new ones Changng De Set 1. Squeeze the tool handles untl the ratchet releases. 2. Usng a small flat blade screwdrver or cross-recessed screwdrver, turn the de holdng screw counterclockwse, and remove t. 3. Usng the screwdrver, push the de set out of the tool. 4. Insert the de set wth the color dots facng outward as shown n Fgure Close the tool handles. Re-nstall the de holdng screw. Turn the screw clockwse untl t s tght Adjustng Cable Strpper (Fgure 8) If the cable jacket s cut too shallow and does not strp properly from the conductor bundle or f t s cut too deeply and the conductor nsulaton s also cut, adjust the flat oval cable strpper on the tool accordng to the followng. The de set must be n the tool when adjustng the flat oval cable strpper. 1. Close the 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 Blade Set-Up Gage (avalable separately and part of Blade Replacement Kt ) or a 1.02 [.040] shm between the statonary and movable blades. Slde the movable blade aganst the gage or shm, and tghten the screws. The recommended shm thckness does not account for a larger than normal conductor nsulaton. Adjust the blade gap accordng to specfc needs Replacng Cable Strpper Blades (Fgure 8) If the flat oval cable strpper blades are worn or damaged, replace the fxed blade assembly and movable blade assembly accordng to the followng. 1. Remove the four screws holdng both blades n place. Remove the fxed blade assembly and movable blade assembly from the tool. 2. Poston the new blades onto the tool wth the beveled edges facng nward. 3. Install and tghten the screws. Adjust the flat oval cable strpper accordng to Paragraph of 6

5 Movable Blade Assembly Screw (2 Places) Fgure 8 6. MAINTENANCE AND INSPECTION Inspect the 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 the tool wth the handles closed n a clean, dry area Daly Mantenance Adjustng Cable Strpper De Set Must Be Installed n Tool Blade Set-Up Gage (Ref) : DO NOT cycle the tool wthout the de set n place; otherwse, damage to the strppng blades may occur. Replacng Blades n Cable Strpper Fxed Blade Assembly Beveled Edges of Blades Face Inward Movable Blade Assembly Cable (Ref) Movable Blade Support Plate 6.4 [.25] (Length) Screw (2 Places) Fxed Blade Support Plate 9.7 [.38] (Length) Screw (2 Places) Falure to perform daly mantenance and perodc nspecton can cause defectve modular plug termnatons leadng to dscontnutes on ndvdual wre crcuts. Foregn partcles should be cleaned 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 Perodc Inspecton DO NOT lubrcate surfaces of the de set that contact the product. These areas must be kept clean to ensure a usable modular plug assembly. It s recommended 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 1. Remove the de set from the tool, then remove all lubrcaton, accumulated flm, and debrs by mmersng the des and tool head n a mld commercal degreaser. 2. Check for mssng or defectve pns, rngs, or other retanng hardware. Replace parts as necessary. 3. 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 tool and de set s nspected for proper 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. 3. Release the handles to open the de set, and remove the termnated modular plug assembly. 4. Test the crmp for proper crmp heght accordng to Step 4 n Secton 4. If the plug crmp heght s wthn acceptable lmts, lghtly lubrcate the tool and de set. If the crmp heght s not wthn acceptable lmts, return the tool (wth de set) for evaluaton (refer to Secton 7). 7. REPLACEMENT AND REPAIR Customer-replaceable parts are provded n Fgure 9. A blade replacement kt and hand tool kts are avalable separately. A complete nventory should be stocked and controlled to prevent lost tme when replacement of parts s necessary. Order replacement parts through your CommScope account representatve. 5 of 6

6 For tool evaluaton and customer repar servce, contact your CommScope account representatve. 8. REVISION SUMMARY Revsons to ths nstructon sheet nclude: Rebranded to CommScope. Updated tables n Fgures 2 and 9. ITEM PART NUMBER DESCRIPTION QTY PER TOOL SCREW, Pan Head (De Holdng) 4-40 x.250 Long PIN, Grooved RING, Retanng, Crescent PIN, Center, Straght RING, Retanng, Crescent [ ] DIE SET TOOL ASSEMBLY FRAME (Wthout De Set) RING, Retanng, Crescent PIN, Handle (Pawl) BLADE REPLACEMENT KIT 1 Refer to Fgure 2 for cross-reference of tool-to-de set part numbers. Avalable separately: PART NUMBER DESCRIPTION BLADE REPLACEMENT KIT Blade Set-Up Gage, 4 Pan Head Screws, 1 Cutter Blade Screw, 5 Wre Cutter Blades, 5 Fxed Blade Holders, 5 Slder Blade Assembles HAND TOOL KIT Carryng Case, Screwdrver, Set of Strp Blades, Cutoff Blade, 2 Support Plates, 4 Pan Head Screws, and JacKnack Tool HAND TOOL KIT Same tems as n Kt and: Modular Plug Hand Tool and the followng De Sets: 4-Poston Lne, 6-Poston Lne, and 8-Poston HAND TOOL KIT Same tems as n Kt and: Modular Plug Hand Tool and the followng De Sets: 4-Poston Lne, 6-Poston Lne, 8-Poston, and 4-Poston Handset HAND TOOL KIT Same tems as n Kt and: Modular Plug Hand Tool and the followng De Sets: 4-Poston Handset, 4-Poston Lne,6-Poston Lne, 8-Poston, and 8-Poston Hgh Performance Fgure 9 6 of 6