Application Specification
Modular Plug Connectors
(Standard and Small Conductor)
114-6016
07 OCT 08
Rev G
NOTE
i
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2 .
Figures and illustrations are for identification only and are not drawn to scale.
_
1. INTRODUCTION
This specification covers the requirement for application of standard and small conductor Modular Plug
Connectors for voice and data applications. The modular plugs are available in standard and small conductor,
unshielded or shielded, with 2, 4, 6, 8, or 10 terminals on 1.02 [.040] centerline spacing. These modular plugs
are also available in line and keyed housing styles. The modular plugs contain solid wire terminals or stranded
wire terminals; each terminal design optimized for its specific application.
The modular plugs accept flat oval (“silver satin”) cable or round jacketed, unshielded or shielded cable with 2,
4, 6, 8, or 10 conductors. Specific wire approved is tinsel wire size 28 AWG, 7– and 19–strand wire, stranded
wire sizes 28 through 24 AWG, and solid wire sizes 26 through 24 AWG. Wire size 24 AWG is approved
provided the insulated conductor outside diameter is less than or equal to 0.99 [.039].
Each modular plug features two internal strain reliefs to protect the modular plug–to–cable and
terminal–to–conductor interface from damage when subjected to pulling or bending forces—the primary strain
relief grips the jacket and the secondary strain relief acts on the conductors. These modular plugs are
terminated using the insulation piercing technique. The modular plugs are available in loose piece for
terminating with manual or pneumatically–powered tools.
When corresponding with personnel, use the terminology provided in this specification to facilitate your
inquiries for information. Basic terms and features of this product are provided in Figure 1.
Unshielded Modular Plug
Terminal 1
Secondary (Conductor)
Strain Relief
Terminal 1
Shielded Modular Plug
Primary (Jacket)
Strain Relief
Housing
Housing
Locking Latch
Shield
Cable
Opening
Solid Wire Terminal
Termination
Stranded Wire Terminal
Termination
Figure 1
E
2008 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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LOC B
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
Modular Plug Connectors (Standard and Small Conductor)
114-6016
2. REFERENCE MATERIAL
2.1. Revision Summary
S
S
S
S
S
Updated document to corporate requirements
Removed offset modular plugs
Removed strip form modular plugs
Removed obsolete Hand Tool 231649–1 and Modular Plug Adapter 318510–1
Removed AMP–O–LECTRIC* Model “G” terminating machines (and applicators) and 626 pneumatic
tooling assemblies (and straight action tool holder assemblies)
2.2. Customer Assistance
Reference Product Base Part Number 554739 and Product Code 1423 are representative of Modular Plug
Connectors (standard and small conductor). Use of these numbers will identify the product line and expedite
your inquiries through a service network established to help you obtain product and tooling information. Such
information can be obtained through a local Representative or, after purchase, by calling PRODUCT
INFORMATION at the number at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, call PRODUCT INFORMATION at the number at the bottom of page 1.
2.4. Specifications
Product Specification 108–1163 provides product performance and test information.
Application Specification 114–6053 provides product description and application requirements for high
performance modular plug connectors, and 114–2048 (through hole) and 114–6040 (surface mount) provides
product description and application requirements for mating modular jack assemblies.
2.5. Instructional Material
Instruction Sheets (408–series) provide product assembly instructions or tooling setup and operation
procedures and Customer Manuals (409–series) provide machine setup and operating procedures. Documents
available which pertain to this product are:
408–3151
408–4093
408–4167
408–4389
408–9743
408–9767
408–9919
409–10010
Modular Plug Connector Chordal Hand Tool 231648–1
(For 2–, 4–, and 6–Position Line Modular Plugs)
PRO–CRIMPER* III Hand Tool Assembly 58560–1 (For 10–Position Modular Plugs)
PRO–CRIMPER III Hand Tool Assembly 224928–1 (For External Strain Relief Application)
Crimp Height Gage 904170–1
Terminating Modules 856196–[ ] for Use with Modular Plug Dual Terminators 1320840–[ ]
Modular Plug Hand Tools (Premium Grade) 231652–[ ]
Modular Plug Single Terminators 354711–[ ] and Tooling Kits 354714–[ ]
Modular Plug Dual Terminators 1320840–[ ]
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Modular Plug Connectors (Standard and Small Conductor)
114-6016
3. REQUIREMENTS
3.1. Material
Modular plug housings are made of flame retardant polycarbonate rated Underwriter Laboratories, Inc. (UL) 94
V–0. The terminals are made of phosphor bronze under–plated with nickel; terminal area is plated with gold,
and insulation piercing tips are plated with gold flash. Shields are made of brass plated with bright tin–lead and
under–plated with copper. External strain reliefs are made of brass plated with tin and under–plated with
copper.
3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the modular plug
material.
B. Shelf Life
The modular plugs should remain in the shipping containers until ready for use to prevent plating damage
to the terminals. The modular plugs should be used on a first in, first out basis to avoid storage
contamination that could adversely affect performance.
3.3. Chemical Exposure
Do not store modular plugs near any chemical listed below as they may cause stress corrosion cracking in
the terminals.
Alkalies
Amines
3.4. Cable Selection
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
Standard modular plugs accept cable with insulated conductor outside diameter range of 0.74 through 0.99
[.029 through .039].
Small conductor modular plugs accept cable with insulated conductor outside diameter range of 0.74 through
0.86 [.029 through .034]. These modular plug housings are tinted blue to differentiate from standard modular
plugs.
NOTE
Not all standard modular plugs have a small conductor modular plug equivalent.
i
A. 2- and 4-Conductor Cable
Conductor sizes: 28, 26, or 24 AWG with insulation outside diameter of 0.74 through 0.99 [.029 through
.039]. For the modular plug to accept the conductor, the maximum diameter (0.99 [.039]) must not be
exceeded
Conductor types: tinsel (28 AWG only), 28 through 26 AWG 7–strand wire, or 26 through 24 AWG solid
wire
Cable jacket insulation types:
1. Flat oval
Height: 2.29+0.25 [.090+.010]
Width for 2–conductor: 3.81+0.13 [.150+.005]
Width for 4–conductor: 4.83+0.25 [.190+.010]
2. Round
Maximum outside diameter: 2.54 [.100]
Rev
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Modular Plug Connectors (Standard and Small Conductor)
114-6016
B. 6-Conductor Cable
Conductor sizes: 28, 26, or 24 AWG with insulation outside diameter of 0.74 through 0.99 [.029 through
.039]. For the modular plug to accept the conductor, the maximum diameter (0.99 [.039]) must not be
exceeded.
Conductor types: unshielded: 7–strand wire for sizes 28 through 26 AWG or solid wire for sizes 26 through
24 AWG, shielded: 7–strand wire, 5 conductors for sizes 28 through 26 AWG and 1 drain wire sizes 24
through 22 AWG or 6–conductor cable with drain wire
Cable jacket insulation types:
1. Unshielded flat oval
Height: 2.29+0.25 [.090+.010]
Width: 6.60+0.25 [.260+.010]
2. Shielded flat oval
Height: 2.79 [.110] max
Width: 6.86 [.270] max
3. Round: 4.57 [.180] max outside diameter
Shield type: metalized polyester foil
C. 8- and 10-Conductor Cable
Conductor sizes: 28, 26, or 24 AWG with insulation outside diameter of 0.74 through 0.99 [.029 through
.039]. For the modular plug to accept the conductor, the maximum diameter (0.99 [.039]) must not be
exceeded.
Conductor types: unshielded: 7–strand wire for sizes 28 through 24 AWG or solid wire for sizes 26 through
24 AWG, shielded: 7–strand wire, 7 conductors for sizes 28 through 24 AWG and 1 drain wire sizes 24
through 22 AWG or 8–conductor cable with drain wire
Cable jacket insulation types:
1. Unshielded flat oval
Height: 2.29+0.25 [.090+.010]
Width: 8.89+0.25 [.350+.010]
2. Shielded flat oval
Height: 2.79 [.110] max
Width: 9.02 [.355] max
3. Round: 5.46 [.215] max outside diameter
Shield type: metalized polyester foil only, braided shield should not be used
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Modular Plug Connectors (Standard and Small Conductor)
114-6016
3.5. Cable Preparation
Proper strip length is necessary to properly insert the cable into the modular plugs. The strip length for the
cable and specific cable and modular plug combinations is shown in Figure 2.
NOTE
Reasonable care must be taken not to nick or cut the cable conductor insulation during the stripping operation.
i
Typical Flat Oval Cable
Unshielded
Shielded
Unshielded
Typical Round Cable
Shielded
Insulated
Conductors
Strip Length
Strip Length
MODULAR PLUG
FLAT OVAL
TYPE
POSITION/TERMINAL
Stranded
Solid
CABLE
ROUND
STRIP LENGTH
Stranded
Solid
Unshielded, Handset
4/4
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
n
6.35-7.14
[.25-.28]
12.7-14.3
[.25-.56]
8/8
Unshielded,
Unshielded Keyed
10/10
6/2
6/4
6/6
Unshielded,
Unshielded Line
8/4
8/8
10/10
n
n
n
n
n
n
6.35-7.14
6 35 7 14
n
n
n
n
[.25 .28]
[.25-.28]
12.7-14.3
12 7 14 3
[.50 .56]
[.50-.56]
6/4, 6/6, 8/8
Unshielded,
Unshielded Small Conductor (Blue)
6.35-7.14
[.25-.28]
D
10/10
6/6
8/8
6/6
8/4
n
n
n
n
n
n
n
6.35-7.14
[.25-.28]
14.3 [.56]
14.3 [.56]
14.3 [.56]
Unshielded, Long Body
Shielded, Line
Shielded, Long Body
Shielded, Line
Shielded Line, Keyed
8/8
Shielded, Small Conductor (Blue)
14.3 [.56]
14 3 [ 56]
D
8/8
n
14.3 [.56]
D
For conductor outside insulation diameter range of 0.74 through 0.86 [.029 through .034]
Figure 2
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