Application
Specification
114-6016
26 JAN 16 Rev L
Modular Plug Connectors (Standard and Small Conductor)
NOTE
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 are for
identification only.
1. INTRODUCTION
This specification covers the requirements 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 universal terminals for use with
solid or stranded wire.
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.
Basic terms and features of this product are provided in Figure 1.
Unshielded Modular Plug
Shielded Modular Plug
Terminal 1
Secondary (Conductor)
Strain Relief
Terminal 1
Housing
Primary (Jacket)
Strain Relief
Housing
Locking Latch
Figure 1
Shield
Cable Opening
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
Modified paragraph 1, modified paragraph 2.2 with new Catalog and Customer drawing numbers and
updated product specification in paragraph 2.3.
Removed termination illustrations from figure 1, paragraph 2.3, instruction sheet from paragraph 2.5,
UL rating from paragraph 3.1 and CSA file from section 4.
Restructured paragraph 2-3 and associated sub-sections, modified and/or removed info., revised
figure 2 and added new table 1
Removed 408-3151 info. in paragraph 2.4, reference to chordal hand tool in 5.1 and removed related
figure of hand tool in Figure 8.
2.2. Customer Assistance
Reference product catalog series and drawing numbers:
MP-88_-_-_ Customer drawing number 2843005
1
of 10
© 2015 CommScope, Inc.
All rights reserved
114-6016
MP-66_-_-_ Customer drawing number 2843026
MP-6__-_-_ Customer drawing number 2843025
MP-44U-_-_ Customer drawing number 2843027
MP-1010U-R-_ Customer drawing number 2843028
These catalog series represent standard and small conductor modular plug connectors. Additionally, the
number of contacts vary based on the catalog series selected. Use this information to obtain catalog number/
material number and tooling information.
2.3. Specifications
Product Specification 108-131013 provides product performance and test information.
2.4. 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. Instructional material
that pertains to this product is:
408-4093
408-4167
408-4389
408-9743
408-9767
408-9919
409-10010
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-[ ]
3. REQUIREMENTS
3.1. Material
Modular plug housings are made of flame retardant polycarbonate. The terminals are made of phosphor
bronze under-plated with nickel; terminal area is plated with gold or palladium nickel and gold. Shields are
made of brass plated with bright tin-lead and under-plated with copper or stainless steel plated with nickel.
External strain reliefs are made of brass plated with tin and under-plated with copper.
3.2. Storage
3.2.1.
Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
material.
3.2.2.
Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to
components. The product should be used on a first in, first out basis to avoid storage contamination that
could adversely affect performance.
3.2.3.
Chemical Exposure
Do not store product near any chemical listed below as they may cause stress corrosion cracking in the
material.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
3.3. Cable Selection and Preparation
3.3.1.
Selection
The modular plugs accept the wire described below.
Rev
L
2
of 10
114-6016
Strip
Length
12.7-14.3
[.50-.56]
12.7-14.3
[.50-.56]
14.3
[.56]
14.3
[.56]
14.3
[.56]
14.3
[.56]
12.7-14.3
[.50-.56]
14.3
[.56]
6.35-7.14
[.25-.28]
6.35-7.14
[.25-.28]
14.3
[.56]
14.3
[.56]
14.3
[.56]
14.3
[.56]
6.35-7.14
[.25-.28]
Description
Unshielded 8-Postion
Conductor
(AWG)
1
Insulation OD
Cable
Type
Round
Flat Oval
Round
Flat Oval
Round
Flat Oval
Cable Jack OD
(Max)
0.20"
(5.1mm)
0.10" x 0.35"
(2.54 x 8.89 mm)
0.20"
(5.1mm)
0.10" x 0.35"
(2.54 x 8.89 mm)
0.20"
(5.1mm)
0.10" x 0.35"
(2.54 x 8.89 mm)
0.20"
(5.1mm)
0.18"
(4.6mm)
0.09" x 0.26"
(2.29 x 6.61 mm)
0.195"
(4.96mm)
0.11" x 0.27"
(2.79 x 6.85 mm)
0.195"
(4.96mm)
0.11" x 0.27"
(2.79 x 6.85 mm)
0.09" x 0.26"
(2.29 x 6.61 mm)
24-26 Solid
24-26 Stranded
Shielded 8-Position
0.034" to 0.039"
(0.86 to 0.99mm)
Unshielded 8-Postion,
Small Conductor
26-28 Solid
26-28 Stranded
0.029" to 0.034"
(0.74 to 0.86mm)
Unshielded Keyed, 8-Postion
Shielded Keyed, 8-Position
24-26 Solid
24-26 Stranded
0.034" to 0.039"
(0.86 to 0.99mm)
Round
Unshielded 6-Postion,
Standard Body
Round
Flat Oval
Round
Flat Oval
Round
Flat Oval
26 -28 Solid
26 -28 Stranded
24-26 Solid
24-26 Stranded
26 -28 Solid
26 -28 Stranded
24-26 Solid
24-26 Stranded
24-26 Solid
24-26 Stranded
24-26 Solid
24-26 Stranded
0.029" to 0.034"
(0.74 to 0.86mm)
0.034" to 0.039"
(0.86 to 0.99mm)
0.029" to 0.034"
(0.74 to 0.86mm)
0.034" to 0.039"
(0.86 to 0.99mm)
0.034" to 0.039"
(0.86 to 0.99mm)
0.034" to 0.039"
(0.86 to 0.99mm)
Round
Flat Oval
Round
Flat Oval
Unshielded 6-Postion,
Long Body
24-26 Solid
24-26 Stranded
0.034" to 0.039"
(0.86 to 0.99mm)
Shielded 6-Position,
Long Body
Unshielded 6-Postion, Small
Conductor, Standard Body
Unshielded 6-Postion,
4-Contacts
Unshielded 6-Postion,
2-Contacts
Unshielded 4-Postion,
Headset
Flat Oval
0.09" x 0.26"
(2.29 x 6.61 mm)
6.35-7.14
[.25-.28]
0.11"
(2.8mm)
0.09" x 0.19"
(2.29 x 4.83 mm)
0.21"
(5.3mm)
6.35-7.14
[.25-.28]
6.35-7.14
[.25-.28]
12.7-14.3
[.50-.56]
Unshielded 10-Postion,
Note 1: Typical conductor size supported by insulation OD. Insulation OD is the determining specification.
Table 1
Rev
L
3
of 10
114-6016
3.3.2.
Preparation
Proper strip length as shown in Figure 2 is necessary to properly insert the cable into the modular plugs.
The strip length for the cable and specific cable and modular plug combinations are shown in Table 1.
NOTE
Reasonable care must be taken not to nick or cut the cable conductor insulation during the stripping operation.
Flat Oval Shielded Cable
This cable must be prepared according to the following. Refer to Figure .
3.3.2.1.1.1.1. Insert a blade tip between the conductors and shield. Slit the jacket and shield 14.29
[9/16] back from the end along one edge of the cable. Repeat on the opposite cable edge.
3.3.2.1.1.1.2.
the jacket.
Pull the slit ends away from the conductors. Separate the shield from the slit ends of
3.3.2.1.1.1.3. Cut off the slit ends of the jacket 14.29 [9/16] from the end of the conductors. Care
should be taken not to cut shield ends.
3.3.2.1.1.1.4.
Fold each shield end back on itself to approximately one-half of its length.
3.3.2.1.1.1.5. Bend each folded shield back on top of the jacket. The shield must extend
approximately 9.52 [3/8] back on the jacket and the exposed conductors must be approximately 14.29
[9/16] in length.
3.3.2.1.1.1.6. If the drain wire is to be terminated within the modular plug, insert the drain wire into
the wire circuit of the modular plug, and terminate according to the instructions packaged with the
applicable tooling.
3.3.2.1.1.1.7. If the drain wire is to be terminated to the modular plug shield, bend the drain wire
back tightly across the center of the cable shield on the side of the cable that will face the locking latch
side of the modular plug when the cable is inserted. Cut the drain wire to the same length as the cable
shield.
Typical Flat Oval Cable
Unshielded
Shielded
Typical Round Cable
Unshielded
Shielded
Insulated
Conductors
Strip Length
(Refer to Table)
Strip Length
(Refer to Table)
Figure 2
Round Shielded Cable
This cable must be prepared according to the following. Refer to Figure .
(a) Insert a blade tip between the shield and jacket. Slit the jacket 15.88 [5/8] back from the end.
3.3.2.1.1.1.8. Pull the jacket away from the shield, and fold it back over the cable. Cut off the slit
portion of the jacket 15.88 [5/8] from the end of the conductors. Care shall be taken not to cut the
shield.
Rev
L
4
of 10
114-6016
3.3.2.1.1.1.9. Find the overlap seam in the shield, and pull the shield away from the conductors while
being careful not to damage the shield.
3.3.2.1.1.1.10. Fold the shield back over the cable.
Flat Oval Shielded Cable
Flat Oval
Shielded Cable
Note:
Not to Scale
Jacket
Shield
14.9 [9/16]
Slit
Conductors
9.52 [3/8]
Shield
Trimmed
Shield
Folded
14.29 [9/16]
Shield Cut
14.29 [9/16] Length
of Exposed
Conductors
Drain Wire
Figure 3
3.3.2.1.1.1.11. Trim the shield to approximately a length of 9.52 [3/8]. Form the shield smoothly
around the outside of the cable. Untwist the conductors and orient them in desired sequence. Trim the
conductors evenly to a length of 14.29 [9/16].
3.3.2.1.1.1.12. If the drain wire is to be terminated within the modular plug, insert the drain wire into
the wire circuit of the modular plug, and terminate according to the instructions packaged with the
applicable tooling.
3.3.2.1.1.1.13. If the drain wire is to be terminated to the modular plug shield, bend the drain wire
back tightly across the center of the cable shield on the side of the cable that will face the locking latch
side of the modular plug when the cable is inserted. Cut the drain wire to the same length as the cable
shield.
Rev
L
5
of 10
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