Application 114-6053

Specification 26 JAN 16 Rev D

High-Performance Modular Plug Connectors

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 high performance modular plug connectors for voice and data applications.
The modular plugs are available in unshielded or shielded with 8 positions on 1.02 [.040] centerline spacing. These modular plugs are
also available in line and keyed housing styles. The modular plugs contain terminals that accept solid or stranded cable.
Each modular plug consists of a housing and a load bar. Each modular plug features an internal primary strain relief to protect the
modular plug-to-cable interface from damage when subjected to pulling or bending forces. 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.
NOTE
High-performance modular plug connectors are intended to be used for Category 5e system applications when terminated in
accordance with the requirements given in this document. These requirements comply with standards developed by
Telecommunications Industry Association and Electronic Industries Alliance (TIA/EIA).
Basic terms and features of this product are provided in Figure 1.

Unshielded Modular Plug

(Shown)
Cable Opening Primary (Jacket)
Strain Relief

Terminal 1 Load Bar

Housing

Locking Latch

Figure 1

2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
 Revised 2.3 to call out new Product Spec.
 Removed UL rating from paragraph 3.1
 Removed 4,6, and 10 position from paragraph 3.3

© 2015 CommScope, Inc. 1 of 10

All rights reserved
 114-6053

2.2. Customer Assistance

Reference product catalog series and drawing number:
 MP-5E_-_ Customer drawing number 2843004
This catalog series represents standard conductor modular plug connectors. 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:
408-4389 Crimp Height Gage 904170-1
408-9743 Terminating Modules 856196-[ ] for Use with Modular Plug Dual Terminators 1320840-[ ]
408-9767 Modular Plug Hand Tools (Premium Grade) 231652-[ ]
408-9919 Modular Plug Single Terminators 354711-[ ] and Tooling Kits 354714-[ ]
409-10010 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 tin or nickel or stainless
steel plated with nickel. 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 product material.

B. 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.
3.3. Chemical Exposure
Do not store product near any chemical listed below as they may cause stress corrosion cracking in the material.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates

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3.4. Cable Selection and Preparation

A. Selection
The modular plugs accept the wire described in the following.
WIRE
MODULAR PLUG INDIVIDUAL INSULATION
TYPE SIZE (AWG)
OUTSIDE DIAMETER
Standard Conductor Solid 23-24 0.89-0.99 [.035-.039]
Standard Conductor Stranded 24-26 0.89-0.99 [.035-.039]

8-position plugs accept cable having an overall round jacket diameter of:
Round: 4.83 [.190] to 5.59 [.220]

B. Preparation
Unshielded Cable
Proper strip length is necessary to properly insert the cable into the modular plugs. The strip length for the cable is given in
Figure 2.
NOTE
Reasonable care must be taken not to nick or cut the cable conductor insulation during the stripping operation.

Shielded Cable
This cable must be prepared according to the following. Refer to Figure 2.
(a) Insert a blade tip between the shield and jacket. Slit the jacket 25.4 [1.0] back from the end. The conductor insulation
must not be nicked.
(b) Pull the jacket away from the shield, and fold it back over the cable. Cut off the slit portion of the jacket. Care shall be
taken not to cut the shield. The conductors enclosed by the shield should extend 25.4 [1.0].
(c) Find the overlap seam in the shield, and pull the shield away from the conductors while being careful not to damage the
shield.
(d) Fold the shield back over the cable.
(e) Trim the shield to approximately 9.52 [3/8] in length. Form the shield smoothly around the outside of the cable. Make
sure that the conductive surface of the shield is exposed; if it is not, form another fold.
(f) 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. Trim the drain wire to the same length as the cable shield.

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Typical Unshielded Cable

Note: Not to Scale

25.4 [1.0]
Approx Strip
Length

Typical Shielded Cable

Shielded
Cable

25.4 Shield
[1.0]
Slit 9.52 [3/8]
Conductors
Jacket Shield
Trimmed
Jacket

Drain Wire

Figure 2

C. Conductor Arrangement
1. The conductors must be grouped in pairs according to the desired electrical schematic (T568A or T568B) given in
figure 3, and the conductor pairs must be arranged in the sequence shown in figure 3, Detail A.
2. The end of the cable jacket must be squeezed so that approximately 8 [.30] of the jacket flattens and the conductor
pairs are side-by-side. The sequence of the conductor pairs should extend into the flat portion of the cable jacket.
Refer to figure 3, Detail A.
3. While holding the end of the cable jacket, the conductor pairs must be untwisted and arranged in the modular plug
positions for the chosen electrical schematic (T568A or T568B) as shown in Figure 3, Detail B. It is critical that the
conductor pairs do not untwist inside the cable jacket. Conductor 6 must be crossed over conductors 4 and 5. It is
extremely important that the twist for conductor 6 be maintained as it crosses over top of conductors 4 and 5. Refer to
figure 3, Detail C.
4. Maintaining the proper orientation of the conductors, the conductors must be trimmed evenly-leaving approximately
19 [.75] from the end of the jacket to the tips of the conductors. See figure 3, Detail C.
NOTE
It is recommended to maintain twist on any conductor pair outside the cable jacket if it can be achieved with conductor pairs
remaining in the chosen electrical schematic.

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Detail A Conductors 1 and 2

Conductors 3 and 6

Conductors 4 and 5
Conductors 7 and 8
8 [.30] (Approx)
Flat Portion

Detail B Modular Plug Positions for Modular Plug Positions for

T568A T568B

Detail C Twist for Conductor Pairs Maintained Inside Cable Jacket

Conductors 4 and 5

Conductor 6
(Twist Maintained)
Trimmed to
19 [.75] (Approx)

CONDUCTOR NUMBER
CONDUCTOR CONDUCTOR COLOR CODE FOR ELECTRICAL
PAIR (Abbreviation) SCHEMATIC
NUMBER (See Note)
OPTION 1 OPTION 2 T568A T568B
1 White-Blue (W-BL) Green (G) 5 5
Blue (BL)■ Red (R) 4 4
2 White-Orange (W-O) Black (BK) 3 1
Orange (O) Yellow (Y) 6 2
3 White-Green (W-G) Blue (BL) 1 3
Green (G)■ Orange (O) 2 6
4 White-Brown (W-BR) Brown (BR) 7 7
Brown (BR)■ Slate (S) 8 8
■ A white marking is acceptable.
Note: Because of their identical pair groupings, cables arranged according to either T568A or T568B may be used
interchangeably provided both ends are arranged with the same pin/pair scheme.
Figure 3

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3.5. Termination Requirements

A. Conductor Location
1. The conductors must be fully inserted into the load bar in the proper orientation. The floor of the load bar between
the cable notch and conductor constraining area may be used to bring the 8-conductor tips into the same plane (this
can be an aid for inserting the conductors into the load bar). The edge of the cable jacket should rest against the
notch of the load bar. The conductors must be trimmed evenly and square to the front edge of the load bar so that
approximately 5 [.20] of each conductor protrudes from the front of the load bar. Refer to Figure 4, Detail A.
2. The load bar must be slid toward the tips of the conductors so that approximately 1 [.04] of each conductor is
exposed. The conductors must not extend too far into the load bar; otherwise, the load bar will twist and become
deformed. Refer to Figure 4, Detail B.

Detail A Detail B
Notch Conductor Slide Load Bar
No. 1 Forward
Position

Load
Bar
1 [.04] of Each Conductor
5 [.20 ] (Conductors Exposed
Trimmed)
Top View
Load Bar
Incorrect Correct
Load Bar Deformed Load Bar Should Be Flat
Bottom View

Notch of Load Bar Against

Edge of Cable Jacket
Figure 4

3. The load bar must be fully inserted into the mating feature within the housing of the modular plug. See Figure 5,
Detail A. The conductors must be completely inserted and bottomed in the wire circuits and clearly visible through
the front of the housing. See Figure 5, Detail B.
NOTE
If the conductors are not bottomed in the wire circuits, the load bar must be remove, conductors re-trimmed, and the
conductors re-inserted. If the conductors are too short, the conductors must be re-stripped.

Detail A Detail B
All Conductors Visible
Housing Through Front of Housing

Mating Feature
Within Housing

Load Bar with Cable Cable Jacket

Against Notch in
Load Bar
Figure 5

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4. After termination, it is preferred that all conductors are bottomed against the end of the wire entry circuits. If
individual conductors are not completely inserted in the housing, they must be inserted at least past the terminal and
into the reference zone to ensure a proper electrical interface. Refer to Figure 6.

B. Crimp Height
The crimp height shall be measured from the top of the terminals to the bottom of the housing (not including locking tab) and
must be within the dimension provided in Figure 6.

NOTE
All terminals must be at approximately the same height. A crimp height gage is available for measuring modular plug crimp
height (refer to Section 5 for part number and description).

C. Internal Strain Reliefs

The primary strain relief must be fully engaged on the cable jacket. The primary strain relief must be fully engaged to isolate the
termination area from external forces applied to the cable. It is acceptable for the primary strain relief to cut into the jacket as long
as the conductor insulation is not compromised. See Figure 6.
NOTE
For unshielded modular plug, the primary strain relief can be visually inspected through the side of the housing.

6.02±0.13 [.237±.005] Primary Strain Relief

Crimp Height Engaging Cable
(Requirement Per FCC Terminal Jacket
Part 68, Subpart F)

Cross-Section
Shown

Conductors Against
End of Wire Circuits
(Preferred Conductor 0.00-0.25 [.000-.010]
Location) Reference Zone (Conductor Location)

Figure 6

3.6. Ancillary Items

A. External Strain Relief

NOTE
The external strain relief can only be used with select 8- and 10-position (shielded and unshielded) modular plugs.

The external strain relief provides a secure grip (360º wrap) on the cable jacket for extraordinary strain relief on the cable and a
redundant low impedance ground path to equipment. For shielded modular plugs, the external strain relief also provides a secure
grip on the foil shield and a chassis ground through the modular plug shield. If a boot is used, an external strain relief containing a
retention hole for securing the boot is available (the boot must be installed after the external strain relief with retention hole).
NOTE
Using the boot and the external strain relief with retention hole will provide optimum strain relief performance.

Assembly of the external strain relief onto the modular plug must meet the requirements given in Figure 7.

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External Strain External Strain Relief Seated

Relief Flat Against Modular Plug External Strain Relief
with Retention Hole (for
Support Barrel Securing the Boot)
Evenly Crimped
and Firm Around
the Cable

Support Barrel Does

Not Cut Into Cable

Figure 7
B. Boot
A boot is used to prevent the cable from kinking and bending too sharp at the modular plug cable opening. The boot is available with or
without a hood. The hooded boot also prevents the modular plug locking latch from snagging other locking latches or cables.
The boots are available to fit cable insulation diameters of 5.33 [.210] through 6.35 [.250] for modular plugs. The maximum cable
diameter is marked on the inside of each boot. Some boots are colored to provide a color-coded cable configuration to ensure
appropriate connections. Others are transparent to allow cable color to show through. The boot must be installed, small diameter end
first, onto the cable before the stripping procedure. Boots are made of elastomer polyolefin or flame redarded PolyCarbonate. Refer to
Figure 8.

Boot Without Hood Boot With Hood

Notch in Boot Facing Hood or Boot Over

Modular Plug Locking Latch Modular Plug Locking Latch

Cable Insulation Diameter

Within Maximum Cable
Diameter Marked Inside
Boot

Slim Line Boot with Color Clip Option

Color Clip Slot

Figure 8

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3.7. Mating
The modular plug must be inserted into the mating jack until it bottoms. When fully inserted, the modular plug locking tab will engage
the jack housing and prevent the connectors from separating. The connectors will not unmate unless the modular plug locking latch is
fully depressed. After mating, there will be a small amount of axial movement (travel) between the mated modular plug and jack, and
with some combinations, depending on tolerance variations between original equipment manufacturers (OEM), could be up to 0.76
[.030].
3.8. Repair
These modular plugs cannot be repaired; damaged modular plugs must be removed and discarded. The cable must be cut from the
modular plug and re-terminated onto a new modular plug.

4. QUALIFICATION
Standard and small conductor high-performance modular plug connectors are Component Recognized by Underwriters Laboratories
Inc. (UL) in File E81956 (DUXR2/DUXR8)

5. TOOLING
Tooling part numbers and instructional material packaged with the tooling are shown in figure 9.

Modular Plug Hand Terminating Modules Modular Plug Single Modular Plug Dual
Tools (Premium 856196-[ ] for Use with Terminators 354711-[ ] and Terminators
Grade) 231652-[ ] Modular Plug Dual Tooling Kits 354714-[ ] 1320840-[ ] (409-
with Die Sets Terminators 1320840-[ ] (408-9919) 10010)
853400-[ ] (408- (408-9743)
9767)

Crimp Height Gage 904170-1 (408-4389)

Figure 9

5.1. Hand Tools

The premium grade modular plug hand tool terminates these modular plugs to all types of cable indicated in this document. The tool
also cuts and strips unshielded flat oval cable. This tool is designed for field application, installation, and repair.

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5.2. Terminators
The terminators are pneumatically powered, bench-mounted tools controlled by a foot valve to terminate modular plugs to create a
cable assembly. Terminating modules fit interchangeably into the dual terminators. During termination, the dual terminators test the
assembly for electrical circuit continuity. The single terminators require a specific tooling kit to terminate one modular plug style and
does not provide testing. These tools provide for high-volume applications.

5.3. Crimp Height Gage

The crimp height gage is used to measure the crimp height of the terminated modular plug. The gage consists of a connector nest and
a GO/NO-GO spanner.

6. VISUAL AID
The illustration below shows a typical application of standard and small conductor high performance modular plug connectors. This
illustration should be used by production personnel to ensure a correctly applied product. Applications which do not appear correct
should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the
product or tooling.

ALL TERMINALS MUST HAVE

PROPER CRIMP HEIGHT AND BE AT
APPROXIMATELY SAME HEIGHT
PRIMARY STRAIN RELIEF MUST
ENGAGE CABLE JACKET

ALL CONDUCTORS MUST BE

BOTTOMED AGAINST END OF
MODULAR PLUG WIRE CIRCUITS

THERE MUST BE NO
DAMAGE TO HOUSING
OR LOCKING LATCH
THERE MUST BE NO NICKS
OR CUTS IN CABLE

Figure 10

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