Attach A Modular Plug To UTP Cable

by Jeff Fisher

It is pretty rare to need to put modular plugs on unshielded twisted pair (UTP) category rated cable, so when someone asks us how, we usually ask a few questions to find out why they want to do it in the first place. Most of the time—when systems are designed correctly—it isn't necessary to put modular plugs on the ends of UTP cable. If you are, you're probably trying to accomplish one of two things:

  1. If you're trying to make your own patch cords, take it from us, you'll be sorry. It will cost you far more in materials, time, and frustration than premade patch cords could ever cost. Check out our patch cables.
  2. The other reason is to terminate your cat 5 cables coming from remote rooms to a network hub. Normally, we recommend that you terminate these cables to a 110 punch down block like our 47689N8 then use patch cables to go from the block to your hub. Why? As you'll see if you attempt to follow the procedure below, punching down wires to 110 connectors is much easier than putting modular plugs on the ends of cables.

But if you're determined...you can't say you haven't been warned. wink

modplug1.jpg Using the SAR8450, strip 1" of outer insulation off of the end of the Cat 5 cable.

modplug2.jpg Untwist and straighten the pairs and arrange them in the following sequence, from top to bottom:

  1. White/Green
  2. Green
  3. White/Orange
  4. Blue
  5. White/Blue
  6. Orange
  7. White/Brown
  8. Brown

modplug3.jpg Using the 200002 cutters, cut the wires straight across 1/2" from the jacket.

modplug4.jpg Hold the modular plug with the tab down, make sure the wires are still arranged in the sequence described above, and carefully slide the cable into the modular plug. The wires should each slide into a separate channel in the end of the plug.Important: Work all the wires to the very end of the connector or a proper connection may not be made!

Slide the plug into the larger hole of the 300018 tool and crimp the connector onto the end of the cable.


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