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Pin Outs

Terminating in a 8 pin modular plug is specified in ANSI T1.403. USOC RJ 48 pinning is required.

Step 1    Using a safety razor blade, utility knife, or similar tool, ring the plastic outer sheath approximately 1-1/2 inches from the end.  Remove the 1-1/2 inch slug from the construction.  The two individually shielded pairs are now exposed.

Note:  If the blade modestly nicked the tape and even the insulation, continue anyway.  These will be removed in future steps.  (See Figure 1)

Step 2   Remove all tapes flush with the jacket line.

Tip:  A simple nick at the lip of each tape will permit easy tearing around the film.  This is a very simple process.

You should now have a white x orange pair and a white x blue pair exposed.  (See Figure 2)

Step 3   The insulation system of this construction is made up of a dual layered composite.  Removing the outer layer (foam) will leave the inner insulation behind.  Remove the outer insulation of all four leads leaving the inner insulation adhered to the copper wire.

The trick is to cut the outer layer without injuring the inner layer.  Inexpensive insulation strippers are best suited for this step.  Preferably the design will permit a depth setting to be adjusted and locked with the tool.  If the setting is by AWG, start with 18 AWG as the setting.  If the tool uses a non-indexed setting, a trial and error approach may be necessary.

In either event, the removal process must be performed using a pull direction in a straight line with the cable's construction.   If the pull direction is at an angle, the inner insulation is at risk.  (See Figure 3)

Step 4   Quabbin Wire & Cable suggests the use of modular plugs that include a "load bar".  This type of plug GREATLY reduces termination time, frustration, and errors. 

The load bar accommodates quick, precise arrangement of leads and drains prior to insertion into the plug cavity.

The pin out (color code arrangement) for USOC connector RJ48C is as shown in the "load bar" figure.   The jack at the demarc expects to see this arrangement.  (See Figure 4)

Step 5    Slide the loaded "load bar" toward and flush with the jacket.  Measuring from the jacket's edge, cut the extended leads and drains straight across and evenly leaving 5/8 inch.  (See Figure 5)

Step 6    Slip the load bar outward toward the end of the cut leads.  Stop the load bar just short of the immediate end.

Note:  The purpose of the load bar is to "aim" the leads so that they enter the plug cavity precisely positioned to pass through to the correct pin positions.  (See Figure 6)

Step 7    With the plug's release trigger positioned downward, and the orange conductor positioned left-most, press the cable with load bar into the plug cavity causing the leads to now extend to the far end of the plug nose.

When correctly positioned:

1. The conductors should extend to the end of the plug

2. The load bar should be firmly seated so as to resist further movement in either direction

3. The outer jacket should enter the plug cavity about 1/4 inch 

   (See Figure 7)

Step 8    Using a mod plug crimping tool containing an 8-pin compression die, press the assembled cable and modular connector into the die.   Manually complete the mating of the cable and plug by compressing the handles through a complete cycle.

The pins should now have continuity with the conductors and the jacket should now be held in place by an included strain relief.

Remove the assembly from the crimping tool.

This terminated end is ready for installation at the demarc point.  (See Figure 8)

Questions? Comments?