Instruction Sheet 860392406

Issue 4 January 2012

SYSTIMAX® Solutions

Installation Procedures for Pre-

Radiused LC Fiber Optic Connectors
Epoxy and EZ Method
(Multimode and Singlemode)
Behind-The-Wall (BTW) and Jumper LC Connectors

www.commscope.com
 Table of Contents
1 General.................................................................................................................................1
1.1 Connector Description .......................................................................................................................1
1.2 Consumables Kits for Pre-Radiused BTW LC Connectors ................................................................2
1.3 Tool Kit Required for Epoxy or EZ Method ........................................................................................2
1.4 Ordering Information..........................................................................................................................3
1.5 How to Contact Us.............................................................................................................................3
2 Safety Precautions..............................................................................................................3
3 Assembly Instructions for Epoxy Method........................................................................4
3.1 Set Up Curing Oven...........................................................................................................................4
3.2 Buffer and Cordage Preparation ........................................................................................................4
3.2.1 Buffer Preparation ..................................................................................................................4
3.2.2 Cordage Preparation ..............................................................................................................6
3.3 Epoxy Preparation ...........................................................................................................................10
3.4 Connector Installation ......................................................................................................................11
3.4.1 Prepare the Connector .........................................................................................................11
3.4.2 Apply Epoxy .........................................................................................................................11
3.4.3 Insert Fiber, BTW LC and Jumper LC ..................................................................................12
3.4.4 Install Crimp Sleeve (Jumper LC Only) ................................................................................13
3.4.5 Cure Connector Assemblies.................................................................................................14
3.4.6 Cool Connector Assemblies and Attach Buffer Support Boot...............................................14
3.4.7 Score the Fiber.....................................................................................................................14
3.4.8 Polish Connector EndMultimode and Singlemode..............................................................14
4 Assembly Instructions for EZ Method ............................................................................15
4.1 Fiber Preparation .............................................................................................................................15
4.2 Prepare Adhesive ............................................................................................................................16
4.3 Prepare Primer ................................................................................................................................16
4.4 Connector Installation ......................................................................................................................17
4.4.1 Apply Primer to the Connector Tip .......................................................................................17
4.4.2 Apply Primer to Buffer ..........................................................................................................17
4.4.3 Apply Adhesive to Connector ...............................................................................................17
4.4.4 Insert Fiber into Connector ...................................................................................................18
4.4.5 Cure Adhesive and Attach Buffer Support Boot ...................................................................18
4.4.6 Score the Fiber.....................................................................................................................19
5 Polishing Instructions ......................................................................................................19
5.1 Polish Connector EndMultimode and Singlemode .........................................................................19
5.1.1 Step 1. Remove Fiber Stub .................................................................................................20
5.1.2 Step 2. Remove Excess Adhesive ......................................................................................20
5.1.3 Step 3. Singlemode — Improve Return Loss ......................................................................21
5.2 Repair Polishing (Only If Needed) ...................................................................................................22
5.3 Final Assembly ................................................................................................................................22
6 Assembly on Nonbuffered Fiber .....................................................................................22
7 Fiber Inspection ................................................................................................................23
8 Cleaning Instructions .......................................................................................................24
8.1 LC Connector...................................................................................................................................24
8.2 LC Adapter ......................................................................................................................................24
9 Mount Adapter...................................................................................................................24
10 Ordering Information ........................................................................................................25
10.1 Epoxy...............................................................................................................................................25
10.2 Adhesive..........................................................................................................................................25
10.3 Obtain Locally ..................................................................................................................................25

ii
 Instruction Sheet 860392406
Issue 4 January 2012

Installation Procedures for Pre-Radiused LC

Behind-The-Wall (BTW) and Jumper LC
Fiber Optic Connectors
Epoxy and EZ Method Singlemode and Multimode Versions

1 General
1.1 Connector Description
The LC Behind-The-Wall (BTW) connector is used to terminate outside plant (OSP) cables as well as
building cables. The LC Fiber Optic Simplex/Duplex Jumper Connectors can be used to terminate
simplex or duplex 1.6/2.0mm cordage. Both are intended for use in central offices, local area networks
(LANs), premises distribution systems such as SYSTIMAX® structured cabling systems, computer
backplane connections, computer peripheral interconnections, device terminations, and other
applications where quality, small-size, high-density, low-loss, and a low-cost infrastructure are required.
The installation procedures in this document are intended for the termination of the Pre-Radiused LC
Connectors listed below. The “R” in the connector code designates the connector as having a radiused
end face.
Connector Code Fiber Type Jacket Size Material ID
MFC-LCR-09-BG MM Simplex 0.9 mm 760034181
MFC-LCR-09-BG-100-BULK-PACK MM Simplex, 100 Bulk Pack 0.9 mm 760091546
SFC-LCR-09-BL SM Simplex 0.9 mm 760034199
SFC-LCR-09-BL-100-BULK-PACK SM Simplex, 100 Bulk Pack 0.9 mm 760031401
MFC-LCR-16-BG MM Simplex 1.6 / 2.0 mm 760034140
MFC-LCR-16-BG-100-BULK-PACK MM Simplex, 100 Bulk Pack 1.6 / 2.0 mm 760091553
MDC-LCR-16-BG MM Duplex 1.6 / 2.0 mm 760034157
MDC-LCR-16-BG-100-BULK-PACK MM Duplex, 100 Bulk Pack 1.6 / 2.0 mm 760034165
SFC-LCR-16-BL SM Simplex 1.6 / 2.0 mm 760034173
SFC-LCR-16-BL-100-BULK-PACK SM Simplex, 100 Bulk Pack 1.6 / 2.0 mm 760091561
SDC-LCR-16-BL SM Simplex 1.6 / 2.0 mm 760091439
SDC-LCR-16-BL-100-BULK-PACK SM Simplex, 100 Bulk Pack 1.6 / 2.0 mm 760091447
MFC-LCR-30-BG MM Simplex 3.0 mm 760111476
MFC-LCR-30-BG-100-BULK-PACK MM Simplex, 100 Bulk Pack 3.0 mm 760111484
SFC-LCR-30-BL SM Simplex 3.0 mm 760111492
SFC-LCR-30-BL-100-BULK-PACK SM Simplex, 100 Bulk Pack 3.0 mm 760111500
MDC-LCR-30-BG MM Duplex 3.0 mm 760111518
MDC-LCR-30-BG-100-BULK-PACK MM Duplex, 100 Bulk Pack 3.0 mm 760111526
SDC-LCR-30-BL SM Duplex 3.0 mm 760111534
SDC-LCR-30-BL-100-BULK-PACK SM Duplex, 100 Bulk Pack 3.0 mm 760111542

! WARNING: These procedures are not intended for use on flat-tipped LC Connectors.

© 2012 CommScope, Inc. Page 1

All rights reserved
Printed in U.S.A.
25 Pages
Instruction Sheet 860392406
Issue 4 January 2012

Removable
duplex yoke
Cable support Cable supports

Crimp sleeve Crimp sleeves

Support boot

Connector Connectors Connector

LC Simplex Jumper Components* LC Duplex Jumper Components LC BTW Components
* Available one per package for simplex cord and two per package for singlemode duplex cord.

Note: In addition to the BTW connector for 0.9mm buffered fiber, a simplex and duplex LC jumper
connector is offered for 1.6mm MiniCord® jumper termination. Installation of the jumper connector
is also covered in this document. The jumper connector can be used in the assembly of various
lengths of patch cords.
The optical performance of field-installed connectors and passive links should be verified using
the procedures outlined in SYSTIMAX Structured Connectivity Solutions Field Testing
Guidelines for Fiber Optic Cabling Systems. Allowable link losses should be determined using the
Fiber Link-Loss Calculator.
Both documents can be accessed through the BusinessPartner website at http://www.mycommscope.com/.

1.2 Consumables Kits for Pre-Radiused LC Connectors

Kit Type (Note) Kit Number Material ID Kit Includes
Multimode Kit-C-Univ-M-100 760 066 720 Polishing paper, and other materials required to
assemble 100 multimode LC connectors.
Singlemode Kit-C-Univ-S-100 760 066 738 Polishing paper, and other materials required to
assemble 100 singlemode LC connectors.
Direct termination D-181755 700 006 117 Buffer tubing and cable end prep materials for
of OSP cables approximately 100 OSP fibers.
Repair Kit Kit-C-250M-R-1000 700 218 076 25 sheets of Type F polishing paper
Note: Kits do not contain connectors, adhesive, primer, isopropyl alcohol, or non-ozone depleting canned air.

1.3 Tool Kit Required for Epoxy or EZ Method

Choose one of the following tool kits:
Kit Type Kit Number Material ID Kit Includes
EZ Tool Kit 1032H* 700 005 838 Tools for BTW LC, SC, and STII
Epoxy EZ Tool Kit 1032B5 700 006 026 Tools for BTW, LC, SC, ST, Oven (110 volt)
Epoxy EZ Tool Kit 1032B6 700 005 960 Tools for BTW, LC, SC, ST, Oven (220 volt)
Jumper LC D-182959 700 005 853 Tools for LC Jumper terminations, used in
Upgrade Kit conjunction with 1032B kits.
*The 1032H (Minitool) Kit is used for EZ termination only since it does not include a curing oven.

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 Instruction Sheet 860392406
Issue 4 January 2012

1.4 Ordering Information

Section 10 contains ordering information for adhesive and epoxy.

1.5 How to Contact Us

 To find out more about CommScope® products, visit us on the web at

http://www.commscope.com/ .
 For technical assistance regarding SYSTIMAX® products:
 Within the United States, contact your local account representative or technical
support at 1-800-344-0223. Outside the United States, contact your local account
representative or Authorized Business Partner.
 Within the United States, report any missing/damaged parts or any other issues to
CommScope Customer Claims at 1-866-539-2795. Outside the United States,
contact your local account representative or Authorized Business Partner.

2 Safety Precautions
 Safety glasses should be worn at all times while performing these assembly instructions.
 Avoid skin contact with the adhesive and the primer.
 Optical fibers may emit radiation if the far end is connected with a working laser or light-
emitting diode (LED). Never view the fiber end of a cable or plug with an optical
instrument until absolute verification is established that the fiber is disconnected from any
laser or LED source.

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Instruction Sheet 860392406
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3 Assembly Instructions for Epoxy Method

Note: For EZ method, see Section 4.

3.1 Set Up Curing Oven

1. Place oven on a level surface and away from combustibles.
2. Connect the power cord to a power source (120 V 60 Hz AC for the 200A oven and 220 V 50
Hz AC for the 200A1 international oven).
3. Locate the six heat tube assemblies (700002330) supplied with the D-182959 Upgrade Kit
(700005853).
4. Insert the heat tube assemblies into the heater ports.
Note: Be certain that the metal portion of each heat tube assembly is fully inserted into the
heater ports.
5. Push the ON/OFF switch to the ON position (lamp in switch illuminates).
Note: A READY lamp will illuminate when the oven reaches its operating temperature of
266F (130C).
CAUTION: After the oven reaches its operating temperature, the metal portion of the heat
tube assembly will be extremely HOT at 266F (130C). Allow the oven and heat tube
assemblies to cool before handling and storing.

Heat tube Lifting lug (one on each

assembly side of heat tube assembly)

Power cord Metal portion

of heat tube
assembly

ON
P USH OFF
Curing oven
READY

EN
RING OV
200 A CU

3.2 Buffer and Cordage Preparation

The epoxy method can be used to terminate LC connectors unto 900µm buffered (BTW), or
1.6/2.0/3.0mm cordage (jumper). This section describes both types of terminations.
3.2.1 Buffer Preparation
1. Remove cable sheath and outer jacket.

! CAUTION: Be careful not to cut into fibers while removing cable sheath and outer jacket.
Note: For CommScope cable, use sheath removal tool R-4366.
Note: Be certain to expose enough buffered fiber to:
 Allow access to the curing oven and other connector preparation functions
 Prevent stress on fibers during connector preparation
 Provide adequate fiber length for placement in associated equipment cabinet.
Note: Typical working length for buffered fibers is 24 to 36 inches (0.6 to 0.9 meters).
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 Instruction Sheet 860392406
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2. Install buffer support boot by slipping the small end of boot onto the buffered fiber.
Buffered fiber

Buffer
support
boot

3. Measure and mark the buffered fiber 7/16 to 1/2 inch (11 to 13mm) from the end by using the
scale or template provided in the tool kit.

7/16 to 1 2 inch
(11 to 13 mm)

4. Locate Micro-Strip or Heat-Strip Tool provided in the tool kit.

Note: Refer to 1026A Heat-Strip Tool operating instructions for setup.
5. Strip 7/16 to 1/2 inch (11 to 13mm) of the buffered fiber.
1026A Heat-
Strip Tool

Buffer
Align mark on buffer
with heat-strip blades

6. Clean stripped fiber by saturating a wipe with isopropyl alcohol (>91% 2-propanol + water)
and wiping the fiber from the edge of the buffer toward the end of the fiber.
Note: If residue remains on the fiber, use a clean wipe saturated with isopropyl alcohol to
wipe the fiber again.
7. Place prepared buffer into the grooves of the 971A-2 holder block to avoid breaking or
contamination of the fiber (holder blocks are provided in the D-182959 Upgrade Kit).

Partial view
of a 971A-2
holder block

Prepared fiber in
0.9-mm groove

Buffer support
boot

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Instruction Sheet 860392406
Issue 4 January 2012

3.2.2 Cordage Preparation (1.6mm, 2.0mm, and 3.0mm Cordage)

3.2.2.1 Assemble Connector Components
Simplex Applications on a Simplex Cord
1. Thread a cable support onto the simplex cord, narrow end first.
2. Thread a crimp sleeve onto the cord. The metal end of the crimp sleeve should be oriented
toward the end of the cord.
3. Repeat Steps 1 and 2 for the other end of the cord.

Narrow end of
cable support

Cable support

Metal end of
crimp sleeve

Crimp sleeve

Duplex Applications on a Duplex Cord with Replaceable Duplex Yoke

1. Split the jacket on the duplex cord into two separate cords at least 9 inches (230mm) from
the end.
2. Determine the buffer color of each cord by looking at the end of the cordage. The duplex cord
should have a blue buffer and an orange buffer.
3. Locate the B channel opening on the duplex yoke.
4. At the first end, thread the cord with the blue buffer through the B channel opening.
5. Locate the A channel opening on the duplex yoke.
6. Thread the cord with the orange buffer through the A channel opening.
Note: Alternatively, if a hinged duplex yoke (see picture on next page) is supplied, it may be
placed on the duplex cordage at this time, in the orientation described in this section
and/or installed after the connectors have been terminated (see Section 5).
7. Thread a cable support onto each cord, narrow end first.
8. Place a yellow crimp sleeve on the cord with the blue buffer and a white crimp sleeve on the
cord with the orange buffer. The metal end of the crimp sleeves should be oriented toward
the end of the cord.
9. On the opposite end of the duplex cord, split the jacket into two separate cords at least 9
inches (230mm) from the end.
10. Determine which cord has the blue buffer and which cord has the orange buffer.
11. Locate the A channel opening on the duplex yoke.
12. Thread the cord with the blue buffer through the A channel opening.
13. Locate the B channel opening on the duplex yoke.
14. Thread the cord with the orange buffer through the B channel opening.
15. Thread a cable support onto each cord, narrow end first.
16. Place a yellow crimp sleeve on the cord with the blue buffer and a white crimp sleeve on the
cord with the orange buffer. The metal end of the crimp sleeves should be oriented toward
the end of the cord.
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 Instruction Sheet 860392406
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Hinged
yoke

Cable support LC unibody

connector

Removeable
duplex yoke
Cable support B channel
opening

Cable support Crimp sleeve

A channel (yellow)
Removeable opening
duplex yoke B channel
opening
Blue buffer
Cable support Crimp sleeve Orange buffer
(white)
A channel
opening

Crimp sleeve
(yellow) Orange buffer
Blue buffer

3.2.2.2 Remove Outer Jacket and Trim Strengthening Yarn

1. Locate the template and pen provided in the D-182959 Upgrade Kit.
2. Measure and mark outer jacket at 1.125 inches (29mm) and at 1.375 inches (35mm) from the
end.
1.375 inches
(35 mm)

1.125 inches
(29 mm)
3. Use the 700A stripping tool to remove outer jacket at the 1.125 inches (29mm) mark.
Stripping tool
(blue handles)

Number 1
notch

Outer jacket
being removed
4. Lightly twist the strengthening yarn into one bundle and use scissors to cut yarn flush with the
end of the outer jacket.

Buffered
fiber

Outer jacket
Cut strengthening
yarn flush with outer jacket

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Instruction Sheet 860392406
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5. Use the 700A stripping tool to remove outer jacket at the 1.375 inches (35mm) mark. This will
expose 0.25 inch (6mm) of yarn.

Stripping tool
(blue handles)

Number 1
notch

Outer jacket
being removed
6. Flare the shortened strengthening yarn evenly around the cable. The brush from the 1026A
stripper tool can be used.
3.2.2.3 Remove Buffer and Fiber Coating
Note: Refer to 1026A Heat-Strip Tool operating instructions for heat-strip tool setup. The Heat-
Strip Tool is used mainly for nylon and Hytrel® buffered fiber.
1. Locate the Micro-Strip or Heat-Strip Tool.
2. Locate the gold LC stripper guide tube (D-182959 Upgrade Kit).
3. Fully insert the tube into the tool
4. Insert buffered fiber into the guide tube until the jacket and strengthening yarn hit the
appropriate stop inside the guide tube.
Note: Do not force the cord into the guide tube. If the buffer does not go through the guide tube
easily, trim 0.03125 inch (0.8mm) from end of buffer. The end of the buffer occasionally
becomes flattened when the cord is initially cut. The buffered fiber should protrude
approximately 0.55 inch (14mm) into the guide tube.

1026A heat-strip tool

Gold LC stripper
guide tube

Outer jacket

! CAUTION: Proper stripping lengths and procedures are required for best connector
pull-proof performance.
5. When stripping nylon or Hytrel buffered fiber, close the handles of the tool and wait 6 to 10
seconds for the softening of the buffer to occur.
6. Wrap the cord around your index finger and pull the fiber from the tool with one smooth and
straight motion.
Note: Wrapping the cord around your index finger may prevent the buffered fiber from
slipping out of the jacket during the stripping operation.

! CAUTION: The buffer must not be allowed to move within the cord while stripping.
Do not strip additional buffer length if buffer pulls from cordage. Buffer
will normally push back into cord during connector plug assembly.

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 Instruction Sheet 860392406
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0.55 inch
(14 mm)

0.25 inch
(6 mm)

3.2.2.4 Clean Stripped Fiber

1. Saturate a wipe with isopropyl alcohol (>91% 2-propanol + water).
2. Start at the coating end and wipe toward the fiber end.
3. Place the prepared cord into the grooves of the 971A-2 holder block to avoid breaking or
contamination of the fiber (holder blocks are provided in the D-182959 Upgrade Kit).
Note: If residue remains on the fiber, use a clean wipe saturated with isopropyl alcohol to
wipe the fiber again.

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Instruction Sheet 860392406
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3.3 Epoxy Preparation

The supplied epoxy comes in a two-part package. A divider separates the resin from the
hardener. The divider must be removed to allow the epoxy to be mixed. The epoxy is then loaded
into a syringe.

! CAUTION: Avoid contact of epoxy with skin.

1. Remove the divider between the resin and the hardener.
2. Mix the epoxy using the divider.
Divider used to
mix epoxy

Note: The epoxy must be thoroughly mixed until both parts are blended into a smooth
uniform color.
3. Locate the syringe in the multimode LC Consumable Kit or Singlemode LC Consumable Kit.
4. Place the syringe tip on the syringe and twist to lock in place.
5. Remove the plunger from the syringe.
6. Fold the epoxy package in half and cut off one of the package corners.
7. Squeeze the mixed epoxy into the syringe.
Note: A 3/4-inch (19mm) length of epoxy will be enough for about 50 connectors.

Epoxy being
loaded into
syringe

Syringe

8. Replace the plunger into the syringe.

9. Remove air pockets from the syringe by holding the syringe tip upward and ejecting epoxy
until the air pockets are removed.

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 Instruction Sheet 860392406
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3.4 Connector Installation

Connectors are provided in packages that must be ordered by product codes (see Section 1.1 for LC
Connector Product Codes). Each connector is fitted with a white dust cap to protect the connector tip
from damage and contamination. During the connector installation process, a holder with extension
(provided in the 1032H Kit and the D-182959 Upgrade Kits) is used to protect the fiber protruding from
the connector tip and to aid in the handling of the small connectors. The slot in the extension holds the
buffer in the correct position until the epoxy sets.

3.4.1 Prepare the Connector

1. Locate the connector to be installed and remove the white dust cap.
2. Hold the connector towards the light and check to make sure the hole and the tip are clear.
3. If necessary, clear the hole using the music wire (furnished).
When terminating to 900µm buffer, locate a connector holder with extension and snap the
BTW LC into the holder.
4. When terminating 1.6/2.0/3.0mm cordage, locate an LC holder (w/o extension) and snap the
jumper LC into the holder.
Trigger
Buffer Duplex
Latch Latch
slot or jumper
connector
Simplex (no trigger)
BTW Connector jumper Latch
connector holder with connector
extension

Remove
connector Connector
white dust cap holder

3.4.2 Apply Epoxy

Epoxy is injected into two areas of the connector: (1) inside of the ferrule and (2) at the back of the
ferrule. The syringe is first used to inject epoxy into the ferrule. This epoxy bonds the stripped fiber to
the ferrule. Before removing the syringe from the connector, epoxy must next be deposited at the back
of the ferrule. This epoxy bonds the buffer at the back of the ferrule.
Note: DO NOT apply an excessive amount of epoxy to either the ferrule or at the back of the ferrule,
as per figures below.

Epoxy Here Epoxy here

Small
Ferrule Small tube
Tip of tube No Tip of
ferrule Epoxy ferrule
Here (face) Back of
connector

Back of Back of Back of

No epoxy here
ferrule connector ferrule
BTW Connector Jumper Connector

1. Locate the small tube inside the back of the connector.

2. Carefully insert the tip of the syringe into the small tube until it bottoms.

! CAUTION: In the following step, do not apply excess epoxy to the tip of the ferrule.
3. Inject epoxy into the ferrule by slowly pressing the syringe plunger until the epoxy just
appears at the connector tip (face of the ferrule).
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Instruction Sheet 860392406
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4. Deposit epoxy at the back of the ferrule by pulling the tip of the syringe back slightly and
momentarily injecting a small amount of epoxy at the back of the ferrule.

! CAUTION: When removing syringe from the connector in the following step, do not
allow epoxy on syringe tip to contaminate the small tube or the back of the connector.

Cutaway view
Cutaway view showing small
showing small tube
Holder with
tube Holder
extension
Syringe Syringe

BTW connector Jumper connector

5. Release pressure on plunger, wait a moment, and then remove the syringe from the
connector.

3.4.3 Insert Fiber, BTW LC and Jumper LC

3.4.3.1 Insert Fiber, BTW LC

1. Remove prepared fiber from holder block.
2. Insert the exposed fiber into the small tube inside the connector and carefully feel for the
opening in the ferrule.
Note: Rotating the fiber or the connector assembly may help to locate the opening.

! CAUTION: Only perform the following step once.

3. When the fiber is seated, pull it back slightly and watch for fiber movement at the tip of the
connector to make sure the fiber is not broken.
4. Reposition the fiber back into the connector.
5. Ensure that the buffer support boot is pushed back on cable.
Holder with
extension BTW connector
Buffered Buffer
Fiber fiber support
boot

6. Push buffer in slot at end of holder extension.

7. Store up to 12 BTW connectors in the 971A-2 holder blocks.

.
Boot
971A-2 holder blocks
Holder with
BTW connector

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 Instruction Sheet 860392406
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3.4.3.2 Insert Fiber, Jumper LC

1. Remove prepared fiber from holder block.
2. Insert the exposed fiber into the small tube inside the connector and carefully feel for the
opening in the ferrule.
Note: Rotating the fiber or the connector assembly may help to locate the opening.

! CAUTION: Only perform the following step once.

3. When the fiber is seated, pull it back slightly and watch for fiber movement at the tip of the
connector to make sure the fiber is not broken.
4. Reposition the fiber back into the connector.
Holder

Fiber Buffered
fiber

Jumper Strengthening Prepared

connector yarn cable

3.4.4 Install Crimp Sleeve–Jumper LC Only (1.6mm, 2.0mm, and 3.0mm Cordage)
5. Slip the cable crimp sleeve assembly over the back of the connector while capturing the
strengthening yarn.
6. Using the 1510LC crimping tool (supplied in the D-182959 kit), place the square edge of the
connector against one edge of the crimp jaw with the crimp sleeve assembly lying through
the crimp jaws.

! CAUTION: Crimping the crimp sleeve more than once can weaken the connector.
CRIMP ONLY ONCE.
7. Apply pressure until crimping tool completely closes and automatically opens.

Holder Holder
Crimping Crimping
tool jaws tool jaws

Place jaws Crimp Crimp

Place jaws
against back sleeve sleeve
against back
edge of edge of
connector connector
Simplex Jumper Connector Duplex Jumper Connector
4. For 3.0mm cordage, the crimp can on the crimp sleeve assembly is longer than the
standard 1.6mm cordage crimp sleeve. An additional crimp is required along the length
of the crimp sleeve.

5. Store crimped connector vertically in the holder block until up to 12 simplex or 6 duplex
connectors have been crimped.

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Instruction Sheet 860392406
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Crimpe
connector

971A-2 holder blocks

3.4.5 Cure Connector Assemblies

1. When the desired number of connectors has been prepared, place the holder block next to
the preheated oven.
2. Place prepared connector assemblies into the heat tubes in the oven ports.
3. Ensure that the connector assemblies are sitting at the bottom of the oven ports.
4. Remove the assemblies from the oven and heat tubes after they have cured for 10 minutes.

3.4.6 Cool Connector Assemblies and Attach Buffer Support Boot

1. Place cured assemblies back into the holder block to cool.

2. Select a connector assembly and remove the fiber buffer from the holder slot.
3. Push the cable support boot onto the connector.
4. Repeat Steps 2 and 3 for each connector assembly.

3.4.7 Score the Fiber

1. Remove the connector from the connector holder.

2. Obtain the 975A cleaving/scoring tool. Then, place the cleaving/scoring tool against the
ferrule and exposed fiber.
Note: Score the fiber as close to the ferrule as possible while at the same time being
careful not to break the fiber.
3. Using one stroke of the cleaving/scoring tool, gently score the exposed fiber.
4. Remove the exposed fiber by gently pulling straight away from the cable.
Note: If fiber did not readily pull off, score fiber again on opposite side and gently pull fiber.
5. Dispose of the fiber scraps in a safe manner.
Note: The adhesive surface on a piece of tape is a convenient place to hold fiber pieces
until disposal.
Cleaving
tool
Exposed
fiber
Use ONE
stroke to Connector
score fiber ferrule

3.4.8 Polish Connector EndMultimode and Singlemode

Proceed to Section 5.
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 Instruction Sheet 860392406
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4 Assembly Instructions for EZ Method

4.1 Fiber Preparation
1. Remove cable sheath and outer jacket.

! CAUTION: Be careful not to cut into fibers while removing cable sheath and outer
jacket.
Note: Be certain to expose enough buffered fiber to:
 Allow access to the curing oven and other connector preparation functions
 Prevent stress on fibers during connector preparation
 Provide adequate fiber length for placement in associated equipment cabinet.
Note: Typical working length for buffered fibers is 24 to 36 inches (0.6 to 0.9 meters).
Buffered fiber

Buffer
support
boot

2. Install buffer support boot by slipping the small end of boot onto the buffered fiber.
3. Measure and mark the buffered fiber 7/16 to 1/2 inch (11 to 13mm) from the end by using the
scale or template provided in the tool kit.

7/16 to 1 2 inch
(11 to 13 mm)

4. Locate the Micro-Strip or Heat-Strip Tool provided in the Tool Kit.

Note: Refer to 1026A Heat-Strip Tool operating instructions for setup.
5. Strip 7/16 to 1/2 inch (11 to 13mm) of the buffered fiber.
Note: If residue remains on the fiber, use a clean wipe saturated with isopropyl alcohol to
wipe the fiber again.
6. Clean stripped fiber by saturating a wipe with isopropyl alcohol (>91% 2-propanol + water)
and wiping the fiber from the edge of the buffer toward the end of the fiber.

1026A Heat-
Strip Tool

Buffer
Align mark on buffer
with heat-strip blades

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Instruction Sheet 860392406
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7. Place prepared buffer into the grooves of the 971A-2 holder block to avoid breaking or
contamination of the fiber (holder blocks are provided in the D-182959 Upgrade Kit).

Partial view
of a 971A-2
holder block

Prepared fiber in
0.9-mm groove

Buffer support
boot

4.2 Prepare Adhesive

! WARNING: Avoid contact of adhesive with skin.

Note: Refer to Table A for recommended adhesive temperatures.

Table A. Recommended Usage Temperatures for Adhesive

Condition Temperature
Storage -5C to 30C (23F to 86F)
Installation 0C to 38C (32F to 100F)
Operating -40C to 75C (-40F to 167F)

1. Shake the bottle of adhesive vigorously.

2. Remove the cap from the bottle.
Note: If bottle has not been opened, use a straight pin to make a hole in the tip of nozzle.
3. Remove plunger from syringe and twist a syringe tip onto the end of syringe.
4. Squeeze bottle to squirt adhesive into syringe.
5. Place plunger into syringe and expel air from syringe.
Note: Alternately, simply twist a syringe tip onto the nozzle of the adhesive bottle, making
sure it fits snugly.

4.3 Prepare Primer

! WARNING: Avoid contact of primer with skin.

1. Place the 1-inch long (25mm) syringe tip onto the syringe and twist to lock in place.
2. Shake the bottle of primer vigorously.
3. Remove plunger from syringe.
4. Squeeze primer bottle to squirt adhesive into syringe.
5. Place plunger into syringe to expel excess air.
Note: Alternatively, simply twist a syringe tip onto the nozzle of the primer bottle, making
sure it fits snugly.
Note: Once the installation procedure has been completed, any extra primer in the syringe
may be placed back into the original bottle; however, the syringe tip should be thrown
away to avoid getting adhesive, which may be on the tip, mixed in with the primer.

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 Instruction Sheet 860392406
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4.4 Connector Installation

Connectors are provided in packages that must be ordered by product codes (see Section 1.1
for LC Connector Product Codes). Each connector is fitted with a white dust cap to protect the
connector tip from damage and contamination. During the connector installation process a holder
with extension is used to protect the fiber protruding from the connector tip and to aid in the
handling of the small connectors. The slot in the extension holds the buffer in the correct position
until the adhesive sets.

4.4.1 Apply Primer to the Connector Tip Connector

latch Buffer
slot
1. Locate connector and connector holder with BTW
extension (700 005 135). connector
Connector
2. Remove the white dust cap from tip of connector. holder with
3. Place two texwipes on the work table, one on top Remove extension
of the other, and place a drop of primer on the connector
white dust
texwipes. cap
4. Wipe the tip of the ferrule through the drop of
primer on the texwipes, one time.
5. Snap connector into the connector holder.

4.4.2 Apply Primer to Buffer

! CAUTION: DO NOT get primer on the fiber or the holder block.

1. Remove the prepared buffer fiber from the holder block.
2. Carefully place one drop of primer onto buffer, just back from where the buffer was stripped
(do not put primer on the bare fiber).
3. Replace prepared buffered fiber in holder block.
Place one drop
of primer here

Remove prepared
buffer fiber from
holder block

4.4.3 Apply Adhesive to Connector

1. Locate the small tube at the back of the connector.
2. Carefully insert syringe tip (with attached adhesive bottle) into the small tube until tip bottoms
at the back of the ferrule.
Adhesive here
No adhesive here

Small
Tip of tube
ferrule

Back of
Back of connector
ferrule

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Instruction Sheet 860392406
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! CAUTION: In the following step, do not apply excess adhesive to connector tip of ferrule.
The adhesive is a low viscosity fluid and if applied in excess will flow to the ferrule's chamfer
and sidewalls. Excess adhesive on the ferrule chamfer and sidewalls should be removed with
the edge of a wipe.
3. Inject adhesive into the ferrule by slowly pressing and squeezing the adhesive bottle until the
adhesive exits the connector tip.
4. Deposit adhesive at the back of the ferrule by pulling the syringe tip back slightly and
momentarily injecting a small amount of adhesive at the back of the ferrule.

! CAUTION: When removing syringe tip from the connector in the following step, do not
allow adhesive on syringe tip to contaminate the small tube or the back of the connector.
5. Release pressure on bottle, wait a moment, and then remove syringe tip from the connector.
Cutaway view
showing small
tube
Holder with
extension
Syringe

BTW connector

4.4.4 Insert Fiber into Connector

1. Remove prepared fiber from holder block.
2. Insert the exposed fiber into the small tube inside the connector and carefully feel for the
opening in the ferrule.
Note: Rotating the fiber or the connector assembly may help to locate the opening.

! CAUTION: Only perform the following step once.

3. When the fiber is seated, pull it back slightly and watch for fiber movement at the tip of the
ferrule to make sure the fiber is not broken.
4. Reposition the fiber back into the connector.
5. Ensure the buffer support boot is pushed well away from the holder extension slot and back
onto buffered fiber.
6. Push buffer in slot at end of holder extension.
7. Place the connector holder into holder block. This will prevent adhesive from flowing onto the
ferrule chamfer and sidewall surfaces.
Holder with
extension BTW connector
Buffered Buffer
Fiber fiber support
boot

4.4.5 Cure Adhesive and Attach Buffer Support Boot

1. Allow adhesive to cure for 1 minute.

Note: Excessive adhesive on the ferrule will not cure and must be cleaned off after polishing.
2. Remove the connector from connector holder.

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 Instruction Sheet 860392406
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! CAUTION: In the following step, exercise care not to break the exposed fiber.
3. Use the edge of a wipe to clean any uncured adhesive from around the fiber where it
protrudes from the ferrule tip.
4. Push the cable support boot onto the connector.
Note: Exercise care not to break the exposed fiber.

4.4.6 Score the Fiber

1. Obtain the 975A cleaving/scoring tool. Then, place the scoring edge of the cleaving/scoring
tool against the ferrule and exposed fiber.
Note: Score the fiber as close to the ferrule as possible while at the same time being
careful not to break the fiber.
2. Using one stroke of the cleaving/scoring tool, gently score the exposed fiber.
3. Remove the exposed fiber by gently pulling straight away from the cable or by pushing
against the free end of the exposed fiber until the fiber pops off.
Note: If fiber did not readily pull off, score fiber again on opposite side and gently pull fiber.
4. Dispose of the fiber scraps in a safe manner.
Note: The adhesive surface on a piece of tape is a convenient place to hold fiber pieces
until disposal.
Cleaving
tool
Exposed
fiber
Use ONE
stroke to Connector
score fiber ferrule

5 Polishing Instructions
5.1 Polish Connector EndMultimode and Singlemode

! WARNING: These procedures are not intended for use on flat-tipped LC Connectors.

! CAUTION: Contaminants on polishing materials can cause scratches on the end face of
the fiber/ferrule. Throughout the entire polishing process, keep work area and all polishing
materials clean. Clean polishing papers between each step using a wipe moistened with
alcohol.

! CAUTION: Uncured adhesive on ferrule cylindrical surface can cause problems during
mating/demating of connectors. Clean all ferrule surfaces using a wipe moistened with alcohol.
Note: Table B (multimode) and Table C (singlemode) provide quick overviews for polishing.
Note: Cut one sheet of type H polishing paper (green, mylar-backed) into four pieces.

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5.1.1 Step 1. Remove Fiber Stub

a. In one hand, hold one of the cut pieces of type Position puck during
Type H (green) polishing so it is supported
H polishing paper (green, dull side facing the
polishing paper by fingers on back side of
connector). paper
b. In the other hand, hold the connector in the
polishing puck.
Note: When performing the following step,
support the polishing puck with the
fingers on back side of paper. Be
careful not to break the fiber stub.
c. Air polish using light figure-8 motions about 1
inch (25mm) in diameter; carefully polish off
fiber stub. Gently begin light figure-8 strokes to
allow polishing paper to polish down the fiber
stub without snagging or breaking the stub.
Polish approximately 20 strokes.

5.1.2 Step 2. Remove Excess Adhesive

a. Use canned air to clean the back and front of
one sheet of type H polishing paper (green).
Note: Each sheet of polishing paper is cut to fit squarely on the polishing plate.
b. Saturate a wipe with isopropyl alcohol (>91% 2-propanol + water).
c. Obtain a glass plate and a polishing tool (T2000A or T2001A) from the tool kit.
d. Clean the connector ferrule, glass plate, and polishing tool with the saturated wipe between
polishing steps.
e. Use canned air to blow dry the connector ferule, glass plate, and the polishing tool.
f. Insert the LC connector into the T2000A or T2001A polishing tool.
g. Place one sheet of type H (6"x 6") polishing paper (green), dull side up, over the plate.
h. Gently place the polishing tool and connector onto the polishing paper.
Note: In the following step, you should not feel any drag between the fiber and the paper.
Start with light pressure and use figure-8 strokes that are approximately 2 inches (51
mm) high and 1 inch (25mm) wide. The figure-8 strokes must be well rounded to
ensure complete removal of the adhesive from the end of the ferrule.
i. Polish MM and SM Connectors:
 MM Connectors – Gently polish the connector for 12-15 large figure-8 strokes to remove
all epoxy/adhesive from the ferrule end face. For a more uniform polish, rotate the
connector and puck 90 degrees every ten strokes.
 SM Connectors – Using firm pressure, polish the connector with 8-10 large figure-8
strokes to remove all epoxy/adhesive from the ferrule end face.

! DANGER: Optical fibers may emit radiation if the far end is connected with a
working laser or light-emitting diode (LED). Never view the fiber end of a cable or
plug with the naked eye or any optical instrument until absolute verification is
established that the fiber is disconnected from any laser or LED source.

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 Instruction Sheet 860392406
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j. Using a 7X magnifier or LC microscope supplied

in the 1032B5/B6 or 1032H Kit, check the tip of
the ferrule. No excess adhesive should surround
the fiber, ferrule chamfer, and cylindrical
surfaces.
One sheet type H
Note: If excess adhesive is found, continue to
polishing paper
use type H polishing paper (green) to remove (green) dull side up
the excess. Inspect after every 5 polishing
strokes.
Note: To be certain that the ferrule is free of any
uncured adhesive, clean the connector tip,
chamfer, and cylindrical surfaces with a
moistened wipe.
Note: This concludes the polishing procedure for multimode connectors.
Section 5.1.3 is to be performed on singlemode connectors only.
5.1.3 Step 3. Singlemode — Improve Return Loss
a. Place one sheet of type E (white) polishing paper over the type H paper (green), dull side up.
b. Remove the connector from the polishing tool.
c. Place a small amount of distilled water on the type E paper and distribute the water over the
polishing area using several figure-8 strokes with the empty polishing tool.
d. Place the connector back into the LC polishing tool.
e. Polish the connector using 6-8 well-rounded, figure-8 strokes.
Note: To be certain that the ferrule is free of any uncured adhesive, clean the connector tip,
chamfer, and cylindrical surfaces with a moistened wipe.
Note: This concludes the polishing procedure for singlemode connectors.
Table B. Overview—Polishing Multimode
No. of Figure-8
Step Polishing Materials Notes
Strokes
1 Type H (green, mylar backed) 20, then as required Air polish with polishing
puck to remove fiber stub.
2 1 sheet (green) type H over 12-15, then as required Dry polish to remove cured
polishing plate adhesive.
Repair 2 sheets type F (yellow) over 10 strokes, then as Wet type F paper with
polish, only Type H (green) polishing required to remove flaw distilled water.
if needed paper (25 strokes max)

Table C. Overview—Polishing Singlemode

No. of Figure-8
Step Polishing Materials Notes
Strokes
1 Type H (green, mylar backed) 20, then as required Air polish with polishing
puck to remove fiber stub.
2 1 sheet (green) type H over 8-10, then as required Dry polish to remove cured
polishing plate adhesive.
3 1 sheet (white) type E over H 6 Wet type E paper with
polishing paper on plate distilled water for final polish.
Repair 2 sheets type F (yellow) over 10 strokes, then as Wet type F paper with
polish, only Type H (green) polishing required to remove flaw distilled water. After flaw is
if needed paper (25 strokes max) removed, repeat Step 3.

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5.2 Repair Polishing (Only If Needed)

1. Place two sheets of type F paper (yellow, from kit 700 218 076)), one on top of the other,
over Type H polishing paper, dull side up, placed on the glass plate.
2. Wet the polishing surface with distilled water. Distribute the water over the polishing area
using several figure-8 strokes with an empty polishing tool.
3. Install the connector into the polishing tool.
4. Using firm pressure, polish the connector using 10 well-rounded figure-8 strokes, to attempt
to remove the flaw. If the flaw is not removed, continue to polish, but do not exceed 25 repair
strokes total, to avoid over polishing the ferrule. If an unacceptable flaw is still present after
25 strokes, the connector should be replaced/reterminated.
Note: This concludes the repair procedure for multimode fibers.
Note: To be certain that the ferrule is free of any uncured adhesive, clean the connector tip,
chamfer, and cylindrical surfaces with a moistened wipe.
5. For singlemode fibers only, repeat Section 5.1.3 in Section 5.1.

5.3 Final Assembly

Once the polishing is finished and the end finish is acceptable, cover the end of the connector
with a white dust cap.
Note: To be certain that the ferrule is free of any uncured adhesive, clean the connector tip,
chamfer, and cylindrical surfaces with a moistened wipe.

Finished
connector

Install white
dust cap

6 Assembly on Nonbuffered Fiber

Note: Use the appropriate procedures for preparing outside plant (OSP) cable. See
636-299-110-5 for more information on grounding, blocking, and buffering fiber optic
cable.
1. Follow the instructions in the D-181755 Kit for direct termination.
Note: To prevent cutting the fiber by mistake, do not attempt to remove the fiber coating
until a buffer tube has been placed over the bare fiber.
Note: The fiber should extend 5/8 inch (15.9mm) beyond the end of the buffer tube.
2. Clean blade area on mechanical stripper and adjust the stop to remove 5/8 inch (15.9mm) of
coating from the fiber.
3. Insert the fiber through the guide tube until the fiber butts against the stop.
4. Close the tool handles and gently pull the fiber from the tool to strip the coating.
5. Complete the connector assembly on nonbuffered fiber by using Section 4 (EZ Method).

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 Instruction Sheet 860392406
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7 Fiber Inspection
! DANGER: Optical fibers may emit radiation if the far end is connected with a
working laser or light-emitting diode (LED). Never view the fiber end of a cable or
plug with the naked eye or any optical instrument until absolute verification is
established that the fiber is disconnected from any laser or LED source.
Note: The fiber end face should be clean and contaminant free.
1. Dampen a wipe with fiber cleaning solution or isopropyl alcohol (>91% 2-propanol + water).
2. Clean all surfaces of the ferrule with the dampened wipe, followed by a dry wipe.
3. Locate the LC microscope supplied in the 1032B5/B6 or 1032H Kit.
4. Insert the ferrule end of the connector into the microscope adapter (center hole).

! DANGER: A high-intensity light may be used at the other end of the fiber to
illuminate fiber core.
5. Open the microscope barrels to illuminate the connector tip and use the side wheel to focus.

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8 Cleaning Instructions
8.1 LC Connector
1. Dampen a wipe with isopropyl alcohol (>91% 2-propanol + water).
2. Clean all surfaces of the ferrule with the dampened wipe, followed by a dry wipe.
3. Always inspect after cleaning and before installation.

! CAUTION: The adhesive used in this process is a low viscosity fluid and can migrate
to the ferrule sidewalls if not cleaned. Functionality and signal
performance will be affected if the connector tip is not thoroughly
cleaned. Discard cleaning sticks after each use.
8.2 LC Adapter
1. If access to the adapter is only available from one side, use a dry adapter cleaning stick (or
LC adapter brush) to clean the inside of adapter.
2. If access is available from both sides of the adapter, clean the adapter with an adapter
cleaning stick ( or an LC adapter brush) moistened with alcohol followed by a dry adapter
cleaning stick (or LC adapter brush). Inspect connector end face.

! CAUTION: Do not try to clean the inner adapter sleeve with a standard pipe cleaner.
The inner diameter of the sleeve is too small.

9 Adapter–Mounting and Orientation

! CAUTION: The adapter should never be installed from the front of a panel or outlet.
1. Locate the panel or outlet where the adapter is to be mounted.
2. Install the adapter from the rear of the panel or outlet.
Note: The position markings (B and A) are for transmit-to-receive polarity guidance. It is
possible to mount the adapter in any of four possible orientations (three are
illustrated below) to achieve correct polarity and position of the signal within a panel.
Refer to the document SYSTIMAX SCS Duplex Fiber Polarity Guidelines for LC and
SC Connectors for further information. Depending on the particular panel or outlet,
some orientations may offer improved finger access to the connectors for insertion
and removal in dense applications.
Install Install Install
from rear from rear from rear

Adapter Mounted 90 Adapter Mounted Adapter Mounted 90

Counterclockwise Horizontally Clockwise

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 Instruction Sheet 860392406
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10 Ordering Information

10.1 Epoxy
The approved epoxies for use with the SYSTIMAX® epoxy field installations can be obtained from
the following distributors;
Product: EPO-TEK 353ND Product: Tra-Bond F123MV
USA USA
Epoxy Technologies, Inc. Tra-Con, Inc.
14 Fortune Drive 45 Wiggans Avenue
Billerica, MA 01821 Bedford, MA 01730
Tel. 1-800-227-2201 Tel. 1-800-872-2661
Asia, (Japan) Asia, (Singapore)
Daizo Corporation Tra-Con Singapore
Tel. 81-3-3246-2251 Tel. 65-29-93-071
Fax 81-3-3246-2271
Europe, (France)
Poltec PI, S.A.
Tel. 33 1 48 10 39 30
Fax 33 1 48 10 08 03

10.2 Adhesive
For the EZ installation procedures, the following adhesives are required:
 648 Retaining Compound (10ml) #21443
 7090 Solventless Primer (1 oz. Bottle) # 19368
 495 Superbonder (3 gram tube ) #49504 (required on 0.9mm installations)

The approved adhesives can be obtained from SYSTIMAX or any Loctite Distributor. To order
from SYSTIMAX, request Material ID 760000810 EZ Adhesives. To find the Loctite Distributor
nearest you either
 Log onto their Website www.loctite.com
OR
 call 1-800-323-5106

10.3 Obtain Locally

 Distilled water.
 Isopropyl alcohol (>91% 2-propanol + water).
 Canned air (non-ozone depleting).]

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