Instruction Sheet SignalPinContactRepairKits 354687-1, -2,and -3 408--9979 ForZ-PACK*Connectors 19FEB 10 RevD PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsisavailable. pin contact tail and reinforces it while the tool pushes Contact Replacement Insertion Tool the signal pin contact out. Tool 380392--8 Assembly 354995--1 The extraction tool assembly has two positions for the signal pin contact tip—BACK or INSIDE the pin support tube and FORWARD or BEYOND the pin support tube. The tool pin tip has a concave surface Replacement to aid in positioning the tool over the contact and to Setscrew maintain its location during the removal process. Pin Assembly 1--22642--9 354994--1 The tip of the insertion tool assembly is a T--shaped Tool steel section. It has a larger, flat back section, a Spacer Tip narrow, ribbed front section, and a slot between the (See Table) ribs. Pusher 679037--1 3. USINGTHEREPAIRKIT Pin Support 3.1. ContactRemoval Tube Extraction Tool 1. Assemble the pusher (PN 679037--1) with the Assembly 354996--1 setscrew onto the contact replacement tool. 2. Snap the extraction tool assembly into the Z--PACK REPAIRKIT SPACER contact replacement tool. CONNECTORTYPE 3. Locate the rear of the signal pin contact to be 354687--1 2mmHMandFB 679043--1 removed. 354687--2 HS36-- and10--Row 679043--2 4. Place the spacer over the signal pin contact tail 354687--3 HM12--Row 679043--3 (for mid--plane/long--tail product). Figure 1 If the repair is being made prior to assembling the NOTE connector housing, use the higher surface of the spacer. If the repair is being made after 1. INTRODUCTION i assembling the rear housing, use the lower Signal Pin Repair Kits 354687--1, --2, and --3 are used surface of the spacer. to insert and extract signal pin contacts from Z--PACK connectors. See Figure 1. 5. Depending on the location of the tip of the signal pin contact in relation to the board (or spacer) Parts shown in Figure 1 are also available NOTE surface, position the tool tip as follows: separately. —If the tip of the signal pin contact is flush with i the board (or spacer) surface, position the tool tip in the FORWARD position (refer to Figure 2) and place the tool tip on the signal pin contact tip. The Reasons for reissue of this instruction sheet are signal pin contact tip should be located in the provided in Section 4, REVISION SUMMARY. concave tip of the tool. 2. DESCRIPTION To be sure of proper location, slowly spin the tool NOTE between your thumb and index finger. If the tool Each repair kit features a basic contact replacement tip remains on the contact tip, the tool tip is tool with a spring--loaded adapter tip, an extraction i properly located. tool assembly, single--pin insertion tool assembly, replacement pin assembly, pusher, and spacer. —If the signal pin contact tip is below the board (or spacer) surface, position the tool tip in the The spacer, which is used to accommodate long tail signal pin contacts, is a block that fits over the signal FORWARD position and place into the hole. E2010 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change. 1 of 2 PRODUCT INFORMATION1--800--522--6752 Forlatest revision and Regional CustomerService, All Rights Reserved visit ourwebsite atwww.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOCB *Trademark. Otherproduct names, logos, orcompany names might be trademarks of theirrespective owners. 408-9979 SignalPinContactRepairKits354687-1, -2,and -3 3. The push shoulders on the sides of the signal Tool Tip in pin contact should each be against the ribs on the Forward Position tool tip. The axis of the pin should be the same as the axis of the tool tip, with the flat section of the pin parallel to the BACK of the tip. See Figure 4. Insertion Tool Assembly Replacement Contact Figure 2 —If the signal pin contact tip is above the board (or spacer) surface, position the tool tip in the BACK position (refer to Figure 3) and place the tool over the contact tail, which will extend into the pin support tube. Tool Tip in Back Position Figure 4 4. Orient and start the replacement contact through the top of the connector housing and into the appropriate cavity. The flat surface of the back of the tip should be parallel to the side walls of the connector housing. If replacing an outer row contact against the wall, the ribs in the front of the tool should fit between the plastic reinforcement ribs of the housing. Before applying force to the replacement contact, CAUTION Figure 3 make sure that the contact is aligned properly in the connector housing. The tool must be held ! 6. Make sure that the board is securely supported, perpendicular to the pc board. with clearance for the signal pin contact to be pushed clear. 5. Apply force to the tool until the tool bottoms on the connector housing and the contact is fully 7. Position the tool perpendicular to the pc board seated. surface. Use one hand to maintain the position of the tool, and use the other hand to exert the After the contact is fully seated, the push NOTE required force on the tool. Push the contact shoulders must be flush with the internal ribs on straight out of pc board and connector housing. the floor of the connector housing. i 3.2. ContactInsertion 6. Remove the tool from the contact, making sure 1. Snap the insertion tool assembly onto the not to damage the other contacts. If damaged contact replacement tool. contacts are evident, they must be replaced. 2. Orient and insert the replacement contact into the tip of the insertion tool. The pin should fit snugly between the ribs in the front of the tip. 4. REVISIONSUMMARY Revisions to this instruction sheet include: DO NOT push the end of the contact with your DANGER finger—the contact will penetrate the skin. Pinch S Updated instruction sheet to corporate the pin between your thumb and index finger. requirements 2 of 2 TycoElectronicsCorporation RevD