SPS 4382-2 Stock Number S-Kit-l Contents: Solder and Paste Flux (enough for 10 repairs) and Template

Procedure: The special solder supplied in the kit is not a rosin-core solder. Paste flux must be used to get the solder to flow. The solder included in the kit remains elastic when cool to prevent joints from breaking due to thermal expansion. It is necessary to remove the tuner bottom cover to gain access to the ground connections on the tuner wrap. Use caution when
removing the solder from the ground tabs; excessive heat can lift/damage the copper traces. Also, make sure there is adequate ventilation when using solder and flux and do not inhale the fumes.

Note: The tuner wrap was changed from steel to copper, and then to zinc. All three materials are tin-plated, and therefore look the same. The copper wrap can be identified by removing the top cover of the tuner (the cover that is not soldered on). Copper will be visible at the top edges of the wrap. Copper is an excellent conductor of heat, therefore, it is necessary to apply more heat to remove the bottom cover of the tuner. The zinc wrap will look identical to the steel tuner wrap. However, a small magnet will stick to the steel tuner wrap but will not stick to either the copper or zinc wraps. The zinc wrap will melt at approximately 800 degrees, so it is necessary to keep the tip temperature of the soldering iron below 775 degrees when working on a zinc wrap. Remove Solder From Interior Tabs: (Figure 2) Completely remove all solder from the interior tabs of the tuner wrap and from the copper pads. Refer to figure 2 for tuner Use the template wrap tab locations. supplied in the kit (Figure 1) as an aid in locating the tabs. Placing the solder braid flat against the wrap tab and perpendicular to the board will minimize the risk of Figure 1 Install Template damaging the copper or lifting surface mounted devices. Reminder: Make sure to use adequate ventilation whenever working with solder or flux.
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2. Re-solder Interior Tabs: Apply the paste flux generously to each interior ground connection of the tuner wrap. Use the supplied solder to reconnect all of the interior wrap grounds. The solder has a dull appearance when cool. This is normal and does not indicate a cold solder joint. The solder joint s h o u l d b e s m o o t h in appearance. A rough finish does indicate a bad solder connection. A tip temperature of 750-800 degrees Fahrenheit works well with the solder.

Install 6 Jumper Wires: (Figure 31 Refer to Service Information Notice n/96005 to determine if jumpers are needed. Install jumper wires at the locations shown in figure 3. Use 24 or 26 gauge solid hook-up wire for all jumpers. It is important that all Figure 2 Interior Solder Connections jumpers be connected to the printed circuit board and not to the wrap, and that jumpers A, B, C, and D are connected outside of the tuner wrap. Jumper C must be long enough to fit over the outside of the tuner bottom cover. Jumpers E and F inside the tuner wrap must be kept as short as possible and dressed against the board in order to prevent oscillations. It is not necessary to use the supplied solder to attach the jumper wires, standard 60/40 rosin-core solder should be used. Re-Solder External Wrap Connections: Re-solder all of the external wrap connections. external wrap connections. A Use standard 60/40 rosin-core solder for all ,B

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Remove Excess Solder Flux and Secure Jumper Wires: Remove excess solder flux before attaching the bottom cover of the tuner. Use hot melt glue to secure the jumper wires to the printed circuit board. The jumper wires inside the E tuner wrap do not need to be glued in The jumper wires on the place. outside of the tuner should be glued on the insulation near each end.

Figure 3 Jumper Wire Locations