c. Qulckly move the soldering iron tip to the junction of the
component lead and the printed circuit foil, and hold it
there only until the solder flows onto and around both the
component lead and the foil.
CAUTION: Work quickly to avoid overheating the circuit
board printed foil.
d. Closely inspect the solder area and remove any excess
or splashed solder with a small wire-bristle brush.
Some chassis circuit boards have slotted holes (oblong) through
which the IC leads are inserted and then bent flat against the
circuit foil. When holes are the slotted type, the following
technique should be used to remove and replace the IC. When
working with boards using the familiar round hole, use the
standard technique as outlined in parapraphs 5 and 6 above.
1. Desolder and straighten each IC lead in one operation by
gently prying up on the lead with the soldering iron tip as the
2. Draw away the melted solder with an anti-static suction-
type solder removal device (or with solder braid) before
removing the IC.
1. Carefully insert the replacement IC in the circuit boare.
2. Carefully bend each IC lead against the circuit foil pad and
3. Clean the soldered areas with a small wire-bristle brush.
(It is not necessary to reapply acrylic coating to the areas).
"Small-Signal" Discrete Transistor
1. Remove the defective transistor by clipping its leads as
close as possible to the component body.
2. Bend into a "U" shape the end of each of three leads
remaining on the circuit board.
3. Bend into a "U" shape the replacement transistor leads.
4. Connect the replacement transistor leads to the
corresponding leads extending from the circuit board and
crimp the "U" with long nose pliers to insure metal to metal
contact then solder each connection.
Power Output, Transistor Device
1. Heat and remove all solder from around the transistor leads.
2. Remove the heatsink mounting screw (if so equipped).
3. Carefully remove the transistor from the heat sink of the
4. Insert new transistor in the circuit board.
5. Solder each transistor lead, and clip off excess lead.
6. Replace heatsink.
1. Remove defective diode by clipping its leads as close as
possible to diode body.
2. Bend the two remaining leads perpendicula y to the circuit
3. Observing diode polarity, wrap each lead of the new diode
around the corresponding lead on the circuit board.
4. Securely crimp each connection and solder it.
5. Inspect (on the circuit board copper side) the solder joints of
the two "original" leads. If they are not shiny, reheat them
and if necessary, apply additional solder.
Fuse and Conventional Resistor
1. Clip each fuse or resistor lead at top of the circuit board
2. Securely crimp the leads of replacement component around
notch at stake top.
3. Solder the connections.
CAUTION: Maintain original spacing between the replaced
component and adjacent components and the circuit board
to prevent excessive component temperatures.
Circuit Board Foil Repair
Excessive heat applied to the copper foil of any printed circuit
board will weaken the adhesive that bonds the foil to the circuit
board causing the foil to separate from or "lift-off" the board.
The following guidelines and procedures should be followed
whenever this condition is encountered.
At IC Connections
To repair a defective copper pattern at IC connections use the
following procedure to install a jumper wire on the copper
pattern side of the circuit board. (Use this technique only on IC
1. Carefully remove the damaged copper pattern with a sharp
knife. (Remove only as much copper as absolutely
2. carefully scratch away the solder resist and acrylic coating
(if used) from the end of the remaining copper pattern.
3. Bend a small "U" in one end of a small gauge jumper wire and
carefully crimp it around the IC pin. Solder the IC connection.
4. Route the jumper wire along the path of the out-away
copper pattern and let it overlap the previously scraped end
of the good copper pattern. Solder the overlapped area and
clip off any excess jumper wire.
At Other Connections
Use the following technique to repair the defective copper
pattern at connections other than IC Pins. This technique
involoves the installation of a jumper wire on the component
side of the circuit board.
1. Remove the defective copper pattern with a sharp knife.
Remove at least 1/4 inch of copper, to ensure that a
hazardous condition will not exist if the jumper wire opens.
2. Trace along the copper pattern from both sides of the
pattern break and locate the nearest component that is
directly connected to the affected copper pattern.
3. Connect insulated 20-gauge jumper wire from the lead of
the nearest component on one side of the pattern break to
the lead of the nearest component on the other side.
Carefully crimp and solder the connections.
CAUTION: Be sure the insulated jumper wire is dressed so
the it does not touch components or sharp edges.
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