TB-2044 INSTRUCTIONS FOR REPLACEMENT OF UHD TUNING FORK CONTACTS REVISION - SPECIFICATION REVISION STATUS. Revision SCR No. Description Initial Date

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1 TB-2044 INSTRUCTIONS FOR REPLACEMENT SPECIFICATION REVISION STATUS Revision SCR No. Description Initial Date Initial Release (Supercedes TB-258) H. Cook by Amphenol Backplane Systems. The material contained in this document is proprietary to Amphenol Backplane Systems. It may not be disclosed to third parties in any form or by any means, electronic, mechanical, photocopying, or recording without the prior written permission of Amphenol Backplane Systems.

2 TB INSTRUCTIONS FOR REPLACEMENT PURPOSE 1.1 This technical bulletin describes the process for repair/replacement for Ultra High Density Tuning Fork Contacts in printed wiring boards. 2.0 PAGE NO. 2 OF 5 TOOLS 2.1 Insulator Removal Tool Part No Long Nose Pliers Part No Contact Insertion Tool Part No Plastic Tipped Mallet Part No

3 TB INSTRUCTIONS FOR REPLACEMENT PAGE NO. 3 OF 5 PROCEDURE 2.1 Insulator Removal - The insulator block must be removed prior to contact removal. Place protective tape over the backplane surface next to the insulators to be removed (see Figure 1). Support the backpanel on parallel supports as close to the pin pattern as possible. Use insulator removal tool, Part No Insert the removal tool over the insulator, keeping the tool square to the backplane. On shielded connectors, ensure the gripping surfaces of the extractor are within the cutouts of the shield to prevent damaging the shield (see Figure 1). Close the handle to loosen insulator, then lift tool and insulator away from the backplane. Shield Cutout Protective Tape 2.2 Insulator to be Replaced Figure 1 Insulator Removal Removal of Damaged Tuning Fork - Using tool, Part No , or 4 long nose pliers, firmly grasp the tuning fork and pull away from backplane while holding the backplane in place. Use caution to avoid damaging adjacent contacts. Contact should pull away without excessive force (4 to 10 pounds). Discard removed contact. NOTE: Insulator block and contact should not be reused.

4 TB-2044 INSTRUCTIONS FOR REPLACEMENT PAGE NO. 4 OF Replacement - Select the correct contact part number from the contact replacement field kit (see Table 1); must be 091 series with the correct tail length. Support the backplane on parallel supports as close to the pin pattern as possible. Supports should be higher than the components to prevent damage. Place the replacement contact into the insertion tool, Part No Hold the insertion tool so that it is vertical to the backplane in all planes. Make sure that the contact is in the proper orientation with the other contacts in the connector. Insert contact tail in to the vacant hole while gently inserting tool over the adjacent contacts for alignment. Tap the tool gently with a small plastic tipped mallet until the insertion tool is fully seated against the backplane. Remove the insertion tool from the contacts by pulling normal to the backplane. Inspect for proper seating and alignment of the contact. The seating height is built into the insertion tip, however tool wear can affect height. The contact height should be the same as the adjacent contacts. Select proper replacement insulator part number. Place the insulator over the contacts. A block with a flat area approximately the same size as the insulator should be used to seat the insulator. Tap block with plastic tipped mallet to seat the insulator into place. Inspect for proper alignment of contacts and insulator. Item Amphenol Part No Case Center Insulator N/A N/A Center Insulator N/A N/A 5 Short Nose Pliers Contact Insertion Tool Insulator Removal Tool Right Insulator N/A 5 5 Right Insulator N/A N/A Left Insulator N/A 5 5 Left Insulator N/A N/A 40 Position Insulator Tuning Fork Contact Tuning Fork Contact Tuning Fork Contact Tuning Fork Contact Tuning Fork Contact Tuning Fork Contact Table 1 Content List of Contact Replacement Field Kits

5 TB-2044 INSTRUCTIONS FOR REPLACEMENT PAGE NO. 5 OF Inspection Criteria Figure 2 Acceptable Closed Contact Bent Contact Figure 3 Unacceptable