The Motorola HSN4035 is a versatile and reliable amplifier-loudspeaker kit that offers exceptional audio performance for a wide range of applications. With its powerful speaker and high-quality amplifier, it delivers clear and intelligible sound, making it ideal for use in various settings such as classrooms, auditoriums, conference rooms, and public address systems. The kit includes a 9-foot cable for convenient placement of the speaker, and its easy-to-use controls allow for precise volume adjustment.
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SERVICE INSTRUCTIONS
FOR
AMPLIFIER-LOUDSPEAKER
MOTOROLA KIT HSN4035( )
1998 by Motorola, Inc.
Radio Network Solutions Group
8000 W. Sunrise Boulevard
Ft. Lauderdale, FL 33322
All rights reserved.
*6881109C65*
68P81109C65-O
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reference Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Initial Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacing Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Volume Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing 9-Foot Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Final Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exploded View and Repair Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 i
ii
List of Figures
Figure 1. Test Connector Schematic/Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Amplifier-Loudspeaker Test and Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3. Separating Front and Rear Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. PCB Connections to External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 5. Removing and Installing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6. Removing Volume Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7. Preparing New Volume Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 8. Connecting Leads to New Volume Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 9. Removing and Installing 9-Foot Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 10. Installing 9-Foot Cable in Strain Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 11. Final Reassembly of Amplifier-Loudspeaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12. Amplifier-Loudspeaker, Motorola Kit HSN4035( ), Exploded View . . . . . . . . . . . . . . . . . 17
List of Tables
Table 1. Test Equipment and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 2. Test Connector Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 3. Repair Parts Required for Speaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 4. Repair Parts Required for Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 5. Printed Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 6. Repair Parts Required for Volume Potentiometer Replacement. . . . . . . . . . . . . . . . . . . . . . 10
Table 7. Repair Parts Required for 9-Foot Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 8. 9-Foot Cable Connections to PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 9. Repair Parts Required for Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 10. Repair Parts for Amplifier-Loudspeaker Motorola Kit HSN4035( ) . . . . . . . . . . . . . . . . . . . 17 iii
iv
LIST OF EFFECTIVE PAGES
Service Instructions
For
Amplifier-Loudspeaker
Motorola Kit HSN4035( )
Motorola Publication Number 68P81109C65-O
Issue Dates of Original and Revised Pages are:
Original:March 1999
The Number of pages in this publication is 33 consisting of the following:
Page Number
Front cover
Inside front cover (blank)
Title i through viii
1 through 18
Revision
Letter
O
O
O
O
O
Page Number
Questionnaire (Front)
Questionnaire (Back
Replacement Parts
Ordering (Inside back cover)
Back cover
Revision
Letter
O
O
O
O
NOTE: The letter O in the Revision Letter column in the table above denotes an original page.
Original pages ARE NOT identified as such in the page footers except for the absence of a change letter and date.
Safety Summary
Exposure to Radio
Frequency Energy
(National and
International
Standards and
Guidelines)
•
•
Your Motorola two-way Radio, which generates and radiates radio frequency (RF) electromagnetic energy (EME), is designed to comply with the following national and international standards and guidelines regarding exposure of human beings to radio frequency electromagnetic energy:
•
•
•
Federal Communications Commission Report and Order
No. FCC 96-326 (August 1996)
American National Standards Institute (C95-1-1992)
National Council on Radiation Protection and Measurements
(NCRP - 1986)
International Commission on Non-Ionizing Radiation Protection
(ICNRP - 1986)
European Committee for Electrotechnical Standardization
(CENELEC)
Env. 50166 - 1 1995E - Human Exposure to Electromagnetic
Fields Low Frequency (0 Hz to 10kHz)
-
-
Env. 50166 - 2 1995E - Human Exposure to Electromagnetic
Fields High Frequency (10kHz to 300Ghz)
Proceedings of SC211/8 1996 - Safety Considerations for
Human Exposure to E.M.Fs from Mobile Telecommunications
Equipment (M.T.E.) in the Frequency Range 30MHz - 6GHz
(E.M.F - Electromagnetic Fields)
To assure optimal radio performance and that human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards, transmit only when people inside and outside the vehicle are at least the minimum distance away from a properly installed, externally-mounted antenna.
16 to 50 Watts
More than 50 Watts
The table below lists the minimum distance for several different ranges of rated radio power.
Rated Power and Distance
Rated Power of Vehicle-installed
Mobile Two-way Radio
7 to 15 Watts
Minimum Distance from
Transmitting Antenna
1 Foot
(30.5 Centimeters)
2 Feet
(61 Centimeters)
3 Feet
(91.5 Centimeters) v
vi
Mobile Antenna
Installation
Control Station
Operation
•
•
Install the vehicle antenna external to the vehicle and in accordance with:
The requirements of the antenna manufacturer/supplier
Instructions in the Radio Installation Manual
When radio equipment is used to operate as a control station, it is important that the antenna be installed outside the building and away from places where people may be in close proximity.
Note
Refer to Table 1 on page 2 for rated power and minimum distance values for transmitting antennas.
Airbag Warning
LP Gas Warning
VEHICLES EQUIPPED WITH AIR BAGS
An air bag inflates with great force. DO NOT place objects, including communications equipment, in the area over the air bag or in the air bag deployment area. If the communications equipment is installed improperly and the air bag inflates, this can cause serious injury.
Installation of vehicle communication equipment should be performed by a professional installer/technician qualified in the requirements for such installations.
An air bag’s size, shape and deployment area can vary by vehicle make, model and front compartment configuration (e.g., bench seat vs. bucket seats). Contact the vehicle manufacturer’s corporate headquarters, if necessary, for specific air bag information for the vehicle make, model and front compartment configuration involved in your communication equipment installation.
It is mandatory that radios installed in vehicles fuelled by liquefied petroleum gas conform to the National Fire Protection Association standard NFPA 58, which applies to vehicles with a liquid propane (LP) gas container in the trunk or other sealed off space within the interior of the vehicle. The NFPA58 requires the following:
•
•
•
Any space containing radio equipment shall be isolated by a seal from the space in which the LP gas container and its fittings are located.
Removable (outside) filling connections shall be used.
The container space shall be vented to the outside.
Anti-Lock Braking System (ABS) and
Anti-Skid Braking System Precautions
!
!
W A R N I N G
Disruption of the anti-skid/anti-lock braking system by the radio transmitter may result in unexpected vehicle motion.
Motorola recommends the following radio installation precautions and vehicle braking system test procedures to ensure that the radio, when transmitting, does not interfere with operation of the vehicle braking system.
Installation Precautions
1.
Always provide as much distance as possible between braking modulator unit and radio, and between braking modulator unit and radio antenna and associated antenna transmission line.
Before installing radio, determine location of braking modulator unit in vehicle. Depending on make and model of vehicle, braking modulator unit may be located in trunk, under dashboard, in engine compartment, or in some other cargo area.
If you cannot determine location of braking modulator unit, refer to vehicle service manual or contact a dealer for the particular make of vehicle.
2.
If braking modulator unit is located on left side of the vehicle, install radio on right side of vehicle, and conversely.
3.
Route all radio wiring including antenna transmission line as far away as possible from braking modulator unit and associated braking system wiring.
4.
Never activate radio transmitter while vehicle is in motion and vehicle trunk lid is open.
Braking System Tests
The following procedure checks for the most common types of interference that may be caused to vehicle braking system by a radio transmitter.
1.
Run vehicle engine at idle speed and set vehicle transmission selector to PARK. Release brake pedal completely and key radio transmitter. Verify that there are no unusual effects (visual or audible) to vehicle lights or other electrical equipment and accessories while microphone is NOT being spoken into.
2.
Repeat step 1. except do so while microphone IS being spoken
into.
3.
Press vehicle brake pedal slightly just enough to light vehicle
brake light(s). Then repeat step 1. and step 2.
4.
Press the vehicle brake pedal firmly and repeat step 1. and step 2.
vii
viii
POTENTIALLY
EXPLOSIVE
ATMOSPHERES
5.
Ensure that there is a minimum of two vehicle lengths between front of vehicle and any object in vehicle’s forward path. Then, set vehicle transmission selector to DRIVE. Press brake pedal just far enough to stop vehicle motion completely. Key radio transmitter. Verify that vehicle does not start to move while microphone is NOT being spoken into.
6.
Repeat step 5. except do so while microphone IS being spoken
into.
7.
Release brake pedal completely and accelerate vehicle to a speed between 15 and 25 miles/25 and 40 kilometers per hour. Ensure that a minimum of two vehicle lengths is maintained between front of vehicle and any object in vehicle’s forward path. Have another person key radio transmitter and verify that vehicle can be braked normally to a moderate stop while microphone is NOT being spoken into.
8.
Repeat step 7. except do so while microphone IS being spoken
into.
9.
Release brake pedal completely and accelerate vehicle to a speed of 20 miles/30 kilometers per hour. Ensure that a minimum of two vehicle lengths is maintained between front of vehicle and any object in vehicle’s forward path. Have another person key radio transmitter and verify that vehicle can be braked properly to a sudden (panic) stop while microphone is NOT being spoken into.
10. Repeat step 9. except do so while microphone IS being spoken
into.
11. Repeat step 9. and step 10. except use a vehicle speed of 30 miles/
50 kilometers per hour.
Turn off your two-way radio when you are in any area with a potentially explosive atmosphere, unless it is a radio type especially qualified for use in such areas (for example, Factory Mutual Approved).
Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death.
Areas with potentially explosive atmospheres include fueling areas such as: below decks on boats; fuel or chemical transfer or storage facilities; areas where the air contains chemicals or particles, such as grain, dust or metal powders; and any other area where you would normally be advised to turn off your vehicle engine. Areas with potentially explosive atmospheres are often but not always posted.
To avoid possible interference with blasting operations, turn off your radio when you are near electrical blasting caps, in a blasting area, or in areas posted: “Turn off two-way radio”. Obey all signs and instructions.
Introduction
Reference
Publications
Note
The empty parentheses at the end of the kit numbers used throughout this publication stand for the alphabetical character (A, B, etc.) that denotes the revision level of the kit.
The revision levels of the kits may change from time to time without affecting the validity of these service instructions.
This publication provides field level troubleshooting and repair instructions for Amplifier-Loudspeaker Motorola Kit HSN4035. The
Amplifier-loudspeaker is a component of the Dual Control Head configuration of the MCS 2000 Mobile Radio. Troubleshooting and repair of the Amplifier-Loudspeaker are limited to localizing and repairing a fault to one of the following:
• Volume control potentiometer and its associated wiring
• Loudspeaker and its associated wiring
• Circuit card assembly (PCB) and its associated wiring
• 9-Foot (Power and signal) Cable
Provided in this publication for the Amplifier-Loudspeaker are the following procedures in the order listed:
• Test setup
• Test and Troubleshooting
• Disassembly
• Repair
• Reassembly
Motorola Publication 68P81088C64 - Operating Instructions Manual
Addendum for Motorola MCS 2000 Dual Control Head Radio
Motorola Publication 68P81109C63 - Installation Instructions for
Motorola MCS 2000 Dual Control Head Radio
Motorola Publication 68P81109C64 - Retrofit Instructions for
Motorola MCS 2000 Radio, Single Control Head to Dual Control Head
Conversion
Motorola Publication 68P02058U20 - GM 900, MC 900, GM 1200,
MCX 1200, GM 2000, MCS 2000, MC 2100 Mobile Radios; Installation
Instructions; All Frequencies
1
Test Setup
1. Secure the test equipment listed in Table 1 or its equivalents.
2. Refer to Figure 1 and Table 2 on page 3 and assemble a test connector for the amplifie5-loudspeaker as follows:
1. Crimp a 24-inch length of stranded insulated 18 AWG hookup wire onto each of the four female connector pins.
2. Insert female connector pins into positions 1, 2, 4, and 5 in
Molex connector body.
3. Tag free end of wires as shown in Figure 1.
3. Turn on power supply, set power supply output voltage to 13.8
VDC, and set current limit to 1.5 Amperes. Then turn off power supply.
4. Connect positive (+) terminal of power supply to pin 5 of test connector assembled in step 2 above. Connect negative terminal of power supply to pin 4 of test connector.
5. Turn on function generator and set it up to generate a 1-kHz sinewave signal with an amplitude of 230-mV rms and a DC offset of +4.4 Vdc.
6. Connect function generator output to pins 1 and 4 (return) of test connector.
7. On amplifier-loudspeaker to be tested, set Volume potentiometer knob to mechanical midrange.
8. Plug connector on amplifier-loudspeaker 9-foot cable into test connector. Then energize power supply.
Description
Test Connector
DC Power Supply
Audio Analyzer
Function Generator
Digital Multimeter
Oscilloscope
Resistor, Fixed, 4-Ohms (+/- 20 percent) 20 Watts
Table 1 Test Equipment and Special Tools
Manufacturer
Fabricated at Test
Facility
Hewlett Packard
Hewlett Packard
Hewlett Packard
Fluke
Tektronix
Dale
Model No./Part No.
Notes
See Figure 1 and Table
2 Below
6200 Must be capable of providing 13.8-Vdc, 2.0
Amperes regulated power.
8903B
3311A Must be capable of providing a 1-kHz test signal with a +4.4-Vdc offset .
27
TDS 544A or 2430A
H25, 4-Ohms See note at end of this table
2
Description
Roto-Torq Adjustable Torque
Screwdriver
Spanner Nut Bit for Adjustable
Torque Screwdriver
Table 1 Test Equipment and Special Tools
Manufacturer
Motorola
Model No./Part No.
Kit RSX-4043A
Motorola 66-80371B34
Notes
Note
Motorola Test Box RKN4460( ) can be substituted for the
4-Ohm 20-Watt fixed resistor specified in table 1. When pins 2 and 6 of female connector on back of test box are shorted together and SPKR/LOAD switch on top of test box is set to
LOAD, a suitable 4-Ohm 20-Watt resistance is available between the two EXTERNAL LOAD jacks on top of test box.
4 1
Analog Ground Audio Input
5 2
B+ Ground
6 3
MAEPF-26585-O
Figure 1 Test Connector Schematic/Wiring Diagram
Table 2 Test Connector Components
Motorola Part No.
1584953L01
2984706E06
Not Applicable
Description
Molex Connector Body, 6 Pin
Molex Connector Pin, Female
Hookup Wire, Stranded, Insulated, 18
AWG, 24-Inches Long
Quantity
1
4
4
Test Procedure
Troubleshooting
Procedures
The test procedure for the amplifier-loudspeaker is presented in the test and troubleshooting procedures pyramid diagram, Figure 2.
The troubleshooting procedure for the amplifier-loudspeaker are presented in the test and troubleshooting procedures pyramid diagram, Figure 2 on page 4.
3
START TEST
Perform Procedure Titled
Replacing Volume
Potentiometer, If That Does
Not Repair Fault, Perform
Procedure Titled
Replacing PCB.
No
Any
Sound Output
From
Amplifier-Loudpeaker?
No
1. Turn Off Power Supply.
2. Perform Procedure Titled
Separating Front and
Rear Housings.
3. Turn On Power Supply.
Yes
Is
Sound Output
Undistorted and About
Normal Listening
Volume?
Yes
No
1. Turn Off Power Supply.
2. Perform Procedure Titled
Separating Front and
Rear Housings.
3. Disconnect One Speaker
Lead at Speaker End.
4. Connect a 4-Ohm
Resistor Between TP10
and TP11 on PCB.
5. Turn On Power Supply.
Rotate Volume
Potentiometer Knob Slowly
From Fully Counterclockwise
Position to Fully
Clockwise Position.
Does
Volume Potentiometer
Adjust Sound Output
Smoothly Over its Entire Range?
Yes
Is Sound
Output Undistorted
At All Settings of Volume
Potentiometer?
Yes
Amplifier-Loudspeaker
Is In Good
Operating Condition.
End of Test.
No
Is
13.8Vdc
Present Between Terminals
TP12 (+) and TP13 (-) on PCB?
No
Perform Procedure Titled
Replacing 9-Foot Cable.
If That Does Not Repair
Fault, Perform Procedure
Titled Replacing PCB.
Yes
Is
1-kHz 230mVrms
Signal Present Between
TP1 and TP2 (Rtn) on PCB?
Yes
No
Is
1-kHz 220mVrms
(440mV p-p) Signal Present
Between TP7 and
TP2 (Rtn) on
PCB?
Yes
No
Perform Procedure
Titled Replacing PCB.
Is
1-kHz 180mVrms
(320mV p-p) Signal Present
Between TP8 and TP2 (Rtn) on PCB?
(Note 2)
No
Perform Procedure Titled
Replacing Volume
Potentiometer.
If That Does Not Repair
Fault, Perform Procedure
Titled Replacing PCB.
Yes
1. Turn Off Power Supply.
2. Disconnect One Speaker
Lead at Speaker End.
3. Connect a 4-Ohm Resistor
Between TP10 and TP11
on PCB.
4. Turn On Power Supply.
Is
1-kHz 3.2Vrms (8.8V p-p)
Signal Present Between
TP10 and TP11 on PCB
(Note 3)?
No
Perform Procedure
Titled Replacing PCB.
Yes
1. Connect Distortion Analyzer
Between TP10 and TP11 on PCB.
2. Rotate Volume Potentiometer
Knob Slowly Over its Entrire
Range.
Notes:
1. All specified voltage, current, and resistance values have a tolerance
of 10% unless indicated otherwise.
2. Signal between TP8 and TP2 has a DC offset of approximately +160mV.
3. Signal between TP10 and TP11 has a DC offset of approximately +6.1V.
Is
Harmonic Distortion of Signal Between TP10 and
TP11 5% or Less for
All Settings of
Volume Pot.?
Yes
No
Perform Procedure
Titled Replacing Speaker
MAEPF-26581-O
Repair Procedures
Initial Disassembly
1. Refer to Figure 3. Push tips of two identical or similar small flat blade screwdrivers into opening between front and rear housings.
2. Push both screwdriver blades simultaneously away from speaker to pop up and release front housing from rear housing.
!
C a u t i o n
When performing step 3, be very careful to avoid damaging loudspeaker cone, which faces upward directly below front cover.
3. Pull front housing off of rear housing carefully, which will expose speaker cone.
4. Grasp speaker at its edges and lift it up and out of rear housing.
Leave wires (black Zipcord) connected to PCB and set speaker face down next to right side of rear housing.
Dimple
Rear
Housing
Front
Housing
Gasket
Figure 3 Separating Front and Rear Housings
MAEPF-26667-O
5
Replacing Speaker
Repair Parts Required The repair parts required for replacing the speaker in the Amplifier-
Loudspeaker are listed in Table 3.
Table 3 Repair Parts Required for Speaker Replacement
Motorola Part
No.
5085891B01
3285203C01
1110027B23
Description
Speaker, 5-inch
Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
1
1
Quantity
Required
As
Required
Replacement Procedure 1. Perform procedure titled Initial Disassembly on page 5.
Note
In step 2, disconnect speaker wires from speaker end only (i.e., do not disconnect speaker wires from PCB).
2. Refer to Figure 4 on page 8. Using a soldering iron, disconnect black (Zipcord) wires at speaker end of wires that connect speaker to
PCB. Discard old speaker.
3. Using a soldering iron, connect wires disconnected in step 2 to terminals of new speaker, Motorola part no. 5085891B01. Either wire can be connected to either speaker terminal.
4. Perform procedure titled Final Reassembly on page 15 .
Replacing Printed
Circuit Board
Repair Parts Required The repair parts required for replacing the printed circuit board (PCB) in the Amplifier-Loudspeaker are listed in Table 4.
Table 4 Repair Parts Required for Printed Circuit Board Replacement
Motorola Part
No.
0105956V07
1110022A55
Description
Printed Circuit Board
Thermal Grease
Quantity
Required
1
As Required
6
Table 4 Repair Parts Required for Printed Circuit Board Replacement
Motorola Part
No.
3285203C01
1110027B23
Description
Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
1
Quantity
Required
As Required
Replacement Procedure 1. Perform procedure titled Initial Disassembly on page 5.
Note
In step 2, do not discard any of the wires after they are disconnected. All wires are reused.
2.Refer to Table 5 and Figure 4 on page 8. Using a soldering iron, disconnect the following 11 wires at PCB .
1. The six 9-foot cable wires (bare, black, white/black, blue, red, white) from TP1 through TP6
2. The three Volume potentiometer leads (blue, gray, white) from TP7 through TP9
3. The two speaker wires (black Zipcord conductors) from TP10 and TP11
3. Refer to Figure 5 on page 9. Remove the four M3x0.5 machine screws that attach PCB to inside of rear housing. Save screws for use in step 6.
4. Carefully lift PCB straight up and out of rear housing.
5. Apply a thin layer of thermal compound, Motorola part no.
1110022A55, to shaded area shown in Figure 5.
6. Mount new PCB to inside of rear housing using the four M3x0.5 machine screws removed in step 3. Torque screws to 7.5 inch pounds (0.848 Newton meter).
7. Refer to Table 5 and Figure 4 on page 8. Using a soldering iron, reconnect the 11 wires to the new PCB .
8. Perform procedure titled Final Reassembly on page 15.
Wire Color
Blue
Black
White/Black
Bare
Table 5 Printed Circuit Board Connections
From/To Component
9-Foot Cable
9-Foot Cable
9-Foot Cable
9-Foot Cable
PCB Terminal
Number
TP1
TP2
TP3
TP4
7
8
Wire Color
Red
White
Blue
Gray
White
Black
Black
Table 5 Printed Circuit Board Connections
From/To Component
9-Foot Cable
9-Foot Cable
Volume Pot. Counterwise End)
Volume Pot. Center (Arm)
Volume Pot. Clockwise End
Speaker (Either Terminal)
Speaker (Either Terminal)
PCB Terminal
Number
TP5
TP6
TP7
TP8
TP9
TP10
TP11
TP10 TP11
TP7
TP8
TP9
TP4
TP6 TP3 TP5 TP2 TP1
MAEPF-26669 -O
Figure 4 PCB Connections to External Components
Thermal Grease
Location
(Shaded Area)
Circuit
Board
Rear
Housing
MAEPF-26577-O
Figure 5 Removing and Installing PCB
9
Replacing Volume
Potentiometer
Repair Parts Required The repair parts required for replacing the Volume Potentiometer in the Amplifier-Loudspeaker are listed in Table 6.
Table 6 Repair Parts Required for Volume Potentiometer Replacement
Motorola Part
No.
Description
1805629V05
3205082E01
0402838X01
0205609X01
3205082E48
3285203C01
1110027B23
3285968B01
1110027B23
Volume Potentiometer
O-Ring, Volume Potentiometer
(The smaller of the two O rings)
Wave Washer
Spanner Nut
O-Ring, Spanner Nut
(The larger of the two O-rings)
Gasket
Gasket Lubricant
Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
Hookup Wire, 24 AWG, Stranded Alpha FIT-221
-1/16
Alpha UL1007
(Grey, Blue, and White)
Heat Shrinkable Sleeving, 0.062 in. I.D.,
0.375-in.long
1
1
1
1
1
1
1
1
Quantity
Required
As Required
As Required
As Required
Replacement Procedure 1. Perform procedure titled Initial Disassembly on page 5.
2. Using soldering iron, disconnect the three wires (blue, gray, white) from the three terminals of Volume potentiometer.
3. Refer to Figure 6 on page 11. Pull knob straight off of Volume potentiometer shaft.
4. Using an adjustable torque screwdriver, Motorola kit RSX4043( ) with a spanner wrench tip, Motorola part no. 6680371B03, remove spanner nut that retains Volume potentiometer in rear housing.
5. Grasp Volume potentiometer from back and pull it carefully straight back and out of rear housing. Discard wave washer, which falls off potentiometer shaft when potentiometer is pulled out of rear housing.
10
Volume
Potentiometer
Key
6. Refer to Figure 7 on page 12. Carefully slide a new O-ring,
Motorola part no. 3205082E01, over shaft and threaded bushing until it is flat on face of new potentiometer.
7. Refer to Figure 6. Insert new potentiometer into hole in rear housing. Be certain than key engages into slot in rear housing.
8. Place a new wave washer, Motorola Part No. 3205082E48, over threaded shaft of new potentiometer.
9. Refer to Figure 7 on page 12. Install a new O-ring. Motorola Part
No. 3205082E48, on a new spanner nut, Motorola Part No.
0205609X01.
10.Thread spanner nut onto threaded shaft of new potentiometer until it is hand tight.
11.Using an adjustable torque screwdriver, Motorola kit RSX4043( ) with a spanner wrench tip, Motorola part no. 6680371B03, tighten spanner nut to a torque of 8-inch-pounds (0.91 Newton
Meter).
12.Using solder iron, connect wires to new Volume potentiometer as shown in Figure 8 on page 12.
13.Perform procedure titled Final Reassembly on page 15.
Wave
Washer
Volume
Knob
Spanner
Nut
Figure 6 Removing Volume Potentiometer
MAEPF-26573-O
11
12
Volume
Potentiometer
Base of
Threaded Shaft
Spanner Nut
Groove
Volume Potentiometer O-ring
Motorola P/N 3205082E01
Spanner Nut O-ring
Motorola P/N 3205082E48
Figure 7 Preparing New Volume Potentiometer
MAEPF-26570-O
Volume
Potentiometer
Volume Potentiometer
Terminals
Volume Potentiometer
Terminals
Heat Shrink Sleeve (3),
1/16 in. diameter x 0.375 in. long
24 AWG Wire,
2.5 in. long
Blue
Gray
White
Figure 8 Connecting Leads to New Volume Potentiometer
MAEPF-26571-O
Replacing 9-Foot Cable
Repair Parts Required The repair parts required for replacing the 9-Foot Cable in the
Amplifier-Loudspeaker are listed in Table 7.
Table 7 Repair Parts Required for 9-Foot Cable Replacement
Motorola Part
No.
3085853B01
4285841A02
3285203C01
1110027B23
Description
9-Foot Cable
Strain Relief
Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
1
1
1
Quantity
Required
As
Required
Replacement Procedure 1. Perform procedure titled Initial Disassembly on page 5.
2. Refer to Figure 4 on page 8. Using soldering iron, disconnect the seven 9-foot cable wires (blue, black, white/black, bare, red, white, blue) from TP1 through TP6 on PCB.
3. Refer to Figure 9 on page 14. Remove locknut from strain relief on
9-foot cable. Then remove strain relief (with 9-foot cable still clamped in it) from rear housing and discard it.
4. Refer to Figure 10 on page 15. Insert unwired end of new 9-foot cable, Motorola part no. 3085853B01, into new strain relief,
Motorola part no. 428541A02, so that cable jacket protrudes 0.25inch or slightly less past inside edge of strain relief.
5. Using a torque wrench,torque clampnut on strain relief to
12-inch-pounds (1.36 Newton Meters).
6. Hold strain relief in one hand and pull 9-foot cable with other hand to verify that 9-foot cable is clamped tightly in strain relief.
7. Refer to figure 9 on page 14. Route unwired end of new 9-foot cable into rear housing until strain relief is flush with outside of rear housing.
8. Hand thread locknut onto strain relief and tighten it hand tight.
Then, using a torque wrench, torque locknut to 12 inch-pounds
(1.36 Newton meters).
9. Refer to Table 4 on page 6. Using a soldering iron, cut to length, strip, tin, and solder the leads of the new 9-foot cable to PCB.
10.Perform procedure titled Final Reassembly on page 15.
13
14
Table 8 9-Foot Cable Connections to PCB
Wire Color
Blue
Black
White/Black
Bare
Red
White
PCB Terminal
Number
TP1
TP2
TP3
TP4
TP5
TP6
Strain Relief
Locknut
Rear
Housing
Strain
Relief
Surface must be flush with exterior surface of rear housing
9-Foot Cable
MAEPF-26575-O
Figure 9 Removing and Installing 9-Foot Cable
9 Foot Cable
Wire Leads
Cable Jacket Must Not
Protude Further than 0.25 in.
Beyond Strain Relief
Strain
Relief
9 Foot
Cable
9 Foot
Cable
MAEPF-26574-O
Figure 10 Installing 9-Foot Cable In Strain Relief
Final Reassembly
Repair Parts for Final
Reassembly
Final reassembly consists of replacing the gasket and then installing the front housing of the amplifier-loudspeaker onto the rear housing.
The repair parts required for final reassembly of the Amplifier-
Loudspeaker are listed in table 9.
Table 9 Repair Parts Required for Final Reassembly
Motorola Part
No.
3285203C01
1110027B23
Description
Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
Quantity
Required
1
As
Required
15
Front Housing
See Detail A
Front Edge of Gasket
Delta
Gasket
Back Edge of Gasket
Detail A
MAEPF-26578-O
Figure 11 Final Reassembly of Amplifier-Loudspeaker
Reassembly Procedure 1. Place speaker back into rear housing with terminals on speaker oriented over TP10 and TP11 on PCB. Be certain that speaker wires
Zipcord) fold forward towards center of PCB and then back and are not pinched between back of speaker and PCB.
2. Refer to Figure 11. Remove and discard gasket from front housing.
3. Lubricate new gasket Motorola part no. 3285203C01, using gasket lubricant Motorola part no. 1110027B23.
4. Place new gasket into front housing being certain that gasket is oriented as shown in Figure 11.
5. Snap front housing onto rear housing.
6. Inspect entire recess area around the housing to verify that gasket is not pinched between front and rear housings. If gasket is not pinched, reassembly is complete. If gasket is pinched, proceed to step 7.
7. perform procedure titled Initial Disassembly on page 5. Then repeat steps 2 through 6 above.
16
Exploded View and
Repair Parts List
Figure 12 is an exploded view, which illustrates and locates all repair parts for the Amplifier-Loudspeaker, Motorola kit HSN4035( ). Table 8 lists all repair parts for the Amplifier-Loudspeaker and provides
Motorola part numbers for all repair parts. Table 10 crossreferences the repair parts to the parts illustrated on Figure 12.
13
5
4
3
1 12
6
7
8
9
4
10
11
2
Figure 12 Amplifier-Loudspeaker, Motorola Kit HSN4035( ) Exploded View
MAEPF-26569-O
Table 10 Repair Parts for Amplifier-Loudspeaker Motorola Kit HSN4035( )
6
7
4
5
1
2
3
Reference No. on
Figure 12
Descriprion
Gasket
Speaker
Printed Circuit Board
Locknut, Strain Relief
9-Foot Cable
Wave Washer, Volume Pot.
Spanner Nut, Volume Pot.
Motorola Part No.
3285203C01
5085891B01
0105956V07
4285841A02
3085853B01
0402838X01
0205609X01
17
18
Table 10 Repair Parts for Amplifier-Loudspeaker Motorola Kit HSN4035( )
Reference No. on
Figure 12
11
12
13
8
9
10
Descriprion
O-Ring, Volume Pot. Spanner Nut
Knob, Volume Pot.
Volume Pot.
O-Ring, Volume Pot. Shaft
Lubricant, Gasket
Thermal Compound, PCB Heatsink
Motorola Part No.
3205082E48
3604250J01
1805629V05
3205082E01
1110027B23
1110022A55
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MCS 2000™ Mobile Radio Amplifier-Loudspeaker
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TEPF-9679-T
1
Service Instructions
Amplifier-Loudspeaker
Motorola Kit HSN4035( )
Motorola Publication 68P81109C65-O
*6881109C65-O*
6881109C65-O
advertisement
Key Features
- Compact and lightweight design for easy portability
- High-quality speaker for clear and powerful sound
- Amplifier with volume control for customized listening experience
- 9-foot cable for extended reach
- Easy to assemble and disassemble for convenient storage and transportation