GAI-Tronics 12514-004, 12514-005, 12514-006 User Manual
Pub. 42003- 026C
GAI-TRONICS® CORPORATION
A HUBBELL COMPANY
Thermoplastic El as tomer Cord
Replacement Kit
MODELS 12514-004, 12514-005, AND 12514-006
Confidentiality Notice
This manual is pr ovided s olely as a n op erat ional, installation, and maintenance guide and contains sens itive
bus ines s and t echnic al infor ma tion which is conf idential and propriet ary to GAI-Tronics. GAI - Tronic s
retains a ll intellectual pr operty and other rights in or to t he inf ormation c ontained herein, and s uch
informa tion may only be used in connection wit h the operation of you r GAI- Tronic s pr oduct or system.
This ma nual may not be disclosed in any form, in whole or in p art, dir ec tly or indirectly, to any t hird pa rty.
General Information
The cord replacement kits c an be us ed on t he following models:
240 248 257 272 701-804 9081 9105A
246 250 258 701-602 9001 9085 9205A
247 256 262 701-802 9005 9101A 12576-215
This kit includes the following parts:
Qty Description
1 Ha n d set Cord Fastener Clip
2 Tie Wraps
1 6-foot Retractile Thermoplastic Elastomer Cord (Kit 12514-004 Only)
1 15-foot Retractile Thermoplastic Elastomer Cord (Kit 12514-005 Only)
1 25-foot Retractile Thermoplastic Elastomer Cord (Kit 12514-006 Only)
Installation Instructions
Models 240, 246, 247, 248, 250, 256, 257, and 258
Removal of Old Cord
1. Loosen a nd remove the scr ews secur i ng the front panel. Pull the front pa nel away from the ba c k
enclosure.
2. Disconnect the modular telephone line from the printed circ uit board. Disc onnect the 4 telephone wires
from the printed circuit board assembly (PCBA).
GAI-Tronics Corporation P.O. Box 1060, Reading, PA 19607-1060 USA
610-777-1374 800-492-1212 Fax : 610-796-5954
ISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
V
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HERMOPLASTIC ELASTOMER CORD REPLACEMENT KIT Page: 2 of 11
3. When replacing an ex isting P VC cord, use a Heyco® bus hing tool or a needle nose pliers t o squeeze the
notch on t he front p anel side of the s train relief bushing a nd pull out the bus hing.
RECEIVER
GREEN
RED
GASKET
RECEIVER
CAP
COPPER SPRING
WHITE
PRESSBAR
TRANSMITTER
TRANSMITTER
CAP
WASHER
PLASTIC CUP
COPPER PLUNGER
BLUE
YELLOW
BLACK
Figure 1. Handset Outline Diagram
4. When replacing a thermoplastic elastomer c ord, remove the handset cord fastener clip located on the
bac k side of the front panel. The fastener clip secur es the bus hing and the cord to the front p anel.
5. Pull the old cord through t he front p anel and s et aside.
6. Remove the lower cap from the handset. L i f t out the tr ansmitter a nd the tr ansmitter cu p. Di sconnect
both wires.
7. Remove the receiver c ap, lif t out the receiver and disconnect both wir es .
8. Pull the wire harness out of t he handset.
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HERMOPLASTIC ELASTOMER CORD REPLACEMENT KIT Page: 3 of 11
Installation of New Cord
9. Snip of f the cord’ s blue and yellow wires as close to
their origin as possible. Insert the wire harness from
the new cord into the handset. Refer to Figu re 2.
10. Connec t the red and green cord wires to the Rec eiver
Amplif ier PCB A. R epla ce the receiv er a n d the
receiver ca p .
11. Connec t the black and white cord wires to the
tr ansmitter cu p. R e- c onnect the black, brown, and
red wires of the Receiver Amplifier PCBA to t he
transmitter cup. Replace the transmitter cup,
transmitter, and cap. Note the notch on the
transmitter cup. When placing the transmitter cup in
the handset, align the notc h to catch the bushing on
the coil cord to secure the cord firmly in the handset.
12. Ins ert t he end of the new cord t hrough the front panel
until t he b u shing is flu sh aga i nst the panel.
13. P ress the bus hing tight a gainst the fr ont pa nel, and
insert the handset cor d f ast ener c lip onto the rear of
the bushing, agains t the back side of the front panel.
14. Rec onnect the 4 t elephone wires to the PCB A as
follows:
Red to E1 Green to E2
White to E3 Black to E4
Figure 2. Hands et W i ring Diagram
15. Rec onnect the modular telephone wir e to the RJ 11
jack on t he PCBA, and fa sten the front panel to the
rear en closur e.
Models 9001, 9005, 9081, and 9085
Removal of Old Cord
1. Unscrew the 4 front p anel captive sc rews a nd open the fr ont pa nel. Unsna p the blue rib bon cab l e from
the ba c k panel of t he sta tion. Loosen the inter ior hinges a nd remove the front panel.
2. Remove the 5 screws securing the back box to the printed circuit board assembly (PCBA). Remove
the back box.
3. Identify if your s tat ion is an older or a newer model. The older models ha ve an unsecured terminal that
is not anchored to the pr inted circ uit board.
For older models: Disconnect the wires from the PCBA.
Red fr om E1 White from E2 Black f rom E3
Yellow from E4 Blue from E5 Green from the uns ecured t erminal.
For newer models: Disconnect the wires f rom the PCBA.
Red fr om E 1 Green from E2 B lack from E3
Yellow from E4 Blue from E5 White from E7
®
4. When replacing a PVC cord, use a Heyco
bus hing tool or a needle nose pliers to squeeze the not c h on
the fr ont panel s i de of the strain relief bushing and pu ll out the bushing.
5. Feed the bu shing and t he wires through the front p anel to free the cord f rom the panel.
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HERMOPLASTIC ELASTOMER CORD REPLACEMENT KIT Page: 4 of 11
6. At the handset end, unscrew the transmitter cap and lift out the tr ansmitter. D i sconnect the blac k and
white wires from the transmitter.
7. Unscrew the receiver c ap and lift ou t the r eceiver. Disconnect the red and green wires f rom the
receiver.
8. Using an Allen wrench, loosen the 2 Allen nut s securing the p ressbar. Li f t out the pla stic p ress bar, t he
metal casing, and the 2 pieces of cop per.
9. Lift out the recta ngular pla stic cup a nd disconnect t he b l ue and yellow wires . Pu ll the old cord ou t of
the handset.
Installation of New Cord
10. F eed the red and green wires t hrough t he transmitter end of the handset, thr ough the center of the
hand set to t h e receiv er end. Secure the red and green wires to the recei v er.
11. Place the recei v er into its location. T ighten the receiver cap.
12. F eed the yell ow and the bl ue wir es th rou gh the handset to the pres sbar area.
13. Secure the yellow and blue wires to the terminals in the plastic cup. Place the plastic cup in the
handset.
14. Refer to Figure 1. Place the copper piece with the rubber center in first, with the solid rubber side
fac ing outwa rd.
15. P lace the ot her copp er piece so that the bend faces ou tward.
16. P lace the plast ic piece such that the GAI-Tronics logo side is facing outward. P lace the meta l bra c ket
on top and tight en the Allen screws.
17. Attach the black and white wires to the transmitter.
18. Place the transmitter into its location, making sure that the cord guide snaps firmly onto the cord to
secure it. Tighten the transmitter cap.
19. F eed the ot her end of the cord thr ough the panel from the front of the unit.
20. Us e the new
hands et cord fastener clip to secur e the bushing and the cord to the rear of the front panel.
21. Reconnec t the wires to the PCBA:
For older models:
Red to E1 White to E2 Black to E3
Yellow to E4 Blue to E5 Green to the unsecured terminal
(Insulate with electrical tape or equiv.)
For newer models:
Red to E1 Green to E2 Black to E3
Yellow to E4 Blue to E5 White to E7
22. Secure the back box by tightening the 5 screws.
23. Connect the front panel to the b ack panel by inser ting the hinges in the appropriat e op enings .
24. S ecure the ribbon c able to the bac k section of the station by snapping it int o the appropria te connector
and closing the side t abs .
25. Cl ose the fr ont pa nel and tight en the 4 captive sc rews.
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