Motorola HSN4035 Service Instructions Manual

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Page 1



SERVICE INSTRUCTIONS

FOR

AMPLIFIER-LOUDSPEAKER

MOTOROLA KIT HSN4035( )

*6881109C65*

68P81109C65-O

Page 2

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

Page 3

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

Page 4

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

Page 5

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 O Questionnaire (Front) O Inside front cover (blank) O Questionnaire (Back O Title O Replacement Parts

i through viii O Back cover O 1 through 18 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.

Revision

Letter

Page Number

Ordering (Inside back cover)

Revision

Letter

Page 6

•

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.

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 1 Foot

16 to 50 Watts 2 Feet

More than 50 Watts 3 Feet

Minimum Distance from Transmitting Antenna

(30.5 Centimeters)

(61 Centimeters)

(91.5 Centimeters)

Page 7

Mobile Antenna

•

Installation

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

Control Station Operation

Note

Airbag Warning

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.

Refer to Table 1 on page 2 for rated power and minimum distance values for transmitting antennas.

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.

LP Gas Warning

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.

Page 8

Anti-Lock Braking System (ABS) and Anti-Skid Braking System Precautions

Disruption of the anti-skid/anti-lock braking system by the radio

transmitter may result in unexpected vehicle motion.

W A R N I N G

Installation Precautions

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.

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

Page 9

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.

POTENTIALLY EXPLOSIVE ATMOSPHERES

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.

viii

Page 10

Introduction

The empty parentheses at the end of the kit numbers used throughout this publication stand for the alphabetical

Note

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:

Reference Publications

• 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

Page 11

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.

Table 1 Test Equipment and Special Tools

Description Manufacturer Model No./Part No. Notes

Test Connector Fabricated at Test

Facility

DC Power Supply Hewlett Packard 6200 Must be capable of

Audio Analyzer Hewlett Packard 8903B Function Generator Hewlett Packard 3311A Must be capable of

See Figure 1 and Table 2 Below

providing 13.8-Vdc, 2.0 Amperes regulated power.

providing a 1-kHz test signal with a +4.4-Vdc

offset . Digital Multimeter Fluke 27 Oscilloscope Tektronix TDS 544A or 2430A Resistor, Fixed, 4-Ohms (+/- 20

percent) 20 Watts

Dale H25, 4-Ohms See note at end of this

table

Page 12

Description Manufacturer Model No./Part No. Notes

Roto-Torq Adjustable Torque Screwdriver

Spanner Nut Bit for Adjustable Torque Screwdriver

Note

Analog Ground

Table 1 Test Equipment and Special Tools

Motorola Kit RSX-4043A

Motorola 66-80371B34

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.

Audio Input

B+

Ground

MAEPF-26585-O

Motorola Part No. Description Quantity

1584953L01 Molex Connector Body, 6 Pin 1 2984706E06 Molex Connector Pin, Female 4 Not Applicable Hookup Wire, Stranded, Insulated, 18

Test Procedure

Troubleshooting Procedures

Figure 1 Test Connector Schematic/Wiring Diagram

Table 2 Test Connector Components

AWG, 24-Inches Long

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.

Page 13

START TEST

Any

Sound Output

From

Amplifier-Loudpeaker?

Yes

Sound Output

Undistorted and About

Normal Listening

Volume?

Yes

Rotate Volume

Potentiometer Knob Slowly

From Fully Counterclockwise

Position to Fully

Clockwise Position.

1. Turn Off Power Supply.

2. Perform Procedure Titled

Separating Front and Rear Housings.

3. Turn On Power Supply.

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.

Present Between Terminals

13.8Vdc

TP12 (+) and TP13 (-)

on PCB?

Yes

1-kHz 230mVrms

Signal Present Between

TP1 and TP2 (Rtn)

on PCB?

Yes

1-kHz 220mVrms

(440mV p-p) Signal Present

Between TP7 and

TP2 (Rtn) on

PCB?

Yes

Perform Procedure Titled

Replacing 9-Foot Cable.

If That Does Not Repair

Fault, Perform Procedure

Titled Replacing PCB.

Perform Procedure

Titled Replacing PCB.

Perform Procedure Titled

Replacing Volume

Potentiometer, If That Does

Not Repair Fault, Perform

Procedure Titled

Replacing PCB.

Does

Volume Potentiometer

Adjust Sound Output

Smoothly Over

its Entire Range?

Yes

Is Sound

Output Undistorted

Figure 2 Amplifier-Loudspeaker Test and Troubleshooting Procedures

At All Settings

of Volume

Potentiometer?

Yes

Amplifier-Loudspeaker

Is In Good

Operating Condition.

End of Test.

1-kHz 180mVrms (320mV p-p) Signal Present Between TP8 and TP2 (Rtn)

on PCB?

(Note 2)

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.

1-kHz 3.2Vrms (8.8V p-p)

Signal Present Between TP10 and TP11 on PCB

(Note 3)?

Yes

Perform Procedure Titled

Replacing Volume

If That Does Not Repair

Fault, Perform Procedure

Titled Replacing PCB.

Perform Procedure

Titled Replacing PCB.

Potentiometer.

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.

1. Connect Distortion Analyzer Between TP10 and TP11 on PCB.

2. Rotate Volume Potentiometer Knob Slowly Over its Entrire Range.

Harmonic Distortion

of Signal Between TP10 and

TP11 5% or Less for

All Settings of Volume Pot.?

Yes

Perform Procedure

Titled Replacing Speaker

MAEPF-26581-O

Page 14

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.

When performing step 3, be very careful to

avoid damaging loudspeaker cone, which faces upward directly below front cover.

C a u t i o n

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

Figure 3 Separating Front and Rear Housings

Front

Housing

Gasket

MAEPF-26667-O

Page 15

Replacing Speaker

Repair Parts Required

Motorola Part

No.

5085891B01 Speaker, 5-inch 1 3285203C01 Gasket (Required for Final Assembly of

1110027B23 Gasket Lubricant (Required for Final

Replacement Procedure

The repair parts required for replacing the speaker in the AmplifierLoudspeaker are listed in Table 3.

Table 3 Repair Parts Required for Speaker Replacement

Description

Amplifier-Loudspeaker)

Assembly of Amplifier-Loudspeaker)

Quantity

Required

As Required

1. Perform procedure titled Initial Disassembly on page 5.

In step 2, disconnect speaker wires from speaker end

Note

only (i.e., do not disconnect speaker wires from PCB).

Replacing Printed Circuit Board

Repair Parts Required

Table 4 Repair Parts Required for Printed Circuit Board Replacement

Motorola Part

No.

0105956V07 Printed Circuit Board 1

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 .

The repair parts required for replacing the printed circuit board (PCB) in the Amplifier-Loudspeaker are listed in Table 4.

Description

Quantity

Required

1110022A55 Thermal Grease As Required

Page 16

Table 4 Repair Parts Required for Printed Circuit Board Replacement

Motorola Part

No.

3285203C01 Gasket (Required for Final Assembly of

1110027B23 Gasket Lubricant (Required for Final

Replacement Procedure

Description

Amplifier-Loudspeaker)

Assembly of Amplifier-Loudspeaker)

Quantity

Required

As Required

1. Perform procedure titled Initial Disassembly on page 5.

In step 2, do not discard any of the wires after they are

Note

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.

Table 5 Printed Circuit Board Connections

Wire Color From/To Component

PCB Terminal

Number

Blue 9-Foot Cable TP1 Black 9-Foot Cable TP2 White/Black 9-Foot Cable TP3 Bare 9-Foot Cable TP4

Page 17

Wire Color From/To Component

Red 9-Foot Cable TP5 White 9-Foot Cable TP6 Blue Volume Pot. Counterwise End) TP7 Gray Volume Pot. Center (Arm) TP8 White Volume Pot. Clockwise End TP9 Black Speaker (Either Terminal) TP10 Black Speaker (Either Terminal) TP11

Table 5 Printed Circuit Board Connections

PCB Terminal

TP11 TP10

Number

TP6

TP3

Figure 4 PCB Connections to External Components

TP5

TP2

TP1

TP7 TP8

TP9

TP4

MAEPF-26669 -O

Page 18

Thermal Grease

Location

(Shaded Area)

Circuit

Board

Rear

Housing

Figure 5 Removing and Installing PCB

MAEPF-26577-O

Page 19

Replacing Volume Potentiometer

Repair Parts Required

Table 6 Repair Parts Required for Volume Potentiometer Replacement

Motorola Part

No.

1805629V05 Volume Potentiometer 1 3205082E01 O-Ring, Volume Potentiometer

0402838X01 Wave Washer 1 0205609X01 Spanner Nut 1 3205082E48 O-Ring, Spanner Nut

3285203C01 Gasket 1

The repair parts required for replacing the Volume Potentiometer in the Amplifier-Loudspeaker are listed in Table 6.

Description

(The smaller of the two O rings)

(The larger of the two O-rings)

Quantity

Required

1110027B23 Gasket Lubricant 1 3285968B01 Gasket (Required for Final Assembly of

1110027B23 Gasket Lubricant (Required for Final

Alpha FIT-221

-1/16 Alpha UL1007

(Grey, Blue, and White)

Replacement Procedure

Amplifier-Loudspeaker)

As Required

Assembly of Amplifier-Loudspeaker) Hookup Wire, 24 AWG, Stranded As Required

Heat Shrinkable Sleeving, 0.062 in. I.D.,

0.375-in.long

As Required

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.

Page 20

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.

Volume

Potentiometer

Key

Wave

Washer

Figure 6 Removing Volume Potentiometer

Volume

Knob

Spanner

Nut

MAEPF-26573-O

Page 21

Volume

Potentiometer

Threaded Shaft

Volume Potentiometer O-ring

Motorola P/N 3205082E01

Spanner Nut O-ring

Motorola P/N 3205082E48

Figure 7 Preparing New Volume Potentiometer

Base of

Spanner Nut

Groove

MAEPF-26570-O

Volume

Potentiometer

Volume Potentiometer

Terminals

Blue

Gray

White

Figure 8 Connecting Leads to New Volume Potentiometer

Volume Potentiometer

Terminals

Heat Shrink Sleeve (3),

1/16 in. diameter x 0.375 in. long

24 AWG Wire,

2.5 in. long

MAEPF-26571-O

Page 22

Replacing 9-Foot Cable

Repair Parts Required

Table 7 Repair Parts Required for 9-Foot Cable Replacement

Motorola Part

No.

3085853B01 9-Foot Cable 1 4285841A02 Strain Relief 1 3285203C01 Gasket (Required for Final Assembly of

1110027B23 Gasket Lubricant (Required for Final

Replacement Procedure

The repair parts required for replacing the 9-Foot Cable in the Amplifier-Loudspeaker are listed in Table 7.

Description

Amplifier-Loudspeaker)

Assembly of Amplifier-Loudspeaker)

Quantity

Required

As Required

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.

Page 23

Table 8 9-Foot Cable Connections to PCB

Wire Color

Blue TP1 Black TP2 White/Black TP3 Bare TP4 Red TP5 White TP6

PCB Terminal

Number

Strain Relief

Locknut

Rear

Housing

Surface must be

flush with exterior

surface of rear housing

Strain Relief

9-Foot Cable

MAEPF-26575-O

Figure 9 Removing and Installing 9-Foot Cable

Page 24

Cable Jacket Must Not

Protude Further than 0.25 in.

Beyond Strain Relief

9 Foot Cable

Wire Leads

Final Reassembly

Strain Relief

9 Foot

Cable

Figure 10 Installing 9-Foot Cable In Strain Relief

Final reassembly consists of replacing the gasket and then installing the front housing of the amplifier-loudspeaker onto the rear housing.

9 Foot

Cable

MAEPF-26574-O

Repair Parts for Final Reassembly

Motorola Part

3285203C01 Gasket (Required for Final Assembly of

1110027B23 Gasket Lubricant (Required for Final

The repair parts required for final reassembly of the AmplifierLoudspeaker are listed in table 9.

Table 9 Repair Parts Required for Final Reassembly

No.

Amplifier-Loudspeaker)

Assembly of Amplifier-Loudspeaker)

Description

Quantity

Required

As Required

Page 25

Front Housing

See Detail A

Front Edge

of Gasket

Detail A

Delta

Gasket

Back Edge

of Gasket

Reassembly Procedure

MAEPF-26578-O

Figure 11 Final Reassembly of Amplifier-Loudspeaker

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.

Page 26

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.

Figure 12 Amplifier-Loudspeaker, Motorola Kit HSN4035( ) Exploded View

Table 10 Repair Parts for Amplifier-Loudspeaker Motorola Kit HSN4035( )

Reference No. on Figure 12

1 Gasket 3285203C01

Descriprion Motorola Part No.

MAEPF-26569-O

2 Speaker 5085891B01 3 Printed Circuit Board 0105956V07 4 Locknut, Strain Relief 4285841A02 5 9-Foot Cable 3085853B01 6 Wave Washer, Volume Pot. 0402838X01 7 Spanner Nut, Volume Pot. 0205609X01

Page 27

Table 10 Repair Parts for Amplifier-Loudspeaker Motorola Kit HSN4035( )

Reference No. on Figure 12

8 O-Ring, Volume Pot. Spanner Nut 3205082E48 9 Knob, Volume Pot. 3604250J01 10 Volume Pot. 1805629V05 11 O-Ring, Volume Pot. Shaft 3205082E01 12 Lubricant, Gasket 1110027B23 13 Thermal Compound, PCB Heatsink 1110022A55

Descriprion Motorola Part No.

Page 28

Complete

Incomplete

Correct

Incorrect

Clear

Confusing

Size

Adequate

Size

Too Small

Not Covered

in This Manual

Disassembly

Procedures

Alignment

Procedures

Exploded

Views

Schematic

Diagrams

Circuit Board

Details

Electrical Parts

Lists

Exploded View

Parts List

SERVICE MANUAL QUESTIONNAIRE

We believe that reports from users provide valuable information for producing quality manuals. By taking a few moments to answer the following questions as they relate to this speciﬁc manual, you can take an active role in the continuing effort to ensure that our manuals contain the most accurate and complete information of beneﬁt to you. Thank you for your cooperation.

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In reference to Manual Number: 68P81109C65-O

MCS 2000™ Mobile Radio Ampliﬁer-Loudspeaker

1. Please check all the appropriate boxes:

2. How would you rate the overall organization of this manual? excellent very good good fair poor

3. Did this Service manual provide you with the information necessary to service and maintain

the speciﬁc equipment?

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5. We would appreciate any corrections or recommendations f or impro ving this manual. Please

include the speciﬁc page number(s) of the diagram or procedure in question.

a. Disassembly Procedures:(Page No. __________ ) b. Alignment Procedures:(Page No. __________ ) c. Exploded Views:(Page No. __________ )

Page 29

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IF MAILED

IN THE

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Please specify the page number along with any corrections or recommendations for improvement. d. Schematic Diagrams: (Page No. __________ ) e. Component Location Details: (Page No. __________ ) f. Electrical Parts List: (Page No. __________ ) g. Exploded View Parts List: (Page No. __________ )

6. General comments/suggestions:

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Page 30

REPLACEMENT PARTS ORDERING

ORDERING INFORMATION

When ordering replacement parts or equipment information, the complete identiﬁcation number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufﬁcient description of the desired component to identify it.

MAIL ORDERS

Send written orders to the following addresses:

Replacement Parts/ Test Equipment/Manuals/ Crystal Service Items:

Motorola Inc. United States and Canada Accessories and Aftermarket Division Attention: Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196

United States and Canada Accessories and Aftermarket Division: Servicers Training (VHS Video Tapes): Call: 1-800-422-4210 Call: 847-576-2828

1-800-826-1913 (For Federal Government Orders) 1-847-538-8023 (International Orders)

Federal Government Orders:

Motorola Inc. United States and Canada Accessories and Aftermarket Division Attention: Order Processing 7230 Parkway Drive Landover, MD 21076

TELEPHONE ORDERS

Crystal and channel element orders should specify the crystal or channel element type number, crystal and carrier frequency, and the model number in which the part is used.

International Orders:

Motorola Inc. United States and Canada Accessories and Aftermarket Division Attention: International Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196

FAX ORDERS

United States and Canada Accessories and Aftermarket Division: Federal Government Orders: FAX: 847-538-8198 (Domestic) FAX: 410-712-4991

847-576-3023 (International) International: 410-712-6200

Parts ID: 847-538-8194

PARTS CUSTOMER SERVICE PRODUCT CUSTOMER SERVICE

United States and Canada Accessories and Aftermarket Division:

Call: 1-800-422-4210 Parts Identiﬁcation: Call: 847-538-0021

Customer Response Center (Sales and Service Assistance):

Call: 1-800-247-2346 FAX: 1-800-232-9272

TEPF-9679-T

Page 31

Service Instructions

Amplifier-Loudspeaker

Motorola Publication 68P81109C65-O

Motorola Kit HSN4035( )

*6881109C65-O*

6881109C65-O

Motorola HSN4035 Service Instructions Manual

Table of Contents

List of Figures

List of Tables

Safety Summary

Introduction

Reference Publications

Test Setup

Troubleshooting Procedures

Repair Procedures

Initial Disassembly

Replacing Speaker

Final Reassembly