Orion G27902 User Manual

subwoofer

10.2 10.4

10.2 10.4

HCCA

HCCA

Cone

Cone

Replacement

Replacement

kit

Kit

12.2 12.4

12.2 12.4

15.2 15.4

15.2 15.4

TABLE OF CONTENTS

What’s Included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Re-cone Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Re-cone Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Alternate step 7—for 10" Woofers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

HCCA Woofer Re-cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

WHAT’S INCLUDED

1 ea re-cone assembly
1 ea 5mm ball tip right angle Allen wrench
2 ea 5mm x 10 Allen head screw for clamping ring (spare)
2 ea 5mm x 20 Allen head screw for spider ring (spare)
8 ea steel alignment needles for voice coil alignment

INTRODUCTION

Before you start:

1. Inspect the cone replacement parts. If any parts are damaged, the kit needs to
be returned for replacement.

2. Have all components of the recone kit ready for installation before
disassembling the woofer - do not leave the speaker gap (disassembled) and
exposed for any length of time. This could result in foreign contamination which
will affect woofer life and performance. Be careful not to drop or damage the
re-cone kit in any way or your project will not function correctly.

3. These woofers are heavy. To prevent injury to yourself, have another person
available when moving the woofer and for help in positioning during the re­coning process.

4. We recommend that you have BLUE (removable) thread locker for best results.
Do not use RED (permament) thread locker.

5. It is very important to perform re-coning in a clean environment free of
contamination and most importantly free of metal particles. Do not attempt re­coning in an garage or other area where metal is cut or filed. The incredibly
strong magnet on the woofers will attract metal particles to the gap area from
a few feet away. Metal particles in the gap will permanently damage the
speaker.

1

RE-CONE KIT

A re-cone kit is available for these speakers and can be obtained from your dealer. The
part number for each model is listed below.

RE-CONE STEPS

Note: Step seven in the re-cone process must be altered when re-coning the 10"
Woofers. See section Alternate step 7—for 10" Woofers at the end of this manual.

Refer to the exploded view at the end of this manual while using the following
procedure.

Note: Before beginning, record the positions of terminals and logos so the new
re-cone assembly can be installed the same way.

1. Remove Spider Ring bolts (eight), from the bottom side of the basket. Bolts can
be removed with included Allen wrench. To get access the basket may need to
be turned on its side.

2. Place the speaker facing up and remove the Edge Clamping Ring. There are 8 Allen
head bolts on the 10 & 12" models and 12 on the 15" model that clamp the
surround edge to the basket. These are removed using the included Allen wrench.

3. The Moving Parts Assembly (cone/spider) can now be removed from the basket.
Note that the edge has a small amount of PVA adhesive attaching it to the basket.
Lifting one section of the edge will break this bond and facilitate lifting the edge
free. Be sure to remove any residual residue before installing the new assembly.
Alcohol and a Q tip or soft lint-free rag can be used to clean the surface.

4. Make note of any obvious problems, (voice coil burnt, mechanical marks on the
coil, etc.) Discard the old Moving Parts Assembly. Contact Technical Support for
advice regarding observed abnormal conditions. Be sure to remove all remnants
of the old voice coil assembly before trying to install the new re-cone kit. If there
is any residue present in the gap, it can be cleaned with alcohol and a Q tip.

Model Description Re-cone Kit p/n

HCCA10.2CK ORION HCCA 10" 2 OHM Re-Cone Kit 27902
HCCA10.4CK ORION HCCA 10" 4 OHM Re-Cone Kit 27904
HCCA12.2CK ORION HCCA 12" 2 OHM Re-Cone Kit 27907
HCCA12.4CK ORION HCCA 12" 4 OHM Re-Cone Kit 27909
HCCA15.2CK ORION HCCA 15" 2 OHM Re-Cone Kit 27912
HCCA15.4CK ORION HCCA 15" 4 OHM Re-Cone Kit 27914

2

Note: Do not bend needles during this procedure.

5. Turn the speaker on its side and insert one steel needle (centering pin) into each
alignment hole in the backplate of the woofer (total of 8—these are the small
diameter holes, not the larger holes—see figure below), Ensure that the pins are
inserted completely.

6. Turn the speaker on its magnet with the cone facing up and align the pins so
that they are all touching the pole piece (toward the center not the outside
edge) and symmetrically arranged.

Note: If re-coning a 10" woofer see the alternate step 7 at the end of this section.

7. CAREFULLY lower the new Re-Cone Assembly (moving parts) into the basket
making sure that all of the pins are inside the voice coil, the illustration below
of the interior components of the woofer shows the correct positioning of the
steel needles inside the voice coil former. Align terminals, logo, and screw holes
before pushing the re-cone assembly in place. Minimize the amount of rotation
required to center the screw holes once in place. The assembly should slide
smoothly into place with just a small bit of friction between the pins and the
voice coil. Do not push down any further than is needed for the surround and

3

Steel needles

(shown inserted)

Partial View

Pole Piece

Steel Needles

Magnet

Partial View
(Do Not Remove
Basket from Magnet)

4

spider ring to touch their mounting locations. Do Not Force. If the fit is tight,
start over and make sure there is no foreign object in the gap or alignment pin
out of place.

8. Return the speaker to its back and thread the Spider Ring bolts through the
basket and into the Spider Ring. Make sure to use a small amount of thread
locker (BLUE) on the threads. Do not tighten completely. The spider ring should
be able to move freely (about 1mm in all directions).

9. OPTIONAL STEP—Put a small amount of white glue on the basket where the
surround edge will seat. You will need to lift the edge slightly. It may be easier
to use a brush for this application. Only a thin layer is needed. Move quickly to
step 10 before the glue can start to dry.

10. Make sure the surround edge is seated in the groove in the basket. (It should do
this naturally.) Place the edge clamp over the edge and thread each bolt into
place. (Make sure to add a small amount of thread locker to each thread. When
each bolt is seated against the clamping ring make sure that the clamping ring
is parallel to the basket. Turn each bolt 1 turn and then proceed to the opposite
bolt on the basket similar to tightening lug nuts on a tire. Continue tightening
until all bolts are snug. If they are all seated correctly the gap between the
clamp ring and basket should be even on all 4 sides. The gap should be between
0 and .5 mm.

11. Once the re-cone assembly is over the pins and the surround is clamped down,
the spider ring will be centered. Tighten the bolts on the basket following the
same procedure as in step 10 (edge clamping ring) until snug. Do not over
tighten as this will mechanically distort the basket.

12. Turn the speaker on its side and remove the centering pins.

13. CAREFULLY move the speaker cone in and out and check for any obvious rubs.

Voice Coil
Former

Steel
Needles

Magnet

Partial View

(Do Not Remove Basket from Magnet)

Note: It is easy to put too much pressure on one side of the cone and cause a
rub, so be careful to apply even and centered pressure on the cone. If there is an
obvious rub, then remove the re-cone assembly carefully and following the
above procedure re-install. If everything seems OK, then proceed to next step.

14. Install your speaker back in its enclosure. Connect the speaker to your system
and adjust your system so you are listening to the subwoofer only. Start at a very
low volume and listen for any mechanical rubbing sounds. Continue to increase
volume until you reach the maximum power for your system. If you do not hear
mechanical noise, i.e. voice coil rubbing, congratulations! you are done.

15. If you do hear coil rubbing, turn the system off immediately and start the entire
procedure again from the beginning. Inspect the gap carefully for metal particles.
If you see any, clean them out with masking tape. (The adhesive will hold the
metal and allow you to remove it. If you can't remove all of the particles or if you
can not successfully complete the re-cone, contact Customer Service at 1-800-753­0800, or email your question(s) to [e-mail].

5

ALTERNATE STEP 7—FOR 10" WOOFERS

Note: Only the step for the 10” Woofers is given.

7. CAREFULLY lower the new re-cone assembly (moving parts) into the basket by
tilting the voice coil (shown below) while making sure that all of the pins are
inside the voice coil former (refer to the illustration at step 7 previously shown).
Pressure can be put on the spider ring assembly to angle the spider, but be
careful not to bend the cone as this will cause permanent damage.

Note: Ensure that the cone is not damaged during this process.

Align terminals, logo, and screw holes before pushing the re-cone assembly in
place into the basket. The terminal block tilted down should end up near the top
of one of the basket openings as shown in the second illustration. A closer view
of the position of this terminal block is shown in the third illustration. This will
allow the clearance for the opposite terminal block to drop down into the
basket.

The re-cone assembly can now be released to a horizontal position. Refer to the
fourth illustration The assembly should slide smoothly into place with just a
small bit for friction between the pins and the voice coil. Do not push down any
further than is needed for the surround and spider ring to touch their mounting
locations. Do Not Force

. If the fit is tight, start over and make sure there is no

foreign object in the gap or alignment pin out of place.

6

Surround

Edge

Spider

Ring

Voice

Coil

7

l

Basket

Re-Cone
Assembly

Spider
Ring

Terminal
Block

Voice Coi

Terminal
Block

Basket
Opening

8

HCCA WOOFER RE-CONE ASSEMBLY

Part Description Quantity

1 Allen head screw

8 pieces
(12 pieces

on

15” woofers)
2 Edge Clamping Ring 1 piece
3 Re-cone assembly 1 set
4 Motor & Basket Assembly 1 set
5 Allen head screw 8 pieces
6 Steel needle 8 pieces

NO WARRANTY

THIS PRODUCT IS SOLD "AS-IS"

DIRECTED ELECTRONICS (hereinafter "SELLER") MAKES NO WARRANTY of any kind
(express, implied or otherwise) in connection with this Product. THIS PRODUCT IS SOLD AS­IS, AND YOU THE PURCHASER ASSUME THE ENTIRE RISK AS TO ITS QUALITY AND
PERFORMANCE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE THAT EXCEEDS THE FOREGOING WARRANTY IS HEREBY
EXPRESSLY DISCLAIMED BY SELLER TO THE MAXIMUM EXTENT ALLOWED BY LAW
AND IS EXCLUDED FROM ANY AGREEMENT MADE BY ACCEPTING THIS OFFER. SELLER

neither assumes nor authorizes any person to assume for it any liability in connection with the
sale of this Product. SELLER has absolutely no liability for any and all acts of third parties
including distributors, authorized dealers or installers. SELLER will not be liable for any direct,
indirect, special, incidental or consequential damages, loss or expense arising in connection
with the use of the Product or the inability to use the Product for any purpose whatsoever.
This Product is not eligible for return or exchange. Any return of this Product to SELLER will
be declined at Shipper's expense.

All exclusions and limitation are made only to the extent permitted by applicable law and
shall be of no effect to the extent in conflict with the express requirements of applicable law.
Some states do not allow the exclusion or limitation of incidental or consequential damages.
In such states, the exclusion or limitations stated herein may not apply to you. You may have
specific legal or other rights which vary from state to state. p/n 920-0034 01-07

For more information on Orion products please visit us at www.orioncaraudio.com
© 2007 Directed Electronics, All rights reserved. G27902.04.07.09.12.14 01-07