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.
Table of Contents List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . .
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 Revision Letter Page Number Revision Letter Front cover O Questionnaire (Front) O Inside front cover (blank) O Questionnaire (Back O Title O Replacement Parts Ordering (Inside back cover) O i through viii
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.
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.
Anti-Lock Braking System (ABS) and Anti-Skid Braking System Precautions ! WARNING 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.
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.
Introduction 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.
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.
Table 1 Test Equipment and Special Tools Description Manufacturer Model No./Part No. Roto-Torq Adjustable Torque Screwdriver Motorola Kit RSX-4043A Spanner Nut Bit for Adjustable Torque Screwdriver Motorola 66-80371B34 Note Notes Motorola Test Box RKN4460( ) can be substituted for the 4-Ohm 20-Watt fixed resistor specified in table 1.
START TEST Any Sound Output From Amplifier-Loudpeaker? 1. Turn Off Power Supply. 2. Perform Procedure Titled Separating Front and Rear Housings. 3. Turn On Power Supply. No Perform Procedure Titled Replacing 9-Foot Cable. If That Does Not Repair Fault, Perform Procedure Titled Replacing PCB. No Yes Yes Is Sound Output Undistorted and About Normal Listening Volume? Is 13.8Vdc Present Between Terminals TP12 (+) and TP13 (-) on PCB? 1. Turn Off Power Supply. 2.
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. ! Caution When performing step 3, be very careful to avoid damaging loudspeaker cone, which faces upward directly below front cover. 3.
Replacing Speaker Repair Parts Required The repair parts required for replacing the speaker in the AmplifierLoudspeaker are listed in Table 3. Table 3 Repair Parts Required for Speaker Replacement Motorola Part No. Quantity Required Description 5085891B01 Speaker, 5-inch 1 3285203C01 Gasket (Required for Final Assembly of Amplifier-Loudspeaker) 1 1110027B23 Gasket Lubricant (Required for Final Assembly of Amplifier-Loudspeaker) As Required Replacement Procedure 1.
Table 4 Repair Parts Required for Printed Circuit Board Replacement Motorola Part No. Quantity Required Description 3285203C01 Gasket (Required for Final Assembly of Amplifier-Loudspeaker) 1 1110027B23 Gasket Lubricant (Required for Final Assembly of Amplifier-Loudspeaker) 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.
Table 5 Printed Circuit Board Connections Wire Color From/To Component PCB Terminal Number 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.
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.
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.
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 MAEPF-26570-O Figure 7 Preparing New Volume Potentiometer 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.
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.
Table 8 9-Foot Cable Connections to PCB Wire Color PCB Terminal Number Blue TP1 Black TP2 White/Black TP3 Bare TP4 Red TP5 White TP6 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 14
Cable Jacket Must Not Protude Further than 0.25 in. Beyond Strain Relief 9 Foot Cable Wire Leads Strain Relief 9 Foot Cable 9 Foot Cable MAEPF-26574-O Figure 10 Installing 9-Foot Cable In Strain Relief Final Reassembly Final reassembly consists of replacing the gasket and then installing the front housing of the amplifier-loudspeaker onto the rear housing. Repair Parts for Final Reassembly The repair parts required for final reassembly of the AmplifierLoudspeaker are listed in table 9.
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.
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.
Table 10 Repair Parts for Amplifier-Loudspeaker Motorola Kit HSN4035( ) Reference No. on Figure 12 18 Descriprion Motorola Part No. 8 O-Ring, Volume Pot. Spanner Nut 3205082E48 9 Knob, Volume Pot. 3604250J01 10 Volume Pot. 1805629V05 11 O-Ring, Volume Pot.
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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.
Service Instructions Amplifier-Loudspeaker Motorola Kit HSN4035( ) Motorola Publication 68P81109C65-O *6881109C65-O* 6881109C65-O
