Motorola HSN4035, Service Instructions Manual

Page 1: ...CE 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 ...

Page 2: ...ction 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 ...

Page 3: ...onents 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 HSN...

Page 4: ...r 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: ...GES 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 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 ...

Page 6: ...equency 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 ener...

Page 7: ...ront compartment configuration involved in your communication equipment installation LP Gas Warning 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 NFP...

Page 8: ...tact 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 ...

Page 9: ...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 POTENTIALLY EXPLOSIVE ATMOSPHERES Turn off your two way radio when you are...

Page 10: ... and Troubleshooting Disassembly Repair Reassembly Reference Publications 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 ...

Page 11: ...r 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 Equi...

Page 12: ...escription Quantity 1584953L01 Molex Connector Body 6 Pin 1 2984706E06 Molex Connector Pin Female 4 Not Applicable Hookup Wire Stranded Insulated 18 AWG 24 Inches Long 4 Table 1 Test Equipment and Special Tools Description Manufacturer Model No Part No Notes 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 ...

Page 13: ... Analyzer Between TP10 and TP11 on PCB 2 Rotate Volume Potentiometer Knob Slowly Over its Entrire Range Perform Procedure Titled Replacing PCB Perform Procedure Titled Replacing Speaker 1 Turn Off Power Supply 2 Perform Procedure Titled Separating Front and Rear Housings 3 Turn On Power Supply Perform Procedure Titled Replacing 9 Foot Cable If That Does Not Repair Fault Perform Procedure Titled Re...

Page 14: ...ng 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 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 Figure 3 ...

Page 15: ... 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 3 Repair Parts Required for Speaker Replacement Motorola Part No Description Quantity Required 5085891B01 Speaker 5 inch 1 3285203C01 Gasket Required for Final Assembly of Amplifier Loudspeaker 1 ...

Page 16: ...d 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 3285203C01 Gasket Required for Final Assembly of Amplifier Loudspeak...

Page 17: ...m TP8 White Volume Pot Clockwise End TP9 Black Speaker Either Terminal TP10 Black Speaker Either Terminal TP11 Table 5 Printed Circuit Board Connections Wire Color From To Component PCB Terminal Number Figure 4 PCB Connections to External Components MAEPF 26669 O TP4 TP9 TP8 TP7 TP11 TP10 TP1 TP2 TP5 TP3 TP6 ...

Page 18: ...9 MAEPF 26577 O Circuit Board Thermal Grease Location Shaded Area Rear Housing Figure 5 Removing and Installing PCB ...

Page 19: ...ack 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 Table 6 Repair Parts Required for Volume Potentiometer Replacement Motorola Part No Description Quantity Required 1805629V05 Volume Potentiometer 1 3205082E01 O Ring Volume Potentiometer The smaller of the two O rings 1 0402838X01 ...

Page 20: ...ll 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...

Page 21: ... Motorola P N 3205082E01 Spanner Nut Groove Figure 7 Preparing New Volume Potentiometer MAEPF 26571 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 Gray Blue White Figure 8 Connecting Leads to New Volume Potentiometer ...

Page 22: ...ng 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 stra...

Page 23: ...Terminal Number Blue TP1 Black TP2 White Black TP3 Bare TP4 Red TP5 White TP6 Figure 9 Removing and Installing 9 Foot Cable MAEPF 26575 O Strain Relief Locknut Rear Housing 9 Foot Cable Surface must be flush with exterior surface of rear housing Strain Relief ...

Page 24: ...ed in table 9 Table 9 Repair Parts Required for Final Reassembly Motorola Part No Description Quantity Required 3285203C01 Gasket Required for Final Assembly of Amplifier Loudspeaker 1 1110027B23 Gasket Lubricant Required for Final Assembly of Amplifier Loudspeaker As Required MAEPF 26574 O 9 Foot Cable Wire Leads Cable Jacket Must Not Protude Further than 0 25 in Beyond Strain Relief Strain Relie...

Page 25: ...la 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 Di...

Page 26: ...nces 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 Descriprion Motorola Part No 1 Gasket 3285203C01 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 Figure ...

Page 27: ...4250J01 10 Volume Pot 1805629V05 11 O Ring Volume Pot Shaft 3205082E01 12 Lubricant Gasket 1110027B23 13 Thermal Compound PCB Heatsink 1110022A55 Table 10 Repair Parts for Amplifier Loudspeaker Motorola Kit HSN4035 Reference No on Figure 12 Descriprion Motorola Part No ...

Page 28: ...ir poor 3 Did this Service manual provide you with the information necessary to service and maintain the specific equipment very much so generally yes to some extent no 4 How do you rate this particular Service Manual excellent very good good fair poor 5 We would appreciate any corrections or recommendations for improving this manual Please include the specific page number s of the diagram or proc...

Page 29: ...rts List Page No __________ 6 General comments suggestions Name Company Customer COSC MSS FTR Other Address City State Zip Phone Number Please include Area Code PLEASE USE TAPE TO SEAL POSTAL REGULATIONS PROHIBIT USE OF STAPLES NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 9040 FT LAUDERDALE FL POSTAGE WILL BE PAID BY ADDRESSEE Attention Media a...

Page 30: ...e chassis or kit of which it is a part and sufficient description of the desired component to identify it 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 Replacement Parts Test Equipment Manuals Crystal Service Items Motorola Inc United States and Canada Accessories and Afterma...

Page 31: ...Motorola Publication 68P81109C65 O 6881109C65 O 6881109C65 O Service Instructions Amplifier Loudspeaker Motorola Kit HSN4035 ...