Telex Airman 8, Maintenance & Overhaul Manual

Page 1: ...F 01U 327 718 Rev 02 1 16 19 Airman 8 Headset Maintenance Overhaul Manual for Airman 8 Headset Headphone...

Page 2: ...2 Airman 8 Record of Revisions 01 08 2018 Created 02 01 2019 Add CTNs to Sec2 4 Parts List Rev No Revision Date Change Description...

Page 3: ...usker Hwy Lincoln NE 68507 U S A Attn Aircraft Product Support Mgr Telephone 877 863 4168 Parts Ordering Replacement parts may be ordered from our parts department When ordering please include the fol...

Page 4: ...terations to the product are prohibited CAUTION An ESD protection method should be applied before proceeding with any Mechanical Electrical instructions CAUTION Use of any replacement part which does...

Page 5: ...de Disassembly 15 2 3 1 6 Non Boom Side Disassembly 17 2 3 2 Assembly 20 2 3 2 1 Boom Side Assembly 20 2 3 2 2 Non Boom Side Assembly 25 2 3 2 3 Attach the mic prefilter 29 2 3 2 4 Reinstall the headb...

Page 6: ...5 4 Validate the Non boom Side PCBA 42 3 1 6 ANR Troubleshooting and Workflow 43 3 1 6 1 Cleaning the Headset and Connectors 45 3 1 6 2 Cleaning the Ear Cushions and Headband Pads 45 3 1 6 3 Replacin...

Page 7: ...tion headset on the market and the only FAA approved ANR headset to utilize Telex s proprietary battery free noise reduction system 1 1 2 Models Covered TABLE 1 AIRMAN 8 Models and Connector Wiring AI...

Page 8: ...Introduction Specifications Airman 8 1 3 Reference View 1 Headband Holder and Pad 2 Headset Slider 3 Ear Cushion 4 Ear Cup Rotator 5 Boom Rotator 6 Cord with Strain Relief 7 Boom 8 Microphone Windscre...

Page 9: ...T PAN HEAD K15 X 6MM BLK ZINC 6 6 9a 54857101 F 01U 150 106 WIRE 28 AWG 212 WHITE 2 2 10a 54857103 F 01U 150 110 WIRE 28 AWG RED 2 2 11 S F01U342083 F 01U 342 083 CORD UNIT PJ Y BLOCK 1 1 12 S F01U342...

Page 10: ...EAD K15 X 3 5MM 25PCS 4 4 27 ESP F01U351884 F 01U 359 827 HEADBAND PAD HOLDER 1 1 28a e S F01U347879 F 01U 347 879 HEADBAND CLIP 2 PCS 29a S F01U348100 F 01U 348 100 HEADBAND COVER AND HEADBAND PAD a...

Page 11: ...ly process such as the locations of disconnected wires When soldering be careful not to touch the plastic housing of the headset headphone with the soldering iron 2 3 1 Disassembly IMPORTANT Only disa...

Page 12: ...shion up and away from the ear cup 3 Starting at the top of the ear cup 1 carefully work the cushion around the cup 2 until it is in place 3 4 Verify the cushion is seated properly by visually inspect...

Page 13: ...k one side of the headpad holder over the headband cover 3 Snap the other side of headpad holder in place Be sure the headpad holder edge is over the headband cover NOTE The headpad holder should be c...

Page 14: ...ter from the mic 2 3 1 4 Remove the Yoke Assembly from the Headband Assembly To remove the yoke assembly from the headband assembly do the following 1 On the yoke assembly use a fingernail to lift the...

Page 15: ...and sleeve do the following 1 At the same time push the two retaining cams located in the speaker assembly out of the way 2 Rotate the speaker faceplate approximately 15 clockwise IMPORTANT Do not pul...

Page 16: ...16 Parts List and Disassembly Assembly Airman 8 4 Remove the housing and the yoke glider assembly 5 Using a T 5 screwdriver remove two screws as shown 6 Remove the PCBA...

Page 17: ...to be done before going forward Remove the headband cover clips if present on page 11 Replace Cushions and Windscreen on page 12 Remove the mic prefilter on page 14 Remove the Yoke Assembly from the...

Page 18: ...18 Parts List and Disassembly Assembly Airman 8 2 Using a T 5 screwdriver remove three screws as shown 3 Remove the housing and the yoke glider assembly...

Page 19: ...crewdriver remove two screws as shown 5 Remove the PCBA 6 Using a soldering iron carefully disconnect the wires from the speaker and overhead cord and ANR mic solder terminals as needed IMPORTANT Take...

Page 20: ...overhead cord to PCBA J11 red J12 blue J9 white J10 shield J17 black 2 Solder the cable assembly to PCBA See Wiring Diagram Airman8 2010 and Airman8 0211 on page 49 3 Thread the boom mic wires throug...

Page 21: ...are to route the overhead cord and headset cord through the corresponding grooves provided on the boom 2 6 Verify the overhead cord is not caught between the ANR mic 3 and the boom mic housing Positio...

Page 22: ...rough the housing and solder to the PCBA J13 red J14 white 9 Place yoke on the housing NOTE Take care to verify the orientation of the yoke because it does not rotate 360 10 Place the switch cover on...

Page 23: ...ic assembly NOTE Make sure the overhead cord is in the correct slot and the jacket is fully inside the housing Also make sure the headset cord is properly located in the housing 12 Using a T 5 screwdr...

Page 24: ...on the overhead cord in the retaining clip and then align the knob of the faceplate toward the bottom 14 Align the four tabs on the faceplate and then rotate counterclockwise to lock NOTE Verify all f...

Page 25: ...3 2 2 Non Boom Side Assembly To assemble the non boom side assembly do the following 1 Solder overhead cord to PCBA J11 red J12 blue J9 white J10 shield J17 black 2 Using the two shorter screws attach...

Page 26: ...ed wire with the polarity dot on the speaker as shown 4 Route the speaker wires through the housing and solder to the PCBA J13 red J14 white 5 Place yoke on the housing NOTE Take care to verify the or...

Page 27: ...Airman 8 Parts List and Disassembly Assembly 27 7 Place the cover on the housing 8 Using a T 5 screwdriver replace the three screws as shown to attach the yoke and housing to the PCBA...

Page 28: ...ion the overhead cord in retaining clip and align the knob of the faceplate toward the bottom 10 Align the four tabs shown on the faceplate and then rotate counterclockwise to lock NOTE Verify all fou...

Page 29: ...round the glider 2 3 2 3 Attach the mic prefilter To attach the prefilter do the following 1 Carefully attach the prefilter to the mic 2 3 2 4 Reinstall the headband cover To reinstall the headband co...

Page 30: ...Assembly from the Headband Assembly To replace the yoke assembly on the headband assembly do the following 1 Slide the yoke assembly onto the headband 2 Place the glider stop in the appropriate hole...

Page 31: ...cover clips if present To replace the headband cover clips do the following 1 Carefully snap the clip on to the headband IMPORTANT Some headsets a snap feature 2 at each end of the headband cover If t...

Page 32: ...round the metal headband until it is in place Current Version Headpad Holder and Headpad To replace the headpad holder do the following 1 At one end of the headpad holder carefully pry the holder from...

Page 33: ...Airman 8 Parts List and Disassembly Assembly 33 5 Firmly press the headband pad into place...

Page 34: ...34 Parts List and Disassembly Assembly Airman 8...

Page 35: ...erformance All other maintenance requires replacement of parts fixing open wires or removing shorted wires See specific instructions later in this section for ANR or boom microphone adjustment 3 1 1 R...

Page 36: ...36 Maintenance Airman 8...

Page 37: ...bends or breaks Note any cable assemblies which need to be replaced 3 1 2 3 Review user replaceable items To review user replaceable items do the following Check ear cushions Check headband pads Check...

Page 38: ...38 Maintenance Airman 8...

Page 39: ...microphone plug of the headset For more information see Connectors on page 50 3 Test for an audio signal If audio signal is detected the board the valid If audio signal is not detected the board shoul...

Page 40: ...se until the microphone gain adjustment access hole is aligned and open 2 Insert a 2mm x 5mm flat bladed screwdriver into the gain adjustment access hole NOTE If gain adjustment access hole is properl...

Page 41: ...Airman 8 Maintenance 41 3 1 5 Speaker Troubleshooting and Workflow...

Page 42: ...asured at 270 or less there is a short in the speaker path 3 1 5 3 Validate the Boom Side PCBA To validate the boom side PCBA do the following 1 On the boom side PCBA send a 1kHz sine wave 1Vrms signa...

Page 43: ...Airman 8 Maintenance 43 3 1 6 ANR Troubleshooting and Workflow...

Page 44: ...positive probe at J11 If measure is near 0 switch is open 3 Move the switch to On position If measure is at 3 3Vdc 10 the switch is good If measure at any other measurement the switch is bad Replace t...

Page 45: ...is recommended you replace ear cushions and headband pads periodically every six 6 months or sooner if needed See Ear Cushion Replacement on page 12 and Headband Pad Replacement on page 12 To replace...

Page 46: ...lts the windscreen should be replaced IMPORTANT Do not use any liquid on the foam windscreen To remove the windscreen do the following Grasp the microphone windscreen and gently pull away from microph...

Page 47: ...Airman 8 Maintenance 47 3 Coil the cord into a loop 4 Place the coiled cord and headset in the carrying case...

Page 48: ...48 Maintenance Airman 8...

Page 49: ...iagrams 4 1 1 Wiring Diagram Airman8 2010 and Airman8 0211 Wire Notes Wire Notes J15 no connection Outside mic side J6 outer shield black Inside J1 white Outside mic side J2 inner shield blue Inside J...

Page 50: ...8 PJ055 Connector Diagram for Airman8 0210 FIGURE 3 PJ 068 and PJ055 Wiring Diagram for Airman8 0210 Tip Not Used Ring Mic Signal White Sleeve Mic GND Blue Shield Tip Headphone Signal Red Sleeve Headp...

Page 51: ...ctor Diagram for Airman8 0211 FIGURE 4 XLR Connector for Airman8 0211 1 Headphone Signal Red 2 Headphone GND Black Outer Shield 3 Mic Power and Signal White 4 Mic GND and ANR Return Blue Inner Shield...

Page 52: ...Bosch Security Systems Inc 12000 Portland Avenue South Burnsville MN 55337 U S A www boschcommunications com...