GAI-Tronics 12514-007 User manual

Pub. 42003-035B
GAI-Tronics Corporation P.O. Box 1060, Reading, PA 19607-1060 USA
610-777-1374 n800-492-1212 nFax: 610-775-6540
GAI-TRONICS CORPORATION
PVC Coil Cord Replacement Kit
Models 12514-007, 12514-008, and 12514-009
Confidentiality Notice
This manual is provided solely as an operational, installation, and maintenance guide and contains
sensitive business and technical information which is confidential and proprietary to GAI-Tronics.
GAI-Tronics retains all intellectual property and other rights in or to the information contained herein,
and such information may only be used in connection with the operation of your GAI-Tronics product or
system. This manual may not be disclosed in any form, in whole or in part, directly or indirectly, to any
third party.
General Information
These kits are for use on the following models:
•240 •250 •611 •701-201 •701-205 •7165-002
•246 •256 •6115 •701-202 •711-002 •726-101
•247 •257 •616 •701-203 •7115-002 •7265-101
•248 •258 •6165 •701-204 •716-002
This kit includes the following components:
Qty Description
1Strain-relief Bushing
16-foot PVC cord (Kit 12514-007 only)
115-foot PVC cord (Kit 12514-008 only)
125-foot PVC cord (Kit 12514-009 only)
Installation
Models 240, 246, 247, 248, 250, 256, 257, 258
Removal of old cord
1. Loosen and remove the screws securing the front panel. Pull the front panel assembly away from the
back enclosure.
2. Disconnect the modular telephone line from the PC board. Disconnect the four handset wires from
the PC board.
3. When replacing a PVC cord, use a Heyco® bushing tool, or a set of needlenose pliers, to squeeze the
notch on the front panel side of the strain relief bushing and pull out the bushing.

Pub. 42003-035B
MODELS 12514-007, 12514-008, AND 12514-009 PVC COIL CORD REPLACEMENT KIT Page: 2of 6
\\s_eng\gtcproddocs\standard ioms - current release\kits (42003)\42003-035b.doc
4. When replacing a thermoplastic elastomer cord, remove the C-clip securing the bushing and the cord
to the rear of the front panel assembly.
5. Pull the old cord through the front panel assembly.
6. Remove the lower cap from the handset. Lift out the transmitter and disconnect both wires.
7. Remove the receiver cap, lift out the receiver and disconnect both wires.
8. Pull the wire harness out of the handset and discard the cord.
Installation of the new cord
1. Insert the wire harness from the new cord into the handset.
2. Snip off the blue and yellow wires as close to their origin as possible. Connect the red and green
wires to the receiver. Replace the receiver and the receiver cap.
3. Connect the black and white wires to the transmitter. Replace the transmitter, transmitter cup, and
cap. Refer to Figure 1. Note the notch on the transmitter. When placing the transmitter in the
handset, align the notch to catch the bushing on the coil cord to secure the cord firmly in the handset.
4. Insert the end of the new cord through the front panel assembly until the bushing is flush against the
panel.
Figure 1. Handset Assembly with Pressbar

Pub. 42003-035B
MODELS 12514-007, 12514-008, AND 12514-009 PVC COIL CORD REPLACEMENT KIT Page: 3of 6
\\s_eng\gtcproddocs\standard ioms - current release\kits (42003)\42003-035b.doc
5. Press the bushing tight against the front panel, and insert the C-clip on the rear of the bushing on the
back side of the front panel assembly, or use a Heyco® bushing tool to squeeze the Heyco® bushing
back into the front panel opening.
6. Reconnect the four telephone wires to the PC board in this manner: red to E1; green to E2; white to
E3; black to E4.
7. Reconnect the modular telephone wire to the RJ11 jack on the PC board and fasten the front panel
assembly to the rear enclosure.
Models 701-201, 701-202, 701-203, 701-204, and 701-205
Removal of old cord
1. Unscrew the four front panel screws and remove the handset amplifier from the enclosure.
2. Unscrew the handset transmitter cap and lift out the transmitter.
3. Disconnect the wires from the transmitter.
4. Unscrew the receiver cap. Lift out the receiver.
5. Disconnect the red and green wires from the handset PC board. For stations with a pressbar handset,
proceed to Step 6. For stations without a pressbar handset, proceed to Step 8.
6. Loosen the two screws securing the pressbar. Lift off the metal retainer, plastic pressbar, curved
spring and plunger.
7. Lift out the rectangular plastic cup and disconnect the blue and yellow wires.
8. Pull the old cord out of the handset. Place the amplifier to easily access the rear of the unit.
9. Loosen the four screws securing the backbox to the amplifier. The backbox will still be connected to
the amplifier. Carefully separate a the two pieces.
10. Disconnect the yellow (E5), blue (E6), red (E4), white (E1), black (E2) and green (E3) wires from the
PC board. Stations without pressbar handsets will not have the blue and yellow wires.
11. Using a Heyco® bushing tool or needlenose pliers, pull the bushing and the cord through the front
panel and discard.

Pub. 42003-035B
MODELS 12514-007, 12514-008, AND 12514-009 PVC COIL CORD REPLACEMENT KIT Page: 4of 6
\\s_eng\gtcproddocs\standard ioms - current release\kits (42003)\42003-035b.doc
Installation of new cord
1. Feed the red and green wires through the transmitter end of the handset, through the center of the
handset receiver end. Place the brass eyelets on the receiver as indicated in Figure 2. Feed the screws
through the handset PCBA through the eyelet and into the receiver. Secure the wires as indicated in
Figure 2.
2. Place the receiver in the cup. Tighten the
receiver cap. For stations with a pressbar
handset, proceed to Stop 3. For stations
without a pressbar handset, proceed to
Step 8.
3. Feed the yellow and blue wires through
the handset to the pressbar area.
4. Secure the wires to the terminals in the
plastic cup. Place the plastic cup in the
handset.
5. See Figure 1 above. Place the copper
piece with the rubber center in first, with
the solid rubber side facing up and the
notch in the appropriate slot.
6. Place the other copper piece so that the bend faces out.
7. Place the plastic piece such that the GTC logo side is facing up. Place the metal bracket on top and
tighten the screws.
8. FOR HANDSETS WITHOUT A PRESSBAR ONLY: Snip off the blue and yellow wires as close to
their origin as possible.
9. Attach the wires to the transmitter terminals.
10. Place the transmitter in the transmitter cap, making sure that the cord guide snaps firmly onto the cord
to secure it. Screw on the transmitter cap.
11. Feed the end of the cord through from the front panel of the phone and use the Heyco® bushing tool
or needlenose pliers to secure the bushing on the amplifier front.
12. Connect the wires to the PC board: red to E4, white to E1, black to E2, yellow to E5, blue to E6 and
green to E3. Stations without pressbar handsets will not have the blue and yellow wires.
13. Secure the backbox by tightening the four screws.
14. Reinstall the amplifier into the enclosure.
Figure 2. Receiver Detail for 701 Models

Pub. 42003-035B
MODELS 12514-007, 12514-008, AND 12514-009 PVC COIL CORD REPLACEMENT KIT Page: 5of 6
\\s_eng\gtcproddocs\standard ioms - current release\kits (42003)\42003-035b.doc
Models 711-002, 7115-002, 611C, and 6115
Removal of old cord
1. Remove the two mounting screws from the mounting bracket. Remove the subset from the mounting
bracket.
2. Remove the four screws on the left side of the unit.
3. Locate the PC board. On the side closest to you, you will see the six handset wires. Unplug all six of
the wires.
4. Use a Heyco® bushing tool to remove the bushing securing the cord to the subset. Pull the cord
through the hole and remove.
5. At the handset end, unscrew the transmitter cap, lift out the transmitter and disconnect the wires.
6. Unscrew the receiver cap, lift out the receiver and disconnect the red and green wires from the
receiver.
7. FOR HANDSETS WITH PRESSBAR ONLY: Loosen the two screws securing the pressbar. Lift off
the metal retainer, plastic pressbar, curved spring and plunger. Lift out the rectangular plastic cup and
disconnect the blue and yellow wires.
8. Pull the old cord out of the handset and discard.
Installation of new cord
1. Feed the red and green wires through the transmitter end of the handset, through the center of the
handset to the receiver end. Secure the wires to the receiver.
2. Place the receiver in the cup. Tighten the receiver cap.
3. FOR HANDSETS WITH PRESSBAR ONLY: Feed the yellow and blue wires through the handset
to the pressbar area. Secure the wires to the terminals in the plastic cup. Place the plastic cup in the
handset. Refer to Figure 1. Place the copper piece with the rubber center in first, with the solid
rubber side up. Install the curved spring. Place the plastic pressbar in with the GTC logo side up.
Place the metal bracket on top. Tighten the screws.
4. Attach the black and white wires to the transmitter terminals.
5. Place the transmitter in the transmitter cup, making sure that the cord guide snaps firmly onto the cord
to secure it. Screw on the transmitter cap.
6. Feed the other end of the cord through from the front panel of the phone and use a Heyco® tool or
needlenose pliers to secure the bushing on the front of the subset.
7. Reconnect the wires to the PC board according to the labels on the board.
8. Replace the four screws to reassemble the unit.
9. Use the two mounting screws to secure the subset to the mounting bracket.

Pub. 42003-035B
MODELS 12514-007, 12514-008, AND 12514-009 PVC COIL CORD REPLACEMENT KIT Page: 6of 6
\\s_eng\gtcproddocs\standard ioms - current release\kits (42003)\42003-035b.doc
Models 616C, 6165, 716-002, and 7165-002
Removal of old cord
1. Remove the unit from the wall or mounting surface.
2. Remove the four back panel screws.
3. Follow Steps 3 through 7 under “Removal of old cord” in the section for 611C, 6115, 711-002, and
7115-002 above.
Installation of new cord
1. Follow Steps 1 through 7 under “Installation of new cord” in the section for 611C, 6115, 711-002,
and 7115-002 above.
2. Replace the four back panel screws.
3. Remount the unit.
Models 726 and 7265-101
Removal of old cord
1. Loosen the four screws securing the housing to the base.
2. Hinge the housing forward to access the inside of the subset.
3. Follow Steps 3 through 7 under “Removal of old cord” in the section for 611C, 6115, 711-002, and
7115-002 above.
Installation of new cord
1. Follow Steps 1 through 7 under “Installation of new cord” in the section for 611C, 6115, 711-002,
and 7115-002 above.
2. Place the housing on the base and tighten the four screws.