Mattel INtelliViSiON" 2609 User manual

SUBASSEMBL
V
SERVICE
MANUAL
I
NtElliViSiON"
Intelligent
Television
MODEL 2609
MATTEL ELECTRONICS
5150 Rosecrans Avenue
Hawthorne,
California
90250

TABLE OF
CONTENTS
I.
Diagnostic Routine
..............................................
. Page 2
II. Preliminary Checklist
.........................................
. Page 5
III. Troubleshooting
.................................................
Page 6
IV. Disassembly Instructions
A. Console Disassembly Page 10
B.
Logic Board Replacement
.....................................
Page 10
C.
Power Supply Board Replacement
.............................
Page 12
D.
Transformer Assembly Replacement
.........
.
.................
Page
12
V.
Handcontroller Repair
..................................
.
.........
Page 13
VI. Power Supply Board Repair
......................................
Page 17
VII. Parts List
........................................................
Page 18
VIII. Exploded View
of
Console Assembly
..............................
Page
20
TOOLS AND
EQUIPMENT
REQUIRED
•
Color
TV Receiver
• Basic Electronic Hand Tools
• Digital
Multimeter
(DMM)
• Test Cartridge MTE-201
-1-

DIAGNOSTIC
ROUTINE
SECTION
I.
Follow
this
procedure
until
you
find
a
malfunction.
Then
refer
to
the
PRELIMINARY
CHECKLIST
(Section
II, page 5 )
and
TROUBLESHOOTING
(Section
III,
page
6 )
and
locate
the
problem
or
condition.
Follow
instructions
to
correct
the
fault.
Before
re-
assembling
the
Master
Component,
go
through
this
DIAGNOSTIC
ROUTINE
again.
TURN
ALL
AUTOMATIC
COLOR CIRCUITS
TO
MANUAL
POSITION.
1.
Connect
the
Master
Component
to
TV,
plug
in
power
cord, set
the
Antenna
Switch
Box
to
TV and
determine
that
the
set
works
cor-
rectly on broadcast stations.
If
there is any
problem,
refer
to
the
PRELIMINARY
CHECKLIST.
2.
Set
the
Antenna
Switch
Box
to
GAME. Set
the
Channel
Select
switch
of
the TV
to
the
deSignated channel
for
the
Master
Component.
CARTRIDGE
3.
Insert
the
MTE-201
Test
Cartridge.
Slide
the
ON/OFF
Switch
to
the
ON
position
and
depress
the
Reset
Button
on
the
Master
Com-
ponent.
The
unit
will
proceed
through
a series
of
checks.
4.
At
the
completion
of
the
above test
sequence, the
Hand
Controller
test
display
will
appear
as
shown
in
Figure
1.
(a.) Press each key
on
the
Hand
Con-
trollers,
one
at a
time
and
verify
that
each
corresponding
test image
turns
from
yellow
to
white
when the
appropriate
key is depressed.
NOTE:
The
right
Hand
Controller
will affect
the
left test image and vice versa. -2-
(b.) Press
the
top
side
buttons
on
the
Hand
Controllers
one
at atime. Make sure
that
the
pair
of
Fs
change
from
yellow
to
white.
(c.) Press each
lower
side
button
on
the
Hand
Controllers
one
at a
time
and see
that
the
letters
Land
R
change
from
yellow
to
white.
(d.) Depress
the
directional
disc
on
each
Hand
Controller
and a
white
arrow
will appear
in
the
black
circle. As
the
directional
disc
is
rotated,
the
arrow
wi
II
rotate.
Check
to
see
that
the
arrow
pOints in 16
different
directions.
(e.)
Check
the
row
of
colored
boxes
for
similarity
as listed in Figure
1.
Next, depress
the
digit
keys 1 and 9
simulta-
neously
on
either
Hand
Controller
and
the
test
sequence
will
proceed
to
the
sound
checks.
1
l:r
9
TO
CONTINUE
1 2 3 1 2 3
I F 4 5 6 FI I F 4 5 6 FI
I L 7 8 9
RI
I L 7 8 9
RI
c 0 E c o E
•
812345678
COLOR
CODE:
I.
Blick
6.
light
Gr
••n
II.
BrDwn
2.
Blue
7.
Yellow
12.
Mlgenll
3.
Red
8.
White
13.
LIght
Blul
4.
Tin
9.
GrlY
14.
YIIIDw/Bnen
5.
Dirk
Green
10.
Orlngl
15.
Purple
Figure
1
Hand
Controller
Test Pattern

5.
Verify the
following
sequence
of
sounds
is
heard:
(a.) A
low
frequency
rumble
.
(b.) A high
note
stepping
down
through
five octaves (repeated three times).
(c.) Random noise (hissing)
starting
at a
high
volume and
diminishing
slightly.
(d.) A single tone, starting at a
high
volume
and
diminishing
slowly
.
(e.)
Two
gunshots, one at normal volume,
the
second
at
half
volume.
If all
of
these sounds are heard
as
described,
depress the CLEAR key
on
either Hand
Con-
troller. In the event any part of the test has
failed, depress the ENTER key. (NOTE: The
test sequence
cannot
be advanced if the
CLEAR
or
ENTER key is depressed
while
sounds are being generated.)
6.
The next segment
of
the test presents a
series of patterns,
ending
with the pattern
illustrated in Figure 2.
Check
colors
in the test
pattern against Figure 2
for
similarity
and defi-
nition
. If test pattern
accuracy
is satisfactory,
press the CLEAR key. If it is
unsatisfactory
,
press the ENTER key.
..
. - -
--
.- ..
--
.-
.-
...
-_.
r .
>--- I ?
~
J 4
5 6
7~
.
7 I
I ' 1
A '
L'~'
1B
3
Ie
4
4 6
r
J
~
I
IE
2
2
IF
8 3
IG
4
.
~OK,
ENTER
=
BAD
1:17 ".-
COLOR
CODE
I.
Black
6.
Light
Green
II.
Brown
2.
Blue
7.
Yettow
12.
Magenta
3.
Red
8.
White
13
.
Light
Blue
4.
Tan
9.
Gray
14
.
Yettow
/
Green
5.
Dark
Green
10
.
Orange
15
.
Purple
Figure 2
-3-
7.
The next
portion
of
the test sequence is a
pattern
of
colored
blocks
with the
two
larger
blocks alternating with
the
words
MODE
TWO,
as
illustrated in Figure
3.
Check
colors
in test
pattern against Figure 3
for
similarity
and
defi-
nit
ion.
If
test pattern
accuracy
is satisfactory,
press
the
CLEAR key. If it is unsatisfactory,
press the ENTER key.
COLOR
CODE
: I.
Black
2. Bl
ue
3.
Red
4.
Tan
'.
'
.~
1:43
~
.
__
_ _
.-
_
-=-=-=
= =
==::::J
6.
Light
Green
7.
Yellow
B.
While
9.
Gray
11.
Brown
12.
Magenla
13
.
Lighl
Blue
14
.
Yellow
/
Green
5.
Dark
Green
10.
Orange
15.
Purple
Figure 3
8.
The last test alternatelyflashes the patterns
"FIB"
and "VIS." Press CLEAR
for
pass
or
ENTER
for
fail.
If
no
failure has been detected,the
title
page
for
Baseball will appear; this indicates the Master
Component
has passed all the
automatic
and
[
l.J<J!
J
~
~
~
LUosl
~
~
~
~
Figure 4
~
1-
Uo
9]
[lJ1S
J

operator
tests. In the event a
failure
has been
detected. instead
of
the
title
page being
displayed. a
display
as
shown
in Figure 4
will
appear
or
the test will
indicate
"Failure
at Test
_
"followed
by a letter between A and
Z.
If
either is displayed. refer
to
Section
111-6.
Page
9.
9. The
next
test is an actual game
check
to
confirm
the
functional
operation
of
the Master
Component. When the
title
page
for
Baseball is
displayed.
follow
the
instructions
provided
with
the
MTE-201 Test
Cartridge
to
play
112
inning
of
Baseball.
Upon
successful
completion
of
the
baseball
game. the test
routine
for
the Master
Compo-
nent
is
complete.
10. This Diagnostic Routine can be
repeated-
from the
beginning-any
time
.
Just
press
the
RESET
button
.
-4-

PRELIMINARY CHECKLIST
SECTION II:
Before you refer
to
the
TROUBLESHOOTING
Section
which
follows,
look
at
this
list
of
pos-
sible
quick
solutions. Then,
if
any problem
persists, you
should
be able
to
find
it
in
TROUBLESHOOTING.
Turn
ON/OFF
Switch
to
ON
and press RESET.
With
the
Test
Cartridge
still inserted,
go
through
the
DIAGNOSTIC
ROUTINE
and
check
for
these problems:
PROBLEM POSSIBLE
SOLUTION
SCREEN IS
BLANK
-Press
any
key on
either
Hand
Controller
key pad
to
recover picture.
NO
TV
PROGRAMS
-
Check
connection
of
cable
from
Antenna
Switch
Box
to
antenna
connector
on
TV.
-Make sure
Antenna
Switch
Box is set at
TV.
-Make sure that coax cable is attached.
BUZZING
OR
DISTORTED
SOUND
-
Adjust
TV
fine
tuning
controls.
-If there is broadcast interference
from
a
strong
signal,
disconnect
antenna coax
from
Antenna
Switch
Box. (This
must
be
reconnected
for
broadcast viewing.)
NO
GAME
SOUND
EFFECTS -
Turn
up TV
volume
control.
-
Adjust
fine
tuning
.
WHITE-GRAY
SCREEN
OR SCREEN
IS
ONE
COLOR
-Make sure
cartridge
is
properly
inserted.
SNOWY SCREEN (NO
RF
CARRIER) -Make sure:
-
TV
tuner
is set
on
the
proper
channel.
-
Antenna
Switch
Box is set at GAME.
-
Game
coax cable is
properly
plugged
into
Antenna
Switch
Box
.
-Power
switch
is ON.
-Check all
connections
,
including
power
plug
.
TEST
IMAGE
NOT
DISTINCT
,
AS IF FROM WEAK
SIGNAL
-
Adjust
fine
tuning
, brightness, and con-
trast
controls
.
TEST
IMAGE
BLURRED,
-
Check
connections
at
Antenna
Switch
Box,
TV
antenna
connector,
and game
output
connector.
WOBBLY, OR
NO
COLOR
-
Adjust
fine
tuning,
brightness, contrast,
and color.
-
If
there
is
broadcast interference
from
a
strong
signal, di
sconnect
antenna cable
from
Antenna
Switch
Box
. (This
must
be
reconnected
for
broadcast viewing.)
-5-

TROUBLESHOOTING
SECTION
III
Find
the
Phrase
in
the
left-hand
column
below
which
best describes the
malfunction
or
con-
dition
you
encountered.
Follow
each
step
of
MALFUNCTION/CONDITION
1.
NO
TV
PROGRAMS,
NO
INTELLIVISION
TEST
PATTERNS,
SNOWY
OR
WHITE-GRAY
SCREEN.
the related
instructions.
Then
repeat
the
entire
DIAGNOSTIC
ROUTINE
as
described
in
Section
I.
SERVICE
INSTRUCTIONS
1.0
Verify
that
TV
receiver works.
1.1
Disconnect
Antenna
Switch
Box
assembly
and replace
with
a
known
good
unit.
1.2
Disconnect
Antenna
Cable and
replace
with
a
good
one.
1.3
Disassemble Master
Component
(See
Section
IV-A,
Page10).
1.4
Unplug
Master
Component
and
check
ON/OFF
switch
for
continuity.
1.5 When the
Component
is
dis-
assembled,
perform
the
following
test
procedure:
-6-
(a)
Carefully
remove
5-pin
ribbon
con-
nector
and
2-pin
plug
from
the
Power
Supply
Board
(see
Figure
5, Page 8).
(b)
Plug in
Master
Component
and
turn
ON/OFF
Switch
to
ON.
(e)
Connect
negative
probe
of
volt-
meter
to
Ground
Test
Point
on
the
Power
Supply
Board.
Connect
positive
probe
to
+5 Volt
Test
Point. Refer
to
Figure
5.
Meter
should
read 4.85-5.15
VDC.
(d)
With negative
probe
still
on
Ground,
connect
positive
probe
to
+12 Volt Test
Point.
Meter
should
read 11.64-12.36
VDC.
(e) With negative
probe
still on Ground,
connect
positive
probe
to
+16 Volt Test
Point.
Meter
should
read at least +16
VDC.
(f)
Connect
positive
probe
to
ground
and negative
probe
to -2.1 Volt Test
Point. Meter
should
read 1.95-2.25 VDC.
(g)
Connect
neyative
probe
to
ground
and
positive
probe
to
+5.65
volt
con-
nector
pin.
Meter
should
read
at
least
12 VDC.

MALFUNCTION/CONDITION
SERVICE
INSTRUCTIONS
1.
CONTINUED
.........................
(h)
Turn
power
off.
Reconnect
5-pin
ribbon
cable
and
2-pin
plug.
Turn
power
on
and remeasure
voltage
at
+5.65
volt
connector
pin.
Meter
should
read 5.45 -5.85 VDC.
If
voltage
is
not
within
limits,
turn
off
power
and
measure resistance
of
R2
(Figure
5).
I
,I
I
, . . '
DO
NOT
CHECK
SUPPLY
VOLTAGES
AT
THE
J3
RIBBON
CONNECTOR
AS METER PROBES
COULD
DAMAGE
CONNECTOR
PINS.
CHECK
VOLTAGES
AT
THE TEST
POINTS
SHOWN
IN
FIGURE
5.
-7-
If
OK, replace
logic
board.
If
not
OK,
troubleshoot
power
supply
board.
(i)
If
voltages
are present, replace
the
Logic
Board
(See
Section
IV-B,
Page
10).
(j)
If
the
abovevoltages are not present,
remove
the
5-pin
Transformer
Con-
nector
from
the
Power
Supply
Board.
DO
NOT
push
meter
probes
into
socket
holes
to
measure
voltage
or
socket
will
be damaged.
Touch
meter
probes
to
the
slide
contacts
visible
on
the
top
of
the
socket
to
measure voltages.
Set
meter
on AC, and
check
for
these
voltages:
-
With
probes in holes #3 and #1, meter
should
read
7,6 -9.4
VAC
RMS.
-
With
probes in holes #3 and
#2,
meter
should
read
7,6 -9.4
VAC
RMS.
-With probes in holes
#4
and #5, meter
should
read
15,3 -18,7
VAC
RMS,
(k)
If
all
voltages
read
as
described
in
Step
(j),
repair
or
replace
the
Power
Supply
Board
(See
Section
IV-C, Page
12).
(I)
If
any
voltages
differ
from
the
values
in
Step
(j), replace
the
Transformer
Assembly
(See
Section
IV-D,
Page12).
Verify
that
replacement
of
the
Trans-
former
Assembly
and/or
Power
Supply
Board
has
corrected
any
supply
volt-
age
problem
by
repeating steps
(b)
through
(h)
above.
If
voltages
are
correct
and a
known-
good
Logic
Board
has been
installed
but
symptoms
persist,
the
fault
could
be
with
Power
Connector
J3 on
the
Power
Supply
Board.

+
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8+
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--<I@--
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TP1
CI
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~
J3
rn
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OPTIONAL
CONFIGURATION
I
GAIO
THAU
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MAY
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REPLACE
eAg
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TP5
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-
TP6
Figure
5 Test
Points
Location
Diagram
TP-1
.....................................................
GROUND
TP-2
..................................................
+5V
DC
TEST
TP-3
................................................
+12V
DC
TEST
TP-4
................................
+16V
DC
TEST
(Non·Regulated)
TP-5
........................
-2.1V
DC
TEST
(Early
Production
-3.3V)
TP-6
....................................
+5.65V
DC
(Non-Regulated)
MALFUNCTION/CONDITION
2.
TEST
PATTERNS
OR
GAME
PICTURE
JUMBLED,
OR
UNWANTED
CHARACTERS
ON
SCREEN
3.
NO
SOUND
OR
GARBLED
SOUND
4.
BAD
ON/OFF
SWITCH
5.
TEST
CARTRIDGE
DOES
NOT
RESPOND
TO
HAN
D-CONTROLLER
(S)
SERVICE
INSTRUCTIONS
2.1
Follow
Procedure
1.5 (a)
thru
(I)
(See
Section"
I-I, Page 6).
3.1
Make
sure
that
TV
volume
is
turned
up, and
that
sounds
on
broadcast
stations
are
good.
3.2 Replace
Logic
Board
(See
Section
IV-B,
Page10).
4.1
Replace
Transformer
Assembly
(See
Section
IV-D,
Page
12).
5.1
Replace
Hand
Controllers
(See
Section
IV-B, Page
10).
5.2
If
Procedure
5.1
doesn't
cure
the
problem,
replace
Logic
Board
(See Sec-
tion
IV-B, Page
10).
-8-

MALFUNCTION/CONDITION
6.
TEST
INDICATES
FAILURE
IN PARTS
OTHER
THAN
HAND-CONTROLLERS
7.
NO
APPARENT
FAILURE
-
ALL
TESTS
PASS
SERVICE
INSTRUCTIONS
6.1 Replace
Logic
Board
(See
Section
IV-B, Page
10).
7.1
Insert
customer's
game
cartridge
in
Component
and
watch
for: mistakes in
lettering
on
title
picture,
jumbled
play-
field,
or
unwanted
characters. Test
with
a
known-good
Game
Cartridge.
If
prob-
lems
continue,
follow
Procedure
1.5 (a)
thru
(I),
Section
111-1,
Page 6 . If
prob-
lems
do
not
appear,-customer's
cartridge
is
defective
.
7.2 NOTE:
FOLLOW
THIS
STEP FOR
SHOP
SERVICE
ONLY:
Insert MTE-201 Test
Cartridge
and press
Reset. Run
the
diagnostic
tests until
the
television screen
shows
the
title
page
for
Baseball (the screen
will
show
"Mattei
Electronics
presents Baseball").
DO
NOT
touch
any
keys
or
switches.
Disconnect
or
turn
off
the TV set and let
the
Master
Component
burn-in
for
90 minutes.
After
90 minutes,
re-connect
or
turn on
the
television set.
The
title
page
should
be
seen on
the
television screen. Press Reset
and run
the
diagnostic
tests and play
V2
inning
of
baseball. If
the
results again
show
no
failures, the Master
Component
is
considered
to
be
GOOD.
IMPORTANT
REMINDER
After
completing
any
TROUBLESHOOTING
or
DISASSEMBLY, always
go
through
the
DIAGNOSTIC
ROUTINE
described
in
Section
I
before
reassembling
the
unit.
8.
TEST
CARTRIDGE
CHECK
8.1
Should
you
suspect
the
MTE-201
Test
Cartridge
to
be defective, it can be
tested
as
follows:
Depress keys 2 and 8
simultaneously
when
the
Hand
Controller
Test is
displayed
(Figure
1)
and a
check-
sum
will
be displayed.
The
display
should
look
like
this:
CART
CHECKSUM
LO=
00002371677
CART
CHECKSUM
HI=
00003372642
If
any
other
numbers
appear
or
the
num-
bers differ, it
indicates
a failure in
the
test
cartridge
and
another
cartridge
should
be
used.
-9-

SECTION
IV:
DISASSEMBLY INSTRUCTIONS
WARNING:
Use care
when
connecting
or
disconnecting
hand
controller
connectors
from
logic
board.
Do
not
touch
the
pins on
the
logic
board
as
static
discharge
may
damage
internal
circuitry.
A.
CONSOLE
DISASSEMBLY
Be sure
unit
is
unplugged
before
disassembly.
(1)
Turn
Console
upside
down
and
loosen
(6)
Phillips
head screws.
(2)
Turn
Console
right-side
up,
allow
the
(6)
screws
to
fall out,
then
pull
upon
the
ONI
OFF
glamour
cap
to
remove.
DO
NOT
remove
the
RESET
button.
(3) Remove
top
case
and
slip
Hand
Controllers
through
openings.
NOTE:
When
re-assembling
Console,
replace
Hand
Controller
tray
first.
Refer
to
Figure
6
for
position
of
Controller
wires.
B.
LOGIC
BOARD
OR
HAND
CONTROLLERS
REPLACEMENT
(1)
Follow
Console
Disassembly
procedure
above -steps (1)
through
(3).
(2)
Remove (6)
screws
from
Hand
Controller
tray
,
and
remove
the
tray.
(3)
Disconnect
Switch
Box
cable
from
console
and remove
any
cartridge.
(4)
Carefully
disconnect
the
5-pin
ribbon
connector
and
the 2-pin
connector
from
Power
Supply
Board.
The
Logic
Board
and
metal
shields
go
together.
DO
NOT
try
to
separate
them.
(5)
Lift
Logic
Board
straight
up.
Carefully
disconnect
Hand
Controllers
(if a
problem
exists
in
just
one
Controller,
it is
not
necessary
to
remove
both
of
them).
When
replacing
Connectors
to
Logic
Board,
the
Connector
must
be
inserted
according
to
the
illustra-
tion
in
Figure
6,
page
11.
-10-

Pin No.
1
Brown
o
»=
.j -
--
--
,,-----....::==----;H~A
ND
CON
TROLL
ER CONNECTOR
Figure 6
-11-

C. POWER SUPPLY BOARD
REPLACEMENT
(1) Remove (6) screws from Hand
Controller
tray
. Remove the
tray
.
(2) Carefully
disconnect
the 5-pin
ribbon
connector,
the 2-pin
connector
and the 5-pin
transformer
connector
from
the
Power
Supply
Board.
(3) Remove
(2)
screws from the Power
Supply
Board and replace
the
Board (but
not
the
Hand
Controller
tray -yet).
* SAFETY
PRECAUTION
*
FIBER INSULATOR(S)
MUST
BE PROPERLY REPLACED UNDER POWER SUPPLY
BOARD. IF
UNIT
WAS EQUIPPED WITH TWO INSULATORS, BE SURE
THAT
BOTH
ARE REPLACED.
D. TRANSFORMER ASSEMBLY
REPLACEMENT
NOTE:
Unplug
Master
Component
before
attempting
parts replacement.
(1)
Disconnect
5-pin Ribbon
Connector
from
Logic
and Power
Supply
Boards.
(2) Unscrew the Hand
Controller
tray
and Power
Supply
Board.
(3) Remove the Power
Supply
Board and any insulation underneath it.
(4) Remove the 5-pin
Transformer
connector
from
Power
Supply
Board.
(5) Remove (4) screws, 2
from
the
Transformer
and 2
from
the
ON/OFF
switch.
(6)
Replace the
Transformer
Assembly, reversing the above steps.
r----------------------IMPORTANTREMINDER----------------------~
After
completing
any
TROUBLESHOOTING
or
DISASSEMBLY, always go
through
the
entire
DIAGNOSTIC
routine described in Section I before reassembling the unit.
-12-

HAND CONTROLLER REPAIR
IMPORTANT: Make sure foreign material
...
dirt, dust, etc., does
not
come In contact with
the
circuit
matrix
or
other plastic parts.
Unplug MasterComponentfrom powersource.
Disconnect switch box cable.
(a.) Disassembly: Turn the Hand Con-
troller
upside
down
on
a
flat
surface
and
hold
it firmly. Use a Phillips-head screw driver
to
remove the 4 screws. Remove bottom screws
first. Set all 4 screws aside in a safe place.
Refer to Figure 7 below.
Figure 7
FOAM
TA
PE
CONN~CTOR
BLOCK
-13-
SI
DE
ACTION
I
~
ITONS
!<l-~~
~I?~~~<?~
KE
YPA
D
I~~
~
!@
g
:
~cm
'
c::.-.{
-I
I
i
"
~
~'
STA
TI
C
......
'~
"-
"l
SHIELD
~~,
4
SC
REWS
I
Figure 8
BO
TT
OM
H
OUS
I
NG

(1) While
holding
the
top
and
bottom
housings together. turn the Hand
Controller
right side up. Set
it
back on a
flat
surface. (See
Figure 9.)
Figure 9
(2) Carefully
lift
the
top
off
and set
it
aside. Hold the number keypad and the
Gold
Directional Disc in place with one hand.
(3) Remove the Gold Directional Disc
and Spring.
(4) Remove the
Action
Buttons
from
both sides.
(5) Remove the static shield and the
circuit
matrix from the
lower
housing
. (See
Figure 8.)
(6) Remove the cable
from
the
lower
housing by
lifting
the cable strain relief
up
and
out
of
the housing. Pry up the cable
connector
blockfrom its
mount
in the housing. CAUTION:
Be
careful not to
touch
or
bend the metal
prongs. (See Figures
10
and 11.)
(7) If
bottom
housing has a raised
lip
around the directional disc guidepost, replace
the bottom housing.
-14-
Figure 10
CA
BLE
CONNECTOR
BLOCK
Figure
11
NECTOR
BLOCK

(b.)
Component
Replacement
and
Reassembly.
(1)
Place
the
replacement
cable
assembly in the
lower
housing
as
shown in
Figures 10 and
11
.
(2) Make sure the replacement
circuit
matrix is
correctly
folded
as
shown in Figure
12
below.
Figure
12
0
00
0 0
000
Apply
foam tape (2609-6159)
to
circu
it
matrix
as
required. Refer
to
Figure
13.
Install the
cir-
cuit
matrix
as
shown in Figure 8 and make
sure
it
fits
snugly
over the
top
and
bottom
posts.
Foam tape is
to
be applied
directly
to
thefolded
circuit
matrix. Tape
is
to
be captured between
matrix and domed legend, and pressed
to
secure its position. Refer
to
Figure13.
-15-
CAUTION: AVOID EXCESSIVE
FOLDING
OR
HANDLING OF THE
CIRCUIT
MATRIX.
Figure 13 Foam Tape Replacement

(3) Install the static shield over the
folded
circuit
matrix, making sure the posts go
through both sets of holes (shield and matrix).
Refer
to
Figure
8.
Hold the matrix and shield
in place with fingers.
(4) Install the keypad over the matrix
and static shield. Again make sure both posts
go through keypad holes.
(5) Check that the components are
correctly installed. Place the washer underthe
top layers
of
the
circuit
matrix and over the
directional disc post
as
shown in Figure
8.
(6) Press action buttons
firmly
in posi-
tion. The scalloped edge should be on the
BOTTOM, FACING INWARD. The buttons will
only
fit
one way. Refer
to
Figure 14 below.
SCAL
LOPED
EDG
E
Figure 14
(7)
Mount
the spring and Directional
Disc. Refer
to
Figure
8.
(8) Before reinstalling the
top
housing,
make sure the
circuit
matrix and keypad are
securely in place so that the
top
and
bottom
holes fit overthe
smaJl
brown posts. See Figure
15.
-16-
Figure
15
(9) Install the top housing. Hold the
top
and bottom securely together while you turn
the Hand
Controller
over.Replace the4screws,
TOP SCREWS FIRST. Tighten until
firmly
in
place. This
is
important
to
make all the
circuit
connections. DO
NOT
OVERTIGHTEN.
(10) Connect the Hand
Controller
to
a
working MIC and using the MTE-201 Test
Cartridge, check
for
proper operation.

POWER SUPPLY BOARD REPAIR
Printed
Circuit
Board
component
layout
is
shown
in
Figure
5
(page
8).
,------T--------
-
-T:-
- - -
-,
CRI
CR2
CR3
I
TRANSFORMER
AN1
L!~V~_~H~EMBLY
______
_
DETAIL A
NOTES:
,.
ALL
RESISTANCE VALUES ARE IN OHMS.
CRIO
CRll
CRl2
Rl
220
'hW
CR9
2.
1V
0)-
Ul
U2
~
7 7
J3
I
---------~
PCB-Power
Supply
2.
ALL
CAPACITANCE
VALUES ARE IN MICROFARADS.
+5V
-2.
1V
+16V
UNREG
+12V
GND
3.
DIODES
CR10THRU
CR12 MAY
BEUSED
IN
PLACEOFZENER
DIODECR9
(SEE DETAILA).
-17-

REF. NO.
CD
o
C1
C2
C3
C4
-
Cl0
Cll,C12
R1
R2
CRl
-CR8
CR9
CR10 -CR12
P2
J3
P5
Ul
U2
CD
o
CD
PARTS
LIST
DESCRIPTION PART NO.
Logic Board Assembly
........
.
....................
..
....
2609-9169
Power Supply Board Assembly
........................
.
....
2609-9539
Capacitor, 10,000uF 16V Elect
.............................
0085-0005
Capacitor, 100uF 16V Elect. . .
..
.
...
....
..
. .
.....
.
..
.
..
. . . 0085-0004
Capacitor, 2200uF 25V Elect
........................
.
...
..
0085-0006
Capacitor, O.luF 25V
......
.
..
.
...............
.
..........
0085-1510
CapaCitor, 0.22uF 25V
........
.
..........................
0085-1410
Resistor, 220 ohm
Y2W
5%
. . .
..
...........................
0095-0576
Resistor, 12 ohm
3W
10%
WW
..
.
....
...
..........
.
..
.
.....
0089-0928
Diode,IN4001
..............
.
..........................
0099-1030
Diode, Zener IN746
.....................................
0086-0425
Diode,IN400l
...............
.
.........................
0099-1030
Plug, 5 pin
............................................
2609-9239
Jack, 5 pin
........
.
...................................
0099-0390
Plug,2 pin
..................
.
.........................
0089-0007
I.e.
uA
7805 .
..............
.
..........................
0098-2130
Small Heatsink
for
U1
.........
.
.........................
0099-0310
Large
Heatsink
for
Ul
.......
.
.....................
..
....
0089-0606
I.C.
LM 340T12
........................................
0098-2140
Heatsink
for
U2
..
•
..............................
.
......
0099-1570
Transformer ON/OFF Switch Assembly
.............
. . .
......
2609-9629
ON/OFF Switch
.............
..
..................
.
......
2609-9559
Tray
.......................
.
.........................
2609-2149
-18-

REF. NO.
o
(j)
®
@
®
@
®
@
e
DESCRIPTION
PART
NO.
Top Housing Assembly
...................................
2609-9719
Inlay, Plain
............................................
2609-4529
Spring,
Reset
..........................................
2609-4269
Button
Reset
....................................
.
.....
2609-2129
Glamor Cap, ON/OFF Switch
................
.
............
2609-2139
Inlay, Control
........
, .
....
,
....................
.
......
2609-4519
Pushnut Fastener
.................................
.
....
.0405-0852
Foot
.
...........................
.
......
.
.......
.
.....
2609-9489
Handcontroller Assembly
.................................
2609-9059
Top Housing
..............................
.
............
2609-9069
Direction Disc
w/lnlay
...................................
2609-9089
Spring, Direction Disc
...................................
2609-4279
Side
Action
Button
...............................
.
.....
2609-2099
Keypad (Domed Legend) .
......•.
.
...
. . . . .
.....
.
.........
2609-6379
Static
Shield
•....••.......•............................
2609-4549
Circuit Matrix
......
.
..........................
.
........
2609-9589
Foam Tape
..........
.
.................................
2609-6159
Mylar
Washer
.............................
.
............
2609-4019
Cable Assembly
.....................•..................
2609-9579
Bottom
Housing
.....
.
..............
.
...................
2609-2059
Screw, 5-20 x 7/16 in
...........
.
........................
0405-0842
Antenna Switch Box
........
.
.......
.
.............
.
.....
2609-9609
R.F. Cable . .
..
..
.......
.
........
.
.....................
2609-9599
-19-
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