Motorola HSN4035 Operating instructions

SERVICE INSTRUCTIONS
FOR
AM PLIFIER-LOUDSPEAKER
M OTOROLA KIT HSN4035( )
 1998 by Motorola, Inc.
Radio Network Solutions Group
8000 W. Sunrise Boulevard
Ft. Lauderdale, FL 33322
All rights reserved.
*6881109C65*
68P81109C65-O

Table of Cont ent s
Li st o f Fi g u r e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i
Li st o f Ta b les . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i i
Li st o f Ef f ect i v e P a g es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i v
Sa f et y Su m m a ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
In t ro d u c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Re f er e n ce P u b l i c a t io n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Te st Set u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Te st P ro c e d u re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tro u b l e sh o o t in g Pro ced u res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Re p a i r Pro ced u res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
In itial Disassem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacin g Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacin g Prin ted Circuit Bo ard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacin g Vo lum e Po ten tio m eter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0
Replacin g 9-Fo o t Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fin al Reassem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ex p l o d ed Vi e w a n d Re p a i r P a rt s Li st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7
i

List of Figures
Figure 1. Test Con n ector Sch em atic/W irin g Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Am plifier-Lou d speaker Test an d Troublesh ootin g Pro cedures . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3. Separatin g Fron t an d Rear Hou sin gs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. PCB Con n ection s to Extern al Com pon en ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 5. Rem ovin g an d In stallin g PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6. Rem ovin g Volum e Poten tiom eter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7. Prep arin g New Volu m e Poten tiom eter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 8. Con n ectin g Lead s to New Volu m e Poten tiom et er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 9. Rem ovin g an d In stallin g 9-Foot Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 10. In stallin g 9-Foot Cable in Strain Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 11. Fin al Reassem bly of Am p lifier-Loudsp eaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12. Am plifier-Lou d speaker, Mo torola Kit HSN4035( ), Exp loded View . . . . . . . . . . . . . . . . . 17
ii

List of Tables
Table 1. Test Equ ipm en t an d Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 2. Test Co n n ector Com pon en ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 3. Repair Parts Requ ired for Speaker Replacem en t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 4. Repair Parts Requ ired for Prin ted Circuit Board Rep lacem en t . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 5. Prin t ed Circuit Board Con n ect ion s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 6. Repair Parts Requ ired for Volum e Poten tiom eter Replacem en t . . . . . . . . . . . . . . . . . . . . . . 10
Table 7. Repair Parts Requ ired for 9-Foot Cable Replacem en t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 8. 9-Foot Cable Con n ection s to PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 9. Repair Parts Requ ired for Fin al Assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 10. Rep air Parts for Am p lifier-Loud speaker Mo torola Kit HSN4035( ) . . . . . . . . . . . . . . . . . . . 17
iii

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 O Back cover O
1 through 18 O
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:M arch 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 footers except for the absence of a change
letter and date.
iv

Exposure t o Radio
Frequency Energy
( Nat ional and
Int ernat ional
St andards and
Guidelines)
Your Motorola two-way Radio, wh ich gen erates an d rad iates rad io
freq u en cy (RF) electrom agn etic en ergy (EME), is design ed to com ply
with th e followin g n at ion al an d in tern ation al stan d ard s an d gu id e-
lin es regard in g exposure of h um an bein gs to rad io freq u en cy electro-
m agn etic en ergy:
• Fed eral Com m un ication s Com m ission Rep ort an d Order
No. FCC 96-326 (Au gu st 1996)
• Am erican Nation al Stan dard s In stitute (C95-1-1992)
• Nation al Cou n cil on Radiat ion Prot ection an d Measurem en t s
(NCRP - 1986)
• In tern ation al Com m ission on Non -Io n izin g Rad iation Protection
(ICNRP - 1986)
• Euro p ean Co m m ittee for Electrotech n ical Stan dard izat ion
(CENELEC)
- En v. 50166 - 1 1995E - Hu m an Exp osu re t o Elect rom agn etic
Fields Low Freq u en cy (0 Hz to 10kHz)
- En v. 50166 - 2 1995E - Hu m an Exp osu re t o Elect rom agn etic
Fields High Frequ en cy (10kHz to 300Gh z)
- Proceed in gs of SC211/ 8 1996 - Safety Con sid eration s for
Hu m an Exposu re to E.M.Fs from Mobile Telecom m u n ication s
Equ ipm en t (M.T.E.) in th e Freq uen cy Ran ge 30MHz - 6GHz
(E.M.F - Electrom agn etic Fields)
To assure optim al radio perform an ce an d th at h u m an exposure to
rad io freq u en cy electrom agn etic en ergy is with in th e gu id elin es set
forth in th e abo ve stan d ards, tran sm it only wh en peop le in sid e an d
ou tsid e th e veh icle are at least th e m in im u m distan ce away from a
properly in stalled , extern ally-m oun ted an ten n a.
Th e table below lists th e m in im u m distan ce for several differen t
ran ges of rated radio power.
Rated Power of Vehicle-installed
Mobile Two-way Radio
Minimum Distance from
Transmitting Antenna
7 to 15 Watts 1 Foot
(30.5 Centimeters)
16 to 50 Watts 2 Feet
(61 Centimeters)
More than 50 Watts 3 Feet
(91.5 Centimeters)
Safet y Summary
v
Rated Power and Distance

M obile Ant enna
Inst allat ion
In stall th e veh icle an ten n a external to th e veh icle an d in accord an ce
with :
• Th e req u irem en ts o f th e an ten n a m an u factu rer/su pp lier
• In stru ction s in th e Rad io In stallatio n Man u al
Cont rol St at ion
Operat ion
Wh en radio eq u ipm en t is used to operate as a con trol stat ion , it is
im portan t t h at th e an ten n a be in stalled ou tside th e buildin g an d away
from places wh ere p eople m ay be in close proxim it y.
Airbag W arning
In stallatio n of veh icle com m u n ication equ ip m en t sh ou ld be
perform ed by a p rofession al in staller/tech n ician qu alified in th e
requirem en t s for su ch in stallatio n s.
An air bag’s size, sh ap e an d deploym en t area can vary by veh icle m ake,
m odel an d fron t com partm en t con figuration (e.g., ben ch seat vs.
bu cket seats). Con tact th e veh icle m an u facturer’s corp o rat e
h ead q u arters, if n ecessary, for specific air bag in form ation for th e
veh icle m ake, m odel an d fron t com partm en t con figu rat ion in volved
in you r com m u n ication eq u ip m en t in stallation .
LP Gas W arning It is m an dato ry t h at rad ios in stalled in veh icles fuelled by liq u efied
petroleu m gas con form to th e Nation al Fire Protection Associatio n
stan dard NFPA 58, wh ich app lies to veh icles with a liquid propan e (LP)
gas con tain er in th e tru n k or oth er sealed off space with in th e in terior
of th e veh icle. Th e NFPA58 requ ires th e followin g:
• An y space con tain in g rad io eq uipm en t sh all be isolated by a seal
from th e space in wh ich th e LP gas con tain er an d its fittin gs are
located .
• Rem o vable (outside) fillin g co n n ection s sh all be u sed .
• Th e con tain er space sh all be ven ted to th e ou tsid e.
Note
Refer to Table 1 o n p age 2 fo r rated po w er an d m in im um d istan ce
values fo r tran sm ittin g an ten n as.
VEHICLES EQUIPPED WITH AIR BAGS
An air bag in flates with great force. D O NOT place objects,
in cludin g com m u n ication s eq u ipm en t, in th e area over th e air
bag or in th e air bag dep loym en t area. If th e com m u n ication s
eq u ipm en t is in stalled im pro p erly an d th e air bag in flates, th is
can cau se serious in ju ry.
vi

Ant i-Lock Braking Syst em ( ABS) and
Ant i-Skid Braking Syst em Precaut ions
Disrup tio n o f th e an ti-skid/ an ti-lo ck brakin g system by th e radio
tran sm itter m ay result in un ex pected veh icle m otio n .
Motoro la recom m en ds th e followin g radio in stallat ion precaution s
an d veh icle brakin g system test proced u res to en su re th at th e radio,
wh en t ran sm ittin g, does n ot in terfere with operatio n of th e veh icle
brakin g system .
Installation Precautions
1. Always p rovide as m uch d istan ce as p ossible between brakin g
m odulato r un it an d rad io, an d between brakin g m odu lator un it
an d rad io an ten n a an d associated an ten n a tran sm ission lin e.
Before in stallin g radio, determ in e locat ion of brakin g m odulator
un it in veh icle. Dep en din g on m ake an d m odel of veh icle,
brakin g m odu lator un it m ay be located in tru n k, un der
dash board, in en gin e com p artm en t, or in so m e o th er cargo area.
If you can n ot d et erm in e location of brakin g m od ulat or u n it,
refer to veh icle service m an u al or con tact a d ealer for th e
particular m ake of veh icle.
2. If brakin g m odulat or u n it is lo cated on left side of th e veh icle,
in stall rad io on righ t sid e o f veh icle, an d con versely.
3. Rou te all rad io wirin g in clu d in g an ten n a tran sm ission lin e as far
away as possible from brakin g m odu lator un it an d associated
brakin g system wirin g.
4. Never activate rad io tran sm itt er wh ile veh icle is in m otion an d
veh icle tru n k lid is op en .
Braking System Tests
Th e followin g proced u re ch ecks for th e m o st com m on typ es of
in terferen ce th at m ay be cau sed to veh icle brakin g system by a radio
tran sm itter.
1. Run veh icle en gin e at idle sp eed an d set veh icle tran sm ission
selector to PARK. Release brake pedal com p letely an d key radio
tran sm itter. Verify th at th ere are n o un usu al effects (visual or
audible) to veh icle ligh ts or oth er electrical eq u ip m en t an d
accessories wh ile m icro p h on e is NOT bein g sp oken in to.
2. Rep eat step 1. excep t d o so wh ile m icrop h on e IS bein g spoken
in to.
3. Press veh icle brake pedal sligh tly ju st en ou gh to ligh t veh icle
brake ligh t(s). Th en rep eat st ep 1. an d step 2.
4. Press th e veh icle brake ped al firm ly an d rep eat step 1. an d step 2.
!
W A R N I N G
!
vii

5. En su re th at th ere is a m in im u m of two veh icle len gth s between
fron t of veh icle an d an y object in veh icle’s forward p ath . Th en ,
set veh icle tran sm ission selector to DRIVE. Press brake p edal just
far en ough to stop veh icle m o tion com p letely. Key radio
tran sm itter. Verify th at veh icle does n ot start to m ove wh ile
m icrop h on e is NO T bein g spoken in to.
6. Rep eat step 5. excep t d o so wh ile m icrop h on e IS bein g spoken
in to.
7. Release brake p edal com pletely an d accelerate veh icle to a sp eed
between 15 an d 25 m iles/25 an d 40 kilom eters per h ou r. En su re
th at a m in im u m of two veh icle len gth s is m ain tain ed between
fron t of veh icle an d an y object in veh icle’s forward p ath . Have
an ot h er person key radio tran sm itter an d verify th at veh icle can
be braked n orm ally to a m od erate stop wh ile m icroph on e is NO T
bein g sp oken in to .
8. Rep eat step 7. excep t d o so wh ile m icrop h on e IS bein g spoken
in to.
9. Release brake p edal com pletely an d accelerate veh icle to a sp eed
of 20 m iles/ 30 kilo m eters per h our. En su re th at a m in im um of
two veh icle len gth s is m ain tain ed between fron t of veh icle an d
an y object in veh icle’s forward p ath . Have an oth er p erson key
rad io tran sm itter an d verify th at veh icle can be braked p roperly
to a sudden (pan ic) sto p wh ile m icrop h on e is NOT bein g spoken
in to.
10. Rep eat step 9. excep t d o so wh ile m icrop h on e IS bein g spoken
in to.
11. Rep eat step 9. an d step 10. excep t use a veh icle speed of 30 m iles/
50 kilom eters per h ou r.
POTENTIALLY
EXPLOSIVE
ATM OSPHERES
Turn o ff you r two-way radio wh en you are in an y area with a po ten -
tially exp losive atm osp h ere, un less it is a rad io type especially q u ali-
fied for u se in su ch areas (for exam p le, Factory Mutu al App ro ved ).
Sp arks in a p o ten tially exp losive atm osp h ere can cau se an explosion
or fire resultin g in bod ily in ju ry or even d eath .
Areas with poten tially exp losive atm osp h eres in clu d e fuelin g areas
su ch as: below d ecks on boat s; fu el or ch em ical tran sfer o r storage
facilities; areas wh ere th e air co n tain s ch em icals or p articles, such as
grain , dust or m etal p owders; an d an y o th er area wh ere you wo u ld
n orm ally be ad vised to turn off you r veh icle en gin e. Areas with
poten tially exp losive atm osp h eres are often bu t n ot always posted .
To avoid p ossible in terferen ce with blast in g operation s, turn off your
rad io wh en you are n ear electrical blastin g cap s, in a blastin g area, or
in areas posted: “Turn o ff two-way radio”. Obey all sign s an d in stru c-
tion s.
viii

1
Int roduct ion
Th is p ublication p rovid es field level troublesh ootin g an d rep air
in stru ct ion s for Am plifier-Lou d speaker Motorola Kit HSN4035. Th e
Am p lifier-lou dspeaker is a com p on en t o f th e Du al Co n trol Head
con figuration of th e MCS 2000 Mobile Rad io. Troublesh ootin g an d
repair of th e Am plifier-Lou d speaker are lim ited t o localizin g an d
repairin g a fault to on e of th e followin g:
• Volu m e con trol poten tiom eter an d its associated wirin g
• Lou dspeaker an d its asso ciated wirin g
• Circu it card assem bly (PCB) an d its associated wirin g
• 9-Foot (Po wer an d sign al) Cable
Provided in th is pu blicat ion for th e Am p lifier-Lou d speaker are th e
followin g p rocedu res in t h e o rder listed:
• Test set u p
• Test an d Trou blesh ootin g
• Disassem bly
• Rep air
• Reassem bly
Reference
Publicat ions
Motoro la Publication 68P81088C64 - Op eratin g In st ru ction s Man u al
Adden dum for Motorola MCS 2000 Du al Con trol Head Radio
Motoro la Publication 68P81109C63 - In stallation In stru ction s for
Motoro la MCS 2000 Du al Con tro l Head Radio
Motoro la Publication 68P81109C64 - Retrofit In stru ction s for
Motoro la MCS 2000 Rad io, Sin gle Con tro l Head to Du al Con trol Head
Con versio n
Motoro la Pu blicat ion 68P02058U20 - GM 900, MC 900, GM 1200,
MCX 1200, GM 2000, MCS 2000, MC 2100 Mobile Rad ios; In stallatio n
In stru ction s; All Freq u en cies
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.
Note

2
Test Set up 1. Secu re th e test eq u ip m en t listed in Table 1 or its equivalen t s.
2. Refer to Figu re 1 an d Table 2 on page 3 an d assem ble a test
con n ector for th e am p lifie5-lou d speaker as follo ws:
1. Crim p a 24-in ch len gth of stran d ed in sulated 18 AWG
h oo kup wire on to each of th e fou r fem ale con n ect or p in s.
2. In sert fem ale con n ector p in s in to p osition s 1, 2, 4, an d 5 in
Molex con n ecto r bo d y.
3. Tag free en d of wires as sh own in Figure 1.
3. Turn on p ower su p p ly, set p ower supp ly o u tp u t voltage to 13.8
VDC, an d set cu rren t lim it to 1.5 Am p eres. Th en tu rn off p ower
su pply.
4. Con n ect p ositive (+) term in al of p o wer supply to p in 5 of test
con n ector assem bled in step 2 above. Co n n ect n egative t erm in al
of power su p p ly to pin 4 of test co n n ecto r.
5. Turn on fun ction gen erator an d set it u p to gen erate a 1-kHz
sin ewave sign al with an am p litu de of 230-m V rm s an d a DC offset
of +4.4 Vdc.
6. Con n ect fu n ction gen erator ou tpu t to pin s 1 an d 4 (ret u rn ) o f t est
con n ector.
7. On am p lifier-loudspeaker to be tested, set Volu m e p oten tiom eter
kn ob to m ech an ical m id ran ge.
8. Plu g co n n ecto r o n am p lifier-loudspeaker 9-foot cable in to test
con n ector. Th en en ergize power supply.
Table 1 Test Equipm ent and Special Tools
Description M anufacturer M odel No./ Part No. Notes
Test Connector Fabricated at Test
Facility
See Figure 1 and Table
2 Below
DC Power Supply Hewlett Packard 6200 Must be capable of
providing 13.8-Vdc, 2.0
Amperes regulated
power.
Audio Analyzer Hewlett Packard 8903B
Function Generator Hewlett Packard 3311A Must be capable of
providing a 1-kHz test
signal with a +4.4-Vdc
offset .
Digital Multimeter Fluke 27
Oscilloscope Tektronix TDS 544A or 2430A
Resistor, Fixed, 4-Ohms (+/- 20
percent) 20 Watts
Dale H25, 4-Ohms See note at end of this
table

3
Test Procedure Th e test proced u re for th e am plifier-lou dsp eaker is presen ted in th e
test an d troublesh ootin g p roced u res pyram id d iagram , Figure 2.
Troubleshoot ing
Procedures
Th e trou blesh ootin g p rocedu re fo r th e am p lifier-loudsp eaker are
presen ted in th e test an d trou blesh ootin g p rocedu res pyram id
diagram , Figu re 2 on p age 4.
Roto-Torq Adjustable Torque
Screwdriver
Motorola Kit RSX-4043A
Spanner Nut Bit for Adjustable
Torque Screwdriver
Motorola 66-80371B34
Table 2 Test Connector Com ponents
M otorola Part No. Description 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 Equipm ent and Special Tools
Description M anufacturer M odel No./ Part No. Notes
M otorola Test Box RKN4460( ) can be substituted for the
4-Ohm 20-Watt fixed resistor specified in table 1. W hen pins 2
and 6 of female connector on back of test box are shorted
together and SPKR/ LOAD switch on top of test box is set to
LOAD, a suitable 4-Ohm 20-Watt resistance is available
between the two EXTERNAL LOAD jacks on top of test box.
Note
Audio Input
Ground
3
2
1
Analog Ground
B+
6
5
4
Figure 1 Test Connector Schem atic/W iring Diagram
MAEPF-26585-O

4
Perform Procedure Titled
Replacing Volume
Potentiometer, If That Does
Not Repair Fault, Perform
Procedure Titled
Replacing PCB.
Any
Sound Output
From
Amplifier-Loudpeaker?
Is
Sound Output
Undistorted and About
Normal Listening
Volume?
Does
Volume Potentiometer
Adjust Sound Output
Smoothly Over
its Entire Range?
Is Sound
Output Undistorted
At All Settings
of Volume
Potentiometer?
Is
13.8Vdc
Present Between Terminals
TP12 (+) and TP13 (-)
on PCB?
Is
1-kHz 230mVrms
Signal Present Between
TP1 and TP2 (Rtn)
on PCB?
Is
1-kHz 220mVrms
(440mV p-p) Signal Present
Between TP7 and
TP2 (Rtn) on
PCB?
Is
1-kHz 180mVrms
(320mV p-p) Signal Present
Between TP8 and TP2 (Rtn)
on PCB?
(Note 2)
Is
1-kHz 3.2Vrms (8.8V p-p)
Signal Present Between
TP10 and TP11 on PCB
(Note 3)?
Is
Harmonic Distortion
of Signal Between TP10 and
TP11 5% or Less for
All Settings of
Volume Pot.?
No
No
No
No No
Yes
Yes
Yes
Yes Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
MAEPF-26581-O
1. Turn Off Power Supply.
2. Disconnect One Speaker
Lead at Speaker End.
3. Connect a 4-Ohm Resistor
Between TP10 and TP11
on PCB.
4. Turn On Power Supply.
1. Connect Distortion 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 Replacing PCB.
Perform Procedure
Titled Replacing PCB.
Perform Procedure Titled
Replacing Volume
Potentiometer.
If That Does Not Repair
Fault, Perform Procedure
Titled Replacing PCB.
Rotate Volume
Potentiometer Knob Slowly
From Fully Counterclockwise
Position to Fully
Clockwise Position.
Amplifier-Loudspeaker
Is In Good
Operating Condition.
End of Test.
1. Turn Off Power Supply.
2. Perform Procedure Titled
Separating Front and
Rear Housings.
3. Disconnect One Speaker
Lead at Speaker End.
4. Connect a 4-Ohm
Resistor Between TP10
and TP11 on PCB.
5. Turn On Power Supply.
Notes:
1. All specified voltage, current, and resistance values have a tolerance
of 10% unless indicated otherwise.
2. Signal between TP8 and TP2 has a DC offset of approximately +160mV.
3. Signal between TP10 and TP11 has a DC offset of approximately +6.1V.
START TEST
Figure 2 Am plifier-Loudspeaker Test and T roubleshooting Procedures

5
Repair Procedures
Initial Disassembly 1. Refer to Figure 3. Push t ips of two id en tical or sim ilar sm all flat
blad e screwdrivers in to open in g between fron t an d rear h ou sin gs.
2. Pu sh both screwd river blades sim ultan eously away from speaker to
pop u p an d release fron t h ou sin g from rear h ousin g.
3. Pu ll fron t h ousin g off of rear h ou sin g carefully, wh ich will exp o se
sp eaker con e.
4. Grasp speaker at its edges an d lift it up an d out of rear h ousin g.
Leave wires (black Zipcord) co n n ected t o PCB an d set sp eaker face
down n ext to righ t sid e of rear h ou sin g.
!
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 Separating Front and Rear Housings
Dimple
Gasket
Rear
Housing
Front
Housing
MAEPF-26667-O

6
Replacing Speaker
Repair Part s Required Th e rep air p arts req u ired for rep lacin g th e speaker in th e Am p lifier-
Lou dsp eaker are listed in Table 3.
Replacement Procedure 1. Perform p rocedu re tit led Initial Disassem bly on page 5.
2. Refer to Figure 4 on p age 8. Usin g a solderin g iron , discon n ect
black (Zip cord ) wires
at speaker end of wires th at con n ect speaker to
PCB. Discard old sp eaker.
3. Usin g a sold erin g iron , con n ect wires discon n ected in step 2 to
term in als o f n ew speaker, Motorola p art n o. 5085891B01. Eit h er
wire can be co n n ected to eith er speaker t erm in al.
4. Perform p rocedu re tit led Final Reassem bly on page 15 .
Replacing Printed
Circuit Board
Repair Part s Required Th e rep air parts req u ired for replacin g th e prin ted circu it board (PCB)
in th e Am plifier-Lou d speaker are list ed in Table 4.
Table 3 Repair Parts Required for Speaker Replacem ent
Motorola Part
No. Description Quantity Required
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
Table 4 Repair Parts Required for Printed Circuit Board Replacem ent
Motorola Part
No. Description Quantity
Required
0105956V07 Printed Circuit Board 1
1110022A55 Thermal Grease As Required
Note In step 2 , disc o n n ec t sp eake r w i res fro m sp eak er e n d
o n ly (i.e., do n o t disco n n ect sp eaker w ires fro m PCB).

7
Replacement Procedure 1. Perform p rocedu re tit led Initial Disassem bly on page 5.
2.Refer to Table 5 an d Figure 4 on page 8. Usin g a solderin g iro n ,
discon n ect t h e followin g 11 wires
at PCB .
1. Th e six 9-foot cable wires (bare, black, wh ite/ black, blue, red ,
wh ite) from TP1 th rou gh TP6
2. Th e th ree Volum e p o ten tiom et er leads (blu e, gray, wh ite)
from TP7 th rough TP9
3. Th e two speaker wires (black Zipcord co n d u ct ors) from TP10
an d TP11
3. Refer to Figure 5 on p age 9. Rem ove th e fou r M3x0.5 m ach in e
screws th at attach PCB to in side of rear h ousin g. Save screws for
use in step 6.
4. Carefu lly lift PCB straigh t up an d out of rear h ousin g.
5. Apply a th in layer of th erm al com p oun d, Motorola part n o.
1110022A55, to sh ad ed area sh own in Figure 5.
6. Moun t n ew PCB to in side of rear h ou sin g u sin g th e fou r M3x0.5
m ach in e screws rem oved in step 3. Torq ue screws t o 7.5 in ch
poun ds (0.848 Newton m eter).
7. Refer to Table 5 an d Figure 4 on page 8. Usin g a solderin g iron ,
recon n ect th e 11 wires to th e new PCB .
8. Perform p rocedu re tit led Final Reassem bly on page 15.
3285203C01 Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
1
1110027B23 Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
As Required
Table 5 Printed Circuit Board Connections
Wire Color From/To Component PCB Terminal
Number
Blue 9-Foot Cable TP1
Black 9-Foot Cable TP2
White/Black 9-Foot Cable TP3
Bare 9-Foot Cable TP4
Table 4 Repair Parts Required for Printed Circuit Board Replacem ent
Motorola Part
No. Description Quantity Required
Note
In step 2, do n o t d iscard an y o f th e w ires after th ey are
discon n ected. All w ires are reused.

8
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. 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 Com ponents
MAEPF-26669 -O
TP4
TP9
TP8
TP7
TP11TP10
TP1
TP2
TP5
TP3
TP6

9
MAEPF-26577-O
Circuit
Board
Thermal Grease
Location
(Shaded Area) Rear
Housing
Figure 5 Removing and Installing PCB

10
Replacing Volume
Potentiometer
Repair Part s Required Th e rep air p arts req u ired for rep lacin g th e Volum e Pot en tiom eter in
th e Am plifier-Loudspeaker are listed in Table 6.
Replacement Procedure 1. Perform p rocedu re tit led Initial Disassem bly on page 5.
2. Usin g solderin g iron , discon n ect th e th ree wires (blue, gray, wh it e)
from th e th ree term in als of Volum e p oten tiom eter.
3. Refer to Figure 6 on p age 11. Pull kn ob st raigh t off of Volum e
poten tio m eter sh aft.
4. Usin g an ad ju stable t orq u e screwd river, Mo torola kit RSX4043( )
with a sp an n er wren ch tip, Motorola part n o. 6680371B03,
rem ove span n er n u t th at retain s Vo lu m e poten tiom et er in rear
h ou sin g.
5. Grasp Volum e p oten tio m et er from back an d p u ll it carefully
straigh t back an d ou t of rear h ou sin g. Discard wave wash er, wh ich
falls off poten tiom eter sh aft wh en p oten t iom eter is pulled ou t of
rear h ou sin g.
Table 6 Repair Parts Required for V olum e Potentiom eter Replacem ent
Motorola Part
No. Description Quantity
Required
1805629V05 Volume Potentiometer 1
3205082E01 O-Ring, Volume Potentiometer
(The smaller of the two O rings)
1
0402838X01 Wave Washer 1
0205609X01 Spanner Nut 1
3205082E48 O-Ring, Spanner Nut
(The larger of the two O-rings)
1
3285203C01 Gasket 1
1110027B23 Gasket Lubricant 1
3285968B01 Gasket (Required for Final Assembly of
Amplifier-Loudspeaker)
1
1110027B23 Gasket Lubricant (Required for Final
Assembly of Amplifier-Loudspeaker)
As Required
Alpha FIT-221
-1/16
Hookup Wire, 24 AWG, Stranded As Required
Alpha UL1007
(Grey, Blue,
and White)
Heat Shrinkable Sleeving, 0.062 in. I.D.,
0.375-in.long
As Required

11
6. Refer to Figu re 7 on page 12. Carefu lly slide a n ew O-rin g,
Motoro la part n o. 3205082E01, over sh aft an d th read ed bush in g
un til it is flat on face of n ew po ten tiom eter.
7. Refer to Figure 6. In sert n ew poten tiom eter in to h ole in rear
h ou sin g. Be cert ain th an key en gages in to slot in rear h ou sin g.
8. Place a n ew wave wash er, Motorola Part No. 3205082E48, o ver
th read ed sh aft of n ew p oten t iom eter.
9. Refer to Figu re 7 on page 12. In stall a n ew O -rin g. Motoro la Part
No. 3205082E48, on a n ew span n er n u t, Motoro la Part No.
0205609X01.
10.Th read span n er n ut o n to th read ed sh aft of n ew po ten tiom eter
un til it is h an d tigh t .
11.Usin g an ad ju stable torq u e screwdriver, Motorola kit RSX4043( )
with a sp an n er wren ch tip, Motorola part n o. 6680371B03,
tigh ten span n er n ut t o a torq u e of 8-in ch -p o u n d s (0.91 Newton
Meter).
12.Usin g solder iron , con n ect wires to n ew Volu m e poten tiom eter as
sh own in Figu re 8 on page 12.
13.Perform p roced u re tit led
Final Reassem bly on page 15.
MAEPF-26573-O
Volume
Potentiometer
Key
Wave
Washer Volume
Knob
Spanner
Nut
Figure 6 Rem oving V olum e Potentiom eter