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1. Keeler Wireless 2 Headband amp Charger Service Manual d ALWAYS READ THE INSTRUCTIONS A HALMA GROUP COMPANY Keeler Limited Clewer Hill Road Windsor Berks United Kingdom SL4 4AA Tel No 44 0 1 753 857177Fax No 44 0 1 753 830247 Issue A 07 07 2008 2415 P 7013 Keeler CONTENTS Introduction Service Principles Precautions Headband Disassembly Remove Control Unit Open Control Unit Control PCB Cable Assy Headband Reassembly Rebuild Control Unit Replace Control Unit Final Reassembly Spares Spare Parts List Headband Main Unit Spare Parts List Control Box Charger Disassembly Replacements Replace PCB Assy Replace Battery Contact PCB Assy Replace LED PCB Assy Reassembly Spares Spare Parts List Issue A 07 07 2008 Wireless 2 Service Manual 2415 P 7013 oOo N OO A A U 10 11 12 13 14 15 16 16 17 17 17 18 18 19 20 Wireless 2 Service Manual Keeler 2415 P 7013 Introduction This manual covers servicing of both the Wireless 2 Headband and Wireless 2 Charger unit Service Principles Where a sub assembly is specified the individual parts are not available as the assembly of the sub assembly involves the use of specific tooling jigs and adhesives Issue A 07 07 2008 Page 1 Wireless 2 Service Manual Keeler 2415 P 7013 Tools Required The tools required will be in a standard electro mechanical toolkit Issue A 07 07 2008 Page 2 Wireless 2 Servi
2. Issue A 07 07 2008 Page 8 Wireless 2 Service Manual Keeler 2415 P 7013 Headband 1 Carefully remove the Comfort Pad 15 Double sided adhesive tape is applied during assembly to retain the pad in place until the Control Box is fitted Remove 1 off M4 x 25 Pozi Screw 17 from the Headband Adjuster joining it to the Extension Bar 9 It will now be possible to remove both sides of the Headband from the Mounting Plate 10 Feed both sides of the replacement Headband into the Mounting Plate Fit the Adjuster through the back of the Mounting Plate 10 and fit it to the Extension Bar 9 with 1 off M4 x 25 Pozi Screw 17 Ensure that the Extension Bar is fully engaged with the Adjuster Meshing of the Adjuster with the Headband will be adjusted after the Control Box has been fitted Issue A 07 07 2008 Page 9 Wireless 2 Service Manual Keeler 2415 P 7013 Reassembly Rebuild Control Unit 1 Check that the Control Unit PCB 8 is fitted and screwed down 2 Check that the wiring in the Control Unit is correct according to the diagram below and that all soldered joints are sound Wires from Vantage Cable Assembly 1202 P 5832 3 Offer the Front Moulding 3 to the Rear Moulding 4 ensuring that the Cable Strain Relief 1 is correctly positioned in the cut out 4 Refit the Front Moulding 3 using 4 off M2 x 20 Csk PT screws through the PCB end 2 at the end and 2 in the middle and 2 off
3. 1 off M2 x 8 Pozi Pan Head PT Screw 5 and 1 off M2 Washer 19 Ensure that the Ferrite Beads 10 are positioned under where the PCB 8 will sit 10 Fit the PCB 8 to the Rear Moulding using 2 off M2 x 8 Pozi Pan Head PT Screws 5 Issue A 07 07 2008 Page 7 Wireless 2 Service Manual Keeler 2415 P 7013 Cable Assy 1 Remove 2 off M2 x 8 Pozi Pan Head PT Screws 5 holding the PCB 8 to the Rear Moulding Assembly 4 Remove 1 off M2 x 8 Pozi Pan Head PT Screw 5 and 1 off M2 Washer 19 from the Cable Retainer on the Cable 12 from the Dimmer Block Carefully unsolder 1 off Black and 1 off Red wire from the Contacts on the Rear Moulding Assembly 4 Carefully unsolder 4 wires from the Control PCB 8 Fit the replacement cable assembly ensuring that 5 1 The Cable Strain Relief 1 is fitted with the battery logo facing the plug on the Dimmer block end of the cable 5 2 Cable Retainer 12 is fitted 5 mm from the end of the cable sheath as shown below 5 3 The Ferrite bead 10 is threaded over the 4 wires 6 Solder the wires to the PCB as shown on the diagram above Solder 1 off Black and 1 off Red wire to the Contacts on the Rear Moulding Assembly Fit the Cable Retainer 12 with its cable to the Rear Moulding 4 using 1 off M2 x 8 Pozi Pan Head PT Screw 5 and 1 off M2 Washer 19 Fit the PCB to then Rear Moulding using 2 off M2 x 8 Pozi Pan Head PT Screws 5
4. 6 Sp73 00002 1945 P 5014 1945 P 7021 EP19 70011 EP39 70335 EP39 70336 1945 P 5015 WP13 01008 SP13 05089 SP73 00003 EP79 40899 1945 P 7020 Issue A 07 07 2008 Wireless 2 Service Manual 2415 P 7013 Description Charger PCB Mounting block Battery Contact PCB Assy Keeler Nameplate M2 5 x 10 Pozi Pan Hd Screw M3 x 8 Pozi Pan Hd PT Screw Charger LED PCB Assy Charger Main PCB Assy Charger Base Moulding Retaining Moulding Retaining Spring Charger Top Assy M3 Plain Washer M3 x 5 Pozi Pan Hd PT Screw M3 x10 Pozi Pan Hd PT Screw Cable Tie Fixings Kit Marked above Page 20
5. 8 and 2 off M2 5 x 10 Pozi Csk PT Screws 6 holding the Control Unit Assembly 2 to the Rear Cover Plate 10 Issue A 07 07 2008 Page 5 Wireless 2 Service Manual Keeler 2415 P 7013 Open Control Unit 1 Remove 4 off M2 x 20 Pozi Csk PT Screws 7 and 2 off 4 off M2 x 8 Pozi Csk PT Screws 6 from the rear of the Control Unit 2 Lift off the Front Cover Moulding 3 Issue A 07 07 2008 Page 6 Wireless 2 Service Manual Keeler 2415 P 7013 Replacements Control PCB 1 Remove 2 off M2 x 8 Pozi Pan Head PT Screws 5 holding the PCB 8 to the Rear Moulding Assembly 4 Remove 1 off M2 x 8 Pozi Pan Head PT Screw 5 and 1 off M2 Washer 19 from the Cable Retainer on the Cable 12 from the Dimmer Block Lift out the PCB 8 4 Carefully unsolder 1 off Black and 1 off Red wire leading from the Contacts Wires from Vantage Cable on the Rear Moulding Assembly from the PCB Carefully unsolder 10 wires from the Control PCB 8 Black Wire Yellow wire Assembly 1202 P 5832 Solder the 10 wires to the replacement PCB as shown on the above diagram ensuring that the 4 wires from the Dimmer Cableform 12 pass through the Ferrite Bead 10 and still have the Strain Relief 1 and Tie Wrap 9 are still in place Solder 1 off Black and 1 off Red wire from the Contacts on the Rear Moulding Assembly to the PCB 8 Fit the Tie Wrap 12 with its cable 9 to the Rear Moulding 4 using
6. M2 x 8 Csk PT Screws at the other end Issue A 07 07 2008 Page 10 Wireless 2 Service Manual Keeler 2415 P 7013 Replace Control Unit 1 Check that the Comfort Pad 15 is fitted over the Headband Rear Cover Plate 10 If not apply 2 pieces of double sided adhesive tape 11 as shown and fit the Comfort Pad 15 using the adhesive tape to temporarily hold the Pad in place 2 Offer the Control Box Assembly 2 onto the Headband Rear Cover Plate 10 ensuring that the cable is pointing upwards 3 Fit 2 off M2 5 x 25 Csk Pozi PT Screws 8 through the PCB side of the Control Unit and 2 off M2 5 x 10 Csk Pozi PT Screws 6 through the Battery side to fix the Control Unit 2 to the Headband Rear Cover Plate 10 4 Refit the Keeler Label 14 to the face of the Control Unit 2 Issue A 07 07 2008 Page 11 Wireless 2 Service Manual Keeler 2415 P 7013 Final Reassembly 1 Fit the Detent Plate 7 to the front of the Control Unit ensuring that it fits over the 2 pegs on the front of the Control Unit 2 2 Ensure that 2 sides of the Headband are equally fitted inside the Headband Rear Cover Plate 10 by gently pushing the Extension Bar 9 back into the Comfort Pad 15 to disengage the Adjuster with the teeth on the sides of the Headband 3 Pull the sides of the Headband out as far as possible and move them about gently until they re engage with the Adjuster at the end of their travel 4 Refit the Headband Knob 12
7. ce Manual Keeler 2415 P 7013 Precautions Care should be taken to carry out any repair work on a clean soft surface to minimise damage to the outside of the unit Solvents should not be used for cleaning Anti static precautions must be used when servicing the electronic components in this product Issue A 07 07 2008 Page 3 Wireless 2 Service Manual Keeler 2415 P 7013 Headband Disassembly It is easier to work if the Optics Assembly and Browbar are removed by unscrewing the 2 knobs attaching the Browbar to the Headband and unplugging the cable from the Dimmer Block If the Control Unit is permanently wired to the Dimmer Block it is not recommended to disconnect the cable but to carefully protect the Optics Assembly whilst carrying out servicing The first level of disassembly is required for most repairs Issue A 07 07 2008 Page 4 Wireless 2 Service Manual Keeler 2415 P 7013 Remove Control Unit 1 Remove 2 off M5 x 4 Pozi Pan head Screws 5 from the Clamp 4 on the Headband 2 Using a pointed blade under the edge of the Adhesive Bezel 13 carefully lift the Bezel off 3 Remove 1 off No 8 x 12 7 Pan Head Screw 3 from the centre of the Knob 12 4 Remove the Knob 12 and Detent Plate 7 5 Using a pointed blade under the edge of the Keeler Label 14 carefully lift the Label off exposing the Screws holding the Control Unit to the Rear Cover Plate 10 6 Remove 2 off M2 5 x 25 Pozi Csk PT Screws
8. ead Screws Plug the connector onto J3 on the main PCB Tidy the wires using 1 off Tie Wrap 22 Issue A 07 07 2008 Page 17 Wireless 2 Service Manual Keeler 2415 P 7013 Replace LED PCB Assy 1 Unplug the appropriate connector from the main PCB 2 Remove 1 off M3 x 8 Pozi Pan Head Screw 5 3 4 Place the replacement LED PCB Assy 6 into position and fix with 1 off Remove the old LED PCB Assy 6 M3 x 8 Pozi Pan Head Screw 5 Tidy the wires using 1 off Tie Wrap 22 Reassembly 1 2 Check that the 3 connectors J1 J2 J3 are correctly connected Place the Main PCB Assy 7 onto the main unit taking care to ensure that the Contact Springs are not damaged and move freely in their cut outs Fix the Main PCB 7 using 2 off M3 x 8 Pozi Pan Head Screw 5 4 Fit the Base Moulding 8 using 6 off M3 x 10 Pozi Pan Head Screw 21 Issue A 07 07 2008 Page 18 Wireless 2 Service Manual Keeler 2415 P 7013 Spares Spare parts can be supplied in accordance with the following list The parts indicated with are only available as part of the Fixings kit Current prices for spare parts are available from Technical Service Technical Service Keeler Ltd Clewer Hill Road Windsor Berks SL4 4AA Phone 44 0 1753 827110 Fax 44 0 1753 827114 Issue A 07 07 2008 Page 19 Keeler Spare Parts List ltem 1 oO oOo N oO oO A W N N po a a N N OQ O Part No EP39 70337 1945 P 7023 EP39 70334 SP72 5508
9. g Main Housing Rear Moulding Assy M2 x 8 Pan Head Screw M2 x 8 CSK PT Screw M2 x 20 Csk PT Screw Head Unit PCB Tie Wrap Ferrite Bead Vantage Cable Assy M2 Washer 2415 P 7013 Page 15 Wireless 2 Service Manual Keeler 2415 P 7013 Charger Disassembly 1 Remove 6 M3 x 10 Pozi Pan head Screws 21 fixing the Charger Base Moulding 8 to the main unit 2 Remove 2 off M3 x 8 Pozi Pan head Screws 5 holding the PCB 7 to the main unit 3 Lift off the PCB 7 taking care not to damage the Contact Springs mounted on the PCB and noting the wires connected to the PCB Issue A 07 07 2008 Page 16 Wireless 2 Service Manual Keeler 2415 P 7013 Replacements Replace PCB Assy 1 2 3 Carefully unplug the 3 connectors from the 2 LEDs 6 and the Battery Contact PCB 2 Take the replacement PCB Assy 7 and reconnect to the PCB 2 1 LED 2 to J1 2 2 LED 1 to J2 2 3 Battery Contact PCB to J3 Offer the PCB Assy 7 to the main unit taking care not to damage the Contact Springs attached to the PCB Replace Battery Contact PCB Assy 1 2 Unplug the connector from J3 on the main PCB 7 Remove 2 off M2 5 x 10 Pozi Pan Head Screws holding the Charger PCB Mounting block 1 to the main unit Locate the replacement Battery Contact PCB Assy 2 into the recess on the Charger PCB Mounting Block 1 Holding the 2 parts together offer them to the main unit and retain with 2 off M2 5 x 10 Pozi Pan H
10. using 1 off No 8 x 12 7 Pan Head Screw 3 5 Carefully refit the Knob Bezel 13 6 Refit the Strain Relief Clamp 4 over the Cable with Approx 90mm of cable between the Clamp 4 and the plug to the Dimmer Block Issue A 07 07 2008 Page 12 Wireless 2 Service Manual Keeler 2415 P 7013 Spares Spare parts can be supplied in accordance with the following list The parts indicated with are only available as part of the Fixings kit Issue A 07 07 2008 Page 13 Keeler Spare Parts List Headband Main Unit ltem 1 oN O oO A O 12 13 14 15 16 Part No 2099 P 5010 SP70 80024 EP39 70232 SP72 00003 SP72 50002 EP39 70324 SP72 50003 EP39 70328 EP29 59902 EP39 70327 EP39 70325 EP39 70317 EP39 70331 EP39 70344 1299 P 7198 Issue A 07 07 2008 Wireless 2 Service Manual Description Mk 2 Headband Assembly No8 x 12 7 Pan Head Screw Strain Relief Clamp M2 x 4 Pozi Pan Head Screw M2 5 x 10 Csk Pozi PT Screw Detent Plate M2 5 x 25 Csk Pozi PT Screw Extension Bar Headband Rear Cover Plate Headband Knob Knob Bezel Keeler Nameplate Comfort Pad Headband Top Knob Fixings Marked above and below 2415 P 7013 Page 14 Keeler Wireless 2 Service Manual Spare Parts List Control Box EP39 70316 EP29 59929 1299 P 7171 SP72 00004 SP72 00001 SP72 00006 EP39 70321 EP79 11115 EP79 10374 1202 P 5832 WP 12 01007 Issue A 07 07 2008 Cable Strain Relief Main Housing Front Mouldin
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