PRODUCT MAINTENANCE PRODUCT MAINTENANCE

BULLETIN NO: FM-587-JF

ZX A-Series:
EQUIPMENT: Part No: 773-5000-017
ZX500, ZX1000, ZX2000 and ZX3500
DATE: Oct 2010

UNITS AFFECTED: Built before June 2010

PAGES: 4
PURPOSE: Controller Raise & Lower Buttons

Review the following documentation thoroughly prior to implementing.

ATTENTION:
The Following Procedure Must Be Carried Out By An Electrically Competent Person Using
Appropriate ESD and Soldering Procedures,
“Electrically Competent Person” as defined in the IEC-215 Safety Standard

It has come to our attention that several customers are seeing the output power of their ZX A-
Series transmitter spontaneously dropping to zero. This symptom has been diagnosed to a
contact failure of the mechanical pushbutton switch itself. After investigating this issue, we
have seen that the switches seem to develop a surface film from contaminants inside the switch
that will eventually interrupt the N.C. (Normally Closed) contacts. In addition to the
recommended cleaning; a gasket is being added to protect the push button switches from
additional contamination.

Time Required: 30 Minutes

Parts Required:
(1) 0550115006 *CLEANER CONTACT 6OZ SPRAY (Caig Labs Deoxit DN5S-6N)
(1) 9435567532 ZX PANEL GASKET
(10) 3560087000 CABLE TIE TYRAP (Mini 3.9” Panduit PLT1M-C or equivalent)

Tools Required: Technician’s hand tools: Phillips head screw driver, small wrenches,
Wire Clipper

Procedure:

1. Remove and lockout power to the transmitter.

2. Open the front door of the transmitter to gain access to the transmitter controller.

3. Locate the brace bar at the back edge of the controller board. Carefully free all the cables
from it by cutting and removing all cable ties with wire clippers. Do not cut the cables or
wires.

4. Remove all cable connections to the controller board at these connectors: (See Fig. #1)
a. J12
b. J11
c. J10
d. J09
e. J07
f. J06
g. J05
h. J04
i. J01

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FM-587-JF
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 Figure #1 Bar Brace Removed, Unplug circled connections.

5. Remove brace bar and two standoffs as well as 3 Phillips head screws from
the controller card that hold it to the panel.

6. You should now be able to remove the controller from the transmitter.

7. Squirt a single burst of the contact cleaner up under each of the 5 switch caps and let it run
down the alignment shaft into the switch body. After several moments, exercise the
switches 4-5 times. (See Fig. #2)

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FM-587-JF
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 Figure #2 Spraying cleaner under a Switch Cap.

8. Next with the Controller board laying on a flat surface apply the provided gasket overlay
(Harris p/n 943-5567-532 to the push button and LED side of the board. (See Figure #3).
Make sure all of the LED’s are straight up and each one can be seen through the holes in
the gasket material. The board can then be returned to its location in the transmitter and
operation continued.

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FM-587-JF
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 Figure #3 New foam gasket in place on the controller board, left. The foam, right.

9. Repeat steps 1-5 in reverse order. Procedure complete. No alignments or adjustments

should be required.

10. In the event a new controller board must be installed the operator can follow the set up
instructions from Section 5 Maintenance and Alignment, paragraph 5.5.4 Transmitter
Controller PCB

This completes the modification.

Service Bulletins are also available on the Harris Web Site at http://www.broadcast.harris.com

Should you have any questions relating to this bulletin, please contact:

Radio Field Service PO Box 4290 Quincy, Illinois 62305

tsupport@harris.com, Fax +1 217 221-7086, Tel +1 217 222 8200

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FM-587-JF
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