Equipment for Assembly

Fluke Multimeter 115 True RMS

Glue Ring Jig

Flathead screwdriver

60 Watt desk lamp

HIOS Cl 4000 Electric screw driver

Anti-static table cover

OverviewAssembly of front panel

Place ring on panel Place keypad on panelPlace speaker on panel

Final AssemblyInsure the foam pad is in place on the solar panel which is soldered to the PCBConnect speaker wires to Molex connector on the PC boardPlace PCB dome, face down, in its place inside the front panelArrange speaker wires to right side of speaker Make sure the clear back panel is clean of all dust and dirtRemove plastic from solar panel and insert into clear back panelHinge clear back panel onto the front; lower into place; check to make sure snaps in placeSecure screws in bottom of back panelPlace under sun lamp; check voltage at the battery Molex connector in the back panel - should be between

4.5-5.2 voltsPlug battery into Molex connecterFold battery wires to the leftAdd ID card and slip door into place Screw door closed

Final inspectionPlug in player to charge; make sure LED lights upTurn on player and check that all buttons function as they shouldCheck for sound quality - no buzzing; replace speaker if necessaryUse ear buds; make sure there is audio in both earsCheck reset by pushing down volume/off togetherCheck that player is cosmetically cleanCheck ID card has correct informationCheck case color; make sure door logo is correct (paper work)Place in clear ziplock bag with appropriate instruction manual

Assembly of front panelPlace ring on panel

Place keypad on panel

Place speaker on panel

Prepare glue ringRemove ring from around glue pad, pinch both the pad and the ring and pull in different directions.

Place ring on panel

Step #1

Place ring, sticky side up, on the jig

Step #2

Align panel with top of jig; lay panel down flat; then, press down with both hands using equal pressure

Place keypad on PanelStep #1

Use your fingernail to peel off paper layer from around the keypad

Step #2

Make sure keypad cutouts line up with the screw posts; then, turn over to make sure you can not see any white edges showing

Place keypad on Panel

Step#3

When you are certain all is properly aligned, press down on edges making sure the keypad is sticking.

Step#4

Tap the panel to be certain it stays in place

Place speaker on panel

Step #1

Take paper layer off the glue ring using flathead screwdriver

Step #2Hold speaker by the wires in a 3 o'clock position; then press down gently

Step #3 Slide ID card between the

speaker and top panel wall. Also

check that speaker does not

cross the line where the PCB is

positioned

Final assembly Connect speaker wires to Molex connector on the PC board

Place PCB dome, face down, in its place inside the front panel

Arrange speaker wires to right side of speaker

Make sure the clear back panel is clean of all dust and dirt

Remove plastic from solar panel and insert into clear back panel

Hinge clear back panel together with the front panel, and snap into

place

Place under sun lamp; check voltage at the battery Molex connector

in the back panel - should be between 4.5-5.2 volts

Secure screws in bottom of back panel

Plug in battery Molex connecter

Fold battery wires to the left

Add ID card and slip door into place

Screw door closed

Plug your speaker into the Molex connecter

Gently plug the end of the wire connected to the speaker into the Molex connector on the PC board.

Place PCB dome, shiny side down, in its place inside the front panel, and arrange speaker wires to the right side of speaker

After placing the PC board face down in the panel, insure all wires are tucked to the sides of the speaker. It is recommended to use a flat head screw driver to achieve this.

Remove plastic from back Panel

While peeling the plastic, be sure not to touch the clear part of the cover

Examine clear back Panel for dust and dirt

Without touching the clear section, hold the panel up to a light to check for scratches or smudges

Remove plastic from solar panel and insert

Step #1

Peel plastic off front of solar panel without scratching it.

Step #2

Press the solar panel into the cover first, and press into place

Hinge clear back panel onto front, and lower into place

The inside wires should not rest on top of the audio jack or speaker molex connector. After hinging cover on the back, lay it down gently. When it is lined up, press down until it snaps into place

Be certain that Molex connector for the battery protrudes through back panel

Place under sun lamp; check voltage at the battery Molex connector in the back panel - should be between 4.5 - 5.2 volts

Step #2Place solar panel 10 cm (about a hands width) beneath a 60 Watt lamp

Step #1Set the Fluke Multimeter to DC/V

Read voltage at the battery Molex connector

Place the metal probes on the contact points while the unit is beneath the lamp. The readout should be between 4.5 - 5.2 volts

Screw on the back panel

Secure both screws on back of panel making sure not to strip out the screw posts

Plug battery into Molex connecter

Plug battery into connector, making sure it is facing the right direction. Fold wires to the left

Add ID card and slip door into place

Set card, ID side up, in place over the battery; then, slide door in place and secure with screw

Final inspection

Plug in player to charge; make sure LED lights up

Turn on player and check that all buttons function as they should

Check for sound quality - no buzzing; replace speaker if necessary

Use ear buds; make sure there is audio in both ears

Check reset by pushing down volume/off together

Check that player is cosmetically clean

Check ID card has correct information

Check case color; make sure door logo is correct (paper work)

Place in clear ziplock bag with appropriate instruction manual