3M™ Wireless Communication System Model XT-1

Headset Service Procedures – Using assemblies

Technical Bulletin - #140
The document below
Lists the 3M™ Wireless Communication System Model XT-1 headset assemblies available for servicing (with 3M OEM SKUs)
Describes the standard procedure for conducting break-fix and maintenance tasks on the 3M™ Wireless Communication
System Model XT-1 headset using readily available assemblies from 3M

Only 3M OEM parts (SKU‘s listed below) should be used for servicing. These procedures should be conducted in a repair center
facility.
.

3M™ Wireless Communication System Model XT-1 Headset Service Parts – Assemblies

3M™ Wireless Communication System Model XT-1 Headset Standard Break-Fix Service Procedures

1. Replacing the Ear Cup and/or Ear Pad and/or Head Pad and/or Microphone Windscreen.
2. Replacing the Inner Case Assembly, Outer Case Assembly, and Boom Microphone Assembly.
3. Replacing Battery Latch Parts, Battery Latch Spring, or Battery Holder PWA.
4. Replacing the Headband Assembly.
5. Replacing the Indicator LED Lens and the Programming Station IR Lens.
Replacing the Ear Cup and/or Ear Pad and/or Head Pad and/or Microphone Windscreen

Replacing the Ear Cup and/or Ear Pad

Tools Required: None
3M OEM Parts and SKUs:

Procedure:
1. To replace the ear cup or ear pad, use your fingers to twist and pull the ear cup
and ear pad together, from the speaker on the headset case. Ear Pad

2. Gently separate the ear pad from the ear cup. Ear Cup
Headset Speaker
Replace the damaged ear pad and/or ear cup with a new one and reassemble.

3. Align the assembled ear cup and ear pad with the headset speaker, then FIGURE 1
twist and press into place.

Replacing the Head Pad:

Tools Required: None

3M OEM Parts and SKUs:

Head Pad
Procedure:
1. To replace the head pad, use your fingers to peel the old pad away from the battery case.
Clean off all adhesive residue remaining on the surface.

2. Remove the protective backing from a new self-adhesive head pad and
press into place on the inside surface of the battery case. FIGURE 2-a

Replace Microphone Windscreen on the headset

Tools Required: None

3M OEM Parts and SKUs: FIGURE 2-b

Procedure:
1. Remove the old microphone windscreen from the headset. Microphone Windscreen

2. Install the replacement microphone windscreen from the manager’s kit by stretching the opening
of new windscreen and slide over Microphone.
Replacing the Inner Case Assembly, Outer Case Assembly, and Boom Microphone Assembly
FIGURE 3

Replacing the Inner Case Assembly

Tools Required:
1 - Small size Phillips screwdriver
1 - External retaining ring removal tool

3M OEM Parts and SKUs:

FIGURE 4
Procedure:
Important Note:
Be careful to avoid pinching wires between case halves when
reassembling the electronics case. Damaged wiring may cause the
headset to fail during use.
FIGURE 5

1. Make sure power is off and remove the battery from the headset as illustrated in Fig 3.

2. Remove the ear pad by using your fingers to pull the ear pad from the ear cup.
Then grasp the headset firmly in one hand, and pull the ear cup off the speaker
with the fingers of the other hand. See Fig 4.

3. To disassemble the electronics side of the headset begin by removing the three
screws shown in the illustration in Fig 5.

4. Carefully separate the inner and outer halves of the case assembly.
Support the Inner Case so the speaker cable is not strained.
Important Note:
It is important to disconnect the speaker from the main circuit
board as soon as the inner and outer case are separated to avoid
FIGURE 6
stress on the wires inside the sealed enclosure. Replace the entire
inner case assembly if the wires are broken at the speaker.

5. Remove the speaker wiring connector from the main circuit board. See Fig 6.

6. To install the new replacement Inner Case, connect the speaker wiring connector Speaker Wiring
Connector
on the speaker wires to the connector on the main circuit board.

7. Make sure the LED Lens is still in place. Otherwise, follow the procedure
Replacing the Indicator LED Lens to re-install the LED Lens.
FIGURE 7
8. Bring the two halves together and replace the screws as shown in Fig 5.

9. Reinstall the battery (Fig 7) and check operation of the headset prior to returning
it to regular operation.
Replacing Boom Microphone Assembly
Tools Required:
1 - Small size Phillips screwdriver
1 - External retaining ring removal tool
FIGURE 8
3M OEM Parts and SKUs:

Procedure:
1. Repeat steps 1-4 from the previous procedure Replacing Inner Case Assembly. Retaining Ring
PC Board
2. Disconnect Microphone Boom Assembly wires by pulling the connector off
the main circuit board. See Fig 8.

3. Locate and remove the retaining ring using the retaining ring tool. See illustration. Microphone
Assembly Connector
Important Note:
Make sure you set the retaining ring tool adjustment screw to Clip
limit how far the retaining ring is expanded. Unless this is done,
the retaining ring will stretch out of shape to a point where it will
not stay in its groove. Nylon Washer

4. Remove the clip, nylon washer and boom microphone assembly.

Boom Microphone Assembly

5. Install replacement boom microphone by performing steps 1-3 in reverse order.

6. Reinstall the battery and check operation of the headset prior to FIGURE 9
returning it to regular operation.

Replacing Outer Case Assembly

Tools Required:
1 - Small size Phillips screwdriver

3M OEM Parts and SKUs:

Procedure:
1. Replace the Outer Case Assembly as follows: FIGURE 10
a. Remove the boom microphone assembly as described in the previous
procedure and install it in the new replacement outer case.
b. Connect the connector on the boom microphone wires to the
connector on the main circuit board.
c. Reassemble the inner and outer case halves by bringing the two halves
together and replace the screws as shown in Fig 9.

2. Make sure the LED Lens is still in place. Otherwise, follow the procedure
Replacing the Indicator LED Lens to re-install the LED Lens.

3. Reinstall the battery (Fig 10) and check operation of the headset prior to
returning it to regular operation.
Replacing Battery Latch Parts (Battery Button, Battery Latch, or Battery Latch Spring)
and /or Battery Holder PWA (Printed Wiring Assembly) FIGURE 16

Replacing Battery Latch Parts

Tools Required:
1 - Number 0 Phillips Screwdriver
1 - Tweezers
1 - Small size Phillips screwdriver

3M OEM Parts and SKUs:

FIGURE 17

Procedures:
1. Make sure power is off and remove the battery from the headset. See Fig 16.

2. Disassemble the battery housing side of the headset by removing

screws as shown in the illustration. See Fig 17.

3. Carefully separate the two halves of the housing. See Fig 18-a.

4. Holding the battery half of the housing in one hand, carefully separate
the Battery Latch from the Battery Latch Button. See Fig 18-b.
NOTE: It may be necessary to compress the two retainer posts on FIGURE 18-a
the Battery Latch Button to release the Battery Latch.

5. Remove and set aside the two pieces that make up the button/latch assembly.

6. Locate the spring in the housing and remove it using a tweezers or

equivalent tool, to grasp and lift the spring up and away from the housing. See Fig 19.

7. Replace any broken Battery Latch parts (Battery Button, Latch, or Spring) Battery
Battery half
and reassemble onto the battery housing performing steps 1-6 in Cover
of housing
reverse order.

FIGURE 18-b

FIGURE 19 Battery Latch Button

Battery Latch Battery Latch Spring

Replacing Battery Holder PWA (Printed Wiring Assembly)
Tools Required:
1 - Number 0 Phillips Screwdriver
1 - Soldering iron
1 - Small size Phillips screwdriver
3MTM ¼’’ Polyimide Film Tape (SKU# 70-0160-3918-5)
FIGURE 20
3M OEM Parts and SKUs:

Procedure:
1. Make sure power is off and remove the battery from the headset. See Fig 16. Battery Holder PWA

2. Disassemble the battery housing side of the headset by removing

screws as shown in the illustration. See Fig 17.
Mounting Posts

3. Carefully separate the two halves of the housing. See Fig 18.

4. Carefully pull the Battery Holder PWA off the mounting posts. See Fig 20.
FIGURE 21-a
5. Use a soldering iron to remove the two wires from the PWA, Fig 21-a
Remove the defective PWA from the housing and discard.

6. Install a replacement Battery Holder PWA by soldering the red wire to

the (+) connection point and the black wire to the (-) connection point. See Fig 21-b.

7. Make sure the wires are centered to the headband and

wind around the guide posts as illustrated in Fig 22. FIGURE 21-b
NOTE: Use a small piece of double sided tape (illustrated in
Blue in Fig 22) on the end of the metal headband to _
ensure the wire is centered. +
Doing this avoids any possibility of the wires getting Soldering Iron
pinched when reassembling the Battery Cover.

8. Apply a strip of 3MTM ¼’’ Polyimide Film Tape to make

sure the wires are held in place as shown in Fig 22. FIGURE 22
Double Sided Tape

9. Reassemble the battery cover and replace the screws. See Fig 23.
3MTM 1/4’’ Polyimide
Film Tape
FIGURE 23

Headband

Guide Posts

Battery half
of housing

Battery
Cover
Replacing the Headband Assembly
Tools Required: FIGURE 24
1 - Small size Phillips Screwdriver
1 - Tweezers
1 - Soldering iron
3MTM ¼’’ Polyimide Film Tape (SKU# 70-0160-3918-5) Electronics Side Battery Housing Side

3M OEM Parts and SKUs:

Procedure:
Replacing the Headband Assembly requires you to disassemble
both the Electronics Side and the Battery Housing Side of the headset. See Fig 24. FIGURE 25

Battery Housing Side:

You may follow the first 5 steps outlined in the procedure Replacing Battery
PWA (Printed Wiring Assembly). Or, alternatively, follow the steps outlined below.
FIGURE 26
1. Make sure the power is off and remove the battery from the headset. See Fig 25.

2. Disassemble the battery housing side of the headset by removing

screws and carefully separating the two halves of the housing. See Fig 26.

3. Carefully pull the Battery Holder PWA off the mounting posts, and
use a soldering iron to remove the two wires from the PWA. See Fig 27.

4. Install a replacement headband assembly by soldering the Red wire

to the (+) connection point on the Battery Holder PWA, and the black wire
to the (-) connection point. See Fig 28.
Battery
Battery half
5. Reposition the Battery Holder PWA on the mounting posts of the Cover
of housing
battery half of the housing.

6. Make sure the wires are centered to the headband and

wind around the guide posts as illustrated in Fig 29.
NOTE: Use a small piece of double sided tape (illustrated in Blue in Fig 29) FIGURE 27

on the end of the metal headband to ensure the wire is centered.

Doing this avoids any possibility of the wires getting pinched when
reassembling the Battery Cover. Battery Holder PWA

7. Apply a strip of 3MTM ¼’’ Polyimide Film Tape to make

sure the wires are held in place as shown in Fig 29. FIGURE 28 Mounting
Posts
8. Reassemble the battery cover and replace the screws. _
Double Sided Tape
+

3MTM 1/4’’ Polyimide Film Tape

FIGURE 29
Headband

Guide Posts
 Electronics Side: FIGURE 30

1. Remove the ear pad, ear cup, and the three screws from the inner case of the headset.
.
2. Separate the case halves, ever so slightly. Carefully raise the inner case just over
the On-Off button and slide down slightly to separate. See Fig 31-a.
Support the inner case so the speaker wires are not strained.

4. Disconnect the headband's power wiring connector located at the

Headband
top of the main circuit board. See Fig 31-a. Clip

5. Locate the headband clip positioned just under the headband entry FIGURE 31-a
opening on the outer case assembly.
Power cable
6.Carefully pull the power wire cable out of the top groove of the headband clip. connector
See Fig 31-b.

7. Remove the headband clip from the headband end by rotating it 90 degrees
FIGURE 31-b
and pulling it free of the headband. See Fig 31-b and Figs 32-a,b,c and d.
Headband
Clip
8. Pull the headband assembly (including the wiring cable) free of the outer case.

9. Insert the power cable from the replacement Headband through the top of the
outer case.
Hold replacement Headband Clip with the open wire groove facing up.
Hold the Clip so the curved portion inside the slot of the Clip faces next to the
curved section of the Headband end. See Fig 32-a.
Rotate the Clip 90 degrees as you slide it into the curved section of
the Headband end as shown in illustration. See Fig 32-b, 32-c and 32-d.

10.Carefully press the power wires, one on top of the other, into the
top wire groove of the Clip.
Be sure to press the wires completely down into the wire groove. FIGURE 32-a FIGURE 32-b FIGURE 32-c FIGURE 32-d

11.Plug in the power cable connector.

Route the power cable between the On-Off button and the large
capacitor on the PWA. See Fig 33. Center of
NOTE: The power cable MUST route down the center of the PWA or the PWA
the Headband will not extend properly. FIGURE 33
Large
capacitor
12. Apply a strip of3MTM ¼’’ Polyimide Film Tape to make sure the wires are
held in place as shown in Fig 29.
On-Off
13. Make sure the LED Lens is still in place. Otherwise, follow the procedure button
Replacing the Indicator LED Lens to re-install the LED Lens.

14.Assemble the case halves by inserting the tab at the top of the inner case 3MTM 1/4’’
through the slot at the top of the outer case and carefully lower it over Polyimide Film
Tape
the On-Off button and snap it shut at the bottom. See Fig 34. FIGURE 34
Tab on top of the
Care must be taken not to pinch any wires. inner case

15.Replace three case screws, ear cup, and pad.

 FIGURE 11
Replacing the Indicator LED Lens:
Tools Required:
1 - Small size Phillips Screwdriver

3M OEM Parts and SKUs:

FIGURE 12-a FIGURE 12-b

Procedure:
1. Make sure the power is off and remove the battery from the headset. See Fig 11

2. Remove the ear pad by using your fingers to pull the ear pad from the ear cup.
Then grasp the headset firmly in one hand, and pull the ear cup off the speaker
with the fingers of the other hand. See Fig 12-a

3. Disassemble the earpiece side of the headset by removing screws shown in Fig 12-b.

4. Carefully separate the inner and outer case assembly. See Fig 13 Outer Case Inner Case

5. Use the tip of a small screwdriver to gently push the lens out of the housing. See Fig 14
FIGURE 13

6. Replace the removed indicator LED lens.

7. Reassemble the inner and outer case halves by bringing the two halves
together and replace the three screws.
Indicator LED Lens

FIGURE 14
8. Reinstall the battery (Fig 15) and check operation of the
headset prior to returning it to regular operation.

FIGURE 15
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and determining whether it is fit for user's particular purpose and suitable for user's method of application.
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