Hafler DH-500 User Manual download pdf (Page 8)

MECHANICAL ASSEMBLY

For security in shipping, the power transformer

and the amplifier module have been fastened to the

chassis. Remove the chassis cover, the inner front

panel and the larger front plate, and set these aside.

Be particularly careful in handling the amplifier

module. to see that the leads of the

upright

compo-

nents on the circuit boards are not stressed.

This

module accounts for more than half the kit cost,

and has already been thoroughly tested for

specified performance before it was packed.

Turn the chassis upside down, and rest it on the

module and transformer to remove these parts. In-

clude all of the hardware you have removed with

the rest when you check off the components

against the parts list in the back of this manual. We

recommend this check-off to be sure you have ev-

erything, and to enable you to identify any unfamil-

iar items by comparing them with the pictorial

diagram. Although the perspective of the diagram

has sometimes been distorted to show connections

more clearly, it should enable you to recognize any

unfamiliar component. An egg carton is ideal for

keeping small items like hardware at hand.

It will simplify matters if you first separate the

nuts

from the

nuts, which have the same outside dimen-

sions. A

screw will pass through a

nut, aiding iden-

tification.

“set”

of hardware includes one screw and one KEP nut

(with its attached lockwasher). Always install the

lockwasher side of the nut first. If the size of the hardware

is not specified, use the

size, which is the smallest.

#10

is the largest. Always insert the screw from the outside of

the chassis.

With the chassis upside down, select the 4 rubber

feet and 4 sheet metal screws. The screw head re-

cesses fully into the foot. Install these in the holes

which are about I” in from each corner.

Select the AC line cord and the plastic strain relief.

Separate the two conductors of the cord for 2 in-

ches. Strip

l/4”

of insulation from each lead. Twist

the bare strands tightly, and tin each lead. 13” from

the ends make a sharp “V” in the cord by bending it

sharply back on itself. Install the strain relief as

shown, with the small end of the strain relief

nearest the stripped end of the line cord. Crimp the

two halves of the strain relief around the wire at the

V with heavy pliers, to partially form it before in-

sertion into the back panel. Considerable squeez-

ing is necessary, because the thick insulation “pops

back” quickly. Then grip the larger diameter of the

strain relief with the tips of heavy pliers, squeeze it

tightly, and insert the end of the cord through the

back panel AC hole from the outside. Note that the

hole has two flat sides, and the relief is shaped ac-

cordingly. This is a very tight

fit-you

will have to

pull on the cord to help-but it snaps into position

when fully inserted.

Select the two input sockets and 4 sets of hardware.

Install the sockets at LS and RS inside the chassis

so that the short lug is nearest the hole in the chas-

sis between the two sockets.

Select the single ground lug (with lockwasher

teeth) and one set of hardware. Install it between

the input sockets. Point it toward the bottom, and

bend it out for access. Be certain this lug is tight.

The locking teeth must cut through the chassis

paint for a good ground connection.

Select the two round fuse holders with caps, and

their

l/2”

hardware: rubber washers, metal

lockwashers, and nuts. First install the rubber

washer on each holder, so it will be outside the

chassis, and then fasten them at locations LF and

RE The holes have flats which mate with the fuse

holder to keep it from turning. Point the tip lugs to-

wards each other. Be sure all of this hardware is

tight, as it will not be accessible once the amplifier

is completed.

Select the two red output terminals and their

hardware: the red washers, 4 nuts without

lockwashers, and two plain connecting lugs. Note

that each part of the terminal has a flat which mates

with the flat top of the chassis hole. Install the ter-

minals in the two center holes LR and RR so that

the washer flat is engaged, tighten one nut securely,

add the lug pointing up, and tighten the second nut.

Select the two black output terminals, their hard-

ware, and two plain connecting lugs. Install them at

LB and RB as in the previous step.

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Hafler DH-500 User Manual Page 8

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