2. 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

3. Overview Assembly of front panel Place ring on panel Place keypad on panel Place speaker on panel Final Assembly Insure the foam pad is in place on the solar panel which is soldered to the PCB 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 onto the front; lower into place; check to make sure snaps in place Secure screws in bottom of 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 Plug battery into Molex connecter Fold battery wires to the left Add ID card and slip door into place Screw door closed 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

4. Assembly of front panel Place ring on panel Place keypad on panel Place speaker on panel

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

6. 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

7. Place keypad on Panel Step #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

8. 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

9. Place speaker on panel Step #1 Take paper layer off the glue ring using flathead screwdriver Step #2 Hold 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

10. 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

11. 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.

12. 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.

13. Remove plastic from back Panel While peeling the plastic, be sure not to touch the clear part of the cover

14. 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

15. 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

16. 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

17. Place under sun lamp; check voltage at the battery Molex connector in the back panel - should be between 4.5 - 5.2 volts Step #2 Place solar panel 10 cm (about a hands width) beneath a 60 Watt lamp Step #1 Set the Fluke Multimeter to DC/V

18. 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

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

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

21. 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

22. 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