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Aviation Headset Functional Testing

Aviation headsets are functionally tested with a simple talk-listen check using a compatible aviation intercom.

1. Insert headset plug(s) into intercom jack (s).

2. Don headset and speak into microphone. You should hear yourself (sidetone) in both ears.

3. Cycle volume control(s) over full range while continuing to speak to ascertain proper control operation.

4. If you are testing a stereo headset on a monaural intercom you will hear audio in only the left (mic) side
unless the stereo - monaural switch in the comm cord yoke is in the monaural position.

5. If no audio is heard you can isolate the problem to the microphone or earphone side of the headset by
plugging a second known-good headset into the test intercom. This will allow the microphone and
earphone circuits to be cross tested.

6. The communication functions of ENC headsets are tested exactly as in steps 1 through 5 above. The active
noise attenuation function is independent of the communication signal paths.

7. To check for proper ENC operation provide operating power by way of batteries when using an XL module
or a 12 to 28 volt source in the case of the XP module.

8. When the power is turned on you should hear a low level hiss in each ear. Room noise should quiet
somewhat but may not be too noticeable unless there are significant low frequency components in the noise.
Each side should be free of any oscillation or other undesirable sounds. If a problem is common to both
sides suspect a power supply or wiring problem.
Headset Problem Solving Guide

Problem Possible Cause Recommended Correction

No Output Defective Mic, Broken wire Replace mic, cord or reconnect wire
Low Output “ “ Replace mic
High Output “ “ Replace mic
Mic Static “ “ Replace mic
Intermittent Mic Loose mic set screw or defective Tighten mic set screws or replace mic
Communication cords
Intermittent at plugs Dirty plugs or broken wire at plugs Clean plugs, see if problem is corrected, if not
replace comm cord
Intermittent at dome Broken wire in cord at dome Replace comm cord
No output from headset Broken wire somewhere in cord Replace comm cord
Intermittent at yoke Broken wire at yoke Replace comm cord
Mic cord
Intermittent mic cord Broken wires at connector Replace mic cord
No output Defective earphone, broken wire Replace earphone, replace cord or reconnect wire
Low output “ “ Replace earphone
Earphone static “ “ Replace earphone
Intermittent earphone “ “ Replace earphone
Distorted output “ “ Replace earphone
Volume control(s)
Intermittent volume control Defective volume control Replace volume control
Only 1 earphone working Broken wire Resolder wire
Loose volume control Loose nut Tighten nut
Mic booms
Broken flex boom Defective adhesive, customer abuse Replace boom
Broken wire boom Defective boom Replace boom
Headband spring
Broken headband spring Defective headband spring Replace headband spring

??Each headset sent in for repair should have it’s plugs cleaned, domes buffed or cleaned as best as
they can, old ear seals, filters and any headpad that is worn out replaced.
Trouble Shooting Chart
Standard Noise
Cancelling Headsets

Begin: Buff plugs and put in mono mode. Plug

headset into an aviation intercom and speak into mic..
Can you hear both earphones?

Can you hear from one earphone?

Measure volume control(s) with meter on No
green & black contacts of the audio plug.
If they don't change the readings First make sure that it isn't in Any shorts between plugs on comm cord? **
accordingly, then they are bad. Note: In stereo mode, then replace
stereo, measure resistance from tip to earphone from silent side. Is it
sleeve & ring to sleeve. In mono measure ok now? Note: Stereo headset Yes No
tip to sleeve. plugged into mono intercom will
only have sound in left ear
unless yoke switch is moved to
mono position. Find colors of shorted
lines & pinpoint from Take another good headset &
inside comm cord put it's mic. plug into the DC
Yes dome. Comm instead. Speak into the
second while listening to the
first. Can you hear yourself?
If left side, check all readings
Do "wiggle" test on cords Yes
between green wire split. If right
for all headsets Put good mic into headset.
side, disconnect one wire from
Do you hear now?
earphone & check wires at both No
ends of overhead cord, & wires
between ear & overhead. No
Rotate volume controls with
meter on tip (green) & sleeve
Check readings between mic (black) contacts of audio plug.
screws (or female mic cord plug) Any response?
& mic comm plug for shorts or
opens. Open left dome & check
between mic plug & bad line & No
dome to mic cord Yes
Disconnect black &
green wires just inside
dome. Check for open
Make sure that you're not in in comm cord, broken
stereo mode. Is that it? wires before or at splits
in dome, or two shorted
No earphones.

**For stereo headset troubleshooting, using mono intercom, in mono mode the ring (yellow) wire is Then earphone is shorted on
open & the tip (green) splits off into both earphones. In "S" mode, ring is switched closed to right OR good volume side.
ear. The left ear (green) is completed & the black ground is connected to both ears.
JF 10-07-99
Trouble Shooting Chart
Electronic Noise
Cancelling Headsets

Begin: Buff plugs, install good batteries & put in

mono mode. Put headset into an aviation intercom &
speak into mic.. Can you hear both earphones?

Test volume controls in both stereo & mono mode.

YES NO Can you hear from one earphone?
Test OK?

Rotate volume control To find short in Any shorts at plugs? **

Turn on power module. Does If volume controls do not effect on silent side while headset follow known
it cancel noise in both ears? circuit they are defective. YES
measuring at the shorted colors by
YES sleeve & tip (black & disconnecting one of
green) of the audio them at each junction
Did it cancel in one ear? NO plug. Works OK? point until pinpointed. Use 2nd good
Test each ear headset to see if
module one at a YES YES NO you can hear that
time, with volume YES mic. Can you hear
controls. If either Defective ear
Replace the Did it sound like the Check for open in now?
one does not cancel module. Problem is in the mic
ear module ANR went on? NO the green/volume/
equally or efficiently, line. Use the regular
that did not ear/black line in that
replace that module. YES aviation trouble- NO
cancel. dome (or overhead
Flip Switch on cord shooting flowchart to
Cancel now? Both ear Measure voltage at if applicable)
to Stereo mode. test.
Does this bypass modules are orange & brown wires Turn on the ANR.
one ear module? defective as they exit the power Can you hear
NO Both ear
(A loud squeal module towards the YES now?
Out of both
signifies improper dome. Does it read modules YES
wiring at module.) Follow the orange YES 12 volts? are bad. NO
& brown wires NO
Did you hear the ANR turn
from where they NO Replace the one on at all?
enter the dome to you heard.
YES the ear module Troubleshoot the
that did not Look for open in In power module check YES
wires starting at the switch operation & its rest of the NO
cancel until the headset as though
open is found. brown & orange wires, check wires to &
NO it were a normal Replace one Replace
Do wiggle coming out of the from battery contacts,
aviation headset ear module. both ear
test to check power module & up test L.E.D., & then if all
with no output in Can you modules. If
cords for all to where they enter else fails, troubleshoot
one ear. hear that that does
headsets the dome. the PC Board.
side? not solve the
YES problem
Look for short at plugs & NO there is
trace those shorted Rotate vol. probably
colors up through wires Controls while more than
Troubleshoot as one open.
by stopping at each measuring at
Both ears though it were a Start from
solder juncture to YES green & black
were bad for regular aviation plugs &
disconnect one. contacts of audio NO
different headset with no continue up
plug. Do both
reasons. output at ears. into domes.
affect circuit?
** Note: The dual plugs on ANR headsets are wired the same as stereo.
Also be aware that feedback from a bad com mic. can make the ear modules
sound "tinny" or less efficient. Replace before swapping ear modules.
JF 10-07-99