Motorola Astro Digital Mobile Radio Xtl5000 Basic 6881096c73 O Manual

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-5
Figure 8-2.  W5 and W7 Pushbutton Control-Head Assembly Screw Sequence
7. Carefully separate the printed circuit board, internal spacer, and elastomer keypad assembly 
from the front panel.
On rotary control-head models, care must be taken not to damage the flex circuit when 
separating the printed circuit board from the front housing. Do not disturb the buttons in the 
front panel.
On rotary control-head models, the...

June 13, 20036881096C73-O
8-6Disassembly/Reassembly Procedures: Replacement Procedures
4. For dash-mounted radios, plug the interconnect flex from the radio into the control head, slide 
the control head into the headbridge, and fasten the control head with the two front panel 
screws (torqued to 6-8 in.-lbs).
OR
For remote-mount control heads, replace the front panel into the remote control head back 
housing, make sure the gasket is in place, then torque the screws to 6-8 in.-lbs. Replace any 
plugs...

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-7
4. Replace the captive screws [12] and the leaf assembly spring [11] in the front housing, and 
torque them to 6-8 in.-lbs.
NOTE:Before assembling the leaf assembly spring, check that the insulator [10] on the 
board is present. Ensure that the leaf assembly spring and captive screws are 
aligned properly to prevent stripping the front housing screw bosses.
5. Close the assembly by replacing the front housing [41] and...

June 11, 20036881096C73-O
8-8Disassembly/Reassembly Procedures: Replacement Procedures
8.2.4.2  Reassembly
1. Reconnect the interconnect flex to the radio, noting proper alignment of the mating 
connections.
2. Reassemble the front panel into the radio and replace the screws.
3. Torque the screws to 6-8 in.-lbs.
8.2.5 Radio Disassembly
Use the following procedure to disassemble your radio:
1. Ensure all accessory connections, power, antenna, and microphone are unplugged.
If the radio is a remote-mount...

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-9
3. Firmly grasp the front panel of the control head, and carefully remove the control-head 
assembly from the radio. Be careful not to pull on the attached flex.
Figure 8-4.  Removing the Control Head
4. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar 
the face of the display.
5. Carefully disconnect the control-head flex from the control head or remote interconnect 
panel,...

June 11, 20036881096C73-O
8-10Disassembly/Reassembly Procedures: Replacement Procedures
6. Remove the plastic headbridge by squeezing in the center of the top and bottom sides of the 
part and pulling away from the transceiver.
NOTE:Be careful to avoid pulling on the flex.
Figure 8-6.  Removing the Headbridge
7. Carefully remove the control-head flex from the transceiver by grasping the provided handle 
and separating it from the connector.
Figure 8-7.  Removing the Flex (Main-Board Connector) 

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-11
Figure 8-8.  Control-Head Flex (Removed)
8. Remove the headbridge seal from the transceiver.
Figure 8-9.  Headbridge Seal (Removed)
The following steps MUST be performed for secure-equipped 
radios prior to removal of the cover or damage to the radio 
could occur.
!
C a u t i o n 

June 11, 20036881096C73-O
8-12Disassembly/Reassembly Procedures: Replacement Procedures
9. For secure option-equipped radios, do the following prior to disassembly of the transceiver:
a. Remove the two screws holding the secure (UCM) shield in place.
b. Pull the UCM shield away from the assembly and remove it.
c. Insert a flathead screwdriver into the space in the upper-left corner of the secure pocket, 
and gently pry the secure interface board (universal encryption module) away from the 
chassis....

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-13
10. Remove the 10 top-cover screws using a T20 Torx bit. These screws have sealing washers 
that should be kept with the screw.
Figure 8-11.  Removing the Top Cover Screws
11. Remove the top cover by lifting up simultaneously on both side edges. It may be necessary to 
gently pry the cover off using a plastic tool. 
Figure 8-12.  Lifting the Top Cover 

June 11, 20036881096C73-O
8-14Disassembly/Reassembly Procedures: Replacement Procedures
Figure 8-13.  Removing the Top Cover
12. Disconnect the rear accessory jack’s flex from the main board.
Figure 8-14.  Removing the J2 Rear Accessory Flex from the Main Board