Motorola Astro Digital Mobile Radio Xtl5000 Basic 6881096c73 O Manual

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-25
8. Place the cover on the chassis and seat it properly. You can compress the cover and chassis 
together to squeeze the seal into place and make torquing the screws easier.
Figure 8-29.  Preparing to Place the Top Cover on the Chassis
9. Inspect and reassemble the sealing washers to the ten (10) top cover screws, and then 
torque down screws in the indicated order.
All the screws must be torqued to 24-28 in.-lbs, and...

June 11, 20036881096C73-O
8-26Disassembly/Reassembly Procedures: Replacement Procedures
10. For secure option-equipped radios, do the following:
a. Inspect the kapton tape on the back of the secure interface board for damage and replace 
if necessary.
b. Ensure the universal encryption module (UCM) is securely plugged into the secure inter-
face board.
c. Carefully align the secure interface board in its chassis pocket, and plug it into the main 
board. Press down along the edges of the board to fully...

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-27
Figure 8-32.  Installing the Headbridge Seal
13. Grasp the handle on the transceiver end of the control-head flex (dash or remote), and plug 
the flex into the 50-pin connector on the side of the main board.
Figure 8-33.  Installing the Control-Head Flex in the Transceiver 

June 11, 20036881096C73-O
8-28Disassembly/Reassembly Procedures: Replacement Procedures
14. Hold the headbridge with one hand, and squeeze the center of the long span.
15. Align the headbridge with the transceiver, thread the control-head flex through the 
headbridge, and push the headbridge into place. You might hear a small snap as the 
alignment tabs engage. If the headbridge does not align properly on the first try, do not try to 
slide it back and forth on the transceiver. This will cause the seal...

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-29
18. Insert the control head to the transceiver.
Figure 8-36.  Inserting the Control Head Into the Transceiver
19. Secure the control head to the transceiver with the two screws using the 2.5 mm hex-key bit. 
Apply 6-8 in.-lbs. of torque for each screw.
Figure 8-37.  Installing the Control-Head Screws 

June 11, 20036881096C73-O
8-30Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure
8.3 Chassis Thermal Pad Replacement Procedure
Use the following procedures for replacing the chassis thermal pads.
Figure 8-38.  Chassis Thermal Pad Locations
To replace the pink thermal pads (Items 1, 2, and 4):
1. Use a plastic flat-edge tool (like a black-stick solder aid) to lift the pad from the chassis 
surface.
2. Discard the old pad. Use a soft cloth to remove any remaining residue. Alcohol...

6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure 8-31
To repair the black thermal pad (Item 3):
1. Use a plastic flat-edge tool (like a black-stick solder aid) to lift the pad from the chassis 
surface. The pad is an elastomer-coated sheet of foil. The foil sheet will lift off in pieces. The 
black elastomer residue will remain on the chassis.
2. Scrape the residue off using a plastic flat-edge tool, such as a dismantling tool (Motorola P/N...

June 11, 20036881096C73-O
8-32Disassembly/Reassembly Procedures: Fastener Torque Chart
8.4 Fastener Torque Chart
Table 8-3 lists the various fasteners by part number and description, followed by the torque values 
and the location where used. Torque all fasteners to the recommended value when assembling the 
radio.
Table 8-3.  Fastener Torque Chart
Part NumberDescription
Repair 
Torque
(in.-lbs.)
Where Used
0310907A20 Screw, Torx M3x10 6-8 Mainboard (3), Secure Shield (2)
0385870E01 Screw, Torx M4x25...

Chapter 9 Basic Troubleshooting
9.1 Introduction
This section of the manual contains troubleshooting charts, error codes, and flexible circuit 
information. This section can help you isolate a problem to the board level. Board-level 
troubleshooting does not attempt to isolate problems to the component level. Component-level 
service information can be found in the ASTRO XTL 5000 Digital Mobile Radio Detailed Service 
Manual. (Refer to the Related Publications section of this manual on page xii for the...

June 11, 20036881096C73-O
9-2Basic Troubleshooting: Introduction
4TXDRS232 Transmit DataThis is part of the 4-wire RS232 interface to 
external data accessories, programming 
cables, etc.
5RXDRS232 Receive DataThis is part of the 4-wire RS232 interface to 
external data accessories, programming 
cables, etc.
6USB-USB - DataThis is part of the 2-wire USB differential data 
bus for future USB accessories.
7USB+USB + DataThis is part of the 2-wire USB differential data 
bus for future USB accessories....