Motorola Gp640 Gp680 Basic 68p64115b23a Manual

							Radio Disassembly—Detailed3-7
3.Remove the O-ring.
4.Slide off the ground contact from the top corner boss of the radio chassis.
6.3 Keypad, Display, and Keypad/Option Board Disassembly
1.If the disassembly of the keypad, the keypad printed circuit board, or the display is required,
lift the microphone flex circuit up, and carefully remove the microphone and its boot from the
front cover pocket. (See Figure 3-6.)
2.Lay this flex circuit to one side.
3.To remove the keypad retainer shield:
a. Insert the tip of a“penknife size,”flat blade screwdriver in the opening at the end of the
keypad retainer arm tab.
b. Pry the tab away from the side of the front cover until it moves past the ledges on the
side wall. Duplicate this procedure for each of the four retainer arm tabs.
4.Note that the two“top hooks”are still held underneath the front cover—right below the
speaker. Lift the keypad retainer out of the front cover; then, lift and pivot the two hooks out of
the front cover.
5.If disassembly involves the removal of the display module, disconnect the display flex from the
keypad option board connector by lifting the latch on the connector. (This is similar to the pro-
cess for releasing the flexes.)
6.The display module is attached to the front cover with a double-sided adhesive pad. Carefully
pull up on the display module, using a small screwdriver, if necessary, and remove it from the
front cover. Use a new piece of double-sided adhesive to re-mount the display to the cover.Figure 3-6Remove Retainer
CAUTION: Take care not to damage the display. Do not cut, bend, or pinch the heat seal. Display
modules contain CMOS devices. Be sure to use ESD protection.
Keypad Retainer
Arm Tabs (4)
Retainer
Top Hooks
RetainerFlat Blade
Screwdriver Speaker-Microphone
Flex Circuit Tail
! 
						

							3-8MAINTENANCE
7.The keypad/option board, and the keypad, can be removed without the use of tools.
6.4 Speaker, Microphone, and Universal Connector Flex Disassembly
1.Turn the screw at the bottom of the dustcover counterclockwise with your fingers. Lift the dust-
cover out of its pocket.
2.Using a screwdriver, push down on the portion of the speaker retainer bracket pointing toward
the bottom of the radio. Then, remove the retainer by slightly pushing it toward the top of the
radio until you slide it past the front cover slot.
3.Pull the rubber microphone boot from its seated position. Unless you are replacing the micro-
phone, leave it in the boot.
4.Peel-off the universal connector flex circuit escutcheon (label).
5.Pry the flex circuit (adhesive held) backer board away from the front cover, and remove the
universal connector tail of the speaker-microphone assembly through its opening in the front
cover. Figure 3-7Removing the Keypad Retainer and Other Boards from the Radio Body
NOTEAt this point, the Option Board Installation Procedure should be performed, if necessary.
NOTEThe dustcover must be removed to remove the speaker-microphone assembly flex circuit.
The speaker is held in place with a two-legged retainer bracket. The bracket legs are
secured by the front cover slots. Be careful not to damage the speaker when removing the
retainer bracket.
NOTEThe speaker-microphone assembly flex circuit goes through the front cover wall to the out-
side wall. To replace this assembly, you must peel-off the universal connector escutcheon
label. The existing escutcheon cannot be reassembled; a new part must be used. (See item
number 10 on the exploded view drawing.)
Keypad/Option Board
Retainer
Display Module
Keypad
Radio Body
1
2
3 
						

							Radio Disassembly—Detailed3-9
6.After the universal connector tail of the speaker-microphone assembly is removed, the
assembly can be completely removed. If it is necessary to replace the speaker or
microphone, or both, do it while the flex circuit is removed from the front cover. When
reassembling the microphone in its boot, make sure the microphone port faces the round hole
in the bottom of the boot.
6.5 PTT Disassembly
1.If required, the PTT bezel, and the PTT seal assembly, can be disassembled using a small
screwdriver, as follows:
a. Pry back the T-tab found inside the front cover (in between the four buttons on the PTT
assembly).
b. Remove the PTT bezel by slightly bowing it until the top and bottom tabs are released
from the slots in the front cover.
c. The PTT seal can be easily lifted from the bezel without the use of tools.Figure 3-8Removal Speaker-Microphone Assembly
Figure 3-9PTT Removal
SpeakerNotch In
Speaker @ 12:00
Speaker Orientation
Tab @ 12:00
Microphone BootUniversal Connector
Tail
Microphone
Speaker Microphone
Flex Circuit Assembly
TabPTT Bezel
Tab T Shaped Retainer Tab
PTT Seal 
						

							3-10MAINTENANCE
6.6 Control Top Disassembly
1.To remove the control top assembly, place a screwdriver next to the antenna boss, and pry it
against the control top escutcheon. This will lift the control top escutcheon away from its
double-sided adhesive. Grab the double-sided adhesive near the volume potentiometer, and
lift it away.
2.Remove the control top seal, emergency button, and transmit light pipe.
7.0 Radio Reassembly — Detailed
7.1 PTT Reassembly
1.Replace transmit light pipe and control top seal.
2.Place a new control top escutcheon adhesive against the front cover. Press the control top
escutcheon tightly against the adhesive.
3.Put the PTT seal in the PTT bezel.
7.2 Control Top Reassembly
1.Place the bezel top tab in the top slot inside the front cover PTT opening. Slightly bow the
bezel so that the bottom tab can fall inside the bottom slot.
2.Press the PTT assembly against the front cover opening.
7.3 Speaker, Microphone, and Universal Connector Flex Reassembly
1.Feed the universal connector tail of the speaker-microphone flex assembly through the open-
inginthesidewallofthefrontcover.
2.Peel-off the adhesive liner on the back of the universal connector tail of the flex circuit. Attach
the flex tail to the front cover using the guide pins for correct alignment.
3.Replace the universal connector escutcheon. Make sure that all the connector openings align
with the gold pads on the flex circuit.
4.Align the notch in the speaker at the twelve o’clock position with the tab on the front cover.
(See Figure 3-8.)
5.Place the speaker retainer bracket into the hole on the top of the front cover, and bend the
retainer down to fit underneath the boss below the speaker.
7.4 Keypad, Display, and Keypad Option Board Reassembly
1.If you are replacing the display, use a new double-sided adhesive display pad (item number
17 on the exploded view diagram).
2.Replace the keypad, and the keypad/option board. Make sure the display module flex tail is
connected correctly to the connector on the keypad/option board.
3.Insert the“top hooks”of the keypad retainer into the slots below the speaker (above the
display) in the front cover. Snap all four of the retainer arm tabs in place in the front cover.
NOTELook inside the front cover to make sure the T-tab is fully engaged with the front cover. If
necessary, press the T-tab toward the top of the radio until it becomes fully engaged. 
						

							Radio Reassembly—Detailed3-11
4.Re-insert the microphone and boot into the pocket in the front cover.
5.Lay the speaker-microphone flex on top of keypad/option board retainer.
7.5 Chassis Assembly Reassembly
1.Slide on the ground contact (if necessary) on the top corner boss of the chassis.
2.Replace the O-ring. The tabs on the O-ring should reach around the chassis and point down.
3.Stretch the O-ring to place it into the retaining pocket at the bottom end of the chassis.
4.Ensure that the antenna nut insulator is correctly replaced by pushing it all the way to the top
of the antenna nut.
5.Replace the battery contact seal (if necessary) surrounding the battery contact.
6.Place the main circuit board straight down on top of the chassis.
7.Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis.
7.6 Chassis and Front Cover Reassembly
1.Align the chassis assembly end-to-end with the front cover assembly.
2.Insert the tails of the flex circuits into their respective connectors at the bottom of the front
cover.
3.Push down the latches on the connectors to hold the flex circuits to the main board.
4.Slide the volume potentiometer and frequency switch shafts into their respective holes in the
front cover.
NOTEPull the speaker-microphone flex circuit out of harm’s way during reassembly.
Figure 3-10Lock retainer catches to the radio’s body
NOTEWhen properly assembled, the retainers on the O-ring should align with the slots on the
chassis. If this is not the case, remove and replace the O-ring until it is aligned with the
chassis and completely seated in place around the perimeter.
NOTEBe sure the battery contact seal protrudes through the chassis and is not pinched under the
chassis.
Catches
Retainer 
						

							3-12MAINTENANCE
5.Push the chassis assembly completely into the top of the front cover until it settles in place.
6.Be sure the O-ring is properly seated.
7.Snap the bottom of the chassis into the front cover.
8.Reassemble the knobs, dust cover, antenna, and battery.
8.0 Option Board Installation
1.With the keypad retainer removed, the keypad backer board can be removed without the use
of tools.
2.Remove the jumper flex from the connector on the keypad board. Notice the orientation of the
flex to the connector. Arrows on the jumper flex point to the correct way of inserting the flex
into the connector.
3.Discard the keypad backer board.
4.The“breakaway”tab at the top of all option boards contains an extra row of keys and is used
to accommodate other radio models.
5.Break-off and discard the option board tab, taking care not to damage the option board. Trim
any tab fragments that may remain on the option board.Figure 3-11Fastening the Chassis
Radio Chassis 
						

							Option Board Installation3-13
6.Reassemble the option board to the front cover assembly.
7.Insert the display flex circuit into the connector on the option board.
8.Insert the jumper flex circuit into the connector on the option board. Notice the orientation of
the flex circuit. Arrows on the jumper flex point to the correct way of inserting the flex into the
connector.
9.Replace the retainer by placing the two top hooks into the slots below the speaker in the front
cover; then, pivot the retainer into the front cover. Ensure that all four tab arms snap correctly
into the front cover.
10.With the keypad option board, display, and retainer correctly in place, the front cover assem-
bly can now be reassembled as described in Paragraph 7.6 (Chassis and Front Cover Reas-
sembly).Figure 3-12Changing the Keypad/Option Board
Retainer
Keypad/Option
Board
Display FlexJumper Flex
TO KP 
						

							3-14MAINTENANCE
9.0 Mechanical View and Parts List
9.1 GP640 Exploded View and Parts List
Figure 3-13GP640 Radio Exploded Mechanical View
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							Mechanical View and Parts List3-15
ItemMotorola
Par t
NumberDescription
1See Chapter 6Antenna
2 3680529Z01 Knob, Volume
33680530Z01Knob, Frequency
4 1380525Z01 Escutcheon, Top
53380644Z01Escutcheon, Label
6 3280533Z01 Seal, Control Top
76180527Z01Litepipe, Tx
8 1364279B06 Front, label
91586059A01Dust Cover, Universal
Connector
10 1386058A01 Escutcheon, Universal Flex
111580666Z03Front Cover, Basic
12 Not Field
ReplaceableEscutcheon, FM
137580532Z01Keypad, Side Control
14 1380528Z01 Bezel, Side Control
157580620Z03
7580620Z04Keypad, Blank
Keyp ad , Fu l l
16 0104007J99 Keypad Board Assembly
174280498Z01Retainer, Keypad PCB
18 3586057A01 Felt Speaker
191480577C01Boot, Microphone
20 5085962A02 Speaker
215013920A04Microphone
22 8480549Z01 Flex, UC
232113740A41Capacitor, 33pF
24 4280504Z01 Retainer, Speaker
250304726J04Screw
26 See Chapter 6 Back Cover Kit incl. chassis
main board
278480475Z02Flex, Keypad/Controller
28 1480652Z01 Insulator, Antenna
297580556Z01Pad, Thermal
30 3280534Z01 Seal, Contact
313280536Z01Gasket, o-Ring
32 3980698Z01 Contact, Ground, Compliant,
VHF
332780518Z01Chassis
34 See Chapter 6 Battery
35HLN9714ABeltclip
ItemMotorola
Par t
NumberDescription 
						

							3-16MAINTENANCE
9.2 GP680 Exploded View and Parts List
Figure 3-14GP680 Radio Exploded View
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