Motorola Mototrbo Dr3000 Repeater Basic 6866576d03 A Manual

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Disassembly Procedures — Detailed 5-7
5.6.4 Removing Transmit Radio
(Refer to Figure 5-5)
1. Disconnect flex cable from 30-position connector on Transmit radio, noting orientation of 
cable which is identified with a solid blue line. This is important for reassembly.
2. Disconnect SSI flex cable from the connector on the Transmit radio, noting orientation of 
cable which is identified with a solid black line. This is important for reassembly.
3. Loosen and remove the four M4 lock nuts that secure the Transmit radio assembly with a 
7 mm socket driver.
4. Disconnect the power cable from the Transmit radio.
5. Disconnect the antenna cable from the Transmit radio.
6. Disconnect the accessory connector from the Transmit radio.
7. Lift the Transmit radio assembly out of the enclosure and place on a flat surface.
8. Loosen and remove the two M5 screws and washers that secure the Transmit radio to the 
bracket using a T25 TORX™ driver.
Figure 5-5.  Tx Radio Disassembly
Transmit Radio
Heatsink
Thermal Pad
Transmit Bracket
M5 Screw (1)
M5 Screw (1)
M3 Screws (7)
Wa s h e r 
						

							February 21, 20076866576D03-A
5-8Disassembly /Reassembly  Procedures: Disassembly Procedures — Detailed
5.6.4.1  Removing Thermal Pad and Heatsink
(Refer to Figure 5-5)
1. Remove all of the seven screws which secure the heatsink to the Transmit radio using a T10 
TORX™ driver.
2. Remove the heatsink from the Transmit radio.
3. Peel off and discard the thermal pad.
4. Replace all worn parts.
5.6.5 Removing Receive Radio, Power Supply and Connector Board Assembly
(Refer to Figure 5-6)
1. Disconnect SSI flex cable from the connector on the Receive radio, noting orientation of cable 
which is identified with a dotted line. This is important for reassembly.
2. Disconnect the antenna cable from the Receive radio.
3. Disconnect the power cable from the Receive radio.
4. Remove the two screws securing the retainer clip using a T20 TORX™ driver.
5. Remove accessory connector from the back side of repeater by inserting a flat blade 
screwdriver into the slot located on the top of the connector.
6. Disconnect all of the cables from their mating connectors located on the connector board 
assembly.
7. Loosen and remove the five M4 lock nuts that secure the Receive radio assembly with a 
7 mm socket driver.
NOTE:The two lock nuts at the side on base will require a magnetic lock nut driver with extension of 
greater than 150 mm).
8. Slide Receive radio assembly slightly forward before lifting it out of the enclosure.  
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Disassembly Procedures — Detailed 5-9
9. Take precaution not to damage the power supply or the connector board assembly and place 
assembly on a flat surface.
Figure 5-6.  Receive Radio Removal
Receive Bracket
Receive Radio
Power Supply
Connector Board
M3 Screws (5)
M5 Screws
Washer Assembly 
						

							February 21, 20076866576D03-A
5-10Disassembly /Reassembly  Procedures: Disassembly Procedures — Detailed
5.6.5.1  Disassembly of Receive Radio
(after Receive radio assembly is removed from repeater)
1. With assembly on a flat surface, loosen and remove the two M5 screws and washers that 
secure the Receive radio to the bracket using a T25 TORX™ driver.
2. Slide the Receive radio out of the bracket.
5.6.5.2  Disassembly of Connector Board Assembly
(after Receive radio assembly is removed from repeater)
1. With assembly on a flat surface, detach the connector board assembly from Receive radio 
assembly by removing the five M3 screws using a T10 TORX™ driver.
2. Store connector board assembly in anti-static bag when it is not being serviced.
5.6.5.3  Disassembly of Power Supply 
(after Receive radio assembly is removed from repeater)
1. With assembly on a flat surface, loosen and remove the four M5 screws and washers that 
secure the power supply to the bracket using a T25 TORX™ driver.
2. Slide power supply out from bracket.
3. Disconnect Y-split cable from power supply before sending to manufacturer.
NOTE:Power Supply should be serviced by manufacturer. 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Disassembly — Detailed 5-11
5.7 Transmit and Receive Radio Disassembly — Detailed
To remove Transmit and Receive radios from the repeater, refer to Sections 5.6.4 and 5.6.5 
accordingly.
5.7.1 Transceiver Board and Receiver Board Removal
1. Remove the seven screws from the die cast cover using the T20 TORX™ driver as shown in 
Figure 5-7. 
NOTE:Do not remove the O-rings from the screws.
2. Lift the die cast cover from the chassis.
Figure 5-7.  Die Cast Cover Removal.
Die Cast
Cover
Screws (7)
Radio 
Chassis
  
						

							February 21, 20076866576D03-A
5-12Disassembly /Reassembly  Procedures: Transmit and Receive Radio Disassembly — Detailed
3. Remove the accessory connector from the radio assembly by inserting a flat-blade 
screwdriver into the slot on the side of the connector as shown in Figure 5-8.
Figure 5-8.  Accessory Connector Removal
4. Remove the RF/DC retention clips by gently prying them out with a flat-blade screwdriver as 
shown in Figure 5-9.
Figure 5-9.  RF/DC Retention Clips Removal The accessory connector should never be removed when the cover is still 
assembled to the radio.
!
C a u t i o n
Flat-blade
Screwdriver
SlotAccessory
Connector
RF/DC Retention ClipsFlat-blade
Screwdriver
Flat-blade
Screwdriver 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Disassembly — Detailed 5-13
5. Remove the transceiver board by sliding a finger into the opening provided at the front of the 
radio and gently press up on the 30-pin connector, lifting up the front of the board, as shown 
in Figure 5-10. Then, slide the transceiver board towards the front of the radio to allow the 
RF/DC connectors to clear the chassis. Handle the transceiver board by the edges only and 
store it in an antistatic bag.
NOTE:If the RF/DC connector gaskets remain in the chassis, remove them and place them back on 
the connectors.
Figure 5-10.  Transceiver Board Removal The thermal pads can act as an adhesive and cause stress to critical 
components on the transceiver board if the transceiver board is lifted too 
quickly.
!
C a u t i o n 
						

							February 21, 20076866576D03-A
5-14Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed
5.8 Transmit and Receive Radio Reassembly — Detailed
The following reassembly procedures are applicable to both the Transmit and Receive radios.
1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks, 
cuts, etc.) or debris. Refer to the exploded view and bill of materials for the correct part 
numbers and replace parts, as necessary. Reseat all new seals on their respective parts. 
For both the die cast cover and the chassis, thoroughly inspect the shield gasketing for 
damage and verify all thermal pads are in place and free from damage and debris. See 
Section 5.8.2: Thermal Pad Replacement Procedure on page 5-19 to replace damaged pads.
Figure 5-11.  Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover
2. Thoroughly inspect the transceiver board and verify all thermal pads are in place and free 
from damage. See Section 5.8.2: Thermal Pad Replacement Procedure on page 5-19 to 
replace damaged pads.
Figure 5-12.  Transceiver Board with Thermal Pads
Chassis with Thermal Pads
and Shield GasketingDie Cast Cover with Thermal Pads
and Shield Gasketing
PA Thermal Pad (7515581H01)Transistor
Audio PA Component Thermal Pads
(7515582H01) 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Reassembly — Detailed 5-15
3. Assembly of the GPS Plug
Push the GPS plug into the chassis opening until it is fully seated. Refer to Figure 5-13.
Figure 5-13.  Replacing GPS Plug
5.8.1 Transceiver Board and Receiver Board Reassembly
1. Insert the transceiver board into the chassis by tilting the transceiver board (approximately 30 
degrees) and sliding it into place, taking care to line up the RF and DC connectors with the 
openings in the back of the chassis.
Ensure that the transceiver board alignment holes are positioned over the chassis alignment 
bosses and then push the board down to fully seat.
Figure 5-14.  Placing the Transceiver Board in the Chassis
Do not leave the transceiver board in the chassis for extended periods of time 
without the RF/DC retention clips, or damage to the board connectors may 
occur.
GPS Plug
GPS Plug
Locating Bosses
!
C a u t i o n 
						

							February 21, 20076866576D03-A
5-16Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed
2. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to 
properly locate the transceiver board. Refer to Figure 5-15. 
Figure 5-15.  Inserting RF/DC Retention Clips
3. Insert the accessory connector into the radio assembly and press into place until the 
connector is flushed with the chassis. Refer to Figure 5-16.
Figure 5-16.  Inserting Accessory Connector
RF/DC
Retention Clips
Accessory 
Connector