Motorola Mototrbo Dr3000 Repeater Basic 6866576d03 A Manual

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Reassembly — Detailed 5-17
4. Place the PA pad on to the die cast cover by aligning the two holes in the PA pad with the 
alignment pins on the die cast cover. 
5. Fit the O-ring onto the die cast cover securely. Refer to Figure 5-17.
Figure 5-17.  Assembling of PA Pad and O-ring
PA  P a d
Die Cast Cover
O-ring 
						

							February 21, 20076866576D03-A
5-18Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed
6. Place the die cast cover onto the chassis orienting the die cast cover so that screw holes 6 
and 7 align with the bosses on the chassis as shown in Figure 5-18.
Figure 5-18.  Assembling Die Cast Cover onto Chassis
Radio Chassis
Die Cast Cover
Screws (7) 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Reassembly — Detailed 5-19
7. Using a T20 TORX™ driver, tighten the seven screws between 2.94 N-m (26 lbs-in) in the 
order shown in Figure 5-19.
8. Repeat tightening the seven screws in the order shown otherwise the first three screws will 
likely be loose.
Figure 5-19.  Screw Sequence to Tighten Die Cast Cover
5.8.2 Thermal Pad Replacement Procedure
A. Chassis Thermal Pad Replacement Procedure
Harmonic Filter Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad. 
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary. 
Care should be taken to minimize any cleaning-agent contact with the surrounding shield 
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place it 
white side down on the chassis as shown in Figure 5-20.
Figure 5-20.  Replacing Thermal Pads
Harmonic Filter
Radio Chassis Pad (7515580H01) Harmonic Filter
Pad (7515579H01) 
						

							February 21, 20076866576D03-A
5-20Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed
Driver Thermal pad Replacement 
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad. 
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary. 
Care should be taken to minimize any cleaning-agent contact with the surrounding shield 
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the 
pad on to the chassis, aligning the edges of the pad with the edges of the chassis, as shown 
in Figure 5-21.
Figure 5-21.  Aligning Driver Pad on Chassis
4. Apply even pressure to the pad and remove the protective liner.
B. Transceiver Board Thermal Pad Replacement Procedure
Transistor Thermal Pads and PA Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift each pad from the transceiver board. Discard the old pads. 
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary. 
3. Once the surface is clean and dry, remove each new pad from the shipping liner, and place in 
the proper location on top of each transistor component and the audio PA with the white side 
down (see Figure 5-22).
Figure 5-22.  Placing Thermal Pads on PA and Transistor Components
Driver Pad
Radio Chassis (7515357H01)
PA Thermal Pad (7515581H01)Transistor
Audio PA Component Thermal Pads
(7515582H01) 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Reassembly — Detailed 5-21
5.8.3 Reassembly of Receive Radio, Power Supply and Connector Board Assembly
(Refer to Figure 5-6)
Visually inspect repeater enclosure to ensure that no metal shavings or debris are found.
5.8.3.1  Reassembly of Power Supply
1. Align the two mounting holes on each side of the bracket with the mounting holes on the 
power supply.
2. Secure the power supply and the bracket with four M5 screws and washers.
3. Tighten the four M5 screws to 3.0 N-m.
4. Firmly connect the single connection end of Y-split cable to power cable of power supply.
5.8.3.2  Reassembly of Receive Radio
1. Insert the Receive radio into the top half of the bracket.
2. Align mounting hole on each side of the receive chassis to the mounting holes on the bracket.
3. Secure the Receive radio and the bracket with two M5 screws and washers.
4. Tighten the two M5 screws to 3.0 N-m.
5.8.3.3  Reassembly of Connector Board Assembly
1. Align the five mounting holes on the connector board assembly onto the five standoffs on the 
receive bracket and install five M3 screws.
2. Tighten the five M3 screws to 1.0 N-m.
5.8.3.4  Reassembly of the Receive Bracket Assembly to the Enclosure
1. Align and mount the receive bracket assembly onto the five stud screws in the enclosure.
2. Ensure that the dimple locator (bump) on the enclosure is nested within the hole on the 
receive bracket before installing and tightening the lock nuts.
3. Tighten the five lock nuts to 2.0 N-m.
NOTE:The two lock nuts at the side on base will require a magnetic lock nut driver with extension of 
greater than 150 mm).
4. Connect the antenna cable to the Receive radio.
5. Insert the BNC connector of the antenna cable through the back panel of the enclosure and 
secure it using a lock washer and nut.
6. Tighten the nut to 0.7 N-m using a 16 mm deep well socket driver.
7. Firmly connect one of the connectors from the dual end of Y-split cable to the Receive radio.
NOTE:All cables (except the antenna cable), are routed at the bottom rear receive bracket.
8. Insert the accessory connector through the opening of the enclosure onto the edge of the 
connector board assembly.
9. Make sure that the accessory connector is completely inserted onto the connector board 
assembly and the back end surface of the accessory connector is flushed firmly against the 
back panel of enclosure.
10. Mount the retainer clip and secure it with two M4 screws.
11. Tighten the screws to 2.0 N-m. 
						

							February 21, 20076866576D03-A
5-22Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed
12. Insert the solder terminal end of the SSI cable into the 11-position connector at the front face 
of Receive radio. A dashed black line is visible from the top view.
5.8.4 Reassembly of Transmit Radio
(Refer to Figure 5-5)
5.8.4.1  Replacing the Thermal Pad and Heatsink
1. Make sure that mating surfaces of Heatsink and Transmit radio are cleaned and free from any 
debris.
2. Align the holes on the thermal pad to the screw holes in the Transmit radio and place thermal 
pad onto the Transmit radio.
3. Align the holes on the heatsink to the screw holes in the Transmit radio and place heatsink 
onto the thermal pad.
4. Secure but do not tighten the seven screws previously removed.
5. When all seven screws are secured, tighten the screws to 1.0 N-m. Refer to Figure 5-19.
5.8.4.2  Reassembly of the Transmit Bracket Assembly to the Enclosure
1. Position the Transmit radio onto the transmit bracket so that the label “FRONT” on bracket is 
facing the front face of radio.
2. Align the mounting holes on the Transmit radio and the transmit bracket on both sides.
3. Attach and secure the M5 screws and washers on each side of the bracket.
4. Tighten the screws to 3.0 N-m, making sure the Transmit radio remains horizontal.
5. Align and mount the transmit bracket assembly onto the four stud screws in the enclosure.
6. Ensure that dimple locator (bump) on the enclosure is nested within the hole on the transmit 
bracket before installing and tightening the lock nuts.
7. Secure the four lock nuts (two on each side) onto the stud screws. 
8. Tighten the four lock nuts to 2.0 N-m.
9. Connect the antenna cable to the Transmit radio.
10. Insert the N-Type connector of the antenna cable through the back panel of the enclosure 
and secure it using a lock washer and nut.
11. Tighten the nut to 0.7 N-m using a 19 mm deep well socket driver.
12. Firmly connect one of the connectors from the dual end of Y-split cable to the Transmit radio.
13. Connect the black colored end of accessory cable connector to rear of Transmit radio making 
sure that the locking connector tab is facing up.
14. Connect the white colored end of the accessory cable connector to the connector board 
assembly making sure that the locking connector tab is facing toward the front of repeater.
NOTE:Make sure that the accessory connectors at both ends are locked in place. A clicking sound 
can be heard from the locking tab.
15. Insert the solder terminal end of the SSI flex cable (positioned bottom side of PCB) into the 
11-position connector in the Transmit radio. A solid black line is visible from the top view.
16. Insert the solder terminal end of the flex cable (positioned top side of PCB) into the 30-
position connector in the Transmit radio. A solid blue line is visible from the top view. 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Transmit and Receive Radio Reassembly — Detailed 5-23
5.8.5 Reassembly of Fan
1. Position the fan in the enclosure with arrow pointing outward and the wires on the fan at the 
bottom right corner of the fan.
Figure 5-23.  Fan Orientation
2. Position the fan grill outside of the enclosure aligning with the screw holes.
3. Install four 3.5 mm screws through the fan grill, the rear panel of the enclosure and onto the 
fan clip.
4. Secure the fan and tighten the four screws to 1.2 N-m through each of the fan clip.
5. Plug the fan cable plug into the 4-position fan connector on the connector board assembly.
NOTE:It is recommended that you dress and tie wrap the blue ethernet cable and the fan cables.
5.8.6 Reassembly of Repeater Indicator Board
Refer to Figure 5-3.
1. Holding Repeater Indicator Board on outer edge, insert the clips of light guide into mounting 
holes, making sure the light guide snaps into place.
2. Align the four mounting holes on the Repeater Indicator Board onto the four standoffs on the 
front panel.
3. Install and secure the four M3 screws.
4. Tighten the four M3 screws to 1.0 N-m.
5. Use the four M6 screws to secure the front panel onto the enclosure. Tighten the screws to 
3.7 N-m.
6. Connect the blue ethernet cable onto the ethernet connector on the Repeater Indicator 
Board.
7. Insert the flex cable onto the 30-position connector on the Repeater Indicator Board. The 
solder terminal end of the flex cable is faced towards the front panel. A solid black line is 
visible from the top view.
5.8.7 Reassembly of Cover 
1. Place the cover on the enclosure.
2. Secure the two M4 screws on each side of the cover and one at the top. Tighten the screws 
to 2.0 N-m.
Screws
Back of Enclosure Position of arrow
Fan 
						

							February 21, 20076866576D03-A
5-24Disassembly /Reassembly  Procedures: Repeater Exploded Mechanical Views and Parts Lists
5.9 Repeater Exploded Mechanical Views and Parts Lists
Figure 5-24.  Repeater Assembly Exploded View
1 54 
17
9   137
12
15
1011
14
16
8
6
3
2 32
33
16
Transmit Bracket & 
See following pages 
Receive Bracket &
Radio assembly
See following pages
for breakdown.
Front Panel
complete assembly
See following pages 
for breakdown. Radio Assembly
for breakdown. 
						

							6866576D03-AFebruary 21, 2007
Disassembly /Reassembly  Procedures: Repeater Exploded Mechanical Views and Parts Lists 5-25
Figure 5-25.  Receive Bracket and Radio Assembly Exploded View
Figure 5-26.  Transmit Bracket and Radio Assembly Exploded View
20
31 23
18
19
22
21
282726
25
24
19
31 
						

							February 21, 20076866576D03-A
5-26Disassembly /Reassembly  Procedures: Repeater Exploded Mechanical Views and Parts Lists
Figure 5-27.  Front Panel Complete Assembly Exploded View
Table 5-3.  Repeater Exploded View Parts List
Item No. Description Part Number
1Screw, TT6x1.0x10, Starpan, EM6219 (black)0312016A54
2  Repeater Indicator Board PMLN4814_
3 Cable, Flex SSI3015639H01
4  Cable, Flex 30-Position 3015634H01
5 Fan Assembly5915618H01
6 Enclosure Assembly 1515837H01
7 To p  C o v e r1515655H01
8  Cable, RF Tx, W/N-Type 3015573H01
9 Cable, RF Rx, W/BNC3015574H01
10 Fan Grill 1383852R01
11  Screw, TT3.5x0.6x16, Star SLT Pan0310909E50
12  M6 Ground Nut 0285854Y01
13 M6 Ground Screw0310909A95
14  Accessory Retainer Clip 4216361H01
15 Accessory Connector0178042A01
16  Screw, M4x0.7x13.0, Starpan STLZNC 0310909E63
2 2229
30