Motorola Portable Radio Ep450 Basic Hkln4215a Manual

December 3, 2003HKLN4215A
6-6Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
6.4.1.2  Dust Cover Disassembly
1.Gently pry the top of the dust cover away from the body of the radio. (See Figure 6-6).
2.Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed.
3.Separate the dust cover away from the body of the radio. The dust cover key is fragile; apply only 
light pressure to the key while removing the dust cover.
Figure 6-6....

HKLN4215ADecember 3, 2003
Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-7
6.4.1.4  Keyboard Removal
1.Carefully pry the four keypad retainer locking tabs free from the housing use a scribe.
2.Lift the keypad retainer up from the bottom and slide the top tabs out.
3.Slide keypad retainer out of chassis carefully to prevent damage to flex cable.
4.Lift LCD keypad board out of housing (Figure 6-8).
5.Lift keypad out of housing.
6.4.1.5  PTT Disassembly
1.If...

December 3, 2003HKLN4215A
6-8Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
6.4.1.6  Chassis Disassembly
1.Remove the O-ring.
2.Use a Torx™ screwdriver with a T6 bit to remove the four screws (Figure 6-10) holding the main 
board to the chassis.
.
3.The audio jack shroud can be removed from the main board.Figure 6-9.  PTT Removal
CAUTION:  Refer to the CMOS CAUTION paragraph (see 3.3) before removing the main board. Be sure 
to use Electrostatic Discharge...

HKLN4215ADecember 3, 2003
Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-9
4.Lift the main board from the chassis (Figure 6-10).
5.Remove the battery contact seal.
6.4.2 Radio Re-assembly - Detailed
6.4.2.1  Dust Cover Re-assembly
1.Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening
(Figure 6-11).
2.Press the dust cap until the tail is fully into the hole.
3.Twist the dust cap counter-clockwise until the cap is seated...

December 3, 2003HKLN4215A
6-10Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
4.Locate the speaker tab and align it with the tab opening in the front housing (Figure 6-13).
5.Insert the speaker tab into the speaker recess in the housing. Ensure the speaker is seated flush 
in the housing.
6.Insert one end of the speaker retainer into the slot in the front housing (See Figure 6-13).
 
7.Install the retainer screw using a T6 Torx screwdriver. Torque to 2.3 -...

HKLN4215ADecember 3, 2003
Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-11
6.4.2.3  Keypad and LCD/Keyboard Re-assembly
1.Attach the flex cable from the LCD module to the keyboard, if not already attached (Figure 6-15).
2.Remove protective mylar from window and from keypad, if present.
3.Install the new keypad into the housing. Use the two housing posts for keypad alignment 
(Figure 6-14).
4.Remove mylar from LCD if present.
5.Install the LCD/Keypad...

December 3, 2003HKLN4215A
6-12Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
6.Attach the flex cable into the connector on the keypad board, if not already connected.
7.Bend the flex cable as shown (Figure 6-15)
6.4.2.4  Keyboard Retainer Re-assembly
1.Insert the flex cable through the slot at the bottom of the keyboard retainer (Figure 6-16).
2.Insert the two top tabs of the keyboard retainer into the two tab retainers located on each side of 
the speaker...

HKLN4215ADecember 3, 2003
Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-13
.
6.4.2.6  Chassis and Front Cover Re-assembly
1.Dress and connect the speaker wires..
a. Connect the speaker wire assembly into the 2-pin connector on the main board and 
bend the wires at the board connector so the wires are positioned toward the top of the 
radio (Figure 6-18). 
b. Connect the microphone wire assembly into the two hole socket on the main board and 
bend the...

December 3, 2003HKLN4215A
6-14Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
2.Position the radio (Figure 6-19), and reconnect the flex connector from the keyboard into the con-
nector located on the bottom of the main board, pushing up the 2 end tabs.
3.Slide the volume potentiometer and frequency switch shafts into their respective holes in the front 
cover. Look through the accessory connector opening to make certain that the wires are not 
pinched,...

HKLN4215ADecember 3, 2003
Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-15
5.Snap chassis assembly completely into the top of the front cover (Figure 6-20) until it settles in 
place.
6.Make sure the 0-ring is properly seated. If the O-ring seal is pinched, separate the chassis from 
the housing using the knob removal/chassis opener and dress O-ring properly.
7.Snap the bottom of the chassis into the front cover.
8.Check that O-ring is visible at the...