Motorola Portable Radio Ep450 Basic Hkln4215a Manual
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December 3, 2003HKLN4215A 6-16Display Model Disassembly and Re-assembly: Mechanical View and Parts List 6.5 Mechanical View and Parts List 6.5.1 EP450 Display Exploded View and Parts List Figure 6-22. EP450 Display Radio Exploded View 1 2829 3132 33 2 3 4 5 6 78 9 1011 12 13 14 15 16 17 18 19 2 0 21 22 23 24 25 26 27 30
Mechanical View and Parts List6-17 ItemMotorola Part NumberDescription 1See Section 6Antenna 2 3680530Z02 Knob, Frequency 31386440Z01 1386440Z02Escutcheon, Top; 4 Ch. Escutcheon, Top; 16 Ch. 4 5886627Z01 Antenna Adaptor/Seal (Optional) 51586391Z03Housing, Full, with Lens 6 3586621Z01 Speaker, Felt 73886489Z01PTT, Rubber 8 4586439Z01 PTT, Plastic 95085738Z08Speaker 10 4286620Z01 Retainer Speaker 113586621Z02Felt, Microphone 12 0780608V01 Boot, Microphone 135085880L01Microphone 14 5104949J16 Display, LCD Module 150104017J18Keypad Board Assy 16 1586437Z01 Shroud, Audio Jack 173286431Z02Seal, Main O-ring 18 7586436Z01 Pad, PA Interface 192786389Z01Chassis 20 3286435Z01 Seal, Battery Contact Block 210304726J05Screws, Chassis; 4 Used 22 4286648Z01 Plate, Retainer 230909059E19Connector, 28-pin 24 0986632Z02 9 Pin Connector 257586654Z03Keypad, Full 26 5586445Z02 Latch Assembly 274105944K01Spring, Latch; 2 Used 28 3886441Z01 Cap, Dust 293286432Z01Seal, Control Shaft 30 0386434Z01 Screw, Speaker Retainer 313386443Z01Label, Escutcheon Seal 32 6186446Z02 Lightpipe 333680529Z01Knob, Volume NON-REFERENCED ITEMS 3386625Z01Nameplate, Motorola Nameplate, EP450 ItemMotorola Part NumberDescription
December 3, 2003HKLN4215A Notes: 6-18Display Model Disassembly and Re-assembly: Mechanical View and Parts List
Chapter 7 Non-Display Model Disassembly and Re-assembly 7.1 Introduction This section provides details about the following: Preventive maintenance (inspection and cleaning) Safe handling of CMOS and LDMOS devices Disassembly and re-assembly of the radio Repair procedures and techniques 7.2 Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 7.2.1 Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional. It is not recommended to inspect the interior electronic circuitry. 7.2.2 Cleaning Procedures The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the radio. External surfaces include the front cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime. The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (70% by volume). Cleaning External Plastic Surfaces Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices.Note: Internal surfaces should be cleaned only when the radio is disassembled for service or repair. CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plas- tics. Avoid using aerosol sprays, tuner cleaners, and other chemicals. !
December 3, 2003HKLN4215A 7-2Non-Display Model Disassembly and Re-assembly: Safe Handling of CMOS and LDMOS Devices Cleaning Internal Circuit Boards and Components Isopropyl alcohol (70%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the dislodged material out and away from the inside of the radio. Make sure that controls or tunable components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process since this could cause the liquid to collect in unwanted places. After completing the cleaning process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or back cover. 7.3 Safe Handling of CMOS and LDMOS Devices Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair. Handling precautions are mandatory for CMOS circuits and are especially important in low humidity conditions. DO NOT attempt to disassemble the radio without first referring to the following CAUTION statement. Note: Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage). CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are properly grounded. Take the following precautions when working on this unit: Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together. Do not insert CMOS devices into conventional plastic “snow” trays used for storage and transportation of other semiconductor devices. Ground the working surface of the service bench to protect the CMOS device. We recommend using the Motorola Static Protection Assembly (part number 0180386A82), which includes a wrist strap, two ground cords, a table mat, and a floor mat. Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX- 4015.) Do not wear nylon clothing while handling CMOS devices. Do not insert or remove CMOS devices with power applied. Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present. When straightening CMOS pins, provide ground straps for the apparatus used. When soldering, use a grounded soldering iron. If at all possible, handle CMOS devices by the package and not by the leads. Prior to touching the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.!
HKLN4215ADecember 3, 2003 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-3 7.4 Disassembling and Re-assembling the Radio — General Since these radios may be disassembled and re-assembled with the use of only four (board to casting) screws, it is important to pay particular attention to the snaps and tabs, and how parts align with each other. The following tools are required for disassembling the radio (see 3.2 for a list of service aids): knob remover/chassis opener penknife-size screwdriver TORX™ T6 screwdriver If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. See Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: Chassis Disassembly Speaker Disassembly PTT Disassembly 7.4.1 Radio Disassembly — Detailed 7.4.1.1 Front Cover From Chassis Disassembly 1.Turn off the radio 2.Remove the battery (Figure 7-1): a. Slide the battery latch into the unlock position. Disengage by pushing downward and holding the latch towards the front of the radio. b. With the battery latch disengaged, slide the battery down from the top of the radio about 1/2 in. Once the battery is free from the battery rails, lift it directly away from the radio. c. Remove the battery from the radio. Figure 7-1. Battery Removal Battery Latch Lock Unlock
December 3, 2003HKLN4215A 7-4Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3.Remove the antenna. 4.Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis opener tool (Motorola part # 6686533Z01). (Figure 7-2) 5.Separate the chassis from the front housing assembly by using the knob remover/chassis opener too. Place the broad side of the opener into the slots located at the base of the radio (Figure 7-3). Press the handle on the opener downwards. This pressing action forces the thin inner plastic wall toward the base of the radio, releasing the two chassis base tabs.. Figure 7-2. Antenna and Knob Removal Note: Both knobs slide on and off. However the knobs are designed to fit very tightly on the shaft. Figure 7-3. Chassis Removal CAUTION: Marring the front cover O-ring sealing area will prevent the radio from sealing properly. If the O-ring is damaged, replace it with a new one. Note:The speaker wire assembly microphone wire assembly and keypad ribbon connector con- necting the front housing assembly and the chassis prevent the two units from being com- pletely separated Radio Chassis Knob Remover/ Chassis Opener !
HKLN4215ADecember 3, 2003 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-5 6.Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case. (Figure 7-4). Rotate the chassis counterclockwise out of the housing and position next to the housing. Take care not to damage the speaker and microphone wires that are still connected to the chassis (Figure 7-4). 7.Unplug the speaker wire assembly from the 2-pin connector on the chassis. 8.Unplug the microphone wire assembly from the socket on the chassis. 9.Move the chassis away from the housing and place on a clean work surface. 7.4.1.2 Dust Cover Disassembly 1.Gently pry the top of the dust cover away from the body of the radio. (See Figure 7-5). 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 7-5. Dust Cover Disassembly Figure 7-4. Microphone and Speaker Connections Speaker Connector Microphone ConnectorShroud key c. Separate dust cover from body. b. Rotate dust cover 90° to a. Pry dust cover from body. allow key to be removed.
December 3, 2003HKLN4215A 7-6Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.1.3 Speaker and Microphone Disassembly 1.Remove the screw from the speaker retainer using a T6 Torx screwdriver (Figure 7-6). 2.Lift the retainer off the speaker, sliding end of retainer out of corner slot on the housing. 3.Lift the speaker out from the front housing. 4.Carefully lift microphone assembly out of housing. 7.4.1.4 PTT Disassembly 1.If required, the PTT (Figure 7-7) can be disassembly using a small screwdriver, as follows: a. Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab. b. Pry the PTT away from the radio housing. c. Inspect the two hooks. If bent or broken, the PTT must be replaced. d. Remove the PTT seal. Note: The speaker is held in place with a retainer bracket. Be careful not to damage the speaker when removing the retainer bracket. Figure 7-6. Removal Speaker-Microphone Assembly Retainer Bracket Radio Housing Speaker Wire Connector Microphone Assembly
HKLN4215ADecember 3, 2003 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-7 7.4.2 Chassis Disassembly 1.Remove the O-ring. 2.Use a Torx™ screwdriver with a T6 bit to remove the four screws (Figure 7-8) holding the main board to the chassis. 3.The audio jack shroud can be removed from the main board. 4.Lift the main board from the chassis. 5.Remove the battery contact seal.Figure 7-7. PTT Removal CAUTION: Refer to the CMOS CAUTION paragraph (7.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards. Figure 7-8. Removal of Main Board from Chassis Flat BladeScrewdriver PTT Seal Ta b Ta b Hooks ! Main Board Radio Chassis Audio Jack Shroud O-Ring