Motorola Pr400 Basic 6881096c24 A Manual

6881096C24-AJuly, 2004
Limited Keypad 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 Chapter 4 for a list of service aids):
...

July, 20046881096C24-A
7-4Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
4.Pry off the volume and channel selector knobs from their shafts using the knob remover/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 
tool. Place the broad side of the opener into the slots located at the base of the radio (Figure 7-3). 
Press the handle of the...

6881096C24-AJuly, 2004
Limited Keypad 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).
7.Rotate the bottom of the chassis up about 20° to access the keyboard flex connector. Push down 
2 end tabs to release flex connector at the bottom of the chassis.
8.Rotate the chassis counterclockwise out of the housing and...

July, 20046881096C24-A
7-6Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
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 7-6).
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...

6881096C24-AJuly, 2004
Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-7
7.4.1.4  Keyboard Removal
1.Carefully pry the four keypad retainer locking tabs free from the housing using a scribe.
2.Lift the keypad retainer up from the bottom and slide the top tabs out.
3.Slide keypad retainer out of housing carefully to prevent damage to flex cable.
4.Lift LCD keypad board out of housing (Figure 7-8).
5.Lift keypad out of housing. Note:
Use care when...

July, 20046881096C24-A
7-8Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
7.4.1.5  PTT Disassembly
1.If required, the PTT (Figure 7-9) 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. 
7.4.2 Chassis Disassembly
1.Remove the...

6881096C24-AJuly, 2004
Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-9
7.4.3 Radio Re-assembly - Detailed
7.4.3.1  Dust Cover Re-assembly
1.Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 7-
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 properly onto the recess.
4.Press the cap again to ensure it fully covers the...

July, 20046881096C24-A
7-10Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
3.Insert the Boot and microphone sub-assembly into the microphone recess in the housing and 
route wires as shown in Figure 7-12.
4.Locate the speaker tab and align it with the tab opening in the front housing (Figure 7-13).
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...

6881096C24-AJuly, 2004
Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-11
7.Install the retainer screw using a T6 Torx screwdriver. Torque to 2.3 - 2.5 lb/in.
7.4.3.3  Keypad and LCD/Keyboard Re-assembly
1.Attach the flex cable connector from the LCD module to the keyboard, if not already attached 
(Figure 7-15).
2.Remove protective mylar from window and from keypad, if present.
3.Install the new keypad into the housing. Use the two housing posts...

August, 20046881096C24-A
7-12Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General
6.Attach the flex cable connector into the connector on the keypad board, if not already connected.
7.Bend the flex cable connector as shown (Figure 7-15).
7.4.3.4  Keyboard Retainer Re-assembly
1.Insert the flex cable connector through the slot at the bottom of the keyboard retainer (Figure 7-
16).
2.Insert the two top tabs of the keyboard retainer into the two tab retainers...