Motorola Pr400 Basic 6881096c24 A Manual
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6881096C24-AAugust, 2004 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-13 5.Replacing the O-ring. a. If you have the older chassis (2786389Z01) use the older O-ring (3286431Z02). Position the O-ring in the top groove by the volume/frequency switches. Stretch the O-ring to place it into the retaining groove at the bottom end of the chassis. b. If you have the newer chassis (2786389Z02) use the newer O-ring (3286431Z05). Posi- tion the O-ring with the plug on the right side (speaker connector side). Push the plug all the way into the chassis slot until it is touching the chassis flange. Repeat for the left side. Stretch the O-ring to place it into the retaining groove at the top and bottom end of the chassis. 6.Check the top corner of the chassis by flipping the O-ring, if the O-ring came out easily, twist the O-ring and re-try until the O-ring is held properly by the chassis. 7.4.3.6 Chassis and Front Cover Re-assembly 1.Dress and connect the speaker wires.Figure 7-17. Installation of Main Board onto Chassis Note: Care should be taken when dressing the speaker and microphone wires to avoid pinching them between the speaker magnet and shield, or between the accessory connector and housing. Note: Ensure that the plug orientation is correct with the exposed pins in the wire casing facing upward and fully plugged in. Main Board Radio Chassis Battery Contact Seal Interface Pad Frequency & Volume SwitchesAudio Jack Shroud (Replace after Plugging in Speaker and Mic) O-Ring
July, 20046881096C24-A 7-14Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 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 7-18). b. Connect the microphone wire assembly into the two hole socket on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio (Figure 7-18). c. Slide the audio jack shroud onto accessory connector (Figure 7-17). 2.Position the radio (Figure 7-19) and reconnect the flex cable connector from the keyboard into the connector 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, between the shroud and housing.Figure 7-18. Microphone and Speaker Wires Figure 7-19. Keyboard Flex Cable Connection Speaker Connector Microphone Connector Shroud Radio Chassis Flex Cable Connector End Tabs
6881096C24-AJuly, 2004 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-15 4.Push the topside of the board chassis upward until it touches the housing end. Before snapping the board into the housing, perform the following checks: a. Open the dust cap and ensure the wires are not pinched between the shroud and housing. b. Ensure the O-ring is seated in the groove. c. Ensure that the bottom side of the dust cap is fully pressed into the housing before the snapping the board into place. 5.Snap chassis assembly completely into the top of the front cover (Figure 7-20) 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 corners. 9.Re-assemble the knobs, antenna, and battery. 7.4.3.7 PTT Re-assembly 1.Place the PTT seal over the ridge around the top hole. Press down to seat the seal around the ridge. 2.Place the bottom tab in the slot inside the front housing PTT opening. Slightly slide down the PTT and bow it by placing one finger under the middle of the PTT, so that the top tab can be aligned and inserted into the top slot (Figure 7-21a). 3.Press the PTT assembly against the front cover opening (Figure 7-21b). Figure 7-20. Fastening the Chassis Figure 7-21. PTT Re-assembly Radio Chassis a. Place bottom tab into bottom slot. Place top tab into top slot.b. Push down on PTT toward bottom of radio so hooks do not get crushed.
August, 20046881096C24-A 7-16Limited Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List 7.5 Mechanical View and Parts List 7.5.1 PR400 Limited-Keypad Exploded View and Parts List Figure 7-22. PR400 Limited Keypad Radio Exploded View 1 2829 3132 33 2 3 4 5 6 78 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 30
Mechanical View and Parts List7-17 6881096C24-AAugust, 2004 ItemMotorola Part NumberDescription 1See Section 6Antenna 2 3680530Z02 Knob, Frequency 31386440Z03Escutcheon, Top; 32 Ch. 4 5886627Z01 Antenna Adaptor/Seal (Optional) 51586391Z02Housing, Limited, with Lens 6 3586621Z01 Speaker, Felt 73886489Z01PTT, Rubber 8 4586439Z01 PTT, Plastic 90186638Z01Speaker Assembly 10 4286620Z01 Retainer Speaker 113586621Z02Felt, Microphone 12 0780608V01 Boot, Microphone 130186639Z01Microphone Plug Assembly 14 5104949J16 Display, LCD Module 150104017J19Keypad Board Assy 16 1586437Z01 Shroud, Audio Jack 173286431Z05Seal, Main O-ring 18 7586436Z02 Pad, PA Interface 192786389Z02Chassis 20 3286435Z01 Seal, Battery Contact Block 210304726J05Screws, Chassis; 4 Used 22 4286648Z01 Plate, Retainer 238486617Z0128-pin, Flex 25 7586654Z02 Keypad, Limited 265586445Z02Latch Assembly 27 4105944K01 Spring, Latch; 2 Used 283886441Z01Cap, Dust 29 3286432Z01 Seal, Control Shaft 300386434Z01Screw, Speaker Retainer 31 3386443Z01 Label, Escutcheon Seal 326186446Z02Lightpipe 33 3680529Z01 Knob, Volume NON-REFERENCED ITEMS 3386625Z01 Nameplate, Motorola ItemMotorola Part NumberDescription
July, 20046881096C24-A 7-18Limited Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List This Page Intentionally Blank
Chapter 8 Non-Keypad Model Disassembly and Re-assembly 8.1 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 8.2 Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 8.2.1 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. 8.2.2 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. !
July, 20046881096C24-A 8-2Non-Keypad 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. 8.3 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.!
6881096C24-AJuly, 2004 Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 8-3 8.4 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): 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 8.4.1 Radio Disassembly — Detailed 8.4.1.1 Front Cover From Chassis Disassembly 1.Turn off the radio. 2.Remove the battery (Figure 8-1): 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 8-1. Battery Removal Battery Latch Lock Unlock
July, 20046881096C24-A 8-4Non-Keypad 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 8-2) 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 8-3). 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 8-2. Antenna and Knob Removal Note: Both knobs slide on and off. However the knobs are designed to fit very tightly on the shaft. Figure 8-3. 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 !