Motorola Sse 5000 6881094c12 A Manual

							6881094C12-ANovember 11, 2004
Disassembly/Reassembly Procedures: Disassembly/Reassembly Procedures for Accessories 7-9
7.4.4 Carry Case
This section explains how to assemble the carry case, belt loop and T-strap.
1. Slide the belt loop onto your belt.
2. Snap the two horizontal snaps of the T-strap onto the back of the carry case so that the cords 
lead upwards.
3. Insert the radio snugly into the carry case.
4. Pull the cords of the T-strap over the top of the radio, on either side of the Channel Select 
knob.
5. Snap the other end of the T-strap onto the front of the carry case.
6. Turn the carry case, with the radio strapped in, upside down.
7. Align the knob on the back of the carry case with the open end of the groove on the front of 
the belt loop.
8. Slide the carry case all the way down into the groove.
9. Turn the carry case and radio right side up.
Figure 7-6.  Assembling the Carry Case
7
5
5
311 
						

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7-10Disassembly/Reassembly Procedures: Disassembly/Reassembly Procedures for Radio Knobs
7.4.5 Universal Connector Dust Cover
This section explains how to remove and attach the dust cover for the universal connector.
7.4.5.1  Remove the Universal Connector Dust Cover
1. Use a Phillips-head screwdriver to unscrew the screw at the top of the dust cover. 
2. Pull the dust cover away and up until it is separated from the radio.
7.4.5.2  Attach the Universal Connector Dust Cover
1. Hook the bottom of the dust cover into the slot on the left rear of the radio, just below the 
accessory connector. 
2. Align the screw on the dust cover with the hole on the radio, behind the antenna connector.
3. Use a Phillips-head screwdriver to screw the dust cover firmly into place.
Figure 7-7.  Attaching the Universal Connector Dust Cover
7.5 Disassembly/Reassembly Procedures for Radio Knobs
NOTE:Numbers in parentheses ( ) refer to item numbers in Figure 7-1 on page 7-3 and Table 7-1 on 
page 7-4.
Table 7-2.  Tools Used for Disassembly/ReassemblyWhen the universal connector is not in use, keep it covered 
with the dust cover.
ToolCommentPart No.
ROTO-TORQ Tool Adjustable torque driver RSX4043_
Phillips Head Star Bit Used for attaching/detaching power contact screws. 6680321B79
Channel and Volume Switch 
Spanner Nut BitUsed for attaching/detaching volume control and channel 
select switch spanner nuts.6680370B88
Antenna Spanner Nut Bit Used for attaching/detaching antenna spanner nuts. 6680371B34
T-10 Torx Bit Used for attaching/detaching radio bolts. 6680387A74
!
C a u t i o n
SCREW
DUST
COVERSLOT
TA B CONNECTORTHREADED
HOLE 
						

							6881094C12-ANovember 11, 2004
Disassembly/Reassembly Procedures: Disassembly/Reassembly Procedures for Radio Knobs 7-11
7.5.1 Channel Select Knob
This section explains how to remove and install the Channel Select knob.
NOTES:
• Remove the battery from the radio before removing or installing the Channel Select knob.
• The Channel Select knob is a two-part kit, consisting of a knob and an insert. Once an insert is 
removed, it cannot be used again. Therefore, remove an insert only if the channel select switch 
must be replaced, or if the control top must be removed from the chassis. 
• When the channel select insert must be removed, a new one must be used for reassembly.
7.5.1.1  Remove the Channel Select Knob
1. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.
2. Grasp the Channel Select knob (32) and pull it upward, while rocking the knob back and forth, 
until it is free from the Channel Select knob retainer insert (36), or the insert is free from the 
shaft.
3. To remove the knob retainer insert (36), place the tip of a thin-bladed screwdriver into the slot 
of the insert, and pry the insert open by twisting the screwdriver. This will allow you to easily 
remove the insert from the channel select switch shaft. Discard the removed insert.
7.5.1.2  Install the Channel Select Knob
1. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.
2. Place a new Channel Select knob retainer insert (36) on the channel select shaft, orienting 
the “TOP” marking on the insert upwards and aligning the insert’s D-shaped hole with the D-
shaped shaft. Press downward firmly on the insert until the top of it is flush with the top of the 
channel select shaft.
3. Place the Channel Select knob (32) on the retainer insert (36), aligning the three ribs of the 
insert to the corresponding slots on the inside of the knob. Press downward firmly on the knob 
until it seats securely in place.
7.5.2 Volume Knob
This section explains how to remove and install the Volume knob.
NOTES:
• Remove the battery from the radio before removing or installing the Volume knob.
• The Volume knob is a two-part kit, consisting of a knob and an insert. Once an insert is 
removed, it cannot be used again. Therefore, remove an insert only if the volume control must 
be replaced, or if the control top must be removed from the chassis. 
• When the volume insert must be removed, a new one must be used for reassembly.
7.5.2.1  Remove the Volume Knob
1. Turn the Volume knob (33) to the off position.
2. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.
3. Grasp the Volume knob (33) and pull it upward, while pushing it toward the back of the radio, 
until it is free from the Volume knob retainer insert (37), or the insert is free from the shaft.
4. To remove the knob retainer insert (37), place the tip of a thin-bladed screwdriver into the slot 
of the insert, and pry the insert open by twisting the screwdriver. This will allow you to easily 
remove the insert from the volume control shaft. Discard the removed insert. 
						

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7-12Disassembly/Reassembly Procedures: Disassembly Procedures for SSE 5000 Radio
5. Using needle-nosed pliers or some other pointed instrument, remove the volume torque 
o-ring (29).
7.5.2.2  Install the Volume Knob
1. Place the volume torque o-ring (29) over the volume control shaft.
2. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.
3. Place a new Volume knob retainer insert (37) on the volume control shaft, orienting the “TOP” 
marking on the insert upwards and aligning the insert’s D-shaped hole with the D-shaped 
shaft. Press downward firmly on the insert until the top of it is flush with the top of the volume 
control shaft.
4. Place the Volume knob (33) on the retainer insert (37), aligning the three ribs of the insert to 
the corresponding slots on the inside of the knob. Press downward firmly on the knob until it 
seats securely in place.
7.6 Disassembly Procedures for SSE 5000 Radio
This section contains instructions for disassembling the radio.
NOTE:Numbers in parentheses ( ) refer to item numbers in Figure 7-1 on page 7-3 and Table 7-1 on 
page 7-4.
7.6.1 Separate the Chassis and Housing Assemblies
1. Turn the radio off by rotating the On/Off/Volume knob (33) fully counter-clockwise until you 
hear a click.
2. Remove the battery, the universal connector dust cover or any accessory (other than the 
antenna) connected to the radio.
NOTE:It is not necessary to remove the Volume knob (33) and insert (37) or Channel 
Select knob (32) and insert (36) to service the chassis assembly (13). However, if 
any top control is suspected, then the knobs and inserts should be removed prior to 
removing the chassis assembly (13) from the housing assembly (1). See Section 
7.5.1.1: “Remove the Channel Select Knob” on page 7-11 and Section 7.5.2.1: 
“Remove the Volume Knob” on page 7-11.
3. Remove the two self-sealing bolts (59) on the bottom of the radio using a ROTO-TORQ 
adjustable torque screwdriver with a T-10 TORX bit (see Table 7-2 on page 7-10 for part 
numbers). 
NOTE:Inspect the seals of the bolts after removal. If the seals are damaged, discard both 
the seals and the bolts and replace with new self-sealing bolts. 
4. Remove the chassis (13) from the radio housing (1) by grasping the antenna and gently 
pulling upward to separate the assembly from the housing. Do not depress the PTT button 
during removal.
NOTE:Inspect the universal connector insulator (10), located inside the housing on the 
back face, for damage. If it is damaged, replace the insulator, taking care to ensure 
that all contacts facing the inside of the radio are covered and keeping the insulator 
away from the main o-ring (63) sealing area.
7.6.2 Disassemble the Chassis Assembly
NOTE:If the radio is equipped with hardware encryption, the encryption board (67) is attached to the 
front side of the VOCON board (64) via a 40-pin connector. 
						

							6881094C12-ANovember 11, 2004
Disassembly/Reassembly Procedures: Disassembly Procedures for SSE 5000 Radio 7-13
1. Put the housing assembly (1) aside.
2. Remove the main seal/toggle support (63) from around the chassis assembly (13). 
NOTE:Inspect the main-seal/toggle support for damage. If it is damaged, replace with a 
new seal prior to reassembly.
3. With the front of the radio facing upward, remove the three chassis bolts (60) from the front 
chassis (50) using a ROTO-TORQ adjustable torque screwdriver with a T-10 TORX bit (see 
Table 7-2 on page 7-10 for part numbers).
4. Remove the front chassis assembly (50).
5. Disconnect the encryption board (67), if present, by separating the 40-pin connector from the 
VOCON board (64). 
6. Disconnect the 20-pin control flex connector and the 20-pin display flex connector from the 
VOCON board (64).
7. Remove the VOCON board (64) from the back chassis (13) by lifting the board from the 
bottom and pulling the board out and away from the assembly.
8. Lift out the 26-pin compression connector (62).
9. Remove the main shield (61) and transceiver board (65) from the back chassis (13) in unison 
by lifting both parts from the bottom of the radio until they clear the center boss of the back 
chassis. Once clear of the center boss, they can be pulled out and away from the assembly. 
NOTE:Inspect the back chassis (13) to make sure that the thermal pad (26) is attached to 
the chassis. If the pad is attached to the transceiver board, remove it from the board, 
discard it, and attach a new thermal pad to the chassis heat sink island.
10. Separate the main shield (61) from the transceiver board (65). 
NOTE:Inspect the conductive gasket of the main shield for damage. If the conductive 
gasket seal is damaged, discard the main shield and replace it with a new one.
NOTE:The hex lock nuts (16), which hold the housing to the chassis assembly (13), are located in 
recesses at the bottom of the back chassis. These nuts are retained by the hex lock nut 
retainers (17). If the hex lock nuts need to be replaced, they can be removed with tweezers. 
7.6.3 Disassemble the Control Top
1. Referring to Section 7.5.1.1: “Remove the Channel Select Knob” on page 7-11 and Section 
7.5.2.1: “Remove the Volume Knob” on page 7-11, remove the Channel Select knob (32), 
channel select insert (36), Volume control knob (33), volume control insert (37), and volume 
torque o-ring (29).
2. Remove the volume control and channel select spanner nuts (14) using a ROTO-TORQ 
adjustable torque screwdriver with the volume/channel switch spanner nut bit (see Table 7-
2 on page 7-10 for part numbers).
3. Remove the volume control and channel select wave washers (19).
4. Remove the antenna spanner nut (15) using a ROTO-TORQ adjustable torque screwdriver 
with the antenna spanner nut bit (see Table 7-2 on page 7-10 for part numbers).
5. Remove the antenna star lock washer (18) and the antenna wave washer (20).
6. Remove the external RF retainer clip (35) by sliding the clip towards the bottom of the radio, 
in a direction parallel to the back face of the radio, until the clip disengages from the external 
RF contact (22) and the clip is free of the back chassis (13).
7. Remove the external RF contact (22) from the control top (40) by gently pushing the contact 
from the inside of the radio until it is free from the back of the radio.  
						

							November 11, 20046881094C12-A
7-14Disassembly/Reassembly Procedures: Disassembly Procedures for SSE 5000 Radio
NOTE:Inspect the RF contact seal (25) for damage. If it is damaged, discard it and replace 
with a new seal.
8. Remove the control top (40) from the back chassis (13) by pulling the control top away from 
the back chassis.
9. Remove the LCD module (41) by lifting the module away from the LCD module bracket (21), 
while feeding the 20-pin LCD module flex connector through the hole in the bracket. Use care 
not to damage the flex of the LCD module during removal.
10. Remove the TX/RX lightpipe (39) from the LCD module bracket (21) by lifting the lightpipe 
from the bracket. 
NOTE:Inspect the lightpipe seal (25) for damage. If it is damaged, discard it and replace 
with a new seal.
11. Remove the display button (34) and seal (28) from the control top (40) by pushing the display 
button from the outside surface of the control top until the seal and button fall free from the 
control top. 
NOTE:Inspect the display button seal (28) for damage. If it is damaged, discard it and 
replace with a new seal.
12. Remove the antenna bushing (38) from the back chassis (13) by lifting the bushing from the 
back chassis. 
NOTE:Inspect the antenna bushing o-ring (30) for damage. If it is damaged, discard it and 
replace with a new seal.
7.6.4 Disassemble the Housing Baseplate
NOTE:All repairs to the baseplate assembly can, and should, be made with the radio chassis inside 
the radio.
1. If not done already, remove the two self-sealing bolts (59) on the bottom of the radio using a 
ROTO-TORQ adjustable torque screwdriver with a T-10 TORX bit (see Table 7-2 on page 7-
10 for part numbers). 
NOTE:Inspect the seals of the bolts after removal. If the seals are damaged, discard both 
the seals and the bolts and replace with new self-sealing bolts. 
2. Remove the three radio power contact screws (5) using a ROTO-TORQ adjustable torque 
screwdriver with a Phillips star bit (see Table 7-2 on page 7-10 for part numbers). 
3. Remove the three power contacts (6).
4. Remove the baseplate contact insulator (8).
5. Remove the baseplate (2).
6. Remove the battery latch (4).
7. Remove the latch spring (7).
8. Remove the baseplate seal (9). 
NOTE:Inspect the baseplate seal for damage. If it is damaged, discard it and replace with 
a new seal.
9. Inspect the radio port seal (3). 
NOTE:If the port seal is punctured or damaged, it must be replaced with a new port seal. 
If the port seal needs to be replaced, it can be peeled off of the housing. All residual 
adhesive on the housing must be removed before replacing the port seal. 
						

							6881094C12-ANovember 11, 2004
Disassembly/Reassembly Procedures: Reassembly Procedures for SSE 5000 Radio 7-15
7.7 Reassembly Procedures for SSE 5000 Radio
This section contains instructions for reassembling the radio.
NOTE:Numbers in parentheses ( ) refer to item numbers in Figure 7-1 on page 7-3 and Table 7-1 on 
page 7-4.
7.7.1 Reassemble the Control Top
1. Install the antenna bushing (38) by sliding it into the antenna bushing recess in the back 
chassis (13). Ensure that the antenna bushing o-ring (30) is in place before proceeding.
2. Install the lightpipe (39) into the LCD bracket (21). Ensure that the lightpipe o-ring (25) is in 
place before proceeding
3. Install the display button (34) and seal (28) into the control top (40). Ensure that the seal is 
pressed firmly in place and is fully retained in the recess of the control top.
4. Install the LCD module (41) into the LCD bracket (21), orienting the display such that the 
locating hole of the LCD support frame aligns with the locating pin of the LCD bracket, while 
feeding the 20-pin flex connector of the LCD through the hole in the LCD bracket. 
NOTE:If the glass surface of the LCD display requires cleaning, gently clean the glass 
surface using a soft, lint-free cloth.
NOTE:Before placing the control top (40) onto the back chassis (13), inspect the channel select and 
volume control seals (31) and toggle switch seal (27) for damage. If any are damaged, discard 
and replace with new seal(s).
5. Install the control top (40) onto the back chassis (13), aligning the controls and the antenna 
bushing (38) of the radio through their respective holes in the control top.
6. Install the external RF contact (22) into the back of the control top (40). Push the RF contact 
fully into place until it is flush with the back of the control top.
7. While holding the RF contact (22) flush to the back of the control top (40) and ensuring the 
short “L” leg of the retainer clip (35) is pointing towards the front of the radio, install the 
external RF retainer clip by sliding it towards the top of the radio, in a direction parallel to the 
back face of the radio, until the clip engages and “snaps” onto the external RF contact (22).
8. Place the antenna wave washer (20) and then the antenna star lock washer (18) over the 
antenna bushing (38). 
9. Place the antenna spanner nut (15) onto the antenna bushing (38). Using a ROTO-TORQ 
adjustable torque screwdriver with the antenna spanner nut bit (see Table 7-2 on page 7-10 
for part numbers), tighten the antenna spanner nut to 20 in-lbs.
10. Place the volume control and channel select wave washers (19) over the volume control and 
channel select recesses. 
11. Place the volume control and channel select spanner nuts (14) over the volume control and 
channel select wave washers (19). Using a ROTO-TORQ adjustable torque screwdriver with 
the volume/channel switch spanner nut bit (see Table 7-2 on page 7-10 for part numbers), 
tighten the volume control and channel select spanner nuts to 8 in-lbs.
12. Referring to Section 7.5.1.1: “Remove the Channel Select Knob” on page 7-11 and Section 
7.5.2.1: “Remove the Volume Knob” on page 7-11, install the Channel Select knob (32), 
channel select insert (36), Volume control knob (33), volume control insert (37), and volume 
torque o-ring (29). 
						

							November 11, 20046881094C12-A
7-16Disassembly/Reassembly Procedures: Reassembly Procedures for SSE 5000 Radio
7.7.2 Reassemble the Chassis Assembly
1. Ensure that the thermal pad (26) is attached to the back chassis (13). If it is not, attach a new 
thermal pad to the chassis heat sink island.
2. Install the transceiver board (65) by orienting the board at an angle so that it can be inserted 
into the antenna contact area of the back chassis (13), with the alignment post of the back 
chassis aligned with the alignment hole of the board. Once the chassis post and the board 
hole are aligned, the board can be lowered onto the support rails of the back chassis. 
NOTE:Take care not to snag the RF contact clip (69) or the RF ground clip (35) on the back 
chassis during assembly.
3. Install the main shield (61) by orienting the shield at an angle so that it can be inserted into 
the antenna contact area of the back chassis (13), with the alignment post of the back chassis 
aligned with the alignment hole of the main shield. Once the chassis post and the main shield 
hole are aligned, the main shield can be lowered onto the surface of the transceiver board. 
4. Install the 26-pin compression connector (62). It can only be inserted in one way: with the 
two-peg edge pointing downward on the right side.
5. While holding the 20-pin connectors of the control and display flex away from the surface of 
the main shield (61), install the VOCON board (64) by orienting the board at slight angle so 
that it can be inserted into the antenna contact area of the back chassis (13), with the 
alignment post of the back chassis aligned with the alignment hole of the board. Once the 
chassis post and the board hole are aligned, the board can be lowered onto the main shield.
6. Plug the 20-pin connector at the end of the LCD module flex into the mating connector on the 
VOCON board (64).
7. Plug the 20-pin connector at the end of the controls flex into the mating connector on the 
VOCON board (64).
8. If so equipped, install the encryption board (67) by orienting the board at a slight angle so that 
it can be inserted under the LCD bracket (21), while the board is being plugged into the 40-
pin connector of the VOCON board (64).
9. Place the hex lock nut retainers (17) into the rounded end of the hex lock nuts (16). 
10. Place two lock nuts (16) with retainers (17) into the lock nut recesses at the bottom of the 
back chassis (13), orienting the hex lock nut retainers towards the top of the radio and the 
flats of the nuts parallel to the sides of the nut recesses.
11. Install the front chassis assembly (50) into the back chassis assembly (13), orienting the 
speaker cone (56) towards the outside of the radio, and using the three chassis bolt bosses 
as assembly guides.
12. Insert three chassis bolts (60) through the front chassis (50). Using a ROTO-TORQ 
adjustable torque screwdriver with a T-10 TORX bit (see Table 7-2 on page 7-10 for part 
numbers), tighten the three chassis bolts to 18 in-lbs.
13. Install the main seal/toggle support (63), orienting the toggle support part of the seal such that 
it hangs towards the bottom of the radio at the toggle switch side of the radio. Ensure that the 
main seal is captured between the front and back chassis and the control top (40). 
14. Push the toggle switch support into the area between the front and back chassis, directly 
under the toggle switch backer.
7.7.3 Join the Chassis and Housing Assemblies
1. While holding the chassis assembly (13) in one hand and the housing assembly (1) in the 
other, insert the chassis assembly into the housing, orienting the speaker towards the front of 
the radio. 
						

							6881094C12-ANovember 11, 2004
Disassembly/Reassembly Procedures: Reassembly Procedures for SSE 5000 Radio 7-17
2. Push the chassis assembly into the housing, taking care not to pinch the main seal (63) 
between the housing (1) and the control top (40). Do not depress the PTT button during 
assembly.
3. Install the two self-sealing bolts (59) through the baseplate (2) on the bottom of the radio. 
Using a ROTO-TORQ adjustable torque screwdriver with a T-10 TORX bit (see Table 7-2 on 
page 7-10 for part numbers), tighten the two self-sealing bolts to 18 in-lbs.
NOTE:Inspect the seals of the bolts before assembly. If the seals are damaged, discard 
both the seals and the bolts and replace with new self-sealing bolts. 
7.7.4 Reassemble the Housing Baseplate
NOTE:All repairs to the baseplate assembly can, and should, be made with the radio chassis inside 
the radio.
1. Inspect the radio port seal (3). 
NOTE:If the port seal is punctured or damaged, it must be replaced with a new port seal. 
If the port seal needs to be replaced, it can be peeled off of the housing. All residual 
adhesive on the housing must be removed before replacing the port seal.
2. Install the baseplate seal (9). Ensure that the baseplate seal is seated around the two 
threaded radio contact bushings and the remainder of the seal is in the baseplate seal recess 
of the housing. 
NOTE:Inspect the baseplate seal for damage. If it is damaged, discard it and replace with 
a new seal.
3. Install the latch spring (7) into the latch spring recess in the housing, with the convex form 
facing the bottom of the radio.
4. Install the battery latch (4) into the battery latch recess in the housing, with the battery catch 
facing the bottom of the radio.
5. Install the baseplate (2), taking care not to push the baseplate seal (9) into the housing. You 
can verify this by looking into the bottom of housing to see if the seal has been pushed into 
the housing.
6. Install the baseplate contact insulator (8).
7. Install the three power contacts (6).
8. Install the three radio power contact screws (5) using a ROTO-TORQ adjustable torque 
screwdriver with a Phillips star bit (see Table 7-2 on page 7-10 for part numbers). Tighten all 
three screws to 2.5 in-lbs.
9. If not done already, install the two self-sealing bolts (59) through the baseplate (2) on the 
bottom of the radio. Using a ROTO-TORQ adjustable torque screwdriver with a T-10 TORX 
bit (see Table 7-2 on page 7-10 for part numbers), tighten the two self-sealing bolts to 18 in-
lbs. 
NOTE:Inspect the seals of the bolts before assembly. If the seals are damaged, discard 
both the seals and the bolts and replace with new self-sealing bolts. 
NOTE:If the Channel Select knob (32) or Volume knob (33) were removed prior to servicing the main 
chassis, reinstall them. See Section 7.5.1.2: “Install the Channel Select Knob” on page 7-11 
and Section 7.5.2.2: “Install the Volume Knob” on page 7-12. 
						

							November 11, 20046881094C12-A
7-18Disassembly/Reassembly Procedures: Reassembly Procedures for SSE 5000 Radio
Notes