Motorola Two Way Portable Radio Ht1000 Jt1000 Mt2000 Mts2000 Mtx Series 6881200c75 B Manual

							29
Disassembly and 
Reassembly
6
!
C a u t i o n
THIS RADIO CONTAINS STATIC-SENSITIVE 
DEVICES. DO NOT OPEN THE RADIO UNLESS 
PROPERLY GROUNDED. TAKE THE FOLLOWING 
PRECAUTIONS WHEN WORKING ON THIS UNIT.
1. Store and transport all complementary metal-
oxide semiconductor (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.
2. 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. 
3. 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.
4. Do not wear nylon clothing while handling 
CMOS devices.
5. Neither insert nor remove CMOS devices 
with power applied. Check all power supplies 
that are to be used for testing CMOS devices 
to be certain that there are no voltage 
transients present.
6. When straightening CMOS pins, provide 
ground straps for apparatus used.
7. When soldering, use a grounded soldering 
iron.
8. 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.
9 
						

							30
GeneralSince this product disassembles and reassembles without the use of 
any screws, it is important for the technician to pay particular 
attention to the snaps and tabs, and how parts align with each other.
NOTE:In the disassembly/reassembly procedure, the 
numbers in parentheses refer to call-out 
numbers in the referenced figures.
Disassembly to Board 
Level1. Turn off the radio.
2. Remove the battery (see Figure 4).
a. Hold the radio such that the battery is tilted down.
b. Press down on the two battery-release levers.
c. With the release levers pulled down, the top of the battery 
will fall away from the radio.
d. Remove the battery completely from the radio.
3. Loosen the antenna by turning it in a counterclockwise direction, 
and remove it from the radio.
4. Remove the volume on/off knob and the channel selector switch 
knob by pulling them off their respective switch shafts.
NOTE:Both knobs slide on and off but fit very snug 
on their respective switch shafts. A small flat 
blade screwdriver may be necessary to help pry 
the knobs loose. Take care not to mar the 
surrounding radio surface.
5. Separate the front cover assembly from the internal electronics 
(chassis) (see Figure 5).
a. Insert the chassis/front cover separation tool (Motorola part 
no. 6680334E07) or like instrument in the slotted area at the 
bottom center of the radio. Take care not to mar the O-ring 
sealing area on the housing.
MAEPF-22524-A
A
Figure 4  Removing the Battery 
						

							31 b. Pry the bottom of the chassis free from the cover by pushing 
the separation tool down and rotating the handle of the 
separation tool over and behind the base of the radio. This 
prying action forces the thin inner plastic wall toward the 
base of the radio, which releases the two chassis base tabs.
NOTE:A flexible ribbon cable (front cover/display 
flex), which connects to the front cover 
assembly and the chassis, keeps you from 
completely separating the two units.
c. Lay the chassis down, and rotate the front cover back and 
partially away from the chassis (see Figure 6).
MAEPF-22571-O
Chassis
Assembly
Front Cover
Assembly Small Flat Blade
Screwdriver
Figure 5  Separating the Cover From the Chassis 
						

							326. Disconnect the front cover display flex from the connector on the 
chassis.
NOTE:A special locking connector secures the flex to 
the chassis (see Figure 7).
a. Use the flex connector opening tool, large curved end 
(Motorola part no. 6680334E08), or like instrument to help 
raise the sliding portion of the connector approximately 1/8 
of an inch from its seated position. A slight prying action will 
achieve the best results for unlocking the connector.
b. Remove the flex from the chassis connector.
7. Remove the contoured O-ring/antenna bushing seal from the 
chassis.
8. Disconnect the controls flex from the connector on the controller 
board by following the procedure in step 6a and 6b.
MAEPF-27016-O
Front Cover/
Display FlexFront Cover
Assembly
Chassis
Assembly
TECHNICAL PUBLICATIONS DEPT.
MAEPF-22572-O
Front Cover/
Display FlexFront Cover
Assembly
Chassis
Assembly
Unit with 
early Front Shield Unit with 
latest Front Shield 
Figure 6  Rotating the Front Cover
Top Corner
Pry Here
Top Corner
Pry HereFlex Locked
in ConnectorFlex Released
From Connector
1/8”
Figure 7  Disconnecting the Flex 
						

							33 NOTE:A large portion of the controls flex is attached to the 
large metal shield (front shield) with adhesive. Do not 
remove the controls flex from the front shield.
9. As a unit, separate the control top, the front shield, and the 
controls flex from the chassis and circuit boards (see Figure 8).
NOTE:Three locking clips (four tabs on early front shield) 
secure the front shield to the chassis and hold the RF 
board and the controller board in the chassis. 
a. Loosen the front shield by prying each of the three clips (four 
tabs on early front shield) away from the chassis. Be careful 
not to pry the clips/tabs any more than is necessary to free 
them from their respective retaining slots. To completely 
loosen the shield from the chassis, a slight lifting and 
clockwise twisting action may be required.
b. Insert a small, flat-blade screwdriver in the recessed area of 
the control top and pry the control top slightly away from the 
chassis.
c. Completely remove the control top/front shield/controls flex 
unit from the chassis.
10.Carefully remove the RF board and the controller board from the 
chassis. Figure 8  Separating Control Top From the Chassis
Four (4)
Large Tabs
Controls
Flex Front
Shield
PTT Switch
Area Control
Top
MAEPF-22574-A
Recessed
Area for
Pryin
g Loose
Three (3)
Locking Clips
Controls
Flex Front
Shield
PTT Switch
Area Control
Top
MAEPF-27017-O
Recessed
Area for
Prying Loose
Unit with 
early Front Shield Unit with 
latest Front Shield  
						

							34
NOTE:The RF board and the controller board are 
connected together with a stiff connector strip 
(P301/P704. See Figure 9.
Disassembly of 
Control Top1. Remove the rubber controls seal from the control top.
2. Turn the control top such that the grey switch housing cover is 
facing up.
a. Five retaining clips hold the switch housing cover to the 
switch housing. Clips 1, 2, and 3 are important during 
disassembly (see Figure 10).
NOTE:To perform step 2b, two tools will be required; 
your thumbnail or small, flat-blade 
screwdriver, and a pen, pencil, or another 
small, flat-blade screwdriver.
b. Using your thumbnail or small, flat-blade screwdriver, lift the 
tab that covers the base of the LED approximately 1/16 of an 
inch from its seated position. While applying constant lifting 
pressure there, (in order) release clips 1, 2, and 3 with the 
other tool.
c. The cover will pop loose from the switch housing.
3. Push the three switches and the LED out of the switch housing.
MAEPF-22575-AChassisConnector
Strip RF BoardController
Board
Figure 9  Removing the RF and Controller Boards
Switch Housing
Cover
Switch
Housing
Lift
TabClip 1
Clip 2 Clip 3Clip 4Clip 5
MAEPF-22576-OFigure 10  Switch Housing Retaining Clips 
						

							35
4. The remainder of the controls flex is attached to the switch 
housing with adhesive. Do not remove the flex from the switch 
housing unless it is absolutely necessary.
Disassembly of Front 
Cover Assembly1. On top display model radios only, release the display board by 
using a “press and pull” action on the top two corners of the 
display board. Press down on the two top corners of the display 
board and pull the top of the board away from the two corner 
retaining tabs. The display board will free itself from the retaining 
tabs and two retaining slots in the front cover housing.
2. Remove the wedge connector (part of the front cover flex, located 
behind the universal connector), by sliding it out of the plastic 
rails that hold it in place. A slight prying action, alternating back 
and forth on the bottom corners of the connector, achieves the 
best results. Be careful not to damage the spring contacts on the 
wedge.
3. Remove the speaker retainer bracket, speaker, microphone, and 
front cover flex from the front cover housing (see Figure 11).
NOTE:The speaker and front cover flex are held in 
position with a three-leg retainer bracket. The 
legs of the bracket are secured by slots in the 
front cover. When removing the retainer 
bracket, use caution not to damage the speaker.
a. Disengage the retainer bracket leg that points toward the 
bottom of the front cover from its retaining tab.
(1) Insert a small, flat-blade screwdriver under the base of the 
bracket leg near the ring.
(2) Lift the bracket leg until it pops loose from under its 
retaining tab.
b. Lift the freed leg of the retainer bracket and use it to pull the 
remaining two legs of the bracket out and away from their 
respective slots in the front cover housing.
c. Pull the rubber microphone boot, containing the 
microphone, from its seated position. Unless you are 
MAEPF-22577-B
Small Flat Blade
Screwdriver
Speaker
Retainer BracketRetaining
Tab
Front Cover
Assembly
Sound
Dampening
Pad
Figure 11  Removing the Speaker and Flex From the Front Cover 
						

							36
replacing the microphone, leave the microphone in the boot.
4. Remove, if necessary, and replace the sound dampening pad.
5. As necessary, replace the speaker and/or microphone while out of 
the front cover housing.
NOTE:If the microphone is replaced, ensure that the 
microphone is reinstalled back into the rubber 
boot with the microphone port facing the 
round hole at the bottom of the boot.
6. On front display model radios only, notice that the keypad/display 
board is secured to the front cover housing using six tabs, three 
small tabs on one side and three larger tabs on the universal 
connector side. Remove the keypad/display board by inserting a 
small flat-blade screwdriver in the circuit board slot provided (slot 
nearest the top retaining tab on the universal connector side of the 
radio, see Figure 12). A slight prying action will release the keypad/
display board. If applicable, remove the rubber keypad.
NOTE:Be careful not to mar the front cover housing 
O-ring sealing area. Doing so will compromise 
the sealing integrity of the radio.
ReassemblyReassembly is the reverse of disassembly. Some suggestions and 
illustrations are provided to help you more easily reassemble the radio.
Keypad/Display Board 
(front display model 
radios only)1. If applicable, replace the rubber keypad.
2. Place the keypad/display board into the front cover housing at an 
angle such that the three small slots on the edge of the board slide 
under the three mating retaining tabs. Ensure that the board slides 
under the tabs.
3. Near the three larger slots on the other side of the board, use finger 
pressure to push and press that side of the board down until it 
snaps into place under the three large retaining tabs.
Front Cover Assembly1. Place the speaker and microphone into their respective positions 
in the front cover. Make sure that the speaker is seated properly in 
the recessed area provided.
Keypad/Display
Board
Six Retaining
Tabs
Insert Screwdriver
Blade in This Slot
Universal
Connector
Figure 12  Removing the Keypad/Display Board 
						

							37 2. Press the rubber microphone boot into its respective recessed area 
in the front cover housing. The little rubber flap in the back of the 
rubber boot should fold up to cover the microphone insertion 
opening.
3. Reinstall the speaker retainer bracket (see Figure 13).
a. Position the spring bracket over the speaker, and toward the 
top of the front cover housing; insert the appropriate two legs 
of the bracket into their respective slots. 
b. Grasp the center portion of the spring bracket (ring area) with 
thumb and forefinger.
c. While holding the ring area of the spring bracket at 
approximately the same height as the speaker’s base, push the 
remaining leg down and into its respective slot.
4. Orient the wedge connector so that its gold contacts face the gold 
contacts of the housing. Align the wedge connector with the 
respective slots in the housing, and slide the connector down into 
place. Ensure that the wedge connector is fully seated into 
position.
1.  Inset Legs
Into Slots2.  Grasp Clip
Here and Here,Then Push Leg Into Slot
MAEPF-22578-A  Figure 13  Reinstalling the Speaker Retainer Bracket 
						

							385. On top display model radios only, seat the display board by 
inserting the two display board tabs into their mating slots in the 
front cover housing. Push the top of the display board toward the 
top of the radio until the front cover housing retaining tabs 
engage the display board and secure it into position.
ChassisInside of the chassis where the RF board fits is a protruding block that 
functions as the PA heatsink. To help provide maximum heat transfer, 
ensure that the PA heatsink block (top surface) includes a thermal pad 
(Motorola part number 7505922Z01) adhered to it.
Place the RF board and controller board into the chassis. Ensure that 
the plastic cover that more rigidly holds the two boards together is 
snapped into place.
Control Top1. Reinstall the switches and LED into the switch housing.
2. Reinstall the switch housing cover onto the switch housing by 
sliding tabs 4 and 5 of the cover into their respective clips on the 
housing. Then press down on the cover to engage tabs 1, 2, and 3.
Control Top/
Front Shield/
Controls Flex 
as a Unit to Chassis1. Slide the control top into the appropriate position in the chassis, 
and place the front shield into position over the chassis and circuit 
boards.
2. Check to see that the three clip recesses (four large tabs on early 
front shield) of the front shield are aligned with the respective 
slots on the sides of the chassis, then snap the front shield in 
place. Ensure that the shield is fully seated, especially in the PTT 
switch area.
3.a. Units using early front shield with tabs (no separate clips), 
skip step three (3); proceed to step four (4). 
b. Units using latest front shield with separate clips – Insert clip 1 
(Motorola part number 4285350C01) onto front shield by 
orienting clip stamped “1” with front shield recess stamped “1”. 
Insert the narrow hook end of the clip into the slot of the front 
shield. While keeping the clip hook in to the front shield slot, 
press the bent portion of the clip toward the front shield until it 
snaps into place. The two remaining clips (Motorola part number 
4285350C02) are stamped “2”. Insert these clips into the recessed 
areas on the front shield stamped “2”, and snap them into place as 
was done with clip stamped “1”.
4. Slide the connector end of the controls flex into the special 
locking connector mounted on the control board. Ensure that the 
flex is fully seated into the board connector and secure the 
connection.
NOTE:View the flex connection at a slight angle from 
the bottom of the radio (see Figure 14). If the 
flex is fully seated, the orange circuit plating 
will be parallel with the connector top surface 
and three reliefs in the plating will make the 
flex plating appear to be separated. If the 
orange plating of the flex is not parallel with 
the connectors top surface, or the three reliefs