Motorola Xpr 7000 Seris Basic 68009498001 A Manual

							Disassembly/Reassembly Procedures: Introduction 5-1
Chapter 5 Disassembly/Reassembly Procedures
5.1 Introduction
This chapter provides details about the following:
• Preventive maintenance (inspection and cleaning).
• Safe handling of CMOS and LDMOS devices.
• Disassembly and reassembly of the radio.
• Repair procedures and techniques.
5.2 Preventive Maintenance
Periodic visual inspection and cleaning is recommended.
5.2.1 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.
5.2.2 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 (100% by volume).
NOTEInternal surfaces should be cleaned only when the radio is disassembled for service or
repair.
The effects of certain chemicals and their vapors can have harmful results on 
certain plastics. Avoid using aerosol sprays, tuner cleaners and other 
chemicals.
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							5-2Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices
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.
Cleaning Internal Circuit Boards and Components
Isopropyl alcohol (100%) 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 of 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.
5.3 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 CMOS CAUTION 
paragraph in the Disassembly and Reassembly section of the manual.
NOTEAlways use a fresh supply of alcohol and a clean container to prevent contamination by 
dissolved material (from previous usage).
Use all chemicals as prescribed by the manufacturer. Be sure 
to follow all safety precautions as defined on the label or 
material safety data sheet. 
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							Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices 5-3
DO NOT attempt to disassemble the radio without first referring to the following CAUTION 
statement.
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/LDMOS devices in conductive 
material so that all exposed leads are shorted together. Do not insert 
CMOS/LDMOS 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/LDMOS 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, ESD 
shoes and an ESD chair.
• 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 4280385A59).
• Do not wear nylon clothing while handling CMOS/LDMOS devices.
• Do not insert or remove CMOS/LDMOS devices with power applied. 
Check all power supplies used for testing CMOS/LDMOS devices to 
be certain that there are no voltage transients present.
• When straightening CMOS/LDMOS pins, provide ground straps for 
the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS/LDMOS 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.
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							5-4Disassembly/Reassembly Procedures: Repair Procedures and Techniques – General
5.4 Repair Procedures and Techniques – General
Any rework or repair on Environmentally Preferred Products must be done using the appropriate 
lead-free solder wire and lead-free solder paste as stated in the following table:
Parts Replacement and Substitution
When damaged parts are replaced, identical parts should be used. If the identical replacement part 
is not locally available, check the parts list for the proper Motorola part number and order the part 
from the nearest Motorola Radio Products and Solutions Organization (RPSO) listed in Appendix A 
of this manual.
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not 
accessible, some special considerations are required when soldering and unsoldering components. 
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise 
care to avoid pulling the plated circuit out of the hole.
When soldering near a connector:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges. NOTE
Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards — examples shown below) were developed and assembled using 
environmentally preferred components and solder assembly techniques to comply with
the European Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/
95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/
EC. To maintain product compliance and reliability, use only the Motorola specified parts
in this manual.
Table 5-1.  Lead Free Solder Wire Part Number List
Motorola 
Part NumberAlloy Flux TypeFlux Content 
by WeightMelting 
PointSupplier Part 
numberDiameter Weight
1088929Y0195.5Sn/3.8Ag/0.7CuRMA Version2.7-3.2%217C521710.015”1lb spool
Table 5-2.  Lead Free Solder Paste Part Number List
Motorola Part 
NumberManufacturer Part 
NumberViscosity Type Composition & Percent MetalLiquid 
Temperature
1085674C03NC-SMQ230900-1000KCPs 
Brookfield (5rpm)Ty p e 3 
(-325/+500)(95.5%Sn-3.8%Ag-0.7%Cu) 
89.3%217°C 
						

							Disassembly/Reassembly Procedures: Disassembling and Reassembling the Radio — General 5-5
5.5 Disassembling and Reassembling the Radio — General
When disassembling and reassembling the radio, 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:
• TORX™ T3 and T6 screwdriver
• Chassis and Knob Opener (PMLN6208_)
The following item and tools are required for reassembling the radio:
• Grease (1185937A01)
• TORX™ T3 and T6 screwdriver
• Vacuum Pump Kit (NLN9839) - Radio Immersibility Test
• Pressure Pump Kit (NTN4265) - Radio Immersibility Test
• Connector Fitting (5871134M01) - Radio Immersibility Test
• Fitting Seal (3271133M01) - Radio Immersibility Test
• Seal Port (3286058L01)
• Label Ventilation (5478220A01)
If a unit requires further testing or service than is customarily performed at the basic level, please 
send the radio to a Motorola Service Center listed in Appendix B.
To assure the safety and regulatory compliance of the XPR 7000 Series, the 
radio must be repaired only at Motorola service facilities. Please call Motorola 
at 800-422-4210 for the address and contact information of your nearest 
service center
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							5-6Disassembly/Reassembly Procedures: Radio Disassembly – Detailed
5.6 Radio Disassembly – Detailed
5.6.1 Front Cover from Chassis Disassembly
1.Turn off the radio.
2.Remove the battery:
a. Release the battery latch by moving it into the unlock position.
b. With the latch released, slide the battery downwards.
c. Remove the battery from the radio.
3.Remove the antenna by turning it counterclockwise.
Figure 5-1.  Antenna and Battery removal.
Antenna 
						

							Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-7
4.Remove the channel selector knob and volum knob off from their shafts using the knob 
removal tool. 
Figure 5-2.  Channel Selector and Volume Knob removal.
NOTEBoth knobs slide on and off. However, they are supposed to fit very tightly on their shafts.
Volume Control KnobChannel Selector
Knob 
						

							5-8Disassembly/Reassembly Procedures: Radio Disassembly – Detailed
Figure 5-3.  Shroud removal
5.Hook the knob opener under the shroud as shown in Figure 5-5 and detach it with a 
downward motion.
6.Separate the chassis from the housing assembly as follows:
a. Insert the chassis opener into the recess at the bottom of the radio. Apply a downward 
force to separate the chassis from the front housing.
b. Remove the chassis from the front housing.
Figure 5-4.  Chassis removal
Shroud
Chassis Opener 
						

							Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-9
7.Lay the chassis down. Rotate the front cover backward and slightly away from the chassis.
Figure 5-5.  Disconnecting the chassis
8.Lift the latch on the main board to release the keypad from its connector.
9.Remove the flex from the keypad board by pulling it out of its connector gently.
10.Lift the latch on the main board to release the GOB flex from its connector.
Flex
Latch 
						

							5-10Disassembly/Reassembly Procedures: Radio Disassembly – Detailed
5.6.2 Chassis Disassembly
Use a TORX screwdriver with a T6 head to remove the five screws holding the main board to the 
chassis and the three screws holding the GOB.
Figure 5-6.  Chassis disassembly
Main board screws
GOB screws
Chassis
Main board