Motorola Xtl5000 Basic 6881096c73 O Manual

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-5
Figure 8-2.  W5 and W7 Pushbutton Control-Head Assembly Screw Sequence
7. Carefully separate the printed circuit board, internal spacer, and elastomer keypad assembly 
from the front panel.
On rotary control-head models, care must be taken not to damage the flex circuit when 
separating the printed circuit board from the front housing. Do not disturb the buttons in the 
front panel.
On rotary control-head models, the flex circuit must also be unplugged.
8. On rotary control-head models, desolder the XMIT and BUSY LED before removing the 
elastomer keypad.
9. Remove the elastomer keypad from the printed circuit board.
NOTE:Before you unsnap the PC board, notice that the board slips under a hook on the 
right and snaps on the left. This will facilitate assembly.
10. Remove the PC board from the internal spacer. The PC board snaps into and out of the 
spacer.
8.2.2.4  W4, W5, and W7 Reassembly
NOTE:For the following procedure, refer to Chapter 11. Exploded Views and Parts Lists, beginning 
on page 11-1, for the exploded view and associated parts list applicable to the model being 
reassembled.
1. To reassemble, snap the PC board into the internal spacer. Before you press the elastomer 
keypad into the board, make sure that the conductive pads in the board and the elastomer 
keypad are clean and free of any foreign material.
2. On rotary control-head models, solder the XMIT and Busy LEDs onto the PC board.
NOTE:On rotary control-head models, the flex circuit must be connected to the PC board 
prior to attaching the PC board to the spacer.
3. Install the PC board internal spacer and elastomer keypad assembly into the front panel. 
Replace the screws and torque them to 6-8 in.-lbs.
When reassembling the control head, make sure the 
microphone pins are properly inserted through the elastomeric 
keypad. Also make sure the elastomeric keypad inserts are 
secured to the PC board.
416
2
5 3
7
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8-6Disassembly/Reassembly Procedures: Replacement Procedures
4. For dash-mounted radios, plug the interconnect flex from the radio into the control head, slide 
the control head into the headbridge, and fasten the control head with the two front panel 
screws (torqued to 6-8 in.-lbs).
OR
For remote-mount control heads, replace the front panel into the remote control head back 
housing, make sure the gasket is in place, then torque the screws to 6-8 in.-lbs. Replace any 
plugs and cables on the rear of the control head.
8.2.2.5  W9 Disassembly
NOTE: Bracketed numbers are identical to item numbers in  Figure 11-4. “W9 Pushbutton Control 
Head Exploded View” on page 11-5 .
NOTE: Before disassembling the W9 control head, note the location of the labeled bottom.
1. Using a Torx T15 driver, remove the two 30mm machine screws [29] from the back housing  [31] of the control head.
2. Fold the front housing [41] over so that the front housing is face down and the back housing is  on your working surface with the flex cable [18] attached.
3. Using a Torx T10 driver, remove the five 8mm tapping screws [17] from the Display Board Kit  [37], the two 10mm captive screws [12] with the leaf assembly spring [11], and the two 16mm 
tapping screws [38] from the control PC board.
4. Remove the Command Board Kit [36] from the back housing and the Display Board Kit [37]  from the front housing.
5. Remove the elastomer keypad [7], ON/OFF switch gasket [34], the “D” Connector Gasket  [33], the solder side shield [16], and the component side shield [19] from the PC boards.
NOTE: Be careful to not bend the tabs on the shields when removing them and align them 
carefully when replacing the shields. When working with chips and SOT (small 
outline transistor) parts, use extreme caution when heating. Never reuse a chip or 
SOT part; always replace with the correct Motorola part.
8.2.2.6  W9 Reassembly
NOTE: Bracketed numbers are identical to item numbers in  Figure 11-4. “W9 Pushbutton Control 
Head Exploded View” on page 11-5 .
1. Install the new PC board with the elastomer keypad, the ON/OFF switch gasket, the “D”  Connector Gasket, the “D” Connector O-ring, the solder-side shield, and the component-side 
shield in the appropriate locations.
2. Reassemble the Command Board Kit [36] into the back housing [31], making sure that the  power switch is in the proper location and replace the two tapping screws [38], torquing them 
to 6-8 in.-lbs.
3. Reassemble the Display Board Kit [37] into the front housing [41], making sure that the  elastomer keypad [7] is in the proper location. Take care to avoid misalignment of connector pins. On dash 
mount radios, remove the radio top cover to allow visual 
inspection during connector alignment.
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							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-7
4. Replace the captive screws [12] and the leaf assembly spring [11] in the front housing, and 
torque them to 6-8 in.-lbs.
NOTE:Before assembling the leaf assembly spring, check that the insulator [10] on the 
board is present. Ensure that the leaf assembly spring and captive screws are 
aligned properly to prevent stripping the front housing screw bosses.
5. Close the assembly by replacing the front housing [41] and the two screws in the back 
housing [31]. Torque the screws to 6-8 in.-lbs.
8.2.3 Remote Back Housing Interface Board Disassembly/Reassembly
8.2.3.1  W4, W5, and W7 Disassembly
1. Unplug the microphone.
2. Disconnect the control cable from the control head on remote models.
3. Remove the two front panel screws using a 2.5 mm hex-key driver.
4. Grasp the front panel firmly, and carefully unplug the control head assembly from the radio or 
remote control head back housing.
5. Remove the two remote back housing interface attachment screws.
6. Remove the remote control head interface board from the remote control head back housing.
8.2.3.2  W4, W5, and W7 Reassembly
1. Attach the new interface PC board to the back housing with two screws torqued to 6-8 in.-lbs.
2. Reassemble the back housing to the front housing with two screws torqued to 4-6 in.-lbs.
8.2.4 Remote Interconnect Board Assembly/Reassembly
8.2.4.1  Assembly
1. Remove the two front panel screws using a 2.5 mm hex key driver.
2. Grasp the front panel firmly, and carefully unplug it from the radio.
3. Remove the three screws that hold the remote interconnect board to the front panel using a 
Torx T10 driver.
4. Install the new remote interconnect board onto the front panel, and replace the screws. 
Torque the screws to 6-8 in.-lbs.Take care to avoid misalignment of connector pins.
Take care to avoid misalignment of connector pins. Remove 
the radio top cover to allow visual inspection during connector 
alignment.
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							June 11, 20036881096C73-O
8-8Disassembly/Reassembly Procedures: Replacement Procedures
8.2.4.2  Reassembly
1. Reconnect the interconnect flex to the radio, noting proper alignment of the mating 
connections.
2. Reassemble the front panel into the radio and replace the screws.
3. Torque the screws to 6-8 in.-lbs.
8.2.5 Radio Disassembly
Use the following procedure to disassemble your radio:
1. Ensure all accessory connections, power, antenna, and microphone are unplugged.
If the radio is a remote-mount radio, disconnect the remote-mount control cable from the front 
of the transceiver.
2. Remove the two front control-head screws using a 2.5 mm hex-key bit. Save them for later 
use.
Figure 8-3.  Removing the Front Panel Screws 
						

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-9
3. Firmly grasp the front panel of the control head, and carefully remove the control-head 
assembly from the radio. Be careful not to pull on the attached flex.
Figure 8-4.  Removing the Control Head
4. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar 
the face of the display.
5. Carefully disconnect the control-head flex from the control head or remote interconnect 
panel, and set the control head aside.
Figure 8-5.  Removing the Flex (Control-Head Connector) 
						

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8-10Disassembly/Reassembly Procedures: Replacement Procedures
6. Remove the plastic headbridge by squeezing in the center of the top and bottom sides of the 
part and pulling away from the transceiver.
NOTE:Be careful to avoid pulling on the flex.
Figure 8-6.  Removing the Headbridge
7. Carefully remove the control-head flex from the transceiver by grasping the provided handle 
and separating it from the connector.
Figure 8-7.  Removing the Flex (Main-Board Connector) 
						

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-11
Figure 8-8.  Control-Head Flex (Removed)
8. Remove the headbridge seal from the transceiver.
Figure 8-9.  Headbridge Seal (Removed)
The following steps MUST be performed for secure-equipped 
radios prior to removal of the cover or damage to the radio 
could occur.
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8-12Disassembly/Reassembly Procedures: Replacement Procedures
9. For secure option-equipped radios, do the following prior to disassembly of the transceiver:
a. Remove the two screws holding the secure (UCM) shield in place.
b. Pull the UCM shield away from the assembly and remove it.
c. Insert a flathead screwdriver into the space in the upper-left corner of the secure pocket, 
and gently pry the secure interface board (universal encryption module) away from the 
chassis.
Figure 8-10.  Removing the Secure Interface Board
Universal
Encryption
Module Secure
Shield Screws
Secure
Interface
BoardFlat
Blade
Screwdriver
MAEPF-27658-O  
						

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-13
10. Remove the 10 top-cover screws using a T20 Torx bit. These screws have sealing washers 
that should be kept with the screw.
Figure 8-11.  Removing the Top Cover Screws
11. Remove the top cover by lifting up simultaneously on both side edges. It may be necessary to 
gently pry the cover off using a plastic tool. 
Figure 8-12.  Lifting the Top Cover 
						

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8-14Disassembly/Reassembly Procedures: Replacement Procedures
Figure 8-13.  Removing the Top Cover
12. Disconnect the rear accessory jack’s flex from the main board.
Figure 8-14.  Removing the J2 Rear Accessory Flex from the Main Board