Motorola Xts1500 Xts2500 Basic 6881094c09 B Manual
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Disassembly/Assembly 43 4. Pull the 16-Position Select and the On/Off/Volume Control knobs off their shafts using the Chassis Opener tool. 5. After you remove the On/Off/Volume Control knob, remove the Teflon ® washer and set it aside. 6. Separate the chassis from the front cover by inserting the chassis opener between the thin, plastic retaining wall and the metal chassis at the bottom of the radio.Figure 28. Knob Removal Be careful not to mar the O-ring sealing area on the housing. Marring the front cover O-ring sealing areas will prevent the radio from sealing properly. Figure 29. Chassis Removal ! W A R N I N G ! KNOBS OPENER CHASSIS OPENER
Disassembly/Assembly 447. Slowly pry the bottom of the chassis away from the front cover by pushing the chassis opener tool down. Rotate the handle of the tool over and behind the base of the radio. This prying action forces the thin inner plastic wall toward the base of the radio, releasing the two chassis tabs. 8. Remove the chassis assembly by holding the chassis in one hand while slowly, with a firm side-to-side motion, removing the chassis. 9. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis. The chassis assembly has switches that can be damaged if the chassis is removed too quickly. Be careful not to damage the switches at the top of the board. Figure 30. Chassis Separation Flexible ribbon circuits (flexes) connecting the front cover assembly and the chassis prevent you from completely separating the two units. Display radios and radios with option boards have two flexes. Figure 31. Unlatching the Flex Connectors ! C a u t i o n ! C a u t i o n
Disassembly/Assembly 45 10. Carefully lift the latches on the main circuit board to release the flexible circuits from their connectors. NOTE:For proper reassembly, note how the flex circuits are folded. 11. Remove the concentric lever from the front cover assembly. Chassis DisassemblyFor this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. 1. If disassembly of the chassis or the main board is required, then use a TORX™ screwdriver with a T7-IP head to remove the five screws holding the main board and shield to the chassis. 2. Remove the O-ring from around the bushing at the antenna connector 3. Lift the main board from the chassis as shown in Figure 32.Table 17. Chassis Disassembly Exploded View Item Number Motorola Part NumberDescription 19 0385563D01 Screw (5 required) 21 2785787C01 Chassis Cover, Rear 22 3285270D01 Seal, Main O-ring 34 2685785C01 Main Shield 35 Typical Main Board Refer to the Handling Precautions on page 4 before removing the main board. Be sure to use ESD protection when handing circuit boards. ! C a u t i o n
Disassembly/Assembly 464. Most repairs to the main board can be performed without further disassembly of the chassis. If it is necessary to replace the O-ring, remove the small O-ring retainers from their slots in the chassis. Note the alignment of the retainers for reassembly. 5. Remove the O-ring. Backup Battery DisassemblyFor this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. 1. The backup battery can be removed without disassembling the board or the chassis. 2. Remove the backup battery retaining clip by sliding it away from the main circuit board, as shown in Figure 33. 3. Insert a small, flat head screwdriver between the battery and the battery holder. Gently pry the battery out of the battery holder.Figure 32. Removing the Main Board from the Chassis Table 18. Backup Battery Disassembly Exploded Vie w Item Number Motorola Part NumberDescription 23 4285633D01 Retaining Clip 26 6003710K08 Battery, Backup
Disassembly/Assembly 47 Keypad and Keypad/Option Board DisassemblyFor this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. (For the Model II keypad, please refer to the exploded view and parts list on page 34.) 1. The keypad and keypad board can be disassembled without the disassembly of the display or speaker/microphone flex assembly. 2. If the disassembly of the keypad or the keypad printed circuit board is required, lift the microphone flex circuit up to move it out of the way. 3. Disconnect the display connector, and move the tail of flex circuit out of the way. 4. To remove the keypad retainer shield, insert the tip of a “penknife size,” flat-bladed screwdriver in the opening at the end of the keypad retainer arm tab. Pry the tab away from the side of the front cover until it moves past the ledges on the side wall. Repeat this procedure for the four remaining retainer arm tabs.Figure 33. Remove the Backup Battery Table 19. Keypad and Keypad/Option Board Exploded View Item Number Motorola Part NumberDescription 2 0185948D01 Keypad Board, Model III 3 8485939D01 Assembly Speaker/Microphone/Universal Connector Flex 6 7285726C01 Display Module 7 7585776C01 Keypad, Full (for Model III only) 9 4285214D01 Retainer, Keypad 22 3285270D01 Seal, Main O-ring Be careful not to mar the O-ring sealing area on the housing. Marring the front cover O-ring sealing areas will prevent the radio from sealing properly. ! W A R N I N G !
Disassembly/Assembly 485. Lift the keypad retainer out of the front cover. 6. The keypad/option board and the keypad can be removed without the use of tools.Figure 34. Retainer Removal Figure 35. Keypad Retainer and Boards Removal
Disassembly/Assembly 49 Display DisassemblyFor this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. (For the Model II display, please refer to the exploded view and parts list on page 34.) 1. The display assembly can be removed without the disassembly of the keypad board or the speaker-microphone flex assembly. If the disassembly involves the removal of the display module, disconnect the display flex from the keypad option board connector. 2. The display module snaps into the front cover assembly. Insert two flat-bladed screwdrivers between the flexible beam at the top of the display module (one on each side). Deflect the beam down until it moves past the hooks on the front cover. The display module is hooked to the front cover at the base of the display. Lift the top of the display module past the hooks and remove it from the front cover. Table 20. Display Disassembly Exploded View Item Number Motorola Part NumberDescription 1 1585746D03 Cover, Front Assembly Kit (Model III) 2 0185948D01 Keypad Board, Model III 6 7285726C01 Display Module 9 4285214D01 Retainer, Keypad Take care not to damage the display. Do not cut, bend, or pinch the heat seal. Display modules contain CMOS devices. Be sure to use ESD protection. Figure 36. Display Disassembly ! C a u t i o n
Disassembly/Assembly 50 Speaker, Microphone, and Universal Connector Flex DisassemblyFor this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. 1. The speaker-microphone assembly can be removed without the disassembly of the display or the keypad assemblies. If disassembly of the speaker-microphone assembly is necessary, removal of the universal connector dust cover is optional (see Figure 23 on page 40). 2. Remove the plastic spacer at the bottom of the speaker. The spacer can be removed by pulling upward with a slight, side-to-side motion until it clears the retaining ribs in the front cover. Take special care to prevent damage to the tail of the speaker flex circuit while the flex is still in place. 3. Using a screwdriver, push down on the portion of the speaker retainer bracket that is pointing toward the bottom of the radio. Then, remove the retainer by slightly pushing it toward the top of the radio until you slide it past the front cover slot. 4. Remove the microphone boot retainer by inserting a penknife-sized screwdriver in the notch between the retainer and the housing. Pry the retainer away from the housing and remove the clip. 5. Remove the microphone rubber boot by sliding it out of the pocket in the front cover. Take care not to pull on the flex cable while pulling on the microphone boot. Unless you are replacing the microphone, leave it in the boot. At this point, the speaker and microphone are disconnected, but the assembly is still attached to the universal connector by 13 pins in the printed circuit backer board. 6. To remove the speaker-microphone flex circuit from the universal connector, carefully grasp the flex circuit at a point directly across from the universal connector pins. Applying firm pressure, gradually pull the flex away from the pins. Table 21. Speaker, Microphone, and Universal connector Flex Disassembly Exploded View Item Number Motorola Part NumberDescription 1 1585746D03 Cover, Front Assembly Kit 3 8485939D01 Assembly Speaker/Microphone/Universal Connector Flex 10 4285446D01 Retainer, Speaker 11 4285632D01 Retainer, Microphone Boot 12 4385717D01 Spacer, Plastic 14 1485218D01 Boot, Microphone
Disassembly/Assembly 51 NOTE:There are notches on the ends of the 13-pin printed circuit backer board. If necessary, you can insert a small screwdriver in one of the notches to pry the backer board away from the front cover. After the universal connector portion of the speaker-microphone flex circuit is detached, the assembly can be completely removed. If it is necessary to replace the speaker or the microphone, or both, do it while the flex circuit is removed from the front cover. PTT DisassemblyFor this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. 1. If required, the PTT bezel and the PTT seal assembly can be disassembled using a small screwdriver. 2. Remove the PTT bezel by pushing the snaps out at the top and pulling the bezel up toward the top of the front cover so that the T-tab slides up and out. 3. The PTT seal can be easily lifted from the bezel without the use of tools.Figure 37. Speaker-Microphone Removal Table 22. PTT Disassembly Exploded View Item Number Motorola Part NumberDescription 1 1585746D03 Cover, Front Assembly Kit 4 1385149D01 Bezel, PTT 5 7585959C01 Keypad, PTT/Side Controls
Disassembly/Assembly 52 Radio Reassembly— DetailedThe following steps describe how to reassemble the radio. This includes the following major components: PT T Keypad/option board Display Speaker, microphone, universal connector flex Chassis Backup Battery Chassis and front cover PTT Reassembly1. Put the PTT seal in the PTT bezel. 2. Align the PTT bezel and seal to the front cover housing so that the bottom tabs will engage with the opening in the front cover. 3. Slide the PTT bezel down so that the T-tab engages into the front cover opening. 4. Snap the top snaps. NOTE:Look inside the front cover to be sure the T-tab and snaps are fully engaged with the front cover.Figure 38. PTT Removal