FlexRadio Systems FLEX-6000 Signature Series User manual

Page 1 © 2013 FlexRadio Systems
FLEX-6000 Handle Installation Guide
July 2, 2013
Thank you for purchasing the FLEX-6000 Handle Kit. The following guide will provide the necessary step-
by-step procedure for installing the FLEX-6000 Handle accessory.
If you are installing both the FLEX-6000 Handle assembly and the FLEX-6000 Rack Mounting Brackets,
install the FLEX-6000 Handle assembly first.
Table of Contents
OBTAINING TE C HN I CA L SUPPO RT............................................................................................................... 2
GETTING STARTED........................................................................................................................................... 2
Packaging and Handle Kit Contents........................................................................................................ 2
REMOVING THE FLEX-6000 FRAM E BE Z E L ............................................................................................... 3
Removing the Set Screws........................................................................................................................ 3
Remove the Front Cover Screws ............................................................................................................. 4
Remove the Side Plate Screws ................................................................................................................ 5
Removing the Top Cover and Chassis Retaining Bar .............................................................................. 6
Removing the Frame Bezel ..................................................................................................................... 9
INSTALLING THE FLEX-6000 HANDLE ASSEMBLY ............................................................................................... 10
Installing the Handle Assembly............................................................................................................. 10
Re-Installing Top Chassis Cover ............................................................................................................ 12
Re-Installing the Side Plate Screws ....................................................................................................... 13
Re-installing the Cover Screws.............................................................................................................. 14
Re-Installing the Set Screws.................................................................................................................. 14

Page 2 © 2013 FlexRadio Systems
Obtaining Technical Support
If you encounter any issues installing your FLEX-6000 accessory, please contact FlexRadio Systems
technical support by opening a HelpDesk ticket on-line at http://helpdesk.flexradio.com or by phone at +1
[phone] extension #2. Please leave a voice mail message if you don’t get an answer as all of our
engineers are probably busy on existing calls.
Hours of Operation: Our Technical Support engineers are available Monday –Friday from 8:00am-5:30pm
Central Time. If you call after business hours, on a holiday or weekend, please leave a detailed message
and we will return your call during regular business hours in the order it was received.
You may always submit a HelpDesk support ticket at any time.
If you need assistance opening a HelpDesk ticket, please refer to the HelpDesk Assistance Center home
page for step-by-step instructions.
Getting Started
Packaging and Handle Kit Contents
Your FLEX-6000 Handle Kit will arrive in packaging similar to the one shown below.

Page 3 © 2013 FlexRadio Systems
Remove the contents of and verify that the following items are included before proceeding. Refer to the
image below.
Two (2) FLEX-6000 Handle assembly
One (1) TORX L wrench
Removing the FLEX-6000 Frame Bezel
The FLEX-6000 right front frame bezel (corner piece) must be removed before installing the handle
assembly.
Removing the Set Screws
Using the short “L” portion of the TORX wrench, remove the top Set screw as shown below. Retain the
set screws for re-installation.

Page 4 © 2013 FlexRadio Systems
Remove the bottom set screw as shown below.
Remove the Front Cover Screws
After removing both set screws remove both of the top and bottom Cover screws using the long portion
of the “L” TORX wrench. Retain the Set screws for re-installation. The image below shows the removal of
the top Cover screw.
Remove the bottom Cover screw once the top Cover screw has been removed.

Page 5 © 2013 FlexRadio Systems
Remove the Side Plate Screws
After removing the cover screws remove both of the top and bottom Side Plate screws using the long
portion of the “L” TORX wrench. Retain the Side Plate screw for re-installation. The image below shows
the removal of the top Side Plate screw.
Remove the bottom Side Plate screw once the top Side Plate screw has been removed.
After removing the Set, Cover and Side plate screws, the corner of your FLEX-6000 should look like the
image below.

Page 6 © 2013 FlexRadio Systems
Removing the Top Cover and Chassis Retaining Bar
The top chassis cover for the radio needs to be removed before the corner bezels can be removed.
Using the long portion of the “L” TORX wrench remove the two (2) remaining short Top Cover Side screws
from the left side of the FLEX-6000. Then remove the remaining two (2) short Top Cover Side screws from
the right side of the FLEX-6000. Retain the Top Cover Side screws for re-installation. The image below
shows the removal of the right side top Cover Side screws.
After removing the top cover side screws remove the four (4) long Top Cover screws using the long
portion of the “L” TORX wrench. Retain the Top Cover screws for re-installation. The image below shows
the removal of the Top Cover screws.

Page 7 © 2013 FlexRadio Systems
Once the top cover retaining screws have been removed, gently pull the Top Cover upwards to remove it
from the FLEX-6000. The image below shows the removal of the Top Cover.
After the Top Cover has been removed, the Front Chassis Retaining Bar must be removed in order to
remove the corner Bezels. Using a #2 Phillips screw driver remove the two (2) Front Chassis Retaining Bar
screws and washers from the right and left side of the Front Chassis Retaining Bar. Retain the Front
Chassis Retaining Bar screws and washers for re-installation. The image below shows the removal of the
right side Front Chassis Retaining Bar screw.

Page 8 © 2013 FlexRadio Systems
After both Front Chassis Retaining Bar screws have been removed, gently pull upward on the Front
Chassis Retaining Bar to remove it from the chassis. Retain the Front Chassis Retaining Bar for re-
installation. The image below shows the Front Chassis Retaining Bar being removed.
The image below shows the FLEX-6000 chassis with the Front Chassis Retaining Bar removed making it
ready to remove the corner Frame Bezels. Be very careful not to disturb the PA inductor coils during the
Front Chassis Retaining Bar removal.

Page 9 © 2013 FlexRadio Systems
Removing the Frame Bezel
Grasp the right front Frame Bezel as shown below and gently pull or rock it forward while pulling slightly
upward to remove it from the chassis. Do not rock the bezel from side to side as that may bend the
bottom cover plate and side panels.
The image below shows the right front Frame Bezel after removal.
Remove the left front Frame Bezel after the right side front Frame Bezel has been removed.

Page 10 © 2013 FlexRadio Systems
Installing the FLEX-6000 Handle Assembly
Once the front frame bezel has been removed, the handle assembly can be installed.
Installing the Handle Assembly
Gently slide the Handle Assembly into the same location where the front Frame Bezel was removed as
shown below. Slide the handle all the way in so that the six (6) screw holes line up with the radio chassis
screw holes. Do not rock the Handle Assembly from side to side as that may bend the bottom cover plate
and side panels.
Repeat the procedure for the left handle. The image below shows both Handle Assemblies installed.

Page 11 © 2013 FlexRadio Systems
Reinstall the Front Chassis Retaining Bar by placing on top of the radio with the black edge facing
outward and aligning the screw holes with the chassis holes. Install a chassis retaining bar screw and
washer. Do not tighten the screw at this time. The image below shows the installation of right side
chassis retaining bar screw.
Install the left side chassis retaining bar screw and washer after the right side chassis retaining bar screw
has been installed. Making sure that the holes in the Handle Assembly are aligned with the chassis holes,
tighten the chassis retaining bar screws to hold the Handle Assembly in place. The image below shows
the tightening of the left chassis retaining bar screw.

Page 12 © 2013 FlexRadio Systems
Re-Installing Top Chassis Cover
Place the top cover on top of the chassis aligning it with the chassis screw holes as shown in the image
below.
After replacing the top cover re-install the four (4) long Top Cover screws using the long portion of the “L”
TORX wrench. Do not over tighten the Top Cover screws. The image below shows the removal of the Top
Cover screws.

Page 13 © 2013 FlexRadio Systems
After replacing the four (4) long Top Cover screws, re-install two (2) short Top Cover Side screws on the
left side of the FLEX-6000 in the middle and rear positions. Then re-install the two (2) short Top Cover Side
screws from the right side of the FLEX-6000 in the middle and rear positions. Do not over tighten the Top
Side Cover screws. The image below shows the re-installation of the middle right side top Cover Side
screws.
Re-Installing the Side Plate Screws
After inserting the Handle assembly re-install both of the top and bottom Side Plate screws using the long
portion of the “L” TORX wrench. Do not over tighten the Side Plate screws. The image below shows the
installation of the top Side Plate screw. Re-install the bottom Side Plate screw once the top Side Plate
screw has been installed.

Page 14 © 2013 FlexRadio Systems
Re-installing the Cover Screws
After inserting the Side Plate screws re-install both of the top and bottom Cover screws using the long
portion of the “L” TORX wrench. Do not over tighten the Cover screws. The image below shows the
installation of the top Cover screw.
Re-install the bottom Cover screw once the top Cover screw has been installed.
Re-Installing the Set Screws
After inserting the Cover screws re-install both of the top and bottom Set screws using the short “L”
portion of the TORX wrench making sure they are flush with the side panel. Do not over tighten the Set
screws. The image below shows the installation of the top Set screw.
Re-install the bottom Set screw once the top Set screw has been installed.
NOTE: If you are also installing FLEX-6000 Rack Mounting Brackets, you may skip this step

Page 15 © 2013 FlexRadio Systems
Once all of the screws have been reinstalled, the right corner of your FLEX-6000 should look like the image
below.
Re-install the side Cover and Set screws on the left side of the FLEX-6000 as described above. Once
completed the radio should look like the image shown below.