MOTOTRBO XPR 2500 Mobile Radio Basic Service Manual Series/XPR2500 68009620001 A XPR2500

User Manual: -XPR Series/XPR2500 Basic service manual 68009620001-A

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PROFESSIONAL DIGITAL TWO-WAY RADIOS

MOTOTRBOTM
TM 2500
XPR
ALPHANUMERIC
DISPLAY MOBILE
BASIC SERVICE
MANUAL

Foreword
This manual covers all XPR™ 2500 Mobiles, unless otherwise specified. It includes all the information necessary to
maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level
of service goes down to the board replacement level and is typical of some local service centers, Motorola Authorized
Dealers, self-maintained customers, and distributors.

!
Caution

These servicing instructions are for use by qualified personnel only. To
reduce the risk of electric shock, do not perform any servicing other than
that contained in the Operating Instructions unless you are qualified to do
so. Refer all servicing to qualified service personnel.

Product Safety and RF Exposure Compliance
ATTENTION!
Before using the mobile two-way product, XPR™ 2500, read the RF Energy Exposure and Safety guide
that ships with the radio which contains important operating instructions for safe usage and RF
energy awareness and control for Compliance with applicable Standards and Regulations.

Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce
in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in
the Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or
distributed in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola
products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the
copyrights, patents or patent applications of Motorola, except for the normal non-exclusive license to use that arises by
operation of law in the sale of a product.

Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written
permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any
means, electronic or mechanical, for any purpose without the express written permission of Motorola.

Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.

Trademarks
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective
owners.
© 2013 Motorola Solutions, Inc. All rights reserved.

Notes

iii

Document History
The following major changes have been implemented in this manual since the previous edition.
Edition
68009620001-A

Description
Initial Release.

Date
June 2013

Notes

Table of Contents

Table of Contents
Foreword ..........................................................................................................i
Product Safety and RF Exposure Compliance .............................................................................................i
Computer Software Copyrights ....................................................................................................................i
Document Copyrights ...................................................................................................................................i
Disclaimer.....................................................................................................................................................i
Trademarks ..................................................................................................................................................i

Document History ........................................................................................ iii
Commercial Warranty ...................................................................................xi
Limited Warranty ........................................................................................................................................xi
MOTOROLA COMMUNICATION PRODUCTS ..............................................................................xi
I. What This Warranty Covers And For How Long .....................................................................xi
II. General Provisions ................................................................................................................ xii
III. State Law Rights .................................................................................................................. xii
IV. How To Get Warranty Service ............................................................................................. xii
V. What This Warranty Does Not Cover.................................................................................... xii
VI. Patent And Software Provisions ......................................................................................... xiii
VII. Governing Law................................................................................................................... xiii

Chapter 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9

Notations Used in This Manual .................................................................................................... 1-1
Radio Description ........................................................................................................................ 1-1
Control Head Description............................................................................................................. 1-2
1.3.1 Control Head Controls ..................................................................................................... 1-2
MOTOTRBO Mobile Radio Model Numbering Scheme............................................................... 1-3
VHF High Power (136–174 MHz) Model Chart ........................................................................... 1-4
VHF Low Power (136–174 MHz) Model Chart ........................................................................... 1-4
UHF1 High Power (403–470 MHz) Model Chart ........................................................................ 1-5
UHF1 Low Power (403–470 MHz) Model Chart ......................................................................... 1-5
Specifications............................................................................................................................... 1-6

Chapter 2
2.1
2.2
2.3
2.4
2.5
2.6

Introduction ......................................................................... 1-1

Test Equipment and Service Aids ..................................... 2-1

Recommended Test Equipment .................................................................................................. 2-1
Service Aids ................................................................................................................................. 2-2
Programming Cables ................................................................................................................... 2-3
Programming and Test Cable ...................................................................................................... 2-3
Test Cable ................................................................................................................................... 2-4
Accessory Cable .......................................................................................................................... 2-5

Table of Contents

Chapter 3
3.1
3.2
3.3

General ........................................................................................................................................ 3-1
Setup............................................................................................................................................ 3-1
Alphanumeric Display Model Test Mode ..................................................................................... 3-2
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-2
3.3.2 RF Test Mode .................................................................................................................. 3-2
3.3.3 Alphanumeric Display Test Mode .................................................................................... 3-3
3.3.4 LED Test Mode................................................................................................................ 3-3
3.3.5 Backlight Test Mode ........................................................................................................ 3-3
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-3
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-3
3.3.8 Audio Loopback Test Mode ............................................................................................. 3-3
3.3.9 Audio Loopback Earpiece Test Mode.............................................................................. 3-4
3.3.10 Button Test Mode ............................................................................................................ 3-4

Chapter 4
4.1
4.2
4.3
4.4

5.3
5.4
5.5
5.6

5.7

5.8
5.9

Radio Programming and Tuning ....................................... 4-1

Introduction .................................................................................................................................. 4-1
Customer Programming Software Setup ..................................................................................... 4-1
AirTracer Application Tool............................................................................................................ 4-2
Radio Tuning Setup ..................................................................................................................... 4-3

Chapter 5
5.1
5.2

Transceiver Performance Testing ..................................... 3-1

Disassembly/Reassembly Procedures ............................. 5-1

Introduction .................................................................................................................................. 5-1
Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
Repair Procedures and Techniques – General............................................................................ 5-4
Disassembling and Reassembling the Radio – General.............................................................. 5-5
Radio Disassembly – Detailed ..................................................................................................... 5-5
5.6.1 Control Head Removal .................................................................................................... 5-5
5.6.2 Top Cover Removal......................................................................................................... 5-6
5.6.3 Transceiver Board Removal ............................................................................................ 5-7
5.6.4 Disassembly of Alphanumeric Display Control Head .................................................... 5-12
Radio Reassembly – Detailed.................................................................................................... 5-16
5.7.1 Reassembly of Alphanumeric Display Control Head ..................................................... 5-16
5.7.2 Radio Assembly............................................................................................................. 5-20
5.7.3 Thermal Pad Replacement Procedure .......................................................................... 5-21
5.7.4 Transceiver Board Reassembly..................................................................................... 5-25
5.7.5 Option Board Installation ............................................................................................... 5-33
5.7.6 Assemble Control Head to Radio Assembly.................................................................. 5-35
Exploded Mechanical Views and Parts Lists ............................................................................. 5-36
5.8.1 Radio Assembly Exploded View and Parts List ............................................................ 5-36
5.8.2 Alphanumeric Display Control Head Exploded View and Parts List .............................. 5-38
Torque Chart .............................................................................................................................. 5-39

Table of Contents

Chapter 6
6.1
6.2
6.3

Basic Troubleshooting ....................................................... 6-1

Introduction .................................................................................................................................. 6-1
6.1.1 High Power RF Precaution .............................................................................................. 6-1
Replacement Service Kit Procedures .......................................................................................... 6-1
Power-Up Error Codes ................................................................................................................ 6-2

Chapter 7
7.1

vii

Accessories ......................................................................... 7-1

Introduction .................................................................................................................................. 7-1
7.1.1 Antennas ......................................................................................................................... 7-1
7.1.2 Audio ............................................................................................................................... 7-2
7.1.3 Cables ............................................................................................................................. 7-2
7.1.4 Mounting Kits................................................................................................................... 7-2
7.1.5 Miscellaneous Accessories ............................................................................................. 7-3
7.1.6 Service Tools................................................................................................................... 7-3

Appendix A Replacement Parts Ordering..............................................A-1
A.1
A.2
A.3
A.4
A.5
A.6
A.7

Basic Ordering Information ..........................................................................................................A-1
Motorola Online ...........................................................................................................................A-1
Mail Orders ..................................................................................................................................A-1
Telephone Orders ........................................................................................................................A-1
Fax Orders ...................................................................................................................................A-1
Parts Identification .......................................................................................................................A-2
Product Customer Service ...........................................................................................................A-2

Appendix B Motorola Service Centers...................................................B-1
B.1
B.2
B.3
B.4

Servicing Information ...................................................................................................................B-1
Motorola Service Center ..............................................................................................................B-1
Motorola Federal Technical Center .............................................................................................B-1
Canadian Technical Logistics Center ..........................................................................................B-1

Appendix C Limited Level 3 Servicing ...................................................C-1
C.1
C.2

Maintenance ................................................................................................................................C-1
Component Location and Parts List.............................................................................................C-1

Glossary ......................................................................................... Glossary-1

viii

List of Figures

List of Figures
Figure 1-1
Figure 1-2
Figure 2-1
Figure 2-2
Figure 2-3
Figure 2-4
Figure 2-5
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-4
Figure 5-5
Figure 5-6
Figure 5-7
Figure 5-8
Figure 5-9
Figure 5-10
Figure 5-11
Figure 5-12
Figure 5-13
Figure 5-14
Figure 5-15
Figure 5-16
Figure 5-17
Figure 5-18
Figure 5-19
Figure 5-20
Figure 5-21
Figure 5-22
Figure 5-23
Figure 5-24
Figure 5-25
Figure 5-26
Figure 5-27
Figure 5-28
Figure 5-29
Figure 5-30
Figure 5-31
Figure 5-32
Figure 5-33
Figure 5-34
Figure 5-35
Figure 5-36
Figure 5-37
Figure 5-38

Radio Control Head.............................................................................................................. 1-2
Mobile Radio Model Numbering Scheme............................................................................. 1-3
Front Telco MMP USB Programming Cable PMKN4147_ ................................................... 2-3
Back 20 Pin MAP USB Programming Cable PMKN4148_................................................... 2-3
Back 20 Pin MAP Test and USB Programming Cable PMKN4149_ .................................... 2-3
Back 20 Pin MAP Test Cable PMKN4150_ .......................................................................... 2-4
Back 16 Pin MAP Universal Cable PMKN4151_ ................................................................. 2-5
Customer Programming Software Setup from Front Connector .......................................... 4-1
Customer Programming Software Setup from Rear Accessory Connector ......................... 4-2
Customer Programming Software Setup with Test Box Connection .................................... 4-2
Radio Tuning Equipment Setup ........................................................................................... 4-3
Radio Tuning Equipment Setup (Alternative Method) .......................................................... 4-3
Typical Control Head Removal............................................................................................. 5-5
Flexible Connection Removal .............................................................................................. 5-6
Top Cover Removal (Image May Not Match Exact Product)................................................ 5-6
Option Board Removal (Image May Not Match Exact Product) ........................................... 5-7
Die Cast Main Shield Removal ............................................................................................ 5-8
PA Screw Removal............................................................................................................... 5-9
Accessory Connector Removal ............................................................................................ 5-9
DC Cable Removal ............................................................................................................ 5-10
RF Connector Nut Removal ............................................................................................... 5-10
Transceiver Board Removal............................................................................................... 5-11
Control Head Flex Removal ............................................................................................... 5-12
Speaker Tape Removal ...................................................................................................... 5-12
Keypad Assembly Removal ............................................................................................... 5-13
Speaker Removal............................................................................................................... 5-13
PCB Removal..................................................................................................................... 5-14
Indicator Barrier Removal .................................................................................................. 5-14
LCD and LCD Flex Removal .............................................................................................. 5-15
LCD Display Assembly....................................................................................................... 5-16
Indicator Barrier Assembly ................................................................................................. 5-16
Speaker Assembly ............................................................................................................. 5-17
Assembling PCB to Keypad ............................................................................................... 5-17
Speaker Connection ........................................................................................................... 5-18
Assembling Keypad to Control Head Housing ................................................................... 5-18
Assembling Speaker Tape to PCB ..................................................................................... 5-19
Assembling Control Head Flex to Control Head Board ...................................................... 5-19
Thermal Pads and Shield Gasketing on Chassis and Die Cast Main Shield ..................... 5-20
Chassis with Thermal Pads................................................................................................ 5-20
Replacing Regulator Thermal Pads ................................................................................... 5-21
Replacing Audio PA Thermal Pad ...................................................................................... 5-22
Replacing Final Driver Thermal Pad .................................................................................. 5-23
Replacing PCB Thermal Pad ............................................................................................. 5-24
Applying Thermal Grease .................................................................................................. 5-25
Placing the Transceiver Board in the Chassis.................................................................... 5-25
Inserting RF Lock Washer and Nut .................................................................................... 5-26
Screw Sequence to Compress PCB .................................................................................. 5-26
Installing PA Screws........................................................................................................... 5-27
Screw Removal .................................................................................................................. 5-27
Inserting Accessory Connector .......................................................................................... 5-28

List of Figures

Figure 5-39
Figure 5-40
Figure 5-41
Figure 5-42
Figure 5-43
Figure 5-44
Figure 5-45
Figure 5-46
Figure 5-47
Figure 5-48
Figure 5-49
Figure 5-50
Figure 5-51
Figure 5-52
Figure 5-53
Figure C-1

Assembling Die Cast Main Shield onto Chassis ................................................................ 5-28
Screw Sequence to Tighten Die Cast Main Shield ............................................................ 5-29
RF Connector Nut Final Torque ......................................................................................... 5-29
Installing DC Cable Assembly............................................................................................ 5-30
Inspection of Cover Assembly with Seal ............................................................................ 5-31
Assembling Cover onto Chassis ........................................................................................ 5-31
Rear Latch in Secure Position ........................................................................................... 5-32
MAP Connector Cover Installation ..................................................................................... 5-32
Orientation of Option Board Flex to Option Board ............................................................. 5-33
Assemble Option Board to Radio Chassis (Image May Not Match Exact Product) ........... 5-33
Align Option Board to Mounting Holes ............................................................................... 5-34
Assemble Control Head to Chassis ................................................................................... 5-35
Flex Connection Connectors.............................................................................................. 5-35
Radio Assembly Exploded View ........................................................................................ 5-36
Alphanumeric Display Control Head Exploded View ......................................................... 5-38
PCB Top Side View ..............................................................................................................C-1

List of Tables

List of Tables
Table 1-1
Table 2-1
Table 2-2
Table 2-3
Table 2-4
Table 3-1
Table 3-2
Table 3-3
Table 3-4
Table 3-5
Table 3-6
Table 3-7
Table 4-1
Table 5-1
Table 5-2
Table 5-3
Table 5-4
Table 5-5
Table 6-1
Table C-1.

Radio Frequency Ranges and Power Levels ....................................................................... 1-1
Recommended Test Equipment ........................................................................................... 2-1
Service Aids ......................................................................................................................... 2-2
Wire Diagram for PMKN4150_............................................................................................. 2-4
Wire Diagram for PMKN4151_ ............................................................................................ 2-5
Initial Equipment Control Settings ........................................................................................ 3-1
Front Panel Access Test Mode Displays .............................................................................. 3-2
Test Environments................................................................................................................ 3-5
Test Channel Spacing .......................................................................................................... 3-5
Test Frequencies ................................................................................................................. 3-5
Transmitter Performance Checks......................................................................................... 3-6
Receiver Performance Checks ............................................................................................ 3-7
Radio Software Program Kit................................................................................................. 4-1
Lead Free Solder Wire Part Number List ............................................................................. 5-4
Lead Free Solder Paste Part Number List ........................................................................... 5-4
Radio Exploded View Parts List ......................................................................................... 5-37
Alphanumeric Display Control Head (PMLN6441_) Exploded View Parts List .................. 5-38
Torque Specifications for Nuts and Screws ........................................................................ 5-39
Power-Up Error Codes ......................................................................................................... 6-2
Component Parts List.......................................................................................................... C-1

Commercial Warranty

Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS
I. What This Warranty Covers And For How Long
MOTOROLA SOLUTIONS, INC. (“MOTOROLA”) warrants the MOTOROLA manufactured
Communication Products listed below (“Product”) against defects in material and workmanship
under normal use and service for a period of time from the date of purchase as scheduled below:

XPR 2500 Digital Mobile Radios

Two (2) Years

Product Accessories

One (1) Year

The mobiles additionally ship with a standard 1-year Repair Service Advantage (RSA)(for U.S.
customers) or Extended Warranty (for Canada customers) options can be selected for an additional
fee. At the time of order you must choose the warranty option.
For more RSA or Extended Warranty information, please refer to the price pages or Motorola Online
(https://businessonline.motorolasolutions.com) > Resource Center > Services > Service Product
Offerings > Repair Service Advantage or Extended Warranty.
Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.
This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.
MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.

xii

Commercial Warranty

II. General Provisions
This warranty sets forth the full extent of MOTOROLA's responsibilities regarding the Product.
Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive
remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR
DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE
DISCLAIMED BY LAW.

III. State Law Rights
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.
This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.

IV. How To Get Warranty Service
You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also call
Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty Does Not Cover
A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs
(including, without limitation, the addition to the Product of non-Motorola supplied equipment)
which adversely affect performance of the Product or interfere with Motorola's normal
warranty inspection and testing of the Product to verify any warranty claim.
F.

Product which has had the serial number removed or made illegible.

G. Freight costs to the repair depot.
H. A Product which, due to illegal or unauthorized alteration of the software/firmware in the
Product, does not function in accordance with MOTOROLA’s published specifications or the
FCC type acceptance labeling in effect for the Product at the time the Product was initially
distributed from MOTOROLA.
I.

Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.

Normal and customary wear and tear.

Commercial Warranty

xiii

VI. Patent And Software Provisions
MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:
A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such
claim;
B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its
settlement or compromise; and
C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the
subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to
continue using the Product or parts or to replace or modify the same so that it becomes
noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and
accept its return. The depreciation will be an equal amount per year over the lifetime of the
Product or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.

VII. Governing Law
This Warranty is governed by the laws of the State of Illinois, USA.

xiv

Commercial Warranty

Notes

Chapter 1 Introduction

1.1

Notations Used in This Manual
Throughout the text in this publication, you will notice the use of note and caution notations. These
notations are used to emphasize that safety hazards exist, and due care must be taken and
observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.

CAUTION indicates a potentially hazardous situation which, if
not avoided, might result in equipment damage.

Caution

1.2

Radio Description
The XPR 2500 mobile radios are available in the following frequency ranges and power levels.
Table 1-1 Radio Frequency Ranges and Power Levels
Freq. Band

Bandwidth

Power Level

VHF

136–174 MHz

1–25 Watts
25–45 Watts

UHF B1

403–470 MHz

1–25 Watts
25–40 Watts

These radios are among the most sophisticated two-way radios available. They have a
robust design for radio users who need high performance, quality, and reliability in their daily
communications. This architecture provides the capability of supporting a multitude of legacy and
advanced features resulting in a more cost-effective two-way radio communications solution.

1-2

1.3

Introduction: Control Head Description

Control Head Description
The control head used with the radio has logic circuitry that operates the standard and optional
features built into the system.
The following illustration shows the typical radio control head.
LED
Indicators

Power Button

Channel Changing
Rocker

Volume Changing
Rocker
LCD Screen

Accessory Connector

Programmable Buttons

OK/Menu Button

Speaker

Return/Home Button

Figure 1-1 Radio Control Head

1.3.1

Control Head Controls
• POWER BUTTON – Turns the radio on and off.
• VOLUME CHANGING ROCKER – Press top side to increment or bottom side to decrement the
volume.
• CHANNEL CHANGING ROCKER – Press top side to increment or bottom side to decrement
the channel.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display) – 132x36 display provides visual information about many radio
features.
• OK/MENU BUTTON – One button to provide menu navigation and selection interface.
• PROGRAMMABLE BUTTONS – Four buttons are field programmable using the CPS.
• RETURN/HOME BUTTON – One button which quickly brings you to the home page.

Introduction: MOTOTRBO Mobile Radio Model Numbering Scheme

1.4

MOTOTRBO Mobile Radio Model Numbering Scheme

Model No.Example :
Position

1-3

12
Unique Variations
N: Standard Package

AZ: Asia
LA: Latin America
AA: North America (except Mexico)
MD: Europe/Middle East/
Africa/Australia
Mobile

Version Letter

MOTOTRBO Mobile
XPR 2500 : 02
Band
J : 136–174 MHz
M : 217–222 MHz
P : 300–400 MHz
Q : 403–470 MHz
T : 450–512 MHz
X : 450–520 MHz
U : 806–941 MHz
V : 806–870 MHz

Power Level
N: 1–25W
P: 25–40W
Q: 25–45W
R: 1–40W
M: 10–35W
Physical Packages
H: Mid Tier (Alphanumeric Display)

Figure 1-2 Mobile Radio Model Numbering Scheme

Feature Level
1: Mini-U (Mobile)
2: BNC (Mobile)
Primary System Type
A: Conventional
B: Trunking
C: Analog Only
Primary Operation
J: Basic (No GPS, No Bluetooth)
K: GPS and Bluetooth
L: GPS Only
M: Bluetooth Only
Channel Information
9: Variable/Programmable
Channel Spacing

1-4

1.5

Introduction: VHF High Power (136–174 MHz) Model Chart

VHF High Power (136–174 MHz) Model Chart
VHF 136–174 MHz 25–45W, Mini-U
Model
AAM02JQH9JA1_N

Item

Description
136–174 MHz, 25–45W, MOTOTRBO XPR 2500 Alphanumeric
Display Mobile

Description

X PMUD3240_S

*Service Kit, VHF, 25–45W

X PMLN6441_

Alphanumeric Display Model Control Head

X 68009614001

Mobile Quick Reference Guide and Safety Booklet

X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1.6

VHF Low Power (136–174 MHz) Model Chart
VHF 136–174 MHz 1–25W, Mini-U
Model
AAM02JNH9JA1_N

Item

Description
136–174 MHz, 1–25W, MOTOTRBO XPR 2500 Alphanumeric
Display Mobile

Description

X PMUD3241_S

*Service Kit , VHF, 1–25W

X PMLN6441_

Alphanumeric Display Model Control Head

X 68009614001

Mobile Quick Reference Guide and Safety Booklet

X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

Introduction: UHF1 High Power (403–470 MHz) Model Chart

1.7

1-5

UHF1 High Power (403–470 MHz) Model Chart
UHF1 403–470 MHz 25–40W, Mini-U
Model

Description

AAM02QPH9JA1_N

Item

403–470 MHz, 25–40W, MOTOTRBO XPR 2500 Alphanumeric
Display Mobile

Description

X PMUE4164_S

*Service Kit, UHF1, 25–40W

X PMLN6441_

Alphanumeric Display Model Control Head

X 68009614001

Mobile Quick Reference Guide and Safety Booklet

X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1.8

UHF1 Low Power (403–470 MHz) Model Chart
UHF1 403–470 MHz 1–25W, Mini-U
Model
AAM02QNH9JA1_N

Item

Description
403–470 MHz, 1–25W, MOTOTRBO XPR 2500 Alphanumeric
Display Mobile

Description

X PMUE4168_S

*Service Kit, UHF1, 1–25W

X PMLN6441_

Alphanumeric Display Model Control Head

X 68009614001

Mobile Quick Reference Guide and Safety Booklet

X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1-6

1.9

Introduction: Specifications

Specifications
General
Specification

VHF

Model:

UHF1
Alphanumeric Display

Channel Capacity:

128

Typical RF Output:
Low Power
High Power

1–25 W
25–45 W

1–25 W
25–40 W

Frequency Range:

136–174 MHz

403–470 MHz

Dimensions: (HxWxL)

1.7 x 6.7 x 5.3 in
(44 x 169 x 134 mm)

Weight:

2.9 lbs. (1.3 kg)

Current Drain:
Standby
Rx @ rated audio
Transmit

0.81 A max
2 A max
1–25 W: 11.0 A max
25–40 W: 14.5 A max
25–45 W: 14.5 A max

FCC Description:

1–25 W:
ABZ99FT3090
25–45 W:
ABZ99FT3091

1–25 W:
ABZ99FT4092
25–40 W:
ABZ99FT4093

IC Description:

1–25 W:
109AB-99FT3090
25–45 W:
109AB-99FT3091

1–25 W:
109AB-99FT4092
25–40 W:
109AB-99FT4093

Introduction: Specifications

1-7

Receiver
Specification

VHF

Model:
Frequency:

UHF1
Alphanumeric Display

136–174 MHz

Channel Spacing:

403–470 MHz
12.5 kHz/25 kHz*

Frequency
Stability:
(-30°C to +60°C, +25°C
Ref)

±0.5 ppm

Analog Sensitivity
(12 dB SINAD):

0.3 µV
0.22 µV (typical)

Digital Sensitivity:
(5% BER)

0.25 µV
0.19 µV (typical)

Intermodulation
TIA603D:
Adjacent Channel
Selectivity
TIA603D:
Spurious
Rejection
TIA603D:
Rated Audio:

Audio Distortion @
Rated Audio:

75 dB

70 dB

50 dB @ 12.5 kHz,
75 dB @ 25 kHz

50 dB @ 12.5 kHz,
70 dB @ 25 kHz

75 dB

70 dB
4 W (Internal)
7.5 W (External – 8 ohms)
13 W (External – 4 ohms)
3% (Typical)

Hum and Noise:

-40 dB @ 12.5 kHz
-45 dB @ 25 kHz

Audio Response:

TIA603D

Conducted
Spurious Emission
(TIA603D):

-57 dBm

*25 kHz may not be available in the U.S. for Part 90 operation due to the FCC’s Narrowbanding
requirements.

1-8

Introduction: Specifications

Transmitter
Specification

VHF

Model:
Frequency:

Alphanumeric Display
136–174 MHz

Channel Spacing:

Modulation
Limiting:
FM Hum and Noise:
Conducted/
Radiated
Emission:
Adjacent
Channel Power
(TIA603D):

403–470 MHz
12.5 kHz/25 kHz*

Frequency
Stability:
(-30°C to +60°C, +25°C
Ref)
Power Output:
Low Power
High Power

UHF1

±0.5 ppm

1–25 W
25–45 W

1–25 W
25–40 W
±2.5 kHz @ 12.5 kHz
±5.0 kHz @ 25 kHz
-40 dB @ 12.5 kHz
-45 dB @ 25 kHz
-36 dBm <1 GHz
-30 dBm >1 GHz
60 dB @ 12.5 kHz
70 dB @ 25 kHz

Audio Response:

TIA603D

Audio Distortion:

FM Modulation:

12.5 kHz: 11K0F3E
25 kHz: 16K0F3E

4FSK Digital
Modulation:
Digital Vocoder Type:
Digital Protocol:

12.5 kHz Data: 7K60F1D & 7K60FXD
12.5 kHz Voice: 7K60F1E & 7K60FXE
Combination of 12.5 kHz Voice & Data: 7K60F1W
AMBE+2™
ETSI TS 102 361-1
ETSI TS 102 361-2
ETSI TS 102 361-3

*25 kHz may not be available in the U.S. for Part 90 operation due to the FCC’s Narrowbanding
requirements.

Introduction: Specifications

1-9

Self-Quieter
VHF

UHF1

153.6 MHz +/- 10 kHz

422.4 MHz

172.8 MHz +/- 10 kHz

–

Military Standards 810C, D, E, F & G
MIL-STD 810C

MIL-STD 810D

MIL-STD 810E

MIL-STD 810F

MIL-STD 810G

Method Proc./Cat Method Proc./Cat Method Proc./Cat Method Proc./Cat Method

Proc./Cat

Low
Pressure

500.1

500.2

500.3

500.4

500.5

High
Temperature

501.1

I, II

501.2

I/A1,
II/A1

501.3

I/A,
II/AI

501.4

I/HOT,
II/HOT

501.5

I/AI, II

Low
Temperature

502.1

502.2

I/C3,
II/C1

502.3

I/C3,
II/C1

502.4

I/C3,
II/C1

502.5

I/C3, II

Temperature
Shock

503.1

–

503.2

I/A1/C3

503.3

I/AI/C3

503.4

503.5

I/C

Solar
Radiation

505.1

505.2

505.3

505.4

505.5

I/A1

Rain

506.1

I, II

506.2

I, II

506.3

I, II

506.4

I, III

506.5

I, III

Humidity

507.1

507.2

507.3

507.4

–

507.5

II - Aggravated

Salt Fog

509.1

–

509.2

–

509.3

–

509.4

–

509.5

–

Dust

510.1

510.2

510.3

510.4

510.5

Vibration

514.2

VIII/F,
Curve-W

514.3

I/10,
II/3

514.4

I/10,
II/3

514.5

I/24

514.6

I/24

Shock

516.2

I, II

516.3

I, IV

516.4

I, IV

516.5

I, IV

516.6

I, IV,
V, VI

1-10

Introduction: Specifications

Environmental Specifications
Operating Temperature

-30°C / +60°C

Storage Temperature

-40°C / +85°C

Thermal Shock

Per MIL-STD

Humidity

Per MIL-STD

ESD
Dust and Water Intrusion
Packaging Test

IEC 61000-4-2 Level 3
IP54, MIL-STD**
Per MIL-STD

**Radio meets IP54 and MIL-STD rating with microphone sealing boot and rear accessory connector cover
properly installed.
Specifications subject to change without notice. All specifications shown are typical.
Radio meets applicable regulatory requirements. Version 1 05/13

Chapter 2 Test Equipment and Service Aids

2.1

Recommended Test Equipment
The list of equipment contained in Table 2-1 includes most of the standard test equipment required
for servicing Motorola mobile radios.
Table 2-1 Recommended Test Equipment

Equipment

Characteristic

Example

Application

Service Monitor

Can be used as a
substitute for items
marked with an asterisk
(*)

Aeroflex 3920 or equivalent

Frequency/deviation meter and
signal generator for wide-range
troubleshooting and alignment

Digital RMS
Multimeter*

100 µV to 300 V
5 Hz to 1 MHz
10 Mega Ohm Impedance

Fluke 179 or equivalent
(www.fluke.com)

AC/DC voltage and current
measurements. Audio voltage
measurements.

RF Signal
Generator*

100 MHz to 1 GHz
-130 dBM to +10 dBM
FM Modulation 0 kHz to
10 kHz

Agilent N5181
(www.agilent.com) or equivalent

Receiver measurements

Oscilloscope*

2 Channels
50 MHz Bandwidth
5 mV/div to 20 V/div

Tektronix TDS1001b
(www.tektronix.com) or
equivalent

Waveform measurements

Power Meter and
Sensor*

5% Accuracy
100 MHz to 500 MHz
50 Watts

Bird 43 Thruline Watt Meter
(www.bird-electronic.com) or
equivalent

Transmitter power output
measurements

RF Millivolt Meter

100 mV to 3 V RF
10 kHz to 1 GHz

Boonton 92EA
(www.boonton.com) or
equivalent

RF level measurements

Power Supply

0 V to 32 V
0 A to 20 A

B&K Precision 1790
(www.bkprecision.com) or
equivalent

Voltage supply

2-2

2.2

Test Equipment and Service Aids: Service Aids

Service Aids
Table 2-2 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-2 Service Aids
Motorola
Part Number

Description

Application

RLN4460_

Test Box

Enables connection to audio/accessory jack. Allows
switching for radio testing.

RVN5115_

Customer Programming
Software on CD-ROM

Allows servicer to program radio parameters, tune and
troubleshoot radios.

PMKN4147_

Front Telco MMP USB
Programming Cable

Connects the radio’s front connector to a USB port for
radio programming and data applications.

PMKN4148_

Back 20 Pin MAP USB
Programming Cable

Connects the radio’s rear connector to a USB port for
radio programming and data applications.

PMKN4149_

Back 20 Pin MAP Test and USB
Programming Cable

Connects the radio’s rear connector to a USB port for
radio programming, data applications, testing and
alignment.

PMKN4150_

Back 20 Pin MAP Test Cable

Connects the radio’s rear connector for testing. Must
use in conjunction with PMKN4147_ (Front Telco MMP
USB Programming Cable) for radio programming and
alignment.

PMKN4151_

Back 16 Pin MAP Universal
Cable

Connects the radio’s rear connector to the center 16
pins with unterminted connectors at the user end.

HPN4007_

Power Supply

Provides the radio with power when bench testing.

PMEN4041_

Chassis Eliminator Kit

Test Fixture used to bench test the radio PCB.

6686119B01

Control Head Dismantling Tool

Assists in the removal of radio control head.

Test Equipment and Service Aids: Programming Cables

2.3

2-3

Programming Cables

Figure 2-1 Front Telco MMP USB Programming Cable PMKN4147_
20

Figure 2-2 Back 20 Pin MAP USB Programming Cable PMKN4148_

2.4

Programming and Test Cable
DB 25 CONNECTOR
1

USB CONNECTOR

915±15
CABLE
1455±24
CABLE

WIRE DIAGRAM
20 PIN
ACCESSORY PORT CONNECTOR

PIN 19

VCC (5v) (USB VBUS)

WIRE COLOR

USB

RED

PIN 1

PIN 18

DATA -

WHITE

PIN 2

PIN 17

DATA +

GREEN

PIN 3

GROUND (USB)

BLACK

PIN 4

DB25P

PIN 20
DRAIN WIRE AND BRAID

TO MOBILE RADIO
ACCESSORY
CONNECTOR

19 1

15 17
VIEWED FROM
FRONT (PIN END)
OF CONNECTOR

20 2

16 18

DRAIN WIRE/BRAID SHELL

PIN 1

SPEAKER -

ORANGE

PIN 2 & 7

PIN 2

EXT MIC AUDIO

GREY

PIN 10 & 15

PIN 3

PROGM INPUT (EXT. PTT)

PINK

PIN 20

PIN 5

FLAT TX AUDIO

YELLOW

PIN 18

PIN 7

GROUND (DB25)

BLACK

PIN 16

PIN 15

RSSI

BROWN

PIN 19

PIN 16

SPEAKER +

PURPLE

PIN 1 & 5

Figure 2-3 Back 20 Pin MAP Test and USB Programming Cable PMKN4149_

2-4

Test Equipment and Service Aids: Test Cable

2.5

Test Cable

WIRE DIAGRAM
20 PIN
ACCESSORY PORT CONNECTOR

WIRE COLOR

DB25P

PIN
No.

DESCRIPTION

SPEAKER -

ORANGE

2&7

EXT MIC

GREY

10 & 15

GPI_1
(EXT PTT)

PINK

FLAT TX

YELLOW

GROUND

BLACK

RSSI

BROWN

SPEAKER +

PURPLE

1&5

Table 2-3 Wire Diagram for PMKN4150_

Figure 2-4 Back 20 Pin MAP Test Cable PMKN4150_

15
17

16
18

Test Equipment and Service Aids: Accessory Cable

2.6

2-5

Accessory Cable
PIN POSITION

Figure 2-5 Back 16 Pin MAP Universal Cable PMKN4151_
Table 2-4 Wire Diagram for PMKN4151_

WIRE DIAGRAM
16 PIN
CONNECTOR

WIRE COLOR

WIRE LEAD
SIDE

PURPLE

GREY

GREEN

PINK

YELLOW / DRAIN WIRE

NC *

WHT / BLK

ORANGE

WHT / BRN

BLUE

WHT / RED

BROWN

WHT / ORG

RED

WHT / GRN

16 PIN
CONNECTOR

WIRE COLOR

WIRE LEAD
SIDE

BLACK

WHITE

(*) NOTE: CRIMP YELLOW WIRE AND DRAIN WIRE TO TERMINAL ON 26 PIN CONNECTOR.
TIN YELLOW WIRE AND DRAIN WIRE TOGETHER ON WIRE LEAD SIDE

2-6

Test Equipment and Service Aids: Accessory Cable

Notes

Chapter 3 Transceiver Performance Testing

3.1

General
These radios meet published specifications through their manufacturing process by utilizing
high-accuracy laboratory-quality test equipment. The recommended field service equipment
approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must
be maintained in compliance with the manufacturer’s recommended calibration schedule.

3.2

Setup
Supply voltage is provided using a 13.8 VDC power supply. (Note: applying 13.8 VDC at the DC
power cable will ensure a minimum of 13.2 VDC at the DC connector of the radio). The equipment
required for alignment procedures is shown in the Radio Tuning Equipment Setup Diagram,
Figure 4-4.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number

Title

3-2

Front Panel Access Test Mode Displays

3-3

Test Environments

3-4

Test Channel Spacing

3-5

Test Frequencies

3-6

Transmitter Performance Checks

3-7

Receiver Performance Checks

Table 3-1 Initial Equipment Control Settings
Service Monitor

Power Supply

Test Set

Monitor Mode: Power Monitor

Voltage: 13.8 VDC

Speaker set: A

RF Attenuation: -70

DC On/Standby:
Standby

Speaker/load:
Speaker

AM, CW, FM: FM

Volt Range: 20 V

PTT: OFF

Oscilloscope Source: Mod
Oscilloscope Horizontal: 10 mSec/Div
Oscilloscope Vertical: 2.5 kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: middle setting
Monitor Vol: 1/4 setting

Current: 20 A

3-2

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

3.3

Alphanumeric Display Model Test Mode

3.3.1

Entering Display Radio Test Mode
1. Turn the radio on.
2. Within ten seconds after self test is complete, press button P2, five times in succession.
3. The radio beeps and will show a series of displays that will give information regarding various
version numbers and subscriber specific information. The displays are described in
Table 3-2.
Table 3-2 Front Panel Access Test Mode Displays
Name of Display

Description

Appears

Service Mode

The literal string indicates the radio has entered test mode.

Always

Host Version

The version of host firmware.

Always

DSP Version

The version of DSP firmware.

Always

Model Number

The radio’s model number as programmed in the codeplug.

Always

MSN

The radio’s serial number as programmed in the codeplug.

Always

FLASHCODE

The FLASH codes as programmed in the codeplug.

Always

RF Band

The radio’s band.

Always

NOTE: The radio stops at each display for 2 seconds before moving to the next information display.
If the information cannot fit into 1 line, the radio display scrolls automatically character by
character after 1 second to view the whole information. If the Top Navigation Button () is
pressed before the last information display, the radio shall suspend the information display
until the user presses Bottom Navigation Button ( ) to resume the information display. The
radio beeps for each button press. After the last display, RF Test Mode will be displayed.

3.3.2

RF Test Mode
When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or air test.
In RF Test Mode, the display upon the first line is “RF Test”, together with the power level icon at the
right end of the first line. The display upon the second line is the test environment, the channel
number and channel spacing (“CSQ CHXX SP25”). The default test environment is CSQ.
1. Each short press of button P2 changes the test environment
(CSQ->TPL->DIG->USQ->CSQ). The radio beeps once when radio toggles to CSQ, beeps
twice for TPL, beeps three times for DIG and beeps four times for USQ.
NOTE: DIG is digital mode and other test environments are analog mode as described in
Table 3-3.
2. Each short press of button P1 toggles the channel spacing between 20 kHz, 25 kHz and
12.5 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

3-3

3. Pressing of the Channel Changing Rocker changes the test channel from 1 to 14. Press the
top side to increase or bottom side to decrease the channel number. The radio beeps in each
position. The channel test frequencies are described in Table 3-5.

3.3.3

Alphanumeric Display Test Mode
1. Press and hold button P1 in RF Test Mode. The radio beeps once and momentarily displays
‘Display Test Mode’.
2. Upon entering Display Test Mode, the radio displays a horizontal line on row 8 (center row).
3. With each button press, the radio fills up the screen with 2 horizontal lines from the center row
(1 line each above and below the center row) until the top and bottom of the screen (row 7–0
and 9–16) is completely filled.
4. When the screen is filled up with the horizontal lines, any button press clears the screen and
displays vertical lines at column 0, 6, 12, 18, 24, 30, 36, 42, 48, 54, 60. Any button press fills
the screen with vertical lines, (1 line to the right of all existing lines) until the display is filled.

3.3.4

LED Test Mode
1. Press and hold button P1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button press, the radio lights on the red LED and displays “Red LED On”.
3. Consequently, upon any button press, the red LED is turned off and the radio lights on the
green LED and displays “Green LED On”.
4. Consequently, upon any button press, the green LED is turned off and the radio shall light on
the yellow LED and displays “Yellow LED On”.

3.3.5

Backlight Test Mode
1. Press and hold button P1 after LED Test Mode. The radio beeps once and displays
“Backlight Test Mode”.
2. The radio lights on both LCD and keypad backlight together.

3.3.6

Speaker Tone Test Mode
1. Press and hold button P1 after Backlight Test Mode. The radio beeps once and displays
“Speaker Tone Test Mode”.
2. The radio generates a 1 kHz tone with the internal speaker.

3.3.7

Earpiece Tone Test Mode
1. Press and hold button P1 after Speaker Tone Test Mode. The radio beeps once and displays
“Earpiece Tone Test Mode”.
2. The radio generates a 1 kHz tone with the earpiece.

3.3.8

Audio Loopback Test Mode
1. Press and hold button P1 after Earpiece Tone Test Mode. The radio beeps once and
displays “Audio Loopback Test Mode”.
2. The radio shall route any audio on the mic to the internal speaker.

3-4

3.3.9

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

Audio Loopback Earpiece Test Mode
1. Press and hold button P1 after Audio Loopback Test Mode. The radio beeps once and
displays “Audio Loopback Earpiece Test”.
2. The radio shall route any audio on the mic to the accessory earpiece.

3.3.10 Button Test Mode
1. Press and hold button P1 after Audio Loopback Earpiece Test Mode. The radio beeps once
and displays “Button Test”.
2. The radio also displays the Button Command Opcode (BCO) and state (BCO/state) on the
screen upon any button state changes.
3. The radio must be powered off to end Test Mode.

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

3-5

Table 3-3 Test Environments
No. of
Beeps

Description

Function

Carrier Squelch
(CSQ)

RX: unsquelch if carrier detected
TX: mic audio

Tone Private-Line
(TPL)

RX: unsquelch if carrier and tone (192.8 Hz) detected
TX: mic audio + tone (192.8 Hz)

Digital
(DIG)

RX: unsquelch if carrier and digital code detected
TX: mic audio

Unsquelch
(USQ)

RX: constant unsquelch
TX: mic audio
Table 3-4 Test Channel Spacing
Number of Beeps

Channel Spacing

20 kHz

25 kHz

12.5 kHz

Table 3-5 Test Frequencies
Test Mode

Test Channel
Low Power

Test Channel
High Power

VHF
(MHz)

UHF1
(MHz)

136.075

403.000

136.075

403.000

142.575

414.150

142.575

414.150

146.575

425.350

146.575

425.350

155.575

436.500

155.575

436.500

161.575

447.675

161.575

447.675

167.575

458.850

167.575

458.850

174.975

470.000

174.975

470.000

3-6

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

Table 3-6 Transmitter Performance Checks
Test Name

Communications
Analyzer

Radio

Test Set

Comment

Reference
Frequency
(see Note
below
Table 3-6)

Mode: PWR MON
4th channel test frequency*
Monitor: Frequency error
Input at RF In/Out

TEST MODE,
Test Channel 4,
carrier squelch

PTT to
continuously
transmit (during
the performance
check)

Frequency error:
±90 Hz (VHF)
±150 Hz (UHF)

Power RF

As above

TEST MODE
Test Channel 4,
carrier squelch

As above

Low Power Set:
1.0–1.3 W: (VHF 1–25 W,
UHF1 1–25 W)
25–29 W: (VHF 25–45 W,
UHF1 25–40 W)

TEST MODE
Test Channel 11,
carrier squelch

High Power Set:
25–29 W: (VHF 1–25 W,
UHF1 1–25 W)
40–47 W: (UHF1 25–40 W)
45–53 W: (VHF 25–45 W)

Voice
Modulation

Mode: PWR MON
4th channel test frequency*
atten to -70, input to RF In/
Out
Monitor: DVM, AC Volts
Set 1 kHz Mod Out level for
800mVrms at test set,
800mVrms at AC/DC test
set jack

TEST MODE
Test Channel 4,
carrier squelch

As above, meter
selector to mic

Deviation:
2.5 kHz Max.
(12.5 kHz Ch. Sp.)
4 kHz Max.
(20 kHz Ch. Sp.)
5 kHz Max.
(25 kHz Ch. Sp.)

Voice
Modulation
(internal)

Mode: PWR MON
4th channel test frequency*
atten to -70, input to RF In/
Out

TEST MODE,
Test Channel 4
carrier squelch
output at
antenna

Remove
modulation input

Deviation:
2.5 kHz Max.
(12.5 kHz Ch. Sp.)
4 kHz Max.
(20 kHz Ch. Sp.)
5 kHz Max.
(25 kHz Ch. Sp.)

TPL
Modulation

As above
4th channel test frequency*
BW to narrow

TEST MODE,
Test Channel 4
TPL

As above

Deviation:
0.25–0.5 kHz
(12.5 kHz Ch. Sp.)
0.4–0.8 kHz
(20 kHz Ch. Sp.)
0.5–1.0 kHz
(25 kHz Ch. Sp.)

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

3-7

Table 3-6 Transmitter Performance Checks (Continued)
Test Name

Communications
Analyzer

Radio

Test Set

Comment

FSK Error

DMR mode. FSK error

TEST MODE,
Digital mode,
transmit with
O.153 test
pattern

Key up radio
with O.153 test
pattern
modulation
using Tuner

Not Exceed 5%

Magnitude
Error

DMR mode. Magnitude error

As above

Not Exceed 1%

Symbol
Deviation

DMR mode. Symbol
deviation

As above

Symbol Deviation should
be within 648 +/-10% and
1944 +/-10%

Transmitter
BER

DMR mode

As above

Transmitter BER should be
0%

* See Table 3-5
NOTE: It is recommended that the reference oscillator be recalibrated after two years to maintain
optimized Dual Capacity Direct Mode performance.
Table 3-7 Receiver Performance Checks
Test Name

Communications
Analyzer

Radio

Test Set

Comment

Rated Audio

Mode: GEN
Output level: 1.0 mV RF
4th channel test frequency*
Mod: 1 kHz tone at
3 kHz deviation
Monitor: DVM: AC Volts

TEST MODE
Test Channel 4,
25 kHz channel
spacing,
carrier squelch

PTT to OFF
(center), meter
selector to
Audio PA

Set volume control to
7.5 Vrms

Distortion

As above, except to
distortion

As above

Distortion <5.0%

Sensitivity
(SINAD)

As above, except SINAD,
lower the RF level for 12 dB
SINAD.

As above

PTT to OFF
(center)

RF input to be <0.3 µV

RF level set to 1 mV RF

As above

PTT to OFF
(center), meter
selection to
Audio PA, spkr/
load to speaker

Set volume control to
7.5 Vrms

As above, except change
frequency to a conventional
system. Raise RF level from
zero until radio unsquelches.

out of TEST
MODE; select a
conventional
system

As above

Unsquelch to occur at
<0.25 µV.
Preferred SINAD =
9–10 dB

IFR DMR mode. Signal
generator with O.153 test
pattern

Test mode,
Digital mode,
receive O.153
test pattern

Read BER using
Tuner. Adjust
RF level to get
5% BER

RF level to be
<0.3 µV for 5% BER

Noise Squelch
Threshold
(only radios
with
conventional
system need
to be tested)
Receiver BER

* See Table 3-5

3-8

Transceiver Performance Testing: Alphanumeric Display Model Test Mode

Notes

Chapter 4 Radio Programming and Tuning

4.1

Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner and AirTracer applications, which are all designed for use on a Windows 8/7/Vista/
XP operating system. These programs are available in one kit as listed in Table 4-1. An Installation
Guide is also included with the kit.
NOTE: Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1 Radio Software Program Kit
Kit Number

MOTOTRBO CPS, Tuner and AirTracer Applications CD

RVN5115_

Customer Programming Software Setup
The Customer Programming Software setups, shown in Figure 4-1 and Figure 4-2, are used to
program the radio.
NOTE: Refer to the appropriate program on-line help files for the programming procedures.
CAUTION: Computer USB ports can be sensitive to Electronic Discharge.
Do not touch exposed contacts on cable when connected to a computer.

Front Connector

ACC
R a d io

4.2

Description

DC
RF

13.8VDC
Power
Supply

Front Telco MMP USB
Programming Cable PMKN4147_

USB

Figure 4-1 Customer Programming Software Setup from Front Connector

4-2

Radio Programming and Tuning: AirTracer Application Tool

Radio

ACC

Rear Accessory
Connector

Back 20 Pin MAP USB
Programming Cable PMKN4148_

DC
RF

13.8 VDC
Power
Supply

USB

Figure 4-2 Customer Programming Software Setup from Rear Accessory Connector

Radio

ACC

Back 20 Pin MAP Test and USB
Programming Cable PMKN4149_

Rear Accessory
Connector

Test Box RLN4460_
No
Connection

DC
RF

13.8 VDC
Power
Supply

USB

Figure 4-3 Customer Programming Software Setup with Test Box Connection

4.3

AirTracer Application Tool
The MOTOTRBO AirTracer application tool has the ability to capture over-the-air digital radio traffic
and save the captured data into a file. The AirTracer application tool can also retrieve and save
internal error logs from MOTOTRBO radios. The saved files can be analyzed by trained Motorola
personnel to suggest improvements in system configurations or to help isolate problems.

Radio Programming and Tuning: Radio Tuning Setup

Radio Tuning Setup
A personal computer (PC), Windows 8/7/Vista/XP and a tuner program (which is available as part of
the MOTOTRBO CPS kit) are required to tune the radio. To perform the tuning procedures, the radio
must be connected to the PC and test equipment setup as shown in Figure 4-4 or Figure 4-5.
Tx

Audio In
Test Box
RLN4460_

Audio Generator

SINAD Meter
AC Voltmeter

Back 20 Pin MAP Test and USB
Programming Cable PMKN4149_

R a d io

ACC
DC

13. 8 V D C
Power
Supply

30 dB Pad

USB

Mini UHF
to BNC Adaptor
(if needed)

Service Monit o r

WATT meter

RF Generator

Figure 4-4 Radio Tuning Equipment Setup

Front Telco MMP USB
Programming Cable PMKN4147_

USB
Back 20 Pin MAP Test
Cable PMKN4150_

ACC
R a d io

4.4

4-3

13. 8 V D C
Power
Supply

30 dB Pad

Mini UHF
to BNC Adaptor
(if needed)

Audio In
Test Box
RLN4460_

Audio Generator

SINAD Meter
AC Voltmeter

Service Monitor

RF Generator

Figure 4-5 Radio Tuning Equipment Setup (Alternative Method)

WATT meter

4-4

Radio Programming and Tuning: Radio Tuning Setup

Notes

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.
• Repair procedures and techniques.
• Disassembly and reassembly of the radio.

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 control
head and housing assembly. These surfaces should be cleaned whenever a periodic visual
inspection reveals the presence of smudges, grease, and/or grime.
NOTE: Internal surfaces should be cleaned only when the radio is disassembled for service or repair.
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).

!
Caution

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.
The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
chemicals.

5-2

Disassembly/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. Once the cleaning process is
complete, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, control head and housing assembly.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).

5.3

Safe Handling of CMOS and LDMOS Devices
Complementary Metal Oxide Semiconductor (CMOS) and Laterally Diffused Metal Oxide
Semiconductor (LDMOS) 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/LDMOS circuits and are especially important in low
humidity conditions.

Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices

DO NOT attempt to disassemble the radio without first referring to the following CAUTION
statement.

!
Caution

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 a wrist strap, two
ground cords, a table mat, 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.

5-3

5-4

5.4

Disassembly/Reassembly Procedures: Repair Procedures and Techniques – General

Repair Procedures and Techniques – General
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 2) Directive 2011/65/EU and
Waste Electrical and Electronic Equipment (WEEE) Directive 2012/19/EU. To
maintain product compliance and reliability, use only the Motorola specified parts in this
manual.

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:
Table 5-1 Lead Free Solder Wire Part Number List
Motorola
Part Number

Alloy

Flux Type

Flux Content
by Weight

Melting
Point

Supplier Part
number

Diameter

Weight

1088929Y01

95.5Sn/3.8Ag/0.7Cu

RMA Version

2.7–3.2%

217°C

52171

0.015”

1lb spool

Table 5-2 Lead Free Solder Paste Part Number List
Motorola Part
Number

Manufacturer Part
Number

1085674C03

NC-SMQ230

Viscosity

Type

Composition & Percent Metal

900–1000KCPs
Brookfield (5rpm)

Type 3
(-325/+500)

(95.5%Sn-3.8%Ag-0.7%Cu)
89.3%

Liquid
Temperature
217°C

Parts Replacement and Substitution
Check the parts list for the proper Motorola part number and order the part from the nearest Motorola
Radio Products and Solutions Organization 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.

Disassembly/Reassembly Procedures: Disassembling and Reassembling the Radio – General

5.5

5-5

Disassembling and Reassembling the Radio – General
Since these radios may be disassembled and reassembled with the use of only eleven screws
(board to casting), 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 and assembling the radio:
• Small Flat Blade Screwdriver
• Control Head Dismantling Tool (Motorola Part No. 6686119B01)
• Torque Driver (2–36 lbs-in or 0.2–4.0 N-m), (Motorola Part No. RSX4043A)
• TORX™ T10 Driver Bit (Motorola Part No. 6680387A74)
• TORX™ T8 Driver Bit (Motorola Part No. 6680387A72)
• TORX™ T6 Driver Bit (Motorola Part No. 6680387A70 - for use with Option Board only)
• 9/16” Deep Socket Driver (RF Connector Nut)
If a unit requires more complete testing or service than is customarily performed at the basic level,
please send radio to a Motorola Service Center listed in Appendix B.
The following disassembly procedures should be performed only if necessary.

5.6

Radio Disassembly – Detailed
The procedure to remove and replace the control head, top cover or transceiver board is similar for
all models. A typical procedure is therefore provided in this section followed by detailed disassembly
procedures for each specific control head model.

5.6.1

Control Head Removal
1. Insert the dismantling tool in the groove between the control head and the radio assembly as
shown in Figure 5-1.
2. Press the dismantling tool under the control head to release the snap features.

Dismantling
Tool

Figure 5-1 Typical Control Head Removal

5-6

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

3. Pull the control head away from the radio assembly as shown in Figure 5-2.
NOTE: During the control head disassembly, the control head PCB may snap out of position. The
control head PCB will need to be snapped back in place prior to reassembly.

Flex Cable

Figure 5-2 Flexible Connection Removal
4. Remove the flex cable from the socket on the radio assembly as shown in Figure 5-2.

5.6.2

Top Cover Removal
1. Insert the dismantling tool between the top cover and the chassis as shown in
Figure 5-3.
2. Press on the dismantling tool until one side wall of the top cover starts to clear the chassis
trunnion mounting features.
3. Repeat step 2 for the other side of the top cover.
4. A small flat screwdriver may be required to release the rear catch.
5. Lift the top cover from the chassis.
Trunnion Mounting
Feature

Dismantling
Tool

Figure 5-3 Top Cover Removal (Image May Not Match Exact Product)

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5.6.3

Transceiver Board Removal
1. Using a T6 TORX™ driver, remove the screws securing the option board to the chassis
(Option Board Only).
2. Unplug the flex from the transceiver board (Option Board Only).

Option Board Flex

Screws

Option Board
Figure 5-4 Option Board Removal (Image May Not Match Exact Product)

5-7

5-8

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

3. Remove the eight screws from the die cast main shield, the one screw directly on the PCB
and the two screws from the DC Cable using the T10 TORX™ driver as shown in Figure 5-5.
4. Lift the die cast main shield from the chassis.

Die Cast
Main Shield

Screws (11)

Radio
Chassis

Figure 5-5 Die Cast Main Shield Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-9

5. Remove the two screws from the PCB using the T8 TORX™ driver as shown in Figure 5-6.
NOTE: Do not remove the washers from the screws.

Screws (2)
Radio
Chassis

Figure 5-6 PA Screw Removal
6. Remove the accessory connector cap.
7. Remove the accessory connector from the radio assembly by pulling the connector straight
out of the radio chassis as shown in Figure 5-7.

!
Caution

The accessory connector should never be removed when the die cast main
shield is still assembled to the radio.

Figure 5-7 Accessory Connector Removal

5-10

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

8. Remove the DC Cable by gently pulling it away from the radio chassis as shown in
Figure 5-8.

Figure 5-8 DC Cable Removal
9. Remove the RF connector nut and lock washer using a 9/16” deep socket driver
(Figure 5-9).

RF Lock Washer and Nut

Figure 5-9 RF Connector Nut Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-11

10. Remove the transceiver board by grabbing and lifting the SMT shields and lift the transceiver
board, as shown in Figure 5-10. Then, slide the transceiver board towards the front of the
radio to allow the RF connector to clear the chassis. Handle the transceiver board by the
edges only and store it in an antistatic bag.
NOTE: If the RF connector gasket remain in the chassis, remove it and place it back on the connector.
Every time the Transceiver Board is removed, the Final Driver Thermal Pad must be replaced.

!
Caution

The thermal pads can act as an adhesive and cause stress to critical
components on the transceiver board if the transceiver board is lifted too
quickly.

Figure 5-10 Transceiver Board Removal

5-12

5.6.4

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

Disassembly of Alphanumeric Display Control Head
1. Unplug the control head flex from the control head board by gently pulling the flex out of the
connector as shown in Figure 5-11.

Control Head Flex

Figure 5-11 Control Head Flex Removal
2. Remove the speaker tape from the PCB by using a tweezer as shown in Figure 5-12.
3. Disconnect the speaker connector from the control head board.

Speaker Tape

Speaker Connector

Figure 5-12 Speaker Tape Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-13

4. Remove the keypad assembly from the control head housing by pushing on the keypad
buttons while disengaging the control head PCB by deflecting the control head housing side
walls. Once the keypad begins to separate from the control head housing, pull both
components apart. Refer to Figure 5-13.
Keypad Buttons
to Push

Deflecting Direction

Keypad Buttons
to Push

Deflecting Direction

Figure 5-13 Keypad Assembly Removal
5. Remove the speaker from the keypad assembly as shown in Figure 5-14.

Speaker

Figure 5-14 Speaker Removal

5-14

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

6. Gently lift the keypad upwards to disengage the PCB tabs from the keypad openings.
Simultaneously, remove the keypad flaps around the PCB. Then remove the PCB from the
keypad. Refer to Figure 5-15.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.
PCB Tab Protruding
Through Keypad
Opening

Grounding
Contact

Keypad Flaps
Constraining The
PCB On All 4 Sides
Figure 5-15 PCB Removal
7. Gently remove the indicator barrier from the keypad as shown in Figure 5-16.
Indicator Barrier

Figure 5-16 Indicator Barrier Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-15

8. Gently push the LCD display latch and remove the LCD from the PCB. Refer to Figure 5-17.
9. Remove the LCD flex from the connector.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.
LCD Latch

LCD Flex
Grounding
Contacts
Figure 5-17 LCD and LCD Flex Removal

Connector

5-16

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7

Radio Reassembly – Detailed

5.7.1

Reassembly of Alphanumeric Display Control Head
1. Connect the display flex to the connector on the PCB.
2. Align the LCD alignment pins to the PCB holes.
3. Firmly press along the outer perimeter of the display until the LCD display latch is attached to
the PCB. Refer to Figure 5-18.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

Grounding
Contacts

Connector

Figure 5-18 LCD Display Assembly
4. Gently assemble the indicator barrier to the keypad as shown in Figure 5-19.
Indicator Barrier

Figure 5-19 Indicator Barrier Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-17

5. Assemble the speaker to the keypad. Refer to Figure 5-20.
NOTE: Be sure to orient the speaker in the direction of the wire and connector towards the middle of
the control head.

Figure 5-20 Speaker Assembly
6. Assemble PCB assembly to the keypad as shown in Figure 5-21.
NOTE: Verify that the PCB is properly positioned to the keypad:
1) The four PCB tabs should protrude through the keypad openings.
2) The PCB should be seated to the keypad so the keypad flaps constrain the PCB.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.
PCB Tab Protruding
Through Keypad
Opening

Grounding
Contacts

Keypad Flaps
Constraining The
PCB On All 4 Sides
Figure 5-21 Assembling PCB to Keypad

5-18

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

7. Connect the speaker plug to its mating connector on the control head board as shown in
Figure 5-22.
Speaker Connector

Figure 5-22 Speaker Connection
8. Assemble the keypad with the PCB and speaker assembled to the control head housing.
Refer to Figure 5-23.
NOTE: PCB needs to be snapped into the control head housing. Ensure entire keypad is fully seated
to the control head housing.
Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

Grounding
Contacts

Figure 5-23 Assembling Keypad to Control Head Housing

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-19

9. Assemble the speaker tape on the speaker wire and PCB. Press the speaker tape and make
sure it sticks firmly on the PCB. Refer to Figure 5-24.

Speaker Tape

Figure 5-24 Assembling Speaker Tape to PCB
10. Gently plug the control head flex to the control head board as shown in Figure 5-25.

Figure 5-25 Assembling Control Head Flex to Control Head Board

5-20

5.7.2

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Radio Assembly
1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks,
cuts, etc.) or debris. Refer to the exploded view and bill of materials for the correct part
numbers and replace parts, as necessary. Replace all new seals on their respective parts.
For both the die cast main shield and the chassis, thoroughly inspect the shield gasketing for
damage and verify all thermal pads are in place and free from damage and debris. See
Section 5.7.3: Thermal Pad Replacement Procedure on page 5-21 to replace damaged pads.

Die Cast Main Shield
and Shield Gasketing
Chassis with Thermal Pads
and Shield Gasketing
Figure 5-26 Thermal Pads and Shield Gasketing on Chassis and Die Cast Main Shield
2. Thoroughly inspect the chassis and verify all thermal pads are in place and free from
damage. See Section 5.7.3: Thermal Pad Replacement Procedure on page 5-21 to replace
damaged pads.
NOTE: Every time the Transceiver Board is removed, the Final Driver Thermal Pad must be
replaced.
Audio PA Thermal Pad
Regulator
(75012059001)
Thermal
Final Driver Thermal Pad
Pad
(75012058002)
(75012018001)

Thermal Grease (1110022A55)
Figure 5-27 Chassis with Thermal Pads

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.3

5-21

Thermal Pad Replacement Procedure
Regulator Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place it
on the chassis as shown in Figure 5-28.

Regulator Thermal
Pad (75012018001)

Figure 5-28 Replacing Regulator Thermal Pads

5-22

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Audio PA Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis as shown in Figure 5-29.

Audio PA Thermal Pad
(75012059001)

Figure 5-29 Replacing Audio PA Thermal Pad

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-23

Final Driver Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift each pad from the transceiver board. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis as shown in Figure 5-30.

Final Driver Thermal Pad
(75012058002)

Figure 5-30 Replacing Final Driver Thermal Pad

5-24

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

PCB Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the transceiver board. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the transceiver board as shown in Figure 5-31.
NOTE: The PCB Thermal Pad is NOT placed for the UHF1 1–25W models. Placing the pad on a
UHF1 1–25W model may degrade radio performance.

Thermal Pad
(75012018001)

Figure 5-31 Replacing PCB Thermal Pad

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.4

5-25

Transceiver Board Reassembly
1. Apply thermal grease to the PA area. Refer to Figure 5-32.

Thermal Grease
(1110022A55)

Figure 5-32 Applying Thermal Grease
2. Insert the transceiver board into the chassis by tilting the transceiver board (approximately 45
degrees) and sliding it into place, taking care to line up the RF connector with the opening in
the back of the chassis.
NOTE: Prior to board installation verify thal all thermal pads are present. Verify that a thermal pad is
present on the PCB.
Push the board down to fully seat it to the radio chassis.

Figure 5-33 Placing the Transceiver Board in the Chassis

5-26

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

3. Using a 9/16” deep socket driver install the lock washer and nut to an initial torque of 0.9 N-m
(8 lbs-in). Refer to Figure 5-34.

RF Lock Washer and Nut
Figure 5-34 Inserting RF Lock Washer and Nut
4. Using a T10 TORX™ driver insert three main shield thread forming screws (M3) at locations
3, 5 and 6 to compress the PCB. Tighten the screws to 1.0 N-m (9 lbs-in).
NOTE: This step is required; otherwise, damage could result to the final transmitter PA device.

3
5

Figure 5-35 Screw Sequence to Compress PCB

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-27

5. While the board is pressed down, align the PA holes on PCB to mounting holes on chassis
and insert two (M2.5) machine screws with washers (see Figure 5-36 for PA Screw
sequence). Using a T8 TORX™ tighten the screws to 0.45 N-m (4 lbs-in).

Install This Screw First

Install This Screw Second

Figure 5-36 Installing PA Screws
6. Using a T10 TORX™ driver remove the screws from locations 3, 5 and 6.

Figure 5-37 Screw Removal

5-28

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

7. Insert the accessory connector into the radio assembly and press into place until the
connector is flush with the chassis. Refer to Figure 5-38.

Accessory
Connector
Figure 5-38 Inserting Accessory Connector
8. Place the main shield on the transceiver board and lock in place the accessory connector by
aligning the main shield locking tabs to the pockets of the accessory connector.
9. Insert eight main shield thread forming screws (M3) through the shield and one thread
forming screw (M3) through the board.
10. Using a T10 TORX™ driver follow the sequence marked on the main shield and tighten all
nine screws to 1.47 N-m (13 lbs-in). Refer to Figure 5-39.
11. Retighten the eight screws on the main shield a second time.

Figure 5-39 Assembling Die Cast Main Shield onto Chassis

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-29

6
8

Figure 5-40 Screw Sequence to Tighten Die Cast Main Shield
12. Use a 9/16” deep socket driver to further tighten the nut to a final torque of 2.15 N-m
(19 lbs-in).

RF Connector Lock Washer and Nut
Figure 5-41 RF Connector Nut Final Torque

5-30

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

!
Caution

Do not leave the transceiver board in the chassis for extended periods of time
without the RF lock washer and nut assembled, or damage to the board
connectors may occur.

13. Install the DC Cable Assembly to the radio chassis slot. Ensure that it is seated correctly on
the chassis hook located below the DC Cable.
14. Insert two thread forming screws (M3).
15. Using a T10 TORX™ driver, tighten the screws to 1.47 N-m (13 lbs-in). Refer to Figure 5-42.

Figure 5-42 Installing DC Cable Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-31

16. Thoroughly inspect the cover assembly with seal attached. Ensure the seal is fully seated on
the cover and the locking tabs engaged at all six locations.

Locking Tab
(6 Places)

Figure 5-43 Inspection of Cover Assembly with Seal
17. Gently spread both sides of the cover.
18. Align the top cover to the chassis and snap the cover in place uniformly. Ensure the alignment
posts on the cover slide into the alignment slots on the chassis and that the rear latch is
secure.

Main Cover

Radio Chassis

Figure 5-44 Assembling Cover onto Chassis

5-32

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

NOTE: Ensure the DC Cable locking tabs fit in the designated slots on the connector overmold. Avoid
biting of locking tabs on the overmold.

DC Cable Locking Tabs

Figure 5-45 Rear Latch in Secure Position
19. Install the MAP Connector cover.

MAP Connector Cover
Figure 5-46 MAP Connector Cover Installation

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.5

5-33

Option Board Installation
1. Orient the option board flex so that contacts face option board. Secure connector latch to
option board as referenced in Figure 5-47. Note white line on flex should be aligned with
connector latch.

Latch

Option Board Flex

Figure 5-47 Orientation of Option Board Flex to Option Board
2. Maintaining the bend orientation, connect the flex cable from the option board to the main
board connector.

Option Board Flex

Screws

Option Board

Figure 5-48 Assemble Option Board to Radio Chassis (Image May Not Match Exact Product)

5-34

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

3. Align option board to mounting holes ensuring that the flex tabs are against the chassis
alignment posts.
Flex Tab

Chassis
Alignment Posts
Figure 5-49 Align Option Board to Mounting Holes
4. Using a T6 TORX™ driver, tighten the three screws to 0.28 N-m (2.5 lbs-in) to secure the
option board to the chassis.
NOTE: Regulatory Requirements
All MOTOTRBO radios are designed and engineered to meet all regulatory requirements for the
country or region of sale. Any option board designed for the MOTOTRBO Option Board ADK must
not compromise the regulatory compliance of the MOTOTRBO radio.
The 3rd party developer is responsible for providing all information, upon request by a regulatory
authority, in regards to any materials or substances used in the manufacture of an option board as it
pertains to its end-of-life.
Please review the terms of the MOTOTRBO License Agreement for more information on the
Licensed Developer or Application Partner responsibilities for regulatory compliance.

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.6

5-35

Assemble Control Head to Radio Assembly
1. Verify that the flex cable is fully seated in the connector on the control head assembly.

!
Caution

Make sure the main cover is assembled onto the radio chassis before
assembling the control head onto the radio chassis.
During the control head disassembly, the control head PCB may snap out of
position. The control head PCB will need to be snapped back in place prior to
reassembly.

Radio Chassis
Control Head

Figure 5-50 Assemble Control Head to Chassis
2. Assemble flex cable to the flex connector in the radio assembly, making sure it is fully seated.
Control Head Connector

Option Board Connector
Figure 5-51 Flex Connection Connectors
3. Assemble the control head to the radio chassis by aligning one side of the control head
assembly tabs to one side of the radio chassis tabs and then rotate the control head
assembly until the other side engages.

5-36

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5.8

Exploded Mechanical Views and Parts Lists

5.8.1

Radio Assembly Exploded View and Parts List

9
10
11
5

12
13

4
3

Figure 5-52 Radio Assembly Exploded View

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5-37

Table 5-3 Radio Exploded View Parts List
Item No.

Description

Part Number

Chassis, Die Cast

0104056J09

Thermal Pad, Final Driver

75012058002

Thermal Pad, Regulator

75012018001

Thermal Pad, Audio PA

75012059001

PCB, Transceiver

See Section 1.5 to
1.8 to identify proper
board.

Main Shield, Die Cast

26012273001

Screw - M3x0.5x13mm

0310943J12

Main Cover and Gasket Assembly

15012229001

Screw - M2.5x0.45x12mm with Washer

03012037002

Thermal Pad, PA Output Match
VHF 25–45W, VHF 1–25W, UHF1 25–40W

75012018001

UHF1 1–25W

NOT PLACED

Lock Washer, RF Connector

04012004001

Nut, RF Connector

02012015001

Accessory Connector Cover

3202607Y01

Accessory Connector

28012058001

DC Cable Assembly

28012059001

5-38

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5.8.2

Alphanumeric Display Control Head Exploded View and Parts List
10
9

8
7
6

3
2
1

Figure 5-53 Alphanumeric Display Control Head Exploded View

Table 5-4 Alphanumeric Display Control Head (PMLN6441_) Exploded View Parts List
Item no

Description

Part No

Nameplate, XPR 2500

33012051010

Label, Accessory Indicator

54012312001

Housing Front Assembly, Alphanumeric Control
Head Plus

0104057J46

Nameplate, Motorola Logo

33012052001

Speaker

5015935H02

Keypad, Alphanumeric Control Head Plus

75012212001

Light Guide Holder

07012052001

2 Line Monochrome Display Module

72012024001

PCB Assembly

0104057J47*

Cable Flex, Control Head

30012065001

Speaker Tape

11012133001

*Note: The PCB Assembly is not available for servicing. Must order PMLN6441_ (Alphanumeric
Display Control Head Kit)

Disassembly/Reassembly Procedures: Torque Chart

5.9

5-39

Torque Chart
Table 5-5 lists the various nuts and screws by part number and description, followed by the torque
values in different units of measure. Torque all screws to the recommended value when assembling
the radio.
Table 5-5 Torque Specifications for Nuts and Screws
Part
Number

Description

Driver/Socket

Torque
N-m

lbs-in

kg-cm

02012015001

Nut, RF Connector

9/16” deep socket
driver

2.15

21.9

0310909E03

Screw, M2x0.4x6mm, Pan Head

T6 Torx™

0.28

2.5

2.9

03012037002

Screw, M2.5x0.45x12mm, Pan Head

T8 Torx™

0.45

4.6

0310943J12

Screw, M3x0.5x13mm, Pan Head

T10 Torx™

1.5

5-40

Disassembly/Reassembly Procedures: Torque Chart

Notes

Chapter 6 Basic Troubleshooting

6.1

Introduction
This chapter contains error codes and board replacement procedures. This section can help you
isolate a problem to the board level. If the radio does not pass all the performance checks in
Chapter 3 or exhibits an error code listed below, then the circuit board should be replaced. Please
send the radio to a Motorola Service Center listed in Appendix B.
NOTE: To access the various connector pins, use the housing eliminator/test fixture along with the
diagrams found in this section of the manual. (See Section, "Service Aids" on page 2-2, for
the appropriate Motorola service aids and tools part numbers.)

6.1.1

High Power RF Precaution

!
Caution

6.2

The radio might transmit while the technician believes the radio is in receive
mode under the following conditions: radio failure, digital affiliation, a
defective PTT button, or other unintentional activations.
To avoid possible equipment damage, when performing both transmit and
receive tests, a suitable attenuator rated at 100 W or more should always
be used with test equipment connected to the RF connector. The only
exception to this is when the equipment’s input power rating is higher than
the maximum output power of the radio.

Replacement Service Kit Procedures
Once a problem has been isolated to a specific board, install the appropriate service kit (see Model
Charts in section 1.5 on page 1-4 through section 1.8 on page 1-5), which is orderable from Motorola
Radio Products and Solutions Organization at 1-800-422-4210.
Refer to https://businessonline.motorolasolutions.com for further information.
If a board is replaced, it does not necessarily need to be retuned if it has been factory tuned. It
should however be checked for performance before being placed into service. Of particular concern
is the Bias DAC, which will need to be set for the appropriate final device bias current prior to keying
up the radio. If the bias is not properly set it may be possible to cause damage to the transmitter.

!
Caution

The Tuner Tool only allows the serial number of a blank board to be entered
once. Be very attentive during this procedure.

6-2

6.3

Basic Troubleshooting: Power-Up Error Codes

Power-Up Error Codes
When the radio is turned on (powered-up), the radio performs cursory tests to determine if its basic
electronics and software are in working order. Problems detected during these tests are presented
as error codes on the radio’s display. The presence of an error should prompt the user that a
problem exists and that a service technician should be contacted.
Self-test errors are classified as either fatal or non-fatal. Fatal errors inhibit user operation; non-fatal
errors do not. Use the following tables to aid in understanding particular power-up error code
displays.
Table 6-1 Power-Up Error Codes
Error Code

Description

Error Type

Corrective Action

ERROR 01/02

FLASH ROM Codeplug
Checksum

NON-FATAL

Reprogram the codeplug.

ERROR 01/22

Tuning Codeplug
Checksum

NON-FATAL

Reprogram the tuning partition.

FAIL 01/82

FLASH ROM Codeplug
Checksum

FATAL

Reprogram the codeplug.

FAIL 01/90

General Hardware Error

FATAL

Turn the radio off, then on. If
problem persists, send radio to
the nearest Motorola Solutions
Depot.

FAIL 01/92

Security Partition
Checksum

FATAL

Reprogram the security partition.

FAIL 01/93

FlashPORT AUTHENT
CODE Failure

FATAL

Contact the depot.

FAIL 01/A2

Tuning Codeplug
Checksum

FATAL

Reprogram the tuning partition.

FAIL 02/90

RF Hardware Error

FATAL

Send radio to the nearest
Motorola Solutions Depot.

Chapter 7 Accessories

7.1

Introduction
Motorola provides the following approved accessories to improve the productivity of your digital
mobile two-way radio.
For a list of Motorola-approved antennas, and other accessories, visit the following web site:
http://www.motorolasolutions.com

7.1.1

Antennas
Part No.

Description

HAD4006_

VHF, 136–144 MHz, 1/4 Wave Roof Mount, Mini-U

HAD4007_

VHF, 144–150.8 MHz, 1/4 Wave Roof Mount, Mini-U

HAD4008_

VHF, 150.8–162 MHz, 1/4 Wave Roof Mount, Mini-U

HAD4009_

VHF, 162–174 MHz, 1/4 Wave Roof Mount, Mini-U

HAD4022_

VHF, 132–174 MHz, 3.0 dB Gain, Through-hole Mount, Mini-U

HAE4002_

UHF, 403–430 MHz, 1/4 Wave Roof Mount, Mini-U

HAE4003_

UHF, 450–470 MHz, 1/4 Wave Roof Mount, Mini-U

HAE4010_

UHF, 406–420 MHz, 3.5 dB Gain Roof Mount, Mini-U

HAE4011_

UHF, 450–470 MHz, 3.5 dB Gain Roof Mount, Mini-U

HAE6022_

UHF, 403–527 MHz, 2.0 dB Gain, Through-hole Mount, Mini-U

RAE4004_RB

UHF, 445–470 MHz, 5.0 dB Gain Roof Mount, Mini-U

7-2

7.1.2

7.1.3

7.1.4

Accessories: Introduction

Audio
Part No.

Description

GMMN4065_

Visor Microphone (Omni-Direction)

HLN9073_

Microphone Hang-up Clip (requires install)

HLN9414_

Microphone Hang-up Clip (Universal – no install required)

HSN8145_

External Speaker 7.5 W

PMLN6481_

Telephone Style Handset Kit (Includes Hang Up Cup)

PMMN4089_

Enhanced Keypad Microphone

PMMN4090_

Compact Microphone with Clip

PMMN4091_

Heavy Duty Microphone

RSN4001_

External Speaker 13 W

PMLN6520_

Telephone Style Handset

Cables
Part No.

Description

HKN4137_

Mobile Power Cable 10 FT., 14 AWG, 15 A

HKN4191_

Mobile Power Cable 10 FT., 12 AWG, 20 A

HKN4192_

Mobile Power Cable 20 FT., 10 AWG, 20 A

PMKN4147_

Front Telco MMP USB Programming Cable

PMKN4148_

Back 20 Pin MAP USB Programming Cable

HKN9327_R

Ignition Switch Cable

PMKN4151_

Back 16 Pin MAP Universal Cable

GMKN4084_

Speaker Extension Cable

Mounting Kits
Part No.

Description

FTN6083_

DIN Mount

RLN6466_

Low Profile Trunnion Kit

RLN6467_

High Profile Trunnion KIt

RLN6468_

Key Lock Trunnion Kit

03012045001

Trunnion Wing Screw M5x0.8x9.9 mm

Accessories: Introduction

7.1.5

7.1.6

7-3

Miscellaneous Accessories
Part No.

Description

RLN4836_R

External PTT with Emergency Footswitch

RLN4856_

Footswitch with Remote PTT

RLN4857_

Pushbutton with Remote PTT

HLN9457_

16 Pin MAP Connector Kit

GMBN1021_

Rear Accessory Connector Seal with Connector and Pins

PMLN6544_

Generic Option Board

PMLN5620_

Connector Extender (20 pcs)

Service Tools
Part No.

Description

GPN6145_

Mobile Radio Power Supply Unit

HPN4007_

Desktop Power Supply 1–60W

6686119B01

Control Head Removal Tool

66012020001

RFIC Repair Kit

PMEN4041_

Chassis Eliminator Kit

PMKN4149_

Back 20 Pin MAP Test and USB Programming Cable

PMKN4150_

Back 20 Pin MAP Test Cable

RLN4460_

Radio Test Box

6680388A26

Mobile Crimping Tool

GKN6266_

Power Supply Cable (for GPN6145)(PWR CBL DC BASE RENA)

3060665A04

Power Cable (US Plug) (110V CHGR LINE CORD)

RSX4043_

Torque Driver

6680387A74

TORX™ T10 Driver Bit

6680387A72

TORX™ T8 Driver Bit

6680387A70

TORX™ T6 Driver Bit

7-4

Accessories: Introduction

Notes

Appendix A

A.1

Replacement Parts Ordering

Basic Ordering Information
Some replacement parts, spare parts, and/or product information can be ordered directly. While
parts may be assigned with a Motorola part number, this does not guarantee that they are available
from Motorola Radio Products and Solutions Organization (RPSO). Some parts may have become
obsolete and no longer available in the market due to cancelations by the supplier. If no Motorola
part number is assigned, the part is normally not available from Motorola, or is not a user-serviceable
part. Part numbers appended with an asterisk are serviceable by Motorola Depot only.

A.2

Motorola Online
Motorola Online users can access our online catalog at
https://businessonline.motorolasolutions.com
To register for online access, please call 1-800-422-4210 (for U.S. and Canada Service Centers
only). International customers can obtain assistance at https://businessonline.motorolasolutions.com

A.3

Mail Orders
Mail orders are only accepted by the US Federal Government Markets Division (USFGMD).
Motorola
7031 Columbia Gateway Drive
3rd Floor - Order Processing
Columbia, MD 21046
U.S.A.

A.4

Telephone Orders
Radio Products and Solutions Organization*
(United States and Canada)
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
1-847-538-8023 (United States and Canada)
U.S. Federal Government Markets Division (USFGMD)
1-877-873-4668
8:30 AM to 5:00 PM (Eastern Standard Time)

A.5

Fax Orders
Radio Products and Solutions Organization*
(United States and Canada)
1-800-622-6210
1-847-576-3023 (United States and Canada)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchase Orders)

A-2

A.6

Replacement Parts Ordering: Parts Identification

Parts Identification
Radio Products and Solutions Organization*
(United States and Canada)
1-800-422-4210

A.7

Product Customer Service
Radio Products and Solutions Organization (United States and Canada)
1-800-927-2744
* The Radio Products and Solutions Organization (RPSO) was formerly known as the Radio
Products Services Division (RPSD) and/or the Accessories and Aftermarket Division (AAD).

Appendix B

B.1

Motorola Service Centers

Servicing Information
If a unit requires further complete testing, knowledge and/or details of component level
troubleshooting or service than is customarily performed at the basic level, please send the radio to
a Motorola Service Center as listed below or your nearest Authorized Service Center.

B.2

Motorola Service Center
1220 Don Haskins Drive
Suite A
El Paso, TX 79936
Tel: 915-872-8200

B.3

Motorola Federal Technical Center
10105 Senate Drive
Lanham, MD 20706
Tel: 1-800-969-6680
Fax: 1-800-784-4133

B.4

Canadian Technical Logistics Center
181 Whitehall Drive
Markham, Ontario
L3R 9T1
Toll Free: 800-543-3222

B-2

Motorola Service Centers Canadian Technical Logistics Center

Notes

Appendix C

C.1

Limited Level 3 Servicing

Maintenance
For details on the following, please refer to Chapter 5 Disassembly/Reassembly Procedures –
Section 5.2 on page 5-1 to Section 5.4 on page 5-4.
• Preventive maintenance (inspection and cleaning).
• Safe handling of CMOS and LDMOS devices.
• Repair procedures and techniques.

C.2

Component Location and Parts List

3
2

TP4103

17
R3175

C3112

VR4110

TP4102

J4100

E4100

E4101
19

R3107
C3129

U3204

C3222

C3171

E3111

C3124
8
5

R3108
C3150
C3173

E3113 R3146
C3144
C3118

E3104
C3154

U1004
9 6
4

R3141

D3104

C3119

U3102
6
5

R3111

U1010

C3116
C3175

R3116

3120

R1001

R1042

R1045

C1021

5 4
3

C1010
C1009

C1005
C1008

C1035 C1002

C3123
R1023

C3122 R3147

C3151 C3153
5
U3108
6 10

C3223

R3254

C3224

C3219

E1004

R3119

E1002

R3200

C3228

R3203

C3257

C3226

6
34
C1060
C1047

C1032 C1029

E1001
E1003

R3173

C1020

R3280

U3103

038

C1003

C3221

U3100

20
C2015

Q3209
2
3

R3204

C2010

C2014

C2013

C1045
C2006
C1023
C1044
C2007
C1022
C1018
C1025
R1019
R1026
C1006
C1007

C1041

C3204
R1051 C3248

C1013

C1026
R1012
C1042
C1019
C1001

C3140

C1028

R3181
C3180
R3180

0934

R1077

4 3
6
U3106

Q1002
2
3

2
3

C3139
0921

U0903

C1017

R1049

R3287 R3290

U3202 C3231
R3285 C3227 C3218
E3202

R1046

Q3205

R1050
C1014

C1036

Q3001

C0732
3

C0775

E3109
R0935

SH0700

R1060
C3229

C2020

R1011
R1064
R1062
R1024
R1030
R1027
R1021

R1014

R0712

R1036
R1035

C1015

2
C0701
R0700
R0718

M0700

R0723

R0711

C0754
C0753

R0739

Q0701

TP0708

R0741

C0731

C0812

R0725

R0740

R0727

R0735

R0738

R0743

C0727

TP3109

C3152
R3101

5
U3109
6 10

C2012

C2016

C0706

R3110

5
3
4
C3102

C3225
R3208 C3209

C2009

C0710
R0704

R3176

C2005

037

C3046

C3021

C3020

6
34
R3230
G1

C3214
C2004

C2011

R3002

R3003
3

C3014
Q3000

C3013

R3015

R3142
R3138

R3262
C3230 R3265

C2008

R0883

R0922

C0901

R3132
R3263

R3231

R1052
R1044
R1033
R1040
R1069
R1010
R1025
R1031
R1028
R1022
R1018
R1016

C3111
R3106

R3102

R3264

R3256

TP0710

R0720

R0737

L0854

R0732

R0734

C0764
C0761

R0746

C0854

R0709

R0710

C0789

C3106

R3261

C3012

2
6

7
8
C0814

C0750
C0823

R0742

L0852

C0929

C0825

R3004

R3001
R0736

C0745
C0828

Q3201

E4102

TP4101

C0716

C0712

C0707

C3003

C3002

E0703
C0818

R3005
R3006

C0752

C0867

C0932

C0847

C0934

C0933

C0848

C0928

C0855

R3150

R0774

R0786
R0785

R0783

R0775
R0784

R0779

R0782

R0777

R0776

R0781

R0758

R0778

C0938
R0766
R0769

C0858
C0857

E3100

E0701

C0718

L0727
8

C0733

3
C0853

C0916

U0902

R0928

R0965

R0921
SH0900

C0742

Q0702

R0952

R0951
L0951

R0913

2 C0911

TP0900

RT0900

C0721
C0740

L0711

L0950

R0955
3
R0932 4 5
U0904

C0772

C0714

C0746

C0808

C0840
C0841

C0842

C0868

R0792 C0869 C0805
R0793
R0799 C0862 C0771

08
05 R0 12
80
9
08

C0845

C0803
C0821
C0790

C0844
R0767

C
0
C 79
08 2
07 04
74
01
08
C

C0870 C0865
C0874 C0863

R
06

R0803 R0811
R
0
R0804 R0810 8

L0885
3
2
4
L0876

D0876

L0875
C0815

C0819

C0851

C0807

C0820

C0852

C0770
C0810
C0759

L0877

D0700

C0951
3
2
R0950

C0950

D0875

G1
R0957

R0958

C0953

R0953
D0951
2
3
C0954

R0954

R0960
C0902
R0961
C0957
R0962
R0919
TP0904

R0749

C0776

C0737

L0710

C0822

R0904
R0931
R0940
C0918
R0914
TP0903
TP0902
R0939
R0744 R0915
C0919
R0933
R0929
R0920
R0923
R0917
C0926
R0916
R0924
R0745
R0959
C0900
C0917
C0925

C0843 R0771 C0860
C0861
C0782

C0788

C0956

R0800
R0790
R0797
R0796
R0794
R0789
R0770
R0795
R0772 R0788
R0787
R0773

C0769

C3042

C0723

C0780
C0781

C0955

R0930

C0756
C0757

C3047

C0800
C0755
C0751 C0730
C0748

C0779
C0768

C0876

C0795

R0807R0798 R0760
R0791 R0763
R0808

73
07 02
08
C

L0712

C0875

L0857

C0880

C0787
C0785
C0786
C0850
C0816

D0950

C0952

C0864

R0956
L0952

C3044

C0940
C0726

E4103

C3050
M3000

C0942

C0872

C0859
C0791 C0873

D0877

C0941

R0768

L0706

L0708

C0767

C0722

R0780

C0736
C0758
C0811

C0824
C0809
C0846

C3051

C0766

U3112

J0700

Figure C-1 PCB Top Side View

Table C-1. Component Parts List
No.

Circuit Ref.

Motorola Part Number

Description

J0700

09009348001

Mini-UHF Female RF Connector

U3204

51012450001

IC Audio Amplifier 1 Per Package

Q0702

48012067002 (UHF1 1–25W/VHF 1–25W)
48012022001 (UHF1 25–40W/VHF 25–45W)

RF MOSFET Power Transistor

C-2

Limited Level 3 Servicing: Component Location and Parts List

Notes

Glossary

This glossary contains an alphabetical listing of terms and their definitions that are applicable to
portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and
some terms are merely generic in nature.

Term

Definition

Analog

Refers to a continuously variable signal or a circuit or device designed to
handle such signals.

Band

Frequencies allowed for a specific purpose.

CMOS

Complementary Metal Oxide Semiconductor.

CPS

Customer Programming Software: Software with a graphical user interface
containing the feature set of a radio.

Default

A pre-defined set of parameters.

Digital

Refers to data that is stored or transmitted as a sequence of discrete symbols
from a finite set; most commonly this means binary data represented using
electronic or electromagnetic signals.

DPL

Digital Private-Line: A type of digital communications that utilizes privacy call,
as well as memory channel and busy channel lock out to enhance
communication efficiency.

FCC

Federal Communications Commission.

Frequency

Number of times a complete electromagnetic-wave cycle occurs in a fixed unit
of time (usually one second).

GPIO

General-Purpose Input/Output.

GPS

Global Positioning System.

Integrated Circuit: An assembly of interconnected components on a small
semiconductor chip, usually made of silicon. One chip can contain millions of
microscopic components and perform many functions.

Intermediate Frequency.

kHz

kilohertz: One thousand cycles per second. Used especially as a radio
frequency unit.

LCD

Liquid-Crystal Display: An LCD uses two sheets of polarizing material with a
liquid-crystal solution between them. An electric current passed through the
liquid causes the crystals to align so that light cannot pass through them.

LDMOS

Laterally Diffused Metal Oxide Semiconductor.

LED

Light Emitting Diode: An electronic device that lights up when electricity is
passed through it.

MDC

Motorola Digital Communications.

Glossary-2

Term

Definition

MHz

Megahertz: One million cycles per second. Used especially as a radio
frequency unit.

Paging

One-way communication that alerts the receiver to retrieve a message.

PC Board

Printed Circuit Board. Also referred to as a PCB.

Private-Line Tone Squelch: A continuous sub-audible tone that is transmitted
along with the carrier.

Programming Cable

A cable that allows the CPS to communicate directly with the radio using USB.

Receiver

Electronic device that amplifies RF signals. A receiver separates the audio
signal from the RF carrier, amplifies it, and converts it back to the original
sound waves.

Repeater

Remote transmit/receive facility that re-transmits received signals in order to
improve communications range and coverage (conventional operation).

Radio Frequency: The portion of the electromagnetic spectrum between audio
sound and infrared light (approximately 10 kHz to 10 GHz).

Receive.

Signal

An electrically transmitted electromagnetic wave.

Spectrum

Frequency range within which radiation has specific characteristics.

Squelch

Muting of audio circuits when received signal levels fall below a pre-determined
value. With carrier squelch, all channel activity that exceeds the radio’s preset
squelch level can be heard.

TOT

Time-out Timer: A timer that limits the length of a transmission.

TPL

Tone Private Line.

Transceiver

Transmitter-receiver. A device that both transmits and receives analog or digital
signals. Also abbreviated as XCVR.

Transmitter

Electronic equipment that generates and amplifies an RF carrier signal,
modulates the signal, and then radiates it into space.

Transmit.

UHF

Ultra-High Frequency.

USB

Universal Serial Bus: An external bus standard that supports data transfer rates
of 12 Mbps.

VHF

Very High Frequency.

VIP

Vehicle Interface Port.

XPR

Refers to Digital Professional Radio model names in the MOTOTRBO
Professional Digital Two-Way Radio System.

Motorola Solutions, Inc.
1303 East Algonquin Road
Schaumburg, Illinois 60196 U.S.A.
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and
the Stylized M logo are trademarks or registered trademarks
of Motorola Trademark Holdings, LLC and are used under license.
All other trademarks are the property of their respective owners.
© 2013 Motorola Solutions, Inc. All rights reserved.
June 2013.
www.motorolasolutions.com/mototrbo

*68009620001*
68009620001-A

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