MOTOTRBO XPR 3000e Basic Service Manual Series/XPR3300e XPR3500e MN002209A01 AA V1 XPR3300e

User Manual: -XPR Series/XPR3300e XPR3500e Basic Service Manual MN002209A01-AA V1

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iii

Foreword
This manual covers all models of the XPR™ series Portable Radios, 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, self-maintained customers, and distributors.

Product Safety and RF Exposure Compliance

!
Caution

Before using this product, read the operating instructions
for safe usage contained in the Product Safety and RF
Exposure booklet enclosed with your radio.
ATTENTION!

This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
Before using this product, read the RF energy awareness information and operating instructions in the
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number
6881095C98) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site:
http://www.motorolasolutions.com/

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.
© 2016 Motorola Solutions, Inc.
All rights reserved.

Notes

Document History
The following major changes have been implemented in this manual since the previous edition:
Edition

MN002209A01-AA

Description
Initial Release

Date
Jan. 2016

Notes

Table of Contents

vii

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

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

Battery and Charger Warranty .................................................................xviii
Workmanship Warranty .......................................................................................................................... xviii
Capacity Warranty .................................................................................................................................. xviii

Chapter 1
1.1
1.2
1.3
1.4
1.5

Notations Used in This Manual .................................................................................................... 1-1
Radio Description ........................................................................................................................ 1-1
1.2.1 Limited Keypad Model ..................................................................................................... 1-2
1.2.2 Non Display Model .......................................................................................................... 1-3
Portable Radio Model Numbering Scheme ................................................................................. 1-4
Model Charts ............................................................................................................................... 1-5
1.4.1 VHF Model Chart............................................................................................................. 1-5
1.4.2 UHF Model Chart............................................................................................................. 1-6
Specifications............................................................................................................................... 1-7

Chapter 2
2.1
2.2
2.3

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

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

Recommended Test Equipment .................................................................................................. 2-1
Service Aids ................................................................................................................................. 2-2
Programming, Testing and Alignment Cable ............................................................................... 2-3

viii

Table of Contents

Chapter 3
3.1
3.2
3.3

3.4

General ........................................................................................................................................ 3-1
Setup............................................................................................................................................ 3-1
Display Model Test Mode ............................................................................................................ 3-3
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-3
3.3.2 RF Test Mode .................................................................................................................. 3-3
3.3.3 Display Test Mode ........................................................................................................... 3-7
3.3.4 LED Test Mode................................................................................................................ 3-7
3.3.5 Backlight Test Mode ........................................................................................................ 3-7
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-7
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-7
3.3.8 Audio Loopback Earpiece Test Mode.............................................................................. 3-7
3.3.9 Battery Check Test Mode ................................................................................................ 3-8
3.3.10 Button/Knob/PTT Test Mode ........................................................................................... 3-8
Non-Display Model Test Mode..................................................................................................... 3-9
3.4.1 Entering Non-Display Radio Test Mode .......................................................................... 3-9
3.4.2 RF Test Mode .................................................................................................................. 3-9
3.4.3 LED Test Mode................................................................................................................ 3-9
3.4.4 Speaker Tone Test Mode ................................................................................................ 3-9
3.4.5 Earpiece Tone Test Mode ............................................................................................. 3-10
3.4.6 Audio Loopback Earpiece Test Mode............................................................................ 3-10
3.4.7 Battery Check Test Mode .............................................................................................. 3-10
3.4.8 Button/Knob/PTT Test Mode ......................................................................................... 3-10

Chapter 4
4.1
4.2
4.3
4.4

5.3
5.4
5.5
5.6

5.7

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

Introduction .................................................................................................................................. 4-1
Customer Programming Software Setup ..................................................................................... 4-1
AirTracer Application Tool............................................................................................................ 4-2
Radio Tuning Setup ..................................................................................................................... 4-2
4.4.1 RF Plug Dissassembly..................................................................................................... 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 ..................................................................................................... 5-6
5.6.1 Front Kit from Chassis Disassembly................................................................................ 5-6
5.6.2 Back Kit Disassembly .................................................................................................... 5-12
5.6.3 Keypad, Display, and Keypad Board Disassembly........................................................ 5-14
5.6.4 Side Buttton, Speaker, Microphone, and UC-Audio Flex Disassembly ......................... 5-16
Radio Reassembly - Detailed .................................................................................................... 5-20
5.7.1 Speaker Reassembly..................................................................................................... 5-20
5.7.2 Side Button, Keypad, Display and Keypad Board Reassembly..................................... 5-22
5.7.3 Back Kit Reassembly..................................................................................................... 5-26
5.7.4 Back Kit and Front Kit Reassembly ............................................................................... 5-29

Table of Contents

5.8

5.9

5.7.5 RF Plug Reassembly..................................................................................................... 5-32
Ensuring Radio Immersibility ..................................................................................................... 5-34
5.8.1 Servicing........................................................................................................................ 5-34
5.8.2 Accidental Immersion .................................................................................................... 5-34
5.8.3 Specialized Test Equipment .......................................................................................... 5-34
5.8.4 Vacuum Pump Kit NLN9839.......................................................................................... 5-34
5.8.5 Pressure Pump Kit NTN4265 ........................................................................................ 5-35
5.8.6 Miscellaneous Hardware ............................................................................................... 5-35
5.8.7 Vacuum Test ................................................................................................................. 5-35
5.8.8 Pressure Test ................................................................................................................ 5-36
5.8.9 Troubleshooting Leak Areas.......................................................................................... 5-37
5.8.9.1 Front Housing ................................................................................................. 5-37
5.8.9.2 Chassis ........................................................................................................... 5-37
5.8.9.3 Battery Contact Seal....................................................................................... 5-38
5.8.9.4 Ventilation Seal and Ventilation Label ............................................................ 5-38
5.8.9.5 Battery Maintenance....................................................................................... 5-38
5.8.10 Troubleshooting Charts ................................................................................................. 5-40
Radio Exploded Mechanical Views and Parts Lists ................................................................... 5-43
5.9.1 Limited Keypad Model Exploded View and Parts List ................................................... 5-43
5.9.2 Non Keypad Model Exploded View and Parts List ........................................................ 5-46
5.9.3 Torque Chart ................................................................................................................. 5-50

Chapter 6
6.1
6.2
6.3
6.4

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

Introduction .................................................................................................................................. 6-1
Replacement Back Cover Kit Procedures ................................................................................... 6-1
Power-Up Error Codes (Display Model only) ............................................................................... 6-2
Operational Error Codes .............................................................................................................. 6-4

Chapter 7
7.1

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

Introduction .................................................................................................................................. 7-1
7.1.1 Batteries .......................................................................................................................... 7-1
7.1.2 Carry Devices .................................................................................................................. 7-1
7.1.3 Antennas ......................................................................................................................... 7-2
7.1.4 Service/Replacement Parts ............................................................................................. 7-2
7.1.5 CPS ................................................................................................................................. 7-2

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

Table of Contents

B.1
B.2
B.3
B.4

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

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

List of Figures

List of Figures
Figure 1-1.
Figure 1-2.
Figure 1-3.
Figure 2-1.
Figure 2-2.
Figure 3-1.
Figure 3-2.
Figure 4-1.
Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure 4-5.
Figure 4-6.
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.

Limited Keypad Model.......................................................................................................... 1-2
Non Display Model ............................................................................................................... 1-3
Portable Radio Model Numbering Scheme.......................................................................... 1-4
Programming, Testing and Alignment Cable........................................................................ 2-3
Pin Layout of Side Connector .............................................................................................. 2-4
DMR Radio Transmitter and Receiver Testing Setup .......................................................... 3-2
Battery Check Test Mode Display ........................................................................................ 3-8
CPS Programming Setup..................................................................................................... 4-1
Radio Tuning Equipment Setup ........................................................................................... 4-2
RF Plug disassembly ........................................................................................................... 4-3
RF Adaptor insertion ............................................................................................................ 4-3
RF Adaptor screw ................................................................................................................ 4-4
RF Connector....................................................................................................................... 4-4
Battery removal .................................................................................................................... 5-6
Battery removal .................................................................................................................... 5-6
Antenna removal .................................................................................................................. 5-7
Volume and Channel Knob removal. ................................................................................... 5-8
Front Kit-Back Kit Screw removal ........................................................................................ 5-8
Back Kit disassembly ........................................................................................................... 5-9
Back Kit removal ................................................................................................................ 5-10
Disconnecting the interface UC-audio flex and keypad-display flex (Limited Keypad Model) 511
Disconnecting the UC-audio flex (Non Keypad Model)...................................................... 5-11
Top control seal removal .................................................................................................... 5-12
Back Kit disassembly ......................................................................................................... 5-12
Battery contact seal removal.............................................................................................. 5-13
UC-audio flex removal........................................................................................................ 5-14
K18 screw removal ............................................................................................................ 5-14
Display flex removal ........................................................................................................... 5-15
Keypad removal ................................................................................................................. 5-15
PTT retainer removal ......................................................................................................... 5-16
Side button removal ........................................................................................................... 5-16
UC escutcheon removal..................................................................................................... 5-17
UC-audio flex removal........................................................................................................ 5-18
Speaker retainer screw removal......................................................................................... 5-18
Speaker retainer removal ................................................................................................... 5-19
Speaker assembly.............................................................................................................. 5-20
UC-audio flex ..................................................................................................................... 5-20
UC escutcheon .................................................................................................................. 5-21
Speaker retainer reassembly ............................................................................................. 5-21
Side button reassembly ..................................................................................................... 5-22
PTT retainer reassembly.................................................................................................... 5-22
Display module reassembly ............................................................................................... 5-23
Keypad reassembly............................................................................................................ 5-23
Keypad board reassembly ................................................................................................. 5-24
Display flex reassembly ..................................................................................................... 5-24
Speaker retainer reassembly ............................................................................................. 5-25
UC-Audio Flex Pad Reassembly........................................................................................ 5-25
Thermal pad ....................................................................................................................... 5-26
Battery contact seal reassembly ........................................................................................ 5-27

xii

List of Figures

Figure 5-37.
Figure 5-38.
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.

Mainboard reassembly ....................................................................................................... 5-27
Top control seal reassembly............................................................................................... 5-28
Interface flexes reassembly (Limited Keypad Model)......................................................... 5-29
Interface flexes reassembly (Non Keypad Model).............................................................. 5-29
Front kit reassembly ........................................................................................................... 5-30
Knob reassembly ............................................................................................................... 5-30
Attaching the antenna ........................................................................................................ 5-31
RF Plug reassembly ........................................................................................................... 5-32
Nameplate replacement ..................................................................................................... 5-32
Product Nameplate Reassembly........................................................................................ 5-33
Connector Fitting - Fitting Seal Pump Connector............................................................... 5-34
Limited Keypad Model Exploded View ............................................................................... 5-43
Non-Keypad Model Exploded View.................................................................................... 5-46

List of Tables

xiii

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

Radio Frequency Ranges and Power Levels....................................................................... 1-1
Recommended Test Equipment ........................................................................................... 2-1
Service Aids ......................................................................................................................... 2-2
Pin Configuration of Side Connector.................................................................................... 2-4
Initial Equipment Control Settings ........................................................................................ 3-1
Front Panel Access Test Mode Displays.............................................................................. 3-3
Test Environments................................................................................................................ 3-4
Test Frequencies.................................................................................................................. 3-4
Transmitter Performance Checks ........................................................................................ 3-5
Receiver Performance Checks ............................................................................................ 3-6
Software Installation Kits Radio Tuning Setup ..................................................................... 4-1
Lead Free Solder Wire Part Number List ............................................................................. 5-4
Lead Free Solder Paste Part Number List ........................................................................... 5-4
Limited Keypad Model Exploded View Parts List ............................................................... 5-44
Non Keypad Model Exploded View Parts List .................................................................... 5-47
Additional Parts List ........................................................................................................... 5-48
Torque Specifications for Screws ....................................................................................... 5-50
Power-Up Error Codes......................................................................................................... 6-2
Operational Error Codes ...................................................................................................... 6-4

xiv

Related Publications

Related Publications
IMPRES Adaptive Single-Unit Charger User Manual ..................................................................6816787H01
IMPRES Adaptive Multi-Unit Charger User Manual.....................................................................6816789H01
IMPRES Adaptive Multi-Unit Charger Service Manual ................................................................ 6871357L01
Remote Speaker Microphone User Manual ................................................................................. 6871003L01
IMPRES Remote Speaker Microphone User Manual .................................................................. 6871004L01
Product Safety and RF Exposure ............................................................................................... 6881095C98
*MOTOTRBO™ Portable User Guide CD ....................................................................................HKLN4282_

Commercial Warranty

Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS
I. What This Warranty Covers And For How Long
MOTOROLA 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 Series Digital Portable Radios

Two (2) Years

Product Accessories (Excluding Batteries and Chargers)

One (1) Year

The portables additionally ship with a standard 1-year Repair Service Advantage (RSA) (for U.S.
customers) or 1-year Extended Warranty (for Canada customers). However, at the time of order, you
may choose to omit these warranties. For more RSA or Extended Warranty information, please refer
to the portable price pages or Motorola Online (https://businessonline.motorola.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.

xvi

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 1-800-927-2744 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. Rechargeable batteries if:
- any of the seals on the battery enclosure of cells are broken or show evidence of tampering.
- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.
H. Freight costs to the repair depot.

Commercial Warranty

xvii

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.

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

K. Normal and customary wear and tear.

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.

xviii

Battery and Charger Warranty

Workmanship Warranty
The workmanship warranty guarantees against defects in workmanship under normal use and
service.

All MOTOTRBO Batteries

Two (2) Years

IMPRES Chargers (Single-Unit and Multi-Unit, Non-Display)

Two (2) Years

IMPRES Chargers (Multi-Unit with Display)

One (1) Year

Capacity Warranty
The capacity warranty guarantees 80% of the rated capacity for the warranty duration.

Nickel Metal-Hydride (NiMH) or Lithium-Ion (Li-lon) Batteries

12 Months

IMPRES Batteries, When Used Exclusively with IMPRES
Chargers

18 Months

Introduction: Notations Used in This Manual

1-1

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

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

WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or injury.

1.2

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

Bandwidth

Power Level

VHF

136–174 MHz

1 Watt or 5 Watt

UHF

403–512 MHz

1 Watt or 4 Watt

These digital 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

1.2.1

Introduction: Radio Description

Limited Keypad Model

Antenna

Channel Selector Knob
On/Off Volume Control Knob
LED Indicator

Universal Connector

PTT Button
Microphone

Speaker

Side Button 1
Side Button 2

Display
OK Button

Limited Keypad

Figure 1-1. Limited Keypad Model
• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counterclockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATOR – Red, green and amber light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display) – 65 x132 full dot matrix grayscale display provides visual
information about many radio features..
• MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface.
• FRONT BUTTONS and SIDE BUTTONS – These four buttons are field programmable using
the CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• UNIVERSAL CONNECTOR – Interface point for all accessories to be used with the radio. It has
eight points to which specific accessories will connect and be activated.
• SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like
keypad tones and voice audio).

Introduction: Radio Description

1.2.2

1-3

Non Display Model

Antenna
Channel Selector Knob
On/Off Volume Control Knob
LED Indicator

PTT Button

Universal Connector

Microphone

Speaker

Side Button 1
Side Button 2

Figure 1-2. Non Display Model
• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counterclockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATOR – Red, green and orange light-emitting diodes indicate operating status.
• SIDE BUTTONS – These 2 buttons are field programmable using the CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• UNIVERSAL CONNECTOR – Interface point for all accessories to be used with the radio. It has
eight points to which specific accessories will connect to and be activated.
• SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like
keypad tones and voice audio).

1-4

1.3

Introduction: Portable Radio Model Numbering Scheme

Portable Radio Model Numbering Scheme
Model No.Example :
Position

12
Unique Variation
N: Standard Package

AZ: Asia
LA: Latin America
AA: North America
MD: Europe

Version Letter
H: Portable
XPR 3000 Model Series: 02

Band
J: 136-174 MHz
R: 403-527 MHz

Power Level
C: 1.0,2.0,2.5 or 3.5 Watt
D: 4.0-5.0 Watt

Physical Packages
C: Plain Model
H: Monochrome Display LKP
T: No Display - Limited Tier

Feature Level
1: Standard w/ FM
2. Non-FM
3. CSA IE CEx ATEX
4. CQST

Primary System Type
A: Conventional
B: Trunking
C: Analog Only

Primary Operation
U: WiFi Only
W: Basic (No WiFi, Bluetooth, GOB)

Channel Information
8: Variable/Programmable Channel Spacing
w/ unique # of channels
9: Variable/Programmable Channel Spacing

Figure 1-3. Portable Radio Model Numbering Scheme

Introduction: Model Charts

1.4

Model Charts

1.4.1

VHF Model Chart

1-5

XPR 3000e Series, VHF, 136–174 MHz
Model
AAH02JDH9VA1AN
AAH02JDC9VA1AN

Item
X

PMLD4735_
X PMLD4736_

PMLN7294_
X PMLN7272_

Description
XPR 3500e, 136–174 MHz, 5W, CFS WiFi, MOTOTRBO
Limited Keypad Portable
XPR 3300e, 136–174 MHz, 5W, CFS WiFi, MOTOTRBO
Non Keypad Portable

Description
Back Cover Kit, CFS WiFi, MOTOTRBO Limited Keypad
Portable
Back Cover Kit, CFS WiFi, MOTOTRBO Non Keypad
Portable
Front Cover Kit Limited Keypad
Front Cover Kit Non Keypad

X X PMAD4117_

VHF Helical Antenna (136–155 MHz)

X X PMAD4116_

VHF HelicalAntenna (144–165 MHz)

X X PMAD4118_

VHF Helical Antenna (152–174 MHz)

X X PMAD4119_

VHF Stubby Antenna (136–148 MHz)

X X PMAD4120_

VHF Stubby Antenna (146–160 MHz)

X X PMAD4121_

VHF Stubby Antenna (160–174 MHz)

1-6

1.4.2

Introduction: Model Charts

UHF Model Chart

XPR 3000e Series, UHF, 403–512 MHz
Model
AAH02RDH9VA1AN
AAH02RDC9VA1AN

Item
X

PMLE5107_
X PMLE5073_

PMLN7294_
X PMLN7272_

Description
XPR 3500e, 403-512 MHz, 4W, CFS WiFi, MOTOTRBO
Limited Keypad Portable
XPR 3300e, 403-512 MHz, 4W, CFS WiFi, MOTOTRBO
Non Keypad Portable

Description
Back Cover Kit, CFS WiFi, MOTOTRBO Limited Keypad
Portable
Back Cover Kit, CFS WiFi, MOTOTRBO Non Keypad
Portable
Front Cover Kit Limited Keypad
Front Cover Kit Non Keypad

X X PMAE4069_

UHF Stubby Antenna 403–450 MHz

X X PMAE4070_

UHF Stubby Antenna 440–490 MHz

X X PMAE4071_

UHF Stubby Antenna 470–527 MHz

X X PMAE4068_

UHF Whip Antenna 403–527 MHz

X X PMAE4079_

Slim UHF Whip Antena 403–527 MHz

Introduction: Specifications

1.5

1-7

Specifications
General
Channel Capacity

Limited Keypad
XPR 3500

Non Keypad
XPR 3300

128

Frequency
Dimensions (HxWxT) w/
NiMH battery
Weight
(with Core Slim LiIon
battery)
(with IMPRES LiIon
battery)
(with LiIon IP57 battery)

VHF: 136 – 174 MHz
UHF: 403 – 512 MHz
122.0 x 56.0 x 39.4 mm

122.0 x 56.0 x 39.4 mm

281g

264g

281g

264g

299g

282g

Power Supply

7.5V nominal

FCC Description

UHF : AZ489FT7068
VHF : AZ489FT7069

IC Description

UHF : 109U-89FT7068
VHF : 109U-89FT7069

Average battery life at 5/5/90 duty cycle with battery saver enabled in carrier squelch
and transmitter in high power.
Core NiMH IP56 Battery
(1400mAh)

Analog: 9.5 hrs
Digital: 12.0 hrs

Core Li-Mn Low Temp
Submersible Battery
(1400maH)

Analog: 9.5 hrs
Digital: 12.0 hrs

IMPRES IP56 LiIon
Battery (1600mAh)

Analog: 11.0 hrs
Digital: 14.5 hrs

Core Slim LiIon Battery
(1650 mAH)

Analog: 11.5 hrs
Digital: 15.0 hrs

Slim IMPRES LiIon Battery
(2050 mAH)

Analog: 14.0 hrs
Digital: 18.5 hrs

IMPRES LiIon Battery
(2250 mAH)

Analog: 16.0 hrs
Digital: 20.5 hrs

IMPRES TIA4950 Hi-Cap
LiIon Battery (2900 mAH)

Analog: 20.0 hrs
Digital: 26.5 hrs

IMPRES Ultra Hi-Cap
LiIon Battery (3000 mAH)

Analog: 21.0 hrs
Digital: 27.5 hrs

NOTE Weight can have 5% margin of error

1-8

Introduction: Specifications

Receiver
Frequencies
Channel Spacing
Frequency Stability (-30°C to
+60°C)

Limited Keypad
XPR 3500

Non Keypad
XPR 3300

VHF: 136 – 174 MHz
UHF: 403 – 512 MHz
12.5 kHz/ 20 kHz/ 25* kHz
+/-0.5 ppm

Analog Sensitivity (12 dB SINAD)

0.26 uV (0.15 uV typical)

Digital Sensitivity (5% BER)

0.22 uV ( 0.13 uV typical)

Intermodulation (TIA603D)

70 dB

Adjacent Channel Selectivity
TIA603A
TIA603D

60 dB @ 12.5 kHz, 70 dB @ 20/25 kHz
45 dB @ 12.5 kHz, 70 dB @ 20/25 kHz

Spurious Rejection (TIA603D)

70 dB

Rated Audio
Audio Distortion @ Rated Audio

500 mW
5% (3% typical)

Hum and Noise

-40 dB @ 12.5 kHz
-45 dB @ 20/25 kHz

Audio Response

TIA603D

Conducted Spurious Emission
(TIA603D)

-57 dBm

NOTE *25 kHz is NOT available in the USA. FCC narrowbanding rules do not allow operation of

this model on 25 kHz configuration in Part 90 VHF/UHF frequencies.

Introduction: Specifications

Transmitter

1-9

Limited Keypad
XPR 3500

Frequencies

Non Keypad
XPR 3300

VHF: 136 – 174 MHz
UHF: 403 – 512 MHz

Channel Spacing

12.5 kHz/25* kHz

Frequency Stability (-30°C to
+60°C)

+/-0.5 ppm

Power Output (Low Power)

Power Output (High Power)

VHF: 5 W
UHF: 4 W

Modulation Limiting

+/-2.5 kHz @ 12.5 kHz
+/-5.0 kHz @ 25 kHz*

FM Hum and Noise

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

Conducted / Radiated Emission

-36 dBm < 1 GHz
-30 dBm > 1 GHz

Adjacent Channel Power

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

12.5kHz Data: 7K60F1D & 7K60FXD
12.5kHz Voice: 7K60F1E & 7K60FXE

Digital Vocoder Type
Digital Protocol

AMBE+2™
ETSI-TS102361-1
ETSI-TS102361-2
ETSI-TS102361-3

NOTE *25 kHz is NOT available in the USA. FCC narrowbanding rules do not allow operation of

this model on 25 kHz configuration in Part 90 VHF/UHF frequencies.
Conforms to:
ETSI TS 102 361 (Parts 1, 2 & 3) - ETSI DMR
Standard
ETSI EN 300 086 - ETSI RF Specifications (Analog)
ETSI EN 300 113 - ETSI RF Specifications (Digital)

1999/5/EC (R&TTE - Radio and Telecommunications
Terminal Equipment)
2002/95/EC (RohS - Banned Substances)
2002/96/EC (WEEE - Waste Electrical and Electronic
Equipment)
94/62/EC (Packaging and Packaging Waste)
Radio meets applicable regulatory requirements.

1-10

Introduction: Specifications

VHF Self-Quieter Frequencies

UHF Self-Quieter Frequencies

139.2

403.2

144

422.4

148.8

427.2

153.6

432

158.4

446.4

160

456

163.2

460.8

168

465.6

172.03

480

172.8

499.2
504
508.8
519.25

Military Standards
Applicable
MIL–STD

810C

810D

810E

810F

810G

Metho
ds

Procedures

Meth
ods

Procedures

Method
s

Procedures

Methods

Procedures

Methods

Prodecures

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/A1, II/
A1

501.4

I/Hot,
II/Hot

501.5

I/A1, II/A1

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/C1

Temperature
Shock

503.1

503.2

A1/C3

503.3

A1/C3

503.4

503.5

I-C

Solar
Radiation

505.1

505.2

I/HotDry

505.3

I/HotDry

505.4

I/HotDry

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

II/HotHumid

507.3

II/HotHumid

507.4

–

507.5

I/Hot-Humid

Salt fog

509.1

509.2

509.3

509.4

–

509.5

–

Dust

510.1

I, II

510.2

I, II

510.3

I, II

510.4

I, II

510.5

I, II

Vibration

514.2

VIII/F,
CurveW, XI

514.3

I/
Cat10,
II/Cat3

514.4

I/Cat10,
II/Cat3

514.5

I/Cat24
II/Cat5

514.6

I/Cat24, II/
Cat5

Shock

516.2

I, II

516.3

I, IV

516.4

I, IV

516.5

I, IV

516.6

I, IV

Introduction: Specifications

1-11

Environmental Specifications
*Operating Temperature

-30 °C to +60 °C

Storage Temperature

-40 °C to +85 °C

Thermal Shock

Per MIL-STD

Humidity

Per MIL-STD

ESD

IEC 61000-4-2 Level 4

Water Intrusion

IEC 60529 -IP67

Packaging Test

MIL-STD 810D and E

* Operating temperature specification with LiIon battery is -10 °C to +60 °C.
Operating temperature specification with NiMH battery is -20 °C to +60 °C.

1-12

Introduction: Specifications

Notes

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 portable radios.
Table 2-1. Recommended Test Equipment

Equipment

Characteristics

Example

Application

Service
Monitor

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

Aeroflex 3920
(www.aeroflex.com),

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
Audio Frequency 100 Hz
to 10 kHz

Agilent N5181A
(www.agilent.com),
Ramsey RSG1000B
(www.ramseyelectronics.com), or
equivalent

Receiver measurements

Oscilloscope *

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

Leader LS8050
(www.leaderusa.com),
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

Test Equipment and Service Aids Service Aids

2.2

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 No.

Description

Application

RLN4460_

Portable Test Set

Enables connection to the 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.

PMKN4115_

Portable Programming Cable

This cable connects the radio to a USB port for radio
programming and data applications.

PMKN4117_

Portable Programming, Testing &
Alignment Cable

This cable connects the radio to a USB port for radio
programming, testing and alignment.
Note: 1. This cable does not support external PTT
using Testbox.
2. This cable does not auto route to external Audio
path once the cable is attached.
3. All test instructions will require through software
tool (eg. CPS, Tuner, etc.)

PMNN4428_

7.5V Universal Battery Eliminator

Connects to radio via battery eliminator cable.

PMLN6154_

RF Adaptor

Application adapts radio's antenna port to BC
cabling of test equipment.

PMLN6201_

RF Adaptor Holder

Holds RF adaptor in place.

PMLN6422_

SMA RF Cable

RF cable with SMA and N-type connector

1185937A01

Grease

Acts to lubricate parts.

TL000013A01

Chassis and Knob Opener

Separates the chassis from the front housing.

NLN9839_

Vacuum Pump Kit

Allows servicer to test for leakages.

NTN4265_

Pressure Pump Kit

Allows servicer to locate leakages.

5871134M01

Connector Fitting

This connector allows the vacuum hose to be
connected to the radio chassis.

3271133M01

Fitting Seal

This seal secures the connector fitting to the radio
chassis.

Test Equipment and Service Aids Programming, Testing and Alignment Cable

Programming, Testing and Alignment Cable
#14

#25
“P1”

#13

PMKN4117A

“P4”

#1
#3
#5
#7

DATA CABLE

2.3

2-3

#2
#4
#6
#8

“P3”
#1

“P2”

Figure 2-1. Programming, Testing and Alignment Cable

2-4

Test Equipment and Service Aids Programming, Testing and Alignment Cable

Table 2-3. Pin Configuration of Side Connector

CONNECTION
P1

VCC (5V)

DATA+

DATA-

GROUND

1&5

EXTERNAL SPEAKER+

2&7

EXTERNAL SPEAKER-

EXTERNAL MIC+

EXTERNAL MIC-

P3
Function

1
3

4
6

Figure 2-2. Pin Layout of Side Connector

Transceiver Performance Testing General

3-1

Chapter 3 Transceiver Performance Testing

3.1

General
These radios meet published specifications through their manufacturing process by utilizing highaccuracy 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.
Although these radios function in digital and analog modes, all testing is done in analog mode.

3.2

Setup
Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.

Do NOT use any form of connector, e.g. wires, crocodile
clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.
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 Frequencies

3-5

Transmitter Performance Checks

3-6

Receiver Performance Checks

Table 3-1. Initial Equipment Control Settings

Service Monitor

Power Supply

Test Set

Monitor Mode: Power Monitor

Voltage: 7.5Vdc

Speaker set: A

RF Attn: -70

DC on/standby:
Standby

Speaker/load:
Speaker

AM, CW, FM: FM

Volt Range: 10V

PTT: OFF

3-2

Transceiver Performance Testing Setup

Table 3-1. Initial Equipment Control Settings

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

Power Supply

Test Set

Current: 2.5A

Setup:
Set up the DMR Transmitter and Receiver Test as per Figure 3-1.
a. Connect the Programming cable to the radio and to the computer.
b. Remove RF plug (black) as shown in Figure 4.5, on page 4-3
c. Connect the RF antenna adaptor to the 50 Ohm RF Input/Output port of the radio as
shown in Figure 3-1.
Connect the other end of the RF antenna adaptor to the T/R port of the Radio Test Set 3920 using
the RF cable shown in Figure 3-1.
See “RF Adaptor Assembly” on page 4-3 for complete RF Adaptor Assembly steps.

Ant. Input / Output

T/R Port
Modulated RF Test
Signal / Tx
modulated RF Signal

Programming Cable

Battery Eliminator

Power Supply
Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup

Transceiver Performance Testing Display Model Test Mode

3.3

Display Model Test Mode

3.3.1

Entering Display Radio Test Mode

3-3

1. Turn the radio on.
2. Within 10 seconds after Self Test is complete, press Side Button 2 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 Left Navigation Key () is
pressed before the last information display, the radio shall suspend the information display
until the user presses Right Navigation Key () 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. The default test environment is CSQ.
1. Each short press of Side Button 2 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.

3-4

Transceiver Performance Testing Display Model Test Mode

Table 3-3. Test Environments

No. of
Beeps

Description

Function

Carrier Squelch
(CSQ)

RX: if carrier detected
TX: mic audio

Tone Private-Line
(TPL)

RX: unsquelch if carrier and tone detected
TX: mic audio + tone

Digital Mode
(DIG)

RX: if carrier detected
TX: mic audio

Unsquelch
(USQ)

RX: constant unsquelch
TX: mic audio

2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz* and 12.5
kHz . The radio beeps twice for 25 kHz* and beeps three times for 12.5 kHz.
3. Turning of the Channel Knob changes the test channel from 1 to 14 as described in
Table 3-4. The radio beeps in each position.
Table 3-4. Test Frequencies

Channel
Selector
Switch
Position

Test
Channel

UHF

VHF

350 MHz

1 Low Power
9 High Power

TX#1 or #9
RX#1 or #9

403.15
403.15

136.075
136.075

350.025
350.025

2 Low Power
10 High Power

TX#2 or #10
RX#2 or #10

423.25
423.25

143.575
143.575

357.525
357.525

3 Low Power
11 High Power

TX#3 or #11
RX#3 or #11

444.35
444.35

146.575
146.575

364.525
364.525

4 Low Power
12 High Power

TX#4 or #12
RX#4 or #12

465.45
465.45

155.575
155.575

371.525
371.525

5 Low Power
13 High Power

TX#5 or #13
RX#5 or #13

485.55
485.55

161.575
161.575

378.525
378.525

6 Low Power
14 High Power

TX#6 or #14
RX#6 or #14

506.65
506.65

167.575
167.575

385.525
385.525

7 Low Power
15 High Power

TX#7 or #15
RX#7 or #15

526.75
526.75

173.975
173.975

392.525
392.525

8 Low Power
16 High Power

TX#8 or #16
RX#8 or #16

527.00
527.00

174.000
174.000

399.925
399.925

NOTE *25 kHz is NOT available in the USA. FCC narrowbanding rules do not allow operation of

this model on 25 kHz configuration in Part 90 VHF/UHF frequencies.

Transceiver Performance Testing Display Model Test Mode

3-5

Table 3-5. Transmitter Performance Checks

Test Name

Communications
Analyzer

Radio

Test Set

Comments

Reference
Frequency

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

TEST MODE,
Test Channel 4
carrier squelch

Please use the
PTT Toggle button
in Tuner for
continous transmit.

Frequency error to be
±201Hz for UHF
±68 Hz for VHF

Power RF

As above

Low Power:
0.9 – 1.5W (VHF/
UHF)
High Power:
4.0 – 4.8W (UHF)
High Power:
5.0 – 6.0W (VHF)

Voice
Modulation

Mode: PWR MON
4th channel test
frequency*
atten to -70, input to RF
In/Out
Monitor: DVM: AC Volts
Set 1kHz Mod Out level
for 0.025Vrms at test
set,
80mVrms at AC/DC
test set jack

As above

As above, meter
selector to mic

Deviation:
≥ 4.0 kHz but ≤ 5.0
kHz (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

Press PTT switch on
radio. Say “four”
loudly into the radio
mic. Measure
deviation:
≥ 4.0 kHz but ≤ 5.0
kHz (25 kHz* Ch Sp)

TPL
Modulation

As above
4th channel test
frequency*
BW to narrow

TEST MODE,
Test Channel 4
TPL

As above

Deviation:
≥500Hz but ≤1000Hz
(25 kHz* Ch Sp).

* See Table 3-4
NOTE *25 kHz is NOT available in the USA. FCC narrowbanding rules do not allow operation of

this model on 25 kHz configuration in Part 90 VHF/UHF frequencies.

3-6

Transceiver Performance Testing Display Model Test Mode

Table 3-6. Receiver Performance Checks

Communications
Analyzer

Radio

Reference
Frequency

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

TEST MODE,
Test Channel 4
carrier squelch
output at
antenna

Please use the
PTT Toggle
button in Tuner
for continous
transmit.

Frequency error to be
±201Hz for UHF
±68 Hz for VHF

Rated Audio

Mode: GEN
Output level: 1.0mV RF
6th channel test
frequency*
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts

TEST MODE
Test Channel 6
carrier squelch

Meter selector to
Audio PA

Set volume
control to 2.83 Vrms

Distortion

As above, except to
distortion

As above

Distortion <3.0%

Sensitivity
(SINAD)

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

As above

Nil

RF input to be
<0.35μV

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

RF level set to 1mV RF

As above

Meter selection
to Audio PA,
speaker/load to
speaker

Set volume
control to 2.83Vrms

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
<0.25μV.
Preferred SINAD = 6
– 8dB

Test Name

* See Table 3-4

Test Set

Comments

Transceiver Performance Testing Display Model Test Mode

3.3.3

3-7

Display Test Mode
1. Press and hold Side Button 1 to enter display test mode.
2. Upon any button or key press, the LCD shall display the growing horizontal bars. Press any
button until the LCD display turns black and change to vertical bars. Press any button until
LCD display full screen black and change to icon display.
3. The LCD shall display RSSI icon (with full bar), monitor icon, tone disabled icon, priority-two
channel scan icon, unread message icon, emergency icon, talkaround icon, and battery
strength indicator icon (with full bar).
4. The LCD display shall become clear and consequently display the rest of the icons, high
power level icon (H), companding icon, option board icon, and secure operation icon upon
any button/key press.

3.3.4

LED Test Mode
1. Press and hold Side Button 1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button/key press, the radio lights the red LED and displays “Red LED On”.
3. Consequently, upon any button/key press, the red LED is turned off and the radio lights the
green LED and displays “Green LED On”.
4. Upon any successive button/key press, the green LED is turned off, and the radio shall light
both LEDs up while displaying “Both LEDs On”. Since there is only one LED on the portable,
the LED color will be amber when the radio lights both LEDs.

3.3.5

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

3.3.6

Speaker Tone Test Mode
1. Press and hold Side Button 1 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 Side Button 1 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 Earpiece Test Mode
1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once and
displays “Audio Loopback Earpiece Test Mode”.
2. The radio shall route any audio on the external mic to the earpiece.

3-8

3.3.9

Transceiver Performance Testing Display Model Test Mode

Battery Check Test Mode
1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once and momentarily displays “Battery Check Test Mode”.
2. The radio will display the following:

Rem. Capacity100%

Figure 3-2. Battery Check Test Mode Display

3.3.10 Button/Knob/PTT Test Mode
1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once and
displays “Button Test”(line 1).
2. Rotate the Volume Knob; “2/1” through “2/255” appears. The radio beeps at each position.
3. Rotate the Channel Knob; When rotate the channel knob in clockwise, “4/1” appear. When
rotate the channel knob in counter clockwise, “4/-1” appear. The radio beeps at each position.
4. Press Side Button 1; “96/1” appears & radio beeps; release, “96/0” appears & radio beeps.
5. Press Side Button 2; “97/1”appears & radio beeps; release, “97/0” appears & radio beeps.
6. Press the PTT Switch; “1/1” appears & radio beeps; release, “1/0” appears & radio beeps.
7. Keypad Checks:
- Press P1, “160/1” appears & radio beeps; release, “160/0” appears & radio beeps.
- Press P2, “161/1” appears & radio beeps; release, “161/0” appears & radio beeps.
- Press MENU, “139/1” appears & radio beeps; release, “139/0” appears & radio beeps.
- Press BACK, “129/1” appears & radio beeps; release, “129/0” appears & radio beeps.
- Press , "128/1" appears & radio beeps; "128/0" appears & radio beeps.
- Press , "130/1" appears & radio beeps; "130/0" appears & radio beeps.
- Press OK, "85/1" appears & radio beeps; "85/0" appears & radio beeps.

Transceiver Performance Testing Non-Display Model Test Mode

3.4

Non-Display Model Test Mode

3.4.1

Entering Non-Display Radio Test Mode

3-9

1. Turn the radio on.
2. Within 10 seconds after “Self Test” is complete, press Side Button 2 five times in succession.
3. The radio beeps.

3.4.2

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”.
1. Each short press of Side Button 2 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 Side Button 1 toggles the channel spacing between 25 KHz* and 12.5
KHz. The radio beeps twice for 25KHz* and beeps three times for 12.5KHz.
3. Turning of the Channel Knob changes the test channel from 1 to 14 as described in
Table 3-4. The radio beeps in each position.

3.4.3

LED Test Mode
1. Press and hold Side Button 1 in RF Test Mode. The radio beeps once.
2. Upon any button/key press, the radio lights up the red LED.
3. Consequently, upon any button/key press, the red LED is turned off and the radio turns on the
green LED.
4. Consequently, upon any button/key press, the green LED is turned off the radio shall turn on
both LEDs.

3.4.4

Speaker Tone Test Mode
1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once.
2. The radio generates a 1 KHz tone with the internal speaker.
NOTE *25 kHz is NOT available in the USA. FCC narrowbanding rules do not allow operation of

this model on 25 kHz configuration in Part 90 VHF/UHF frequencies.

3-10

3.4.5

Transceiver Performance Testing Non-Display Model Test Mode

Earpiece Tone Test Mode
1. Press and hold Side Button 1 after Speaker Tone Test Mode. The radio beeps once.
2. The radio generates a 1 KHz tone with the earpiece.

3.4.6

Audio Loopback Earpiece Test Mode
1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once.
2. The radio shall route any audio on the external mic to the earpiece.

3.4.7

Battery Check Test Mode
1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once.
2. The radio LED lights up accordingly; green LED for High Battery Level, amber LED for Mid
Battery Level and blinking red LED for Low Battery Level.

3.4.8

Button/Knob/PTT Test Mode
1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once.
2. Rotate the Volume Knob; the radio beeps at each position.
3. Rotate the Channel Knob; the radio beeps at each position.
4. Press Side Button 1; the radio beeps; release, the radio beeps.
5. Press Side Button 2; the radio beeps; release, the radio beeps.
6. Press the PTT Switch; the radio beeps; release, the radio beeps.

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 in a Windows 7/Vista/XP
environment. 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. Software Installation Kits Radio Tuning Setup
Description

4.2

Part Number

MOTOTRBO CPS and AirTracer on CD-ROM

PMVN4130_

MOTOTRBO Tuner on CD-ROM

PMVN4131_

Customer Programming Software Setup
The CPS programming setup, shown in Figure 4-1 is used to program the radio.
NOTE

Refer to appropriate program on-line help files for the programming procedures.

!
Caution

Computer USB ports can be sensitive to Electrostatic Discharge. Do not touch
exposed contacts on cable when connected to a computer.

Radio

Battery

Portable Programming
Cable
PMKN4115_

Figure 4-1. CPS Programming Setup

4-2

4.3

Radio Programming and Tuning AirTracer Application Tool

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.

4.4

Radio Tuning Setup
A personal computer (PC), Windows 7/Vista/XP and a tuner program are required to tune the radio.
NOTE Refer to the appropriate program online help files for the tuning procedures.

To perform the tuning procedures, the radio must be connected to the PC and test equipment setup
as shown in Figure 4-2.
Battery
Eliminator
7.5V Reg.
PMNN4428
+12VDC
Power
Supply

Service Monitor
or Counter

Transmit

RF Adaptor

Wattmeter
Radio

Receive

10 dB Pad

RF Generator
Audio In
Test Box
RLN4460_
Programming, Testing &
Alignment Cable
PMKN4117

Figure 4-2. Radio Tuning Equipment Setup

Tx Audio Generator
Rx

Sinad Meter
AC Voltmeter

Radio Programming and Tuning Radio Tuning Setup

4.4.1

4-3

RF Plug Dissassembly
1.

Use a tweezer to lift up one end of the RF plug and pull it out.

RF Plug

Figure 4-3. RF Plug disassembly
2.

Insert the RF Adaptor into the front housing.
RF Adaptor

Figure 4-4. RF Adaptor insertion

4-4

Radio Programming and Tuning Radio Tuning Setup

Screw in the RF adaptor to the front housing.

Figure 4-5. RF Adaptor screw
4.

Insert the RF connector.

Figure 4-6. RF Connector

Disassembly/Reassembly Procedures Introduction

5-1

Chapter 5 Disassembly/Reassembly Procedures

5.1

Introduction
This chapter provides details about the following:
• Preventive maintenance (inspection and cleaning).
• Safe handling of CMOS and LDMOS devices.
• Disassembly and reassembly of the radio.
• Repair procedures and techniques.

5.2

Preventive Maintenance
Periodic visual inspection and cleaning is recommended.

5.2.1

Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.

5.2.2

Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the front kit,
housing assembly and battery case. 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

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. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front kit or back cover.
NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by

dissolved material (from previous usage).

!
Caution

5.3

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.

Safe Handling of CMOS and LDMOS Devices
Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent
device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION
paragraph in the Disassembly and Reassembly section of the manual.

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 the Motorola Static
Protection Assembly (part number 0180386A82), which includes 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) Directive 2002/
95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/
EC. To maintain product compliance and reliability, use only the Motorola specified parts
in this manual.

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%

217C

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
When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
from the nearest Motorola Radio Products and Solutions Organization (RPSO) listed in Appendix A
of this manual.
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.
When soldering near a connector:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges.

Disassembly/Reassembly Procedures Disassembling and Reassembling the Radio — General

5.5

Disassembling and Reassembling the Radio — General
When disassembling and reassembling the radio, it is important to pay particular attention to the
snaps and tabs, and how parts align with each other.
The following tools are required for disassembling the radio:
• TORX™ T screwdriver
• Chassis and Knob Opener (p/n: TL000013A01)
The following item and tools are required for reassembling the radio:
• Grease (1185937A01)
• TORX™ T screwdriver
• Vacuum Pump Kit (NLN9839) - Radio Immersibility Test
• Pressure Pump Kit (NTN4265) - Radio Immersibility Test
• Connector Fitting (5871134M01) - Radio Immersibility Test
• Fitting Seal (3271133M01) - Radio Immersibility Test
• Ventilation Seal (3286058L01)
• Ventilation Label (LB000256A01)
If a unit requires further testing or service than is customarily performed at the basic level, please
send the radio to a Motorola Service Center listed in Appendix B.

!
Caution

To assure the safety and regulatory compliance of the , the radio must be
repaired only at Motorola service facilities. Please call Motorola at 800-4224210 for the address and contact information of your nearest service center

5-5

5-6

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

5.6

Radio Disassembly – Detailed

5.6.1

Front Kit from Chassis Disassembly
1.

Turn off the radio.

Remove the battery:
a. Release the battery latch by moving it into the unlock position.

Latch

Figure 5-1. Battery removal
b. With the latch released, slide the battery downwards.

Figure 5-2. Battery removal
3.

Remove the battery from the radio.

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Remove the antenna by turning it counterclockwise.

Figure 5-3. Antenna removal

5-7

5-8

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Remove the volume and channel knobs off from their shafts using the knob removal tool.

Volume Knob
Channel Knob

Figure 5-4. Volume and Channel Knob removal.
NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.

Separate the back kit from the front kit as follows:
a. Unscrew the screw using TORX T6 screwdriver as shown in Figure 5-5.

Figure 5-5. Front Kit-Back Kit Screw removal

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

b. Use the chassis and knob opener to separate the back kit from the front kit.

Figure 5-6. Back Kit disassembly

5-9

5-10

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

c. Slide out the back kit slowly from the front kit.

Figure 5-7. Back Kit removal

Do not force the chassis out if it gets stuck by pulling it.
This will cause damage to the front kit.

Do not pull out the chassis forcefully as this will cause
damage to the flex connector.

Lay the front kit down. Rotate the back kit backward and slightly away from the front kit.

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

5-11

Lift the ZIF connector latch on the mainboard assembly to release the flex and separate the
back kit from the front kit.

Interface Keypad-Display
Flex

Interface UC-Audio
Flex

Figure 5-8. Disconnecting the interface UC-audio flex and keypad-display flex (Limited Keypad Model)

Figure 5-9. Disconnecting the UC-audio flex (Non Keypad Model)

5-12

5.6.2

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Back Kit Disassembly
1.

Remove the top control seal.

Figure 5-10. Top control seal removal
2.

Use a TORX screwdriver with a T6 head to remove the 5 M2 screws holding the mainboard
assembly to the back kit.

Figure 5-11. Back Kit disassembly

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Remove the battery contact seal.

Figure 5-12. Battery contact seal removal

5-13

5-14

5.6.3

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Keypad, Display, and Keypad Board Disassembly
1.

Disconnect the UC-audio flex.

Figure 5-13. UC-audio flex removal
2.

Remove the display retainer after removing the 2 K18 screws.

Figure 5-14. K18 screw removal

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

5-15

Disconnect the display flex from the keypad board and remove it from the front kit.

Figure 5-15. Display flex removal
4.

Remove the keypad and display module from the front kit.

Display module

Keypad

Figure 5-16. Keypad removal

5-16

5.6.4

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Side Buttton, Speaker, Microphone, and UC-Audio Flex Disassembly
1.

Pull out the PTT retainer.

PTT Retainer

Figure 5-17. PTT retainer removal
2.

Remove the side button.

Side button

Figure 5-18. Side button removal

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Peel off the UC escutcheon.

Figure 5-19. UC escutcheon removal.

5-17

5-18

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Pull the UC-audio flex (adhesive held) FR4 from the front housing. Push the UC-audio flex
through the UC slot into the housing.

Figure 5-20. UC-audio flex removal
5.

Remove the K18 screw securing the speaker retainer.

Figure 5-21. Speaker retainer screw removal

Disassembly/Reassembly Procedures Radio Disassembly – Detailed

Remove the speaker assembly from the front kit and separate the speaker module and
retainer.

Figure 5-22. Speaker retainer removal

5-19

5-20

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

5.7

Radio Reassembly - Detailed

5.7.1

Speaker Reassembly
1.

Insert the UC-audio flex through the speaker retainer so that the speaker retainer is placed
directly on the speaker assembly.

Figure 5-23. Speaker assembly
NOTE Ensure the flex is on top of the retainer to prevent it being torn during reassembly.

Use a tweezer to pull UC-audio flex circuit through the UC slot and place the speaker
assembly in the recess on the front kit.

Figure 5-24. UC-audio flex

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

5-21

Replace with a new UC escutcheon.

Figure 5-25. UC escutcheon
4.

Ensure the mic is seated properly in the mic boot. Screw in the K18 screw to the speaker
retainer.

Mic

Figure 5-26. Speaker retainer reassembly

5-22

5.7.2

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Side Button, Keypad, Display and Keypad Board Reassembly
1.

Insert side button to the front housing.

Side button

Figure 5-27. Side button reassembly
NOTE Ensure the side button is seated firmly without any pinching as this will impact the sealing

performance
2.

Replace the PTT retainer.

PTT Retainer

Figure 5-28. PTT retainer reassembly

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Place the display module into the display module recess.

Figure 5-29. Display module reassembly
4.

Place the keypad into the front kit and press firmly in place.

Figure 5-30. Keypad reassembly
NOTE Ensure the keypad mushroom rib is fully seated in the sealing groove to prevent any

pinching or bulging.

5-23

5-24

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Tongue in the keypad board.

Figure 5-31. Keypad board reassembly
6.

Connect the display flex and gently latch it down.

Figure 5-32. Display flex reassembly

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

5-25

Hold up the UC-audio flex and insert the display retainer. Screw in the K18 screw to the
speaker retainer.

Figure 5-33. Speaker retainer reassembly
NOTE Ensure the UC-audio flex is not trapped under the speaker retainer.

Connect the UC-audio flex to the keypad board and gently press the ZIF connector until it
latches shut.

Affix a poron pad on top of the UC-audio flex.

Figure 5-34. UC-Audio Flex Pad Reassembly

5-26

5.7.3

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Back Kit Reassembly
1.

Replace the thermal pad on the chassis.

Figure 5-35. Thermal pad
2.

Affix the chassis label on both the left and right side of the chassis.

Replace battery contact seal on the chassis. Orientate the battery contact seal so that the

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

5-27

wider edge is at the top side as per Figure 5-36.

Wider edge

Figure 5-36. Battery contact seal reassembly

!
Caution

Make sure the battery contact seal is not twisted or lifted when
the mainboard assembly is placed on the chassis.

Place the mainboard assembly on the chassis and replace the 5 M2 screws.

3
4

Figure 5-37. Mainboard reassembly

5-28

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Insert the top control seal into the volume and channel shaft. Push on the wing of the top
control seal as shown in Figure 5-38, until it is seated on the base of the switches.

Wing

Figure 5-38. Top control seal reassembly

!
Caution

Ensure the top control seal is seated properly on the shafts.

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

5.7.4

Back Kit and Front Kit Reassembly
1.

Apply a thin layer of grease to the full perimeter of the dispensed O-ring.

Connect the 2 flexes to the mainboard ZIF connector and gently latch it firmly shut.

Figure 5-39. Interface flexes reassembly (Limited Keypad Model)

Figure 5-40. Interface flexes reassembly (Non Keypad Model)

5-29

5-30

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Slide in the back kit into the front kit and firmly press down to snap it in.

Figure 5-41. Front kit reassembly
4.

Fasten the 2 Front Kit-Back Kit screws by using TORX™ T6 screwdriver.

Slide in the volume and channel knob fully on the shafts on the front kit.

Figure 5-42. Knob reassembly

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

Attach antenna by turning it in clockwise.

Figure 5-43. Attaching the antenna

5-31

5-32

5.7.5

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

RF Plug Reassembly
1.

If required, replace the RF plug by using a tweezer.

Figure 5-44. RF Plug reassembly
2.

If Motorola nameplate is damaged, remove nameplate with a tweezer and replace a new one.

Figure 5-45. Nameplate replacement
3.

Make sure the RF plug and nameplate is flush to the housing and not bulging up. If its bulging
up disassemble and reassemble back.

Disassembly/Reassembly Procedures Radio Reassembly - Detailed

5-33

If product nameplate is damaged, remove nameplate with a tweezer and replace a new one.

Figure 5-46. Product Nameplate Reassembly
NOTE Regular maintenance (at least annually) of this area is recommended to ensure

contamination free interface and to prolong the life of the battery contacts.

5-34

5.8

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

Ensuring Radio Immersibility
This section discusses radio immersibility concerns, tests, and disassembly and reassembly of the
XPR series radios.

5.8.1

Servicing
The XPR series radios shipped from the Motorola factory have passed vacuum testing and should
be capable of restoring the watertight integrity of the radio.

!
Caution

5.8.2

It is strongly recommended that the maintenance of the radio be deferred to
qualified service personnel and service shops. This is of paramount importance
as irreparable damage to the radio can result from service by unauthorized
persons. If disassembly is necessary, unauthorized attempts to repair the radio
may void any existing warranties or extended performance agreements with
Motorola. It is also recommended that immersibility be checked annually by
qualified service personnel/workshop that is authorized by Motorola.

Accidental Immersion
If the radio is accidentally dropped in water, shake the radio to remove the excess water from the
speaker grille and microphone port area before operating; otherwise, the sound may be distorted
until the water has evaporated, or is dislodged from these areas.

5.8.3

Specialized Test Equipment
This section summarizes the specialized test equipment necessary for testing the integrity of the
XPR series radios.
To ensure that the radio is truly a watertight unit, special testing, test procedures, and specialized
test equipment are required. The special testing involves a vacuum check of the radio and pressure
testing (troubleshooting) for water leaks if the vacuum check fails. The specialized test equipment/
instrument (Table 2-2 on page 2-2) is authorized by Motorola and needed to perform the vacuum
check and pressure testing, if required. Any equipment/tools/instruments not mentioned in the table
must not be used to perform these test.

5.8.4

Vacuum Pump Kit NLN9839
The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. A connector fitting
(part number 5871134M01) and fitting seal (part number 3271133M01) pump connector, which must
be ordered separately, connects the vacuum hose to the radio’s chassis.

Fitting Seal
(part

number
3271133M0

Connector
Fitting
(part
number
5871134M01)

Figure 5-47. Connector Fitting - Fitting Seal Pump Connector

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

5.8.5

5-35

Pressure Pump Kit NTN4265
The pressure pump kit includes a pressure pump with gauge, and a pressure hose. As with the
vacuum pump kit above, the connector fitting - fitting seal pair connects the pressure hose to the
radio’s chassis.

5.8.6

Miscellaneous Hardware
Other items needed for testing the immersibility radio include:

5.8.7

•

Large water container

•

Deionized (DI) water

•

A supply of replacement parts: Battery Contact Seal, Breathing Vent Label and Breathing
Vent Membrane.

Vacuum Test
The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the
radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly
sealed, watertight unit. Before starting the vacuum test:
•

Remove the battery.

•

Remove the universal connector dustcover to expose the universal connector.

•

Remove the breathing vent label and breathing vent membrane.

To conduct the vacuum test:
1.

Attach antenna firmly to the radio.

Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by
blocking off the open end of the hose and operating the pump a few times. The actual reading
of the gauge at this point is not important; it is important that the gauge pointer remained
steady, indicating no vacuum leaks in the pump.

Ensure that the fitting seal is attached to the hose-to-chassis pump connector. Screw the
pump connector into the tapped hole in the chassis.

Please do not bend or over tighten pump connector to the chassis.

Caution

Attach the open end of the hose to the pointed end of the pump connector.

Place the radio on a flat surface with the chassis facing upward.

Operate the pump until the gauge indicates 6 in. Hg of vacuum on the radio.Observe the
gauge for approximately 1 minute.

•

If the needle falls 0.5 in. Hg or less (one scale interval, for example, from 3 in. Hg to 2.5 in.
Hg), then the radio has passed the vacuum test and is approved for immersibility. No
additional testing will be required.

•

If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 3 in. Hg to less
than 2.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if

5-36

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

immersed. Additional troubleshooting of the radio will be required; complete this procedure,
then go to Section 5.8.8, Pressure Test.
7.

5.8.8

Remove the vacuum hose and pump connector from the radio.

Pressure Test
Pressure testing the radio is necessary only if the radio has failed the vacuum test. Do not perform
the pressure test until the vacuum test has been completed. Pressure testing involves creating a
positive pressure condition inside the radio, immersing the radio in water, and observing the radio
for a stream of bubbles (leak). Since all areas of the radio are being checked, observe the entire unit
carefully for the possibility of multiple leaks before completing this test.
To conduct the pressure test:
1.

Screw the pump connector (with fitting seal) into the tapped hole in the chassis.

Attach one end of the pressure hose to the pump connector and the other end to the pressure
pump.

Attach antenna firmly to the radio.

Operate the pump until the gauge reads approximately 1 psig.

Pressure any greater than 1 psig might push air around the main seal

Caution

Maintain the pressure at 1 psig and immerse the radio into a water-filled container.

Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.

NOTE Some air entrapment may cause the accumulation of bubbles, especially in the grille area,

but the bubbles should not be continuous.

Please do not bend or over tighten pump connector to the chassis.

Caution

Note all of the seal areas that show signs of leakage. Pinpoint the problem(s) to one (or more)
of the following areas:

•

Front Housing

•

Chassis kit

•

Battery Contact Seal

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

Remove the radio from the water container, and dry the radio thoroughly. Be especially
careful to dry the area around the main seal to prevent contamination of the internal
electronics while the unit is open

!
Caution

5-37

Keep the area around the chassis’s vacuum port dry by ensuring that there is no
water around it.

Remove the pump connector from the chassis.

10. Radio after performing Pressure Test must undergo baking process in a temperature chamber
for constant temperature soaking at 60°C for 1 hour. This is to ensure no moisture is trapped
inside the radio and prevent contamination of the internal electronics after reassembling the
radio.

5.8.9

Troubleshooting Leak Areas
Before repairing any leak, first read all of the steps within the applicable section. This will help to
eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot
only the faulty seal areas listed in Section 5.8.8 "Pressure Test" on page 5-36, and when multiple
leaks exist, in the order listed.
NOTE Before reassembling the radio, always install a Battery Contact Seal in the defective area.

5.8.9.1 Front Housing
Do one or both of the following:
1.

If a leak occurs at the Lens (Display Models only), Universal Connector, chassis/Housing
interface, PTT button area of the housing, replace the housing. Refer to Section 5.6 "Radio
Disassembly – Detailed" on page 5-6.
a.

Remove the housing assembly from the radio.

Discard the housing assembly.

Install a new housing assembly to the radio.

If the leak occurs at the control top area, remove the knobs in order to determine the leak
location:
a.

Conduct the Pressure Test.

Identify the leak location.

5.8.9.2 Chassis
To replace the Chassis Assembly:
1.

Refer to Section Section 5.6.1 "Front Kit from Chassis Disassembly" on page 5-6, remove
the chassis assembly from the radio.

Refer to Section Section 5.6.2 "Back Kit Disassembly" on page 5-12, remove the Mainboard
from chassis.

Assemble a new chassis assembly; discard the old chassis assembly.

Reassemble the chassis assembly followed by installing into front kit. (Refer to Section 5.7
"Radio Reassembly - Detailed" on page 5-20.

5-38

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

5.8.9.3 Battery Contact Seal
To replace the Battery Contact Seal:
1.

Refer to Section 5.6 "Radio Disassembly – Detailed" on page 5-6 to remove the Battery
Contact Seal.

Remove the Battery Contact Seal from the Chassis.

Inspect the Battery Contact Seal, Chassis and surrounding areas for foreign material that
might prevent the Battery Contact Seal from sealing properly.

Install a new Battery Contact Seal; discard the old Seal.

Reassemble the chassis assembly followed by installing into front kit. (Refer to Section 5.7
"Radio Reassembly - Detailed" on page 5-20).

IMPORTANT:

Both Ventilation Label (LB000256A01) and Ventilation Seal
(3286058L01) need to be replaced after vacuum test, pressure test or
water leakage troubleshooting.

5.8.9.4 Ventilation Seal and Ventilation Label
To replace the Ventilation Seal and Ventilation Label:
1.

Remove the Ventilation Label that covers the Ventilation Seal from the chassis.

Remove the Ventilation Seal.

Ensure that the chassis’s surface (at the Ventilation Label & Ventilation Seal recessed) is
clean, no/minimum scratches and free from any adhesive or other foreign materials.

Install a new Ventilation Seal, covering the vent port hole, in the small recessed area in the
chassis. Ensure that no oily substance come in contact with the seal.

Install a new Ventilation Label over the Ventilation Seal in the larger recessed area in the
chassis. Press down evenly over the label’s surface to ensure good adhesion.

5.8.9.5 Battery Maintenance
1.

As part of an Annual Battery Maintenece Program or as required (when the battery contacts
are dirty or show signs of wear) it is recommended that the Battery‘s Radio-side and Chargerside contacts are cleaned with DeoxIT®GOLD cleaner/lubricant.

DeoxIT®GOLD (Supplier CAIG Labs, P/N G100P) cleaner/lubricant pen has been found to be
very effective at cleaning and extending the life of the battery‘s contacts. DeoxIT®GOLD
cleaner/lubricant is available at numerous electronics suppliers (Radio Shack, McMaster Carr,
Fry’s, etc.) and directly from manufacturer, CAIG Labs, at http://www.caig.com.

This pen based package is recommended as it provides better access to the recessed contacts of the battery. The pen’s tip may need to be modified (trimmed on the sides) to improve
penetration into the battery contact slots. Per the manufacturer’s instructions, shake the pen
until the fluid begins to flow and wipe the battery's contact surface with the felt tip. After
cleaning, inspect the contact surfaces for signs of advanced wear.

Advanced contact wear is defined as wear through either the contact platings (gold and
nickel) to the base metal (copper). Copper exposure is characterized by a distinctive orangebrown metal appearance surrounded by the silvery nickel underplate and gold top coat.

In some cases, a magnified (10x minimum) inspection may be required to verify wear through
to the base material. Polishing of the gold or nickel surface is common and is not considered
a need for replacement. In instances where advanced wear is evident, the battery should be
replaced.

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

5-39

After cleaning the contact areas of any foreign material, let the lubricant/cleaner dry for 2 minutes. Replace the battery on the radio and test for intermittency by moving the battery relative
to the radio as might occur in regular use.

NOTE Regular maintenance (at least annually) of this area is recommended to ensure

contamination free interface and to prolong the life of the battery contacts.

5-40

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

5.8.10 Troubleshooting Charts
Start

1. Remove Battery
2. Remove Universal
Connector Dustcover
3. Remove ventilation label
and seal

A
1. Attach antenna firmly to the radio.
2. Attach vacuum hose to vacuum
pump
3. Ensure fitting seal is attached to
hose-to-chassis pump connector
4. Screw pump connector into
chassis’s tapped hole
5. Attach vacuum hose to pump
connector
6. Place radio on flat surface
7. Operate pump (gauge = 6 in. Hg)

Gauge
does not fall
below
0.5 in. Hg

Full
equipment for
pressure test
procedure
available

YES

Run Pressure Test

YES
NO
1.Replace
ventilation label
and seal
2. Radio approved
for immersibility

End

Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

5-41

End
Start

Send radio to
Motorola Depot
or
Motorola Service Center

1Remove pump and
connectors from radio
2. Remove antenna
3. Separate front housing kit

YES

Changed
front housing
kit

Changed
chassis
kit

YES

Apply grease to the full
perimeter of the chassis O-ring
and replace the Chassis Kit
without PCBs

Replace front
housing kit with
new unit

Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)

5-42

Disassembly/Reassembly Procedures Ensuring Radio Immersibility

Start

1. Remove vacuum hose from
pump connector
2. Attach pressure hose to
pump connector

1. Operate pressure pump
(pressure = 1 psig)
2. Immerse radio into a waterfilled container

1. Remove Knobs

Continuous
Series of
bubbles

YES

Bubbles from
Front
Housing

End

YES

1. Dry the radio
2. Apply grease to the full
perimeter of the chassis O-Ring
and replace Chassis Kit and
repeat steps in Troubleshooting
Flow Chart for Vacuum Test

* Only for Display Model

1. Dry the radio
2.Replace
Ventilation Label and
Ventilation Seal
3. Radio approved
for immersibility
Bubbles from
Chassis

Bubbles from
Lens*/Universal Connector/
chassis/
Housing Interface/ PTT

YES

1. Dry the radio
2. Apply grease to the full
perimeter of the chassis O-Ring
and replace Chassis Kit and
repeat steps in Troubleshooting
Flow Chart for Vacuum Test

Bubbles from
Battery Contact Seal

YES

1. Dry the radio
2. Replace Battery Contact Seal,
Apply grease to the full
perimeter of the chassis O-Ring
and replace Chassis Kit. Repeat
steps in Troubleshooting Flow Chart
for Vacuum Test

Troubleshooting Flow Chart for Pressure Test & Leakage Areas

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

Radio Exploded Mechanical Views and Parts Lists

5.9.1

Limited Keypad Model Exploded View and Parts List

9.18

10.2.1

11
13

12
14

10.2.5.1

10.2.5

10.2.4

10.2.3

10.1

10.2.5.2

9.14

9.22
10.2.2

9.23

9.21

9.20

9.19

9.17

9.16

9.14

9.12
9.15

9.13

9.11

9.10

9.9

9.8

9.6

9.7

9.1

9.2

5 4

9.3

9.4

9.5

5.9

5-43

Figure 5-48. Limited Keypad Model Exploded View

5-44

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

Table 5-3. Limited Keypad Model Exploded View Parts List
Item

Description

Part Number

Nameplate (Product Number)

Refer Table 5-5

Nameplate (Motorola)

33012026001

RF Plug

38012018001

Volume Knob

36012016001

Channel Knob

36012017001

Antenna ID Band

Refer Table 5-5

Antenna

Refer Table 5-5

Aesthetic Cover

0104058J40

Front Cover Kit*

PMLN7271_

9.1

PTT Retainer

42012035001

9.2

Side Button

KP000087A01

9.3

Housing Assembly

0104067J09

9.4

PTT Keypad

KP000086A01

9.5

PTT Paddle

HN000696A01

9.6

UC Escutcheon

33012020001

9.7

Microphone Membrane

SL000209A01

9.8

Microphone Boot

SL000208A01

9.9

Microphone

50012012001

9.10

Speaker Mesh

HW000738A01

9.11

Speaker

AC000028A02

9.12

UC-Audio Flex

PF001002A01

9.13

Speaker Retainer

42012044001

9.14

K18 Screw (Keypad-Display Retainer &
Speaker Retainer)

0385273D06

9.15

Front Display Poron

75012078001

9.16

Display Module (2-Line Monochrome)

72012014002

9.17

Back Display Poron

HW000757A01

9.18

Display Retainer

42012034001

9.19

Conductive Pad

75012147001

9.20

Limited Keypad

75012080001

9.21

Keypad Board Assembly

0104065J98

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

5-45

Table 5-3. Limited Keypad Model Exploded View Parts List
Item

Description

Part Number

9.22

Interface Keypad-Display Flex

PF001004A01

9.23

Interface UC-Audio Flex

PF001005A01

Back Cover Kit***

Refer Table 5-5

10.1

Main Board Assembly

Part of Back Kit

10.2

Chassis Assembly**

PMLN7273_

10.2.1

M2 Screw (Main Board Assembly)

03012034001

10.2.2

Top Control Seal

32012269001

10.2.3

Thermal Pad

75012234001

10.2.4

Battery Contact Seal

32012110001

10.2.5

Chassis (With dispensed O-Ring)

0104067J11

10.2.5.1

Chassis Left Label

LB000706A01

10.2.5.2

Chassis Right Label

LB000706A02

Front Kit-Back Kit Screw

0316281H01

Compro Label

LB000560A01

Ventilation Seal

3286058L01

Ventilation Label

LB000256A01

UL Label (Repaired)

Battery

Refer Table 5-5

Belt Clip

Refer Table 5-5

NOTE

*Items included in Front Cover Kit (PMLN7271_)
** Items included in Chassis Assembly (PMLN7273_)
*** Back Cover Kit (Refer to Table 5-5) included Chassis Assembly (PMLN7273_)

5-46

Non Keypad Model Exploded View and Parts List

9.1
9.7

10.2.5.2
17

10.2.5.1

10.2.3
10.2.5

10.2.4

10.1

9.14
10.2.2

9.13

9.12

10.2.1

9.10
9.11

9.9 9.8

9.6
8

9.2

9.3

9.4 9.5

5.9.2

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

Figure 5-49. Non-Keypad Model Exploded View

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

5-47

Table 5-4. Non Keypad Model Exploded View Parts List
Item

Description

Part Number

Nameplate (Product Number)

Refer Table 5-5

Nameplate (Motorola)

33012026001

RF Plug

38012018001

Volume Knob

36012016001

Channel Knob

36012017001

Antenna ID Band

Refer Table 5-5

Antenna

Refer Table 5-5

Aesthetic Cover

0104058J40

Front Cover Kit*

PMLN7272_

9.1

PTT Retainer

42012035001

9.2

Side Button

KP000087A01

9.3

Housing Assembly

0104067J10

9.4

PTT Keypad

KP000086A01

9.5

PTT Paddle

HN000696A01

9.6

UC Escutcheon

33012020001

9.7

Microphone Membrane

SL000209A01

9.8

Microphone Boot

SL000208A01

9.9

Microphone

50012012001

9.10

Speaker Mesh

HW000738A01

9.11

Speaker

AC000028A02

9.12

UC-Audio Flex

PF001006A01

9.13

Speaker Retainer

42012044001

9.14

K18 Screw (Keypad-Display Retainer &
Speaker Retainer)

0385273D06

Back Cover Kit***

Refer Table 5-5

10.1

Main Board Assembly

Part of Back Kit

10.2

Chassis Assembly**

PMLN7273_

10.2.1

M2 Screw (Main Board Assembly)

03012034001

10.2.2

Top Control Seal

32012269001

10.2.3

Thermal Pad

7515526H01

10.2.4

Battery Contact Seal

32012110001

5-48

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

Table 5-4. Non Keypad Model Exploded View Parts List
Item

Description

10.2.5

Part Number

Chassis (With dispensed O-Ring)

0104067J11

10.2.5.1

Chassis Left Label

LB000706A01

10.2.5.2

Chassis Right Label

LB000706A02

Front Kit-Back Kit Screw

0316281H01

Compro Label

LB000560A01

Ventilation Seal

3286058L01

Ventilation Label

LB000256A01

UL Label (Repaired)

Battery

Refer Table 5-5

Belt Clip

Refer Table 5-5

NOTE

*Items included in Front Kit (PMLN7272_)
** Items included in Chassis Assembly (PMLN7273_)
*** Back Kit (Refer to Table 5-5) included Chassis Assembly (PMLN7273_)

Table 5-5. Additional Parts List
Item

Description

Part Number

Battery
Core NIMH 1300 mAH

PMNN4415_

Core Slim LiIon 1500 mAH

PMNN4406_

IMPRES LiIon 1500 mAH

PMNN4417_

IMPRES LiIon Non-FM 2150 mAH

PMNN4418_

XPR 3300e

33012039025

XPR 3500e

33012039026

Back Cover Kit, 136–174 MHz, 5W, Limited
Keypad Portable, WiFi

PMLD4733_S

Back Cover Kit, 136–174 MHz, 5W, Limited
Keypad Portable

PMLD4734_S

Back Cover Kit, 136–174 MHz, 5W, Non Keypad
Portable

PMLD4737_S

Back Cover Kit, 403–527 MHz, 4W, Limited
Keypad Portable, WiFi

PMLE5074_S

Nameplate

Back Kit

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

Table 5-5. Additional Parts List (Continued)
Item

Antenna ID
Band

Belt Clips

Description

Part Number

Back Cover Kit, 300–360 MHz, 4W, Non Keypad
Portable

PLMLD4749_

Back Cover Kit, 350–400 MHz, 4W, Limited
Keypad Portable, WiFi

PMLD4755_S

Back Cover Kit, 350–400 MHz, 4W, Limited
Keypad Portable

PMLD4800_S

Back Cover Kit, 350–400 MHz, 4W, Non
Keypad Portable

PMLD4799_S

Antenna ID Band (Grey- Pack Of 10 PCS)

32012144001

Antenna ID Band (Yellow- Pack Of 10 PCS)

32012144002

Antenna ID Band (Green- Pack Of 10 PCS)

32012144003

Antenna ID Band (Blue- Pack Of 10 PCS)

32012144004

Antenna ID Band (Purple- Pack Of 10 PCS)

32012144005

Belt Clip 2”

PMLN4651_

Belt Clip 2.5"

PMLN7008_

5-49

5-50

5.9.3

Disassembly/Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists

Torque Chart
Table 5-6 lists the various 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 5-6. Torque Specifications for Screws
Part Number

Description

0385273D06

K18 Screw (Speaker Retainer)
K18 Screw (Keypad-Display Retainer)

03012034001

0316281H01

Driver/
Socket

Torque
lbs-in

N-m

T6 Torx
T6 Torx

2.0 to 2.2
1.5 to 1.7

0.23 to 0.25
0.17 to 0.19

M2 Screw (Mainboard Assembly) New Chassis
M2 Screw (Mainboard Assembly) Rework Chassis

T6 Torx

3.1 to 3.5

0.35 to 0.40

T6 Torx

2.0

0.23

Front Kit-Back Kit Screw

T6 Torx

2.1 to 2.3

0.24 to 0.26

Chapter 6 Basic Troubleshooting

6.1

Introduction
This chapter contains error codes and board replacement procedures. If the board does not pass all
the performance checks in Chapter 3 or exhibits an error code listed below, then the circuit board
should be replaced. If repair requires knowledge of details of component level troubleshooting,
please send 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 the section, "Service Aids" on page 2-2,
for the appropriate Motorola service aids and tools parts numbers.)

6.2

Replacement Back Cover Kit Procedures
Once a problem has been isolated to a specific board, install the appropriate service kit (See Model
Charts in Chapter 1), which is orderable. from Motorola Radio Products and Solutions Organization
at 1-800-422-4210.
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 the blank board to be entered
once. Be very attentive during this procedure.

6-2

Basic Troubleshooting Power-Up Error Codes (Display Model only)

6.3

Power-Up Error Codes (Display Model only)
Upon powering up, the radio performs certain tests to determine if its basic electronics and software
are in working order. Any error detected has an associated error code that is presented on the radio
display. These error codes are intended to be used by a service technician when the radio
generates the Self Test Fail Tone. If these tests are successfully completed, the radio will generate
the Self Test Tone.
There are two classes of detectable errors, fatal and non-fatal. If it is considered as a fatal error, then
the normal radio operation will be inhibited. Fatal errors include hardware errors detected by the
microprocessor and certain memory errors. These memory errors include incorrect ROM checksum,
incorrect RAM checksum, and incorrect checksums of codeplug (Persistent Storage) blocks that
contain operating parameters. If the codeplug block operating parameters are corrupted, operation
of the unit on the proper frequency, system, and group are in question. Attempts to use this
information could provide the user with a false sense of security that others are receiving his
messages. Corrupted codeplug blocks of call IDs, or their associated aliases are considered nonfatal errors. While the user may be inconvenienced, normal communication is still possible.
Table 6-1. Power-Up Error Codes

Error Code

Description

Error Type

Corrective Action

ERROR 01/02 Call ID or associated
aliases codeplug block
checksum is wrong.

Non-Fatal

Normal communication is still possible, but the
user may be inconvenienced.
Reprogram codeplug.

ERROR 01/22 Tuning Codeplug block
checksum is wrong.

Non-Fatal

Normal communication is still possible.

FAIL 01/82

External Codeplug block
checksum is wrong.

Fatal

Reprogram codeplug.

FAIL 01/92

Secure Codeplug check- Fatal
sum error

Reprogram codeplug.

FAIL 01/A2

Tuning Codeplug block
checksum is wrong.

Fatal

Reprogram codeplug.

FAIL 01/81

ROM Checksum is
wrong.

Fatal

Reprogram FLASH Memory, then retest. If
message reoccurs, replace main board or
send radio to nearest Motorola Depot.

FAIL 01/88

Radio RAM Test Failure.

Fatal

Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.

FAIL 01/90
or
FAIL 02/90

General hardware test
failure.

Fatal

Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.

FAIL 02/81

DSP ROM Checksum is
wrong.

Fatal

Reprogram FLASH Memory, then retest. If
message reoccurs, replace main board or
send radio to nearest Motorola Depot.

FAIL 02/82

DSP RAM1 test failure.

Fatal

Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.

Basic Troubleshooting Power-Up Error Codes (Display Model only)

6-3

Table 6-1. Power-Up Error Codes (Continued)
Error Code

Description

Error Type

Corrective Action

FAIL 02/84

DSP RAM2 test failure.

Fatal

Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.

FAIL 02/88

DSP RAM test failure.

Fatal

Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.

FAIL 02/C0

DSP ROM Checksum is
wrong.

Fatal

Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.

No Display

Display module is not
connected properly.
Display module is damaged.

Fatal

Check connection between main board and
display module.
Replace with new display module.

NOTE A non-display radio emits only the Self Test Fail Tone if it fails the self-test

6-4

6.4

Basic Troubleshooting Operational Error Codes

Operational Error Codes
During radio operation, the radio performs dynamic tests to determine if the radio is working properly.
Problems detected during these tests are presented as error codes on the radio’s display. The
presence of an error code should prompt a user that a problem exists and that a Motorola Authorized
MOTOTRBO dealer should be contacted. Use Table 6-2 to aid in understanding particular
operational error codes.
Table 6-2. Operational Error Codes
Error Code

Description

Error Type

Corrective Action

FAIL 001

Synthesizer Out-of-Lock

NON-FATAL

1. Reprogram the codeplug.
2. Refer to Detailed Service
Manual.

FAIL 002

Personality checksum or
system block error

NON-FATAL

Reprogram the codeplug.

Chapter 7 Accessories

7.1

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

7.1.1

7.1.2

Batteries
Part No.

Description

PMNN4406_

Core Slim Li-Ion Battery (1500 mAH)

PMNN4406_R

Core Slim Li-Ion Battery (1500 mAH) w/box

PMNN4435_R

Li-Mn 1400 mAh low temp -30°C Battery Submersible (IP57)

PMNN4491_

IMPRES Slim Li-Ion IP68 2200T Battery

PMNN4493_

IMPRES Li-Ion IP68 3000T LV Battery

PMNN4488_

IMPRES Li-Ion VIB IP68 3000T LV Battery

PMNN4490_

IMPRES Li-Ion TIA4950 HAZLOC IP68 2900T LV Battery

PMNN4409_R

IMPRES Li-Ion 2250 mAh Battery

PMNN4488_R

IMPRES Ultra Hi-Cap 3000 mAh Battery with Vibrating Belt Clip

PMNN4490_R

IMPRES TIA4950 Hi-Cap 2900 mAh Battery

PMNN4491_R

IMPRES Slim Li-Ion 2050 mAh Battery

PMNN4493_R

IMPRES Ultra Hi-Cap 3000 mAh Battery

Carry Devices
Part No.

Description

PMLN5863_

Hard Leather CC 3in Fixed Limited Keypad

PMLN5864_

Hard Leather CC 3in Fixed Non Display

PMLN5865_

Hard Leather CC 3in Swl Limited Keypad

PMLN5866_

Hard Leather CC 3in Swl Non Display

PMLN5867_

Hard Leather CC 2.5in Swl Limited Keypad

PMLN5868_

Hard Leather CC 2.5in Swl Non Display

PMLN5869_

Nylon Case 3in Fixed Limited Keypad

PMLN5870_

Nylon Case 3in Fixed Non Display

7-2

7.1.3

7.1.4

7.1.5

Accessories: Introduction

Antennas
Part No.

Description

PMAD4117_

VHF Helical Antenna (136–155 MHz)

PMAD4116_

VHF HelicalAntenna (144–165 MHz)

PMAD4118_

VHF Helical Antenna (152–174 MHz)

PMAD4119_

VHF Stubby Antenna (136–148 MHz)

PMAD4120_

VHF Stubby Antenna (146–160 MHz)

PMAD4121_

VHF stubby antenna (152–174 MHz)

PMAE4069_

UHF Stubby Antenna 403–450 MHz

PMAE4070_

UHF Stubby Antenna 440–490 MHz

PMAE4071_

UHF Stubby Antenna 470–512 MHz

PMAE4079_

Slim UHF Whip Antena 403–527 MHz

Service/Replacement Parts
Part No.

Description

66012034001

Chassis and Knob Opener

CPS
Part No.

Description

RVN5115_

CPS MOTOTRBO

Appendix A

A.1

Replacement Parts Ordering

Basic Ordering Information
When ordering replacement parts or equipment information, the complete identification number
should be included. This applies to all components, kits, and chassis. If the component part number
is not known, the order should include the number of the chassis or kit of which it is a part, and
sufficient description of the desired component to identify it.

A.2

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

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
The 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)
1-800-826-1913 Federal Government Parts - Credit Cards Only
8:30 AM to 5:00 PM (Eastern Standard Time)

A.5

Fax Orders
The Radio Products and Solutions Organization*
(United States and Canada)
1-800-622-6210
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
The 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 Motorola 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 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.

B.2

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

B.3

Motorola Canadian Technical Logistics Center
Motorola Canada Ltd.
8133 Warden Avenue
Markham, Ontario, L6G 1B3
Tel: 800-543-3222
Fax: 888-331-9872 or 1-905-948-5970

B.4

Motorola Federal Technical Center
10105 Senate Drive
Lanham, MD 20706
Tel: 1800-969-6680
Fax: 1800-784-4113

B-2

Motorola Service Centers: Motorola Federal Technical Center

Notes

Glossary

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.

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: Pins whose function is programmable.

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 radiofrequency 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.

LED

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

LKP

Limited Keypad Model

MDC

Motorola Digital Communications.

Glossary-2

Term

Definition

MHz

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

NKP

Non Keypad Model

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 predetermined 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.

VIP

Vehicle Interface Port.

Glossary-3

Term

Notes

Definition

ZIF

Zero Insertion Force

XPR

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

Glossary-4

Notes

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.
© 2016 Motorola Solutions, Inc. All rights reserved.
January 2016.
www.motorolasolutions.com/mototrbo

*MN002209A01*
MN002209A01-AA

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