MOTOTRBO XPR 5350/XPR 5550 Mobile Radio Basic Service Manual Series/XPR5350 68009515001 B XPR5350

User Manual: -XPR Series/XPR5350 Basic service manual 68009515001-B

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PROFESSIONAL DIGITAL TWO-WAY RADIO

MOTOTRBO™ MOBILE

XPR™ 5350 NUMERIC DISPLAY MOBILE (WITH BLUETOOTH & GPS)
XPR™ 5550 COLOR DISPLAY MOBILE (WITH BLUETOOTH & GPS)

BASIC SERVICE MANUAL

Foreword
This manual covers all XPR™ 5000 Series Mobiles, unless otherwise specified. It includes all the information necessary to
maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level
of service goes down to the board replacement level and is typical of some local service centers, Motorola Authorized
Dealers, self-maintained customers, and distributors.

!
Caution

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

Product Safety and RF Exposure Compliance

!
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 6881095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, and other accessories, visit the following web site which
lists approved accessories: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.
© 2011, 2012 Motorola Solutions, Inc. All rights reserved.

Notes

iii

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

Description

Date

68009515001-A

Initial Release.

Dec., 2011

68009515001-B

Added UHF2 Band Information.
Updated Table 3-6 Transmitter Performance
Checks, Table 5-4 Color Display Control Head
Exploded View Parts List and Table 5-5 Numeric
Display Control Head Exploded View Parts List.

Dec. 2012

Notes

Table of Contents

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

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

Chapter 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10

Notations Used in This Manual .................................................................................................... 1-1
Radio Description ........................................................................................................................ 1-1
Control Head Description............................................................................................................. 1-2
1.3.1 Control Head Controls (Color Display Model) ................................................................. 1-2
1.3.2 Control Head Controls (Numeric Display Model)............................................................. 1-3
MOTOTRBO Mobile Radio Model Numbering Scheme............................................................... 1-4
VHF High Power (136–174 MHz) Model Chart ........................................................................... 1-5
VHF Low Power (136–174 MHz) Model Chart ........................................................................... 1-6
UHF1 High Power (403–470 MHz) Model Chart ........................................................................ 1-7
UHF1 Low Power (403–470 MHz) Model Chart ........................................................................ 1-8
UHF2 (450–512 MHz) Model Chart ........................................................................................... 1-9
Specifications ........................................................................................................................... 1-10

Chapter 2
2.1
2.2
2.3

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

Recommended Test Equipment .................................................................................................. 2-1
Service Aids ................................................................................................................................. 2-2
Programming Cables ................................................................................................................... 2-3

Chapter 3
3.1
3.2

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

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

General ........................................................................................................................................ 3-1
Setup ........................................................................................................................................... 3-1

Table of Contents

3.3

3.4

Color Display Model Test Mode ................................................................................................... 3-2
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-2
3.3.2 RF Test Mode .................................................................................................................. 3-2
3.3.3 Color Display Test Mode ................................................................................................. 3-3
3.3.4 LED Test Mode................................................................................................................ 3-3
3.3.5 Backlight Test Mode ........................................................................................................ 3-3
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-3
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-3
3.3.8 Audio Loopback Test Mode ............................................................................................. 3-4
3.3.9 Audio Loopback Earpiece Test Mode.............................................................................. 3-4
3.3.10 Button/Knob/PTT Test Mode ........................................................................................... 3-4
Numeric Display Model Test Mode .............................................................................................. 3-4
3.4.1 Entering Display Radio Test Mode .................................................................................. 3-4
3.4.2 RF Test Mode .................................................................................................................. 3-4
3.4.3 Display Test Mode ........................................................................................................... 3-5
3.4.4 LED Test Mode................................................................................................................ 3-5
3.4.5 Speaker Tone Test Mode ................................................................................................ 3-5
3.4.6 Earpiece Tone Test Mode ............................................................................................... 3-5
3.4.7 Audio Loopback Test Mode ............................................................................................. 3-5
3.4.8 Audio Loopback Earpiece Test Mode.............................................................................. 3-5
3.4.9 Button/Knob/PTT Test Mode ........................................................................................... 3-5

Chapter 4
4.1
4.2
4.3
4.4

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

Chapter 5
5.1
5.2
5.3
5.4
5.5
5.6

5.7

5.8

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

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

Introduction .................................................................................................................................. 5-1
Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
Repair Procedures and Techniques – General............................................................................ 5-4
Disassembling and Reassembling the Radio – General.............................................................. 5-5
Radio Disassembly – Detailed ..................................................................................................... 5-5
5.6.1 Control Head Removal .................................................................................................... 5-5
5.6.2 Top Cover Removal......................................................................................................... 5-6
5.6.3 Transceiver Board Removal ............................................................................................ 5-7
5.6.4 Disassembly of Color Display Control Head.................................................................. 5-14
5.6.5 Disassembly of Numeric Display Control Head ............................................................. 5-19
Radio Reassembly – Detailed.................................................................................................... 5-22
5.7.1 Color Display Control Head ........................................................................................... 5-22
5.7.2 Numeric Display Control Head ...................................................................................... 5-27
5.7.3 Radio Assembly............................................................................................................. 5-32
5.7.4 Thermal Pad Replacement Procedure .......................................................................... 5-33
5.7.5 Transceiver Board Reassembly..................................................................................... 5-35
5.7.6 Assemble Control Head to Radio Assembly.................................................................. 5-48
Exploded Mechanical Views and Parts Lists ............................................................................. 5-50
5.8.1 Radio Assembly Exploded View and Parts List ............................................................ 5-50

Table of Contents

5.9

5.8.2 Control Head Exploded Views and Parts Lists .............................................................. 5-52
Torque Chart.............................................................................................................................. 5-54

Chapter 6
6.1
6.2
6.3
6.4

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

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

Chapter 7
7.1

vii

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

Introduction .................................................................................................................................. 7-1
7.1.1 Audio ............................................................................................................................... 7-1
7.1.2 Speakers ......................................................................................................................... 7-1
7.1.3 Desktop Accessories ....................................................................................................... 7-1
7.1.4 Mounting Kits................................................................................................................... 7-2
7.1.5 Cables ............................................................................................................................. 7-2
7.1.6 Antennas ......................................................................................................................... 7-2
7.1.7 Bluetooth ......................................................................................................................... 7-4
7.1.8 Miscellaneous Accessories ............................................................................................. 7-4

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

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

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

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

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

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

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

viii

List of Figures

List of Figures
Figure 1-1
Figure 1-2
Figure 1-3
Figure 2-1
Figure 2-2
Figure 2-3
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-4
Figure 5-5
Figure 5-6
Figure 5-7
Figure 5-8
Figure 5-9
Figure 5-10
Figure 5-11
Figure 5-12
Figure 5-13
Figure 5-14
Figure 5-15
Figure 5-16
Figure 5-17
Figure 5-18
Figure 5-19
Figure 5-20
Figure 5-21
Figure 5-22
Figure 5-23
Figure 5-24
Figure 5-25
Figure 5-26
Figure 5-27
Figure 5-28
Figure 5-29
Figure 5-30
Figure 5-31
Figure 5-32
Figure 5-33
Figure 5-34
Figure 5-35
Figure 5-36
Figure 5-37
Figure 5-38
Figure 5-39
Figure 5-40

Radio Control Head (Color Display Model) .......................................................................... 1-2
Radio Control Head (Numeric Display Model) ..................................................................... 1-3
Mobile Radio Model Numbering Scheme............................................................................. 1-4
Mobile Front Programming Cable HKN6184_...................................................................... 2-3
Mobile & Repeater Rear Programming Cable PMKN4010_ ................................................ 2-3
Mobile & Repeater Rear Accessory Programming and Test Cable PMKN4016_ ................ 2-3
Customer Programming Software Setup from Front Connector .......................................... 4-1
Customer Programming Software Setup from Rear Accessory Connector ......................... 4-2
Customer Programming Software Setup with Test Box Connection .................................... 4-2
Radio Tuning Equipment Setup ........................................................................................... 4-3
Typical Control Head Removal............................................................................................. 5-5
Flexible Connection Removal .............................................................................................. 5-6
Top Cover Removal (Image May Not Match Exact Product)................................................ 5-6
Expansion Board and Flex Removal (Image May Not Match Exact Product) ...................... 5-7
GPS Nameplate Removal .................................................................................................... 5-7
GPS Connector Nut Removal .............................................................................................. 5-8
GPS Cable Removal ............................................................................................................ 5-8
Option Board Removal (Image May Not Match Exact Product) ........................................... 5-9
Acoustic Plug Removal ........................................................................................................ 5-9
Die Cast Main Shield Removal .......................................................................................... 5-10
PA Screw Removal............................................................................................................. 5-11
Accessory Connector Removal .......................................................................................... 5-11
DC Connector Retention Clip Removal.............................................................................. 5-12
RF Connector Nut Removal ............................................................................................... 5-12
Transceiver Board Removal............................................................................................... 5-13
Control Head Flex Removal ............................................................................................... 5-14
Volume/Channel Knob Removal ........................................................................................ 5-14
Control Head Screws and Speaker Removal ..................................................................... 5-15
PCB Retainer Removal ...................................................................................................... 5-15
Control Head Board Removal ............................................................................................ 5-16
Power Button Removal ...................................................................................................... 5-16
Keypad Removal ................................................................................................................ 5-17
Volume Encoder Seal and Mic Jack Seal Removal ........................................................... 5-17
Display Pad Gasket Removal ............................................................................................ 5-18
Color Display Removal from PCB ...................................................................................... 5-18
Control Head Flex Removal ............................................................................................... 5-19
Volume/Channel Knob Removal ........................................................................................ 5-19
Control Head Board Removal ............................................................................................ 5-20
Power Button and Keypad Removal .................................................................................. 5-20
Speaker Removal (Optional) .............................................................................................. 5-21
Volume Encoder Seal and Mic Jack Seal Removal ........................................................... 5-21
Power Button Placement.................................................................................................... 5-22
Keypad Assembly............................................................................................................... 5-22
Assembly to Control Head Housing ................................................................................... 5-23
Assembling Color Display to PCB ...................................................................................... 5-23
Assembling Mic Jack Seal and Display Pad Gasket .......................................................... 5-24
Assembling Control Head Board to Control Head Assembly ............................................. 5-24
Assembling PCB Retainer.................................................................................................. 5-25
Assembling Speaker .......................................................................................................... 5-25
Orientation of Speaker ....................................................................................................... 5-26

List of Figures

Figure 5-41
Figure 5-42
Figure 5-43
Figure 5-44
Figure 5-45
Figure 5-46
Figure 5-47
Figure 5-48
Figure 5-49
Figure 5-50
Figure 5-51
Figure 5-52
Figure 5-53
Figure 5-54
Figure 5-55
Figure 5-56
Figure 5-57
Figure 5-58
Figure 5-59
Figure 5-60
Figure 5-61
Figure 5-62
Figure 5-63
Figure 5-64
Figure 5-65
Figure 5-66
Figure 5-67
Figure 5-68
Figure 5-69
Figure 5-70
Figure 5-71
Figure 5-72
Figure 5-73
Figure 5-74
Figure 5-75
Figure 5-76
Figure 5-77
Figure 5-78
Figure 5-79
Figure 5-80
Figure 5-81
Figure 5-82
Figure 5-83
Figure C-1
Figure C-2

Volume/Channel Knob Assembly....................................................................................... 5-26
Power Button Placement ................................................................................................... 5-27
Keypad Assembly .............................................................................................................. 5-27
Assembly to Control Head Housing ................................................................................... 5-28
Assembling Mic Jack Seal ................................................................................................. 5-28
Assemble Speaker ............................................................................................................. 5-29
Speaker Retainer Assembly............................................................................................... 5-29
Assembling Control Head Board to Control Head Assembly ............................................. 5-30
Screw Sequence ................................................................................................................ 5-30
Volume/Channel Knob Assembly....................................................................................... 5-31
Thermal Pads and Shield Gasketing on Chassis and Die Cast Main Shield ..................... 5-32
Chassis with Thermal Pads................................................................................................ 5-32
Replacing Regulator Thermal Pads ................................................................................... 5-33
Replacing Audio PA Thermal Pad...................................................................................... 5-34
Replacing Final Driver Thermal Pad .................................................................................. 5-34
Applying Thermal Grease .................................................................................................. 5-35
Placing the Transceiver Board in the Chassis ................................................................... 5-35
Inserting DC Retention Clip................................................................................................ 5-36
Inserting RF Lock Washer and Nut .................................................................................... 5-37
Screw Sequence to Compress PCB .................................................................................. 5-37
Installing PA Screws........................................................................................................... 5-38
Inserting Accessory Connector .......................................................................................... 5-38
Assembling Die Cast Main Shield onto Chassis ................................................................ 5-39
Screw Sequence to Tighten Die Cast Main Shield ............................................................ 5-40
RF Connector Nut Final Torque ......................................................................................... 5-40
Acoustic Plug Installation ................................................................................................... 5-41
Inspection of Cover Assembly with Seal ............................................................................ 5-41
Assembling Cover onto Chassis ........................................................................................ 5-42
GPS Cable Installation ....................................................................................................... 5-43
GPS Cable Installation ....................................................................................................... 5-43
Flex Connection Connectors.............................................................................................. 5-44
Expansion Board Assembly ............................................................................................... 5-44
GPS Nameplate Assembly................................................................................................. 5-45
GPS Antenna Connector Assembly ................................................................................... 5-45
Orientation of Option Board Flex to Option Board ............................................................. 5-46
Assemble Option Board to Radio Chassis (Image May Not Match Exact Product) ........... 5-46
Align Option Board to Mounting Holes ............................................................................... 5-47
Assemble O-ring to Chassis (Image May Not Match Exact Product)................................. 5-48
Assemble Control Head to Chassis ................................................................................... 5-48
Flex Connection Connectors.............................................................................................. 5-49
Radio Assembly Exploded View ........................................................................................ 5-50
Color Display Control Head Exploded View....................................................................... 5-52
Numeric Display Control Head Exploded View .................................................................. 5-53
PCB Top Side View ..............................................................................................................C-1
PCB Bottom Side View ........................................................................................................C-2

List of Tables

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

Radio Frequency Ranges and Power Levels ....................................................................... 1-1
Recommended Test Equipment ........................................................................................... 2-1
Service Aids ......................................................................................................................... 2-2
Initial Equipment Control Settings ........................................................................................ 3-1
Front Panel Access Test Mode Displays .............................................................................. 3-2
Test Environments................................................................................................................ 3-6
Test Channel Spacing .......................................................................................................... 3-6
Test Frequencies ................................................................................................................ 3-6
Transmitter Performance Checks......................................................................................... 3-7
Receiver Performance Checks ............................................................................................ 3-8
Radio Software Program Kit................................................................................................. 4-1
Lead Free Solder Wire Part Number List ............................................................................. 5-4
Lead Free Solder Paste Part Number List ........................................................................... 5-4
Radio Exploded View Parts List ......................................................................................... 5-51
Color Display Control Head (PMLN5678_) Exploded View Parts List................................ 5-52
Numeric Display Control Head (PMLN5677_) Exploded View Parts List........................... 5-53
Torque Specifications for Nuts and Screws ........................................................................ 5-54
Power-Up Error Codes ......................................................................................................... 6-2
Operational Error Codes ...................................................................................................... 6-2
Component Parts List.......................................................................................................... C-2

Commercial Warranty

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

XPR Series Digital Mobile Radios

Two (2) Years

Product Accessories

One (1) Year

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

xii

Commercial Warranty

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

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

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

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

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

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

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

Normal and customary wear and tear.

Commercial Warranty

xiii

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

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

xiv

Commercial Warranty

Notes

Chapter 1 Introduction

1.1

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

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

Caution

1.2

Radio Description
The XPR 5000 series mobile radios are available in the following frequency ranges and power
levels.
Table 1-1 Radio Frequency Ranges and Power Levels
Freq. Band

Bandwidth

Power Level

VHF

136–174 MHz

1–25 Watts
25–45 Watts

UHF B1

403–470 MHz

1–25 Watts
25–40 Watts

UHF B2

450–512 MHz

1–40 Watts

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

1-2

Introduction: Control Head Description

1.3

Control Head Description
The control head used with the radio has logic circuitry that operates the standard and optional
features built into the system.
The following illustrations show the typical radio control heads.
Power Button

LED
Indicators

OK/Menu Button

Volume/Channel Knob

LCD Screen

Scroll Up/Down

Speaker
Mic Connector

Programmable Buttons
Return/Home Button
Figure 1-1 Radio Control Head (Color Display Model)

1.3.1

Control Head Controls (Color Display Model)
• POWER BUTTON – Turns the radio on and off.
• VOLUME/CHANNEL KNOB – Rotate clockwise to increase volume level; rotate
counterclockwise to decrease volume level. Push knob to activate channel function; rotate
clockwise and counterclockwise to select channel.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display) – 160x72 display provides visual information about many radio
features.
• OK/MENU BUTTON – One button to provide menu navigation and selection interface.
• PROGRAMMABLE BUTTONS – Four buttons are field programmable using the CPS.
• SCROLL UP/DOWN BUTTONS – Press buttons to scroll.
• RETURN/HOME BUTTON – One button which quickly brings you to the home page.

Introduction: Control Head Description

1-3

Power Button
LED
Indicators

Volume/Channel Knob
LED Display

Mic Connector

P4
Speaker

Programmable Buttons

Figure 1-2 Radio Control Head (Numeric Display Model)

1.3.2

Control Head Controls (Numeric Display Model)
• POWER BUTTON – Turns the radio on and off.
• VOLUME/CHANNEL KNOB – Rotate clockwise to increase volume level; rotate
counterclockwise to decrease volume level. Push knob to activate channel function; rotate
clockwise and counterclockwise to select channel.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LED NUMERIC DISPLAY – Two digit numeric display.
• PROGRAMMABLE BUTTONS – Four buttons are field programmable using the CPS.

1-4

1.4

Introduction: MOTOTRBO Mobile Radio Model Numbering Scheme

MOTOTRBO Mobile Radio Model Numbering Scheme

Model No.Example :
Position

12
Unique Variations
N: Standard Package

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

Version Letter

MOTOTRBO Mobile
XPR 5000 Series : 28
Band
J : 136–174 MHz
M : 217–222 MHz
P : 300–400 MHz
Q : 403–470 MHz
T : 450–512 MHz
X : 450–520 MHz
U : 806–941 MHz
V : 806–870 MHz

Power Level
N: 1–25W
P: 25–40W
Q: 25–45W
R: 1–40W
M: 10–35W
Physical Packages
C: Low Tier (Numeric Display)
H: Mid Tier (Monochrome Display)
N: High Tier (Color Display)

Figure 1-3 Mobile Radio Model Numbering Scheme

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

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

1.5

1-5

VHF High Power (136–174 MHz) Model Chart
VHF 136–174 MHz 25–45W, Mini-U
Model
AAM28JQC9KA1_N
AAM28JQN9KA1_N

Item

Description
136–174 MHz, 25–45W, MOTOTRBO XPR 5350 Numeric Display
Mobile with Bluetooth and GPS
136–174 MHz, 25–45W, MOTOTRBO XPR 5550 Color Display
Mobile with Bluetooth and GPS

Description

X X PMUD2567_S

*Service Kit, VHF, 25–45W

X X PMLN6042_S

Service Kit, Bluetooth and GPS Expansion Board

X X PMLN5718_S

Service Kit, Generic Option Board

Numeric Display Model Control Head

PMLN5677_
X PMLN5678_

X X 68009508001

Color Display Model Control Head
Mobile Quick Reference Guide and Safety Booklet

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

1-6

1.6

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

VHF Low Power (136–174 MHz) Model Chart
VHF 136–174 MHz 1–25W, Mini-U
Model
AAM28JNC9KA1_N
AAM28JNN9KA1_N

Item

Description
136–174 MHz, 1–25W, MOTOTRBO XPR 5350 Numeric Display
Mobile with Bluetooth and GPS
136–174 MHz, 1–25W, MOTOTRBO XPR 5550 Color Display
Mobile with Bluetooth and GPS

Description

X X PMUD2566_S

*Service Kit , VHF, 1–25W

X X PMLN6042_S

Service Kit, Bluetooth and GPS Expansion Board

X X PMLN5718_S

Service Kit, Generic Option Board

Numeric Display Model Control Head

PMLN5677_
X PMLN5678_

X X 68009508001

Color Display Model Control Head
Mobile Quick Reference Guide and Safety Booklet

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

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

1.7

1-7

UHF1 High Power (403–470 MHz) Model Chart
UHF1 403–470 MHz 25–40W, Mini-U
Model
AAM28QPC9KA1_N
AAM28QPN9KA1_N

Item

Description
403–470 MHz, 25–40W, MOTOTRBO XPR 5350 Numeric Display
Mobile with Bluetooth and GPS
403–470 MHz, 25–40W, MOTOTRBO XPR 5550 Color Display
Mobile with Bluetooth and GPS

Description

X X PMUE3649_S

*Service Kit, UHF1, 25–40W

X X PMLN6042_S

Service Kit, Bluetooth and GPS Expansion Board

X X PMLN5718_S

Service Kit, Generic Option Board

Numeric Display Model Control Head

PMLN5677_
X PMLN5678_

X X 68009508001

Color Display Model Control Head
Mobile Quick Reference Guide and Safety Booklet

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

1-8

1.8

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

UHF1 Low Power (403–470 MHz) Model Chart
UHF1 403–470 MHz 1–25W, Mini-U
Model
AAM28QNC9KA1_N
AAM28QNN9KA1_N

Item

Description
403–470 MHz, 1–25W, MOTOTRBO XPR 5350 Numeric Display
Mobile with Bluetooth and GPS
403–470 MHz, 1–25W, MOTOTRBO XPR 5550 Color Display
Mobile with Bluetooth and GPS

Description

X X PMUE3645_S

*Service Kit, UHF1, 1–25W

X X PMLN6042_S

Service Kit, Bluetooth and GPS Expansion Board

X X PMLN5718_S

Service Kit, Generic Option Board

Numeric Display Model Control Head

PMLN5677_
X PMLN5678_

X X 68009508001

Color Display Model Control Head
Mobile Quick Reference Guide and Safety Booklet

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

Introduction: UHF2 (450–512 MHz) Model Chart

1.9

1-9

UHF2 (450–512 MHz) Model Chart
UHF2 450–512 MHz 1–40W, Mini-U
Model
AAM28TRC9KA1_N
AAM28TRN9KA1_N

Item

Description
450–512 MHz, 1–40W, MOTOTRBO XPR 5350 Numeric Display
Mobile with Bluetooth and GPS
450–512 MHz, 1–40W, MOTOTRBO XPR 5550 Color Display
Mobile with Bluetooth and GPS

Description

X X PMUE4140_S

*Service Kit, UHF B2, 1–40W

X X PMLN6042_S

Service Kit, Bluetooth and GPS Expansion Board

X X PMLN5718_S

Service Kit, Generic Option Board

Numeric Display Model Control Head

PMLN5677_
X PMLN5678_

X X 68009508001

Color Display Model Control Head
Mobile Quick Reference Guide and Safety Booklet

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

1-10

Introduction: Specifications

1.10 Specifications
General
Specification
Model:
Channel Capacity:

VHF

UHF1

UHF2

Numeric
Display

Color
Display

Numeric
Display

Color
Display

Numeric
Display

Color
Display

1000

Typical RF Output:
Low Power
High Power

1–25 W
25–45 W

1–25 W
25–40 W

–
1–40 W

Frequency Range:

136–174 MHz

403–470 MHz

450–512 MHz

Dimensions:
(HxWxL)

2.1 x 6.9 x 8.1 in
(53.3 x 175.3 x 205.7 mm)

Weight:

3.9 lbs. (1.8 kg)

Current Drain:
Standby
Rx @ rated audio
Transmit

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

FCC Description:

1–25 W:
ABZ99FT3086
25–45 W:
ABZ99FT3087

1–25 W:
ABZ99FT4087
25–40 W:
ABZ99FT4088

1–40 W:
ABZ99FT4085

IC Description:

1–25 W:
109AB-99FT3086
25–45 W:
109AB-99FT3087

1–25 W:
109AB-99FT4087
25–40 W:
109AB-99FT4088

1–40 W:
109AB-99FT4085

Introduction: Specifications

1-11

Receiver
Specification
Model:

VHF
Numeric
Display

Frequencies:
Channel Spacing:

UHF1
Color
Display

136–174 MHz

Numeric
Display

UHF2
Color
Display

12.5 kHz/25 kHz

12.5 kHz/20 kHz/25 kHz*
0.3 µV
0.22 µV (Typical)

Digital Sensitivity:
(5% BER)

0.25 µV
0.19 µV (Typical)

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

Audio Distortion @
Rated Audio:
Hum and Noise:

Color
Display

450–512 MHz

403–470 MHz

Analog
Sensitivity (12 dB
Sinad):

Intermodulation
TIA603D:

Numeric
Display

78 dB

75 dB

50 dB @ 12.5 kHz,
80 dB @ 25 kHz

50 dB @ 12.5 kHz,
75 dB @ 25 kHz

80 dB

75 dB
3 W (Internal)
7.5 W (External – 8 ohms)
13 W (External – 4 ohms)
3% (Typical)
-40 dB @ 12.5 kHz
-45 dB @ 20/25 kHz

Audio Response:

TIA603D

Conducted
Spurious Emission
(TIA603D):

-57 dBm

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

*Note: 20 kHz/25 kHz for Industry Canada only. UHF2 excludes 20 kHz.

1-12

Introduction: Specifications

Transmitter
Specification
Model:

VHF
Numeric
Display

Frequencies:
Channel Spacing:

UHF1
Color
Display

136–174 MHz

Color
Display

403–470 MHz

12.5 kHz/20 kHz/25 kHz*

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

Numeric
Display

UHF2
Numeric
Display

Color
Display

450–512 MHz
12.5 kHz/25 kHz

±0.5 ppm

1–25 W
25–45 W

1–25 W
25–40 W

–
1–40 W

Modulation
Limiting:

±2.5 kHz @ 12.5 kHz
±4.0 kHz @ 20 kHz
±5.0 kHz @ 25 kHz

±2.5 kHz @ 12.5 kHz
±5.0 kHz @ 25 kHz

FM Hum and Noise:

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

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

Conducted/
Radiated
Emission:

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

Adjacent
Channel Power
(TIA603D):

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

60 dB @ 12.5 kHz
70 dB @ 25 kHz

Audio Response:

TIA603D

Audio Distortion:

FM Modulation
4FSK Digital
Modulation

12.5 kHz: 11K0F3E
25 kHz: 16K0F3E
12.5 kHz Data: 7K60F1D & 7K60FXD
12.5 kHz Voice: 7K60F1E & 7K60FXE
Combination of 12.5 kHz Voice & Data: 7K60F1W

Digital Vocoder
Type:

AMBE+2™

Digital Protocol:

ETSI TS 102 361-1
ETSI TS 102 361-2
ETSI TS 102 361-3

*Note: 20 kHz/25 kHz for Industry Canada only. UHF2 excludes 20 kHz.

Introduction: Specifications

1-13

Self-Quieter
VHF

UHF1

UHF2

–

489.000 MHz

GPS
Specification
Model:

VHF
Numeric
Display

UHF1
Color
Display

Numeric
Display

Color
Display

UHF2
Numeric
Display

Color
Display

Accuracy specs are for long-term tracking (95th percentile values > 5 satellites
visible at a nominal -130 dBm signal strength).
TTFF (Time to First
Fix) Cold Start:

< 1 minute

TTFF Hot Start:

< 10 seconds

Horizontal
Accuracy:

< 5 meters

Bluetooth®
Specification
Model:

VHF
Numeric
Display

UHF1
Color
Display

Numeric
Display

Color
Display

UHF2
Numeric
Display

Version:

Supports Bluetooth 2.1 + EDR Specification.

Range:

Class 2, 10 meters

Color
Display

1-14

Introduction: Specifications

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

MIL-STD 810D

MIL-STD 810E

MIL-STD 810F

MIL-STD 810G

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

Proc./Cat

Low
Pressure

500.1

500.2

500.3

500.4

500.5

High
Temperature

501.1

I, II

501.2

I/A1,
II/A1

501.3

I/A,
II/AI

501.4

I/HOT,
II/HOT

501.5

I/AI, II

Low
Temperature

502.1

502.2

I/C3,
II/C1

502.3

I/C3,
II/C1

502.4

I/C3,
II/C1

502.5

I/C3, II

Temperature
Shock

503.1

–

503.2

I/A1/C3

503.3

I/AI/C3

503.4

503.5

I/C

Solar
Radiation

505.1

505.2

505.3

505.4

505.5

I/A1

Rain

506.1

I, II

506.2

I, II

506.3

I, II

506.4

I, III

506.5

I, III

Humidity

507.1

507.2

507.3

507.4

–

507.5

II - Aggravated

Salt Fog

509.1

–

509.2

–

509.3

–

509.4

–

509.5

–

Dust

510.1

510.2

510.3

510.4

510.5

Vibration

514.2

VIII/F,
Curve-W

514.3

I/10,
II/3

514.4

I/10,
II/3

514.5

I/24

514.6

I/24

Shock

516.2

I, II

516.3

I, IV

516.4

I, IV

516.5

I, IV

516.6

I, IV,
V, VI

Environmental Specifications
Operating Temperature

-30°C to +60°C

Storage Temperature

-40°C to +85°C

Temperature Shock

Per MIL-STD

Humidity

Per MIL-STD

ESD
Water and Dust Intrusion

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

Chapter 2 Test Equipment and Service Aids

2.1

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

Equipment

Characteristic

Example

Application

Service Monitor

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

Aeroflex 2945B, Aeroflex 3920,
or equivalent

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

Digital RMS
Multimeter*

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

Fluke 179 or equivalent
(www.fluke.com)

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

RF Signal
Generator*

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

Agilent N5181
(www.agilent.com) or equivalent

Receiver measurements

Oscilloscope*

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

Tektronix TDS1001b
(www.tektronix.com) or
equivalent

Waveform measurements

Power Meter and
Sensor*

5% Accuracy
100 MHz to 500 MHz
50 Watts

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

Transmitter power output
measurements

RF Millivolt Meter

100 mV to 3 V RF
10 kHz to 1 GHz

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

RF level measurements

Power Supply

0 V to 32 V
0 A to 20 A

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

Voltage supply

2-2

2.2

Test Equipment and Service Aids: Service Aids

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

Description

Application

RLN4460_

Test Set

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

RVN5115_

Customer Programming
Software on CD-ROM

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

PMKN4010_

Mobile & Repeater Rear
Programming Cable

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

PMKN4016_

Mobile & Repeater Rear
Accessory Programming and
Test Cable

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

PMKN4018_

Mobile & Repeater Rear
Accessory Connector Universal
Cable

Connects the radio’s rear connector to accessory
devices such as desk sets. Cable contains all 26 wires
and is unterminated at the user end.

HKN6184_

Mobile Front Programming Cable

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

HPN4007_

Power Supply

Provides the radio with power when bench testing.

PMEN4027_

Housing Eliminator

Test Fixture used to bench test the radio PCB.

6686119B01

Control Head Dismantling Tool

Assists in the removal of radio control head.

66012025001

Volume/Channel Knob Removal
Tool

Assists in the removal of the Volume/Channel knob.

66012020001

RFIC (U0000) Repair Stencil

Fixture to screen solder paste onto the IC leads for
replacement.

Test Equipment and Service Aids: Programming Cables

2.3

2-3

Programming Cables

Figure 2-1 Mobile Front Programming Cable HKN6184_

Figure 2-2 Mobile & Repeater Rear Programming Cable PMKN4010_

DB 25 CONNECTOR
1

13
1

USB CONNECTOR

TABLE 2-3: WIRE DIAGRAM
26 PIN
ACCESSORY PORT CONNECTOR

915±15
CABLE
1455±24
CABLE

TO MOBILE RADIO
ACCESSORY
CONNECTOR

1
2

25
26

VIEWED FROM
FRONT (PIN END)
OF CONNECTOR

USB

PIN
NO.

DESCRIPTION

VCC (5v)

DATA -

DATA +

GND

DRAIN WIRE AND BRAID

SHELL

DB25P

4
9

SPEAKER -

EXT MIC

DIGI IN I
(EXT PTT)

GND

SPEAKER +

Figure 2-3 Mobile & Repeater Rear Accessory Programming and Test Cable PMKN4016_

2-4

Test Equipment and Service Aids: Programming Cables

Notes

Chapter 3 Transceiver Performance Testing

3.1

General
These radios meet published specifications through their manufacturing process by utilizing
high-accuracy laboratory-quality test equipment. The recommended field service equipment
approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must
be maintained in compliance with the manufacturer’s recommended calibration schedule.
NOTE: 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 13.8 VDC power supply. (Note: applying 13.8 VDC at the DC
power cable will ensure a minimum of 13.2 VDC at the DC connector of the radio). The equipment
required for alignment procedures is shown in the Radio Tuning Equipment Setup Diagram,
Figure 4-4.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number

Title

3-2

Front Panel Access Test Mode Displays

3-3

Test Environments

3-4

Test Channel Spacing

3-5

Test Frequencies

3-6

Transmitter Performance Checks

3-7

Receiver Performance Checks

Table 3-1 Initial Equipment Control Settings
Service Monitor

Power Supply

Test Set

Monitor Mode: Power Monitor

Voltage: 13.8 VDC

Speaker set: A

RF Attenuation: -70

DC On/Standby:
Standby

Speaker/load:
Speaker

AM, CW, FM: FM

Volt Range: 20 V

PTT: OFF

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

Current: 20 A

3-2

Transceiver Performance Testing: Color Display Model Test Mode

3.3

Color Display Model Test Mode

3.3.1

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

Description

Appears

Service Mode

The literal string indicates the radio has entered test mode.

Always

Host Version

The version of host firmware.

Always

DSP Version

The version of DSP firmware.

Always

Model Number

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

Always

MSN

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

Always

FLASHCODE

The FLASH codes as programmed in the codeplug.

Always

RF Band

The radio’s band.

Always

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

3.3.2

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

Transceiver Performance Testing: Color Display Model Test Mode

3-3

3. Push and hold in the Volume/Channel knob for approximately two seconds to enter the
Channel mode. Turn the Volume/Channel knob clockwise to increase from channel 1 to
channel 14 or counterclockwise to decrease the channel number. The radio beeps in each
position. The channel test frequencies are described in Table 3-5.
NOTE: The Volume/Channel knob will stay in Channel mode until the Volume/Channel knob is
pushed in momentarily. This is not the case in normal operation.

3.3.3

Color Display Test Mode
1. Press and hold button P1 in RF Test Mode. The radio beeps once and momentarily displays
‘Display Test Mode’.
2. On the next button press, the negative image of Display Test Mode will appear.
3. With each successive button press, the display background will change from Red, to Green,
and then to Blue.
4. With each successive button press, a horizontal bar will increase in size and change color,
from Red, to Green, to Blue, to Black, back to Red, to Green, to Blue, to Black, and finally, the
entire display background will change to Red.
5. With each successive button press, vertical bars will grow and change color, from Red, to
Green, to Blue, to Black, back to Red, and finally, the entire display background will change to
Green.
6. On the next button press, the display will clear and 12 icons will appear at the top of the
display.

3.3.4

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

3.3.5

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

3.3.6

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

3.3.7

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

3-4

3.3.8

Transceiver Performance Testing: Numeric Display Model Test Mode

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

3.3.9

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

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

3.4

Numeric Display Model Test Mode

3.4.1

Entering Display Radio Test Mode
1. Turn the radio on.
2. Within ten seconds after self test is complete, press button P2, five times in succession.
3. The radio beeps.

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 button P2 changes the test environment
(CSQ->TPL->DIG->USQ->CSQ). The radio beeps once when radio toggles to CSQ, beeps
twice for TPL, beeps three times for DIG and beeps four times for USQ.
NOTE: DIG is digital mode and other test environments are analog mode as described in
Table 3-3.
2. Each short press of button P1 toggles the channel spacing between 20 kHz, 25 kHz and
12.5 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.
3. Push and hold in the Volume/Channel knob for approximately two seconds to enter the
Channel mode. Turn the Volume/Channel knob clockwise to increase from channel 1 to
channel 14 or counterclockwise to decrease the channel number. The radio beeps in each
position. The channel test frequencies are described in Table 3-5.
NOTE: The Volume/Channel knob will stay in Channel mode until the Volume/Channel knob is
pushed in momentarily. This is not the case in normal operation.

Transceiver Performance Testing: Numeric Display Model Test Mode

3.4.3

3-5

Display Test Mode
1. Press and hold button P1 in RF Test Mode. The radio beeps once and enters
‘Display Test Mode’.
2. Upon entering Display Test Mode, press any button to turn on the two character seven
segment display.

3.4.4

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

3.4.5

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

3.4.6

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

3.4.7

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

3.4.8

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

3.4.9

Button/Knob/PTT Test Mode
1. Press and hold button P1 after Audio Loopback Earpiece Test Mode. The radio beeps once.
2. Rotate the volume knob, the radio beeps at each position.
3. Press any button, the radio beeps.
4. The radio must be powered off to end Test Mode.

3-6

Transceiver Performance Testing: Numeric Display Model Test Mode

Table 3-3 Test Environments
No. of
Beeps

Description

Function

Carrier Squelch
(CSQ)

RX: unsquelch if carrier detected
TX: mic audio

Tone Private-Line
(TPL)

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

Digital
(DIG)

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

Unsquelch
(USQ)

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

Channel Spacing

20 kHz

25 kHz

12.5 kHz

Table 3-5 Test Frequencies
Test Mode

Test Channel
Low Power

Test Channel
High Power

VHF
(MHz)

UHF1
(MHz)

UHF2
(MHz)

136.075

403.000

450.000

136.075

403.000

450.000

142.575

414.150

462.800

142.575

414.150

462.800

146.575

425.350

475.700

146.575

425.350

475.700

155.575

436.500

488.500

155.575

436.500

488.500

161.575

447.675

501.300

161.575

447.675

501.300

167.575

458.850

514.200

167.575

458.850

514.200

174.975

470.000

527.000

174.975

470.000

527.000

Transceiver Performance Testing: Numeric Display Model Test Mode

3-7

Table 3-6 Transmitter Performance Checks
Test Name

Communications
Analyzer

Radio

Test Set

Comment

Reference
Frequency

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

TEST MODE,
Test Channel 4,
carrier squelch

PTT to
continuously
transmit (during
the performance
check)

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

Power RF

As above

TEST MODE
Test Channel 4,
carrier squelch

As above

Low Power Set:
1.0–1.3 W: (VHF 1–25 W,
UHF1 1–25 W,
UHF2 1–40 W)
25–29 W: (VHF 25–45 W,
UHF1 25–40 W)

TEST MODE
Test Channel 11,
carrier squelch

High Power Set:
25–29 W: (VHF 1–25 W,
UHF1 1–25 W)
40–47 W: (UHF1 25–40 W,
UHF2 1–40 W)
45–53 W: (VHF 25–45 W)
Voice
Modulation

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

TEST MODE
Test Channel 4,
carrier squelch

As above, meter
selector to mic

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

Voice
Modulation
(internal)

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

TEST MODE,
Test Channel 4
carrier squelch
output at
antenna

Remove
modulation input

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

TPL
Modulation

As above
4th channel test frequency*
BW to narrow

TEST MODE,
Test Channel 4
TPL

As above

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

* See Table 3-5

3-8

Transceiver Performance Testing: Numeric Display Model Test Mode

Table 3-7 Receiver Performance Checks
Communications
Analyzer

Test Name

Radio

Test Set

Comment

Rated Audio

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

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

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

Set volume control
to 7.75 Vrms

Distortion

As above, except to
distortion

As above

Distortion <5.0%

Sensitivity
(SINAD)

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

As above

PTT to OFF
(center)

RF input to be
<0.3 µV

RF level set to 1 mV RF

As above

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

Set volume control
to 7.75 Vrms

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

out of TEST
MODE; select a
conventional
system

As above

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

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

* See Table 3-5

Chapter 4 Radio Programming and Tuning

4.1

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

MOTOTRBO CPS, Tuner and AirTracer Applications CD

RVN5115_

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

Front Connector

ACC

R a d io

4.2

Description

DC
RF

13.8VDC
Power
Supply

Mobile Front Programming Cable HKN6184_

USB

Figure 4-1 Customer Programming Software Setup from Front Connector

4-2

Radio Programming and Tuning: AirTracer Application Tool

Radio

ACC

Rear Accessory
Connector

Mobile & Repeater Rear
Programming Cable PMKN4010_

DC
RF

13.8 VDC
Power
Supply

USB

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

Radio

ACC

Mobile & Repeater Rear Accessory
Programming and Test Cable PMKN4016_

Rear Accessory
Connector

Test Box RLN4460_
No
Connection

DC
RF

13.8 VDC
Power
Supply

USB

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

4.3

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

Radio Programming and Tuning: Radio Tuning Setup

Radio Tuning Setup
A personal computer (PC), Windows 7/Vista/XP and a tuner program (which is available as part of
the MOTOTRBO CPS kit) are required to tune the radio. To perform the tuning procedures, the radio
must be connected to the PC and test equipment setup as shown in Figure 4-4.
Audio In
Test Box
RLN44 60_

Audio Generator

SINAD Meter
AC Voltmeter

Mobile & Repeater Rear Accessory
Programming and Test Cable PMKN4016_
ACC
R a d io

4.4

4-3

13. 8 V D C
Power
Supply

30 dB Pad

Mini UHF
to BNC Adaptor
(if needed)

USB

Service Monit o r

RF Generator

Figure 4-4 Radio Tuning Equipment Setup

WATT meter

4-4

Radio Programming and Tuning: Radio Tuning Setup

Notes

Chapter 5 Disassembly/Reassembly Procedures

5.1

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

5.2

Preventive Maintenance
Periodic visual inspection and cleaning is recommended.

5.2.1

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

5.2.2

Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the control
head and housing assembly. These surfaces should be cleaned whenever a periodic visual
inspection reveals the presence of smudges, grease, and/or grime.
NOTE: Internal surfaces should be cleaned only when the radio is disassembled for service or repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (100% by volume).

!
Caution

Use all chemicals as prescribed by the manufacturer. Be sure to follow all
safety precautions as defined on the label or material safety data sheet.
The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
chemicals.

5-2

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

Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
Cleaning Internal Circuit Boards and Components
Isopropyl alcohol (100%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge
embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the
dislodged material out and away from the inside of the radio. Make sure that controls or tunable
components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process
since this could cause the liquid to collect in unwanted places. Once the cleaning process is
complete, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, control head and housing assembly.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).

5.3

Safe Handling of CMOS and LDMOS Devices
Complementary Metal Oxide Semiconductor (CMOS) and Laterally Diffused Metal Oxide
Semiconductor (LDMOS) devices are used in this family of radios, and are susceptible to damage by
electrostatic or high voltage charges. Damage can be latent, resulting in failures occurring weeks or
months later. Therefore, special precautions must be taken to prevent device damage during
disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS/LDMOS circuits and are especially important in low
humidity conditions.

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

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

!
Caution

This radio contains static-sensitive devices. Do not open the radio unless you are
properly grounded. Take the following precautions when working on this unit:

• Store and transport all CMOS/LDMOS devices in conductive
material so that all exposed leads are shorted together. Do not insert
CMOS/LDMOS devices into conventional plastic “snow” trays used
for storage and transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the
CMOS/LDMOS device. We recommend using a wrist strap, two
ground cords, a table mat, a floor mat, ESD shoes, and an ESD
chair.
• Wear a conductive wrist strap in series with a 100k resistor to
ground. (Replacement wrist straps that connect to the bench top
covering are Motorola part number 4280385A59).
• Do not wear nylon clothing while handling CMOS/LDMOS devices.
• Do not insert or remove CMOS/LDMOS devices with power applied.
Check all power supplies used for testing CMOS/LDMOS devices to
be certain that there are no voltage transients present.
• When straightening CMOS/LDMOS pins, provide ground straps for
the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS/LDMOS devices by the package and
not by the leads. Prior to touching the unit, touch an electrical
ground to remove any static charge that you may have
accumulated. The package and substrate may be electrically
common. If so, the reaction of a discharge to the case would cause
the same damage as touching the leads.

5-3

5-4

5.4

Disassembly/Reassembly Procedures: Repair Procedures and Techniques – General

Repair Procedures and Techniques – General
NOTE

Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards – examples shown below) were developed and assembled using environmentally
preferred components and solder assembly techniques to comply with the European
Union’s Restriction of Hazardous Substances (ROHS) 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%

217°C

52171

0.015”

1lb spool

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

Manufacturer Part
Number

1085674C03

NC-SMQ230

Viscosity

Type

Composition & Percent Metal

900–1000KCPs
Brookfield (5rpm)

Type 3
(-325/+500)

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

Liquid
Temperature
217°C

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

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

5.5

5-5

Disassembling and Reassembling the Radio – General
Since these radios may be disassembled and reassembled with the use of only ten screws (board to
casting), it is important to pay particular attention to the snaps and tabs, and how parts align with
each other.
The following tools are required for disassembling and assembling the radio:
• Small Flat Blade Screwdriver
• Control Head Dismantling Tool (Motorola Part No. 6686119B01)
• Volume/Channel Knob Removal Tool (Motorola Part No. 66012025001)
• Torque Driver (2-36 lbs-in or 0.2-4.0 N-m), (Motorola Part No. RSX4043A)
• TORX™ T10 Driver Bit (Motorola Part No. 6680387A74)
• TORX™ T8 Driver Bit (Motorola Part No. 6680387A72)
• TORX™ T6 Driver Bit (Motorola Part No. 6680387A70 - for use with GPS Models and Option
Board only)
• 5/16” or 8 mm Socket Driver (GPS Models Only)
• 9/16” Deep Socket Driver (RF Connector Nut)
If a unit requires more complete testing or service than is customarily performed at the basic level,
please send radio to a Motorola Service Center listed in Appendix B.
The following disassembly procedures should be performed only if necessary.

5.6

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

5.6.1

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

Dismantling
Tool

Figure 5-1 Typical Control Head Removal

5-6

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

3. Pull the control head away from the radio assembly as shown in Figure 5-2.

Expansion Board
Flex Cable

Control Head Seal
Option Board

Figure 5-2 Flexible Connection Removal
4. Remove the flex cable from the socket on the radio assembly as shown in Figure 5-2.
5. Then remove control head seal, if required.

5.6.2

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

Dismantling
Tool

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

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5.6.3

5-7

Transceiver Board Removal
GPS Antenna Connector Removal
1. Using a T6 TORX™ driver, remove the screws securing the expansion board to the chassis.
2. Unplug the GPS cable MCX connector from the expansion board.
NOTE: Disconnect the MCX connector by grabbing and pulling on the MCX connector body and not
the GPS cable itself.
3. Unplug the flex from the transceiver board.
Expansion Board Flex

Expansion Board

To
R

MCX Connector
Screws
Figure 5-4 Expansion Board and Flex Removal (Image May Not Match Exact Product)
NOTE: Skip steps 4 through 6 if GPS cable and nameplate do not require servicing.
4. Use a flat-blade screwdriver to lift the GPS nameplate from the chassis. See Figure 5-5.
NOTE: If the GPS nameplate is removed it will need to be replaced.

GPS Nameplate

Figure 5-5 GPS Nameplate Removal

5-8

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5. Using a 5/16” or 8 mm socket driver, remove the nut from the GPS antenna connector and
remove the lock washer from the connector. See Figure 5-6.

GPS Antenna Connector

Figure 5-6 GPS Connector Nut Removal
6. Remove the GPS cable from the chassis by pulling on the GPS cable strain relief.

Pull on GPS Cable Strain Relief
in This Direction

GPS Cable Strain Relief

Figure 5-7 GPS Cable Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

Option Board Removal
7. Using a T6 TORX™ driver, remove the screws securing the option board to the chassis.
8. Unplug the flex from the transceiver board.

Option Board Flex

Option Board
Screws
Figure 5-8 Option Board Removal (Image May Not Match Exact Product)

Transceiver Board Removal
9. Remove the acoustic plug by pulling up on it.

Acoustic Plug

Figure 5-9 Acoustic Plug Removal

5-9

5-10

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

10. Remove the nine main shield screws from the die cast main shield and the PCB screw
directly on the PCB using the T10 TORX™ driver as shown in Figure 5-10.
11. Lift the die cast main shield from the chassis.

Die Cast
Main Shield

Main Shield
Screws (9)

Radio
Chassis
PCB Screw (1)

Figure 5-10 Die Cast Main Shield Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-11

12. Remove the two screws from the PCB using the T8 TORX™ driver as shown in Figure 5-11.
NOTE: Do not remove the washers from the screws.
Screws (2)
Radio
Chassis

Figure 5-11 PA Screw Removal
13. Remove the accessory connector from the radio assembly by inserting a flat-blade
screwdriver into the slot on the top of the connector as shown in Figure 5-12.

!
Caution

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

Slot

Insert Flat-blade
Screwdriver Here

Accessory
Connector

Figure 5-12 Accessory Connector Removal

5-12

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

14. Remove the DC Connector retention clip by gently prying it out with a flat-blade screwdriver
as shown in Figure 5-13.

DC Retention Clip

Flat-blade
Screwdriver

Figure 5-13 DC Connector Retention Clip Removal
15. Remove the RF connector nut and lock washer using a 9/16” deep socket driver
(Figure 5-14).

RF Connector Nut

Figure 5-14 RF Connector Nut Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-13

16. Remove the transceiver board by sliding a finger into the opening provided at the front of the
radio and gently pressing up on the PCB between the connectors, lifting up the front of the
transceiver board, as shown in Figure 5-15. Then, slide the transceiver board towards the
front of the radio to allow the RF/DC connectors to clear the chassis. Handle the transceiver
board by the edges only and store it in an antistatic bag.
NOTE: If the RF/DC connector gaskets remain in the chassis, remove them and place them back on
the connectors. Every time the Transceiver Board is removed, the Final Driver Thermal Pad
must be replaced.

!
Caution

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

Figure 5-15 Transceiver Board Removal

5-14

5.6.4

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

Disassembly of Color Display Control Head
1. Disconnect the speaker plug from the control head board.
2. Unplug the control head flex from the control head board by gently pulling the flex out of the
connector.

To
R
ad
io

Control Head Flex
Speaker Connector

Figure 5-16 Control Head Flex Removal
3. Remove the volume/channel knob from the control head housing by lifting it with the volume/
channel knob removal tool.
Housing Assembly

Volume/Channel Knob

Figure 5-17 Volume/Channel Knob Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-15

4. Remove the five screws from the control head board using the T10 TORX™ driver.
5. Remove the speaker.
NOTE: Remove the speaker retainer only if required.

Speaker
Screws
Speaker Retainer

Figure 5-18 Control Head Screws and Speaker Removal
6. Gently spread the side walls of the control head housing to release the PCB retainer tabs
from the housing.

Gently Spread Housing

PCB Retainer
Figure 5-19 PCB Retainer Removal

5-16

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

7. Remove the control head board from the control head assembly by pressing on the keypad
buttons and mic jack. Handle the control head board by the edges only and store it in an
antistatic bag.
NOTE: Do not touch or contaminate the conductive contacts on the control head PCB.

Control Head Board

Figure 5-20 Control Head Board Removal
8. Remove the power button by lifting it from the control head housing.
9. Separate the light barrier from the power button, if required.

Control Head Housing
Power Button

Light Barrier

Figure 5-21 Power Button Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-17

10. Separate the keypad from the keypad frame.
11. Remove the keypad frame from the control head board by compressing the retaining latch
features.

Control Head
Board

Keypad Frame

Keypad
Figure 5-22 Keypad Removal
12. Separate the volume encoder seal and mic jack seal from the control head board.

Volume Encoder Seal
Mic Jack Seal

Figure 5-23 Volume Encoder Seal and Mic Jack Seal Removal

5-18

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

13. Separate the display pad gasket from the color display.
Color Display

Display Pad Gasket

Figure 5-24 Display Pad Gasket Removal
14. Disconnect the display flex from the connector on the PCB.
15. Gently pull or lift on one side of the display to slowly separate the display from the adhesive.

Display Adhesive

Control Head Board

Color Display

Figure 5-25 Color Display Removal from PCB

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5.6.5

5-19

Disassembly of Numeric Display Control Head
1. Disconnect the speaker plug from the control head board.
2. Unplug the control head flex from the control head board by gently pulling the flex out of the
connector.

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Control Head Flex
Speaker Connector
Figure 5-26 Control Head Flex Removal
3. Remove the volume/channel knob from the control head housing by lifting it with the volume/
channel knob removal tool.

Housing Assembly

Volume/Channel Knob

Figure 5-27 Volume/Channel Knob Removal

5-20

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

4. Remove the seven screws from the control head board using the T10 TORX™ driver.
5. Remove the control head board from the control head assembly by pressing on the mic jack.
Handle the control head board by the edges only and store it in an antistatic bag.
NOTE: Do not touch or contaminate the conductive contacts on the control head board.

Control Head Board
Screws
Figure 5-28 Control Head Board Removal
6. Remove the power button by lifting it from the control head housing.
7. Separate the light barrier from the power button, if required.
8. Remove the keypad assembly from the control head housing by pushing on the keypad.
9. Separate the keypad from the keypad frame.
Control Head Housing
Power Button

Light Barrier

Keypad
Keypad Frame
Figure 5-29 Power Button and Keypad Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5-21

10. Optional: If required, the speaker can be removed by removing the speaker retainer from the
control head housing using the T10 TORX™ driver to remove the screw and unhook the
retainer from the control head housing.
11. Remove the speaker from the control head housing.
NOTE: Remove the speaker retainer only if required.

Speaker Retainer

Screw
Speaker

Figure 5-30 Speaker Removal (Optional)
12. Separate the volume encoder seal and mic jack seal from the control head board.

Volume Encoder Seal

Mic Jack Seal

Figure 5-31 Volume Encoder Seal and Mic Jack Seal Removal

5-22

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7

Radio Reassembly – Detailed

5.7.1

Color Display Control Head
1. Assemble the power button and light barrier and then place the subassembly inside the
control head housing. Refer to Figure 5-32.
Control Head Housing
Power Button

Light Barrier

Figure 5-32 Power Button Placement
2. Assemble the keypad to the keypad frame. Refer to Figure 5-33.
a. If attached to the control head board, remove by compressing the retaining latch features.

Keypad
Frame

Keypad

Figure 5-33 Keypad Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-23

3. Assemble the keypad frame assembly and volume encoder seal to the control head housing
until fully seated. Refer to Figure 5-34.

Volume Encoder
Seal

Keypad Frame Assembly
Figure 5-34 Assembly to Control Head Housing
4. Align the color display alignment pins to the PCB holes.
5. Firmly press along the outer perimeter of the display to activate the adhesion of the display to
the display adhesive.
6. Connect the display flex to the connector on the PCB.

Display Adhesive

Control Head Board
Color Display

Figure 5-35 Assembling Color Display to PCB

5-24

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

7. Assemble the mic jack seal around the mic jack as shown in Figure 5-36. Be sure to place
mic jack seal flush to the PCB.
NOTE: Make sure the mic jack is free from dust or debris.
8. Assemble the display pad gasket to the display.

Mic Jack
Mic Jack Seal

Display Pad Gasket

Figure 5-36 Assembling Mic Jack Seal and Display Pad Gasket
9. Assemble the control head flex to the mating connector on the control head board, making
sure it is fully seated as shown in Figure 5-37.
10. Assemble the control head board to the control head assembly.

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Control Head Flex

Control Head Board
Figure 5-37 Assembling Control Head Board to Control Head Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-25

11. Assemble the PCB retainer to the control head assembly until it is fully seated. You will need
to feed the control head flex through the PCB retainer.

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PCB Retainer

Figure 5-38 Assembling PCB Retainer
12. Assemble the speaker retainer to the speaker. It will snap over the speaker magnet. See
Figure 5-39.
NOTE: Be sure to orient the speaker in the direction of the wire and connector towards the middle of
the control head. See Figure 5-40.
13. Assemble the speaker to the control head assembly. Assemble the screws in a cross pattern
with the single PCB screw installed last.
14. Connect the speaker plug to its mating connector on the control head board.

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Speaker
Speaker Retainer

Figure 5-39 Assembling Speaker

Screws

5-26

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Speaker Terminal

Speaker Connector

Figure 5-40 Orientation of Speaker
15. Orientate the volume/channel knob so that the internal D-shaped opening matches the
volume encoder shaft and press the volume/channel knob into the control head assembly
until it is fully seated and the knob rotates freely. Refer to Figure 5-41.

Volume Encoder Shaft
Volume/Channel Knob

Housing Assembly

Figure 5-41 Volume/Channel Knob Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.2

5-27

Numeric Display Control Head
1. Assemble the power button and light barrier and then place the subassembly inside the
control head housing. Refer to Figure 5-42.

Control Head Housing
Power Button
Light Barrier

Figure 5-42 Power Button Placement
2. Assemble the keypad to the keypad frame. Refer to Figure 5-43.
Note Orientation of Keypad to Keypad Frame
Alignment Feature

Keypad Frame
Lettering Should Read Left To Right

P4 Key (Red)

Figure 5-43 Keypad Assembly

Keypad

5-28

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

3. Assemble the keypad frame assembly and volume encoder seal to the control head housing
until they are fully seated. Refer to Figure 5-44.

Volume Encoder Seal

Keypad Frame Assembly
Figure 5-44 Assembly to Control Head Housing
4. Assemble the mic jack seal around the mic jack as shown in Figure 5-45. Be sure to place
mic jack seal flush to the PCB.
NOTE: Make sure the mic jack is free from dust or debris.

Mic Jack
Mic Jack Seal

Figure 5-45 Assembling Mic Jack Seal

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-29

5. Assemble the speaker retainer to the speaker. It will snap over the speaker magnet. See
Figure 5-46.
NOTE: Be sure to orient the speaker in the direction of the wire and connector towards the middle of
the control head.
6. Assemble the speaker to the control head assembly.

Speaker

Speaker Retainer
Screw

Figure 5-46 Assemble Speaker
7. Hook one side of the speaker retainer into the control head assembly as shown in
Figure 5-47.
8. Place a screw into the other end of the speaker retainer and using a T10 TORX™ driver,
tighten the screw to 0.88 N-m (7.8 lbs-in).

Hook Retainer Here
Figure 5-47 Speaker Retainer Assembly

5-30

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

9. Assemble the control head flex to the mating connector on the control head board, making
sure it is fully seated as shown in Figure 5-48.
10. Assemble the control head board to the control head assembly.

Screws

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Control Head Board

Figure 5-48 Assembling Control Head Board to Control Head Assembly
11. Using a T10 TORX™ driver, tighten the seven screws to 0.88 N-m (7.8 lbs-in) following the
sequence as shown in Figure 5-49.
12. Connect the speaker plug to its mating connector on the control head board.

Figure 5-49 Screw Sequence

2
4

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-31

13. Orientate the volume/channel knob so that the internal D-shaped opening matches the
volume encoder shaft and press the volume/channel knob into the control head assembly
until it is fully seated and the knob rotates freely. Refer to Figure 5-50.

Volume Encoder Shaft

Volume/Channel Knob

Housing Assembly

Figure 5-50 Volume/Channel Knob Assembly

5-32

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.3

Radio Assembly
1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks,
cuts, etc.) or debris. Refer to the exploded view and bill of materials for the correct part
numbers and replace parts, as necessary. Replace all new seals on their respective parts.
For both the die cast main shield and the chassis, thoroughly inspect the shield gasketing for
damage and verify all thermal pads are in place and free from damage and debris. See
Section 5.7.4: Thermal Pad Replacement Procedure on page 5-33 to replace damaged pads.

Die Cast Main Shield
and Shield Gasketing

Chassis with Thermal Pads
and Shield Gasketing

Figure 5-51 Thermal Pads and Shield Gasketing on Chassis and Die Cast Main Shield
2. Thoroughly inspect the chassis and verify all thermal pads are in place and free from
damage. See Section 5.7.4: Thermal Pad Replacement Procedure on page 5-33 to replace
damaged pads.
NOTE: Every time the Transceiver Board is removed, the Final Driver Thermal Pad must be
replaced.
Audio PA Thermal Pad (75012059001)
Regulator
Thermal
Pad
(75012018001)

Final Driver Thermal Pad (75012058002)

Thermal Grease (1175109A03)
Figure 5-52 Chassis with Thermal Pads

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.4

5-33

Thermal Pad Replacement Procedure
Regulator Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place it
on the chassis as shown in Figure 5-53.

Regulator Thermal
Pad (75012018001)

Figure 5-53 Replacing Regulator Thermal Pads
Audio PA Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.

5-34

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis as shown in Figure 5-54.

Audio PA Thermal Pad
(75012059001)

Figure 5-54 Replacing Audio PA Thermal Pad
Final Driver Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift each pad from the transceiver board. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis as shown in Figure 5-55.

Final Driver Thermal Pad
(75012058002)

Figure 5-55 Replacing Final Driver Thermal Pad

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.5

5-35

Transceiver Board Reassembly
1. Apply thermal grease to the PA area. Refer to Figure 5-56.

Thermal Grease (1175109A03)
Figure 5-56 Applying Thermal Grease
2. Insert the transceiver board into the chassis by tilting the transceiver board (approximately 45
degrees) and sliding it into place, taking care to line up the RF and DC connectors with the
openings in the back of the chassis.
Push the board down to fully seat it to the radio chassis and ensure that the transceiver board
alignment slots are positioned in line with the chassis alignment bosses.
Alignment Bosses

Figure 5-57 Placing the Transceiver Board in the Chassis

5-36

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

!
Caution

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

3. Insert the DC retention clip and fully seat it. Refer to Figure 5-58.

DC Retention Clip

Figure 5-58 Inserting DC Retention Clip

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-37

4. Using a 9/16” deep socket driver install the lock washer and nut to an initial torque of 0.9 N-m
(8 lbs-in). Refer to Figure 5-59.

RF Lock Washer and Nut
Figure 5-59 Inserting RF Lock Washer and Nut
5. Using a T10 TORX™ driver insert four main shield thread forming screws (M3) at locations 3,
4, 5 and 6 to compress the PCB. Tighten the screws to 1.0 N-m (9 lbs-in).
NOTE: This step is required; otherwise, damage could result to the final transmitter PA device.

3
5

Figure 5-60 Screw Sequence to Compress PCB

5-38

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

6. While the board is pressed down, align the PA holes on PCB to mounting holes on chassis
and insert two (M2.5) machine screws with washers (see Figure 5-61 for PA Screw
sequence). Using a T8 TORX™ tighten the screws to 0.45 N-m (4 lbs-in).

Install This Screw First

Install This Screw Second

Figure 5-61 Installing PA Screws
7. Using a T10 TORX™ driver remove the screws from locations 3, 4, 5 and 6.
8. Insert the accessory connector into the radio assembly and press into place until the
connector is flushed with the chassis. Refer to Figure 5-62.

Accessory
Connector

Figure 5-62 Inserting Accessory Connector

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-39

9. Place the main shield on the transceiver board and lock in place the accessory connector by
aligning the main shield locking tabs to the pockets of the accessory connector.
10. Insert nine main shield thread forming screws (M3) through the shield and one thread forming
screw (M3) through the board.
11. Using a T10 TORX™ driver follow the sequence marked on the shield and tighten the screws
to 1.47 N-m (13 lbs-in). Refer to Figure 5-64.

Main Shield
Screws (9)

Die Cast Main Shield

PCB Screw (1)

Radio Chassis

Figure 5-63 Assembling Die Cast Main Shield onto Chassis

5-40

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

1
5

6
2

Figure 5-64 Screw Sequence to Tighten Die Cast Main Shield
12. Use a 9/16” deep socket driver to further tighten the nut to a final torque of 2.15 N-m
(19 lbs-in).

RF Connector Lock Washer and Nut

Figure 5-65 RF Connector Nut Final Torque

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-41

13. Install the acoustic plug. An arrow is molded into the part to indicate the start side.

Acoustic Plug

Figure 5-66 Acoustic Plug Installation
14. Thoroughly inspect the cover assembly with seal attached. Ensure the seal is fully seated on
the cover and the locking tabs engaged at all seven locations.

Locking Tab
(7 Places)

Figure 5-67 Inspection of Cover Assembly with Seal

5-42

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

15. Gently spread both sides of the cover.
16. Align the top cover to the chassis and snap the cover in place uniformly. Ensure the alignment
posts on the cover slide into the alignment slots on the chassis.

Main Cover

Radio Chassis

Figure 5-68 Assembling Cover onto Chassis

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-43

17. Assembly of the GPS cable.
NOTE: Skip steps a through d if the GPS cable was not serviced.
a. If attached, remove the nut and washer from the GPS antenna connector.
b. Insert the GPS cable assembly through the opening in the chassis. Orient the MCX connector
as shown in Figure 5-69.
c.

Pull the GPS cable strain relief until it is fully installed. See Figure 5-70.

d. Assemble the lock washer and the nut to the GPS antenna connector. Using a 5/16” or
8 mm socket driver, tighten the nut to 1.7 N-m (15 lbs-in). See Figure 5-70.
NOTE: Do not pull directly on cable wire.

GPS Cable

MCX Connector

Figure 5-69 GPS Cable Installation

GPS Antenna Connector

Washer and Nut

GPS Cable Strain Relief

Figure 5-70 GPS Cable Installation

5-44

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

e. Connect the GPS cable MCX connector to the expansion board.
f.

Connect the flex cable from the expansion board to the main board connector.

Control Head Connector

Ethernet Connector

Option Board Connector

Expansion Board Connector

Figure 5-71 Flex Connection Connectors
g. Using a T6 TORX™ driver, tighten the three screws to 0.28 N-m (2.5 lbs-in) to secure the
expansion board to the chassis.

Expansion Board Flex

Expansion Board
To
R

MCX Connector
Screws

Figure 5-72 Expansion Board Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-45

NOTE: Skip steps h through j if the GPS nameplate was not serviced.
h. Clean chassis nameplate surface with alcohol prior to applying the GPS nameplate.
i.

Peel off the paper liner to the GPS nameplate. Place the long side of the GPS nameplate
against the long side of the recessed area on the chassis.

NOTE: If the GPS nameplate is removed it will need to be replaced.
j.

Rotate the nameplate to the recessed surface and apply pressure.

GPS Nameplate

Figure 5-73 GPS Nameplate Assembly
NOTE: Skip step k if the GPS cable was not serviced.
k.

Snap the GPS dust cap (if not already installed) to the accessory connector retainer and
place the GPS dust cap over the GPS antenna connector.

GPS Connector Dust Cap

Figure 5-74 GPS Antenna Connector Assembly

5-46

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

18. Orient the option board flex so that contacts face option board. Secure connector latch to
option board as referenced in Figure 5-75. Note white line on flex should be aligned with
connector latch.
Latch

Option Board Flex

Figure 5-75 Orientation of Option Board Flex to Option Board
19. Maintaining the bend orientation, connect the flex cable from the option board to the main
board connector.

Option Board Flex

Option Board
Screws
Figure 5-76 Assemble Option Board to Radio Chassis (Image May Not Match Exact Product)

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-47

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

Chassis
Alignment Posts

Figure 5-77 Align Option Board to Mounting Holes
21. Using a T6 TORX™ driver, tighten the three screws to 0.28 N-m (2.5 lbs-in) to secure the
option board to the chassis.
NOTE: Regulatory Requirements
All MOTOTRBO radios are designed and engineered to meet all regulatory requirements for the
country or region of sale. Any option board designed for the MOTOTRBO Option Board ADK must
not compromise the regulatory compliance of the MOTOTRBO radio.
The 3rd party developer is responsible for providing all information, upon request by a regulatory
authority, in regards to any materials or substances used in the manufacture of an option board as it
pertains to its end-of-life.
Please review the terms of the MOTOTRBO License Agreement for more information on the
Licensed Developer or Application Partner responsibilities for regulatory compliance.

5-48

5.7.6

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Assemble Control Head to Radio Assembly
1. Assemble the control head O-ring seal on the radio as shown in Figure 5-78.

Control Head
O-ring Seal
Figure 5-78 Assemble O-ring to Chassis (Image May Not Match Exact Product)
2. Verify that the flex cable is fully seated in the connector on the control head assembly.

!
Caution

Make sure the Main Cover is assembled onto the Radio Chassis before
assembling the Control Head onto the Radio Chassis. This will help prevent
damage to the ground springs in the Control Head.

Radio Chassis

Control Head

Figure 5-79 Assemble Control Head to Chassis

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5-49

3. Assemble flex cable to the flex connector in the radio assembly, making sure it is fully seated.

Control Head Connector

Ethernet Connector

Expansion Board Connector

Option Board Connector

Figure 5-80 Flex Connection Connectors
4. Assemble the control head to the radio chassis by aligning one side of the control head
assembly tabs to one side of the radio chassis tabs and then rotate the control head
assembly until the other side engages.
5. Verify that the control head seal is not pinched and not visible. If a pinch is found,
disassemble the control head, reseat the O-ring and reassemble the control head.

5-50

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5.8

Exploded Mechanical Views and Parts Lists

5.8.1

Radio Assembly Exploded View and Parts List

13
12
11
10
9
8

16
17

7
18

6
5
3

1
1

22
21

Figure 5-81 Radio Assembly Exploded View

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5-51

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

Description

Part Number

Screw - M2x0.4x6mm

0310909E03

Bluetooth/GPS Expansion Board

PMLN6042_S*

Flex, Expansion Board

Included in
PMLN6042_S

GPS Cable Assembly

Included in
PMLN6042_S

O-Ring, Control Head

3216200H01

Chassis, Die Cast

27009303001

Acoustic Plug

32012172001

Thermal Pad, Regulator (QTY:3)

75012018001

Thermal Pad, Audio PA

75012059001

PCB, Transceiver

See Section 1.5 to
1.9 to identify proper
board.

Screw - M2.5x0.45x12mm with Washer

03012037001

Clip, DC Retention

42009281001

Main Shield, Die Cast

26009377001

Screw - M3x0.5x13mm

0310943J12

Main Cover and Gasket Assembly

15012083001

Thermal Pad, Final Driver

75012058002

GPS Dust Cap

3216338H01

Accessory Connector

42009282001

GPS Plug (not required)

32009445001

GPS Nameplate

54012193001

Generic Option Board

PMLN5718_S**

Flex, Option Board

84012231001

* Includes: Item No. 1 (Screw - M2x0.4x6mm)
Item No. 2 (Bluetooth/GPS Expansion Board)
Item No. 3 (Flex, Expansion Board)
Item No. 4 (GPS Cable Assembly)
Item No. 17 (GPS Dust Cap)
Item No. 20 (GPS Nameplate)
** Includes: Item No. 1 (Screw - M2x0.4x6mm)
Item No. 21 (Generic Option Board)
Item No. 22 (Flex, Option Board)

5-52

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5.8.2

Control Head Exploded Views and Parts Lists
14
13

12
11

9
8
6

4
3
2

15
16
1
17

Figure 5-82 Color Display Control Head Exploded View
Table 5-4 Color Display Control Head (PMLN5678_) Exploded View Parts List
Item no

Description

Part No

Volume/Channel Knob Assembly

36012018001

Housing Assembly

0104045J47

Power Button

38012007001

Light Barrier, Power Button

07012020001

Mic Jack Seal

3264133H01

Volume Encoder Seal

32012140001

Color Display Pad Gasket

32012094001

Color Display

72012017001

PCB Assembly Rev A
PCB Assembly Rev B

0104045J49
0104055J61

PCB Retainer

42012024001

Speaker

5015134H02

Speaker Retainer

42012023001

Screw - K30x1.2x12mm

03012038001

Control Head Flex Cable

30012045001

Keypad Frame

42012026001

Keypad

75012061001

Nameplate Front Label for XPR 5550

33012017001

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5-53

9
8
7
6
5
4
3
2
10
11

1
12

Figure 5-83 Numeric Display Control Head Exploded View
Table 5-5 Numeric Display Control Head (PMLN5677_) Exploded View Parts List
Item no

Description

Part No

Volume/Channel Knob Assembly

36012018001

Housing Assembly

0104045J48

Power Button

38012007001

Light Barrier, Power Button

07012020001

Mic Jack Seal

3264133H01

Volume Encoder Seal

32012140001

PCB Assembly Rev A
PCB Assembly Rev B

0104045J50
0104055J60

Screw - K30x1.34x8mm

0371370L01

Control Head Flex Cable

30012045001

Keypad Frame

42012025001

Keypad

75012060001

Speaker Retainer

42012030001

Speaker

5015134H02

Nameplate Front Label for XPR 5350

33012017008

5-54

5.9

Disassembly/Reassembly Procedures: Torque Chart

Torque Chart
Table 5-6 lists the various nuts and screws by part number and description, followed by the torque
values in different units of measure. Torque all screws to the recommended value when assembling
the radio.
Table 5-6 Torque Specifications for Nuts and Screws
Part
Number

Description

Driver/Socket

Torque
N-m

lbs-in

kg-cm

30012044001

Nut, GPS Antenna Connector

5/16” or 8 mm
socket driver

1.7

17.3

02012015001

Nut, RF Connector

9/16” deep socket
driver

2.15

21.9

03012038001

Screw, K30x1.2x12mm, Pan Head

T10 Torx™

0.88

7.8

9.0

0371370L01

Screw, K30x1.34x8mm, Pan Head

T10 Torx™

0.88

7.8

9.0

0310909E03

Screw, M2x0.4x6mm, Pan Head

T6 Torx™

0.28

2.5

2.9

03012037001

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

T8 Torx™

0.45

4.6

0310943J12

Screw, M3x0.5x13mm, Pan Head

T10 Torx™

1.5

Chapter 6 Basic Troubleshooting

6.1

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

6.1.1

High Power RF Precaution

!
Caution

6.2

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

Replacement Service Kit Procedures
Once a problem has been isolated to a specific board, install the appropriate service kit (see Model
Charts in section 1.5 on page 1-5 through section 1.9 on page 1-9), which is orderable from Motorola
Radio Products and Solutions Organization at 1-800-422-4210.
Refer to http://www.motorola.com/businessonline for further information.
If a board is replaced, it does not necessarily need to be retuned if it has been factory tuned. It
should however be checked for performance before being placed into service. Of particular concern
is the Bias DAC, which will need to be set for the appropriate final device bias current prior to keying
up the radio. If the bias is not properly set it may be possible to cause damage to the transmitter.

!
Caution

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

6-2

6.3

Basic Troubleshooting: Power-Up Error Codes

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

6.4

Description

Error Type

Corrective Action

ERROR 01/02

FLASH ROM Codeplug
Checksum

NON-FATAL

Reprogram the codeplug.

ERROR 01/22

Tuning Codeplug
Checksum

NON-FATAL

Reprogram the tuning partition.

FAIL 01/82

FLASH ROM Codeplug
Checksum

FATAL

Reprogram the codeplug.

FAIL 01/90

General Hardware Error

FATAL

Turn the radio off, then on.

FAIL 01/92

Security Partition
Checksum

FATAL

Reprogram the security partition.

FAIL 01/93

FlashPORT AUTHENT
CODE Failure

FATAL

Contact the depot.

FAIL 01/A2

Tuning Codeplug
Checksum

FATAL

Reprogram the tuning partition.

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 service technician
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

Reprogram the codeplug.
Send radio to the nearest
Motorola Depot.

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

7.1.1

7.1.2

7.1.3

Audio
Part No.

Description

HMN4098_

Telephone Style Handset

RMN5050_

Desktop Microphone

RMN5052_

Compact Microphone

RMN5053_

Heavy Duty Microphone with Enhanced Audio

RMN5054_

Visor Microphone with Enhanced Audio

RMN5127_

4-Way Navigation Keypad Microphone with Enhanced Audio

Speakers
Part No.

Description

RSN4002_

13 Watt External Speaker

RSN4003_

7.5 Watt External Speaker

RSN4004_

5 Watt External Speaker

Desktop Accessories
Part No.

Description

GLN7318_

Desktop Tray without Speaker

RSN4005_

Desktop Tray with Speaker

HPN4007_

Power Supply and Cable

GPN6145_

Switchmode Power Supply (1-25 Watt Models)(CE Marked)

GKN6266_

Radio Power Cable (for GPN6145)

NTN7373_R

3060665A04 US Line Cord

HKN9088_

Mobile Mini-U Antenna Adaptor, 8-foot Cable

PMLN5072_

Hardware Kit for Rear Accessory Connector

7-2

7.1.4

7.1.5

7.1.6

Accessories: Introduction

Mounting Kits
Part No.

Description

RLN6465_

In Dash (DIN) Mounting Kit

RLN6466_

Low Profile Trunnion Kit

RLN6467_

Standard Profile Trunnion KIt

RLN6468_

Key Lock Trunnion Kit

Cables
Part No.

Description

HKN4137_

Power Cable to Battery, 3m (10 ft.), 15 amp (1–25W)

HKN4191_

Power Cable to Battery, 3m (10 ft.), 20 amp (1–45W)

HKN4192_

Power Cable to Battery, 6m (20 ft.), 20 amp (1–45W)

HKN6184_

Mobile Front Programming Cable

PMKN4010_

Mobile & Repeater Rear Programming Cable

PMKN4016_

Mobile & Repeater Rear Accessory Programming and Test Cable

PMKN4018_

Mobile & Repeater Rear Accessory Connector Universal Cable

PMKN4033_

Cable, Mobile Mic Extension, 10 feet

PMKN4034_

Cable, Mobile Mic Extension, 20 feet

PMKN4070_

IMPRES Mobile MMP Non PC Adaptor

PMKN4072_

IMPRES Mobile MAP Non PC Adaptor

RKN4136_

Ignition Sense Cable

Antennas
Part No.

Description

HAD4006_

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

HAD4007_

VHF, 146–150.8 MHz, 1/4 Wave, Through-hole Mount, Mini-U

HAD4008_

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

HAD4009_

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

HAD4014_

VHF, 146–172 MHz, 3.0 dB Gain, Through-hole Mount, Mini-U

HAD4022_

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

HAE4002_

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

HAE4003_

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

HAE4004_

UHF, 470–527 MHz, 1/4 Wave, Through-hole Mount, Mini-U

HAE4010_

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

HAE4011_

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

HAE4012_

UHF, 470–494 MHz, 3.5 dB Gain, Through-hole Mount, Mini-U

HAE4013_

UHF, 470–512 MHz, 3.5 dB Gain, Through-hole Mount, Mini-U

Accessories: Introduction

7-3

Part No.

Description

HAE6022_

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

RAE4004_RB

UHF, 445–470 MHz, 5.0 dB Gain, Through-hole Mount, Mini-U
(with base)

RAD4214_

Combination GPS/VHF 136–144 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

RAD4215_

Combination GPS/VHF 146–150.8 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

RAD4216_

Combination GPS/VHF 150.8–162 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

RAD4217_

Combination GPS/VHF 162–174 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

RAD4218_

Combination GPS/VHF 146–172 MHz, 3.0 dB Gain,
Through-hole Mount, Mini-U

PMAE4030_

Combination GPS/UHF 403–430 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

PMAE4031_

Combination GPS/UHF 450–470 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

PMAE4032_

Combination GPS/UHF 406–420 MHz, 3.5 dB Gain,
Through-hole Mount, Mini-U

PMAE4033_

Combination GPS/UHF 450–470 MHz, 3.5 dB Gain,
Through-hole Mount, Mini-U

PMAE4034_

Combination GPS/UHF 450–470 MHz, 5.0 dB Gain,
Through-hole Mount, Mini-U

HAE6019_

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

HAE6020_

Combination GPS/UHF 470–527 MHz, 1/4 Wave,
Through-hole Mount, Mini-U

HAE6024_

Combination GPS/UHF 470–494 MHz, 3.0 dB Gain,
Through-hole Mount, Mini-U

HAE6026

Combination GPS/UHF 494–512 MHz, 3.0 dB Gain,
Through-hole Mount, Mini-U

PMAN4000_

Fixed Mount GPS Active Antenna

PMAN4001_

Window Mount GPS Active Antenna

PMAN4002_

Magnetic Mount GPS Active Antenna

Replacement Antennas
RAE4004_

UHF, 445–470 MHz, 5.0 dB Gain, Through-hole Mount, Mini-U
(without base)

RAD4223_

Kit, Antenna VHF 162–174 MHz, 1/4 Wave

RAD4224_

Kit, Antenna VHF 150.8–162 MHz, 1/4 Wave

RAD4225_

Kit, Antenna VHF 146–150.8 MHz, 1/4 Wave

RAD4226_

Kit, Antenna VHF 136–144 MHz, 1/4 Wave

7-4

7.1.7

7.1.8

Accessories: Introduction

Part No.

Description

RAD4227_

Kit, Antenna VHF 146–172 MHz, 3.0 dB Gain

PMAE4039_

Kit, Antenna UHF 403–430 MHz, 1/4 Wave

PMAE4040_

Kit, Antenna UHF 406–420 MHz, 3.5 dB Gain

PMAE4041_

Kit, Antenna UHF 450–470 MHz, 1/4 Wave

PMAE4042_

Kit, Antenna UHF 450–470 MHz, 3.5 dB Gain

PMAE4043_

Kit, Antenna UHF 450–470 MHz, 5.0 dB Gain

HAE6027_

Kit, Antenna UHF 494–512 MHz, 3.0 dB Gain, Through-hole Mount

HAE6028_

Kit, Antenna UHF 470–494 MHz, 3.0 dB Gain, Through-hole Mount

HAE6029_

Kit, Antenna UHF 403–527 MHz, 2.0 dB Gain, Through-hole Mount

HAE6030_

Kit, Antenna UHF 470–527 MHz, 1/4 Wave, Through-hole Mount

PMAN4004_

Kit, Combo GPS+RF, Base Only, Through-hole Mount, Mini-U

Bluetooth
Part No.

Description

NNTN8125_

Operations Critical Wireless Earpiece, 12” Cable

NNTN8126_

Operations Critical Wireless Earpiece, 9.5” Cable

NNTN8127_

Operations Critical Wireless Push to Talk POD

NTN2572_

Replacement Wireless Earpiece, 12” Cable

NTN2575_

Replacement Wireless Earpiece, 9.5” Cable

PMPN4009_

Micro USB Charger (US)

89409N

HK200 Bluetooth Headset

Miscellaneous Accessories
Part No.

Description

HLN9073_

Microphone Hang-up Clip (All Microphones)

HLN9414_

Universal Microphone Hang-up Clip (All Microphones)

HKN9557_

PL259/Mini-U Antenna Adaptor, 8-foot Cable

PMEN4027_

Chassis Eliminator Kit

PMLN6042_S

Bluetooth/GPS Expansion Board

PMLN5718_S

Generic Option Board

RLN5926_

Push Button PTT

RLN5929_

Emergency Footswitch

3075336B07

Compact Microphone Replacement Cable

3075336B10

Heavy Duty/Keypad Microphone Replacement Cable

6686119B01

Control Head Dismantling Tool

66012025001

Volume/Channel Knob Removal Tool

Appendix A

A.1

Replacement Parts Ordering

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

A.2

Motorola Online
Motorola Online users can access our online catalog at
http://www.motorola.com/businessonline
To register for online access, please call 1-800-422-4210 (for U.S. and Canada Service Centers
only). International customers can obtain assistance at http://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
Radio Products and Solutions Organization*
(United States and Canada)
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
1-847-538-8023 (United States and Canada)
U.S. Federal Government Markets Division (USFGMD)
1-877-873-4668
8:30 AM to 5:00 PM (Eastern Standard Time)

A.5

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

A-2

A.6

Replacement Parts Ordering: Parts Identification

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

A.7

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

Appendix B

B.1

Motorola Service Centers

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

B.2

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

B.3

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

B.4

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

B-2

Motorola Service Centers Motorola Canadian Technical Logistics Center

Notes

Appendix C

C.1

Limited Level 3 Servicing

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

Component Location and Parts List

2
P3000

1
2

3
J0700

3
U3204

4
4

2
Q0705

C.2

Figure C-1 PCB Top Side View

C-2

Limited Level 3 Servicing: Component Location and Parts List

5
F4000

Figure C-2 PCB Bottom Side View

Table C-1. Component Parts List
No.

Circuit Ref.

Motorola Part Number

Description

J0700

09009348001

Mini-UHF Female RF Connector

P3000

09009344001

DC Power Connector

U3204

51009509001

IC Audio Amplifier 1 Per Package

Q0705

48012067002 (UHF1 LP/VHF LP)
48012022001 (UHF1 HP/VHF HP/UHF2)

F4000

6515076H01

RF MOSFET Power Transistor
Fast Blow 3A, 24V Fuse

Glossary

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

Term

Definition

Analog

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

Band

Frequencies allowed for a specific purpose.

CMOS

Complementary Metal Oxide Semiconductor.

CPS

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

Default

A pre-defined set of parameters.

Digital

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

DPL

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

FCC

Federal Communications Commission.

Frequency

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

GPIO

General-Purpose Input/Output.

GPS

Global Positioning System.

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

Intermediate Frequency.

kHz

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

LCD

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

LDMOS

Laterally Diffused Metal Oxide Semiconductor.

LED

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

MDC

Motorola Digital Communications.

Glossary-2

Term

Definition

MHz

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

Paging

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

PC Board

Printed Circuit Board. Also referred to as a PCB.

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

Programming Cable

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

Receiver

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

Repeater

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

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

Receive.

Signal

An electrically transmitted electromagnetic wave.

Spectrum

Frequency range within which radiation has specific characteristics.

Squelch

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

TOT

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

TPL

Tone Private Line.

Transceiver

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

Transmitter

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

Transmit.

UHF

Ultra-High Frequency.

USB

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

VHF

Very High Frequency.

VIP

Vehicle Interface Port.

XPR

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

Motorola Solutions, Inc.
1303 East Algonquin Road
Schaumburg, Illinois 60196 U.S.A.
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and
the Stylized M logo are trademarks or registered trademarks
of Motorola Trademark Holdings, LLC and are used under license.
All other trademarks are the property of their respective owners.
© 2011, 2012 Motorola Solutions, Inc. All rights reserved.
December 2012.
www.motorolasolutions.com/mototrbo

*68009515001*
68009515001-B

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