MOTOTRBO XPR 8300/XPR 8400 Repeater Basic Service Manual Series/XPR8300 XPR8400 6816810H01 J XPR8300

User Manual: -XPR Series/XPR8300 XPR8400 Basic Service Manual 6816810H01-J

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PROFESSIONAL DIGITAL TWO-WAY RADIO SYSTEM

MOTOTRBO™
REPEATER
BASIC SERVICE
MANUAL
XPR™ 8300 REPEATER
XPR™ 8400 REPEATER

Foreword
This manual covers all models of the XPR™ 8300/XPR™ 8400 Repeater, unless otherwise specified. It includes all the
information necessary to maintain peak product performance and maximum working time, using levels 1 and 2
maintenance procedures. This level of service goes down to the board replacement level and is typical of some local
service centers, Motorola Authorized Dealers, self-maintained customers, and distributors.

!
Caution

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

Product Safety and RF Exposure Compliance
ATTENTION!
Before using this product, XPR™ 8300/XPR™ 8400 Repeater, read the RF Exposure and Safety guide
that ships with the repeater which contains important operating instructions for safe usage and RF
energy awareness and control for Compliance with applicable Standards and Regulations.

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

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

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

Trademarks
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective
owners.
© 2006–2011, 2013, 2014 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

6816810H01-A

Initial Release.

Dec. 2006

6816810H01-B

Added VHF High Power Band Information.

June 2007

6816810H01-C

Added VHF Low Power and UHF Low Power
Band Information.

Nov. 2007

6816810H01-D

Added 20 kHz information to Chapter 1 and UHF
Band 2 models.

June 2008

6816810H01-E

Changed Channel Capacity from 1 to 16 for all
bands in Section 1.9 Specifications.
Changed Windows 2000/XP to Windows Vista/XP
in Chapter 4, Sections 4.1 and 4.3 and added
Repeater Alignment Procedure.

June 2009

6816810H01-F

Added statements “VHF/UHF Brick Version A
Models” and “VHF/UHF Brick Version B Models”
in related sections.
Removed Repeater Alignment Procedure.

Sept. 2010

6816810H01-G

Added Appendix C, Digital Telephone Patch
(DTP) Tuning Guideline.

May 2011

6816810H01-H

Added detailed process for replacing and
initializing service kits for repeaters in Section 6.2
Replacement Service Kit Procedures.

June 2013

6816810H01-J

Added new Transmit Radio Service Kit
PMTE4026_S to UHF2 Model Chart and
PMTE4028_S to UHF1 HP Model Chart.
Added new Receive Radio Service Kit
PMTE4016_S to UHF2 Model Chart and
PMTE4013_S to UHF1 HP Model Chart.

Mar. 2014

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

Chapter 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9

Notations Used in This Manual .................................................................................................... 1-1
Repeater Description ................................................................................................................... 1-1
MOTOTRBO Repeater Model Numbering Scheme..................................................................... 1-2
VHF High Power MOTOTRBO Repeater (136–174 MHz) Model Chart ...................................... 1-3
VHF Low Power MOTOTRBO Repeater (136–174 MHz) Model Chart ...................................... 1-3
UHF1 High Power MOTOTRBO Repeater (403–470 MHz) Model Chart .................................. 1-4
UHF1 Low Power MOTOTRBO Repeater (403–470 MHz) Model Chart .................................... 1-4
UHF2 High Power MOTOTRBO Repeater (450–512 MHz) Model Chart ................................... 1-5
Specifications............................................................................................................................... 1-6

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 .................................................................................................................. 2-2

Chapter 3
3.1
3.2

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

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

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

Table of Contents

Chapter 4
4.1
4.2
4.3

Introduction .................................................................................................................................. 4-1
Customer Programming Software Setup ..................................................................................... 4-1
Repeater Tuning Setup ................................................................................................................ 4-2

Chapter 5
5.1
5.2
5.3
5.4
5.5
5.6

5.7
5.8

5.9
5.10

6.2
6.3
6.4

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............................................................................ 5-3
Disassembling and Reassembling the Repeater – General ........................................................ 5-4
Disassembly Procedures – Detailed ............................................................................................ 5-4
5.6.1 Disassembly of Cover...................................................................................................... 5-4
5.6.2 Disassembly of Repeater Indicator Board ....................................................................... 5-5
5.6.3 Disassembly of Fan ......................................................................................................... 5-7
5.6.4 Removing Transmit Radio ............................................................................................... 5-8
5.6.4.1 Removing Thermal Pad and Heatsink .............................................................. 5-9
5.6.5 Removing Receive Radio, Power Supply and Connector Board Assembly .................... 5-9
5.6.5.1 Disassembly of Receive Radio ....................................................................... 5-11
5.6.5.2 Disassembly of Connector Board Assembly................................................... 5-11
5.6.5.3 Disassembly of Power Supply ........................................................................ 5-11
Transmit and Receive Radio Disassembly – Detailed ............................................................... 5-12
5.7.1 Transceiver Board and Receiver Board Removal ......................................................... 5-12
Transmit and Receive Radio Reassembly – Detailed................................................................ 5-15
5.8.1 Transceiver Board and Receiver Board Reassembly.................................................... 5-17
5.8.2 Thermal Pad Replacement Procedure .......................................................................... 5-22
5.8.3 Reassembly of Receive Radio, Power Supply and Connector Board Assembly........... 5-25
5.8.3.1 Reassembly of Power Supply......................................................................... 5-25
5.8.3.2 Reassembly of Receive Radio........................................................................ 5-25
5.8.3.3 Reassembly of Connector Board Assembly ................................................... 5-25
5.8.3.4 Reassembly of the Receive Bracket Assembly to the Enclosure ................... 5-25
5.8.4 Reassembly of Transmit Radio...................................................................................... 5-26
5.8.4.1 Replacing the Thermal Pad and Heatsink ...................................................... 5-26
5.8.4.2 Reassembly of the Transmit Bracket Assembly to the Enclosure .................. 5-26
5.8.5 Reassembly of Fan........................................................................................................ 5-29
5.8.6 Reassembly of Repeater Indicator Board...................................................................... 5-29
5.8.7 Reassembly of Cover .................................................................................................... 5-30
Repeater Exploded Mechanical Views and Parts Lists.............................................................. 5-30
Torque Chart .............................................................................................................................. 5-35

Chapter 6
6.1

Repeater Programming and Tuning .................................. 4-1

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

Introduction .................................................................................................................................. 6-1
6.1.1 High Power RF Precaution .............................................................................................. 6-1
Replacement Service Kit Procedures .......................................................................................... 6-1
6.2.1 Replacing and Initializing Service Kits for XPR 8300/XPR 8400 Repeaters ................... 6-2
LED Indicator Descriptions .......................................................................................................... 6-3
Ethernet LED Indicator Descriptions ........................................................................................... 6-3

Table of Contents

Chapter 7
7.1

vii

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

Introduction .................................................................................................................................. 7-1
7.1.1 Antennas ......................................................................................................................... 7-1
7.1.2 Cables ............................................................................................................................. 7-1
7.1.3 Miscellaneous Accessories ............................................................................................. 7-1

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

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

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

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

Appendix C Digital Telephone Patch (DTP) Tuning Guideline ............C-1
C.1

C.2

MRTI2000 ....................................................................................................................................C-1
C.1.1 Hardware Connection......................................................................................................C-1
C.1.2 Jumpers on Phone patch.................................................................................................C-2
C.1.3 Programming and Tuning ................................................................................................C-2
C.1.3.1 Programming the Phone Patch with PC Tool provided by Gai-Tronics ............C-2
C.1.3.2 Enter Diagnostic Test Mode .............................................................................C-3
C.1.3.3 TX Softpot Adjustment......................................................................................C-3
C.1.3.4 Mobile-to-Phone Audio Path.............................................................................C-3
Zetron M30 ..................................................................................................................................C-4
C.2.1 Hardware Connection......................................................................................................C-4
C.2.2 Jumpers on Phone patch.................................................................................................C-4
C.2.3 Setting up the Zetron Input and Output Signal Levels.....................................................C-5
C.2.3.1 Hardware Setup and Basic Check....................................................................C-5
C.2.3.2 Force a Reset, Recover to Factory Default Setting ..........................................C-5
C.2.3.3 Enter Program Mode ........................................................................................C-5
C.2.3.4 Program to Half Duplex Mode and COR to Answer .........................................C-5
C.2.3.5 Set Transmit Audio Gain ..................................................................................C-5
C.2.3.6 Set Receive Level.............................................................................................C-6

viii

Table of Contents

C.3

Zetron M735................................................................................................................................ C-7
C.3.1 Hardware Connection ..................................................................................................... C-7
C.3.2 Jumpers on Phone patch................................................................................................ C-7
C.3.3 Setting up the Zetron Input and Output Signal Levels .................................................... C-8
C.3.3.1 Hardware Setup and Basic Check................................................................... C-8
C.3.3.2 Enter Program Mode ....................................................................................... C-8
C.3.3.3 Force a Reset .................................................................................................. C-8
C.3.3.4 Set Tx Audio Level........................................................................................... C-9
C.3.3.5 99# Exit Program Mode ................................................................................... C-9
C.3.3.6 Discriminator Input Level Adjust ...................................................................... C-9

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

List of Figures

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

Repeater Model Numbering Scheme................................................................................... 1-2
Mobile & Repeater Rear Programming Cable PMKN4010_ ................................................ 2-2
Mobile & Repeater Rear Accessory Programming and Test Cable PMKN4016_ ................ 2-3
Customer Programming Software Setup from Rear Accessory Connector ......................... 4-1
Repeater Tuning Equipment Setup...................................................................................... 4-2
Removing Top Cover of Repeater Enclosure....................................................................... 5-4
Disconnecting Ethernet Cable and Flex Cable .................................................................... 5-5
Disconnecting Ethernet Cable, Flex Cable and Ribbon Cable............................................. 5-6
Repeater Indicator Board Disassembly................................................................................ 5-7
Fan Orientation .................................................................................................................... 5-7
Tx Radio Disassembly ......................................................................................................... 5-8
Receive Radio Removal..................................................................................................... 5-10
Die Cast Cover Removal.................................................................................................... 5-12
Rear Accessory Connector Removal ................................................................................. 5-13
RF/DC Retention Clips Removal........................................................................................ 5-13
Transceiver Board Removal............................................................................................... 5-14
Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover .............................. 5-15
Transceiver Board with Thermal Pads ............................................................................... 5-15
Transceiver Board with Thermal Pads (VHF/UHF 32 MB Bricks) ...................................... 5-16
Replacing GPS Plug .......................................................................................................... 5-16
Placing the Transceiver Board in the Chassis ................................................................... 5-17
Inserting RF/DC Retention Clips ........................................................................................ 5-18
Inserting Rear Accessory Connector ................................................................................. 5-18
Assembling of PA Heat Sink System (VHF 8 MB Brick) .................................................... 5-19
Assembling of PA Pad and O-ring (VHF 32 MB and UHF Bricks) ..................................... 5-20
Assembling of PA Pad and O-ring (VHF 8 MB Brick)......................................................... 5-20
Assembling Die Cast Cover onto Chassis ......................................................................... 5-21
Screw Sequence to Tighten Die Cast Cover...................................................................... 5-22
Replacing Thermal Pads.................................................................................................... 5-22
Aligning Driver Pad on Chassis.......................................................................................... 5-23
Placing Thermal Pads on PA and Transistor Components ................................................ 5-24
Placing Thermal Pads on PA and Transistor Components (VHF/UHF 32 MB
Bricks) ................................................................................................................................ 5-24
Assembly of Accessory Cable Harness ............................................................................. 5-27
Mounting the Adhesive Tape Flex Cable to Power Supply ................................................ 5-28
Flex Cable Assembly (VHF/UHF 32 MB Repeaters) ......................................................... 5-28
Fan Orientation .................................................................................................................. 5-29
Repeater Assembly Exploded View ................................................................................... 5-30
Repeater Assembly Exploded View (VHF/UHF 32 MB Repeaters) ................................... 5-31
Receive Bracket and Radio Assembly Exploded View ...................................................... 5-32
Transmit Bracket and Radio Assembly Exploded View ..................................................... 5-32
Front Panel Complete Assembly Exploded View............................................................... 5-33
MRTI2000 and Repeater Hardware Connection..................................................................C-1
MRTI2000 Rx Audio Path Setting ........................................................................................C-2
MRTI2000 Operation Mode Setting .....................................................................................C-2
MRTI2000 Access/Deaccess Setting...................................................................................C-3
Zetron M30 Hardware Connection .......................................................................................C-4
Zetron M735 Hardware Connection .....................................................................................C-7

Related Publications

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

Frequency Ranges and Power Levels ................................................................................. 1-1
Recommended Test Equipment ........................................................................................... 2-1
Service Aids ......................................................................................................................... 2-2
Initial Equipment Control Settings ........................................................................................ 3-1
Receiver Performance Checks ............................................................................................ 3-2
Repeater Software Program Kits.......................................................................................... 4-1
Lead Free Solder Wire Part Number List ............................................................................. 5-3
Lead Free Solder Paste Part Number List ........................................................................... 5-3
Repeater Exploded View Parts List.................................................................................... 5-33
Torque Specifications for Nuts and Screws ........................................................................ 5-35
LED Indicator Descriptions................................................................................................... 6-3
Ethernet LED Indicator Descriptions .................................................................................... 6-3

List of Tables

Related Publications
XPR 8300/XPR 8380/XPR 8400 Repeater Installation Guide .....................................................6816814H01

xii

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:

Repeater

Two (2) Years

Product Accessories

One (1) Year

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.

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.

Commercial Warranty

xiii

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.

xiv

Commercial Warranty

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.

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

1.2

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

Repeater Description
The XPR 8300/XPR 8400 repeater is available in the following frequency ranges and power levels.
Table 1-1. Frequency Ranges and Power Levels
Frequency
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

This repeater is among the most sophisticated two-way repeaters available. It has a robust design
for 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 repeater communications solution.

1-2

1.3

Introduction: MOTOTRBO Repeater Model Numbering Scheme

MOTOTRBO Repeater Model Numbering Scheme

Model No.Example :
Position

12
Unique Model Variations
N: Standard Package

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

Version Letter

MOTOTRBO Repeater
Model Series
Band
J : 136-174 MHz
Q: 403-470 MHz
T: 450-512 MHz
Power Level
N: 1-25W
R: 1-40W
P: 25-40W
Q: 25-45W

Physical Packages
R: Repeater

Feature Level
1: Mini-U
2: BNC
7: Rack Mount

Primary System Type
A: Conventional

Primary Operation
J: w/o GPS
L: w/ GPS

Channel Spacing
9: Variable/Programmable

Figure 1-1. Repeater Model Numbering Scheme

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

1.4

1-3

VHF High Power MOTOTRBO Repeater (136–174 MHz) Model Chart
VHF 136–174 MHz, 25–45 W
Model
AAM27JQR9JA7AN
AAM27JQR9JA7BN

Description
136–174 MHz, 25–45 W, XPR 8300 8 MB Repeater
136–174 MHz, 25–45 W, XPR 8400 32 MB Repeater

Item
X

Description

PMLN5269_S

Repeater Indicator Board

PMLN5644_S

Connector Board Assembly

PMLN5643_S

Repeater Indicator Board

PMTD4001_S

Repeater XCVR Service Kit

PMTD4007_S

Repeater XCVR Service Kit

PMPN4001_

Power Supply

3087791G01

120V Line Cord

6816814H01

XPR 8300/XPR 8380/XPR 8400 Installation Guide

6881095C99

Product Safety and RF Exposure Booklet

X
X

X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1.5

VHF Low Power MOTOTRBO Repeater (136–174 MHz) Model Chart
VHF 136–174 MHz, 1–25 W
Model
AAM27JNR9JA7AN
AAM27JNR9JA7BN

Description
136–174 MHz, 1–25 W, XPR 8300 8 MB Repeater
136–174 MHz, 1–25 W, XPR 8400 32 MB Repeater

Item
X

Description

PMLN5269_S

Repeater Indicator Board

PMLN5644_S

Connector Board Assembly

PMLN5643_S

Repeater Indicator Board

PMTD4002_S

Repeater XCVR Service Kit

PMTD4006_S

Repeater XCVR Service Kit

PMPN4001_

Power Supply

3087791G01

120V Line Cord

6816814H01

XPR 8300/XPR 8380/XPR 8400 Installation Guide

6881095C99

Product Safety and RF Exposure Booklet

X
X

X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1-4

1.6

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

UHF1 High Power MOTOTRBO Repeater (403–470 MHz) Model Chart
UHF1 403–470 MHz, 25–40 W
Model
AAM27QPR9JA7AN
AAM27QPR9JA7BN

Description
403–470 MHz, 25–40 W, XPR 8300 8 MB Repeater
403–470 MHz, 25–40 W, XPR 8400 32 MB Repeater

Item
X

Description

PMLN5269_S

Repeater Indicator Board

PMLN5644_S

Connector Board Assembly

PMLN5643_S

Repeater Indicator Board

PMTE4004_S

Repeater XCVR Service Kit

PMTE4013_S

Repeater UHF1 RX Radio Service Kit

PMTE4028_S

Repeater UHF1 TX Radio Service Kit

PMPN4001_

Power Supply

3087791G01

120V Line Cord

6816814H01

XPR 8300/XPR 8380/XPR 8400 Installation Guide

6881095C99

Product Safety and RF Exposure Booklet

X
X

X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1.7

UHF1 Low Power MOTOTRBO Repeater (403–470 MHz) Model Chart
UHF1 403–470 MHz, 1–25 W
Model
AAM27QNR9JA7AN
AAM27QNR9JA7BN

Description
403–470 MHz, 1–25 W, XPR 8300 8 MB Repeater
403–470 MHz, 1–25 W, XPR 8400 32 MB Repeater

Item
X

Description

PMLN5269_S

Repeater Indicator Board

PMLN5644_S

Connector Board Assembly

PMLN5643_S

Repeater Indicator Board

PMTE4005_S

Repeater XCVR Service Kit

PMTE4014_S

Repeater XCVR Service Kit

PMPN4001_

Power Supply

3087791G01

120V Line Cord

6816814H01

XPR 8300/XPR 8380/XPR 8400 Installation Guide

6881095C99

Product Safety and RF Exposure Booklet

X
X

X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

Introduction: UHF2 High Power MOTOTRBO Repeater (450–512 MHz) Model Chart

1.8

1-5

UHF2 High Power MOTOTRBO Repeater (450–512 MHz) Model Chart
UHF2 450–512 MHz, 1–40 W
Model
AAM27TRR9JA7AN
AAM27TRR9JA7BN

Description
450–512 MHz, 1–40 W, XPR 8300 8 MB Repeater
450–512 MHz, 1–40 W, XPR 8400 32 MB Repeater

Item
X

Description

PMLN5269_S

Repeater Indicator Board

PMLN5644_S

Connector Board Assembly

PMLN5643_S

Repeater Indicator Board

PMTE4006_S

Repeater XCVR Service Kit

PMTE4016_S

Repeater UHF2 RX Radio Service Kit

PMTE4026_S

Repeater UHF2 TX Radio Service Kit

PMPN4001_

Power Supply

3087791G01

120V Line Cord

6816814H01

XPR 8300/XPR 8380/XPR 8400 Installation Guide

6881095C99

Product Safety and RF Exposure Booklet

X
X

X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1-6

Introduction: Specifications

1.9

Specifications
General
Specification

VHF

UHF1

Channel Capacity
Technical RF Output
Low Power
High Power
Frequency
Dimensions (HxWxL)

UHF2

16
1–25 W
25–45 W

1–25 W
25–40 W

–
1–40 W

136–174 MHz

403–470 MHz

450–512 MHz

5.22” x 19” x 11.67”
(132.6 mm x 482.6 mm x 296.5 mm)

Weight

31 lbs (14 kg)

Voltage
Requirements

100–240 V AC 47–63 Hz
(13.6 V DC)

Current Drain:
Standby:

1.0 A (100 V AC)
0.5 A (240 V AC)
1.0 A (typical)(13.4 V DC)

Transmit: Low Power

3.0 A (100 V AC)
1.5 A (240 V AC)
10 A (typical)(13.4 V DC)

High Power

4.0 A (100 V AC)
1.8 A (240 V AC)
12 A (typical)(13.4 V DC)

Operating
Temperature Range

-30°C to +60°C

Max Duty Cycle
FCC Description
IC Description

100%
1–25 W: ABZ99FT3026
25–45 W: ABZ99FT3025

1–25 W: ABZ99FT4026
25–40 W: ABZ99FT4025

1–40 W: ABZ99FT4027

1–25 W: 109AB-99FT3026 1–25 W: 109AB-99FT4026 1–40 W: 109AB-99FT4027
25–45 W: 109AB-99FT3025 25–40 W: 109AB-99FT4025

Introduction: Specifications

1-7

Receiver
Specification
Frequency

VHF

UHF1

UHF2

136–174 MHz

403–470 MHz

450–512 MHz

Channel Spacing

12.5 kHz/20 kHz/25 kHz

Frequency Stability
(-30°C to +60°C)

±0.5 ppm

Analog Sensitivity
(12 dB SINAD)

0.30 µV
0.22 µV (typical)

Digital Sensitivity

1% BER: 0.71 µV
0.32 µV (typical)
5% BER: 0.3 µV
0.22 µV (typical)

Intermodulation
(TIA603C)
Adjacent Channel
Selectivity:
TIA603
TIA603C
Spurious Rejection
(TIA603C)
Audio Distortion @
Rated Audio

78 dB

75 dB

65 dB @ 12.5 kHz,
80 dB @ 25 kHz
50 dB @ 12.5 kHz,
80 dB @ 25 kHz

65 dB @ 12.5 kHz,
75 dB @ 25 kHz
50 dB @ 12.5 kHz,
75 dB @ 25 kHz

80 dB

75 dB
3% typical

Hum and Noise

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

Audio Response

TIA603C

Conducted Spurious
Emission (TIA603C):

-57 dBm

1-8

Introduction: Specifications

Transmitter
Specification
Frequency

VHF

UHF1

UHF2

136–174 MHz

403–470 MHz

450–512 MHz

Channel Spacing

12.5 kHz/20 kHz/25 kHz

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

±0.5 ppm
1–25 W
25–45 W

1–25 W
25–40 W

Modulation Limiting

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

Digital Modulation Fidelity
(4FSK)

FSK Error 5%
FSK Magnitude 1%

FM Hum and Noise

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

Conducted/Radiated
Emission

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

Adjacent Channel Power
(TIA603C)

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

Audio Response

TIA603C

Audio Distortion

FM Modulation

12.5 kHz : 11K0F3E
25 kHz : 16K0F3E

4FSK Digital Modulation

–
1–40 W

12.5 kHz Data Only : 7K60FXD
12.5 kHz Data & Voice : 7K60FXE
AMBE +2™

Digital Vocoder Type
Digital Protocol

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

Self-Quieter
VHF

UHF1

UHF2

144 MHz

464.025 MHz

498.825 MHz

147.45 MHz

–

172.025 MHz +/- 5 kHz

–

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 repeaters.
Table 2-1. Recommended Test Equipment

Equipment

Characteristic

Example

Application

Service Monitor

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

Aeroflex 3920, or equivalent

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

Digital RMS
Multimeter*

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

Fluke 179 or equivalent
(www.fluke.com)

AC/DC voltage and current
measurements. Audio voltage
measurements

RF Signal
Generator*

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

Agilent N5181
(www.agilent.com) or equivalent

Receiver measurements

Oscilloscope*

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

Tektronix TDS1001b
(www.tektronix.com) or
equivalent

Waveform measurements

Power Meter and
Sensor*

5% Accuracy
100 MHz to 500 MHz
50 Watts

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

Transmitter power output
measurements

RF Millivolt Meter

100 mV to 3 V RF
10 kHz to 1 GHz

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

RF level measurements

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

Description

Application

RLN4460_

Test Box

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

RVN5115_

Customer Programming
Software on CD-ROM

Allows servicer to program repeater parameters, tune
and troubleshoot repeaters.

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.

2.3

Programming Cables

Figure 2-1. Mobile & Repeater Rear Programming Cable PMKN4010_

Test Equipment and Service Aids: Programming Cables

DB 25 CONNECTOR
1

USB CONNECTOR

13
1

2-3

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

915±15
CABLE
1455±24
CABLE

USB

PIN
NO.

DESCRIPTION

VCC (5v)

DATA -

DATA +

GND

DRAIN WIRE AND BRAID

SHELL

DB25P

4
TO MOBILE RADIO
ACCESSORY
CONNECTOR

VIEWED FROM
FRONT (PIN END)
OF CONNECTOR

SPEAKER -

EXT MIC

DIGI IN I
(EXT PTT)

GND

SPEAKER +

Figure 2-2. 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
The MOTOTRBO Repeater meets 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 120/240 VAC. The equipment required for alignment procedures is connected as
shown in the Repeater Tuning Equipment Setup Diagram, Figure 4-2.
Initial equipment control settings should be as indicated in Table 3-1. Table 3-2 lists Receiver
Performance Checks information.

Table 3-1. Initial Equipment Control Settings
Service Monitor

Test Set

Monitor Mode: Power Monitor

Speaker set: A

RF Attenuation: -70

Speaker/load:
Speaker

AM, CW, FM: FM

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

3-2

Transceiver Performance Testing: Setup

Table 3-2. Receiver Performance Checks
Test Name

Communications
Analyzer

Radio

Test Set

Comment

Rated Audio

Mode: GEN
Output level: 1.0 mV RF
Mod: 1kHz tone at
3 kHz deviation
Monitor: DVM: AC Volts

Use tuner tool
to program
repeater to an
appropriate
test frequency
with carrier
squelch.

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

Set volume to
7.75 Vrms via
tuner tool.

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 1mV RF

As above

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

Set volume to
7.75 Vrms via
tuner tool.

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)

Chapter 4 Repeater Programming and Tuning

4.1

Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner application, which are all designed for use on Windows 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. Repeater Software Program Kits

4.2

Description

Kit Number

MOTOTRBO CPS, Tuner and AirTracer Applications CD

RVN5115_

Customer Programming Software Setup
The Customer Programming Software setup, shown in Figure 4-1 is used to program the repeater.
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.

Repeater
ACC
AC

Rear Accessory
Connector

Mobile & Repeater Rear
Programming Cable PMKN4010_

120 / 240 VAC

Tx Port
Rx Port

USB

Figure 4-1. Customer Programming Software Setup from Rear Accessory Connector

4-2

4.3

Repeater Programming and Tuning: Repeater Tuning Setup

Repeater Tuning Setup
A personal computer (PC), Windows Vista/XP and a tuner program (which is available as part of the
MOTOTRBO CPS kit) are required to tune the repeater. To perform the tuning procedures, the
repeater must be connected to the PC and test equipment setup as shown in Figure 4-2.

Audio In
Test Box
RLN4460_

Audio Generator

SINAD Meter
AC Voltmeter

Mobile & Repeater Rear Accessory
Programming and Test Cable PMKN4016_
ACC
USB
AC
Tx Port

120 / 240 VAC
30 dB Pad

Rx Port

Service Monitor

RF Generator

Figure 4-2. Repeater Tuning Equipment Setup

WATT meter

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 repeater.
• Disassembly and reassembly of the Transmit and Receive radios.

5.2

Preventive Maintenance
Periodic visual inspection and cleaning is recommended.

5.2.1

Inspection
Check that the external surfaces of the repeater 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 repeater. External surfaces include the top
cover and repeater enclosure.
Periodically clean smudges and grime from exterior enclosure. Use a soft, non-abrasive cloth
moistened in a mild soap and water solution. Rinse the surface using a second cloth moistened in
clean water, and clean any dirt or debris from the fan grill and louvers on the front side.
NOTE: Internal surfaces should be cleaned only when the repeater is disassembled for service or
repair.
The only recommended agent for cleaning the external repeater 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).
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 repeater. 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 top cover and repeater enclosure.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).

5-2

5.3

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

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 repeaters, 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.
DO NOT attempt to disassemble the repeater without first referring to the following CAUTION
statement.

!
Caution

This repeater contains static-sensitive devices. Do not open the repeater 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.

Disassembly/Reassembly Procedures: Repair Procedures and Techniques – General

5.4

5-3

Repair Procedures and Techniques – General
NOTE

Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards – examples shown below) were developed and assembled using environmentally
preferred components and solder assembly techniques to comply with the European
Union’s Restriction of Hazardous Substances (ROHS 2) Directive 2011/65/EU and
Waste Electrical and Electronic Equipment (WEEE) Directive 2012/19/EU. To
maintain product compliance and reliability, use only the Motorola specified parts in this
manual.

Any rework or repair on Environmentally Preferred Products must be done using the appropriate
lead-free solder wire and lead-free solder paste as stated in the following table:
Table 5-1. Lead Free Solder Wire Part Number List
Motorola
Part Number

Alloy

Flux Type

Flux Content
by Weight

Melting
Point

Supplier Part
number

Diameter

Weight

1088929Y01

95.5Sn/3.8Ag/0.7Cu

RMA Version

2.7–3.2%

217°C

52171

0.015”

1lb spool

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

Manufacturer Part
Number

1085674C03

NC-SMQ230

Viscosity

Type

Composition & Percent Metal

900–1000KCPs
Brookfield (5rpm)

Type 3
(-325/+500)

(95.5%Sn–3.8%Ag–0.7%Cu)
89.3%

Liquid
Temperature
217°C

Parts Replacement and Substitution
When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
from the nearest Motorola Radio Products and Solutions Organization listed in Appendix A of this
manual.
Rigid Circuit Boards
This repeater 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.

5-4

5.5

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

Disassembling and Reassembling the Repeater – General
The following tools are required for disassembling the repeater:
• Small Flat Blade Screwdriver
• TORX™ T30 Driver Bit
• TORX™ T25 Driver Bit
• TORX™ T20 Driver Bit
• TORX™ T15 Driver Bit
• TORX™ T10 Driver Bit
• 7 mm Magnetic Socket Driver (extension of >150 mm)
• 16 mm Deep Well Socket Driver
• 19 mm Deep Well Socket Driver
If a unit requires more complete testing or service than is customarily performed at the basic level,
please send repeater to a Motorola Service Center listed in Appendix B.
The following disassembly procedures should be performed only if necessary.

5.6

Disassembly Procedures – Detailed
The following are typical procedures to remove and replace the Transmit radio, Receive radio,
Repeater Indicator Board, connector board assembly and other miscellaneous parts.
1. Power cord and all external cables must be disconnected before opening up repeater.
2. Take the proper grounding precautions as stated in Section 5.3: Safe Handling of CMOS and
LDMOS Devices on page 5-2.
3. When disassembling repeater, retain all screws for reuse.

5.6.1

Disassembly of Cover
1. Remove the five screws that retain the cover to the housing as shown in Figure 5-1 using a
T20 TORX™ driver.

Screws

Back View of Repeater

Top Cover
Front View of Repeater

Figure 5-1. Removing Top Cover of Repeater Enclosure

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

5.6.2

5-5

Disassembly of Repeater Indicator Board
(Refer to Figure 5-2 or Figure 5-3 and Figure 5-4)
1. Disconnect the blue Ethernet cable from the Ethernet connector on the Repeater Indicator
Board.
2. Disconnect the flex cable from the 30-position connector on the Repeater Indicator Board,
noting orientation of cable which is identified with a solid black line. This is important for
reassembly.

Ethernet
Connector

Repeater, LED
and USB
Converter Board

Flex Cable
Figure 5-2. Disconnecting Ethernet Cable and Flex Cable

5-6

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

3. For PMLN5643_, remove the ribbon cable from the 8-pin connector as well.

8-Pin Ribbon Cable

Ethernet
Connector

Repeater
Indicator
Board

Flex Cable

Figure 5-3. Disconnecting Ethernet Cable, Flex Cable and Ribbon Cable
4. Detach the front panel by removing the four M6 screws located on the front face of panel
using a T30 TORX™ driver.
5. Place the front panel on a flat surface with the Repeater Indicator Board facing up.
6. Detach the Repeater Indicator Board from front panel by removing the four M3 screws using
a T10 TORX™ driver.
7. Hold the Repeater Indicator Board on its outer edge with your finger tips, squeeze together
the catch of each clip and slightly press them through the board to remove the light guide.

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

5-7

8. Store Repeater Indicator Board in an anti-static bag when it is not being serviced.

Front Panel

M6 Screws (4)

Repeater Indicator Board

Light Guide
M3 Screws (4)
Figure 5-4. Repeater Indicator Board Disassembly

5.6.3

Disassembly of Fan
1. Unplug the fan cable from the mating connector on the connector board assembly.
2. Detach the fan assembly by removing the four screws that secure the fan grill and fan
assembly to the back of the enclosure using a T15 TORX™ driver.
3. Carefully remove fan, noting position of arrow which identifies direction of air flow. This is
important for reassembly.
Screws

Position of arrow
Back of Enclosure
Fan

Figure 5-5. Fan Orientation

5-8

5.6.4

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

Removing Transmit Radio
(Refer to Figure 5-6)
1. Disconnect the flex cable from the 30-position connector on the Transmit radio, noting the
orientation of the cable which is identified with a solid red line. This is important for
reassembly.
2. Remove the flex cable (with double sided adhesive tape) from the power supply.
3. Make sure that the double sided adhesive tape material is completely removed from the
power supply.
4. Disconnect the SSI flex cable from the connector on the Transmit radio, noting the orientation
of the cable which is identified with a solid black line. This is important for reassembly.
5. Loosen the four M4 lock nuts that secure the Transmit radio assembly with a
7 mm socket driver.
6. Slide Transmit radio assembly slightly forward before lifting it out of the enclosure.
7. Disconnect the power cable from the Transmit radio.
8. Disconnect the antenna cable from the Transmit radio.
9. Disconnect the accessory connector from the Transmit radio.
10. Lift the Transmit radio assembly out of the enclosure and place on a flat surface.
11. Loosen and remove the two M5 screws and washers that secure the Transmit radio to the
bracket using a T25 TORX™ driver.
M3 Screws (7)
Heatsink

Thermal Pad
Transmit Radio

M5 Screw (1)
M5 Screw (1)

Washer
Transmit Bracket
Figure 5-6. Tx Radio Disassembly

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

5-9

5.6.4.1 Removing Thermal Pad and Heatsink
(Refer to Figure 5-6)
1. Remove all of the seven screws which secure the heatsink to the Transmit radio using a T10
TORX™ driver.
2. Remove the heatsink from the Transmit radio.
3. Peel off and discard the thermal pad.
4. Replace all worn parts.

5.6.5

Removing Receive Radio, Power Supply and Connector Board Assembly
(Refer to Figure 5-7)
1. Disconnect the SSI flex cable from the connector on the Receive radio, noting the orientation
of the cable which is identified with a dotted line. This is important for reassembly.
2. Disconnect the antenna cable from the Receive radio.
3. Disconnect the power cable from the Receive radio.
4. Remove the two screws securing the retainer clip using a T20 TORX™ driver.
5. Remove accessory connector from the back side of repeater by inserting a flat blade
screwdriver into the slot located on the top of the connector.
6. Disconnect all of the cables from their mating connectors located on the connector board
assembly.
7. Loosen the five M4 lock nuts that secure the Receive radio assembly with a
7 mm socket driver.
NOTE: The two lock nuts at the side on base will require a magnetic lock nut driver with extension of
greater than 150 mm.
8. Slide Receive radio assembly slightly forward before lifting it out of the enclosure.

5-10

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

9. Take precaution not to damage the power supply or the connector board assembly and place
assembly on a flat surface.

Connector Board Assembly

Receive Bracket

Receive Radio

M5 Screws

M3 Screws (5)

Power Supply
Washer

Figure 5-7. Receive Radio Removal

Disassembly/Reassembly Procedures: Disassembly Procedures – Detailed

5-11

5.6.5.1 Disassembly of Receive Radio
(after Receive radio assembly is removed from repeater)
1. With assembly on a flat surface, loosen and remove the two M5 screws and washers that
secure the Receive radio to the bracket using a T25 TORX™ driver.
2. Slide the Receive radio out of the bracket.

5.6.5.2 Disassembly of Connector Board Assembly
(after Receive radio assembly is removed from repeater)
1. With assembly on a flat surface, detach the connector board assembly from Receive radio
assembly by removing the five M3 screws using a T10 TORX™ driver.
2. Store connector board assembly in anti-static bag when it is not being serviced.

5.6.5.3 Disassembly of Power Supply
(after Receive radio assembly is removed from repeater)
1. With assembly on a flat surface, loosen and remove the four M5 screws and washers that
secure the power supply to the bracket using a T25 TORX™ driver.
2. Slide power supply out from bracket.
3. Disconnect Y-split cable from power supply before sending to manufacturer.
NOTE: Power Supply should be serviced by manufacturer.

5-12

5.7

Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly – Detailed

Transmit and Receive Radio Disassembly – Detailed
To remove Transmit and Receive radios from the repeater, refer to Sections 5.6.4 and 5.6.5
accordingly.

5.7.1

Transceiver Board and Receiver Board Removal
1. Remove the seven screws from the die cast cover using the T20 TORX™ driver as shown in
Figure 5-8.
NOTE: Do not remove the O-rings from the screws.
2. Lift the die cast cover from the chassis.
NOTE: For VHF bricks only: check that the two thermal pads on the heat sink block are intact.
Replace them if damaged. Refer to Figure 5-19.

Screws (7)
Die Cast
Cover

Radio
Chassis

Figure 5-8. Die Cast Cover Removal.

Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly – Detailed

5-13

3. Remove the rear accessory connector from the radio assembly by inserting a flat-blade
screwdriver into the slot on the side of the connector as shown in Figure 5-9.

!
Caution

The rear accessory connector should never be removed when the cover is still
assembled to the radio.

Flat-blade
Screwdriver
Rear Accessory
Connector

Slot

Figure 5-9. Rear Accessory Connector Removal
4. Remove the RF/DC retention clips by gently prying them out with a flat-blade screwdriver as
shown in Figure 5-10.
RF/DC Retention Clips

Flat-blade
Screwdriver

Figure 5-10. RF/DC Retention Clips Removal

Flat-blade
Screwdriver

5-14

Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly – Detailed

5. Remove the transceiver board by sliding a finger into the opening provided at the front of the
radio and gently press up on the 30-pin connector, lifting up the front of the board, as shown
in Figure 5-11. 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.

!
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 5-11. Transceiver Board Removal

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5.8

5-15

Transmit and Receive Radio Reassembly – Detailed
The following reassembly procedures are applicable to both the Transmit and Receive radios.
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. Reseat all new seals on their respective parts.
For both the die cast cover 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 5.8.2: Thermal Pad Replacement Procedure on page 5-22 to replace damaged pads.

Chassis with Thermal Pads
and Shield Gasketing

Die Cast Cover with Thermal Pads
and Shield Gasketing

Figure 5-12. Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover
2. Thoroughly inspect the transceiver board and verify all thermal pads are in place and free
from damage. See Section 5.8.2: Thermal Pad Replacement Procedure on page 5-22 to
replace damaged pads. For VHF/UHF 32 MB bricks, refer to Figure 5-14.
Transistor
Thermal Pads
(75012018001)

PA Thermal Pad (75012015001)

Audio PA Component

Figure 5-13. Transceiver Board with Thermal Pads

5-16

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

Transistor
Thermal Pads
(75012018001)

PA Thermal Pad (75012015001)

Audio PA Component

Apply Thermal Grease (1180113S01)
on Final Heat Spreader and Driver Heat Sink
Figure 5-14. Transceiver Board with Thermal Pads (VHF/UHF 32 MB Bricks)
3. Assembly of the GPS Plug
Push the GPS plug into the chassis opening until it is fully seated. Refer to Figure 5-15.

GPS Plug
GPS Plug

Figure 5-15. Replacing GPS Plug

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5.8.1

5-17

Transceiver Board and Receiver Board Reassembly
1. Insert the transceiver board into the chassis by tilting the transceiver board (approximately 30
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.
Ensure that the transceiver board alignment holes are positioned over the chassis alignment
bosses and then push the board down to fully seat.
Locating Bosses

Figure 5-16. Placing the Transceiver Board in the Chassis

!
Caution

Do not leave the transceiver board in the chassis for extended periods of time
without the RF/DC retention clips, or damage to the board connectors may
occur.

5-18

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

2. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to
properly locate the transceiver board. Refer to Figure 5-17.

RF/DC
Retention Clips

Figure 5-17. Inserting RF/DC Retention Clips
3. Insert the rear accessory connector into the radio assembly and press into place until the
connector is flushed with the chassis. Refer to Figure 5-18.

Rear Accessory
Connector
Figure 5-18. Inserting Rear Accessory Connector

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5-19

4. Place the PA pad on to the die cast cover by aligning the two holes in the PA pad with the
alignment pins on the die cast cover. For VHF 32 MBand UHF bricks, refer to Figure 5-20.
For VHF 8 MB bricks only: PA heat sink block and thermal pads need to be placed on to the
pressure pad before it gets assembled to the die cast cover. Refer to Figure 5-19 and
Figure 5-21.
a. Remove thermal pad (7571835M01) from the shipping liner and place it on to the heat
sink block by aligning the rounded corners. Remove the protective liner from the exposed
side of the thermal pad.
b. Insert the heat sink block with the thermal pad attached into the compartment on the PA
pressure pad, until it is fully seated. The attached thermal pad should be fully visible after
assembly.
c. Remove thermal pad (7571836M01) from the shipping liner and place it on to the exposed
metal surface of heat sink block by orienting the thermal pad so its shape matches the
opening on the pressure pad.
d. Remove the protective liner from the exposed side of the thermal pad (7571836M01).
Thermal Pad
(7571836M01)

VHF Pressure Pad

Heat Sink
(2671834M01)

Thermal Pad
(7571835M01)
Figure 5-19. Assembling of PA Heat Sink System (VHF 8 MB Brick)

5-20

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5. Fit the O-ring onto the die cast cover securely. Refer to either Figure 5-20 or Figure 5-21.

O-ring

PA Pad

Die Cast Cover

Figure 5-20. Assembling of PA Pad and O-ring (VHF 32 MB and UHF Bricks)

O-ring

PA Pad

Die Cast Cover

Figure 5-21. Assembling of PA Pad and O-ring (VHF 8 MB Brick)

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5-21

6. Place the die cast cover onto the chassis orienting the die cast cover so that screw holes 6
and 7 align with the bosses on the chassis as shown in Figure 5-22.

Screws (7)

Die Cast Cover

Radio Chassis

Figure 5-22. Assembling Die Cast Cover onto Chassis

5-22

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

7. Using a T20 TORX™ driver, tighten the seven screws between 2.94 N-m (26 lbs-in) in the
order shown in Figure 5-23.
8. Repeat tightening the seven screws in the order shown otherwise the first three screws will
likely be loose.

Figure 5-23. Screw Sequence to Tighten Die Cast Cover

5.8.2

Thermal Pad Replacement Procedure
A. Chassis Thermal Pad Replacement Procedure
Harmonic Filter 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
white side down on the chassis as shown in Figure 5-24.
Harmonic Filter
Pad (75012017001)

Harmonic Filter
Pad (75012016001)

Radio Chassis

Figure 5-24. Replacing Thermal Pads

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5-23

Driver Thermal pad Replacement (Not applicable to VHF/UHF 32 MB bricks)
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis, aligning the edges of the pad with the edges of the chassis, as shown
in Figure 5-25.

Driver Pad
(7515357H01)

Radio Chassis

Figure 5-25. Aligning Driver Pad on Chassis
4. Apply even pressure to the pad and remove the protective liner.

5-24

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

B. Transceiver Board Thermal Pad Replacement Procedure
Transistor Thermal Pads and PA Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift each pad from the transceiver board. Discard the old pads.
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 each new pad from the shipping liner, and place in
the proper location on top of each transistor component and the audio PA with the white side
down (see Figure 5-26). For VHF/UHF 32 MB bricks, refer to Figure 5-27.

Transistor
Thermal Pads
(75012018001)

PA Thermal Pad (75012015001)

Audio PA Component

Figure 5-26. Placing Thermal Pads on PA and Transistor Components

Transistor
Thermal Pads
(75012018001)

PA Thermal Pad (75012015001)

Audio PA Component

Apply Thermal Grease (1180113S01)
on Final Heat Spreader and Driver Heat Sink
Figure 5-27. Placing Thermal Pads on PA and Transistor Components (VHF/UHF 32 MB
Bricks)

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5.8.3

5-25

Reassembly of Receive Radio, Power Supply and Connector Board Assembly
(Refer to Figure 5-7)
Visually inspect repeater enclosure to ensure that no metal shavings or debris are found.

5.8.3.1 Reassembly of Power Supply
1. Align the two mounting holes on each side of the bracket with the mounting holes on the
power supply.
2. Secure the power supply and the bracket with four M5 screws and washers.
3. Tighten the four M5 screws to 3.0 N-m.
4. Firmly connect the single connection end of Y-split cable to power cable of power supply.

5.8.3.2 Reassembly of Receive Radio
1. Insert the Receive radio into the top half of the bracket.
2. Align mounting hole on each side of the receive chassis to the mounting holes on the bracket.
3. Secure the Receive radio and the bracket with two M5 screws and washers.
4. Tighten the two M5 screws to 3.0 N-m.

5.8.3.3 Reassembly of Connector Board Assembly
1. Align the five mounting holes on the connector board assembly onto the five standoffs on the
receive bracket and install five M3 screws.
2. Tighten the five M3 screws to 1.0 N-m.

5.8.3.4 Reassembly of the Receive Bracket Assembly to the Enclosure
1. Align and mount the receive bracket assembly onto the five stud screws in the enclosure.
2. Ensure that the dimple locator (bump) on the enclosure is nested within the hole on the
receive bracket before installing and tightening the lock nuts.
3. Tighten the five lock nuts to 2.0 N-m.
NOTE: The two lock nuts at the side on base will require a magnetic lock nut driver with extension of
greater than 150 mm.
4. Connect the antenna cable to the Receive radio.
5. Insert the BNC connector of the antenna cable through the back panel of the enclosure and
secure it using a lock washer and nut.
6. Tighten the nut to 2.3 N-m using a 16 mm deep well socket driver.
7. Firmly connect one of the connectors from the dual end of Y-split cable to the Receive radio.
NOTE: All cables (except the antenna cable), are routed at the bottom rear receive bracket.
8. Insert the accessory connector through the opening of the enclosure onto the edge of the
connector board assembly.
9. Make sure that the accessory connector is completely inserted onto the connector board
assembly and the back end surface of the accessory connector is flushed firmly against the
back panel of enclosure.

5-26

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

10. Mount the retainer clip and secure it with two M4 screws.
11. Tighten the screws to 2.0 N-m.
12. Insert the solder terminal end of the SSI cable into the 11-position connector at the front face
of Receive radio. A dashed black line is visible from the top view.

5.8.4

Reassembly of Transmit Radio
(Refer to Figure 5-6)

5.8.4.1 Replacing the Thermal Pad and Heatsink
1. Make sure that mating surfaces of Heatsink and Transmit radio are cleaned and free from any
debris.
2. Align the holes on the thermal pad to the screw holes in the Transmit radio and place thermal
pad onto the Transmit radio.
3. Align the holes on the heatsink to the screw holes in the Transmit radio and place heatsink
onto the thermal pad.
4. Secure but do not tighten the seven screws previously removed.
5. When all seven screws are secured, tighten the screws to 1.0 N-m. Refer to Figure 5-23.

5.8.4.2 Reassembly of the Transmit Bracket Assembly to the Enclosure
1. Position the Transmit radio onto the transmit bracket so that the label “FRONT” on bracket is
facing the front face of radio.
2. Align the mounting holes on the Transmit radio and the transmit bracket on both sides.
3. Attach and secure the M5 screws and washers on each side of the bracket.
4. Tighten the screws to 3.0 N-m, making sure the Transmit radio remains horizontal.
5. Align and mount the transmit bracket assembly onto the four stud screws in the enclosure.
6. Ensure that dimple locator (bump) on the enclosure is nested within the hole on the transmit
bracket before installing and tightening the lock nuts.
7. Secure the four lock nuts (two on each side) onto the stud screws.
8. Tighten the four lock nuts to 2.0 N-m.
9. Connect the antenna cable to the Transmit radio.
10. Insert the N-Type connector of the antenna cable through the back panel of the enclosure
and secure it using a lock washer and nut.
11. Tighten the nut to 2.3 N-m using a 19 mm deep well socket driver.
12. Firmly connect one of the connectors from the dual end of Y-split cable to the Transmit radio.
13. Connect the black colored end of accessory cable connector to rear of Transmit radio making
sure that the locking connector tab is facing up.
14. Connect the white colored end of the accessory cable connector to the connector board
assembly making sure that the locking connector tab is facing toward the front of repeater.
NOTE: Make sure that the accessory connectors at both ends are locked in place. A clicking sound
can be heard from the locking tab.

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5-27

15. Position accessory cable harness against side of fan body. See Figure 5-28.

Fan

Accessory
Cable
Harness

Figure 5-28. Assembly of Accessory Cable Harness
16. Insert the solder terminal end of the SSI flex cable (positioned bottom side of PCB) into the
11-position connector in the Transmit radio. A solid black line is visible from the top view.
17. Insert the solder terminal end of the flex cable (positioned top side of PCB) into the
30-position connector in the Transmit radio. A solid red line is visible from the top view.
18. On the flex cable, peel the paper on the back of the adhesive tape. (Not applicable for VHF/
UHF 32 MB repeaters).
19. Make sure that the surface on the power supply is free of grease and debris where the flex
cable adhesive tape will be applied. (Not applicable for VHF/UHF 32 MB repeaters).

5-28

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

20. Apply the adhesive tape so that the vertical left edge of the adhesive tape aligns with the left
vertical edge of the power supply as shown in Figure 5-29. Notice that the bottom edge of the
flat cable is touching or almost touching the bottom of the enclosure. (Not applicable for VHF/
UHF 32 MB repeaters).

Note: Tape edge is located
near edge of power supply

Adhesive tape location on
the other side of cable

Note: This edge touching or almost
touching the bottom of the enclosure

Figure 5-29. Mounting the Adhesive Tape Flex Cable to Power Supply

Flex Cable

Figure 5-30. Flex Cable Assembly (VHF/UHF 32 MB Repeaters)

Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly – Detailed

5.8.5

5-29

Reassembly of Fan
1. Position the fan in the enclosure with arrow pointing outward and the wires on the fan at the
bottom right corner of the fan.
Screws

Position of arrow
Back of Enclosure
Fan

Figure 5-31. Fan Orientation
2. Position the fan grill outside of the enclosure aligning with the screw holes.
3. Install four 3.5 mm screws through the fan grill and the rear panel of the enclosure.
4. Secure the fan and tighten the four screws to 1.6 N-m and into threaded insert.
5. Plug the fan cable plug into the 4-position fan connector on the connector board assembly.
NOTE: It is recommended that you dress and tie wrap the blue Ethernet cable and the fan cables.

5.8.6

Reassembly of Repeater Indicator Board
(Refer to Figure 5-4)
1. Holding Repeater Indicator Board on outer edge, insert the clips of light guide into mounting
holes, making sure the light guide snaps into place.
2. Align the four mounting holes on the Repeater Indicator Board onto the four standoffs on the
front panel.
3. Install and secure the four M3 screws.
4. Tighten the four M3 screws to 1.0 N-m.
5. Use the four M6 screws to secure the front panel onto the enclosure. Tighten the screws to
3.7 N-m.
6. Connect the blue Ethernet cable from the Connector board onto the Ethernet connector on
the Repeater Indicator Board.
7. Insert the flex cable onto the 30-position connector on the Repeater Indicator Board. The
solder terminal end of the flex cable is faced towards the front panel. A solid black line is
visible from the top view.
8. Connect the 8-pin DC cable from the Connector board onto the 8-pin connector on the
Repeater Indicator Board (Applicable for VHF/UHF 32 MB repeaters only).

5-30

Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists

5.8.7

Reassembly of Cover
1. Place the cover on the enclosure.
2. Secure the two M4 screws on each side of the cover and one at the top. Tighten the screws
to 2.0 N-m.

5.9

Repeater Exploded Mechanical Views and Parts Lists

Transmit Bracket &
Radio Assembly
See following pages
for breakdown.

32
7
13
12

34
15
10

17
5
9

6
3
16
2

Receive Bracket &
Radio assembly
See following pages
for breakdown.

Front Panel
complete assembly
See following pages
for breakdown.

Figure 5-32. Repeater Assembly Exploded View

Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists

Transmit Bracket &
Radio Assembly.
See following pages
for breakdown.

5-31

32
7
10
9

12
17
11
16
13
14

15
34

35
2

Front Panel
complete assembly.
See following pages
for breakdown.

3
1

Receive Bracket &
Radio assembly.
See following pages
for breakdown.

Figure 5-33. Repeater Assembly Exploded View (VHF/UHF 32 MB Repeaters)

5-32

Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists

23
20 31

18
19

22
21

Figure 5-34. Receive Bracket and Radio Assembly Exploded View

26
25
24

31
Figure 5-35. Transmit Bracket and Radio Assembly Exploded View

Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists

2
Figure 5-36. Front Panel Complete Assembly Exploded View
Table 5-3. Repeater Exploded View Parts List
Item No.

Description

Part Number

Screw, TT6x1.0x10, Starpan, EM6219 (black)

0312016A54

Repeater Indicator Board (VHF/UHF 8 MB Repeaters)
Repeater Indicator Board (VHF/UHF 32 MB Repeaters)

PMLN5269_
PMLN5643_

Cable, Flex SSI

3015639H01

Cable, Flex 30-Position (VHF/UHF 8 MB Repeaters)
Cable, Flex 30-Position (VHF/UHF 32 MB Repeaters)

3015634H01
3015634H02

Fan Assembly

5915618H01

Enclosure Assembly

1515837H01

Top Cover

1515655H01

Cable, RF Rx, W/BNC

3015574H01

Cable, RF Tx, W/N-Type

3015573H01

Fan Grill

1383852R01

Screw, TT3.5x0.6x16, Star SLT Pan

0371805M01

M6 Ground Nut

0285854Y01

M6 Ground Screw

0310909A95

Accessory Retainer Clip

4216361H01

Rear Accessory Connector

0178042A01

5-33

5-34

Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists

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

Description

Part Number

Screw, M4x0.7x13.0, Starpan STLZNC

0310909E63

Lock Nut M4

0285854Y02

Power Supply

PMPN4001_

Screw, M5x0.8x8.0, Starpan STLZNC

0310909A74

Receive Radio Brick Assembly

See Sections 1.4
through 1.8 to identify
proper Repeater
XCVR Service Kit.

Connector Board Assembly
(For use with 8 MB and 32 MB Repeaters)

PMLN5644_

Screw, M3x0.5x5, Starpan STLZNC

0310909A30

RX Bracket Assembly

0715656H01

Transmit Radio Brick Assembly

See Sections 1.4
through 1.8 to identify
proper Repeater
XCVR Service Kit.

Thermal Pad

7515633H01

Heatsink

2615620H01

Screw, M3x0.5x10, Starpan STLZNC

0310909A33

Tx Bracket

0715654H01

Front Panel Assembly only (handles not included)

6415658H04

Light Guide

6116326H01

Washer

0400002647

Cable Assembly, Tx to Connector Board

3015570H01

Cable, Power, Y-Split

3085859M01

Cable, Ethernet

3015575H01

Cable, DC (VHF/UHF 32 MB Repeaters)

30009303001

Disassembly/Reassembly Procedures: Torque Chart

5-35

5.10 Torque Chart
Table 5-4 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 repeater.
Table 5-4. Torque Specifications for Nuts and Screws
Part
Number

Description

Driver/ Socket

Torque
N-m

lbs-in

kg-cm

0285854Y01

Grounding Nut, M6

10 mm dip socket

2.0

17.70

20.4

0285854Y02

Lock Nut, M4 x 0.8, ext tooth

7 mm socket

2.0

17.70

20.4

0310909A30

Screw, M3.0 x 0.5 x 5 mm

T10 Torx™

1.0

8.9

10.2

0310909A33

Screw, M3 x 0.5 x 10 mm

T10 Torx™

1.0

8.9

10.2

0310909A74

Screw, M5 x 0.8 x 8 mm

T25 Torx™

3.0

26.6

30.6

0371805M01

Screws, M3.5 x 0.5 x 16 mm

T15 Torx™

1.6

14.2

16.3

0310909A95

Grounding Screw, M6 x 1 x 25

T30 Torx™

2.0

17.7

20.4

0312016A54

Screws, TT6 x 1.0 x 10 mm
Star Thread Rolling Screw

T30 Torx™

3.7

32.7

37.7

0310909E63

Screw, M4 x 0.7 x 7 mm,
Slotted Star

T20 Torx™

2.0

17.7

20.4

3015574H01

BNC Type connector

16 mm deep well socket

2.3

20.4

23.5

3015573H01

N Type connector

19 mm deep well socket

2.3

20.4

23.5

5-36

Disassembly/Reassembly Procedures: Torque Chart

Notes

Chapter 6 Basic Troubleshooting

6.1

Introduction
This chapter contains error codes and board replacement procedures. If the repeater does not pass
all the performance checks in Chapter 3, then please send the repeater 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 repeater 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 repeater.

Replacement Service Kit Procedures
Once a problem has been isolated to a specific board, install the appropriate service kit (see Model
Charts on page 1-3), which is orderable from Motorola Solutions Parts Organization at
1-800-422-4210. Refer to https://businessonline.motorolasolutions.com for further information.
If a board is replaced, it does not need to be retuned if it has been purchased through Motorola
Solutions Parts, as it is already factory tuned. It should however be checked for performance before
being placed into service.

!
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

6.2.1

Basic Troubleshooting: Replacement Service Kit Procedures

Replacing and Initializing Service Kits for XPR 8300/XPR 8400 Repeaters
1. Note the firmware version in the repeater, before beginning the service kit replacement.
2. It is recommended to archive the existing Codeplug that is programmed in the repeater.
3. Remove the Defective Transmit Radio per the instructions in Section 5.6.4 on page 5-8.
4. Verify the Firmware version in the new Transmit Radio. If it is the same as the existing
Receive Radio, proceed to step 7.
NOTE: Ignition Sense voltage (13.5 Vdc) needs to be applied to pin 25 in order for the radio to power
up (XPR 8400).
5. If the firmware version in the repaired Transmit Radio is newer than the version in the
Receive Radio, the Receive Radio must be upgraded prior to installing the new replacement
Transmit Radio. To upgrade the Receive Radio independently, remove the RSSI cable from
the front of the transceiver and connect the programming cable directly to the Rear
Accessory Connector of the Receive Radio.
NOTE: Ignition Sense voltage (13.5 Vdc) needs to be applied to pin 25 in order for the radio to power
up (XPR 8400). Use the CPS to upgrade the Receive Radio to the same version as the new
Transmit Radio.

!
Caution

When upgrading the repeater radios individually, you must ALWAYS use the
Repeater firmware package from MOL. Never attempt to upgrade a repeater
radio with the Mobile firmware packages.

6. If the replacement Transmit Radio has an older version than the original Receive Radio,
repeat the above upgrade process with the replacement Transmit Radio.
7. Install the new Transmit Radio according to the reassembly instructions in Section 5.8.4 on
page 5-26.
8. The replacement Transmit Radio will require the Serial Number of the Repeater to be entered
before it can be read or programmed with the CPS. Connect the repeater to the MOTOTRBO
Tuner and follow the instructions to enter the serial number noted on the back label of the
repeater, into the newly installed Transmit Radio. Tuning is not required, as the Transmit and
Receive Radios have been factory tuned for both TX and RX parameters
9. After powering on the repeater and verifying functionality, either program with the existing
archive, or read and reprogram the repeater with a new configuration. (This is necessary
since the programming information is stored in the Transmit Radio.

Basic Troubleshooting: LED Indicator Descriptions

6.3

6-3

LED Indicator Descriptions
Table 6-1. LED Indicator Descriptions
LED
Power

Description

Solid GREEN

Repeater powered by AC

Solid RED

Repeater powered by back-up battery

Off

Repeater powered off

Solid RED

Repeater function disabled

Blinking RED

Repeater in self test mode

Off

Repeater in normal operational mode

Digital

Solid BLUE

Repeater in Digital mode

Analog

Solid YELLOW

Repeater in Analog mode

TX-A

Solid GREEN

Repeater transmitting (Analog)

Solid GREEN

Repeater transmitting on Slot A (Digital)

Solid YELLOW

Repeater receiving (Analog)

Solid YELLOW

Repeater receiving on Slot A (Digital)

TX-B

Solid GREEN

Repeater transmitting on Slot B (Digital)

RX-B

Solid YELLOW

Repeater receiving on Slot B (Digital)

Repeater
Disable

RX-A

6.4

Status

Ethernet LED Indicator Descriptions
Table 6-2. Ethernet LED Indicator Descriptions
LED
Yellow

Green

Status

Description

Solid YELLOW

Link valid

Blinking YELLOW

Tx/Rx activity

Solid GREEN

100 Mbits speed

Off

10 Mbits speed

NOTE: Table 6-2 is only applicable for VHF/UHF 32 MB Repeaters.

6-4

Basic Troubleshooting: Ethernet LED Indicator Descriptions

Notes

Chapter 7 Accessories

7.1

Introduction
Motorola provides the following approved accessories to improve the productivity of your repeater.
For a list of Motorola-approved accessories, visit the following web site:
http://www.motorolasolutions.com

7.1.1

7.1.2

7.1.3

Antennas
Part No.

Description

RDD4527_

VHF 3 dB Gain Antenna 150–158 MHz

RDE4554_

3.8 dB Gain Omni Antenna 488–512 MHz

RDE4555_

3.8 dB Gain Omni Antenna 470–488 MHz

RDE4556_

3.8 dB Gain Omni Antenna 450–470 MHz

RDE4557_

3.8 dB Gain Omni Antenna 403–420 MHz

Cables
Part No.

Description

PMKN4010_

Mobile & Repeater Rear Programming Cable

PMKN4016_

Mobile & Repeater Rear Accessory Programming and Test
Cable

PMKN4018_

Mobile & Repeater Rear Accessory Connector Universal
Cable

RKN4152_

Battery Back-up Cable

Miscellaneous Accessories
Part No.

Description

PMLE4476_

Wall Mount Kit for MOTOTRBO Repeater

PMLE4548_

Rack Mount for 1 duplexer and 1 preselector

RRX4032_

Tower Mounting Hardware for RRX4038

RRX4038_

RF Surge Suppressor

RFE4000_

Untuned Duplexer, 450–470 MHz

HFE8400_

Untuned Duplexer, 406–450 MHz

HFE8401_

Untuned Duplexer, 470–512 MHz

HFE8454_

Untuned Duplexer, 490–527 MHz

HFE8459_

UHF Preselector, 440–474 MHz

7-2

Accessories: Introduction

Part No.

Description

HFE8460_

UHF Preselector, 474–527 MHz

HFD8188_

VHF Duplexer, 144–155 MHz
(min & max freq sep 4.5 MHz/6 MHz)

HFD8189_

VHF Duplexer, 155–162 MHz
(min & max freq sep 4.5 MHz/6 MHz)

HFD8190_

VHF Duplexer, 162–174 MHz
(min & max freq sep 4.5 MHz/6 MHz)

HFD8461_

VHF Preselector, 144–160 MHz

HFD8462_

VHF Preselector, 160–174 MHz

Appendix A

A.1

Replacement Parts Ordering

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

A.2

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

A.3

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

A.4

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

A.5

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

A-2

A.6

Replacement Parts Ordering: Parts Identification

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

A.7

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

Appendix B

B.1

Motorola Service Centers

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

B.2

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

B.3

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

B.4

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

B-2

Motorola Service Centers: Canadian Technical Logistics Center

Notes

Appendix C

C.1

Digital Telephone Patch (DTP) Tuning
Guideline

MRTI2000

C.1.1 Hardware Connection
PL1877A (MRTI2000)
1

PL Strip

PL Strip Return

Monitor

Monitor Return

PTT

PTT Sense

Data TX

TX Audio

TX Audio Return

RX Audio Return

RX Audio

PL Detect

Carrier Detect

Optional Input #1

Patch Inhibit

Optional Input #2

Repeater

Shield Audio Cable(1)

Shield braid of Tx Audio
Shield braid of Rx Audio

PTT(2)

Tx Audio

Audio GND

Rx Audio

COR(2)

Figure C-1. MRTI2000 and Repeater Hardware Connection
1. Apply shielded audio cable for Tx and Rx Audio connections to avoid any possible
interference to speech signal. The connection of the shielded cable braid is indicated in
Figure C-1.
2. The GPIO pin for PTT and COR function is configured in the CPS. Confirm that the CPS
setting matches the Pin information. See “Figure C-1. MRTI2000 and Repeater Hardware
Connection” on page C-1.
IMPORTANT:

Refer to the MRTI2000 service manual (Pub. 43004-019B) to install and
program the phone patch for initial setup. See Section “C.1.3
Programming and Tuning” on page C-2 for more information on how to
setup the Digital Telephone Patch application.

C-2

Digital Telephone Patch (DTP) Tuning Guideline: MRTI2000

C.1.2 Jumpers on Phone patch
JU202 – out (default), to support low Rx Audio input level.

C.1.3 Programming and Tuning
C.1.3.1 Programming the Phone Patch with PC Tool provided by Gai-Tronics
Figure C-2 configures RX audio path, Figure C-3 configures the phone patch to work under
Half-Duplex mode and Figure C-4 configures the Access and Deaccess code.

Figure C-2. MRTI2000 Rx Audio Path Setting

Figure C-3. MRTI2000 Operation Mode Setting

Digital Telephone Patch (DTP) Tuning Guideline: MRTI2000

C-3

Figure C-4. MRTI2000 Access/Deaccess Setting

C.1.3.2 Enter Diagnostic Test Mode
1. To enter Diagnostic Test Mode, simultaneously press the UP and DOWN buttons.
2. To enter another test when at Diagnostic Test Mode, press the PATCH ON/OFF button.
3. To exit, press both the UP and PATCH ON/OFF buttons simultaneously.
NOTE: Each time a new test is selected, a test timer is set to 15 minutes. If this timer reaches zero,
the patch resets itself to idle, ready for normal operation.

C.1.3.3 TX Softpot Adjustment
1. Press both the UP and DOWN buttons simultaneously to enter Diagnostic Test 1. This
procedure also activates PTT, and generates a 1000 Hz tone to the transmitter.
2. Press the UP or DOWN button to adjust the transmit level. Monitor the Tx Audio line to reach
226 mVpp at Tx Audio line.
3. After the desired level is achieved, press the PATCH ON/OFF button. The value set remains
stored in memory unless it is changed through an adjustment in Test 1.
4. To exit the test, press the UP and PATCH ON/OFF buttons simultaneously.

C.1.3.4 Mobile-to-Phone Audio Path
1. Rx Audio path setting is performed as indicated in Figure C-2, no additional tuning is
required.

C-4

C.2

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M30

Zetron M30

C.2.1 Hardware Connection

Zetron M30

Repeater

12VDC

12V DC

GND

12V DC GND

DISC

GND

TX AUD

Braid of Shield Cable
Braid of Shield Cable

Power GND

Rx Audio

Audio GND

Tx Audio
Audio GND
PTT(2)
COR(2)

GND

PTT

18
17

COR IN

EE CODE

AUX OUT

Shield Audio Cable(1)
Figure C-5. Zetron M30 Hardware Connection

1. Apply shielded audio cable for Tx and Rx Audio connections to avoid any possible
interference to speech signal. The connection of the shielded cable braid is indicated in
Figure C-5.
2. The GPIO pin for PTT and Carrier Operated Relay (COR) function is configured in the CPS.
Confirm that the CPS setting matches the Pin information. See “Figure C-5. Zetron M30
Hardware Connection” on page C-4.
IMPORTANT:

Refer to the Zetron M30 service manual (part number 025-9140P) to
install and program the phone patch for initial setup. See Section “C.2.3
Setting up the Zetron Input and Output Signal Levels” on page C-5 for
more information on how to setup the Digital Telephone Patch
application.

C.2.2 Jumpers on Phone patch
JP8 – C, COR polarity, low active
JP7 – B, external COR

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M30

C-5

C.2.3 Setting up the Zetron Input and Output Signal Levels
There are two ways to access the required Zetron M30 test mode. The method using a DTMF
telephone is described in detail, to access using a PC or terminal please refer to Zetron manual.
Equipment Required:
• MOTOTRBO radio
• Local DTMF (Touch-Tone) phone and analog PSTN phone line
• Oscilloscope
• Signal Generator (optional - dependent on tuning method used. See
section C.2.3.6 on page C-6)
• Audio Box (optional - dependent on tuning method used. See section C.2.3.6 on page C-6)

C.2.3.1 Hardware Setup and Basic Check
1. Connect Phone Patch to the repeater according to Figure C-5.
2. Connect analog telephone line from the PSTN or from a local PBX to the phone patch.
3. Power up both. The power LED should be lit on both.

C.2.3.2 Force a Reset, Recover to Factory Default Setting
1. Press down the “connect” button on the front of the Analog Phone Patch (APP), then power
up.
2. Hold the “connect” button until the phone light starts blinking (about four seconds), then
release the button.

C.2.3.3 Enter Program Mode
1. Dial the line number of APP.
2. Hold for about 14 rings until a two-beep prompt tone is heard.
3. Enter the program mode access code, “12123”.
NOTE: Disconnect the repeater to enter program mode to avoid Base Radio (BR) assertion of Carrier
Operated Relay (COR) even when BR is powered off.

C.2.3.4 Program to Half Duplex Mode and COR to Answer
1. Enter 40# – Program operation mode to “Half Duplex Mode”
2. Enter 60# – Program mobile answer mode to “COR To Answer”

C.2.3.5 Set Transmit Audio Gain
1. Enter programming mode C.2.3.3.
2. At jumper JP-3 in the “B” (LOW Gain), enter the DTMF command “92#”.
3. The transmitter is keyed and a 1 kHz test tone is generated for 30 seconds.
4. Using the oscilloscope to monitor the Tx Audio line tone signal, adjust the Transmit Level pot
(R5) to 226 mVpp at Tx Audio line.
5. If the desired deviation of 226 mVpp cannot be achieved, move JP-3 to the “A” (HI Gain)
position and repeat step 2 to step 4 above.

C-6

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M30

C.2.3.6 Set Receive Level
Receive Level setting impacts the speech volume heard at the phone end. The settings below are
recommended and adjustment is allowed depending on requirement. Two calibration methods are
available. Use either Method 1 or Method 2 to do the tuning.
• Method 1 – Since the Motorola repeater has the same Rx Audio output level under digital and
analog mode, refer to the Zetron M30 service manual, (Chapter 5 Installation) to set the Rx
level under analog mode first and then switch to digital mode directly when the setting is ready.
No additional setting is required.
• Method 2 – Tuning with injected sine tone from MOTOTRBO subscriber, under digital mode.
Equipment: Oscilloscope, MOTOTRBO Portable/Mobile subscriber, Audio Box (Motorola part
number: RLN4460B), Signal Generator
NOTE: Disable “Digital Mic AGC” on MOTOTRBO subscriber with the CPS before calibration.
1. Enter programming mode C.2.3.3.
2. Open the shell of M30 and connect the oscilloscope probe to U1 PIN 14.
3. Setup DTP connection and verify that phone call is setup correctly.
4. If a MOTOTRBO Portable radio is used,
a. Configure the Signal Generator to output 1031 Hz sine tone, amplitude set as 22.6 mVpp
(8 mVrms).
b. Inject the signal to the Audio Box audio input port.
c. Attach the Audio Box GCAI connector to the accessory port of the MOTOTRBO
subscriber .
d. Setup a phone call and during the phone call, assert PTT knob on Audio Box to transmit
from radio, phone should hear the tone.
5. If a MOTOTRBO Mobile radio is used,
a. Configure the Signal Generator to output 1031 Hz sine tone, amplitude set as 226.3 mVpp
(80 mVrms).
b. Inject the signal to the MOTOTRBO mobile radio rear port, PIN 11 Tx Audio, Signal
Generator’s ground connects to MOTOTRBO mobile radio rear port, PIN 18 Audio
ground.
c. Setup a phone call and during the phone call, assert MOTOTRBO mobile radio’s external
PTT with rear port PIN 17 PTT to transmit from radio, phone should hear the tone.
6. While MOTOTRBO subscriber radio (Portable or Mobile) is transmitting with the tone, verify
that the repeater Rx Audio output is close to 1.0 Vpp and adjust the RECEIVE GAIN (R4) on
M30 for a 1.0 Vpp tone signal at U1 PIN 14. If this level with JP-1 in position A is not reached,
move it to position B.

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M735

C.3

C-7

Zetron M735

C.3.1 Hardware Connection
Zetron M735
1

9-12 VAC or +12VDC

9-12 VAC

Power Ground

Ground

PTT N.C.

PTT Common

PTT N.O.

Auxiliary output

Auxiliary input

COR Input

Transmit Audio

Repeater

12V DC

12V DC GND

Braid of Shield Cable

TX / Gnd

CTCSS / DCS Output

Disc / Gnd

Receiver Audio

Shield of Shield Cable

Power GND

PTT(2)

COR(2)

Tx Audio

Audio GND

Rx Audio

Shield Audio Cable(1)
Figure C-6. Zetron M735 Hardware Connection
1. Apply shielded audio cable for Tx and Rx Audio connections to avoid any possible
interference to speech signal. The connection of the shielded cable braid is indicated in
Figure C-6.
2. The GPIO pin for PTT and COR function is configured in the CPS. Confirm that the CPS
setting matches the Pin information. See “Figure C-6. Zetron M735 Hardware Connection” on
page C-7.
IMPORTANT:

Refer to the Zetron M735 service manual (part number 025-9369E.1) to
install and program the phone patch for initial setup. See Section “C.3.3
Setting up the Zetron Input and Output Signal Levels” on page C-8 for
more information on how to setup the Digital Telephone Patch
application.

C.3.2 Jumpers on Phone patch
JP21 – B, External COR
JP31 – A, negative COR
JP24 – A, flat output at Tx Audio

C-8

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M735

C.3.3 Setting up the Zetron Input and Output Signal Levels
There are two ways to access the required Zetron M735 test mode. The method using a DTMF
telephone is described in detail, to access using a PC or terminal please refer to Zetron manual.
Equipment Required:
• MOTOTRBO radio
• Local DTMF (Touch-Tone) phone
• Oscilloscope

C.3.3.1 Hardware Setup and Basic Check
1. Connect Phone Patch to the repeater according to Figure C-6.
2. Connect analog telephone line from the PSTN or from a local PBX to the phone patch.
3. Power up both, the power LED should be lit on both.

C.3.3.2 Enter Program Mode
Either,
1. Call up the Model 735 phone number.
2. When prompted by the Model 735 (925 Hz beep) to over-dial a user number or ANI, enter the
program access code (12735 by default).
CAUTION:

A high pitched modem tone is heard. Enter the DTMF # which will stop the
Model 735 from looking for a modem. After that, five short beeps are heard to
confirm access to the DTMF programming mode.

Or,
1. Connect M735 to a PC via RS-232 cable
2. Open the settings menu and select Communications.
3. Then set the following parameters:
- Baud rate = 2400
- Data bits = 8
- Stop bits = 1
- Parity = None
- Flow Control = XON/XOFF
- COM Port = the port the modem is connected to or configured for these parameters set up
the basic rules of communication between the modem and the PC. If there is no
connection, change the Baud rate to 4800.

C.3.3.3 Force a Reset
Enter command 1 10# [2 beeps] 12345# to confirm [5 beeps]

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M735

C-9

C.3.3.4 Set Tx Audio Level
1. Enter programming mode C.3.3.2.
2. Input command 111#, the transmitter will be keyed, and a 250 Hz tone will be generated from
the transmitter. Each time any DTMF digit other than “#” or “*” is pressed, the Model 735 will
cycle to the next tone in the list (250, 500, 1K, 2K, 3K).
3. Press a key twice to go to the 1 kHz tone. Monitor Tx Audio output signal with oscilloscope.
Adjust R60 (TX AUD) to reach 226 mVpp for the 1 kHz tone. JP25 can be used to increase or
decrease the output if needed. JP25 in position A increases the output and decreases it in
position B. Once the level is set for a 1 kHz tone, cycle through the tones and verify a flat
response. JP24 can be used to set the tones for a flat response.
4. Press # to exit the test mode.
5. Setup a Radio to Phone call, monitor the ring back tone and busy disconnect tone from the
phone line at Tx Audio PIN, and make sure there is no clipping or other distortion on the
signals.

C.3.3.5 99# Exit Program Mode
C.3.3.6 Discriminator Input Level Adjust
Receive Level setting impacts the speech volume heard at the phone end. The settings below are
recommended and adjustment is allowed depending on requirement. Two calibration methods are
available. Use either Method 1 or Method 2 to do the tuning.
• Method 1 – Since the Motorola repeater has the same Rx Audio output level under digital and
analog mode, refer to the Zetron M735 service manual, (Section II Installation) to set the Rx
level under analog mode first and then switch to digital mode directly when the setting is ready.
No additional setting is required.
• Method 2 – Tuning with injected sine tone from MOTOTRBO subscriber under digital mode.
Equipment: Oscilloscope, MOTOTRBO Portable/Mobile subscriber, Audio Box (Motorola part
number: RLN4460B), Signal Generator
NOTE: Disable “Digital Mic AGC” on portable subscriber with CPS.
1. Enter programming mode C.3.3.2.
2. Open the shell of M735 and connect the oscilloscope probe to TP4 on M735 board.
3. Setup DTP connection and verify that phone call is setup correctly.

C-10

Digital Telephone Patch (DTP) Tuning Guideline: Zetron M735

4. If a MOTOTRBO Portable radio is used,
a. Configure Signal Generator to output 1031 Hz sine tone, amplitude set as 22.6 mVpp
(8 mVrms).
b. Inject the signal to the Audio Box audio input port.
c. Attach the Audio Box GCAI connector to the accessory port of the MOTOTRBO
subscriber.
d. Setup a phone call and during the phone call, assert PTT knob on Audio Box to transmit
from radio, phone should hear the tone.
5. If a MOTOTRBO Mobile radio is used,
a. Configure Signal Generator to output 1031 Hz sine tone, amplitude set as 226.3 mVpp
(80 mVrms).
b. Inject the signal to MOTOTRBO mobile radio rear port, PIN 11 Tx Audio, Signal
Generator’s ground connects to MOTOTRBO mobile radio rear port, PIN 18 Audio
ground.
c. Setup a phone call and during the phone call, assert MOTOTRBO mobile radio’s external
PTT with rear port PIN 17 PTT to transmit from radio, phone should hear the tone.
6. While MOTOTRBO subscriber radio (Portable or Mobile) is transmitting with the tone, verify
that the repeater Rx Audio output is close to 1.0 Vpp and then adjust R59 on M735 for a
1.0 Vpp tone signal at TP4.

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.

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
RS232.

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 Repeater 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.
© 2006 – 2011, 2013, 2014 Motorola Solutions, Inc. All rights reserved.
March 2014.
www.motorolasolutions.com/mototrbo

*6816810H01*
6816810H01-J

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