Motorola DP2000e basic service manual

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MOTOTRBO

PROFESSIONAL DIGITAL TWO-WAY RADIO

™

PORTABLE

™

MOTOTRBO

PORTABLE DP2000e Series BASIC SERVICE MANUAL

JULY 2019

2019

*MN002211A01*

MN002211A01-AE

MN002211A01-AE Contents

List of Figures..............................................................................................................5

List of Tables............................................................................................................... 7

Foreword......................................................................................................................9

Product Safety and RF Exposure Compliance.............................................................................. 9

Computer Software Copyrights......................................................................................................9

Document Copyrights.................................................................................................................... 9

Disclaimer......................................................................................................................................9

Trademarks..................................................................................................................................10

Document History..................................................................................................... 11

Notations Used in This Manual................................................................................12

Chapter 1: Introduction.............................................................................................13

1.1 Radio Description.................................................................................................................. 13

1.1.1 Limited Keypad Model............................................................................................. 14

1.1.2 Non-Keypad Model.................................................................................................. 15

1.2 Portable Radio Model Numbering Scheme........................................................................... 16

1.3 Model Charts......................................................................................................................... 17

1.3.1 UHF Model Chart..................................................................................................... 18

1.3.2 VHF Model Chart..................................................................................................... 18

1.3.3 300 MHz Model Chart.............................................................................................. 19

1.3.4 350 MHz Model Chart.............................................................................................. 19

1.4 Specifications.........................................................................................................................19

Chapter 2: Test Equipment and Service Aids........................................................ 25

2.1 Recommended Test Equipment............................................................................................ 25

2.2 Service Aids...........................................................................................................................26

2.3 Programming, Testing, and Alignment Cable........................................................................ 27

Chapter 3: Transceiver Performance Testing........................................................ 30

3.1 Setup..................................................................................................................................... 30

3.1.1 Setting Up DMR Transmitter and Receiver Test......................................................30

3.2 Display Model Test Mode...................................................................................................... 31

3.2.1 Entering Display Radio Test Mode.......................................................................... 31

3.2.2 RF Test Mode.......................................................................................................... 32

3.2.2.1 Testing RF Channel Selections..................................................................32

3.2.3 Display Test Mode................................................................................................... 35

3.2.4 LED Test Mode........................................................................................................36

3.2.5 Backlight Test Mode................................................................................................ 36

MN002211A01-AE

Contents

3.2.6 Speaker Tone Test Mode........................................................................................ 36

3.2.7 Earpiece Tone Test Mode........................................................................................37

3.2.8 Audio Loopback Earpiece Test Mode

3.2.9 Battery Check Test Mode........................................................................................ 37

3.2.10 Button/Knob/PTT Test Mode................................................................................. 38

3.3 Non-Display Model Test Mode.............................................................................................. 39

3.3.1 Entering Non-Display Radio Test Mode...................................................................39

3.3.2 RF Test Mode.......................................................................................................... 39

3.3.2.1 Testing RF Channel Selections..................................................................40

3.3.3 LED Test Mode........................................................................................................43

3.3.4 Speaker Tone Test Mode........................................................................................ 43

3.3.5 Earpiece Tone Test Mode........................................................................................44

3.3.6 Audio Loopback Earpiece Test Mode......................................................................44

3.3.7 Battery Check Test Mode........................................................................................ 44

3.3.8 Button/Knob/PTT Test Mode................................................................................... 44

......................................................................37

Chapter 4: Radio Programming and Tuning...........................................................46

4.1 Customer Programming Software Setup............................................................................... 46

4.2 AirTracer Application Tool..................................................................................................... 46

4.3 Radio Tuning Setup...............................................................................................................47

4.3.1 RF Plug Disassembly...............................................................................................47

Chapter 5: Disassembly/Reassembly Procedures.................................................50

5.1 Preventive Maintenance........................................................................................................ 50

5.2 Safe Handling of CMOS and LDMOS Devices......................................................................51

5.3 General Repair Procedures and Techniques........................................................................ 51

5.4 Disassembling and Reassembling the Radio........................................................................ 53

5.5 Detailed Radio Disassembly..................................................................................................53

5.5.1 Front Kit from Chassis Disassembly........................................................................ 53

5.5.2 Back Kit Disassembly.............................................................................................. 58

5.5.3 Keypad, Display, and Keypad Board Disassembly..................................................59

5.5.4 Side Button, Speaker, Microphone, and UC-Audio Flex Disassembly.................... 62

5.6 Detailed Radio Reassembly.................................................................................................. 65

5.6.1 Speaker Reassembly...............................................................................................65

5.6.2 Side Button, Keypad, Display, and Keypad Board Reassembly..............................67

5.6.3 Back Kit Reassembly...............................................................................................71

5.6.4 Front Kit Reassembly...............................................................................................74

5.6.5 RF Plug Reassembly............................................................................................... 76

5.7 Ensuring Radio Immersibility................................................................................................. 78

5.7.1 Servicing.................................................................................................................. 78

5.7.2 Accidental Immersion...............................................................................................78

MN002211A01-AE Contents

5.7.3 Specialized Test Equipment.................................................................................... 78

5.7.4 Vacuum Pump Kit.................................................................................................... 78

5.7.5 Pressure Pump Kit...................................................................................................79

5.7.6 Miscellaneous Hardware

5.7.7 Vacuum Test............................................................................................................79

5.7.8 Pressure Test...........................................................................................................80

5.7.9 Troubleshooting Leak Areas....................................................................................81

5.7.9.1 Front Housing Troubleshooting..................................................................81

5.7.9.2 Replacing Battery Contact Seal................................................................. 81

5.7.9.3 Replacing Chassis Assembly.....................................................................82

5.7.9.4 Replacing Ventilation Seal and Ventilation Label.......................................82

5.7.9.5 Battery Maintenance.................................................................................. 82

5.7.10 Troubleshooting Charts..........................................................................................84

5.8 Radio Exploded Mechanical View and Parts List.................................................................. 87

5.8.1 Limited Keypad Model............................................................................................. 87

5.8.2 Non-Keypad Model.................................................................................................. 90

5.8.3 Additional Parts List................................................................................................. 92

5.9 Torque Chart..........................................................................................................................93

..........................................................................................79

Chapter 6: Basic Troubleshooting...........................................................................95

6.1 Replacement Back Cover Kit Procedures............................................................................. 95

6.2 Power-Up Error Codes.......................................................................................................... 95

6.3 Operational Error Codes........................................................................................................97

Appendix A: EMEA Regional Warranty, Service, and Technical Support........... 98

Appendix B: Service Information.............................................................................99

Appendix C: Limited Level 3 Servicing.................................................................101

C.1 Component and Parts List...................................................................................................102

Glossary...................................................................................................................104

MN002211A01-AE

List of Figures

Figure 1: Limited Keypad Model.............................................................................................................14

Figure 2: Non-Keypad Model..................................................................................................................15

Figure 3: Programming, Testing, and Alignment Cable

Figure 4: Pin Layout of Side Connector..................................................................................................29

Figure 5: DMR Radio Transmitter and Receiver Testing Setup............................................................. 31

Figure 6: Battery Check Test Mode Display...........................................................................................37

Figure 7: CPS Programming Setup........................................................................................................46

Figure 8: Radio Tuning Equipment Setup.............................................................................................. 47

Figure 9: RF Plug disassembly...............................................................................................................48

Figure 10: RF Adaptor insertion............................................................................................................. 48

Figure 11: RF Adaptor screw..................................................................................................................49

Figure 12: RF Connector........................................................................................................................49

Figure 13: Battery removal..................................................................................................................... 54

Figure 14: Battery removal..................................................................................................................... 54

Figure 15: Antenna removal................................................................................................................... 55

Figure 16: Volume and Channel Knob removal......................................................................................55

Figure 17: Front Kit-Back Kit Screw removal..........................................................................................56

Figure 18: Back Kit disassembly............................................................................................................ 56

Figure 19: Back Kit removal................................................................................................................... 57

Figure 20: Disconnecting the interface UC-audio flex and keypad-display flex (Limited Keypad

Model)................................................................................................................................................57

Figure 21: Disconnecting the UC-audio flex (Non-Keypad Model).........................................................58

Figure 22: Top control seal removal.......................................................................................................58

Figure 23: Back Kit disassembly............................................................................................................ 59

Figure 24: Battery contact seal removal.................................................................................................59

Figure 25: UC-audio flex removal...........................................................................................................60

Figure 26: K18 screw removal................................................................................................................60

Figure 27: Display flex removal.............................................................................................................. 61

Figure 28: Keypad removal.................................................................................................................... 61

Figure 29: PTT retainer removal.............................................................................................................62

Figure 30: Side button removal.............................................................................................................. 62

Figure 31: UC escutcheon removal........................................................................................................63

Figure 32: UC-audio flex removal...........................................................................................................63

Figure 33: Speaker retainer screw removal............................................................................................64

Figure 34: Speaker retainer removal......................................................................................................64

Figure 35: Speaker assembly.................................................................................................................65

..........................................................................28

MN002211A01-AE List of Figures

Figure 36: UC-audio flex.........................................................................................................................66

Figure 37: UC escutcheon......................................................................................................................66

Figure 38: Speaker retainer reassembly

................................................................................................ 67

Figure 39: Side button reassembly.........................................................................................................67

Figure 40: PTT retainer reassembly.......................................................................................................68

Figure 41: Display module reassembly.................................................................................................. 68

Figure 42: Keypad reassembly...............................................................................................................69

Figure 43: Keypad board reassembly.....................................................................................................69

Figure 44: Display flex reassembly.........................................................................................................70

Figure 45: Speaker retainer reassembly................................................................................................ 70

Figure 46: UC-audio flex pad reassembly.............................................................................................. 71

Figure 47: Replace thermal pad............................................................................................................. 71

Figure 48: Affix chassis label..................................................................................................................72

Figure 49: Battery contact seal reassembly........................................................................................... 72

Figure 50: Mainboard reassembly..........................................................................................................73

Figure 51: Top control seal reassembly................................................................................................. 73

Figure 52: Interface flexes reassembly (Limited Keypad Model)............................................................74

Figure 53: Interface flexes reassembly (Non-Keypad Model)................................................................ 74

Figure 54: Front kit reassembly..............................................................................................................75

Figure 55: Knob reassembly...................................................................................................................75

Figure 56: Attaching the antenna........................................................................................................... 76

Figure 57: RF Plug reassembly..............................................................................................................76

Figure 58: Nameplate replacement........................................................................................................ 77

Figure 59: Product nameplate reassembly.............................................................................................77

Figure 60: Connector Fitting - Fitting Seal Pump Connector..................................................................79

Figure 61: Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)................................................ 84

Figure 62: Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)................................................ 85

Figure 63: Troubleshooting Flow Chart for Pressure Test and Leakage Areas..................................... 86

Figure 64: Limited Keypad Model Exploded View..................................................................................87

Figure 65: Non-Keypad Model Exploded View.......................................................................................90

Figure 66: PCB Top View.....................................................................................................................102

Figure 67: PCB Bottom View................................................................................................................103

MN002211A01-AE

List of Tables

Table 1: Radio Frequency Ranges and Power Levels........................................................................... 13

Table 2: Portable Radio Model Numbering Scheme.............................................................................. 16

Table 3: Sales Models – Description of Symbols

Table 4: Table Legend for Model Charts................................................................................................17

Table 5: DP2000e Series, UHF, 403–527 MHz Model Chart................................................................. 18

Table 6: DP2000e Series, VHF, 136–174 MHz Model Chart................................................................. 18

Table 7: DP2000e Series, 300 MHz, 300–360 MHz Model Chart.......................................................... 19

Table 8: DP2000e Series, 350 MHz, 350–400 MHz Model Chart.......................................................... 19

Table 9: General Specifications..............................................................................................................19

Table 10: Receiver Specifications.......................................................................................................... 20

Table 11: Transmitter Specifications...................................................................................................... 21

Table 12: Self-Quieter Frequencies........................................................................................................22

Table 13: Military Standards...................................................................................................................23

Table 14: Environmental Specifications................................................................................................. 24

Table 15: Test Equipment...................................................................................................................... 25

Table 16: Service Aids............................................................................................................................26

Table 17: Pin Configuration of Side Connector...................................................................................... 28

Table 18: Initial Equipment Control Settings.......................................................................................... 30

Table 19: Front Panel Access Test Mode Displays................................................................................31

Table 20: Test Environments..................................................................................................................32

Table 21: Test Frequencies....................................................................................................................33

Table 22: Transmitter Performance Checks...........................................................................................33

Table 23: Receiver Performance Checks...............................................................................................34

Table 24: Button/Knob/PTT Checks.......................................................................................................38

Table 25: Keypad Checks...................................................................................................................... 38

Table 26: Test Environments..................................................................................................................40

Table 27: Test Frequencies....................................................................................................................40

Table 28: Transmitter Performance Checks...........................................................................................41

Table 29: Receiver Performance Checks...............................................................................................42

Table 30: Button/Knob/PTT Checks.......................................................................................................44

Table 31: Software Installation Kits Radio Tuning Setup....................................................................... 46

Table 32: Lead Free Solder Wire Part Number List............................................................................... 52

Table 33: Lead Free Solder Paste Part Number List..............................................................................52

Table 34: Limited Keypad Model Exploded View Parts List................................................................... 88

Table 35: Non-Keypad Model Exploded View Parts List........................................................................90

Table 36: Batteries................................................................................................................................. 92

................................................................................... 16

MN002211A01-AE List of Tables

Table 37: Nameplates............................................................................................................................ 92

Table 38: Back Kits.................................................................................................................................92

Table 39: Antenna ID Band (in pack of 10 pieces)

.................................................................................93

Table 40: Belt Clips................................................................................................................................ 93

Table 41: Torque Specifications for Screws...........................................................................................93

Table 42: Types of Error Code............................................................................................................... 96

Table 43: Types of Error Code............................................................................................................... 97

Table 44: List of Telephone Numbers.................................................................................................... 99

Table 45: Component Parts List...........................................................................................................103

MN002211A01-AE

Foreword

This manual 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 Solutions authorized dealers, self-maintained customers, and distributors.

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

This manual includes radio specification of LEX L11, general description of LEX L11, recommended test equipment, service aids, general maintenance recommendations, procedures for assembly and disassembly, and exploded views and parts lists.

Product Safety and RF Exposure Compliance

CAUTION: This radio is restricted to occupational use only to satisfy FCC RF energy exposure

requirements. Before using this product, read the Product Safety and RF Exposure booklet enclosed with your radio which contains important operating instructions for safe usage and RF energy awareness and control for compliance with applicable standards and regulations.

For a list of Motorola Solutions-approved antennas, batteries, and other accessories, visit http://

www.motorolasolutions.com

Computer Software Copyrights

The Motorola Solutions products described in this manual may include copyrighted Motorola Solutions computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola Solutions 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 Solutions computer programs contained in the Motorola Solutions 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 Solutions. Furthermore, the purchase of Motorola Solutions 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 Solutions, 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 Solutions. 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 Solutions.

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 Solutions reserves the right to make changes to any products herein to improve readability, function, or design. Motorola Solutions 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.

MN002211A01-AE Foreword

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.

European Union (EU) Waste of Electrical and Electronic Equipment (WEEE) directive

The European Union's WEEE directive requires that products sold into EU countries must have

the crossed out trash bin label on the product (or the package in some cases). As defined by the WEEE directive, this cross-out trash bin label means that customers and end-users

in EU countries should not dispose of electronic and electrical equipment or accessories in household waste.

Customers or end-users in EU countries should contact their local equipment supplier representative or service centre for information about the waste collection system in their country.

MN002211A01-AE

Document History

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

Edition Description Date

MN002211A01-AA Initial Release January 2016

MN002211A01-AB Updated Self Quieter Fre-

quencies in Specification section.

MN002211A01-AC Updated TIA Label to Non-

field replaceable in Exploded View Parts Lists.

MN002211A01-AD Removed Footer. June 2019

MN002211A01-AE Added Limited Level 3 Servic-

ing section.

Updated Channel Capacity in Specifications, General Specifications table.

December 2017

September 2018

July 2019

MN002211A01-AE Notations Used in This Manual

Notations Used in This Manual

Throughout the text in this publication, you will notice the use of warning, caution, and notice notations. These notations are used to emphasize that safety hazards exist, and due care must be taken and observed.

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

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

NOTICE: NOTICE indicates an operational procedure, practice, or condition that is essential to emphasize.

Chapter 1

Introduction

1.1

Radio Description

These portable radios are available in the following frequency ranges and power levels.

Table 1: Radio Frequency Ranges and Power Levels

Frequency Band Bandwidth Power Level

VHF 136–174 MHz 1 W or 5 W

UHF 403–527 MHz 1 W or 4 W

300 Band 300–360 MHz 1 W or 4 W

350 Band 350–400 MHz 1 W or 4 W

MN002211A01-AE

Introduction

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

MN002211A01-AE Chapter 1: Introduction

1.1.1

Limited Keypad Model

This section explains the name and description of your radio buttons.

Figure 1: Limited Keypad Model

Label Item Description

1 Channel Selector Knob Rotate clockwise to increment channel and

counter-clockwise to decrement channel.

2 On/Off/Volume Knob To turn on the radio, rotate clockwise until the

knob clicks; To turn off the radio, rotate counterclockwise until the knob clicks. Rotate clockwise to increase volume level; rotate counter-clockwise to decrease volume level.

3 LED Indicator Red, green, and amber light-emitting diodes indi-

cate operating status.

4 Push-To-Talk (PTT) Press to execute voice operations (for example,

Group Call and Private Call).

5 Microphone Allows the voice to be sent when PTT or voice

6 Side Buttons These buttons are field programmable using the

operations are activated.

Customer Programming Software (CPS).

MN002211A01-AE

Chapter 1: Introduction

Label Item Description

7 Menu Navigation Buttons Five buttons to provide menu navigation and se-

lection interface.

8 Front Buttons These buttons are field programmable using the

CPS.

9 Liquid Crystal Display (LCD) 65 x132 full dotk-matrix grayscale display pro-

vides visual information about many radio features.

10 Speaker Outputs all tones and audio that are generated

by the radio (for example, keypad tones and voice audio).

11 Universal Connector Interface point for all accessories to be used with

the radio. It has eight points to which specific accessories connect and be activated.

12 Antenna Provides the needed RF amplification when

transmitting or receiving.

1.1.2

Non-Keypad Model

This section explains the name and description of your radio buttons.

Figure 2: Non-Keypad Model

MN002211A01-AE Chapter 1: Introduction

Label Item Description

1 Channel Selector Knob Rotate clockwise to increment and counter-

clockwise to decrement the channel.

2 On/Off/Volume Knob To turn on the radio, rotate clockwise until the

knob clicks; To turn off the radio, rotate counterclockwise until the knob clicks. Rotate clockwise to increase volume level; rotate counter-clockwise to decrease volume level.

3 LED Indicator Red, green, and amber light-emitting diodes indi-

cate operating status.

4 Push-To-Talk (PTT) Press to execute voice operations (for example,

Group Call and Private Call).

5 Microphone Allows the voice to be sent when PTT or voice

operations are activated.

6 Side Buttons These buttons are field programmable using the

Customer Programming Software (CPS).

7 Speaker Outputs all tones and audio that are generated

by the radio (for example, keypad tones and voice audio).

8 Universal Connector Interface point for all accessories to be used with

the radio. It has eight points to which specific accessories connect and be activated.

9 Antenna Provides the needed RF amplification when

transmitting or receiving.

1.2

Portable Radio Model Numbering Scheme

Table 2: Portable Radio Model Numbering Scheme

Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Typical Model Number

Table 3: Sales Models – Description of Symbols

Position Description Value

1 Region AA = North America

MD H 0 2 J D C 9 U A 2 A N xy

AZ = Asia

LA = Latin America

MD = Europe/Middle East/Africa

2 Type of Unit H = Portable

3 Model Series 23 = DP2000 Model Series: 02

5 Band J = 136–174 MHz

MN002211A01-AE

Chapter 1:

Position Description Value

K = 300–360 MHz N = 350–400 MHz R = 403–527 MHz

6 Power Level C = 1.0, 2.0, 2.5, or 3.5 W

D = 4.0–5.0 W

7 Physical Packages C = Plain Model (Low Tier)

H = Monochrome Display Limited Keypad (Mid Tier) T = Non-Keypad (Limited Tier)

8 Channel Information 8 = Variable/Programmable Channel Spacing with unique

number of channels

9 = Variable/Programmable Channel Spacing

9 Primary Operation U = WiFi Only

W = Basic (No embedded GOB, Bluetooth, and WiFi)

Introduction

10 Primary System

Type

11 Feature Level 1 = Standard with FM

12 Version Letter N/A

13 Unique Variation N = Standard Package

14 Custom Housing 03 = GP328D

1.3

A = Conventional

B = Trunking

C = Analog Only

2 = Non-FM

3 = CSA IE CEx ATEX

4 = CQST

04 = GP338D

Model Charts

Table 4: Table Legend for Model Charts

Legend Description

X The part is compatible with checked model. _ The latest version kit. When ordering a kit, refer to your specific kit for the

suffix number.

MN002211A01-AE Chapter 1: Introduction

1.3.1

UHF Model Chart

Table 5: DP2000e Series, UHF, 403–527 MHz Model Chart

Model/Item Description MDH02RDH9VA1AN DP2600e, 403–527 MHz, 4 W, MO-

TOTRBO Limited Keypad Portable

MDH02RDC9VA1AN DP2400e, 403–527 MHz, 4 W, MO-

TOTRBO Non-Keypad Portable

X PMLE5076_ Back Cover Kit, MOTOTRBO Limited

Keypad Portable

X PMLE5075_ Back Cover Kit, MOTOTRBO Non-Key-

pad Portable

X PMLN7271_ Front Cover Kit Limited Keypad

X PMLN7272_ Front Cover Kit Non-Keypad

X X PMAE4068_ UHF Whip Antenna (403–527 MHz)

X X PMAE4069_ UHF Stubby Antenna (403–450 MHz)

X X PMAE4070_ UHF Stubby Antenna (440–490 MHz)

X X PMAE4071_ UHF Stubby Antenna (470–527 MHz)

X X PMAE4079_ Slim UHF Whip Antena (403–527 MHz)

1.3.2

VHF Model Chart

Table 6: DP2000e Series, VHF, 136–174 MHz Model Chart

Model/Item Description MDH02JDH9VA1AN DP2600e, 136–174 MHz, 5 W, MO-

TOTRBO Limited Keypad Portable

MDH02JDC9VA1AN DP2400e, 136–174 MHz, 5 W, MO-

TOTRBO Non-Keypad Portable

X PMLD4734_ BC Kit, 136–174 MHz, 5 W, Limited Key-

pad Portable

X PMLD4737_ BC Kit, 136–174 MHz, 5 W, Non-Keypad

Portable

X PMLN7271_ Front Cover Kit Limited Keypad

X PMLN7272_ Front Cover Kit Non-Keypad

X X PMAD4117_ VHF Helical Antenna (136–155 MHz)

X X PMAD4116_ VHF HelicalAntenna (144–165 MHz)

X X PMAD4118_ VHF Helical Antenna (152–174 MHz)

X X PMAD4119_ VHF Stubby Antenna (136–148 MHz)

X X PMAD4120_ VHF Stubby Antenna (146–160 MHz)

MN002211A01-AE

Chapter 1:

Model/Item Description MDH02JDH9VA1AN DP2600e, 136–174 MHz, 5 W, MO-

TOTRBO Limited Keypad Portable

MDH02JDC9VA1AN DP2400e, 136–174 MHz, 5 W, MO-

TOTRBO Non-Keypad Portable

X X PMAD4121_ VHF Stubby Antenna (160–174MHz)

1.3.3

Introduction

300 MHz Model Chart

Table 7: DP2000e Series, 300 MHz, 300–360 MHz Model Chart

Model/Item Description MDH02KDC9VA1AN DP2400e, 350–400 MHz, 4 W, MOTOTRBO Non-Keypad Portable

PMLD4799_ Back Cover Kit, MOTOTRBO Limited Keypad Portable

PMLN7272_ Front Cover Kit, MOTOTRBO Non-Keypad Portable

PMAD4135_ Stubby Antenna (320–360 MHz)

PMAD4137_ Stubby Antenna (300–337 MHz)

1.3.4

350 MHz Model Chart

Table 8: DP2000e Series, 350 MHz, 350–400 MHz Model Chart

Model/Item Description MDH02NDC9VA1AN DP2400e, 350–400 MHz, 4 W, MOTOTRBO Non-Keypad Portable

PMLD4799_ Back Cover Kit, MOTOTRBO Limited Keypad Portable

PMLN7272_ Front Cover Kit, MOTOTRBO Non-Keypad Portable

PMAD4136_ Stubby Antenna (350–380 MHz)

PMAD4133_ Stubby Antenna (360–400 MHz)

PMAD4139_ VHF Whip Antenna (350–400 MHz)

1.4

Specifications

Table 9: General Specifications

Parameter Limited Keypad Non-Keypad

Channel Capacity 128 32

Frequency VHF: 136–174 MHz

UHF: 403–527 MHz 300 Band: 300–360 MHz 350 Band: 350–400 MHz

MN002211A01-AE Chapter 1: Introduction

Parameter Limited Keypad Non-Keypad

Dimensions (H × W × T) with

122.0 x 56.0 x 39.4 mm 122.0 x 56.0 x 39.4 mm

NiMH battery

Weight with Core Slim Li-Ion

281 g 264 g

battery

Weight with IMPRES Li-Ion

281 g 264 g

battery

Weight with Li-Ion IP57 bat-

299 g 282 g

tery

Power Supply 7.5 V nominal

Average battery life at 5/5/90 duty cycle with battery saver enabled in carrier squelch and transmitter in high power.

Core NiMH IP56 Battery (1400 mAh)

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

IMPRES IP56 Li-Ion Battery (1600 mAh)

Core Slim Li-Ion Battery (1650 mAh)

Analog: 9.5 hr

Digital: 12.0 hr

Analog: 9.5 hr

Digital: 12.0 hr

Analog: 11.0 hr

Digital: 14.5 hr

Analog: 11.5 hr

Digital: 15.0 hr

Slim IMPRES Li-Ion Battery (2050 mAh)

IMPRES Li-Ion Battery (2250 mAh)

IMPRES TIA4950 Hi-Cap LiIon Battery (2900 mAh)

IMPRES Ultra Hi-Cap Li-Ion Battery (3000 mAh)

Analog: 14.0 hr

Digital: 18.5 hr

Analog: 16.0 hr

Digital: 20.5 hr

Analog: 20.0 hr

Digital: 26.5 hr

Analog: 21.0 hr

Digital: 27.5 hr

NOTICE:

Weight can have 5% margin of error. Limited Keypad Model is not applicable to 300 Band.

Table 10: Receiver Specifications

Parameter Limited Keypad and Non-Keypad

Frequency VHF: 136–174 MHz

UHF: 403–527 MHz 300 Band: 300–360 MHz 350 Band: 350–400 MHz

Channel Spacing 12.5 kHz/20 kHz/25 kHz

Parameter Limited Keypad and Non-Keypad

MN002211A01-AE

Chapter 1:

Introduction

Frequency Stability (-30 °C to

±0.5 ppm

+60 °C)

Analog Sensitivity (12 dB SI-

0.26 µV (0.15 µV typical)

NAD)

Digital Sensitivity (5% BER) 0.22 µV (0.13 µV typical)

Intermodulation (TIA603D) 70 dB

Adjacent Channel Selectivity TIA603A: 60 dB @ 12.5 kHz, 70 dB @ 20/25 kHz

TIA603D: 45 dB @ 12.5 kHz, 70 dB @ 20/25 kHz

Spurious Rejection (TIA603D) 70 dB

Rated Audio 500 mW

Audio Distortion @ Rated Au-

5% (3% typical)

dio

Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20/25 kHz

Audio Response TIA603D

Conducted Spurious Emission

-57 dBm

(TIA603C/D)

Table 11: Transmitter Specifications

Parameter Limited Keypad and Non-Keypad

Frequency VHF: 136–174 MHz

UHF: 403–527 MHz 300 Band: 300–360 MHz 350 Band: 350–400 MHz

Channel Spacing 12.5/20/25 kHz

Frequency Stability (-30 °C to

±0.5 ppm

+60 °C)

Power Output (Low Power) VHF/UHF: 0.5 W

300/350 Band: 1 W

Power Output (High Power) VHF: 5 W

UHF/300 Band/350 Band

: 4 W

Modulation Limiting ±2.5 kHz @ 12.5 kHz

±5.0 kHz @ 25 kHz ±4.0kHz @ 20 kHz

FM Hum and Noise -40 dB @ 12.5 kHz

350 Band does not support 20 kHz.

MN002211A01-AE Chapter 1: Introduction

Parameter Limited Keypad and Non-Keypad

-45 dB @ 20/25 kHz

Conducted/Radiated Emission -36 dBm < 1 GHz

-30 dBm > 1 GHz

Adjacent Channel Power 60 dB @ 12.5 kHz

70 dB @ 20/25 kHz

Audio Response TIA603D

Audio Distortion 3%

FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E

4FSK Digital Modulation 12.5kHz Data: 7K60F1D and 7K60FXD

12.5kHz Voice: 7K60F1E and 7K60FXE

Digital Vocoder Type AMBE+2

™

Digital Protocol ETSI-TS102361-1

ETSI-TS102361-2

ETSI-TS102361-3

NOTICE: Limited Keypad Model is not applicable to 300 Band.

Conforms to:

• ETSI TS 102 361 (Parts 1, 2, and 3) - ETSI DMR Standard

•

ETSI EN 300 086 - ETSI RF Specifications (Analog)

• ETSI EN 300 113 - ETSI RF Specifications (Digital)

• 1999/5/EC (R&TTE - Radio and Telecommunications Terminal Equipment)

• 2011/65/EU (RoHS 2 - Banned Substances)

• 2012/19/EU (WEEE - Waste Electrical and Electronic Equipment)

• 94/62/EC (Packaging and Packaging Waste)

• Radio meets applicable regulatory requirements.

Table 12: Self-Quieter Frequencies

UHF (MHz) VHF (MHz) 300 Band (MHz) 350 Band (MHz)

403.2 +/-10KHz 136.8 +/-10KHz 307.2 +/-10KHz 360 +/-10KHz

408 +/-10KHz 139.2 +/-10KHz 312 +/-10KHz 364.8 +/-10KHz

410.4 +/-10KHz 144 +/-10KHz 319.2 +/-10Khz 369.6 +/-10KHz

422.4 +/-10KHz 148.8 +/-10KHz 324 +/-10Khz 384 +/-10KHz

427.2 +/-10KHz 153.6 +/-10KHz 336 +/-10KHz 396 +/-10KHz

432 +/-10KHz 158.4 +/-10KHz 340.8 +/-10KHz -

446.4 +/-10KHz 160 +/-10KHz 345.6 +/-10KHz -

Chapter 1:

UHF (MHz) VHF (MHz) 300 Band (MHz) 350 Band (MHz)

456 +/-10KHz 163.2 +/-10KHz 360 +/-10KHz -

460.8 +/-10KHz 168 +/-10KHz - -

465.6 +/-10KHz 172.03 +/-10KHz - -

468 +/-10KHz 172.8 +/-10KHz - -

480 +/-10KHz - - -

499.2 +/-10KHz - - -

501.6 +/-10KHz - - -

504 +/-10KHz - - -

508.8 +/-10KHz - - -

519.25 +/-10KHz - - -

Table 13: Military Standards

MN002211A01-AE

Introduction

Applicable MILSTD

Low Pressure

High Temperature

Low Temperature

Temperature Shoc k

810C 810D 810E 810F 810G

Meth ods

Procedures

Meth ods

Procedures

Meth ods

Procedures

Meth ods

Procedures

Meth ods

Procedures

500.1 Ⅰ 500.2 Ⅱ 500.3 Ⅱ 500.4 Ⅱ 500.5 Ⅱ

501.1 Ⅰ,

Ⅱ

501.2 Ⅰ/A1 ,

Ⅱ/A1

501.3 Ⅰ/A1 ,

Ⅱ/A1

501.4 Ⅰ/ Hot,

Ⅱ/H

501.5 Ⅰ/A1 ,

Ⅱ/A1

502.1 Ⅰ 502.2 Ⅰ/C 3,

Ⅱ/C

502.3 Ⅰ/C 3,

Ⅱ/C

502.4 Ⅰ/C 3,

Ⅱ/C

502.5 Ⅰ/C 3,

Ⅱ/C

503.1 Ⅰ 503.2 A1/C3503.3 A1/C3503.4 Ⅰ 503.5 Ⅰ-C

Solar

505.1 Ⅱ 505.2 Ⅰ/ Radiation

Rain 506.1 Ⅰ,

Ⅱ

Hu-

507.1 Ⅱ 507.2 Ⅱ/ midity

Hot-

Dry

506.2 Ⅰ,

Ⅱ

Hot-

Humid

505.3 Ⅰ/ Hot-

Dry

506.3 Ⅰ,

Ⅱ

507.3 Ⅱ/ Hot-

Humid

505.4 Ⅰ/

505.5 Ⅰ/A1

Hot-

Dry

506.4 Ⅰ,

Ⅲ

506.5 Ⅰ,

Ⅲ

507.4 – 507.5 Ⅰ/ Hot-

Humid

MN002211A01-AE Chapter 1:

Introduction

Applicable MILSTD

Salt

810C 810D 810E 810F 810G

Meth ods

Procedures

Meth ods

Procedures

Meth ods

Procedures

509.1 Ⅰ 509.2 Ⅰ 509.3 Ⅰ 509.4 – 509.5 –

fog

Dust 510.1 Ⅰ,

Ⅱ

Vibration

514.2 Ⅷ/F, Curv e-W,

Ⅺ

Shock516.2 Ⅰ,

Ⅱ

510.2 Ⅰ,

Ⅱ

514.3 Ⅰ/ Cat1

0, Ⅱ/

Cat3

516.3 Ⅰ,

Ⅳ

510.3 Ⅰ,

Ⅱ

514.4 Ⅰ/ Cat1

0, Ⅱ/

Cat3

516.4 Ⅰ,

Ⅳ

Table 14: Environmental Specifications

Parameter Specifications

Operating Temperature -30 °C to +60 °C

Meth ods

Procedures

510.4 Ⅰ,

Ⅱ

514.5 Ⅰ/ Cat2

4, Ⅱ/

Cat5

516.5 Ⅰ,

Ⅳ

Meth ods

Procedures

510.5 Ⅰ,

Ⅱ

514.6 Ⅰ/ Cat2

4, Ⅱ/

Cat5

516.6 Ⅰ,

Ⅳ

Storage Temperature -40 °C to +85 °C

Thermal Shock Per MIL-STD

Humidity Per MIL-STD

ESD IEC 61000-4-2 Level 4

Water Intrusion IEC 60529 -IP67

Packaging Test MIL-STD 810D and E

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

MN002211A01-AE

Test Equipment and Service Aids

Chapter 2

Test Equipment and Service Aids

This chapter lists the recommended test equipment and service aids, as well as information on field programming equipment that can be used in servicing and programming Motorola Solutions radios.

2.1

Recommended Test Equipment

The list of equipment contained in the following table includes most of the standard test equipment required.

Table 15: Test Equipment

Equipment Characteristics Example Application

Service Monitor

Digital RMS Multimeter

RF Signal Generator

Oscilloscope

Power Meter and Sensor

Can be used as a substitute.

100 µV to 300 V Fluke 179 (www.fluke.com) or

5 Hz to 1 MHz

10 ㏁ Impedance

100 MHz to 1 GHz Agilent N5181A (www.agi-

-130 dBm to +10 dBm

FM Modulation: 0 kHz to 10 kHz

Audio Frequency: 100 Hz to 10 kHz

2 Channel Tektronix TDS1001b

50 MHz Bandwidth

5 mV/div to 20 V/div

5% Accuracy Bird 43 Thruline Watt Meter

100 MHz to 500 MHz

50 W

Aeroflex 3920 (www.aero-

flex.com) or equivalent

equivalent

lent.com), Ramsey

RSG1000B (www.ramseye-

lectronics.com), or equivalent

(www.tektronix.com) or equivalent

(www.bird-electronic.com) or equivalent

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

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

Receiver measurements

Waveform measurements

Transmitter power output measurements

RF Millivoltmeter

Power Supply

Can use Service Monitor as substitute.

100 mV to 3 V RF Boonton 92EA

10 kHz to 1 GHz

0 V to 32 V B&K Precision 1790

0 A to 20 A

RF level measurements (www.boonton.com) or equivalent

Voltage supply (www.bkprecision.com) or equivalent

MN002211A01-AE Chapter 2: Test Equipment and Service Aids

2.2

Service Aids

The following table lists the service aids recommended for working on the radio. While all of these items are available from Motorola Solutions, most are standard workshop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.

Table 16: Service Aids

Motorola Solutions Part No.

RLN4460_ Portable Test Set Enables connection to the audio/accessory jack.

GMVN5141_ CPS on CD-ROM Allows servicer to program radio parameters, tune

PMKN4115_ Portable Programming Cable This cable connects the radio to a USB port for ra-

PMKN4117_ Portable Programming, Testing,

Description Application

Allows switching for radio testing.

and troubleshoot radios.

dio programming and data applications.

This cable connects the radio to a USB port for ra-

and Alignment Cable

dio programming, testing, and alignment.

NOTICE:

• This cable does not support external PTT using Testbox.

This cable does not auto route to ex-

• ternal Audio path once the cable is attached.

• All test instructions will require through software tool (for example, CPS, Tuner, and more.)

PMNN4428_ 7.5 V Universal Battery Elimina-

tor

PMLN6154_ RF Adaptor Adapts radio antenna port to BC cabling of test

PMLN6201_ RF Adaptor Holder Holds RF adaptor in place.

PMLN6422_ SMA RF Cable RF cable with SMA and N-type connector.

1185937A01 Grease Acts to lubricate parts.

TL000013A01Chassis and Knob Opener Removes chassis from the front housing.

NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages.

NTN4265_ Pressure Pump Kit Allows servicer to locate leakages.

5871134M01 Connector Fitting This connector allows the vacuum hose to be con-

3271133M01 Fitting Seal This seal secures the connector fitting to the radio

Connects to radio by using battery eliminator cable.

equipment.

nected to the radio chassis.

chassis.

MN002211A01-AE

Chapter 2: Test Equipment and Service Aids

2.3

Programming, Testing, and Alignment Cable

Programming, Testing, and Alignment Cable and Side Connector are required in servicing and programming radios.

#13

#25 #14

#2 #4 #6 #8

#1 #3 #5

#1#4

MN002211A01-AE Chapter 2: Test Equipment and Service Aids

Figure 3: Programming, Testing, and Alignment Cable

Table 17: Pin Configuration of Side Connector

CONNECTION

P1 P2 P3

Pin Pin Pin Function

- 1 1 VCC (5 V)

P1 P2 P3

Pin Pin Pin Function

- 3 5 Data+

- 2 4 Data-

16 4 8 Ground 1 and 5 - 2 External Speaker+ 2 and 7 - 3 External Speaker-

17 - 6 External Mic+

16 - 7 External Mic-

Figure 4: Pin Layout of Side Connector

MN002211A01-AE

Chapter 2: Test Equipment and Service Aids

CONNECTION

MN002211A01-AE Chapter 3: Transceiver Performance Testing

Chapter 3

Transceiver Performance Testing

These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment.

The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the calibration schedule recommended by the manufacturer.

Although these radios function in digital and analog modes, all testing is done in analog mode.

3.1

Setup

Supply voltage is provided using a 7.5 VDC power supply. procedures is connected as shown in the Radio Tuning Setup chapter.

WARNING: Do NOT use any form of connector, for example wires, crocodile clips, and probes, to supply voltage to the radio, other than the Motorola Solutions approved battery eliminator.

Initial equipment control settings must be as indicated in the following table:

Table 18: Initial Equipment Control Settings

Service Monitor Power Supply Test Set

Monitor Mode: Power Monitor Voltage: 7.5 Vdc Speaker set: A

RF Attn: -70 DC on/standby:

AM, CW, FM: FM Volt Range: 10 V PTT: OFF

Oscilloscope Source: Mod Oscilloscope Horizontal: 10 ms/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

The equipment required for alignment

Speaker/load:

Standby

Current: 2.5 A

Speaker

3.1.1

Setting Up DMR Transmitter and Receiver Test

Procedure:

1 Connect the Programming cable to the radio and computer. 2 Remove the RF plug. 3 Connect the RF antenna adaptor to the 50 Ω RF Input/Output port of the radio.

T/R Port

Power Supply

Ant. Input / Output

Programming Cable

Modulated RF Test

Signal / Tx

modulated RF Signal

Battery Eliminator

MN002211A01-AE

Chapter 3: Transceiver Performance Testing

4 Connect the other end of the RF antenna adaptor to the T/R port of the Radio Test Set 3920

using the RF cable shown in the following figure.

Figure 5: DMR Radio Transmitter and Receiver Testing Setup

See RF Plug Disassembly on page 47 for RF Plug Removal and RF Adaptor Insertion.

3.2

Display Model Test Mode

3.2.1

Entering Display Radio Test Mode

Procedure:

1 Turn the radio on. 2 Within 10 seconds after Self-Test is complete, press Side Button 2 five times in succession.

The radio beeps and shows a series of displays regarding various version numbers and subscriber-specific information. The displays are described in the following table.

Table 19: Front Panel Access Test Mode Displays

Name of Display Description Appears

Service Mode The literal string indicates the radio has entered test

mode.

Host Version The version of host firmware. Always

DSP Version The version of DSP firmware. Always

Model Number The radio model number as programmed in the codeplug. Always

MSN The radio serial number as programmed in the codeplug. Always

FLASHCODE The FLASH codes as programmed in the codeplug. Always

RF Band The radio band. Always

Always

MN002211A01-AE Chapter 3: Transceiver Performance Testing

NOTICE: The radio stops at each display for 2 seconds before moving to the next information display. If the information cannot fit into one line, the radio display scrolls automatically character by character after 1 second to view the whole information. If the

button is pressed before the last information is displayed, the radio suspends the

Left

information display until the user presses the Right button to resume the information display. The last display shows RF Test Mode.

3.2.2

RF Test Mode

When the radio is operating in its normal environment, the radio microcontroller controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration.

However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment with a special routine, called Test Mode or air test.

3.2.2.1

Testing RF Channel Selections

Prerequisites: In RF Test Mode, the first line of your radio displays RF Test and power level icon.

And the second line of your radio displays the test environment, channel number, and channel spacing. The default test environment is CSQ.

Procedure:

1 Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ

->CSQ).

NOTICE: DIG is digital mode and other test environments are analog mode as described in the following table.

Table 20: Test Environments

No. of

Description Function

Beeps

1 Carrier Squelch (CSQ) RX: if carrier detected

TX: mic audio

2 Tone Private-Line

(TPL)

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

3 Digital Mode (DIG) RX: if carrier detected

TX: mic audio

4 Unsquelch (USQ) RX: constant unsquelch

TX: mic audio

The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three times for DIG, and beeps four times for USQ.

Only for radios with display.

MN002211A01-AE

Chapter 3: Transceiver Performance Testing

2 Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz, and

20 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz, and beeps three

times for 12.5 kHz.

3 Turn Channel Knob to change the test channel from 1 to 14.

See Table 21: Test Frequencies on page

33 for test channel descriptions.

The radio beeps in each position.

Table 21: Test Frequencies

Channel Selector Switch Position

1 Low Power 9 High Power

2 Low Power 10 High Power

3 Low Power 11 High Power

4 Low Power 12 High Power

5 Low Power 13 High Power

6 Low Power 14 High Power

7 Low Power 15 High Power

Test Channel UHF VHF 300

Band

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

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

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

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

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

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

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

403.15

423.25

444.35

465.45

485.55

506.65

526.75

136.075

142.575

146.575

155.575

161.575

167.575

173.975

300.025

308.525

317.025

325.525

334.025

342.525

351.025

350 Band

350.025

357.525

364.525

371.525

378.525

385.525

392.525

8 Low Power 16 High Power

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

Table 22: Transmitter Performance Checks

Test Name

Reference Frequency

Communications Analyzer

Mode: PWR MON Fourth channel test

frequency

Monitor: Frequency error

Input at RF In/Out

See Table 21: Test Frequencies

on page 33

527.00

174.000

359.925

Radio Test Set Comments

Test Mode, Test Channel 4 carrier

PTT to continuously transmit.

Frequency error to be: ±68 Hz for VHF

±150 Hz for 300 Band

squelch

±175 Hz for 350 Band

399.925

MN002211A01-AE Chapter 3: Transceiver Performance Testing

Test Name

Communications Analyzer

Radio Test Set Comments

±201 Hz for UHF

Power RF As above As above As above Low Power:

0.9–1.5 W (UHF/VHF/300 Band/350 Band)

High Power:

4.0–4.8 W (UHF/300 Band/350 Band

5.0–6.0 W (VHF)

Voice Modulation

Mode: PWR MON Fourth channel test

frequency

As above As above,

meter selector to mic

Deviation: ≥ 4.0 kHz but ≤ 5.0 kHz (25 kHz Ch Sp).

atten to -70, input to RF In/Out

Monitor: DVM: AC Volts Set 1 kHz Mod Out lev-

el for 0.025 Vrms at test set, 80 mVrms at AC/DC test set jack

)

Internal Voice Modulation

Mode: PWR MON Fourth channel test

frequency

atten to -70, input to RF In/Out

TPL Modulation

As above Fourth channel test

frequency

BW to narrow

Table 23: Receiver Performance Checks

Test Name

Reference Frequency

Communications Analyzer

Mode: PWR MON Fourth channel test

frequency

Monitor: Frequency error

Test Mode, Test Channel 4 carrier squelch output at

Remove modulation input

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

antenna

Test Mode, Test

As above Deviation:

≥500 Hz but ≤1000Hz

(25 kHz Ch Sp). Channel 4 TPL

Radio Test Set Comments

Test Mode, Test Channel 4 carrier

PTT to continuously transmit.

Frequency error to be:

±68 Hz for VHF

±150 Hz for 300 Band squelch

Chapter 3:

MN002211A01-AE

Transceiver Performance Testing

Test Name

Communications Analyzer

Input at RF In/Out

Rated Audio

Mode: GEN Output level: 1.0 mV

RF Sixth channel test

frequency

Mod: 1 kHz tone at 3 kHz deviation

Monitor: DVM: AC Volts

Distortion As above, except dis-

tortion

Sensitivity (SINAD)

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

Noise Squelch

RF level set to 1 mV

RF Threshold (only radios with conventional system need to be tested.)

As above, except

change frequency to a

conventional system.

Raise RF level from

zero until radio un-

squelches.

Radio Test Set Comments

output at antenna. ±175 Hz for 350 Band

±201 Hz for UHF

Test Mode , Test

Meter selector to Audio PA

Set volume control to 2.83 Vrms

Channel 6 carrier squelch

As above As above Distortion <3.0%

As above Nil RF input to be <0.35

μV

As above Meter se-

lection to

Set volume

control to 2.83 Vrms Audio PA, speaker/ load to speaker

Out of Test Mode; select a conven-

As above Unsquelch to occur at

<0.25 μV.

Preferred SINAD =

6–8 dB

tional system.

3.2.3

Display Test Mode

Procedure:

1 Press and hold Side Button 1 to enter display test mode. 2 Upon any button or key press, the LCD displays the growing horizontal bars. Press any button

until the LCD display turns black and change to vertical bars. Press any button until LCD display full screen black and change to icon display.

The LCD displays the following icons:

• RSSI (with full bar) Monitor

•

MN002211A01-AE Chapter

• Tone disabled

• Priority-two channel scan Unread message

•

• Emergency

• Talkaround

• Battery strength indicator (with full bar)

The LCD display become clear and consequently display the rest of the icons, high-power level icon (H), companding icon, option board icon, and secure operation icon upon any button/key press.

3.2.4

Transceiver Performance Testing

LED Test Mode

Procedure:

1 Press and hold Side Button 1 after Display Test Mode.

The radio beeps once and displays LED Test Mode.

2 Press any button/key.

The red LED lights up and the radio displays Red LED On.

3 Press any button/key.

The red LED is turned off. The green LED lights up and the radio displays Green LED On.

4 Press any button/key.

The green LED is turned off. The radio lights up both LEDs up while displaying Both LEDs On. The orange LED lights up.

3.2.5

Backlight Test Mode

Procedure:

Press and hold Side Button 1 after LED Test Mode. The radio beeps once and displays Backlight Test Mode.

The radio turns on both LCD and keypad backlight.

3.2.6

Speaker Tone Test Mode

Procedure:

Press and hold Side Button 1 after Backlight Test Mode. The radio beeps once and displays Speaker Tone Test Mode.

The radio generates a 1 kHz tone with the internal speaker.

Rem. Capacity100%

Chapter 3: Transceiver Performance Testing

3.2.7

Earpiece Tone Test Mode

Procedure:

1 Connect the external accessory to the radio. 2 Press and hold Side Button 1 after Speaker Tone Test Mode.

The radio beeps once and displays Earpiece Tone Test Mode.

The radio generates a 1 kHz tone from the earpiece.

3.2.8

Audio Loopback Earpiece Test Mode

Procedure:

Press and hold Side Button 1 after the Earpiece Tone Test Mode. The radio beeps once and displays Audio Loopback Earpiece Test Mode.

The radio routes any audio on the external mic to the earpiece.

MN002211A01-AE

3.2.9

Battery Check Test Mode

Procedure:

Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps once and momentarily displays Battery Check Test Mode.

The radio displays the following:

Figure 6: Battery Check Test Mode Display

MN002211A01-AE Chapter 3: Transceiver Performance Testing

3.2.10

Button/Knob/PTT Test Mode

Any key press causes the test to advance from one step to the next.

Table 24: Button/Knob/PTT Checks

Action Result

Press and hold Side Button 1. The radio displays Button Test (line 1).

The radio beeps once.

Rotate the Volume Knob. 2/1 through 2/255 appears.

The radio beeps at each position.

Rotate the Channel Knob clockwise. 4/1 appears.

The radio beeps at each position.

Rotate the Channel Knob counterclockwise. 4/-1 appears.

The radio beeps at each position.

Press Side Button 1. 96/1 appears.

The radio beeps.

Release the button. 96/0 appears.

The radio beeps.

Press Side Button 2. 97/1 appears.

The radio beeps.

Release the button. 97/0 appears.

The radio beeps.

Press the PTT

Release the button. 1/0 appears.

Table 25: Keypad Checks

Action Result

Press the P1 button. 160/1 appears.

Release the button. 160/0 appears.

Press the P2 button. 161/1 appears.

button. 1/1

The radio beeps.

appears.

Release the button. 161/0 appears.

The radio beeps.

Press the MENU button. 85/1 appears.

The radio beeps.

Chapter 3: Transceiver Performance Testing

Action Result

Release the button. 139/0 appears.

The radio beeps.

MN002211A01-AE

Press the BACK button. 129/1

The radio beeps.

Release the button. 129/0 appears.

The radio beeps.

Press the Left button. 128/1 appears.

The radio beeps.

Release the button. 128/0 appears.

The radio beeps.

Press the Right

Release the button. 130/0 appears.

Press the OK button. 85/1 appears.

Release the button. 85/0 appears.

3.3

button. 130/1

The radio beeps.

appears.

Non-Display Model Test Mode

3.3.1

Entering Non-Display Radio Test Mode

Procedure:

1 Turn the radio on. 2 Within 10 seconds after Self-Test is complete, press Side Button 2 five times in succession.

The radio beeps.

3.3.2

RF Test Mode

However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment with a special routine, called Test Mode or air test.

MN002211A01-AE Chapter 3: Transceiver Performance Testing

3.3.2.1

Testing RF Channel Selections

Prerequisites: In RF Test Mode, the first line of your radio displays RF Test and power level icon.

And the second line of your radio displays the test environment, channel number, and channel spacing. The default test environment is CSQ.

Procedure:

1 Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ

->CSQ).

NOTICE: DIG is digital mode and other test environments are analog mode as described in the following table.

Table 26: Test Environments

No. of

Description Function

Beeps

1 Carrier Squelch (CSQ) RX: if carrier detected

TX: mic audio

2 Tone Private-Line

(TPL)

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

3 Digital Mode (DIG) RX: if carrier detected

TX: mic audio

4 Unsquelch (USQ) RX: constant unsquelch

TX: mic audio

The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three times for DIG, and beeps four times for USQ.

2 Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz, and

20 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz, and beeps three

times for 12.5 kHz.

3 Turn Channel Knob to change the test channel from 1 to 14.

See Table 27: Test Frequencies on page

40 for test channel descriptions.

The radio beeps in each position.

Table 27: Test Frequencies

Channel Selector Switch Position

1 Low Power 9 High Power

2 Low Power TX#2 or #10 423.25 142.575 308.525 357.525

Only for radios with display.

Test Channel UHF VHF 300

Band

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

403.15

136.075

300.025

350 Band

350.025

MN002211A01-AE

Chapter 3: Transceiver Performance Testing

Channel Selector

Test Channel UHF VHF 300

Switch Position

10 High Power

3 Low Power 11 High Power

4 Low Power 12 High Power

5 Low Power 13 High Power

6 Low Power 14 High Power

7 Low Power 15 High Power

8 Low Power 16 High Power

RX#2 or #10 423.25 142.575 308.525 357.525

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

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

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

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

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

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

Table 28: Transmitter Performance Checks

444.35

465.45

485.55

506.65

526.75

527.00

146.575

155.575

161.575

167.575

173.975

174.000

Band

317.025

325.525

334.025

342.525

351.025

359.925

350 Band

364.525

371.525

378.525

385.525

392.525

399.925

Test Name

Reference Frequency

Communications Analyzer

Mode: PWR MON Fourth channel test

frequency

Monitor: Frequency error

Input at RF In/Out

Radio Test Set Comments

Test Mode, Test Channel 4 carrier

PTT to continuously transmit.

Frequency error to be: ±68 Hz for VHF

±150 Hz for 300 Band

squelch

±175 Hz for 350 Band ±201 Hz for UHF

Power RF As above As above As above Low Power:

0.9–1.5 W (UHF/VHF/300 Band/350 Band)

High Power:

4.0–4.8 W (UHF/300 /350 Band)

Band

5.0–6.0 W (VHF)

Voice Modulation

Mode: PWR MON Fourth channel test

frequency

As above As above,

meter selector to mic

Deviation: ≥ 4.0 kHz but ≤ 5.0 kHz (25 kHz Ch Sp).

See Table 27: Test Frequencies

on page 40

MN002211A01-AE Chapter 3: Transceiver Performance Testing

Test Name

Internal Voice Modulation

TPL Modulation

Communications Analyzer

atten to -70, input to RF In/Out

Monitor: DVM: AC Volts Set 1 kHz Mod Out lev-

el for 0.025 Vrms at test set, 80 mVrms at AC/DC test set jack

Mode: PWR MON Fourth channel test

frequency

atten to -70, input to RF In/Out

As above Fourth channel test

frequency

BW to narrow

Radio Test Set Comments

Test Mode, Test Channel 4 carrier squelch output at

Remove modulation input

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

antenna

Test Mode, Test

As above Deviation:

≥500 Hz but ≤

(25 kHz Ch Sp). Channel 4 TPL

1000Hz

Table 29: Receiver Performance Checks

Test Name

Reference Frequency

Communications Analyzer

Mode: PWR MON Fourth channel test

frequency

Monitor: Frequency error

Input at RF In/Out

Rated Audio

Mode: GEN Output level: 1.0 mV

RF Sixth channel test

frequency

Mod: 1 kHz tone at 3 kHz deviation

Monitor: DVM: AC Volts

Distortion As above, except dis-

tortion

Radio Test Set Comments

Test Mode, Test Channel 4 carrier

PTT to continuously transmit.

Frequency error to be:

±68 Hz for VHF

±150 Hz for 300 Band squelch

output at

±175 Hz for 350 Band antenna.

±201 Hz for UHF

Test Mode , Test

Meter selector to Audio PA

Set volume

control to 2.83 Vrms

Channel 6 carrier squelch

As above As above Distortion <3.0%

MN002211A01-AE

Chapter 3: Transceiver Performance Testing

Test Name

Sensitivity (SINAD)

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

3.3.3

LED Test Mode

Communications Analyzer

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

RF level set to 1 mV RF

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

Radio Test Set Comments

As above Nil RF input to be <0.35

μV

As above Meter se-

lection to Audio PA, speaker/ load to speaker

Out of Test Mode; select a conventional system.

As above Unsquelch to occur at

Set volume control to 2.83 Vrms

<0.25 μV. Preferred SINAD =

6–8 dB

Procedure:

1 Press and hold Side Button 1 after RF Test Mode.

The radio beeps once.

2 Press any button/key.

The red LED lights up.

3 Press any button/key.

The red LED turns off and the radio lights up the green LED.

4 Press any button/key.

The green LED turns off and the radio turns on both LEDs.

3.3.4

Speaker Tone Test Mode

Procedure:

Press and hold Side Button 1 after LED Test Mode.

The radio beeps once.

The radio generates a 1 kHz tone with the internal speaker.

MN002211A01-AE Chapter 3: Transceiver Performance Testing

3.3.5

Earpiece Tone Test Mode

Procedure:

Press and hold Side Button 1 after Speaker Tone Test Mode.

The radio beeps once.

The radio generates a 1 kHz tone with the earpiece.

3.3.6

Audio Loopback Earpiece Test Mode

Procedure:

Press and hold Side Button 1 after Earpiece Tone Test Mode.

The radio beeps once.

The radio routes any audio on the external mic to the earpiece.

3.3.7

Battery Check Test Mode

Procedure:

Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps once.

The radio LED lights up as follows:

• Green LED for High Battery Level Orange LED for Mid Battery Level

•

• Blinking red LED for Low Battery Level

3.3.8

Button/Knob/PTT Test Mode

Any key press causes the test to advance from one step to the next.

Table 30: Button/Knob/PTT Checks

Action Result

Press and hold Side Button 1. The radio beeps once.

Rotate the Volume Knob. The radio beeps at each position.

Rotate the Channel Knob. The radio beeps at each position.

Press Side Button 1. The radio beeps.

Release the button. The radio beeps.

Press Side Button 2. The radio beeps.

Chapter 3: Transceiver Performance Testing

Action Result

Release the button. The radio beeps.

Press the PTT button. The radio beeps.

Release the button. The radio beeps.

MN002211A01-AE

Radio

Battery

Portable Programming Cable PMKN4115_

MN002211A01-AE Chapter 4:

Radio Programming and Tuning

Chapter 4

Radio Programming and Tuning

This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), Tuner, and AirTracer applications, which are all designed for use in a Windows 8/7/2000/XP/Vista environment.

NOTICE: Refer to the online help files of the appropriate program for the programming procedures.

These programs are available in one kit as listed in the following table. An Installation Guide is also included with the kit.

Table 31: Software Installation Kits Radio Tuning Setup

Description Part Number

MOTOTRBO CPS, Tuner, and AirTracer Applications CD GMVN5141_

4.1

Customer Programming Software Setup

Program the radio using the following setup.

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

Figure 7: CPS Programming Setup

4.2

AirTracer Application Tool

The MOTOTRBO AirTracer application tool has the ability to capture over-the-air digital radio traffic and save the captured data into a file.

The AirTracer application tool can also retrieve and save internal error logs from MOTOTRBO radios. The saved files can be analyzed by trained Motorola Solutions personnel to suggest improvements in system configurations or to help isolate problems.

Wattmeter

Audio Generator

Sinad Meter

AC Voltmeter

10 dB Pad

Audio In

Receive

Transmit

RF Generator

RF Adaptor

Test Box

RLN4460_

Radio

Programming, Testing & Alignment Cable PMKN4117

Service Monitor

or Counter

+12VDC

Power Supply

Battery Eliminator

7.5V Reg. PMNN4428

MN002211A01-AE

Chapter 4:

Radio Programming and Tuning

4.3

Radio Tuning Setup

Retuning is not required if service kit has been replaced and factory tuned. However, check service kit for performance before use.

Before keying up the radio, set the Bias DAC for the appropriate final device bias current. If the bias is not properly set, it may cause damage to the transmitter.

CAUTION: Only Motorola Solutions Service Centers or Authorized Motorola Solutions Service Dealers can perform this function.

A personal computer (PC) with Windows, Windows 2000/XP/Vista/Windows 7 and a tuner program are required to tune the radio. See "Radio Tuning Equipment Setup" to perform tuning procedures.

Figure 8: Radio Tuning Equipment Setup

4.3.1

RF Plug Disassembly

Procedure:

1 Use tweezers to lift up one end of the RF plug and pull it out.

MN002211A01-AE Chapter 4: Radio Programming and Tuning

Figure 9: RF Plug disassembly

Label Description

1 RF Plug

2 Insert the RF Adaptor into the front housing.

Figure 10: RF Adaptor insertion

Label Description

1 RF Adaptor

3 Screw in the RF adaptor to the front housing.

Figure 11: RF Adaptor screw

MN002211A01-AE

Chapter 4: Radio Programming and Tuning

4 Insert the RF connector.

CAUTION: Do not attach the RF Connector into the RF Adapter Holder before inserting

the RF Adapter Holder into the housing.

Figure 12: RF Connector

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Chapter 5

Disassembly/Reassembly Procedures

This chapter provides details about the following:

• Preventive maintenance (inspection and cleaning).

• Safe handling of CMOS and LDMOS devices. Repair procedures and techniques.

•

• Disassembly and reassembly of the radio.

5.1

Preventive Maintenance

Periodic visual inspection and cleaning are recommended.

Inspection

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

Cleaning Procedures

The following procedures describe the recommended cleaning agents and the methods to clean the external and internal surfaces of your radio.

External surfaces include the front cover, housing assembly, and battery. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime.

CAUTION: Use all chemicals as prescribed by the manufacturer. Follow all safety precautions as defined on the label or material safety data sheet.

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

NOTICE:

Only clean internal surfaces when your radio is disassembled for service or repair.

Cleaning External Plastic Surfaces

IMPORTANT: The only recommended agent for cleaning the external radio surfaces is a 0.5%

solution of a mild dish-washing detergent in water.

Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from your radio. Use a soft, absorbent, lint-less cloth, or tissue to remove the solution and dry your radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices.

Cleaning Internal Circuit Boards and Components

IMPORTANT:

The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (100% by volume).

Always use fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).

MN002211A01-AE

Chapter 5:

Apply Isopropyl alcohol (100%) 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 your radio. Make sure that controls or tunable components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process since it can cause the liquid to collect in unwanted places. After completing of the cleaning process, use a soft, absorbent, lint-less cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or back cover.

5.2

Disassembly/Reassembly Procedures

Safe Handling of CMOS and LDMOS Devices

Complementary Metal Oxide Semiconductor (CMOS) and Laterally Diffused Metal Oxide Semiconductor (LDMOS) devices are used in this family of radios, and are susceptible to damage by electrostatic or high-voltage charges.

Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair.

Handling precautions are mandatory for CMOS/LDMOS circuits and are especially important in low humidity conditions. Do not attempt to disassemble your radio without referring to the following caution statement.

CAUTION:

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

• Store and transport all CMOS/LDMOS devices in conductive material so that all exposed leads are shorted together. Do not insert CMOS/LDMOS devices into conventional plastic "snow" trays used for storage and transportation of other semiconductor devices.

Ground the working surface of the service bench to protect the CMOS/LDMOS device. It is

• recommended that you use a wrist strap, two ground cords, a table mat, a floor mat, electrostatic discharge (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 Solutions 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.

• Handle CMOS/LDMOS devices by the package and not by the leads. Before touching the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.

5.3

General Repair Procedures and Techniques

Environmentally Preferred Products (EPP) 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 Solutions specified parts in this manual.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

For the identification of lead (Pb) free assemblies, all EPP products carry the EPP Marking, shown in the following examples, on the Printed Circuit Board (PCB). This marking provides information to those performing assembly, servicing, and recycling operation on this product, adhering to the JEDEC Standard No. 97. The EPP Marking takes the form of a label or marking on the PCB.

Any rework or repair on Environmentally Preferred Products must be done using the appropriate leadfree solder wire and lead-free solder paste as stated in the following tables:

Table 32: Lead Free Solder Wire Part Number List

Motorola Solutions Part Number

1088929Y01 95.5Sn/3.8Ag/

Table 33: Lead Free Solder Paste Part Number List

Manufacturer Part Number

NC-SMQ230 900–1000KCPs

Alloy Flux Type Flux Con-

tent by Weight

RMA Ver-

0.7Cu

Viscosity Type Composition

Brookfield (5 rpm)

sion

Type 3 (-325/+500)

2.7–3.2% 217 °C 52171 0.015

and Percent Metal

(95.5%Sn-3.8%A g-0.7%Cu)

89.3%

Melting Point

Supplier Part number

Liquid Temperature

217 °C

Diameter

in.

Weight

1 lb spool

Parts Replacement and Substitution

When damaged parts are replaced, identical parts must be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola Solutions part number and order the part.

Rigid Circuit Boards

This family of radios use bonded, multi-layer, printed circuit boards. Since the inner layers are not accessible, some special considerations are required when soldering and unsoldering components. The plated-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. For soldering components with Hot-Air or infra red solder systems, check the user guide of your solder

system to get information on solder temperature and time for the different housings of the integrated circuits and other components.

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

5.4

Disassembling and Reassembling the Radio

When disassembling and reassembling the radio, it is important to pay particular attention to the snaps and tabs, and how parts align with each other.

CAUTION: To assure the safety and regulatory compliance of your radio, repair your radio only at Motorola Solutions service facilities. Please contact your local dealer or Point of Sale for further instructions.

The following tools are required for disassembling the radio:

• TORX™ T screwdriver Chassis and Knob Opener (TL000013A01)

•

The following tools are required for reassembling the radio:

• Grease (1185937A01)

• TORX T screwdriver

• Vacuum Pump Kit (NLN9839) - Radio Immersibility Test

• Pressure Pump Kit (NTN4265) - Radio Immersibility Test

• Connector Fitting (5871134M01) - Radio Immersibility Test

• Fitting Seal (3271133M01) - Radio Immersibility Test

• Seal Port (3286058L01)

• Ventilation Label (LB000256A01)

NOTICE: If a unit requires further testing or service than is customarily performed at the basic level, send radio to Motorola Solutions Service Center.

5.5

Detailed Radio Disassembly

The section describes the detailed disassembly procedure of your radio.

5.5.1

Front Kit from Chassis Disassembly

Procedure:

1 Turn off the radio. 2 Remove the battery:

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

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 13: Battery removal

Label Description

1 Latch

b With the latch released, slide the battery downwards.

Figure 14: Battery removal

3 Remove the battery from the radio. 4 Remove the antenna by turning it counterclockwise.

Figure 15: Antenna removal

Chapter

MN002211A01-AE

5: Disassembly/Reassembly Procedures

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

Figure 16: Volume and Channel Knob removal.

Label Description

1 Volume Knob

2 Channel Knob

NOTICE: Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.

6 Separate the back kit from the front kit as follows:

a Unscrew the screw using TORX T6 screwdriver.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 17: Front Kit-Back Kit Screw removal

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

Figure 18: Back Kit disassembly

c Slowly slide out the back kit from the front kit.

Figure 19: Back Kit removal

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

CAUTION:

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

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

7 Lay the front kit down. Rotate the back kit backward and slightly away from the front kit. 8 Lift the Zero Insertion Force (ZIF) connector latch on the mainboard assembly to release the flex

and separate the back kit from the front kit.

Figure 20: Disconnecting the interface UC-audio flex and keypad-display flex (Limited Keypad Model)

Label Description

1 Interface Keypad-Display Flex

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Label Description

2 Interface UC-Audio Flex

Figure 21: Disconnecting the UC-audio flex (Non-Keypad Model)

5.5.2

Back Kit Disassembly

Procedure:

1 Remove the top control seal.

Figure 22: Top control seal removal

2 Use a TORX screwdriver with a T6 head to remove the five M2 screws holding the mainboard

assembly to the back kit.

Figure 23: Back Kit disassembly

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

3 Remove the battery contact seal.

Figure 24: Battery contact seal removal

5.5.3

Keypad, Display, and Keypad Board Disassembly

Procedure:

1 Disconnect the UC-audio flex.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 25: UC-audio flex removal

2 Remove the display retainer after removing the two K18 screws.

Figure 26: K18 screw removal

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

Figure 27: Display flex removal

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

4 Remove the keypad and display module from the front kit.

Figure 28: Keypad removal

Label Description

1 Keypad

2 Display Module

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

5.5.4

Side Button, Speaker, Microphone, and UC-Audio Flex Disassembly

Procedure:

1 Pull out the PTT retainer.

Figure 29: PTT retainer removal

Label Description

1 PTT Retainer

2 Remove the side button.

Figure 30: Side button removal

Chapter 5: Disassembly/Reassembly Procedures

Label Description

1 Side Button

3 Peel off the UC escutcheon.

Figure 31: UC escutcheon removal

MN002211A01-AE

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

through the UC slot into the housing.

Figure 32: UC-audio flex removal

5 Remove the K18 screw securing the speaker retainer.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 33: Speaker retainer screw removal

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

Figure 34: Speaker retainer removal

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

5.6

Detailed Radio Reassembly

The section describes the detailed reassembly procedure of your radio.

5.6.1

Speaker Reassembly

Procedure:

1 Insert the UC-audio flex through the speaker retainer so that the speaker retainer is placed

directly on the speaker assembly.

Figure 35: Speaker assembly

NOTICE: Ensure the flex is on top of the retainer to prevent it from being torn during

reassembly.

2 Use tweezers to pull UC-audio flex circuit through the UC slot and place the speaker assembly

in the recess on the front kit.

MN002211A01-AE Chapter 5:

Disassembly/Reassembly Procedures

Figure 36: UC-audio flex

3 Replace with a new UC escutcheon.

Figure 37: UC escutcheon

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

retainer.

Figure 38: Speaker retainer reassembly

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

Label Description

1 Mic

5.6.2

Side Button, Keypad, Display, and Keypad Board Reassembly

Procedure:

1 Insert side button to the front housing.

Figure 39: Side button reassembly

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Label Description

1 Side Button

NOTICE: Ensure the side button is seated firmly without any pinching as this impacts the sealing performance.

2 Replace the PTT retainer.

Figure 40: PTT retainer reassembly

Label Description

1 PTT Retainer

3 Place the display module into the display module recess.

Figure 41: Display module reassembly

Chapter 5: Disassembly/Reassembly Procedures

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

Figure 42: Keypad reassembly

MN002211A01-AE

NOTICE: Ensure the keypad mushroom rib is fully seated in the sealing groove to prevent any pinching or bulging.

5 Tongue in the keypad board.

Figure 43: Keypad board reassembly

6 Connect the display flex and gently latch it down.

MN002211A01-AE Chapter

5: Disassembly/Reassembly Procedures

Figure 44: Display flex reassembly

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

retainer.

Figure 45: Speaker retainer reassembly

NOTICE: Ensure the UC-audio flex is not trapped under the speaker retainer.

8 Connect the UC-audio flex to the keypad board and gently press the Zero Insertion Force (ZIF)

connector until it latches shut.

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

Figure 46: UC-audio flex pad reassembly

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

5.6.3

Back Kit Reassembly

Procedure:

1 Replace the thermal pad on the chassis.

Figure 47: Replace thermal pad

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

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 48: Affix chassis label

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

edge is at the top side.

Figure 49: Battery contact seal reassembly

Label Description

1 Wider Edge

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

4 Place the mainboard assembly on the chassis and replace the five M2 screws.

Figure 50: Mainboard reassembly

5 4

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

Label Description

1-5 Five M2 screws

5 Insert the top control seal into the volume and channel shaft. Push on the wing of the top control

seal as shown in Figure 51: Top control seal reassembly on page 73, until it is seated on the base of the switches.

Figure 51: Top control seal reassembly

Label Description

1 Wing

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

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

5.6.4

Front Kit Reassembly

Procedure:

1 Apply a thin layer of grease to the full perimeter of the dispensed O-ring. 2 Connect the two flexes to the mainboard Zero Insertion Force (ZIF) connector and gently latch it

firmly shut.

Figure 52: Interface flexes reassembly (Limited Keypad Model)

Figure 53: Interface flexes reassembly (Non-Keypad Model)

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

Figure 54: Front kit reassembly

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

4 Fasten the two Front Kit-Back Kit screws by using TORX T6 screwdriver. 5 Slide in the volume and channel knob fully on the shafts on the front kit.

Figure 55: Knob reassembly

6 Attach antenna by turning it in clockwise.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 56: Attaching the antenna

5.6.5

RF Plug Reassembly

Procedure:

1 Replace the RF plug by using tweezers.

Figure 57: RF Plug reassembly

2 If Motorola Solutions nameplate is damaged, remove nameplate with tweezers and replace a

new one.

Figure 58: Nameplate replacement

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

3 Make sure the RF plug and nameplate are flushed to the housing and not bulging up. If it bulges

up, disassemble and reassemble back.

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

Figure 59: Product nameplate reassembly

NOTICE: Maintain this area regularly, at least annually, to prolong battery contacts life

and free interface from contamination.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

5.7

Ensuring Radio Immersibility

This section discusses radio immersibility concerns, tests, and disassembly and reassembly of the radios.

5.7.1

Servicing

Radios shipped from the Motorola Solutions factory have passed vacuum testing and are capable of restoring the watertight integrity of your radio.

CAUTION: It is strongly recommended to defer your radio maintenance to qualified service personnel and service shops. This is of paramount importance as service by unauthorized persons may cause irreparable damage to your radio. If disassembly is necessary, unauthorized attempts to repair the radio may void any existing warranties or extended performance agreements with Motorola Solutions. It is also recommended for qualified service personnel/workshop that is authorized by Motorola Solutions to perform annual check on your radio immersibility.

5.7.2

Accidental Immersion

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

5.7.3

Specialized Test Equipment

This section summarizes the specialized test equipment necessary for testing the integrity of the radios.

To ensure that the radio is truly a watertight unit, special testing, test procedures, and specialized test equipment are required. The special testing involves a vacuum check of the radio and pressure testing (troubleshooting) for water leaks. if the vacuum check fails. The specialized test equipment/instrument mentioned in the Service Aids is authorized by Motorola Solutions and is used to perform the vacuum check and pressure testing, if required. Any equipment/tools/instruments not mentioned in this chapter must not be used to perform these tests.

5.7.4

Vacuum Pump Kit

The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. A connector fitting (5871134M01) and fitting seal (3271133M01) pump connector, which must be

ordered separately, connects the vacuum hose to the radio chassis.

Chapter 5: Disassembly/Reassembly Procedures

Figure 60: Connector Fitting - Fitting Seal Pump Connector

Label Description

1 Fitting Seal

2 Connector Fitting

5.7.5

Pressure Pump Kit

MN002211A01-AE

The pressure pump kit includes a pressure pump with gauge, and a pressure hose. With the vacuum pump kit, the connector fitting - fitting seal pair connects the pressure hose to the

radio chassis.

5.7.6

Miscellaneous Hardware

Other items needed for testing radio immersibility are:

• Large water container

• Deionized (DI) water

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

5.7.7

Vacuum Test

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

Prerequisites:

• Remove the battery.

• Remove the universal connector dustcover to expose the universal connector.

• Remove the breathing vent label and breathing vent membrane.

Procedure:

1 Attach antenna firmly to the radio. 2 Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by blocking

off the open end of the hose and operating the pump a few times. The actual reading of the gauge at this point is not important; it is important that the gauge

pointer remained steady, indicating no vacuum leaks in the pump.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

3 Ensure that the fitting seal is attached to the hose-to-chassis pump connector. Screw the pump

connector into the tapped hole in the chassis.

CAUTION: Do not bend or over tighten pump connector to the chassis.

4 Attach the open end of the hose to the pointed end of the pump connector. 5 Place the radio on a flat surface with the chassis facing upward. 6 Operate the pump until the gauge indicates 6 in. Hg of vacuum on the radio. Observe the gauge

for approximately

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

• If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 3 in. Hg to less than 2.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if immersed. Additional troubleshooting of the radio will be required; complete this procedure, then go to Pressure Test on page 80.

7 Remove the vacuum hose and pump connector from the radio.

5.7.8

1 min.

Pressure Test

Pressure testing involves creating a positive pressure condition inside your radio, immersing radio in water, and observing radio for a stream of bubbles (leak). Since all areas of your radio are being checked, observe the entire unit carefully for the possibility of multiple leaks before completing this test.

NOTICE: Pressure testing the radio is necessary only if the radio has failed the vacuum test. Do not perform the pressure test until the vacuum test has been completed.

Procedure:

1 Screw the pump connector (with fitting seal) into the tapped hole in the chassis. 2 Attach one end of the pressure hose to the pump connector and the other end to the pressure

pump.

3 Attach antenna firmly to your radio. 4 Operate the pump until the gauge reads approximately 1 psig.

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

5 Maintain the pressure at 1 psig and immerse the radio into a water-filled container. 6 Watch for any continuous series of bubbles.

A stream of bubbles indicates a sign of leakage. Some air entrapment may cause the accumulation of bubbles, especially in the grille area, but the bubbles should not be continuous.

CAUTION: Do not bend or over tighten pump connector to the chassis.

7 Note all of the seal areas that show signs of leakage.

Pinpoint the problem to the following areas:

• Front Housing

•

Chassis kit

• Battery Contact Seal

8 Remove the radio from the water container, and dry the radio thoroughly.

MN002211A01-AE

Chapter

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

NOTICE: Dry the area around the main seal with extra care to prevent contamination of the internal electronics while the unit is open.

9 Remove the pump connector from the chassis.

Postrequisites: After performing Pressure Test, your radio must undergo baking process in a

temperature chamber for constant temperature soaking at 60 °C for 1 hour. This is to ensure no moisture is trapped inside the radio and prevent contamination of the internal electronics after reassembling the radio.

5.7.9

Disassembly/Reassembly Procedures

Troubleshooting Leak Areas

Before repairing any leak, read steps in the applicable section. This helps to eliminate unnecessary disassembly and reassembly of a radio with multiple leaks.

Troubleshoot only the faulty seal areas listed in Pressure Test exist, in the order listed.

NOTICE:

Before reassembling the radio, always install a Battery Contact Seal in the defective area.

on page 80, and when multiple leaks

5.7.9.1

Front Housing Troubleshooting

Procedure:

Do one or both of the following:

• If a leak occurs at the Lens (Display Models only), Universal Connector, Chassis/Housing

interface, or PTT button area of the housing, replace the housing, refer to Detailed Radio

Disassembly

1 Remove the housing assembly from the radio. 2 Discard the housing assembly. 3 Install a new housing assembly to the radio.

• If the leak occurs at the control top area, remove the knobs in order to determine the leak

location:

1 Conduct the Pressure Test. 2 Identify the leak location.

5.7.9.2

on page 53.

Replacing Battery Contact Seal

Procedure:

1 Remove the Battery Contact Seal from the Chassis. Refer to "Radio Disassembly" Chapter. 2 Inspect the Battery Contact Seal, Chassis, and surrounding areas for foreign material that might

prevent the Battery Contact Seal from sealing properly.

3 Install a new Battery Contact Seal, discard the old Seal. 4 Reassemble the Chassis assembly followed by installing into Front Kit. Refer to "Radio

Reassembly" Chapter.

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

5.7.9.3

Replacing Chassis Assembly

Procedure:

1 Remove the chassis assembly from the radio. Refer to Front Kit from Chassis Disassembly on

page 53

2 Remove the Mainboard from chassis. Refer to Back Kit Disassembly on page 58. 3 Assemble a new chassis assembly; discard the old chassis assembly. 4 Reassemble the chassis assembly followed by installing into front kit. Refer to Detailed Radio

Reassembly on page 65.

5.7.9.4

Replacing Ventilation Seal and Ventilation Label

Prerequisites: Both Ventilation Label and Gasket need to be replaced after vacuum test, pressure

test, or water leakage troubleshooting.

Procedure:

1 Remove the Ventilation Label that covers the Ventilation Seal from the chassis. 2 Remove the Ventilation Seal. 3 Ensure that the chassis surface (at the Ventilation Label and Ventilation Seal recess) is clean,

no/minimum scratches and free from any adhesive or other foreign materials.

4 Install a new Ventilation Seal, covering the vent port hole, in the small recessed area in the

chassis. Ensure that no oily substance is in contact with the seal.

5 Install a new Ventilation Label over the Ventilation Seal in the larger recessed area in the

chassis. Press down evenly over the label surface to ensure good adhesion.

5.7.9.5

Battery Maintenance

Maintain your radio battery annually or as required; when battery contacts are dirty or show signs of wear. Battery Maintenance prolongs battery contacts life and free battery interface from contamination.

It is recommended that the Battery Radio-side and Charger-side contacts are cleaned with DeoxIT GOLD cleaner/lubricant.

DeoxIT GOLD (Supplier CAIG Labs, part number: G100P) cleaner/lubricant pen is very effective at cleaning and extending the life of the battery contacts. DeoxIT GOLD cleaner/lubricant pen is available at numerous electronics suppliers (Radio Shack, McMaster Carr, Fry's, and more) and directly from manufacturer, CAIG Labs, at http://www.caig.com.

This pen-based package is recommended as it provides better access to the recessed contacts of the battery. The pen tip may need to be modified (trimmed on the sides) to improve penetration into the battery contact slots.

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

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

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

5.7.9.5.1

Maintaining the Battery

Procedure:

1 Shake the lubricant pen until the fluid begins to flow. 2 Wipe battery contact surface with felt tip. 3 After cleaning the contact areas of any foreign material, let the lubricant/cleaner dry for 2

minutes.

4 Replace the battery on the radio. Make sure the battery is attached properly on the radio.

Postrequisites: After cleaning, inspect the contact surfaces for signs of advanced contact wear. See

Battery Maintenance on page 82 for advanced contact wear.

Start

1. Remove Battery

2. Remove Universal Connector Dustcover

3. Remove ventilation label and seal

1. Attach antenna firmly to the radio.

2. Attach vacuum hose to vacuum pump

3. Ensure fitting seal is attached to hose-to-chassis pump connector

4. Screw pump connector into chassis’s tapped hole

5. Attach vacuum hose to pump connector

6. Place radio on flat surface

7. Operate pump (gauge = 6 in. Hg)

Gauge

does not fall

below

0.5 in. Hg

Yes

Run Pressure Test

1.Replace ventilation label and seal

2. Radio approved for immersibility

Full

equipment for

pressure test

procedure

available

Yes

End

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

5.7.10

Troubleshooting Charts

Figure 61: Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)

Start

1.Remove pump and connectors from radio

2. Remove antenna

3. Separate front housing kit

Replace front

housing kit with

new unit

Apply grease to the full

perimeter of the chassis O-ring

and replace the Chassis Kit

without PCBs

Yes

Changed

front housing

kit

Changed

chassis

kit

Yes

Send radio to

Motorola Depot

Motorola Service Center

End

Chapter 5: Disassembly/Reassembly Procedures

Figure 62: Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)

MN002211A01-AE

Start

1. Remove vacuum hose from pump connector

2. Attach pressure hose to pump connector

1. Operate pressure pump (pressure = 1 psig)

2. Immerse radio into a waterfilled container

Continuous

Series of

bubbles

Yes

Bubbles from

Front

Housing

Yes

Bubbles from

Chassis

Yes

Bubbles from

Battery Con-

tact Seal

Yes

Bubbles from Lens*/Universal Connector/

chassis/

Housing Inter-

face/ PTT

1. Dry the radio

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

Yes

1. Remove Knobs

1. Dry the radio

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

1. Dry the radio

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

1. Dry the radio

2.Replace Ventilation Label and Ventilation Seal

3. Radio approved for immersibility

* Only for Display Model

End

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Figure 63: Troubleshooting Flow Chart for Pressure Test and Leakage Areas

10.2.5.1

10.2.5

10.2.4

10.2.3

10.1

10.2.2

9.14

9.23

9.22

9.21

9.20

9.19

9.18

9.17

9.16

9.15

9.14

9.13

9.12

9.11

9.10

9.9

9.8

9.7

9.6

9.5

9.4

9.3

9.2

9.1

10.2.1

10.2.5.2

Chapter 5: Disassembly/Reassembly Procedures

5.8

Radio Exploded Mechanical View and Parts List

5.8.1

Limited Keypad Model

Figure 64: Limited Keypad Model Exploded View

MN002211A01-AE

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Table 34: Limited Keypad Model Exploded View Parts List

Label Description Part Number

1 Nameplate (Product Number) Refer to Additional Parts

List on page 92

2 Nameplate (Motorola Solutions)

33012026001 3 RF Plug 38012018001 4 Volume Knob 36012016001 5 Channel Knob 36012017001 6 Antenna ID Band Refer to Additional Parts

List on page 92

7 Antenna Refer to Additional Parts

List on page 92

8 Aesthetic Cover 0104058J40 9 Front Kit PMLN7271_

9.1 PTT Retainer 42012035001

9.2 Side Button KP000087A01

9.3 Housing Assembly 0104067J09

9.4 PTT Keypad KP000086A01

9.5 PTT Paddle HN000696A01

9.6 UC Escutcheon 33012020001

9.7 Microphone Membrane SL000209A01

9.8 Microphone Boot SL000208A01

9.9 Microphone 50012012001

9.10 Speaker Mesh HW000738A01

9.11 Speaker AC000028A02

9.12 UC-Audio Flex PF001002A01

9.13 Speaker Retainer 42012044001

9.14 K18 Screw (Keypad-Display

0385273D06

Retainer and Speaker Retainer)

9.15 Front Display Poron 75012078001

9.16 Display Module (2-Line Mono-

72012014002

chrome)

9.17 Back Display Poron HW000757A01

9.18 Display Retainer 42012034001

9.19 Conductive Pad 75012147001

9.20 Limited Keypad 75012080001

9.21 Keypad Board Assembly 0104065J98

9.22 Interface Keypad-Display Flex PF001004A01

9.23 Interface UC-Audio Flex PF001005A01

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

Label Description Part Number

10 Back Kit Refer to Additional Parts

List on page 92

10.1 Main Board Assembly Part of Back Kit

10.2 Chassis Assembly PMLN7273_

10.2.1 M2 Screw (Main Board Assem-

03012034001

bly)

10.2.2 Top Control Seal 32012269001

10.2.3 Thermal Pad 75012234001

10.2.4 Battery Contact Seal 32012110001

10.2.5 Chassis (With dispensed O-

0104067J11

Ring)

10.2.5.1

Chassis Left Label LB000706A01

10.2.5.2 Chassis Right Label LB000706A02 11 Front Kit-Back Kit Screw 0316281H01 12 Compro Label LB000560A01 13 Ventilation Seal 3286058L01 14 Ventilation Label LB000256A01 15 TIA Label Non-field replaceable 16 Battery Refer to Additional Parts

List on page 92

17 Belt Clip Refer to Additional Parts

List on page 92

18 RTTE Label 5486749Z01

10.2.5.1

10.2.5

10.2.4

10.2.3

10.1

9.14

9.13

9.12

9.11

9.10

9.9

9.8

9.7

9.6

9.5

9.4

9.3

9.2

9.1

10.2.1

10.2.5.2

10.2.2

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

5.8.2

Non-Keypad Model

Figure 65: Non-Keypad Model Exploded View

List on page 92

Table 35: Non-Keypad Model Exploded View Parts List

Item Description Part Number

1 Nameplate (Product Number) Refer to Additional Parts

2 Nameplate (Motorola Solutions) 33012026001 3 RF Plug 38012018001

MN002211A01-AE

Chapter 5: Disassembly/Reassembly Procedures

Item Description Part Number

4 Volume Knob 36012016001 5 Channel Knob 36012017001 6 Antenna ID Band Refer to Additional Parts

List on page 92

7 Antenna Refer to

Additional Parts

List on page 92

8 Aesthetic Cover 0104058J40 9 Front Cover Kit PMLN7272_

9.1 PTT Retainer 42012035001

9.2 Side Button KP000087A01

9.3 Housing Assembly 0104067J10

9.4 PTT Keypad KP000086A01

9.5 PTT Paddle HN000696A01

9.6 UC Escutcheon 33012020001

9.7 Microphone Membrane SL000209A01

9.8 Microphone Boot SL000208A01

9.9 Microphone 50012012001

9.10 Speaker Mesh HW000738A01

9.11 Speaker AC000028A02

9.12 UC-Audio Flex PF001006A01

9.13 Speaker Retainer 42012044001

9.14 K18 Screw (Keypad-Display

0385273D06

Retainer and Speaker Retainer)

10 Back Kit Refer to Additional Parts

List on page 92

10.1 Main Board Assembly Part of Back Kit

10.2 Chassis Assembly PMLN7273_

10.2.1 M2 Screw (Main Board Assem-

03012034001

bly)

10.2.2 Top Control Seal 32012269001

10.2.3 Thermal Pad 7515526H01

10.2.4 Battery Contact Seal 32012110001

10.2.5 Chassis (With dispensed O-

0104067J11

Ring)

10.2.5.1 Chassis Left Label LB000706A01

10.2.5.2 Chassis Right Label LB000706A02 11 Front Kit-Back Kit Screw 0316281H01 12 Compro Label LB000560A01 13 Ventilation Seal 3286058L01

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Item Description Part Number

14 Ventilation Label LB000256A01 15 TIA Label Non-field replaceable 16 Battery Refer to Additional Parts

List on page 92

17 Belt Clip Refer to

List on page 92

18 RTTE Label 5486749Z01

5.8.3

Additional Parts

Additional Parts List

This list consists of parts compatible to your radio.

Table 36: Batteries

Item Part Number

Core Slim Li-Ion 1500 mAH PMNN4406_

Core NIMH 1300 mAH PMNN4415_

IMPRES Li-Ion 1500 mAH PMNN4417_

IMPRES Li-Ion Non-FM 2150 mAH PMNN4418_

Core Li-Ion 2450 mAH IP68 PMNN4543_

Table 37: Nameplates

Item Part Number

DP 2400e 33012039027

DP 2600e 33012039028

Table 38: Back Kits

Item Part Number

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

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

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

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

PMLD4733_S

PMLD4734_S

PMLD4737_S

PLMLD4749_

PMLD4755_S

PMLD4800_S

Chapter 5: Disassembly/Reassembly Procedures

Item Part Number

MN002211A01-AE

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

Back Cover Kit, 300 MHz, Non-Keypad Portable

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

Table 39: Antenna ID Band (in pack of 10 pieces)

Item Part Number

Grey 32012144001

Yellow 32012144002

Green 32012144003

Blue 32012144004

Purple 32012144005

Table 40: Belt Clips

Item Part Number

2 in. belt clip PMLN4651_

PMLD4799_S

PMLD4646_S

PMLE5074_S

2.5 in. belt clip PMLN7008_

5.9

Torque Chart

Torque Chart lists the various screws by part number and description, followed by the torque values in different units of measure.

NOTICE: Torque all screws to the recommended value when assembling the radio.

Table 41: Torque Specifications for Screws

Part Number Description Driver/Socket Torque

lbs-in N-m

0385273D06

03012034001

K18 Screw (Speaker Retainer)

K18 Screw (Keypad-Display Retainer)

M2 Screw (Mainboard Assembly) - New Chassis

T6 Torx 2.0 to 2.2 0.23 to 0.25

T6 Torx 1.5 to 1.7 0.17 to 0.19

T6 Torx 3.1 to 3.5 0.35 to 0.40

MN002211A01-AE Chapter 5: Disassembly/Reassembly Procedures

Part Number Description Driver/Socket Torque

lbs-in N-m

M2 Screw (Mainboard Assembly) - Rework Chassis

0316281H01 Front Kit-Back

Kit Screw

T6 Torx 2.0 0.23

T6 Torx 2.1 to 2.3 0.24 to 0.26

MN002211A01-AE

Basic Troubleshooting

Chapter 6

Basic Troubleshooting

This chapter contains error codes and board replacement procedures. If the board does not pass all the performance checks in Transceiver Performance Testing on page 30

or exhibits an error code listed below, then the circuit board should be replaced. If repair requires knowledge of details of component level troubleshooting, please send the radio to a Motorola Solutions Service Center.

To access the various connector pins, use the housing eliminator/test fixture along with the diagrams found in this section of the manual. See "Service Aids" for the appropriate Motorola Solutions service aids and tools part numbers.

6.1

Replacement Back Cover Kit Procedures

Once a problem has been isolated to a specific board, install the appropriate back cover kit (Refer to "Model Charts"), which is orderable from Motorola Solutions Radio Products and Solutions Organization.

If a board is replaced, it does not necessarily need to be retuned if it has been factory tuned. It should however be checked for performance before being placed into service. Of particular concern is the Bias DAC, which will need to be set for the appropriate final device bias current prior to keying up the radio. If the bias is not properly set it may cause damage to the transmitter.

CAUTION:

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

6.2

Power-Up Error Codes

Upon powering up, the radio performs certain tests to determine if its basic electronics and software are in working order. Any error detected has an associated error code that is presented on the radio display.

NOTICE: Power-Up error codes are only applicable to Display Models only.

These error codes are intended to be used by a service technician when the radio generates the SelfTest Fail Tone. If these tests are successfully completed, the radio will generate the Self-Test Tone.

NOTICE: Non-display radios emit only the Self-Test Fail Tone if it fails the self-test.

There are two classes of detectable errors: fatal and non-fatal.

Fatal errors

Normal radio operation is inhibited when your radio encounters fatal errors. Fatal errors include hardware errors detected by the microprocessor and certain memory errors. These memory errors include incorrect ROM checksum, incorrect RAM checksum, and incorrect

checksums of codeplug (Persistent Storage) blocks that contain operating parameters. If the codeplug block operating parameters are corrupted, operation of the unit on the proper

frequency, system, and group are in question.

MN002211A01-AE Chapter 6: Basic Troubleshooting

Attempts to use this information could provide a false sense of security that others are receiving your messages.

Non-fatal errors

Corrupted codeplug blocks of call IDs, or their associated aliases are considered non-fatal errors. Normal communication is still possible, but the user may be inconvenienced.

Table 42: Types of Error Code

Error Code Description Error

Type

ERROR 01/02

Call ID or associated aliases codeplug block

Non-Fatal Normal communication is still possible, but

checksum is wrong.

ERROR 01/22

FAIL 01/82 External Codeplug

Tuning Codeplug block checksum is wrong.

Non-Fatal Normal communication is still possible.

Fatal Reprogram codeplug. block checksum is wrong.

FAIL 01/92 Secure Codeplug

Fatal Reprogram codeplug. checksum error.

FAIL 01/A2 Tuning Codeplug block

Fatal Reprogram codeplug. checksum is wrong.

FAIL 01/81 ROM Checksum is

Fatal Reprogram FLASH Memory, then retest. wrong.

FAIL 01/88 Radio RAM test fail-

Fatal Retest radio by turning it off and turning it ure.

FAIL 01/90 or FAIL

General hardware test failure.

Fatal Retest radio by turning it off and turning it

02/90

Corrective Action

the user may be inconvenienced. Reprogram codeplug.

on again.

FAIL 02/81 DSP ROM Checksum

Fatal Reprogram FLASH Memory, then retest. is wrong.

FAIL 02/82 DSP RAM1 test fail-

ure.

FAIL 02/84 DSP RAM2 test fail-

ure.

Fatal Retest radio by turning it off and turning it

on again.

Fatal Retest radio by turning it off and turning it

on again.

FAIL 02/88 DSP RAM test failure. Fatal Retest radio by turning it off and turning it

on again.

FAIL 02/C0 DSP ROM Checksum

is wrong.

No Display Display module is not

connected properly. Display module is

Fatal Retest radio by turning it off and turning it

on again.

Fatal Check connection between main board and

display module. Replace with new display module.

damaged.

NOTICE:

If error message reoccurs, replace main board or send radio to nearest Motorola Solutions Depot.

MN002211A01-AE

Chapter 6: Basic Troubleshooting

6.3

Operational Error Codes

During radio operation, your radio performs dynamic tests to determine if your radio is working properly. Problems detected during these tests are presented as error codes on your radio display. Use the following table to aid in understanding particular operational error codes.

Table 43: Types of Error Code

Error Code

FAIL 001

FAIL 002

Description Error Type Corrective Action

Synthesizer Out-of-Lock. Non-fatal Reprogram the codeplug. Refer

to Detailed Service Manual.

Personality checksum or system block error.

NOTICE: If error message reoccurs, send radio to nearest Motorola Solutions Service Centers or Authorized Motorola Solutions Service Dealers.

Non-fatal Reprogram the codeplug.

MN002211A01-AE Appendix A:

EMEA Regional Warranty, Service, and Technical Support

Appendix A

EMEA Regional Warranty, Service, and Technical Support

Warranty and Service Support

Motorola Solutions offers long-term support for its products. This support includes full exchange and/or repair of the product during the warranty period and service/repair or spare parts support out of warranty. Any "return for exchange" or "return for repair" by an authorized Motorola Solutions Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola Solutions Dealer.

Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Solutions Dealer or Distributor or Reseller contract. These conditions may change from time to time and the following notes are for guidance purposes only.

In instances where the product is covered under a "return for replacement" or "return for repair" warranty, a check of the product should be performed prior to shipping the unit back to Motorola Solutions. This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty.

Prior to shipping any radio back to the appropriate Motorola Solutions warranty depot, please contact Customer Resources. All returns must be accompanied by a Warranty Claim Form, available from your Customer Services representative. Products should be shipped back in the original packaging, or correctly packaged to ensure no damage occurs in transit.

After Warranty Period

After the Warranty period, Motorola Solutions continues to support its products in two ways:

• Motorola Solutions Managed Technical Services (MTS) offers a repair service to both end users and dealers at competitive prices.

• MTS supplies individual parts and modules that can be purchased by dealers who are technically capable of performing fault analysis and repair.

Further Assistance

You can also contact the Customer Help Desk through http://www.motorolasolutions.com.

MN002211A01-AE

Service Information

Appendix B

Service Information

EMEA Technical Support Operations (TSO)

The EMEA Technical Support Operations (TSO) provides a remote Technical Support Service to help customers resolve technical issues and quickly restore networks and systems. This team of highly skilled professionals is available to customers with current service agreements in place that include the Technical Support Service. The TSO technical experts may be accessed through the Service Desk either electronically or using the listed telephone numbers. If you are unsure whether your current service agreement entitles you to benefit from this service, or if you would like more information about the Technical Support Service, contact your local customer support or account manager for further information.

Contact Details

Email: techsupport.emea@motorolasolutions.com

Table 44: List of Telephone Numbers

Country In Country Number to Dial

AUSTRIA 0800 281 195 DENMARK 80 253 546 FRANCE 0800 914 532 or +33 176 775 609 GERMANY 0800 724 6872 or +49 69 22221568 ISRAEL 180 931 5818 ITALY 800 791 276 NETHERLANDS 0800 0249 893 NORWAY 800 14 802 POLAND 00800 1215 772 RUSSIA 810 800 286 15011 SAUDI ARABIA 800 811 0523 SOUTH AFRICA 0800 994 886 SPAIN 9009 416 84 UNITED KINGDOM 0800 731 3496 or +44 207 019 0461 UNITED ARAB EMIRATES 8000 3570 4387 All Other Countries +44 207 019 0461

European Systems Component Centre (ESCC)

The European Systems Component Centre provides a repair service for infrastructure equipment. Customers requiring repair service should contact the Customer Information Desk to obtain a Return Material Authorization number. The equipment should then be shipped to the following address unless advised otherwise.

MN002211A01-AE Appendix B:

Motorola Solutions GmbH, European Systems Component Centre, Am Borsigturm 130,13507 Berlin, Germany

Service Information

Contact Details

• E-Mail:

• Telephone: +49 (0) 30 66861404

• Telefax: +49 (0) 30 66861426

• Monday – Friday 08:00 am to 06:00 pm (CET)

escc.admin@motorolasolutions.com

European Radio Support Centre (ERSC)

ERSC provides a remote Technical Support Service to help customers resolve technical issues and quickly restore their systems. The centre handles service orders for subscribers and accessories. This team of highly skilled professionals is available to the customers that have current ERSC service agreements in place. For further information and to verify if your current service agreement entitles you to benefit from this service, contact your local customer support.

Contact Details

• E-Mail: ersc.admin@motorolasolutions.com

• Telephone: +49 (0) 30 66861555

• Telefax: +49 (0) 30 66861579

Parts Identification and Ordering

If you need help in identifying non-referenced spare parts, direct a request to the Customer Care Organization of a local area Motorola Solutions representative. Orders for replacement parts, kits, and assemblies should be placed directly at the local distribution organization of Motorola Solutions or through the Extranet site Motorola Online at https://emeaonline.motorolasolutions.com.

Updated Versions of Manuals

Verify the current version of the manual at our Extranet site, Motorola Online: https://

emeaonline.motorolasolutions.com.

Your Input

Send questions and comments regarding user documentation to

documentation@motorolasolutions.com.

100

Motorola DP2000e basic service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

List of Figures

List of Tables

Foreword

Product Safety and RF Exposure Compliance

Computer Software Copyrights

Document Copyrights

Disclaimer

Trademarks

Document History

Notations Used in This Manual

Introduction

Radio Description

Limited Keypad Model

Non-Keypad Model

Portable Radio Model Numbering Scheme

Model Charts

UHF Model Chart

VHF Model Chart

300 MHz Model Chart

350 MHz Model Chart

Specifications

Test Equipment and Service Aids

Recommended Test Equipment

Service Aids

Programming, Testing, and Alignment Cable

Transceiver Performance Testing

Setup

Setting Up DMR Transmitter and Receiver Test

Display Model Test Mode

Entering Display Radio Test Mode

RF Test Mode

Testing RF Channel Selections

Display Test Mode

LED Test Mode

Backlight Test Mode

Speaker Tone Test Mode

Earpiece Tone Test Mode

Audio Loopback Earpiece Test Mode

Battery Check Test Mode

Button/Knob/PTT Test Mode

Non-Display Model Test Mode

Entering Non-Display Radio Test Mode

RF Test Mode

Testing RF Channel Selections

LED Test Mode

Speaker Tone Test Mode

Earpiece Tone Test Mode

Audio Loopback Earpiece Test Mode

Battery Check Test Mode

Button/Knob/PTT Test Mode

Radio Programming and Tuning

Customer Programming Software Setup

AirTracer Application Tool

Radio Tuning Setup

RF Plug Disassembly

Disassembly/Reassembly Procedures

Preventive Maintenance

Safe Handling of CMOS and LDMOS Devices

General Repair Procedures and Techniques

Disassembling and Reassembling the Radio

Detailed Radio Disassembly

Front Kit from Chassis Disassembly

Back Kit Disassembly

Keypad, Display, and Keypad Board Disassembly

Side Button, Speaker, Microphone, and UC-Audio Flex Disassembly

Detailed Radio Reassembly

Speaker Reassembly

Side Button, Keypad, Display, and Keypad Board Reassembly

Back Kit Reassembly

Front Kit Reassembly

RF Plug Reassembly

Ensuring Radio Immersibility

Servicing

Accidental Immersion

Specialized Test Equipment