Motorola DP540 BASIC SERVICE MANUAL

MOTOTRBO

PROFESSIONAL DIGITAL TWO-WAY RADIO

™

PORTABLE

™

MOTOTRBO

PORTABLE
DP540 BASIC SERVICE
MANUAL

DECEMBER 2021

©

2021

Motorola Solutions, Inc. All rights reserved

*MN008927A01*

MN008927A01-AA

MN008927A01-AA
Contents

Contents

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

List of Tables............................................................................................................... 6

Foreword .....................................................................................................................7

Disclaimer...................................................................................................................................... 7

Product Safety and RF Exposure Compliance.............................................................................. 7

Intellectual Property and Regulatory Notices.................................................................................7

Document History....................................................................................................... 9

Related Publication...................................................................................................10

Notations Used in This Manual................................................................................11

Chapter 1: Introduction...........................................................................................12

1.1 Radio Description.................................................................................................................. 12

1.1.1 Non-Keypad Model.................................................................................................. 12

1.2 Portable Radio Model Numbering Scheme........................................................................... 14

1.3 Model Chart........................................................................................................................... 15

1.3.1 UHF Model Chart..................................................................................................... 15

1.3.2 VHF Model Chart..................................................................................................... 15

1.4 Specifications.........................................................................................................................16

1.4.1 General.................................................................................................................... 16

1.4.2 Receiver...................................................................................................................17

1.4.3 Transmitter...............................................................................................................17

1.4.4 Self-Quieter..............................................................................................................18

1.4.5 Military Standards.................................................................................................... 19

1.4.6 Environmental.......................................................................................................... 20

Chapter 2: Test Equipment and Service Aids...................................................... 22

2.1 Recommended Test Equipment............................................................................................ 22

2.2 Service Aids...........................................................................................................................23

2.3 Programming, Testing, and Alignment Cable........................................................................ 23

Chapter 3: Transceiver Performance Testing...................................................... 26

3.1 Setup..................................................................................................................................... 26

3.2 Non-Display Model Test Mode.............................................................................................. 27

3.2.1 Entering Non-Display Radio Test Mode...................................................................27

3.2.2 RF Test Mode.......................................................................................................... 27

3.2.3 LED Test Mode........................................................................................................ 32

3.2.4 Speaker Tone Test Mode........................................................................................ 32

3.2.5 Earpiece Tone Test Mode........................................................................................32

2

MN008927A01-AA

Contents

3.2.6 Audio Loopback Earpiece Test Mode...................................................................... 32

3.2.7 Battery Check Test Mode........................................................................................

3.2.8 Button/Knob/PTT Test Mode................................................................................... 33

33

Chapter 4: Radio Programming and Tuning.........................................................34

4.1 Customer Programming Software Setup............................................................................... 34

4.2 AirTracer Application Tool..................................................................................................... 35

4.3 Radio Tuning Setup............................................................................................................... 35

4.3.1 RF Adaptor Holder Assembly.................................................................................. 36

Chapter 5: Disassembly and Reassembly Procedures....................................... 43

5.1 Preventive Maintenance........................................................................................................ 43

5.2 Safe Handling of CMOS and LDMOS Devices......................................................................44

5.3 General Repair Procedures and Techniques........................................................................ 45

5.4 Radio Disassembly and Reassembly.................................................................................... 47

5.5 Detailed Radio Disassembly..................................................................................................47

5.5.1 Chassis and Front Housing Disassembly................................................................ 47

5.5.2 Chassis Disassembly...............................................................................................52

5.5.3 Speaker and Microphone Disassembly................................................................... 53

5.5.4 Dust Cover Disassembly..........................................................................................54

5.5.5 Micro USB Dust Cover Disassembly....................................................................... 54

5.5.6 PTT Disassembly.....................................................................................................55

5.6 Detailed Radio Reassembly.................................................................................................. 56

5.6.1 PTT Reassembly..................................................................................................... 56

5.6.2 Micro USB Dust Cover Reassembly........................................................................ 59

5.6.3 Audio Jack Dust Cover Reassembly........................................................................59

5.6.4 Speaker and Microphone Reassembly.................................................................... 60

5.6.5 Chassis Reassembly............................................................................................... 61

5.6.6 Chassis and Front Housing Reassembly.................................................................65

5.7 Radio Exploded Mechanical View and Parts List.................................................................. 67

5.7.1 Non-Keypad Exploded View.................................................................................... 67

5.7.2 Back Cover Kit Part Numbers.................................................................................. 69

5.7.3 Torque Chart............................................................................................................69

Chapter 6: Basic Troubleshooting ........................................................................70

6.1 Replacement Back Cover Kit Procedures............................................................................. 70

Appendix A: Replacement Parts Ordering........................................................... 71

Appendix B: EMEA Regional Warranty, Service, and Technical Support......... 72

Appendix C: Service Information for EMEA......................................................... 73

Appendix D: Limited Level 3 Servicing.................................................................74

D.1 Components and Parts List...................................................................................................75

3

MN008927A01-AA
Contents

Glossary.....................................................................................................................77

4

MN008927A01-AA

List of Figures

List of Figures

Figure 1: Non-Keypad Model .................................................................................................................13

Figure 2: Portable Programming Cable with TTR (PMKN4128_)

Figure 3: Portable Test Cable (PMKN4156_ ) .......................................................................................25

Figure 4: CPS Programming Setup ....................................................................................................... 34

Figure 5: CPS Programming Setup ....................................................................................................... 35

Figure 6: Radio Tuning Equipment Setup ............................................................................................. 36

Figure 7: Radio Tuning Equipment Setup ............................................................................................. 36

Figure 8: Nameplate disassembly ......................................................................................................... 37

Figure 9: Aligning RF Adaptor ............................................................................................................... 38

Figure 10: Inserting the RF Adaptor ...................................................................................................... 39

Figure 11: Inserting the RF connector ................................................................................................... 40

Figure 12: Affixing the backer ................................................................................................................41

Figure 13: Complete RF adaptor assembly ...........................................................................................42

Figure 14: Battery Removal ...................................................................................................................48

Figure 15: Channel Selector and Volume Knob Removal ..................................................................... 49

Figure 16: Chassis Screw Removal ...................................................................................................... 50

Figure 17: Chassis Removal from Front Housing ..................................................................................51

Figure 18: Speaker and Microphone Wires Removal ............................................................................51

Figure 19: Speaker and Microphone Disassembly ................................................................................53

Figure 20: Dust Cover Disassembly ...................................................................................................... 54

Figure 21: Micro USB Dust Cover Removal .......................................................................................... 55

Figure 22: PTT Disassembly ................................................................................................................. 56

Figure 23: PTT Assembly ...................................................................................................................... 57

Figure 24: PTT Bezel Orientation .......................................................................................................... 58

Figure 25: PTT Reassembly ..................................................................................................................58

Figure 26: Micro USB Dust Cover Reassembly .................................................................................... 59

Figure 27: Audio Jack Dust Cover Reassembly .................................................................................... 60

Figure 28: Speaker and Microphone Reassembly ................................................................................ 61

Figure 29: Battery Contact Seal Assembly ............................................................................................62

Figure 30: Thermal Pad Assembly ........................................................................................................ 63

Figure 31: PCB and Top Control Seal Assembly .................................................................................. 64

Figure 32: Chassis and Front Housing Reassembly ............................................................................. 65

Figure 33: Inserting Chassis Assembly into Housing ............................................................................ 66

Figure 34: PCB Top View ...................................................................................................................... 75

Figure 35: PCB Bottom View .................................................................................................................75

..........................................................24

5

MN008927A01-AA
List of Tables

List of Tables

Table 1: Radio Frequency Ranges and Power Levels .......................................................................... 12

Table 2: Portable Radio Model Numbering Scheme

Table 3: Sales Models – Description of Symbols .................................................................................. 14

Table 4: DP540, UHF, 403–480 MHz Model Chart ............................................................................... 15

Table 5: DP540, VHF, 136–174 MHz Model Chart ............................................................................... 15

Table 6: General Specifications .............................................................................................................16

Table 7: Receiver Specifications ........................................................................................................... 17

Table 8: Transmitter Specifications ....................................................................................................... 17

Table 9: Self-Quieter Specification ........................................................................................................ 18

Table 10: Military Standards (810C–810E) ........................................................................................... 19

Table 11: Military Standards (810F–810H) ............................................................................................20

Table 12: Environmental Specifications ................................................................................................ 20

Table 13: Test Equipment ..................................................................................................................... 22

Table 14: Service Aids ...........................................................................................................................23

Table 15: Pin Configuration of Portable Programming Cable with TTR ................................................ 24

Table 16: Pin Configuration of Portable Test Cable .............................................................................. 25

Table 17: Initial Equipment Control Settings ......................................................................................... 26

Table 18: Test Environments .................................................................................................................27

Table 19: Test Frequencies ...................................................................................................................28

Table 20: Transmitter Performance Checks ..........................................................................................29

Table 21: Receiver Performance Checks ..............................................................................................30

Table 22: Button/Knob/PTT Checks ...................................................................................................... 33

Table 23: Software Installation Kits Radio Tuning Setup ...................................................................... 34

Table 24: Lead Free Solder Wire Part Number List .............................................................................. 46

Table 25: Lead Free Solder Paste Part Number List .............................................................................46

Table 26: Non-Keypad Exploded View Part List ....................................................................................67

Table 27: Back Cover Kit Part Numbers ................................................................................................69

Table 28: Torque Specifications for Screws .......................................................................................... 69

Table 29: Components and Parts List ................................................................................................... 75

............................................................................. 14

6

MN008927A01-AA

Foreword

Foreword

This manual includes all the information necessary to maintain peak product performance and
maximum working time, using levels 1 and 2 maintenance procedures.

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.

CAUTION: Only Underwriter Laboratory (UL) approved service centers are qualified to open
and service UL certified radios. Opening or repairing at unauthorized locations invalidates
hazardous location rating of the radio.

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.

Product Safety and RF Exposure Compliance

CAUTION: 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.

Intellectual Property and Regulatory Notices

Copyrights

The Motorola Solutions products described in this document may include copyrighted Motorola
Solutions computer programs. Laws in the United States and other countries preserve for Motorola
Solutions certain exclusive rights for copyrighted computer programs. Accordingly, any copyrighted
Motorola Solutions computer programs contained in the Motorola Solutions products described in this
document may not be copied or reproduced in any manner without the express written permission of
Motorola Solutions.

No part of this document may be reproduced, transmitted, stored in a retrieval system, or translated
into any language or computer language, in any form or by any means, without the prior written
permission of Motorola Solutions, Inc.

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.

License Rights

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, royalty-free license to use that arises by
operation of law in the sale of a product.

7

MN008927A01-AA
Foreword

Open Source Content

This product may contain Open Source software used under license. Refer to the product installation
media for full Open Source Legal Notices and Attribution content.

European Union (EU) and United Kingdom (UK) Waste of Electrical and
Electronic Equipment (WEEE) Directive

The European Union's WEEE directive and the UK's WEEE regulation require that products sold
into EU countries and the UK must have the crossed-out wheelie bin label on the product (or the
package in some cases). As defined by the WEEE directive, this crossed-out wheelie bin label means
that customers and end-users in EU and UK countries should not dispose of electronic and electrical
equipment or accessories in household waste.

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

Disclaimer

Please note that certain features, facilities, and capabilities described in this document may not be
applicable to or licensed for use on a specific system, or may be dependent upon the characteristics of
a specific mobile subscriber unit or configuration of certain parameters. Please refer to your Motorola
Solutions contact for further information.

©

2021 Motorola Solutions, Inc. All Rights Reserved

8

MN008927A01-AA

Document History

Document History

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

Version Description Date

MN008927A01-AA Initial Release December 2021

9

MN008927A01-AA
Related Publication

Related Publication

The following list contains part numbers and titles of related publications.

6864117B25, Product Safety and RF Energy Exposure Booklet for Portable Two-Way Radios

•

• MN006544A01, DP540 Quick Reference Guide

10

MN008927A01-AA

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.

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

11

MN008927A01-AA
Chapter 1 : Introduction

Chapter 1

Introduction

1.1

Radio Description

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

Table 1: Radio Frequency Ranges and Power Levels

Frequency Band Bandwidth Power Level

UHF 403–480 MHz 1 W or 4 W

VHF 136–174 MHz 1 W or 5 W

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 communication solution.

1.1.1

Non-Keypad Model

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

12

Figure 1: Non-Keypad Model

1

2

3

4
5

10

11

9

8

7

6

MN008927A01-AA

Chapter

1 : Introduction

Label Item Description

1 Antenna Provides the needed RF amplification when

transmitting or receiving.

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

Group call and Private Call).

3 Speaker Plays all tones and audio that are generated by

the radio.

4, 5 Side Buttons These two buttons are field programmable using

the Customer Programming Software (CPS).

6 USB with Dust Cover Dust cover to prevent dust from clogging the

7 Microphone Voice is sent when PTT or voice operations are

8 Accessory Connector with

Dust Cover

9 LED Indicator Red, green, and orange light-emitting diodes in-

10 On/Off/Volume Knob Rotate clockwise until click is heard to turn on ra-

USB port.

activated.

Interface point for all accessories to connect to
the radio.

dicate operating status.

dio; rotate counterclockwise until click is heard to
turn off radio. Rotate clockwise to increase vol­ume level; rotate counterclockwise to decrease
volume level.

13

MN008927A01-AA
Chapter 1 : Introduction

Label Item Description

11 Channel Selector Knob Rotate clockwise to increase the channel; rotate

counterclockwise to decrease the channel.

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

Typical Model
Number

Table 3: Sales Models – Description of Symbols

Position Description Value

1 Region MD = Europe

2 Type of Unit H = Portable

3 Model Series 87 = MOTOTRBO DP540

4

5 Band J = 136–174 MHz

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

7 Physical Packages C = Plain Model

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

MD H 8 7 Y D C 9 J A 2 A N

Y = 403–480 MHz

D = 4.0–5.0 W

number of channels

9 = Variable/Programmable Channel Spacing

9 Primary Operation J = Basic (No GPS, no Bluetooth, no embedded GOB)

K = GPS and Bluetooth

L = GPS only

M = Bluetooth only

N = Bluetooth with embedded GOB

10 Primary System

Type

11 Feature Level 1 = Standard with FM

14

A = Conventional

B = Trunking

C = Analog only

2 = Non-FM

3 = CSA IE CEx ATEX

4 = CQST

Position Description Value

12 Version Letter N/A

13 Unique Variation N = Standard Package

1.3

Model Chart

NOTE:

"X" = Part is compatible with checked model.

"_" = The latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

ANZ = Australia and New Zealand

APAC = Asia Pacific

EMEA = Europe, Middle East, Africa

LACR = Latin America, Caribbean Region

NA = North America Region

1.3.1

UHF Model Chart

MN008927A01-AA

Chapter

1 : Introduction

Table 4: DP540, UHF, 403–480 MHz Model Chart

Model/Item Description

MDH87YDC9JA2_N DP540, 403–480 MHz, Non-Keypad Portable

MDH87YDC9JC2_NDP540, 403–480 MHz, Non-Keypad Portable, Analog

X X PMLE5235_S Back Cover Kit, 403–480 MHz, Non-Keypad Portable

X X PMLN6835_ Front Cover Kit, Non-Keypad Portable

X X PMAE4002_ UHF Stubby Antenna, 403–433 MHz, 9 cm

X X PMAE4003_ UHF Stubby Antenna, 430–470 MHz, 9 cm

X X PMAE4006_ UHF Stubby Antenna, 465–495 MHz, 9 cm

X X PMAE4016_ UHF Whip Antenna, 403–520 MHz, 17 cm

1.3.2

VHF Model Chart

Table 5: DP540, VHF, 136–174 MHz Model Chart

Model/Item Description

MDH87JDC9JA2_N DP540, 136–174 MHz, Non-Keypad Portable

MDH87JDC9JC2_NDP540, 136–174 MHz, Non-Keypad Portable, Analog

X X PMLD4898_S Back Cover Kit, 136–174 MHz, Non-Keypad Portable

X X PMLN6835_ Front Cover Kit, Non-Keypad Portable

15

MN008927A01-AA
Chapter 1 : Introduction

Model/Item Description

MDH87JDC9JA2_N DP540, 136–174 MHz, Non-Keypad Portable

MDH87JDC9JC2_NDP540, 136–174 MHz, Non-Keypad Portable, Analog

X X HAD9742_ VHF Stubby Antenna, 146–162 MHz, 9 cm

X X HAD9743_ VHF Stubby Antenna, 162–174 MHz, 9 cm

X X NAD6502_R VHF Heliflex Antenna, 146–174 MHz, 15 cm

X X PMAD4012_ VHF Stubby Antenna, 136–146 MHz, 9 cm

X X PMAD4014_ VHF Antenna, 136–155 MHz, 14 cm

X X PMAD4042_ VHF Heliflex Antenna, 136–150.8 MHz

1.4

Specifications

1.4.1

General

Table 6: General Specifications

General Specification Value for Non-Keypad

Channel Capacity 16

Frequency

Dimensions H x W x L (mm)

Weight (g):

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

1

Li-Ion battery 120.0 x 55.0 x 34.7

High Capacity Li-Ion battery 120.0 x 55.0 x 39.9

Li-Ion battery 276

High Capacity Li-Ion battery 281

Power Supply 7.5 V (nominal)

Li-Ion battery

High Capacity Li-Ion battery

UHF: 403–480 MHz

VHF: 136–174MHz

Analog: 10.7 hours

Digital: 14.4 hours

Analog: 15.0 hours

Digital: 20.0 hours

1

Weight can have 5% margin of error.

16

1.4.2

Receiver

Table 7: Receiver Specifications

Receiver Specification Value for Non-Keypad

Frequencies UHF: 403–480 MHz

VHF: 136–174 MHz

Channel Spacing 12.5/20/25 kHz

MN008927A01-AA

Chapter

1 : Introduction

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

Analog Sensitivity (12 dB SINAD) 0.3 µV

Digital Sensitivity (5% BER) 0.25 µV

Intermodulation (TIA603D) 70 dB

Adjacent Channel Selectivity TIA603D 45 dB (12.5 kHz)

Spurious Rejection (TIA603D) -70 dB

Rated Audio 0.5 W (internal)

Audio Distortion @ Rated Audio 5% (3% typical)

Hum and Noise -40 dB (12.5 kHz)

Audio Response TIA603D

Conducted Spurious Emission (TIA603D) -57 dBm

+/- 0.5 ppm

0.22 µV (typical)

0.19 µV (typical)

70 dB (20/25 kHz)

-45 dB (20/25 kHz)

1.4.3

Transmitter

Table 8: Transmitter Specifications

Transmitter Specification Value for Non-Keypad

Frequencies UHF: 403–480 MHz

VHF: 136–174 MHz

Channel Spacing 12.5/20/25 kHz

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

Power Output (Low Power) 1 W

Power Output (High Power) UHF: 4 W

+/-0.5 ppm

VHF: 5 W

17

MN008927A01-AA
Chapter 1 : Introduction

Transmitter Specification Value for Non-Keypad

Modulation Limiting +/-2.5 kHz (12.5 kHz)

+/-4 kHz (20 kHz)

+/-5.0 kHz (25 kHz)

FM Hum and Noise -40 dB (12.5 kHz)

-45 dB (20/25 kHz)

Conducted/Radiated Emission -36 dBm < 1 GHz

-30 dBm > 1 GHz

Adjacent Channel Power 60 dB (12.5 kHz)

70 dB (20/25 kHz)

Audio Response TIA603D

Audio Distortion 3% (typical)

FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E

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

12.5 kHz Voice: 7K60F1E and 7K60FXE

Combination of 12.5 kHz Data and Voice:
7K60F1W

Digital Vocoder Type AMBE+2

™

Digital Protocol ETSI-TS102361-1

ETSI-TS102361-2

ETSI-TS102361-3

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)

• 2014/53/EU (RED - Radio Equipment Directive)

• 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.

1.4.4

Self-Quieter

Table 9: Self-Quieter Specification

18

UHF Self-Quieter Frequencies

441.6 MHz

UHF Self-Quieter Frequencies

VHF Self-Quieter Frequencies

1.4.5

Military Standards

Table 10: Military Standards (810C–810E)

444 MHz

460.8 MHz

480 MHz

144.0 MHz

153.6 MHz

160.0 MHz

MN008927A01-AA

Chapter

1 : Introduction

Applica­ble MIL–
STD

Low Pres­sure

High Tem­perature

Low Tem­perature

Tempera­ture Shock

Solar Ra­diation

Rain 506.1 I, II 506.2 I, II 506.3 I,II

Humidity 507.1 II 507.2 II 507.3 II

Salt fog 509.1 I 509.2 I 509.3 –

Blowing
Dust

Blowing
Sand

810C 810D 810E

Methods

500.1 I 500.2 II 500.3 II

501.1 I, II 501.2 I/A1, II/A1 501.3 I-A1, II/A1

502.1 I 502.2 I/C3, II/C1 502.3 I-C3, II/C1

503.1 I 503.2 I/A1C3 503.3 I/A1C3

505.1 II 505.2 I 505.3 I/A1

510.1 I 510.2 I 510.3 I

– – 510.2 II 510.3 II

Proce­dures

Methods

Proce­dures

Methods

Proce­dures

Vibration 514.2 VIII/F, XI 514.3 I/10, II/3 514.4 I/10, II/3

Shock 516.2 I, II, V 516.3 I, IV, VI 516.4 I, IV, VI

19

MN008927A01-AA
Chapter 1 : Introduction

Applica­ble MIL–
STD

Shock

810C 810D 810E

Methods

Proce­dures

516.2 II 516.3 IV 516.4 IV

(Drop)

Table 11: Military Standards (810F–810H)

Applica­ble MIL–
STD

Low Pres-

810F 810G 810H

Methods

Proce­dures

500.4 II 500.6 II 500.6 II

sure

High Tem­perature

Low Tem-

501.4 I/Hot,
II/Hot

502.4 I/C3, II/C1 502.6 I/C3, II/C1 502.7 I/C3, II/C1

perature

Tempera-

503.4 I 503.6 I-C 503.7 I-C

ture Shock

Solar Ra-

506.4 I/A1 505.6 I/A1 505.7 I/A1

diation

Methods

Methods

Proce­dures

Proce­dures

Methods

Methods

Proce­dures

Proce­dures

501.6 I/A1, II/A1 501.7 I/A1, II/A1

Rain 506.4 I, III 506.6 I, III 506.6 I, III

Humidity 507.4 – 507.6 II- Aggra-

vated

507.6 II- Aggra­vated

Salt fog 509.4 – 509.6 – 509.7 –

Blowing

510.4 I 510.6 I 510.7 I

Dust

Blowing

510.4 II 510.6 II 510.7 II

Sand

Vibration 514.5 I/24, II/5 514.7 I/24, II/5 514.8 I/24, II/5

Shock 516.5 I, IV, VI 516.7 I, IV, VI 516.8 I, IV, VI

Shock

516.5 IV 516.7 IV 516.8 IV

(Drop)

1.4.6

Environmental

Table 12: Environmental Specifications

Environmental Specifications

Operating Temperature

2

-30 °C to +60 °C

Storage Temperature -40 °C to +85 °C

2

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

20

Environmental Specifications

Thermal Shock Per MIL-STD

Humidity Per MIL-STD

ESD IEC 61000-4-2 Level 3

Dust and Water Intrusion IEC 60529 -IP54

Packaging Test As per MIL-STD

MN008927A01-AA

Chapter

1 : Introduction

21

MN008927A01-AA
Chapter 2 : Test Equipment and Service Aids

Chapter 2

Test Equipment and Service Aids

This section lists the recommended test equipment and service aids, and information on field
programming equipment. You can use this information in servicing and programming radios.

2.1

Recommended Test Equipment

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

Table 13: Test Equipment

Equipment Characteristics Example Application

Service
Monitor

Digital RMS
Multimeter

RF Signal
Generator

Oscillo­scope

Power Meter
and Sensor

3

3

3

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 TBS1052C

50 MHz Bandwidth

5 mV/div to 20 V/div

5% Accuracy Bird 43 Thruline Watt Meter

3

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

3

Can use Service Monitor as substitute.

22

100 mV to 3 V RF Boonton 9240 (www.boon-

10 kHz to 1 GHz

0 V to 32 V B&K Precision 9103

0 A to 20 A

RF level measurements

ton.com) or equivalent

Voltage supply
(www.bkprecision.com) or
equivalent

MN008927A01-AA

Chapter

2.2

2 : Test Equipment and Service Aids

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 14: Service Aids

Motorola Solu­tions Part No.

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

GMVN6241_ MOTOTRBO CPS 2.0 / RM

PMKN4128_ Portable Programming Cable

PMKN4156_ Portable Test Cable This cable connects the radio to RLN4460 Portable

PMDN4080_R 7.5 V Universal Battery Elimina-

PMLN6154_ RF Adaptor Application adapts radio antenna port to BC ca-

PMLN7119_ RF Adaptor Holder Holds RF Adaptor

1185937A01 Grease Acts to lubricate parts.

N/A Flat Square Tip Plastic Tweezer Remove components during disassembly.

2.3

Description Application

Allows switching for radio testing.

Software DVD containing Customer Programming

Software DVD

with TTR

tor

Software 2.0, Radio Management and associated
tools (including a Tuner).

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

Test Set for test and measurement.

Connects to radio battery eliminator cable.

bling of test equipment.

Programming, Testing, and Alignment Cable

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

23

“P2”

#1#4

“P3”

“P1”

#1#5

#2

#1

#3

#5

#4

MN008927A01-AA
Chapter 2 : Test Equipment and Service Aids

Portable Programming Cable and Portable Test Cable

Figure 2: Portable Programming Cable with TTR (PMKN4128_)

Table 15: Pin Configuration of Portable Programming Cable with TTR

CONNECTION

P1 P2 P3 Function

1 1 - VCC(5 V)

2 2 - Data-

3 3 - Data+

4 - BNC Center Pin TTR

5 4 BNC Shell Ground

24

Figure 3: Portable Test Cable (PMKN4156_ )

#2 #1

#3#4

“P1”

“P2”

#25

#13 #1

#14

MN008927A01-AA

Chapter 2 : Test Equipment and Service Aids

Table 16: Pin Configuration of Portable Test Cable

CONNECTION

P1 P2 Function

1 1, 5 Ground

2 7, 24 External Mic

3 16 External Speaker -

4 17 External Speaker +

25

MN008927A01-AA
Chapter 3 : Transceiver Performance Testing

Chapter 3

Transceiver Performance Testing

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

The recommended field service equipment approaches the accuracy of the manufacturing equipment
with a few exceptions. This accuracy must be maintained 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 17: 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

26

T/R Port

Power Supply

Ant. Input / Output

Programming Cable

Modulated RF Test

Signal / Tx

modulated RF Signal

Battery Eliminator

3.2

Non-Display Model Test Mode

3.2.1

Entering Non-Display Radio Test Mode

MN008927A01-AA

Chapter 3 : Transceiver Performance Testing

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.

3.2.2

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.

When and where to use: However, when the unit is on the bench for testing, alignment, or repair, it
must be removed from its normal environment by using a special routine, called Test Mode or "air test".

Procedure:

1 Short press Side Button 2 to change the test environment (CSQ->TPL->DIG->USQ

->CSQ).

In the following table, DIG is digital mode and other test environments are analog mode.

Table 18: Test Environments

No. of
Beeps

1 Carrier Squelch (CSQ) RX: if carrier detected

2 Tone Private-Line (TPL) RX: unsquelch if carrier and tone detected

Description Function

TX: mic audio

TX: mic audio + tone

27

MN008927A01-AA
Chapter 3 : Transceiver Performance Testing

No. of

Description Function

Beeps

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.

DIG is digital mode and other test environments are analog mode as described in Test
Environments table.

2 Short press Side Button 1 to toggle the channel spacing between 25 kHz and 12.5 kHz.

The radio beeps once when radio toggles to 25 kHz and beep twice for 12.5 kHz.

3 Turn the Channel Knob

to change the test channel from 1 to 16.

Table 19: Test Frequencies

Channel Selector Switch

Test Channel UHF VHF

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

8 Low Power

16 High Power

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

TX#8 or #16

RX#8 or #16

403.150

403.150

414.150

414.150

425.150

425.150

436.450

436.450

447.150

447.150

458.150

458.150

469.850

469.850

479.850

479.850

136.075

136.075

142.575

142.575

146.575

146.575

155.575

155.575

161.575

161.575

167.575

167.575

173.975

173.975

174.000

174.000

The radio beeps at each position.

28

Chapter 3 : Transceiver Performance Testing

Refer to "Test Frequencies" for the test channel descriptions.

Table 20: Transmitter Performance Checks

MN008927A01-AA

Test
Name

Refer­ence Fre­quency

Communications An­alyzer

Mode: PWR MON

Fourth channel test
frequency

Monitor: Frequency er­ror

Radio Test Set Comments

Test
Mode,
Test
Channel

PTT to
continu­ously
transmit.

Frequency error to be:

±68 Hz (VHF)

±201 Hz (UHF)

4 carrier
squelch

Input at RF In/Out

Power RF As above As above As above Low Power

0.9–1.5 W (VHF/UHF)

High Power

4.0–4.8 W (UHF)

5.0–5.8 W (VHF)

Voice
Modula­tion

Mode: PWR MON

Fourth channel test
frequency

As above As above,

meter se­lector to
mic

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

Atten to -70, input to
RF In/Out

Monitor: DVM: AC Volts

Set 1 kHz Mod Out lev­el for 0.025 Vrms at
test set,
80 mVrms at AC/DC
test set jack

5.0 kHz

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

RF Power DMR Mode. Slot 1

Power and Slot 2 Pow­er

Test
Mode,
Test
Channel
4 carrier
squelch
output at
antenna

Test
Mode,
Test
Channel
4
TPL

Test
Mode,
Digital
Mode,
transmit

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)

As above Deviation:

≥500 Hz but ≤1000Hz
(25 kHz Ch Sp).

Key up
radio
without
modula-

TTR Enable is needed
and IFR to be set to
trigger mode with signal
level ~1.5 V

29

MN008927A01-AA
Chapter 3 : Transceiver Performance Testing

Test
Name

Communications An­alyzer

Radio Test Set Comments

without
modula­tion

FSK Error DMR Mode. FSK Error Test

Mode,
Digital
Mode,
transmit
with
O.153
test pat­tern

Magni­tude Error

Symbol
Deviation

Transmit-

DMR Mode. Magnitude

As above As above Not Exceed 1%

error

DMR Mode. Symbol

As above As above Symbol Deviation

Deviation

DMR Mode As above As above Transmitter BER

ter BER

tion using
Tuner

Key up
radio with
O.513
test pat­tern mod­ulation
using Tu­ner

Not Exceed 5%

should be within 648
Hz± 10% and 1944 Hz
± 10%

should be 0%

Table 21: 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
squelch
output at
antenna.

Test
Mode
, Test
Channel
6 carrier
squelch

PTT to
continu­ously
transmit.
(during
the per­formance
check).

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

Frequency error to be:

±68 Hz for VHF

±201 Hz for UHF

Set volume
control to 2.83 Vrms

As above As above Distortion <3.0%

30

Sensitivi­ty (SI­NAD)

As above, except SI­NAD, lower the RF lev-

As above PTT to

OFF
(center)

RF input to be <0.35
μV