Motorola XPR6100, XPR6300, XPR6350, XPR6500, XPR6550 service manual

PROFESSIONAL DIGITAL TWO-WAY RADIO

MOTOTRBO™
PORTABLE
DETAILED SERVICE
MANUAL

XPR™ 6550 DISPLAY PORTABLE (WITH GPS)
XPR™ 6500 DISPLAY PORTABLE
XPR™ 6350 NON-DISPLAY PORTABLE (WITH GPS)
XPR™ 6300 NON-DISPLAY PORTABLE
XPR™ 6100 NON-DISPLAY PORTABLE

Foreword

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

Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions
for safe usage contained in the Product Safety and RF

!

C a u t i o n

This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
Before using this product, read the RF energy awarene ss information a nd operating ins tructions in the
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number
6881095C98) to ensure compliance with RF energy exposure limits.

For a list of Motorola-approved antennas, bat ter ies, and othe r acces sor ie s, visit the f ollo wing web site
which lists approved accessories: http://www.motorolasolutions.com/governmentandenterprise

Computer Software Copyrights

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

Exposure booklet enclosed with your radio.

ATTENTION!

Document Copyrights

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

Disclaimer

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

Trademarks

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

© 2006,2007 - 2012 Motorola Solutions, Inc.
All rights reserved..

Document History

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

Edition Description Date

6880309T31-A Initial Release May 2007
6880309T31-B Added VHF band information. June 2007

iii

6880309T31-C Updated front cover.

Updated Maintenance chapter.
6880309T31-D Added UHF2 band information. June 2008
6880309T31-E Added new Schematics for UHF and VHF

Updated Partslist for UHF and VHF

Added Controller Schematic for 8415113H13

Updated parts list.
6880309T31-F XPR 6100 model information added

Added PCB and parts list for UHF1 and VHF

Added controller schematics for 8486716Z23,

8486716Z24, 8415113H19, 8415113H20

Oct. 2007

Sept. 2011

Jan. 2012

iv

Notes

Table of Contents

Document History .......................................................................................................... iii

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

1.0 Notations Used in This Manual............................................................................1-1

2.0 Radio Description ................................................................................................1-1

Section 2 Maintenance ........................................................................ 2-1

1.0 Introduction..........................................................................................................2-1

2.0 Preventive Maintenance......................................................................................2-1

2.1 Inspection.......................................................................................................2-1

2.2 Cleaning Procedures......................................................................................2-1

2.3 Safe Handling of CMOS and LDMOS Devices ..............................................2-2

3.0 Repair Procedures and Techniques — General..................................................2-4

4.0 Notes For All Schematics and Circuit Boards......................................................2-6

v

Section 3 Test Equipment and Service Aids..................................... 3-1

1.0 Recommended Test Equipment..........................................................................3-1

2.0 Service Aids.........................................................................................................3-2

3.0 Programming, Testing and Alignment Cable.......................................................3-3

Section 4 Power Up Self-Test ............................................................. 4-1

1.0 Power-Up Error Codes (Display Model only).......................................................4-1

2.0 Operational Error Codes......................................................................................4-2

Section 5 Controller Information........................................................ 5-1

1.0 General Controller Block......................................................................................5-1

1.1 OMAP1710 Processor (U1000)......................................................................5-1

1.2 Flash Memory (U2000)...................................................................................5-2

1.3 SDRAM (U2001) ............................................................................................5-2

1.4 MAKO IC (U3000)..........................................................................................5-2

2.0 Controller Board...................................................................................................5-2

2.1 Radio Power Distribution................................................................................5-2

2.2 Clocks.............................................................................................................5-4

2.3 Serial Peripheral Interface (SPI).....................................................................5-5

2.4 Serial Synchronous Interface (SSI)................................................................5-6

2.5 ACC_ID Interface...........................................................................................5-7

2.6 USB Interface.................................................................................................5-7

2.7 Universal Connector (Side Connector)...........................................................5-8

vi

2.8 Keypad Module...............................................................................................5-8

2.9 Display Module ...............................................................................................5-8

2.10 Audio...............................................................................................................5-9

2.11 Troubleshooting Charts ................................................................................5-11

Troubleshooting Flow Chart for Controller (Sheet 1 of 2).....................................5-11

Troubleshooting Flow Chart for Controller (Sheet 2 of 2).....................................5-12

2.12 Controller Schematics ..................................................................................5-13

Complete Controller Schematic Diagram..............................................................5-13

MAKO-Controller Schematic Diagram..................................................................5-14

Complete Controller Microprocessor Schematic Diagram....................................5-15

Complete Controller Microprocessor Schematic Diagram (for 8475130M01) ......5-16

Controller Memory Schematic Diagram................................................................5-17

Controller Memory Schematic Diagram (for 8475130M01) ..................................5-18

Controller Audio and Digital Interface Schematic Diagram (for 8486716Z04)......5-19

Controller Audio and Digital Interface Schematic Diagram (for 8475130M01).....5-20

Controller Audio and Digital Interface Schematic Diagram (for 8486716Z07/

8486716Z13, 8486716Z08 & 8415113H03).................................................5-21

Controller Audio and Digital Interface Schematic Diagram (for 8415113H05)......5-22

Controller Audio and Digital Interface Schematic Diagram (for 8486716Z16 &

8415113H13.................................................................................................5-23

Controller Audio and Digital Interface Schematic Diagram (for 8486716Z23)......5-24

Controller Audio and Digital Interface Schematic Diagram (for 8486716Z24)......5-25

Controller Audio and Digital Interface Schematic Diagram (for 8415113H19)......5-26

Controller Audio and Digital Interface Schematic Diagram (for 8415113H20)......5-27

Controller Power Management Block Schematic Diagram (for 8486716Z04)......5-28

Controller Power Management Block Schematic Diagram (for 8475130M01) .....5-29

Controller Power Management Block Schematic Diagram (for 8486716Z07/

8486716Z13) ................................................................................................5-30

Controller Power Management Block Schematic Diagram (for 8486716Z08)......5-31

Controller Power Management Block Schematic Diagram (for 8415113H03)......5-32

Controller Power Management Block Schematic Diagram (for 8415113H05)......5-33

Controller Power Management Block Schematic Diagram (for 8415113H13)......5-34

Controller Power Management Block Schematic Diagram (for 8486716Z23)......5-35

Controller Power Management Block Schematic Diagram (for 8486716Z24)......5-36

Controller Power Management Block Schematic Diagram (for 8415113H19)......5-37

Controller Power Management Block Schematic Diagram (for 8415113H20)......5-38

Controller Line Regulators for GPS Schematic Diagram......................................5-39

Controller LCD and Speaker Interface Schematic Diagram (for 8486716Z04,

8486716Z07/8486716Z13, 8486716Z08 & 8475130M01)............................5-40

Controller LCD and Speaker Interface Schematic Diagram (for 8415113H03 &

8415113H05)................................................................................................5-41

Controller UC Interface Schematic Diagram (for 8486716Z04 & 8486716Z07/

8486716Z13) ................................................................................................5-42

Controller UC Interface Schematic Diagram (for 8475130M01)...........................5-43

Controller UC Interface Schematic Diagram (for 8486716Z08)............................5-44

Controller UC Interface Schematic Diagram (for 8415113H03 & 8415113H05)...5-45

vii

Controls and Switches Schematic Diagram (for 8486716Z04) ............................5-46

Controls and Switches Schematic Diagram (for 8486716Z07/8486716Z13,

8486716Z08 & 8475130M01) *Emergency Button not applicable for XPR 6100*

5-47
Controls and Switches Schematic Diagram (for 8415113H03 & 8415113H05)...5-48
Controls and Switches Schematic Diagram (for 8486716Z16) *Emergency Button not

applicable for XPR 6100*.............................................................................5-49

Controls and Switches Schematic Diagram (for 8415113H13) *Emergency Button not

applicable for XPR 6100...............................................................................5-50

Controls and Switches Schematic Diagram (for 8486716Z23, 8486716Z24,

8415113H19, 8415113H20).........................................................................5-51

Section 6 UHF1 (403–470 MHz) Information...................................... 6-1

1.0 Transmitter...........................................................................................................6-1

1.1 General...........................................................................................................6-1

2.0 Receiver...............................................................................................................6-4

2.1 Receiver Front-End........................................................................................6-4

2.2 Receiver Back-End.........................................................................................6-5

3.0 Frequency Generation Circuitry...........................................................................6-5

3.1 Synthesizer.....................................................................................................6-6

3.2 VCO - Voltage Controlled Oscillator...............................................................6-6

4.0 Global Positioning System (GPS) Receiver.........................................................6-7

5.0 Allocation of Schematics and Circuit Boards.......................................................6-8

5.1 Controller Circuits...........................................................................................6-8

6.0 Circuit Board/Schematic Diagrams and Parts List...............................................6-9

UHF1 (403–470 MHz) Main Board Top Side PCB No. 8486716Z04 .....................6-9

UHF1 (403–470 MHz) Main Board Bottom Side PCB No. 8486716Z04..............6-10

UHF1 (403–470 MHz) Main Board Top Side PCB No. 8486716Z07/ ..................6-11

UHF1 (403–470 MHz) Main Board Bottom Side PCB No. 8486716Z07/.............6-12

UHF1 (403–470 MHz) Main Board Top Side PCB No. 8486716Z08 . ..................6-13

UHF1 (403–470 MHz) Main Board Bottom Side PCB No. 8486716Z08..............6-14

UHF1 (403–470 MHz) Main Board Top Side PCB No. 8486716Z16 . ..................6-15

UHF1 (403–470 MHz) Main Board Bottom Side PCB No. 8486716Z16..............6-16

UHF1 (403-470 MHz) Main Board Top Side PCB No. 8486716Z23....................6-17

UHF1 (403-470 MHz) Main Board Bottom Side PCB No. 8486716Z23...............6-18

UHF1 (403-470 MHz) Main Board Top Side PCB No. 8486716Z24....................6-19

UHF1 (403-470 MHz) Main Board Bottom Side PCB No. 8486716Z24...............6-20

Complete Radio Schematic Diagram ...................................................................6-21

Complete UHF1 RF Schematic Diagram .............................................................6-22

Complete UHF1 Transmitter Schematic Diagram................................................6-23

UHF1 Transmitter Schematic Diagram ................................................................6-24

UHF1 Harmonic Filter and Antenna Switch Schematic Diagram .........................6-25

Complete UHF1 Receiver Schematic Diagram....................................................6-26

UHF1 Receiver Front End Schematic Diagram ....................................................6-27

UHF1 Receiver Back End Schematic Diagram....................................................6-28

viii

Complete UHF1 Frequency Generating Unit Schematic Diagram........................6-29

UHF1 Synthesizer Schematic Diagram ................................................................6-30

UHF1 Voltage Controlled Oscillator Schematic Diagram......................................6-31

UHF1 GPS Block Schematic Diagram..................................................................6-32

UHF1 Radio Parts List (8486716Z04) ..................................................................6-33

UHF1 Radio Parts List (8486716Z07/) .................................................................6-38

UHF1 Radio Parts List (8486716Z08) ..................................................................6-43

UHF1 Radio Parts List (8486716Z16) ..................................................................6-48

UHF1 Radio Parts List (8486716Z23) ..................................................................6-54

UHF1 Radio Parts List (8486716Z24) ..................................................................6-64

Section 7 UHF2 (450–512 MHz) Information...................................... 7-1

1.0 Transmitter...........................................................................................................7-1

1.1 General...........................................................................................................7-1

2.0 Receiver...............................................................................................................7-4

2.1 Receiver Front-End.........................................................................................7-4

2.2 Receiver Back-End.........................................................................................7-5

3.0 Frequency Generation Circuitry ...........................................................................7-5

3.1 Synthesizer.....................................................................................................7-6

3.2 VCO – Voltage Controlled Oscillator ..............................................................7-6

4.0 Global Positioning System (GPS) Receiver.........................................................7-7

5.0 Allocation of Schematics and Circuit Boards .......................................................7-8

5.1 Controller Circuits ...........................................................................................7-8

6.0 Circuit Board/Schematic Diagrams and Parts List ...............................................7-9

UHF2 (450–512 MHz) Main Board Top Side PCB No. 8475130M01/8475130M02.7-

9

UHF2 (450–512 MHz) Main Board Bottom Side PCB No. 8475130M01/8475130M02

7-10

Complete Radio Schematic Diagram....................................................................7-11

Complete UHF2 RF Schematic Diagram..............................................................7-12

Complete UHF2 Transmitter Schematic Diagram.................................................7-13

UHF2 Transmitter Schematic Diagram

UHF2 Harmonic Filter and Antenna Switch Schematic Diagram..........................7-15

Complete UHF2 Receiver Schematic Diagram.....................................................7-16

UHF2 Receiver Front End Schematic Diagram....................................................7-17

UHF2 Receiver Back End Schematic Diagram.....................................................7-18

Complete UHF2 Frequency Generating Unit Schematic Diagram........................7-19

UHF2 Synthesizer Schematic Diagram ................................................................7-20

UHF2 Voltage Controlled Oscillator Schematic Diagram......................................7-21

UHF2 GPS Block Schematic Diagram..................................................................7-22

UHF2 Radio Parts List (8475130M01/8475130M02)............................................7-23

.................................................................7-14

Section 9 VHF (136–174 MHz) Information ........................................ 8-1

1.0 Transmitter...........................................................................................................8-1

1.1 General...........................................................................................................8-1

2.0 Receiver...............................................................................................................8-4

2.1 Receiver Front-End........................................................................................8-4

2.2 Receiver Back-End.........................................................................................8-5

3.0 Frequency Generation Circuitry...........................................................................8-5

3.1 Synthesizer.....................................................................................................8-6

3.2 VCO - Voltage Controlled Oscillator...............................................................8-6

4.0 Global Positioning System (GPS) Receiver.........................................................8-7

5.0 Allocation of Schematics and Circuit Boards.......................................................8-8

5.1 Controller Circuits...........................................................................................8-8

6.0 Circuit Board/Schematic Diagrams and Parts List...............................................8-9

VHF (136–174 MHz) Main Board Top Side PCB No. 8415113H03.......................8-9

VHF (136–174 MHz) Main Board Bottom Side PCB No. 8415113H03................8-10

VHF (136–174 MHz) Main Board Top Side PCB No. 8415113H05.....................8-11

VHF (136–174 MHz) Main Board Bottom Side PCB No. 8415113H05................8-12

VHF (136–174 MHz) Main Board Top Side PCB No. 8415113H13.....................8-13

VHF (136–174 MHz) Main Board Bottom Side PCB No. 8415113H13................8-14

VHF (136-174 MHz) Main Board Top Side PCB No. 8415113H19......................8-15

VHF (136-174 MHz) Main Board Bottom Side PCB No: 8415113H19.................8-16

VHF (136-174 MHz) Main Board Top Side PCB No. 8415113H20......................8-17

VHF (136-174 MHz) Main Board Bottom Side PCB No: 8415113H20.................8-18

Complete Radio Schematic Diagram ...................................................................8-19

Complete VHF RF Schematic Diagram................................................................8-20

Complete VHF Transmitter Schematic Diagram ..................................................8-21

VHF Transmitter Schematic Diagram...................................................................8-22

VHF Harmonic Filter and Antenna Switch Schematic Diagram ...........................8-23

Complete VHF Receiver Schematic Diagram ......................................................8-24

VHF Receiver Front End Schematic Diagram......................................................8-25

VHF Receiver Back End Schematic Diagram ......................................................8-26

Complete VHF Frequency Generating Unit Schematic Diagram .........................8-27

VHF Synthesizer Schematic Diagram..................................................................8-28

VHF Voltage Controlled Oscillator Schematic Diagram .......................................8-29

VHF GPS Block Schematic Diagram ...................................................................8-30

VHF Radio Parts List (8415113H03)....................................................................8-31

VHF Radio Parts List (8415113H05)....................................................................8-36

VHF Radio Parts List (8415113H13)....................................................................8-41

VHF Radio Parts List (8415113H19)....................................................................8-47

VHF Radio Parts List (8415113H20)....................................................................8-58

ix

Section 10 Troubleshooting Charts ..................................................... 9-1

1.0 VHF, 350 MHz and UHF1 Troubleshooting Charts .............................................9-1

Troubleshooting Flow Chart for Receiver (Sheet 1 of 2)........................................9-1

x

Troubleshooting Flow Chart for Receiver (Sheet 2 of 2).........................................9-2

Troubleshooting Flow Chart for Transmitter ...........................................................9-3

Troubleshooting Flow Chart for Synthesizer...........................................................9-4

Troubleshooting Flow Chart for VCO (Sheet 1 of 2)...............................................9-5

Troubleshooting Flow Chart for VCO (Sheet 2 of 2)...............................................9-6

Troubleshooting Flow Chart for GPS Receiver (Sheet 1 of 3)................................9-7

Troubleshooting Flow Chart for GPS Receiver (Sheet 2 of 3)................................9-8

Troubleshooting Flow Chart for GPS Receiver (Sheet 3 of 3)................................9-9

Section 11 Option Board Information ................................................ 10-1

1.0 Option Board......................................................................................................10-1

2.0 Board Layout/Schematic for Option Board.........................................................10-1

2.1 Parts List for Option Board ...........................................................................10-2

Appendix A Replacement Parts Ordering..............................................A-1

1.0 Basic Ordering Information .................................................................................A-1

2.0 Motorola Online...................................................................................................A-1

3.0 Mail Orders..........................................................................................................A-1

4.0 Telephone Orders...............................................................................................A-1

5.0 Fax Orders..........................................................................................................A-1

6.0 Parts Identification...............................................................................................A-1

7.0 Product Customer Service..................................................................................A-2

Appendix B Motorola Service Centers...................................................B-1

1.0 Servicing Information ..........................................................................................B-1

2.0 Motorola Service Center .....................................................................................B-1

3.0 Motorola Canadian Technical Logistics Center...................................................B-1

4.0 Motorola Federal Technical Center.....................................................................B-1

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

List of Figures xi

List of Figures

Figure 2-1: 12-Layer Circuit Board Detail Viewing................................................................................. 2-6

Figure 5-1: Controller Block Diagram..................................................................................................... 5-1

Figure 5-2: DC Power Distribution Block Diagram................................................................................. 5-2

Figure 5-3: Clock Connections............................................................................................................. .. 5-4

Figure 5-4: SPI Connections............................................................................. ..................................... 5-5

Figure 5-5: SSI Connections............................................................................. ..................................... 5-6

Figure 5-6: ACC_ID Interface Connections............................................................................................ 5-7

Figure 5-7: USB Interface Connections ............................................................ ... ... ....... ... ... ... ... .... .. . ... .. 5-7

Figure 5-8: Audio Block Diagram ........................................................................................................... 5-9

Figure 6-1: UHF Transmitter Block diagram........................................................................................... 6-1

Figure 6-2: Power Control Scheme Basic Block Diagram.................................................... ... ............... 6-3

Figure 6-3: UHF Receiver Block Diagram.............................................................................................. 6-4

Figure 6-4: Frequency Generating Unit Block Diagram ......................................................................... 6-5

Figure 6-5: GPS Receiver Block Diagram.............................................................................................. 6-7

Figure 7-1: UHF Transmitter Block diagram........................................................................................... 7-1

Figure 7-2: Power Control Scheme Basic Block Diagram.................................................... ... ............... 7-3

Figure 7-3: UHF Receiver Block Diagram.............................................................................................. 7-4

Figure 7-4: Frequency Generating Unit Block Diagram ......................................................................... 7-5

Figure 7-5: GPS Receiver Block Diagram.............................................................................................. 7-7

Figure 9-1: VHF Transmitter Block diagram........ ....... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ..... 8-1

Figure 9-2: Power Control Scheme Basic Block Diagram.................................................... ... ............... 8-3

Figure 9-3: UHF Receiver Block Diagram.............................................................................................. 8-4

Figure 9-4: Frequency Generating Unit Block Diagram ......................................................................... 8-5

Figure 9-5: GPS Receiver Block Diagram.............................................................................................. 8-7

Figure 11-1: Option Board Layout.......................................... ................................................................ 10-1

Figure 11-2: Option Board Schematic.................................................................................................... 10-2

xii Related Publications

List of Tables

Table 1-1. Radio Frequency Ranges and Power Levels.......................................................................1-1

Table 2-2. Lead Free Solder Wire Part Number List.............................................................................2-4

Table 2-3. Lead Free Solder Paste Part Number List ..................... ......................................................2-4

Table 3-1. Recommended Test Equipment...........................................................................................3-1

Table 3-2. Service Aids ............................. ... ... .................................................................... ..................3-2

Table 3-3. Pin Configuration of Side Connector....................................................................................3-4

Table 4-4. Power-Up Error Codes.........................................................................................................4-1

Table 4-5. Operational Error Codes ................................ ... .... ... ... ....... ... ... ... ... .... ... ... ... .... ... ... ... ... . ........4-2

Table 6-1. UHF1 Diagrams and Parts List.............................................................................................6-8

Table 7-2. UHF2 Diagrams and Parts List.............................................................................................7-8

Table 8-6. VHF Diagrams and Parts List...............................................................................................8-8

List of Tables xiii

Related Publications

IMPRES Adaptive Single-Unit Charger User Manual..................................................................6816787H01

IMPRES Adaptive Multi-Unit Charger User Manual ....................................................................6816789H01

IMPRES Adaptive Multi-Unit Charger Service Manual................................................................ 6871357L01

Remote Speaker Microphone User Manual................................................................................. 6871003L01

IMPRES Remote Speaker Microphone User Manual................................................................. . 6871004L01

Factory Mutual Approval Manual.................................................................................................6871532L01

*MOTOTRBO™ Portable User Guide CD ....................................................................................HKLN4282_

*CD consists of:
XPR™ 6300/6350 User Guide
XPR™ 6300/6350 Quick Reference Card
XPR™ 6500/6550 User Guide
XPR™ 6500/6550 Quick Reference Card
Safety Leaflet

NOTE

XPR 6100 User Guide is only available via download and not part of the HKL N4282 CD kit.

xiv Related Publications

Commercial Warranty xiv

Commercial Warranty

Limited Warranty

MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication
Products listed below (“Product”) against defect s in material and workmanship under normal use and

service for a period of time from the date of purchase as scheduled below:

XPR Series Digital Portable Radios Two (2) Years
Product Accessories (Excluding Batteries and Chargers) One (1) Year

The portables additionally ship with a standard 1-year Repair Service Advantage (RSA) (for U.S.
customers) or 1-year Extended W arranty (for Canada customer s). However, at the time of order, yo u
may choose to omit these warranties. For more RSA or Extended Warranty information, please refer
to the portable price pages or Motorola Online (https://businessonline.motorola.com) > Resource
Center > Services > Service Product Offerings > Repair Service Advantage or Extended Warranty.

Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the b alance o f the or igina l ap plicable war ra nty per iod. All repla ce d
parts of Product shall become the property of MOTOROLA.

This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other p arty. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTO ROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.

MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.

xv Commercial Warranty

II. General Provisions

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

III. State Law Rights

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.

This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.

IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty se rvice locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also call
Motorola at 1-800-927-2744 US/Canada.

V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary

manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installa tion, alteration,

modification, or adjustment.
D. Breakage or damag e to antennas u nless caused dir ectly by de fe cts in material workmanship.
E. A Product subjected to unauthorized Product modifica tions, disassemblies or repairs (includ-

ing, without limitation, the addition to the Product of non-Motorola supplied equipment) which

adversely affect performance of the Product or interfere with Motorola's normal warranty

inspection and testing of the Product to verify any warranty claim.
F. Product which has had the serial number removed or made illegible.
G. Rechargeable batteries if:

- any of the seals on the battery enclosure of cells are broken or show evidence of tamper­ing.

- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.

H. Freight costs to the repair depot.

Commercial Warranty xvi

I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the Prod-

uct, does not function in accordance with MOTOROLA’s published specifications or the FCC
type acceptance labeling in effect for the Product at the time the Product was initially distrib­uted from MOTOROLA.

J. Scratches or other cosmetic damage to Product su rfaces that does not af fect th e operation of

the Product.

K. Normal and customary wear and tear.

VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or part s infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:

A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such

claim;

B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its

settlement or compromise; and

C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the

subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to con­tinue using the Product or parts or to replace or modify the same so that it becomes nonin­fringing or to grant such purchaser a credit for the Product o r part s as depreciated an d accept
its return. The depreciation will be an equal amount per year over the lifetime of the Product
or parts as established by MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is at t ached to or used in con nection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.

Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to repro duce in copies and di stribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.

VII. Governing Law

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

xvii Battery and Charger Warranty

Battery and Charger Warranty

Workmanship Warranty

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

All MOTOTRBO Batteries Two (2) Years
IMPRES Chargers (Single-Unit and Multi-Unit, Non-Display) Two (2) Years
IMPRES Chargers (Multi-Unit with Display) One (1) Year

Capacity Warranty

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

Nickel Metal-Hydride (NiMH) or Lithium-Ion (Li-lon) Batteries 12 Months
IMPRES Batteries, When Used Exclusively with IMPRES

Chargers

18 Months

Section 1
INTRODUCTION

1.0 Notations Used in This Manual

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

NOTE: An operational procedure, practice, or condition that is essential to emphasize.

!

C a u t i o n

CAUTION indicates a potentially hazardous situation which, if
not avoided, might

2.0 Radio Description

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

Table 1-1. Radio Frequency Ranges and Power Levels

Frequency Band Bandwidth Power Level

UHF R1 403–470 MHz 1 or 3.5, 4 Watt
UHF R2 450–512 MHz 1 or 4 Watt

VHF 136–174 MHz 1 or 3.5, 5 Watt

These radios are among the most sophisticated two-wa y radios available. They have a r obust 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.

result in equipment damage.

1-2 Radio Description

Notes

Section 2
MAINTENANCE

1.0 Introduction

This chapter provides details about the following

• Preventive maintenance (inspection and cleaning).

• Safe handling of CMOS and LDMOS devices.

• Repair procedures and techniques

2.0 Preventive Maintenance

Periodic visual inspection and cleaning is recommended.

2.1 Inspection

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

2.2 Cleaning Procedures

The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the front
cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic
visual inspection reveals the presence of smudges, grease, and/or grime.

NOTE

The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water . The only factory recommended liquid for cle aning the printed circ uit
boards and their components is isopropyl alcohol (100% by volume ).

Cleaning External Plastic Surfaces

Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the

Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.

The effects of cert a in chemicals an d their vap ors can ha ve harmfu l resu lt s on

!

C a u t i o n

certain plastics. Avoid using aerosol sprays, tuner cleaners and other
chemicals.

2-2 Preventive Maintenance

solution and dry the radio. Make sure that no water remains entrapped near the connectors, cra cks,
or crevices.

Cleaning Internal Circuit Boards and Components

Isopropyl alcohol (100%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge
embedded or caked materials located in hard-to-reach areas. The brush str oke should direct the
dislodged material out and away from the inside of the radio. Make sure that controls or tunable
components are not soaked with alco hol. Do no t use h igh -p ressure a ir to h asten the d rying pr ocess
since this could cause the liquid to collect in unwanted places. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front cover or back cover.

NOTE

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

2.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. Ther efore, special precautions must be taken to prevent
device damage during disassembly, troubleshooting, and repair.

Handling precautions are mandatory for CMOS circuits a nd are e specially impor tant in low humidity
conditions.

Preventive Maintenance 2-3

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

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

!

C a u t i o n

• Store and transport all CMOS devices in conductive material so that
all exposed leads are shorted together . Do no t insert CMOS devices
into conventional plastic “snow” trays used for storage and transpor­tation of other semiconductor devices.

• Ground the working surface of the service bench to protec t the
CMOS device. We recommend using a wrist strap, two ground
cords, a table mat, and a floor mat.

• Wear a conductive wrist strap in series with a 100k resistor to
ground. (Replacement wrist straps that connect to the bench top
covering are Motorola part number 4280385A59).

• Do not wear nylon clothing while handling CMOS devices.

• Do not insert or remove CMOS devices with power applied. Check
all power supplies used for testing CMOS devices to be certain that
there are no voltage transients present.

• When straightening CMOS pins, provide grou nd straps for the appa­ratus used.

• When soldering, use a grounded soldering iron.

• If at all possible, handle CMOS devices by the package and not by
the leads. Prior to touching the unit, touch an elec tric al gr ou nd 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.

2-4 Repair Procedures and Techniques — General

3.0 Repair Procedures and Techniques — General

NOTE

Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards — examples shown below) were developed and assembled using environmen­tally preferred components and solder assembly techniques to comply with the Euro­pean Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/95/EC
and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC. To
maintain product compliance and reliability, use only the Motorola specified parts in this
manual.

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

Table 2-2. Lead Free Solder Wire Part Number List

Motorola

Part Number

1088929Y01 95.5Sn/3.8Ag/0.7Cu RMA Version 2.7-3.2% 217C 52171 0.015” 1lb spool

Alloy Flux Type

Flux Content

by Weight

Melting

Point

Supplier Part

number

Diameter Weight

Table 2-3. Lead Free Solder Paste Part Number List

Motorola Part

Number

1085674C03 NC-SMQ230 900-1000KCPs

Manufacturer Part

Number

Viscosity Type Composition & Percent Metal

Brookfield (5rpm)

Type 3

(-325/+500)

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

89.3%

Liquid

Temperature

217°C

Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
from the nearest Motorola Radio Product s and Solutions Organization (RPSO) listed in Appendix A
of this manual.

Rigid Circuit Boards

The family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering componen t s.
The printed through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.

When soldering near connector:

• A void 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.

Repair Procedures and Techniques — General 2-5

Chip Components

Use the RLN4062 Hot-Air Repair Station for chip component replacement. Adjust the temperature
control to 370°C (700°F), and adjust the airflow to a minimum setting. Airflow can vary due to
component density.

• To remove a chip component:

1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm
(1/8") above the component to be removed.

2. Begin applying the hot air. Once the solder reflows, remove the component using a pair of
tweezers.

3. Using a solder wick and a soldering iron or a power de so lde ring station, rem ov e th e exc es s
solder from the pads.

• To replace a chip component using a soldering iron:

1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the solder
pads.

2. Using a pair of tweezers, position the new chip component in place while heating the fresh
solder.

3. Once solder wicks onto the new component, remove the heat from the solder.

4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the compo-

nent. If necessary, touch up the first side. All solder joints should be smooth and shiny.

• To replace a chip component using hot air :

1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.

2. Apply a drop of solder paste flux to each pad.

3. Using a pair of tweezers, position the new component in place.

4. Position the hot-air hand piece approximately 0.3 cm (1/8”) above the component and begin

applying heat.

5. Once the solder wicks to the component, remove the heat and inspect the repair. All joints
should be smooth and shiny.

2-6 Notes For All Schematics and Circuit Boards

Solder mask

L1

copper foil + plated

Prepreg 1080x1

L2

copper foil + plated

Prepreg 1080x1

L3

copper foil + plated

Prepreg 1080x1

L4

0.5 oz

CORE 4mil(2116*1)

L5

0.5 oz

Prepreg 1080x1

L6

0.5 oz

CORE 4mil(2116*1)

L7

0.5 oz

Prepreg 1080x1

L8

0.5 oz

CORE 4mil(2116*1)

L9

0.5 oz

Prepreg 1080x1

L10

copper foil + plated

Prepreg 1080x1

L11

copper foil + plated

Prepreg 1080x1

L12

copper foil + plated

Solder mask

4.0 Notes For All Schematics and Circuit Boards

* Component is frequency sensitive. Refer to the Electrical Parts List for value and usage.

1. Unless otherwise stated, resistances are in Ohms ( k = 1000), and ca pa ci t ances are in picofar ads
(pF) or microfarads (µF).

2. DC voltages are measured from point indicated to chassis ground using a Motorola DC multime­ter or equivalent. Transmitter measurements should be made with a 1.2 µH choke in series with
the voltage probe to prevent circuit loading.

3. Reference Designators are assigned in the following manner:
700/900 Series = Transmitter
000/200 Series = Frequency Generation
400/600 Series = Receiver
1000/2000/3000 Series = Controller
6000 Series = Keypad Board
8000 Series = GPS
9000 Series = Switches and User Interfaces

4. Interconnect Tie Point Legend:
UNSWB+ = Unswitch Battery Voltage (7.5V)
SWB+ = Switch Battery Voltage (7.5V)
R5 = Receiver Five Volts
CLK = Clock
Vdda = Regulated 3.3 Volts (for analog)
Vddd = Regulated 3.3 Volts (for digital)
SYN = Synthesizer
DACRX = Digital to Analog Voltage (For Receiver Front End Filter)
VSF = Voltage Super Filtered (5 volts)
VR = Voltage Regulator

12-LAYER CIRCUIT BOARD DETAIL VIEWING
COPPER STEPS IN PROPER LAYER SEQUENCE

12-LAYER CIRCUIT BOARD DETAIL VIEWING

PTH
1-12

Buried
via
L3­L10

Figure 2-1: 12-Layer Circuit Board Detail Viewing

Section 3
TEST EQUIPMENT AND SERVICE AIDS

1.0 Recommended Test Equipment

The list of equipment contained in Table 3-1 includes most of the standard test equipment required
for servicing Motorola portable radios.

Table 3-1. Recommended Test Equipment

Equipment Characteristics Example Application

Service
Monitor

Digital RMS
Multimeter *

RF Signal
Generator *

Oscilloscope * 2 Channel

Power Meter
and Sensor *

RF Millivolt
Meter

Power Supply 0 V to 32 V

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

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

100 MHz to 1 GHz

-130 dBm to +10 dBm
FM Modulation 0 kHz to
10 kHz
Audio Frequency 100 Hz
to 10 kHz

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

5% Accuracy
100 MHz to 500 MHz
50 Watts

100 mV to 3 V RF
10 kHz to 1 GHz

0 A to 20 A

Aeroflex 2975
(www.aeroflex.com),
Motorola R2670, or equivalent

Fluke 179 or equivalent
(www.fluke.com)

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

Leader LS8050
(www.leaderusa.com),
Tektronix TDS1001b
(www.tektronix.com),
or equivalent

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

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

B&K Precision 1790
(www.bkprecision.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 level measurements

Voltage supply

3-2 Service Aids

2.0 Service Aids

Table 3-2 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.

Table 3-2. Service Aids

Motorola

Part No.

RLN4460_ Portable Test Set Enables connection to the audio/access or y jack .

Service Aids Customer Programming

Software on CD-ROM

PMKN4012_ Portable Programming Cable This cable connects the radio to a USB port for radio

PMKN4013_ Portable Programming, T esting &

Alignment Cable
PMNN4076_ 7.5V Universal Battery Eliminator Connects to radio via battery eliminator cable.
5880348B33 DMR SMA to BNC RF Adaptor Adapts radio’s antenna port to BNC cabling of test

PMHN4085_ Bench Test Housing Eliminator Interconnects radio to power supply. Provides for

NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages.
NTN4265_ Pressure Pump Kit Allows servicer to locate leakages.

Description Application

Allows switching for radio testing.
Allows servicer to program radio parameters, tune

and troubleshoot radios.

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

programming, testing and alignment.

equipment.

troubleshooting of the radio when the housing is
removed.

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

nected to the radio chassis.

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

chassis.

Programming, Testing and Alignment Cable 3-3

3.0 Programming, Testing and Alignment Cable

#25

#14

P1

#13

#1

P2

#1

#4

#11

#1

P3

#2

#12

Figure 3-1. Programming, Testing and Alignment Cable

3-4 Programming, Testing and Alignment Cable

Table 3-3. Pin Configuration of Side Connector

CONNECTION

P1 P2 P3

Pin Pin Pin Function

1 3 VCC (5V)
34DATA +
25DATA -

16

17
16
20

6 GROUND

7

1

41

8 SPEAKER ­10 EXTERNAL MIC +
11 EXTERNAL MIC -

9 EXTERNAL PTT

7 SPEAKER +

GROUND

(Coax

Connector)