MOTOTRBO
TM
TWO-WAY RADIOS
XPR 7550 IS Series
BASIC
SERVICE MANUAL
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 testing, programming and maintenance of the radios but
does not cover opening the radios and is typical of some local service centers, 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 CSA Safety Manual
!
C a u t i o n
This radio is restricted to occupational use only to satisfy FCC RF/ICNIRP energy exposure
requirements. Before using this product, read the RF energy awareness information and operating
instructions in the Product Safety and RF Exposure booklet enclosed with your radio to ensure
compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site:
http://www.motorolasolutions.com/governmentandenterprise
(68012006018) enclosed with your radio.
ATTENTION!
i
Intrinsically Safe Radio Information
Hazardous Location Safety Instruction and Approved Accesories Listing for Radio Models below:
• XPR 7550 IS (NAG Full Keypad Model)
The radio listed above is certified for:
• Ambient temperature range: -30°C ≤ Ta mb ≤ 60 °C
• Ingress protection level: IP67
Operational Cautions for Intrinsic Safe Equipment
Radios must ship from the Motorola manufacturing facility with the potentially explosive atmosphere capability and the
intrinsic safety approval labelling (FM, UL, CSA). Radios will not be upgraded to this capability and labeled once they have
been shipped to the field. A modification changes the radio’s hardware from its original design configuration. Modifications
can only be made by the original product manufacturer.
!
C a u t i o n
• Do not operate radio communications equipment in a potentially
explosive atmosphere unless it is a type especially qualified (for
example, FM, UL, CSA approved). An explosion or fire may result.
• Do not operate a radio unit that has been approved as intrinsically
safe product in a potentially explosive atmosphere if it has been
physically damaged (for example, cracked housing). An explosion or
fire may result.
• Do not replace or charge batteries in a potentially explosive
atmosphere. Contact sparking may occur while installing or
removing batteries and cause an explosion or fire.
• Do not replace or change accessories in a potentially explosive
atmosphere. Contact sparking may occur while installing or
removing accessories and cause an explosion or fire.
• Turn the radio off before removing or installing a battery or
accessory.
• Do not disassemble an intrinsically safe product in any way that
exposes the internal circuits of the radio.
• Failure to use an intrinsically safe approved battery or Approved
accessories specifically approved for the radio unit may result in the
dangerously unsafe condition of an unapproved radio combination
being used in a hazardous location.
• Unauthorized or incorrect modification of the intrinsically safe
approved Product will negate the approval rating of the product.
• Incorrect repair or relabeling of any intrinsically safe Agencyapproved radio could adversely affect the Approval rating of the
radio.
• Use of a radio that is not intrinsically safe in a potentially explosive
atmosphere could result in serious injury or death.
iii
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective
owners.
© 2013 Motorola Solutions, Inc.
All rights reserved.
Notes
Document History
The following major changes have been implemented in this manual since the pr evious edition:
Edition Description Date
v
68009608001-A
68009608001-B
Initial Release Mar 2013
Updated frequency and volume knob part number Apr. 2013
vi
Notes
Table of Contents vii
Table of Contents
Foreword..........................................................................................................i
Product Safety and RF Exposure Compliance .............................................................................................i
Intrinsically Safe Radio Information..............................................................................................................i
Operational Cautions for Intrinsic Safe Equipment.......................................................................................i
Computer Software Copyrights ..................................................................................................................iii
Document Copyrights................................................................................................................................. iii
Disclaimer................................................................................................................................................... iii
Trademarks ................................................................................................................................................ iii
Document History ......................................................................................... v
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual.................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.2.1 CSA Full Keypad Model .................................................................................................. 1-2
1.3 .Portable Radio Model Numbering Scheme ................................................................................ 1-3
1.4 Model Charts ............................................................................................................................... 1-4
1.4.1 Model Charts NAG (VHF & UHF) .................................................................................... 1-4
1.5 Specifications CSA ...................................................................................................................... 1-5
Chapter 2 Test Equipment and Service Aids ..................................... 2-1
2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids................................................................................................................................. 2-2
2.3 Programming, Testing and Alignment Cable ............................................................................... 2-3
Chapter 3 Transceiver Performance Testing ..................................... 3-1
3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
3.3 Display Model Test Mode ............................................................................................................ 3-3
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-3
3.3.2 RF Test Mode.................................................................................................................. 3-3
3.3.3 Color Display Test ........................................................................................................... 3-8
3.3.4 LED Test Mode................................................................................................................ 3-8
3.3.5 Backlight Test Mode ........................................................................................................3-8
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-8
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-9
3.3.8 Audio Loopback Earpiece Test Mode.............................................................................. 3-9
3.3.9 Battery Check Test Mode .............................................................................................. 3-10
3.3.10 Button/Knob/PTT Test Mode......................................................................................... 3-10
Chapter 4 Radio Programming and Tuning ....................................... 4-1
viii Table of Contents
4.1 Introduction .................................................................................................................................. 4-1
4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 AirTracer Application Tool............................................................................................................ 4-2
4.4 Radio Tuning Setup ..................................................................................................................... 4-2
Chapter 5 Radio Maintenance Procedures for CSA Certified Radios 51
5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Handling Precautions.......................................................................................................5-2
5.2.3 Cleaning Procedure .........................................................................................................5-2
5.3 Assembly Instruction for CSA Certified Radios............................................................................ 5-4
5.3.1 Antenna,Battery and Dust Cover Disassembly................................................................ 5-4
5.3.2 Antenna,Battery and Dust Cover Reassembly ................................................................ 5-5
5.3.3 Nameplate and Logo Label Replacement ....................................................................... 5-5
Chapter 6 Basic Troubleshooting ....................................................... 6-1
6.1 Introduction .................................................................................................................................. 6-1
6.2 Power-Up Error Codes (Display Model only) ............................................................................... 6-1
6.3 Operational Error Codes .............................................................................................................. 6-3
Appendix A NAG Regional Warranty, Service and Technical Support.A1
Limited Warranty......................................................................................................................................... 1
MOTOROLA COMMUNICATION PRODUCTS .............................................................................. 1
I. What This Warranty Covers And For How Long ..................................................................... 1
II. General Provisions ................................................................................................................. 2
III. State Law Rights .................................................................................................................. 2
IV. How To Get Warranty Service .............................................................................................. 2
V. What This Warranty Does Not Cover..................................................................................... 2
VI. Patent And Software Provisions............................................................................................ 3
VII. Governing Law..................................................................................................................... 3
Glossary.........................................................................................Glossary-1
List of Figures ix
List of Figures
Figure 1-1. CSA Full Keypad Model....................................................................................................... 1-2
Figure 1-2. Portable Radio Model Numbering Scheme.......................................................................... 1-3
Figure 2-1. Programming, Testing and Alignment Cable........................................................................ 2-3
Figure 2-2. Pin Layout of Side Connector .............................................................................................. 2-4
Figure 3-1. Battery Check Test Mode Display ......................................................................................3-10
Figure 4-1. CPS Programming Setup..................................................................................................... 4-1
Figure 4-2. Radio Tuning Equipment Setup ........................................................................................... 4-2
Figure 5-1. Antenna and Battery Removal............................................................................................. 5-4
Figure 5-2. Dust Cover Removal............................................................................................................ 5-4
Figure 5-3. Antenna, Battery and Dust Cover Reassembly.................................................................... 5-5
x Related Publications
List of Tables
Table 1-1. Radio Frequency Ranges and Power Levels....................................................................... 1-1
Table 2-1. Recommended Test Equipment ........................................................................................... 2-1
Table 2-2. Service Aids ......................................................................................................................... 2-2
Table 2-3. Pin Configuration of Side Connector.................................................................................... 2-4
Table 3-1. Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2. Front Panel Access Test Mode Displays .............................................................................. 3-3
Table 3-3. Test Environments................................................................................................................ 3-4
Table 3-4. CSA Test Frequencies ......................................................................................................... 3-4
Table 3-5. Transmitter Performance Checks......................................................................................... 3-5
Table 3-6. Receiver Performance Checks ............................................................................................ 3-7
Table 4-1. Software Installation Kits Radio Tuning Setup ..................................................................... 4-1
Table 6-1. Power-Up Error Codes......................................................................................................... 6-1
Table 6-2. Operational Error Codes ...................................................................................................... 6-3
List of Tables xi
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
Product Safety and RF Exposure ................................................................................................ 6864117B25
l
1-1 Introduction: Notations Used in This Manual
Chapter 1 Introduction
1.1 Notations Used in This Manual
Throughout the text in this publication, you will notice the use of note and caution notations. These
notations are used to emphasize that safety hazards exist, and due care must be taken and
observed.
NOTE
An operational procedure, practice, or condition that is essential to emphasize.
!
C a u t i o n
CAUTION indicates a potentially hazardous situation which, if
not avoided, might result in equipment damage.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or injury.
1.2 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
VHF 136–174 MHz 5 Watt
UHF 403–470 MHz 4 Watt
These digital radios are among the most sophisticated two-way radios available. They have a robust
design for radio users who need high performance, quality, and reliability in their daily
communications. This architecture provides the capability of supporting a multitude of legacy and
advanced features resulting in a more cost-effective two-way radio communications solution.
Introduction: Radio Description 1-2
1.2.1 CSA Full Keypad Model
Antenna
Channel Selector Knob
On/Off Volume Control Knob
Emergency Button
LED Indicator
Universal Connector
Side Button 1
for Accessories
Speaker
PTT Button
Microphone
LCD
Side Button 2
Side Button 3
Menu Navigation Key
Front Buttons
Keypad
Figure 1-1. CSA Full Keypad Model
• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counterclockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display):
- 132x90 highly transflective color display provides visual information about many radio
features.
• MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface.
• KEYPAD – Twelve keys that allows the user to input characters for various text based
operations.
• FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the
CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be
used with the radio. It has twelve points to which specific accessories will connect and be
activated.
• EMERGENCY BUTTON – Turns on and off the Emergency Operations.
• SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like
keypad tones and voice audio).
1-3 Introduction: .Portable Radio Model Numbering Scheme
1.3 .Portable Radio Model Numbering Scheme
Model No.Example : AZ H 5 6 J C N 9 P A 3 A N
Position : 1 2 3 4 5 6 7 8 9 10 11 12 xy
AZ: Asia
LA: Latin America
AA: North America
MD: Europe/Middle East/Africa/Australia
H: Portable
XPR 7000/DP4000/XiR P8000/ DGP 8000 Model Series: 56
Band
J : 136-174 MHz
Q: 403-470 MHz
Power Level
C: 1.0,2.0,2.5 or 3.5 Watt
D: 4.0-5.0 Watt
Physical Packages
C: Low Tier (Plain)
H: Mid Tier (Monochrome Display FKP
Monochrome Display LKP)
N: HIgh Tier (Color Display FKP)
J: 3 Button MOR
T: No Display - Limited Tier
Figure 1-2. Portable Radio Model Numbering Scheme
xy: Custom Housing
GP328D: 03
GP338D: 04
Unique Variation
N: Standard Package
Version Letter
Feature Level
1: Standard w/ FM
2. Non-FM
3. CSA IECEx ATEX
4. CQST
Primary System Type
A: Conventional
B: Trunking
C: Analog Only
Primary Operation
J
:
Basic (No GPS, no Bluetooth, no
embedded GOB)
K
:
GPS and Bluetooth
L
:
GPS Only
M
:
Bluetooth Only
N
:
Bluetooth w/ embedded GOB
P
:
GPS with Embedded GOB
Channel Information
8: Variable/Programmable Channel Spacing
w/ unique # of channels
9: Variable/Programmable Channel Spacing
Introduction: Model Charts 1-4
1.4 Model Charts
1.4.1 Model Charts NAG (VHF & UHF)
XPR 7000 Series, CSA, VHF, 136–174 MHz
Model Description
AAH56JDN9PA3AN XPR 7550 IS (136–174 MHz),5W ,CSA MOTOTRBO Full
Keypad Portable with GPS, GOB
Item Description
X PMAD4067_ GPS Helical Antenna (136–147 MHz)
X PMAD4068_ GPS Helical Antenna (147–160 MHz)
X PMAD4069_ GPS Helical Antenna (160–174 MHz)
X NNTN8386_ MOTOTRBO CSA 157 LiIon HiCap Battery, 2075 mAH
X 54012340001 XPR 7550 IS Nameplate
X 36012024001 Knob, Volume
X 36012025001 Knob, Frequency
X 54012264001 Logo, Label
XPR 7000 Series, CSA, UHF, 403–470 MHz
Model Description
AAH56QDN9PA3AN XPR 7550 IS (403–470 MHz),4W ,CSA MOTOTRBO Full
Keypad Portable with GPS, GOB
Item Description
X PMAE4018_ GPS Folded Monop ole Antenna (403–433 MHz)
X PMAE4024_ GPS Folded Monopole Antenna (430–470 MHz)
X PMAE4023_ GPS Stubby Antenna (430–470 MHz)
X NNTN8386_ MOTOTRBO CSA 157 LiIon HiCap Battery, 2075 mAH
X 54012340001 XPR 7550 IS Nameplate
X 36012024001 Knob, Volume
X 36012025001 Knob, Frequency
X 54012264001 Logo, Label
1-5 Introduction: Specifications CSA
1.5 Specifications CSA
General Full Keypad
Channel Capacity 1000
Frequency VHF: 136 – 174 MHz
UHF: 403 – 470 MHz
Dimensions (HxWxT)
w/ Li-ion battery
Weight
(with Li-ion battery)
Power Supply 7.5 V nominal
FCC Description UHF: ABZ99FT4095
IC Description UHF: 109AB-99FT4095
Average battery life at 5/5/90 duty cycle with battery saver enabled in carrier squelch
and transmitter in high power.
Li-ion Battery 2075mAH (Typical)
Li-ion Battery 1800mAH (Minimum)
NOTE
Weight can have 5% margin of error
138.5 x 56.7 x 39.8 mm
482.5 g
VHF: ABZ99FT3093
VHF: 109AB-99FT3093
Analog : 12 hrs
Digital : 16 hrs
Analog : 10 hrs
Digital : 13.5 hrs
Introduction: Specifications CSA 1-6
Factory Mutual Approval
XPR 7550 IS radio models, intrinsically safe, when properly equipped with the battery NNTN8386_
for, Division 1, Class Ι, Groups A, B, C, D, Class ΙΙ, Groups E, F, G, and Class ΙΙΙ T4.
Receiver Full Keypad
Frequencies VHF: 136 – 174MHz
UHF: 403 – 470 MHz
Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz
Frequency Stability (-30°C to +60°C) +/-0.5 ppm
Analog Sensitivity (12 dB SINAD) 0.3 µV
Digital Sensitivity (5% BER) 0.25 µV
Intermodulation (TIA603C) 70 dB
Adjacent Channel Selectivity
TIA603
60 dB @ 12.5 kHz, 70 dB @ 20 kHz/ 25 kHz
45 dB @ 12.5 kHz, 70 dB @ 20 kHz/ 25 kHz
TIA603C
Spurious Rejection (TIA603C) 70 dB
Rated Audio 0.5 W
Audio Distortion @ Rated Audio 5%
Hum and Noise -40 dB @ 12.5 kHz
-45 dB @ 20 kHz/ 25 kHz
Audio Response TIA603C
Conducted Spurious Emission (TIA603D) -57 dBm
1-7 Introduction: Specifications CSA
Transmitter Full Keypad
Frequencies VHF: 136 – 174 MHz
UHF: 403 – 470 MHz
Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz
Frequency Stability (-30°C to
+/-0.5 ppm
+60°C)
Power Output
(High Power)
(Low Power)
VHF: 5 W
UHF: 4 W
VHF/UHF: 1W
Modulation Limiting +/-2.5 kHz @ 12.5 kHz
+/-4.0 kHz @ 20 kHz
+/-5.0 kHz @ 25 kHz
FM Hum and Noise -40 dB @ 12.5 kHz
-45 dB @ 20 kHz/ 25 kHz
Conducted / Radiated Emission -36 dBm < 1 GHz
-30 dBm > 1 GHz
Adjacent Channel Power 60 dB @ 12.5 kHz
70 dB @ 20 kHz/ 25 kHz
Audio Response TIA603C
Audio Distortion 3%
FM Modulation 12.5 kHz: 11K0F3E
25 kHz: 16K0F3E
4FSK Digital Modulation 12.5 kHz Data Only: 7K60F1D & 7K60FXD
12.5 kHz Data & Voice: 7K60F1E & 7K60FXE
Combination of 12.5 kHz Voice and Data:
7K60F1W
Digital Vocoder Type AMBE+2™
Digital Protocol ETSI-TS102361-1
ETSI-TS102361-2
ETSI-TS102361-3
Introduction: Specifications CSA 1-8
VHF Self-Quieter Frequencies
139.200 +/- 10 KHz
144.000 +/- 10 KHz
148.800 +/- 10 KHz
151.000 +/- 10 KHz
151.740 +/- 10 KHz
153.600 +/- 10 KHz
158.400 +/- 10 KHz
163.200 +/- 10 KHz
168.000 +/- 10 KHz
171.900 +/- 10 KHz
172.800 +/- 10 KHz
UHF Self-Quieter Frequencies
403.200 ± 10 KHz
408.000 ± 10 KHz
412.800 ± 10 KHz
416.000 ± 10 KHz
422.400 ± 10 KHz
432.000 ± 10 KHz
440.000 ± 10 KHz
441.600 ± 10 KHz
449.550 ± 10 KHz
451.200 ± 10 KHz
456.000 ± 10 KHz
460.800 ± 10 KHz
468.000 ± 10 KHz
GPS Full Keypad
TTFF (Time To First Fix) Cold Start < 60 seconds
TTFF (Time To First Fix) Hot Start ≤ 10 seconds
Horizontal Accuracy < 5 meters
Accuracy specs are for long-term tracking (95th percentile values > 5 satellites visible at a nominal
-130 dBm signal strength)
TTFF specs are for >5 satelites at a nominal -130dBm signal strength
1-9 Introduction: Specifications CSA
Military Standards
Applicable
MIL–STD
Low Pressure 500.1 I 500.2 II 500.3 II 500.4 II 500.5 II
High
Temperature
Low
Temperature
Temperature
Shock
Solar
Radiation
Rain 506.1 I, II 506.2 I, II 506.3 I,II 506.4 I, III 506.5 I, III
Humidity 507.1 II 507.2 II 507.3 II 507.4 – 507.5 II
Salt fog 509.1 - 509.2 - 509.3 – 509.4 – 509.5 –
Dust 510.1 I 510.2 I 510.3 I 510.4 I 510.5 I
Vibration 514.2 VIII/F,
Shock 516.2 I, II 516.3 I, IV 516.4 I, IV 516.5 I, IV 516.6 I, IV, VI
810C 810D 810E 810F 810G*
Methods Procedures Methods Procedures Methods Procedures Methods Procedures Methods Prodecures
501.1 I, II 501.2 I/A1,II/A1501.3 I-A1, II/A1501.4 I/Hot, II/
502.1 I 502.2 I/C3, II/C1502.3 I-C3, II/
C1
503.1 - 503.2 I/A1/C3 503.3 I/A1/C3 503.4 I 503.5 I-C
505.1 II 505.2 I 505.3 I 505.4 I 505.5 I-A1
514.3 I/10, II/3 514.4 I/10, II/3 514.5 I/24 514.6 II/5
CurveW
502.4 I-C3, II/C1502.5 I, II
Hot
501.5 I/A1, II
NOTE
*Tested to MIL standard G which supersedes previous version
Environmental Specifications
*Operating Temperature -30 °C to +60 °C
Storage Temperature -40 °C to +85 °C
Thermal Shock Per MIL-STD
Humidity Per MIL-STD
ESD IEC 61000-4-2 Level 3
Dust and Water Intrusion IEC 60529 -IP67
* Operating temperature specification with Li-ion battery is -10 °C to +60 °C.
Chapter 2 Test Equipment and Service Aids
2.1 Recommended Test Equipment
The list of equipment contained in Table 2-1 includes most of the standard test equipment required
for servicing Motorola portable radios.
Table 2-1. 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
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
Aeroflex 3920
(www.aeroflex.com),
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
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
Power Supply 0 V to 32 V
0 A to 20 A
B&K Precision 1790
(www.bkprecision.com)
or equivalent
Voltage supply
2-2 Test Equipment and Service Aids: Service Aids
2.2 Service Aids
Table 2-2 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-2. Service Aids
Motorola
Part No.
RLN4460_ Portable Test Set Enables connection to the audio/accessory jack.
RVN5115_ Customer Programming
Software on DVD-ROM - NAG
PMKN4012B* Portable Programming Cable This cable connects the radio to a USB port for radio
PMKN4013C* Portable Programming, Testing &
Alignment Cable
5880384G68 DMR SMA to BNC RF Adaptor Adapts radio’s antenna port to BNC cabling of test
PMLN6430_ Battery Eliminator Connects to radio via battery eliminator cable.
* Earlier versions of programming cables will not work with the radio.
** Load selection is set to MX, no external load is required.
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 radio
programming, testing and alignment.
equipment.
Test Equipment and Service Aids: Programming, Testing and Alignment Cable 2-3
2.3 Programming, Testing and Alignment Cable
#25
#14
P1
#13
#1
P2
#1
#4
P3
#1
#11
#2
#12
Figure 2-1. Programming, Testing and Alignment Cable
2-4 Test Equipment and Service Aids: Programming, Testing and Alignment Cable
Table 2-3. Pin Configuration of Side Connector
CONNECTION
P1 P2 P3
Pin Pin Pin Function
1 GROUND
1 3 VCC (5V)
34DATA+
25DATA-
16 4 6 GROUND
1 & 5
2 & 7
20
17
16
1-Wire
D+
GND
Spkr -
Mic +
GPIO_0
Vbus
D-
Spkr +
GPIO_3
7 EXTERNAL SPEAKER+
8 EXTERNAL SPEAKER-
9 EXTERNAL PTT
10 EXTERNAL MIC+
11 EXTERNAL MIC-
slot for accessory
connector hook
1
2
3
4
5
6
7
8
9
10
11
12
GPIO_4
Mic -
Figure 2-2. Pin Layout of Side Connector
Chapter 3 Transceiver Performance Testing
3.1 General
These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment. The recommended field service equipment approaches
the accuracy of the manufacturing equipment with few exceptions. This accuracy must be
maintained in compliance with the manufacturer’s recommended calibration schedule.
Although these radios function in digital and analog modes, all testing is done in analog mode.
3.2 Setup
Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.
Do NOT use any form of connector, e.g. wires, crocodile
clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number Title
3-2 Front Panel Access Test Mode Displays
3-3 Test Environments
3-4 Test Frequencies
3-5 Transmitter Performance Checks
3-6 Receiver Performance Checks
Table 3-1. Initial Equipment Control Settings
Service Monitor Power Supply Test Set
Monitor Mode: Power Monitor Voltage: 7.5Vdc Speaker set: A
RF Attn: -70 DC on/standby:
Standby
AM, CW, FM: FM Volt Range: 10V PTT: OFF
Speaker/load:
Speaker
3-2 Transceiver Performance Testing Setup
Table 3-1. Initial Equipment Control Settings
Service Monitor Power Supply Test Set
Oscilloscope Source: Mod
Oscilloscope Horizontal: 10mSec/Div
Oscilloscope Vertical: 2.5kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: Middle setting
Monitor Vol: 1/4 setting
Current: 2.5A
Transceiver Performance Testing Display Model Test Mode 3-3
3.3 Display Model Test Mode
3.3.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within 10 seconds after Self Test is complete, press Side Button 2 five times in succession
3. The radio beeps and will show a series of displays that will give information regarding various
version numbers and subscriber specific information. The displays are described in Table 3-2.
Table 3-2. Front Panel Access Test Mode Displays
Name of Display Description Appears
Service Mode The literal string indicates the radio has entered test mode. Always
Host Version The version of host firmware. Always
DSP Version The version of DSP firmware. Always
Model Number The radio’s model number as programmed in the codeplug. Always
MSN The radio’s serial number as programmed in the codeplug. Always
FLASHCODE The FLASH codes as programmed in the codeplug. Always
RF Band The radio’s band. Always
NOTE
The radio stops at each display for 2 seconds before moving to the next information display.
If the information cannot fit into 1 line, the radio display scrolls automatically character by
character after 1 second to view the whole information. If the Left Navigation Key (
pressed before the last information display, the radio shall suspend the information display
until the user presses Right Navigation Key (
radio beeps for each button press. After the last display, RF Test Mode will be displayed.
X) to resume the information display. The
3.3.2 RF Test Mode
When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or air test.
In RF Test Mode, the display upon the first line is “RF Test”, together with the power level icon at the
right end of the first line. The display upon the second line is the test environment, the channel
number and channel spacing. The default test environment is CSQ.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
W) is
NOTE
DIG is digital mode and other test environments are analog mode as described in Table 3-3.
3-4 Transceiver Performance Testing Display Model Test Mode
Table 3-3. Test Environments
No. of
Beeps
1 Carrier Squelch
2 Tone Private-Line
3 Digital Mode
4 Unsquelch
2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz
3. Turning of the Channel Knob changes the test channel from 1 to 16 as described in
Description Function
RX: if carrier detected
(CSQ)
(TPL)
(DIG)
(USQ)
and 20 kHz as. The radio beeps once when radio toggles to 20kHz, beeps twice for 25 kHz
and beeps three times for 12.5 kHz.
Table 3-4. The radio beeps in each position.
TX: mic audio
RX: unsquelch if carrier and tone detected
TX: mic audio + tone
RX: if carrier detected
TX: mic audio
RX: constant unsquelch
TX: mic audio
Table 3-4. CSA Test Frequencies
Channel
Selector
Switch
Test
Channel
VHF UHF
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
RX#1
TX#2
RX#2
TX#3
RX#3
TX#4
RX#4
TX#5
RX#5
TX#6
RX#6
TX#7
RX#7
TX#8
RX#8
136.075 403.025
143.575 414.225
146.575 425.425
155.575 436.525
161.575 447.825
167.575 459.025
173.975 469.975
174.000 –
Transceiver Performance Testing Display Model Test Mode 3-5
Table 3-5. Transmitter Performance Checks
Tes t N a me
Reference
Frequency
Power RF As above As above As above Low Power:
Voice
Modulation
Communications
Analyzer
Mode: PWR MON
4th channel test
frequency*
Monitor: Frequency
error
Input at RF In/Out
Mode: PWR MON
4th channel test
frequency*
atten to -70, input to RF
In/Out
Monitor: DVM: AC Volts
Set 1kHz Mod Out level
for 0.025Vrms at test
set,
80mVrms at AC/DC
test set jack
Radio Test Set Comments
TEST MODE,
Test Channel 4
carrier squelch
As above As above, meter
PTT to
continuously
transmit
(during the
performance
check)
selector to mic
Frequency error to be
±201Hz for UHF
±68Hz for VHF
1 W (VHF/UHF)
High Power:
4W (UHF)
5W (VHF)
Deviation:
≥ 4.0 kHz but ≤ 5.0
kHz (25 kHz Ch Sp).
Voice
Modulation
(internal)
TPL
Modulation
RF Power DMR mode. Slot 1
FSK Error DMR mode. FSK error TEST MODE,
Mode: PWR MON
4th channel test
frequency*
atten to -70, input to RF
In/Out
As above
4th channel test
frequency*
BW to narrow
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 without modulation
Digital mode,
transmit with
0153 test
pattern
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:
≥500Hz but ≤1000Hz
(25 kHz Ch Sp).
Key up radio without modulation
using Tuner
Key up radio with
0513 test pattern
modulation using
Tuner
TTR Enable is
needed and IFR to be
set to trigger mode
with signal level
~1.5V
Not Exceed 5%
3-6 Transceiver Performance Testing Display Model Test Mode
Table 3-5. Transmitter Performance Checks
Tes t N ame
Magnitude
Error
Symbol
Deviation
Transmitter
BER
* See Table 3-4
Communications
Analyzer
DMR mode. Magnitude
error
DMR mode. Symbol
deviation
DMR mode As above As above Transmitter BER
Radio Test Set Comments
As above As above, Not Exceed 1%.
As above As above Symbol Deviation
should be within
648Hz +/-10% and
1944Hz +/-10%
should be 0%
Transceiver Performance Testing Display Model Test Mode 3-7
Table 3-6. Receiver Performance Checks
Tes t N ame
Reference
Frequency
Rated Audio Mode: GEN
Distortion As above, except to
Sensitivity
(SINAD)
Noise
Squelch
Threshold
(only radios
with
conventional
system need
to be tested)
Communications
Analyzer
Mode: PWR MON
4th channel test
frequency*
Monitor: Frequency error
Input at RF In/Out
Output level: 1.0mV RF
6th channel test
frequency*
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts
distortion
As above, except SINAD,
lower the RF level for
12dB SINAD.
RF level set to 1mV RF As above PTT to OFF
As above, except change
frequency to a
conventional system.
Raise RF level from zero
until radio unsquelches.
Radio Test Set Comments
TEST MODE,
Test Channel 4
carrier squelch
output at
antenna
TEST MODE
Test Channel 6
carrier squelch
As above As above Distortion <5.0%
As above PTT to OFF
Out of TEST
MODE; select
a conventional
system
PTT to
continuously
transmit
(during the
performance
check)
Load selection is
set to MX, No
External load is
required
(center)
(center), meter
selection to
Audio PA,
speaker/load to
speaker
As above Unsquelch to occur at
Frequency error to be
±201Hz for UHF
±68Hz for VHF
Set volume control to
3.16 Vrms
RF input to be <0.3μV
Set volume control to
3.16 Vrms
<0.25μV.
Preferred SINAD = 9
– 10dB
Receiver
BER
* See Table 3-4
IFR DMR mode. Signal
generator with 0.153 test
pattern
Test Mode,
Digital mode,
receive 0.153
test pattern
Read BER using
Tuner. Adjust RF
level to get 5%
BER
RF level to be
<0.35uV for 5% BER
3-8 Transceiver Performance Testing Display Model Test Mode
3.3.3 Color Display Test
1. Press any button to test the LCD display, press button X until the display are fixed. Then,
press and hold the first side button until the screen change.
2. Upon key
border inset from the edge by 2 pixels and the text "Display Test Mode" in black.
3. Upon key
boarder inset from the edge by 2 pixels and the text "Display Test Mode" in White.
4. Upon key
5. Upon key
6. Upon key
7. Upon key
Red>Green>Blue>Black>Red>Green>Blue>Black>Red (Full Screen).
8. Upon key
Red>Green>Blue>Black>Red>Black (Full Screen).
9. Upon key “>”press, until all icons in color show. The housing shall display RSSI icon (with full
bar), monitor icon, high power level icon (H), tone disabled icon, priority-two channel scan
icon, option board icon, unread message icon, emergency icon, talkaround icon, and battery
strength indicator icon (with full bar).
10. The housing shall clear the screen and display the rest of the icons in color, (low power level
icon (L), companding icon, and secure operation icon) upon key “>”press. Then, press and
hold the first side button until the screen change.
Xpress, the housing shall display a White screen with 2 pixels wide of a black
Xpress, the housing shall display a Black screen with 2 pixels wide of a White
Xpress, the housing shall display a full screen in Red.
Xpress, the housing shall display a full screen in Green.
Xpress, the housing shall display a full screen in Blue.
Xpress, the housing shall display the growing horizontal bars with a cyclic color of
Xpress, the housing shall display the growing vertical bars with a cyclic color of
3.3.4 LED Test Mode
1. Press and hold Side Button 1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button/key press, the radio lights the red LED and displays “Red LED On”.
3. Consequently, upon any button/key press, the red LED is turned off and the radio lights the
green LED and displays “Green LED On”.
4. Upon any successive button/key press, the green LED is turned off, and the radio shall light
both LEDs up while displaying “Both LEDs On”. Since there is only one LED on the portable,
the LED color will be orange when the radio lights both LEDs.
3.3.5 Backlight Test Mode
1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once and displays
“Backlight Test Mode”.
2. The radio turns on both LCD and keypad backlight together.
3.3.6 Speaker Tone Test Mode
1. Press and hold Side Button 1 after Backlight Test Mode. The radio beeps once and displays
“Speaker Tone Test Mode”.
2. The radio generates a 1 KHz tone with the internal speaker.
Transceiver Performance Testing Display Model Test Mode 3-9
3.3.7 Earpiece Tone Test Mode
1. Press and hold Side Button 1 after Speaker Tone Test Mode. The radio beeps once and
displays “Earpiece Tone Test Mode”.
2. The radio generates a 1 KHz tone with the earpiece.
3.3.8 Audio Loopback Earpiece Test Mode
1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once and
displays “Audio Loopback Earpiece Test Mode”.
2. The radio shall route any audio on the external mic to the earpiece.
3-10 Transceiver Performance Testing Display Model Test Mode
3.3.9 Battery Check Test Mode
1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once and momentarily displays “Battery Check Test Mode”.
2. The radio will display the following:
Rem. Capacity100%
Figure 3-1. Battery Check Test Mode Display
3.3.10 Button/Knob/PTT Test Mode
1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once and
displays “Button Test”(line 1).
2. Rotate the Volume Knob; “2/1” through “2/255” appears. The radio beeps at each position.
3. Rotate the Channel Knob; When rotate the channel knob in clockwise, “4/1” appear. When
rotate the channel knob in counter clockwise, “4/-1” appear. The radio beeps at each position.
4. Press Side Button 1; “96/1” appears & radio beeps; release, “96/0” appears & radio beeps.
5. Press Side Button 2; “97/1”appears & radio beeps; release, “97/0” appears & radio beeps.
6. Press Side Button 3; “98/1”appears & radio beeps; release, “98/0” appears & radio beeps.
7. Press the PTT Switch; “1/1” appears & radio beeps; release, “1/0” appears & radio beeps.
8. Press Top Button; “148/1” appears & radio beeps; release, “148/0” appears & radio beeps.
9. Keypad Checks:
-Press 0, “48/1” appears & radio beeps; release, “48/0” appears & radio beeps.
-Press 1, “49/1” appears & radio beeps; release, “49/0” appears & radio beeps.
-Press 2, “50/1” appears & radio beeps; release, “50/0” appears & radio beeps.
-Press 3, “51/1” appears & radio beeps; release, “51/0” appears & radio beeps.
-Press 4, “52/1” appears & radio beeps; release, “52/0” appears & radio beeps.
-Press 5, “53/1” appears & radio beeps; release, “53/0” appears & radio beeps.
-Press 6, “54/1” appears & radio beeps; release, “54/0” appears & radio beeps.
-Press 7, “55/1” appears & radio beeps; release, “55/0” appears & radio beeps.
-Press 8, “56/1” appears & radio beeps; release, “56/0” appears & radio beeps.
-Press 9, “57/1” appears & radio beeps; release, “57/0” appears & radio beeps.
-Press *, “58/1” appears & radio beeps; release, “58/0” appears & radio beeps.
- Press #, “59/1” appears & radio beeps; release, “59/0” appears & radio beeps.
-Press P1, “160/1” appears & radio beeps; release, “160/0” appears & radio beeps.
-Press P2, “161/1” appears & radio beeps; release, “161/0” appears & radio beeps.
-Press MENU, “85/1” appears & radio beeps; release, “85/0” appears & radio beeps.
Transceiver Performance Testing Display Model Test Mode 3-11
- Press BACK, “129/1” appears & radio beeps; release, “129/0” appears & radio beeps.
- Press
- Press
- Press ▲, "135/1" appears & radio beeps; release, "135/0" appears & radio beeps.
- Press
W, “128/1” appears & radio beeps; release, “128/0” appears & radio beeps.
X, “130/1” appears & radio beeps; release, “130/0” appears & radio beeps.
▼, "136/1" appears & radio beeps; release, "136/0" appears & radio beeps.
Chapter 4 Radio Programming and Tuning
4.1 Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner and AirTracer applications, which are all designed for use in a Windows 2000/XP/
Windows 7 environment. These programs are available in one kit as listed in Table 4-1. An
Installation Guide is also included with the kit.
NOTE
Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1. Software Installation Kits Radio Tuning Setup
Description Part Number
Customer Programming Software on DVD-ROM RVN5115_
4.2 Customer Programming Software Setup
The CPS programming setup, shown in Figure 4-1 is used to program the radio.
NOTE
C a u t i o n
Refer to appropriate program on-line help files for the programming procedures.
!
Computer USB ports can be sensitive to Electrostatic Discharge. Do not touch
exposed contacts on cable when connected to a computer.
Battery
Radio
Programming, Testing
& Alignment Cable
PMKN4012B
PMKN4013C or later.
Figure 4-1. CPS Programming Setup
Radio Programming and Tuning: AirTracer Application Tool 4-2
4.3 AirTracer Application Tool
The MOTOTRBO AirTracer application tool has the ability to capture over-the-air digital radio traffic
and save the captured data into a file. The AirTracer application tool can also retrieve and save
internal error logs from MOTOTRBO radios. The saved files can be analyzed by trained Motorola
personnel to suggest improvements in system configurations or to help isolate problems.
4.4 Radio Tuning Setup
A personal computer (PC), Windows 2000/XP/Windows 7and a tuner program are required to tune
NOTE
Refer to appropriate program on-line help files for the tuning procedures.
the radio. To perform the tuning procedures, the radio must be connected to the PC, radio interface
box (RIB), and test equipment setup as shown in Figure 4-2.
+12VDC
Power
Supply
Battery
Eliminator
7.5V Reg.
RF Adaptor
Radio
Programming, Testing &
Alignment Cable
PMKN4013C or later
10 dB Pad
Transmit
Receive
RF Generator
Audio In
Test Box
RLN4460_
Service Monitor
or Counter
Wattmeter
Tx
Audio Generator
Rx
Sinad Meter
AC Voltmeter
Figure 4-2. Radio Tuning Equipment Setup
5-1 Radio Maintenance Procedures for CSA Certified Radios: Introduction
Chapter 5 Radio Maintenance Procedures for CSA
Certified Radios
5.1 Introduction
This chapter provides details about the following:
• Preventive maintenance (inspection and cleaning).
5.2 Preventive Maintenance
Periodic visual inspection and cleaning is recommended.
5.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional.
Do not inspect the interior electronic circuitry.
To assure the safety and regulatory compliance of the CSA
certified radios, the radio must be repaired only at Motorola
service facilities. Please refer to the region specific
Appendices for the address and contact information of your
nearest Motorola service center.
If the following is observed during inspection of the radios the CSA compliance and safe use of the
radios in hazardous environments may be impacted:
1. Modifications of the enclosure, antennas or battery.
2. Batteries antennas or accessories other than the Motorola approved one are attached to the
radio.
3. The bottom label or the battery CSA label is damaged and the content is partly or completely
unreadable.
4. Stickers or additional labels on the external enclosure of the radio and the battery.
5. Aditional labels on the chassis and the battery cover that cover the original Motorola labels.
6. The antenna isolation is damaged broken or partly missing.
7. The dust cover is damaged or broken.
8. The battery contact seal is damaged.
9. Engraving on the radio housing, chassis or the battery enclosure.
10. Cracks or deep scratches in the lens or the radio and battery enclosure.
11. Missing screws or damaged tamper labels (indicate the radios have been opened by
unauthorized persons).
Radio Maintenance Procedures for CSA Certified Radios: Preventive Maintenance 5-2
12. Signs that the equipment had been exposed to temperatures, chemical substances or
mechanical stress exceeding the limits and specification of Motorola like:
I. Discoloration of the plastic parts.
II. Signs of heavy corrosion on the chassis of the radios.
III. Signs of deformation of the radios or battery enclosure (bended antennas are
permissible as long the plastic is still intact).
IV. Difficulty in screwing/unscrewing the antenna (damaged thread).
V. Difficulty to latch and unlatch the battery (battery interface or latch may be damaged).
If any of the above is observed, those radios in particular have to be repaired or defective parts have
to be replaced.
5.2.2 Handling Precautions
The MOTOTRBO Series Digital Portable radio meets IP67 specifications, allowing the radio to
withstand adverse field conditions such as being submersed in water.
• If the radio has been submersed in water, shake the radio well to remove any water that may be
trapped inside the speaker grille and microphone port. Trapped water could cause decreased
audio performance.
• If the radio’s battery contact area has been exposed to water, clean and dry battery contacts on
both the radio and the battery before attaching the battery to the radio. The residual water could
short-circuit the radio.
• If the radio has been submersed in a corrosive substance (e.g. saltwater), rinse the radio and
battery in fresh water then dry the radio and battery.
• To clean the exterior surfaces of the radio, use a diluted solution of mild dishwashing detergent
and fresh water (i.e. one teaspoon of detergent to one gallon of water).
• Never poke the vent (hole) located on the radio chassis above the battery contact. This vent
allows for pressure equalization in the radio. Doing so may create a leak path into the radio and
the radio’s submersibility may be lost.
• Never obstruct or cover the vent, even with a label.
• Ensure that no oily substances come in contact with the vent.
• The radio with antenna attached properly is designed to be submersible to a maximum depth of
1 meter (3.28 feet) and a maximum submersion time of 30 minutes. Exceeding either maximum
limit or use without antenna may result in damage to the radio.
• When cleaning the radio, do not use a high pressure jet spray on the radio as this will exceed
the 1 meter depth pressure and may cause water to leak into the radio.
Do not disassemble the radio. This could damage radio seals
!
C a u t i o n
and result in leak paths into the radio. Radio maintenance
should only be done in service depot that is equipped to test
and replace the seal on the radio.
5.2.3 Cleaning Procedure
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.
5-3 Radio Maintenance Procedures for CSA Certified Radios: Preventive Maintenance
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (100% by volume).
In hazardous enviroments only use a wet (water) cloth to clean the radios. The
!
C a u t i o n
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
chemicals.
NOTE
Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
Do not use chemicals to clean the radio. Only use cleaning
!
C a u t i o n
agents as prescribed by the manufacturer. Be sure to follow
all safety precautions as defined on the label or material
safety data sheet.
Radio Maintenance Procedures for CSA Certified Radios: Assembly Instruction for CSA Certified Radios 5-4
5.3 Assembly Instruction for CSA Certified Radios
5.3.1 Antenna,Battery and Dust Cover Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Release the battery latch by moving it into the unlock position.
b. With the latch released, slide the battery downwards.
c. Remove the battery from the radio.
3. Remove the antenna by turning it counterclockwise.
Antenna
Dust Cover
Figure 5-1. Antenna and Battery Removal
4. Remove dust cover by turning thumb screw counterclockwise.
Thumb Screw
Figure 5-2. Dust Cover Removal
5-5 Radio Maintenance Procedures for CSA Certified Radios: Assembly Instruction for CSA Certified Radios
5.3.2 Antenna,Battery and Dust Cover Reassembly
1. Attach the dust cover to the opening and secure it by turning the thumb screw clockwise until
it is fastened securely.
2. Insert the battery and slide upwards until a click is heard.
3. Fix the antenna by placing it in the antenna slot and turning it clockwise until it is fastened
securely.
Antenna
Dust Cover
Figure 5-3. Antenna, Battery and Dust Cover Reassembly
Battery, antenna and dustcover or one of the approved
accessories have to be attached to the radio in the hazardous
environment.
5.3.3 Nameplate and Logo Label Replacement
1. Remove damaged nameplate and logo label by peeling off carefully and replace by affixing
new nameplate and logo label.
5-6 Radio Maintenance Procedures for CSA Certified Radios: Assembly Instruction for CSA Certified Radios
Notes
Chapter 6 Basic Troubleshooting
6.1 Introduction
This chapter contains error codes. If repair requires radio level troubleshooting, please send radio to
a Motorola Service Center listed in Appendix A.
6.2 Power-Up Error Codes (Display Model only)
Upon powering up, the radio performs certain tests to determine if its basic electronics and software
are in working order. Any error detected has an associated error code that is presented on the radio
display. These error codes are intended to be used by a service technician when the radio
generates the Self Test Fail Tone. If these tests are successfully completed, the radio will generate
th e S el f Te s t To ne .
There are two classes of detectable errors, fatal and non-fatal. If it is considered as a fatal error, then
the normal radio operation will be inhibited. Fatal errors include hardware errors detected by the
microprocessor and certain memory errors. These memory errors include incorrect ROM checksum,
incorrect RAM checksum, and incorrect checksums of codeplug (Persistent Storage) blocks that
contain operating parameters. If the codeplug block operating parameters are corrupted, operation
of the unit on the proper frequency, system, and group are in question. Attempts to use this
information could provide the user with a false sense of security that others are receiving his
messages. Corrupted codeplug blocks of call IDs, or their associated aliases are considered nonfatal errors. While the user may be inconvenienced, normal communication is still possible.
Table 6-1. Power-Up Error Codes
Error Code Description Error Type Corrective Action
ERROR 01/02 Call ID or associated
aliases codeplug block
checksum is wrong.
ERROR 01/22 Tuning Codeplug block
checksum is wrong.
FAIL 01/82 External Codeplug block
checksum is wrong.
FAIL 01/92 Secure Codeplug check-
sum error
FAIL 01/A2 Tuning Codeplug block
checksum is wrong.
FAIL 01/81 ROM Checksum is
wrong.
FAIL 01/88 Radio RAM Test Failure. Fatal Retest radio by turning it off and turning it on
FAIL 01/90
or
FAIL 02/90
General hardware test
failure.
Non-Fatal Normal communication is still possible, but the
user may be inconvenienced.
Reprogram codeplug.
Non-Fatal Normal communication is still possible.
Fatal Reprogram codeplug.
Fatal Reprogram codeplug.
Fatal Reprogram codeplug.
Fatal Reprogram FLASH Memory, then retest. If
message reoccurs, send radio to nearest
Motorola Depot.
again. If message reoccurs send radio to
nearest Motorola Depot.
Fatal Retest radio by turning it off and turning it on
again. If message reoccurs send radio to
nearest Motorola Depot.
Basic Troubleshooting: Power-Up Error Codes (Display Model only) 6-2
Table 6-1. Power-Up Error Codes (Continued)
Error Code Description Error Type Corrective Action
FAIL 02/81 DSP ROM Checksum is
wrong.
Fatal Reprogram FLASH Memory, then retest. If
message reoccurs send radio to nearest
Motorola Depot.
FAIL 02/82 DSP RAM1 test failure. Fatal Retest radio by turning it off and turning it on
again. If message reoccurs send radio to
nearest Motorola Depot.
FAIL 02/84 DSP RAM2 test failure. Fatal Retest radio by turning it off and turning it on
again. If message reoccurs send radio to
nearest Motorola Depot.
FAIL 02/88 DSP RAM test failure. Fatal Retest radio by turning it off and turning it on
again. If message reoccurs, replace main
board or send radio to nearest Motorola
Depot.
FAIL 02/C0 DSP ROM Checksum is
wrong.
Fatal Retest radio by turning it off and turning it on
again. If message reoccurs send radio to
nearest Motorola Depot.
No Display Display module is not
Fatal Send radio to nearest Motorola Depot.
connected properly.
Display module is
damaged.
6-3 Basic Troubleshooting: Operational Error Codes
6.3 Operational Error Codes
During radio operation, the radio performs dynamic tests to determine if the radio is working properly.
Problems detected during these tests are presented as error codes on the radio’s display. The
presence of an error code should prompt a user that a problem exists and that a Motorola Authorized
MOTOTRBO dealer should be contacted. Use Table 6-2 to aid in understanding particular
operational error codes.
Table 6-2. Operational Error Codes
Error Code Description Error Type Corrective Action
FAIL 001 Synthesizer Out-of-Lock NON-FATAL 1. Reprogram the codeplug.
2. Refer to Detailed Service
Manual.
FAIL 002 Personality checksum or
system block error
NON-FATAL Reprogram the codeplug.
6-4 Basic Troubleshooting: Operational Error Codes
Notes
Appendix A NAG Regional Warranty, Service and
Technical Support
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 defects in material and workmanship under normal use and
service for a period of time from the date of purchase as scheduled below:
XPR Series Digital Portable Radios Three (3) 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 Warranty (for Canada customers). However, at the time of order, you
may choose to omit these warranties. For more RSA or Extended Warranty information, please refer
to the 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 balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.
This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.
MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.
NAG Regional Warranty, Service and Technical Support: Limited Warranty -2
II. General Provisions
This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product.
Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive
remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR
DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE
DISCLAIMED BY LAW.
III. State Law Rights
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.
This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.
IV. How To Get Warranty Service
You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also
V. What This Warranty Does Not Cover
A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs (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.
-3 NAG Regional Warranty, Service and Technical Support: Limited Warranty
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 surfaces that does not affect the 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 parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:
A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such
claim;
B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its
settlement or compromise; and
C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the
subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept
its return. The depreciation will be an equal amount per year over the lifetime of the Product
or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.
VII. Governing Law
This Warranty is governed by the laws of the State of Illinois, USA.
-4 NAG Regional Warranty, Service and Technical Support: Limited Warranty
Notes
Glossary Glossary
This glossary contains an alphabetical listing of terms and their definitions that are applicable to
portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and
some terms are merely generic in nature.
Term Definition
APAC Asia Pacific Region
ANZ Australia and New Zealand
Analog Refers to a continuously variable signal or a circuit or device designed
to handle such signals.
ATEX ATmosphere EXplosive
Band Frequencies allowed for a specific purpose.
CPS Customer Programming Software: Software with a graphical user
interface containing the feature set of a radio.
Default A pre-defined set of parameters.
DP Refers to Digital Professional Radio model names in the MOTOTRBO
Professional Digital Two-Way Radio System.
Digital Refers to data that is stored or transmitted as a sequence of discrete
symbols from a finite set; most commonly this means binary data
represented using electronic or electromagnetic signals.
DPL Digital Private-Line: A type of digital communications that utilizes
privacy call, as well as memory channel and busy channel lock out to
enhance communication efficiency.
EMEA Europe, the Middle East and Africa
FCC Federal Communications Commission.
Frequency Number of times a complete electromagnetic-wave cycle occurs in a
fixed unit of time (usually one second).
GPIO General-Purpose Input/Output: Pins whose function is programmable.
GPS Global Positioning System.
IC Integrated Circuit: An assembly of interconnected components on a
small semiconductor chip, usually made of silicon. One chip can contain
millions of microscopic components and perform many functions.
IF Intermediate Frequency.
kHz kilohertz: One thousand cycles per second. Used especially as a radio-
frequency unit.
Glossary-2
Term Definition
LACR Latin American and Caribbean Region
LCD Liquid-Crystal Display: An LCD uses two sheets of polarizing material
with a liquid-crystal solution between them. An electric current passed
through the liquid causes the crystals to align so that light cannot pass
through them.
LED Light Emitting Diode: An electronic device that lights up when electricity
is passed through it.
MDC Motorola Digital Communications.
MHz Megahertz: One million cycles per second. Used especially as a radio-
frequency unit.
NAG North America Group
Paging One-way communication that alerts the receiver to retrieve a message.
PC Board Printed Circuit Board. Also referred to as a PCB.
PL Private-Line Tone Squelch: A continuous sub-audible tone that is
transmitted along with the carrier.
Programming Cable A cable that allows the CPS to communicate directly with the radio
using USB.
Receiver Electronic device that amplifies RF signals. A receiver separates the
audio signal from the RF carrier, amplifies it, and converts it back to the
original sound waves.
Repeater Remote transmit/receive facility that re-transmits received signals in
order to improve communications range and coverage (conventional
operation).
RF Radio Frequency: The portion of the electromagnetic spectrum between
audio sound and infrared light (approximately 10 kHz to 10 GHz).
RX Receive.
Signal An electrically transmitted electromagnetic wave.
Spectrum Frequency range within which radiation has specific characteristics.
Squelch Muting of audio circuits when received signal levels fall below a pre-
determined value. With carrier squelch, all channel activity that exceeds
the radio’s preset squelch level can be heard.
TOT Time-out Timer: A timer that limits the length of a transmission.
TPL Tone Private Line.
Transceiver Transmitter-receiver. A device that both transmits and receives analog
or digital signals. Also abbreviated as XCVR.
Glossary-3
Term Definition
Transmitter Electronic equipment that generates and amplifies an RF carrier signal,
modulates the signal, and then radiates it into space.
TX Transmit.
UHF Ultra-High Frequency.
USB Universal Serial Bus: An external bus standard that supports data
transfer rates of 12 Mbps.
VIP Vehicle Interface Port.
Motorola Solutions, Inc.
1303 East Algonquin Road
Schaumburg, Illinois 60196 U.S.A.
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and
the Stylized M logo are trademarks or registered trademarks
of Motorola Trademark Holdings, LLC and are used under license.
All other trademarks are the property of their respective owners.
© 2013 Motorola Solutions, Inc. All rights reserved.
April 2013.
www.motorolasolutions.com/mototrbo
*68009608001*
68009608001-B
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