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ASTRO Digital XTL 5000 VHF/UHF Range 1/700

1. Flex Figure 5 5 Disconnecting the chassis 8 latch on the main board to release the keypad from its connector 9 Remove the flex from the keypad board by pulling it out of its connector gently 10 Lift the latch on the main board to release the GOB flex from its connector 5 10 Disassembly Reassembly Procedures Radio Disassembly Detailed 5 6 2 Chassis Disassembly Use a TORX screwdriver with a T6 head to remove the five screws holding the main board to the chassis and the three screws holding the GOB Main board Mc Zs o Main board screws U Figure 5 6 Chassis disassembly Disassembly Reassembly Procedures Radio Disassembly Detailed 5 11 Lift the main board from the chassis Lift the latch to separate the flex for the GOB Lift the GOB from the chassis Release all the tabs from the catches gt Remove the O ring and battery contact seal Battery Contact Seal Figure 5 7 O ring removal 5 12 Disassembly Reassembly Procedures Radio Disassembly Detailed 5 6 3 Keypad Display and Keypad Board Disassembly 1 If the disassembly of the keypad the keypad printed circuit board or the display is required remove the retainer by using a TORX screwdriver with a T6 head to remove the four screws 2 Slide out the retainer from
2. 5 19 Keypad Display and Keypad Board reassembly for Full Keypad 5 20 O nng reassembly i et eee dottore te BR eta ep ERR ee E RR EET Dn ERG 5 21 Chassis reassembly Lec dedit ehe Geo ent sabia ieee 5 22 G3OB reassemlbly i eer itae o pecu e He XP ad aid n ERR 5 23 Chassis reassembly de Dee EL puede ce Fed LL ee odes eode de ce Poe codd eua 5 24 Bluetooth removal for Full Keypad sssssseeee eene enemies 5 25 Bluetooth removal for Non Keypad nennen nennen 5 25 Bluetooth reassembly for Full Keypad sssseenn emen 5 26 Bluetooth reassembly for Non 5 26 Connector Fitting Fitting Seal Pump 5 29 Full Keypad Model Exploded ener 5 38 PGB TOD VI W o deett i e Dead a en tuse ule ie et tee C 2 PGB BottomVIOW oe Reino a tie aei 2 xii Related Publications List of Tables Table 1 1 Table 2 1 Table 2 2 Table 2 3 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 4 1 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 6 1 Table 6 2 Radio Fr
3. cet na iei etin etie a 1 8 Chapter 2 Test Equipment and Service Aids 2 1 2 1 Recommended Test 2 1 2 2 Service ALAS metet dte ied hende E N fete 2 2 2 3 Programming Testing and Alignment Cable enne 2 3 viii Chapter3 Transceiver Performance Testing 3 1 3 1 V 3 1 3 2 Setup eve Tee eee E eee 3 1 3 3 Display Model Test a 3 3 3 3 1 Entering Display Radio Test 3 3 3 9 2 RF Test Rendre Te Aaa eret Ver n nene 3 3 3 3 3 LED Test M d erede tec alle dee e a e d e aov 3 7 334 Backlight Test Mode e eee n a P eds 3 7 3 3 5 Speaker Tone Test Mode 3 7 3 3 6 Earpiece Tone Test Mode ennt nnne 3 7 3 3 7 Audio Loopback Earpiece Test 3 7 3 3 8 Battery Check Test e ease setenta nasi tens snas dnas sanie 3 8 3 3 9 Button Knob PTT Test eene nennen nennen nennen nnns 3 8 3 4 Display Model Test
4. Test Name Communications Radio Test Set Comments Analyzer Reference Mode PWR MON TEST MODE PTT to Frequency error to be Frequency 4th channel test Test Channel4 continuously 604Hz for UHF frequency carrier squelch transmit Monitor Frequency during the 204Hz for VHF error performance Input at RF In Out check Power RF As above As above As above Low Power 1 0 1 6W VHF UHF High Power 4 0 4 8W UHF High Power 5 0 6 0W VHF Voice Mode PWR MON As above As above meter Deviation Modulation 4th channel test selector to mic 4 0 kHz but lt 5 0 frequency kHz 25 kHz Ch Sp 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 Voice Mode PWR MON TEST MODE Remove Press PTT switch on Modulation 4th channel test Test Channel 4 modulation input radio Say four internal frequency carrier squelch loudly into the radio atten to 70 input to RF output at mic Measure In Out antenna deviation gt 4 0 kHz but lt 5 0 kHz 25 kHz Ch Sp TPL As above TEST MODE As above Deviation Modulation 4th channel test Test Channel 4 gt 500 2 but lt 1000Hz frequency TPL 25 kHz Ch Sp BW to narrow See Table 3 4 3 6 Transceiver Performance Testing Display Model Test Mode Table 3 6 Receiver Performance Checks Test Name commilnications Radio Test Set Comments Analyzer Reference Mode P
5. Z 5 Figure 1 1 Display Model ON OFF VOLUME KNOB Rotate clockwise until click is heard to turn on radio rotate counter clockwise 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 For color display only 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
6. E 7 1 1 1 iBatteries oo senno te eee teles et te 7 1 102 Antennas sse hens Me mtn 7 1 Tta Garry Devices bed en Shad acts Da en id be 7 1 7 1 4 Service Replacement Parts ener en nnns nnne nnne 7 2 11 5 OBS donamus fette 7 2 7 1 6 Miscellaneous 7 2 Appendix Replacement Parts Ordering A 1 A 1 Basic Ordering Information cuc te PH tete ae tae ete e e E EIE Res A 1 A 2 Motorola ze ette ie ere tea enne he em mE II A 1 A 3 1 A4 Telephone Orders diei em RE M DEDE Us RU E ond Sete peepee ane A 1 A 5 Orders devint eost dofus e elle tt ta EI D A 1 x Table of Contents A 6 Parts Identification aia certe o etude tta ate ee ia de o ene de eun A 2 A 7 Product Customer Service taste dec ratos coe A 2 Appendix B Motorola Service B 1 B 1 SEMVICING INTOFMANOM MS O B 1 B 2 Motorola Service Center t eL ME debt ea ile aba dicm d e A T ba B 1 Motorola Canadian Technical Logistics Center sssssssee emn B 1 B 4 Motorola Federal Techni
7. Press 128 1 appears amp radio beeps release 128 0 appears 4 radio beeps Press 130 1 appears amp radio beeps release 130 0 appears 4 radio beeps Press A 135 1 appears amp radio beeps release 135 0 appears amp radio beeps Press V 136 1 appears amp radio beeps release 136 0 appears amp radio beeps 3 4 Display Model Test Mode 341 Monochrome Display Test 1 6 Press any button to test the LCD display press button gt until the display are fixed Then press and hold the first side button until the screen change Upon any button key press the LCD shall display the growing horizontal bars Press button P until the LCD display full screen in Black and change to vertical bars Press button until the LCD display full screen Black and change to icon display The LCD 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 The LCD shall clear the screen and display the rest of the icons low power level icon L companding icon and secure operation icon upon any button key press Then press and hold the first side button until the screen change 3 4 2 Color Display Test 1 oC R Press any button to test the LCD display press button gt until the display a
8. Slide the universal connector flex into UC slot Hook in the speaker retainer with speaker assembly at the top left corner of the housing Affix the appropriate screw on the speaker retainer Place the mic boot in the appropriate slot Place a new universal connector escutcheon on the universal connector flex circuit 5 20 Disassembly Reassembly Procedures Radio Reassembly Detailed 5 7 2 Keypad Display and Keypad Board Reassembly 1 Place the LCD and keypad followed by the keypad board and keypad retainer in the housing 2 Reconnect the speaker flex LCD flex and PTT flex to the keypad board and keypad retainer 3 Slide the keypad retainer in to the latch 4 Use a TORX screwdriver with a T6 head to affix the screws SEO 5955 NONO SO Figure 5 17 Keypad Display and Keypad Board reassembly for Full Keypad Disassembly Reassembly Procedures Radio Reassembly Detailed 5 21 5 7 3 Chassis Reassembly O ring reassembly Ensure that the main O ring is not twisted and untangle it to its actual form if needed before performing reassembly Insert D into the bottom two notches on the chassis Fit C around the bottom two corners of the chassis Insert B1 to B4 following the sequence as shown in Figure 5 18 Secure A into the top 2 notches of the chassis Replace the battery contact seal Battery Contact Seal Figure 5 18 O ring reassembly Disassembly Reassembly Procedures Radio Rea
9. 4070 UHF Stubby Antenna 440 490 MHz X X PMAE4071 _ UHF Stubby Antenna 470 512 MHz X X PMAE4079 UHF Slim Whip Antenna 403 512 MHz 1 8 1 5 Introduction Specifications Display Non Display XPR 7550 XPR 7350 Frequency VHF 136 174 MHz 403 512 MHz Dimensions HxWxT w NiMH battery 130 3 x 55 2 38 7 mm 130 3 x 55 15 x 37 2 mm Weight with CoreNiMH battery with Hi Cap Li lon non FM battery with Li lon Slim battery with Core Slim Li lon battery with IMPRES Hi Cap Li ion FM battery Specifications Power Supply 7 5V nominal FCC Description VHF ABZ99FT3085 ABZ99F T4086 IC Description VHF 109AB 99FT3085 UHF 109AB 99F T4086 Average battery life at 5 5 90 duty cycle with battery saver enabled in carrier squelch and transmitter in high power Core NiMH 1300mAh battery Analog 6 7 hrs Analog 7 hrs Digital 9 8 hrs Digital 10 2 hrs Core Slim Li lon 1500 mAH battery Analog 7 7 hrs Analog 8 hrs Digital 11 3 hrs Digital 11 8 hrs IMPRES Li ion Slim 1500mAH Analog 7 7 hrs Analog 8 hrs battery Digital 11 3 hrs Digital 11 8 hrs IMPRES Hi Cap Li ion Non FM 2150 Analog 11 1 hrs Analog 11 5 hrs mAH battery Digital 16 2 hrs Digital 17 hrs IMPRES Hi Cap Li ion FM 2300 Analog 11 9 hrs Analog 12 3 hrs mAH battery Digital 17 3 hrs Digital 18 1 hrs NOTE Weight can have 5 margin of error Factory Mutual Approval MOTOTRBO XPR 7000 Series portable
10. 503 3 VA1 C3 503 4 Shock Solar 505 1 505 2 505 3 Radiation E 810G o Procedures 500 5 501 5 I A1 II 502 5 I Hot 1 Hot I C3 II 503 5 505 5 5065 fnm 507 5 Mo 509 5 510 5 514 6 5 516 6 1 IV VI gt 5 ooo be sez vie 1514 3 u10 0 3 514 4 514 5 rex ees fov Tow e 1 24 I IV NOTE Tested to MIL standard G which supersedes previous version 1 14 Environmental Specifications Operating Temperature Storage Temperature Thermal Shock ESD IEC 61000 4 2 Level 3 Water Intrusion IEC 60529 IP57 Packaging Test MIL STD 810D and E Operating temperature specification with Lilon battery is 10 C to 60 C Operating temperature specification with NiMH battery is 20 C to 60 C Introduction Specifications Chapter 2 Test Equipment and Service Aids Generator 130 dBm to 10 dBm FM Modulation 0 kHz to 10 kHz Audio Frequency 100 Hz to 10 kHz www agilent com Ramsey RSG1000B www ramseyelectronics com or equivalent 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 R
11. 6 F4020 6515076H01 Fuse Fast Blow 3A 24V C 4 Notes Limited Level 3 Servicing Component and Parts list 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 Analog Band CPS Default Digital DPL FCC Frequency GPIO GPS IC kHz LCD LED MDC Definition Refers to a continuously variable signal or a circuit or device designed to handle such signals Frequencies allowed for a specific purpose Customer Programming Software Software with a graphical user interface containing the feature set of a radio A pre defined set of parameters 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 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 Federal Communications Commission Number of times a complete electromagnetic wave cycle occurs in a fixed unit of time usually one second General Purpose Input Output Pins whose function is programmable Global Positioning System Integrated Circuit An assembly of interconnected componen
12. 10 Mesh Speaker 35012040001 11 Speaker Electromagnetic 36mm Dia 50012013001 12 Retainer Assembly Speaker 0104045J57 13 Keypad Retainer Screw 0378212A02 14 Microphone EMI Electret Condenser 50012012001 15 Boot Microphone 32012099001 16 Mic Membrane with Stiffener 3578241A02 17 BlueTooth GPS Antenna 85012045001 18 Screw Shoulder M1 2 X 3 2 MM 0371160D01 19 Plain Front Housing Poron 75012131001 20 Plain UC Flex Poron 75012103001 21 UC to Keypad Flex Part of Front Cover kit 22 Seal Top Control 32012089001 23 Screw Main Board and GOB Board 03012034001 24 Back Cover Kit Assembly See Table 5 5 25 Main O Ring 32012097001 26 Option Board Kit PMLN5718AS 27 GOB to Mainboard Flex 84012217003 28 Plain PTT Flex Poron 75012102001 29 Chassis Part of Back Cover kit 30 Rubber Plug 38012017001 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Table 5 4 Non Display Model Exploded View Parts List 31 Housing Shroud 15012092001 32 Battery Contact Seal 32012096001 33 Gasket 3286058L01 34 Warning Label 3371496L01 35 Gore Label 5478220A01 36 RF Label 54012133001 37 Label Chassis See Table 5 5 38 Nameplate See Table 5 5 39 Battery See Chapter 7 Accessories 40 Belt Clip See Table 5 5 41 7515526H01 NOTE Comprises of 4 5 8 10 11 12 13 14 15 16 17 18 19 20 21 and 28 Comprise of 22 23 24 25 26 29
13. 7 2 Keypad Display and Keypad Board 5 20 Table of Contents ix 5 7 8 Chassis Reassembly eraa AT ra a aA 5 21 5 7 4 Chassis and Front Cover 5 24 5 7 5 Bluetooth Antenna Kit 5 25 5 7 5 1 Bluetooth Antenna Kit Disassembly 5 25 5 7 5 2 Bluetooth Antenna Kit 5 26 5 7 0 GOB Installation eec qe ia er dui el m hed P tc eter 5 27 5 8 Ensuring Radio Immersibility A nnns 5 29 9 81 SERVICING ebd i ee utente ttt ent 5 29 5 8 2 Accidental Immersion a r Ar e aaa esee ennt nnne 5 29 5 8 3 Specialized Test Equipment cri aaa 5 29 5 8 4 Vacuum Pump Kit 9839 5 29 5 8 5 Pressure Pump 4265 5 30 5 8 6 Miscellaneous Hardware cccecceeeeeceeceeceeeeeeeeeeececeeaaaaeaaeceeeeeeeeeeeseesececacaesaeeeeeeeeeess 5 30 5 87 NMACUUIMN decis Hec datore dote Balac iad tees 5 30 5 9 8 Pressure eStore mtb tit
14. AM to 7 00 PM Central Standard Time Monday through Friday Chicago U S A 1 800 422 4210 1 847 538 8023 United States and Canada U S Federal Government Markets Division USFGMD 1 800 826 1913 Federal Government Parts Credit Cards Only 8 30 AM to 5 00 PM Eastern Standard Time Fax Orders The Radio Products and Solutions Organization United States and Canada 1 800 622 6210 847 576 3023 United States and Canada USFGMD Federal Government Orders 1 800 526 8641 For Parts and Equipment Purchase Orders A 6 A 7 Replacement Parts Ordering Parts Identification Parts Identification The Radio Products and Solutions Organization United States and Canada 1 800 422 4210 Product Customer Service Radio Products and Solutions Organization United States and Canada 1 800 927 2744 The Radio Products and Solutions Organization RPSO was formerly known as the Radio Products Services Division RPSD and or the Accessories and Aftermarket Division AAD Appendix Motorola Service Centers B 1 B 2 B 3 B 4 Servicing Information If a unit requires further testing knowledge and or details of component level troubleshooting or service than is customarily performed at the basic level please send the radio to a Motorola Service Center as listed below Motorola Service Center 1220 Don Haskins Drive Suite A El Paso TX 79936 Telephone 915 872 8200 Motorola Canadian Technical Logistics
15. Accessories 2 Volume Knob 36012005001 3 Frequency Knob 36012004001 4 Emergency Button 38012008001 5 Nameplate Front 33012037001 6 Front Cover Kit See Table 5 5 7 UC Escutcheon Part of Front Cover kit 8 Dust Cover Assembly 15012157001 9 Bluetooth GPS Antenna 85012045001 10 Screw Shoulder M1 2 X 3 2 MM 0371160D01 11 Label Agency Indicator Not Field Replaceable 12 Full Keypad See Table 5 5 13 Front Dampener Color Display 75012070001 14 Color Display Padding 75012137001 15 Color Display Module 72012010001 16 Back Dampener Color Display 75012069001 17 Conductive Pad Small 75012148001 18 Conductive Pad Big 75012143001 19 Keypad to Mainboard Flex 84012214005 20 UC to Keypad Flex Part of Front Cover kit 21 TX Shield Poron 75012117001 22 Keypad Stiffener 75012094001 23 Keypad LCD Retainer 42012029001 24 Mesh Speaker 35012040001 25 Speaker Electromagnetic 36mm Dia 50012013001 26 Retainer Assembly Speaker 0104045J57 27 Keypad Retainer Screw 0378212A02 28 Conductive Poron 3916290H01 5 39 5 40 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Table 5 3 Full Keypad Model Exploded View Parts List 29 Microphone EMI Electret Condenser 50012012001 30 Boot Microphone 32012099001 31 Mic Membrane with Stiffener 3578241A02 32 Screw Main Board and GOB board 03012034001 33 Screw Thread Forming 03864342702 34 Seal Top Contr
16. Cable 2 3 Programming Testing and Alignment Cable 25 14 0000000000 pem 1 1 P1 13 MOTOROLA 2 40 Figure 2 1 Programming Testing and Alignment Cable 4 Test Equipment and Service Aids Programming Testing and Alignment Cable Table 2 3 Pin Configuration of Side Connector P3 Function 1 GROUND 1 3 VCC 5V 3 4 DATA 2 5 DATA 16 4 6 GROUND 1 amp 5 7 EXTERNAL SPEAKER 2 amp 7 8 EXTERNAL SPEAKER 20 9 EXTERNAL PTT 17 10 EXTERNAL MIC 16 11 EXTERNAL MIC slot for accessory aou connector hook i Na Y 1 Wire de SN Vbus 7 CA G NO SON l m 2 COMES Ma B Tht ON AC uf 4 c GND 5 O N ATS ES 2 Spkr 8 9 59 m _ OO Spkr 4 9 J 3 42 GW Mic OE WB Lu SF UN Ee Figure 2 2 Layout of Side Connector Chapter 3 Transceiver Performance Testing 3 1 3 2 General These radios meet published specifications through their manufacturing process by utilizing high accuracy laboratory quality test equipment The recommended field service equipment approaches the accuracy of the manufacturing e
17. Detailed 5 6 1 Front Cover from Chassis 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 q Antenna Figure 5 1 Antenna and Battery removal Disassembly Reassembly Procedures Radio Disassembly Detailed 5 7 4 Remove the channel selector knob and volum knob off from their shafts using the knob removal tool Volume Control Knob Figure 5 2 Channel Selector and Volume Knob removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts 5 8 Disassembly Reassembly Procedures Radio Disassembly Detailed Shroud Figure 5 3 Shroud removal 5 Hook the knob opener under the shroud as shown in Figure 5 5 and detach it with a downward motion 6 Separate the chassis from the housing assembly as follows a Insert the chassis opener into the recess at the bottom of the radio Apply a downward force to separate the chassis from the front housing b Remove the chassis from the front housing OSS Chassis Opener Figure 5 4 Chassis removal Disassembly Reassembly Procedures Radio Disassembly Detailed 5 9 7 Lay the chassis down Rotate the front cover backward and slightly away from the chassis Latch
18. Mode eese 3 9 341 Monochrome Display 3 9 3 4 2 Color Display t e Ud e RE tdg 3 9 3 5 Non Display Model Test 3 10 3 5 1 Entering Non Display Radio Test Mode 3 10 3 5 2 RF Test Mode cec eee ec pee erede eee e eR e e e tes 3 10 3 5 3 LED Test ree Rhe tec rep o Bester 3 10 3 5 4 Speaker Tone nemen 3 10 3 5 5 Earpiece Tone Test Mode 3 11 3 5 6 Audio Loopback Earpiece Test 3 11 3 5 7 Battery Check Test nennen nennen nene 3 11 3 5 8 Button Knob PTT Test Mode 3 11 Chapter 4 Radio Programming and Tuning 4 1 4 1 Introdctlons ertet Ub a te RR a dins 4 1 4 2 Customer Programming Software Setup sse eee mnes 4 1 4 3 Air Tracer Application lt T OOM net cette fte ea etre oa ne t alee epa TER ER RERO 4 1 4 4 Radio TUNING Setup Em 4 2 Chapter 5 Disassembly Reassembly Procedures 5 1 5 1 Introd Ct ettet eet tet eene e eter des tete e e e e our edu 5 1 5 2 Prevent
19. Mode 1 Press and hold Side Button 1 after Display Test Mode The radio beeps once and displays LED Test Mode 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 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 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 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 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 8 Transceiver
20. O ring Battery Contact Seal 8 Remove the radio from the water container and dry the radio thoroughly Be especially careful to dry the area around the main seal to prevent contamination of the internal 5 32 Disassembly Reassembly Procedures Ensuring Radio electronics while the unit is open A Keep the area around the chassis s vacuum port dry by ensuring that there is no water around it Caution 9 Remove the pump connector from the chassis 10 Radio after performing Pressure Test must undergo baking process in a temperature chamber for constant temperature soaking at 60 C for 1 hour This is to ensure no moisture is trapped inside the radio and prevent contamination of the internal electronics after reassembling the radio 5 8 9 Troubleshooting Leak Areas Before repairing any leak first read all of the steps within the applicable section This will help to eliminate unnecessary disassembly and reassembly of a radio with multiple leaks Troubleshoot only the faulty seal areas listed in Section 5 8 8 Pressure Test on page 5 31 and when multiple leaks exist in the order listed NOTE Before reassembling the radio always install a new Main seal O ring Battery Contact Seal in the defective area 5 8 9 1 Front Housing Do one or both of the following 1 If a leak occurs at the Lens Display Models only Universal Connector chassis Housing interface PTT button area of the housing repl
21. Performance Testing Display Model Test Mode 3 3 8 Battery Check Test Mode 1 2 Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode The radio beeps once and momentarily displays Battery Check Test Mode The radio will display the following Rem Capacity100 Figure 3 1 Battery Check Test Mode Display 3 3 9 Button Knob PTT Test Mode 1 QN Press and hold Side Button 1 after Battery Check Test Mode The radio beeps once displays Button Test line 1 Rotate the Volume Knob 2 1 through 2 255 appears The radio beeps at each position 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 Press Side Button 1 96 1 appears amp radio beeps release 96 0 appears amp radio beeps Press Side Button 2 97 1 appears 4 radio beeps release 97 0 appears 4 radio beeps Press Side Button 3 98 1 appears amp radio beeps release 98 0 appears amp radio beeps Press the PTT Switch 1 1 appears amp radio beeps release 1 0 appears amp radio beeps Press Top Button 148 1 appears 4 radio beeps release 148 0 appears 4 radio beeps Keypad Checks Press 0 48 1 appears amp radio beeps release 48 0 appears amp radio beeps Press 1 49 1 appears amp radio be
22. Test Pressure testing the radio is necessary only if the radio has failed the vacuum test Do not perform the pressure test until the vacuum test has been completed Pressure testing involves creating a positive pressure condition inside the radio immersing the radio in water and observing the radio for a stream of bubbles leak Since all areas of the radio are being checked observe the entire unit carefully for the possibility of multiple leaks before completing this test To conduct the pressure test 1 Screw the pump connector with fitting seal into the tapped hole in the chassis 2 Attach one end of the pressure hose to the pump connector and the other end to the pressure pump Attach antenna firmly to the radio Operate the pump until the gauge reads approximately 1 psig A N Pressure any greater than 1 psig might push air around the main seal Caution 5 Maintain the pressure at 1 psig and immerse the radio into a water filled container 6 Watch for any continuous series of bubbles A stream of bubbles indicates a sign of leakage NOTE Some air entrapment may cause the accumulation of bubbles especially in the grille area but the bubbles should not be continuous A Please do not bend or over tighten pump connector to the chassis Caution 7 Note all of the seal areas that show signs of leakage Pinpoint the problem s to one or more of the following areas Front Housing Chassis Main Seal
23. 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 Rechargeable batteries if any of the seals on the battery enclosure of cells are broken or show evidence of tamper ing 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 xvii l 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 distrib uted 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
24. between the connector pins Examine your work closely for shorts due to solder bridges Disassembly Reassembly Procedures Disassembling and Reassembling the Radio General 5 5 5 5 Disassembling and Reassembling the Radio General When disassembling and reassembling the radio it is important to pay particular attention to the snaps and tabs and how parts align with each other The following tools are required for disassembling the radio TORX T3 and T6 screwdriver Chassis and Knob Opener PMLN6208 The following item and tools are required for reassembling the radio Grease 1185937A01 TORX T3 and T6 screwdriver Vacuum Pump Kit NLN9839 Radio Immersibility Test Pressure Pump Kit NTN4265 Radio Immersibility Test Connector Fitting 5871134M01 Radio Immersibility Test Fitting Seal 3271133 01 Radio Immersibility Test Seal Port 3286058L01 Label Ventilation 5478220A01 If a unit requires further testing or service than is customarily performed at the basic level please send the radio to a Motorola Service Center listed in Appendix B radio must be repaired only at Motorola service facilities Please call Motorola at 800 422 4210 for the address and contact information of your nearest Caution service center 1 To assure the safety and regulatory compliance of the XPR 7000 Series the 5 6 Disassembly Reassembly Procedures Radio Disassembly Detailed 5 6 Radio Disassembly
25. 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 Cleaning Internal Circuit Boards and Components Isopropyl alcohol 100 may be applied with a stiff non metallic short bristled brush to dislodge embedded or caked materials located in hard to reach areas The brush stroke should direct the dislodged material out and away from the inside of the radio Make sure that controls or tunable components are not soaked with alcohol Do not use high pressure air to hasten the drying process since 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 prevent contamination by dissolved material from previous usage M Use all chemicals as prescribed by the manufacturer Be sure to follow all safety precautions as defined on the label or Caution material safety data sheet 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 fail
26. connector flex through the UC slot into the housing Remove the speaker retainer from the speaker assembly Remove the assembly from the front housing Disassembly Reassembly Procedures Radio Disassembly Detailed 5 15 5 6 5 Emergency Button Assembly Dissassembly 1 The Emergency button can be removed without the use of tools once the speaker retainer is removed Figure 5 11 Emergency Button disassembly for Full Keypad Model Disassembly Reassembly Procedures Radio Disassembly Detailed Figure 5 12 Emergency Button disassembly for Non Keypad Model Disassembly Reassembly Procedures Radio Reassembly Detailed 5 17 5 7 Radio Reassembly Detailed 5 7 1 Emergency Button and Speaker Reassembly 1 Slot in the emergency button in its proper slot Figure 5 13 Emergency Button reassembly for Full Keypad 5 18 Disassembly Reassembly Procedures Radio Reassembly Detailed Emergency Button Figure 5 14 Emergency Button reassembly for Non Keypad __ 4 44 Speaker Retainer Speaker Mic and Flex Figure 5 15 Speaker reassembly for Full Keypad Disassembly Reassembly Procedures Radio Reassembly Detailed 5 19 NOTE Speaker Mic and Flex Figure 5 16 Speaker reassembly for Non Keypad Insert the flexes through the speaker retainer so that the speaker retainer is placed directly on the speaker assembly Ensure all the flexes are above the speaker retainer
27. lt 1GHz 30 dBm gt 1GHz Adjacent Channel Power 60 dB 12 5 kHz 70 dB 20 25 kHz Audio Response TIA603D FM Modulation 12 5 kHz 11KOF3E 25 kHz 16KOF3E 4FSK Digital Modulation 12 5kHz Data 7K60F1D amp 7K60FXD 12 5kHz Voice 7K60F1E amp 7K60FXE Combination of 12 5kHz Voice and Data 7K60F1W Digital Vocoder Type AMBE 2 Digital Protocol ETSI TS 102 361 1 2 3 Introduction Specifications VHF Self Quieter Frequencies withGOB w out GOB 148 8 10kHz 150 525 10kHz 153 6 10kHz 172 8 10kHz 1 11 withGOB w out GOB 1 12 Introduction Specifications Display Non Display XPR 7550 XPR 7350 TTFF Time To First Fix Cold lt 60 seconds Start o 130dBm 95 TTFF Time To First Fix Hot Start lt 10 seconds 130dBm 95 Horizontal Accuracy 2 lt 5 meters Accuracy Cold Start Accuracy specs for long term tracking 95th percentile values gt 5 satellites visible at a nominal 130 dBm signal strength Bluetooth Display Non Display XPR 7550 XPR 7350 Supports Bluetooth 2 1 EDR Specification Introduction Specifications 1 13 Military Standards Applicable 810C 810D 810E MIL STD Methods Procedures Method Procedures Methods Procedures Methods 5 LowPressure 5001 5002 J High 501 1 501 2 l A1 II 501 3 1 501 4 Temperature A1 A Low 502 1 502 2 3 1 502 3 I C3 Il 5024 Temperature C1 C1 Temperature 503 1 503 2 U A1 C3
28. radios have been certified by FM in accordance with U S Codes as intrinsically safe for use in Class Il III Division 1 Groups D E F when properly equipped with a Motorola FM approved battery option They are also approved for use in Class Division 2 Groups A B C D Introduction Specifications 1 9 Receiver Display Non Display XPR 7550 XPR 7350 Frequencies VHF 136 174 MHz 403 512MHz 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 Digital Sensitivity 5 BER 0 25 0 19yV typical Intermodulation TIA603D 70 dB Adjacent Channel Selectivity 1T 5 kHz 70 dB 20 25 kHz TIAGOS3D 2T 5 kHz 70 dB 20 25 kHz Spurious Rejection TIA603D 70 dB Audio Distortion Rated Audio 5 typical Hum and Noise 40 dB 12 5 kHz 45 dB 20 25 kHz Audio Response TIA603D Conducted Spurious Emission 57 dBm TIA603D 1 10 Introduction Specifications Transmitter Display Non Display XPR 7550 XPR 7350 Frequencies VHF 136 174 MHz UHF 403 512 MHz Channel Spacing 12 5 kHz 20 kHz 25 kHz Frequency Stability 30 C to 60 C 0 5 ppm Power Output High Power VHF 5 W UHF1 UHF2 4 W Modulation Limiting 2 5 kHz 12 5 kHz 4 0 2 20 kHz 5 0 kHz 25 kHz FM Hum and Noise 40 dB 12 5 kHz 45 dB 6 20 25 kHz Conducted Radiated Emission 36 dBm
29. the housing assembly 3 Disconnect the speaker flex LCD flex and PTT flex from the keypad board NOTE The LCD keypad board and keypad can be removed without the use of tools 285 T DIN S S Oo Figure 5 8 Keypad Display and Keypad Board disassembly for Full Keypad Disassembly Reassembly Procedures Radio Disassembly Detailed 5 13 5 6 4 Speaker Microphone and Universal Connector Flex Disassembly 1 2 3 4 a Pull the microphone boot from its seated position Remove the speaker retainer screw using the TORX T6 screwdriver Peel off the universal connector flex circuit escutcheon Pull the UC flex circuit adhesive held backer board from the font cover Push the universal connector flex through the UC slot into the housing Remove the speaker retainer from the speaker assembly Remove the assembly from the front housing Speaker Retainer J3 Screw Figure 5 9 Speaker removal for Full Keypad ae o Noa e Disassembly Reassembly Procedures Radio Disassembly Detailed PTT flex connector Figure 5 10 Speaker removal for Non Keypad Pull the rubber microphone boot from its seated position Remove the screw using the TORX T6 screwdriver Disconnect the PTT flex and peel the speaker assembly flex from the housing Peel off the universal connector flex circuit escutcheon Pull the UC flex circuit adhesive held backer board from the font cover Push the universal
30. 30 31 32 34 36 and 38 Table 5 5 Additional Part List information Item Description Part Number eh ers FRONT COVER KIT ENGLISH BT FKP PMLN6116A I FRONT COVER KIT BT NKP PMLN6111A Keypad Full Keypad English 75012064004 Back Kit BC Kit 136 174MHz 5W FKP GPS BT PMLD4480AS BC Kit 136 174MHz 5W NKP GPS BT PMLD4486AS BC Kit 403 527MHz 4W FKP GPS BT PMLE4689AS BC Kit 403 527MHz 4W NKP GPS BT PMLE4695AS Nameplate XPR 7350 33012015001 XPR 7550 33012015002 Belt Clips Belt Clip 2 PMLN4651A Belt Clip 2 5 PMLN7008A Label Chassis Label 54012134001 5 43 5 44 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists 5 9 3 Torque Chart Table 5 6 lists the various screws by part number and description followed by the torque values in different units of measure Torque all screws to the recommended value when assembling the radio Part Number Table 5 6 Torque Specifications for Screws Description Driver Socket Torque Ibs in 03012034001 Screw Main Board T6 Torx 3 1 to 3 5 0386434202 Screw Speaker Retainer T6 Torx 2 3 to 2 5 0378212A02 0371160D01 Screw Keypad Retainer Screw Bluetooth Antenna T6 Torx T3 Torx 1 1 to 1 3 0 4 to 0 6 Chapter 6 Basic Troubleshooting 6 1 6 2 Introduction This chapter contains error codes and board replacement procedures If the board does not pass all the performance checks in Chapter 3 or exhibi
31. AY BE DISCLAIMED BY LAW Ill State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY This warranty gives specific legal rights and there may be other rights which may vary from state to state IV How To Get Warranty Service You must provide proof of purchase bearing the date of purchase and Product item serial number in order to receive warranty service and also deliver or send the Product item transportation and insurance prepaid to an authorized warranty service location Warranty service will be provided by Motorola through one of its authorized warranty service locations If you first contact the company which sold you the Product it can facilitate your obtaining warranty service You can also call Motorola at 1 800 927 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 Defects or damage from improper testing operation maintenance installation alteration modification or adjustment 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
32. BUTTON Turns on and off the Emergency Operations Introduction Radio Description SPEAKER Outputs all tones and audio that are generated by the radio e g features like keypad tones and voice audio 1 4 Introduction Radio Description 1 2 2 Non Display Model Figure 1 2 Non Display Model ON OFF VOLUME KNOB Rotate clockwise until click is heard to turn on radio rotate counter clockwise 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 SIDE BUTTONS These 3 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 to 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
33. Center Motorola Canada Ltd 8133 Warden Avenue Markham Ontario L6G 1B3 Tel 1800 543 3222 Fax 1800 331 9872 or 1 905 948 5970 Motorola Federal Technical Center 10105 Senate Drive Lanham MD 20706 Tel 1800 969 6680 Fax 1800 784 4113 B 2 Motorola Service Centers Motorola Federal Technical Center Notes Appendix C Limited Level 3 Servicing C 1 C 2 Maintenance For details on the following please refer to Chapter 5 Disassembly Reassembly Procedures on page 5 1 to section 5 4 on page 5 4 Section 5 2 on page 5 1 to Section 5 4 on page 5 4 Preventive maintenance inspection and cleaning Safe handling of CMOS and LDMOS devices Repair procedures and techniques Chip Components Use a 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 desoldering station remove the excess 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 o
34. JDC9KA1AN 136 174 MHz 5W MOTOTRBO Non Keypad Portable with GPS and BT Item Description X PMLD4480 S BC Kit 136 174 MHz 5W MOTOTRBO Full Keypad Portable with GPS and BT X PMLD4486 S BC Kit 136 174 MHz 5W MOTOTRBO Non Keypad Portable with GPS and BT X PMLN6116 Front Cover Kit Full Keypad Portable with Bluetooth English X PMLN6111 Front Cover Kit Non Keypad Portable with Bluetooth X X PMLN5718 S Option Board Kit X X PMADA117 VHF Helical antenna 136 155 MHz X X PMAD4116_ VHF Helical antenna 144 165 MHz X X PMAD4118_ VHF Helical antenna 152 174 MHz X X PMAD4119_ VHF stubby antenna 136 148 MHz X X PMAD4120_ VHF stubby antenna 146 160 MHz X X PMAD4121 _ VHF stubby antenna 160 174 MHz Introduction Model Charts 1 4 2 UHF Model Chart XPR 7000 Series UHF 403 512MHz Model Description ___ AAH5G6RDNSKA1AN 403 512 MHz 4W MOTOTRBO Full Keypad Portable with GPS and BT AAH56RDC9KA1AN 403 512 MHz 4W MOTOTRBO Non Keypad Portable with GPS and BT Item Description X PMLE4689 5 BC Kit 403 512MHz 4W Full Keypad Portable with GPS and BT X PMLE4695 S BC Kit 403 512MHz 4W Non Keypad Portable with GPS and BT X PMLN6116 Front Cover Kit Full Keypad Portable with Bluetooth English X PMLN6111 Front Cover Kit Non Keypad Portable with Bluetooth X X PMLN5718 S Option Board Kit X X PMAE4069 Stubby Antenna 403 450 MHz X X
35. MLN6208A Chassis and Knob Opener 7 1 5 CPS Part No Description RVN5115 CPS MOTOTRBO 7 1 6 Miscellaneous Accesories Part No Description PMLN5718 S Generic Option Board Appendix A Replacement Parts Ordering A 1 A 2 A 3 A 4 A 5 Basic Ordering Information Some replacement parts spare parts and or product information can be ordered directly While parts may be assigned with a Motorola part number this does not guarantee that they are available from Motorola Radio Products and Solutions Organization RPSO Some parts may have become obsolete and no longer available in the market due to cancelations by the supplier If no Motorola part number is assigned the part is normally not available from Motorola or is not a user serviceable part Part numbers appended with an asterisk are serviceable by Motorola Depot only Motorola Online Motorola Online users can access our online catalog at https www motorola com businessonline To register for online access please call 1 800 422 4210 for U S and Canada Service Centers only International customers can obtain assistance at https www motorola com businessonline Mail Orders Mail orders are only accepted by the US Federal Government Markets Division USFGMD Motorola 7031 Columbia Gateway Drive 3rd Floor Order Processing Columbia MD 21046 U S A Telephone Orders The Radio Products and Solutions Organization United States and Canada 7 00
36. OROLA 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 xviii 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 Core Chargers Single Unit and Multi Unit Non Display Two 2 Years Capacity Warranty The capacity warranty guarantees 80 of the rated capacity for the warranty duration Nickel Metal Hydride NiMH or Lithium lon Li lon Batteries 12 Months IMPRES Batteries When Used Exclus
37. PROFESSIONAL DIGITAL TWO WAY RADIO MOTOTRBO XPR 7000 SERIES 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 self maintained customers and distributors Product Safety and RF Exposure Compliance for safe usage contained in the Product Safety and RF Caution Exposure booklet enclosed with your radio 1 Before using this product read the operating instructions ATTENTION This radio is restricted to occupational use only to satisfy FCC RF 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 Motorola Publication part number 6881095C98 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 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 preser
38. WR MON TEST MODE PTT to Frequency error to be Frequency 4th channel test Test Channel 4 continuously 604Hz for frequency carrier squelch transmit Monitor Frequency error output at during the 204Hz for VHF Input at RF In Out antenna performance check Rated Audio Mode GEN TEST MODE PTT to OFF Set volume Output level 1 0mV RF Test Channel 6 center meter control to 2 83 Vrms 6th channel test carrier squelch selector to Audio frequency PA Set volume control to Mod 1kHz tone at 3 16 Vrms IECEx 3kHz deviation CSA 800 900 Monitor DVM AC Volts Distortion As above except to As above As above Distortion lt 3 0 distortion Sensitivity As above except SINAD As above PTT to OFF RF input to be SINAD lower the RF level for center lt 0 35 12dB SINAD Noise RF level set to 1mV RF As above PTT to OFF Set volume Squelch center meter control to 2 83Vrms Threshold selection to only radios Audio PA Set volume control to with speaker load to 3 16 Vrms IECEx conventional speaker CSA 800 900 system need to be tested As above except change Out of TEST As above Unsquelch to occur at frequency to a select lt 0 25uV conventional system a conventional Preferred SINAD 9 Raise RF level from zero system 10dB until radio unsquelches See Table 3 4 Transceiver Performance Testing Display Model Test Mode 3 7 3 3 3 3 3 4 3 3 5 3 3 6 3 3 7 LED Test
39. ace the housing Refer to Section 5 6 Radio Disassembly Detailed on page 5 6 a Remove the housing assembly from the radio b Discard the housing assembly and main seal O ring c Install a new main seal O ring around the chassis assembly according to Figure 5 d Install a new housing assembly to the radio e Inspect the main seal for proper seating f Observe carefully to ensure that the main seal O ring is not pinched between the housing and the chassis interface 2 Ifthe leak occurs at the control top area remove the knobs in order to determine the leak location a Conduct the Pressure Test b Identify the leak location 5 8 9 2 Chassis Main Seal O ring To replace the main seal O ring 1 Refer to Section 5 6 1 Front Cover from Chassis Disassembly on page 5 6 remove the chassis assembly from the radio Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 33 Refer to Section 5 6 2 Chassis Disassembly on page 5 10 remove the Main Board from chassis Remove the main seal O ring Inspect the seal area around the chassis for foreign material that might prevent the main seal O ring from sealing properly Assemble a new O ring discard the old O ring For detailed O ring assembly sequence refer to clause 2 step i to step viii of Section 5 7 3 Chassis Reassembly on page 5 21 Reassemble the chassis assembly followed by installing into Front Cover Refer to Section 5 7 Radio R
40. als in order to improve communications range and coverage conventional operation Radio Frequency The portion of the electromagnetic spectrum between audio sound and infrared light approximately 10 kHz to 10 GHz Receive An electrically transmitted electromagnetic wave Frequency range within which radiation has specific characteristics 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 Time out Timer A timer that limits the length of a transmission Tone Private Line Transmitter receiver A device that both transmits and receives analog or digital signals Also abbreviated as XCVR Electronic equipment that generates and amplifies an RF carrier signal modulates the signal and then radiates it into space Transmit Ultra High Frequency Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps Vehicle Interface Port Refers to Digital Professional Radio model names in the MOTOTRBO Professional Digital Two Way Radio System Glossary 3 Notes MOTOROLA 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
41. am the codeplug 2 Refer to Detailed Service Manual FAIL 002 Personality checksum or NON FATAL Reprogram the codeplug system block error Chapter 7 Accessories 7 1 Introduction Motorola provides the following approved accessories to improve the productivity of your digital portable two way radio For a list of Motorola approved antennas batteries and other accessories visit the following web site http www motorola com governmentandenterprise 711 Batteries Kit No Description PMNN4407_ IMPRES Li ion Slim Battery 1500mAH PMNN4409 _ IMPRES Hi Cap Li ion Non FM Battery 2150 mAH NNTN8129 IMPRES Hi Cap Li ion FM Battery 2300 mAH PMNN4406 Core Slim Li lon Battery 1500 mAH PMNN4412_ Core NiMH battery 1300mAh 7 1 2 Antennas Kit No Description VHF Helical antenna 136 155 MHz VHF Helical antenna 144 165 MHz VHF Helical antenna 152 174 MHz VHF stubby antenna 136 155 MHz VHF stubby antenna 144 165 MHz 7 1 3 Carry Devices Kit No Description PMLN5838 _ HARD LEATHER CC 3inch FIX LKP FKP PMLN5839_ HARD LEATHER CC 3inch FIX PLAIN 7 2 Accessories Introduction PMLN5840_ HARD LEATHER CC 3inch SWL LKP FKP PMLN5846_ HARD LEATHER CC 3inch SWL PLAIN PMLN5842 _ HARD LEATHER CC 2 5inch SWL LKP FKP PMLN5843 _ HARD LEATHER CC 2 5inch SWL PLAIN PMLN5844 _ NYLON CC 3inch FIX LKP FKP PMLN5845 NYLON CC 3inch FIX PLAIN 7 1 4 Service Replacement Parts Part No Description P
42. arranty Covers And For How Long sse Il General Provisions Ed ede dn dta eite e Moet dte pictas xvi IE State Law RIONE nn en ERU Sen BRI ERE ERE xvi IV How To Get Warranty Service enne nennen nennen enne xvi V What This Warranty Does Not nennen ener nnns xvi Patent And Software Provisions ssssssssseeeeee nenne nennen nennen xvii VII xGoverning eet eet bt bn oe Di n EE e e er RR xvii Battery and Charger Warranty xviii Workimanmship nep EID HERR bte xviii Capacity Warranty eise E RR ca denen duets ness IMS xviii Chapter 1 Introduction titt CH RE 1 1 1 1 Notations Used in This aa EE R errem nennen emnes 1 1 1 2 Radio Description 2 CREER ABO d 1 1 12 1 Full Display Model acri n espe c ko trace abe de REIR ORE MER 1 2 1 2 2 Non Display MOGe i irt Pee en mi ee ined ret 1 4 1 3 Portable Radio Model Numbering Scheme ssssssssseeeeee eene nennen 1 5 1 4 Model edt REPRE REIR ARR OR ERR TRE RATER 1 6 TASK MAF Model Chat ts ince e le ite teet laces a Pe e idea 1 6 1 4 2 OUAR Model Charta 2 nee Pte ai ep cose tee t er e ederet 1 7 1 5
43. audio Introduction Portable Radio Model Numbering Scheme 1 5 1 3 Portable Radio Model Numbering Scheme Model No Example AZ H 5 5 Q D H 9 L A 1 A N Position 1 2 3 4 5 6 7 8 9 10 11 12 Lo Unique Variation N Standard Package AZ Asia Australia LA Latin America AA North America Version Letter MD Europe Middle East Africa H Portable Feature Level 1 Standard w FM XPR 7000 Model Series 56 2 Non FM XPR 3000 Model Series 02 3 CSA IE CEx ATEX 4 CQST Band 3 J 136 174 MHz pimay m R 403 527 MHz Trunking Power Level Primary Operation 2 3 5 Watt Basic No GPS no Bluetooth no ao embedded GOB K GPS and Bluetooth L GPS Only Physical Packages C i Tier Plain M Bluetooth Only N Bluetooth w embedded GOB H Mid Tier Monochrome Display FKP Monochrome Display LKP N HIgh Tier Color Display FKP Channel Information J 3 Button _ 8 Variable Programmable Channel Spacing T No Display Limited Tier w unique of channels 9 Variable Programmable Channel Spacing Figure 1 3 Portable Radio Model Numbering Scheme 1 6 Introduction Model Charts 1 4 Model Charts 1 4 4 VHF Model Chart XPR 7000 Series VHF 136 174 MHz ____ ________ Deserption __ AAH56JDN9KA1AN 136 174 MHz 5W MOTOTRBO Full Keypad Portable with GPS and BT AAH56
44. cal Center ener nnne B 1 Appendix C Limited Level 3 Servicing C 1 C 1 Maintenance edo nin uis 1 C2 Chip Components meet tains hte et deh aac C 1 Component and Parts list eene nemen e C 2 SIOS SAY e PEE Glossary 1 List of Figures List of Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 2 1 Figure 2 2 Figure 3 1 Figure 4 1 Figure 4 2 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Figure 5 9 Figure 5 10 Figure 5 11 Figure 5 12 Figure 5 13 Figure 5 14 Figure 5 15 Figure 5 16 Figure 5 17 Figure 5 18 Figure 5 19 Figure 5 20 Figure 5 21 Figure 5 22 Figure 5 23 Figure 5 24 Figure 5 25 Figure 5 26 Figure 5 27 Figure C 1 Figure C 2 xi Display Mod l M 1 2 Non Display Model 5 2 yr pe e Re knee Fere ted en aee 1 4 Portable Radio Model Numbering Scheme sese enn 1 5 Programming Testing and Alignment Cable essem 2 3 Pin Layout of Side 2 4 Battery Check Test Mode Display ssssssssseeee enm enn nennen 3 8 CPS Programming enne nnnm nennen
45. ck the pump and hose for leaks by blocking off the open end of the hose and operating the pump a few times The actual reading of the gauge at this point is not important it is important that the gauge pointer remained steady indicating no vacuum leaks in the pump 3 Ensure that the fitting seal is attached to the hose to chassis pump connector Screw the pump connector into the tapped hole in the chassis A Please do not bend or over tighten pump connector to the chassis Caution 4 Attach the open end of the hose to the pointed end of the pump connector 5 Place the radio on a flat surface with the chassis facing upward 6 Operate the pump until the gauge indicates 6 in Hg of vacuum on the radio Observe the gauge for approximately 1 minute If the needle falls 0 5 in Hg or less one scale interval for example from 3 in Hg to 2 5 in then the radio has passed the vacuum test and is approved for immersibility No additional testing will be required If the needle falls more than 0 5 in Hg one scale interval for example from 3 in Hg to less than 2 5 in Hg then the radio has failed the vacuum test and the radio might leak if Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 31 immersed Additional troubleshooting of the radio will be required complete this procedure then go to Section 5 8 8 Pressure Test 7 Remove the vacuum hose and pump connector from the radio 5 8 8 Pressure
46. d membrane 1 Attach antenna firmly to the radio 2 Attach vacuum hose to vacuum pump 3 Ensure fitting seal is attached to hose to chassis pump connector 4 Screw pump connector into chas sis s tapped hole 5 Attach vacuum hose to pump connector 6 Place radio on flat surface 7 Operate pump gauge 6 in Hg equipment for pressure test procedure available Run Pressure Test 1 Replace Breath ing Vent label and Breathing Vent Membrane 2 Radio approved for immersibility End Troubleshooting Flow Chart for Vacuum Test Sheet 1 of 2 5 36 Disassembly Reassembly Procedures Ensuring Radio Immersibility End Start Send radio to Motorola Depot or Motorola Service Center 1 Remove pump and connectors from radio 2 Remove antenna 3 Separate front housing kit Changed back chassis kit Examined main O ring fitting Changed front housing kit Changed main O ring Examine and Replace front Replace main Replace new reassemble housing kit with O ring with chassis kit main O ring new unit new unit without PCBs Troubleshooting Flow Chart for Vacuum Test Sheet 2 of 2 Disassembly Reassembly Procedures Ensuring Radio Immersibility End 1 Remove vacuum hose from pump connector 2 Attach pressure hose to pump connector 1 Operate pressure pump pressure 1 psig 2 Immerse radio into a wa
47. e and Breathing Vent Label 1 Remove the Breathing Vent Label that covers the Breathing Vent Membrane from the chassis Remove the Breathing Vent Membrane Ensure that the chassis s surface at the Breathing Vent Label amp Breathing Vent Membrane recessed is clean no minimum scratches and free from any adhesive or other foreign materials Install a new Breathing Vent Membrane covering the vent port hole in the small recessed area in the chassis Ensure that no oily substance come in contact with the seal Install a new Breathing Vent Label over the Breathing Vent Membrane in the larger recessed area in the chassis Press down evenly over the label s surface to ensure good adhesion 5 8 9 5 Battery Maintenance 1 NOTE As part of an Annual Battery Maintenece Program or as required when the battery contacts are dirty or show signs of wear it is recommended that the Battery s Radio side and Charger side contacts are cleaned with DeoxIT GOLD cleaner lubricant DeoxIT GOLD Supplier CAIG Labs P N G100P cleaner lubricant pen has been found to be very effective at cleaning and extending the life of the battery s contacts DeoxIT GOLD cleaner lubricant is available at numerous electronics suppliers Radio Shack McMaster Carr Fry s etc and directly from manufacturer CAIG Labs at http www caig com This pen based package is recommended as it provides better access to the recessed con tacts of the battery The pe
48. eassembly Detailed on page 5 17 Inspect the main seal O ring for proper seating Observe carefully to ensure that the main seal O ring is not pinched between the housing and the chassis NOTE When installing the assembled chassis to the Front Cover ensure the O ring at the top two corners are not dislodged from the chassis groove 5 8 9 3 Battery Contact Seal To replace the Battery Contact Seal 1 Refer to Section 5 6 Radio Disassembly Detailed on page 5 6 to remove the Battery Contact Seal Remove the Battery Contact Seal from the Chassis Inspect the Battery Contact Seal Chassis and surrounding areas for foreign material that might prevent the Battery Contact Seal from sealing properly Install a new Battery Contact Seal discard the old Seal Replace a new main seal O ring discard the old O ring Reassemble the chassis assembly followed by installing into Front Cover Refer to Section 5 7 Radio Reassembly Detailed on page 5 17 Inspect the main seal O ring for proper seating Observe carefully to ensure that the main seal O ring is not pinched between the housing and the chassis IMPORTANT Both Gore Label 5478220A01 and Gasket 3286058L01 need to be replaced after vacuum test pressure test or water leakage troubleshoot ing 5 34 Disassembly Reassembly Procedures Ensuring Radio 5 8 9 4 Breathing Vent Membrane and Breathing Vent Label To replace the Breathing Vent Membran
49. ecksum is wrong Reprogram codeplug ERROR 01 22 Tuning Codeplug block Non Fatal Normal communication is still possible checksum is wrong FAIL 01 82 External Codeplug block Fatal Reprogram codeplug checksum is wrong FAIL 01 92 Secure Codeplug check Fatal Reprogram codeplug sum error FAIL 01 A2 Tuning Codeplug block Fatal Reprogram codeplug checksum is wrong FAIL 01 81 ROM Checksum is Fatal Reprogram FLASH Memory then retest If wrong message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 01 88 Radio 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 01 90 General hardware test Fatal Retest radio by turning it off and turning it on or failure again If message reoccurs replace main FAIL 02 90 board or send radio to nearest Motorola Depot FAIL 02 81 DSP ROM Checksum 15 Fatal Reprogram FLASH Memory then retest If wrong message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 02 82 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 Basic Troubleshooting Power Up Error Codes Display Model only Table 6 1 Power Up Error Codes Continued 6 3 Error Code Description Error Type Corrective Ac
50. ecommended Test Equipment Equipment Characteristics Example Application Service Can be used as a Aeroflex 3920 Frequency deviation meter and Monitor substitute for items www aeroflex com signal generator for wide range marked with an asterisk troubleshooting and alignment Digital RMS 100 uV to 300 V Fluke 179 or equivalent AC DC voltage and Multimeter 5 Hz to 1 MHz www fluke com current measurements Audio 10 Mega Ohm Impedance voltage measurements RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements Oscilloscope 2 Channel 50 MHz Bandwidth 5 mV div to 20 V div Leader 1 58050 www leaderusa com Tektronix TDS1001b www tektronix com or equivalent Waveform measurements Power Meter and Sensor 5 Accuracy 100 MHz to 500 MHz 50 Watts Bird 43 Thruline Watt Meter www bird electronic com or equivalent Transmitter power output measurements RF Millivolt Meter Power Supply 100 mV to 3 V RF 10 kHz to 1 GHz 0Vto32V OAto20A Boonton 92EA www boonton com or equivalent B amp K Precision 1790 www bkprecision com or equivalent RF level measurements 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 equival
51. enna Kit Reassembly 1 Place the Bluetooth module in the housing and fasten with a Torx 3 screwdriver amp 8 Screw Bluetooth module Figure 5 24 Bluetooth reassembly for Full Keypad Sg Screw Bluetooth module V Figure 5 25 Bluetooth reassembly for Non Keypad Disassembly Reassembly Procedures Radio Reassembly Detailed 5 27 5 7 6 GOB Installation 1 Fold the option board flex cable as shown 2 Peel the adhesive strip off from the spacer supplied and affix the spacer to the bottom side of the option board where marked 5 28 Disassembly Reassembly Procedures Radio Reassembly Detailed 3 Gently lift the connector flap of the option board and connect the option board flex cable Gently close the flap 4 Insert the option board with the motherboard into the chassis as shown below Option Board Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 29 5 8 5 8 1 5 8 2 5 8 3 5 8 4 Ensuring Radio Immersibility This section discusses radio immersibility concerns tests and disassembly and reassembly of the XPR series radios Servicing The XPR series radios shipped from the Motorola factory have passed vacuum testing and should be capable of restoring the watertight integrity of the radio qualified service personnel and service shops This is of paramount importance as irreparable damage to the radio can result from service by unauthorized Caution pers
52. ent item capable of the same performance may be substituted for the item listed Table 2 2 Service Aids Motorola e Acn Description Application Part No RLN4460_ Portable Test Set Enables connection to the audio accessory jack Allows switching for radio testing RVN5115_ Customer Programming Allows servicer to program radio parameters tune Software on CD ROM and troubleshoot radios PMKN4012B Portable Programming Cable This cable connects the radio to a USB port for radio programming and data applications PMKN4013C Portable Programming Testing amp This cable connects the radio to a USB port for radio Alignment Cable programming testing and alignment PMNN4428 _ 7 5V Universal Battery Eliminator Connects to radio via battery eliminator cable PMLN6154 _ RF Adaptor Adapts radio s antenna port to BNC cabling of test equipment PMLN6208 _ Chassis and Knob Opener Enables the removal of chassis from radio housing PMLN6155 _ RF Adaptor Holder Holds RF connector to radio NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages NTN4265 _ Pressure Pump Kit Allows servicer to locate leakages 5871134M01 Connector Fitting This connector allows the vacuum hose to be connected to the radio chassis 3271133M01 Fitting Seal This seal secures the connector fitting to the radio chassis Earlier versions of programming cables will not work with the radio Test Equipment and Service Aids Programming Testing and Alignment
53. eps release 49 0 appears amp radio beeps Press 2 50 1 appears amp radio beeps release 50 0 appears amp radio beeps Press 3 51 1 appears amp radio beeps release 51 0 appears amp radio beeps Press 4 52 1 appears amp radio beeps release 52 0 appears amp radio beeps Press 5 53 1 appears amp radio beeps release 53 0 appears amp radio beeps Press 6 54 1 appears amp radio beeps release 54 0 appears amp radio beeps Press 7 55 1 appears amp radio beeps release 55 0 appears amp radio beeps Press 8 56 1 appears amp radio beeps release 56 0 appears amp radio beeps Press 9 57 1 appears amp radio beeps release 57 0 appears amp radio beeps Press 58 1 appears amp radio beeps release 58 0 appears amp radio beeps Press 59 1 appears amp radio beeps release 59 0 appears amp radio beeps Press P1 160 1 appears amp radio beeps release 160 0 appears amp radio beeps Press P2 161 1 appears amp radio beeps release 161 0 appears amp radio beeps Press MENU 85 1 appears amp radio beeps release 85 0 appears amp radio beeps Transceiver Performance Testing Display Model Test Mode 3 9 Press BACK 129 1 appears amp radio beeps release 129 0 appears amp radio beeps
54. equency Ranges and Power 1 1 Recommended Test Equipment nennen nnne 2 1 Service AdS EM 2 2 Pin Configuration of Side Connector sssssssssesseeeene nennen nnne 2 4 Initial Equipment Control 3 1 Front Panel Access Test Mode 3 3 Test Environments 3 4 Test Frequencies ate ead 3 4 Transmitter Performance 3 5 Receiver Performance Checks 3 6 Software Installation Kits Radio Tuning Setup 4 1 Lead Free Solder Wire Part Number List 5 4 Lead Free Solder Paste Part Number 5 4 Full Keypad Model Exploded View Parts List sess 5 39 Non Display Model Exploded View Parts List 5 42 Additional Part List information 5 43 Torque Specifications for Screws 5 44 Power Up Error Codes ricette erattu can ee eque E neun 6 2 Operational Error Codes 6 4 List of Tab
55. g 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 xvi Commercial Warranty 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 M
56. he radio Repair procedures and techniques Preventive Maintenance Periodic visual inspection and cleaning is recommended 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 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 Internal surfaces should be cleaned only when the radio is disassembled for service or repair 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 The effects of certain chemicals and their vapors can have harmful results on certain plastics Avoid using aerosol sprays tuner cleaners and other Caution Chemicals 5 2 5 3 Disassembly Reassembly Procedures Safe Handling of CMOS and LDMOS Devices Cleaning External Plastic Surfaces Apply the 0 5 detergent water solution sparingly with a stiff non metallic short
57. ive Maintenance seeeeiseee eee deseen nest dante antena assa ds nane dn tad dn 5 1 5 21 IIRSDOCTlOTIc cito rete ent n reti ee ot aH Oe 5 1 5 22 Cleaning Procedures idi Hec d tee idet oe or da Do den de ee 5 1 5 3 Safe Handling of CMOS and LDMOS 5 2 5 4 Repair Procedures and Techniques 5 4 5 5 Disassembling and Reassembling the Radio 5 5 5 6 Radio Disassembly Detailed ssssssssssseeeeene nenne ennemi nennen 5 6 5 6 1 Front Cover from Chassis Disassembly 5 6 5 6 2 Chassis enne nennen nennen nnne enn 5 10 5 6 3 Keypad Display and Keypad Board 5 12 5 6 4 Speaker Microphone and Universal Connector Flex Disassembly 5 13 5 6 5 Emergency Button Assembly Dissassembly 5 15 5 7 Radio Reassembly Detailed eere enne nnns 5 17 5 7 1 Emergency Button and Speaker 5 17 Table of Contents 5
58. ively with IMPRES 18 Months Chargers Introduction Notations Used in This Manual 1 1 Chapter 1 Introduction 1 1 1 2 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 A N CAUTION indicates a potentially hazardous situation which if not avoided might result in equipment damage Caution WARNING indicates a potentially hazardous situation which if not avoided could result in death or injury WARNING 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 1 Watt or 5 Watt UHF 403 512 MHz 1 Watt or 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 1 2 1 2 1 Introduction Radio Description Full Display Model
59. les xiii Related Publications IMPRES Adaptive Single Unit Charger User Manual see 6816787H01 IMPRES Adaptive Multi Unit Charger User 6816789H01 IMPRES Adaptive Multi Unit Charger Service Manual eese 6871357L01 Remote Speaker Microphone User 6871003L01 IMPRES Remote Speaker Microphone User 6871004L01 Factory Mutual Approval emere nennen nennen nennen 6871532L01 Product Safety and RF Exposure s eoi ear r E EE e nenne enne rrr 6881095C98 XPR 7350 Portable Non Display User Guide English sene 68009500001 XPR 7350 Portable Non Display User Guide French esse 68009499001 MOTOTRBO User Guide CD iere eee do td d eerte a red E d e a HKLN4344 _ xiv Related Publications XV Commercial Warranty Limited Warranty MOTOROLA COMMUNICATION PRODUCTS 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
60. lications 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 2012 Motorola Solutions Inc All rights reserved Notes Document History The following major changes have been implemented in this manual since the previous edition Edition Description Date 68009498001 A Initial Release May 2012 vi Notes Table of Contents vii Table of Contents POPC WOM iii Product Safety and RF Exposure iii Computer Software Copyrights EEEE ndn iii Document Copyrights o e DD EEUU iii DISCLAIM s den oe der oe edu OR dt beide eee e EH ER iii Trademarks 5 2 ait eade ote Bm enu Dc iii Document 3 eicere ceca Eras eo uuu d ddddeskdu qs se Qu V Commercial Warranty 0 eene rir ea ce nnmnnn I Ene RAE ERIS XV Limited Warranty ien MU nd XV MOTOROLA COMMUNICATION PRODUCTS sse nnne nnne enn XV What This W
61. ment Cable PMKN4012B PMKN4013C or later Figure 4 1 CPS Programming Setup 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 4 4 Radio Programming and Tuning Radio Tuning Setup internal error logs MOTOTRBO radios The saved files can be analyzed by trained Motorola personnel to suggest improvements in system configurations or to help isolate problems Radio Tuning Setup A personal computer PC Windows 2000 XP Windows 7and a tuner program are required to tune 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 Battery Service Monitor Eliminator or Counter 7 5V Reg RF Adaptor ransmi VIBUDE Wattmeter Supply RF Generator _ Test Box Programming Testing amp Alignment Cable PMKN4013C or later Figure 4 2 Radio Tuning Equipment Setup Disassembly Reassembly Procedures Introduction 5 1 Chapter 5 Disassembly Reassembly Procedures 5 1 5 2 5 2 1 5 2 2 Introduction This chapter provides details about the following Preventive maintenance inspection and cleaning Safe handling of CMOS and LDMOS devices Disassembly and reassembly of t
62. ms 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 the Self Test Tone 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 non fatal 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 Non Fatal Normal communication is still possible but the aliases codeplug block user may be inconvenienced ch
63. n s tip may need to be modified trimmed on the sides to improve penetration into the battery contact slots Per the manufacturer s instructions shake the pen until the fluid begins to flow and wipe the battery s contact surface with the felt tip After cleaning inspect the contact surfaces for signs of advanced wear Advanced contact wear is defined as wear through either the contact platings gold and nickel to the base metal copper Copper exposure is characterized by a distinctive orange brown metal appearance surrounded by the silvery nickel underplate and gold top coat In some cases a magnified 10x minimum inspection may be required to verify wear through to the base material Polishing of the gold or nickel surface is common and is not considered a need for replacement In instances where advanced wear is evident the battery should be replaced After cleaning the contact areas of any foreign material let the lubricant cleaner dry for 2 min utes Replace the battery on the radio and test for intermittency by moving the battery relative to the radio as might occur in regular use Regular maintenance at least annually of this area is recommended to ensure contamination free interface and to prolong the life of the battery contacts Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 35 5 8 10 Troubleshooting Charts 1 Remove Battery 2 Remove Universal Connector Dustcover 3 Remove breathing vent label an
64. ne 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 component 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 the solder wicks to the component remove the heat and inspect the repair All joints should be smooth and shiny 2 Limited Level 3 Servicing Component and Parts list Component and Parts list Figure C 1 PCB Top View M4020 Figure C 2 PCB Bottom View Limited Level 3 Servicing Component and Parts list Table C 1 Component Parts List No Circuit Ref Motorola Part Num Description 1 SW4044 4086470701 SPST Tact Switch 2 M0800 0987378K01 SM Coaxial Connector E0800 02012010001 Female 3 S4010 40012023001 Frequency Switch 4 54030 1875103C04 Volume Rotary On Off Switch 5 M4020 0915184H01 Battery Contact Connector
65. nennen nnns 4 1 Radio Tuning Equipment Setup eene nennen nnne nne 4 2 Antenna and Battery removal sssssssssesesee eee 5 6 Channel Selector and Volume Knob removal sse 5 7 Shroud removal aicr r die cer ded e dide reddi ee dad t b die doe e dad d ee 5 8 removal rater ees b re Mate eR wince 5 8 Disconnecting the chassis scenon eese 5 9 Chassis disassembly nita cree ca Aea AAAS ARRET S EAAS A Gaia 5 10 O rinig removal ree ree ed ee ee 5 11 Keypad Display and Keypad Board disassembly for Full 5 12 Speaker removal for Full Keypad nnne 5 13 Speaker removal 5 14 Emergency Button disassembly for Full Keypad 5 15 Emergency Button disassembly for Non Keypad 5 16 Emergency Button reassembly for Full Keypad 5 17 Emergency Button reassembly for Non Keypad 5 18 Speaker reassembly for Full Keypad 5 18 Speaker reassembly for Non
66. number 5871134M01 and fitting seal part number 3271133M01 pump connector which must be ordered separately connects the vacuum hose to the radio s chassis Fitting Seal part number 3271133M01 Connector Fitting part number 5871134M01 Figure 5 26 Connector Fitting Fitting Seal Pump Connector 5 30 Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 8 5 Pressure Pump Kit NTN4265 5 8 6 5 8 7 The pressure pump kit includes a pressure pump with gauge and a pressure hose As with the vacuum pump kit above the connector fitting fitting seal pair connects the pressure hose to the radio s chassis Miscellaneous Hardware Other items needed for testing the immersibility radio include Large water container Deionized DI water A supply of replacement parts Main seal O ring Battery Contact Seal Breathing Vent Label and Breathing Vent Membrane Vacuum Test The vacuum test uses a vacuum pump and gauge The pump creates a vacuum condition inside the radio and the gauge monitors the radio for a stable vacuum reading that is checking for a properly sealed watertight unit Before starting the vacuum test Remove the battery Remove the universal connector dustcover to expose the universal connector Remove the breathing vent label and breathing vent membrane To conduct the vacuum test 1 Attach antenna firmly to the radio 2 Attach the vacuum hose to the vacuum pump Che
67. ode 1 Press and hold Side Button 1 in RF Test Mode The radio beeps once Upon any button key press the radio lights up the red LED Consequently upon any button key press the red LED is turned off and the radio turns on the green LED 4 Consequently upon any button key press the green LED is turned off the radio shall turn on both LEDs 3 5 4 Speaker Tone Test Mode 1 Press and hold Side Button 1 after LED Test Mode The radio beeps once 2 The radio generates a 1 KHz tone with the internal speaker Transceiver Performance Testing Non Display Model Test Mode 3 11 3 5 5 Earpiece Tone Test Mode 1 Press and hold Side Button 1 after Speaker Tone Test Mode The radio beeps once 2 The radio generates a 1 KHz tone with the earpiece 3 5 6 Audio Loopback Earpiece Test Mode 1 Press and hold Side Button 1 after Earpiece Tone Test Mode The radio beeps once 2 The radio shall route any audio on the external mic to the earpiece 3 5 7 Battery Check Test Mode 1 Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode The radio beeps once 2 The radio LED lights up accordingly green LED for High Battery Level orange LED for Mid Battery Level and blinking red LED for Low Battery Level 3 5 8 Button Knob PTT Test Mode 1 Press and hold Side Button 1 after Battery Check Test Mode The radio beeps once Rotate the Volume Knob the radio beeps at each position Rotate the Channel Knob the radio beeps at each po
68. of their respective owners 2012 Motorola Solutions Inc All rights reserved May 2012 www motorolasolutions com mototrbo ge 68009498001
69. ol 32012089001 35 Back Cover Kit Assembly See Table 5 5 36 Main O Ring 32012097001 37 Option Board Kit PMLN5718AS 38 GOB to Mainboard Flex 84012217003 39 Chassis Part of Back Cover kit 40 Rubber Plug 38012017001 41 Housing Shroud 15012092001 42 Battery Contact Seal 32012096001 43 Nameplate See Table 5 5 44 Warning Label 3371496L01 45 Gasket 3286058L01 46 Gore Label 5478220A01 47 RF Label 54012133001 48 Chassis Label Not Field Replaceable 49 Battery See Chapter 7 Accessories 50 Belt Clip See Table 5 5 51 Pad Thermal 7515526H01 NOTE Comprises of 4 5 7 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 and 33 Comprise of 32 34 35 36 37 39 40 41 42 44 and 47 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists 5 9 2 Non Keypad Model Exploded View and Parts List 5 41 5 42 Item Description Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Table 5 4 Non Display Model Exploded View Parts List Part Number 1 Antenna See Chapter 7 Accessories 2 Knob Frequency 36012004001 3 Knob Volume 36012005001 4 Emergency Button 38012008001 5 Nameplate Front 33012037001 6 Front Cover Kit Not Field Replaceable 7 Label Agency Indicator 54012222001 UC Escutcheon Part of Front Cover kit 9 Dust Cover Assembly 15012157001
70. onmentally Preferred Products must be done using the appropriate lead free solder wire and lead free solder paste as stated in the following table Table 5 1 Lead Free Solder Wire Part Number List Motorola Flux Content Melting Supplier Part Part Number Alloy Flux Type by Weight Diameter 1088929Y01 95 5Sn 3 8Ag 0 7Cu RMA Version 2 7 3 2 217C 52171 0 015 110 spool Table 5 2 Lead Free Solder Paste Part Number List Motorola Part Manufacturer Part Liquid EMT a 1085674C03 NC SMQ230 900 1000KCPs Type 3 95 59 Sn a 0 7 217 Brookfield 5 325 500 3 Parts Replacement and Substitution When damaged parts are replaced identical parts should be used If the identical replacement part is not locally available check the parts list for the proper Motorola part number and order the part from the nearest Motorola Radio Products and Solutions Organization RPSO listed in Appendix A of this manual Rigid Circuit Boards This 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 components The printed through holes may interconnect multiple layers of the printed circuit Therefore exercise care to avoid pulling the plated circuit out of the hole When soldering near a connector Avoid accidentally getting solder in the connector Be careful not to form solder bridges
71. ons If disassembly is necessary unauthorized attempts to repair the radio may void any existing warranties or extended performance agreements with Motorola It is also recommended that immersibility be checked annually by qualified service personnel workshop that is authorized by Motorola 1 It is strongly recommended that the maintenance of the radio be deferred to Accidental Immersion If the radio is accidentally dropped in water shake the radio to remove the excess water from the speaker grille and microphone port area before operating otherwise the sound may be distorted until the water has evaporated or is dislodged from these areas Specialized Test Equipment This section summarizes the specialized test equipment necessary for testing the integrity of the XPR series radios To ensure that the radio is truly a watertight unit special testing test procedures and specialized test equipment are required The special testing involves a vacuum check of the radio and pressure testing troubleshooting for water leaks if the vacuum check fails The specialized test equipment instrument Table 2 2 on page 2 2 is authorized by Motorola and needed to perform the vacuum check and pressure testing if required Any equipment tools instruments not mentioned in the table must not be used to perform these test Vacuum Pump Kit NLN9839 The vacuum pump kit includes a vacuum pump with gauge and a vacuum hose A connector fitting part
72. play until the user presses Right Navigation Key gt to resume the information display The radio beeps for each button press After the last display RF Test Mode will be displayed 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 gt TPL gt DIG gt USQ gt CSQ The radio beeps once when radio toggles to beeps twice for TPL beeps three times for DIG and beeps four times for USQ NOTE DIG is digital mode and other test environments are analog mode as described in Table 3 3 Transceiver Performance Testing Display Model Test Mode Table 3 3 Test Environments No of 2 A Description Function Beeps 1 Carrier Squelch RX if carrier detected CSQ TX mic audio 2 Tone Private Line RX unsquelch if carrier and tone detec
73. quipment 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 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 warning 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 Speaker load Standby Speaker AM CW FM FM Volt Range 10V PTT OFF Transceiver Performance Testing Setup Table 3 1 Initial Equipment Control Settings Service Monitor Power Supply Test Set Oscilloscope Source Mod Current 2 5A Oscilloscope Horizontal 10mSec Div Oscilloscope Vertical 2 5kHz Div Oscilloscope Trigge
74. r Auto Monitor Image Hi Monitor Bandwidth Narrow Monitor Squelch Middle setting Monitor Vol 1 4 setting 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 Within 10 seconds after Self Test is complete press Side Button 2 five times in succession 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 4 is pressed before the last information display the radio shall suspend the information dis
75. re fixed Then press and hold the first side button until the screen change Upon key P press the housing shall display a White screen with 2 pixels wide of a black border inset from the edge by 2 pixels and the text Display Test Mode in black Upon key P press the housing shall display a Black screen with 2 pixels wide of a White boarder inset from the edge by 2 pixels and the text Display Test Mode in White Upon key P press the housing shall display a full screen in Red Upon key P press the housing shall display a full screen in Green Upon key gt press the housing shall display a full screen in Blue Upon key gt press the housing shall display the growing horizontal bars with a cyclic color of Red gt Green gt Blue gt Black gt Red gt Green gt Blue gt Black gt Red Full Screen Upon key gt press the housing shall display the growing vertical bars with a cyclic color of Red gt Green gt Blue gt Black gt Red gt Black Full Screen Upon key gt 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 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 gt p
76. ress Then press and hold the first side button until the screen change 3 10 3 5 3 5 1 3 5 2 3 5 3 Transceiver Performance Testing Non Display Model Test Mode Non Display Model Test Mode Entering Non 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 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 air test 1 Each short press of Side Button 2 changes the test environment CSQ gt TPL gt DIG gt USQ 2 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 NOTE DIG is digital mode and other test environments are analog mode as described in Table 3 3 2 Each short press of Side Button 1 toggles the channel spacing between 25 KHz 12 5 KHz and 20 KHz as The radio beeps once when radio toggles to 20KHz beeps twice for 25KHz and beeps three times for 12 5KHz 3 Turning of the Channel Knob changes the test channel from 1 to 14 as described in Table 3 4 The radio beeps in each position LED Test M
77. sition Press Side Button 1 the radio beeps release the radio beeps Press Side Button 2 the radio beeps release the radio beeps Press Side Button 3 the radio beeps release the radio beeps Press the PTT Switch the radio beeps release the radio beeps Press Top Button the radio beeps release the radio beeps 3 12 Transceiver Performance Testing Non Display Model Test Mode Notes Chapter 4 Radio Programming and Tuning 4 1 4 2 4 3 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 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 MOTOTRBO CPS Tuner and AirTracer Applications CD Customer Programming Software Setup The CPS programming setup shown in Figure 4 1 is used to program the radio NOTE Refer to appropriate program on line help files for the programming procedures A N Computer USB ports can be sensitive to Electrostatic Discharge Do not touch exposed contacts on cable when connected to a computer Caution EA f m Programming Testing Battery amp Align
78. ssembly Detailed 5 22 S lt GOB screws Main board screws Figure 5 19 Chassis reassembly 1 Place the main board onto the chassis 2 Tighten the main board screws in the sequence shown in Figure 5 16 3 Place the GOB on the chassis Disassembly Reassembly Procedures Radio Reassembly Detailed 5 23 4 Tighten the GOB screws following the sequence shown in Figure 5 17 et GOB Figure 5 20 GOB reassembly 5 Connect GOB flex to the main board 5 24 Disassembly Reassembly Procedures Radio Reassembly Detailed 5 7 4 Chassis and Front Cover Reassembly 1 a gt Connect the flex to the main board and the keypad board Insert top chassis tabs into the recesses on front cover and the tabs are fully inserted Gently push down the chassis into the front cover until it snaps in place Align the shroud with the top of the front housing and slide it in place Insert knobs antenna and battery Shroud Figure 5 21 Chassis reassembly Disassembly Reassembly Procedures Radio Reassembly Detailed 5 25 5 7 5 Bluetooth Antenna Kit Disassembly Reassembly 5 7 5 1 Bluetooth Antenna Kit Disassembly 1 Use T3 Torx screwdriver to unfasten the bluetooth module e lt j Screw Figure 5 22 Bluetooth removal for Full Keypad 45 Screw Figure 5 23 Bluetooth removal for Non Keypad 5 26 Disassembly Reassembly Procedures Radio Reassembly Detailed 5 7 5 2 Bluetooth Ant
79. 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 con tinue using the Product or parts or to replace or modify the same so that it becomes nonin fringing 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 MOT
80. ted TPL TX mic audio tone 3 Digital Mode RX if carrier detected DIG TX mic audio 4 Unsquelch RX constant unsquelch USQ TX mic audio 2 Each short press of Side Button 1 toggles the channel spacing between 25 kHz 12 5 kHz 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 Turning of the Channel Knob changes the test channel from 1 to 14 as described in Table 3 4 The radio beeps in each position Table 3 4 Test Frequencies Channel Selector Test Switch Channel URIE Mr Position 1 Low Power TX3 or 9 403 15 136 075 9 High Power RX 1 9 403 15 136 075 2 Low Power TX 2 or 10 423 25 142 575 10 High Power RX 2 10 423 25 142 575 3 Low Power or 11 444 35 146 575 11 High Power RX 3 or 11 444 35 146 575 4 Low Power TX 4 12 465 45 155 575 12 High Power or 12 465 45 155 575 5 Low Power TX 5 or 13 485 55 161 575 13 High Power RX 5 or 13 485 55 161 575 6 Low Power TX 6 14 506 65 167 575 14 High Power RX 6 or 14 506 65 167 575 7 Low Power TX 7 or 15 526 75 173 975 15 High Power RX 7 or 15 526 75 173 975 8 Low Power TX 8 or 16 527 00 174 000 16 High Power RX 8 16 527 00 174 000 Transceiver Performance Testing Display Model Test Mode Table 3 5 Transmitter Performance Checks
81. ter filled container Continuou Series of bubbles YES NO 1 Dry the radio 2 Replace Breathing Vent label and Breathing Vent Membrane 3 Radio approved for immersibility YES Bubbles from YES Bubbles from Chassis NO NO Bubbles from YES Battery Con Bubbles from Lens Univer salConnector 5 37 1 Remove Knobs NO 1 Dry the radio YES 2 Replace Housing Main Seal O Ring and repeat H ed steps in Troubleshooting ousing Inter Flow Chart for Vacuum Test face PTT Only for Display Model 1 Dry the radio 2 Replace Main Seal O ring and repeat steps in Troubleshooting Flow Chart for Vacuum Test 1 Dry the radio 2 Replace Battery Contact Seal Main Seal O Ring and repeat steps in Troubleshooting Flow Chart for Vacuum Test Troubleshooting Flow Chart for Pressure Test amp Leakage Areas 5 38 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists 5 9 Radio Exploded Mechanical Views and Parts Lists 5 9 1 Full Keypad Model Exploded View and Parts List Figure 5 27 Full Keypad Model Exploded View Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Item Description Table 5 3 Full Keypad Model Exploded View Parts List Part Number 1 Antenna See Chapter 7
82. 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 gt Resource Center gt Services gt Service Product Offerings gt 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 writin
83. tion FAIL 02 84 DSP RAM2 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 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 CO DSP ROM Checksum is Fatal Retest radio by turning it off and turning it on wrong again If message reoccurs replace main board or send radio to nearest Motorola Depot No Display Display module is not Fatal Check connection between main board and connected properly display module Display module is dam Replace with new display module aged NOTE A non display radio emits only the Self Test Fail Tone if it fails the self test Basic Troubleshooting Operational Error Codes 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 Reprogr
84. ts an error code listed below then the circuit board should be replaced If repair requires knowledge of details of component level troubleshooting please send radio to a Motorola Service Center listed in Appendix B NOTE To access the various connector pins use the housing eliminator test fixture along with the diagrams found in this section of the manual See the section Service Aids on page 2 2 for the appropriate Motorola service aids and tools parts numbers Replacement Back Cover Kit Procedures Once a problem has been isolated to a specific board install the appropriate service kit See Model Charts in Chapter 1 which is orderable from Motorola Radio Products and Solutions Organization at 1 800 422 4210 If a board is replaced it does not necessarily need to be retuned if it has been factory tuned It should however be checked for performance before being placed into service Of particular concern is the Bias DAC which will need to be set for the appropriate final device bias current prior to keying up the radio If the bias is not properly set it may be possible to cause damage to the transmitter A The Tuner Tool only allows the serial number of the blank board to be entered once Be very attentive during this procedure Caution 6 2 Basic Troubleshooting Power Up Error Codes Display Model only 6 3 Power Up Error Codes Display Model only Upon powering up the radio perfor
85. ts on a small semiconductor chip usually made of silicon One chip can contain millions of microscopic components and perform many functions Intermediate Frequency kilohertz One thousand cycles per second Used especially as a radio frequency unit 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 Light Emitting Diode An electronic device that lights up when electricity is passed through it Motorola Digital Communications Glossary 2 Term MHz Paging PC Board PL Programming Cable Receiver Repeater RF RX Signal Spectrum Squelch TOT TPL Transceiver Transmitter TX UHF USB VIP XPR Definition Megahertz One million cycles per second Used especially as a radio frequency unit One way communication that alerts the receiver to retrieve a message Printed Circuit Board Also referred to as a PCB Private Line Tone Squelch A continuous sub audible tone that is transmitted along with the carrier A cable that allows the CPS to communicate directly with the radio using USB 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 Remote transmit receive facility that re transmits received sign
86. ula EATER IE 5 31 5 8 9 Troubleshooting Leak tette nente nnn 5 32 5 8 9 T oie eo NE Mm end 5 32 5 8 9 2 Chassis Main Seal O ring emen 5 32 5 8 9 3 Battery Contact 5 33 5 8 9 4 Breathing Vent Membrane and Breathing Vent 1 5 34 5 8 9 5 Battery Maintenance 5 34 5 8 10 Troubleshooting Charts lieet etie tbt toe EPI tape a 5 35 5 9 Radio Exploded Mechanical Views and Parts Lists sss 5 38 5 9 1 Full Keypad Model Exploded View and Parts 5 38 5 9 2 Non Keypad Model Exploded View and Parts 5 41 5 9 3 Torque Chant eb aiias o d iet toL 5 44 Chapter 6 Basic Troubleshooting 6 1 6 1 IMtFOGDUCHON meet 6 1 6 2 Replacement Back Cover Kit Procedures 6 1 6 3 Power Up Error Codes Display Model only enm ene 6 2 6 4 Operational Error Codes ec e DI Meets uina aditu 6 4 Chapter7 Accessories cierre ER e REDE 7 1 7 1 oa ales
87. umber 4280385A59 Do not wear nylon clothing while handling CMOS LDMOS devices Do not insert or remove CMOS LDMOS devices with power applied Check all power supplies used for testing CMOS LDMOS devices to be certain that there are no voltage transients present When straightening CMOS LDMOS pins provide ground straps for the apparatus used When soldering use a grounded soldering iron If at all possible handle CMOS LDMOS devices by the package and not by the leads Prior to touching the unit touch an electrical ground to remove any static charge that you may have accumulated The package and substrate may be electrically common If so the reaction of a discharge to the case would cause the same damage as touching the leads 5 3 5 4 5 4 Disassembly Reassembly Procedures Repair Procedures and Techniques General 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 2 vy intct 245 C Any rework or repair on Envir
88. ures occurring weeks or months later Therefore special precautions must be taken to prevent device damage during disassembly troubleshooting and repair Handling precautions are mandatory for CMOS circuits and are especially important in low humidity conditions DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION paragraph in the Disassembly and Reassembly section of the manual Disassembly Reassembly Procedures Safe Handling of CMOS and LDMOS Devices DO NOT attempt to disassemble the radio without first referring to the following CAUTION statement AN Caution 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 Store and transport all CMOS LDMOS devices in conductive material so that all exposed leads are shorted together Do not insert CMOS LDMOS devices into conventional plastic snow trays used for storage and transportation of other semiconductor devices Ground the working surface of the service bench to protect the CMOS LDMOS device We recommend using the Motorola Static Protection Assembly part number 0180386A82 which includes a wrist strap two ground cords a table mat and a floor mat ESD shoes and an ESD chair Wear a conductive wrist strap in series with a 100k resistor to ground Replacement wrist straps that connect to the bench top covering are Motorola part n
89. ve 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 app

ASTRO Digital XTL 5000 VHF/UHF Range 1/700

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