XPR 4380 4580 BSM

Professional Digital Two-Way Radio System &
SMARTNET® and Privacy Plus™ Trunked Mobile Radios
Basic Service Manual

Mobile
XPR™ 4380 Numeric Display Mobile

XPR™ 4580 Display Mobile
i
Foreword
This manual covers all XPR™ Series Mobiles, unless otherwise specified. It includes all the information necessary to
maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level
of service goes down to the board replacement level and is typical of some local service centers, Motorola Authorized
Dealers, self-maintained customers, and distributors.
These servicing instructions are for use by qualified personnel only. To

! reduce the risk of electric shock, do not perform any servicing other than
Caution that contained in the Operating Instructions unless you are qualified to do
so. Refer all servicing to qualified service personnel.
Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions for safe usage
! contained in the Product Safety and RF Exposure booklet enclosed with
Caution your radio.
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 6881095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, and other accessories, visit the following web site which
lists approved accessories: http://www.motorola.com/governmentandenterprise
Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce
in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in
the Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or
distributed in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola
products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the
copyrights, patents or patent applications of Motorola, except for the normal non-exclusive license to use that arises by
operation of law in the sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written
permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any
means, electronic or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA and the Stylized M logo are registered in the U.S. Patent & Trademark Office. All other product or service
names are the property of their respective owners.
© 2009 by Motorola, Inc.
All rights reserved.
ii
Notes
iii
Document History
The following major changes have been implemented in this manual since the previous edition.
Edition Description Date
68009272001-A Initial Release. Nov. 2009

iv
Notes
Table of Contents v
Table of Contents
Foreword ..........................................................................................................i
Product Safety and RF Exposure Compliance .............................................................................................i
Computer Software Copyrights ....................................................................................................................i
Document Copyrights ...................................................................................................................................i
Disclaimer.....................................................................................................................................................i
Trademarks ..................................................................................................................................................i
Document History ........................................................................................ iii
Commercial Warranty ..................................................................................xii

Limited Warranty ....................................................................................................................................... xii
MOTOROLA COMMUNICATION PRODUCTS ............................................................................. xii
I. What This Warranty Covers And For How Long .................................................................... xii
II. General Provisions ............................................................................................................... xiii
III. State Law Rights ................................................................................................................. xiii
IV. How To Get Warranty Service ............................................................................................ xiii
V. What This Warranty Does Not Cover................................................................................... xiii
VI. Patent And Software Provisions ......................................................................................... xiv
VII. Governing Law................................................................................................................... xiv
Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.3 Control Head Description............................................................................................................. 1-2
1.3.1 Control Head Controls (Display Model) ........................................................................... 1-2
1.3.2 Control Head Controls (Numeric Display Model)............................................................. 1-3
1.4 MOTOTRBO Mobile Radio Model Numbering Scheme............................................................... 1-4
1.5 800/900 MHz Model Chart .......................................................................................................... 1-4
1.6 Specifications .............................................................................................................................. 1-5
Chapter 2 Test Equipment and Service Aids ..................................... 2-1

2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids ................................................................................................................................. 2-2
2.3 Programming Cables ................................................................................................................... 2-2
Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
3.3 Display Model Test Mode ............................................................................................................ 3-2
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-2
vi Table of Contents
3.3.2 RF Test Mode .................................................................................................................. 3-2

3.3.3 Display Test Mode ........................................................................................................... 3-3
3.3.4 LED Test Mode................................................................................................................ 3-3
3.3.5 Backlight Test Mode ........................................................................................................ 3-3
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-3
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-3
3.3.8 Audio Loopback Test Mode ............................................................................................. 3-3
3.3.9 Audio Loopback Earpiece Test Mode.............................................................................. 3-4
3.3.10 Button/Knob/PTT Test Mode ........................................................................................... 3-4
3.4 Numeric Display Model Test Mode .............................................................................................. 3-4
3.4.1 Entering Display Radio Test Mode .................................................................................. 3-4
3.4.2 RF Test Mode .................................................................................................................. 3-4
3.4.3 Display Test Mode ........................................................................................................... 3-4
3.4.4 LED Test Mode................................................................................................................ 3-5
3.4.5 Speaker Tone Test Mode ................................................................................................ 3-5
3.4.6 Earpiece Tone Test Mode ............................................................................................... 3-5
3.4.7 Audio Loopback Test Mode ............................................................................................. 3-5
3.4.8 Audio Loopback Earpiece Test Mode.............................................................................. 3-5
3.4.9 Button/Knob/PTT Test Mode ........................................................................................... 3-5
Chapter 4 Radio Programming and Tuning ....................................... 4-1

4.1 Introduction .................................................................................................................................. 4-1
4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 AirTracer Application Tool............................................................................................................ 4-2
4.4 Radio Tuning Setup ..................................................................................................................... 4-3
Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1

5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
5.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
5.4 Repair Procedures and Techniques – General............................................................................ 5-4
5.5 Disassembling and Reassembling the Radio – General.............................................................. 5-5
5.6 Radio Disassembly – Detailed ..................................................................................................... 5-5
5.6.1 Control Head Removal .................................................................................................... 5-5
5.6.2 Top Cover Removal......................................................................................................... 5-6
5.6.3 Transceiver Board Removal ............................................................................................ 5-7
5.6.4 GPS Antenna Connector Removal (For GPS models only) .......................................... 5-10
5.6.5 Disassembly of Display Model Control Head................................................................. 5-10
5.6.6 Disassembly of Numeric Display Model Control Head .................................................. 5-12
5.6.7 Option Board Module Removal...................................................................................... 5-15
5.7 Radio Reassembly – Detailed.................................................................................................... 5-16
5.7.1 Display Model Control Head .......................................................................................... 5-16
5.7.2 Numeric Display Model Control Head............................................................................ 5-21
5.7.3 Radio Assembly............................................................................................................. 5-28
5.7.4 GPS Plug or GPS Antenna Connector Reassembly ..................................................... 5-29
5.7.5 Transceiver Board Reassembly..................................................................................... 5-30
5.7.6 Thermal Pad Replacement Procedure .......................................................................... 5-36
5.7.7 Assemble Control Head and Decorative Cover to Radio Assembly .............................. 5-37
Table of Contents vii
5.7.8 Option Board Module Reassembly................................................................................ 5-38

5.8 Exploded Mechanical Views and Parts Lists ............................................................................. 5-40
5.8.1 Radio Assembly Exploded View and Parts List............................................................. 5-40
5.8.2 Control Head Exploded Views and Parts Lists .............................................................. 5-42
5.9 Torque Chart.............................................................................................................................. 5-44
Chapter 6 Basic Troubleshooting ....................................................... 6-1

6.1 Introduction .................................................................................................................................. 6-1
6.1.1 High Power RF Precaution .............................................................................................. 6-1
6.2 Replacement Service Kit Procedures .......................................................................................... 6-1
6.3 Power-Up Error Codes ................................................................................................................ 6-2
6.4 Operational Error Codes .............................................................................................................. 6-3
Chapter 7 Accessories ......................................................................... 7-1

7.1 Introduction .................................................................................................................................. 7-1
7.1.1 Audio ............................................................................................................................... 7-1
7.1.2 Speakers ......................................................................................................................... 7-1
7.1.3 Mounting Kits................................................................................................................... 7-1
7.1.4 Remote Mount Adaptor Kit Accessories.......................................................................... 7-1
7.1.5 Cables ............................................................................................................................. 7-2
7.1.6 Antennas ........................................................................................................................ 7-2
7.1.7 Miscellaneous Accessories ............................................................................................. 7-3
7.1.8 Replacement Button Parts and Kits................................................................................. 7-3
Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information ..........................................................................................................A-1
A.2 Motorola Online ...........................................................................................................................A-1
A.3 Mail Orders ..................................................................................................................................A-1
A.4 Telephone Orders ........................................................................................................................A-1
A.5 Fax Orders ...................................................................................................................................A-1
A.6 Parts Identification .......................................................................................................................A-2
A.7 Product Customer Service ...........................................................................................................A-2
Appendix B Motorola Service Centers...................................................B-1

B.1 Servicing Information ...................................................................................................................B-1
B.2 Motorola Service Center ..............................................................................................................B-1
B.3 Motorola Federal Technical Center .............................................................................................B-1
B.4 Motorola Canadian Technical Logistics Center ...........................................................................B-1
Glossary ......................................................................................... Glossary-1

viii List of Figures
List of Figures
Figure 1-1 Radio Control Head (Display Model).................................................................................... 1-2

Figure 1-2 Radio Control Head (Numeric Display Model) ..................................................................... 1-3
Figure 1-3 Mobile Radio Model Numbering Scheme............................................................................. 1-4
Figure 2-1 Mobile Front Programming Cable HKN6184_...................................................................... 2-2
Figure 2-2 Mobile & Repeater Rear Programming Cable PMKN4010_ ................................................ 2-2
Figure 2-3 Mobile & Repeater Rear Accessory Programming and Test Cable PMKN4016_ ................ 2-3
Figure 4-1 Customer Programming Software Setup from Front Connector .......................................... 4-1
Figure 4-2 Customer Programming Software Setup from Rear Accessory Connector ......................... 4-2
Figure 4-3 Customer Programming Software Setup with Test Box Connection .................................... 4-2
Figure 4-4 Radio Tuning Equipment Setup ........................................................................................... 4-3
Figure 5-1 Typical Control Head Removal............................................................................................. 5-5
Figure 5-2 Flexible Connection Removal .............................................................................................. 5-6
Figure 5-3 Top Cover Removal.............................................................................................................. 5-6
Figure 5-4 Die Cast Cover Removal...................................................................................................... 5-7
Figure 5-5 Rear Accessory Connector Removal ................................................................................... 5-8
Figure 5-6 RF/DC Retention Clips Removal.......................................................................................... 5-8
Figure 5-7 GPS Cable Removal ............................................................................................................ 5-9
Figure 5-8 Transceiver Board Removal................................................................................................. 5-9
Figure 5-9 LCD Display Flex Removal ................................................................................................ 5-10
Figure 5-10 Left and Right Arrow Key Removal .................................................................................... 5-10
Figure 5-11 Control Head Board Removal ............................................................................................ 5-11
Figure 5-12 Keypad Removal ................................................................................................................ 5-11
Figure 5-13 Volume Knob Removal....................................................................................................... 5-12
Figure 5-14 Control Head Board Removal ............................................................................................ 5-12
Figure 5-15 Icon Light Guide Removal .................................................................................................. 5-13
Figure 5-16 Keypad Removal ................................................................................................................ 5-13
Figure 5-17 Icon Light Guide Holder Removal ...................................................................................... 5-14
Figure 5-18 Speaker and Volume Knob Removal ................................................................................. 5-14
Figure 5-19 Removing Option Flex from Option Board ......................................................................... 5-15
Figure 5-20 Removing Option Board from Radio Assembly.................................................................. 5-15
Figure 5-21 LCD Display Placement ..................................................................................................... 5-16
Figure 5-22 Keypad Assembly............................................................................................................... 5-16
Figure 5-23 Light Guide Assembly ........................................................................................................ 5-17
Figure 5-24 Assembling Mic Jack Seal ................................................................................................. 5-17
Figure 5-25 Assembling Board to Control Head Assembly ................................................................... 5-18
Figure 5-26 Screw Sequence ................................................................................................................ 5-18
Figure 5-27 Speaker Assembly ............................................................................................................. 5-19
Figure 5-28 Speaker Retainer Assembly ............................................................................................... 5-19
Figure 5-29 Left and Right Arrow Key Assembly................................................................................... 5-20
Figure 5-30 Flex Cable Assembly ......................................................................................................... 5-20
Figure 5-31 Volume Knob Assembly ..................................................................................................... 5-21
Figure 5-32 Icon Light Guide Holder Assembly ..................................................................................... 5-21
Figure 5-33 Keypad Assembly............................................................................................................... 5-22
Figure 5-34 Icon Light Guide Assembly ................................................................................................ 5-22
Figure 5-35 Light Guide and Light Guide Holder Assembly .................................................................. 5-23
Figure 5-36 Mic Jack Seal Assembly .................................................................................................... 5-23
Figure 5-37 LED Display Assembly ....................................................................................................... 5-24
Figure 5-38 Printed Circuit Board Assembly ......................................................................................... 5-24
Figure 5-39 Screw Sequence ................................................................................................................ 5-25
Figure 5-40 Speaker Assembly ............................................................................................................. 5-25
List of Figures ix
Figure 5-41 Speaker Retainer Assembly............................................................................................... 5-26

Figure 5-42 Flex Cable Assembly ......................................................................................................... 5-26
Figure 5-43 Volume Knob Assembly ..................................................................................................... 5-27
Figure 5-44 Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover .............................. 5-28
Figure 5-45 Transceiver Board with Thermal Pad ................................................................................. 5-28
Figure 5-46 GPS Plug Assembly........................................................................................................... 5-29
Figure 5-47 Bend in the GPS Antenna Connector ................................................................................ 5-29
Figure 5-48 GPS Antenna Connector Assembly ................................................................................... 5-30
Figure 5-49 Placing the Transceiver Board in the Chassis ................................................................... 5-30
Figure 5-50 Routing GPS Connector on to Transceiver Board ............................................................. 5-31
Figure 5-51 Inserting RF/DC Retention Clips ........................................................................................ 5-32
Figure 5-52 Inserting Rear Accessory Connector ................................................................................. 5-32
Figure 5-53 Assembling of PA Pad and O-ring (800/900 models)......................................................... 5-33
Figure 5-54 Assembling Die Cast Cover onto Chassis ......................................................................... 5-34
Figure 5-55 Screw Sequence to Tighten Die Cast Cover...................................................................... 5-35
Figure 5-56 Replacing Thermal Pads.................................................................................................... 5-36
Figure 5-57 Placing Thermal Pads on PA and Transistor Components ................................................ 5-36
Figure 5-58 Mic Jack Pad and Speaker Pad on Chassis ...................................................................... 5-37
Figure 5-59 Folding Option Flex ............................................................................................................ 5-38
Figure 5-60 Assembling Option Board to Radio Chassis ...................................................................... 5-38
Figure 5-61 Assembling Option Flex to Option Board ........................................................................... 5-39
Figure 5-62 Inserting Option Flex End .................................................................................................. 5-39
Figure 5-63 Radio Assembly Exploded View ........................................................................................ 5-40
Figure 5-64 Display Control Head Exploded View ................................................................................ 5-42
Figure 5-65 Numeric Display Control Head Exploded View .................................................................. 5-43
x List of Tables
List of Tables
Table 1-1 Radio Frequency Ranges and Power Levels ....................................................................... 1-1
Table 2-1 Recommended Test Equipment ........................................................................................... 2-1
Table 2-2 Service Aids ......................................................................................................................... 2-2
Table 3-1 Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2 Front Panel Access Test Mode Displays .............................................................................. 3-2
Table 3-3 Test Environments................................................................................................................ 3-5
Table 3-4 Test Channel Spacing .......................................................................................................... 3-6
Table 3-5 Test Frequencies .................................................................................................................. 3-6
Table 3-6 Transmitter Performance Checks......................................................................................... 3-7
Table 3-7 Receiver Performance Checks ............................................................................................ 3-8
Table 4-1 Radio Software Program Kit................................................................................................. 4-1
Table 5-1 Lead Free Solder Wire Part Number List ............................................................................. 5-4
Table 5-2 Lead Free Solder Paste Part Number List ........................................................................... 5-4
Table 5-3 Radio Exploded View Parts List ......................................................................................... 5-41
Table 5-4 Display Control Head (PMLN4759_) Exploded View Parts List ......................................... 5-42
Table 5-5 Numeric Display Control Head (PMLN4967_) Exploded View Parts List........................... 5-43
Table 5-6 Torque Specifications for Nuts and Screws ........................................................................ 5-44
Table 6-1 Power-Up Error Codes ......................................................................................................... 6-2
Table 6-2 Operational Error Codes ...................................................................................................... 6-3
Related Publications xi
Related Publications
MOTOTRBO Mobile User Guide CD ........................................................................................... HKLN4410_

xii Commercial Warranty
Commercial Warranty
Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS
I. What This Warranty Covers And For How Long

MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication
Products listed below (“Product”) against defects in material and workmanship under normal use and
service for a period of time from the date of purchase as scheduled below:
XPR Series Digital Mobile Radios Two (2) Years
Product Accessories One (1) Year
The mobiles 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 price pages or Motorola Online (https://www.motorola.com/businessonline) > Resource Center
> Services > Service Product Offerings > Repair Service Advantage or Extended Warranty.
Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.
This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.
MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.
Commercial Warranty xiii
II. General Provisions

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

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.
This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.
IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also call
Motorola at 1-888-567-7347 US/Canada.
V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs
(including, without limitation, the addition to the Product of non-Motorola supplied equipment)
which adversely affect performance of the Product or interfere with Motorola's normal
warranty inspection and testing of the Product to verify any warranty claim.
F. Product which has had the serial number removed or made illegible.
G. Freight costs to the repair depot.
H. A Product which, due to illegal or unauthorized alteration of the software/firmware in the
Product, does not function in accordance with MOTOROLA’s published specifications or the
FCC type acceptance labeling in effect for the Product at the time the Product was initially
distributed from MOTOROLA.
I. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
J. Normal and customary wear and tear.
xiv Commercial Warranty
VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:
A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such
claim;
B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its
settlement or compromise; and
C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the
subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to
continue using the Product or parts or to replace or modify the same so that it becomes
noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and
accept its return. The depreciation will be an equal amount per year over the lifetime of the
Product or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.
VII. Governing Law

This Warranty is governed by the laws of the State of Illinois, USA.
Chapter 1 Introduction
1.1 Notations Used in This Manual

Throughout the text in this publication, you will notice the use of note and caution notations. These
notations are used to emphasize that safety hazards exist, and due care must be taken and
observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.
! CAUTION indicates a potentially hazardous situation which, if

not avoided, might result in equipment damage.
Caution
1.2 Radio Description

The XPR series mobile radios are available in the following frequency ranges and power levels.
Table 1-1 Radio Frequency Ranges and Power Levels
Freq. Band Bandwidth Power Level
800/900 MHz 806–870 MHz, 10–35 Watts

896–941 MHz* 10–30 Watts
*For frequencies 901–902, 940–941 MHz, FCC Rule Part 24 limits power to 7W ERP.
Antennas HAF4025_ and HAF4029_ can be used with reduced power setting for these
frequencies.
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 Introduction: Control Head Description
1.3 Control Head Description

The control head used with the radio has logic circuitry that operates the standard and optional
features built into the system.
The following illustrations show the typical radio control heads.
Power Button
Channel Rocker
LED LCD Screen
Volume Knob
Indicators
Speaker
Mic Connector Menu Buttons
Programmable Buttons
Figure 1-1 Radio Control Head (Display Model)
1.3.1 Control Head Controls (Display Model)

• POWER BUTTON – Turns the radio on and off.
• VOLUME KNOB – Rotate clockwise to increase volume level; rotate counter-clockwise to
decrease volume level.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display) – 132x34 full dot matrix display provides visual information about
many radio features.
• MENU OPERATION BUTTONS – Five buttons to provide menu navigation and selection
interface.
• PROGRAMMABLE BUTTONS – Four buttons are field programmable using the CPS.
• CHANNEL CHANGING ROCKER – Press top side to increment or bottom side to decrement
the channel.
Introduction: Control Head Description 1-3
LED Numeric Display

Power Button
Channel Rocker
LED
Indicators Indicator Icons
Volume Knob
Speaker
Mic Connector
Programmable Buttons
Figure 1-2 Radio Control Head (Numeric Display Model)
1.3.2 Control Head Controls (Numeric Display Model)

• POWER BUTTON – Turns the radio on and off.
• VOLUME KNOB – Rotate clockwise to increase volume level; rotate counter-clockwise to
decrease volume level.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LED NUMERIC DISPLAY – Two digit numeric display.
• PROGRAMMABLE BUTTONS – Two buttons are field programmable using the CPS.
• CHANNEL CHANGING ROCKER – Press top side to increment or bottom side to decrement
the channel.
• INDICATOR ICONS – Indicates status of various functions including private call, talkaround and
scan.
1-4 Introduction: MOTOTRBO Mobile Radio Model Numbering Scheme
1.4 MOTOTRBO Mobile Radio Model Numbering Scheme
Model No.Example : AA M 2 7 Q P H 9 L A 1 A N
Position : 1 2 3 4 5 6 7 8 9 10 11 12
Unique Model Variations

AZ: Asia N: Standard Package
LA: Latin America
AA: North America (except Mexico)
MD: Europe/Middle East/ Version Letter
Africa/Australasia
Mobile
Feature Level
1: Mini-U
Mobile Model Series 2: BNC
3: Wall Mount
4: Desktop
Band 5: Rack Mount
J : 136–174 MHz
Q: 403–470 MHz
T : 450–527 MHz Primary System Type
X : 450–520 MHz A: Conventional
U : 806–941 MHz B: Trunking
Power Level C: Analog Only
N: 1–25W
R: 1–40W Primary Operation
M: 10–35W Physical Packages J: w/o GPS
P: 25–40W C: Numeric Display Model L: w/ GPS
Q: 25–45W H: Display Model
Channel Spacing
9: Variable/Programmable
Figure 1-3 Mobile Radio Model Numbering Scheme
1.5 800/900 MHz Model Chart

800/900 MHz 10–35W, Mini-U
Model Description
AAM27UMH9LB1_N 806–941 MHz, 10–35W, XPR 4580 Display Mobile with GPS
AAM27UMC9LB1_N 806–941 MHz, 10–35W, XPR 4380 Numeric Display Mobile with GPS
Item Description
X X PMUF1398_S *Service Kit, 800/900 MHz, 10–35W (default - Digital firmware)
X PMLN4967_ Numeric Display Model Control Head
X PMLN4759_ Display Model Control Head
X X HKLN4410_ User Guide CD
X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
NOTE: The following Options are available for the models above.
QA01639 ADD: SmartNet/SmartZone Trunking
QA01640 ADD: Digital Conventional Operations
Introduction: Specifications 1-5
1.6 Specifications
General
Specification 800/900 MHz
Model: Numeric Display Display
Channel Capacity: 32 160
Typical RF Output Frequency Range:

806–870 MHz 10–35 W
896–941 MHz* 10–30 W
Dimensions: (HxWxL) 2.01 x 6.89 x 8.11 in

(51 x 175 x 206 mm)
Weight: 4.0 lbs. (1.8 kg)
Current Drain:
Standby 0.81 A max
Rx @ rated audio 2 A max
Transmit 12 A max
FCC Description ABZ99FT5010
IC Description 109AB-99FT5010
frequencies.
1-6 Introduction: Specifications
Receiver
Frequencies: 851–870 MHz

935–941 MHz
Channel Spacing: 12.5 kHz/25 kHz

(12.5 only @ 900 MHz)
Frequency Stability: ±0.5 ppm

(-30°C to +60°C)
Analog Sensitivity (12 dB Sinad): 0.3 µV

0.22 µV (typical)
Digital Sensitivity: 5% BER: 0.3 µV
Intermodulation (TIA603C) 75 dB
Adjacent Channel Selectivity

TIA603 65 dB @12.5 kHz,
75 dB @ 25 kHz
TIA603C 50 dB @ 12.5 kHz,
75 dB @ 25 kHz
Spurious Rejection (TIA603C) 75 dB
Rated Audio: 3 W (Internal)

7.5 W (External – 8 ohms)
13 W (External – 4 ohms)
Audio Distortion @ Rated Audio: 3% (Typical)
Hum and Noise: -45 dB @ 12.5 kHz

-45 dB @ 25 kHz
Audio Response: TIA603C
Conducted Spurious Emission -57 dBm

(TIA603C):
Introduction: Specifications 1-7
Transmitter
Frequencies: 806–825, 851–870, 896–935, 935–941 MHz*
Channel Spacing: 12.5 kHz/25 kHz
Frequency Stability: ±0.5 ppm

(-30°C to +60°C)
Typical RF Output Frequency Range:

806–870 MHz 10–35 W
896–941 MHz* 10–30 W
Modulation Limiting: ±2.5 kHz @ 12.5 kHz

±5.0 kHz @ 25 kHz
FM Hum and Noise: -40 dB
Conducted/Radiated Emission: -36 dBm <1 GHz

-30 dBm >1 GHz
Adjacent Channel Power (TIA603C): 50 dB @ 12.5 kHz

60 dB @ 25 kHz
Audio Response: TIA603C
Audio Distortion: 3%
FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E
4FSK Digital Modulation 12.5 kHz Data Only: 7K60FXD

12.5 kHz Data & Voice: 7K60FXE
Digital Vocoder Type: AMBE+2™
frequencies.
1-8 Introduction: Specifications
GPS

Accuracy specs are for long-term tracking (95th percentile values > 5 satellites visible
at a nominal -130 dBm signal strength).
TTFF (Time to First Fix) Cold < 1 minute
Start:
TTFF Hot Start: < 10 seconds
Horizontal Accuracy: < 10 meters
Military Standards 810E & F
MIL-STD 810E MIL-STD 810F

Methods Procedures Methods Procedures
Low Pressure 500.3 II 500.4 II
High Temperature 501.3 I/A, II/AI 501.4 I/HOT, II/HOT
Low Temperature 502.3 I/C3, II/C1 502.4 I/C3, II/C1
Temperature Shock 503.3 I/AIC3 503.4 I
Solar Radiation 505.3 I 505.4 I
Rain 506.3 I, II 506.4 I, III
Humidity 507.3 II 507.4 –
Salt Fog 509.3 I 509.4 I
Dust 510.3 I 510.4 I
Vibration 514.4 I/10, II/3 514.5 I/24
Shock 516.4 I, IV 516.5 I, IV
Environmental Specifications
Operating Temperature -30°C to +60°C

Storage Temperature -40°C to +85°C
Temperature Shock Per MIL-STD
Humidity Per MIL-STD
ESD IEC 801-2 KV
Water and Dust Intrusion IP54, MIL-STD
Chapter 2 Test Equipment and Service Aids
2.1 Recommended Test Equipment

The list of equipment contained in Table 2-1 includes most of the standard test equipment required
for servicing Motorola mobile radios.
Table 2-1 Recommended Test Equipment
Equipment Characteristic Example Application
Service Monitor Can be used as a Motorola R2670, or equivalent Frequency/deviation meter and
substitute for items signal generator for wide-range
marked with an asterisk troubleshooting and alignment
(*)
Digital RMS 100 µV to 300 V Fluke 179 or equivalent AC/DC voltage and current
Multimeter* 5 Hz to 1 MHz (www.fluke.com) measurements. Audio voltage
10 Meg Ohm Impedance measurements.
RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements

Generator* -130 dBm to +10 dBM (www.agilent.com), Ramsey
FM Modulation 0 kHz to RSG1000B
10 kHz (www.ramseyelectronics.com),
or equivalent
Oscilloscope* 2 Channel Leader LS8050 Waveform measurements

50 MHz Bandwidth (www.leaderusa.com),
5 mV/div to 20 V/div Tektronix TDS1001b
(www.tektronix.com), or
equivalent
Power Meter and 5% Accuracy Bird 43 Thruline Watt Meter Transmitter power output
Sensor* 100 MHz to 500 MHz (www.bird-electronic.com) or measurements
50 Watts equivalent
RF Millivolt Meter 100 mV to 3 V RF Boonton 92EA RF level measurements

10 kHz to 1 GHz (www.boonton.com) or
equivalent
Power Supply 0 V to 32 V B&K Precision 1790 Voltage supply

0 A to 20 A (www.bkprecision.com) or
equivalent
2-2 Test Equipment and Service Aids: Service Aids
2.2 Service Aids

Table 2-2 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-2 Service Aids
Motorola
Description Application
Part Number
RLN4460_ Test Set Enables connection to audio/accessory jack. Allows

switching for radio testing.
RVN5115_ Customer Programming Allows servicer to program radio parameters, tune and
Software on CD-ROM troubleshoot radios.
PMKN4010_ Mobile & Repeater Rear Connects the radio’s rear connector to a USB port for
Programming Cable radio programming and data applications.
PMKN4016_ Mobile & Repeater Rear Connects the radio’s rear connector to a USB port for
Accessory Programming and radio programming, data applications, testing and
Test Cable alignment.
PMKN4018_ Mobile & Repeater Rear Connects the radio’s rear connector to accessory
Accessory Connector Universal devices such as desk sets. Cable contains all 26 wires
Cable and is unterminated at the user end.
HKN6184_ Mobile Front Programming Cable Connects the radio’s front connector to a USB port for
radio programming and data applications.
HLN8027_ Mini UHF to BNC Adaptor Adapts radio antenna port to BNC cabling of test
equipment.
HPN4007_ Power Supply Provides the radio with power when bench testing.
8180384Y11 Housing Eliminator Test Fixture used to bench test the radio PCB.
6686119B01 Removal Tool Assists in the removal of radio control head.
2.3 Programming Cables
Figure 2-1 Mobile Front Programming Cable HKN6184_
Figure 2-2 Mobile & Repeater Rear Programming Cable PMKN4010_

Test Equipment and Service Aids: Programming Cables 2-3
DB 25 CONNECTOR USB CONNECTOR
1 13
4
14 25
1455 24
CABLE
915 15 WIRE DIAGRAM
CABLE
REAR ACCESSORY
CONNECTOR USB DB25P
PIN NO. DESCRIPTION

3 VCC (5 V) 1
2 DATA - 2
TO MOBILE RADIO
REAR ACCESSORY 1 DATA + 3
CONNECTOR
4 GND
9 SPEAKER - 7
11 EXT MIC 17
25 1 DIGI IN 1
17 20
VIEWED FROM (EXT PTT)
FRONT (PIN END)
OF CONNECTOR 16 GND 16
26 2
10 SPEAKER + 1
Figure 2-3 Mobile & Repeater Rear Accessory Programming and Test Cable PMKN4016_
2-4 Test Equipment and Service Aids: Programming Cables
Notes
Chapter 3 Transceiver Performance Testing
3.1 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 equipment with few exceptions. This accuracy must be
maintained in compliance with the manufacturer’s recommended calibration schedule.
NOTE: Although these radios function in digital and analog modes, all testing is done in analog mode.
3.2 Setup
Supply voltage is provided using a 13.8 VDC power supply. (Note: applying 13.8 VDC at the DC
power cable will ensure a minimum of 13.2 VDC at the DC connector of the radio). The equipment
required for alignment procedures is connected as shown in the Radio Tuning Equipment Setup
Diagram, Figure 4-4.
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 Channel Spacing
3-5 Test Frequencies
3-6 Transmitter Performance Checks
3-7 Receiver Performance Checks
Table 3-1 Initial Equipment Control Settings
Service Monitor Power Supply Test Set
Monitor Mode: Power Monitor Voltage: 13.8 VDC Speaker set: A
RF Attenuation: -70 DC On/Standby: Speaker/load:

Standby Speaker
AM, CW, FM: FM Volt Range: 20 V PTT: OFF
Oscilloscope Source: Mod Current: 20 A

Oscilloscope Horizontal: 10 mSec/Div
Oscilloscope Vertical: 2.5 kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: middle setting
Monitor Vol: 1/4 setting
3-2 Transceiver Performance Testing: Display Model Test Mode
3.3 Display Model Test Mode

3.3.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within ten seconds after self test is complete, press button P2, five times in succession.
3. The radio beeps and will show a series of displays that will give information regarding various
version numbers and subscriber specific information. The displays are described in
Table 3-2.
Table 3-2 Front Panel Access Test Mode Displays
Name of Display Description Appears
Service Mode The literal string indicates the radio has entered test mode. Always
Host Version The version of host firmware. Always
DSP Version The version of DSP firmware. Always
Model Number The radio’s model number as programmed in the codeplug. Always
MSN The radio’s serial number as programmed in the codeplug. Always
FLASHCODE The FLASH codes as programmed in the codeplug. Always
RF Band The radio’s band. Always
NOTE: The radio stops at each display for 2 seconds before moving to the next information display.
If the information cannot fit into 1 line, the radio display scrolls automatically character by
character after 1 second to view the whole information. If the Left Navigation Button (W) is
pressed before the last information display, the radio shall suspend the information display
until the user presses Right Navigation Button ( X) 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 (“CSQ CHXX SP25”). The default test environment is CSQ.
1. Each short press of button P2 changes the test environment
(CSQ->TPL->DIG->USQ->CSQ). The radio beeps once when radio toggles to CSQ, beeps
twice for TPL, beeps three times for DIG and beeps four times for USQ.
NOTE: DIG is digital mode and other test environments are analog mode as described in Table 3-3.
2. Each short press of button P1 toggles the channel spacing between 20 kHz, 25 kHz and
12.5 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.
3. Turning of the Channel Rocker changes the test channel from 1 to 14 as described in
Table 3-5. The radio beeps in each position.
Transceiver Performance Testing: Display Model Test Mode 3-3
3.3.3 Display Test Mode

1. Press and hold button P1 in RF Test Mode. The radio beeps once and momentarily displays
‘Display Test Mode’.
2. Upon entering Display Test Mode, the radio displays a horizontal line on row 8 (center row).
3. With each button press, the radio fills up the screen with 2 horizontal lines from the center row
(1 line each above and below the center row) until the top and bottom of the screen (row 7–0
and 9–16) is complete filled.
4. When the screen is filled up with the horizontal lines, any button press clears the screen and
displays vertical lines at column 0, 6, 12, 18, 24, 30, 36, 42, 48, 54, 60. Any button press fills
the screen with vertical lines, (1 line to the right of any existing lines) until the display is filled.
5. When the screen is filled up with the vertical lines, any button press clears the screen and
displays the first 10 available icons on the screen. Successive button press displays the
remaining 4 icons.
3.3.4 LED Test Mode

1. Press and hold button P1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button press, the radio lights on the red LED and displays “Red LED On”.
3. Consequently, upon any button press, the red LED is turned off and the radio lights on the
green LED and displays “Green LED On”.
4. Consequently, upon any button press, the green LED is turned off and the radio shall light on
the yellow LED and displays “Yellow LED On”.
3.3.5 Backlight Test Mode

1. Press and hold button P1 after LED Test Mode. The radio beeps once and displays
“Backlight Test Mode”.
2. The radio lights on both LCD and keypad backlight together.
3.3.6 Speaker Tone Test Mode

1. Press and hold button P1 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.
3.3.7 Earpiece Tone Test Mode

1. Press and hold button P1 after Speaker Tone Test Mode. The radio beeps once and displays
“Earpiece Tone Test Mode”.
2. The radio generates a 1 kHz tone with the earpiece.
3.3.8 Audio Loopback Test Mode

1. Press and hold button P1 after Earpiece Tone Test Mode. The radio beeps once and
displays “Audio Loopback Test Mode”.
2. The radio shall route any audio on the mic to the earpiece.
3-4 Transceiver Performance Testing: Numeric Display Model Test Mode
3.3.9 Audio Loopback Earpiece Test Mode

1. Press and hold button P1 after Audio Loopback 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.
3.3.10 Button/Knob/PTT Test Mode

1. Press and hold button P1 after Audio Loopback Earpiece Test Mode. The radio beeps once
and displays “Button Test” (line 1).
2. The radio also displays the button/knob/PTT button command opcode (BCO) and state
(BCO/state) on the screen (line 2) upon any button state changes.
3.4 Numeric Display Model Test Mode

3.4.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within ten seconds after self test is complete, press button P2, five times in succession.
3. The radio beeps.
3.4.2 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.
1. Each short press of button P2 changes the test environment
(CSQ->TPL->DIG->USQ->CSQ). The radio beeps once when radio toggles to CSQ, beeps
twice for TPL, beeps three times for DIG and beeps four times for USQ.
NOTE: DIG is digital mode and other test environments are analog mode as described in Table 3-3.
2. Each short press of button P1 toggles the channel spacing between 20 kHz, 25 kHz and
12.5 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.
3. Turning of the Channel Rocker changes the test channel from 1 to 14 as described in
Table 3-5. The radio beeps in each position.
3.4.3 Display Test Mode

1. Press and hold button P1 in RF Test Mode. The radio beeps once and enters
‘Display Test Mode’.
2. Upon entering Display Test Mode, press any button to turn on the two character seven
segment display.
3. Press any button to display the three icons on the screen.
Transceiver Performance Testing: Numeric Display Model Test Mode 3-5
3.4.4 LED Test Mode

1. Press and hold button P1 after Display Test Mode. The radio beeps once.
2. Upon any button press, the radio lights on the red LED.
3. Consequently, upon any button press, the red LED is turned off and the radio lights on the
green LED.
4. Consequently, upon any button press, the green LED is turned off and the radio shall light on
the yellow LED.
3.4.5 Speaker Tone Test Mode

1. Press and hold button P1 after LED Test Mode. The radio beeps once.
2. The radio generates a 1 kHz tone with the internal speaker.
3.4.6 Earpiece Tone Test Mode

1. Press and hold button P1 after Speaker Tone Test Mode. The radio beeps once.
2. The radio generates a 1 kHz tone with the earpiece.
3.4.7 Audio Loopback Test Mode

1. Press and hold button P1 after Earpiece Tone Test Mode. The radio beeps once.
2. The radio shall route any audio on the mic to the earpiece.
3.4.8 Audio Loopback Earpiece Test Mode

1. Press and hold button P1 after Audio Loopback Test Mode. The radio beeps once.
2. The radio shall route any audio on the external mic to the earpiece.
3.4.9 Button/Knob/PTT Test Mode

1. Press and hold button P1 after Audio Loopback Earpiece Test Mode. The radio beeps once.
2. Rotate the volume knob, the radio beeps at each position.
3. Press any button, the radio beeps.
Table 3-3 Test Environments
No. of
Description Function
Beeps
1 Carrier Squelch RX: unsquelch if carrier detected

(CSQ) TX: mic audio
2 Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detected
(TPL) TX: mic audio + tone (192.8 Hz)
3 Digital RX: unsquelch if carrier and digital code detected
(DIG) TX: mic audio
4 Unsquelch RX: constant unsquelch
(USQ) TX: mic audio
Table 3-4 Test Channel Spacing
Number of Beeps Channel Spacing
1 Not Applicable
2 25 kHz
3 12.5 kHz
Table 3-5 Test Frequencies
Test Test
Test 800/900
Channel Channel
Mode (MHz)
Low Power High Power
TX 1 8 806.575
RX 1 8 851.025
TX 2 9 825.575
RX 2 9 855.025
TX 3 10 862.575
RX 3 10 860.525
TX 4 11 897.575
RX 4 11 869.925
TX 5 12 900.575
RX 5 12 935.025
TX 6 13 936.575
RX 6 13 938.025
TX 7 14 940.975
RX 7 14 940.975
Transceiver Performance Testing: Numeric Display Model Test Mode 3-7
Table 3-6 Transmitter Performance Checks

Communications
Test Name Radio Test Set Comment
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error:
Frequency 4th channel test frequency* Test Channel 4, continuously ±300 Hz (8/900)
Monitor: Frequency error carrier squelch transmit (during
Input at RF In/Out the performance
check)
Power RF As above TEST MODE As above Low Power:
Test Channel 4, 10–12 W: (8/900 10-35 W)
carrier squelch
TEST MODE High Power:

Test Channel 11, 35–42 W: (8/900 10–35 W)
carrier squelch
Voice Mode: PWR MON TEST MODE As above, meter Deviation:
Modulation 4th channel test frequency* Test Channel 4, selector to mic 2.5 kHz Max.
atten to -70, input to RF In/ carrier squelch (12.5 kHz Ch. Sp.).
Out 4 kHz Max.
Monitor: DVM, AC Volts (20 kHz Ch. Sp.).
Set 1kHz Mod Out level for 5 kHz Max.
800mVrms at test set, (25 kHz Ch. Sp.).
800mVrms at AC/DC test
set jack
Voice Mode: PWR MON TEST MODE, Remove Deviation:
Modulation 4th channel test frequency* Test Channel 4 modulation input 2.5 kHz Max.
(internal) atten to -70, input to RF In/ carrier squelch (12.5 kHz Ch. Sp.).
Out output at 4 kHz Max.
antenna (20 kHz Ch. Sp.).
5 kHz Max.
(25 kHz Ch. Sp.).
TPL As above TEST MODE, As above Deviation:
Modulation 4th channel test frequency* Test Channel 4 0.25–0.5 kHz
BW to narrow TPL (12.5 kHz Ch. Sp.).
0.4–0.8 kHz
(20 kHz Ch. Sp.).
0.5–1.0 kHz
(25 kHz Ch. Sp.).
* See Table 3-5
Table 3-7 Receiver Performance Checks
Communications
Test Name Radio Test Set Comment
Analyzer
Rated Audio Mode: GEN TEST MODE PTT to OFF Set volume control
Output level: 1.0 mV RF Test Channel 4, (center), meter to 7.75 Vrms
4th channel test frequency* 25 kHz channel selector to
Mod: 1 kHz tone at spacing, Audio PA
3 kHz deviation carrier squelch
Monitor: DVM: AC Volts
Distortion As above, except to As above As above Distortion <5.0%

distortion
Sensitivity As above, except SINAD, As above PTT to OFF RF input to be

(SINAD) lower the RF level for 12 dB (center) <0.3 µV
SINAD.
RF level set to 1 mV RF As above PTT to OFF Set volume control

(center), meter to
Noise Squelch selection to 7.75 Vrms
Threshold Audio PA,
(only radios spkr/ load to
with speaker
conventional
system need As above, except change out of TEST As above Unsquelch to occur
to be tested) frequency to a conventional MODE; select a at <0.25 µV.
system. Raise RF level from conventional Preferred SINAD =
zero until radio unsquelches. system 9–10 dB
* See Table 3-5

Chapter 4 Radio Programming and Tuning
4.1 Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner and AirTracer applications, which are all designed for use on a Windows Vista/XP
operating system. 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 Radio Software Program Kit
Description Kit Number
MOTOTRBO CPS, Tuner and AirTracer Applications CD RVN5115_
4.2 Customer Programming Software Setup

The Customer Programming Software setups, shown in Figure 4-1 and Figure 4-2, are used to
program the radio.
NOTE: Refer to the appropriate program on-line help files for the programming procedures.
CAUTION: Computer USB ports can be sensitive to Electronic Discharge.

Do not touch exposed contacts on cable when connected to a computer.
Front Connector
ACC
R a d io
DC 13.8VDC
Power
RF Supply
Mobile Front Programming Cable HKN6184_ USB
Figure 4-1 Customer Programming Software Setup from Front Connector

4-2 Radio Programming and Tuning: AirTracer Application Tool
Rear Accessory Mobile & Repeater Rear

Connector Programming Cable PMKN4010_
ACC
Radio
DC
RF 13.8 VDC
Power
Supply
USB
Figure 4-2 Customer Programming Software Setup from Rear Accessory Connector
Mobile & Repeater Rear Accessory Test Box RLN4460_

Rear Accessory
Connector Programming and Test Cable PMKN4016_ No
ACC
Connection
Radio
DC
RF 13.8 VDC
Power
Supply
USB
Figure 4-3 Customer Programming Software Setup with Test Box Connection
4.3 AirTracer Application Tool

The MOTOTRBO AirTracer application tool has the ability to capture over-the-air digital radio traffic
and save the captured data into a file. The AirTracer application tool can also retrieve and save
internal error logs from MOTOTRBO radios. The saved files can be analyzed by trained Motorola
personnel to suggest improvements in system configurations or to help isolate problems.
Radio Programming and Tuning: Radio Tuning Setup 4-3
4.4 Radio Tuning Setup

A personal computer (PC), Windows Vista/XP and a tuner program (which is available as part of the
MOTOTRBO CPS kit) are required to tune the radio. To perform the tuning procedures, the radio
must be connected to the PC and test equipment setup as shown in Figure 4-4.
Audio In Tx Audio Generator

Test Box
RLN44 60_
Rx SINAD Meter
AC Voltmet er
Mobile & Repeater Rear Accessory

Programming and Test Cable PMKN4016_
ACC 13. 8VDC

Power USB
R a d io
DC Supply
RF
30 dB Pad
Tx
Service Monitor
Mini UHF
to BNC
Tx
HLN8027_ WATT meter
(if needed )
RF Generator
Figure 4-4 Radio Tuning Equipment Setup

4-4 Radio Programming and Tuning: Radio Tuning Setup
Notes
Chapter 5 Disassembly/Reassembly Procedures
5.1 Introduction
This chapter provides details about the following:
• Preventive maintenance (inspection and cleaning).

• Safe handling of CMOS and LDMOS devices.
• Disassembly and reassembly of the radio.
• Repair procedures and techniques.
5.2 Preventive Maintenance

Periodic visual inspection and cleaning is recommended.
5.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.
5.2.2 Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the control
head and housing assembly. 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
chemicals.
Caution
5-2 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-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. Once the cleaning process is
complete, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, control head and housing assembly.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
5.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. 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.
Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices 5-3
DO NOT attempt to disassemble the radio without first referring to the following CAUTION
statement.
This radio contains static-sensitive devices. Do not open the radio unless you are
! properly grounded. Take the following precautions when working on this unit:
Caution • Store and transport all CMOS devices in conductive material so that
all exposed leads are shorted together. Do not insert CMOS devices
into conventional plastic “snow” trays used for storage and
transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the
CMOS device. We recommend using a wrist strap, two ground
cords, a table mat, and a floor mat.
• Wear a conductive wrist strap in series with a 100k resistor to
ground. (Replacement wrist straps that connect to the bench top
covering are Motorola part number 4280385A59).
• Do not wear nylon clothing while handling CMOS devices.
• Do not insert or remove CMOS devices with power applied. Check
all power supplies used for testing CMOS devices to be certain that
there are no voltage transients present.
• When straightening CMOS pins, provide ground straps for the
apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS devices by the package and not by
the leads. Prior to touching the unit, touch an 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.
5-4 Disassembly/Reassembly Procedures: Repair Procedures and Techniques – General
5.4 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 environmen-
tally preferred components and solder assembly techniques to comply with the Euro-
pean Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/95/EC
and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC. To
maintain product compliance and reliability, use only the Motorola specified parts in this
manual.
Any rework or repair on Environmentally Preferred Products must be done using the appropriate
lead-free solder wire and lead-free solder paste as stated in the following table:
Table 5-1 Lead Free Solder Wire Part Number List
Motorola Flux Content Melting Supplier Part

Alloy Flux Type Diameter Weight
Part Number by Weight Point number
1088929Y01 95.5Sn/3.8Ag/0.7Cu RMA Version 2.7–3.2% 217C 52171 0.015” 1lb spool
Table 5-2 Lead Free Solder Paste Part Number List
Motorola Part Manufacturer Part Liquid

Viscosity Type Composition & Percent Metal
Number Number Temperature
1085674C03 NC-SMQ230 900–1000KCPs Type 3 (95.5%Sn-3.8%Ag-0.7%Cu) 217°C

Brookfield (5rpm) (-325/+500) 89.3%
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 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 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

Since these radios may be disassembled and reassembled with the use of only seven screws (board
to casting), 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:
• Small Flat Blade Screwdriver
• Dismantling Tool (Motorola Part No. 6686119B01)
• Torque Driver (5-30 lbs-in or 0.6-3.5 N-m), (Motorola Part No. RSX4043A)
• TORX™ T20 Driver Bit
• TORX™ T10 Driver Bit
• TORX™ T6 Driver Bit (for use with Option Board only)
• 5/16” Socket Driver (GPS Models Only)
If a unit requires more complete testing or service than is customarily performed at the basic level,
please send radio to a Motorola Service Center listed in Appendix B.
The following disassembly procedures should be performed only if necessary.
5.6 Radio Disassembly – Detailed

The procedure to remove and replace the control head, top cover or transceiver board is similar for
all models. A typical procedure is therefore provided in this section followed by detailed disassembly
procedures for each specific control head model.
5.6.1 Control Head Removal

1. Insert the dismantling tool in the groove between the control head and the radio assembly as
shown in Figure 5-1.
2. Press the dismantling tool under the control head to release the snap features.
Dismantling
Tool
Figure 5-1 Typical Control Head Removal

5-6 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed
3. Pull the control head away from the radio assembly as shown in Figure 5-2.
Mic Jack Pad
Flex Cable
Control Head Seal
Speaker Pad
Socket
Figure 5-2 Flexible Connection Removal
4. Remove the flex cable from the socket on the radio assembly as shown in Figure 5-2.
5. Then remove control head seal, mic jack pad and speaker pad.
5.6.2 Top Cover Removal

1. Insert the dismantling tool between the top cover and the chassis as shown in
Figure 5-3.
2. Press on the dismantling tool until the side wall of the top cover clears the chassis trunnion
mounting features.
3. Lift the top cover from the chassis.
Trunnion Mounting
Feature
Dismantling
Tool
Figure 5-3 Top Cover Removal
NOTE: See Section 5.6.7 for Option Board Removal procedure (Option Board Module Only).
Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-7
5.6.3 Transceiver Board Removal

1. Remove the seven screws from the die cast cover using the T20 TORX™ driver as shown in
Figure 5-4.
NOTE: Do not remove the O-rings from the screws.
2. Lift the die cast cover from the chassis.
Screws (7)
Die Cast
Cover
Radio
Chassis
Figure 5-4 Die Cast Cover Removal

3. Remove the rear accessory connector from the radio assembly by inserting a flat-blade
screwdriver into the slot on the side of the connector as shown in Figure 5-5.
! The rear accessory connector should never be removed when the cover is still
assembled to the radio.
Caution
Rear Accessory Slot

Flat-blade Connector
Screwdriver
Figure 5-5 Rear Accessory Connector Removal

4. Remove the RF/DC retention clips by gently prying them out with a flat-blade screwdriver as
shown in Figure 5-6.
RF/DC Retention Clips Flat-blade

Screwdriver
Flat-blade
Screwdriver
Figure 5-6 RF/DC Retention Clips Removal

5. For GPS models, disconnect the GPS cable from the radio as shown in Figure 5-7.
GPS Cable
Figure 5-7 GPS Cable Removal
6. Remove the transceiver board by sliding a finger into the opening provided at the front of the
radio and gently pressing up on the 30-pin connector, lifting up the front of the transceiver
board, as shown in Figure 5-8. Then, slide the transceiver board towards the front of the radio
to allow the RF/DC connectors to clear the chassis. Handle the transceiver board by the
edges only and store it in an antistatic bag.
NOTE: If the RF/DC connector gaskets remain in the chassis, remove them and place them back on
the connectors.
!
The thermal pads can act as an adhesive and cause stress to critical
components on the transceiver board if the transceiver board is lifted too
Caution quickly.
Figure 5-8 Transceiver Board Removal

5.6.4 GPS Antenna Connector Removal (For GPS models only)

1. Using a 5/16” socket driver, remove the nut from the GPS antenna connector and remove the
lock nut washer from the connector.
2. Push the connector into the chassis and pull upwards on the cable to remove the connector
from the chassis.
5.6.5 Disassembly of Display Model Control Head

1. Disconnect the speaker plug from the control head board.
2. Unplug the LCD display flex from the control head board by gently lifting upwards on the door
of the connector.
LCD Display Flex
Figure 5-9 LCD Display Flex Removal
3. Remove the left and right arrow keys from the front of the control head assembly by using
your fingers.
Left Arrow Key
Right Arrow Key
Figure 5-10 Left and Right Arrow Key Removal

4. Remove the five screws from the control head board using the T10 TORX™ driver.
NOTE: Do not touch or contaminate the conductive contacts on the control head board.
Control Head Board
Figure 5-11 Control Head Board Removal
5. Remove the keypad from the control head housing by lifting up on the rubber keypad.
Keypad
Figure 5-12 Keypad Removal

NOTE: Care should be taken not to touch or contaminate the conductive pads on the keypad.
6. Remove the LCD display from the control head housing.

7. Remove the speaker retainer from the control head housing using the T10 TORX™ driver to
remove the screw and unhook the retainer from the control head housing.
8. Remove the speaker from the control head housing.
9. Remove the volume knob from the control head housing by pulling it until the snaps are
released.
Housing Assembly
Volume Knob
Figure 5-13 Volume Knob Removal
5.6.6 Disassembly of Numeric Display Model Control Head

1. Disconnect the speaker plug from the control head board.
2. Remove the five screws from the control head board using the T10 TORX™ driver.
3. Remove the control head board from the control head assembly by pressing on the keypad
buttons and mic jack. Handle the control head board by the edges only and store it in an
antistatic bag.
Control Head Board
Figure 5-14 Control Head Board Removal
NOTE: Do not touch or contaminate the conductive contacts on the control head board.
4. Remove the icon light guide from the icon light guide holder.
Icon Light Guide
Figure 5-15 Icon Light Guide Removal
5. Remove the keypad from the control head housing by lifting up on the rubber keypad.
Rubber Keypad
Figure 5-16 Keypad Removal
6. Remove the icon light guide holder from the keypad.
Keypad
Light Guide Holder
Figure 5-17 Icon Light Guide Holder Removal
7. Remove the speaker retainer from the control head housing using the T10 TORX™ driver to
remove the screw and unhook the retainer from the control head housing.
8. Remove the speaker from the control head housing.
9. Remove the volume knob from the control head housing by pulling it until the snaps are
released.
Volume Knob
Figure 5-18 Speaker and Volume Knob Removal

5.6.7 Option Board Module Removal

1. Remove option flex from the radio assembly and option board as shown in Figure 5-19.
Option Board
Option Flex (8415457H01)
Figure 5-19 Removing Option Flex from Option Board
2. Remove the four screws and the option board from the radio assembly using the T6 TORX™
driver as shown in Figure 5-20.
Option Board
Screws (0386104Z04)
Figure 5-20 Removing Option Board from Radio Assembly

5-16 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed
5.7 Radio Reassembly – Detailed

5.7.1 Display Model Control Head
1. Place the LCD display inside the control head housing, making sure to align the D-shaped
feature on the LCD display with the pin feature on the housing. Refer to Figure 5-21.
LCD Assembly D-Shaped Feature
Pin Feature
Housing Assembly
Figure 5-21 LCD Display Placement
2. Assemble the keypad to the control head housing:

a. If attached, remove the right and left arrow buttons by pulling them off the keypad.
Set these aside to be assembled later.
b. Assemble the keypad in the control head housing making sure to align the keys with the
openings in the control head housing. Refer to Figure 5-22.
Left Arrow Key Housing Assembly
Right Arrow
Key
Keypad
Assembly
Figure 5-22 Keypad Assembly
Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-17
3. Assemble the light guide and light guide holder into the keypad slot as shown in Figure 5-23.
Housing Assembly Light Guide
Light Guide Holder
Figure 5-23 Light Guide Assembly
4. Assemble PCB to the control head assembly.

a. Assemble the mic jack seal around the mic jack as shown in Figure 5-24.
NOTE: Make sure the mic jack is free from dust or debris.
Mic Jack Seal
Mic Jack
Figure 5-24 Assembling Mic Jack Seal

b. Assemble the board to the control head assembly using the mic jack as the primary point
of alignment. Make sure the LCD display flex is extended through the slot on the board.
Verify the board is seated properly, as the guide pin on the housing should extend through
the board. Refer to Figure 5-25.
Slot
Guide Pin
Figure 5-25 Assembling Board to Control Head Assembly

c. Using a T10 TORX™ driver, tighten the five screws to 0.882 N-m (7.8 lbs-in) following the
sequence as shown in Figure 5-26.
4
5
3 2 1
Figure 5-26 Screw Sequence

5. Assemble the speaker into the control head assembly.

a. Place the speaker in the control head assembly as shown in Figure 5-27.
Speaker Terminal
Speaker Terminal
Figure 5-27 Speaker Assembly
b. Hook one side of the speaker retainer into the control head assembly as shown in Figure
5-28.
Hook Retainer Here
Figure 5-28 Speaker Retainer Assembly

c. Place a screw into the other end of the speaker retainer and using a T10 TORX™ driver,
tighten the screw to 0.882 N-m (7.8 lbs-in).
d. Connect the speaker plug to its mating connector on the control head board.
6. Insert the LCD display flex to the connector on the control head board and gently close the
door.
7. Assemble the left and right arrow keys into the openings in the control head housing and
press into place as shown in Figure 5-29.
Housing Assembly
Left Arrow
Key
Right Arrow
Key
Figure 5-29 Left and Right Arrow Key Assembly
8. Assemble the flex cable to the mating connector on the control head board, making sure it is
fully seated as shown in Figure 5-30.
Flex Cable
Figure 5-30 Flex Cable Assembly

9. Orient the volume knob so that the internal D-shaped opening matches the volume encoder
shaft and press the volume knob into the control head assembly until the snap features are
engaged and the knob rotates freely. Refer to Figure 5-31.
Volume Knob
Volume Encoder Shaft
Figure 5-31 Volume Knob Assembly
5.7.2 Numeric Display Model Control Head

1. Place the icon light guide holder into the keypad. Refer to Figure 5-32.
Keypad
Icon Light Guide Holder
Figure 5-32 Icon Light Guide Holder Assembly

2. Assemble the keypad in the control head housing making sure to align the keys with the
openings in the control head housing. Refer to Figure 5-33.
Control Head Housing
Keypad
Figure 5-33 Keypad Assembly

3. Assemble the icon light guide into the icon light guide holder as shown in Figure 5-34.
Icon Light Guide

Icon Light Guide Holder
Figure 5-34 Icon Light Guide Assembly

4. Assemble the light guide and light guide holder into the keypad slot as shown in Figure 5-35.
Light Guide Holder
Light Guide
Figure 5-35 Light Guide and Light Guide Holder Assembly
5. Assemble PCB to the control head assembly.

a. Assemble the mic jack seal around the mic jack as shown in Figure 5-36.
Mic Jack Seal

Mic Jack
Figure 5-36 Mic Jack Seal Assembly
NOTE: Make sure the mic jack seal is free from dust or debris.
b. Assemble the LED display spacer and LED display to the control head PCB as shown in
Figure 5-37.
Control Head PCB
LED Display Spacer
LED Display
Figure 5-37 LED Display Assembly
c. Assemble the board to the control head assembly using the mic jack as the primary point
of alignment. Verify the board is seated properly, as the guide pin on the housing should
extend through the board. Refer to Figure 5-38.
Guide Pin
Figure 5-38 Printed Circuit Board Assembly

d. Using a T10 TORX™ driver, tighten the five screws to 0.882 N-m (7.8 lbs-in) following the
sequence as shown in Figure 5-39.
2 1
3
Figure 5-39 Screw Sequence
6. Assemble the speaker into the control head assembly.

a. Place the speaker in the control head assembly as shown in Figure 5-40.
Speaker Terminal
Speaker Terminal
Figure 5-40 Speaker Assembly

b. Hook one side of the speaker retainer into the control head assembly as shown in Figure
5-41.
Hook Retainer Here
Figure 5-41 Speaker Retainer Assembly
c. Place a screw into the other end of the speaker retainer and using a T10 TORX™ driver,
tighten the screw to 0.882 N-m (7.8 lbs-in).
d. Connect the speaker plug to its mating connector on the control head board.
7. Assemble the flex cable to the mating connector on the control head board, making sure it is
fully seated as shown in Figure 5-42.
Flex Cable
Figure 5-42 Flex Cable Assembly

8. Orientate the volume knob so that the internal D-shaped opening matches the volume
encoder shaft and press the volume knob into the control head assembly until the snap
features are engaged and the knob rotates freely. Refer to Figure 5-43.
Volume Knob
Volume Encoder Shaft
Figure 5-43 Volume Knob Assembly

5.7.3 Radio Assembly

1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks,
cuts, etc.) or debris. Refer to the exploded view and bill of materials for the correct part
numbers and replace parts, as necessary. Reseat all new seals on their respective parts.
For both the die cast cover and the chassis, thoroughly inspect the shield gasketing for
damage and verify all thermal pads are in place and free from damage and debris. See
Section 5.7.6: Thermal Pad Replacement Procedure on page 5-36 to replace damaged pads.
Chassis with Thermal Pads Die Cast Cover with Thermal Pads
and Shield Gasketing and Shield Gasketing
Figure 5-44 Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover
2. Thoroughly inspect the transceiver board and verify all thermal pads are in place and free
from damage. See Section 5.7.6: Thermal Pad Replacement Procedure on page 5-36 to
replace damaged pads.
PA Thermal Pad (75012015001)

Transistor
Thermal Pads
(75012018001)
Audio PA Component
Driver Pad
(7515577H01)
Apply Thermal Grease
(1180113S01)
Figure 5-45 Transceiver Board with Thermal Pad
5.7.4 GPS Plug or GPS Antenna Connector Reassembly

1. Assembly of the GPS Plug
Push the GPS plug into the chassis opening until it is fully seated. Refer to Figure 5-46.
GPS Plug GPS Plug
Figure 5-46 GPS Plug Assembly
2. Assembly of the GPS Antenna Connector (for GPS models only)

a. Add a gradual 90 degree bend in the cable of the GPS antenna connector. The bend should
be in the same direction as the flat section of the threaded connector and should be after the
heat shrink tubing. Refer to Figure 5-47.
Heat Shrink Tubing
Flat Section of
Threaded Connector
Figure 5-47 Bend in the GPS Antenna Connector

b. Orient the GPS antenna connector as shown in Figure 5-48 and push the connector through
the opening in the chassis.
GPS Antenna Connector
Figure 5-48 GPS Antenna Connector Assembly
c. Assemble the lock nut washer and the nut to the GPS antenna connector. Using a
5/16” socket driver, tighten the nut to 1.7 N-m (15 lbs-in).
5.7.5 Transceiver Board Reassembly

1. Insert the transceiver board into the chassis by tilting the transceiver board (approximately 30
degrees) and sliding it into place, taking care to line up the RF and DC connectors with the
openings in the back of the chassis.
Ensure that the transceiver board alignment holes are positioned over the chassis alignment
bosses and then push the board down to fully seat.
Locating Bosses
Figure 5-49 Placing the Transceiver Board in the Chassis

Do not leave the transceiver board in the chassis for extended periods of time
! without the RF/DC retention clips, or damage to the board connectors may
Caution occur.
NOTE: For GPS models, prior to the assembly of the transceiver board, position the cable of the GPS
antenna connector with the notch in the transceiver board, so that the cable will extend
through the transceiver board after the transceiver board is assembled. Then plug the GPS
antenna connector cable to the mating connector on the transceiver board. Refer to
Figure 5-50.
GPS Antenna
Connector Cable
Notch
Figure 5-50 Routing GPS Connector on to Transceiver Board

2. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to
properly locate the transceiver board. Refer to Figure 5-51.
RF/DC
Retention Clips
Figure 5-51 Inserting RF/DC Retention Clips
3. Insert the rear accessory connector into the radio assembly and press into place until the
connector is flushed with the chassis. Refer to Figure 5-52.
For GPS models only, place the GPS cap included on the accessory retainer on the GPS
antenna connector until it is fully seated.
Rear Accessory
Connector
Figure 5-52 Inserting Rear Accessory Connector

4. Fit the O-ring on to the die cast cover securely. Refer to Figure 5-53.
O-ring
PA Pad
Die Cast Cover
Figure 5-53 Assembling of PA Pad and O-ring (800/900 models)

5. Place the die cast cover onto the chassis orienting the die cast cover so that screw holes 6
and 7 align with the bosses on the chassis as shown in Figure 5-54.
Screws (7)
Die Cast Cover
Radio Chassis
Figure 5-54 Assembling Die Cast Cover onto Chassis

6. Using a T20 TORX™ driver, tighten the seven screws between 2.94 N-m (26 lbs-in) in the
order shown in Figure 5-55.
7. Repeat tightening the seven screws in the order shown otherwise the first three screws will
likely be loose.
Figure 5-55 Screw Sequence to Tighten Die Cast Cover

5.7.6 Thermal Pad Replacement Procedure

A. Chassis Thermal Pad Replacement Procedure
Harmonic Filter Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place it
white side down on the chassis as shown in Figure 5-56.
Harmonic Filter
Pad (75012017001)
Harmonic Filter
Pad (75012016001)
Radio Chassis
Figure 5-56 Replacing Thermal Pads
B. Transceiver Board Thermal Pad Replacement Procedure

Transistor Thermal Pads and PA Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift each pad from the transceiver board. Discard the old pads.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
3. Once the surface is clean and dry, remove each new pad from the shipping liner, and place in
the proper location on top of each transistor component and the audio PA (see Figure 5-57).
PA Thermal Pad (75012015001)

Transistor
Thermal Pads
(75012018001)
Audio PA Component
Driver Pad
(7515577H01)
Thermal Grease (1180113S01)
Figure 5-57 Placing Thermal Pads on PA and Transistor Components

NOTE: See Section 5.7.8 for Option Board Reassembly procedure (Option Board Module Only).
5.7.7 Assemble Control Head and Decorative Cover to Radio Assembly

1. Assemble the mic jack pad, speaker pad, and control head O-ring seal on the radio as shown
in Figure 5-58.
Mic Jack Pad
Flex Connector Control Head

O-ring Seal
Speaker Pad
Figure 5-58 Mic Jack Pad and Speaker Pad on Chassis
2. Verify that the flex cable is fully seated in connector on the control head assembly.
3. Assemble flex cable to the flex connector in the radio assembly, making sure it is fully seated.
4. Assemble the control head to the radio, applying pressure evenly across the entire control
head, so that all snap features engage at the same time.
5. Verify that the control head seal is not pinched and visible. If a pinch is found, disassemble
the control head, reseat the O-ring and reassemble the control head.
6. Refit the top cover over the assembled radio assembly. Press the cover down until it snaps
into place.
5.7.8 Option Board Module Reassembly

1. Fold the option flex along edge of the stiffener as shown in Figure 5-59.
Stiffener
Figure 5-59 Folding Option Flex
2. Mount option board on the radio chassis using four screws and tighten the screws using a
T6 TORX™ driver to 0.17 N-m (1.5 lbs-in). Refer to Figure 5-60.
Option Board
Radio Chassis
Screws (0386104Z04)
Figure 5-60 Assembling Option Board to Radio Chassis

3. Assemble option flex (8415457H01) onto option board by aligning up 40-pin mating
connectors. Refer to Figure 5-61.
40-Pin Connectors Option Board
Figure 5-61 Assembling Option Flex to Option Board
4. Firmly press the stiffener backing on the option flex until connectors are fully seated. Also
make sure option flex end gets fully inserted into 14-pin socket on the radio board. Refer to
Figure 5-62.
Option Flex
14-Pin Socket
Firmly Press Here
Stiffener
Figure 5-62 Inserting Option Flex End
NOTE: Regulatory Requirements

All MOTOTRBO radios are designed and engineered to meet all regulatory requirements for the
country or region of sale. Any option board designed for the MOTOTRBO Option Board ADK must
not compromise the regulatory compliance of the MOTOTRBO radio.
The 3rd party developer is responsible for providing all information, upon request by a regulatory
authority, in regards to any materials or substances used in the manufacture of an option board as it
pertains to its end-of-life.
Please review the terms of the MOTOTRBO License Agreement for more information on the
Licensed Developer or Application Partner responsibilities for regulatory compliance.
5-40 Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists
5.8 Exploded Mechanical Views and Parts Lists

5.8.1 Radio Assembly Exploded View and Parts List
15
14
13
12
11
16
10
9
7
17
6
18
5
4
19
3
20
21
2
Figure 5-63 Radio Assembly Exploded View

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists 5-41
Table 5-3 Radio Exploded View Parts List
Item No. Description Part Number

1 Pad, Speaker Support 0716573H01
2 Pad, Mic Jack Support 0716572H01
3 O-Ring, Control Head 3216200H01
4 Chassis, Die Cast 2775808M01
5 Pad, Driver 800/900 7515577H01
6 GPS Antenna Connector 3015953H01
7 Pads, Transistor Thermal (Qty:3) 75012018001
8 Pad, PA Thermal 75012015001
9 PCB, Transceiver See Section 1.5 to
identify proper board.
10 Pad, 800/900 Pressure 7578263A01
11 O-Ring, Main 3215586H01
12 Cover, Die Cast 1575810M01
13 & 14 Assembly, M4X0.7 Screw, O-Ring Assembly *0104023J41
15 Cover, Decorative 1516006H01
16 Clips, RF/DC Retention (Qty:2) 4285702E01
17 GPS Cap 3216338H01
18 GPS Plug 3216339H01
19 Rear Accessory Connector 0178042A01
20 Pad, Harmonic Filter 75012017001
21 Pad, Harmonic Filter 75012016001
NOTE: *Part consists of 3216871H01, O-Ring, Screw (Qty:7) and 0371274L02, Screws (Qty:7)
5-42 Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists
5.8.2 Control Head Exploded Views and Parts Lists
8
7 9
6
5
4 10
3
2
1
11
12
13
Figure 5-64 Display Control Head Exploded View
Table 5-4 Display Control Head (PMLN4759_) Exploded View Parts List
Item no Description Part No

1 Volume Knob Assembly 3616060H01
2 Housing Assembly 0115670H01
3 LCD Display Module 7215559H01
4 Keypad Assembly 7515521H01
5 Indicator Light Guide Holder 0715537H01
6 Indicator Light Guide 6115536H01
7 Mic Jack Seal 3264133H01
8 PCB Assembly 0104020J68
9 Control Head Flex Cable 3015638H01
10 Screws 0371370L01
11 Speaker Retainer 4215135H01
12 Speaker 5015134H02
13 Radio Model Nameplate for XPR 4580 3316323H18
Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists 5-43
9
8 10
7
6 11
5
3
2
12
1
13
14
15
16
Figure 5-65 Numeric Display Control Head Exploded View
Table 5-5 Numeric Display Control Head (PMLN4967_) Exploded View Parts List
Item no Description Part No

1 Volume Knob Assembly 3616060H01
2 Housing Assembly 0171214L01
3 Icon Light Guide Holder 0771089L01
4 Keypad Assembly 7571162L01
5 Indicator Light Guide Holder 0715537H01
6 Indicator Light Guide 6115536H01
7 Mic Jack Seal 3264133H01
8 LED Display 7216958H01
9 PCB Assembly 0104022J64
10 Control Head Flex Cable 3015638H01
11 Screws 0371370L01
12 LED Display Spacer 4371389L01
13 Speaker Retainer 4215135H01
14 Icon Light Guide 6171088L01
15 Speaker 5015134H02
16 Radio Model Nameplate for XPR 4380 3316323H19
5-44 Disassembly/Reassembly Procedures: Torque Chart
5.9 Torque Chart

Table 5-6 lists the various nuts and 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.
Table 5-6 Torque Specifications for Nuts and Screws
Part Torque
Description Driver/Socket
Number N-m lbs-in kg-cm
3015953H01 GPS Antenna Connector 5/16” socket driver 1.7 15 17
0371370L01 Screw, M3x1.34, Pan Head T10 Torx™ 0.88 7.8 9.0
0371274L02 Screw, M4x0.7, Pan Head T20 Torx™ 3.16 28 32.2
0386104Z04 Screw, M2x0.4, Pan Head T6 Torx™ 0.17 1.5 1.73
Chapter 6 Basic Troubleshooting
6.1 Introduction
This chapter contains error codes and board replacement procedures. This section can help you
isolate a problem to the board level. If the radio does not pass all the performance checks in
Chapter 3 or exhibits an error code listed below, then the circuit board should be replaced. Please
send the 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 Section, "Service Aids" on page 2-2, for
the appropriate Motorola service aids and tools part numbers.)
6.1.1 High Power RF Precaution
The radio might transmit while the technician believes the radio is in receive
! mode under the following conditions: radio failure, digital affiliation, a

defective PTT button, or other unintentional activations.
Caution
To avoid possible equipment damage, when performing both transmit and
receive tests, a suitable attenuator rated at 100 W or more should always
be used with test equipment connected to the RF connector. The only
exception to this is when the equipment’s input power rating is higher than
the maximum output power of the radio.
6.2 Replacement Service Kit Procedures

Once a problem has been isolated to a specific board, install the appropriate service kit (see Model
Chart in section 1.5 on page 1-4), which is orderable from Motorola Radio Products and Solutions
Organization at 1-800-422-4210.
Refer to http://www.motorola.com/businessonline for further information.
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.
! The Tuner Tool only allows the serial number of a blank board to be entered
once. Be very attentive during this procedure.
Caution
6-2 Basic Troubleshooting: Power-Up Error Codes
6.3 Power-Up Error Codes

When the radio is turned on (power-up), the radio performs cursory tests to determine if its basic
electronics and software are in working order. Problems detected during these tests are presented
as error codes on the radio’s display. The presence of an error should prompt the user that a
problem exists and that a service technician should be contacted.
Self-test errors are classified as either fatal or non-fatal. Fatal errors inhibit user operation; non-fatal
errors do not. Use the following tables to aid in understanding particular power-up error code
displays.
Table 6-1 Power-Up Error Codes
Error Code Description Error Type Corrective Action

ERROR 01/02 FLASH ROM Codeplug NON-FATAL Reprogram the codeplug.
Checksum
ERROR 01/7E Peripheral device non-fatal NON-FATAL Re-connect the peripheral device.
error
ERROR 01/7F Peripheral device fatal error FATAL Replace the peripheral device.
ERROR 01/22 Tuning Codeplug NON-FATAL Reprogram the tuning partition.
Checksum
FAIL 01/81 FLASH ROM Checksum FATAL Reprogram the radio firmware.
FAIL 01/82 FLASH ROM Codeplug FATAL Reprogram the codeplug.
Checksum
FAIL 01/88 External SRAM Failure FATAL Turn the radio off, then on.
FAIL 01/90 General Hardware FATAL Turn the radio off, then on.
FAIL 01/92 Security Partition FATAL Reprogram the security partition.
Checksum
FAIL 01/93 FlashPORT AUTHENT FATAL Contact the depot.
CODE Failure
FAIL 01/A2 Tuning Codeplug FATAL Reprogram the tuning partition.
Checksum
FAIL 02/81 DSP ROM Checksum FATAL Reprogram the DSP firmware.
FAIL 02/88 DSP RAM Fatal Error FATAL Turn the radio off, then on.
FAIL 02/90 General DSP Hardware FATAL Turn the radio off, then on.
Failure
FAIL 01/A0 Back End Receiver IC FATAL Turn the radio off, then on. Send
Failure radio to the nearest Motorola
Depot.
FAIL 02/C0 DSP Internal RAM Fatal FATAL Turn the radio off, then on. Send
Error radio to the nearest Motorola
Depot.
Basic Troubleshooting: Operational Error Codes 6-3
6.4 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 service technician
should be contacted. Use Table 6-2 to aid in understanding particular operational error codes.
Table 6-2 Operational Error Codes
Error Code Description Error Type Corrective Action

FAIL 001 Synthesizer Out-of-Lock NON-FATAL 1. Reprogram the codeplug.
2. Send radio to the nearest
Motorola Depot.
FAIL 002 Personality checksum or NON-FATAL Reprogram the codeplug.

system block error
6-4 Basic Troubleshooting: Operational Error Codes
Notes
Chapter 7 Accessories
7.1 Introduction
Motorola provides the following approved accessories to improve the productivity of your digital
mobile two-way radio.
For a list of Motorola-approved antennas, and other accessories, visit the following web site:
http://www.motorola.com/governmentandenterprise
7.1.1 Audio
Part No. Description
HMN4098_ Telephone Style Handset
RMN5052_ Compact Microphone
RMN5053_ Heavy Duty Microphone with Enhanced Audio
RMN5054_ Visor Microphone with Enhanced Audio
RMN5065_ Keypad Microphone with Enhanced Audio
7.1.2 Speakers
RSN4002_ 13 Watt External Speaker
RSN4003_ 7.5 Watt External Speaker
RSN4004_ 5 Watt External Speaker
7.1.3 Mounting Kits

RLN5933_ In Dash (DIN) Mounting Kit
RLN6077_ Low Profile Trunnion Kit
RLN6078_ High Profile Trunnion KIt
RLN6079_ Key Lock Trunnion Kit
7.1.4 Remote Mount Adaptor Kit Accessories

PMLN5404_ MOTOTRBO Mobile Remote Mount Adaptor Kit
Note: Required firmware version R01.0400 or later. Cables not
included, select from the choices below.
PMKN4074_ MOTOTRBO Mobile Remote Mount 3 Meter Cable Kit
PMKN4073_ MOTOTRBO Mobile Remote Mount 5 Meter Cable Kit
7-2 Accessories: Introduction
7.1.5 Cables

HKN4137_ Power Cable to Battery, 3m (10 ft.), 15 amp (1–25W)
HKN6184_ Mobile Front Programming Cable
PMKN4010_ Mobile & Repeater Rear Programming Cable
PMKN4016_ Mobile & Repeater Rear Accessory Programming and Test
Cable
PMKN4018_ Mobile & Repeater Rear Accessory Connector Universal Cable
RKN4136_ Ignition Sense Cable
7.1.6 Antennas
HAF4025_ UHF, 806–941 MHz, 1/4 Wave, Through-hole Mount, Mini-U
HAF4026_ UHF, 806–941 MHz, 3 dB gain, Through-hole Mount, Mini-U
HAF4013_ UHF, 806–941 MHz, stubby, Through-hole Mount, Mini-U
HAF4027_ UHF, 806–941 MHz, 5 dB gain, Through-hole Mount, Mini-U
For XPR 4380/XPR 4580 GPS Models only:
HAF4029_ Combination GPS/UHF, 806–941 MHz, 1/4 Wave,
Through-hole Mount, Mini-U
HAF4030_ Combination GPS/UHF, 806–941 MHz, 3dB gain,
HAF4032_ Combination GPS/UHF, 806–941 MHz, stubby,
HAF4033_ Combination GPS/UHF, 806–941 MHz, 5dB gain,
PMAN4000_ Fixed Mount GPS Active Antenna
PMAN4001_ Window Mount GPS Active Antenna
PMAN4002_ Magnetic Mount GPS Active Antenna
Replacement Antennas for XPR 4380/XPR 4580 GPS Models only:
HAF4019_ Kit, Antenna UHF, 806–941 MHz, 1/4 Wave,
HAF4020_ Kit, Antenna UHF, 806–941 MHz, 3dB gain,
HAF4022_ Kit, Antenna UHF, 806–941 MHz, stubby,
HAF4023_ Kit, Antenna UHF, 806–941 MHz, 5dB gain,
PMAN4004_ Kit, Combo GPS+RF, Base Only, Through-hole Mount, Mini-U
Accessories: Introduction 7-3
7.1.7 Miscellaneous Accessories

HKN9557_ PL259/Mini-U Antenna Adaptor, 8-foot Cable
HLN7001_ Option Board Interface Kit
HLN9073_ Microphone Hang-up Clip (All Microphones)
HLN9414_ Universal Microphone Hang-up Clip (All Microphones)
PMLN5072_ Hardware Kit for Rear Accessory Connector
PMLN5496_S Generic Option Board Upgrade Kit
RLN5926_ Push Button PTT
RLN5929_ Emergency Footswitch
7.1.8 Replacement Button Parts and Kits

Part No. Description Button
7515562H02 Button - P1
7515562H03 Button - P2
7515562H04 Button - P3
7515562H05 Button - P4
7515562H06 Button - Emergency
7515562H07 Button - Talkaround
7515562H08 Button - Low/High
7515562H09 Button - Scan
7515562H10 Button - Monitor
7515562H11 Button - Group Call
7515562H12 Button - Text Message
7515562H13 Button - VOX
7515562H14 Button - Backlight
7515562H15 Button - Remote Monitor
7515562H16 Button - Radio Kill
7515562H17 Button - Radio Check
7515562H18 Button - Phone
7515562H19 Button - Aux1

7-4 Accessories: Introduction
Part No. Description Button

7515562H20 Button - Aux2
7515562H21 Button -H&L (Horn and Lights)
7515562H22 Button - Option Board
7515562H23 Button - Zone
7515562H24 Button - Scrambling
7515562H25 Button - Orange
7515562H26 Button - Contacts
7515562H27 Button - Radio Check 2
HKLN4291_ Display Mobile Button Kit (Includes buttons for Monitor, Scan,
Backlight, Emergency, Talkaround, Text Message and
Contacts)
HKLN4292_ Mobile Button Kit (Includes buttons for Remote Monitor, Radio
Check, Radio Disable and VOX)
HKLN4293_ Numeric Display Mobile Button Kit (Includes buttons for
Monitor and Scan)
PMLN5070_ Display Mobile Navigation Button Replacement Kit (Includes
Left and Right navigation, OK, Menu and Back buttons)
PMLN5071_ Mobile Option Button Standard Replacement Kit (Includes P1,
P2, P3 and P4 buttons)
Appendix A Replacement Parts Ordering
A.1 Basic Ordering Information

When ordering replacement parts or equipment information, the complete identification number
should be included. This applies to all components, kits, and chassis. If the component part number
is not known, the order should include the number of the chassis or kit of which it is a part, and
sufficient description of the desired component to identify it.
A.2 Motorola Online

Motorola Online users can access our online catalog at
http://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 http://www.motorola.com/businessonline
A.3 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.
A.4 Telephone Orders

Radio Products and Solutions Organization*
(United States and Canada)
7:00 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)
1-877-873-4668
8:30 AM to 5:00 PM (Eastern Standard Time)
A.5 Fax Orders

1-800-622-6210
1-847-576-3023 (United States and Canada)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchase Orders)
A-2 Replacement Parts Ordering Parts Identification
A.6 Parts Identification

1-800-422-4210
A.7 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 B Motorola Service Centers
B.1 Servicing Information

If a unit requires further complete 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.
B.2 Motorola Service Center

45D Butterfield Trail
El Paso, TX 79906
Tel: 1-800-227-6772
B.3 Motorola Federal Technical Center

4395 Nicole Drive
Lanham, MD 20706
Tel: 1-800-969-6680
Fax: 1-800-784-4133
B.4 Motorola Canadian Technical Logistics Center

Motorola Canada Ltd.
8133 Warden Avenue
Markham, Ontario, L6G 1B3
Tel: 1-800-543-3222
Fax: 1-888-331-9872 or 1-905-948-5970
B-2
Notes
Glossary Glossary
This glossary contains an alphabetical listing of terms and their definitions that are applicable to
portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and
some terms are merely generic in nature.
Term Definition
Analog Refers to a continuously variable signal or a circuit or device designed to

handle such signals.
Band Frequencies allowed for a specific purpose.
CPS Customer Programming Software: Software with a graphical user interface

containing the feature set of a radio.
Default A pre-defined set of parameters.
Digital Refers to data that is stored or transmitted as a sequence of discrete symbols

from a finite set; most commonly this means binary data represented using
electronic or electromagnetic signals.
DPL Digital Private-Line: A type of digital communications that utilizes privacy call,
as well as memory channel and busy channel lock out to enhance
communication efficiency.
FCC Federal Communications Commission.
Frequency Number of times a complete electromagnetic-wave cycle occurs in a fixed unit

of time (usually one second).
GPIO General-Purpose Input/Output.
GPS Global Positioning System.
IC Integrated Circuit: An assembly of interconnected components on a small

semiconductor chip, usually made of silicon. One chip can contain millions of
microscopic components and perform many functions.
IF Intermediate Frequency.
kHz kilohertz: One thousand cycles per second. Used especially as a radio
frequency unit.
LCD Liquid-Crystal Display: An LCD uses two sheets of polarizing material with a
liquid-crystal solution between them. An electric current passed through the
liquid causes the crystals to align so that light cannot pass through them.
LED Light Emitting Diode: An electronic device that lights up when electricity is
passed through it.
MDC Motorola Digital Communications.
MHz Megahertz: One million cycles per second. Used especially as a radio
frequency unit.
Paging One-way communication that alerts the receiver to retrieve a message.

Glossary-2
Term Definition
PC Board Printed Circuit Board. Also referred to as a PCB.
PL Private-Line Tone Squelch: A continuous sub-audible tone that is transmitted

along with the carrier.
Programming Cable A cable that allows the CPS to communicate directly with the radio using USB.
Receiver Electronic device that amplifies RF signals. A receiver separates the audio
signal from the RF carrier, amplifies it, and converts it back to the original
sound waves.
Repeater Remote transmit/receive facility that re-transmits received signals in order to

improve communications range and coverage (conventional operation).
RF Radio Frequency: The portion of the electromagnetic spectrum between audio

sound and infrared light (approximately 10 kHz to 10 GHz).
RX Receive.
Signal An electrically transmitted electromagnetic wave.
Spectrum Frequency range within which radiation has specific characteristics.
Squelch Muting of audio circuits when received signal levels fall below a pre-determined
value. With carrier squelch, all channel activity that exceeds the radio’s preset
squelch level can be heard.
TOT Time-out Timer: A timer that limits the length of a transmission.
TPL Tone Private Line.
Transceiver Transmitter-receiver. A device that both transmits and receives analog or

digital signals. Also abbreviated as XCVR.
Transmitter Electronic equipment that generates and amplifies an RF carrier signal,

modulates the signal, and then radiates it into space.
TX Transmit.
UHF Ultra-High Frequency.
USB Universal Serial Bus: An external bus standard that supports data transfer
rates of 12 Mbps.
VHF Very High Frequency.
VIP Vehicle Interface Port.
XPR Refers to Digital Professional Radio model names in the MOTOTRBO

Professional Digital Two-Way Radio System.
Motorola Inc.
1301 E. Algonquin Rd.
Schaumburg, IL 60196-1078, U.S.A.
MOTOROLA and the Stylized M Logo are

registered in the U.S. Patent and Trademark Office.
All other product or service names are the property
of their respective owners.
© 2009 by Motorola, Inc.
All rights reserved.
November 2009.
www.motorola.com/mototrbo
*68009272001*
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Professional Digital Two-Way Radio System &

SMARTNET® and Privacy Plus™ Trunked Mobile Radios

Basic Service Manual

XPR™ 4380 Numeric Display Mobile

These servicing instructions are for use by qualified personnel only. To

Product Safety and RF Exposure Compliance

Computer Software Copyrights

Edition Description Date

68009272001-A Initial Release. Nov. 2009

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

Commercial Warranty ..................................................................................xii

Chapter 1 Introduction ......................................................................... 1-1

Chapter 2 Test Equipment and Service Aids ..................................... 2-1

Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.3.2 RF Test Mode .................................................................................................................. 3-2

Chapter 4 Radio Programming and Tuning ....................................... 4-1

Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1

5.7.8 Option Board Module Reassembly................................................................................ 5-38

Chapter 6 Basic Troubleshooting ....................................................... 6-1

Chapter 7 Accessories ......................................................................... 7-1

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

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

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

Figure 1-1 Radio Control Head (Display Model).................................................................................... 1-2

Figure 5-41 Speaker Retainer Assembly............................................................................................... 5-26

MOTOTRBO Mobile User Guide CD ........................................................................................... HKLN4410_

I. What This Warranty Covers And For How Long

XPR Series Digital Mobile Radios Two (2) Years

Product Accessories One (1) Year

II. General Provisions

III. State Law Rights

IV. How To Get Warranty Service

V. What This Warranty Does Not Cover

VI. Patent And Software Provisions

VII. Governing Law

1.1 Notations Used in This Manual

! CAUTION indicates a potentially hazardous situation which, if

1.2 Radio Description

Table 1-1 Radio Frequency Ranges and Power Levels

Freq. Band Bandwidth Power Level

800/900 MHz 806–870 MHz, 10–35 Watts

1.3 Control Head Description

Figure 1-1 Radio Control Head (Display Model)

1.3.1 Control Head Controls (Display Model)

LED Numeric Display

Figure 1-2 Radio Control Head (Numeric Display Model)

1.3.2 Control Head Controls (Numeric Display Model)

1.4 MOTOTRBO Mobile Radio Model Numbering Scheme

Unique Model Variations

Figure 1-3 Mobile Radio Model Numbering Scheme

1.5 800/900 MHz Model Chart

Specification 800/900 MHz

Model: Numeric Display Display

Channel Capacity: 32 160

Typical RF Output Frequency Range:

Dimensions: (HxWxL) 2.01 x 6.89 x 8.11 in

Weight: 4.0 lbs. (1.8 kg)

FCC Description ABZ99FT5010

Specification 800/900 MHz

Model: Numeric Display Display