DP1400 Basic Service Manual

MOTOTRBOTM TWO-WAY RADIOS
DP1400 TM
BASIC SERVICE
MANUAL
i
Foreword
This manual covers all models of the DP series Portable Radios, unless otherwise specified. It includes all the information
necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance
procedures. This level of service goes down to the board replacement level and is typical of some local service centers,
self-maintained customers, and distributors.
RF Energy Exposure and Product Safety Guide for Portable Two-Way Radios
ATTENTION!
Before using the portable two way product, DP1400 , read the RF Energy Exposure and Safety guide
that ships with the radio which contains important operating instructions for safe usage and RF energy
awareness and control for Compliance with applicable Standards and Regulations.
Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective
owners.
© 2014 Motorola Solutions, 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
68012008074-A Initial Release June 2013
68012008074-B Added GOB information Jan. 2015

iv
Notes
Table of Contents v
Table of Contents
Foreword ..........................................................................................................i
......................................................................................................................................................................i
RF Energy Exposure and Product Safety Guide for Portable Two-Way Radios ..........................................i
Computer Software Copyrights ....................................................................................................................i
Document Copyrights ...................................................................................................................................i
Disclaimer.....................................................................................................................................................i
Trademarks ..................................................................................................................................................i
Document History ........................................................................................ iii
Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.2.1 Non Keypad Model .......................................................................................................... 1-2
1.3 .Portable Radio Model Numbering Scheme ................................................................................ 1-3
1.4 Model Charts ............................................................................................................................... 1-4
1.4.1 VHF Model Chart............................................................................................................. 1-4
1.4.2 UHF Model Chart............................................................................................................. 1-5
1.5 Specifications............................................................................................................................... 1-6
Chapter 2 Test Equipment and Service Aids ..................................... 2-1

2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids ................................................................................................................................. 2-2
2.3 Portable Programming Cable ...................................................................................................... 2-3
2.4 Portable Test Cable ..................................................................................................................... 2-5
Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
3.2.1 RF Test Mode.................................................................................................................. 3-2
3.3 Test Mode .................................................................................................................................... 3-7
3.3.1 Entering Test Mode ......................................................................................................... 3-7
3.3.2 RF Test Mode.................................................................................................................. 3-7
3.3.3 LED Test Mode................................................................................................................ 3-7
3.3.4 Speaker Tone Test Mode ................................................................................................ 3-7
3.3.5 Earpiece Tone Test Mode ............................................................................................... 3-8
3.3.6 Audio Loopback Earpiece Test Mode.............................................................................. 3-8
3.3.7 Battery Check Test Mode ................................................................................................ 3-8
3.3.8 Button/Knob/PTT Test Mode ........................................................................................... 3-8
Chapter 4 Radio Programming and Tuning ....................................... 4-1

vi Table of Contents
4.1 Introduction .................................................................................................................................. 4-1

4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 AirTracer Application Tool............................................................................................................ 4-2
4.4 Radio Tuning Setup ..................................................................................................................... 4-2
Chapter 5 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 ..................................................................................................... 5-6
5.6.1 Front Cover from Chassis Disassembly .......................................................................... 5-6
5.6.2 Generic Option Board (GOB) Disassembly ................................................................... 5-12
5.6.3 Chassis Disassembly..................................................................................................... 5-16
5.6.4 Speaker and Microphone Disassembly ......................................................................... 5-17
5.6.5 Audio Jack Dust Cover Disassembly............................................................................. 5-18
5.6.6 Micro USB Dust Cover Disassembly ............................................................................. 5-20
5.7 Radio Reassembly - Detailed .................................................................................................... 5-22
5.7.1 Micro USB Dust Cover Reassembly.............................................................................. 5-22
5.7.2 Audio Jack Dust Cover Reassembly ............................................................................. 5-23
5.7.3 Speaker and Microphone Reassembly.......................................................................... 5-24
5.7.4 Chassis Reassembly ..................................................................................................... 5-25
5.7.5 Generic Option Board (GOB) Reassembly.................................................................... 5-29
5.7.6 Chassis and Front Housing Reassembly....................................................................... 5-33
5.8 Radio Exploded Mechanical View and Parts Lists ..................................................................... 5-36
5.8.1 Non Option Board .......................................................................................................... 5-36
5.8.2 Option Board Capable ................................................................................................... 5-39
5.8.3 Torque Chart.................................................................................................................. 5-42
Chapter 6 Basic Troubleshooting ....................................................... 6-1

6.1 Introduction .................................................................................................................................. 6-1
6.2 Replacement Back Cover Kit Procedures.................................................................................... 6-1
Appendix A EMEA Regional Warranty, Service and Technical Support ..

A-1
A.1 Warranty and Service Support .....................................................................................................A-1
A.1.1 Warranty Period and Return Instructions.........................................................................A-1
A.1.2 After Warranty Period ......................................................................................................A-1
A.2 European Radio Support Centre (ERSC) ....................................................................................A-2
A.3 Piece Parts...................................................................................................................................A-2
A.4 Technical Support ........................................................................................................................A-3
A.5 Further Assistance From Motorola...............................................................................................A-3
Appendix B Limited Level 3 Servicing ...................................................B-1

Table of Contents vii
B.1 Maintenance ................................................................................................................................B-1

B.2 Chip Components ........................................................................................................................B-1
B.3 Component and Parts list ............................................................................................................B-2
Glossary ......................................................................................... Glossary-1

viii List of Figures
List of Figures
Figure 1-1. Non Keypad Model............................................................................................................... 1-2

Figure 1-2. Portable Radio Model Numbering Scheme .......................................................................... 1-3
Figure 2-1. Portable Programming Cable with TTR (PMKN4128_)........................................................ 2-3
Figure 2-2. Portable Test Cable (PMKN4156_ ) ..................................................................................... 2-5
Figure 4-1. CPS Programming Setup ..................................................................................................... 4-1
Figure 4-2. Radio Tuning Equipment Setup ........................................................................................... 4-2
Figure 5-1. Battery Removal................................................................................................................... 5-6
Figure 5-2. Channel Selector and Volume Knob Removal ..................................................................... 5-7
Figure 5-3. Chassis Removal ................................................................................................................. 5-8
Figure 5-4. Chassis Removal from Front Housing ................................................................................. 5-9
Figure 5-5. Audio Jack Shroud Assembly Removal ............................................................................. 5-10
Figure 5-6. Speaker and Microphone Wires Removal .......................................................................... 5-11
Figure 5-7. Unlatching the Actuator ...................................................................................................... 5-13
Figure 5-8. Actuator on Mainboard ....................................................................................................... 5-14
Figure 5-9. Option Board Flex Removal ............................................................................................... 5-14
Figure 5-10. Option Board Disassembly................................................................................................. 5-15
Figure 5-11. Flex Removal ..................................................................................................................... 5-15
Figure 5-12. Chassis Disassembly ......................................................................................................... 5-16
Figure 5-13. Speaker and Microphone Disassembly .............................................................................. 5-17
Figure 5-14. Dust Cover Disassembly .................................................................................................... 5-18
Figure 5-15. Audio Jack Dust Cover Removal ....................................................................................... 5-19
Figure 5-16. Prying the Micro USB Dust Cover ...................................................................................... 5-20
Figure 5-17. Micro USB Dust Cover Removal ........................................................................................ 5-21
Figure 5-18. Micro USB Dust Cover Reassembly .................................................................................. 5-22
Figure 5-19. Audio Jack Dust Cover Reassembly .................................................................................. 5-23
Figure 5-20. Speaker and Microphone Reassembly .............................................................................. 5-24
Figure 5-21. Battery Contact Seal Assembly.......................................................................................... 5-25
Figure 5-22. Thermal Pad Assembly ...................................................................................................... 5-26
Figure 5-23. PCB and Top Control Seal Assembly................................................................................. 5-27
Figure 5-24. Poron Pad Alignment ......................................................................................................... 5-28
Figure 5-25. Complete Option Board Assembly ..................................................................................... 5-29
Figure 5-26. Folding the Flex.................................................................................................................. 5-30
Figure 5-27. Chassis and Front Housing Reassembly ........................................................................... 5-33
Figure 5-28. Audio Jack Shroud Reassembly ........................................................................................ 5-34
Figure 5-29. Inserting Chassis Assembly into Housing .......................................................................... 5-35
Figure B-1. PCB Top View ......................................................................................................................B-2
List of Tables ix
List of Tables
Table 1-1. Radio Frequency Ranges and Power Levels....................................................................... 1-1

Table 2-1. Recommended Test Equipment ........................................................................................... 2-1
Table 2-2. Service Aids ......................................................................................................................... 2-2
Table 2-3. Pin Configuration of Portable Programming Cable with TTR............................................... 2-4
Table 2-4. Pin Configuration of Portable Test Cable ............................................................................. 2-6
Table 3-1. Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2. Test Environments................................................................................................................ 3-2
Table 3-3. Test Frequencies.................................................................................................................. 3-3
Table 3-4. Transmitter Performance Checks ........................................................................................ 3-4
Table 3-5. Receiver Performance Checks ............................................................................................ 3-5
Table 4-1. Software Installation Kits Radio Tuning Setup ..................................................................... 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. Exploded View Part List ..................................................................................................... 5-37
Table 5-4. Exploded View Part List ..................................................................................................... 5-40
Table 5-5. Front Housing Service Kits................................................................................................. 5-41
Table 5-6. Back Cover Kit Part Numbers ............................................................................................ 5-41
Table 5-7. Torque Specifications for Screws ....................................................................................... 5-42
x Related Publications
Related Publications
Product Safety and RF Exposure ................................................................................................ 6864117B25
DP1400 User Guide................................................................................................................... 68012008075
DP1400 Quick Reference Guide................................................................................................ 68012008076
Introduction: Notations Used in This Manual 1-1
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
WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or injury.
1.2 Radio Description

The DP1400 portable radios are available in the following frequency ranges and power levels.
Table 1-1. Radio Frequency Ranges and Power Levels
Frequency Band Bandwidth Power Level
VHF 136–174 MHz 1 Watt or 5 Watt
UHF 403–470 MHz 1 Watt or 4 Watt
These digital radios are among the most sophisticated two-way radios available. They have a robust
design for radio users who need high performance, quality, and reliability in their daily
communications. This architecture provides the capability of supporting a multitude of legacy and
advanced features resulting in a more cost-effective two-way radio communications solution.
1-2 Introduction: Radio Description
1.2.1 Non Keypad Model
Antenna
Channel Selector Knob

On/Off Volume Control Knob
LED Indicator
Push-to-Talk (PTT) Button Accesory Connector

with Dust Cover
Speaker
Microphone
Side Button 1 (Programmable)
Side Button 2 (Programmable)

USB with Dust Cover
Figure 1-1. Non Keypad Model

• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counter-
clockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATOR – Red, green and orange light-emitting diodes indicate operating status.
• SIDE BUTTONS – These 2 buttons are field programmable using the CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• ACCESSORY CONNECTOR WITH DUST COVER – Interface point for all accessories to be
used with the radio. It has eight points to which specific accessories will connect to and be
activated.
• SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like
keypad tones and voice audio).
• USB WITH DUST COVER – Dust cover to prevent dust from clogging USB port.
Introduction: .Portable Radio Model Numbering Scheme 1-3
1.3 .Portable Radio Model Numbering Scheme
Model No.Example : AZ H 5 5 Q D H 9 L A 1 A N
Position : 1 2 3 4 5 6 7 8 9 10 11 12
AZ: Asia
LA: Latin America
AA: North America
MD: Europe/Middle East/Africa Unique Variation
N: Standard Package
H: Portable
Version Letter
MOTOTRBO DP1400: 01
Feature Level
1: Standard w/ FM
2. Non-FM
Band 3. CSA IE CEx ATEX
J: 136-174 MHz 4. CQST
R: 403-470 MHz
Primary System Type
A: Conventional
B: Trunking
Power Level C: Analog Only
C: 1.0,2.0,2.5 or 3.5 Watt
D: 4.0-5.0 Watt
Primary Operation
J : Basic (No GPS, no Bluetooth, no
Physical Packages embedded GOB)
C: Low Tier (Plain) K : GPS and Bluetooth
H: Mid Tier (Monochrome Display LKP) L : GPS Only
N: HIgh Tier (Color Display FKP) M: Bluetooth Only
J: 3 Button MOR N : Bluetooth w/ embedded GOB
T: No Display - Limited Tier
Channel Information
8: Variable/Programmable Channel Spacing
w/ unique # of channels
9: Variable/Programmable Channel Spacing
Figure 1-2. Portable Radio Model Numbering Scheme

1-4 Introduction: Model Charts
1.4 Model Charts

1.4.1 VHF Model Chart
DP1400 Series, VHF, 136–174 MHz

Model Description
MDH01JDC9JA2_N DP1400 136–174 MHz, 5W, Non Keypad
MDH01JDC9JC2_N DP1400 136–174 MHz, 5W, Non Keypad, Analog
MDH01JDC9JE2_N DP1400 136–174 MHz, 5W, Non Keypad, Option Board Capable.
MDH01JDC9JF2_N DP1400 136–174 MHz, 5W, Non Keypad, Option Board Capable,
Analog
Item Description
X WAED4508_ BC Kit 136–174 MHz, 5W, Non Keypad
X WAED4507_ BC Kit 136–174 MHz, 5W, Non Keypad, Analog
X WAED4529_ BC Kit 136–174 MHz, 5W, Non Keypad, Option Board Capable
X WAED4530_ BC Kit 136–174 MHz, 5W, Non Keypad, Option Board Capable,
Analog
X X PMLN6345_ Front Cover Kit, Non Keypad
X X PMLN7210_ Front Cover Kit, Non Keypad, Option Board Capable
X X PMLN7228_ Option Board Installation Kit
X X X X HAD9742_ VHF Stubby, 146–162 MHz
X X X X HAD9743_ VHF Stubby, 162–174 MHz
X X X X NAD6502_R VHF Heliflex, 146–174 MHz
X X X X PMAD4012_ VHF Heliflex136–155 MHz
NOTE X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix
number.
NOTE Analog model radios that are upgraded to digital with a license key will need to request
for Analog Service Kit.
Introduction: Model Charts 1-5
1.4.2 UHF Model Chart
DP1400 Series, UHF, 403–470 MHz

Model Description
MDH01QDC9JA2_N DP1400 403–470 MHz, 5W, Non Keypad
MDH01QDC9JC2_N DP1400 403–470 MHz, 5W, Non Keypad, Analog
MDH01QDC9JE2_N DP1400 403–470 MHz, 5W, Non Keypad, Option Board Capable
MDH01QDC9JF2_N DP1400 403–470 MHz, 5W, Non Keypad, Option Board Capable,
Analog
Item Description
X WAEE4472_ BC Kit 403–470 MHz, 4W, Non Keypad
X WAEE4471_ BC Kit 403–470 MHz, 4W, Non Keypad, Analog
X WAEE4499_ BC Kit 403–470 MHz, 5W, Non Keypad, Option Board Capable
X WAEE4500_ BC Kit 403–470 MHz, 5W, Non Keypad, Option Board Capable,
Analog
X X PMLN6345_ Front Cover Kit, Non Keypad
X X PMLN7210_ Front Cover Kit, Non Keypad, Option Board Capable
X X PMLN7228_ Option Board Installation Kit
X X X X PMAE4016_ UHF Whip Antenna (430–470MHz)
X X X X PMAE4002_ UHF 9cm Stubby Antenna (403–433MHz)
X X X X PMAE4003_ UHF 9cm Helical Antenna (430–470MHz)
NOTE X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix
number.
NOTE Analog model radios that are upgraded to digital with a license key will need to request
for Analog Service Kit.
1-6 Introduction: Specifications
1.5 Specifications
General DP1400
Channel Capacity 16
Frequency VHF: 136 – 174 MHz

UHF: 403 – 470 MHz
Dimensions (HxWxT) w/ NiMH 130mm x 62.5mm x 42mm

battery
Weight
(with NiMH 1400 mAh) 406 g
(with Slim Li-Ion 1600 mAh battery) 341 g
(with High Cap Li-Ion 2200 mAh 346 g
battery)
Power Supply 7.5V (nominal)
FCC Description VHF: ABZ99FT3092

UHF: ABZ99FT4094
IC Description VHF: 109AB-99FT3092

UHF: 109AB-99FT4094
Average battery life at 5/5/90 duty cycle with battery saver enabled in
carrier squelch and transmitter in high power.
NiMH 1400 mAh battery Analog: 9 hours

Digitial: 11.5 hours
Core Slim Li-Ion 1600 mAh battery Analog: 10.5 hours

Digital: 13.5 hours
High Cap Li-Ion 2200 mAh battery Analog: 14.5 hours

Digital: 18.5 hours
NOTE Weight can have 5% margin of error

Introduction: Specifications 1-7
Receiver DP1400
Frequencies VHF: 136 – 174 MHz

UHF: 403 – 470MHz
Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz
Frequency Stability (-30°C to +/-0.5 ppm

+60°C, +25 °C Ref)
Analog Sensitivity (12 dB SINAD) 0.3 µV

0.22 µV (typical)
Digital Sensitivity (5% BER) 0.25 µV

0.19 µV (typical)
Intermodulation (TIA603C) 70 dB
Adjacent Channel Selectivity

TIA603D 45 dB @ 12.5kHz
70 dB @ 20kHz/25kHz
Spurious Rejection (TIA603D) 70 dB
Rated Audio 0.5 W (internal)
Audio Distortion @ Rated Audio 5% (3% typical)
Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20 kHz/ 25 kHz
Audio Response TIA603D
Conducted Spurious Emission -57 dBm

(TIA603D)
Speaker Impedance 16 Ohms
Voltage @ Rated Audio 2.828 V

Transmitter DP1400
Frequencies VHF: 136 – 174 MHz

UHF: 403 – 470MHz
Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz
Frequency Stability (-30°C to +/-0.5 ppm

+60°C, +25 °C Ref)
Power Output (Low Power) 1W
Power Output (High Power) VHF: 5 W

UHF: 4 W
Modulation Limiting +/-2.5 kHz @ 12.5 kHz

± 4.0 kHz @ 20 kHz
+/-5.0 kHz @ 25 kHz
FM Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20 kHz/ 25 kHz
Conducted / Radiated Emission -36 dBm < 1 GHz

-30 dBm > 1 GHz
Adjacent Channel Power 60 dB @ 12.5 kHz

70 dB @ 20/25 kHz
Audio Response TIA603D
Audio Distortion 3%(typical)
FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E
4FSK Digital Modulation 12.5 kHz Data: 7K60F1D & 7K60FXD

12.5 kHz Voice: 7K60F1E & 7K60FXE
Combination of 12.5 kHz Data and Voice: 7K60F1W
Digital Vocoder Type AMBE+2™
Digital Protocol ETSI-TS102361-1

ETSI-TS102361-2
ETSI-TS102361-3
Conforms to:
ETSI TS 102 361 (Parts 1, 2 & 3) - ETSI DMR Standard
ETSI EN 300 086 - ETSI RF Specifications (Analog)
ETSI EN 300 113 - ETSI RF Specifications (Digital)
1999/5/EC (R&TTE - Radio and Telecommunications Terminal Equipment)
2002/95/EC (RohS - Banned Substances)
2002/96/EC (WEEE - Waste Electrical and Electronic Equipment)
94/62/EC (Packaging and Packaging Waste)
Radio meets applicable regulatory requirements.
Introduction: Specifications 1-9
VHF Self-Quieter Frequencies UHF Self-Quieter Frequencies
144 MHz +/- 5 kHz 420 MHz +/- 5 kHz
153.6 MHz +/- 5 kHz 440 MHz +/- 5 kHz
172.8 MHz +/- 5 kHz
Military Standards
Applicable 810C 810D 810E 810F 810G
MIL–STD
Methods Procedures Methods Procedures Methods Procedures Methods Procedures Methods Prodecures
Low Pressure 500.1 I 500.2 II 500.3 II 500.4 II 500.5 II

High 501.1 I, II 501.2 I/A1,II/ 501.3 I-A1, II/ 501.4 I/Hot, II/ 501.5 I-A1, II
Temperature A1 A1 Hot
Low 502.1 I 502.2 I/C3, II/ 502.3 I-C3, II/ 502.4 I-C3, II/ 502.5 I-C3, II
Temperature C1 C1 C1
Temperature 503.1 - 503.2 I/A1/C3 503.3 I/A1/C3 503.4 I 503.5 I-C
Shock
Solar 505.1 II 505.2 I 505.3 I 505.4 I 505.5 I-A1
Radiation
Rain 506.1 I, II 506.2 I, II 506.3 I,II 506.4 I, III 506.5 I, III
Humidity 507.1 II 507.2 II 507.3 II 507.4 – 507.5 II-
Aggravat
ed
Salt fog 509.1 - 509.2 - 509.3 – 509.4 – 509.5 –
Dust 510.1 I 510.2 I 510.3 I 510.4 I 510.5 I
Vibration 514.2 VIII/F, 514.3 I/10, II/3 514.4 I/10, II/3 514.5 I/24 514.6 I-cat.24
Curve-W
Shock 516.2 I, II 516.3 I, IV 516.4 I, IV 516.5 I, IV 516.6 I, IV, V,
VI
Environmental Specifications
*Operating Temperature -30 °C to +60 °C
Storage Temperature -40 °C to +85 °C
Thermal Shock Per MIL-STD
Humidity Per MIL-STD
ESD IEC 61000-4-2 Level 3
Water Intrusion IEC 60529 -IP54
Packaging Test As per MIL-STD
* Operating temperature specification with LiIon battery is -10 °C to +60 °C.

Operating temperature specification with NiMH battery is -20 °C to +60 °C.
Chapter 2 Test Equipment and Service Aids
2.1 Recommended Test Equipment

The list of equipment contained in Table 2-1 includes most of the standard test equipment required
for servicing Motorola portable radios.
Table 2-1. Recommended Test Equipment
Equipment Characteristics Example Application

Service Can be used as a Aeroflex 3920 Frequency/deviation meter and
Monitor substitute for items (www.aeroflex.com), signal generator for wide-range
marked with an asterisk troubleshooting and alignment
(*)
Digital RMS 100 µV to 300 V Fluke 179 or equivalent AC/DC voltage and
Multimeter * 5 Hz to 1 MHz (www.fluke.com) current measurements. Audio
10 Mega Ohm Impedance voltage measurements
RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements

Generator * -130 dBm to +10 dBm (www.agilent.com),
FM Modulation 0 kHz to Ramsey RSG1000B
10 kHz (www.ramseyelectronics.com), or
Audio Frequency 100 Hz equivalent
to 10 kHz
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 5% Accuracy Bird 43 Thruline Watt Meter Transmitter power output
and Sensor * 100 MHz to 500 MHz (www.bird-electronic.com) or measurements
50 Watts equivalent
RF Millivolt 100 mV to 3 V RF Boonton 92EA RF level measurements

Meter 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 Part
Description Application
No.
RLN4460_ Portable Test Set Enables connection to the audio/accessory jack.
Allows switching for radio testing.
GMVN5141_ Customer Programming Allows servicer to program radio parameters, tune

Software on DVD-ROM and troubleshoot radios.
PMKN4128_ Portable Programming Cable This cable connects the radio to a USB port for radio
programming and data applications.
PMKN4156_ Portable Test Cable This cable connects the radio to RLN4460 Portable
Test Set for test and measurement.
0180305K08EPP 7.5V Universal Battery Connects to radio battery eliminator cable.

Eliminator
5886564Z01 RF Adaptor Application adapts radio's antenna port to BC

cabling of test equipment.
1185937A01 Grease Acts to lubricate parts.
6686533Z01 Chassis and Knob Opener Separates the chassis from the front housing.
N/A Flat Square Tip Plastic Remove components during disassembly.

Tweezer
Test Equipment and Service Aids: Portable Programming Cable 2-3
2.3 Portable Programming Cable
#4
#2
“P1”
#5
#1
#5
#3
#1
“P3”
#4
#1
“P2”
Figure 2-1. Portable Programming Cable with TTR (PMKN4128_)

2-4 Test Equipment and Service Aids: Portable Programming Cable
Table 2-3. Pin Configuration of Portable Programming Cable with TTR
CONNECTION
P1 P2 P3 Function
1 1 VCC(5V)
2 2 DATA-
3 3 DATA+
4 BNC Center Pin TTR
5 4 BNC Shell GROUND

Test Equipment and Service Aids: Portable Test Cable 2-5
2.4 Portable Test Cable
“P2”
#25
#14
#13
#1
#3
#4
#2
#1
“P1”
Figure 2-2. Portable Test Cable (PMKN4156_ )

2-6 Test Equipment and Service Aids: Portable Test Cable
Table 2-4. Pin Configuration of Portable Test Cable
CONNECTION
P1 P2 Function
1 1,5 GROUND
2 7,24 EXTERNAL MIC
3 16 EXTERNAL SPEAKER -
4 17 EXTERNAL SPEKAER +
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.
Although these radios function in digital and analog modes, all testing is done in analog mode.
3.2 Setup
Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.
Do NOT use any form of connector, e.g. wires, crocodile

clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number Title
3-2 Test Environments
3-3 Test Frequencies
3-4 Transmitter Performance Checks
3-5 Receiver Performance Checks
Table 3-1. Initial Equipment Control Settings
Service Monitor Power Supply Test Set

Monitor Mode: Power Monitor Voltage: 7.5Vdc Speaker set: A
RF Attn: -70 DC on/standby: Speaker/load:

Standby Speaker
AM, CW, FM: FM Volt Range: 10V PTT: OFF

3-2 Transceiver Performance Testing Setup
Table 3-1. Initial Equipment Control Settings (Continued)
Service Monitor Power Supply Test Set

Oscilloscope Source: Mod Current: 2.5A
Oscilloscope Horizontal: 10mSec/Div
Oscilloscope Vertical: 2.5kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: Middle setting
Monitor Vol: 1/4 setting
3.2.1 RF Test Mode

When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or air test.
In RF Test Mode, the display upon the first line is “RF Test”, together with the power level icon at the
right end of the first line. The display upon the second line is the test environment, the channel
number and channel spacing. The default test environment is CSQ.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-2.
Table 3-2. Test Environments
No. of
Description Function
Beeps
1 Carrier Squelch RX: if carrier detected
(CSQ) TX: mic audio
2 Tone Private-Line RX: unsquelch if carrier and tone detected

(TPL) TX: mic audio + tone
3 Digital Mode RX: if carrier detected

(DIG) TX: mic audio
4 Unsquelch RX: constant unsquelch

(USQ) TX: mic audio
2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz
and 20 kHz as. The radio beeps once when radio toggles to 20kHz, beeps twice for 25 kHz
and beeps three times for 12.5 kHz.
3. Turning of the Channel Knob changes the test channel from 1 to 16 as described in
Table 3-3. The radio beeps in each position.
Transceiver Performance Testing Setup 3-3
Table 3-3. Test Frequencies
Channel
Selector Test
VHF UHF
Switch Channel
Position
1 Low Power TX#1 or #9 136.075 403.15
9 High Power RX#1 or #9 136.075 403.15
2 Low Power TX#2 or #10 142.575 414.15

10 High Power RX#2 or #10 142.575 414.15
3 Low Power TX#3 or #11 146.575 425.15

11 High Power RX#3 or #11 146.575 425.15
4 Low Power TX#4 or #12 155.575 436.45

12 High Power RX#4 or #12 155.575 436.45
5 Low Power TX#5 or #13 161.575 447.15

13 High Power RX#5 or #13 161.575 447.15
6 Low Power TX#6 or #14 167.575 458.15

14 High Power RX#6 or #14 167.575 458.15
7 Low Power TX#7 or #15 173.975 469.85

15 High Power RX#7 or #15 173.975 469.85
8 Low Power TX#8 or #16 174.000 470.000

16 High Power RX#8 or #16 174.000 470.000
Table 3-4. Transmitter Performance Checks
Communications
Test Name Radio Test Set Comments
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test Test Channel 4 continuously ±68 Hz for VHF
frequency* carrier squelch transmit
Monitor: Frequency (during the ±201 Hz for UHF
error performance
Input at RF In/Out check)
Power RF As above As above As above Low Power:

0.9 – 1.5W (VHF/
UHF)
High Power:
4.0 – 4.8W (UHF)
High Power:
5.0 – 5.8W (VHF)
Voice Mode: PWR MON As above As above, meter Deviation:

Modulation 4th channel test selector to mic ≥ 4.0 kHz but ≤ 5.0
frequency* kHz (25 kHz Ch Sp).
atten to -70, input to RF
In/Out
Monitor: DVM: AC Volts
Set 1kHz Mod Out level
for 0.025Vrms at test
set,
80mVrms at AC/DC
test set jack
Voice Mode: PWR MON TEST MODE, Remove Press PTT switch on
Modulation 4th channel test Test Channel 4 modulation input radio. Say “four”
(internal) frequency* carrier squelch loudly into the radio
atten to -70, input to RF output at mic. Measure
In/Out antenna deviation:
≥ 4.0 kHz but ≤ 5.0
kHz (25 kHz Ch Sp)
TPL As above TEST MODE, As above Deviation:

Modulation 4th channel test Test Channel 4 ≥500Hz but ≤1000Hz
frequency* TPL (25 kHz Ch Sp).
BW to narrow
RF Power DMR mode. Slot 1 TEST MODE, Key up radio TTR Enable is
Power and Slot 2 Digital Mode, without modulation needed and IFR to be
Power transmit using Tuner set to trigger mode
without with signal level
modulation ~1.5V
Transceiver Performance Testing Setup 3-5
Table 3-4. Transmitter Performance Checks
Communications
Analyzer
FSK Error DMR Mode. FSK Error TEST MODE, Key up radio with Not Exceed 5%
Digital Mode, O.513 test pattern
transmit with modulation using
O.153 test Tuner
pattern
Magnitude DMR Mode. Magnitude As above As above Not Exceed 1%

Error error
Symbol DMR Mode. Symbol As above As above Symbol Deviation

Deviation Deviation should be within
648Hz +/- 10% and
1944Hz +/- 10%
Transmitter DMR Mode As above As above Transmitter BER

BER should be 0%
* See Table 3-3
Table 3-5. Receiver Performance Checks
Communications
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test Test Channel 4 continuously ±68Hz for VHF
frequency* carrier squelch transmit
Monitor: Frequency error output at (during the ±201Hz for UHF
Input at RF In/Out antenna performance
check)
Rated Audio Mode: GEN TEST MODE PTT to OFF (cen- Set volume
Output level: 1.0mV RF Test Channel 6 ter), meter selec- control to 2.83 Vrms
6th channel test carrier squelch tor to Audio PA
frequency*
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts
Distortion As above, except to As above As above Distortion <3.0%

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

(SINAD) lower the RF level for (center) <0.35μV
12dB SINAD.
Table 3-5. Receiver Performance Checks
Communications
Analyzer
Noise RF level set to 1mV RF As above PTT to OFF Set volume
Squelch (center), meter control to 2.83Vrms
Threshold selection to Audio
(only radios PA, speaker/load
with to speaker
conventional
system need As above, except change Out of TEST As above Unsquelch to occur at
to be tested) frequency to a MODE; select <0.25μV.
conventional system. a conventional Preferred SINAD = 9
Raise RF level from zero system – 10dB
until radio unsquelches.
Receiver IFR DMR mode. Signal TEST MODE, Read BER using RF level to be
BER generator with O.153 test Digital Mode, Tuner. Adjust RF <0.35μV for 5% BER
pattern transmit with level to get 5%
O.153 test BER
pattern
Receiver IFR DMR Mode. Signal Test Mode, RF level = -47dBm. Adjust volume until
Rated Audio generator with 1031 test Digital Mode, Set audo analyzer Vrms = 2.83V
pattern receive 1031 to read Vrms.
test pattern Adjust volume to
get rated audio
Receiver IFR DMR Mode. Signal As above As above. Then set Not exceed 5%
Audio generator with 1031 test audio analyzer to
Distortion pattern measure distortion
* See Table 3-3

Transceiver Performance Testing Test Mode 3-7
3.3 Test Mode

3.3.1 Entering Test Mode
1. Turn the radio on.
2. Within 10 seconds after “Self Test” is complete, press Side Button 2 five times in
succession.
3. The radio beeps.
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”.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-2.
2. Each short press of Side Button 1 toggles the channel spacing between 20 kHz/25 kHz*,
12.5 kHz and 20 KHz. The radio beeps once when radio toggles to 20KHz, beeps twice for 25
kHz* and beeps three times for 12.5 kHz.
3. Turning of the Channel Knob changes the test channel from 1 to 16 as described in
Table 3-3. The radio beeps in each position.
3.3.3 LED Test Mode

1. Press and hold Side Button 1 in RF Test Mode. The radio beeps once.
2. Upon any button/key press, the radio lights up the red LED.
3. Consequently, upon any button/key press, the red LED is turned off and the radio turns on the
green LED.
4. Consequently, upon any button/key press, the green LED is turned off the radio shall turn on
both LEDs.
3.3.4 Speaker Tone Test Mode

1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once.
2. The radio generates a 1 kHz tone with the internal speaker.
3-8 Transceiver Performance Testing Test Mode
3.3.5 Earpiece Tone Test Mode

1. Press and hold Side Button 1 after Speaker Tone Test Mode. The radio beeps once.
2. The radio generates a 1 KHz tone with the earpiece.
3.3.6 Audio Loopback Earpiece Test Mode

1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once.
2. The radio shall route any audio on the external mic to the earpiece.
3.3.7 Battery Check Test Mode

1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once.
2. The radio LED lights up accordingly; green LED for High Battery Level, amber LED for Mid
Battery Level and blinking red LED for Low Battery Level.
3.3.8 Button/Knob/PTT Test Mode

1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once.
2. Rotate the Volume Knob; the radio beeps at each position.
3. Rotate the Channel Knob; the radio beeps at each position.
4. Press Side Button 1; the radio beeps; release, the radio beeps.
5. Press Side Button 2; the radio beeps; release, the radio beeps.
6. Press the PTT Switch; the radio beeps; release, the radio beeps.
Chapter 4 Radio Programming and Tuning
4.1 Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner and AirTracer applications, which are all designed for use in a Windows 8/7/Vista/
XP environment. These programs are available in one kit as listed in Table 4-1. An Installation Guide
is also included with the kit.
NOTE Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1. Software Installation Kits Radio Tuning Setup
Description Part Number
MOTOTRBO CPS and AirTracer on CD-ROM GMVN5141_
4.2 Customer Programming Software Setup

The CPS programming setup, shown in Figure 4-1 is used to program the radio.
NOTE Refer to appropriate program on-line help files for the programming procedures.
! Computer USB ports can be sensitive to Electrostatic Discharge. Do not touch

exposed contacts on cable when connected to a computer.
Caution
Radio PC
Battery Portable Programming

Cable PMKN4128_
Figure 4-1. CPS Programming Setup

4-2 Radio Programming and Tuning: AirTracer Application Tool
4.3 AirTracer Application Tool

The MOTOTRBO AirTracer application tool has the ability to capture over-the-air digital radio traffic
and save the captured data into a file. The AirTracer application tool can also retrieve and save
internal error logs from MOTOTRBO radios. The saved files can be analyzed by trained Motorola
personnel to suggest improvements in system configurations or to help isolate problems.
4.4 Radio Tuning Setup
A personal computer (PC), Windows 8/7/Vista/XP and a tuner program are required to tune the
NOTE Refer to the appropriate program online help files for the tuning procedures.
radio. To perform the tuning procedures, the radio must be connected to the PC and test equipment
setup as shown in Figure 4-2.
Service Monitor
Or Counter
Transmit
Battery Eliminator
7.5V Reg. 0180305K08EPP Wattmeter
RF Adaptor
Receive
RF Generator
+12VDC Radio 10dB pad
Power Supply
Audio In Tx
Audio Generator
Test Box
RLN4460_ Rx
Sinad meter
Portable Programming Portable Test AC Voltmeter

Cable PMKN4128_ Cable PMKN4156_
PC
Figure 4-2. Radio Tuning Equipment Setup

Disassembly/Reassembly Procedures: Introduction 5-1
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 front
cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic
visual inspection reveals the presence of smudges, grease, and/or grime.
NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (100% by volume).
!
The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
Caution chemicals.
5-2 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. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front cover or back cover.
NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
!
Use all chemicals as prescribed by the manufacturer. Be sure
to follow all safety precautions as defined on the label or
Caution material safety data sheet.
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. DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION
paragraph in the Disassembly and Reassembly section of the manual.
Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices 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/LDMOS devices in conductive

material so that all exposed leads are shorted together. Do not insert
CMOS/LDMOS devices into conventional plastic “snow” trays used
for storage and
transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the
CMOS/LDMOS device. We recommend using the Motorola Static
Protection Assembly (part number 0180386A82), which includes a
wrist strap, two ground cords, a table mat, a floor mat, ESD shoes
and an ESD chair.
• Wear a conductive wrist strap in series with a 100k resistor to
ground. (Replacement wrist straps that connect to the bench top
covering are Motorola part number 4280385A59).
• Do not wear nylon clothing while handling CMOS/LDMOS devices.
• Do not insert or remove CMOS/LDMOS devices with power applied.
Check all power supplies used for testing CMOS/LDMOS devices to
be certain that there are no voltage transients present.
• When straightening CMOS/LDMOS pins, provide ground straps for
the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS/LDMOS devices by the package and
not by the leads. Prior to touching the unit, touch an electrical
ground to remove any static charge that you may have
accumulated. The package and substrate may be electrically
common. If so, the reaction of a discharge to the case would cause
the same damage as touching the leads.
5-4 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
environmentally preferred components and solder assembly techniques to comply with
the European Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/
95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/
EC. To maintain product compliance and reliability, use only the Motorola specified parts
in this manual.
Any rework or repair on Environmentally Preferred Products must be done using the appropriate
lead-free solder wire and lead-free solder paste as stated in the following table:
Table 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
11012015002 IPN800610 1000-1700 poise Type 4 (95.5Sn 3.8Ag 0.7Cu) 217°C

88.5%
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
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

When disassembling and reassembling the radio, it is important to pay particular attention to the
snaps and tabs, and how parts align with each other.
The following tools are required for disassembling the radio:
• TORX™ T6 screwdriver
• Chassis and Knob Opener (p/n: 6686533Z01)
• Flat square tip plastic tweezer
The following item and tools are required for reassembling the radio:
• Grease (1185937A01)
• TORX™ T6 screwdriver
• Flat square tip plastic tweezer
If a unit requires further testing or service than is customarily performed at the basic level, please
send the radio to a Motorola Service Center.
!
To assure the safety and regulatory compliance of the radio must be repaired
only at Motorola service facilities. Please call Motorola at 800-422-4210 for the
Caution address and contact information of your nearest service center
5-6 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed
5.6 Radio Disassembly – Detailed

5.6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Slide the battery latch into the unlock position. Disengage by pressing the latch downward
fully and holding the latch towards the front of the radio.
NOTE Ensure metal latch is not protruding out from the slot on the plastic housing
b. With the battery latch disengaged, slide the battery down from the top of the radio. Once
the battery is free from the battery rails, lift it directly away from the radio.
NOTE Do not put too much pressure on the battery while sliding it out from top of the radio.
c. Remove the battery from the radio.

3. Remove the antenna by turning it counterclockwise.
Battery
Figure 5-1. Battery Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-7
4. Pry off the volume and channel selector knobs from their shafts using the knob remover/
chassis opener tool (Motorola p/n: 6686533Z01).
Volume Control Knob
Channel Selector
Knob
Figure 5-2. Channel Selector and Volume Knob Removal
NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.
Figure 5-3. Chassis Removal

5. Separate the chassis from the front housing assembly by using the knob remover/chassis
opener tool. Place the broad side of the opener into the slots located at the base of the radio
as shown in Figure 5-3. Press the handle of the opener downwards. This pressing action
forces the thin inner plastic wall towards the base of the radio, releasing the two chassis base
tabs.
!
Marring the front housing O-ring, sealing area will prevent the
radio from sealing properly. If the O-ring is damaged, replace
Caution it with a new one.
NOTE The speaker wire and microphone wire connecting the front housing assembly and the
chassis assembly prevent the two units from being completely separated.
Figure 5-4. Chassis Removal from Front Housing

6. Slowly slide out the chassis assembly from the front housing Figure 5-4 until the volume and
channel selector shafts are free from the top of the housing.
!
Do not pull out the chassis forcefully. This will cause damage
to the speaker and microphone wires that are still connected
Caution to the chassis assembly.
Accesory Connector
Audio Jack Shroud Assembly
Figure 5-5. Audio Jack Shroud Assembly Removal

7. Remove the audio jack shroud assembly from the accessory connector on the main board.
Speaker Wire
Microphone Wire
Figure 5-6. Speaker and Microphone Wires Removal

8. Rotate the chassis counterclockwise out of the housing, and position them side by side.
9. Peel off the poron pad on back kit.
10. Unplug the speaker wire and microphone wire from the 2-pin connector on the main board.
5.6.2 Generic Option Board (GOB) Disassembly

1. Use a tweezer to gently remove the poron pad on top of the actuator.
Poron
2. Place plastic flat-tip tweezer on the central part of the actuator, gently unlatch the actuator by
rotating it about 100°.
Flex
Figure 5-7. Unlatching the Actuator
! Do not attempt to unlatch the actuator by applying load on the

both ends of actuator.
Caution
“A” Area
Figure 5-8. Actuator on Mainboard
! Do not touch upper part of the housing (“A” area) at anytime,

as it may lead to breakage.
Caution
3. Remove the flex from the fully opened connector by pulling it out gently.
Figure 5-9. Option Board Flex Removal

4. Use TORX screwdriver with T6 bit to remove 2 screws holding the option board to front
housing.
5. Lift the option board with flex from the front kit.
Option Board
Front Kit
Figure 5-10. Option Board Disassembly

6. Gently lift the connector actuator on the option board to release the flex.
7. Remove the flex from the connector by pulling it out of its connector gently.
Flex
Option Board
Figure 5-11. Flex Removal

5.6.3 Chassis Disassembly

1. Use a TORX screwdriver with a T6 bit to remove the three screws holding the main board to
the chassis.
Mainboard screws
Top Control Seal
O-ring
Tab
Groove
Battery Contact Seal
Figure 5-12. Chassis Disassembly

2. Lift the main board from the chassis.
3. Remove the O-ring by releasing the two tabs from the grooves on the chassis.
4. Remove the top control seal and battery contact seal.
5.6.4 Speaker and Microphone Disassembly

1. Remove the screw from the speaker retainer, Figure 5-13, using a TORX screwdriver with a
T6 bit.
NOTE The speaker is held in place with a retainer. Be careful not to damage the speaker when
removing the bracket retainer.
2. Lift the retainer off the speaker by sliding the end of the retainer out of the corner slot on the
housing.
3. Lift the speaker out of the housing.
4. Carefully lift the microphone assembly out of the housing. If you are replacing the
microphone, remove it from the rubber boot.
Screw
Speaker Retainer
Speaker
Microphone
Microphone Boot
Figure 5-13. Speaker and Microphone Disassembly

5.6.5 Audio Jack Dust Cover Disassembly

1. Gently pry the top of the dust cover away from the body of the housing as in Figure 5-14.
Dust Cover
Figure 5-14. Dust Cover Disassembly

2. Face the audio jack side and rotate the dust cover 90° in counter clockwise direction. Flip
open the dust cover 90° in clockwise direction as in Figure 5-15 to allow the key to be
removed.
Key
Figure 5-15. Audio Jack Dust Cover Removal

3. Separate the dust cover from the front housing.
NOTE The dust cover key is fragile; apply only light pressure to the key while removing the dust
cover. If the key is damaged, replace with a new dust cover.
5.6.6 Micro USB Dust Cover Disassembly

1. If required, the micro USB dust cover can be disassembled using a flat square tip plastic tweezer
as follows:
a. Insert the tip of a plastic tweezer underneath the dust cover from the side. Pry the dust cover
to release the top tab as Figure 5-16.
Top Tab
Figure 5-16. Prying the Micro USB Dust Cover

b. Cut off the head from the inside of the housing with cutter as Figure 5-17.
Top Tab
Head
Inside of front housing
Figure 5-17. Micro USB Dust Cover Removal

c. Separate the dust cover from the front housing.
NOTE Micro USB dust cover is non-serviceable. Replace with a new one during reassembly.
5-22 Disassembly/Reassembly Procedures: Radio Reassembly - Detailed
5.7 Radio Reassembly - Detailed

5.7.1 Micro USB Dust Cover Reassembly
1. Insert the tail of the dust cover into the bottom hole on the front housing micro USB opening.
2. By using a long nose plier, pull the tail inward from the inside of the housing until the head is
fully inserted.
3. Cut off the tail with a cutter.
4. Insert the top tab into the slot on the housing.
Tab
Insertion Point
Head
Tail
Figure 5-18. Micro USB Dust Cover Reassembly

Disassembly/Reassembly Procedures: Radio Reassembly - Detailed 5-23
5.7.2 Audio Jack Dust Cover Reassembly

1. Insert the dust cover key into the slot on the housing at a 90° angle.
2. Flip the dust cover 90° in counter clockwise direction to allow the key to be fully inserted into
the housing as shown in Figure 5-19.
Key
Figure 5-19. Audio Jack Dust Cover Reassembly

3. With one hand pressing on the bottom of the dust cover, rotate the dust cover 90° in clockwise
direction.
4. Press the dust cover to ensure it fully covers the audio jack opening.
5.7.3 Speaker and Microphone Reassembly

1. Check if the microphone and speaker felts are in position and not damaged. If damaged,
replace felts.
2. Insert the microphone into the microphone rubber boot.
3. Place the microphone assembly into the microphone recess on the housing and route the
wire into the wire slot.
4. Align the groove on the speaker to the tab on the housing and place the speaker into the
speaker recess. Ensure the speaker is seated flush to the housing as shown in Figure 5-20.
Retainer Slot
Speaker Wire
Routing
Speaker Recess
Speaker Groove
Housing Tab
Microphone Recess
Microphone Wire Slot
Figure 5-20. Speaker and Microphone Reassembly

5. Insert one end of the speaker retainer into the corner slot on the housing. Align the other end
to the screw boss.
6. With one hand holding the retainer to the housing, fasten the screw using a T6 TORX
screwdriver. Tighten torque should be between 2.7 to 2.9 lb/in.
NOTE When fastening the speaker retainer screw, make sure the speaker wire is routed under
the retainer as shown in Figure 5-20 to prevent pinching by the retainer.
5.7.4 Chassis Reassembly

1. Assemble the battery contact seal onto the opening of the chassis in the correct orientation as
shown in Figure 5-21.
NOTE Make sure the battery contact seal protrudes through the chassis, following the recess
shape.
Battery Contact Seal
Figure 5-21. Battery Contact Seal Assembly

2. Assemble the main O-ring onto the chassis by pushing the two tabs all the way into the
chassis main O-ring groove. Stretch the O-ring to fit it around the sides of the chassis.
NOTE Make sure the main O-ring is not twisted.

3. Remove both the thermal pads and place the new ones onto their respective recess on the
chassis by using a clean plastic tweezer. Thin thermal pad (black color) is to be placed on the
recess to the left of the battery contact seal. Thick thermal pad (green color) is to be placed
on the recess to the bottom of the battery contact seal.
NOTE Replace with new thermal pads each time when the board is disassembled from chassis
and ensure that both the thermal pads are placed correctly in their respective position
and orientation.
Thin Thermal Pad Recess

(Black color)
Thermal pads
correctly placed
in the respective recess
Thick Thermal Pad

(Green color)
Figure 5-22. Thermal Pad Assembly

4. Insert the top control seal into the volume and channel selector shafts until it is seated on the
switches.
NOTE Replace the battery contact seal, main O-ring and top control seal with a new one if
marred.
5. Assemble the main board to the chassis by aligning the board to the PCB guide protruded
from the chassis, with the volume and frequency switches facing downward. The top control
seal link must be tucked under the PCB guide as shown in Figure 5-23..
NOTE Make sure the battery contact seal is not pinched under the chassis.
PCB Guide
Align board to
Top Control Seal
the PCB Guide
must be tucked under
the PCB Guide
Top Control Seal
Link
Figure 5-23. PCB and Top Control Seal Assembly

6. Align the 3 screw holes to the screw bosses on the chassis.
7. Use a T6 TORX screwdriver to fasten the screws holding the main board to the chassis.
Tighten torque should be between 3.7 to 3.9 lb/in. (refer back to Figure 5-12).
8. Adhere the poron pad align to the pointed shield corner as Figure 5-24.
Poron Pad
Figure 5-24. Poron Pad Alignment

5.7.5 Generic Option Board (GOB) Reassembly

1. Gently lift the connector actuator on the option board and connect the flex.
Flex
Option Board
2. Gently close the actuator.
Actuator
Figure 5-25. Complete Option Board Assembly

3. Fold the flex gently as per the sequence from no.1 to no.5
1 2
3 4
Figure 5-26. Folding the Flex

4. Place the option board with flex into the front kit.
5. Use TORX screw driver with T6 bit to fasten the 2 screws to the front housing.
Option Board
Front Kit
6. Gently insert the flex into the fully opened actuator.

7. Insert the flex and gently close the connector by pushing down at the center of the actuator.
! Do not touch upper part of the housing (“A” area) at anytime,

as it may lead to breakage.
Caution
5.7.6 Chassis and Front Housing Reassembly

1. Apply a thin layer of grease on both the sides and the bottom (except the top) of the main
O-ring.
2. Connect the speaker and microphone wires from the housing to the 2-pin connector on the
main board.
Speaker Wire
Microphone Wire
Figure 5-27. Chassis and Front Housing Reassembly

Audio Jack Shroud
Bottom Edge (insert first)
Figure 5-28. Audio Jack Shroud Reassembly

3. Attach the audio jack shroud assembly to the accessory connector on the main board by
inserting the bottom edge of the shroud first, followed by the top edge as shown in Figure 5-
28.
4. Slide the chassis assembly into the front housing with the volume and channel selector shafts
to the respective opening on the housing. Snap the bottom side of the chassis assembly into
the housing as shown in Figure 5-29.
Figure 5-29. Inserting Chassis Assembly into Housing
! Make sure the speaker and microphone wires are not pinched
in between the audio jack shroud and housing.
Caution
! Make sure the main O-ring is not pinched in between the

chassis and housing.
Caution
5. Attach the volume and channel selector knobs into their respective shafts.
6. Attach the antenna and battery.
5-36 Disassembly/Reassembly Procedures: Radio Exploded Mechanical View and Parts Lists
5.8 Radio Exploded Mechanical View and Parts Lists

5.8.1 Non Option Board
4 5.1
1
5.2
5.3 5
5.8
5.4
5.9
5.5
5.6 5.10
5.11
5.7
6.2
6.1
6.3 6.4
6
6.6
6.5
6.8
6.7
7
6.9
9
Disassembly/Reassembly Procedures: Radio Exploded Mechanical View and Parts Lists 5-37
Table 5-3. Exploded View Part List
Item Description Part Number
1 Antenna Refer VHF Model Chart

Table 1.4.1 VHF Model
Chart and UHF Model
Chart Table 1.4.2 UHF
Model Chart
2 Knob, Frequency 3680530Z02
3 Knob, Volume 3680529Z01
4 Product Number Label 33012039019
5 Front Cover Kit PMLN6345_
5.1 Nameplate 33012026001
5.2 Front Housing Assembly Part of item No.5 (Front
Cover Kit)
5.3 Dust Cover, Audio Jack 15012242001
5.4 Dust Cover, Micro USB 38012042001
5.5 Felt, Microphone 3586621Z04
5.6 Boot, Microphone 0780608V01
5.7 Microphone Assembly 0104055J51
5.8 Felt, Speaker 35012094001
5.9 Speaker Assembly 0104055J50
5.10 Speaker Retainer 4286620Z01
5.11 Screw, Speaker Retainer 0386434Z02
6 Back Cover Kit See Table 5-6 Back Cover
Kit Part Numbers Back
Cover Kits
6.1 Main O-Ring 3286431Z05
6.2 Poron Pad 75012247001
6.3 Screw, Main Board 0304726J05
6.4 Top Control Seal 32012232001
6.5 Main PCB Assembly Part of item No.6 (Back
Cover Kit)
6.6 Thermal Pad (thin) 7515526H01
6.7 Thermal Pad (thick) 75012205001
6.8 Battery Contact Seal 3286435Z01
6.9 Chassis Assembly 0104056J93
7 Shroud Assembly, Audio Jack 01012093001
8 Battery Refer Accessory Leaflet

9 Belt Clip Refer Accessory Leaflet
5.8.2 Option Board Capable
4 5.1
1
5.2
5.3
5
5.8
5.4
5.9
5.5
5.6 5.10
5.11
5.7
11.3
11.1
11.2
10
6.2 6
6.1
6.3 6.4
6.6
6.5
6.8
6.7
7
6.9
9
1 Antenna Refer VHF Model Chart

Table 1.4.1 VHF Model
Chart and UHF Model
Chart Table 1.4.2 UHF
Model Chart
2 Knob, Frequency 3680530Z02
3 Knob, Volume 3680529Z01
4 Product Number Label 33012039019
5 Front Cover Kit, Option Board Capable PMLN7210_
5.1 Nameplate 33012026001
5.2 Front Housing Assembly Part of item No.5 (Front
Cover Kit)
5.3 Dust Cover, Audio Jack 15012242001
5.4 Dust Cover, Micro USB 38012042001
5.5 Felt, Microphone 3586621Z04
5.6 Boot, Microphone 0780608V01
5.7 Microphone Assembly 0104055J51
5.8 Felt, Speaker 35012094001
5.9 Speaker Assembly 0104055J50
5.10 Speaker Retainer 4286620Z01
5.11 Screw, Speaker Retainer 0386434Z02
6 Back Cover Kit See Table 5-6 Back
Cover Kit Part Numbers
Back Cover Kits
6.1 Main O-Ring 3286431Z06
6.2 Poron Pad 75012247001
6.3 Screw, Main Board 0304726J05
6.4 Top Control Seal 32012232001
6.5 Main PCB Assembly Part of item No.6 (Back
Cover Kit)
6.6 Thermal Pad (thin) 7515526H01
6.7 Thermal Pad (thick) 75012205001
6.8 Battery Contact Seal 3286435Z01
6.9 Chassis Assembly 2786389Z03
7 Shroud Assembly, Audio Jack 01012093001
8 Battery Refer Accessory Leaflet

9 Belt Clip Refer Accessory Leaflet
10 Option Board Available from
application developer
*11 Option Board Installation Kit PMLN7228_
11.1 Screw, Option Board Part of PMLN7228_
11.2 Poron, Option Board Part of PMLN7228_
11.3 Flex, Option Board Part of PMLN7228_
NOTE * Item 11 is not featured in the exploded view as it is a kit.
Table 5-5. Front Housing Service Kits
Item Description Motorola Part Number

Front Kit Front Cover Kit, Non-Keypad Portable PMLN6345_
Front Kit Front Cover Kit, Non-Keypad Portable, Option Board Capable PMLN7210_
Table 5-6. Back Cover Kit Part Numbers
Item Description Motorola Part Number

Back Kit Back Cover Kit, VHF, 5 W, MOTOTRBO Non-Display WAED4508_
Portable WAED4507_ (Analog)
Back Kit Back Cover Kit, VHF, 5 W, MOTOTRBO Non-Display WAED4529_
Portable, Option Board Capable WAED4530_ (Analog)
Back Kit Back Cover Kit, UHF, 4 W, MOTOTRBO Non-Display WAEE4472_
Portable WAEE4471_ (Analog)
Back Kit Back Cover Kit, UHF, 4 W, MOTOTRBO Non-Display WAEE4499_
Portable, Option Board Capable WAEE4500_ (Analog)
5.8.3 Torque Chart

Table 5-7 Torque Specifications for Screws lists the various screws by part number and description,
followed by the torque values in different units of measure. Torque all screws to the recommended
value when assembling the radio.
Table 5-7. Torque Specifications for Screws
Driver/ Torque
Part Number Description
Socket lbs-in
0304726J05 Screw, Main Board T6 TORX 3.7 to 3.9
0386434Z02 Screw, Speaker Retainer T6 TORX 2.7 to 2.9
FN000157A01 Screw, Option Board T6 TORX 1.8 to 2.0
Chapter 6 Basic Troubleshooting
6.1 Introduction
If the board does not pass all the performance checks in Chapter 3, then the circuit board should be
replaced. If repair requires knowledge of details of component level troubleshooting, please send
radio to a Motorola Service Center listed in Appendix A.
6.2 Replacement Back Cover Kit Procedures

Once a problem has been isolated to a specific board, install the appropriate service kit (See Model
Charts in Chapter 1), which is orderable.
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 the blank board to be entered
once. Be very attentive during this procedure.
Caution
6-2 Basic Troubleshooting: Replacement Back Cover Kit Procedures
Notes
Appendix A EMEA Regional Warranty, Service and
Technical Support
A.1 Warranty and Service Support

Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warranty period, and service/ repair or spare parts support out of warranty.
Any "return for exchange" or "return for repair" by an authorized Motorola Dealer must be
accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an
Authorized Motorola Dealer.
A.1.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only.
In instances where the product is covered under a "return for replacement" or "return for repair"
warranty, a check of the product should be performed prior to shipping the unit back to Motorola.
This is to ensure that the product has been correctly programmed or has not been subjected to
damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources (Please see page A-3). All returns must be accompanied by a Warranty Claim
Form, available from your Customer Services representative. Products should be shipped back in
the original packaging, or correctly packaged to ensure no damage occurs in transit.
A.1.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola's Managed Technical Services (MTS) offers a repair service to both end users and
dealers at competitive prices.
2. MTS supplies individual parts and modules that can be purchased by dealers who are techni-
cally capable of performing fault analysis and repair.
A-2 EMEA Regional Warranty, Service and Technical Support: European Radio Support Centre (ERSC)
A.2 European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:
Email: essc@motorolasolutions.com
Austria: 01206091087 Italy: 0291483230
Israel: 180 931 5818 Poland: 00 800 141 0252
Denmark: 043682114 Netherlands: 0202061404
Norway: 24159815 Lithuania: 880 030 828
France: 0157323434 Portugal: 0217616160
Germany: 06950070204 Spain: 0912754787
UK : 02030 277499 South Africa: 0800981900
Saudi Arabia: 800 844 5345 Lithuania: 880 030 828
Russia: 810 800 228 41044/

810 800 120 1011
All other countries: +44 2030 277499
Or dial the European Repair and Service Centre:

Telephone: +49 30 6686 1555
Fax ERSC: +49 30 6686 1579
Email ERSC: ERSC@motorolasolutions.com
Please use these numbers for repair enquiries only.
A.3 Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly. While parts
may be assigned with a Motorola part number, this does not guarantee that they are available from
Motorola Radio Products and Solutions Organization (RPSO). Some parts may have become
obsolete and no longer available in the market due to cancellations by the supplier. If no Motorola
part number is assigned, the part is normally not available from Motorola, or is not a userserviceable
part. Part numbers appended with an asterisk are serviceable by Motorola Depot only.
Orders for replacement parts, kits and assemblies should be placed directly on Motorola's local
distribution/dealer organisation or via Motorola Online at: http://www.motorola.com/emeaonline
* 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).
EMEA Regional Warranty, Service and Technical Support: Technical Support A-3
A.4 Technical Support

Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions
which may be encountered.
Russia and Armenia – Andrey Nagornykh Central and East Europe – Siggy Punzenberger
Telephone: +7 495 787 8910 Telephone: +49 (0) 6128 70 2342
Fax: +7 495 785 0185 Fax: +49 (0) 6128 95 1096
Email: mwcb47@motorolasolutions.com Email: TFG003@motorolasolutions.com
Middle East and Africa – Wayne Holmes Germany – Customer Connect Team
Telephone: +49 (0) 6126 957 6237 Telephone: +49 (0) 30 6686 1539
Fax: +49 (0) 6126 957 6826 Fax: +49 (0) 30 6686 1916
Email: wayne.holmes@motorolasolutions.com Email: ESSC@motorolasolutions.com
France – Armand Roy Italy – Ugo Gentile

Telephone: +33 1 6935 7868 Telephone: +39 02 5220 7825
Fax: +33 1 6935 7808 Fax: +39 02 5220 7810
Email: armand.roy@motorolasolutions.com Email: Ugo.Gentile@motorolasolutions.com
France – Laurent Irrmann

Telephone: +33 1 6935 7866
Fax: +33 1 6935 7808
Email: laurent.irrmann@motorolasolutions.com
A.5 Further Assistance From Motorola

You can also contact the Customer Help Desk through the following web address.
http://www.motorolasolutions.com
A-4 EMEA Regional Warranty, Service and Technical Support: Further Assistance From Motorola
Notes
Appendix B Limited Level 3 Servicing
B.1 Maintenance
For details on the following, please refer to “Chapter 5 Disassembly/Reassembly Procedures” on
page 5-1 to section 5.4 on page 5-4.
Section 5.2 on page 5-1 to Section 5.4 on page 5-4.
• Preventive maintenance (inspection and cleaning).
• Safe handling of CMOS and LDMOS devices.
• Repair procedures and techniques.
B.2 Chip Components

Use a Hot-Air Repair Station for chip component replacement. Adjust the temperature control to
370°C (700°F), and adjust the airflow to a minimum setting. Airflow can vary due to component
density.
• To remove a chip component:
1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm
(1/8") above the component to be removed.
2. Begin applying the hot air. Once the solder reflows, remove the component using a pair
of tweezers.
3. Using a solder wick and a soldering iron or a power desoldering station, remove the
excess solder from the pads.
• To replace a chip component using a soldering iron:
1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the
solder pads.
2. Using a pair of tweezers, position the new chip component in place while heating the
fresh solder.
3. Once solder wicks onto the new component, remove the heat from the solder.
4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the
component. If necessary, touch up the first side. All solder joints should be smooth and
shiny.
• To replace a chip component using hot air:
1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.
2. Apply a drop of solder paste flux to each pad.
3. Using a pair of tweezers, position the new component in place.
4. Position the hot-air hand piece approximately 0.3 cm (1/8") above the component and
begin applying heat.
5. Once the solder wicks to the component, remove the heat and inspect the repair. All
joints should be smooth and shiny.
Limited Level 3 Servicing: Component and Parts list
1
VR4040
3 4 2 4 2 4 2 4
SW4002 R0914 SW4001 SW4000
C4041
R4041
C4042
R4042
C0932
C4040
VR4041
C0931
VR4042
3 3 3
E0900
C3121
R0924
C0906
R0925
R4040 C3103
R0918 U3107 R3100 A10 M10
C3102 R2103 R2101 R2106

4 3
R3121
R0917 L0900
R0906
C0901
2
TP_SPI0_CLK
C3127
4
5
C0903 R0915
TP_CS3B
C2104
3
4 3 U3101
C3152
C0908 R4500
U3105
R3151
M0800 R3222
3
R0907 C3104
R3152
E0800 R0916 8 5 J0700
R0905
5 R0910 3 C4510
C0907
2
4
Q0900 U0900 R3150 C3105
R3120
R0922 R0909 4 6 C3122 Q1002 U2100
C0905 R3158 C4509
C3150
5
16
4
C3101
C3100
C3124
12
C3125
R0908 R3125 3 C4511
R0913
R0926
L0400 C3151
6
D0401
C2100
R0927
U3150
4 5
L0401
C4512
C0904
R0912
C3120
C0401
2 C3155 R3157
C3126
C0902 U0902 Q0703 Q3125
R0920 C0909
C4513
C0402
R1024 R1023
R1016 R1015
R1022 R1021
R1004
3 R0911
4 3
8
C0817 2
C3032
C0411
C3031
2
4 3
C0423
C0422
R0420
C3033
R3104 R3103
C4514
C3108
A1 M1
Figure B-1. PCB Top View

Q0800
C0400 4 3 3 C3153 C3154

C0403
E0460
C0412 C4515
R1003
R1045
R1046
R1002
R2100
C2101
C2105
C0900
L0818
U3106
C0453
C0404
R1020
R1018
L0807 R9006 C4516
C3110
R3112
R3154
R3153
R3155
R3156
C3107
L0808 5 R0704 Q3126
L0402 R0435
C0433 R0434
C0043
C0405 Q0421 C4519
C1009
W1
C3034
VR4021
R3013
R0441 4 6
U3004
R9005 C4518
C0407
R0421
C4022
R4022
L0403
3 3
C0406 R0001
6 4 5 R3111 R3102 R0002 R9004 C4517
C2005
R3123
C2008
R3134
2 C0424 C0044 C2007 R2000
R0423 R0422 Q0420 R9007 C4520
E0300
C2006
Q0301
L0404 C0425
6 4
C4528
R1019
R1017
C0408 C0430 R2002 R2001 C2004
C0409
3
R0008 C4529
C0429
R0436 L0423 L0303

C0308
L0405 C0420 R0425
R0470 R0467
C0310
C0410 R0007 C4530
R0424 C0307 C4531
R0411
L0426 C0309
VR4020
R0410 C0428 6 Q0461 R0009
L0302 R0309 C4532
R0469
R0412
L0422
R0307 U1000
2
3 4
13
C0427 C4523
10
R0426 C0306
L0420 Q0302
R0440 R0439
R0466
R0303
U2000 C4524
C0302 C0313
C0301 C0303 Q0300
R0308
M4020
5
Q0460
C0305
5
S4010 C0431
2
C4525
D0420
R0306 C4021
3
3 C0426 3 4 C4526
R0427
C0452
2 C0460 C0304 R0305 C4020
L0300
TP_SB3
2 C4527
C0421
8 5 R0468 L0301 C4023
R0310
U0460
C1300
12
U0420
R3026
3
R0465
C4521
14
C0312
R0304 R0300
6 4
L0424
4 C4024 C4522
2
C2003
C2002
3
C0451 R0462
TP_TXD
C4507
F4020
R0428
R0432
3 R0301
R0461
R0460
U0421
R0438
R4032 C0461 TP_TXFS
C2000
C2001
C4500
R2003
C0311
C0300
C4013
C1034
C2010
R1035 R1006 R1005

C4012 L0304 C4501
R0463 R0464
R4012 W19 A19
6
R4013 SH0400 R0302 TP_TXCLK C4502

VR4010 TP_CS0
R1014
R3017
R3018
SH0300
R1031
R1030
R1033
R1032
R4011 TP_FREONCK
Component and Parts list
U1300 C4503
E1003
3
R4010
C1006
C4011 C4504
4 3
U1081
C4010
E1001
R3016 C4505
C1007
C1008
9 R0104 E0200 C1081
C0260
C0261
C4030
Q0201
C4506
Q0251
4 3
R0103
C0210 4 3 R3106
U1080
C4032 TP_SW_TP2
6 4 L0256
R0252
C1082
L0255
R0254
C0270
C1000
R1036
3 E0250
E1002
VR4030
6 C0211 5 5
L0207
C4031 C4508
3
R4031
C0106
6
C0105
C4001 L0257 C0214
C0217
3 4
C0264
3 4
L0205
R0201
C0209
R0204
C0219 C0218
8 R0253 Q0250 D1001
R0102
VR4031 C0262 R1081 C1080 Q1001 Q1000
C0258 3 C0267
2 L0206 SH1000
R0255
VR4101
C0263
L0204
C0215
C0213
10
C0265
C0257
C0268
C0216
R1037
C0266
L0254 VR4112
L0253 C0255 3
E4100
C0212
4 4 5 C0103
R0200
4 3
C0035 4 3 R1028
C0254 C0256 Q0200
7
C0207
L0203
R0202
R0203
C0208
VR4100
R0101 C0250
C0252
FL4100
C0253
C0251
C0206 6
R0100
C0101 C0205 R1029
C0259
R0251
Q4100
L0252
C0204
S4020 6 2 6
C0202
C0201
C0203
L0251 VR0202
J3500 C0102
VR0253 L0202
L0200
C0104
VR0250
VR0203
VR0201
L0250
3 5
L0201
C0200
C0100 VR0200
VR0252 VR0251
7
SH0200
6
B.3
B-2
Limited Level 3 Servicing: Component and Parts list B-3
Table B-1 Component Parts List
No. Circuit Ref Motorola Part Num.
1 SW_PTT,SW_UP,SW_DOWN 4070354A01
2 J_RF50 0986428Z02
3 S_FREQ 40012029002
4 S_VOLUME 1880619Z06
5 M_BATTERY 0986565Z02
6 F4020 65012019001
B-4 Limited Level 3 Servicing: Component and Parts list
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.
DP Refers to Digital Professional Radio model names in the MOTOTRBO
Professional Digital Two-Way Radio System.
Digital Refers to data that is stored or transmitted as a sequence of discrete
symbols from a finite set; most commonly this means binary data
represented using electronic or electromagnetic signals.
DPL Digital Private-Line: A type of digital communications that utilizes
privacy call, as well as memory channel and busy channel lock out to
enhance communication efficiency.
FCC Federal Communications Commission.
Frequency Number of times a complete electromagnetic-wave cycle occurs in a
fixed unit of time (usually one second).
GPIO General-Purpose Input/Output: Pins whose function is programmable.
GPS Global Positioning System.
IC Integrated Circuit: An assembly of interconnected components on a
small semiconductor chip, usually made of silicon. One chip can contain
millions of microscopic components and perform many functions.
IF Intermediate Frequency.
kHz kilohertz: One thousand cycles per second. Used especially as a radio-
frequency unit.
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.
Glossary-2
Term Definition
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.
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.
VIP Vehicle Interface Port.
Motorola Solutions, Inc.
1303 East Algonquin Road
Schaumburg, Illinois 60196 U.S.A.
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and

the Stylized M logo are trademarks or registered trademarks
of Motorola Trademark Holdings, LLC and are used under license.
All other trademarks are the property of their respective owners.
© 2013,2015 Motorola Solutions, Inc. All rights reserved.
Jan 2015.
www.motorolasolutions.com/mototrbo
*68012008074*
68012008074-B

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MOTOTRBOTM TWO-WAY RADIOS

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Edition Description Date

68012008074-A Initial Release June 2013

68012008074-B Added GOB information Jan. 2015

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

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

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

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

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

4.1 Introduction .................................................................................................................................. 4-1

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

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

Appendix A EMEA Regional Warranty, Service and Technical Support ..

Appendix B Limited Level 3 Servicing ...................................................B-1

B.1 Maintenance ................................................................................................................................B-1

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

Figure 1-1. Non Keypad Model............................................................................................................... 1-2

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

1.1 Notations Used in This Manual

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

! CAUTION indicates a potentially hazardous situation which, if

WARNING indicates a potentially hazardous situation

1.2 Radio Description

Table 1-1. Radio Frequency Ranges and Power Levels

Frequency Band Bandwidth Power Level

VHF 136–174 MHz 1 Watt or 5 Watt

UHF 403–470 MHz 1 Watt or 4 Watt

1.2.1 Non Keypad Model

Channel Selector Knob

Push-to-Talk (PTT) Button Accesory Connector

Side Button 2 (Programmable)

Figure 1-1. Non Keypad Model

1.3 .Portable Radio Model Numbering Scheme

Figure 1-2. Portable Radio Model Numbering Scheme

1.4 Model Charts

DP1400 Series, VHF, 136–174 MHz

NOTE X = Item Included

1.4.2 UHF Model Chart

DP1400 Series, UHF, 403–470 MHz

NOTE X = Item Included

Frequency VHF: 136 – 174 MHz

Dimensions (HxWxT) w/ NiMH 130mm x 62.5mm x 42mm

Power Supply 7.5V (nominal)

FCC Description VHF: ABZ99FT3092

IC Description VHF: 109AB-99FT3092

NiMH 1400 mAh battery Analog: 9 hours

Core Slim Li-Ion 1600 mAh battery Analog: 10.5 hours

High Cap Li-Ion 2200 mAh battery Analog: 14.5 hours

NOTE Weight can have 5% margin of error

Frequencies VHF: 136 – 174 MHz

Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz

Frequency Stability (-30°C to +/-0.5 ppm

Analog Sensitivity (12 dB SINAD) 0.3 µV

Digital Sensitivity (5% BER) 0.25 µV

Adjacent Channel Selectivity

Spurious Rejection (TIA603D) 70 dB

Rated Audio 0.5 W (internal)

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