Apx 8500 Mobile Radio: Basic Service Manual

APX™ TWO-WAY RADIOS
APX 8500 MOBILE

RADIO
BASIC SERVICE
MANUAL
Foreword
This manual covers the model of the ASTRO® 25 Subscribers, APX 8500 Mobile Radio. 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.
For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A
list of related publications is provided in the section “ Related Publications”.
Product Safety and RF Exposure Compliance

ATTENTION! Before using this radio, read the guide enclosed with your
radio, which contains important operating instructions for
safe usage and RF energy awareness and control for
compliance with applicable standards and regulations.
For a list of Motorola Solutions-approved antennas, batteries, and other accessories, visit the
following web site, which lists approved accessories: http://www.motorolasolutions.com/en_us/
products/two-way-radios/project-25-radios.html
Manual Revisions
Changes which occur after this manual is printed are described in PMRs (Publication Manual Revisions). These PMRs
provide complete replacement pages for all added, changed, and deleted items. To obtain PMRs, go to
https://businessonline.motorolasolutions.com.
Computer Software Copyrights

The Motorola Solutions products described in this manual may include copyrighted Motorola Solutions computer programs
stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola
Solutions 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 Solutions
computer programs contained in the Motorola Solutions 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 Solutions.
Furthermore, the purchase of Motorola Solutions 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 Solutions. 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 Solutions.
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 Solutions reserves the right to make changes to any products herein to
improve readability, function, or design. Motorola Solutions 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 Solutions Trademark Holdings, LLC and are used under license. All other trademarks are the property of their
respective owners.
© 2016 Motorola Solutions, Inc.All rights reserved.
Notes
v
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
MN003076A01-AA Initial Release Nov. 2016

vi
Notes
Table of Contents vii
Table of Contents
Foreword ........................................................................................................iii
Product Safety and RF Exposure Compliance ........................................................................................... iii
Manual Revisions ....................................................................................................................................... iii
Computer Software Copyrights .................................................................................................................. iii
Document Copyrights ................................................................................................................................. iii
Disclaimer................................................................................................................................................... iii
Trademarks ................................................................................................................................................ iii
Document History ......................................................................................... v
Commercial Warranty ................................................................................xvii

Limited Warranty ..................................................................................................................................... xvii
MOTOROLA SOLUTIONS COMMUNICATION PRODUCTS ..................................................... xvii
Model Numbering, Charts, and Specifications.........................................xxi

Mobile Radio Model Numbering Scheme ................................................................................................. xxi
APX 8500 Model Charts .......................................................................................................................... xxii
ASTRO APX 8500 Emergency Model Chart ........................................................................................... xxii
ASTRO APX 8500 Antennas Model Chart ............................................................................................. xxiii
ASTRO APX 8500 Antennas Model Chart (Cont.) ................................................................................. xxiii
ASTRO APX 8500 Cables Model Chart ................................................................................................. xxiv
ASTRO APX 8500 Cables Model Chart (Cont.) ..................................................................................... xxiv
ASTRO APX 8500 CAN Model Chart...................................................................................................... xxv
ASTRO APX 8500 DEK Model Chart ..................................................................................................... xxvi
ASTRO APX 8500 DEK Model Chart (Cont.) ........................................................................................ xxvii
ASTRO APX 8500 Housing Alarm PS Model Chart ..............................................................................xxviii
ASTRO APX 8500 Mic Model Chart....................................................................................................... xxix
ASTRO APX 8500 Mic Model Chart (Cont.)........................................................................................... xxix
ASTRO APX 8500 Speaker Model Chart ................................................................................................ xxx
APX 8500 Radio Specifications.............................................................................................................. xxxi
Chapter 1 Introduction ......................................................................... 1-1

1.1 Manual Notations ......................................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-2
1.3 FLASHport® ................................................................................................................................................................... 1-2
1.4 O2/O3/O5/O7/O9 Control Head Descriptions .............................................................................. 1-2
1.5 P25 Digital Vehicular Repeater System (DVRS) ......................................................................... 1-2
Chapter 2 Basic Maintenance.............................................................. 2-1

2.1 Introduction .................................................................................................................................. 2-1
2.2 Preventive Maintenance .............................................................................................................. 2-1
viii Table of Contents
2.2.1 Inspection ........................................................................................................................ 2-1

2.2.2 Cleaning Procedures ....................................................................................................... 2-2
2.2.2.1 Cleaning External Plastic Surfaces................................................................... 2-2
2.2.2.2 Cleaning Internal Circuit Boards and Components........................................... 2-2
2.2.3 General Radio Care and Handling Precautions............................................................... 2-2
2.2.4 RF Power Amplifier (RF PA) Heatsinking ........................................................................ 2-3
2.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 2-3
Chapter 3 Basic Theory of Operation ................................................. 3-1

3.1 Introduction .................................................................................................................................. 3-1
3.2 General Overview ........................................................................................................................ 3-1
3.3 Controller Section ........................................................................................................................ 3-2
3.3.1 Introduction ...................................................................................................................... 3-2
3.3.2 Controller Functional Blocks ............................................................................................ 3-3
3.3.3 Voltage Distribution / Power On/Off................................................................................. 3-5
3.3.3.1 Voltage Distribution for Controller and RF Board ............................................. 3-5
3.3.3.2 Power On/Off .................................................................................................... 3-5
3.3.4 Audio Circuitry ................................................................................................................. 3-5
3.3.4.1 RX Audio Path .................................................................................................. 3-5
3.3.4.2 TX Audio Path................................................................................................... 3-7
3.3.5 Secure ............................................................................................................................. 3-7
3.3.6 GPS Overview ................................................................................................................. 3-8
3.3.7 Serial Interfaces............................................................................................................... 3-9
3.4 Transceiver Interface Board (TIB).............................................................................................. 3-10
3.4.1 Quick Disconnect Circuit................................................................................................ 3-11
3.4.2 Controller Area Network (CAN) Transceivers................................................................ 3-11
3.4.3 CAN Termination ........................................................................................................... 3-11
3.5 Analog Mode of Operation ......................................................................................................... 3-12
3.5.1 Receive Operation ......................................................................................................... 3-12
3.5.2 Transmit Operation ........................................................................................................ 3-12
3.6 ASTRO Mode of Operation ........................................................................................................ 3-12
3.7 RF Transmitter Board (TX) ........................................................................................................ 3-13
3.7.1 Radio-Frequency Power Amplifier (RF PA) & Output Network (ON)............................. 3-13
3.7.2 Gain Stages ................................................................................................................... 3-13
3.7.3 Power Control ................................................................................................................ 3-13
3.7.4 Circuit Protection ........................................................................................................... 3-13
3.7.5 RF Transmitter Board to Transceiver Board Interconnect ............................................. 3-14
3.8 RF Transceiver Board (XCVR) .................................................................................................. 3-14
3.8.1 VHF Receiver Front-End ............................................................................................... 3-14
3.8.2 UHF1 and UHF2 Receiver Front-End............................................................................ 3-15
3.8.3 700-800MHZ / Industry Canada Receiver Front-End .................................................... 3-15
3.8.4 Mixer .............................................................................................................................. 3-15
3.8.5 IF Circuitry ..................................................................................................................... 3-15
3.8.6 Receiver Back-End ........................................................................................................ 3-15
3.9 Frequency Generation Unit ........................................................................................................ 3-16
Chapter 4 Test Equipment, Service Aids, and Tools......................... 4-1

4.1 Recommended Test Equipment .................................................................................................. 4-1
4.2 Service Aids and Recommended Tools ....................................................................................... 4-2
4.3 APX Mobile Radios Field Programming and Equipment ............................................................. 4-3
Table of Contents ix
Chapter 5 Performance Checks .......................................................... 5-1

5.1 Introduction .................................................................................................................................. 5-1
5.2 Test Setup ................................................................................................................................... 5-1
5.3 Test Mode .................................................................................................................................... 5-1
5.3.1 Entering Test Mode ......................................................................................................... 5-1
5.3.2 RF Test Mode.................................................................................................................. 5-3
5.3.3 O2 Control Head Test Mode............................................................................................ 5-5
5.4 Receiver Performance Checks .................................................................................................. 5-10
5.5 Transmitter Performance Checks .............................................................................................. 5-11
Chapter 6 Radio Alignment Procedures............................................. 6-1

6.1 Introduction .................................................................................................................................. 6-1
6.2 ASTRO APX Mobile Radio Tuner Software................................................................................. 6-1
6.3 Radio Information ........................................................................................................................ 6-3
6.4 Transmitter Alignments ................................................................................................................ 6-3
6.4.1 PA Bias 1 Alignment........................................................................................................ 6-3
6.4.2 PA Bias 3 Alignment........................................................................................................ 6-5
6.4.3 Reference Oscillator Alignment ....................................................................................... 6-6
6.4.4 Power Detector Calibration.............................................................................................. 6-7
6.4.5 Tx Power Characterization .............................................................................................. 6-9
6.4.6 Tx Current Limit ............................................................................................................. 6-11
6.4.6.1 Tx Voltage Limit .............................................................................................. 6-13
6.4.7 Tx Deviation Balance (Compensation) .......................................................................... 6-15
6.5 Receiver Alignments .................................................................................................................. 6-17
6.5.1 Front End Filter Alignment............................................................................................. 6-17
6.5.2 Procedure for VHF, UHF1 and UHF2 (Auto Tune)........................................................ 6-17
6.5.3 RX Duty Cycle Adjustment ............................................................................................ 6-18
6.6 Performance Testing ................................................................................................................. 6-19
6.6.1 Bit Error Rate (BER) Test .............................................................................................. 6-19
6.6.2 Transmitter Test Pattern................................................................................................ 6-20
Chapter 7 Encryption ........................................................................... 7-1

7.1 Motorola Advanced Crypto Engine Secure Options .................................................................... 7-1
7.1.1 Secure Key Retention...................................................................................................... 7-1
7.1.2 Secure Dispatch Operation ............................................................................................. 7-2
7.1.3 Secure Emergency Operation ......................................................................................... 7-2
7.2 Load an Encryption Key............................................................................................................... 7-2
7.3 Advanced Secure Operation........................................................................................................ 7-2
7.3.1 Multikey Operation........................................................................................................... 7-3
7.4 Select an Encryption Key or Keyset ............................................................................................ 7-3
7.5 Erase a Single Key ...................................................................................................................... 7-3
7.6 Erase All Keys ............................................................................................................................. 7-4
7.7 Over-the-Air Rekeying ................................................................................................................. 7-4
Chapter 8 Disassembly/Reassembly Procedures ............................. 8-1

x Table of Contents
8.1 Introduction .................................................................................................................................. 8-1

8.2 Replacement Procedures ............................................................................................................ 8-1
8.2.1 Required Tools and Supplies........................................................................................... 8-1
8.2.2 Transceiver Interface Board Disassembly/Reassembly .................................................. 8-2
8.2.3 Radio Disassembly .......................................................................................................... 8-3
8.2.3.1 APX 8500 Mid Power Model............................................................................. 8-3
8.2.3.2 O2 Radio Disassembly ................................................................................... 8-10
8.2.4 Radio Reassembly......................................................................................................... 8-20
8.2.4.1 APX 8500 Mid Power Model........................................................................... 8-20
8.2.4.2 O2 Radio Reassembly .................................................................................... 8-41
8.2.4.5 Remote Reassembly ...................................................................................... 8-49
8.3 Chassis Thermal Pad Replacement Procedure ......................................................................... 8-51
8.3.1 Mid Power Models ......................................................................................................... 8-51
8.4 Fastener Torque Chart............................................................................................................... 8-53
Chapter 9 Radio PINOUT functions, Error Codes, and Basic

Troubleshooting9-1
9.1 Introduction .................................................................................................................................. 9-1
9.2 Accessory Connectors ................................................................................................................. 9-2
9.2.1 J700 TIB– Mobile Microphone Port (MMP)...................................................................... 9-2
9.2.2 J2 Mid Power Transceiver – Data and Audio Rear Interface........................................... 9-3
9.2.3 J800 TIB – Controller Area Network (CAN) Interface ...................................................... 9-6
9.3 Replacement Board Procedures .................................................................................................. 9-6
9.4 Power-Up Error Codes................................................................................................................. 9-7
9.5 Operational Error Codes .............................................................................................................. 9-8
9.6 Transmitter Troubleshooting ........................................................................................................ 9-8
9.7 Receiver Troubleshooting ............................................................................................................ 9-9
9.8 Controller Troubleshooting......................................................................................................... 9-10
Chapter 10 Functional Block Diagrams and Connectors ................. 10-1

10.1 APX Mobile Radio Transceiver Functional Block Diagram ........................................................ 10-2
10.2 O3 Dash and Remote Control Head Functional Block Diagram ................................................ 10-3
10.3 APX Mobile Radio Transceiver Interface Board (TIB) Functional Block Diagram ..................... 10-4
10.4 O3 Radio Connector Locations.................................................................................................. 10-6
10.4.1 Mid Power Only ............................................................................................................. 10-6
10.5 O5 Radio Connector Locations.................................................................................................. 10-7
10.5.1 Mid Power Only ............................................................................................................. 10-7
10.5.2 High Power Only............................................................................................................ 10-7
10.6 O9 Transceiver Interface ........................................................................................................... 10-8
Chapter 11 Exploded Views and Parts Lists ...................................... 11-1

11.1 Remote Exploded View and Parts List....................................................................................... 11-2
11.2 APX 8500 O2 Dash Mount Radio Exploded View and Parts List ............................................. 11-3
11.3 APX 8500 O3 Radio Exploded View and Parts List .................................................................. 11-4
11.4 APX 8500 O5 Dash Mount Radio Exploded View and Parts List .............................................. 11-5
Table of Contents xi
11.5 APX 8500 O7 Dash Mount Radio Exploded View and Parts List ............................................. 11-6
Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information ..........................................................................................................A-1
A.2 Motorola Online Service and Support ..........................................................................................A-1
A.3 Accessories Aftermarket Division (AAD) .....................................................................................A-2
Appendix B Environmental Information ................................................B-1
Appendix C Maritime Radio Use in the VHF Frequency Range...........C-1

C.1 Special Channel Assignments .....................................................................................................C-1
C.1.1 Emergency Channel ........................................................................................................C-1
C.1.2 Non-Commercial Call Channel ........................................................................................C-1
C.2 Operating Frequency Requirements............................................................................................C-2
Master Glossary ............................................................................ Glossary-1
Index ...................................................................................................... Index-i

xii List of Figures
List of Figures
Figure 3-1. Mobile Controller Block Diagram.......................................................................................... 3-3

Figure 3-2. Voltage Distribution / Power Diagram .................................................................................. 3-5
Figure 3-3. Receive Baseband Audio Path............................................................................................. 3-6
Figure 3-4. Transmit Baseband Audio Path............................................................................................ 3-7
Figure 3-5. GPS Architecture.................................................................................................................. 3-8
Figure 3-6. Dash-Mount Configuration ................................................................................................... 3-9
Figure 3-7. Remote-Mount Configuration ............................................................................................... 3-9
Figure 3-8. Transceiver Interface Board (TIB) ...................................................................................... 3-10
Figure 3-9. Receiver Block Diagram..................................................................................................... 3-14
Figure 3-10. Configuration of the Frequency Generation Unit for APX 8500 ......................................... 3-16
Figure 5-1. Performance Checks Test Setup.......................................................................................... 5-1
Figure 5-2. O2 Control Head .................................................................................................................. 5-5
Figure 6-1. Radio Alignment Test Setup for APX Mobile Radio .............................................................. 6-1
Figure 6-2. Tuner Main Menu ................................................................................................................. 6-2
Figure 6-3. Radio Information Screen .................................................................................................... 6-3
Figure 6-4. PA Bias 1 Alignment Screen................................................................................................. 6-4
Figure 6-5. PA Bias 3 Alignment Screen................................................................................................. 6-5
Figure 6-6. Reference Oscillator Window ............................................................................................... 6-7
Figure 6-7. Power Detection Calibration Alignment Screen ................................................................... 6-8
Figure 6-8. Tx Power Characterization Alignment Screen.................................................................... 6-10
Figure 6-9. Tx Current Limit Alignment Screen .................................................................................... 6-12
Figure 6-10. Tx Voltage Limit Alignment Screen .................................................................................... 6-14
Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen.................................................. 6-16
Figure 6-12. RX Front End Filter Alignment............................................................................................ 6-18
Figure 6-13. RX Duty Cycle Adjustment AutoTune................................................................................. 6-19
Figure 6-14. Bit Error Rate Screen ......................................................................................................... 6-19
Figure 6-15. Transmitter Test Pattern Screen......................................................................................... 6-21
Figure 7-1. ECAT (Electronic Catalog) Portal ......................................................................................... 7-1
Figure 8-1. TUC Seal Placement............................................................................................................ 8-2
Figure 8-2. Removing the Control Head Screws .................................................................................... 8-3
Figure 8-3. Removing the Control Head ................................................................................................. 8-4
Figure 8-4. Removing the Control Head Flex ......................................................................................... 8-5
Figure 8-5. Removing the TIB Screws.................................................................................................... 8-5
Figure 8-6. Removing the TX Grille ........................................................................................................ 8-6
Figure 8-7. Removing the TX Casting Screws........................................................................................ 8-6
Figure 8-8. Removing the TX Casting .................................................................................................... 8-7
Figure 8-9. Removing the TX PCB ......................................................................................................... 8-7
Figure 8-10. Removing the XCVR Cover ................................................................................................. 8-8
Figure 8-11. Removing the GPS Cable, BT/Wi-Fi Cable, and Accessory Flex......................................... 8-8
Figure 8-12. Removing the XCVR PCB.................................................................................................... 8-9
Figure 8-13. Removing the Control Head Screws .................................................................................. 8-10
Figure 8-14. Removing the Control Head ............................................................................................... 8-11
Figure 8-15. Disconnecting the Transceiver Flex from the Front Housing Assembly ............................. 8-12
Figure 8-16. Removing the Back Housing Assembly ............................................................................. 8-13
Figure 8-17. Removing the Transceiver Flex.......................................................................................... 8-13
Figure 8-18. Removing the Control Head Screws .................................................................................. 8-14
List of Figures xiii
Figure 8-19. Removing the Control Head/TIB ........................................................................................ 8-15

Figure 8-20. Removing the Control Head Flex ....................................................................................... 8-16
Figure 8-21. Removing the Transceiver Screws..................................................................................... 8-17
Figure 8-22. Removing the Control Head............................................................................................... 8-18
Figure 8-23. Disconnecting the Transceiver Flex from the Transceiver ................................................. 8-18
Figure 8-24. Removing the Transceiver Flex.......................................................................................... 8-19
Figure 8-25. Placing Thermal Pad (7575935B01) transmitter (TX) side of main chassis....................... 8-22
Figure 8-26. Placing Thermal Pad 7575767B01 on transmitter (TX) side of main chassis .................... 8-22
Figure 8-27. Placing the Thermal Pad (HW000572A02) on transmitter (TX) side of main chassis........ 8-22
Figure 8-28. All 3 thermal pads located on transmitter (TX) side of main chassis. See Table 8-2. ........ 8-23
Figure 8-29. Installing the Accessory Connector Flex into Main Chassis............................................... 8-24
Figure 8-30. Removing the QMA Lock Washer and QMA Nut ............................................................... 8-24
Figure 8-31. Installing two RF Cables into the Main Chassis ................................................................. 8-24
Figure 8-32. Installing QMA Lock Washer and QMA Nut for each cable connector ............................... 8-25
Figure 8-33. Installing Accessory Connector Screws ............................................................................. 8-25
Figure 8-34. Installing the two RF Cables .............................................................................................. 8-26
Figure 8-35. Placing the thermal pads 7575767B01 and 7575935B01 onto Transmitter (TX) Cover .... 8-26
Figure 8-36. Applying the Thermal Grease onto the Transmitter Board................................................. 8-27
Figure 8-37. Removing the QMA Lock Washer and Nut from RF Connector ......................................... 8-27
Figure 8-38. Placing the transmitter board onto the Transmitter Cover.................................................. 8-28
Figure 8-39. Installing the QMA Lock Washer and Nut into the RF Connector ...................................... 8-28
Figure 8-40. Installing the Grounding Clip on Transmitter Cover ........................................................... 8-29
Figure 8-41. Grounding Clip on Transmitter Cover is critical to ensure DC connector stability.............. 8-29
Figure 8-42. RF bullets used in the Transmitter Board........................................................................... 8-29
Figure 8-43. Installing PA Screws........................................................................................................... 8-30
Figure 8-44. Placing the Transmitter Seal into the main Chassis........................................................... 8-31
Figure 8-45. Placing Transmitter Cover onto the Main Chassis ............................................................. 8-31
Figure 8-46. Securing the RF Cover to the Chassis............................................................................... 8-32
Figure 8-47. Placing Thermal Pad (7575767B01) on transceiver (XVCR) side of main chassis............ 8-33
Figure 8-48. Installing the Coin Cell Battery into Transceiver Board ...................................................... 8-33
Figure 8-49. Securing the Transceiver Board into the Chassis .............................................................. 8-34
Figure 8-50. Connecting Rear Accessory Connector Flex and GPS/BT/Wi-Fi Cables........................... 8-35
Figure 8-51. Connecting RF Cables to Transceiver Board..................................................................... 8-35
Figure 8-52. Placing Thermal Pad on Transceiver (XCVR) Cover ......................................................... 8-36
Figure 8-53. Placing Transceiver Seal ................................................................................................... 8-36
Figure 8-54. Installing the Transceiver Cover......................................................................................... 8-37
Figure 8-55. Installing the RF Grille........................................................................................................ 8-38
Figure 8-56. Installing the TIB Assembly ................................................................................................ 8-38
Figure 8-57. Installing Flex into Controller PCB ..................................................................................... 8-39
Figure 8-59. Aligning Control Head front of chassis, and Installing the Control Head screws ............... 8-40
Figure 8-60. Installing the Transceiver Flex onto the Transceiver .......................................................... 8-41
Figure 8-61. Installing the Back Housing Assembly onto the Transceiver.............................................. 8-42
Figure 8-62. Installing the Transceiver Flex onto the Front Housing Assembly...................................... 8-42
Figure 8-63. Attaching the Front Housing Assembly to the Back Housing Assembly............................. 8-43
Figure 8-64. Attaching the Control Head Screws ................................................................................... 8-44
Figure 8-66. Installing Control Head/TIB Flex to Control Head/TIB........................................................ 8-45
Figure 8-67. Aligning Control Head/TIB front of chassis, and Installing the Control Head/TIB screws .. 8-46
Figure 8-68. Installing the Transceiver Flex onto the Control Head ....................................................... 8-47
Figure 8-69. Attaching the Control Head to the Transceiver .................................................................. 8-48
Figure 8-70. Attaching the Transceiver Screws...................................................................................... 8-48
Figure 8-71. Reinstalling Remote Front Cover Plate.............................................................................. 8-49
Figure 8-72. Attaching the remote screws.............................................................................................. 8-50
xiv List of Figures
Figure 8-73. Chassis Thermal Pad and Grease Locations..................................................................... 8-52

Figure 9-1. J700 MMP Connector........................................................................................................... 9-2
Figure 9-2. J2 Rear Accessory Connector.............................................................................................. 9-3
Figure 9-3. J800 Controller Area Network (CAN) Connector on TIB ...................................................... 9-6
Figure 10-1. APX Mobile Radio Transceiver Functional Block Diagram................................................. 10-2
Figure 10-2. O3 Dash and Remote Control Head Functional Block Diagram ........................................ 10-3
Figure 10-3. Transceiver Interface Board (TIB) CAN Functional Block Diagram ................................... 10-4
Figure 10-4. Transceiver Interface Board (TIB) Power On/Off Functional Block Diagram ..................... 10-5
Figure 10-5. O3 Dash-Mount Radio Connector Locations (Mid Power Only)......................................... 10-6
Figure 10-6. O3 Remote-Mount Radio Connector Locations ................................................................. 10-6
Figure 10-7. O5 Dash-Mount Radio Connector Locations (Mid Power Only)......................................... 10-7
Figure 10-8. O5 Remote-Mount Radio Connector Locations (High Power Only) ................................... 10-7
Figure 10-9. Transceiver Interface Board (TIB), Universal Relay Controller & Control Head View. ....... 10-8
Figure 10-10.Remote-Mount Configuration with 100W or Higher Power Radio ...................................... 10-9
Figure 11-1. Remote Exploded View ...................................................................................................... 11-2
Figure 11-2. APX 8500 O2 Dash Mount Radio Exploded View.............................................................. 11-3
Figure 11-3. APX 8500 O3 Radio Exploded View .................................................................................. 11-4
List of Tables xv
List of Tables
Table 1-1. APX 8500 Frequency Ranges and Power Level.................................................................. 1-2
Table 4-1. Recommended Non-Motorola Solutions Test Equipment .................................................... 4-1
Table 4-2. Service Aids for APX Mobile Radios .................................................................................... 4-2
Table 4-3. APX Mobile Radios Field-Programming Items..................................................................... 4-3
Table 5-1. Test-Mode Displays ............................................................................................................. 5-2
Table 5-2. Rx and Tx Test Frequencies ................................................................................................ 5-4
Table 5-3. Signaling Types.................................................................................................................... 5-4
Table 5-4. Receiver Performance Checks .......................................................................................... 5-10
Table 5-5. Transmitter Performance Checks ...................................................................................... 5-11
Table 6-1. PA Bias 1 Alignment RF Power Amplifier Devices ............................................................... 6-3
Table 6-2. Power Supply Voltage Settings ............................................................................................ 6-3
Table 6-3. PA Bias 1 Alignment Device Bias Current ............................................................................ 6-4
Table 6-4. PA Bias 3 Alignment Amplifier Devices ................................................................................ 6-5
Table 6-6. PA Bias 3 Alignment Device Bias Current ............................................................................ 6-6
Table 6-9. Power Supply Voltage Settings .......................................................................................... 6-11
Table 6-10. Transmit Current Limit Devices.......................................................................................... 6-13
Table 6-11. Bit Error Rate Test Fields ................................................................................................... 6-19
Table 6-12. Transmitter Test Pattern Fields .......................................................................................... 6-20
Table 7-1. Controller Boards with Programmed Secure Algorithms for APX 8500................................ 7-1
Table 8-1. Required Tools and Supplies ............................................................................................... 8-1
Table 8-2. Chassis Thermal Pad and Grease Part Numbers.............................................................. 8-52
Table 8-3. Fastener Torque Chart ....................................................................................................... 8-53
Table 9-1. MMP Connector Signal Descriptions ................................................................................... 9-2
Table 9-2. J2 Rear Accessory Connector Signal and Voltage Descriptions.......................................... 9-3
Table 9-3. J800 Controller Area Network Connector Pin Functions...................................................... 9-6
Table 9-4. Power-Up Error Codes......................................................................................................... 9-7
Table 9-5. Operational Error Codes ...................................................................................................... 9-8
Table 9-6. Transmitter Troubleshooting Chart....................................................................................... 9-8
Table 9-7. Receiver Troubleshooting Chart........................................................................................... 9-9
Table 9-8. Controller Troubleshooting Chart ....................................................................................... 9-10
Table 10-1. Table of Functional Block Diagrams and Connectors......................................................... 10-1
Table 11-1. Table of Exploded Views .................................................................................................... 11-1
Table 11-2. Remote Parts List .............................................................................................................. 11-2
Table 11-3. APX 8500 O2 Dash Mount Radio Parts List ...................................................................... 11-3
Table 11-4. APX 8500 O3 Radio Parts List........................................................................................... 11-4
xvi Related Publications
Related Publications
ASTRO APX Mobile Radio O2 Control Head User Guide ......................................................... 68012006035
ASTRO APX Mobile Radio O3 Control Head User Guide .......................................................... 6875946M01
ASTRO APX Mobile Radio O5 Control Head User Guide .......................................................... 6875947M01
ASTRO APX 8500 And O2, O3, O5, O7 & O9 Control Head Installation Manual.................... MN003109A01
APX 8500 Mobile Radio Detailed Service Manual................................................................... MN003077A01
ASTRO APX Mobile Radio O2 Quick Reference Card .................................................................. PMLN6193
ASTRO APX Mobile Safety Manual ..........................................................................6881095C99/NNTN7851
ASTRO APX Wi-Fi Provisioning Leaflet................................................................ MN001435A01/PMLN7688
Commercial Warranty xvii
Commercial Warranty
Limited Warranty
MOTOROLA SOLUTIONS COMMUNICATION PRODUCTS
I. What This Warranty Covers And For How Long

MOTOROLA SOLUTIONS INC. (“MOTOROLA”) warrants the MOTOROLA SOLUTIONS
manufactured Communication Products listed below (“Product”) against defects in material and
workmanship under normal use and service for a period of time from the date of purchase as
scheduled below:
ASTRO APX 8500 Mobile Radio One (1) Year
Product Accessories One (1) Year
Motorola Solutions, at its option, will at no charge either repair the Product (with new or
reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of
the Product during the warranty period provided it is returned in accordance with the terms of this
warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty
period. All replaced parts of Product shall become the property of MOTOROLA SOLUTIONS.
This express limited warranty is extended by MOTOROLA SOLUTIONS to the original end user
purchaser only and is not assignable or transferable to any other party. This is the complete warranty
for the Product manufactured by MOTOROLA SOLUTIONS. MOTOROLA SOLUTIONS assumes no
obligations or liability for additions or modifications to this warranty unless made in writing and
signed by an officer of MOTOROLA SOLUTIONS. Unless made in a separate agreement between
MOTOROLA SOLUTIONS and the original end user purchaser, MOTOROLA SOLUTIONS does not
warrant the installation, maintenance or service of the Product.
MOTOROLA SOLUTIONS cannot be responsible in any way for any ancillary equipment not
furnished by MOTOROLA SOLUTIONS which is attached to or used in connection with the Product,
or for operation of the Product with any ancillary equipment, and all such equipment is expressly
excluded from this warranty. Because each system which may use the Product is unique,
MOTOROLA SOLUTIONS disclaims liability for range, coverage, or operation of the system as a
whole under this warranty.
xviii Commercial Warranty
II. General Provisions Notes

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

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

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

A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs
(including, without limitation, the addition to the Product of non-Motorola Solutions supplied
equipment) which adversely affect performance of the Product or interfere with Motorola
Solutions's normal warranty inspection and testing of the Product to verify any warranty
claim.
F. Product which has had the serial number removed or made illegible.
G. Rechargeable batteries if:
- any of the seals on the battery enclosure of cells are broken or show evidence of
tampering.
- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.
H. Freight costs to the repair depot.
Commercial Warranty xix
I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the

Product, does not function in accordance with MOTOROLA SOLUTIONS’s published
specifications or the FCC certification labeling in effect for the Product at the time the Product
was initially distributed from MOTOROLA SOLUTIONS.
J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
K. Normal and customary wear and tear.
VI. Patent And Software Provisions

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

This Warranty is governed by the laws of the State of Illinois, USA.
xx Commercial Warranty
Notes
Model Numbering, Charts, and Specifications xxi
Model Numbering, Charts, and Specifications

Mobile Radio Model Numbering Scheme
Typical Model Number: M 3 7 T S S 9 P W 1 A N S P 0 1
Position: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Position 1 - Type of Unit
M = Mobile Positions 13 - 16
L = Table Top Station SP Model Suffix
Positions 2 & 3 - Model Series Position 12 -
Model Series Unique Model Variations
30 = APX 7500 24 = APX 2500 C = Cenelec
25 = APX 6500 22 = APX 4500 N = Standard Package
36 = APX1500 37 = APX 8500
Position 4 - Frequency Band Position 11 - Version
A = Less than 29.7MHz UHF Range Version Letter (Alpha) - Major Change
B = 29.7 to 35.99MHz N = 330 to 370MHz
C = 36 to 41MHz P = 366 to 410MHz Position 10 - Feature Level
D = 42 to 50MHz Q = 403 to 437MHz 1 = Basic 6 = Standard Plus
E = 300 to 345MHz R = 438 to 482MHz 2 = Limited Package 7 = Expanded Package
F = 66 to 80MHz S = 470 to 620MHz 3 = Limited Plus 8 = Expanded Plus
G = 74 to 90MHz T = Product Specific 4 = Intermediate 9 = Full Feature/
H = Product Specific U = 806 to 870MHz* 5 = Standard Package Programmable
VHF Range V = 825 to 870MHz Position 9 - Primary SystemType
J = 136 to 162MHz W = 896 to 941MHz
K = 146 to 178MHz A = Conventional
X = 403-470MHz
L = 174 to 210MHz B = Privacy Plus
Y = 1.0 to 1.6GHz
M = 190 to 235MHz C = Clear SMARTNET
Z = 1.5 to 2.0GHz
D = Advanced Conventional Stat-Alert
* For APX 7500 "K" in Position 4 represents
E = Enhanced Privacy Plus
136-174MHz.
F = Nauganet 888 Series
* For APX 7500 "Q" in Position 4 represents
G = Japan Specialized Mobile Radio (JSMR)
380-470MHz.
* For APX 7500 "S" in Position 4 represent H = Multi-Channel Access (MCA)
470-520MHz. J = CoveragePLUS
K = MPT1327* - Public
* For APX 7500 "U" in Position 4 represent
L = MPT1327* - Private
762-870MHz.
M = Radiocom
Note: Values represented are not absolute,
and are given to indicate range only
. N = Tone Signalling
Position 5 - Power Level P = Binary Signalling
Q = Phonenet
A = 0 to 0.7 Watts K = 36 to 60 Watts
R = IDEN Basic
B = 0.7 to 0.9 Watts L = 61 to 110 Watts
S = IDEN Advanced Feature
C = 1.0 to 3.9 Watts M = Up to 125 Watts
T = JSMR Digital
D = 4.0 to 5.0 Watts N = 1 to 25 Watts
U = LTR Protocol
E = 5.1 to 6.0 Watts P = 25 to 40 Watts
V = Single Sideband
F = 6.1 to 10 Watts Q = 25 to 45 Watts
W = Programmable
G = 10.1 to 15 Watts R = 10 to 35 Watts
X = Secure Conventional
H = 16 to 25 Watts S = 10 to 50 Watts
Y = Secure SMARTNET
J = 26 to 35 Watts T = 25 to 110 Watts
Note: Values represented are not absolute, Z = TETRA
and are given to indicate range only
. 2 = SmartZone
* MPT = Ministry of Posts and Telecommunications
Position 6 - Physical Packages
Position 8 - Primary Operation
A = RF Modem Operation A = Conventional/Simplex
B = Receiver Only B = Conventional/Duplex
C = Standard Control; No Display C = Trunked Twin Type
D = Standard Control; With Display D = Dual Mode Trunked
E = Limited Keypad; No Display E = Dual Mode Trunked/Duplex
F = Limited Keypad; With Display F = Trunked Type I
G = Full Keypad; No Display G = Trunked Type II
H = Full Keypad; With Display H = FDMA* Digital Dual Mode
J = Limited Controls; No Display J = TDMA** Digital Dual Mode
K = Limited Controls; Basic Display K = Single Sideband
L = Limited Controls; Limited Display L = Global Positioning Satellite Capable
M = Rotary Controls; Standard Display M = Amplitude Companded Sideband (ACSB)
N = Enhanced Controls; Enhanced Display N = Digital Dispatch
P = Low Profile; No Display P = Programmable
Q = Low Profile; Basic Display Q = Digital Interconnect
R = Low Profile; Basic Display, Full Keypad R = Digital Multi-Service
S = Tranceiver with Selectable Control Head S = 9600 Capable
T = T = TDMA
U= * FDMA = Frequency Division Multiple Acces s
V = VDV Control Head ** TDMA = Time Division Multiple Access
W = Control Head #2
Position 7 - Channel Spacing
0= 5 = 15KHz
1 = 5KHz 6 = 20/25KHz
2 = 6.25KHz 7 = 30KHz
3 = 10KHz 8 = 12.5/25KHz
4 = 12.5KHz 9 = Variable/Programmable
xxii Model Numbering, Charts, and Specifications
APX 8500 Model Charts

Please refer to appendix A to access ECAT (Electronic Catalog) to see the latest model options and
kit numbers.
ASTRO APX 8500 Emergency Model Chart

M37TSS9PW1AN (APX 8500)
Option Description
G235AC ADD:PTT FOOTSWITCH APEX
W470AT ADD: EMERG ID EXT. FOOTSWITCH APEX
W688AR ADD: EXT EMERG PUSHBUTTON APEX
GA00304AA ADD: PUSHBUTTON PTT
Item No. Description
X GLN7278B PTT FOOTSWITCH (XTL)
X HLN5113C EMER FOOTSWITCH
X HLN5131C EMERGENCY PUSH BUTTON SWITCH
X RLN5926A PUSH BUTTON PTT
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
Model Numbering, Charts, and Specifications xxiii
ASTRO APX 8500 Antennas Model Chart

Option Description
GA01513AA ALL BAND MOBILE ANTENNA (7/8/V/U)
G335AZ 3DB MCYCLE 762-870MHZ
G174AG 3DB LOW PRO MCYC 762-870MH
GA00510AB MCYCLE 1/4 WAVE WHIP 136-144
GA00511AB MCYCLE 1/4 WAVE WHIP 144-150.8
GA00512AB MCYCLE 1/4 WAVE WHIP 150.8-162
X AN000131A01 ANTENNA, WHIP,ALL BAND, MOBILE
X AN000197A10 ANTENNA, STAMPED METAL,3DB MCYCLE 762-870MHZ
X AN000197A11 ANTENNA, STAMPED METAL,3DB LOW PRO MCYC 762-870MH
X AN000197A01 ANTENNA, WHIP,MCYCLE 1/4 WAVE WHIP 136-144
X AN000197A02 ANTENNA, WHIP,MCYCLE 1/4 WAVE WHIP 144-150.8
X AN000197A03 ANTENNA, WHIP,MCYCLE 1/4 WAVE WHIP 150.8-162
X = Item Included
ASTRO APX 8500 Antennas Model Chart (Cont.)

Option Description
G210AC MCYCLE 1/4WAVE WHIP 380-433
GA00509AB MCYCLE LO PRO UNITY 450-512
GA00226AB GPS WIFI ANTENNA
GA00269AB GPS WIFI MCYCLE ANTENNA
X AN000197A05 ANTENNA, WHIP,MCYCLE 1/4WAVE WHIP 380-433
X AN000197A09 ANTENNA, STAMPED METAL,MCYCLE LO PRO UNITY 450-512
X AN000163A01 ANTENNA, STUBBY,GPS/BT/WIFI, SHARK FIN, DECK MOUNT
X AN000163A02 ANTENNA, STUBBY,GPS/BT/WIFI, MOTORCYCLE MOUNT
X = Item Included
xxiv Model Numbering, Charts, and Specifications
ASTRO APX 8500 Cables Model Chart

Option Description
GA00589AA ADD:MMP EXTENSION CABLE 2 FT
GA01114AA INT: DUAL RADIO CABLE KIT
GA01118AA INT: SPEAKER EXTENSION CABLE MP
GA01515AA ADD: J600 ADAPTOR CABLE
GA01516AA INT MMP TO MICRO USB DATA MODEM TETHERING CABLE
G303AB ADD: RS232 DATA INTFC CBL DASH APEX
G304AC ADD: RS232 DATA INTFC CBL TRK APEX
X PMKN4093 O9, MMP EXTENSION CABLE
X HKN6245 ASSEMBLY, 1.5 FEET CAN CABLE
X 54009321002 LABEL,DUAL RADIO PRIMARY AND SECONDARY LABEL
X HKN6246A ASSEMBLY, 30 FEET SPEAKER EXTENSION CABLE
X 54009321002 LABEL,DUAL RADIO PRIMARY AND SECONDARY LABEL
X KT000247A01 KIT, Y-CABLE, J2:J600/J2 APX8500
X 3064079H03 CABLE, PROGRAMMING,MMP TO MICRO USB DATA MODEM TETHERING CABLE
X HKN6160B CABLE 6' RS232 W/IGNITION 26 PIN
X HKN6161B CABLE KIT 20' REMOTE MOUNT DATA
X = Item Included
ASTRO APX 8500 Cables Model Chart (Cont.)

Option Description
G308AD ADD:USB DATA INTFC CABLE-DASH APEX
G309AC ADD:USB DATA INTFC CABLE-TRK APEX
X HKN6163C CABLE, DATA, USB, 1-1/2M, XTL5000
X HKN6172C CABLE, DATA, USB, 4-1/2M, XTL5000
X = Item Included
Model Numbering, Charts, and Specifications xxv
ASTRO APX 8500 CAN Model Chart

Option Description
G582AC ADD: REMOTE MOUNT CABLE 131 FT APEX
G879AC ADD:REMOTE MOUNT CBL 115 FEET APEX
G607AC ADD:CBL REMOTE MOUNT 75 FEET APEX
G609AC ADD: REMOTE MOUNT CBL 50 FEET APEX
G610AC ADD: REMOTE MOUNT CBL 30 FEET APEX
G628AC ADD: REMOTE MOUNT CABLE 17 FT APEX
G618AC ADD:CBL REMOTE MOUNT 10 FEET APEX
X HKN6164B CABLE, REMOTE MOUNT, 39.2M
X HKN6165B CABLE, REMOTE MOUNT, 35M
X HKN6170B CABLE, REMOTE MOUNT, 10 FT
X = Item Included
xxvi Model Numbering, Charts, and Specifications
ASTRO APX 8500 DEK Model Chart

Option Description
GA00260AA ADD: CABLE LIGHTBAR BOX TO TRANSCVR
GA00259AA ADD: UNIVERSAL RELAY CONTROLLER
W355AS ADD: STATUS/MESSAGE 8 APEX
W374AJ ADD: STATUS/MESSAGE 16 APEX
W591AQ ADD: AUXILIARY SWITCH PANEL APEX
W599BF ADD: 8 MODE DIRECT ENTRY APEX
W614AT ADD: 16 MODE DIRECT ENTRY APEX
X 3064153H02 CABLE,4500 MM,ASSEMBLY,CABLE,SHIELDED
X 3064153H05 CABLE,2850 MM,KEYPAD MIC WITH MMP
X 40012006001 CIRCUIT BREAKER, 60A
X PMKN4109A WIRE, AWG 14
X PMLN5436A O9 HUB, STD TILTING MOUNT
X PMLN5436A O9 HUB, STD TILTING MOUNT
X PMUN1046A HARDWARE KIT, 09 RLY CTRL BX
X 40012006001 CIRCUIT BREAKER, 60A
X 6880103W09 DIRECT ENTRY KEYBOARD INST MAN
X HKN6189B CABLE, CH DEK
X HLN1228C DEK STATUS SYS 9000
X HLN6938A HDWR DEK MOUNTING
X HLN1229C DEK STATUS/MESSAGE SYS 9000
X HLN1196C WILDCARD
X HLN1362B DEK 8 MODE SYS 9000
X = Item Included
Model Numbering, Charts, and Specifications xxvii
ASTRO APX 8500 DEK Model Chart (Cont.)

Option Description
W615AW ADD: 24 MODE DIRECT ENTRY APEX
GA00812AA ADD: DEK FOR WHELEN SIREN W/ O3 CH ONLY*
GA00814AA ADD: DEK FOR WHELEN SIREN
X HKN6189B PTT FOOTSWITCH (XTL)
X HLN1362B EMER FOOTSWITCH
X HLN1363B EMERGENCY PUSH BUTTON SWITCH
X HLN1364B PUSH BUTTON PTT
X HBN6003A PACKING BOX
X HKN4265A FUSE CABLE
X HLN1241D DEK HSNG ASEM SYS9000 SIREN/PA
X HLN5331A DEK 9000E SIREN/PA SPARE BUT
X HLN6275A DEK MTNG HDW
X HKN4265A FUSE CABLE
X HLN1241D DEK HSNG ASEM SYS9000 SIREN/PA
X HLN5331A DEK 9000E SIREN/PA SPARE BUT
X HLN6275A DEK MTNG HDW
X HLN5157A DEK MOUNTING HARDWARE
* = Requires J600 (User Y-adapter CB000409A03 for a J600 connector)

X = Item Included
xxviii Model Numbering, Charts, and Specifications
ASTRO APX 8500 Housing Alarm PS Model Chart

Option Description
GA00187AB INT: O5 SHIELD, SUN, MOTORCYCLE
W15AJ ADD:WEATHER PROOF HSNG ENCLO BLK APEX
W665BF ADD: BASE STATION OP W/PS APEX
B116BD ADD:BUZZER 110MA APEX
W116AQ ADD: EXTERNAL ALARM RELAY AND CABLE APX
X NNTN7279B ASSY,ACCY,SHIELD, SUN, MCYCLE
X HLN7022A BLACK MOTORCYCLE ENCLOSURE WITH HDW
X 56012023001 UNIT BOX SPECTRA ST
X 6880101W87 SPECTRA CTL STA INSTR MANUAL
X 6880102W93 SPECTRA MAXTRAC CTRL BASE MAN
X HLN6042A TRAY BASE SPECTRA
X HLN7024A HDW INSTALLATION BASE TRAY
X HLN6953A BUZZER KIT 110 MA
X HKN4258C CABLE RELAY
X HLN6969A XTL 5000, EXTERNAL ALARM RELAY
X HKN6196B CABLE, VIP
X = Item Included
Model Numbering, Charts, and Specifications xxix
ASTRO APX 8500 Mic Model Chart

Option Description
GA01354AA ADD:WIRELESS RSM AND GATEWAY
GA01438AB ADD:GATEWAY RSM
GA01439AB ADD:GATEWAY RSM AND WIRELESS RSM
GA00221AC ADD: MODEL III MMP KEYPAD HANDSET
G892AB ENH:HAND MIC,MMP WTR RESISTANT APX
G90AC ADD: NO MICROPHONE NEEDED APEX
W20CA ADD: KEYPAD MIC MMP APEX
X RLN6551B LONG RANGE WRLS MOBILE BT W/ VC
X PMMN4097C MOBILE MICROPHONE WITH BLUETOOTH GATEWAY
X RLN6552B LONG RANGE WRLS MOBILE BT NO PS
X HMN4097A MODEL III KEYPAD TELEPH HANDSET KIT
X HMN1089B ASSY:PRD OTH,HAND MIC,MMP,WTR REST
X (REFERENCE)_A381 NO MICROPHONE
X HMN4079G XTL5000 KEYPAD MICROPHONE
X = Item Included
ASTRO APX 8500 Mic Model Chart (Cont.)

Option Description
W20CC ADD: KPM MMP (CYRILLIC)
W20CD ADD: KPM MMP (ARABIC)
W20CB ADD: KPM MMP (Hebrew)
W22BB ADD: HAND MIC (MTRCYCLE WP MIC) APX
W22BA ADD: STD PALM MICROPHONE APEX
W382AM ADD: CONTROL STATION DESK MMP MIC
W872AB ADD:MIC VISOR STD APEX
X HMN4109B KEYPAD ASSEMBLY,ASSEMBLY, KEYPAD MIC, CYRILLIC
X HMN4110B KEYPAD ASSEMBLY,ASSEMBLY, KEYPAD MIC, ARABIC
X HMN4108B KEYPAD ASSEMBLY,ASSEMBLY, KEYPAD MICROPHONE
X HMN1079B MOD MOTORCYCLE WP MIC DB9 PIN CONN
X HMN1090C ASSY,MIC,FRNT,GRY,STD PALM MIC (GCA
X RMN5070A DESKTOP MIC (MMP)
X RMN5054B SMART VISOR MIC
X = Item Included
xxx Model Numbering, Charts, and Specifications
ASTRO APX 8500 Speaker Model Chart

Option Description
B18CR ADD: AUXILIARY SPKR 7.5 WATT APEX
B18CS ADD: AUXILIARY SPKR SPEC MCYCL APEX
G142AD ADD: NO SPEAKER NEEDED APEX
G831AD ADD: SPKR 13W WATER RESISTANT
G832AD ADD: SPKR 7.5W WTR RST APEX
W432AG ADD: AUXILARY SPKR 13 W (3.2 ohm)
GA01116AA ADD: DUAL RADIO AUDIO COMBINER KIT
X HSN4031B SPEAKER MODULE ASSEMBLY,EXT SPKR 7.5 W
X HSN6003C MCYCLE WP SPEAKER
X (REFERENCE)_A383 NO SPEAKER
X HSN4040A 3.2 OHM EXTERNAL SPEAKER ASSEMBLY
X HSN4038A SPKR. 7.5 W REMOTE
X HSN4032B SPEAKER MODULE ASSEMBLY,MCS EXT SPKR 13 W
X HKN6250A DUAL RADIO ACCESSORY CABLE
X YLN4713B AUDIO COMBINER KIT ASSEMBLY
X = Item Included
Model Numbering, Charts, and Specifications xxxi
APX 8500 Radio Specifications

For APX 8500 radio product info, please visit:
• APX™ 8500 All-Band P25 Mobile Radio website at:
http://www.motorolasolutions.com/en_us/products/two-way-radios/project-25-radios/mobile-
radios/apx8500.html
• APX™ 8500 All-Band P25 Mobile Radio specifications at:
http://www.motorolasolutions.com/content/dam/msi/docs/products/apx/apx8500/
APX8500_DataSheet.pdf
xxxii
Notes
Chapter 1 Introduction
1.1 Manual Notations
Throughout the manual, you will notice the use of note, caution, warning, and danger 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.
DANGER indicates an imminently hazardous

! situation which, if not avoided, will result in death or
injury.
DANGER
1-2 Introduction: Radio Description
1.2 Radio Description

The ASTRO APX 8500 mobile radio are Motorola Solutions newest two-way mobile radio designed
for your organization’s most demanding needs. These radios are available in the following
frequencies and power levels.
Table 1-1. APX 8500 Frequency Ranges and Power Level
Frequency Band Bandwidth Power Level

VHF 136–174 MHz 1–50 W variable
UHF 380–(< 485 MHz) 1–45 W variable
485–(< 512 MHz) 1–40 W variable
512–(< 520 MHz) 1–25 W variable
700–800 MHz 764–870 MHz 1–30 W variable
806–870 MHz (2–3 W itinerant)
1–35 W variable
The APX 8500 mobile radio are among the most sophisticated two-way radios available. They have
a new robust design for radio users who need high performance, quality, and reliability in their daily
communications. This new architecture supports a multitude of legacy and advanced features
resulting in a more cost-effective two-way radio communications solution.
1.3 FLASHport®
All APX mobile radios are part of the FLASHport program and ship standard with a FLASH IC, which
allows for feature and system upgrades. FLASHport Aftermarket Software is used to upgrade to the
latest version of your System Enhancement Software Package, to upgrade to a different System
Enhancement Software Package, or to order enhancements for existing APX mobile radios in the
field.
1.4 O2/O3/O5/O7/O9 Control Head Descriptions

Each Control Head detailed function and operation is available in the individual User Guides.
Please refer to the related publications provided in Related Publications.
1.5 P25 Digital Vehicular Repeater System (DVRS)

Motorola Solutions offers an MSI Certified APX compatible, 3rd Party, P25 Digital Vehicular
Repeater System (DVRS) that provides low cost portable radio coverage in areas, where only mobile
radio coverage is available, and portable radio coverage is either intermittent or non-existent.
Chapter 2 Basic Maintenance
2.1 Introduction
This section of the manual describes preventive maintenance, handling precautions, and some basic
repair procedures and techniques. Each of these topics provides information vital to the successful
operation and maintenance of your radio.
2.2 Preventive Maintenance

Radios are shipped from the factory with a worst-case frequency error of:
• ±250 Hz for VHF
• ±250 Hz for UHF
• ±600 Hz for 700–800 MHz
• ±600 Hz for 900 MHz
These specifications are tighter than the more stringent FCC requirements of:
• ±2.0 ppm for the 136–174 MHz band
• ±2.0 ppm for the 380–470 MHz band Range 1 / 450–520 MHz band Range 2
• ±1.5 ppm for the 700–800 MHz bands
• ±1.0 ppm for the 900 MHz band
For radios that have been in storage for over six months from the factory ship date, the reference
oscillator should be checked when the radio is initially deployed to the field. It is strongly
recommended that the reference oscillator be checked every time the radio is serviced or at least
once a year, whichever comes first. The crystal contained in the reference oscillator naturally drifts
over time due to its aging characteristic. Periodic (annual) adjustment of the reference oscillator is
important for proper radio operation. Improper adjustment can result in both poor performance and
interference with other users operating on adjacent channels. Refer to section 6.4.3 for reference
oscillator alignment procedures.
2.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. A detailed inspection of the interior electronic circuitry is not needed.
NOTE: Verify that all dust covers are in place.
2-2 Basic Maintenance: Preventive Maintenance
2.2.2 Cleaning Procedures

The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the control
head and radio chassis. These surfaces should be cleaned whenever a periodic visual inspection
reveals the presence of smudges, grease, and/or grime. Internal surfaces should be cleaned only
when the radio is disassembled for servicing or repair.
Use all chemicals as prescribed by the manufacturer. Be sure to follow all
! safety precautions as defined on the label or material safety data sheet.
Caution The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Aerosol sprays, tuner cleaners, circuit board cleaners,
alcohols, and other chemicals should not make contact with plastic or
metal radio housings. Extreme etching to disintegration of the plastic can
result.
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).
2.2.2.1 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. A soft, absorbent, lint-free cloth or tissue should be used to
remove the solution and dry the radio. Make sure that no water remains entrapped near the
connectors, cracks, or crevices.
2.2.2.2 Cleaning Internal Circuit Boards and Components

NOTE: The cleaning can only be done after all the internal circuit boards and components are
removed from the radio chassis.
Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
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. Be careful not to break off electrical
components.
Alcohol is a high-wetting liquid and can carry contamination into unwanted places if an excessive
quantity is used. Make sure that controls or tunable components are not soaked with the liquid. Do
not use high-pressure air to hasten the drying process, since this could cause the liquid to puddle
and collect in unwanted places.
Upon completion of the cleaning process, use a soft, absorbent, lint-free cloth to dry the area. Do not
brush or apply any isopropyl alcohol to any plastic parts.
2.2.3 General Radio Care and Handling Precautions

• Avoid physical abuse: do not pound, drop, or throw the radio. Exposed parts, such as controls
and connectors, might be damaged.
• Operating the radio without an antenna cable attached may lead to radio failure and may void
the warranty.
Basic Maintenance: Safe Handling of CMOS and LDMOS Devices 2-3
2.2.4 RF Power Amplifier (RF PA) Heatsinking

You should never transmit unless the printed-circuit board (PCB) DC and RF connector clips and
internal screws are installed in the chassis. Doing so can result in immediate failure of RF PA devices
or greatly reduced RF PA device life.
2.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS), and Laterally Diffused Metal-Oxide
Semiconductor (LDMOS) 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/LDMOS
circuits and are especially important in low humidity conditions.
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 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 Solutions 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.
2-4 Basic Maintenance: Safe Handling of CMOS and LDMOS Devices
Notes
Chapter 3 Basic Theory of Operation
3.1 Introduction
The ASTRO APX8500 all-band mobile radio is a two-board assembly that consists of a transmitter
board and a transceiver board. The transmitter board consists of the transmitter circuitry, while the
transceiver board consists of the receiver, frequency generation unit (FGU), and the controller
circuitry.
3.2 General Overview

The APX8500 mobile radio is synthesized, fixed-tuned, all-band radios.
The APX 8500 radio is currently only available in a mid power model. It is capable of both analog
operation at 12.5 kHz, 20 kHz, and 25 kHz bandwidths, and ASTRO mode operation at 12.5 kHz
bandwidth.
The APX 8500 mobile radio contain the following assemblies and sections:
• O2 Control Head Assembly – The control head assembly contains the LCD display, User
Interface, and OMAP microprocessor. For the dash mount configuration, the control head
assembly is attached directly to the controller via a flex, and utilizes SSI to communicate. For
remote mount configuration, the control head assembly is attached to the Control Head
Interface Board (CHIB) via a flex and a CAN cable is used to interface the Remote Control
Head to the Transceiver Interface Board (TIB). The TIB assembly plugs directly into the
transceiver board at the back of the radio.
Interface, OMAP microprocessor. The O3 plugs directly into the Transceiver Interface Board
(TIB) assembly mounted at the back of the radio. The only difference between Dash mount and
Remote Mount is the additional 17' Straight cable.
Interface, OMAP microprocessor. For the dash mount configuration, the control head assembly
is attached directly to the controller via a flex, and utilizes SSI to communicate. For remote
mount configuration, the control head assembly is attached to the Control Head Interface Board
(CHIB) via a flex and a CAN cable is used to interface the Remote Control Head to the
Transceiver Interface Board (TIB). The TIB assembly plugs directly into the transceiver board at
the back of the radio.
Interface and OMAP microprocessor. For the dash mount configuration, the control head
assembly is attached directly to the controller via a flex, and utilizes SSI to communicate. For
remote mount configuration, the control head assembly is attached to the Control Head
Interface Board (CHIB) via a flex and a CAN cable is used to interface the Remote Control
Head to the Transceiver Interface Board (TIB). The TIB assembly plugs directly into the
transceiver board at the back of the radio.
Interface, OMAP microprocessor. For the dash mount configuration, the control head assembly
is attached directly to the controller via a flex, and utilizes SSI to communicate. For remote
mount configuration, the control head assembly is attached to the Control Head Interface Board
(CHIB) via a flex and a CAN cable is used to interface the Remote Control Head to the
Transceiver Interface Board (TIB). The TIB assembly plugs directly into the transceiver board at
the back of the radio.
3-2 Basic Theory of Operation: Controller Section
• Transceiver Board – The controller portion of this board contains digital hardware
(microcontroller, memory, logic, and supporting peripherals) governing radio operation,
servicing all radio inputs and outputs, and processing all voice and data. It includes a dual-core
processor (MCU and DSP cores), the processor’s memory devices, an audio and power supply
support IC, an audio CODEC and audio PA, and MACE (Type 3 Secure IC). In addition, it
contains a GNSS (GPS/GLONASS) IC and support circuitry, a combination WLAN/Bluetooth
capable IC and support circuitry, and supporting hardware for external accessory interfaces
such as RS232, USB, SB9600, and logic signals.
• The CHIB contains a SSI-CAN FPGA, a 16 bit CODEC for audio processing, a Class D Audio
PA, and three Controller Area Network (CAN) transceivers. Each CAN transceiver is used to
communicate with the RF transceiver, one for audio, one for data, and one for system power-on
commands.
• Transceiver Interface Board – Contains CAN transceivers and audio and digital routing for
accessories. The TIB is used with the O3 Control Head for Dash and Remote Mount
configuration and is only used for Remote Mount configuration with the O2, O5, O7, and O9
Control Head.
• Radio Frequency Transceiver Board
- Power Amplifier (PA) section – Contains the antenna switch, directional coupler/ detector,
and amplifier(s).
- Front-End Receiver section – Contains the preselector, low-noise amplifier (LNA), and
mixer.
- IF section – Contains the receiver intermediate-frequency (IF) amplifier/filter and the digital
receiver back-end integrated circuit (IC).
- Frequency Generation section – Contains the synthesizer, voltage-controlled oscillators
(VCOs), reference oscillator, and receive and transmit buffers.
3.3 Controller Section

3.3.1 Introduction
The Controller is a section of the transceiver that contains the following elements:
• Voltage regulators and data communication circuitry (RS232, USB, and SB9600)
• Microcontroller, FLASH IC, SDRAM IC
• Transmitter Board interface connector
• CODEC and Audio circuitry
• Power Management and Voltage Regulator IC
• Emergency circuitry
• Secure IC
• Edge connector interface for control head or Transceiver Interface Board (TIB)
• Rear accessory connector for additional accessories
• GNSS circuitry
• WLAN/Bluetooth circuitry
Block diagrams of controller are shown below:
Basic Theory of Operation: Controller Section 3-3
Figure 3-1. Mobile Controller Block Diagram
3.3.2 Controller Functional Blocks

The main functional blocks of the controller are a dual-core microprocessor consisting of an ARM-
based controller and a DSP, Flash memory, and a Double-Data-Rate SDRAM memory. In addition,
the controller includes a Type 3 encryption processor (MACE), a power management IC (CPCAP),
and various external switching and linear voltage regulators. There are two primary clock sources
(19.2 MHz and 32.768 kHz) from which all other controller digital clocks are derived. The audio
section has a stereo CODEC and a class-D audio power amplifier that provides the radio with
multiple internal microphone and speaker inputs/outputs. External interfaces/connectors provide
communication and control to/from accessories, the control head, and the TIB.
The ARM controller core of the OMAP L138 processor handles the power-up sequence of all
devices, including firmware upgrades, and all operating system tasks associated with FLASH and
SDRAM memories and user interface/control-head communication. The FLASH memory (4GB
eMMC) stores the firmware, tuning, and codeplug settings, which upon initialization gets read and
stored into SDRAM (128 MB) for execution. The ARM and DSP core jointly control and configure
audio, wireless and RF devices linked to the Serial Peripheral Interface (SPI) ans Synchronous
Serial Interface (SSI) buses to enable radio FM modulation, and optional wireless communication
protocols. For encryption, a separate ARM processor (MACE) is used to encode and decode
encrypted packets coming in from the main OMAP L138 processor through the SSI interface. Its
firmware is flashed via the main processor to its internal FLASH memory.
The power to all the controller devices is provided by the CPCAP IC and the external switching and
linear regulators on board. The CPCAP IC also provides the 32.768 kHz clock to the OMAP L138
and to the WLAN/Bluetooth IC, and provides a 4.8 MHz clock to the MACE encryption IC.
OMAP L138’s main reference clock, 19.2 MHz, is supplied from the FGU section of the transceiver
board.
The radio has three external microphone input paths and an internal audio PA which provides audio
to an external loudspeaker. There are line level analog audio outputs for monitoring/recording. The
external speaker is driven by a Class D audio amplifier that is capable of delivering a rated power of
15W to a 3.2-ohm speaker. The speaker path uses the CODEC for volume control and to convert the
audio signal from digital DSP samples to analog. All microphone input paths use the CODEC’s ADC
to deliver digital audio samples to the DSP controller.
Both the control head and TIB contain a universal accessory connector (MMP) that provides audio,
USB, and RS232 interfaces to the radio, via the CPCAP power management IC and CODEC. Many
of these same interfaces (in addition to other signals) are available on the radio accessory interface
connector (MAP).
A GNSS IC consisting of a Global Postitioning System (GPS) and GLONASS receiver, an IC that
combines a WLAN transceiver (IEEE 802.11 b/g/n) and a Bluetooth 4.0 capable transceiver, and a 3-
axis accelerometer. The GNSS IC interfaces with the OMAPL138 processor through a shared I2C
bus. The WLAN/Bluetooth IC interfaces with the OMAPL138 processor through a 4-bit SDIO bus.
The APX8500 radio has the ability to connect to a wireless network access point utilizing the WLAN/
Bluetooth IC. The IC supports IEEE 802.11 b/g/n data rate standards as well as the 802.11i security
standard. When this feature is enables, Wi-Fi allows the radio to be wirelessly updated with a new
codeplug and radio software without the need for connecting the MMP or MAP USB cable. The Wi-Fi
AP name and password need to be set in the codeplug and the radio management software enabled
to provide wireless updates. When the radio’s Wi-Fi is actively connected to an AP, a receive signal
strength indicator (RSSI) is shown on the control head display.
3.3.3 Voltage Distribution / Power On/Off
Emergency Ignition
MAP
Control Head /
Transmitter Transceiver
TIB
RFPA Audio PA uC PB
9V 3.3V
Unswitched CPCAP Unswitched
LDO LDO
Switched Switched
Supplies Supplies
Figure 3-2. Voltage Distribution / Power Diagram
3.3.3.1 Voltage Distribution for Controller and RF Board

The APX mobile radios are powered by a 12V vehicle battery (negative ground), or a AC-to-DC
desktop power adapter which enters at the rear of the radio transceiver at a dedicated 2-pin DC
connector. This raw voltage, referred to as “A+”, is routed to both the transmitter and transceiver
board circuitry for post-regulation.
3.3.3.2 Power On/Off

There are three methods that can be used to turn the radio on and off (depending on the codeplug
setting); Power Button on the control head, Ignition sense (ACC) line (via the MAP accessory
connector), and emergency (also via the MAP connector).
The transceiver regulators are controlled by the CPCAP (ASIC). This IC has a Power Management
Controller (PMC) state machine that turns on and off all radio supplies and resets the OMAP L138
microprocessor at power-up, in response to user inputs at the control head or MAP.
3.3.4 Audio Circuitry
3.3.4.1 RX Audio Path

The receive audio path consists of the following main components:
• Texas Instruments OMAP L138
• Texas Instruments Audio CODEC TLV320AIC3204
• TI Audio PA TI TPA3116D2
The Digital audio signal comes from the DSP processor using SSI protocol. The Audio SSI bus is
routed to TI CODEC. The CODEC converts the SSI digital data to analog. This audio is routed to
both the MAP and MMP accessory interfaces to supply line-level audio for monitoring/recording. It is
also routed to the Audio PA, with volume control being programmed via the I2C bus by the
OMAP L138.
The Audio PA converts the analog signal to a PWM output, it also adds 36 dB of gain. The output low
pass filter (LC), filters out the Audio PA switching frequency before the audio is routed to the speaker
output.
RX Audio Lineup
6 dB Gain
FREON TI TLV320AIC3204 HPL
DAC Outputs GCAI_SPKR (Fixed Level)

DSP (to Control Head or TIB MMP Connector
Output
Left
DAC
6 dB Gain
HPR
RX_FILT_AUDIO (Fixed Level)

(to J2/MAP Connector)
SSI SSI
I2C I2C
LOL TI
Right Audio PA MAP Speaker
DAC LOR TPA3116D2
36 dB
Figure 3-3. Receive Baseband Audio Path

3.3.4.2 TX Audio Path

Analog audio comes from the external Microphone attached to the radio via the control head mic port
or the MAP rear accessory connector J2 (Mic_Hi or Aux_Mic). Analog audio is attenuated by 6dB
and is then routed to the CPCAP, which converts the analog audio to digital and sends it to the main
processor using the Audio SSI bus. OMAP L138 processes the audio which is then converted to
Baseband audio and routed to the FGU and then to the transmitter board.
9V BIAS
IN1_L
FREON TI TLV320AIC3204
ADC Inputs -9 dB MIC_HI
DSP (from Control Head or
TIB MMP Connector)
Output
AGC/ IN3_L
LADC LPGA AUX_TX
-21 dB (from J2/MAP Connector)
9V BIAS
SSI SSI
IN2_L
AUX_MIC
(from J2/MAP Connector)
I2C I2C
SPI
0 dB Gain
LINE_OUT_L
SSI DAC PGA MIC_OUT
(to J2/MAP Connector)
SPI CPCAP DAC Output
Figure 3-4. Transmit Baseband Audio Path
3.3.5 Secure
The controller board is able to perform secure encoding and decoding through the MACE IC. In TX
mode, the CODEC supplies the OMAP L138 DSP with audio. When a secure signal has been
selected, it is routed to the MACE via the SSI bus. The encrypted audio is then sent back to the
OMAP L138 which routes it to the FGU for transmission. In RX mode, the encrypted digital audio
sent to the OMAP L138 is first routed to the MACE via the SSI bus. The decrypted audio is then sent
back to the OMAP L138 which routes it to the CODEC to be sent to the speaker.
Keyloading
• See Section 7.2. The KEYLOADER signal comes in on MMP pin 9 of the control head or TIB
J700 connector. It routed to the MACE via CPCAP. There is an algorithm in the MACE which
detects and stores the key as long as the radio is powered.
Tamper and key retention
• The MACE has the option of infinite key retention. The key can be disabled by several means to
avoid compromise. A tamper contact switch will detect mechanical intrusion. A capacitor-
backed supply maintains the static memory when all power to the transceiver is removed. This
volatile key retention option will hold the key for between 5 and 10 minutes on the discharge of
this capacitor.
3.3.6 GPS Overview
Figure 3-5. GPS Architecture
The GNSS architecture employs a single chip GPS and GLONASS receiver which decodes signals
at 1575.42 MHz. It is capable of producing a final position solution including full tracking and data
decode capability. The receiver will operate in the autonomous mode only.
The GNSS receiver is setup in an autonomous one track always (OTA) mode, also known as
continuous navigation. This means it will continuously track satellites for as long as the radio is
powered to ensure the best possible accuracy. In the event the radio loses visibility of the satellites
due to terrain or environmental factors such as driving through a tunnel or in a parking garage, the
receiver will temporarily lose its position fix. It will then begin to reacquire the signal and compute an
updated position once the radio has moved back into an environment where GNSS signals are
present.
The user will be able to view the current latitude, longitude, and time/date stamp on the radio’s
display. The radio can also be configured to send its’ location to the system at predetermined
intervals (LRRP). Depending on system options, the user may be able to enable/disable the GNSS
receiver.
If the GNSS receiver is unable to acquire a position try the following steps.
1. Make sure the unit is in an open sky environment to ensure the presence of GNSS signals (min 5
satellites in view at nominal power levels of -130 dBm).
2. Reset the radio. If a position fix does not occur within 2 minutes go to step 3.
3. Disconnect the GNSS antenna and make sure the center conductor on the antenna is not shorted
to ground. If so, replace the GPS antenna.
4. Measure the voltage on the GNSS SMA connector located on the radio and ensure 5V is present.
If 5V is not present then send the radio in for repair.
5. If steps 1 to 4 have been followed and the GNSS still does not obtain a position fix, then refer to
the Detailed Service Manual for further instructions.
These custom connectors are optimized to meet voltage and current
! requirements for existing accessories and for the compatible flexes that are
used with the APX 8500 radio. Inserting non-Motorola Solutions parts or
Caution pins into these connectors is not recommended. Failure to do so can result
in equipment damage.
3.3.7 Serial Interfaces
Transceiver
Control Head
OMAP L138
USB (MMP)
Host/Device USB
OR RS232
UART UART USB USB
Switch RS232 SB9600 USB

XCVR XCVR Device
Switch J2 USB Host

USB UART MAP OR SB9600
RS232
OMAP 1610
Figure 3-6. Dash-Mount Configuration
Transceiver
TIB
OMAP L138
USB (MMP)
Host/Device Switch USB
OR RS232
UART UART USB USB
RS232 SB9600 USB

XCVR XCVR Device
Switch J2 USB Host

Switch MAP OR SB9600
RS232
Figure 3-7. Remote-Mount Configuration

Several external serial interfaces are supported by the APX8500 transceiver, and shown in the
previous figures for both dash and remote mount operation. These includes RS232, USB Device,
USB Host, and SB9600 at the rear 26-pin J2 connector and RS232, and USB Device/Host, at the
TIB external connector J700. Many of the accessories that connect to the J700 and J2 connectors
are identified through the 1-Wire ® serial protocol. This information tells the controller which serial
bus to configure for the accessory. The 1-Wire ® IC is typically embedded in the cable/accessory for
this purpose.
3-10 Basic Theory of Operation: Transceiver Interface Board (TIB)
There are hardware design limitations that limit the number of serial interfaces that can be used
simultaneously.
• RS232 – This serial interface is available at either the MAP/J2 (rear) connectors, or at the J700
(TIB) connector. The MAP/J2 interface is compliant with industry-standard 12V RS232 logic
and is the default selection when no 1-Wire ® accessory is attached to the J700 connector. If a
1-Wire ® compliant RS232 accessory is attached to the J700 connector, then the bus is no
longer supported at MAP/J2. The J700 RS232 interface is at 5V logic, while the RS232 cable
contains the voltage translation circuitry to make the bus 12V compliant.
• SB9600 – This is a Motorola Solutions proprietary bus used to communicate with certain legacy
accessories. The bus is available at the J2 connector by default.
• USB – USB Host and Device functionality are available at the J700 MMP connector on TIB.
The functionality is again determined by the type of accessory/cable identified by the 1-Wire ®
interface. USB Device is also a dedicated interface at the MAP/J2 connector by default. In
addition, USB Host can be optionally configured at the MAP/J2 connector via the SB9600
interface (the buses share common pins). The SB9600 bus is configured by default, but USB
Host will be configured when a 1-Wire ® compliant USB Device accessory/cable is attached to
the MAP/J2 connector. (Note that if a USB cable is attached to the TIB J700 connector, the
RS232 link at the J2 can still be used. The J2 USB Host and Device interface can also be used
if the J700 USB interface is for Host only).
3.4 Transceiver Interface Board (TIB)

The Transceiver Interface Board (TIB) provides connectivity between the CAN cable and the
transceiver. Opposite to that of the CHIB, the TIB must convert the CAN protocol back to
Synchronous Serial Interface (SSI) via an FPGA, which is sent to the microprocessor. External
connectors on the TIB include the MMP J700 connection for accessories, data programming and
secure key-loading of the transceiver. Power-ON, Power-OFF, and RESET of the transceiver is
accomplished using an ATMEL AVR microcontroller as determined by commands from the
Transceiver or from a remote device, such as a control head, connected to the CAN bus.
Figure 3-8. Transceiver Interface Board (TIB)

Basic Theory of Operation: Transceiver Interface Board (TIB) 3-11
3.4.1 Quick Disconnect Circuit

The function of the quick disconnect circuit, located in the TIB, is to provide immediate muting of all
speaker audio by forcing the radio to reset when a control head's CAN cable is disconnected from
the TIB or from an extension cable that is attached to the TIB. After the disconnection, if there are no
other control heads attached via CAN to the TIB, the radio may be programmed to automatically turn
itself off (approximately 20seconds after the radio reset). This programming is done via the CPS by
check marking the “Control Head(s) Required for Power Up” field. Note that if this field is NOT
checked, the radio will apply its normal power up rules (e.g., ignition) to determine whether to stay on
or to power-off after the reset. The “Control Head(s) Required for Power Up” field is typically 'check
marked' in a configuration that has a single O3 control (that is attached to an extension cable
attached to the TIB) where it is desired that the radio immediately mute all speaker audio and
ultimately power-off when the O3 control head is disconnected.
• If the field is 'check marked', then at least one controlhead must be present for the radio to
remain powered-on after it resets. For example, a system only had 1 control head, and it is
removed, the radio will be powered-off after reset. A system had 2 control heads, and only 1 is
removed, then after reset, the radio will monitor the Ignition sense (ACC) line and compare to
the ignition CPS setting to determine if it will remain powered-on, or power-off. If it had 2 control
heads, and both are removed, the radio will be powered-off after reset.
• If the field is 'blank' (typical usage), then quick disconnect is not activated. For example, if a
system only had 1 control head, and it is removed, then after reset, the radio will monitor the
Ignition sense (ACC) line and compare to the ignition CPS setting to determine if it will remain
powered-on, or power-off. If a system had 2 control heads, and only 1 is removed, the radio will
be powered-on after reset. If a system had 2 control heads, and both are removed, the radio will
monitor the Ignition sense (ACC) line and compare to the ignition CPS setting to determine if it
will remain powered-on, or power-off.
3.4.2 Controller Area Network (CAN) Transceivers

There are a total of three CAN twisted pairs located between the control head and the radio
transceiver. CAN pair 1 is used for digital Audio, CAN pair 2 is used for digital Data and CAN pair 3 is
for digital Power ON/OFF/RESET pulses. If an O5 control head is used, a TIB and CHIB must be
present. If an O3 control head is used, only a TIB must be present, since the O3 control head has the
CAN transceivers located on its PCB. The CAN bus provides a 1MB/s data link. Only the list of
approved Motorola Solutions CAN cables are to be used for any remote mount installations.
3.4.3 CAN Termination

The CAN architecture requires that a termination resistor be connected only at the two end-points of
the CAN bus. The CAN cable contains a jumper that will ground a “detect pin” at the CAN
connectors. Logic within the auto-termination circuit determines how many cables are attached and
enables or disables the termination resistors, for each of the three twisted pairs. The O3 control head
has the termination resistors enabled at all times, since it is always an end-node. The remote mount
cables are able to be connected to either the left CAN connector or to the right CAN connector. That
is why they have the same connector number, with the letter L and R next to the connector to
indicate Left or Right CAN connector. It is not recommended to have CAN cables attached but
dangling free at one end, during operation.
NOTE: Only use Motorola Solutions fixed length CAN cables, as circuitry resides in each cable and
the cable wiring impedance is unique to this remote cabling architecture as well.
3-12 Basic Theory of Operation: Analog Mode of Operation
3.5 Analog Mode of Operation

3.5.1 Receive Operation
When the radio is receiving, the signal comes from the antenna through the RF PA output network
located in the power amplifier section to the front-end receiver assembly. The signal is then filtered,
amplified, and mixed with the first local oscillator signal generated by FGU. The resulting
intermediate-frequency (IF) signal is fed to the IF circuitry where it is again filtered and amplified.
This amplified signal is passed to the back-end receiver IC where it is mixed with the second local
oscillator to create the second IF. The analog IF is processed by an analog-to-digital (A/D) converter
located within the digital back-end IC, where it is converted to a digital bit stream and decimated
down to an I/Q digital sample. This digital signal is then passed on to the DSP, where filtering and
discrimination are performed in the software. For a voice signal, the DSP routes the digital voice data
to the Codec for volume gain control and conversion to an analog signal. The signal passes to the
audio power amplifier, which drives the speaker. For signaling information, the DSP decodes the
message and passes it to the microprocessor.
3.5.2 Transmit Operation

When the radio is transmitting, microphone audio is passed to the gain control circuit, and then to the
Codec, where the signal is digitized. The Codec passes digital data to the DSP, where pre-emphasis
and low-pass (splatter) filtering is done. The DSP may also add signalling information. The DSP then
sends the resulting digitized signal containing both voice and signalling data to the digital synthesizer
IC as a modulation signal for the transmitter voltage controlled oscillator. A modulated carrier is
provided to the RF power amplifier, which transmits the signal under dynamic power control.
3.6 ASTRO Mode of Operation

In the ASTRO mode (digital mode) of operation, the transmitted or received signal is limited to a
discrete set of deviation levels, instead of continuously varying. The receiver handles an
ASTRO-mode signal identically to an analog-mode signal up to the point where the DSP decodes
the received data.
In the ASTRO receive mode, the DSP uses a specifically defined algorithm to recover information.
In the ASTRO transmit mode, microphone audio is processed the same as in the analog mode with
the exception of the algorithm the DSP uses to encode the information. This algorithm will result in
deviation levels that are limited to discrete levels.
Basic Theory of Operation: RF Transmitter Board (TX) 3-13
3.7 RF Transmitter Board (TX)

3.7.1 Radio-Frequency Power Amplifier (RF PA) & Output Network (ON)
The RF PA is a three-stage power amplifier consisting of a GaAs 2-stage amplifier IC, a LDMOS 2-
stage amplifier IC and 3 discrete LDMOS transistors selectable by a 3 to 1 silicon switch. Discrete
inter-stage filters are in place for spur rejection:
• Controlled stage
• Driver stage
• Final stage
The RF PA is followed by the ON section, consisting of discrete circuitry with the following functions:
• Antenna switch
• Harmonic filter
• Power detector
3.7.2 Gain Stages

The controlled stage consists of a two-stage, wideband integrated amplifier with external matching
and a high pass filter which amplifies the input signal from the VCO buffer and provides drive to the
driver stage.Power is controlled via gate bias to the internal stages of the controlled stage, and drain
bias is supplied via K9.1V. The signal runs through a high pass filter to suppress spurs, before
arriving at a wide band driver stage. The driver stage has a fixed gate bias and a fixed drain bias
supplied by the VDS_DRIVER line, which is powered by a 28V boost converter. The Driver stage
then runs into a 3 to 1 silicon switch that selects between the 3 bands (VHF, UHF, 7800). Each band
also has its own low pass/high pass filter to further reduce out of band spurs. From the filters, the
signal travels to its respective narrowband final stage. Each final stage is a single LDMOS transistor
with fixed gate biases and drain biases supplied by the VDS_FINAL line, which is also powered by
the same 28V boost converter as the driver. The output of the final stage feed its respective
harmonic filter and power detector before merging at the antenna switch. The antenna switch selects
between the narrow band final stages and also isolates the RX in TX mode.
3.7.3 Power Control

The power control section regulates the RFPA output power by an automatic level control (ALC)
circuit. The transmitter ALC consists of a digital attenuator, voltage variable attenuator, RF log amp,
digital-to-analog converter (DAC) and buffer/amplifier. The APX 8500 has the addition of the RF
Front End IC (FEIC) for programming GPO signals and supplying DAC control. The power detector
senses the incident power transferred to the antenna via a directional coupler in which the RF signal
is fed to the digital attenuator, voltage variable attenuator and the RF log amp. The RF log amp
compares the input RF power from the directional coupler with the voltage set from the DAC to
generate a DC voltage. The DC voltage is then gained by the buffer/amplifier and fed to the RFPA
stage. The radio’s carrier power level is set by adjusting the DAC voltage set while monitoring the
output power, which is saved in the radio’s memory.
3.7.4 Circuit Protection

The APX8500 radio has various protection mechanisms while transmitting. Monitored signals
include the RFPA driver and final stage drain current, the RFPA final stage temperature, the RFPA
control voltage, and the radio battery voltage are sensed by the power control circuitry. If a fault
condition is detected, the control voltage is reduced, which cuts back the output power to a level that
is safe for the particular operation conditions.
3-14 Basic Theory of Operation: RF Transceiver Board (XCVR)
3.7.5 RF Transmitter Board to Transceiver Board Interconnect

The connector carries multiple signals bridging control lines from the controller section to the PA
board. The connections include A+, SSI, SPI, and I/O lines.
3.8 RF Transceiver Board (XCVR)

The primary duties of the receiver circuits are to detect, filter, amplify, and demodulate RF signals in
the presence of strong interfering noise and unintended signals. This receiver is an All-band receiver,
covering the VHF, UHF1, UHF 2, and 700/800 bands. In addition, this model supports the industry
Canada band. The receiver contains the following blocks:
• Front-end (preselectors and LNAs)
• Mixer
• IF
• Back-end
799-806 MHz 799-806 MHz

SP4T-RSFW6042
700 MHz
SP5T-SKY13415
700 MHz CONGO

SP4T-RSFW6042
IF:
SP4T-RSFW6042
V
109.65
To Antenna S? ADC
800 MHz MHz
Switch 800 MHz
A U
A TO
IF FGU 2
Attenuator; To Rodinia IC
Protection 78
Pre-amp Path
Circuit
VHF Path
HP Filter
Rodinia +
Standard
Path
U1/U2/VHF UHF Path
SSI
2nd LO
Ch 1
Demod RSSI
Demod RSSI
Ch 2
Figure 3-9. Receiver Block Diagram
3.8.1 VHF Receiver Front-End

The VHF receiver operates in the frequency range of 136 to 174 MHz. The primary function of the
receiver front-end is to optimize the rejection of the image frequency and other out-of-band
frequencies while providing low-noise amplification of the received signal. The front-end uses
varactor tuned filters and discrete LNAs. The varactor tuned filters cover from VHF to UHF ranges 1
and 2. The front-end has two possible configurations: standard mode, which provides the best
intermodulation performance, and the optional pre-amp mode, which provides improved sensitivity at
the cost of slightly reduced intermodulation performance. The front-end line-up for standard mode is:
a variable 18 dB attenuator for AGC purposes, a tunable bandpass filter, a low-noise amplifier, and a
fixed highpass filter. In pre-amp mode an additional LNA is added between the attenuator and the
first bandpass filter.
Basic Theory of Operation: RF Transceiver Board (XCVR) 3-15
3.8.2 UHF1 and UHF2 Receiver Front-End

The UHF R1 receiver operates in the frequency range of 380 to 470 MHz and UHF R2 receiver
operates in the frequency range of 450 to 520 MHz. The primary function of the receiver front-end is
to optimize the rejection of the image frequency and other out-of-band frequencies while providing
low-noise amplification of the received signal. The front-end uses varactor-tuned filters and discrete
LNAs. The varactor tuned filters cover from VHF to UHF ranges 1 and 2 The front-end has two
possible configurations:
• Standard mode, which provides the best intermodulation performance; and
• Pre-amp mode (optional), which provides improved sensitivity at the cost of slightly reduced
intermodulation performance.
The front-end line-up for standard mode is: a variable 18 dB attenuator for AGC purposes, a
varactor-tuned image filter, low-noise amplifier, and finally a second varactor tuned image filter. In
pre-amp mode, an additional LNA is added between the attenuator and the first bandpass filter.
3.8.3 700-800MHZ / Industry Canada Receiver Front-End

The 700–800 MHz and Industry Canada receiver front-end operates in three bands. The primary
function of the receiver front-end is to optimize image rejection and selectivity while providing the first
conversion. The front uses a multi-pole switch to select between the 3 bands. The front-end uses
saw-filter technology and includes a wideband, monolithic amplifier. The first filter is a dual-switched
filter that reduces the image frequency response and limits some of the out-of-band interference.
The second filter following the monolithic Low Noise Amplifier (LNA) provides additional image
rejection.
3.8.4 Mixer
The receiver front-end signal is fed to the monolithic Mixer IC where it is down converted to an IF of
109.65 MHz. The mixer is designed to provide low conversion loss and high intermodulation
performance. The mixer is driven by the FGU receiver injection buffer to efficiently drive the mixer
over a wide temperature range with minimum power variation. The injection buffer provides 17 dBm
to the mixer. The design maintains temperature stability, low insertion loss, and high out-of-band
rejection.
3.8.5 IF Circuitry
The crystal filters provide IF selectivity and out-of-band signal protection to the back-end IC. The use
of two 2-pole crystal filters centered at 109.65 MHz, which are isolated from one another by a
discrete IF amplifier, enable the receiver to meet specifications for gain, close-in intermodulation
rejection, adjacent channel selectivity.
3.8.6 Receiver Back-End

The output of the IF circuit is fed directly to the back-end receiver IC. It is capable of down-converting
analog, as well as digital, RF protocols into a baseband signal, which is then transmitted over the
Synchronous Serial Interface (SSI) bus. It also converts the 109.65 MHz signal from the IF section
using a second LO frequency produced by the second LO VCO. This VCO runs at low-side or high-
side injection. The choice of frequency depends on known spurious interference related to the
programmed received frequency.
3-16 Basic Theory of Operation: Frequency Generation Unit
3.9 Frequency Generation Unit

VHF
Congo IC 1 UHF1-2
SPI
Interface HIZ_RF_OUT RX_LO_Injection
CONGO_SPI_CS CEX 7/800
CONGO_SPI_CLK SPI_CLK
CONGO_SPI_DW SPI_DW LOZ_RF_OUT
CONGO_SPI_DR SPI_DR
SSI VHF
Interface
CONGO_SSI_FS TXFS
CONGO_SSI_CLK TXCLK UHF1-2
CONGO_SSI_DATA TXD MN_CP
LOOP TX_Injection
CONGO_SSI_DMCS DMCS MN_ADAPT_CP
FILTER
HP_MOD_OUT
7/800
GPO6 SEL1 VTUNE

LOCK_DET_FGU_CH1 TEST1_LCKDET
GPO7 SEL2 PREMIUM VCO
CONGO_RSTB RSTB
PVCO_IN RF_OUT
LOZ_BUF_EN PVCO_INB
TX_BUFF_EN
REF_CLK_OUT
REF_CLK_IN
REFERENCE
Vcont From RX OSCILLATOR
19.2 MHz
19.2_REF_CLK_ 19.2_REF_CLK_TO_RX
TO_CONTR
Figure 3-10. Configuration of the Frequency Generation Unit for APX 8500
The Frequency Generation Unit (FGU) in Figure 3-10 consists of the following:
• Congo synthesizer IC.
• Voltage Controlled Oscillator (VCO) module.
• Amplifiers and filter circuits.
• 19.2 MHz reference oscillator.
• Associated circuits.
The Reference oscillator provides a frequency standard for the fractional-N synthesizer IC, the
back-end receiver IC, and the controller section. The synthesizer generates local oscillator injection
(LO) frequency, or the transmitter (TX) carrier frequency.
The VCO is a non-serviceable module and containing two oscillator circuits.
In TX mode, the signal out of synthesizer IC is switched to a band dependent filter to reduce the
harmonic levels of the signals. The output of the filters feed the power amplifier. In RX mode, the
output of the synthesizer IC feeds an amplifier and then switched to band specific filter before
feeding the receiver mixer.
Modulation is accomplished by direct digital programming of the Fractional-N synthesizer by the SSI
(Serial Synchronous Interface) signals coming from the controller.
Chapter 4 Test Equipment, Service Aids, and Tools
4.1 Recommended Test Equipment

The list of equipments contained in Table 4-1 includes most of the standard test equipment required
for servicing Motorola Solutions APX mobile radios, as well as several unique items designed
specifically for servicing this family of radios. The Characteristics column is included so that
equivalent equipment can be substituted. However, when no information is provided in this column,
the specific Motorola Solutions model listed is either a unique item or no substitution is
recommended.
Table 4-1 contains a listing of non-Motorola Solutions test equipment recommended for servicing
mobile radios.
Table 4-1. Recommended Non-Motorola Solutions Test Equipment
Model Number Description Application
BIRD Model 43 BIRD Wattmeter Transmitter power measurements
N/A 1:1 Audio Transformer Audio measurement (audio PA must NOT be grounded)
Agilent 6552 Power Supply (0–20 V, 0–25 A) Mobile radio power supply and current measurements
Agilent 8901 Modulation Analyzer Reference frequency measurements
*General Dynamics Digital Radio Test Set Frequency, reference oscillator deviation digital tests
R8000B and compensation measurements
Agilent U8903A and Audio Analyzer Audio signal-level, SINAD, and distortion
Rohde & Schwarz UPV measurements
Keithly 2015-D Audio Analyzing DMM AC/DC voltage and distortion measurements
Fluke 187 or 189 Handheld Digital Multimeter AC/DC voltage and current measurements
(True RMS, AC, AC+DC, dB)
Fluke 190 Series Handheld Oscilloscope Waveform measurements

(60–200 MHz Bandwidth,
2.5 GS/sec, Built-in 500-Count
True RMS Multimeter)
Weinschel 49 30 43 30 dB RF Attenuator For tests that require a modulation analyzer or

wattmeter
4-2 Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools
4.2 Service Aids and Recommended Tools

Refer to below tables in this section for listing and description of the service aids and tools designed
specifically for servicing this APX mobile radios, and the common tools required to disassemble and
maintain the radio well. These kits and/or parts are available from the Motorola Solutions parts
division offices listed in Appendix A, B, C, and D accordingly.
Table 4-2. Service Aids for APX Mobile Radios
Motorola
Solutions Description Application
Part Number
DVN4236_ APX FLASHport Firmware CD Kit with firmware to upgrade the radio, APX FLASHport
CD.
DVN4237_ APX 7500 FLASHport Kit

Kit with firmware to upgrade the radio, APX FLASH port
DVN4299_ APX 2500 / 4500 / 4500Li / 1500 kit.
FLASHport Kit
RVN5224_ APX Customer Programming Programming and radio alignment software.

Software (CPS) and Tuner Software
HKN6160_ 1.8m (6’) 4-wire RS232 data cable 1.8m (6’) cable used for RS232 data applications
through the 26 pin rear accessory connector. Also
provides an Ignition sense (ACC) wire.
HKN6161_ 6.1m (20’) 4-wire RS232 data cable 6.1m (20’) cable used for RS232 data applications
through the 26 pin rear accessory connector (J2).
HKN6163_ 1.8m (6’) USB data cable 1.8m (6’) cable used for USB programming and data
applications through the 26 pin rear accessory
connector (J2) or the J100 remote control head
connector. Also provides Ignition sense (ACC) and
speaker wires. An emergency jumper wire must be
installed between pins 15 (emergency) and 1 (gnd)
when used in dash mount applications.
HKN6172_ 4.5m (15’) USB data cable 4.5m (15’) cable used for USB programming and data
applications through the 26 pin rear accessory
connector (J2) or the J100 remote control head
connector. An emergency jumper wire must be installed
between pins 15 (emergency) and 1 (gnd) when used in
dash mount applications.
HKN6182_ MMP Cable Adapter for Keyloader Use with TIB MMP or dash-mount control head MMP.
Must be combined with KVL cable TKN8531_
HKN6183_ 2-wire MMP RS232 Data Cable Cable for RS232 data applications through the control
head or TIB MMP.
HKN6184_ MMP USB Programming Cable Use with APX 7500 USB programming through the
MMP on its control head or TIB. Can also be used for
data terminal applications.
NOTE: Please refer Table 8-1 for required tools and supplies.
Test Equipment, Service Aids, and Tools: APX Mobile Radios Field Programming and Equipment 4-3
4.3 APX Mobile Radios Field Programming and Equipment

The APX mobile radios can be aligned and programmed in the field. This requires specific
equipment and special instructions. Refer to the online help in Customer Programming Software
(CPS) and Tuner Software (RVN5224_).
The radios use a flash-memory device to store information about frequencies, squelch codes,
signaling codes, time-out timer durations, and other parameters and can be programmed in the field
any number of times without removing the flash memory from the radio.
The APX mobile radios can only be programmed using USB. To program the radio, connect USB
cable HKN6184_ to the control head’s Mobile Microphone Port (MMP) connector. This is the 10-pin
connector to which the microphone is commonly attached. The MMP connector is below the volume
knob and to the left of the LCD display. HKN6163_ and HKN6172_ USB cables can also be used for
radio programming, and can be connected at the remote control head J100 or radio rear J2
connectors. Refer to the CPS Programming Installation Guide (Motorola Solutions part number
6881095C44) for installation and setup procedures for the software.
Once the computer is connected to the radio, the prompts provided by the programming software
can be followed. The following items, available through the Radio Products Services Division (except
the computer), are required when programming APX mobile radios.
Table 4-3. APX Mobile Radios Field-Programming Items
Type or Part Number Description

Customer Programming This software enables you to program the radio’s features and
Software (CPS) and Tuner align its parameters.
Software (RVN5224_)
Personal Computer (PC) Operating System
• Windows® 7 with Service Pack 1, or above
• Windows® 8
Minimum Hardware Requirements

• 1 GHz dual core or higher Pentium grade processor
• 8GB RAM memory, excluding onboard graphics card mem-
ory usage
• 4GB free hard disk space (for Standalone CPS) or 8GB for
CPS with Radio Management Suite.
• DirectX 9-class graphics card
• USB (Universal Serial Bus) Port radio communication
• USB (Universal Serial Bus) Port for iButton dongle
• DVD-ROM drive for software installation
USB Programming Cable Used to connect radio directly to the computer, refer to
Table 4-2.
4-4 Test Equipment, Service Aids, and Tools: APX Mobile Radios Field Programming and Equipment
Notes
Chapter 5 Performance Checks
5.1 Introduction
This section covers performance checks used to verify that the radio meets published specifications.
The recommended test equipment listed in Chapter 4 approaches the accuracy of the manufacturing
equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with
the manufacturer’s recommended calibration schedule.
5.2 Test Setup

The equipment required for APX mobile radio performance checks is connected as shown in the
following diagram.
COMMUNICATIONS
ANALYZER
RF PORT RF WATTMETER
ATTENUATOR
RADIO
AGILENT 8901
MODULATION
ANALYZER
MATCHING RX
SINAD METER
TRANSFORMER
TEST
SPEAKER
AC VOLTMETER
OR
COMMUNICATIONS
ANALYZER
Vert/SINAD Dist/
DVM Counter
Figure 5-1. Performance Checks Test Setup
5.3 Test Mode
!
Be sure to transmit into a series load when keying a radio under test
(e.g. 30dB RF pad). Failure to do so can result in test equipment
Caution damage.
5.3.1 Entering Test Mode

1. To enter test mode, turn the radio on.
2. Within 10 seconds after Self Test is complete, press the Home Button five times in
succession for O2/O5/O7/O9 Control Head (see Figure 5-2 for O2, Figure 5-4 for O5, Figure
5-5 for O7 and Figure 5-6 for O9 Control Head), or press the Side Button 2 five times in
succession for O3 Control Head (see Figure 5-3).
3. The radio shows a series of displays that will give information regarding various version
numbers and subscriber-specific information. The displays are described in Table 5-1.
5-2 Performance Checks: Test Mode
Table 5-1. Test-Mode Displays
Display Name Description Appears
SERVICE Indicates radio has entered test mode Always
HOST VERSION Version of transceiver firmware Always
DSP VERSION Version of transceiver DSP firmware Always
Secure Version Firmware version for encryption When radio is

secure- equipped
Encryption Mode Type of encryption being used When radio is

secure- equipped
CH VERSION Version of Control Head firmware Always
MCHB Version Version of Control Head Board Always
CHIB Version Version of Control Head Interface Board When auxiliary control
head is present / radio
is remote mount
Auxiliary Control Firmware version for auxiliary control head When auxiliary control
Head head is present
Siren Version Firmware version for siren When siren is present
VRS Version Number Firmware version for VRS When VRS is present
MODEL NUMBER Radio’s model number, as programmed in codeplug Always
SERIAL NUMBER Radio’s serial number, as programmed in codeplug Always
ESN Electronic Serial Number Always
ROM Size Memory capacity of flash part Always
FLASHCODE FLASHcodes, programmed as a part of radio’s codeplug Always
RF BAND Frequency band of transceiver Always
TUNING VER Version of Codeplug tuning Always
PROCESSOR VER Version of transceiver microprocessor Always
Note: All displays are temporary and expire without any user intervention. If the information is longer than
the physical length of the control head display, it wraps around to the next display. After the last
display, RF TEST is displayed.
Special attention: while information is scrolling while in test mode, if the "UP" Navigation button is
pressed, the scrolling information will pause until the "DOWN" Navigation button is pressed again.
Repeat with "Up" button to pause any other information. This makes recording radio version
information easier.
Performance Checks: Test Mode 5-3
4. Turn the Mode Rotary Knob for O5 Control Head. The test mode menu, CH TEST, is
displayed.
5. Pressing the Home button enters the RF test mode. The display shows 1 CSQ, indicating test
frequency 1, Carrier SQuelch mode.
6. For the O3 Control Head, pressing the programmed Monitor button enables toggling
between RF TEST and CH TEST.
7. To select, press the Orange (EMERG) button. If the RF TEST is selected, display Shows 1
CSQ, indicating test frequency 1, Carrier SQuelch mode.
8. Go to the RF Test Mode section.
5.3.2 RF Test Mode

A special routine called RF TEST MODE or air test has been incorporated into the radio.
1. For the O2/O5/O7/O9 Control Head, enter the RF test mode by pressing the Home button
when the test mode menu RF TEST is displayed. If RF TEST is not displayed, use the Mode
knob to scroll through the test mode menu until RF TEST is displayed.
2. For the O3 Control Head, enter the RF test mode by pressing the Orange (EMERG) button
when the test mode menu RF TEST is displayed.If RF TEST is not displayed, use the Monitor
button to toggle between RF TEST and CH TEST.
3. For the O2/O5/O7/O9 Control Head, press the Home button to move the cursor back and
forth between the frequency and signaling type (See Table 5-2). Use the Mode knob to scroll
through the available selections.
4. For the O3 Control Head, press the Monitor button to select Channel Spacing (12.5Khz or
25kHz), press the Side Button 1 to change signaling type and press Side Button 2 to
change frequency.
Table 5-2. Rx and Tx Test Frequencies
Channel Rx Frequency (MHz) Tx Frequency (MHz) Po (W)
F1 136.0750 136.0250 55.0
F2 154.2750 154.2250 55.0
F3 173.9250 173.9750 55.0
F4 380.0750 380.0250 49.5
F5 424.9750 424.9250 49.5
F6 484.9750 484.9250 49.5
F7 485.0750 485.0250 44.0
F8 495.0750 495.0250 44.0
F9 519.9250 519.9750 27.5
F10 764.0625 764.0125 33.0
F11 769.0625 794.0125 33.0
F12 806.0625 806.0125 38.5
F13 851.0625 823.9875 38.5
F14 860.0625 851.0125 38.5
F15 869.9375 869.8875 38.5
Table 5-3. Signaling Types
Display Modulation Demodulation Type
CSQ None None Carrier Squelch
TPL 192 Hz 192 Hz Private-Line
AST 1200 Hz N/A ASTRO (digital)
USQ None None Open Squelch
When in the transmit test mode, DTMF modulation produces a sidetone in the speaker. All signaling
types will continually modulate the transmitted signal for detection/measurement by external
instruments.
5.3.3 O2 Control Head Test Mode

The control head test mode is part of the diagnostics built into the radio and is entered through the
front-panel programming sequence. This test mode allows you to perform button and display tests to
verify proper operation.
1. Power up the control head by pressing the Power Button. Press the Menu Select Buttons 1
and 4 simultaneously to enter control head STANDALONE TEST. CH firmware, CH Nautilus,
CH Flashzap version and CH Board version will be displayed before the unit enters the
Control Head Test mode.
2. Press Home to enter sequential test.
3. In Factory Test menu, pressing any buttons will activate the following tests:
- LED test (green, red and yellow)
- Backlight test (Off, Medium and On)
- LCD test (4 borders test)
- Keypad LED test (green, amber, red and common white LED test)
4. Hit any button after this to activate the keypad test. All the 10 buttons notations will be
displayed on the LCD and once the corresponding button is pressed, the notation will
disappear from the LCD.
5. After all 10 buttons are pressed, hit any key to enter Multifunction Knob test.
6. Turn the radio off and back on to exit test mode and return to normal radio operation.
LED Status
Power On/Off Button Indicators Emergency
Button
Up/Down Buttons
Dim Button
Menu Select Buttons Multi-Function

Accessory Knob
Port (Microphone) Home Button
Figure 5-2. O2 Control Head


1. Enter the control head test mode by pressing the POWER ON/OFF Button while holding
down the 1 and 3 button of the keypad. Wait till Standalone Mode is displayed and release the
1 and 3 Button of the keypad. CH Firmware version, CH FPGA version, CH Flashzap version
and CH Board version will be displayed before being able to be in Factory Test.
2. Once in Factory Test menu, pressing any buttons will activate the following tests:
For the Hook Up test that follows right after the LCD test has been completed, place the Hook
Up and remove the Hook Up until Hook Off is shown. Hit any button after this to activate the
32 buttons test that will test the Keypad Buttons, Side Buttons and Top Buttons. All the 32
Buttons notations will be displayed on the LCD and once the corresponding button is
pressed, the notation will disappear from the LCD. After all 32 Buttons are pressed, Test
Completed will be displayed and to turn the CH off, press the ON/OFF button once.
Orange Button
Programmable Button
Programmable Button (Monitor) 14-Character

Display
Side Button 1 (Programmable)
Side Button 2 (Programmable)
Navigation Keys
Data Button


1. After power up, press the HOME button five times to enter the Test Mode menu.
NOTE: Once CH TEST has been selected by pressing Home, turning the Mode knob will
not change the control head test mode back to the RF test mode. You must turn the
radio off and reenter the RF test mode as described earlier.
2. When the control head test mode has been selected, all the icons across the top of the LCD
are displayed briefly and the indicator LED’s on the right side will light briefly. At this point,
pressing any of the control head buttons or turning the knobs will display the button or knob
ID and the value of the button or knob. The value of a button is 1 for a press and 0 for a
release. The power button functions normally and will turn the control head off.
Volume Dim
Mode Emergency
Knob Button
Knob
O5
Home
Power Indicators
On/Off
MMP Navigation
Soft Menu Keys
Connector
Keys


1. Power up the control head by pressing the Power Button. Press the Menu Select Buttons 1
and 4 simultaneously to enter control head STANDALONE TEST. CH firmware, CH Nautilus,
CH Flashzap version and CH Board version will be displayed before the unit enters the
Control Head Test mode.
5. After all 24 buttons are pressed, hit any key to enter Multifunction Knob test.
Power On/Off Button

Emergency
LED Status Indicators Button
Multi-Function Knob DTMF Keypad
Dim
Button
Data Button
Menu Select Buttons Home Button
Navigational Keys
Accessory Port (Microphone)


1. Power up the control head by pressing the Power Button. Press the Soft Menu Keypad
Buttons 2 and 5 simultaneously to enter control head STANDALONE TEST. CH firmware, CH
FPGA version, CH Flashzap version and CH Board version will be displayed before being
able to be in Factory Test.
5. After all 48 buttons are pressed, hit any key to enter Rotary test. Response selector, Volume
rotary and Channel rotary functionality is tested by turning the knob.
Directional
Buttons
Siren Control Response
Buttons Selector
Programmable
Orange Button
Buttons (Top)
Public Address
Power On/Off
Button
Button
LED Indicators
Keypad
Status Icons
4-Way Navigation
Display Backlight
Button
Control Buttons
Data Feature
Menu Select Buttons Button
Volume Knob Mode Knob
Programmable Home Button

Buttons (Bottom)

5-10 Performance Checks: Receiver Performance Checks
5.4 Receiver Performance Checks
Table 5-4. Receiver Performance Checks
Test
Test Name System Analyzer Radio Comments
Condition
Reference Mode: PWR MON TEST MODE, Press and hold Maximum Frequency
Frequency 1st channel test frequency* 1 CSQ output at PTT switch. error is
Monitor: Frequency error antenna. ± 2.0 PPM for VHF and
Input at RF In/Out UHF
± 1.5 PPM for 700/800
MHz
Rated Audio Mode: GEN TEST MODE, Release PTT Set volume control to
Output level: 1.0 mV RF 1 CSQ. switch. 6.45 Vrms across the
1st channel test frequency* 900 MHz only: 3.2 ohm speaker or
Mod: 1 kHz tone at 1.5 kHz Use 12.5 kHz 7.75 Vrms across the 8
deviation channel spacing ohm speaker
Monitor: DVM: AC Volts
900 MHz: 1 kHz tone at 1.5
kHz deviation
Distortion As above, except to distortion As above Release PTT Distortion <= 3.0%
switch.
Sensitivity As above, except SINAD, As above Release PTT RF input to be

(SINAD) lower the RF level for 12 dB switch. < 0.25 µV (7/800) and
SINAD < 0.31 µV (VHF, UHF1
and UHF2)
Noise Squelch RF level set to 1 mV RF As above Release PTT Set volume control to
Threshold switch. 3.16 Vrms across the
(only radios with speaker.
conventional
system need to As above, except change Out of TEST Release PTT Unsquelch to occur at
be tested) frequency to a conventional MODE; switch. < 0.25 µV
system. Raise RF level from select a
zero until radio unsquelches. conventional
system
* Test frequencies are listed in Table 5-2.

Performance Checks: Transmitter Performance Checks 5-11
5.5 Transmitter Performance Checks
Table 5-5. Transmitter Performance Checks
Test
Condition
Reference Mode: PWR MON TEST MODE, Press and hold Maximum Frequency
Frequency 1st channel test frequency** 1 CSQ. PTT switch. error is
Monitor: Frequency error ± 2.0 PPM for VHF and
Input at RF In/Out UHF
± 1.5 PPM for 7/800
MHz
Power RF As above As above Press and hold Refer to the Radio

PTT switch. Specifications in the
front of the manual.
Voice Modulation Mode: PWR MON As above Press and hold Deviation:
1st channel test frequency** PTT switch. VHF, UHF, 7/800 MHz:
attenuation to –70, >=2.5 kHz but
input to RF In/Out, <= 3.5 kHz
Monitor: DVM, AC Volts See the Detailed
Set 1 kHz Mod Out level for 25 Service Manual for test
mVrms at test set, equipment descriptions.
80 mVrms at dummy
microphone or load box input
Voice Modulation Mode: PWR MON As above Connect Press PTT switch on
External 1st channel test frequency** external microphone and say
Microphone attenuation to –70, input to RF microphone. “four” loudly into the
In/Out Press and hold radio mic.
PTT. Measure deviation:
VHF, UHF, 7/800 MHz:
>= 2.5 kHz but
<= 3.5 kHz
See the Detailed
Service Manual for test
equipment descriptions.
PL Modulation Change frequency to 1st TEST MODE, Remove Deviation:

(radios with channel test frequency**; 1 TPL modulation VHF, UHF, 7/800 MHz:
conventional, B/W to narrow input from >= 500 Hz but
clear mode, dummy <= 1000 Hz
coded squelch microphone or See the Detailed
operation only) load box. Service Manual for test
Press and hold equipment descriptions.
PTT switch.
5-12 Performance Checks: Transmitter Performance Checks
Table 5-5. Transmitter Performance Checks (Continued)
Test
Condition
Talkaround Change frequency to Conventional Press and hold Deviation:

Modulation conventional talkaround talkaround PTT switch. VHF, UHF, 7/800 MHz:
(radios with frequency. personality >= 2.5 kHz but
conventional, Mode: PWR MON (clear mode <= 3.5 kHz
clear mode, deviation, attenuation to –70, operation) See the Detailed
talkaround input to RF In/Out 1 CSQ Service Manual for test
operation only) Monitor: DVM, AC Volts equipment descriptions.
Set 1 kHz Mod Out level for
80 mVrms at dummy
microphone or load box.
Talkaround Change frequency to Conventional Press and hold Deviation:

Modulation conventional talkaround talkaround PTT switch. VHF, UHF, 7/800 MHz:
(radios with frequency. personality >= 3.6 kHz but
conventional, Mode: PWR MON (secure mode <= 4.4 kHz
secure mode, deviation, attenuation to –70, operation). See the Detailed
talkaround input to RF In/Out Load key into Service Manual for test
operation only) * Monitor: DVM, AC Volts radio 1 sec. equipment descriptions.
Mod: 1 kHz out level for
80 mVrms at dummy
microphone or load box.
* The secure mode, talkaround modulation test is only required for radios that do not have clear mode
talkaround capability.
** Test frequencies are listed in Table 5-2.
Chapter 6 Radio Alignment Procedures
6.1 Introduction
This section describes both receiver and transmitter radio alignment procedures.
6.2 ASTRO APX Mobile Radio Tuner Software

A personal computer (PC) and Tuner Software are required to align the radio. Refer to the CPS
Programming Installation Guide (Motorola Solutions part number RVN5224_) for installation and
setup procedures for the software. To perform the alignment procedures, the radio must be
connected to the computer and to a universal test set, as shown in the following figure.
COMMUNICATIONS
ANALYZER
RF PORT RF WATTMETER
ATTENUATOR
RADIO
AGILENT 8901
MODULATION
ANALYZER
MATCHING RX
SINAD METER
TRANSFORMER
TEST
SPEAKER
AC VOLTMETER
OR
COMMUNICATIONS
ANALYZER
Vert/SINAD Dist/
DVM Counter
CONTROL HKN6183/HKN6184
HEAD COMPUTER
MAEPF-27657-O
Figure 6-1. Radio Alignment Test Setup for APX Mobile Radio
These procedures should be attempted only by qualified
! service personnel who are operating as an FCC licensed

technician, or are overseen by an FCC licensed technician.
Caution Failure to perform alignment procedures properly may result
in seriously degraded radio or system performance.
6-2 Radio Alignment Procedures: ASTRO APX Mobile Radio Tuner Software
Select Tuner from the Start menu. To read the radio, click on the “read device” icon. Figure 6-2
illustrates how the alignment screens are organized. To access a screen, click on the desired screen
name in the Tuner menu.
Figure 6-2 shows the tuner main menu screen.
Figure 6-2. Tuner Main Menu
Do NOT switch radios in the middle of any alignment
! procedure. Left-click Close button [X] located in the top right

corner of the alignment window to close the screen and return
Caution to the Tuner Main Menu. Improper exits from the Alignment
screens might leave the radio in an improperly configured
state and result in seriously degraded radio or system
performance.
The alignment screens utilize the “softpot,” an analog SOFTware-controlled POTentiometer used for
adjusting all transceiver alignment controls.
Each alignment screen provides the ability to increase or decrease the softpot value by using the
slider or the spin buttons ( and ), or by entering the new value from the keyboard. A graphical
scale on the display indicates the minimum, maximum, and proposed value of the softpot.
Radio Alignment Procedures: Radio Information 6-3
6.3 Radio Information

Figure 6-3 shows a typical Radio Information screen. All of the data appearing here is informational
and cannot be changed.
Figure 6-3. Radio Information Screen
6.4 Transmitter Alignments

NOTE: Screen captures are representative. Actual screen may change with software version.
6.4.1 PA Bias 1 Alignment

NOTE: This alignment is required after replacing (or servicing) the Transceiver or Transmitter boards.
The PA Bias 1 alignment procedure adjusts the drain bias current in one of the RF power amplifier
devices.
Table 6-1. PA Bias 1 Alignment RF Power Amplifier Devices
Band/Power Level Device

VHF 50 W Final 1
UHF 45 W/40 W/25 W Final 1
700–800 MHz 35 W Final 1
NOTE: The appropriate antenna port should be terminated with a 50-ohm load while tuning.
1. Set the power supply voltage as indicated in Table 6-2. Set power supply current limit to 3 A.
Table 6-2. Power Supply Voltage Settings
Band/Power Level Supply Voltage (V) Supply Current Limit (A)

VHF 50 W 13.6 3
UHF 45 W/40 W/25 W 13.6 3
700–800 MHz 35 W 13.6 3
2. Select PA Bias 1 from the Tuner Main Menu. When the screen is displayed, the radio enters
a special bias tune mode, and radio current increases by approximately 190 mA.
6-4 Radio Alignment Procedures: Transmitter Alignments
Figure 6-4. PA Bias 1 Alignment Screen
3. Read baseline current from current meter on power supply.

4. Add baseline current to device bias current to calculate target current.
Table 6-3. PA Bias 1 Alignment Device Bias Current
Band/Power Level Device Bias Current (mA)

VHF 50 W 880
UHF 45 W/40 W/25 W 650
700–800 MHz 35 W 880
5. Left-click the Bias Toggle button to apply bias to gate of device.

6. Adjust softpot value until target current is achieved within ±10%
7. Left-click the Bias Toggle button to remove bias from gate of device.
8. Left-click the Program All button to save tuned value.
9. Left-click Close button [X] located in the top right corner of the alignment window to close
the screen and return to the Tuner Main Menu.
Radio Alignment Procedures: Transmitter Alignments 6-5
6.4.2 PA Bias 3 Alignment

The PA Bias 3 alignment procedure adjusts the drain bias current in one of the RF power amplifier
devices.
Table 6-4. PA Bias 3 Alignment Amplifier Devices
Band/Power Level Device
VHF 50 W Driver
UHF 45 W/40 W/25 W Driver
700–800 MHz 35 W Driver
NOTE: The appropriate antenna port should be terminated with a 50-ohm load while tuning.
1. Set the power supply voltage as indicated in Table 6-5. Set power supply current limit to 3 A.
VHF 50 W 13.6 3
UHF 45 W/40 W/25 W 13.6 3
700–800 MHz 35 W 13.6 3
2. Select PA Bias 3 from the Tuner Main Menu. When the screen is displayed, the radio enters
a special bias tune mode and radio current increases by approximately 190 mA.
Figure 6-5. PA Bias 3 Alignment Screen

3. Read baseline current from current meter on power supply.

4. Add baseline current to device bias current to calculate target current.
Table 6-6. PA Bias 3 Alignment Device Bias Current
Band/Power Level Device Bias Current (mA)
VHF 50 W 75
UHF 45 W/40 W/25 W 225
700–800 MHz 35 W 300
5. Left-click the Bias Toggle button to apply bias to gate of device.

6. Adjust softpot value until target current is achieved within ±10%
7. Left-click the Bias Toggle button to remove bias from gate of device.
6.4.3 Reference Oscillator Alignment

Radios are shipped from the factory with a worst-case frequency error of ±50 Hz. These
specifications are tighter than the more stringent FCC requirements of ±2.0 ppm for VHF and UHF,
and ±1.5 ppm for the 700–800 MHz bands.
For radios that have been in storage for over six months from the factory ship date, the reference
oscillator should be checked when the radio is initially deployed to the field. It is strongly
recommended that the reference oscillator be checked every time the radio is serviced or at least
once a year, whichever comes first.
The crystal contained in the reference oscillator naturally drifts over time due to its aging
characteristic. Periodic (annual) adjustment of the reference oscillator is important for proper radio
operation.
Improper adjustment can result in both poor performance and interference with other users operating
on adjacent channels.
This test can be done with either the R-2670 Communication Analyzer or the Agilent 8901
Modulation Analyzer.
• Initial setup using the R-2670 Communication Analyzer:
- RF Control: MONITOR
- B/W: WB
- Freq: RSS frequency under test
- Attenuation: 20 dB
- Mon RF in: RF I/O
- Meter: RF Display
- Mode: STD
- Input Level: uV or W
- Display: Bar Graphs
- Squelch: Mid-range or adjust as necessary
• Initial setup using the Agilent 8901 Modulation Analyzer:

- Press the green Automatic Operation button on the analyzer.
- Press the FREQ key.
- Type 7.1, followed by the SPCL button, to set the 8901 Modulation Analyzer for maximum
accuracy.
1. Select Reference Oscillator from the Tuner Main Menu (Figure 6-6).
Figure 6-6. Reference Oscillator Window

2. If you are using the R-2670 analyzer, enter the frequency displayed on the Tuner screen in
the "RF control" section of the R-2670. Under the "Meter" section of the display, choose
RF DISPLAY.
3. Connect antenna port to the test equipment (See Figure 6-1). Left-click the PTT Toggle
button on the screen to make the radio transmit. The screen indicates whether the radio is
transmitting.
4. Wait five seconds until the analyzer reading stabilizes, and then record the transmitter
frequency.
5. Adjust the reference oscillator's softpot value until the measured value is as close as possible
to the frequency shown on the screen. Allow approximately five seconds for the analyzer
frequency reading to stabilize after each change. The radio is capable of being tuned within
10 Hz of target frequency.
6. Left-click the Program All button on the screen to dekey the radio and save the tuned values.
6.4.4 Power Detector Calibration

The power detector calibration alignment procedure adjusts the buffer gain for the forward power
detector to minimize radio power variation from radio to radio.
NOTE: The appropriate antenna port should be terminated with calibrated power meter through a
30 db RF pad.
1. Set the power supply voltage and current limit as indicated in Table 6-7.
VHF 50 W 13.6 15
UHF R2 45 W/40 W/25 W 13.6 15

700–800 MHz 35 W 13.6 15
2. Select Power Detection Calibration from the Tuner Main Menu.
Figure 6-7. Power Detection Calibration Alignment Screen
3. Left-click the PTT Toggle button to transmit at indicated frequency.

4. Adjust softpot value until target power is achieved.
5. Left-click the PTT Toggle button to disable transmit mode.
7. For dual band radio, switch antenna port and repeat the alignment procedure for the second
frequency displayed in the tuning screen.
6.4.5 Tx Power Characterization

The Tx Power Characterization alignment procedure characterizes power tuning so that Tx power
can be adjusted with CPS software. You will transmit at two power levels for each test frequency and
record the measured power level with 0.1 W resolution.
NOTE: The appropriate antenna port should be terminated with a calibrated power meter through a
30 db RF pad.
1. Set the power supply voltage and current limit as indicated in Table 6-8.
VHF 50 W 13.6 15
UHF R2 45 W/40 W/25 W 13.6 15
700–800 MHz 35 W 13.6 15

2. Select Tx Power Characterization from the Tuner Main Menu

.
Figure 6-8. Tx Power Characterization Alignment Screen

3. Left-click in the first box of the Measured Power 1 column. The perimeter of the box will turn
green indicating active characterization point.
4. Left-click the PTT Toggle button to transmit at indicated frequency and record power
measurement with 0.1 W resolution. The perimeter of the box will turn red, indicating that the
radio is transmitting.
5. Left-click the PTT Toggle button to disable transmit mode.
6. Enter the power measurement with 0.1 W resolution, overwriting any value that may reside in
the box from previous tuning.
7. Left-click in the first box of the Measured Power 2 column. The perimeter of the box will turn
green, indicating it has become the active characterization point.
8. Repeat steps 4-6.
9. Repeat steps 3-8 for the remaining frequencies.
6.4.6 Tx Current Limit

The Tx Current Limit alignment procedure tunes the Tx current-limiting protection.
NOTE: The appropriate antenna port should be terminated with a calibrated power meter through a
30 dB RFpad.
1. Set the power supply voltage and current limit as per Table 6-9.
VHF 50 W 13.6 15
UHF R2 45 W/40 W/25 W 13.6 15
700–800 MHz 35 W 13.6 15

2. Select Tx Current Limit from the Tuner Main Menu.
Figure 6-9. Tx Current Limit Alignment Screen

3. Select the first test frequency to tune.
4. Left-click the PTT Toggle button to transmit on the indicated frequency in the TX current limit
alignment screen.
5. Left-click the auto tune.
6. Repeat steps 3 through 5 for all test frequencies in the TX current limit alignment screen.
7. Left-click the Program All button to save tuned values.
8. Left click the Close button to close screen and return to the Tuner Main Menu.
Table 6-10. Transmit Current Limit Devices
Band/Power Level Devices
VHF 50 W Final 1 Driver
UHF R2 45 W/40 W/25 W Final 1 Driver
700–800 MHz 35 W Final 1 Driver
6.4.6.1 Tx Voltage Limit

The Tx Voltage limit alignment procedure tunes the TX control voltage limiting protection.
NOTE: The antenna port should be terminated with a calibrated power meter through a 30 dB RF
pad.
1. Set the power supply voltage and current limit as per Table 6-9.
2. Select TX Voltage limit from the Tuner Main Menu.
Figure 6-10. Tx Voltage Limit Alignment Screen

3. Select the first test frequency to tune.
4. Left-click the PTT Toggle button to transmit on the indicated frequency in the TX Voltage limit
alignment screen.
5. Left-click the auto tune.
6. Repeat steps 3 through 5 for all test frequencies in the TX Voltage limit alignment screen.
7. Left-click the Program All button to save tuned values.
8. Left click the Close button to close screen and return to the Tuner Main Menu.
6.4.7 Tx Deviation Balance (Compensation)

NOTE: This alignment is required after replacing (or servicing) components on the transceiver board.
The Tx Deviation Balance (Compensation) alignment procedure balances the modulation
contributions of the low- and high-frequency portions of a baseband signal. Proper alignment is
critical to the operation of signaling schemes that have very low frequency components (for example,
DPL) and could result in distorted waveforms if improperly adjusted. This procedure needs to be
performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF
band is divided into frequency zones with a calibration point (value) in each zone. When performing
this tuning procedure, the PTT Tone Low generates an 300 Hz modulation frequency. The deviation
level of this 300 Hz tone is used as the reference level for adjusting the deviation level of the PTT
Tone High, which is a 3 kHz modulation frequency.
This test can be done with either the R-2670 Communication Analyzer or the Agilent 8901
Modulation Analyzer. The method of choice is the R-2670 Analyzer.
• Initial setup using the R-2670 Communication Analyzer:
- Connect a BNC cable between the "DEMOD OUT" port and the "VERT/SINAD DIST/DMM
COUNTER IN" port on the R-2670.
- Press the SPF key on the R-2670 to display the "SPECIAL FUNCTIONS MENU." Move the
cursor to "High Pass," and select 5 Hz on the soft key menu. Select 20 kHz for the "Low
Pass" setting.
- In the "RF Control" section of the R-2670, enter the frequency displayed on the Tuner
screen. Move the cursor to the "B/W" setting and select "WIDE ±100 kHz" on the soft key
menu.
- Place the R-2670 cursor in the "Display" zone. Select "AC VOLTS" on the soft key menu.
Move the cursor to the "Range" setting and select "AUTO."
• Initial setup using the 8901 Modulation Analyzer:
- Press the FM MEASUREMENT button. (The "Error 03-input level too low" indication is
normal until an input signal is applied.)
- Simultaneously press the Peak - and Peak + buttons. Both LEDs on the buttons should
light.
- Press the 15 kHz LP filter key.
- Press the 50 Hz filter key.
1. Select TX Deviation Balance (Compensation) from the Tuner Main Menu. The screen will
indicate the transmit frequencies to be used. Connect antenna port to the test equipment.
See Figure 6-1.
Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen
2. Left-click the first frequency field.

3. Left-click the PTT Tone Low button.
4. Left-click the PTT Toggle button on the screen to enable transmission. The screen indicates
whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on R-
2670, or the deviation shown on the 8901 Analyzer, stabilizes.
5. Measure and record the AC voltage value from the R-2670 Analyzer or the deviation value
from the 8901 Analyzer.
6. Left-click the PTT Tone High button.
7. Adjust the softpot value until the measured deviation/voltage, when using the high tone, is
within ±0.2% of the value observed when using the low tone.
8. Repeat steps 3-7 for the remaining frequencies.
9. Left-click the Program All button on the screen to dekey the radio and save the tuned values.
Radio Alignment Procedures: Receiver Alignments 6-17
6.5 Receiver Alignments

6.5.1 Front End Filter Alignment
! This procedure should only be attempted by qualified service

technicians.
Caution
The alignment procedure adjusts the front end receiver bandpass filters for the best receiver
sensitivity and selectivity. This procedure should be performed for all test frequencies to allow for
proper software interpolation of frequencies between the test frequencies in the band.
See Figure 6-12.
NOTE: Rx Front End Filter Alignment is required after replacing (or servicing) the transceiver board.
6.5.2 Procedure for VHF, UHF1 and UHF2 (Auto Tune)

Tuning of the radio is done through Rx Front End Filter tuning screen
1. Select the Rx Front End Filter alignment screen. See Figure 6-12.
2. Click on the slider or the "New Softpot Value" text box to select which frequency to tune.
3. Apply RF test signal input with no modulation at -90 dBm on the Test Signal Frequency
displayed at the top of the screen.
4. Left-click the Autotune button.
5. Repeat the steps 2–4 for all frequencies.
6. Left-click the Program All button on the screen to save the tuned values in the radio.
6-18 Radio Alignment Procedures: Receiver Alignments
Figure 6-12. RX Front End Filter Alignment
6.5.3 RX Duty Cycle Adjustment

Tuning of the radio is done through the Rx Duty Cycle Adjustment tuning screen.
1. Select the Rx Duty Cycle Adjustment screen. See Figure 6-13.
2. Apply RF test signal input with no modulation at -60 dBm on the Test Signal Frequency
displayed at the top of the screen.
3. Left-click the Autotune button.
4. Left-click the Program All button on the screen to save the tuned values in the radio.
Radio Alignment Procedures: Performance Testing 6-19
Figure 6-13. RX Duty Cycle Adjustment AutoTune
6.6 Performance Testing

6.6.1 Bit Error Rate (BER) Test
This procedure tests the Bit Error Rate (BER) of the radio's receiver at a desired frequency and
contains the fields described in Table 6-11.
Figure 6-14. Bit Error Rate Screen
Table 6-11. Bit Error Rate Test Fields
Field Description
Rx Frequency Selects the Receive Frequency in MHz.
Test Pattern Selects the Digital test pattern - TIA.
Modulation Type Selects the digital modulation type of the incoming signal on which
BER is to be calculated.
6-20 Radio Alignment Procedures: Performance Testing
Table 6-11. Bit Error Rate Test Fields (Continued)
Field Description
Continuous Operation Allows the user to adjust the number of test repetitions. A selection of
Yes will cause the radio to calculate BER on a continuous basis
indefinitely and update the results on this screen after each
integration time. A selection of No will cause the BER test to execute
only one sample and then update the display.
NOTE: When Continuous Operation = Yes, all fields will be dimmed
while the test is in progress. They will be enabled when the
test is complete, or if the STOP button is pressed.
When Continuous Operation = No, a wait cursor will be

displayed while the test is in progress and return to normal
when the test is done.
Audio Allows the user to select the audio output during a test.
Selecting External will route the same signal to the radio's accessory
connector audio output.
Selecting Internal is not supported.
Selecting Mute will disable the audio output.
BER Integration Time Represents the amount of time during which the Bit Error Rate is to be
calculated. Remember that integration over a longer time period
results in a more precise measurement, at the expense of more time
per measurement.
NOTE: This is especially useful in fading measurements.
The range is from 0.360 to 91.8 seconds in increments of 0.360
seconds.
6.6.2 Transmitter Test Pattern

This procedure allows you to generate test patterns at selectable frequencies and channel spacing
to check the transmitter. The procedure contains the fields described in Table 6-12.
Table 6-12. Transmitter Test Pattern Fields
Field Description
Tx Frequency This field selects the Transmit Frequency directly in MHz.
Channel Spacing This field allows the user to select the desired transmit deviation in kHz.
Test Pattern Type This field represents the type of test pattern which will be transmitted by
the radio when the PTT Toggle button is pressed.
NOTE: Test Pattern Type field will be dimmed while the radio is transmitting.
Radio Alignment Procedures: Performance Testing 6-21
Figure 6-15. Transmitter Test Pattern Screen

6-22 Radio Alignment Procedures: Performance Testing
Notes
Chapter 7 Encryption
7.1 Motorola Advanced Crypto Engine Secure Options

NOTE: This information applies to both conventional and trunked systems.
The controller section contains the MACE (Motorola Advanced Crypto Engine) which encrypts and
decrypts voice and data. MACE is a custom encryption IC and uses an encryption key variable to
perform its encode/decode functions. The encryption key variable is loaded into the MACE using a
key variable loader (KVL). Refer to the key-variable loader (KVL) manual for equipment connections
and setup.
7.1.1 Secure Key Retention

The APX 8500 comes standard with 10 minutes or infinite key retention (CPS setting).
Table 7-1. Controller Boards with Programmed Secure Algorithms for APX 8500
Kit Number Description
NNTN8905_ Controller board, APX8500 UCM
NNTN8906_ Controller board, AES/DVP-XL encryption
NNTN8907_ Controller board, DVP-XL encryption
NNTN8908_ Controller board, ASSY, APX, AES/DES/DES-XL/DES-OFB encryption
NNTN8909_ Controller board, ASSY, APX, AES encryption
NNTN8920_ Controller board, APX, DES/DES-XL/DES-OFB encryption
NNTN8922_ Controller board, APX, ADP encryption
Please refer to the ECAT (Electronic Catalog) for the various kit numbers in order to program secure
algorithms for the APX based 8500.
Figure 7-1. ECAT (Electronic Catalog) Portal

7-2 Encryption: Load an Encryption Key
Please refer to Appendix A for customer support in identifying kit numbers.
7.1.2 Secure Dispatch Operation

For personalities or talkgroups that are programmed to be secure-selectable, press and release the
Secure button to toggle between Secure and Clear.
• An illuminated secure status annunciator indicates that the transmitted signal will be encrypted
when the PTT button is pressed.
• The absence of the secure status annunciator indicates that the transmitted signal will not be
encrypted.
Whether the current personality is strapped for secure or clear, the secure status annunciator
correctly displays the transmit operation as being either secure (encrypted) or clear (non-encrypted).
NOTE: You cannot change from secure to clear while the PTT button is pressed. The radio will
generate an illegal tone and the transmission will be terminated.
Secure-equipped radios automatically determine whether a secure or clear voice message is being
received. This allows you to receive either type of message without having to reset the
programmable secure button.
7.1.3 Secure Emergency Operation

Clear or Secure emergency-call operation is determined by the programming of the selected mode
(or talkgroup) or the default emergency mode, if set up. Otherwise, transmit operation is controlled
by the setting of the secure, programmable button. You will not be able to change from Secure to
Clear, or from Clear to Secure, operation during an emergency call.
7.2 Load an Encryption Key

To load an encryption key into an APX mobile radio:
1. Ensure proper encryption algorithm has been flashed into the radio. (DES_XL, DES-OFB,
AES256, etc)
2. Load an encryption key into the radio’s memory from a key-variable loader (KVL) using the
correct loader for the radio’s encryption type.
3. Attach the keyloader cable to the control head MMP connector in the dash mount
configuration and to the TIB MMP connector in the remote mount configuration.
4. KEYLOADING is displayed on the radio display while the key transfer is in progress.
•For single-key radios, a short tone sounds when a key is successfully loaded.
•For multi-key radios, an alternating tone sounds for a few seconds after keys are
successfully loaded.
NOTE: An invalid encryption key aborts a secure transmission. KEYFAIL is displayed and a keyfail
tone (consecutive medium-pitched beeps) sounds until you release the PTT button.
5. If a mode is not programmed for either secure or clear-only operation, use the secure
programmable button to select secure or clear transmission.
NOTE: You cannot change from secure to clear, or from clear to secure, while pressing the PTT
button.
7.3 Advanced Secure Operation

NOTE: The Advanced Secure feature is available only on radios that have been equipped by the
factory to support it.
Encryption: Select an Encryption Key or Keyset 7-3
Advanced Secure incorporates the Multikey feature and a dual-encryption feature into the existing
secure system. Multikey allows a radio to be equipped with multiple encryption keys. A default key is
included and is associated with the current mode. The keys are strapped to a given mode or are
operator-selectable and can be indexed into groups of keys called keysets. The keys are loaded
using a manual keyloader.
In addition, your radio can support up to eight different encryption algorithms simultaneously.
7.3.1 Multikey Operation

The multikey feature can be used in both conventional and trunked applications.
• Conventional Multikey - The encryption keys can be selectively strapped, one per each
channel. In addition, the programmable radio features include operator-selectable keys,
operator-selectable indices, and operator-selectable key erasure. Encryption keys are loaded
into the radio through a KVL.
• Trunked Multikey - If the radio is used for both conventional and trunked applications, the
encryption keys have to be strapped for trunking on a talkgroup, or announcement group, basis.
In addition, a different encryption key can be strapped to other features, such as Private Call,
Dynamic Regrouping, Failsoft, Interconnect, System Wide, or Emergency Talkgroup.
7.4 Select an Encryption Key or Keyset

1. Press either menu button labeled KEY or KSET if available on the display menu. Alternatively,
press and hold the menu button labeled SEC until a tone sounds.
2. Then press the menu button labeled KEY to select a single key or KSET to select a keyset on
the second menu that is displayed. The display shows the last user-selected and properly
stored encryption key available.
3. Use the NAV key to scroll through the encryption keys until the key or keyset desired is
displayed. If the desired key is erased the display flashes ERASED KEY and the key name
alternately.
4. If a good key then Press select.
•If the selected key is erased, the display flashes shows KEY FAIL and the radio sounds a
momentary keyfail tone.
•If the selected key is not allowed, the display shows ILLEGAL KEY and the radio sounds a
momentary illegal key tone.
7.5 Erase a Single Key

1. Press the menu button labeled ERAS. Alternatively, press and hold the menu button labeled
SEC until a tone sounds. Then press ERAS on the second menu that is displayed.
2. Use the NAV key to scroll through the encryption keys until the key to be erased is displayed.
Alternatively, if a keypad microphone is used, press the numeric keys to jump to the desired
encryption key.
ERASED KEY alternates with the key name if the displayed key is blank.
3. Press the menu button labeled SNGL to erase the selected key.
ERASE SNGL KEY followed by the key name is displayed.

7-4 Encryption: Erase All Keys
4. Press the menu button labeled YES.
The selected key is set to zero.
ERASED is alternately displayed with the key name confirming the erasure.
5. To exit the menu without erasing a key, press the menu button labeled ABRT, the PTT button,
or the home button.
7.6 Erase All Keys

1. Press the menu button labeled ERAS. Alternatively, press and hold the menu button labeled
SEC until a tone sounds. Then press ERAS on the second menu that is displayed.
2. Press the menu button labeled ALL.
ERASE ALL KEYS is displayed.

3. Press the menu button labeled YES. All keys are erased.
ERASED KEY is alternately displayed with the displayed key name confirming the erasure.
4. To exit the menu without erasing the keys, press the menu button labeled ABRT, the PTT
button, or the home button.
7.7 Over-the-Air Rekeying

The over-the-air rekeying (OTAR) feature allows the dispatcher to reprogram the encryption keys in
the radio remotely. The following steps describe how to use this feature.
1. Press the menu button labeled REKY. Alternatively, press and hold the menu button labeled
SEC until a tone sounds. Then press REKY on the second menu that is displayed. If REKY or
SEC is not on the current menu, use the NAV key to scroll through the available menus.
REQUEST REKEY is displayed.

2. Press the PTT button to send the rekey request.
PLEASE WAIT is displayed.
One of the following occurs:

The radio sounds five tones when the dispatcher has received the request.
NOTE: Any subsequent press of the PTT button will exit the OTAR feature and allow you to transmit
in the normal manner. Pressing the HOME or emergency button also exits the feature.
If the display momentarily shows REKEY FAIL and the bad-key tone sounds, then the rekey
operation failed because the radio does not contain the Unique Shadow Key (USK) or Unique Key
Encryption Key (UKEK). You have to load the USK into the radio using the KVL before the radio can
be reprogrammed over the air.
NOTE: If you exit at this point, but stay on the current channel in the dispatch mode, the radio
momentarily shows REKEYED or DENIED and sounds a tone indicating the status of the rekey
request.
If the display shows NO ACK and the bad-key tone sounds, then the dispatcher has not
acknowledged your request after the radio has tried five times to send it. The radio then returns to
the display message in step 1, allowing you to retry the request.
Encryption: Over-the-Air Rekeying 7-5
If the request is accepted and the radio is successfully rekeyed, the display momentarily shows
REKEYED.
If the display momentarily shows DENIED and the bad-key tone sounds, the request has been
denied by the dispatcher, and the radio returns to the home display.
7-6 Encryption: Over-the-Air Rekeying
Notes
Chapter 8 Disassembly/Reassembly Procedures
8.1 Introduction
This section details the procedures necessary to remove and replace the printed circuit boards in
APX mobile radios. After troubleshooting and determining what needs to be replaced, disconnect the
test equipment, the antenna cable, and the power cable.
Disconnect the power cable from the radio before

opening and removing the PCB. Failure to remove power
can result in unit damage caused by transients or
accidental shorts, as well as presenting a shock hazard.
Locate the exploded view of the radio in Chapter 11. Exploded Views and Parts Lists. Keep it handy
for reference as you disassemble and reassemble the radio.
When installing a new circuit board, all mounting screws should be started before any are torqued.
This will help ensure proper alignment.
After installing a new board, perform a complete alignment procedure as outlined in Chapter 6. Radio
Alignment Procedures.
8.2 Replacement Procedures

After performing alignment procedures, always exit the SERVICE menu entirely (to the MAIN MENU)
to properly save all changes. Failure to do so can result in an alignment or other failure.
8.2.1 Required Tools and Supplies

Table 8-1. Required Tools and Supplies
Motorola
Supplier
Tools and Supplies Solutions
Part Number
Part Number
8mm, 10mm, 15mm, 25mm and 28mm Hex Nut bits – –
Anti-static grounding kit 0180386A82 –
Flat-blade screwdriver – –
Long Nose Plier – –
Magnetic screwdriver set with bits 0180320B16 –
Mini-UHF to N-type adapter cable 3085651A01 –
Net Runner M8 – –
Philips PH2 screw bit – –
Plastic scraping tool 6686119B01 –
Removal and insertion tool 6680163F01 –
Roto-Torq adjustable driver – RSX4043
Small, flat-blade screwdriver – –
Solder aid (black stick), HEXACON – MA-800G
Tohnichi 6RTD-A Analog Torque Driver (1-6 in-lbs) – –
8-2 Disassembly/Reassembly Procedures: Replacement Procedures
Table 8-1. Required Tools and Supplies (Continued)
Motorola
Supplier
Tools and Supplies Solutions
Part Number
Part Number
Torx® bits for T8 for TIB; T10 for PCB; and T20 for cover
screws; 9mm thin wall, deep socket for all antenna connector – –
nuts.
9mm Hex Nut Bit (for GPS and QMA connector) – –
Tweezers – –
Wire Stripper – –
Chassis Opener 6685666D01 –
O2/O7 Knob Removal Tool 66012035001 –
Electromagnetic Interference (EMI) metallic shielding tape, or
– –
equivalent
QMA to QMA CB000091A02
QMA to Mini-UHF CB000091A03
QMA to SMA CB000091A04
QMA to N-Type CB000091A05
8.2.2 Transceiver Interface Board Disassembly/Reassembly

The Transceiver Interface Board (TIB) is not field serviceable. Note that the TIB seal part number is
SL000048A01.
NOTE: If the screws are loosened, tighten to 6-8 inch-lbs. Over-torque of the screws can result in
warping of the circuit board and possible board damage.
TIB Seal
Figure 8-1. TUC Seal Placement
Never attach or remove a flex with power supplied to the
! radio. Also, take care to avoid misalignment of Flex connector

pins upon re-attachment. Failure to remove power or align
Caution properly can result in electrical shorting of the circuit board
and possible component damage.
.
Disassembly/Reassembly Procedures: Replacement Procedures 8-3
8.2.3 Radio Disassembly
8.2.3.1 APX 8500 Mid Power Model
!
Steps 1 through 6 MUST be performed, prior to removal of the
Controller and RF Board from the chassis. Otherwise damage
Caution to the transceiver Controller Board could occur.
Use the following procedures to disassemble your radio:

1. Ensure all accessory connections, power, antenna, and microphone are unplugged.
If radio is in remote mount configuration, disconnect the remote-mount control cable (CAN
cable) from the transceiver.
2. Remove the two (2) front control head screws using a T-10 torx bit, do not discard screws.
Figure 8-2. Removing the Control Head Screws

3. Firmly grasp the control head front housing and frame seal, and carefully remove from the
radio. Be careful not to pull the attached flex, to avoid option board damage during control
head removal.
Control Head
Figure 8-3. Removing the Control Head

4. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar
the face of the display.
5. Carefully disconnect control head flex from transceiver’s edge card.

NOTE: “Carefully” means that the control head flex shall be disconnected from its mating
control head connector by applying equal amounts of pressure on both ends of the
mated pair until they fully disconnect. While disconnecting, make sure both mated
pairs are pulled apart in a straight-forward [or “in-line”] direction parallel to the
longitudinal axis of the connector pins.
Figure 8-4. Removing the Control Head Flex

6. Remove the TIB assembly by unscrewing the four (4) TIB assembly screws using a T-10 torx
bit. Do not discard screws.
Figure 8-5. Removing the TIB Screws

7. Remove the Accessory Connector Cover (i.e. HLN6863_) at J2 or J100 using the thumb
screws located on two of the corners. Do not discard the Accessory Connector Cover.
8. Remove the TX Grille from the radio using the Solder Aid (black stick). Place flat tip
underneath the two small cutouts located on one side and carefully pry the TX Grille away
from the radio.
Small Cutout
Figure 8-6. Removing the TX Grille

9. Radio must be oriented as shown below with the bottom of the radio facing up. Remove the
seven (7) controller cover screws using a T-20 torx bit. These screws have sealing washers
that should be kept with the screw. Do not discard screws.
Figure 8-7. Removing the TX Casting Screws

10. Remove the TX Casting from the radio. The seal between the two castings is now free to fall
out. Remove the casting seal and place with TX Casting.
Casting Seal
Figure 8-8. Removing the TX Casting
11. Remove the TX board by gently. Handle the TX board by the edges only, and store in an anti-
static bag. Avoid contact with exposed thermal grease on TX board, thermal grease may be
removed with a dry lint-free cloth.
TX Board
Figure 8-9. Removing the TX PCB

12. FLIP RADIO OVER: Remove the eight (8) RF cover screws using a T-20 torx bit. These
screws have sealing washers that should be kept with the screw. Do not discard screws.
Remove the XCVR Cover seal as well and place with the XCVR Cover.
Figure 8-10. Removing the XCVR Cover
13. Disconnect the GPS and BT/Wi-Fi cables from the controller board by gently holding the
controller board in place and pulling up on the cable’s MMCX connector. Do not pull on the
cable section of the cable as damage may occur. Avoid contact with exposed thermal grease
on controller board, thermal grease may be removed with a dry lint-free cloth. Remove GPS
and BT/Wi-Fi SMA connector nut using a deep 5/16” socket or deep nut driver. Remove the
GPS and BT/Wi-Fi SMA connector lock washer. Do not discard nut or lock washer.
Disconnect the rear accessory flex from the controller board. Remove the two (2) screws
from the Accessory Connector and gently pull through the hole in the casting.
Accessory Flex
GPS and BT/Wi-Fi Cable
Figure 8-11. Removing the GPS Cable, BT/Wi-Fi Cable, and Accessory Flex
14. Remove the XCVR board by gently. Handle the XCVR board by the edges only, and store in
an anti-static bag. Avoid contact with exposed thermal grease on XCVR board, thermal
grease may be removed with a dry lint-free cloth.
.
XCVR Board
Figure 8-12. Removing the XCVR PCB

8.2.3.2 O2 Radio Disassembly

1. Ensure power, antenna, microphone and all accessory connections are unplugged. If the
radio is a remote-mount radio, disconnect the remote-mount control cable from the front of
the transceiver.
2. Remove the four front control head screws using a T20 and discard them.

3. Firmly grasp the front panel of the control head or the Transceiver Interface Board (TIB) for
remote mount, and carefully remove the front housing assembly from the back housing
assembly. Be careful not to pull the attached flex.

4. Lay the control head or TIB face down on a clean, flat surface, being careful not to scratch or
mar the surface of the display.
5. Carefully disconnect the transceiver flex from the front housing assembly or TIB and set the
front housing assembly or TIB aside.
NOTE: The O2/O7 knob removal tool can be used as a lever to simplify the task of
disconnecting the transceiver flex and reduce the risk of damaging the connectors.
Figure 8-15. Disconnecting the Transceiver Flex from the Front Housing Assembly
6. Remove the two transceiver screws using a T10 and pull the back housing assembly away
from the transceiver. Do not reuse the transceiver screws.
NOTE: Be careful to avoid pulling on the flex.
7. Carefully separate the I-seal, from the back housing assembly.
Figure 8-16. Removing the Back Housing Assembly

8. Carefully remove the transceiver flex from the transceiver by grasping the provided handle
and separating it from the connector.
Transceiver Flex
Figure 8-17. Removing the Transceiver Flex


1. Ensure all accessory connections, power, antenna, and microphone are unplugged.
If radio is in remote mount configuration, disconnect the remote-mount control cable (CAN
cable) from the transceiver.
2. Remove the two (2) front control head/TIB screws using a T-10 torx bit, do not discard
screws.

3. Firmly grasp the control head/transceiver interface board (TIB) front housing and frame seal,
and carefully remove from the radio. Be careful not to pull the attached flex, during control
head/TIB removal.
TIB
Control Head
Figure 8-19. Removing the Control Head/TIB
4. Lay the control head or TIB face down on a clean, flat surface, being careful not to scratch or
mar the face of the display.
5. Carefully disconnect control head/TIB flex from transceiver’s edge card.

NOTE: “Carefully” means that the control head flex shall be disconnected from its mating
control head connector by applying equal amounts of pressure on both ends of the
mated pair until they fully disconnect. While disconnecting, make sure both mated
pairs are pulled apart in a straight-forward [or “in-line”] direction parallel to the
longitudinal axis of the connector pins.
Figure 8-20. Removing the Control Head Flex


1. Ensure power, antenna, microphone and all accessory connections are unplugged. If the
radio is a remote-mount radio, disconnect the remote-mount control cable from the front of
the transceiver.
2. Remove the two transceiver screws using a T10 and discard them.
Figure 8-21. Removing the Transceiver Screws

3. Firmly grasp the control head or the Transceiver Interface Board (TIB) for remote mount, and
carefully remove the control head from the transceiver. Be careful not to pull on the attached
flex.

4. Lay the control head or TIB face down on a clean flat surface, and be careful not to scratch or
mar the surface of the display.
5. Carefully remove the transceiver flex from the transceiver by grasping the provided handle
and separating it from the connector. Set the transceiver aside.
Figure 8-23. Disconnecting the Transceiver Flex from the Transceiver

6. Carefully separate the I-seal from the control head or TIB.
NOTE: Be careful not to damage the transceiver flex when separating the I-seal from the
control head or TIB.
7. Carefully disconnect the transceiver flex from the control head or TIB.
NOTE: The O2/O7 knob removal tool can be used as a lever to simplify the task of
disconnecting the transceiver flex and reduce the risk of damaging the connectors.
Transceiver Flex
Figure 8-24. Removing the Transceiver Flex

8.2.4 Radio Reassembly
8.2.4.1 APX 8500 Mid Power Model

NOTE: Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks, cuts,
etc.) or dirt. Reseat all seals on their respective parts.
Use the following procedures to reassemble your radio.
1. Place thermal pad (7575935B01) onto the transmitter side of the main chassis
(CH000031A02) and remove the blue liner.
Figure 8-25. Placing Thermal Pad (7575935B01) transmitter (TX) side of main chassis
2. Place thermal pad (7575767B01) onto the transmitter side of the main chassis
Figure 8-26. Placing Thermal Pad 7575767B01 on transmitter (TX) side of main chassis
3. Place thermal pad (HW000572A02) onto the transmitter side of the main chassis
(CH000031A02)
Figure 8-27. Placing the Thermal Pad (HW000572A02) on transmitter (TX) side of main chassis
Make sure that a total of three thermal pads have been placed and their blue liner removed.
Figure 8-28. All 3 thermal pads located on transmitter (TX) side of main chassis. See Table 8-2.
4. Route accessory connector flex (PA000850A01) into main chassis (CH000031A02).
Figure 8-29. Installing the Accessory Connector Flex into Main Chassis
5. Remove the QMA lock washer and QMA nut before installing the two RF cables
(CB000091A01) through chassis hole.
Figure 8-30. Removing the QMA Lock Washer and QMA Nut
6. Install the 2 RF cables through the chassis. Make sure the RF cable connector body aligns
with the chassis as shown in Figure 8-31.
Figure 8-31. Installing two RF Cables into the Main Chassis

7. Place QMA lock washer (HW000570A01) and QMA nut (FN000153A01) onto each cable
connector in that order. Hand-turn the QMA hex nut to RF connector on main chassis.
Figure 8-32. Installing QMA Lock Washer and QMA Nut for each cable connector
8. Screw in two accessory connector screws (0371838H01) to 7 in-lbs

NOTE: Make sure washer and seal are not missing.
Figure 8-33. Installing Accessory Connector Screws

9. Torque down two RF cables to 13 in-lbs.

NOTE: Ensure nuts are fully tightened and flushed and also torque driver is calibrated during model
assembly.
Figure 8-34. Installing the two RF Cables

10. Place two thermal pads (7575767B01 and 7575935B01) onto transmitter (TX) cover and peel
the blue liner.
Figure 8-35. Placing the thermal pads 7575767B01 and 7575935B01 onto Transmitter (TX) Cover
11. Apply thermal grease (1110022D23) onto the dogbone and lollipop on the transmitter board
(PA000175A01).
NOTE: Make sure dogbone and lollipop heatsink surface fully covered by a layer of thermal.
compound as per picture.
Figure 8-36. Applying the Thermal Grease onto the Transmitter Board
12. Before placing the transmitter board (PA000175A01) into the transmitter cover
(CH000032A02) remove the QMA washer and the nut from main RF connector
NOTE: Ensure all thermal pads are free from contamination before place board and make sure the
o-ring around the main RF connector is in place.
Figure 8-37. Removing the QMA Lock Washer and Nut from RF Connector
13. Thoroughly inspect the RF Housing shield gasketing for damage and verify all RF housing
thermal pads are in place and free of damage. Install RF board by tilting and sliding into
chassis using the edge of the board two (2) RF board handles, taking care to line up the one
(1) two (2) RF and one (1) DC connectors through the rear holes of the chassis. To fully seat
RF board, push back and down on the board using the two (2) RF board handles to slightly
compress RF/DC seals. Ensure that the RF board alignment holes are positioned over the
chassis alignment bosses and that the RF board is fully seated in chassis.
Figure 8-38. Placing the transmitter board onto the Transmitter Cover
14. Place QMA lock washer (HW000570A01) and QMA nut (FN000153A01) in that order onto RF
connector. Hand turn the QMA hex nut to RF connector on main chassis. Torque down to 13
in-lbs.
NOTE: Ensure nut is fully tightened and flushed.
Figure 8-39. Installing the QMA Lock Washer and Nut into the RF Connector
15. Insert the DC retention clip and fully seat it. The clip must be inserted prior to the board
screws to properly locate RF board. Place grounding clip (HW000571A01) on transmitter
cover (CH000032A02).
Figure 8-40. Installing the Grounding Clip on Transmitter Cover

NOTE: The short lead side of the clip should be facing out to the connector.
Figure 8-41. Grounding Clip on Transmitter Cover is critical to ensure DC connector stability
16. Place two CN000069A03 (bullets) into the two CN000069A01 hole on transmitter board
(PA000175A01).
NOTE: Make sure the white side of the bullet is down. Inspect the bullets for any damage.
Figure 8-42. RF bullets used in the Transmitter Board

17. Install the three RF board screws.
18. Screw in three PA screws (0310909A33) using T-10 to 13 in-lbs. Ensure screws are fully
tightened and flushed.
Figure 8-43. Installing PA Screws

19. Place the RF Seal in the main chassis and ensure that it is seated properly.
NOTE: Inspect the thermal pad and ensure no foreign material on the thermal pad prior proceed next
process step.
Figure 8-44. Placing the Transmitter Seal into the main Chassis
20. Place transmitter cover (CH000032A02) onto main chassis (CH000031A02).
21. Make sure the seal is not pinched.Be sure RF cover is properly aligned to chassis. The RF
cover and chassis can be compressed together to squeeze seal into place.
Figure 8-45. Placing Transmitter Cover onto the Main Chassis

22. Inspect the sealing washers to the seven (7) RF cover screws, and then install the screws
onto the RF cover/chassis. Screw in seven transmitter cover screws (0385870E01) to 36 in-
lbs, be sure to torque screws using the indicated order to ensure RF cover is properly seated.
NOTE: Repeat torque order sequence at least twice.
NOTE: Ensure screws are fully tightened and flushed.
Figure 8-46. Securing the RF Cover to the Chassis

23. Once RF cover is fully installed, re-check the RF cover-chassis interface to ensure the RF
cover seal is not pinched.
24. Place thermal pad (7575767B01) on transceiver (XVCR) side of main chassis
Figure 8-47. Placing Thermal Pad (7575767B01) on transceiver (XVCR) side of main chassis
25. Confirm the coin cell battery (600092650001) is still present in slot on transceiver board
(PA000176A01).
Figure 8-48. Installing the Coin Cell Battery into Transceiver Board
26. Place transceiver board (PA000176A01) into main chassis (CH000031A02), ensuring that the
board to board connectors mate by pressing down as shown. Ensure all thermal pads are
free from contamination before place board.
Figure 8-49. Securing the Transceiver Board into the Chassis

27. Begin with the chassis. Thoroughly inspect both sides of the chassis shield gasketing for
damage and verify all chassis thermal pads are in place and free of damage. See section 8.3:
Chassis Thermal Pad Replacement Procedure on page 8-51 to replace damaged pads.
28. Orient the chassis with the bottom facing upwards. Grab the XCVR board by the (2) handles
and place the board backside first so that it can slide into the rear openings in the chassis.
Make sure the board seats properly and all the screw holes line up.
29. After inspecting the GPS/BT/Wi-Fi cable and seating the seal on the SMA connector ferrule,
insert the GPS/BT/Wi-Fi SMA connector through the GPS/BT/Wi-Fi cable chassis opening,
ensuring the notch on the GPS/BT/Wi-Fi connector is down and aligned with the protrusion
on the chassis. Install the lock washer. Install the GPS/BT/Wi-Fi nut using a 9 mm nut driver
and torque nut to 12–14 in-lbf.
30. Insert free end of GPS/BT/Wi-Fi cable through the chassis opening. Connect cables to the
XCVR board.
31. Insert rear accessory flex through rear chassis opening. Be sure flex is oriented with
components facing up. Insert free end of accessory flex through chassis opening.
32. Install the two (2) rear accessory connector screws using a T-10 torx bit. Be sure the rear
accessory screws each have one (1) washer and one (1) seal. Torque rear accessory
connector screws to 6-8 in-lbf
33. Connect rear accessory cable connector to the XCVR board.
Figure 8-50. Connecting Rear Accessory Connector Flex and GPS/BT/Wi-Fi Cables
34. Connect both RF cables (CB000091A01) to transceiver board (PA000176A01).
Figure 8-51. Connecting RF Cables to Transceiver Board

35. Place thermal pad (HW000572A02) on transceiver (XCVR) cover (CH000033A02) and
remove the blue liner.
Figure 8-52. Placing Thermal Pad on Transceiver (XCVR) Cover

36. Route transceiver seal (SL000052A01) into seal groove.
Figure 8-53. Placing Transceiver Seal
37. Place transceiver cover (CH000033A02) onto main chassis assembly. Ensure all thermal
pads are free from contamination before place board.
38. Place XCVR cover seal on the chassis and make sure it is seated properly. Orient the XCVR
cover so that the screw holes line up and place on chassis. Install the eight (8) XCVR cover
screws using a T-20 torx bit making sure they all have their necessary sealing washers.
Figure 8-54. Installing the Transceiver Cover
39. Ensure screws are fully tightened and flushed. Once the Transceiver (XCVR) cover is fully
installed, re-check the cover-chassis interface from the sides to ensure the Transceiver cover
seal was not pinched and that it remained seated in the main chassis so there is no gasket
sealing gap.
40. Check that the DC connector seal on the RF board is properly seated.
41. Check that the RF connector seal on the RF board is properly seated.
42. Once RF cover is fully installed, check the RF cover-chassis interface to ensure the RF cover
seal is not pinched.
43. Hook the RF Grille on the DC power side of the radio and snap into position.
Figure 8-55. Installing the RF Grille

44. Install the Accessory Connector Cover (i.e. HLN6863_) at J2 or J100 by pushing into position
and then securing it with the thumb screws located on two of the corners.
45. Install the TIB assembly by screwing in the four (4) TIB assembly screws using a T-10 torx bit
Figure 8-56. Installing the TIB Assembly

46. Attach the control head/TIB flex edge card connector to edge card. Be sure to properly align
edge card connector to exposed edge card.
Figure 8-57. Installing Flex into Controller PCB

NOTE: Each Control Head has a unique DASH MOUNT flex. Do not mix and match. Only use the
appropriate FLEX with its matching Control Head.
48. Install control head flex to control head. Be sure to properly align connectors prior to
connecting.

49. Align control head to front of chassis using the frame seal. Install two (2) control head screws.
Be sure the control head screws each have one (1) washer and one (1) seal installed. Torque
down control head screws to 8-10 in-lbf.
Figure 8-59. Aligning Control Head front of chassis, and Installing the Control Head screws
8.2.4.2 O2 Radio Reassembly

1. Grasp the handle on the transceiver end of the transceiver flex and plug the flex into the
50-pin connector on the side of the main board.
Figure 8-60. Installing the Transceiver Flex onto the Transceiver

2. Align the I-seal with the back housing assembly, and push the I-seal into place.
3. Align the back housing assembly with the transceiver, thread the flex through the back
housing assembly and push the back housing assembly into place.
4. Secure the back housing assembly to the transceiver with two new transceiver screws using
the T10. Apply 13 in. lbs. of torque for each screw. Simultaneously, firmly press down on the
center of the back housing, and this is to provide sufficient compression to the I-seal during
assembly.
Figure 8-61. Installing the Back Housing Assembly onto the Transceiver
5. Reinstall the transceiver flex onto the front housing assembly or TIB flex onto the TIB
connector.
Figure 8-62. Installing the Transceiver Flex onto the Front Housing Assembly
6. Attach the front housing assembly to the back housing assembly.
Figure 8-63. Attaching the Front Housing Assembly to the Back Housing Assembly
7. Secure the front housing assembly to the back housing assembly with four new control head
screws using the T20. Apply 9 in. lbs. torque for each screw.
Figure 8-64. Attaching the Control Head Screws



2. Install control head/TIB flex to control head/TIB. Be sure to properly align the connectors prior
to connecting.
Control Head
Figure 8-66. Installing Control Head/TIB Flex to Control Head/TIB

3. Align control head/TIB to front of chassis using the frame seal. Install two (2) control head/TIB
screws. Be sure the control head/TIB screws each have one (1) washer and one (1) seal
installed. Torque down control head/TIB screws to 8-10 in-lbf.
Figure 8-67. Aligning Control Head/TIB front of chassis, and Installing the Control Head/TIB screws

1. Reinstall the transceiver flex onto the control head or TIB flex onto the TIB connector.
Figure 8-68. Installing the Transceiver Flex onto the Control Head
2. Align the I-seal with the control head and push the I-seal into place.
NOTE: Be careful not to damage the transceiver flex when pushing the I-seal into place.
3. Grasp the handle at transceiver end of the transceiver flex and plug the flex into the
50-pin connector on main board side.
4. Align the control head with transceiver and push the control head into place on the
transceiver.
Figure 8-69. Attaching the Control Head to the Transceiver

5. Secure the control head to transceiver with two new transceiver screws using T10. Apply
9 in.lbs. torque for each screw.
Figure 8-70. Attaching the Transceiver Screws

8.2.4.5 Remote Reassembly

1. Align Remote Front Cover Plate to front of chassis using the frame seal. Install two (2) control
head screws. Be sure the control head screws each have one (1) washer and one (1) seal
installed. Torque down control head screws to 8-10 in-lbf.
Figure 8-71. Reinstalling Remote Front Cover Plate

2. Install two (2) control head screws. Be sure the control head screws each have one (1)
washer and one (1) seal installed. Torque down control head screws to 8-10 in-lbf.
Figure 8-72. Attaching the remote screws

Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure 8-51
8.3 Chassis Thermal Pad Replacement Procedure

8.3.1 Mid Power Models
3
8-52 Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure
Figure 8-73. Chassis Thermal Pad and Grease Locations
Table 8-2. Chassis Thermal Pad and Grease Part Numbers
Item No. Part No. Description

1 7575935B01 Pad, Thermal, Harmonic Filter
2 7575767B01 Pad, Thermal, Regulator
3 HW000572A02 Pad, Thermal, TX
4 1110022D23 Thermal Grease
Use the following procedures for replacing the chassis thermal pads. To replace the thermal pads:
1. Use a plastic flat-edge tool (like a black-stick solder aid) to lift the pad from the chassis
surface.
2. Discard the old pad. Use a soft cloth to remove any remaining residue. Alcohol can also be
used, if necessary. Care should be taken to minimize any cleaning-agent contact with the
surrounding shield gasket.
3. Once the surface is clean and dry, use tweezers to remove a new pad from the shipping liner,
and place it yellow-side down on the chassis.
4. Apply pressure to the pad to activate the pressure-sensitive adhesive. If applicable, remove
the blue liner with tweezers.
Use of a metal tool will scratch the heat sink surface and reduce
! the thermal effectiveness of the thermal pad which is used to

heat sink heat-sensitive components. Loss of thermal
Caution effectiveness of the thermal pads could result in the overheating
of heat-sensitive radio components and result in their damage.
Disassembly/Reassembly Procedures: Fastener Torque Chart 8-53
8.4 Fastener Torque Chart

Table 8-3 lists the various fasteners by part number and description, followed by the torque values
and the location where used. Torque all fasteners to the recommended value when assembling the
radio.
Table 8-3. Fastener Torque Chart
Repair Torque
Part Number Description Locations Used In A Radio
(in.–lbs.)
0310909A33 Screw, Torx M3x10 12–14 RF Board / Accessory Connector to

Chassis
0385870E01 Screw, Torx M4.0xP0.7x25 34–36 RF Covers and Controller Covers
0364332H02 Screw, Torx M3.0xP0.5x32.5 8–10 O5 Control Head
0364332H04 Screw, Torx M3.0xP0.5x18.0 8–10 Remote Front Coverplate Screws
0371838H01 Screw, Torx M2.5xP0.45x12.0 6–8 Accessory Connector to External

Chassis
0371859H01 Screw, Torx M6.0xP1.0x25.0 50–52 Trunnion Mounting
02009258001 GPS Hex Nut 12–14 GPS/BT/Wi-Fi Connector
03012052001 Screw, Torx M3.0xP0.5x26.0 12–14 O2 Rear Housing
03012063001 Screw, Torx M4.0xP0.7x18.0 8–10 O2 Front Housing
03012062001 Screw, Torx M3.0xP0.5x38.0 8–10 O7 Control Head

8-54 Disassembly/Reassembly Procedures: Fastener Torque Chart
Notes
Chapter 9 Radio PINOUT functions, Error Codes, and
Basic Troubleshooting
9.1 Introduction
This chapter contains pin-out information for the radio, error codes, and system level troubleshooting
suggestions. This section can help you isolate a problem to the board level. Board-level
troubleshooting does not attempt to isolate problems to the component level. Component-level
service information can be found in the APX Mobile Radios And O3, O5 & O9 Detailed Service
Manual. (See the "Related Publications" section of this manual for the specific manual number.)
NOTE: To access the various connector pins, use the housing eliminator/test fixture along with the
diagrams found in this section of the manual. (See the section, "Service Aids and
Recommended Tools", for the appropriate Motorola Solutions service aids and tools parts
numbers.)
With the exception of some inputs on service monitors, a suitable attenuator
! rated at 100 W or more should always be used with all test equipment
connected to the RF connector. Failure to do so can result in test equipment
Caution damage.
When performing both transmit and receive tests, it is still possible that
equipment might be damaged by the radio’s transmitter. This could occur
under the following conditions: trunking-mode affiliation, missing emergency
jumper, a defective PTT button, unintentional PTT activations, or circuit
board malfunction. Therefore, an attenuator is always recommended.
9-2 Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Accessory Connectors
9.2 Accessory Connectors

9.2.1 J700 TIB– Mobile Microphone Port (MMP)
The MMP connector is located on the O2,O7,O5 and O9 control heads and the transceiver interface
board (TIB). Table 9-1 describes the name and function of each pin.
1 2
3 4
5 6
7 8
9 10
Figure 9-1. J700 MMP Connector
Table 9-1. MMP Connector Signal Descriptions
Pin Pin Name

Pin Function
# Control Head (J1) TIB (J700)
1 1-Wire ® 1-Wire ® Signal used to identify accessory.
2 PTT PTT_GPIO3 Active low Push-To-Talk input. Asserting this input
results in MIC_HI microphone input use. Distinguished
from PTT at rear J2 MAP connector, which uses the
AUX_MIC microphone input.
3 SPK SPK Receive audio out designed to drive a 150Ω load.
4 USB_D- / USB_D- / Multiplexed USB D- and RS232 receive signal. The
RS232_RX_5v RS232_RX_5v interface used is based on a 1-Wire ® read of the
connected accessory. The RS232 signals are CMOS
levels, 0-5 V.
5 GND GND Ground.
6 VBUS / VBUS / On both the control head and the TIB, when the MMP
OPT_5V OPT_5V port is configured as a device, this is the VBUS input
used for enumeration. When the MMP port is
configured as a host, this is the VBUS output, capable
of sourcing 500mA.
7 MIC_HI MIC_HI Microphone audio input (80 mV rms nominal)
associated with the PTT* signal at pin 2. Distinguished
from AUX_MIC at the rear J2 MAP connector.
8 USB_D+ / USB_D+ / Multiplexed USB D+ and RS232 transmit signal. The
RS232_TX_5v RS232_TX_5v interface used is based on a 1-Wire ® read of the
connected accessory. The RS232 signals are CMOS
levels, 0-5 V.
9 HUB / KEYFAIL / Multiplexed HUB and KEYFAIL lines on the control
KEYFAIL GPIO_4 head. The TIB has KEYFAIL or GPIO_4 functionality.
10 GPIO_0 GPIO_0 General purpose I/O 0.
Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Accessory Connectors 9-3
9.2.2 J2 Mid Power Transceiver – Data and Audio Rear Interface

J2 (also known as the MAP interface) is located on the back of the transceiver. Table 9-2 describes
the function of each pin. The Male crimping pin can be ordered, according to the wire gauge for the
accessory. Please select part number 3980034F03 for 22-28 gauge wire and 3980034F01 for 18 to
20 gauge wire.
20 7
26 13
19 6
25 12
18 5
24 11
17 4
23 10
16 3
22 9
15 2
21 8
14 1
Figure 9-2. J2 Rear Accessory Connector
Table 9-2. J2 Rear Accessory Connector Signal and Voltage Descriptions
Pin
Pin Name Pin Function
#
1 GROUND Ground Preferred ground for any digital lines on J2.
2 BUS+ / SB9600 BUS+ / Part of the Motorola Solutions SB9600 communications
USB2+ / USB2+ / bus to connect external devices. Also used for USB host
interface. Defaults to BUS+.
3 BUS- / SB9600 BUS- / Part of the Motorola Solutions SB9600 communications
USB2- / USB2- / bus to connect external devices. Also used for USB host
interface. Defaults to BUS-.
4 RS232_TX_9V RS232 Transmit Data Part of the 4-wire RS232 interface to external data
accessories, programming cables, etc.
5 RS232_RX_9V RS232 Receive Data Part of the 4-wire RS232 interface to external data
accessories, programming cables, etc.
6 USB- USB - Data Part of the 2-wire USB device differential data bus for
connecting to items such as a PC (programming cable) or
a modem.
7 USB+ USB + Data Part of the 2-wire USB device differential data bus for
connecting to items such as a PC (programming cable) or
a modem.
8 RESET / SB9600 RESET / Part of the Motorola Solutions SB9600 communications
USB2_VBUS_H / USB2_VBUS_HOST / bus to connect external devices. In USB Host mode, this
signal is the 5V VBUS supply to a downstream device.
Defaults to RESET.
9 BUSY SB9600 BUSY Part of the Motorola Solutions SB9600 communications
bus to connect external devices.
9-4 Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Accessory Connectors
Table 9-2. J2 Rear Accessory Connector Signal and Voltage Descriptions (Continued)
Pin
#
10 RS232_RTS_9V / RS232 Request-To- Part of the 4-wire RS232 interface to external data
AUX_TX Send / AUX_TX accessories. An output normally +9V no load.
Also, formerly called TX_audio. This pin is an input to the
radio. This input is routed to the transmitter through
multiplexed lines that are controlled by the
microprocessor. Nominal input level is 300mVrms
11 RS232_CTS_9V RS232 Clear-To-Send Part of the 4-wire RS232 interface to external data
accessories. An input normally at +9V no load.
12 USB_VBUS_D USB_VBUS_DEVICE 5V VBUS input for USB connectivity, supplied by the USB
Host (i.e. a PC).
13 CHAN ACT Channel Activity Active low output used to indicate detection/unsquelching
of a qualified received signal (idles at 5V). Can also be
configured as an optional logic input or output signal.
14 GROUND Ground Preferred ground for any of the analog lines on J2.
15 EMERGENCY Emergency Input used to detect emergency activation. This pin must
be connected to ground by a cable if emergency is
disabled, even if disabled by CPS. If enabled, this line must
be grounded via a switch, which is normally closed.
16 AUX PTT* Push To Talk Pulling this line to ground will activate PTT function
normally selecting the AUX_MIC input.
17 ONE WIRE 1-Wire ® data 0-5V bidirectional data used for identification of smart
accessories/cables.
18 VIP OUT 1 Vehicular Interface High voltage open drain output used for enabling relays
Output used for accessories such as horn/lights.
19 VIP OUT 2 Vehicular Interface High voltage open drain output used for enabling relays
Output used for accessories such as horn/lights.
20 SPKR+ Speaker + Used along with SPKR- to connect an external speaker.
The audio PA is a bridge amplifier. Refer to Radio
Specifications page for speaker impedances and loads.
21 RX FILT AUDIO Receive Filtered Audio Signal is a fixed level (independent of volume level)
Out received audio signal, including alert tones. Flat or de-
emphasis are programmed by CPS. Output voltage is
approximately 100 mVrms per 1kHz of deviation.
22 MONITOR Monitor overrides PL Active low input used to detect when a rear microphone
accessory is taken 'off-hook', to over-ride PL to alert the
user to busy traffic prior to transmitting (idles at 5V). Can
also be configured as an optional logic input or output
signal.
23 AUX MIC / Rear microphone input / The nominal input level is 80mVrms for 60% deviation
MIC OUT Microphone output when used for motorcycle, but can also support 300 mVrms
for future APCO accessories. The DC impedance is 1560
ohms and the AC impedance is 560 ohms, 1Vrms max. 9V
DC with no input load. Alternatively, can be configured as a
line level output of the microphone audio, for use in a siren
(PA mode) or for an external recorder. The nominal
amplitude is 75mV rms
24 SW B+ Switched Battery Voltage A+ battery voltage is available when the radio is switched
on. Used as supply for certain J2 accessories.
Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Accessory Connectors 9-5
Table 9-2. J2 Rear Accessory Connector Signal and Voltage Descriptions (Continued)
Pin
#
25 IGN sense (ACC) Vehicle Ignition sense Connecting to the ACC line controlled by the vehicle's
(ACC) ignition switch will allow CPS ignition features such as
“ignition required for turn on” to be used. Connecting this
line to the car battery will defeat CPS ignition features.
26 SPKR- Speaker - Used along with SPKR+ to connect an external speaker.
The audio PA is a bridge amplifier. Refer to Radio
Specifications page for speaker impedances and loads.
9-6 Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Replacement Board Procedures
9.2.3 J800 TIB – Controller Area Network (CAN) Interface

J800L and J800R are located on the transceiver interface board (TIB). These two connectors are
identical, in order to aid in future daisy-chaining of other CAN bus accessories. They provide the
Data, digital audio, and power on/off/reset commands for the control head to transceiver
communications. Please refer to the installation manual for ordering part numbers for various lengths
of the CAN remote mount cables. Figure 9-3 illustrates the J800 connector while Table 9-3 describes
the function of each pin.
Figure 9-3. J800 Controller Area Network (CAN) Connector on TIB
Table 9-3. J800 Controller Area Network Connector Pin Functions
Pin
#
1 CAN_1_HIGH TX+ (AUDIO)
2 CAN_1_LOW TX- (AUDIO)
3 CAN_3_HIGH TX+ (PWR) Dedicated for System ON/OFF/RESET
commands.
4 CAN termination detect pin Pin 4 shorted to GND inside each end of the CAN
cable.
5 A+ Only routed on the “03” CAN cable
6 CAN_3_LOW TX- (PWR) Dedicated for System ON/OFF/RESET
commands.
7 GND Drain wire wrapped around GND shield
8 NO PIN
9 CAN_2_HIGH TX+ (DATA)
10 CAN_2_LOW TX- (DATA)
9.3 Replacement Board Procedures

Once a problem has been isolated to a specific board, use one of the following recommended repair
procedures:
• Install a good board from your inventory into the radio.
• Order a replacement board from Radio Products Services Division at 1-800-422-4210. Refer to
Appendix "Replacement Parts Ordering" for further information.
Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Power-Up Error Codes 9-7
9.4 Power-Up Error Codes

When the radio is turned on (power-up), the radio performs cursory tests to determine if its basic
electronics and software are in working order. Problems detected during these tests are presented
as error codes on the radio’s display. The presence of an error should prompt the user that a
problem exists and that a service technician should be contacted.
Self-test errors are classified as either fatal or non-fatal. Fatal errors inhibit user operation; non-fatal
errors do not. Use the following tables to aid in understanding particular power-up error code
displays.
Table 9-4. Power-Up Error Codes
Error Code Description Corrective Action

01/02 FLASH ROM Codeplug Checksum Reprogram the codeplug
Non-Fatal Error
01/12 Security Partition Checksum Send radio to depot
Non-Fatal Error
01/81 Host ROM Checksum Fatal Error Send radio to depot
01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug
01/88 External RAM Fatal Error Send radio to depot
Note: Not a checksum failure
01/90 General Hardware Failure Fatal Error Turn the radio off, then on
01/92 Security Partition Checksum Fatal Error Send radio to depot
01/93 FLASHport Authentication Code Failure Send radio to depot
01/94 Internal EEPROM blank. Fatal Error Send radio to depot
01/98 Internal RAM Fail Fatal Error Send radio to depot
01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot
02/81 DSP ROM Checksum Fatal Error Send radio to depot
02/88 DSP RAM Fatal Error Send radio to depot
Note: Not a checksum failure
02/90 General DSP Hardware Failure Turn the radio off, then on
(DSP startup message not received correctly)
09/10 Secure Hardware Error Turn the radio off, then on.
May have keyload required in
CPS for encryption
09/90 Secure Hardware Fatal Error Turn the radio off, then on
15/10 External Accessory Non-Fatal Error Verify external accessory is
External Accessory is not present on power connected and powers up. Turn
up or did not power up correctly, and external the radio off, then on.
accessory feature is enabled in codeplug.
15/90 External Accessory Fatal Error Verify external accessory is
External Accessory is not present on power connected and powers up. Turn
up or did not power up correctly, and external the radio off, then on.
accessory feature is enabled in codeplug.
9-8 Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Operational Error Codes
9.5 Operational Error Codes

During radio operation, the radio performs dynamic tests to determine if the radio is working properly.
Problems detected during these tests are presented as error codes on the radio’s display. The
presence of an error code should prompt a user that a problem exists and that a service technician
should be contacted. Use Table 9-5 to aid in understanding particular operational error codes.
Table 9-5. Operational Error Codes
Error Code Description Error Type Corrective Action

FAIL 001 Synthesizer Out-of-Lock NON-FATAL 1. Reprogram the codeplug.
2. Send radio to depot
FAIL 002 Personality checksum or NON-FATAL Reprogram the codeplug.
system block error
9.6 Transmitter Troubleshooting

Table 9-6 can help you troubleshoot problems that might occur in the transmitter section of your
radio.
Table 9-6. Transmitter Troubleshooting Chart
Correction or Test (Measurements Taken at

Symptom Possible Cause
Room Temperature)
No RF Power TX Power Level Check TX power level programming (from the
Output Programming appropriate Customer Programming Software).
Radio Transceiver or Refer to the Detailed Service Manual. Send radio to
Transmitter Board depot for repair.
Distorted Bandwidth Is the correct bandwidth selected (use the
Modulation appropriate Customer programming software)?
Is radio properly tuned?
(See Chapter 6: Radio Alignment Procedures.)
Compensation Not Set/ Check the compensation setting.
Working If compensation won’t adjust, go to “Can’t Set
(DPL Distorted) Compensation” below.
Radio Transceiver or Refer to the Detailed Service Manual. Send radio to
Transmitter Board depot for repair.
No Modulation, Check Deviation and Retune, if necessary. (See Chapter 6: Radio
Bad Compensation Alignment Procedures.)
Microphone Microphone Verify that the microphone is correctly plugged into
Sensitivity the MMP connector. Replace if necessary.
Otherwise, refer to the Detailed Service Manual.
Send radio to depot for repair.
No/Low Check Programming or Reprogram the codeplug or refer to the Detailed
Signaling (PL, Radio Transceiver Board Service Manual. Send radio to depot for repair.
DPL, Trunking,
MDC)
Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Receiver Troubleshooting 9-9
Table 9-6. Transmitter Troubleshooting Chart (Continued)

Room Temperature)
Can’t Set Deviation and Vary deviation and compensation controls from
Compensation Compensation maximum to minimum using softpots in the TX
Deviation Balance screen and TX Deviation Limit
screen (using the appropriate radio-programming
software–see Chapter 6: Radio Alignment
Procedures).
Radio Transceiver Board Refer to the Detailed Service Manual. Send radio to
depot for repair.
9.7 Receiver Troubleshooting

Table 9-7 can help you troubleshoot problems that might occur in the receiver section of your radio.
Table 9-7. Receiver Troubleshooting Chart

Room Temperature)
Radio does not Blown power fuse Check the fuse in the red cable.
power-up Blown ignition fuse Check the fuse in the ignition cable, yellow cable
from CHIB, red cable from transceiver J2
connection. Note that the IGNITION field in the
codeplug would need to be set to REQUIRED or
IGN ONLY for the ignition fuse to affect powerup.
Control Head Refer to the detailed service manual for control
head troubleshooting. In addition, if the control
head powers-up then powers-down roughly 8
seconds later (without displaying an error), the
control head has failed. There may also be a failure
on the dash flex between the head and the radio.
Send control head to depot.
Radio Transceiver or If the radio does not draw at least 1A during power-
transmitter board up, there may be a failure on either the transceiver
board or the A+ connection between the
transmitter/transceiver boards. Send radio to
depot.
CAN Cable Ensure that the CAN cable is connected in remote
systems.
Radio will not Radio Transceiver Board Send radio to depot.
power-down
No Receiver Code Plug Check the codeplug to ensure correct frequency
Audio or and signaling (PL, DPL) is enabled (use the
Receive Does appropriate radio-programming software).
Not Unsquelch Speaker Check for speaker leads shorted to ground or open
speaker wires. Replace, if necessary.
Radio Transceiver Board Refer to the Detailed Service Manual. Send radio to
depot.
9-10 Radio PINOUT functions, Error Codes, and Basic Troubleshooting: Controller Troubleshooting
Table 9-7. Receiver Troubleshooting Chart (Continued)

Room Temperature)
Audio Distorted Codeplug Ensure the codeplug is properly configured,
or Not Loud including bandwidth and signaling.
Enough Synthesizer Not On See "Reference Oscillator Alignment".
Frequency/Working
Radio Transceiver Refer to the Detailed Service Manual. Send radio to
depot.
RF Sensitivity Synthesizer Not On Check the local oscillator frequency. See
Poor Frequency/Working "Reference Oscillator Alignment".
Radio Transceiver Refer to the Detailed Service Manual. Send radio to
depot.
Radio Will Not Codeplug Check the offending channel for spurious activity by
Squelch monitoring with a known-good radio or service
monitor.
If possible, remove the offending source (computer,
etc.).
If not, increase the squelch level using the
appropriate radio-programming software.
9.8 Controller Troubleshooting

Table 9-8 can help you troubleshoot problems that might occur in the controller section of your radio.
Table 9-8. Controller Troubleshooting Chart

Room Temperature)
Control head Remote mount CAN Verify all cables securely attached, including power
display says cable attached may be to the radio transceiver.
Maintenance disconnected.
Mode Flexes inside radio or Open Control Head and check if flex is securely
control head may be attached.
loose.
Radio resets Vehicle battery voltage Try radio on bench with power tuned down, and
when PTT too low to allow radio to power supply rated to at least 20 A. Try new vehicle
transmit. battery.
Radio won’t Incorrect codeplug Reprogram the radio via CPS and refer to Help
turn on setting for vehicle section on possible Ignition settings and their
Ignition sense (ACC). functions. Verify that the Ignition sense (ACC) wire
is attached at either the control head or the radio
transceiver.
Chapter 10 Functional Block Diagrams and Connectors
This chapter contains the APX Mobile Radio functional block diagrams and connector locations.
Table 10-1. Table of Functional Block Diagrams and Connectors
Page Figure Name
10-2 Figure 10-1. APX Mobile Radio Transceiver Functional Block Diagram
10-3 Figure 10-2. O3 Dash and Remote Control Head Functional Block Diagram
10-4 Figure 10-3. Transceiver Interface Board (TIB) CAN Functional Block Diagram
10-6 Figure 10-5. O3 Dash-Mount Radio Connector Locations (Mid Power Only)
10-6 Figure 10-6. O3 Remote-Mount Radio Connector Locations
10-7 Figure 10-7. O5 Dash-Mount Radio Connector Locations (Mid Power Only)
10-8 Figure 10-9. Transceiver Interface Board (TIB), Universal Relay Controller & Control Head View.
10-9 Figure 10-10. Remote-Mount Configuration with 100W or Higher Power Radio
10-2 Functional Block Diagrams and Connectors: APX Mobile Radio Transceiver Functional Block Diagram
10.1 APX Mobile Radio Transceiver Functional Block Diagram

799-806 MHz 799-806 MHz
SP4T-RSFW6042
SP5T-SKY13415
700 MHz 700 MHz
SP4T-RSFW6042
SP4T-RSFW6042
IF: V
109.65
To Antenna S? ADC
800 MHz 800 MHz MHz
Switch A
A U
TO
Attenuator, IF FGU2
Protection
Pre-amp Path 78
Circuit VHF Path
HP Filter
Rodinia +
Standard
Path UHF Path
U1/U2/VHF
SSI
2nd LO
VHF
FREQUENCY GENERATION Block Diagram
Congo IC UHF
SPI LO_INJ_TO_Mixer MMP / GCAI

HIZ_RF_OUT MIC HI, GCAI SPKR
Interface Control Head / TIB
Connector
CEX
SPI_CLK LOZ_RF_OUT UHF2
Audio Stereo Audio PA
SPI_DW CPCAP4
DDR CODEC
SPI_DR GPO4 PMIC
128MB MAP
SSI GPO3 eMMC SPI UART SSI,12C Interface
AUX MIC
GPO2 7/800 8GB
Interface RX FILT AUD
GPO1 SDIO
TXFS
TXCLK
MN_CP DDR USB SPI RS232
TXD LOOP SDIO GPIOs
DMCS MN_ADAPT_CP
FILTER SSI,12C
HP_MOD_OUT SDIO,SSI,GPIOs
BT/WLAN
IC
GPO6 SEL1 OMAP L138

TEST1_LCKDET PREMIUM VHF 12C
GNSS IC
GPO7 SEL2 GPIOs
RSTB VCO Dual_Core
PVCO_IN RF_OUT VTUNE Processor McASP Secure IC
PVCO_INB
LOZ_BUF_EN
Control Head, TIB SSI,SPI,GPIOs RS232,
TX_BUFF EN REF_CLK_OUT UHF1-2 TX_INJ_TO_CONTROLLER SB9600 MAP
REF_CLK_IN (CONNECTS TO TX BOARD) INTERFACE
USB HUB
SSI
SPI
REFERENCE GPIOs GPOs VIPs
7/800
OSCILLATOR
Vcontl From 19.2 MHz
Rodinia DAC
REFERENCE
OSCILLATOR 19.2_REF_CLK_TO_RODINIA
19.2_REF_CLK_ BUFFER
TO_CONTR
VHF DIRECTIONAL
COUPLER VHF
100V_ON HARMONIC
Vreverse_VHF 28V_TX_FINAL_VHF
FILTER
MADR-010574
S2 #1 SH2
Final
S1 C2 C1 SH1
Vforward_VHF MRFE6S9060NR1
VG_FINAL_VHF
FINAL_SW1-3
UHF DIRECTIONAL
28V_TX_DRIVER
COUPLER UHF
V1-3
HARMONIC
Vreverse_UHF FILTER 28V_TX_FINAL_UHF 5V_TX
TX1
TX2 Final ANT Driver
Pre- TX_INJ
Final TX3 Switch driver
Vforward_UHF MRFE6S9060NR1 PE42850 MW71C008NT1 RFPA_CNTRL

SP4T MAAP-011232
VG_FINAL_UHF VG_DRIVER
5V_TX
7/800 DIRECTIONAL
COUPLER 7/800
HARMONIC Temp IC VTEMP
RX_IN Vreverse_78 28V_TX_FINAL_78
FILTER
3.3V
Final
Vforward_78 MRFE6S9045NR1
MADR-010574
S2 #2 SH2
VG_FINAL_78
S1 C2 C1 SH1
Figure 10-1. APX Mobile Radio Transceiver Functional Block Diagram

Functional Block Diagrams and Connectors: O3 Dash and Remote Control Head Functional Block Diagram 10-3
10.2 O3 Dash and Remote Control Head Functional Block Diagram
Figure 10-2. O3 Dash and Remote Control Head Functional Block Diagram
10-4 Functional Block Diagrams and Connectors: APX Mobile Radio Transceiver Interface Board (TIB) Functional Block Diagram
10.3 APX Mobile Radio Transceiver Interface Board (TIB) Functional Block Diagram
Figure 10-3. Transceiver Interface Board (TIB) CAN Functional Block Diagram
Functional Block Diagrams and Connectors: APX Mobile Radio Transceiver Interface Board (TIB) Functional Block Diagram 10-5
Figure 10-4. Transceiver Interface Board (TIB) Power On/Off Functional Block Diagram
10-6 Functional Block Diagrams and Connectors: O3 Radio Connector Locations
10.4 O3 Radio Connector Locations

10.4.1 Mid Power Only
5 m (17 ft) Extension Cable
Figure 10-6. O3 Remote-Mount Radio Connector Locations

Figure 10-5. O3 Dash-Mount Radio Connector Locations (Mid Power Only)
Functional Block Diagrams and Connectors: O5 Radio Connector Locations 10-7
10.5 O5 Radio Connector Locations 10.5.2 High Power Only
10.5.1 Mid Power Only
Figure 10-7. O5 Dash-Mount Radio Connector Locations (Mid Power Only) Figure 10-8. O5 Remote-Mount Radio Connector Locations (High Power Only)
10-8 Functional Block Diagrams and Connectors: O9 Transceiver Interface
10.6 O9 Transceiver Interface
5m (17 ft) Extension Cable
O9 to URC Cable
NOTE: URC is an optional

accessory
Figure 10-9. Transceiver Interface Board (TIB), Universal Relay Controller & Control Head View.
Functional Block Diagrams and Connectors: O9 Transceiver Interface 10-9
5m (17 ft) Extension Cable
Figure 10-10. Remote-Mount Configuration with 100W or Higher Power Radio

10-10 Functional Block Diagrams and Connectors: O9 Transceiver Interface
Notes
Chapter 11 Exploded Views and Parts Lists
This chapter contains the exploded views and associated parts lists for the ASTRO APX Mobile radio and accessories. Tables containing pushbutton parts lists are also included at the end of this chapter.
Table 11-1. Table of Exploded Views
Page Figure Name
11-2 Figure 11-1. Remote Exploded View

11-3 Figure 11-2. APX 8500 O2 Dash Mount Radio Exploded View
11-4 Figure 11-3. APX 8500 O3 Radio Exploded View
11-2 Exploded Views and Parts Lists: Remote Exploded View and Parts List
11.1 Remote Exploded View and Parts List

This illustration (Figure 11-1) represents the interface board for all remote mount configurations.
Table 11-2. Remote Parts List
Item No. Motorola Solutions Part No. Description
2 1
2
3
HN000704A01
SL000052A03
0364332H04
Cover, Remote
Seal, Remote Cover
Screw, Zinc Plated, Screw Assy, Sealing
1
Figure 11-1. Remote Exploded View
Exploded Views and Parts Lists: APX 8500 O2 Dash Mount Radio Exploded View and Parts List 11-3
11.2 APX 8500 O2 Dash Mount Radio Exploded View and Parts List
Table 11-3. APX 8500 O2 Dash Mount Radio Parts List
4
1 0104054J54 RF And XCVR Cover Screws
2 CH000032A02 Cover, RF Main W/Choform
3 SL000052A02 Seal, RF Cover
4 HN000622A01 RF Cover Grille
5 HW000571A01 Clip, DC Conn
1 6 PA000175A01 RF Board
7 CB000091A01 Cable, GPS/BT/Wi-Fi Coax Assembly
8 0371838H01 Screw Assembly, Accessory Header
9 PA000850A_ Flex Assembly, Accessory Connector
2 10 CH000031A02 Chassis, Main W/Choform
11 MHLN6999_S Option Board W/ 3 Day Retention
MHLN7000_S * Option Board For APX Mobiles
11 PA000176A01 XCVR Board
12 SL000052A01 Seal, XCVR Cover
3 13 CH000033A02 Cover, XCVR W/Choform
14 PA001123A_ Dash Mount Flex Assembly
5 25 15 3264059H01 I-Seal
6 29 16 0104046J72 O2 Back Housing Assembly
28 17 03012052001 Transceiver Screws
8 18 PMHN4193_ O2 Control Head Grey
PMHN4195_ O2 Control Head Green
19 03012063001 Housing Retention Screws
20 HLN7002_ Mid Power Installation Kit
10 21 04009258001 Washers, GPS/BT/Wi-Fi Internal Tooth
15 22 32009266001 Seal, GPS/BT/Wi-Fi
14 26 23 02009258001 Nut, GPS/BT/Wi-Fi
16 27
9 24 3275731B01 Seal, RF Connector
17 21 22 23 25 3285744E01 Seal, DC Connector
18 26 HN000096A01 Cover, TIB
7 27 SL000048A01 Seal, TIB
28 03012052001 Screw, TIB
29 – MAP accessory cables
11 30 – FCC Label
19 Note: The underscore (_) used at the end of the kit number is replaced with the kit revision letter. When ordering, refer
12 to your specific kit for this suffix letter.
13
20
Figure 11-2. APX 8500 O2 Dash Mount Radio Exploded View

11-4 Exploded Views and Parts Lists: APX 8500 O3 Radio Exploded View and Parts List
11.3 APX 8500 O3 Radio Exploded View and Parts List

Table 11-4. APX 8500 O3 Radio Parts List
4 Item No. Motorola Solutions Part No. Description
1
23 5 HW000571A01 Clip, DC Conn
6 PA000175A01 RF Board
3 12 SL000052A01 Seal, XCVR Cover
13 CH000033A02 Cover, XCVR W/Choform
22 14 0364332H04 Screw, Remote
5 31 15 HLN7002_ Mid Power Installation Kit
30 16 HN000704A01 Cover, Remote
6 8 17 SL000052A03 Seal, Remote
18 04009258001 Washers, GPS/BT/Wi-Fi Internal Tooth
19 32009266001 Seal, GPS/BT/Wi-Fi
20 02009258001 Nut, GPS/BT/Wi-Fi
21 3275731B01 Seal, RF Connector
10 29
22 04009258001 Washers, * GPS/BT/Wi-Fi Internal Tooth
23 PMUN1034_ O3 Control Head (English)
17 28 24
16 PMUN1052_ O3 Control Head (Hebrew)
9 25 26 27 PMUN1053_ O3 Control Head (Cyrillic)

PMUN1054_ O3 Control Head (Arabic)
14 PMUN4227_ O3 Control Head (Siren & Lights)
18 19 20 24 HN000096A02 Cover, TIB, Remote
7 25 SL000048A01 Seal, TIB
26 PA000178A01 PCB, TIB
11 27 03009304001 Screw, PCB, TIB
28 SL000048A02 Seal, TIB Connector
12 29 03012052001 Screw, TIB
30 3364474H_ Label, TIB
13 31 – MAP accessory cables
32 – FCC Label
to your specific kit for this suffix letter.
15
Figure 11-3. APX 8500 O3 Radio Exploded View

Exploded Views and Parts Lists: APX 8500 O5 Dash Mount Radio Exploded View and Parts List 11-5
4 Item No. Motorola Solutions Part No. Description
1 6 PA000175A01 RF Board
10 CH000031A02 Chassis, Main W/Choform
2 11 MHLN6999_S Option Board W/ 3 Day Retention
14 PA001123A_ Dash Flex Kit
22 15 PHCN4000_ O5 Control Head
5 26 25 16 0364332H02 TIB Screws (TIB Housing To Chassis) Assembly
8 17 HLN7002_ Mid Power Installation Kit
6 18 04009258001 Washers, GPS/BT/Wi-Fi Internal Tooth
19 32009266001 Seal, GPS/BT/Wi-Fi
20 02009258001 Nut, GPS/BT/Wi-Fi
21 3275731B01 Seal, RF Connector
10 22 3285744E01 Seal, DC Connector
23 HN000096A01 Cover, TIB
23 24 SL000048A01 Seal, TIB
15 14 25 03012052001 Screw, TIB
24 26 – MAP accessory cables
9
16 18 19 20
27 – FCC Label
Note: The underscore (_) used at the end of the kit number is replaced with the kit revision letter. When ordering, refer to
your specific kit for this suffix letter.
7
11
12
13
17 1

11-6 Exploded Views and Parts Lists: APX 8500 O7 Dash Mount Radio Exploded View and Parts List
4 2 CH000032A02 Cover, RF Main W/Choform
6 PA000175A01 RF Board
1
14 PA001123A_ Dash Mount Flex Assembly
23 15 3264059H01 I-Seal
5 16 PMHN4194_ O7 Control Head English
27 PMHN4192_ O7 Control Head English_Chinese
8 PMHN4197_ O7 Control Head English_Cyrillic
6 26 PMHN4196_ O7 Control Head English_Hebrew
PMHN4191_ O7 Control Head Siren and Light
PMHN4229_ O7 Control Head English Arabic
17 0364332H02 Transceiver Screws
10 18 HLN7002_ Mid Power Installation Kit
19 04009258001 Washers, GPS/BT/Wi-Fi Internal Tooth
15 14 24 20 32009266001 Seal, GPS/BT/Wi-Fi
25
9 21 02009258001 Nut, GPS/BT/Wi-Fi
16 22 3275731B01 Seal, RF Connector
19 20 21 23 3285744E01 Seal, DC Connector
24 HN000096A01 Cover, TIB
7 25 SL000048A01 Seal, TIB
11 26 03012052001 Screw, TIB
27 – MAP accessory cables
12 28 – FCC Label
to your specific kit for this suffix letter.
13
1
18

Appendix A Replacement Parts Ordering
A.1 Basic Ordering Information

When ordering replacement parts or equipment information, the complete identification number
should be included. This applies to all components, kits, and chassis. If the component part number
is not known, the order should include the number of the chassis or kit of which it is a part, and
sufficient description of the desired component to identify it.
The ASTRO APX Mobile Radio Basic Service Manual includes complete parts lists and part
numbers.
Refer to Table of Content for applicable manual numbers.
A.2 Motorola Online Service and Support

For general support, users can access
• http://www.motorolasolutions.com/en_us/support.html
• http://www.motorolasolutions.com/en_us/contact-us.html
• http://www.motorolasolutions.com/en_us/products/two-way-radios/project-25-radios/mobile-
radios/apx8500.html
• Motorola Online Website: https://businessonline.motorolasolutions.com/
To register for online access:

• Domestic customers: please call 800-814-0601 (U.S. and Canada).
• International customers: please go to https://businessonline.motorolasolutions.com/ and click
on “Sign Up Now.”
A-2 Replacement Parts Ordering Accessories Aftermarket Division (AAD)
• ECAT
As a registered user, you have access to the electronic catalogue for purchasing accessories and
radios.
A.3 Accessories Aftermarket Division (AAD)

The Accessories Aftermarket Division (AAD) is able to provide Motorola Solutions Branded
accessories for all your radio needs. Contact Motorola Solutions after you have a KIT number,
identified from the Motorola Online website and/or the ECAT catalog.
You can contact them at:800-422-4210.
Motorola provides the following approved optional accessories to improve the productivity of the
APX Mobile Radios.
For a complete list of Motorola-approved antennas, cables, and other accessories, visit the following
web site: http://www.motorolasolutions.com/en_us/products/two-way-radios/project-25-
radios.html
On the website, search for APX Mobile Radios and you will see the accessories information beside
the specifications of the radio. You can also contact your dealer for more details.
Appendix B Environmental Information
The ASTRO Digital APX mobile radios control head and transceiver was designed using Design for
Environment (DfE) principles.
• Motorola Solutions has used halogen-reduced printed circuit board material in the production of
this
product.
• Motorola Solutions has used No-lead solder in the production of this product.
• There are no embedded batteries in this product.
• Motorola Solutions encourages reuse or recycling of the material used to manufacture this
product. Please contact Motorola Solutions at 1-888-567-7347 or your local sales representa-
tive for rebate
programs and for the latest disassembly and recycling strategies.
• Please do not dispose of this product into a landfill.
B-2 Environmental Information
Notes
Appendix C Maritime Radio Use in the VHF Frequency
Range
C.1 Special Channel Assignments

C.1.1 Emergency Channel
If you are in imminent and grave danger at sea and require emergency assistance, use VHF
Channel 16 to send a distress call to nearby vessels and the United States Coast Guard. Transmit
the following information, in this order:
1. “MAYDAY, MAYDAY, MAYDAY.”

2. “THIS IS _____________________, CALL SIGN __________.”
State the name of the vessel in distress 3 times, followed by the

call sign or other identification of the vessel, stated 3 times.
3. Repeat “MAYDAY” and the name of the vessel.

4. “WE ARE LOCATED AT _______________________.”
State the position of the vessel in distress, using any information

that will help responders to locate you, e.g.:
• latitude and longitude

• bearing (state whether you are using true or magnetic north)
• distance to a well-known landmark
• vessel course, speed or destination
5. State the nature of the distress.

6. Specify what kind of assistance you need.
7. State the number of persons on board and the number needing medical attention, if any.
8. Mention any other information that would be helpful to responders, such as type of vessel,
vessel length and/or tonnage, hull color, etc.
9. “OVER.”
10. Wait for a response.
11. If you do not receive an immediate response, remain by the radio and repeat the transmission
at intervals until you receive a response. Be prepared to follow any instructions given to you.
C.1.2 Non-Commercial Call Channel

For non-commercial transmissions, such as fishing reports, rendezvous arrangements, repair
scheduling, or berthing information, use VHF Channel 9.
C-2 Maritime Radio Use in the VHF Frequency Range Operating Frequency Requirements
C.2 Operating Frequency Requirements

A radio designated for shipboard use must comply with Federal Communications Commission Rule
Part 80 as follows:
• On ships subject to Part II of Title III of the Communications Act, the radio must be capable of
operating on the 156.800 MHz frequency.
• On ships subject to the Safety Convention, the radio must be capable of operating in the:
• Simplex mode on the ship station transmitting frequencies specified in the
156.025–157.425 MHz frequency band, and
• Semiduplex mode on the two frequency channels specified in the table below.
NOTE: Simplex channels 3, 21, 23, 61, 64, 81, 82, and 83 cannot be lawfully used by the general
public in US waters.
Additional information about operating requirements in the Maritime Services can be obtained from
the full text of FCC Rule Part 80 and from the US Coast Guard.
Frequency (MHz)
Channel
Number
Transmit (Tx) Receive (Rx)
1 156.050 160.650
2 156.100 160.700
* 156.150 160.750
4 156.200 160.800
5 156.250 160.850
6 156.300 –
7 156.350 160.950
8 156.400 –
9 156.450 156.450
10 156.500 156.500
11 156.550 156.550
12 156.600 156.600
13** 156.650 156.650
14 156.700 156.700
15** 156.750 156.750
16 156.800 156.800
17** 156.850 156.850
Maritime Radio Use in the VHF Frequency Range Operating Frequency Requirements C-3
Frequency (MHz)
Channel
Number
18 156.900 161.500
19 156.950 161.550
20 157.000 161.600
* 157.050 161.650
22 157.100 161.700
* 157.050 161.650
24 157.200 161.800
25 157.250 161.850
26 157.300 161.900
27 157.350 161.950
28 157.400 162.000
60 156.025 160.625
* 156.075 160.675
62 156.125 160.725
63 156.175 160.775
* 156.225 160.825
65 156.275 160.875
66 156.325 160.925
67** 156.375 156.375
68 156.425 156.425
69 156.475 156.475
71 156.575 156.575
72 156.625 –
73 156.675 156.675
74 156.725 156.725
75 *** ***
76 *** ***
77** 156.875 –
C-4 Maritime Radio Use in the VHF Frequency Range Operating Frequency Requirements
Frequency (MHz)
Channel
Number
78 156.925 161.525
79 156.975 161.575
80 157.025 161.625
* 157.075 161.675
* 157.125 161.725
* 157.175 161.775
84 157.225 161.825
85 157.275 161.875
86 157.325 161.925
87 157.375 161.975
88 157.425 162.025
* Simplex channels 3, 21, 23, 61, 64, 81, 82, and 83 cannot be lawfully used by the general
public in US waters.
** Low power (1 W) only.
*** Guard band.
NOTE: A – in the Receive (Rx) column indicates that the channel is transmit (Tx) only.
Master Glossary Glossary
This glossary contains an alphabetical listing of terms and their definitions that are applicable to
ASTRO portable and mobile subscriber radio products. All terms do not necessarily apply to all
radios, and some terms are merely generic in nature.
The Doc column is for information only and identifies the type of publication in which the term might
be appropriately listed. The Doc codes are listed at the end of the glossary. Do not include the Doc
column information in any other publications.
Term Definition
A/D See analog-to-digital conversion.

active channel A channel that has traffic on it.
ACK Acknowledgment of communication.
ADC See analog-to-digital converter.
ALC See automatic level control.
analog-to-digital Conversion of an instantaneous dc voltage level to a corresponding
conversion digital value. See also D/A.
analog-to-digital A device that converts analog signals into digital data. See also DAC.
converter
ASTRO 25 trunking Motorola Solutions standard for wireless digital trunked
communications.
ASTRO conventional Motorola Solutions standard for wireless analog or digital conventional
communications.
APCO 25 A standard of digital two-way radio communications, developed by the
Association of Public-Safety Communications Officials, providing
maximum radio spectrum efficiency; competition in system life cycle
procurements; effective, efficient and reliable intra-agency and inter-
agency communications; and “user friendly” equipment. See also
Association of Public-Safety Communications Officials.
Association of An association dedicated to an industry-wide effort (known as APCO 25
Public-Safety or Project 25) to set the recommended voluntary standards of uniform
Communications digital two-way radio technology for public safety organizations. This
Officials allows radio interoperability with multiple vendor products which are all
APCO 25 compatible. See also APCO 25.
automatic level A circuit in the transmit RF path that controls RF power amplifier output,
control provides leveling over frequency and voltage, and protects against high
VSWR.
Glossary-2
Term Definition
autoscan A feature that allows the radio to automatically scan the members of a
scan list.
band Frequencies allowed for a specific purpose.
BBP See baseband interface port.
baseband interface Synchronous serial interface to the transceiver board used to transfer
port transmit and receive audio data.
BGA See ball grid array.
ball grid array A type of IC package characterized by solder balls arranged in a grid
that are located on the underside of the package.
Call Alert Privately paging an individual by sending an audible tone.
carrier squelch Feature that responds to the presence of an RF carrier by opening or
unmuting (turning on) a receiver's audio circuit. A squelch circuit
silences the radio when no signal is being received so that the user
does not have to listen to “noise.”
central controller A software-controlled, computer-driven device that receives and
generates data for the trunked radios assigned to it. It monitors and
directs the operations of the trunked repeaters.
channel A group of characteristics, such as transmit/receive frequency pairs,
radio parameters, and encryption encoding.
CAN Controller Area Network protocol. The CAN cable is the remote
communications cable which provides audio, data, and power signaling
information between the Control head and the Transceiver.
CHIB Control Head Interface Board. Used to provide functionality /
connectivity between the CHUC and control head.
CHUC Control Head Universal Connector. A separate board which provides
connectivity to the CHIB and control head.
CODEC See coder/decoder.
coded squelch Used on conventional channels to ensure that the receiver hears only
those communications intended for the receiver.
coder/decoder A device that encodes or decodes a signal.
control channel In a trunking system, one of the channels that is used to provide a
continuous, two-way/data-communications path between the central
controller and all radios on the system.
conventional Typically refers to radio-to-radio communications, sometimes through a
repeater. Frequencies are shared with other users without the aid of a
central controller to assign communications channels. See also
trunking.
Glossary-3
Term Definition
conventional scan A scan list that includes only conventional channels.

list
CPS See Customer Programming Software.
cursor A visual tracking marker (a blinking line) that indicates a location on a
display.
Customer Software with a graphical user interface containing the feature set of an
Programming ASTRO radio.
Software
D/A See digital-to-analog conversion.
DAC See digital-to-analog converter.
deadlock Displayed by the radio after three failed attempts to unlock the radio.The
radio must be powered off and on prior to another attempt.
default A pre-defined set of parameters.
DEK Direct Entry Keyboard.
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.
digital-to-analog Conversion of a digital signal to a voltage that is proportional to the input
conversion value. See also A/D.
digital-to-analog A device that converts digital data into analog signals. See also ADC.
converter
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.
digital signal A microcontroller specifically designed for performing the mathematics
processor involved in manipulating analog information, such as sound, that has
been converted into a digital form. DSP also implies the use of a data
compression technique.
digital signal Object code executed by the Digital Signal Processor in an ASTRO
processor code subscriber radio. The DSP is responsible for computation-intensive
tasks, such as decoding ASTRO signaling.
dispatcher An individual who has radio-system management duties and
responsibilities.
DPL See Digital Private-Line. See also PL.
DSP See digital signal processor.
DSP code See digital signal processor code.
Glossary-4
Term Definition
dynamic regrouping A feature that allows the dispatcher to temporarily reassign selected
radios to a single special channel so they can communicate with each
other.
Failsoft A backup system that allows communication in a non-trunked,
conventional mode if the trunked system fails.
FCC Federal Communications Commission.
firmware Code executed by an embedded processor such as the Host or DSP in
a subscriber radio. This type of code is typically resident in non-volatile
memory and as such is more difficult to change than code executed
from RAM.
FGU See frequency generation unit.
flash A non-volatile memory device similar to an EEPROM. Flash memory
can be erased and reprogrammed in blocks instead of one byte at a
time.
FLASHcode A 13-digit code which uniquely identifies the System Software Package
and Software Revenue Options that are enabled in a particular
subscriber radio. FLASHcodes are only applicable for radios which are
upgradeable through the FLASHport process.
FLASHport A Motorola Solutions term that describes the ability of a radio to change
memory. Every FLASHport radio contains a FLASHport EEPROM or
FLASH memory chip that can be software written and rewritten to, again
and again.
frequency Number of times a complete electromagnetic-wave cycle occurs in a
fixed unit of time (usually one second).
frequency This unit generates ultra-stable, low phase noise master clock and other
generation unit derived synchronization clocks that are distributed throughout the
communication network.
FPGA Field Programmable Gate Array.
General-Purpose Pins whose function is programmable.
Input/Output
GLONASS GLObalnaya NAvigatsionnaya Sputnikovaya Sistema, The Russian
Global Navigation satellite system: Consisting of at least 24 operational
satellites which fly in medium Earth orbit at an altitude of approximately
19,130 km. Each satellite circles the Earth slightly faster than twice a
day. GLONASS provides Time and Location to anywhere on Earth,
where there is an unobstructed line of sight to four or more GPS
satellites. A GLONASS receiver triangulates its position using these
satellites.
Glossary-5
Term Definition
GNSS Global Navigation Satellite System: Standard generic term for satellite
navigation systems that provide geo-spatial positioning with global
coverage. This term includes GPS, GLONASS, Galileo, Beidou and
other regional systems. GNSS is a term used worldwide The advantage
to having access to multiple satellites is accuracy, redundancy and
availability at all times.
GPIO See General-Purpose Input/Output.
GPS Global Positioning System: U.S.A.’s Satellite based radio navigation
system developed by the U.S. Department of Defense and operated by
the U.S. Air Force, which consists of at least 24 operational satellites
which fly in medium Earth orbit at an altitude of approximately 20,180
km. Each satellite circles the Earth twice a day. GPS provides Time and
Location to anywhere on Earth, where there is an unobstructed line of
sight to four or more GPS satellites. A GPS receiver triangulates its
position using these satellites.
hang up Disconnect.
home display The first information display shown after a radio completes its self test.
host code Object code executed by the host processor in an ASTRO subscriber
radio. The host is responsible for control-oriented tasks such as
decoding and responding to user inputs.
IC See integrated circuit.
IF Intermediate Frequency.
IMBE A sub-band, voice-encoding algorithm used in ASTRO digital voice.
inbound signaling Data transmitted on the control channel from a subscriber unit to the
word central control unit.
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.
ISW See inbound signaling word.
key-variable loader A device used to load encryption keys into a radio.
kHz See kilohertz.
kilohertz One thousand cycles per second. Used especially as a radio-frequency
unit.
KVL See key-variable loader.
LED See light emitting diode.
light emitting diode An electronic device that lights up when electricity is passed through it.
Glossary-6
Term Definition
LO See Local oscillator.

Local Oscillator Oscillator used in a super heterodyne receiver to down-convert a
received signal to the intermediate frequency.
low-speed 150-baud digital data sent to the radio during trunked operation while
handshake receiving audio.
LSH See low-speed handshake.
MAP Mobile Accessory Port (26 pin Trapazoid). Used to connect accessories
and programming cables to the radio
Master In Slave Out SPI data line from a peripheral to the MCU.
Master Out Slave In SPI data line from the MCU to a peripheral.
MCU See microcontroller unit.
MDC Motorola Digital Communications.
MDI MCU/DSP Interface internal to the microprocessor IC.
menu entry A software-activated feature shown at the bottom of the display.
Selection of a feature is controlled by the programming of the buttons on
the side of the radio.
MHz See Megahertz.
Megahertz One million cycles per second. Used especially as a radio-frequency
unit.
microcontroller unit Also written as µC. A microprocessor that contains RAM and ROM
components, as well as communications and programming components
and peripherals.
MISO See Master In Slave Out.
MMP Mobile Microphone Port 10 pin round. Used to connect accessories and
programming cables to the control head and the TIB.
mode A programmed combination of operating parameters; for example, a
channel or talkgroup.
mode slaving A radio programmed to automatically provide the proper operation for a
given selected mode.
monitoring Used in conventional operation where the programmed monitor button
is pressed to listen to another user who is active on a channel. This
prevents one user from interfering with another user’s conversation.
MOSI See Master Out Slave In.
multiplexer An electronic device that combines several signals for transmission on
some shared medium (e.g., a telephone wire).
Glossary-7
Term Definition
MUX See multiplexer.

Network Access Network Access Code (NAC) operates on digital channels to reduce
Code voice channel interference between adjacent systems and sites.
non-tactical/revert The user will talk on a preprogrammed emergency channel. The
emergency alarm is sent out on this same channel.
O2 Mobile Control Head.
O3 Hand Held Control head for XTL 5000 and APX 5500 / 6500 / 7500 /
6500Li / 2500 radios.
OMAP An ARM core microcontroller.
open architecture A controller configuration that utilizes a microprocessor with extended
ROM, RAM, and EEPROM.
oscillator An electronic device that produces alternating electric current and
commonly employs tuned circuits and amplifying components.
OSW See outbound signaling word.
OTAR See over-the-air rekeying.
outbound signaling Data transmitted on the control channel from the central controller to the
word subscriber unit.
over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the
radio.
PA Power amplifier.
page A one-way alert with audio and/or display messages.
paging One-way communication that alerts the receiver to retrieve a message.
PC Board Printed Circuit Board. Also referred to as a PCB.
PCIC See Power Control IC.
personality A set of unique features specific to a radio.
phase-locked loop A circuit in which an oscillator is kept in phase with a reference, usually
after passing through a frequency divider.
PL See private-line tone squelch.
PLL See phase-locked loop.
Glossary-8
Term Definition
Power Control IC The power control IC is intended for closed-loop bias control of power
amplifiers. The device facilitates accurate control of the current
delivered to the power amplifier (PA) via a control voltage.
preprogrammed A software feature that has been activated by a qualified radio
technician.
Private A feature that lets you have a private conversation with another radio
(Conversatiion) Call user in the group.
PMR See Publication Manual Revision
private-line tone A continuous sub-audible tone that is transmitted along with the carrier.
squelch See also DPL.
programmable A radio control that can have a radio feature assigned to it.
Programmable A memory chip on which data can be written only once. Once data has
Read-Only Memory been written onto a PROM, it remains there forever.
programming cable A cable that allows the CPS to communicate directly with the radio
using RS232 or USB.
Project 25 See APCO 25.
PTT See Push-to-Talk.
Publication Manual A publication that provides supplemental information for its parent
Revision publication before it is revised and reissued.
Push-to-Talk The switch or button usually located on the left side of the radio which,
when pressed, causes the radio to transmit. When the PTT is released,
the unit returns to receive operation.
radio frequency The portion of the electromagnetic spectrum between audio sound and
infrared light (approximately 10 kHz to 10 GHz).
radio frequency Amplifier having one or more active devices to amplify radio signals.
power amplifier
real-time clock A module that keeps track of elapsed time even when a computer is
turned off.
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.
registers Short-term data-storage circuits within the microcontroller unit or
programmable logic IC.
repeater Remote transmit/receive facility that re-transmits received signals in
order to improve communications range and coverage (conventional
operation).
Glossary-9
Term Definition
repeater/talkaround A conventional radio feature that permits communication through a

receive/transmit facility, which re-transmits received signals in order to
improve communication range and coverage.
RESET Reset line: an input to the microcontroller that restarts execution.
RF See radio frequency.
RF PA See radio frequency power amplifier.
RPT/TA See repeater/talkaround.
RS232 A common interface standard for data communications equipment.
RSSI Received Signal Strength Indicator.
RTC See real-time clock.
RX Receive.
RX DATA Recovered digital data line.
SAP See Serial Audio Port.
selective call A feature that allows you to call a selected individual, intended to
provide privacy and to eliminate the annoyance of having to listen to
conversations of no interest to you.
selective switch Any digital P25 traffic having the correct Network Access Code and the
correct talkgroup.
Serial Audio Port SSI to and from the CODEC used to transfer transmit and receive audio
data.
Serial Peripheral A serial interface comprised of two data lines and a clock line. This
Interface interface is typically used to communicate with other modules and ICs in
the radio.
signal An electrically transmitted electromagnetic wave.
Signal Qualifier An operating mode in which the radio is muted, but still continues to
mode analyze receive data to determine RX signal type.
softpot See software potentiometer.
software Computer programs, procedures, rules, documentation, and data
pertaining to the operation of a system.
software A computer-adjustable electronic attenuator.
potentiometer
spectrum Frequency range within which radiation has specific characteristics.
SPI See Serial Peripheral Interface.
Glossary-10
Term Definition
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.
SRAM See static RAM.
SSI See Synchronous Serial Interface.
Standby mode An operating mode in which the radio is muted but still continues to
monitor data.
static RAM A type of memory used for volatile, program/data memory that does not
need to be refreshed.
status calls Pre-defined text messages that allow the user to send a conditional
message without talking.
Synchronous Serial DSP interface to peripherals that consists of a clock signal line, a frame
Interface synchronization signal line, and a data line.
system central Main control unit of the trunked dispatch system; handles ISW and
controllers OSW messages to and from subscriber units (See ISW and OSW).
tactical/non-revert The user will talk on the channel that was selected before the radio
entered the emergency state.
TalkAround Bypassing a repeater and talking directly to another unit for local unit-to-
unit communications.
talkgroup An organization or group of radio users who communicate with each
other using the same communications path.
talkgroup scan list A scan list that can include both talkgroups (trunked) and channels
(conventional).
thin small-outline A type of dynamic random-access memory (DRAM) package that is
package commonly used in memory applications.
TIB Transceiver Interface Board. Provides connectivity between transceiver
and the CAN cable. Also, interface for accessories when TIB is used on
a highpower transceiver.
time-out timer A timer that limits the length of a transmission.
tone A continuous, sub-audible tone transmitted with the carrier.
TOT See time-out timer.
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.
Glossary-11
Term Definition
Triangulation A method of determining the relative positions of points in space by

measuring the distances, and sometimes angles, between those points
and other reference points whose positions are known. Triangulation
involves the use of trigonometry. It is commonly used in the navigation
of vehicles, aircraft and boats, and is the method used in the Global
Positioning System, in which the reference points are satellites.
trunking The automatic sharing of communications paths between a large
number of users. Allows users to share a smaller number of frequencies
because a repeater or communications path is assigned to a talkgroup
for the duration of a conversation. See also conventional.
trunking priority A scan list that includes talkgroups that are all from the same trunking
monitor scan list system.
TSOP See thin small-outline package.
TX Transmit.
UART See Universal Asynchronous Receiver Transmitter.
UHF Ultra-High Frequency.
USK Unique shadow key.
Universal A microchip with programming that controls a computer's interface to its

Asynchronous attached serial devices.
Receiver Transmitter
UCM Universal Crypto Module
Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps.
USB See Universal Serial Bus.
VCO See voltage-controlled oscillator.
VCOB IC Voltage-Controlled Oscillator Buffer IC.
VHF Very-High Frequency.
VIP Vehicle Interface Port.
VOCON See vocoder/controller.
vocoder An electronic device for synthesizing speech by implementing a
compression algorithm particular to voice. See also voice encoder.
vocoder/controller A PC board that contains an ASTRO radio’s microcontroller, DSP,
memory, audio and power functions, and interface support circuitry.
Glossary-12
Term Definition
voice encoder The DSP-based system for digitally processing analog signals, and
includes the capabilities of performing voice compression algorithms or
voice encoding. See also vocoder.
voltage-controlled An oscillator in which the frequency of oscillation can be varied by
oscillator changing a control voltage.
Waypoint Geographic Coordinates of a specific location. It can also be an
Intermediate point on a route or line of travel.
Wi-Fi Wireless Data Transmission protocol 802.11.
Index Index key loading ............................................................ 7-2
multikey operation ................................................. 7-3
over-the-air rekeying .............................................. 7-4
secure
A dispatch operation ............................................. 7-2
emergency operation ......................................... 7-2
accessory connector, J2 ............................................9-3 interface boards ................................................. 7-1
advanced secure operation .......................................7-2 status annunciator ............................................. 7-2
alignment procedures trunked multikey .................................................... 7-3
power detector calibration ......................................6-7 environmental information .........................................B-1
reference oscillator ................................................6-6 erasing
tuner introduction ...................................................6-1 all encryption keys ................................................. 7-4
Tx current limit ..................................................... 6-11 single encryption key ............................................. 7-3
Tx deviation balance (compensation) ..................6-15 exploded view .............................. 11-3, 11-4, 11-5, 11-6
Tx power characterization ......................................6-9
analog mode of operation ........................................3-12 F
annunciator, secure status ........................................7-2
ASTRO mode of operation ......................................3-12 fastener torque values ............................................ 8-53
field programming
B equipment .............................................................. 4-3
FLASHport technology .............................................. 1-2
bit error rate (BER) test ...........................................6-19 frequency generation unit (FGU) theory of operation
block diagram, functional .........................................10-2 VHF ..................................................................... 3-16
front-panel access test-mode displays ...................... 5-2
functional block diagram ......................................... 10-2
C
chassis pad replacement .........................................8-51 H
codes
operational error ....................................................9-8 handling precautions ................................................. 2-3
power-up error .......................................................9-7 heatsinking precautions, RF PA ................................ 2-3
connector
locations ...............................................................10-7 J
connectors, radio
locations ......................................................10-6, 10-7 J2 accessory connector ............................................ 9-3
control head
theory of operation ...............................................3-10
controller section, radio .............................................3-2 L
copyrights
computer software ....................................................iii loading encryption keys ............................................. 7-2
document ..................................................................iii
M
D
maintenance
descriptions cleaning
radio .......................................................................1-2 external plastic surfaces .................................... 2-2
disassembly/reassembly general ............................................................... 2-2
introduction ............................................................8-1 internal circuit boards and components ............. 2-2
radio general radio care ................................................. 2-2
disassembly .......................................................8-3 handling instructions .............................................. 2-2
reassembly .......................................................8-20 inspection .............................................................. 2-1
required tools and supplies ....................................8-1 preventive .............................................................. 2-1
disclaimer information ..................................................iii manual
displays, front-panel access test-mode .....................5-2 notations ................................................................ 1-1
revisions ...................................................................iii
mode
E analog operation .................................................. 3-12
ASTRO operation ................................................ 3-12
encryption control-head test .............................................5-5, 5-6
advanced secure operation ...................................7-2 performance checks test ....................................... 5-1
conventional multikey ............................................7-3 RF test ................................................................... 5-3
erasing model numbering scheme ..........................................xxi
a single key ........................................................7-3 multikey operation
all keys ...............................................................7-4
Index-ii
conventional .......................................................... 7-3 mixer ................................................................ 3-15

introduction ............................................................ 7-3 recycling information, radio ....................................... B-1
trunked .................................................................. 7-3 reference oscillator alignment ................................... 6-6
replacement parts, ordering ...................................... A-1
replacement, chassis pad ....................................... 8-51
N RF exposure compliance information .......................... iii
RF PA
notations circuit protection .................................................. 3-13
manual .................................................................. 1-1 gain stages .......................................................... 3-13
warning, caution, and danger ................................ 1-1 heatsinking precautions ........................................ 2-3
power control ...................................................... 3-13
O RF test mode ............................................................ 5-3
operation S
advanced secure ................................................... 7-2
analog mode ....................................................... 3-12 screen, tuner
ASTRO mode ...................................................... 3-12 main menu ............................................................ 6-2
control head ........................................................ 3-10 radio information ................................................... 6-3
conventional multikey ............................................ 7-3 transmit current limit alignment .................. 6-12, 6-14
multikey ................................................................. 7-3 secure
trunked multikey .................................................... 7-3 dispatch operation ................................................. 7-2
operational error codes ............................................. 9-8 emergency operation ............................................ 7-2
ordering replacement parts .......................................A-1 interface boards .................................................... 7-1
over-the-air rekeying ................................................. 7-4 status annunciator ................................................. 7-2
overview, basic theory .............................................. 3-1 service aids, recommended ...................................... 4-2
signaling types .......................................................... 5-4
P
T
pad replacement, chassis ....................................... 8-51
parts list test
radio ..........................................11-3, 11-4, 11-5, 11-6 bit error rate (BER) .............................................. 6-19
transceiver interface board .................................. 11-2 equipment, recommended .................................... 4-1
parts, ordering replacement ......................................A-1 setup, performance checks ................................... 5-1
performance checks transmitter test pattern ........................................ 6-20
overview ................................................................ 5-1 test mode
receiver ............................................................... 5-10 control-head ................................................... 5-5, 5-6
signaling types ...................................................... 5-4 displays ................................................................. 5-2
test performance checks .............................................. 5-1
mode .................................................................. 5-1 RF ......................................................................... 5-3
setup .................................................................. 5-1 theory of operation
transmitter ........................................................... 5-11 analog mode ....................................................... 3-12
power detector calibration alignment ........................ 6-7 ASTRO mode ...................................................... 3-12
power-up error codes ................................................ 9-7 controller section ................................................... 3-2
preventive maintenance, periodic ............................. 2-1 output network section components ................... 3-13
product safety information ........................................... iii overview ................................................................ 3-1
programming radio-frequency power amplifier
equipment, field ..................................................... 4-3 circuit protection .............................................. 3-13
components ..................................................... 3-13
R gain stages ...................................................... 3-13
power control ................................................... 3-13
radio VHF
connectors frequency generation unit (FGU) ..................... 3-16
locations ................................................. 10-6, 10-7 receiver
descriptions ........................................................... 1-2 front-end ...................................................... 3-14
information screen ................................................. 6-3 IF circuitry .................................................... 3-15
upgrading with FLASHport .................................... 1-2 mixer ............................................................ 3-15
radio care and handling instructions, general ........... 2-2 tools required, disassembly/reassembly ................... 8-1
receiver tools, recommended ................................................. 4-2
performance checks ............................................ 5-10 torque values, fastener ........................................... 8-53
troubleshooting ...................................................... 9-9 trademark information .................................................. iii
VHF transmit current limit alignment screen .......... 6-12, 6-14
front-end .......................................................... 3-14 transmitter
IF circuitry ........................................................ 3-15 performance checks .............................................5-11
Index-iii
troubleshooting ...................................................... 9-8 transmit current limit alignment .............. 6-12, 6-14
transmitter test pattern test ..................................... 6-20 Tx current limit alignment ........................................6-11
troubleshooting Tx deviation balance (compensation) alignment .... 6-15
introduction ............................................................ 9-1 Tx power characterization alignment ........................ 6-9
J2 accessory connector ........................................ 9-3 types of signaling ...................................................... 5-4
operational error codes ......................................... 9-8
power-up error codes ............................................ 9-7
receiver ................................................................. 9-9 V
replacing boards .................................................... 9-6
transmitter ............................................................. 9-8 view, exploded .............................. 11-3, 11-4, 11-5, 11-6
trunked multikey operation ........................................ 7-3
tuner W
main menu screen ................................................. 6-2
radio alignment introduction .................................. 6-1 warning, caution, and danger notations .................... 1-1
screen warranty information ................................................. xvii
main menu ......................................................... 6-2
radio information ................................................ 6-3
Index-iv
Notes
M
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.
© 2016 Motorola Solutions, Inc. All rights reserved.
November 2016.
www.motorolasolutions.com/APX
*MN003076A01*
MN003076A01-AA

Apx 8500 Mobile Radio: Basic Service Manual

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APX™ TWO-WAY RADIOS

APX 8500 MOBILE

Product Safety and RF Exposure Compliance

Computer Software Copyrights

Edition Description Date

MN003076A01-AA Initial Release Nov. 2016

Document History ......................................................................................... v

Commercial Warranty ................................................................................xvii

Model Numbering, Charts, and Specifications.........................................xxi

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

Chapter 2 Basic Maintenance.............................................................. 2-1

2.2.1 Inspection ........................................................................................................................ 2-1

Chapter 3 Basic Theory of Operation ................................................. 3-1

Chapter 4 Test Equipment, Service Aids, and Tools......................... 4-1

Chapter 5 Performance Checks .......................................................... 5-1

Chapter 6 Radio Alignment Procedures............................................. 6-1

Chapter 7 Encryption ........................................................................... 7-1

Chapter 8 Disassembly/Reassembly Procedures ............................. 8-1

8.1 Introduction .................................................................................................................................. 8-1

Chapter 9 Radio PINOUT functions, Error Codes, and Basic

Chapter 10 Functional Block Diagrams and Connectors ................. 10-1

Chapter 11 Exploded Views and Parts Lists ...................................... 11-1

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

Appendix B Environmental Information ................................................B-1

Appendix C Maritime Radio Use in the VHF Frequency Range...........C-1

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

Index ...................................................................................................... Index-i

Figure 3-1. Mobile Controller Block Diagram.......................................................................................... 3-3

Figure 8-19. Removing the Control Head/TIB ........................................................................................ 8-15

Figure 8-73. Chassis Thermal Pad and Grease Locations..................................................................... 8-52

I. What This Warranty Covers And For How Long

ASTRO APX 8500 Mobile Radio One (1) Year

Product Accessories One (1) Year

II. General Provisions Notes

III. State Law Rights

IV. How To Get Warranty Service

V. What This Warranty Does Not Cover

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

VI. Patent And Software Provisions

VII. Governing Law

Model Numbering, Charts, and Specifications

APX 8500 Model Charts

ASTRO APX 8500 Emergency Model Chart

ASTRO APX 8500 Antennas Model Chart

ASTRO APX 8500 Antennas Model Chart (Cont.)

ASTRO APX 8500 Cables Model Chart

ASTRO APX 8500 Cables Model Chart (Cont.)

ASTRO APX 8500 CAN Model Chart

ASTRO APX 8500 DEK Model Chart

ASTRO APX 8500 DEK Model Chart (Cont.)

* = Requires J600 (User Y-adapter CB000409A03 for a J600 connector)

ASTRO APX 8500 Housing Alarm PS Model Chart

ASTRO APX 8500 Mic Model Chart

ASTRO APX 8500 Mic Model Chart (Cont.)

ASTRO APX 8500 Speaker Model Chart

APX 8500 Radio Specifications

1.1 Manual Notations

! CAUTION indicates a potentially hazardous situation which, if

WARNING indicates a potentially hazardous situation