873347-Mototrbo Xir p8668

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PROFESSIONAL DIGITAL TWO-WAY RADIO
MOTOTRBO™
XiR™ P8600/GP300D SERIES
BASIC SERVICE MANUAL
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All manuals and user guides at all-guides.com
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Foreword
This manual covers all models of the XiR™ series Portable Radios, unless otherwise specified. It includes all the
information necessary to maintain peak product performance and maximum working time, using levels 1 and 2
maintenance procedures. This level of service goes down to the board replacement level and is typical of some local
service centers, self-maintained customers, and distributors.
Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions
! for safe usage contained in the Product Safety and RF
Caution Exposure booklet enclosed with your radio.
ATTENTION!
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
Before using this product, read the RF energy awareness information and operating instructions in the
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number
6804110J47) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site:
http://www.motorolasolutions.com/governmentandenterprise
Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective
owners.
© 2012 Motorola Solutions, Inc.
All rights reserved.
Notes
iii
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
68012003088-A Initial Release Dec. 2012

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

Warranty Period and Return Instructions ...................................................................................................xi
After Warranty Period .....................................................................................................................xi
Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.2.1 Full Display Model ........................................................................................................... 1-2
1.2.2 Limited Display Model ..................................................................................................... 1-3
1.2.3 Non Display Model .......................................................................................................... 1-4
1.3 Portable Radio Model Numbering Scheme ................................................................................. 1-6
1.4 Model Charts ............................................................................................................................... 1-7
1.4.1 VHF Model Chart............................................................................................................. 1-7
1.4.2 UHF Model Chart........................................................................................................... 1-10
1.5 Specifications............................................................................................................................. 1-13
Chapter 2 Test Equipment and Service Aids ..................................... 2-1

2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids ................................................................................................................................. 2-2
2.3 Programming, Testing and Alignment Cable ............................................................................... 2-3
Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
3.3 Display Model Test Mode ............................................................................................................ 3-5
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-5
3.3.2 RF Test Mode.................................................................................................................. 3-5
3.3.3 LED Test Mode................................................................................................................ 3-9
3.3.4 Backlight Test Mode ........................................................................................................ 3-9
3.3.5 Speaker Tone Test Mode ................................................................................................ 3-9
3.3.6 Earpiece Tone Test Mode ............................................................................................... 3-9
vi Table of Contents
3.3.7 Audio Loopback Earpiece Test Mode.............................................................................. 3-9

3.3.8 Battery Check Test Mode .............................................................................................. 3-10
3.3.9 Button/Knob/PTT Test Mode ......................................................................................... 3-10
3.4 Display Model Test Mode .......................................................................................................... 3-11
3.4.1 Monochrome Display Test ............................................................................................. 3-11
3.4.2 Color Display Test ......................................................................................................... 3-11
3.5 Non-Display Model Test Mode................................................................................................... 3-12
3.5.1 Entering Non-Display Radio Test Mode ........................................................................ 3-12
3.5.2 RF Test Mode ................................................................................................................ 3-12
3.5.3 LED Test Mode.............................................................................................................. 3-12
3.5.4 Speaker Tone Test Mode .............................................................................................. 3-12
3.5.5 Earpiece Tone Test Mode ............................................................................................. 3-13
3.5.6 Audio Loopback Earpiece Test Mode............................................................................ 3-13
3.5.7 Battery Check Test Mode .............................................................................................. 3-13
3.5.8 Button/Knob/PTT Test Mode ......................................................................................... 3-13
Chapter 4 Radio Programming and Tuning ....................................... 4-1

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

5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
5.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
5.4 Repair Procedures and Techniques – General............................................................................ 5-4
5.5 Disassembling and Reassembling the Radio — General ............................................................ 5-5
5.6 Radio Disassembly – Detailed ..................................................................................................... 5-6
5.6.1 Front Cover from Chassis Disassembly .......................................................................... 5-6
5.6.2 Chassis Disassembly..................................................................................................... 5-10
5.6.3 Keypad, Display, and Keypad Board Disassembly........................................................ 5-12
5.6.4 Speaker, Microphone, and Universal Connector Flex Disassembly.............................. 5-14
5.6.5 Emergency Button Assembly Dissassembly ................................................................. 5-17
5.7 Radio Reassembly - Detailed .................................................................................................... 5-19
5.7.1 Emergency Button and Speaker Reassembly ............................................................... 5-19
5.7.2 Keypad, Display and Keypad Board Reassembly ......................................................... 5-22
5.7.3 Chassis Reassembly ..................................................................................................... 5-23
5.7.4 Chassis and Front Cover Reassembly .......................................................................... 5-26
5.7.5 Bluetooth Antenna Kit Disassembly/Reassembly.......................................................... 5-27
5.7.5.1 Bluetooth Antenna Kit Disassembly................................................................ 5-27
5.7.5.2 Bluetooth Antenna Kit Reassembly ................................................................ 5-28
5.7.6 GOB Installation............................................................................................................. 5-29
5.8 Ensuring Radio Immersibility ..................................................................................................... 5-31
5.8.1 Servicing ........................................................................................................................ 5-31
5.8.2 Accidental Immersion .................................................................................................... 5-31
5.8.3 Specialized Test Equipment .......................................................................................... 5-31
Table of Contents vii
5.8.4 Vacuum Pump Kit NLN9839.......................................................................................... 5-31

5.8.5 Pressure Pump Kit NTN4265 ........................................................................................ 5-32
5.8.6 Miscellaneous Hardware ............................................................................................... 5-32
5.8.7 Vacuum Test ................................................................................................................. 5-32
5.8.8 Pressure Test ................................................................................................................ 5-33
5.8.9 Troubleshooting Leak Areas.......................................................................................... 5-34
5.8.9.1 Front Housing ................................................................................................. 5-34
5.8.9.2 Chassis (Main Seal O-ring) ............................................................................ 5-34
5.8.9.3 Battery Contact Seal....................................................................................... 5-35
5.8.9.4 Breathing Vent Membrane and Breathing Vent Label .................................... 5-36
5.8.9.5 Battery Maintenance....................................................................................... 5-36
5.8.10 Troubleshooting Charts ................................................................................................. 5-37
5.9 Radio Exploded Mechanical Views and Parts Lists ................................................................... 5-40
5.9.1 Full Keypad Model Exploded View and Parts List ......................................................... 5-40
5.9.2 Limited Keypad Model Exploded View and Parts List ................................................... 5-43
5.9.3 Non Keypad Model Exploded View and Parts List ........................................................ 5-46
5.9.4 Torque Chart ................................................................................................................. 5-50
Chapter 6 Basic Troubleshooting ....................................................... 6-1

6.1 Introduction .................................................................................................................................. 6-1
6.2 Replacement Back Cover Kit Procedures ................................................................................... 6-1
6.3 Power-Up Error Codes (Display Model only) ............................................................................... 6-2
6.4 Operational Error Codes .............................................................................................................. 6-4
Chapter 7 Accessories ......................................................................... 7-1

7.1 Introduction .................................................................................................................................. 7-1
7.1.1 Audio ............................................................................................................................... 7-1
7.1.2 Batteries .......................................................................................................................... 7-3
7.1.3 Chargers.......................................................................................................................... 7-3
7.1.4 Antennas ......................................................................................................................... 7-4
7.1.5 Carry Devices .................................................................................................................. 7-4
7.1.6 Miscellaneous Accessories ............................................................................................. 7-5
Appendix A Replacement Parts & Kits ..................................................A-1

A.1 Level 1 and 2 Maintenance..........................................................................................................A-1
A.1.1 Replacement Parts Ordering ...........................................................................................A-1
A.2 Level 3 Maintenance....................................................................................................................A-1
A.3 Additional Service Kits Information ..............................................................................................A-2
A.3.1 UHF Super Tanapa .........................................................................................................A-2
A.3.2 VHF Super Tanapa..........................................................................................................A-3
Glossary ......................................................................................... Glossary-1

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

Figure 1-2. Limited Keypad Model.......................................................................................................... 1-3
Figure 1-3. Non Keypad Model............................................................................................................... 1-4
Figure 1-4. Portable Radio Model Numbering Scheme .......................................................................... 1-6
Figure 2-1. Programming, Testing and Alignment Cable ........................................................................ 2-3
Figure 2-2. Pin Layout of Side Connector .............................................................................................. 2-4
Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup........................................................... 3-3
Figure 3-2. RF plug................................................................................................................................. 3-4
Figure 3-3. Connect RF Antenna adaptor to radio RF input/output port................................................. 3-4
Figure 3-4. Battery Check Test Mode Display ...................................................................................... 3-10
Figure 4-1. CPS Programming Setup ..................................................................................................... 4-1
Figure 4-2. Radio Tuning Equipment Setup ........................................................................................... 4-2
Figure 5-1. Antenna and Battery removal............................................................................................... 5-6
Figure 5-2. Channel Selector and Volume Knob removal. ..................................................................... 5-7
Figure 5-3. Shroud removal .................................................................................................................... 5-8
Figure 5-4. Chassis removal................................................................................................................... 5-8
Figure 5-5. Disconnecting the chassis.................................................................................................... 5-9
Figure 5-6. Chassis disassembly.......................................................................................................... 5-10
Figure 5-7. O-ring removal ................................................................................................................... 5-11
Figure 5-8. Keypad, Display, and Keypad Board disassembly for Full Keypad .................................... 5-12
Figure 5-9. Keypad, Display, and Keypad Board Disassembly for Limited Keypad.............................. 5-13
Figure 5-10. Speaker removal for Full Keypad ....................................................................................... 5-14
Figure 5-11. Speaker removal for Limited Keypad ................................................................................. 5-15
Figure 5-12. Speaker removal for Non-Keypad ...................................................................................... 5-16
Figure 5-13. Emergency Button disassembly for Full Keypad Model ..................................................... 5-17
Figure 5-14. Emergency Button disassembly for Non Keypad Model .................................................... 5-18
Figure 5-15. Emergency Button reassembly for Full Keypad ................................................................. 5-19
Figure 5-16. Emergency Button reassembly for Non Keypad ................................................................ 5-20
Figure 5-17. Speaker reassembly for Full Keypad.................................................................................. 5-20
Figure 5-18. Speaker reassembly for Non Keypad................................................................................. 5-21
Figure 5-19. Keypad, Display, and Keypad Board reassembly for Full Keypad ..................................... 5-22
Figure 5-20. O-ring reassembly. ............................................................................................................. 5-23
Figure 5-21. Chassis reassembly ........................................................................................................... 5-24
Figure 5-22. GOB reassembly ................................................................................................................ 5-25
Figure 5-23. Chassis reassembly ........................................................................................................... 5-26
Figure 5-24. Bluetooth removal for Full Keypad ..................................................................................... 5-27
Figure 5-25. Bluetooth removal for Non Keypad .................................................................................... 5-27
Figure 5-26. Bluetooth reassembly for Full Keypad................................................................................ 5-28
Figure 5-27. Bluetooth reassembly for Non Keypad............................................................................... 5-28
Figure 5-28. Connector Fitting - Fitting Seal Pump Connector............................................................... 5-31
Figure 5-29. Full Keypad Model Exploded View..................................................................................... 5-40
List of Tables ix
List of Tables
Table 1-1. Radio Frequency Ranges and Power Levels....................................................................... 1-1

Table 2-1. Recommended Test Equipment ........................................................................................... 2-1
Table 2-2. Service Aids ......................................................................................................................... 2-2
Table 2-3. Pin Configuration of Side Connector.................................................................................... 2-4
Table 3-1. Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2. Front Panel Access Test Mode Displays.............................................................................. 3-5
Table 3-3. Test Environments................................................................................................................ 3-6
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Table 3-4. Test Frequencies.................................................................................................................. 3-6
Table 3-5. Transmitter Performance Checks ........................................................................................ 3-7
Table 3-6. Receiver Performance Checks ............................................................................................ 3-8
Table 4-1. Software Installation Kits Radio Tuning Setup ..................................................................... 4-1
Table 5-1. Lead Free Solder Wire Part Number List ............................................................................. 5-4
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Table 5-2. Lead Free Solder Paste Part Number List ........................................................................... 5-4
Table 5-3. Full Keypad Model Exploded View Parts List..................................................................... 5-41
Table 5-4. Limited Keypad Model Exploded View Parts List ............................................................... 5-44
Table 5-5. Non-Keypad Model Exploded View Parts List.................................................................... 5-47
Table 5-6. Additional Part List information .......................................................................................... 5-48
Table 5-7. Torque Specifications for Screws ....................................................................................... 5-50
Table 6-1. Power-Up Error Codes......................................................................................................... 6-2
Table 6-2. Operational Error Codes ...................................................................................................... 6-4
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x Related Publications
Related Publications
IMPRES Adaptive Single-Unit Charger User Manual ..................................................................6816787H01
IMPRES Adaptive Multi-Unit Charger User Manual.....................................................................6816789H01
IMPRES Adaptive Multi-Unit Charger Service Manual ................................................................ 6871357L01
Remote Speaker Microphone User Manual ................................................................................. 6871003L01
IMPRES Remote Speaker Microphone User Manual .................................................................. 6871004L01
Factory Mutual Approval Manual ................................................................................................. 6871532L01
Product Safety and RF Exposure ............................................................................................... 6804110J47
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Warranty and Service Support
Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warranty period, and service/repair or spare parts support out of warranty.
Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only. In instances where the product is covered under a "return for replacement"
or "return for repair" warranty, a check of the product should be performed prior to shipping the unit
back to Motorola. This is to ensure that the product has been correctly programmed or has not been
subjected to damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources or your Motorola dealer, distributor or reseller. All returns must be
accompanied by a Warranty Claim Form, available from your Customer Service representative or
Motorola Online (MOL) or your Motorola dealer, distributor or reseller. Products should be shipped
back in the original packaging, or correctly packaged to ensure no damage occurs in transit.
After Warranty Period
After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola's Managed Technical Services (MTS) offers a repair service to both end users and
dealers at competitive prices.
2. MTS supplies individual parts and modules that can be purchased by dealers who are
technically capable of performing fault analysis and repair.
xii Warranty and Service Support
Notes
Chapter 1 Introduction
1.1 Notations Used in This Manual

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

not avoided, might result in equipment damage.
Caution
Do NOT use any form of connector, e.g. wires, crocodile

clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.
1.2 Radio Description

The XiR series portable radios are available in the following frequency ranges and power levels.
Table 1-1. Radio Frequency Ranges and Power Levels
Frequency Band Bandwidth Power Level
VHF 136–174 MHz 3.5 Watt or 5 Watt
UHF 403–527 MHz 3.5 Watt or 4 Watt
These digital radios are among the most sophisticated two-way radios available. They have a robust
design for radio users who need high performance, quality, and reliability in their daily
communications. This architecture provides the capability of supporting a multitude of legacy and
advanced features resulting in a more cost-effective two-way radio communications solution.
1-2 Introduction: Radio Description
1.2.1 Full Display Model
Antenna
Channel Selector Knob

On/Off Volume Control Knob
LED Indicator Emergency Button
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Side Button 1
Universal Connector
PTT Button
Speaker
Microphone
Side Button 2
Side Button 3
Front Buttons
.co LCD
Menu Navigation Key

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Keypad
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Figure 1-1. Full Keypad Model

• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counter-
clockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display):
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- 132x90 highly transflective color display provides visual information about many radio
features.
• MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface.
• KEYPAD – Twelve keys that allows the user to input characters for various text based
operations. (For color display only)
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• FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the
CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be
used with the radio. It has twelve points to which specific accessories will connect and be
activated.
• EMERGENCY BUTTON – Turns on and off the Emergency Operations.
Introduction: Radio Description 1-3
• SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like
keypad tones and voice audio).
used with the radio. It has twelve points to which specific accessories will connect and be
activated.EMERGENCY BUTTON – Turns on and off the Emergency Operations.
keypad tones and voice audio).
1.2.2 Limited Display Model
Antenna

Side Button 1
Universal Connector
PTT Button
Speaker
Microphone
Side Button 2 LCD

Side Button 3
Menu Navigation Key

Front Buttons
Figure 1-2. Limited Keypad Model

• LCD (Liquid Crystal Display) – 132x72 full dot matrix grayscale display provides visual
information about many radio
• FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the
CPS.
• MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface.
1-4 Introduction: Radio Description

used with the radio. It has twelve points to which specific accessories will connect to and be
activated.
keypad tones and voice audio)
1.2.3 Non Display Model
Antenna

Side Button 1
Universal Connector
PTT Button
Speaker
Microphone
Side Button 2
Side Button 3
Figure 1-3. Non Keypad Model

• LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status.
• SIDE BUTTONS – These 3 buttons are field programmable using the CPS.
used with the radio. It has twelve points to which specific accessories will connect to and be
activated.
Introduction: Radio Description 1-5
keypad tones and voice audio)
1-6 Introduction: Portable Radio Model Numbering Scheme
1.3 Portable Radio Model Numbering Scheme
Model No.Example : AZ H 5 5 Q D H 9 L A 1 A N
Position : 1 2 3 4 5 6 7 8 9 10 11 12 xy
xy: Custom Housing

AZ: Asia
GP328D: 03
LA: Latin America
GP338D: 04
AA: North America
MD: Europe/Middle East/Africa/Australia
Unique Variation
N: Standard Package
H: Portable
Version Letter
XiR P8000 Model Series: 56
XiR P6000 Model Series: 02
Feature Level
1: Standard w/ FM
2. Non-FM
Band 3. CSA IE CEx ATEX
J: 136-174 MHz 4. CQST
R: 403-527 MHz
Primary System Type
A: Conventional
B: Trunking
Power Level C: Analog Only
C: 1.0,2.0,2.5 or 3.5 Watt
D: 4.0-5.0 Watt
Primary Operation
J : Basic (No GPS, no Bluetooth, no
Physical Packages embedded GOB)
C: Low Tier (Plain) K : GPS and Bluetooth
H: Mid Tier (Monochrome Display FKP L : GPS Only
Monochrome Display LKP) M: Bluetooth Only
N: HIgh Tier (Color Display FKP) N : Bluetooth w/ embedded GOB
J: 3 Button MOR
T: No Display - Limited Tier Channel Information
8: Variable/Programmable Channel Spacing
w/ unique # of channels
9: Variable/Programmable Channel Spacing
Figure 1-4. Portable Radio Model Numbering Scheme

Introduction: Model Charts 1-7
1.4 Model Charts

1.4.1 VHF Model Chart
XiR/GP Series, VHF, 136–174 MHz, 5W

Model Description
AZH56JDN9KA1AN 136–174 MHz , 5W, XiR P8668 Full Keypad Portable
with GPS and BT
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AZH56JDN9JA1AN 136–174 MHz , 5W XiR P8660 Full Keypad Portable
AZH56JDN9JA1AN04 136–174 MHz , 5W, GP338D Full Keypad Portable
AZH56JDH9KA1AN 136–174 MHz , 5W, XiR P8628 Limited Keypad
Portable with GPS and BT
.co
AZH56JDH9JA1AN 136–174 MHz , 5W, XiR P8620 Limited Keypad
Portable
AZH56JDH9JA1AN04 136–174 MHz , 5W, GP338D Limited Keypad Portable
AZH56JDC9KA1AN 136–174 MHz , 5W, XiR P8608 Non Keypad Portable
with GPS and BT
AZH56JDC9JA1AN 136–174 MHz , 5W, XiR P8600 Non Keypad Portable
es
AZH56JDC9JA1AN03 136–174 MHz , 5W, GP328D Non Keypad Portable
Item Description
X PMLD4480_S BC Kit, 136–174, 5W, MOTOTRBO Full Keypad
Portable with GPS
X X PMLD4481_S BC Kit, 136–174, 5W, MOTOTRBO Full Keypad
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Portable
X PMLD4483_S BC Kit, 136–174, 5W, MOTOTRBO LImited Keypad
Portable with GPS
X X PMLD4484_S BC Kit, 136–174, 5W, MOTOTRBO LImited Keypad
Portable
X PMLD4486_S BC Kit, 136–174, 5W, MOTOTRBO Non Keypad
Portable with GPS
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X X PMLD4487_S BC Kit, 136–174, 5W, MOTOTRBO Non Keypad

Portable
X PMLN6116_ Front Cover Kit, Full Keypad Portable with Bluetooth
(English)
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(Bopomofo)
(Korean)
(Stroke)
X PMLN5961_ Front Cover Kit, Full Keypad Portable (English)
X PMLN5962_ Front Cover Kit, Full Keypad Portable (Bopomofo)
X PMLN5960_ Front Cover Kit, Full Keypad Portable (Korean)
X X PMLN5959_ Front Cover Kit, Full Keypad Portable (Stroke)
X PMLN6112_ Front Cover Kit, Limited Keypad Portable with Bluetooth
1-8 Introduction: Model Charts
XiR/GP Series, VHF, 136–174 MHz, 5W (Continued)

Model Description
AZH56JDN9KA1AN 136–174 MHz , 5W, XiR P8668 Full Keypad Portable
with GPS and BT
AZH56JDH9KA1AN 136–174 MHz , 5W, XiR P8628 Limited Keypad
Portable with GPS and BT
AZH56JDH9JA1AN 136–174 MHz , 5W, XiR P8620 Limited Keypad
Portable
AZH56JDC9KA1AN 136–174 MHz , 5W, XiR P8608 Non Keypad Portable
with GPS and BT
Item Description
X X PMLN5690_ Front Cover Kit, Limited Keypad Portable
X PMLN6111_ Front Cover Kit, Non Keypad Portable with Bluetooth
X X PMLN5691_ Front Cover Kit, Non Keypad Portable
X X PMLN5718_S Option Board Kit
X X X X X X X X X PMAD4117_ VHF Helical antenna (136–155 MHz)
X X X X X X X X X PMAD4119_ VHF stubby antenna (136–148 MHz)
X X X X X X X X X 32012144001 Antenna ID band (grey-10pcs)
X X X X X X X X X 32012144002 Antenna ID band (yellow-10pcs)
X X X X X X X X X 32012144003 Antenna ID band (green-10pcs)
X X X X X X X X X 32012144004 Antenna ID band (blue-10pcs)
X X X X X X X X X 32012144005 Antenna ID band (purple-10pcs)
XiR/GP Series, VHF, 136–174 MHz, 3.5W

Model Description
AZH56JCN9KA4AN 136–174 MHz , 3.5W, XiR P8668 Full Keypad Portable with GPS
and BT
AZH56JCN9JA4AN04 136–174 MHz, 3.5W, GP338D Full Keypad Portable
AZH56JCH9KA4AN 136–174 MHz, 3.5W, XiR P8628 Limited Keypad Portable with
GPS and BT
AZH56JCH9JA4AN04 136–174 MHz, 3.5W, GP338D Limited Keypad Portable
AZH56JCC9KA4AN 136–174 MHz, 3.5W, XiR P8608 Non Keypad Portable with GPS
and BT
AZH56JCC9JA4AN03 136–174 MHz, 3.5W, GP328D Non Keypad Portable
Item Description
X PMLD4522_S BC Kit, 136–174 MHz, 3.5W, MOTOTRBO Full Keypad Portable
with GPS
X PMLD4523_S BC Kit, 136–174 MHz, 3.5W, MOTOTRBO Full Keypad Portable
X PMLD4524_S BC Kit, 136–174 MHz, 3.5W, MOTOTRBO Limited Keypad
Portable with GPS
X PMLD4525_S BC Kit, 136–174 MHz, 3.5W, MOTOTRBO Limited Keypad
Portable
X PMLD4526_S BC Kit, 136–174 MHz, 3.5W, MOTOTRBO Non Keypad Portable
with GPS
X PMLD4527_S BC Kit, 136–174 MHz, 3.5W, MOTOTRBO Non Keypad Portable
X PMLN6117_ Front Cover Kit, Full Keypad Portable with Bluetooth (Stroke)
X PMLN5959_ Front Cover Kit, Full Keypad Portable (Stroke)
X PMLN5690_ Front Cover Kit, Limited Keypad Portable
X PMLN5691_ Front Cover Kit, Non Keypad Portable
X X X X X X PMAD4117_ VHF Helical antenna (136–155 MHz)
X X X X X X PMAD4119_ VHF stubby antenna (136–148 MHz)
X X X X X X 32012144001 Antenna ID band (grey-10pcs)
X X X X X X 32012144002 Antenna ID band (yellow-10pcs)
X X X X X X 32012144003 Antenna ID band (green-10pcs)
X X X X X X 32012144004 Antenna ID band (blue-10pcs)
X X X X X X 32012144005 Antenna ID band (purple-10pcs)
1.4.2 UHF Model Chart
XiR/ GP Series, UHF, 403–527 MHz, 4W

Model Description
AZH56RDN9KA1AN 403–527 MHz, 4W, XiR P8668 Full Keypad Portable with
GPS and BT
AZH56RDN9JA1AN 403–527 MHz, 4W, XiR P8660 Full Keypad Portable
AZH56RDN9JA1AN04 403–527 MHz, 4W, GP338D Full Keypad Portable
AZH56RDH9KA1AN 403–527 MHz, 4W, XiR P8628 Limited Keypad Portable
with GPS and BT
AZH56RDH9JA1AN 403–527 MHz, 4W, XiR P8620 Limited Keypad Portable
AZH56RDH9JA1AN04 403–527 MHz, 4W, GP338D Limited Keypad Portable
AZH56RDC9KA1AN 403–527 MHz, 4W, XiR P8608 Non Keypad Portable with
GPS and BT
AZH56RDC9JA1AN 403–527 MHz, 4W, XiR P8600 Non Keypad Portable
AZH56RDC9JA1AN0 403–527 MHz, 4W, GP328D Non Keypad Portable
3
Item Description
X PMLE4689_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Full Keypad
Portable with GPS
X X PMLE4690_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Full Keypad
Portable
X PMLE4692_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Limited Keypad
Portable with GPS
X X PMLE4693_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Limited Keypad
Portable
X PMLE4695_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Non Keypad
Portable with GPS
X X PMLE4696_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Non Keypad
Portable
(English)
(Bopomofo)
(Korean)
(Stroke)
X PMLN5961_ Front Cover Kit, Full Keypad Portable (English)
X PMLN5962_ Front Cover Kit, Full Keypad Portable (Bopomofo)
X X PMLN5690_ Front Cover Kit, Limited Keypad Portable
XiR/ GP Series, UHF, 403–527 MHz, 4W (Continued)

Model Description
AZH56RDN9KA1AN 403–527 MHz, 4W, XiR P8668 Full Keypad Portable with
GPS and BT
AZH56RDN9JA1AN 403–527 MHz, 4W, XiR P8660 Full Keypad Portable
AZH56RDN9JA1AN04 403–527 MHz, 4W, GP338D Full Keypad Portable
AZH56RDH9KA1AN 403–527 MHz, 4W, XiR P8628 Limited Keypad Portable
with GPS and BT
AZH56RDH9JA1AN 403–527 MHz, 4W, XiR P8620 Limited Keypad Portable
AZH56RDH9JA1AN04 403–527 MHz, 4W, GP338D Limited Keypad Portable
AZH56RDC9KA1AN 403–527 MHz, 4W, XiR P8608 Non Keypad Portable with
GPS and BT
AZH56RDC9JA1AN 403–527 MHz, 4W, XiR P8600 Non Keypad Portable
AZH56RDC9JA1AN0 403–527 MHz, 4W, GP328D Non Keypad Portable
3
Item Description
X X PMLN5691_ Front Cover Kit, Non Keypad Portable
X X X X X X X X X PMAE4068_ UHF Whip Antenna 403–527 MHz
X X X X X X X X X PMAE4069_ UHF Stubby Antenna 403–450 MHz
X X X X X X X X X PMAE4079_ UHF Slim Whip Antenna 403-527 MHz
X X X X X X X X X 32012144001 Antenna ID band (grey-10pcs)
X X X X X X X X X 32012144002 Antenna ID band (yellow-10pcs)
X X X X X X X X X 32012144003 Antenna ID band (green-10pcs)
X X X X X X X X X 32012144004 Antenna ID band (blue-10pcs)
X X X X X X X X X 32012144005 Antenna ID band (purple-10pcs)
XiR/GP Series, UHF, 403–527 MHz, 3.5W

Model Description
AZH56RCN9KA4AN 403–527 MHz, 3.5W, XiR P8668 Full Keypad Portable with GPS
and BT
AZH56RCN9JA4AN04 403–527 MHz, 3.5W, GP338D Full Keypad Portable
AZH56RCH9KA4AN 403–527 MHz, 3.5W, XiR P8628 Limited Keypad Portable with
m
GPS and BT
AZH56RCH9JA4AN04 403–527 MHz, 3.5W, GP338D Limited Keypad Portable
AZH56RCC9KA4AN 403–527 MHz, 3.5W, XiR P8608 Non Keypad Portable with GPS
and BT
.co
AZH56RCC9JA4AN03 403–527 MHz, 3.5W, GP328D Non Keypad Portable
Item Description
X PMLE4788_S BC Kit, 403–527 MHz, 3.5W, MOTOTRBO Full Keypad Portable
with GPS
X PMLE4789_S BC Kit, 403–527 MHz, 3.5W, MOTOTRBO Full Keypad Portable
X PMLE4790_S BC Kit, 403–527 MHz, 3.5W, MOTOTRBO Limited Keypad
es
Portable with GPS
X PMLE4791_S BC Kit, 403–527 MHz, 3.5W, MOTOTRBO Limited Keypad
Portable
X PMLE4792_S BC Kit, 403–527 MHz, 3.5W, MOTOTRBO Non Keypad Portable
with GPS
uid
X PMLE4793_S BC Kit, 403–527 MHz, 3.5W, MOTOTRBO Non Keypad Portable

X PMLN6117_ Front Cover Kit, Full Keypad Portable with Bluetooth (Stroke)
X PMLN5959_ Front Cover Kit, Full Keypad Portable (Stroke)
X PMLN5690_ Front Cover Kit, Limited Keypad Portable
-g
X PMLN5691_ Front Cover Kit, Non Keypad Portable

X X X X X X PMAE4068_ UHF Whip Antenna 403–527 MHz
X X X X X X PMAE4069_ UHF Stubby Antenna 403–450 MHz
all

X X X X X X PMAE4079_ UHF Slim Whip Antenna 403–527 MHz
X X X X X X 32012144001 Antenna ID band (grey-10pcs)
X X X X X X 32012144002 Antenna ID band (yellow-10pcs)
X X X X X X 32012144003 Antenna ID band (green-10pcs)
X X X X X X 32012144004 Antenna ID band (blue-10pcs)
X X X X X X 32012144005 Antenna ID band (purple-10pcs)
See “Additional Service Kits Information” on page A-2 for guidelines on selecting the appropriate
Service Kit, based on the Model and Super Tanapa combination of your radio
Introduction: Specifications 1-13
1.5 Specifications
General Full Keypad Limited Keypad Non Keypad
XiR P8668/XiR XiR P8628/XiR XiR P8608/XiR P8600/
P8660/GP 338D P8620/GP338D GP328D
Channel Capacity 1000 1000 32
Frequency VHF: 136 – 174 MHz

UHF: 403 – 527 MHz
Dimensions (HxWxT) w/ 130.3 x 55.2 x 38.7 mm 130.3 x 55.2 x 37.2 mm

NiMH battery
Weight
(with LiIon non-FM battery) 355.5g 356.5 323g
Power Supply 7.5V nominal
FCC Description UHF: ABZ99FT4089

VHF: ABZ99FT3085
IC Description UHF: 109AB-99FT4089

VHF: 109AB-99FT3086
Average battery life at 5/5/90 duty cycle with battery saver enabled in carrier squelch and transmitter
in high power.
Core NiMH (1300mAh) Analog: 6.7 hrs Analog: 7 hrs Analog: 7 hrs
battery Digital: 9.8 hrs Digital: 10.2 hrs Digital: 10.2 hrs
Core Slim Li-Ion (1500 Analog: 7.7 hrs Analog: 8 hrs Analog: 8 hrs
mAH) battery Digital: 11.3 hrs Digital: 11.8 hrs Digital: 11.8 hrs
IMPRES Li-ion Slim Analog: 7.7 hrs Analog: 8 hrs Analog: 8 hrs
(1500mAH) battery Digital: 11.3 hrs Digital: 11.8 hrs Digital: 11.8 hrs
IMPRES Hi-Cap Li-ion Analog: 11.1 hrs Analog: 11.5 hrs Analog: 11.5 hrs
Non-FM (2150 mAH) Digital: 16.2 hrs Digital: 17 hrs Digital: 17 hrs
battery
IMPRES Hi-Cap Li-ion FM Analog: 11.9 hrs Analog: 12.3 hrs Analog: 12.3 hrs
(2300 mAH) battery Digital: 17.3 hrs Digital: 18.1 hrs Digital: 18.1 hrs
NOTE Weight can have 5% margin of error
Factory Mutual Approval

MOTOTRBO XiR Series portable radios have been certified by FM in accordance with U.S. Codes
as intrinsically safe for use in Class I, II, III, Division 1, Groups C, D, E, F, G, when properly equipped
with a Motorola FM approved battery option. They are also approved for use in Class I, Division 2,
Groups A, B, C, D.
1-14 Introduction: Specifications
Receiver Full Keypad Limited Keypad Non Keypad

XiR P8668/XiR XiR P8628/XiR XiR P8608/XiR
P8660/GP 338D P8620/GP338D P8600/GP328D
Frequencies VHF: 136 – 174 MHz

UHF: 403 – 527MHz
Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz
Frequency Stability (-30°C to +/-0.5 ppm

+60°C)
Analog Sensitivity (12 dB SINAD) 0.3 µV (0.22 uV typical)
Digital Sensitivity (5% BER) 0.25µV

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

TIA603 60 dB @ 12.5 kHz, 70 dB @ 20/25 kHz
TIA603C 45 dB @ 12.5 kHz, 70 dB @ 20/25 kHz
Spurious Rejection (TIA603C) 70 dB
Rated Audio 0.5 W
Audio Distortion @ Rated Audio 5%(3% typical)
Hum and Noise -40 dB @ 12.5 kHz

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

(TIA603C)
Transmitter Full Keypad Limited Keypad Non Keypad

P8660/GP 338D P8620/GP338D P8600/GP328D
Frequencies VHF: 136 – 174 MHz

UHF: 403 – 527 MHz
Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz
Frequency Stability (-30°C to +/-0.5 ppm

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

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

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

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

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

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

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

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

ETSI-TS102361-2
ETSI-TS102361-3
Conforms to:
ETSI TS 102 361 (Parts 1, 2 & 3) - ETSI DMR Standard
ETSI EN 300 086 - ETSI RF Specifications (Analog)
ETSI EN 300 113 - ETSI RF Specifications (Digital)
1999/5/EC (R&TTE - Radio and Telecommunications Terminal Equipment)
2002/95/EC (RohS - Banned Substances)
2002/96/EC (WEEE - Waste Electrical and Electronic Equipment)
94/62/EC (Packaging and Packaging Waste)
Radio meets applicable regulatory requirements.
VHF Self-Quieter Frequencies UHF Self-Quieter Frequencies
139.2 MHz +/- 10 kHz 403.2 MHz +/- 10 kHz
141.6 MHz +/- 10 kHz 408 MHz +/- 10 kHz
143.36 MHz +/- 10 kHz 412.8 MHz +/- 10 kHz
148.48 MHz +/- 10 kHz 419.895 MHz +/- 10 kHz
148.8 MHz +/- 10 kHz 420 MHz +/- 15 kHz
149.025 MHz +/- 10 kHz 422.4 MHz +/- 10 kHz
150.525 MHz +/- 10 kHz 431.615 MHz +/- 10 kHz
151 MHz +/- 10 kHz 431.895 MHz +/- 10 kHz
151.74 MHz +/- 10 kHz 432 MHz +/- 10 kHz
152.575 MHz +/- 10 kHz 434.43 MHz +/- 10 kHz
153.6 MHz +/- 10 kHz 441.6 MHz +/- 10 kHz
154.625 MHz +/- 10 kHz 443.895 MHz +/- 10 kHz
156.675 MHz +/- 10 kHz 444 MHz +/- 15 kHz
158.4 MHz +/- 10 kHz 449.55 MHz +/- 10 kHz
158.72 MHz +/- 10 kHz 451.2 MHz +/- 10 kHz
163.2 MHz +/- 10 kHz 455.895 MHz +/- 10 kHz
168 MHz +/- 10 kHz 456 MHz +/- 10 kHz
172.8 MHz +/- 10 kHz 456.24 MHz +/- 10 kHz

460.8 MHz +/- 10 kHz
468 MHz +/- 10 kHz
468.735 MHz +/- 10 kHz
480.005 MHz +/- 15 kHz
491.82 MHz +/- 10 kHz
492 MHz +/- 15 kHz
499.2 MHz +/- 10 kHz
504 MHz +/- 10 kHz
516 MHz +/- 15 kHz
GPS Full Keypad Limited Keypad Non Keypad

P8660/GP 338D P8620/GP338D P8600/GP328D
TTFF (Time To First Fix) Cold ≤ 60 seconds

Start @ -130dBm (95%)
TTFF (Time To First Fix) Hot ≤10 seconds
m
Start @ -130dBm (95%)
Horizontal Accuracy (2D < 5 meters

Accuracy) Cold Start
.co
Accuracy specs are for long-term tracking (95th percentile values > 5 satellites visible at a
nominal
-130 dBm signal strength)
Bluetooth® Display Non-Display

es
Version Supports Bluetooth 2.1+ EDR Specification
Range Class 2, 10 meters

uid
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Military Standards
Applicable 810C 810D 810E 810F 810G*
MIL–STD
Methods Procedures Methods Procedures Methods Procedures Methods Procedures Methods Prodecures
Low Pressure 500.1 I 500.2 II 500.3 II 500.4 II 500.5 II

High 501.1 I, II 501.2 I/A1,II/ 501.3 I-A1, II/ 501.4 I/Hot, II/ 501.5 I/A1, II
Temperature A1 A1 Hot
Low 502.1 I 502.2 I/C3, II/ 502.3 I-C3, II/ 502.4 I-C3, II/ 502.5 I, II
Temperature C1 C1 C1
Temperature 503.1 - 503.2 I/A1/C3 503.3 I/A1/C3 503.4 I 503.5 I-C
Shock
Solar 505.1 II 505.2 I 505.3 I 505.4 I 505.5 I-A1
Radiation
Rain 506.1 I, II 506.2 I, II 506.3 I,II 506.4 I, III 506.5 I, III
Humidity 507.1 II 507.2 II 507.3 II 507.4 – 507.5 II
Salt fog 509.1 - 509.2 - 509.3 – 509.4 – 509.5 –
Dust 510.1 I 510.2 I 510.3 I 510.4 I 510.5 I
Vibration 514.2 VIII/F, 514.3 I/10, II/3 514.4 I/10, II/3 514.5 I/24 514.6 II/5
Curve-
W
Shock 516.2 I, II 516.3 I, IV 516.4 I, IV 516.5 I, IV 516.6 I, IV, VI
NOTE *Tested to MIL standard G which supersedes previous version

Environmental Specifications
*Operating Temperature -30 °C to +60 °C
Storage Temperature -40 °C to +85 °C
Thermal Shock Per MIL-STD
Humidity Per MIL-STD
ESD IEC 61000-4-2 Level 3
Water Intrusion IEC 60529 -IP57
Packaging Test MIL-STD 810D and E
* Operating temperature specification with LiIon battery is -10 °C to +60 °C.

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

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

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

Generator * -130 dBm to +10 dBm (www.agilent.com),
FM Modulation 0 kHz to Ramsey RSG1000B
10 kHz (www.ramseyelectronics.com), or
Audio Frequency 100 Hz equivalent
to 10 kHz
Oscilloscope * 2 Channel Leader LS8050 Waveform measurements

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

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

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

Table 2-2 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-2. Service Aids
Motorola
Description Application
Part No.
m
RLN4460_ Portable Test Set Enables connection to the audio/accessory jack.
Allows switching for radio testing.
PMVN4130_ Customer Programming CPS allows Dealers/Distributors to program radio
.co
Software and AirTracer on parameters. AirTracer allows the capturing of radio
CD-ROM traffic into logs for analysis by Motorola.
PMVN4131_ Tuner on CD-ROM Radio Tuning. Only Motorola Service Centers or

Authorized Motorola Service Dealers can perform
this function
PMKN4012B* Portable Programming Cable This cable connects the radio to a USB port for radio
es
programming and data applications.
PMKN4013C* Portable Programming, Testing & This cable connects the radio to a USB port for radio
Alignment Cable programming, testing and alignment.
PMNN4428_ 7.5V Universal Battery Eliminator Connects to radio via battery eliminator cable.
uid
PMLN6154_ RF Adaptor Adapts radio’s antenna port to BNC cabling of test

equipment.
PMLN6422_ RF Cable This cable measures RF related measurements.
PMLN6208_ Chassis and Knob Opener Enables the removal of chassis from radio housing.
PMLN6155_ RF Adaptor Holder Holds RF connector to radio.

-g
NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages.
NTN4265_ Pressure Pump Kit Allows servicer to locate leakages.
5871134M01 Connector Fitting This connector allows the vacuum hose to be

all
connected to the radio chassis.
3271133M01 Fitting Seal This seal secures the connector fitting to the radio
chassis.
* Earlier versions of programming cables will not work with the radio.
Test Equipment and Service Aids: Programming, Testing and Alignment Cable 2-3
2.3 Programming, Testing and Alignment Cable

#25 #14
#1 #4
P1 #13 #1
P2
P3
#1 #2
#11
#12
Figure 2-1. Programming, Testing and Alignment Cable

2-4 Test Equipment and Service Aids: Programming, Testing and Alignment Cable
Table 2-3. Pin Configuration of Side Connector
CONNECTION
P1 P2 P3
Pin Pin Pin Function

1 GROUND
1 3 VCC (5V)
3 4 DATA+
2 5 DATA-
16 4 6 GROUND
1&5 7 EXTERNAL SPEAKER+
2&7 8 EXTERNAL SPEAKER-
20 9 EXTERNAL PTT
17 10 EXTERNAL MIC+
16 11 EXTERNAL MIC-
slot for accessory

GPIO_0 connector hook
1-Wire
Vbus
D+
1
2
D- 3
4
GND 5
6
Spkr +
7
8
9
Spkr - 10
11
GPIO_3 12
Mic +
Mic -
GPIO_4
Figure 2-2. Pin Layout of Side Connector

Chapter 3 Transceiver Performance Testing
3.1 General
These radios meet published specifications through their manufacturing process by utilizing high-
accuracy laboratory-quality test equipment. The recommended field service equipment approaches
the accuracy of the manufacturing equipment with few exceptions. This accuracy must be
maintained in compliance with the manufacturer’s recommended calibration schedule.
Although these radios function in digital and analog modes, all testing is done in analog mode.
3.2 Setup
Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.
Do NOT use any form of connector, e.g. wires, crocodile

clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number Title
3-2 Front Panel Access Test Mode Displays
3-3 Test Environments
3-4 Test Frequencies
3-5 Transmitter Performance Checks
3-6 Receiver Performance Checks
Table 3-1. Initial Equipment Control Settings
Service Monitor Power Supply Test Set

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

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

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

Oscilloscope Source: Mod Current: 2.5A
Oscilloscope Horizontal: 10mSec/Div
Oscilloscope Vertical: 2.5kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: Middle setting
Monitor Vol: 1/4 setting
Transceiver Performance Testing Setup 3-3
Setup:
Set up the DMR Transmitter and Receiver Test as per Figure 3-1.
a. Connect the Programming cable to the radio and to the computer.
b. Remove RF plug (orange) as shown in Figure 3-2.
c. Connect the RF antenna adaptor to the 50 Ohm RF Input/Output port of the radio as
shown in Figure 3-3.
Connect the other end of the RF antenna adaptor to the T/R port of the Radio Test Set 3920 using
the RF cable shown in Figure 3-1.
m
.co
Ant. Input / Output
PMKN4126A
T/R Port
Programming Cable
Modulated RF Test
es
Signal / Tx
modulated RF Signal Battery Eliminator
Power Supply
Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup

uid
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3-4 Transceiver Performance Testing Setup
RF Plug
Figure 3-2. RF plug
RF Antenna Adaptor
(PMLN6154)
Figure 3-3. Connect RF Antenna adaptor to radio RF input/output port

Transceiver Performance Testing Display Model Test Mode 3-5
3.3 Display Model Test Mode

3.3.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within 10 seconds after Self Test is complete, press Side Button 2 five times in succession
3. The radio beeps and will show a series of displays that will give information regarding various
version numbers and subscriber specific information. The displays are described in Table 3-2.
Table 3-2. Front Panel Access Test Mode Displays
Name of Display Description Appears

Service Mode The literal string indicates the radio has entered test mode. Always
Host Version The version of host firmware. Always
DSP Version The version of DSP firmware. Always
Model Number The radio’s model number as programmed in the codeplug. Always
MSN The radio’s serial number as programmed in the codeplug. Always
FLASHCODE The FLASH codes as programmed in the codeplug. Always
RF Band The radio’s band. Always
NOTE The radio stops at each display for 2 seconds before moving to the next information display.
If the information cannot fit into 1 line, the radio display scrolls automatically character by
character after 1 second to view the whole information. If the Left Navigation Key (W) is
pressed before the last information display, the radio shall suspend the information display
until the user presses Right Navigation Key (X) to resume the information display. The
radio beeps for each button press. After the last display, RF Test Mode will be displayed.
3.3.2 RF Test Mode

When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or air test.
In RF Test Mode, the display upon the first line is “RF Test”, together with the power level icon at the
right end of the first line. The display upon the second line is the test environment, the channel
number and channel spacing. The default test environment is CSQ.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-3.
3-6 Transceiver Performance Testing Display Model Test Mode
Table 3-3. Test Environments
No. of
Description Function
Beeps
1 Carrier Squelch RX: if carrier detected
(CSQ) TX: mic audio
2 Tone Private-Line RX: unsquelch if carrier and tone detected

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

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

(USQ) TX: mic audio
2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz
and 20 kHz as. The radio beeps once when radio toggles to 20kHz, beeps twice for 25 kHz
and beeps three times for 12.5 kHz.
3. Turning of the Channel Knob changes the test channel from 1 to 14 as described in
Table 3-4. The radio beeps in each position.
Table 3-4. Test Frequencies
Channel
Selector Test
UHF VHF
Switch Channel
Position
1 Low Power TX#1 or #9 403.15 136.075
9 High Power RX#1 or #9 403.15 136.075
2 Low Power TX#2 or #10 423.25 142.575

10 High Power RX#2 or #10 423.25 142.575
3 Low Power TX#3 or #11 444.35 146.575

11 High Power RX#3 or #11 444.35 146.575
4 Low Power TX#4 or #12 465.45 155.575

12 High Power RX#4 or #12 465.45 155.575
5 Low Power TX#5 or #13 485.55 161.575

13 High Power RX#5 or #13 485.55 161.575
6 Low Power TX#6 or #14 506.65 167.575

14 High Power RX#6 or #14 506.65 167.575
7 Low Power TX#7 or #15 526.75 173.975

15 High Power RX#7 or #15 526.75 173.975
8 Low Power TX#8 or #16 527.00 174.000

16 High Power RX#8 or #16 527.00 174.000
Table 3-5. Transmitter Performance Checks
Communications
Test Name Radio Test Set Comments
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test Test Channel 4 continuously ±201Hz for UHF
frequency* carrier squelch transmit
Monitor: Frequency (during the ±68Hz for VHF
error performance
Input at RF In/Out check)
Power RF As above As above As above Low Power:

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

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

Modulation 4th channel test Test Channel 4 ≥500Hz but ≤1000Hz
frequency* TPL (25 kHz Ch Sp).
BW to narrow
* See Table 3-4

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

distortion
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Sensitivity As above, except SINAD, As above PTT to OFF RF input to be
(SINAD) lower the RF level for (center) <0.35μV
12dB SINAD.
Noise RF level set to 1mV RF As above PTT to OFF Set volume

Squelch (center), meter control to 2.83Vrms
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Threshold selection to
(only radios Audio PA,
with speaker/load to
conventional speaker
system need
to be tested) As above, except change Out of TEST As above Unsquelch to occur at
frequency to a MODE; select <0.25μV.
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conventional system. a conventional Preferred SINAD = 9

Raise RF level from zero system – 10dB
until radio unsquelches.
* See Table 3-4

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3.3.3 LED Test Mode

1. Press and hold Side Button 1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button/key press, the radio lights the red LED and displays “Red LED On”.
3. Consequently, upon any button/key press, the red LED is turned off and the radio lights the
green LED and displays “Green LED On”.
4. Upon any successive button/key press, the green LED is turned off, and the radio shall light
both LEDs up while displaying “Both LEDs On”. Since there is only one LED on the portable,
the LED color will be orange when the radio lights both LEDs.
3.3.4 Backlight Test Mode

1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once and displays
“Backlight Test Mode”.
2. The radio turns on both LCD and keypad backlight together.
3.3.5 Speaker Tone Test Mode

1. Press and hold Side Button 1 after Backlight Test Mode. The radio beeps once and displays
“Speaker Tone Test Mode”.
2. The radio generates a 1 KHz tone with the internal speaker.
3.3.6 Earpiece Tone Test Mode

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

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

1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once and momentarily displays “Battery Check Test Mode”.
2. The radio will display the following:
Rem. Capacity100%
Figure 3-4. Battery Check Test Mode Display
3.3.9 Button/Knob/PTT Test Mode

1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once and
displays “Button Test”(line 1).
2. Rotate the Volume Knob; “2/1” through “2/255” appears. The radio beeps at each position.
3. Rotate the Channel Knob; When rotate the channel knob in clockwise, “4/1” appear. When
rotate the channel knob in counter clockwise, “4/-1” appear. The radio beeps at each position.
4. Press Side Button 1; “96/1” appears & radio beeps; release, “96/0” appears & radio beeps.
5. Press Side Button 2; “97/1”appears & radio beeps; release, “97/0” appears & radio beeps.
6. Press Side Button 3; “98/1”appears & radio beeps; release, “98/0” appears & radio beeps.
7. Press the PTT Switch; “1/1” appears & radio beeps; release, “1/0” appears & radio beeps.
8. Press Top Button; “148/1” appears & radio beeps; release, “148/0” appears & radio beeps.
9. Keypad Checks:
- Press 0, “48/1” appears & radio beeps; release, “48/0” appears & radio beeps.
- Press *, “58/1” appears & radio beeps; release, “58/0” appears & radio beeps.
- Press #, “59/1” appears & radio beeps; release, “59/0” appears & radio beeps.
- Press P1, “160/1” appears & radio beeps; release, “160/0” appears & radio beeps.
- Press P2, “161/1” appears & radio beeps; release, “161/0” appears & radio beeps.
- Press MENU, “85/1” appears & radio beeps; release, “85/0” appears & radio beeps.
- Press BACK, “129/1” appears & radio beeps; release, “129/0” appears & radio beeps.
- Press W, “128/1” appears & radio beeps; release, “128/0” appears & radio beeps.
- Press X, “130/1” appears & radio beeps; release, “130/0” appears & radio beeps.
- Press ▲, "135/1" appears & radio beeps; release, "135/0" appears & radio beeps.
- Press ▼, "136/1" appears & radio beeps; release, "136/0" appears & radio beeps.
3.4 Display Model Test Mode

3.4.1 Monochrome Display Test
1. Press any button to test the LCD display, press button ">" until the display are fixed. Then,
press and hold the first side button until the screen change.
2. Upon any button/key press, the LCD shall display the growing horizontal bars. Press button
X until the LCD display full screen in Black and change to vertical bars.
3. Press button X until the LCD display full screen Black and change to icon display.
4. The LCD shall display RSSI icon (with full bar), monitor icon, high power level icon (H), tone
disabled icon, priority-two channel scan icon, option board icon, unread message icon,
emergency icon, talkaround icon, and battery strength indicator icon (with full bar).
5. The LCD shall clear the screen and display the rest of the icons (low power level icon (L),
companding icon, and secure operation icon) upon any button/key press.
6. Then, press and hold the first side button until the screen change.
3.4.2 Color Display Test

1. Press any button to test the LCD display, press button X until the display are fixed. Then,
press and hold the first side button until the screen change.
2. Upon key Xpress, the housing shall display a White screen with 2 pixels wide of a black
border inset from the edge by 2 pixels and the text "Display Test Mode" in black.
3. Upon key Xpress, the housing shall display a Black screen with 2 pixels wide of a White
boarder inset from the edge by 2 pixels and the text "Display Test Mode" in White.
4. Upon key Xpress, the housing shall display a full screen in Red.
5. Upon key Xpress, the housing shall display a full screen in Green.
6. Upon key Xpress, the housing shall display a full screen in Blue.
7. Upon key Xpress, the housing shall display the growing horizontal bars with a cyclic color of
Red>Green>Blue>Black>Red>Green>Blue>Black>Red (Full Screen).
8. Upon key Xpress, the housing shall display the growing vertical bars with a cyclic color of
Red>Green>Blue>Black>Red>Black (Full Screen).
9. Upon key “>”press, until all icons in color show. The housing shall display RSSI icon (with full
bar), monitor icon, high power level icon (H), tone disabled icon, priority-two channel scan
icon, option board icon, unread message icon, emergency icon, talkaround icon, and battery
strength indicator icon (with full bar).
10. The housing shall clear the screen and display the rest of the icons in color, (low power level
icon (L), companding icon, and secure operation icon) upon key “>”press. Then, press and
hold the first side button until the screen change.
3-12 Transceiver Performance Testing Non-Display Model Test Mode
3.5 Non-Display Model Test Mode

3.5.1 Entering Non-Display Radio Test Mode
1. Turn the radio on.
2. Within 10 seconds after “Self Test” is complete, press Side Button 2 five times in succession.
3. The radio beeps.
3.5.2 RF Test Mode

When the radio is operating in its normal environment, the radio's microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting, according to the customer codeplug
configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be
removed from its normal environment via a special routine, called TEST MODE or “air test”.
1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ
->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three
times for DIG and beeps four times for USQ.
NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-3.
2. Each short press of Side Button 1 toggles the channel spacing between 25 KHz, 12.5 KHz
and 20 KHz as. The radio beeps once when radio toggles to 20KHz, beeps twice for 25KHz
and beeps three times for 12.5KHz.
3. Turning of the Channel Knob changes the test channel from 1 to 14 as described in
Table 3-4. The radio beeps in each position.
3.5.3 LED Test Mode

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

1. Press and hold Side Button 1 after LED Test Mode. The radio beeps once.
2. The radio generates a 1 KHz tone with the internal speaker.
Transceiver Performance Testing Non-Display Model Test Mode 3-13
3.5.5 Earpiece Tone Test Mode

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

1. Press and hold Side Button 1 after Earpiece Tone Test Mode. The radio beeps once.
2. The radio shall route any audio on the external mic to the earpiece.
3.5.7 Battery Check Test Mode
m
1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once.
2. The radio LED lights up accordingly; green LED for High Battery Level, orange LED for Mid
.co
Battery Level and blinking red LED for Low Battery Level.
3.5.8 Button/Knob/PTT Test Mode

1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once.
2. Rotate the Volume Knob; the radio beeps at each position.
3. Rotate the Channel Knob; the radio beeps at each position.
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4. Press Side Button 1; the radio beeps; release, the radio beeps.
7. Press the PTT Switch; the radio beeps; release, the radio beeps.
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8. Press Top Button; the radio beeps; release, the radio beeps.
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3-14 Transceiver Performance Testing Non-Display Model Test Mode
Notes
Chapter 4 Radio Programming and Tuning
4.1 Introduction
This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as
well as the Tuner and AirTracer applications, which are all designed for use in a Windows 2000/XP/
Windows 7 environment. These programs are available in one kit as listed in Table 4-1. An
Installation Guide is also included with the kit.
NOTE Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1. Software Installation Kits Radio Tuning Setup
Description Part Number
MOTOTRBO CPS and AirTracer on CD-ROM PMVN4130_
MOTOTRBO Tuner on CD-ROM PMVN4131_
4.2 Customer Programming Software Setup

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

exposed contacts on cable when connected to a computer.
Caution
R adio
Programming, Testing
Battery & Alignment Cable
PMKN4012B
PMKN4013C or later.
Figure 4-1. CPS Programming Setup

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

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

If the service kit is replaced, it does not necessarily need to be retuned if it has been factory tuned. It
should however be checked for performance before being placed into service. Of particular concern
is the Bias DAC, which will need to be set for the appropriate final device bias current prior to keying
up the radio. If the bias is not properly set it may be possible to cause damage to the transmitter.
! Only Motorola Service Centers or Authorized Motorola Service Dealers can

perform this function.
Caution
NOTE Refer to appropriate program on-line help files for the programming procedures.
A personal computer (PC), Windows 2000/XP/Windows 7and a tuner program are required to tune
the radio. To perform the tuning procedures, the radio must be connected to the PC, radio interface
box (RIB), and test equipment setup as shown in Figure 4-2.
Battery Service Monitor

Eliminator or Counter
7.5V Reg. Transmit
RF Adaptor
Wattmeter
+12VDC
Power Radio 10 dB Pad Receive
Supply RF Generator
Audio In Tx Audio Generator
Test Box
RLN4460_ Rx Sinad Meter
Programming, Testing &
Alignment Cable
AC Voltmeter
PMKN4013C or later
Figure 4-2. Radio Tuning Equipment Setup

Radio Programming and Tuning: RF Adaptor Disassembly 4-3
4.5 RF Adaptor Disassembly
RF Plug
1. Use tweezer to remove the RF plug.
RF Adaptor Holder
Antenna Opening
2. Align RF Adaptor Holder to the antenna opening of the housing. The RF Adaptor Holder
should fit snugly around the outer wall of the antenna opening.
4-4 Radio Programming and Tuning: RF Adaptor Disassembly
Screw
m
RF Connector
.co
es
3. Fasten the screw provided the hold the RF Adapter in place. This is followed by slotting the
RF Connector into the RF Adaptor Holder slot.
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4. The final assembly should look like this.

Disassembly/Reassembly Procedures: Introduction 5-1
Chapter 5 Disassembly/Reassembly Procedures
! Only Motorola Service Centers or Authorized Motorola Service Dealers can

perform this function.
Caution
5.1 Introduction
This chapter provides details about the following:
• Preventive maintenance (inspection and cleaning).

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

Periodic visual inspection and cleaning is recommended.
5.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.
5.2.2 Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the front
cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic
visual inspection reveals the presence of smudges, grease, and/or grime.
NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (100% by volume).
!
The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
Caution chemicals.
5-2 Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
Cleaning Internal Circuit Boards and Components
Isopropyl alcohol (100%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge
embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the
dislodged material out and away from the inside of the radio. Make sure that controls or tunable
components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process
since this could cause the liquid to collect in unwanted places. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front cover or back cover.
NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
!
Use all chemicals as prescribed by the manufacturer. Be sure
to follow all safety precautions as defined on the label or
Caution material safety data sheet.
5.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent
device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION
paragraph in the Disassembly and Reassembly section of the manual.
Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices 5-3
DO NOT attempt to disassemble the radio without first referring to the following CAUTION
statement.
This radio contains static-sensitive devices. Do not open the radio unless you are
! properly grounded. Take the following precautions when working on this unit:
Caution • Store and transport all CMOS/LDMOS devices in conductive

material so that all exposed leads are shorted together. Do not insert
CMOS/LDMOS devices into conventional plastic “snow” trays used
for storage and transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the
CMOS/LDMOS device. We recommend using the Motorola Static
Protection Assembly (part number 0180386A82), which includes a
wrist strap, two ground cords, a table mat, and a floor mat, ESD
shoes and an ESD chair.
• Wear a conductive wrist strap in series with a 100k resistor to
ground. (Replacement wrist straps that connect to the bench top
covering are Motorola part number 4280385A59).
• Do not wear nylon clothing while handling CMOS/LDMOS devices.
• Do not insert or remove CMOS/LDMOS devices with power applied.
Check all power supplies used for testing CMOS/LDMOS devices to
be certain that there are no voltage transients present.
• When straightening CMOS/LDMOS pins, provide ground straps for
the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS/LDMOS devices by the package and
not by the leads. Prior to touching the unit, touch an electrical
ground to remove any static charge that you may have
accumulated. The package and substrate may be electrically
common. If so, the reaction of a discharge to the case would cause
the same damage as touching the leads.
5-4 Disassembly/Reassembly Procedures: Repair Procedures and Techniques – General
5.4 Repair Procedures and Techniques – General

NOTE Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards — examples shown below) were developed and assembled using
environmentally preferred components and solder assembly techniques to comply with
the European Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/
95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/
EC. To maintain product compliance and reliability, use only the Motorola specified parts
in this manual.
Any rework or repair on Environmentally Preferred Products must be done using the appropriate
lead-free solder wire and lead-free solder paste as stated in the following table:
Table 5-1. Lead Free Solder Wire Part Number List
Motorola Flux Content Melting Supplier Part

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

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

Brookfield (5rpm) (-325/+500) 89.3%
Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
from the nearest Motorola Radio Products and Solutions Organization (RPSO) listed in Appendix A
of this manual.
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.
When soldering near a connector:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges.
Disassembly/Reassembly Procedures: Disassembling and Reassembling the Radio — General 5-5
5.5 Disassembling and Reassembling the Radio — General

When disassembling and reassembling the radio, it is important to pay particular attention to the
snaps and tabs, and how parts align with each other.
The following tools are required for disassembling the radio:
• TORX™ T3 and T6 screwdriver
• Chassis and Knob Opener (PMLN6208)
The following item and tools are required for reassembling the radio:
m
• Grease (1185937A01)
• TORX™ T3 and T6 screwdriver
• Vacuum Pump Kit (NLN9839) - Radio Immersibility Test
• Pressure Pump Kit (NTN4265) - Radio Immersibility Test
.co
• Connector Fitting (5871134M01) - Radio Immersibility Test
• Fitting Seal (3271133M01) - Radio Immersibility Test
• Seal Port (3286058L01)
• Label Ventilation (5478220A01)
If a unit requires further testing or service than is customarily performed at the basic level, please
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send the radio to a Motorola Service Center.
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5-6 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed
5.6 Radio Disassembly – Detailed

5.6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Release the battery latch by moving it into the unlock position.
b. With the latch released, slide the battery downwards.
c. Remove the battery from the radio.
3. Remove the antenna by turning it counterclockwise.
Antenna
Figure 5-1. Antenna and Battery removal.

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-7
4. Remove the channel selector knob and volum knob off from their shafts using the knob
removal tool.
Channel Selector
Knob
Volume Control Knob
Figure 5-2. Channel Selector and Volume Knob removal.
NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.
Shroud
Figure 5-3. Shroud removal

5. Hook the knob opener under the shroud as shown in Figure 5-3 and detach it with a
downward motion.
6. Separate the chassis from the housing assembly as follows:
a. Insert the chassis opener into the recess at the bottom of the radio. Apply a downward
force to separate the chassis from the front housing.
b. Remove the chassis from the front housing.
Chassis Opener
Figure 5-4. Chassis removal

7. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis.
Latch
Flex
Figure 5-5. Disconnecting the chassis

8. Lift the latch on the main board to release the keypad from its connector.
9. Remove the flex from the keypad board by pulling it out of its connector gently.
10. Lift the latch on the main board to release the GOB flex from its connector.
5.6.2 Chassis Disassembly

Use a TORX screwdriver with a T6 head to remove the five screws holding the main board to the
chassis and the three screws holding the GOB.
Main board
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Main board screws
.co GOB screws

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Chassis
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Figure 5-6. Chassis disassembly

1. Lift the main board from the chassis.

2. Lift the latch to separate the flex for the GOB.
3. Lift the GOB from the chassis.
4. Release all the tabs from the catches.
5. Remove the O-ring and battery contact seal
.
O-ring Tab
Catch
Battery Contact Seal
Figure 5-7. O-ring removal

5.6.3 Keypad, Display, and Keypad Board Disassembly

1. If the disassembly of the keypad, the keypad printed circuit board, or the display is required,
remove the retainer by using a TORX screwdriver with a T6 head to remove the four screws.
2. Slide out the retainer from the housing assembly.
3. Disconnect the speaker flex, LCD flex and PTT flex from the keypad board.
NOTE The LCD, keypad board and keypad can be removed without the use of tools.
Figure 5-8. Keypad, Display, and Keypad Board disassembly for Full Keypad
Figure 5-9. Keypad, Display, and Keypad Board Disassembly for Limited Keypad
5.6.4 Speaker, Microphone, and Universal Connector Flex Disassembly

1. Pull the microphone boot from its seated position.
2. Remove the speaker retainer screw using the TORX T6 screwdriver.
3. Peel-off the universal connector flex circuit escutcheon.
4. Pull the UC flex circuit (adhesive held) backer board from the font cover. Push the universal
connector flex through the UC slot into the housing.
5. Remove the speaker retainer from the speaker assembly.
6. Remove the assembly from the front housing.
Speaker Retainer
Screw
Speaker, Mic and Flex Assembly

Mic Boot
UC Slot
Figure 5-10. Speaker removal for Full Keypad

Speaker Retainer
Screw
Mic Boot
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UC Slot
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Figure 5-11. Speaker removal for Limited Keypad

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Speaker Retainer
Screw
UC Slot
PTT flex connector
Figure 5-12. Speaker removal for Non-Keypad
1. Pull the rubber microphone boot from its seated position.

2. Remove the screw using the TORX T6 screwdriver.
3. Disconnect the PTT flex and peel the speaker assembly flex from the housing.
4. Peel off the universal connector flex circuit escutcheon.
5. Pull the UC flex circuit (adhesive held) backer board from the font cover. Push the universal
connector flex through the UC slot into the housing.
6. Remove the speaker retainer from the speaker assembly.
7. Remove the assembly from the front housing.
5.6.5 Emergency Button Assembly Dissassembly

1. The Emergency button can be removed without the use of tools once the speaker retainer is
removed.
Figure 5-13. Emergency Button disassembly for Full Keypad Model

Figure 5-14. Emergency Button disassembly for Non Keypad Model

Disassembly/Reassembly Procedures: Radio Reassembly - Detailed 5-19
5.7 Radio Reassembly - Detailed

5.7.1 Emergency Button and Speaker Reassembly
1. Slot in the emergency button in its proper slot.
Figure 5-15. Emergency Button reassembly for Full Keypad

5-20 Disassembly/Reassembly Procedures: Radio Reassembly - Detailed
m
Emergency Button
.co
es
Figure 5-16. Emergency Button reassembly for Non Keypad
uid
Speaker Retainer
Speaker, Mic and Flex

-g
UC Slot
all
Figure 5-17. Speaker reassembly for Full Keypad

Speaker Retainer
Speaker, Mic and Flex
UC Slot
Figure 5-18. Speaker reassembly for Non Keypad

2. Insert the flexes through the speaker retainer so that the speaker retainer is placed directly on
the speaker assembly.
NOTE Ensure all the flexes are above the speaker retainer.
3. Slide the universal connector flex into UC slot.

4. Hook in the speaker retainer with speaker assembly at the top left corner of the housing.
5. Affix the appropriate screw on the speaker retainer.
6. Place the mic boot in the appropriate slot.
7. Place a new universal connector escutcheon on the universal connector flex circuit.
5.7.2 Keypad, Display and Keypad Board Reassembly

1. Place the LCD and keypad followed by the keypad board and keypad retainer in the housing.
2. Reconnect the speaker flex, LCD flex and PTT flex to the keypad board and keypad retainer.
3. Slide the keypad retainer in to the latch.
4. Use a TORX screwdriver with a T6 head to affix the screws.
Figure 5-19. Keypad, Display, and Keypad Board reassembly for Full Keypad
5.7.3 Chassis Reassembly

O-ring reassembly:
i. Ensure that the main O-ring is not twisted and untangle it to its actual form if needed
before performing reassembly.
ii. Insert D into the bottom two notches on the chassis.
iii. Fit C around the bottom two corners of the chassis.
iv. Insert B1 to B4 following the sequence as shown in Figure 5-20.
v. Secure A into the top 2 notches of the chassis.
vi. Replace the battery contact seal.
B1
B2
B3
B4
Battery Contact Seal
Figure 5-20. O-ring reassembly.

Main board screws
GOB screws
Figure 5-21. Chassis reassembly

1. Place the main board onto the chassis.
2. Tighten the main board screws in the sequence shown in Figure 5-21.
3. Place the GOB on the chassis.
4. Tighten the GOB screws following the sequence shown in Figure 5-22.
1
3
m
.co GOB
es
Figure 5-22. GOB reassembly
5. Connect GOB flex to the main board.
uid
-g
all
5.7.4 Chassis and Front Cover Reassembly

1. Connect the flex to the main board and the keypad board.
2. Insert top chassis tabs into the recesses on front cover and the tabs are fully inserted.
3. Gently push down the chassis into the front cover until it snaps in place.
4. Align the shroud with the top of the front housing and slide it in place.
5. Insert knobs, antenna and battery.
Shroud
Figure 5-23. Chassis reassembly

5.7.5 Bluetooth Antenna Kit Disassembly/Reassembly
5.7.5.1 Bluetooth Antenna Kit Disassembly

1. Use a T3 Torx screwdriver to unfasten the bluetooth module.
Screw
Bluetooth module
Figure 5-24. Bluetooth removal for Full Keypad
Screw
Bluetooth module
Figure 5-25. Bluetooth removal for Non Keypad

5.7.5.2 Bluetooth Antenna Kit Reassembly

1. Place the Bluetooth module in the housing and fasten with a Torx 3 screwdriver.
Screw
Bluetooth module slot

Bluetooth module
Figure 5-26. Bluetooth reassembly for Full Keypad
Screw
Bluetooth module slot

Bluetooth module
Figure 5-27. Bluetooth reassembly for Non Keypad

5.7.6 GOB Installation

1. Fold the option board flex cable as shown.
2. Peel the adhesive strip off from the spacer supplied and affix the spacer to the bottom side of
the option board where marked.
3. Gently lift the connector flap of the option board and connect the option board flex cable.
Gently close the flap.
Flex Flex
m
GOB Board
.co GOB Board
es
4. Insert the option board with the motherboard into the chassis as shown below.
Screw
uid
-g
all
Option Board
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-31
5.8 Ensuring Radio Immersibility

This section discusses radio immersibility concerns, tests, and disassembly and reassembly of the
XiR series radios.
5.8.1 Servicing
The XiR series radios shipped from the Motorola factory have passed vacuum testing and should be
capable of restoring the watertight integrity of the radio.
It is strongly recommended that the maintenance of the radio be deferred to
! qualified service personnel and service shops. This is of paramount importance

as irreparable damage to the radio can result from service by unauthorized
Caution persons. If disassembly is necessary, unauthorized attempts to repair the radio
may void any existing warranties or extended performance agreements with
Motorola. It is also recommended that immersibility be checked annually by
qualified service personnel/workshop that is authorized by Motorola.
5.8.2 Accidental Immersion
If the radio is accidentally dropped in water, shake the radio to remove the excess water from the
speaker grille and microphone port area before operating; otherwise, the sound may be distorted
until the water has evaporated, or is dislodged from these areas.
5.8.3 Specialized Test Equipment
This section summarizes the specialized test equipment necessary for testing the integrity of the
XiR series radios.
To ensure that the radio is truly a watertight unit, special testing, test procedures, and specialized
test equipment are required. The special testing involves a vacuum check of the radio and pressure
testing (troubleshooting) for water leaks if the vacuum check fails. The specialized test equipment/
instrument (Table 2-2 on page 2-2) is authorized by Motorola and needed to perform the vacuum
check and pressure testing, if required. Any equipment/tools/instruments not mentioned in the table
must not be used to perform these test.
5.8.4 Vacuum Pump Kit NLN9839
The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. A connector fitting
(part number 5871134M01) and fitting seal (part number 3271133M01) pump connector, which must
be ordered separately, connects the vacuum hose to the radio’s chassis.
Fitting Seal
(part number
3271133M01)
Connector Fitting
(part number
5871134M01)
Figure 5-28. Connector Fitting - Fitting Seal Pump Connector

5-32 Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
5.8.5 Pressure Pump Kit NTN4265
The pressure pump kit includes a pressure pump with gauge, and a pressure hose. As with the
vacuum pump kit above, the connector fitting - fitting seal pair connects the pressure hose to the
radio’s chassis.
5.8.6 Miscellaneous Hardware
Other items needed for testing the immersibility radio include:
• Large water container

• Deionized (DI) water
• A supply of replacement parts: Main seal O-ring, Battery Contact Seal, Breathing Vent Label
and Breathing Vent Membrane.
5.8.7 Vacuum Test
The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the
radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly
sealed, watertight unit. Before starting the vacuum test:
• Remove the battery.

• Remove the universal connector dustcover to expose the universal connector.
• Remove the breathing vent label and breathing vent membrane.
To conduct the vacuum test:
1. Attach antenna firmly to the radio.

2. Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by
blocking off the open end of the hose and operating the pump a few times. The actual reading
of the gauge at this point is not important; it is important that the gauge pointer remained
steady, indicating no vacuum leaks in the pump.
3. Ensure that the fitting seal is attached to the hose-to-chassis pump connector. Screw the
pump connector into the tapped hole in the chassis.
! Please do not bend or over tighten pump connector to the chassis.

Caution
4. Attach the open end of the hose to the pointed end of the pump connector.
5. Place the radio on a flat surface with the chassis facing upward.
6. Operate the pump until the gauge indicates 6 in. Hg of vacuum on the radio.Observe the
gauge for approximately 1 minute.
• If the needle falls 0.5 in. Hg or less (one scale interval, for example, from 3 in. Hg to 2.5 in.
Hg), then the radio has passed the vacuum test and is approved for immersibility. No
additional testing will be required.
• If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 3 in. Hg to less
than 2.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if
immersed. Additional troubleshooting of the radio will be required; complete this procedure,
then go to Section 5.8.8 "Pressure Test".
7. Remove the vacuum hose and pump connector from the radio.
5.8.8 Pressure Test
Pressure testing the radio is necessary only if the radio has failed the vacuum test. Do not perform
the pressure test until the vacuum test has been completed. Pressure testing involves creating a
positive pressure condition inside the radio, immersing the radio in water, and observing the radio
for a stream of bubbles (leak). Since all areas of the radio are being checked, observe the entire unit
carefully for the possibility of multiple leaks before completing this test.
To conduct the pressure test:
1. Screw the pump connector (with fitting seal) into the tapped hole in the chassis.
2. Attach one end of the pressure hose to the pump connector and the other end to the pressure
pump.
4. Operate the pump until the gauge reads approximately 1 psig.
! Pressure any greater than 1 psig might push air around the main seal
Caution
5. Maintain the pressure at 1 psig and immerse the radio into a water-filled container.
6. Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.
NOTE Some air entrapment may cause the accumulation of bubbles, especially in the grille area,
but the bubbles should not be continuous.
! Please do not bend or over tighten pump connector to the chassis.

Caution
7. Note all of the seal areas that show signs of leakage. Pinpoint the problem(s) to one (or more)
of the following areas:
• Front Housing
• Chassis (Main Seal O-ring)
• Battery Contact Seal
8. Remove the radio from the water container, and dry the radio thoroughly. Be especially
careful to dry the area around the main seal to prevent contamination of the internal
electronics while the unit is open
! Keep the area around the chassis’s vacuum port dry by ensuring that there is no
water around it.
Caution
9. Remove the pump connector from the chassis.

10. Radio after performing Pressure Test must undergo baking process in a temperature chamber
for constant temperature soaking at 60°C for 1 hour. This is to ensure no moisture is trapped
inside the radio and prevent contamination of the internal electronics after reassembling the
radio.
5.8.9 Troubleshooting Leak Areas
Before repairing any leak, first read all of the steps within the applicable section. This will help to
eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot
only the faulty seal areas listed in Section 5.8.8 "Pressure Test" on page 5-33, and when multiple
leaks exist, in the order listed.
NOTE Before reassembling the radio, always install a new Main seal O-ring, Battery Contact Seal
in the defective area.
5.8.9.1 Front Housing
Do one or both of the following:
1. If a leak occurs at the Lens (Display Models only), Universal Connector, chassis/Housing
interface, PTT button area of the housing, replace the housing. Refer to Section 5.6 "Radio
Disassembly – Detailed" on page 5-6.
a. Remove the housing assembly from the radio.
b. Discard the housing assembly and main seal O-ring.
c. Install a new main seal O-ring around the chassis assembly according to Figure 5.
d. Install a new housing assembly to the radio.
e. Inspect the main seal for proper seating.
f. Observe carefully to ensure that the main seal O-ring is not pinched between the
housing and the chassis interface.
2. If the leak occurs at the control top area, remove the knobs in order to determine the leak
location:
a. Conduct the Pressure Test.
b. Identify the leak location.
5.8.9.2 Chassis (Main Seal O-ring)
To replace the main seal O-ring:
1. Refer to Section 5.6.1 "Front Cover from Chassis Disassembly" on page 5-6, remove the
chassis assembly from the radio.
2. Refer to Section 5.6.2 "Chassis Disassembly" on page 5-10, remove the Main Board from
chassis.
3. Remove the main seal O-ring.
4. Inspect the seal area around the chassis for foreign material that might prevent the main seal
O-ring from sealing properly.
5. Assemble a new O-ring; discard the old O-ring.
6. For detailed O-ring assembly sequence, refer to clause 2, step i. to step viii. of Section 5.7.3
"Chassis Reassembly" on page 5-23.
7. Reassemble the chassis assembly followed by installing into Front Cover. (Refer to Section
m
5.7 "Radio Reassembly - Detailed" on page 5-19).
8. Inspect the main seal O-ring for proper seating. Observe carefully to ensure that the main
seal O-ring is not pinched between the housing and the chassis.
.co
NOTE When installing the assembled chassis to the Front Cover, ensure the O-ring at the top two
corners are not dislodged from the chassis groove.
5.8.9.3 Battery Contact Seal
To replace the Battery Contact Seal:

es
1. Refer to Section 5.6 "Radio Disassembly – Detailed" on page 5-6 to remove the Battery
Contact Seal.
2. Remove the Battery Contact Seal from the Chassis.
3. Inspect the Battery Contact Seal, Chassis and surrounding areas for foreign material that
might prevent the Battery Contact Seal from sealing properly.
uid
4. Install a new Battery Contact Seal; discard the old Seal.

5. Replace a new main seal O-ring; discard the old O-ring.
6. Reassemble the chassis assembly followed by installing into Front Cover. (Refer to Section
5.7 "Radio Reassembly - Detailed" on page 5-19).
7. Inspect the main seal O-ring for proper seating. Observe carefully to ensure that the main
seal O-ring is not pinched between the housing and the chassis.
-g
IMPORTANT: Both Label Ventilation (5478220A01) and Gasket (3286058L01) need to

be replaced after vacuum test, pressure test or water leakage
troubleshooting.
all
5.8.9.4 Breathing Vent Membrane and Breathing Vent Label
To replace the Breathing Vent Membrane and Breathing Vent Label:
1. Remove the Breathing Vent Label that covers the Breathing Vent Membrane from the
chassis.
2. Remove the Breathing Vent Membrane.
3. Ensure that the chassis’s surface (at the Breathing Vent Label & Breathing Vent Membrane
recessed) is clean, no/minimum scratches and free from any adhesive or other foreign
materials.
4. Install a new Breathing Vent Membrane, covering the vent port hole, in the small recessed
area in the chassis. Ensure that no oily substance come in contact with the seal.
5. Install a new Breathing Vent Label over the Breathing Vent Membrane in the larger recessed
area in the chassis. Press down evenly over the label’s surface to ensure good adhesion.
5.8.9.5 Battery Maintenance

1. As part of an Annual Battery Maintenece Program or as required (when the battery contacts
are dirty or show signs of wear) it is recommended that the Battery‘s Radio-side and Charger-
side contacts are cleaned with DeoxIT®GOLD cleaner/lubricant.
2. DeoxIT®GOLD (Supplier CAIG Labs, P/N G100P) cleaner/lubricant pen has been found to be
very effective at cleaning and extending the life of the battery‘s contacts. DeoxIT®GOLD
cleaner/lubricant is available at numerous electronics suppliers (Radio Shack, McMaster Carr,
Fry’s, etc.) and directly from manufacturer, CAIG Labs, at http://www.caig.com.
3. This pen based package is recommended as it provides better access to the recessed con-
tacts of the battery. The pen’s tip may need to be modified (trimmed on the sides) to improve
penetration into the battery contact slots. Per the manufacturer’s instructions, shake the pen
until the fluid begins to flow and wipe the battery's contact surface with the felt tip. After
cleaning, inspect the contact surfaces for signs of advanced wear.
4. Advanced contact wear is defined as wear through either the contact platings (gold and
nickel) to the base metal (copper). Copper exposure is characterized by a distinctive orange-
brown metal appearance surrounded by the silvery nickel underplate and gold top coat.
5. In some cases, a magnified (10x minimum) inspection may be required to verify wear through
to the base material. Polishing of the gold or nickel surface is common and is not considered
a need for replacement. In instances where advanced wear is evident, the battery should be
replaced.
6. After cleaning the contact areas of any foreign material, let the lubricant/cleaner dry for 2 min-
utes. Replace the battery on the radio and test for intermittency by moving the battery relative
to the radio as might occur in regular use.
NOTE Regular maintenance (at least annually) of this area is recommended to ensure
contamination free interface and to prolong the life of the battery contacts.
5.8.10 Troubleshooting Charts
Start
1. Remove Battery
2. Remove Universal
Connector Dustcover
3. Remove breathing vent label
and membrane
A
2. Attach vacuum hose to vacuum
pump
3. Ensure fitting seal is attached to
hose-to-chassis pump connector
4. Screw pump connector into chas-
sis’s tapped hole
5. Attach vacuum hose to pump
connector
6. Place radio on flat surface
7. Operate pump (gauge = 6 in. Hg)
Gauge Full
does not fall equipment for
NO YES
below pressure test Run Pressure Test
0.5 in. Hg procedure
available
YES
NO
1.Replace Breath-
ing Vent label and
Breathing Vent
B
Membrane
2. Radio approved
for immersibility
End
Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)

End
Start
1Remove pump and Send radio to

connectors from radio Motorola Depot
2. Remove antenna or
3. Separate front housing kit Motorola Service Center
YES
Examined YES Changed YES Changed YES Changed

main O-ring front housing main O-ring back chassis
fitting kit kit
NO NO NO NO
Examine and Replace front Replace main Replace new

reassemble housing kit with O-ring with chassis kit
main O-ring new unit new unit without PCBs

A
Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)

Start
1. Remove vacuum hose from

pump connector
2. Attach pressure hose to
pump connector
1. Operate pressure pump

(pressure = 1 psig)
2. Immerse radio into a water- 1. Remove Knobs
filled container
NO
Bubbles from 1. Dry the radio

Continuous YES Lens*/Univer- YES 2. Replace Housing, Main
YES Bubbles from sal Connector/
Series of Front Seal O-Ring, and repeat
bubbles chassis/ steps in Troubleshooting
Housing Housing Inter- Flow Chart for Vacuum Test.
face/ PTT
NO NO * Only for Display Model
1. Dry the radio

2.Replace Breathing
Vent label and
End Breathing Vent
Membrane
3. Radio approved
1. Dry the radio
for immersibility
YES 2. Replace Main Seal O-ring,
Bubbles from and repeat steps in
Chassis Troubleshooting Flow Chart
for Vacuum Test.
NO
1. Dry the radio

NO Bubbles from YES 2. Replace Battery Contact Seal,
Battery Con- Main Seal O-Ring, and repeat
tact Seal steps in Troubleshooting Flow
Chart for Vacuum Test.
Troubleshooting Flow Chart for Pressure Test & Leakage Areas

5-40 Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists
5.9 Radio Exploded Mechanical Views and Parts Lists

5.9.1 Full Keypad Model Exploded View and Parts List
6
5
11
1
12
13
15 14
m
23
19
4
20
7
.co 23
24
16
10
8
28
18 17
29
30
31
21
es
32
22
25
26
27
37
38
34
uid
39
33
35
36
40
52
46
-g
47
48
49
41
all
42
50
43
44
45
51
Figure 5-29. Full Keypad Model Exploded View

Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists 5-41
Table 5-3. Full Keypad Model Exploded View Parts List
Item Description Part Number
1 Antenna See Chapter 7: Accessories
2 Volume, Knob 36012005001
3 Frequency, Knob 36012004001
4 Emergency Button 38012008001
5 Nameplate, Front 33012037001
6 Front Cover Kit* See Table 5-6
7 UC Escutcheon Part of Front Cover kit
8 Dust Cover Assembly 15012157001
9 Bluetooth / GPS Antenna 85012045001
10 Screw, Shoulder, M1.2 X 3.2 MM 0371160D01
11 Label, Agency Indicator Not Field Replaceable
12 Full Keypad See Table 5-6
13 Front Dampener, Color Display Part of Front Cover Kit
14 Color Display Padding Part of Front Cover Kit
15 Color Display Module 72012010001
16 Back Dampener, Color Display Part of Front Cover Kit
17 Conductive Pad (Small) Part of Front Cover Kit
18 Conductive Pad (Big) Part of Front Cover Kit
19 Keypad Controller, FKP 0104038J16
20 Keypad to Mainboard Flex 84012214005
21 UC to Keypad Flex Part of Front Cover Kit
22 TX Shield Poron Part of Front Cover Kit
23 Keypad Stiffener Part of Front Cover Kit
24 Keypad-LCD Retainer 42012029001
25 Mesh, Speaker Part of Front Cover Kit
26 Speaker, Electromagnetic, 36mm Dia 50012013001
27 Retainer Assembly, Speaker 0104045J57
28 Keypad Retainer Screw 0378212A02
29 Conductive Poron Part of Front Cover Kit
30 Microphone, EMI, Electret Condenser 50012012001

Table 5-3. Full Keypad Model Exploded View Parts List
31 Boot, Microphone 32012099001
32 Mic Membrane with Stiffener Part of Front Cover Kit
33 Screw, Main Board 03012034001
34 Screw, Thread Forming 0386434Z02
35 Seal, Top Control 32012089001
36 Back Cover Kit** See Table 5-6
37 Main O-Ring 32012097001
38 Option Board Kit PMLN5718_S
39 GOB to Mainboard Flex 84012217003
40 Chassis 27012010001
41 Rubber Plug 38012017001
42 Housing, Shroud 15012092001
43 Battery Contact Seal 32012096001
44 Nameplate See Table 5-6
45 Warning Label Part of Back Cover Kit
46 Gasket 3286058L01
47 Label Ventilation 5478220A01
48 RF Label Not Field Replaceable
49 Chassis Label Not Field Replaceable
50 Battery See Chapter 7: Accessories
51 Belt Clip See Table 5-6
52 Pad, Thermal 7515526H01

NOTE: * Comprises of 4,5,7,9,10,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,28,29,30,31, 32 and 34
** Comprises of 33,35,37 ,40, 43, 45,and 52
5.9.2 Limited Keypad Model Exploded View and Parts List
11
4
3
12
2
1
50
7
8
20
9
10
21
13
14
22
15
23
16
24
17
29 25
18
19
30
31
26
32
27
28
33
34
35
49
36
40
41
43
37
46
38
39
42
44
45
47
48
Table 5-4. Limited Keypad Model Exploded View Parts List
1 Antenna See Chapter 7: Acces-

sories
2 Knob, Frequency 36012005001
3 Knob, Volume 36012004001
5 Nameplate Front 33012037001
7 UC Escutcheon Part of Front Cover Kit
9 Bluetooth/GPS Antenna 85012045001
12 Limited Keypad 75012063001
13 UC to Keypad Flex Part of Front Cover Kit
14 TX Shield Poron Part of Front Cover Kit
15 Front Dampener, Display Part of Front Cover Kit
16 4-Line Display Module 72012007001
17 Back Dampener, Display Part of Front Cover Kit
18 Conductive Pad (Small) Part of Front Cover Kit
19 Conductive Pad (Big) Part of Front Cover Kit
20 Keypad Controller, LKP 0104038J17
21 Keypad to Mainboard Flex 84012214005
22 Keypad Stiffener Part of Front Cover Kit
23 Keypad-LCD Retainer 42012029001
24 Keypad Retainer Screw 0378212A02
25 Conductive Poron Part of Front Cover Kit

Table 5-4. Limited Keypad Model Exploded View Parts List
m
36 Main O-Ring 32012097001
37 Chassis 27012010001
.co
38 Rubber Plug 38012017001
40 Gasket 3286058L01

es

uid
46 Label Chassis Not Field Replaceable
47 Battery See Chapter 7: Acces-

sories

-g
50 Color Display Padding Part of Front Cover Kit

NOTE: * Comprises of 4,5,7,9,10,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,28,29,30, 31, 32 and 50
** Comprise of 33, 34, 36,37,44,45,and 49
all
5.9.3 Non Keypad Model Exploded View and Parts List
7
4
3
2
1
17
18
19
12 11 10
8
20
9
14 13
15
16
23 21
26
27
22
24
41
33
25
34
28
35
36
37
29
30
31
32
38
39
40
Table 5-5. Non-Keypad Model Exploded View Parts List
1 Antenna See Chapter 7: Acces-

sories
2 Knob, Frequency 36012005001
3 Knob, Volume 36012004001
5 Nameplate Front 33012037001
8 UC Escutcheon Part of Front Cover kit
17 Bluetooth/GPS Antenna 85012045001
19 Plain Front Housing Poron Part of Front Cover Kit
20 Plain UC Flex Poron Part of Front Cover Kit
21 UC to Keypad Flex Part of Front Cover kit
25 Main O-Ring 32012097001
26 Option Board Kit PMLN5718_S
27 GOB to Mainboard Flex 84012217003
28 Plain PTT Flex Poron Part of Front Cover Kit
29 Chassis 27012010001
30 Rubber Plug 38012017001
33 Gasket 3286058L01
Table 5-5. Non-Keypad Model Exploded View Parts List

37 Label Chassis Not Field Replaceable
39 Battery See Chapter 7: Acces-
sories
NOTE: * Comprises of 4,5,8,10,11,12,13,14,15,16,17,18,19,20,21 and 28
** Comprise of 22,23,25,29,32,34, and 41
Table 5-6. Additional Part List information

Front Cover Front Kit, English (FKP) PMLN5961_
Kit
Front Cover Kit English BT FKP PMLN6116_
Front Kit, Stroke (FKP) PMLN5959_
Front Cover Kit Stroke BT FKP PMLN6117_
Front Kit, Bopomofo (FKP) PMLN5962_
Front Cover Kit Bopomoho BT FKP PMLN6115_
Front Kit, Korean (FKP) PMLN5960_
Front Cover Kit Korean BT FKP PMLN6118_
Front Cover Kit LKP PMLN5690_
Front Cover Kit BT LKP PMLN6112_
Front Cover Kit NKP PMLN5691_
Front Cover Kit BT NKP PMLN6111_
Keypad Full Keypad, English 75012064004
Full Keypad, Stroke 75012064006
Full Keypad, Bopomofo 75012064003
Full Keypad, Korean 75012064005
Back Cover BC Kit 136-174MHz,5W,FKP,GPS,BT PMLD4480_S
Kit
BC Kit 136-174MHz,5W,FKP PMLD4481_S
BC Kit 136-174MHz,5W,LKP,GPS,BT PMLD4483_S
BC Kit 136-174MHz,5W,LKP PMLD4484_S
BC Kit 136-174MHz,5W,NKP,GPS,BT PMLD4486_S
BC Kit 136-174MHz,5W,NKP PMLD4487_S
BC Kit 403-527MHz,4W,FKP,GPS,BT PMLE4689_S

BC Kit 403-527MHz,4W,FKP PMLE4690_S
BC Kit 403-527MHz,4W,LKP,GPS,BT PMLE4692_S
BC Kit 403-527MHz,4W,LKP PMLE4693_S
BC Kit 403-527MHz,4W,NKP,GPS,BT PMLE4695_S
BC Kit 403-527MHz,4W,NKP PMLE4696_S
BC Kit 136-174MHz,3.5W,FKP,GPS,BT,CQST PMLD4522_S
BC Kit 136-174MHz,3.5W,FKP,CQST PMLD4523_S
BC Kit 136-174MHz,3.5W,LKP,GPS,BT,CQST PMLD4524_S
BC Kit 136-174MHz,3.5W,LKP,CQST PMLD4525_S
BC Kit 136-174MHz,3.5W,NKP,GPS,BT,CQST PMLD4526_S
BC Kit 136-174MHz,3.5W,NKP,CQST PMLD4527_S
BC Kit 403-527MHz,3.5W,FKP,GPS,BT,CQST PMLE4788_S
BC Kit 403-527MHz,3.5W,FKP,CQST PMLE4789_S
BC Kit 403-527MHz,3.5W,LKP,GPS,BT,CQST PMLE4790_S
BC Kit 403-527MHz,3.5W,LKP,CQST PMLE4791_S
BC Kit 403-527MHz,3.5W,NKP,GPS,BT,CQST PMLE4792_S
BC Kit 403-527MHz,3.5W,NKP,CQST PMLE4793_S
Nameplate GP328D 33012015019
GP338D 33012015020
XiR P8600 33012015007
XiR P8608 33012015010
XiR P8620 33012015008
XiR P8628 33012015011
XiR P8660 33012015009
XiR P8668 33012015012
Belt Clips Belt Clip 2” PMLN4651_
Belt Clip 2.5" PMLN7008_
5.9.4 Torque Chart

Table 5-7 lists the various screws by part number and description, followed by the torque values in
different units of measure. Torque all screws to the recommended value when assembling the radio.
Table 5-7. Torque Specifications for Screws
Driver/ Torque
Part Number Description
Socket lbs-in
03012034001 Screw, Main Board T6 Torx 2.8
m
0386434Z02 Screw, Thread Forming T6 Torx 2.3 to 2.5
0378212A02 Screw, Keypad Retainer T6 Torx 1.1 to 1.3
0371160D01 Screw, Shoulder, M1.2 X 3.2 T3 Torx 0.4 to 0.6
.co
MMes
uid
-g
all
Chapter 6 Basic Troubleshooting
6.1 Introduction
This chapter contains error codes and board replacement procedures. If the board does not pass all
the performance checks in Chapter 3 or exhibits an error code listed below, then the circuit board
should be replaced. If repair requires knowledge of details of component level troubleshooting,
please send radio to a Motorola Service Center or Motorola Authorised Dealers.
NOTE To access the various connector pins, use the housing eliminator/test fixture along with the
diagrams found in this section of the manual. (See the section, "Service Aids" on page 2-2,
for the appropriate Motorola service aids and tools parts numbers.)
6.2 Replacement Back Cover Kit Procedures

If the Back Cover Kit is replaced, it does not necessarily need to be retuned if it has been factory
tuned. It should however be checked for performance before placed into service. Of particular
concern is the Bias DAC, which will need to be set for the appropriate final device bias current prior
to keying up the radio. Of the bias is not set it may be possible to cause damage to the transmitter.
! Only Motorola Service Centers or Authorised Motorola Service Dealers can

perform this function
Caution
6-2 Basic Troubleshooting: Power-Up Error Codes (Display Model only)
6.3 Power-Up Error Codes (Display Model only)

Upon powering up, the radio performs certain tests to determine if its basic electronics and software
are in working order. Any error detected has an associated error code that is presented on the radio
display. These error codes are intended to be used by a service technician when the radio
generates the Self Test Fail Tone. If these tests are successfully completed, the radio will generate
the Self Test Tone.
There are two classes of detectable errors, fatal and non-fatal. If it is considered as a fatal error, then
the normal radio operation will be inhibited. Fatal errors include hardware errors detected by the
microprocessor and certain memory errors. These memory errors include incorrect ROM checksum,
incorrect RAM checksum, and incorrect checksums of codeplug (Persistent Storage) blocks that
contain operating parameters. If the codeplug block operating parameters are corrupted, operation
of the unit on the proper frequency, system, and group are in question. Attempts to use this
information could provide the user with a false sense of security that others are receiving his
messages. Corrupted codeplug blocks of call IDs, or their associated aliases are considered non-
fatal errors. While the user may be inconvenienced, normal communication is still possible.
Table 6-1. Power-Up Error Codes
Error Code Description Error Type Corrective Action

ERROR 01/02 Call ID or associated Non-Fatal Normal communication is still possible, but the
aliases codeplug block user may be inconvenienced.
checksum is wrong. Reprogram codeplug.
ERROR 01/22 Tuning Codeplug block Non-Fatal Normal communication is still possible, but the
checksum is wrong. user may send radio to nearest Motorola Ser-
vice Centers or Authorised Motorola Service
Centers.
FAIL 01/82 External Codeplug block Fatal Reprogram codeplug. If message reoccurs,
checksum is wrong. send radio to nearest Motorola Service Cen-
ters or Authorised Motorola Service Centers.
FAIL 01/92 Secure Codeplug check- Fatal Reprogram codeplug. If message reoccurs,
sum error. send radio to nearest Motorola Service Cen-
FAIL 01/A2 Tuning Codeplug block Fatal Reprogram codeplug. If message reoccurs,
checksum is wrong. send radio to nearest Motorola Service Cen-
FAIL 01/81 ROM Checksum is Fatal Send radio to nearest Motorola Service Cen-
wrong. ters or Authorised Motorola Service Centers.
FAIL 01/88 Radio RAM Test Failure. Fatal Retest radio by turning it off and turning it on
again, If message reoccurs, send radio to
nearest Motorola Service Centers or Autho-
rised Motorola Service Centers.
FAIL 01/90 General hardware test Fatal Retest radio by turning it off and turning it on
or failure. again, If message reoccurs, send radio to
FAIL 02/90 nearest Motorola Service Centers or Autho-
FAIL 02/81 DSP ROM Checksum is Fatal Send radio to nearest Motorola Service Cen-
wrong. ters or Authorised Motorola Service Centers.
Basic Troubleshooting: Power-Up Error Codes (Display Model only) 6-3
Table 6-1. Power-Up Error Codes (Continued)

FAIL 02/82 DSP RAM1 test failure. Fatal Retest radio by turning it off and turning it on
FAIL 02/84 DSP RAM2 test failure. Fatal Retest radio by turning it off and turning it on
FAIL 02/88 DSP RAM test failure. Fatal Retest radio by turning it off and turning it on
FAIL 02/C0 DSP ROM Checksum is Fatal Retest radio by turning it off and turning it on
wrong. again, If message reoccurs, send radio to
No Display Display module is not Fatal Send radio to nearest Motorola Service Cen-
connected properly. ters or Authorised Motorola Service Centers.
Display module is dam-
aged.
6-4 Basic Troubleshooting: Operational Error Codes
6.4 Operational Error Codes

NOTE A non-display radio emits only the Self Test Fail Tone if it fails the self-test
During radio operation, the radio performs dynamic tests to determine if the radio is working properly.
Problems detected during these tests are presented as error codes on the radio’s display. The
presence of an error code should prompt a user that a problem exists and that a Motorola Authorized
MOTOTRBO dealer should be contacted. Use Table 6-2 to aid in understanding particular
operational error codes.
Table 6-2. Operational Error Codes

FAIL 001 Synthesizer Out-of-Lock NON-FATAL Reprogram codeplug. If message reoccurs,
send radio to nearest Motorola Service
Centers or Authorised Motorola Service
Centers.
FAIL 002 Personality checksum or NON-FATAL Reprogram codeplug. If message reoccurs,
system block error send radio to nearest Motorola Service
Centers or Authorised Motorola Service
Centers.
Chapter 7 Accessories
7.1 Introduction
Motorola provides the following approved accessories to improve the productivity of your digital
portable two-way radio.
For a list of Motorola-approved antennas, batteries and other accessories, visit the following web
m
site: http://www.motorola.com/governmentandenterprise
7.1.1 Audio
.co
Part No. Description
PMMN4025_ Remote Speaker Microphone with Enhanced Audio
RLN6075_ Remote Speaker Microphone Coil Cord Kit (for use with PMMN4025_)
PMMN4024_ Remote Speaker Microphone
PMMN4040_ Remote Speaker Microphone - Submersible (IP57)
es
RLN6074_ Remote Speaker Microphone Coil Cord Kit (for use with PMMN4024_
and PMMN4040_)
PMMN4041_ Public Safety Microphone with Enhanced Audio - 30” Cable
uid

RMN5058_ Lightweight Headset
RLN5878_ Receive Only Surveillance Kit, Black
RLN5879_ Receive Only Surveillance Kit, Beige
RLN5880_ 2-Wire Surveillance Kit, Black with Enhanced Audio
-g
RLN5881_ 2-Wire Surveillance Kit, Beige with Enhanced Audio

RLN5882_ 2-Wire Surveillance Kit with Clear, Comfortable Acoustic Tube, Black
with Enhanced Audio
RLN5883_ 2-Wire Surveillance Kit with Clear, Comfortable Acoustic Tube, Beige
all
with Enhanced Audio

RLN4760_ Small Custom Earpiece, Right Ear, for Surveillance Kits
RLN4761_ Medium Custom Earpiece, Right Ear, for Surveillance Kits
RLN4762_ Large Custom Earpiece, Right Ear, for Surveillance Kits
RLN4763_ Small Custom Earpiece, Left Ear, for Surveillance Kits
RLN4764_ Medium Custom Earpiece, Left Ear, for Surveillance Kits
RLN4765_ Large Custom Earpiece, Left Ear, for Surveillance Kits
RLN5886_ Surveillance Low Noise Kit
RLN6282_ Replacement Ear Tips, Clear - Pack of 25 (for use with RLN5886_)
7-2 Accessories: Introduction
RLN5887_ Surveillance High Noise Kit

5080384F72 Replacement Foam Plugs - Pack of 50 (for use with RLN5887_)
RLN4941_ Receive Only Earpiece
AARLN4885_ Receive Only Earbud
WADN4190_ Over the Ear Receiver (for use with PMMN4024_ and PMMN4025_)
PMLN4620_ D-Shell Receive Only Earpiece
RLN6288_ Earpiece with High Noise Kit, Beige
RLN6289_ Earpiece with High Noise Kit, Black
RLN6279_ Standard Earpiece, Black
RLN6280_ Standard Earpiece, Beige
RLN6284_ Earpiece with Acoustic Tube Assembly, Beige
RLN6285_ Earpiece with Acoustic Tube Assembly, Black
RLN6283_ Replacement Foam Ear Pad and Windscreen
PMLN5102_ Core Ultra-Lite Headset
PMLN5101_ IMPRES Temple Transducer
PMLN5096_ D-Shell Core Earset
PMLN5097_ IMPRES 3-Wire Surveillance, Black
PMLN5106_ IMPRES 3-Wire Surveillance, Beige
PMLN5111_ IMPRES 3-Wire Surveillance with Acoustic Tube, Black
PMLN5112_ IMPRES 3-Wire Surveillance with Acoustic Tube, Beige
1571477L01 Accessory Dust Cover
PMMN4046_ IMPRES Remote Speaker Mic w/Vol, IP57
*PMMN4047_ IMPRES Submersible PSM, 30-in Cable
PMMN4050_ IMPRES Remote Speaker Mic, NC
* Only applicable to UHF1 (403 – 470 MHz) and VHF (136 – 174 MHz) bands.
Accessories: Introduction 7-3
7.1.2 Batteries

PMNN4412_ BATT STD IP67 NIMH 1300M 1400T
PMNN4407_ IMPRES Li-ion Slim Battery (1500 mAH)
PMNN4409_ IMPRES Hi-Cap Li-ion Non-FM Battery (2150 mAH)
PMNN4406_ Core Slim Li-Ion Battery (1500 mAH)
NNTN8129 BATT IMP FM LI ION 2300M 2350T
7.1.3 Chargers

WPLN4232_ IMPRES Single Unit Charger, US Plug
WPLN4233_ IMPRES Single Unit Charger, UK Plug
WPLN4234_ IMPRES Single Unit Charger, Euro Plug
WPLN4235_ IMPRES Single Unit Charger, Australia Plug
WPLN4245_ IMPRES Single Unit Charger, China Plug
WPLN4247_ IMPRES Single Unit Charger with SMPS, Japan Plug
WPLN4212_ IMPRES Multi Unit Charger, US Plug
WPLN4213_ IMPRES Multi Unit Charger, Euro Plug
WPLN4214_ IMPRES Multi Unit Charger, UK Plug
WPLN4215_ IMPRES Multi Unit Charger, Australia Plug
WPLN4219_ IMPRES Multi Unit Charger with Displays, US Plug
WPLN4220_ IMPRES Multi Unit Charger with Displays, Euro Plug
WPLN4221_ IMPRES Multi Unit Charger with Displays, UK Plug
WPLN4222_ IMPRES Multi Unit Charger with Displays, Australia Plug
7.1.4 Antennas
PMAD4117_ VHF helical antenna (136–155 MHz)
PMAD4119_ VHF stubby antenna (136–148 MHz)
PMAE4068_ UHF whip antenna (403–527 MHz)
PMAE4069_ UHF stubby antenna (403–450 MHz)
PMAE4079_ UHF slim whip antenna (403–527MHZ)
7.1.5 Carry Devices

PMLN5838_ Hard Leather CC 3inch FIX LKP FKP
PMLN5839_ Hard Leather CC 3inch FIX PLAIN
PMLN5840_ Hard Leather CC 3inch SWL LKP FKP
PMLN5846_ Hard Leather CC 3inch SWL PLAIN
PMLN5842_ Hard Leather CC 2.5inch SWL LKP FKP
PMLN5843_ Hard Leather CC 2.5inch SWL LKP FKP
PMLN5844_ Hard Leather CC 2.5inch SWL PLAIN
PMLN5845_ NYLON CC 3inch FIX LKP FKP
PMLN5610_ 2.5" replacement swivel belt loop
PMLN5611_ 3.0" replacement swivel belt loop
PMLN4651_ Belt Clip 2”
PMLN7008_ Belt Clip 2.5"
PMLN5863_ Hard Leather CC 3in Fixed LKP
PMLN5864_ Hard Leather CC 3in Fixed NKP
PMLN5865_ Hard Leather CC 3in Swl LKP
PMLN5866_ Hard Leather CC 3in Swl NKP
PMLN5867_ Hard Leather CC 2.5in Swl LKP
PMLN5868_ Hard Leather CC 2.5in Swl NKP
PMLN5869_ Nylon Case 3in Fixed LKP
PMLN5870_ Nylon Case 3in Fixed NKP
Accessories: Introduction 7-5
PMLN5956_ Carry Holder
7.1.6 Miscellaneous Accessories

PMLN5718_S Generic Option Board
Notes
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Appendix A Replacement Parts & Kits
A.1 Level 1 and 2 Maintenance

This manual covers Level 1 and 2 Maintenance:
Level 1 maintenance is the assessment and/or repair of fault in terms of faulty accessory or physical
aspect of product; not including opening of the unit. Limited to replacement of antenna, battery,
handset, external microphones, external knobs, all related frequency programming to customers’
and in some cases alignment/tuning, by Customer Programming software (CPS).
Level 2 maintenance includes all Level I activities plus: Assessment that require opening the
Subscriber Product and rectifying a fault by replacement of a board or module, or replacement of
major mechanical parts (like Front Housing Kit or Control Head Board), followed by alignment/tuning
to ensure the replacement of board/module/major mechanical parts are within Subscriber Product’s
specifications as per the service manual. It does not incorporate discrete component replacement.
A.1.1 Replacement Parts Ordering

Some replacement parts, spare parts, and/or product information can be ordered directly. While parts
may be assigned with a Motorola part number, this does not guarantee that they are available from
Motorola Radio Products and Solutions Organization (RPSO). Some parts may have become
obsolete and no longer available in the market due to cancellations by the supplier. If no Motorola
part number is assigned, the part is normally not available from Motorola, or is not a user-serviceable
part. Part numbers appended with an asterisk are serviceable by Motorola Depot only.
Orders for replacement parts, kits, and assemblies should be placed directly on Motorola’s local
distribution organization or via Motorola Online. For Level 2 maintenance, only Motorola Service
Centers or Authorized Motorola Service Dealers can perform these functions. Any tampering by
nonauthorized Motorola Service Centers voids the warranty of your radio. To find out more about
Motorola Service Centers, please visit http://www.motorolasolutions.com/governmentandenterprise
A.2 Level 3 Maintenance

The Level 3 Maintenance can only be done at the Motorola Service Center/Depot since it can deeply
affect the performance of the radio. To find out more about Motorola Service Center, please visit
http://www.motorolasolutions.com/governmentandenterprise
A-2 Replacement Parts & Kits: Additional Service Kits Information
A.3 Additional Service Kits Information

A.3.1 UHF Super Tanapa

Model Description
AZH56RDN9KA1AN 403–527 MHz, 4W, XiR P8668 Full Keypad
Portable with GPS
AZH56RDN9JA1AN 403–527 MHz, 4W, XiR P8660 Full Keypad
Portable
AZH56RDN9JA1AN04 403–527 MHz, 4W, GP338D Full Keypad
Portable
AZH56RDH9KA1AN 403–527 MHz, 4W, XiR P8628 Limited Keypad
Portable with GPS
AZH56RDH9JA1AN 403–527 MHz, 4W, XiR P8620 Limited Keypad
Portable
AZH56RDH9JA1AN04 403–527 MHz, 4W, GP338D Limited Keypad
Portable
AZH56RDC9KA1AN 403–527 MHz, 4W, XiR P8608 Non Keypad
Portable with GPS
AZH56RDC9JA1AN 403–527 MHz, 4W, XiR P8600 Non Keypad
Portable
AZH56RDC9JA1AN03 403–527 MHz, 4W, GP328D Non Keypad
Portable
Item Description
X PMUE3675AACAAA Super tanapa, without GOB, English
(United States)
X PMUE3675AAEAAA Super tanapa, without GOB, Chinese
Traditional
X PMUE3675AAFAAA Super tanapa, without GOB, Korean
X PMUE3675AADAAA Super tanapa, without GOB, Chinese
(Simplified)
X PMUE3675AACACA Super tanapa, without GOB, English
(United States)
X PMUE3675ABCAAA Super tanapa, with GOB, English (United
States)
X PMUE3675ABEAAA Super tanapa, with GOB, Chinese
(Traditional)
X PMUE3675ABFAAA Super tanapa, with GOB, Korean
X PMUE3675ABDAAA Super tanapa, with GOB, Chinese
(Simplified)
X PMUE3675ABCACA Super tanapa, with GOB, English (United
States)
X PMUE3676AACAAA Super tanapa, without GOB, English
(United States)
X PMUE3676AAEAAA Super tanapa, without GOB, Chinese
(Traditional)
X PMUE3676AAFAAA Super tanapa, without GOB, Korean
Replacement Parts & Kits: Additional Service Kits Information A-3

Model Description
AZH56RDN9KA1AN 403–527 MHz, 4W, XiR P8668 Full Keypad
Portable with GPS
AZH56RDN9JA1AN 403–527 MHz, 4W, XiR P8660 Full Keypad
Portable
AZH56RDN9JA1AN04 403–527 MHz, 4W, GP338D Full Keypad
Portable
AZH56RDH9KA1AN 403–527 MHz, 4W, XiR P8628 Limited Keypad
Portable with GPS
AZH56RDH9JA1AN 403–527 MHz, 4W, XiR P8620 Limited Keypad
Portable
AZH56RDH9JA1AN04 403–527 MHz, 4W, GP338D Limited Keypad
Portable
AZH56RDC9KA1AN 403–527 MHz, 4W, XiR P8608 Non Keypad
Portable with GPS
AZH56RDC9JA1AN 403–527 MHz, 4W, XiR P8600 Non Keypad
Portable
AZH56RDC9JA1AN03 403–527 MHz, 4W, GP328D Non Keypad
Portable
Item Description
X PMUE3676AADAAA Super tanapa, without GOB, Chinese
(Simplified)
X PMUE3676AACACA Super tanapa, without GOB, English
(United States)
X PMUE3676AALAAA Super tanapa, without GOB, Chinese
(Simplified)
X PMUE3678AABAAA Super tanapa, without GOB, English
(United States)
X PMUE3678AABACA Super tanapa, without GOB, English
(United States)
X PMUE3679AABAAA Super tanapa, without GOB, English
(United States)
X PMUE3679AABACA Super tanapa, without GOB, English
(United States)
X PMUE3679AAKAAA Super tanapa, without GOB, English
(United States)
X PMUE3681AAAAAA Super tanapa, without GOB
X PMUE3681AAAACA Super tanapa, without GOB
X PMUE3681ABAAAA Super tanapa, with GOB
X PMUE3681ABAACA Super tanapa, with GOB
X PMUE3682AAAACA Super tanapa, without GOB
X PMUE3682AAJAAA Super tanapa, without GOB
XiR/GP Series, UHF, 403–527 MHz, 3.5W

Model Description
AZH56RCN9KA4AN 403–527 MHz, 3.5W, XiR P8668 Full Keypad Portable with GPS
AZH56RCN9JA4AN04 403–527 MHz, 3.5W, GP338D Full Keypad Portable
AZH56RCH9KA4AN 403–527 MHz, 3.5W, XiR P8628 Limited Keypad Portable with GPS
AZH56RCH9JA4AN04 403–527 MHz, 3.5W, GP338D Limited Keypad Portable
AZH56RCC9KA4AN 403–527 MHz, 3.5W, XiR P8608 Non Keypad Portable with GPS
AZH56RCC9JA4AN03 403–527 MHz, 3.5W, GP328D Non Keypad Portable
Item Description
X PMUE3880AADAAA Super tanapa, without GOB, Chinese (Simplified)
X PMUE3880ABDAAA Super tanapa, with GOB, Chinese (Simplified)
X PMUE3881AALAAA Super tanapa, without GOB, Chinese (Simplified)
X PMUE3882AABAAA Super tanapa, without GOB, English (United States)
X PMUE3883AAKAAA Super tanapa, without GOB, English (United States)
X PMUE3884ABAAAA Super tanapa, with GOB
X PMUE3885AAJAAA Super tanapa, without GOB
Replacement Parts & Kits: Additional Service Kits Information A-5
A.3.2 VHF Super Tanapa
XiR/GP Series, VHF, 136–174 MHz, 5W

Model Description
AZH56JDN9KA1AN 136–174 MHz , 5W, XiR P8668 Full Keypad Portable with
GPS
m
AZH56JDH9KA1AN 136–174 MHz , 5W, XiR P8628 Limited Keypad Portable
with GPS
AZH56JDH9JA1AN 136–174 MHz , 5W, XiR P8620 Limited Keypad Portable
.co
AZH56JDC9KA1AN 136–174 MHz , 5W, XiR P8608 Non Keypad Portable with
GPS
Item Description
es
X PMUD2904AACAAA Super tanapa, without GOB, English (United States)
X PMUD2904AAEAAA Super tanapa, without GOB, Chinese (Traditional)
X PMUD2904AAFAAA Super tanapa, without GOB,Korean
X PMUD2904AADAAA Super tanapa, without GOB, Chinese (Simplified)
uid
X PMUD2904ABCAAA Super tanapa, with GOB, English (United States)

X PMUD2904ABEAAA Super tanapa, with GOB, Chinese (Traditional)
X PMUD2904ABFAAA Super tanapa, with GOB, Korean
X PMUD2904ABDAAA Super tanapa, with GOB, Chinese (Simplified)
X PMUD2917AACAAA Super tanapa, without GOB, English (United States)
X PMUD2917AAEAAA Super tanapa, without GOB, Chinese (Traditional)
-g
X PMUD2917AAFAAA Super tanapa, without GOB, Korean

X PMUD2917AALAAA Super tanapa, without GOB, Chinese (Simplified)
all
X PMUD2918AABAAA Super tanapa, without GOB, English (United States)

X PMUD2903AAKAAA Super tanapa, without GOB, English (United States)
X PMUD2906AAAAAA Super tanapa, without GOB
X PMUD2906ABAAAA Super tanapa, with GOB
X PMUD2905AAJAAA Super tanapa, without GOB
XiR/GP Series, VHF, 136–174 MHz, 3.5W

Model Description
AZH56JCN9KA4AN 136–174 MHz , 3.5W, XiR P8668 Full Keypad Portable with GPS
AZH56JCN9JA4AN04 136–174 MHz, 3.5W, GP338D Full Keypad Portable
AZH56JCH9KA4AN 136–174 MHz, 3.5W, XiR P8628 Limited Keypad Portable with GPS
AZH56JCH9JA4AN04 136–174 MHz, 3.5W, GP338D Limited Keypad Portable
AZH56JCC9KA4AN 136–174 MHz, 3.5W, XiR P8608 Non Keypad Portable with GPS
AZH56JCC9JA4AN03 136–174 MHz, 3.5W, GP328D Non Keypad Portable
Item Description
X PMUD2636ABDAAA Super tanapa, with GOB, Chinese (Simplified)
X PMUD2637AALAAA Super tanapa, without GOB, Chinese (Simplified)
X PMUD2639AAKAAA Super tanapa, without GOB, English (United States)
X PMUD2649ABAAAA Super tanapa, with GOB
X PMUD2660AAJAAA Super tanapa, without GOB
Glossary Glossary
This glossary contains an alphabetical listing of terms and their definitions that are applicable to
portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and
some terms are merely generic in nature.
Term Definition
Analog Refers to a continuously variable signal or a circuit or device designed

to handle such signals.
Band Frequencies allowed for a specific purpose.
CPS Customer Programming Software: Software with a graphical user
interface containing the feature set of a radio.
Default A pre-defined set of parameters.
Digital Refers to data that is stored or transmitted as a sequence of discrete
symbols from a finite set; most commonly this means binary data
represented using electronic or electromagnetic signals.
DPL Digital Private-Line: A type of digital communications that utilizes
privacy call, as well as memory channel and busy channel lock out to
enhance communication efficiency.
FCC Federal Communications Commission.
Frequency Number of times a complete electromagnetic-wave cycle occurs in a
fixed unit of time (usually one second).
GPIO General-Purpose Input/Output: Pins whose function is programmable.
GPS Global Positioning System.
IC Integrated Circuit: An assembly of interconnected components on a
small semiconductor chip, usually made of silicon. One chip can contain
millions of microscopic components and perform many functions.
IF Intermediate Frequency.
kHz kilohertz: One thousand cycles per second. Used especially as a radio-
frequency unit.
LCD Liquid-Crystal Display: An LCD uses two sheets of polarizing material
with a liquid-crystal solution between them. An electric current passed
through the liquid causes the crystals to align so that light cannot pass
through them.
LED Light Emitting Diode: An electronic device that lights up when electricity
is passed through it.
MDC Motorola Digital Communications.
Glossary-2
Term Definition
MHz Megahertz: One million cycles per second. Used especially as a radio-
frequency unit.
Paging One-way communication that alerts the receiver to retrieve a message.
PC Board Printed Circuit Board. Also referred to as a PCB.
PL Private-Line Tone Squelch: A continuous sub-audible tone that is
transmitted along with the carrier.
Programming Cable A cable that allows the CPS to communicate directly with the radio
using USB.
Receiver Electronic device that amplifies RF signals. A receiver separates the
audio signal from the RF carrier, amplifies it, and converts it back to the
original sound waves.
Repeater Remote transmit/receive facility that re-transmits received signals in
order to improve communications range and coverage (conventional
operation).
RF Radio Frequency: The portion of the electromagnetic spectrum between
audio sound and infrared light (approximately 10 kHz to 10 GHz).
RX Receive.
Signal An electrically transmitted electromagnetic wave.
Spectrum Frequency range within which radiation has specific characteristics.
Squelch Muting of audio circuits when received signal levels fall below a pre-
determined value. With carrier squelch, all channel activity that exceeds
the radio’s preset squelch level can be heard.
TOT Time-out Timer: A timer that limits the length of a transmission.
TPL Tone Private Line.
Transceiver Transmitter-receiver. A device that both transmits and receives analog
or digital signals. Also abbreviated as XCVR.
Transmitter Electronic equipment that generates and amplifies an RF carrier signal,
modulates the signal, and then radiates it into space.
TX Transmit.
UHF Ultra-High Frequency.
USB Universal Serial Bus: An external bus standard that supports data
transfer rates of 12 Mbps.
VIP Vehicle Interface Port.
XiR Refers to Digital Professional Radio model names in the MOTOTRBO
Professional Digital Two-Way Radio System.
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Motorola Solutions Malaysia Sdn Bhd,(Co. No. 455657-H)

Plot 2 Bayan Lepas Technoplex Industrial Park
Mukim 12 S.W.D
11900 Penang, Malaysia
MOTOROLA, MOTO, MOTOROLA SOLUTIONS and

the Stylized M logo are trademarks or registered trademarks
of Motorola Trademark Holdings, LLC and are used under license.
All other trademarks are the property of their respective owners.
© 2012 Motorola Solutions, Inc. All rights reserved.
December 2012.
www.motorolasolutions.com/mototrbo
*68012003088*
68012003088-A

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All manuals and user guides at all-guides.

PROFESSIONAL DIGITAL TWO-WAY RADIO

Product Safety and RF Exposure Compliance

Computer Software Copyrights

Edition Description Date

68012003088-A Initial Release Dec. 2012

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

Warranty and Service Support.....................................................................xi

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

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

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

3.3.7 Audio Loopback Earpiece Test Mode.............................................................................. 3-9

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

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

Table of Contents vii

5.8.4 Vacuum Pump Kit NLN9839.......................................................................................... 5-31

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

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

Appendix A Replacement Parts & Kits ..................................................A-1

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

viii List of Figures

Figure 1-1. Full Keypad Model................................................................................................................ 1-2

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

Warranty and Service Support

Warranty Period and Return Instructions

After Warranty Period

xii Warranty and Service Support

1.1 Notations Used in This Manual

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

! CAUTION indicates a potentially hazardous situation which, if

Do NOT use any form of connector, e.g. wires, crocodile

1.2 Radio Description

Table 1-1. Radio Frequency Ranges and Power Levels

Frequency Band Bandwidth Power Level

VHF 136–174 MHz 3.5 Watt or 5 Watt

UHF 403–527 MHz 3.5 Watt or 4 Watt

1-2 Introduction: Radio Description

1.2.1 Full Display Model

Channel Selector Knob

Menu Navigation Key

Figure 1-1. Full Keypad Model

Introduction: Radio Description 1-3

1.2.2 Limited Display Model

Channel Selector Knob

Side Button 2 LCD

Menu Navigation Key

Figure 1-2. Limited Keypad Model

1-4 Introduction: Radio Description

• UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be

1.2.3 Non Display Model

Channel Selector Knob

Figure 1-3. Non Keypad Model

Introduction: Radio Description 1-5

1-6 Introduction: Portable Radio Model Numbering Scheme

1.3 Portable Radio Model Numbering Scheme

xy: Custom Housing

Figure 1-4. Portable Radio Model Numbering Scheme

Introduction: Model Charts 1-7

1.4 Model Charts