Related Manuals for Motorola Expert Series
Summary of Contents for Motorola Expert Series
- Page 1 EX500 ™ EX500 EX600 ™ EX600• • XLS • • EX600 ™ Expert Series Two-Way Radio Basic Service Manual...
- Page 2 SHOULD IMMEDIATELY RETURN THE PRODUCT IN ITS ENTIRETY TO ITS PLACE OF PURCHASE FOR A REFUND. Motorola grants to You a non-exclusive license to use the SOFTWARE in the manner described in the docu- mentation associated with the product. Motorola retains ownership of the SOFTWARE including all patent, copyrights, and other intellectual property rights.
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Page 3: Table Of Contents
Table of Contents Product Safety and RF Exposure Compliance ......v Chapter 1 Introduction Scope of Manual ....................1-1 Warranty and Service Support ................1-1 1.2.1 Warranty Period and Return Instructions ............1-1 1.2.2 After Warranty Period..................1-1 1.2.3 Piece Parts Availability ..................1-2 1.2.4 Technical Support .................... - Page 4 3.7.2 Speaker, Microphone, and Universal Connector Flex Reassembly ....3-10 3.7.3 Chassis Assembly Reassembly ................ 3-10 3.7.4 Chassis and Front Cover Reassembly.............. 3-10 EX600 / EX600•XLS Radio Disassembly and Reassembly — General ....3-11 EX600 / EX600•XLS Radio Disassembly — Detailed ..........3-12 3.9.1 Front Cover from Chassis Disassembly............
- Page 5 Chapter 7 Accessories Antennas ........................ 7-1 Carry Cases for EX500 / EX600 / EX600•XLS ............7-1 Chargers ....................... 7-2 Batteries ........................ 7-2 Audio Accessories....................7-2 Microphones......................7-2 Ear Microphone System..................7-2 Manuals ......................... 7-3 Chapter 8 Model Chart and Test Specifications 136-174 MHz......................
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Page 7: Product Safety And Rf Exposure Compliance
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 68P81095C98) to ensure compliance with RF energy exposure limits. For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which lists approved accessories: http://www.motorola.com/cgiss/index.shtml. - Page 8 Safety and General Information...
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Page 9: Chapter 1 Introduction
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. -
Page 10: Piece Parts Availability
Some replacement parts, spare parts, and/or product information can be ordered directly. If... It Means That... A complete Motorola part number is assigned to The part is available from AAD. the part, and it is not identified as Depot ONLY No part number is assigned The part is not normally available from Motorola. -
Page 11: Technical Support
Technical support is available to assist the dealer/distributor in resolving any malfunction which may be encountered. Initial contact should be by telephone to Customer Resources wherever possible. When contacting Motorola Technical Support, keep the product model number and the unit’s serial number handy. -
Page 12: Radio Model Information
Radio Model Information Radio Model Information The model number and serial number are located on a label attached to the back of your radio. You can determine the RF output power, frequency band, protocols, and physical packages. The example below shows one portable radio model number and its specific characteristics. Table 1-1: Radio Model Number (Example: AAH38KDC9AA3) Type of Model... -
Page 13: Intrinsically Safe Radio Information
WARNING: Do not disassemble an FMRC Approved Product unit in any way that exposes the internal electrical circuits of the unit. Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the field. -
Page 14: Repair Of Fmrc Approved Products
REPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL ARE THE RESPONSIBILITY OF THE USER. You should not repair or relabel any Motorola- manufactured communication equipment bearing the FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC Approval standard for repairs and service (“Class Number 3605”). -
Page 15: Do Not Substitute Options Or Accessories
Repair of FMRC Approved Products 2.2.3 Do Not Substitute Options or Accessories The Motorola communications equipment certified by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or options, or both. - Page 16 Repair of FMRC Approved Products Notes...
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Page 17: Chapter 3 Maintenance
Chapter 3 Maintenance 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 Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. -
Page 18: Safe Handling Of Cmos And Ldmos Devices
• Ground the working surface of the service bench to protect the CMOS 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. -
Page 19: Repair Procedures And Techniques - General
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 Communications parts center listed in section 1.2.3 on page 1-2 of this manual. -
Page 20: Disassembling And Reassembling The Radio - General
Philips head screwdriver If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. (See Chapter 1 for a list of authorized service centers.) The following disassembly procedures should be performed only if necessary: •... -
Page 21: Ex500 Radio Disassembly - Detailed
EX500 Radio Disassembly — Detailed EX500 Radio Disassembly — Detailed 3.6.1 Front Cover from Chassis Disassembly 1. Turn off the radio. 2. Remove the battery: Pull down on the two battery-release buttons. With the buttons pulled down, the top of the battery will fall from the radio. Remove the battery from the radio. - Page 22 EX500 Radio Disassembly — Detailed 5. Separate the chassis from the internal electronics front cover assembly as follows: Insert a small, flat blade screwdriver, or similar instrument, in between the thin retaining wall and the chassis at the bottom of the radio. Do not mar the O-ring sealing area on the housing.
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Page 23: Chassis Assembly Disassembly
EX500 Radio Disassembly — Detailed 7. Lift the latches on the main circuit board to release the flexes from their connectors. Flex Connector Latch Figure 3-4 Unlatch Flex Connectors 3.6.2 Chassis Assembly Disassembly Use a Philips head screwdriver to remove the four screws holding the main board to the chassis. M2x4 Philips screws Main Board O-ring Retainers on chassis... -
Page 24: Speaker, Microphone, And Universal Connector Flex Disassembly
EX500 Radio Disassembly — Detailed 3. Remove the O-ring. 4. Slide off the ground contact from the top corner boss of the radio chassis. 3.6.3 Speaker, Microphone, and Universal Connector Flex Disassembly 1. Turn the screw at the bottom of the dustcover counterclockwise with your fingers. Lift the dustcover out of its pocket. -
Page 25: Controller Board Disassembly
EX500 Radio Reassembly — Detailed 6. After the universal connector tail of the speaker-microphone assembly is removed, the assembly can be completely removed. If it is necessary to replace the speaker or microphone, or both, do it while the flex circuit is removed from the front cover. When reassembling the microphone in its boot, make sure the microphone port faces the round hole in the bottom of the boot. -
Page 26: Speaker, Microphone, And Universal Connector Flex Reassembly
3-10 EX500 Radio Reassembly — Detailed 3.7.2 Speaker, Microphone, and Universal Connector Flex Reassembly 1. Feed the universal connector stiffener of the speaker-microphone flex assembly through the opening in the side wall of the front cover. 2. Peel off the adhesive liner on the back of the universal connector stiffener of the flex circuit. Attach the flex stiffener to the front cover using the guide pins for correct alignment. -
Page 27: Ex600 / Ex600•Xls Radio Disassembly And Reassembly - General
• Torx T6 screwdriver If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. (See Chapter 1 for a list of authorized service centers.) -
Page 28: Ex600 / Ex600•Xls Radio Disassembly - Detailed
3-12 EX600 / EX600•XLS Radio Disassembly — Detailed The following disassembly procedures should be performed only if necessary: • Chassis Assembly Disassembly • Speaker, Microphone, and Universal Connector Flex Disassembly • Controller Board Disassembly • Control Top Disassembly EX600 / EX600•XLS Radio Disassembly — Detailed 3.9.1 Front Cover from Chassis Disassembly 1. - Page 29 EX600 / EX600•XLS Radio Disassembly — Detailed 3-13 4. Pull the volume and channel selector knobs off of their shafts. Knobs Figure 3-10 Knob Removal NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts. 5.
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Page 30: Chassis Assembly Disassembly
3-14 EX600 / EX600•XLS Radio Disassembly — Detailed 6. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis. 7. Lift the latches on the main circuit board to release the flexes from their connectors. Flex Connector Latch Figure 3-12 Unlatch Flex Connectors... -
Page 31: Speaker, Microphone, And Universal Connector Flex Disassembly
EX600 / EX600•XLS Radio Disassembly — Detailed 3-15 1. Lift the main board from the chassis (See Figure 3-5). CAUTION: Refer to the CMOS CAUTION paragraph on page 3-2 of this chapter before removing the main board. Be sure to use ESD protection when handling circuit boards. 2. - Page 32 3-16 EX600 / EX600•XLS Radio Disassembly — Detailed Flex Circuit Flex Circuit Speaker Speaker Microphone Slot for Top Notch (speaker) Speaker Catches Speaker Catches Figure 3-14 Removal Speaker-Microphone Assembly After the universal connector tail of the speaker-microphone assembly is removed, the assembly can be completely removed.
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Page 33: Controller Board, Display Module And Keypad Disassembly
EX600 / EX600•XLS Radio Disassembly — Detailed 3-17 3.9.4 Controller Board, Display Module and Keypad Disassembly 1. Insert a small flat bladed screwdriver to loosen the retainer catches as shown. Remove the retainer. 2. Remove the controller board, display module, and keypad. Figure 3-15 Removing the front cover Retainer Catches Retainer... -
Page 34: Control Top Disassembly
3-18 EX600 / EX600•XLS Radio Reassembly — Detailed 3.9.5 Control Top Disassembly 1. To remove the control top assembly, place a screwdriver next to the antenna boss, and pry it against the control top escutcheon. This will lift the control top escutcheon away from its double-sided adhesive. -
Page 35: Chassis And Front Cover Reassembly
EX600 / EX600•XLS Radio Reassembly — Detailed 3-19 3.10.4 Chassis and Front Cover Reassembly 1. Align the chassis assembly end-to-end with the front cover assembly. 2. Insert the tails of the flex circuits into their respective connectors at the bottom of the front cover. 3. -
Page 36: Mechanical Views And Parts Lists
3-20 Mechanical Views and Parts Lists 3.11 Mechanical Views and Parts Lists 3.11.1 EX500 Exploded View and Parts List Figure 3-18 EX500 Radio Exploded View... - Page 37 Mechanical Views and Parts Lists 3-21 Table 3-1 EX500 Radio Parts List Motorola Part Item Description Number See Chapter 7 Antenna JMLN4638_ Dust Cover 1385905Z01 Universal Connector Seal 0302020P03 Screw for Dust Cover HKLN4054 EX500 Name Plate 6102001P10 Light Pipe...
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Page 38: Ex600 / Ex600•Xls Exploded View And Parts List
3-22 Mechanical Views and Parts Lists 3.11.2 EX600 / EX600•XLS Exploded View and Parts List Figure 3-19 EX600 / EX600•XLS Radio Exploded View... - Page 39 Mechanical Views and Parts Lists 3-23 Table 3-2 EX600 / EX600•XLS Radio Parts List Motorola Part Item Description Number See Chapter 7 Antenna 3680529Z01 Volume Knob 3680530Z02 Channel Selector Knob 1386160Z01 Top Plastic Plate (EX600) 1386160Z02 Top Plastic Plate (EX600•XLS)
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Page 40: Service Aids
The recommended service aids for the EX500, EX600 and EX600•XLS radios are listed in Table 3-3. While all of these items are available from Motorola, most are standard shop equipment items and any equivalent item capable of the same performance may be substituted for the item listed. -
Page 41: Test Equipment
Test Equipment 3-25 3.13 Test Equipment Table 3-4 lists test equipment required to service the EX500, EX600 and EX600•XLS radios and other two-way radios. Table 3-4 Recommended Test Equipment Motorola Part No. Description Characteristics Application R2000, R2400, Service Monitor This monitor will... -
Page 42: Programming/Test Cable
3-26 Programming/Test Cable 3.14 Programming/Test Cable Figure 3-20 Programming/Test Cable Figure 3-21 Pin Configuration of the Side Connector... - Page 43 Programming/Test Cable 3-27 TO RADIO TO RADIO To RIB Box UNIVERSAL TEST SET To Test Box (25 position female connector) (25 position male connector) CONNECTOR RLN4460 EXT SPKR + AUDIO - EXT SPKR - AUDIO + EXT MIC MIC AUDIO OPT SEL 2 OPT SEL 1 RX DATA...
- Page 44 3-28 Programming/Test Cable Notes...
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Page 45: Transceiver Performance Testing
Chapter 4 Transceiver Performance Testing Introduction These radios have been manufactured to meet published specifications through their manufacturing process, with the use of laboratory-quality test equipment of highest accuracy. The recommended field service equipment approaches the accuracy of the manufacturing equipment with a few exceptions. -
Page 46: Test Mode
Test Mode Test Mode 4.3.1 RF Test Mode When the radio is operating in its normal environment, the radio’s microcontroller controls the RF channel selection, transmitter key-up, and receiver muting. However, when the unit is on the bench for testing, alignment or repair, it is removed from its normal environment. It cannot receive commands from its system and, therefore, the internal microcontroller will not key the transmitter nor unmute the receiver. - Page 47 Test Mode Table 4-3 Test Channel Spacing Channel Spacing 25 KHz 12.5 KHz 20 KHz Table 4-4 Test Frequencies Channel Selector Test Channel UHF1 UHF2 Switch Position 1 Low Power TX#1 or #8 136.025 403.025 450.025 8 High Power RX#1 or #8 136.025 403.025 450.025...
- Page 48 Test Mode Table 4-5 Receiver Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode: PWR MON TEST MODE, PTT to continuous Frequency error to be Frequency 4th channel test frequency* Test Channel 4 (during the ±200 Hz VHF Monitor: Frequency error carrier squelch performance...
- Page 49 Test Mode Table 4-6 Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be Frequency 4th channel test frequency* Test Channel 4 continuous ±200 Hz VHF Monitor: Frequency error carrier squelch (during the ±600 Hz UHF...
- Page 50 Test Mode Notes...
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Page 51: Radio Tuning And Programming
Chapter 5 Radio Tuning and Programming Introduction This chapter provides an overview of the Customer Programming Software (CPS) and Universal Tuner which have been designed for use in a Windows 95/98/NT/2000 environment. Both these software will cover all the functions of a traditional Radio Service Software (RSS) package. They are available in separate kits as shown below: Description Kit Number... -
Page 52: Cps Programming Setup
CPS Programming Setup Refer to the CPS online help for detailed tuning procedures. RF Adaptor Battery Service Monitor HLN9756 Eliminator or Counter T ransmit 7.5V Reg. 3.5 mm to JMKN4125 Ferrule BNC Wattmeter +12VDC Power Receive Radio 10 dB Pad Supply RF Generator Audio In... -
Page 53: Cloning Information
Cloning Information Cloning Information Cloning is the process of copying the content of one radio (source radio) into another radio (target radio). Radio content refers to system-type features such as frequency, squelch type options, trunking, etc. Cloning can be performed only on radios with identical model numbers and software options. - Page 54 Cloning Information Notes...
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Page 55: Power Up Self-Test
Reprogram the codeplug with the correct version and retest mismatch, non the radio. If the message recurs, replace the main board or existence of codeplug. send the radio to the nearest Motorola Depot. “EEPRM CS ERROR” Codeplug checksum is Reprogram the codeplug. - Page 56 Error Codes Notes...
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Page 57: Chapter 7 Accessories
Chapter 7 Accessories Antennas 136 -174 MHz, Ferrule Connector NAD6502_R 146-174 MHz, VHF Heliflex PMAD4012 136 - 155 MHz, 9cm Stubby Red Code PMAD4013 155 - 174 MHz, 9cm Stubby Black Code PMAD4014 136 - 155 MHz, 14cm Standard Length Red Code PMAD4015 155 - 174 MHz, 14cm Standard Length Black Code PMAD4023... -
Page 58: Chargers
Chargers Chargers AAHTN3000 120V Single Unit Rapid Charger, U.S. Plug w/English Manual AAHTN3003 Multi Unit Rapid Charger, U.S. Plug w/English Manual HTN9000 Single Unit Pocket Only NLN7967 Wall Mount Kit for Multi-Unit Charger Batteries JMNN4023_R Slim Li-Ion, 1000 mAh, 7.5V Battery JMNN4024_R Li-Ion, 1300 mAh, 7.5V Battery JMNN4025... -
Page 59: Manuals
Manuals BDN6769 Ear Microphone, Beige (for noise levels up to 95dB) - requires Interface Module BDN6770 Ear Microphone, Gray (for high noise levels up to 105dB) - requires Interface Module 0180300E83 Body Switch Push to Talk for Ear Microphone System 0180358B38 Finger Push to Talk Switch for Ear Microphone System Manuals... - Page 60 Manuals Notes...
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Page 61: Model Chart And Test Specifications
Chapter 8 Model Chart and Test Specifications 136-174 MHz EX500/EX600/EX600•XLS, VHF, 136-174 MHz Model Description • AAH38KDH9DU6_N EX600 XLS 136-174 MHz, LTR/Conv., 5W, 160 Ch. AAH38KDC9AA3_N EX500 136-174 MHz 5W 16CH AAH38KDH9AA6_N EX600 136-174 MHz 5W 128 CH Display/DTMF Item Description PMUD1673 EX500 Super Tanapa 136-174 MHz 5W 16CH... -
Page 62: 403-470 Mhz
403-470 MHz 403-470 MHz EX500/EX600/EX600•XLS, UHF Band 1, 403-470 MHz Model Description AAH38RDH9DU6_N EX600•XLS 403-470 MHz LTR/Conv. 4W 160CH AAH38RDC9AA3_N EX500 403-470 MHz 4W 16 CH AAH38RDH9AA6_N EX600 403-470 MHz 4W 128CH Display/DTMF Item Description PMUE1699 EX500 Super Tanapa 403-470 MHz 4W 16CH PMUE1700 EX600 Super Tanapa 403-470 MHz 4W 128CH PMUE1876... -
Page 63: 450-512 Mhz
450-512 MHz 450-512 MHz EX500/EX600/EX600•XLS, UHF Band 2, 450-512 MHz Model Description AAH38SDH9D46_N EX600•XLS 450-512 MHz LTR/Conv. 4W 160CH AAH38SDC9AA3_N EX500 450-512 MHz 4W 16 CH AAH38SDH9AA6_N EX600 450-512 MHz 4W 128CH Display/DTMF Item Description PMUE1701 EX500 Super Tanapa 450-512 MHz 4W 16CH PMUE1702 EX600 Super Tanapa 450-512 MHz 4W 128CH PMHE4004... -
Page 64: Specifications
Specifications Specifications General UHF 1 UHF 2 Frequency: 136-174 MHz 403-470 MHz 450-512 MHz Channel Capacity: EX500: 16 Channels/EX600: 128 Channels 7.5 Volts ±20% Power Supply: Dimensions Standard High Capacity Lithium Battery: 101.5mm x 55.5mm x 30.5mm Ultra High Capacity Lithium Battery: 101.5mm x 55.5mm x 35.5mm Weight: Standard High Capacity Lithium Battery:... - Page 65 Specifications Receiver UHF 1 UHF 2 12.5 kHz 20/25 12.5 kHz 20/25 12.5 kHz 20/25 Frequency 136-174 MHz 403-470 MHz 450-512 MHz 0.35 µV Sensitivity 12dB EIA SINAD: Adjacent Channel Selectivity ETS -60 dB -70 dB -60 dB -70 dB -60 dB -70 dB Intermodulation ETS...
- Page 66 Specifications Notes...
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Page 67: Glossary Of Terms
Minimum-Shift Keying OMPAC Over-Molded Pad-Array Carrier: a Motorola custom package, distinguished by the presence of solder balls on the bottom pads. Outbound Signaling Word: data transmitted on the control channel from the central controller to the subscriber unit. - Page 68 Term Definition Private-Line® tone squelch: a continuous sub-audible tone that is transmitted along with the carrier. Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider. Push-To-Talk: the switch located on the left side of the radio which, when pressed, causes the radio to transmit.
- Page 70 Motorola, The Sylized M logo, and Intelligence Everywhere are trademarks of Motorola, Inc. All other product or service names are the property of their respective owners. © 2002 Motorola, Inc. All rights reserved. Printed in U.S.A. *6881094C00* 68P81094C00-B...