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Motorola AAH38KDC9AA3 N, Basic Service Manual

The Motorola AAH38KDC9AA3 N is a versatile communication device designed for reliable and efficient performance. To fully leverage its features, make sure to refer to the included Basic Service Manual. You can easily download this comprehensive manual for free from manualshive.com, enhancing your user experience and maximizing the potential of your Motorola device.

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Audio Accessories

7-3

7.5

Audio Accessories

7.6

Microphones

7.7

Ear Microphone System

PLMN4519

Earbud with Microphone and PTT Combined, Transmit & Receive, 
Black (2-wire)

BDN6780

Earbud with Microphone and PTT Combined, Transmit & Receive, 
Black (2-wire) (EX500/EX600/EX600²XLS - requires PLMN4455 
adapter)

BDN6719

Flexible Ear Receiver, Black - Earpiece without Volume Control - 
(flexible earloop & speaker which rests external to ear) 
(EX500/EX600/EX600²XLS - requires PLMN4455 adapter)

BDN6781

Earbud, Receive Only, Black (single wire) 
(EX-500/EX600/EX600²XLS - requires PMLN4455 adapter)

NTN8370

Extreme Noise Earpiece Adapter Kit, Noise Reduction Rating = 24dB
(requires PMLN4455 adapter if used with BDN6667, BDN6729, 
BDN6668 & BDN6730)

NTN8371

Low Noise Earpiece Adapter Kit (clear comfortable earpieces can be 
added for extra comfort - must be ordered separately through AAD)
(requires PMLN4455 adapter for use with surveillance kits)

JMMN4073

Remote Speaker Microphone with Swivel Clothing Clip

PMLN4393

Flexible Ear Receiver with 2.5mm Plug (for use with Remote Speaker 
Microphone JMMN4073) - contains a flexible earloop and speaker 
which rests external to the ear

JMMN4064

Ear Microphone VOX/PTT Radio Interface Module

BDN6768

Ear Microphone, Black (for noise levels up to 95dB) - requires 
Interface Module

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

Summary of Contents for AAH38KDC9AA3 N

Page 1: ......

Page 2: ...part of the product not to rent lease or convey the SOFTWARE MOTOROLA SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF THIS SOFTWARE With respect to the U S Government if acquired under FAR policy 52 227 19 the SOFTWARE is provided with Restricted Rights and if acquired under DFARS policy 227 7202 then the SOFTWARE is provided only with the commercial rights of t...

Page 3: ...revious edition Edition Description Date 6881094C00 O Initial edition Mar 2001 6881094C00 B Updated model charts for UHF Band 1 UHF Band 2 and VHF bands for EX560 XLS Added Disassembly and Reassembly Mechanical View and Parts List for EX560 XLS Added Ensuring Radio Immersibility section Jan 2007 ...

Page 4: ...ii Notes ...

Page 5: ... Not Substitute Options or Accessories 2 3 Chapter 3 Maintenance 3 1 Introduction 3 1 3 2 Preventive Maintenance 3 1 3 2 1 Inspection 3 1 3 2 2 Cleaning Procedures 3 1 3 3 Safe Handling of CMOS and LDMOS Devices 3 2 3 4 Repair Procedures and Techniques General 3 3 3 5 Servicing IP67 radios 3 4 3 6 Disassembling and Reassembling the Radio General 3 4 3 7 EX500 Radio Disassembly Detailed 3 5 3 7 1 F...

Page 6: ...ssembly General 3 18 3 13 EX560 XLS Radio Disassembly Detailed 3 19 3 13 1 Front Cover from Chassis Disassembly 3 19 3 13 2 Chassis Assembly Disassembly 3 21 3 13 3 Speaker and Microphone Disassembly 3 22 3 13 4 Controller Board Display Module and Keypad Disassembly 3 22 3 13 5 Control Top Disassembly 3 24 3 14 EX560 XLS Radio Reassembly Detailed 3 24 3 14 1 Control Top Reassembly 3 24 3 14 2 Spea...

Page 7: ... 3 Test Mode 4 2 4 3 1 RF Test Mode 4 2 Chapter 5 Radio Tuning and Programming 5 1 Introduction 5 1 5 2 Radio Tuning Setup 5 1 5 3 CPS Programming Setup 5 2 5 4 Cloning Information 5 3 Chapter 6 Power Up Self Test 6 1 Error Codes 6 1 Chapter 7 Accessories 7 1 Antennas 7 1 7 1 1 EX500 EX600 EX600 XLS 7 1 7 1 2 EX560 XLS 7 1 7 2 Carry Cases 7 2 7 3 Chargers 7 2 7 4 Batteries 7 2 7 5 Audio Accessorie...

Page 8: ...500 EX600 EX600 XLS 8 1 8 1 2 EX560 XLS 8 2 8 2 403 470 MHz 8 3 8 2 1 EX500 EX600 EX600 XLS 8 3 8 2 2 EX560 XLS 8 4 8 3 450 512 MHz 8 5 8 3 1 EX500 EX600 EX600 XLS 8 5 8 3 2 EX560 XLS 8 6 8 4 Specifications 8 7 Glossary of Terms G 1 ...

Page 9: ...ety 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 NOTE Before using this product read the operating instructions for safe usa...

Page 10: ...viii Safety and General Information Notes ...

Page 11: ...s 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 warrant...

Page 12: ...ter hours or weekends 1 800 925 4357 Motorola Parts Accessories and Aftermarket Division United States and Canada Attention Order Processing 2200 Galvin Dr Elgin IL 60123 Parts Identification 1 800 422 4210 Menu 3 If It Means That A complete Motorola part number is assigned to the part and it is not identified as Depot ONLY The part is available from AAD No part number is assigned The part is not ...

Page 13: ...number and the unit s serial number handy For service contact one of the following Depots Please call and confirm your return before sending the unit to the depot for service Motorola Radio Support Center 3761 South Central Avenue Rockford IL 61102 4294 1 800 227 6772 1 815 489 1000 Motorola Toronto Service Center 400 Matheson Blvd W Mississauga Ontario Canada L5R 3M1 1 800 543 3222 1 416 756 5841...

Page 14: ... radio model number and its specific characteristics Table 1 1 Radio Model Number Example AAH38KDC9AA3 Type of Unit Model Series Freq Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package AA H 38 K VHF 136 174MHz D 4 5W C EX500 No display 9 Program mable AA Conven tional 3 EX500 A N R UHF1 403 470MHz H EX600 EX600 XLS Full Keypad with display DU LTR...

Page 15: ...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 WARNING Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualified for such use e g FMRC Approved An explosion or fire may result WARNING Do not operate an FMRC Approved Produc...

Page 16: ...the outer casing of the unit to be opened in a manner which exposes the internal electrical circuits of the unit You do not have to be an FMRC Approved Repair Facility to perform these actions 2 2 2 Relabeling The repair facility shall have a method by which the replacement of FMRC Approval labels are controlled to ensure that any relabeling is limited to units that were originally shipped from th...

Page 17: ... There must be no substitution of items even if the substitute has been previously Approved with a different Motorola communications equipment unit Approved configurations are listed in the FM Approval Guide published by FMRC or in the product FM Supplement This FM Supplement is shipped from the manufacturer with the FM Approved radio and battery combination The Approval Guide or the Approval Stan...

Page 18: ...2 4 Repair of FMRC Approved Products Notes ...

Page 19: ... housing assembly and battery case These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges grease and or grime 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 alcoh...

Page 20: ...tainer to prevent contamination by dissolved material from previous usage CAUTION 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 Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert CMOS devices into con ventional plastic ...

Page 21: ... solder will melt faster and require less heat to be applied to the circuit To replace a component on a flexible circuit 1 Grasp with seizers hemostats the edge of the flexible circuit near the part to be removed 2 Pull gently 3 Apply the tip of the soldering iron to the component connections while pulling with the seizers Chip Components Use either the RLN 4062 Hot Air Repair Station or the Motor...

Page 22: ...the shield on the circuit board using a pair of tweezers Position the heat focus head over the shield and lower it to approximately 1 8 above the shield Turn on the heater and wait for the solder to reflow Once complete turn off the heat raise the heat focus head and wait approximately one minute for the part to cool Remove the circuit board and inspect the repair No cleaning should be necessary 3...

Page 23: ...release buttons b With the buttons pulled down the top of the battery will fall from the radio c Remove the battery from the radio Figure 3 1 Battery Removal 3 Remove the antenna 4 Pull the volume and channel selector knobs off of their shafts Figure 3 2 Knob Removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts Battery Release Buttons Knobs ...

Page 24: ...Z01 down and prying the handle of the tool over and behind the base of the radio This prying action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs Figure 3 3 Chassis Removal 6 Lay the chassis down Rotate the front cover backward and slightly away from the chassis CAUTION Marring the front cover O ring sealing area will prevent the radio from sea...

Page 25: ... to the chassis Figure 3 5 Remove Main Board from Chassis 1 Lift the main board from the chassis See Figure 3 5 2 Remove the four small O ring retainers from their slots in the chassis Note the alignment of the CAUTION Before removing the board refer to the CMOS CAUTION paragraph on page 3 2 Be sure to use ESD protection when handling circuit boards Flex Connector Latch M2x4 Philips screws Main Bo...

Page 26: ...sive held backer board away from the front cover and remove the universal connector tail of the speaker microphone assembly through its opening in the front cover Figure 3 6 Removal of Speaker Microphone Assembly NOTE The dustcover must be removed to remove the speaker microphone assembly flex circuit The speaker is held in place with a two legged retainer bracket The bracket legs are secured by t...

Page 27: ...iver 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 Grab the double sided adhesive near the volume potentiometer and lift it away 2 Remove the control top seal emergency button and transmit light pipe 3 8 EX500 Radio Reassembly Detailed 3 8 1 Control Top Reassembly 1 Replace transmit light pipe co...

Page 28: ...rcuit board straight down on top of the chassis 7 Use a Philips head screwdriver size 0 to fasten the screws holding the main board to the chassis 8 Do not over torque Torque limit is 3 inch lbs 3 8 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 ...

Page 29: ...orx 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 The following disassembly procedures should be performed only if necessary Chassis Assembly Disassembly Speaker Microphone and Universal Connector Flex Disassembly Contro...

Page 30: ... electronics front cover assembly as follows a Insert a small flat bladed 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 Figure 3 9 Battery Removal Figure 3 10 Knob Removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts Battery Release B...

Page 31: ...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 Figure 3 11 Chassis Removal CAUTION Marring the front cover O ring sealing area will prevent the radio from sealing properly NOTE Flexible ribbon circuits flexes connecting the front cover assembly and the chassis pre vent you ...

Page 32: ... out of its pocket 2 Insert a flat bladed screwdriver in between the speaker and housing Then pull up the screwdriver to remove the speaker from the housing Figure 3 13 Remove Main Board from Chassis 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 NOTE The dustcover must be removed to ...

Page 33: ...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 3 10 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 NOTE The speaker microphone assembly flex circuit goes throu...

Page 34: ...ntroller board display module and keypad Figure 3 15 Removing the front cover Figure 3 16 Removing the retainer controller board display module and keypad from the radio body Flex Circuit Retainer Catches Retainer Controller Board Display Module Keypad Front Cover ...

Page 35: ...ff the adhesive liner on the speaker rubber 5 Align the top notch in the speaker at the twelve o clock position with the tab on the front cover See Figure 3 14 Push down the speaker until the two bottom notches fit into the catches on the housing 3 11 3 Chassis Assembly Reassembly 1 Slide on the ground contact if necessary on the top corner boss of the chassis 2 Replace the O ring The tabs on the ...

Page 36: ...disassembled and reassembled with the use of only four board to casting screws 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 Chassis opener Penknife size screwdriver Torx T6 screwdriver If a unit requires more complete testing or service than is customarily performed at the basic le...

Page 37: ...ery release buttons b With the buttons pulled down the top of the battery will fall from the radio c Remove the battery from the radio 3 Remove the antenna 4 Pull the volume and channel selector knobs off of their shafts Figure 3 18 Battery Removal Figure 3 19 Knob Removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts Battery Release Buttons Knobs ...

Page 38: ...r 6685666D01 down and prying the handle of the tool over and behind the base of the radio This prying action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs 6 Lay the chassis down Rotate the front cover backward and slightly away from the chassis Figure 3 20 Chassis Removal CAUTION Marring the front cover O ring sealing area will prevent the radi...

Page 39: ... holding the main board to the chassis 1 Lift the main board from the chassis See Figure 3 22 Figure 3 21 Unlatch Flex Connectors Figure 3 22 Remove Main Board from Chassis 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 Flex Connector Latch M2X4 Torx 6 Screws Main Board O ring Chassis...

Page 40: ...ousing 4 Pull the rubber microphone boot from its seated position Unless you are replacing the micro phone leave it in the boot 5 When reassembling the microphone in its boot make sure the microphone port faces the round hole in the bottom of the boot 3 13 4 Controller Board Display Module and Keypad Disassembly 1 Insert a small flat head screwdriver to loosen the retainer catches as shown Remove ...

Page 41: ...controller board display module and keypad Figure 3 24 Removing the Retainer from the Radio Body Figure 3 25 Removing the Keypad Retainer and Other Boards from the Radio Body Flat Head Screwdriver Keypad Retainer Controller Board Display Module Main Keypad ...

Page 42: ...eassembly 1 Replace the O ring The tabs on the O ring should reach around the chassis and point down 2 Stretch the O ring to place it into the retaining pocket at the bottom end of the chassis 3 Replace the battery contact seal if necessary surrounding the battery contact 4 Place the main circuit board straight down on top of the chassis 5 Use the Torx T6 screwdriver to fasten the screws holding t...

Page 43: ...ore operating otherwise the sound may be distorted until the water has evaporated or is dislodged from these areas 3 15 3 Specialized Test Equipment This section summarizes the specialized test equipment necessary for testing the integrity of EX560 XLS radios To ensure that the radio is truly a watertight unit special testing test procedures and specialized test equipment are required The special ...

Page 44: ... the pressure hose to the radio s chassis 3 15 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 Refer to Section Figure 3 30 EX560 XLS Radio Exploded View on page 3 35 3 15 7 Disassembly Disassemble the ...

Page 45: ...o chassis pump connector Screw the pump connector into the tapped hole in the chassis 3 Attach the open end of the hose to the pointed end of the pump connector 4 Place the radio on a flat surface with the chassis facing upward 5 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 1 in Hg or less for example fro...

Page 46: ... moisture is trapped inside the radio and prevent contamination of the internal electronics after reassembling the radio 3 15 11Troubleshooting 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 3 15 ...

Page 47: ...d ensure the O ring sits inside the chassis groove 7 Reassemble the chassis assembly followed by installing into Front Cover Refer to Section 3 14 EX560 XLS Radio Reassembly Detailed on page 3 24 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 3 15 11 3Battery Contact Seal To replace the Batt...

Page 48: ...ent Membrane and Breathing Vent Label 1 Remove the Breathing Vent Label that covers the Breathing Vent Membrane from the chas sis 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 mate rials 4 Install a new Breathing Vent Membrane covering th...

Page 49: ...Attach vacuum hose to vacuum pump 2 Ensure fitting seal is attached to hose to chassis pump connector 3 Screw pump connector into chas sis s tapped hole 4 Attach vacuum hose to pump connector 5 Place radio on flat surface 6 Operate pump gauge 6 in Hg 7 Observe gauge about 1 min Gauge falls more than 1 in Hg YES NO Run Pressure Test 1 Replace Breath ing Vent label and Breathing Vent Membrane 2 Radi...

Page 50: ...bles from Lens Univer salConnector chassis Housing Inter face PTT 1 Dry the radio 2 Replace Housing Main Seal O Ring Breathing Vent label and Breathing Vent Membrane YES 1 Remove Knobs and Antenna NO 1 Dry the radio 2 Replace Battery Contact Seal Main Seal O Ring Breathing Vent label and Breathing Vent Membrane 1 Dry the radio 2 Replace Main Seal O Ring Breathing Vent label and Breathing Vent Mem ...

Page 51: ...Views and Parts Lists 3 33 3 16 Mechanical Views and Parts Lists 3 16 1 EX500 Exploded View and Parts List Figure 3 29 EX500 Radio Exploded View 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 5 1 2 3 4 ...

Page 52: ...10 1302012P06 Top Plastic Plate 11 3385906Z01 Top Sheet 12 3202000P15 Control Top Seal 13 3502416P03 Speaker Mesh 14 Part of Item 7 PTT Rubber 15 Part of Item 7 PTT Plastic Cover 16 5005679X01 Speaker 17 1480577C01 Boot Microphone 18 8404079G01 Flex PCB Universal 19 See Chapter 8 Controller Board must order front cover kit 20 0385913Z01 4 M2X4 Philips Screws 21 0302020P05 1 M2X1 Philips Screws 22 ...

Page 53: ...Mechanical Views and Parts Lists 3 35 3 16 2 EX560 XLS Exploded View and Parts List Figure 3 30 EX560 XLS Radio Exploded View ...

Page 54: ...2L01 Metal Dome 20 See Chapter 8 Control Board 21 NIL Adhesive Lens 22 NIL Lens 23 7580540Z01 Pad LCD Front 24 5104949J20 LCD Display Module 25 3571525L01 Mesh Speaker 26 5086094Z02 Speaker 27 1416418H01 Boot Microphone 28 5013920A04 Microphone 29 NIL Flex UC 30 2113944F01 Capacitor 31 1405307X01 Insulator Kapton 32 4271514L02 Retainer Speaker 33 0386104Z03 Screws 34 4271526L01 Retainer Keypad 35 ...

Page 55: ...ws and Parts Lists 3 37 3 16 3 EX600 EX600 XLS Exploded View and Parts List Figure 3 31 EX600 EX600 XLS Radio Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 20 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 13 ...

Page 56: ...onnector 13 JMLN4638 Dust Cover 14 7580540Z01 LCD Front Pad 15 5104949J11 LCD Module 16 7586096Z01 Main Keypad 17 4086199Z01 Keypad Polydome 18 See Chapter 8 Controller Board must order front cover kit 19 8404078G01 Flex RF Controller 20 3586092Z01 Speaker Felt 21 1480577C01 Microphone Boot 22 5013920A04 Microphone 23 5086094Z01 Speaker 24 8486095Z01 Flex Universal Connector 25 4286097Z01 Keypad R...

Page 57: ...er radio to be duplicated by copying programmed data from the master radio to another compatible radio RLN4008 Radio Interface Box RIB Enables communications between the radio and the computer s serial communications adapter AAJMKN4125 Battery Eliminator Connects to radio via battery eliminator cable HHLN4134A BNC Adaptor Adapts radio s antenna port to BNC cabling of test equipment 5880348B33 BNC ...

Page 58: ...ge and current measurements S1100 Audio Oscillator 67 to 200Hz tones Used with service monitor for injection of PL tones S1053 SKN6009 SKN6001 AC Voltmeter Power Cable for meter Test leads for meter 1 mV to 300 V 10 Megaohm input impedance Audio voltage measurements R1053 Dual trace Oscilloscope 20 MHz bandwidth 5 mV cm 20 V cm Waveform measurements S1350 ST1215 VHF ST1223 UHF T1013 Wattmeter Plug...

Page 59: ...Programming Test Cable 3 41 3 19 Programming Test Cable Figure 3 32 Programming Test Cable Figure 3 33 Pin Configuration of the Side Connector ...

Page 60: ... INT EXT BOOT CTRL 1 4 15 25 11 GND BIAS BUS BOOT CTRL BUS 1 2 3 4 5 6 8 9 10 11 12 13 7 EXT SPKR EXT SPKR N C EXT MIC OPT SEL 2 OPT SEL 1 RX DATA TX DATA RSSI XMIT RX AUDIO BOOT CTRL N C GND P2 TO RADIO TEST SET RLN4460 P1 TO RADIO UNIVERSAL CONNECTOR J1 TO RIB RLN4008 10K To Test Box 25 position male connector To RIB Box 25 position female connector ...

Page 61: ...nnected from the battery eliminator The equipment required for alignment procedures is connected as shown in the Radio Tuning diagram Figure 5 1 on page 5 2 Initial equipment control settings should be as indicated in the following table and should hold for all alignment procedures except as noted in Table 4 1 Table 4 1 Initial Equipment Control Settings Service Monitor Test Set Power Supply Monit...

Page 62: ...will also hear a corresponding set of tones 4 Press SB1 to scroll through and access test environments as shown in Table 4 2 below 5 Press SB2 for 3 seconds in the Control Head Test mode to return to RF Test mode NOTE To access all 14 test modes on a 4 channel radio the frequency knob and mechanical stop sleeve must be removed see Exploded View diagrams in section 3 16 beginning on page 3 33 XX ch...

Page 63: ...325 142 325 415 025 415 025 462 850 462 850 3 Low Power 10 High Power TX 3 or 10 RX 3 or 10 148 625 148 625 425 025 425 025 475 675 475 675 4 Low Power 11 High Power TX 4 or 11 RX 4 or 11 154 925 154 925 436 025 436 025 488 500 488 500 5 Low Power 12 High Power TX 5 or 12 RX 5 or 12 161 225 161 225 449 025 449 025 501 325 501 325 6 Low Power 13 High Power TX 6 or 13 RX 6 or 13 167 525 167 525 460 ...

Page 64: ...lch PTT to OFF center meter selector to Audio PA Set volume control to 3 46Vrms Distortion As above except to distortion As above As above Distortion 5 0 Sensitivity SINAD As above except SINAD lower the RF level for 12dB SINAD As above PTT to OFF center RF input to be 0 35μ Noise Squelch Threshold only radios with conventional system need to be tested RF level set to 1mV RF As above PTT to OFF ce...

Page 65: ...4 0 kHz but 5 0 kHz 25 kHz Ch Sp Voice Modulation internal Mode PWR MON 4th channel test frequency atten to 70 input to RF In Out TEST MODE Test Channel 4 carrier squelch output at antenna Remove modulation input Press PTT switch on radio Say four loudly into the radio mic Measure deviation VHF UHF 4 0 kHz but 5 0 kHz 25 kHz Ch Sp High Speed Data Modulation As above TEST MODE Test Channel 4 high s...

Page 66: ...4 6 Test Mode Notes ...

Page 67: ...sonal computer and a Universal Tuner To perform the tuning procedures the radio must be connected to the PC RIB Radio Interface Box and Universal Test Set as shown in Figure 5 1 The Tuner for Version R02 03 0 or higher provides the capability for Temperature Compensation Data Programming as well as online instructional help text To read the Temperature Compensation Data 1 From the Menu select Util...

Page 68: ...ad Battery Block Power Supply Audio In Tx Rx Receive T ransmit RF Generator RF Adaptor HLN9756 RIB RLN4008 RIB Power Supply RLN4460 Test Box Rx Gnd Data Tx Data Radio Computer Interface Cable 3080369B72 Program Test Cable RKN4074 Service Monitor or Counter DB15 DB9 AC Plug 120 230 Vac 3 5 mm to Ferrule BNC JMKN4125 12VDC 0180305G54 Battery Eliminator 7 5V Reg RIB RLN4008 RIB Power Supply RLN4460 T...

Page 69: ... in the cloning process Unique IDs may be assigned with the CPS Unsuccessful cloning attempts will not damage the radio Cloning Procedure 1 Turn source and target radios off 2 Connect cloning cable to side connector of both radios 3 Turn on target radio 4 On source radio simultaneously press side buttons 1 and 2 buttons above and directly below PTT then turn radio on Both radios will produce a clo...

Page 70: ...5 4 Cloning Information Notes ...

Page 71: ...e message reoccurs replace the main board or send the radio to nearest Motorola Depot ROM CS ERROR ROM Checksum is wrong Reprogram FLASH Memory then retest If the message recurs replace the main board or send the radio to the nearest Motorola Depot EEPRM HW ERROR Codeplug structure mismatch non existence of codeplug Reprogram the codeplug with the correct version and retest the radio If the messag...

Page 72: ...6 2 Error Codes Notes ...

Page 73: ...MAD4023 150 161 MHz 14cm PMAD4025 150 161 MHz 9cm Stubby UHF 1 403 470 MHz Ferrule Connector PMAE4002 403 433 MHz PMAE4003 430 470 MHz Stubby NAE6483 403 520 MHz Whip UHF 2 450 512 MHz Ferrule Connector PMAE4006 470 510 MHz 9cm Helical PMAE4007 490 512 MHz 9cm PMAE4008 470 512 MHz Monopole Whip NAE6483 403 512 MHz Whip VHF 136 174 MHz NAD6566_ 136 150 8 MHz IP67 20cm NAD6567_ 150 8 162 MHz IP67 18...

Page 74: ...Carry Case with Fixed Swivel Clip D Rings For EX560 XLS Models Only PMLN5089A Nylon Carrying Case for Minnow IP67 Display Radio 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 PMLN5010A Minnow Waris Charger Insert For EX500 EX600 EX600 XLS Mo...

Page 75: ...6729 BDN6668 BDN6730 NTN8371 Low Noise Earpiece Adapter Kit clear comfortable earpieces can be added for extra comfort must be ordered separately through AAD requires PMLN4455 adapter for use with surveillance kits JMMN4073 Remote Speaker Microphone with Swivel Clothing Clip PMLN4393 Flexible Ear Receiver with 2 5mm Plug for use with Remote Speaker Microphone JMMN4073 contains a flexible earloop a...

Page 76: ...ide EX600 English French 6880309T53 User Guide EX560 XLS English French 6881095C10 User Guide EX600 XLS English French 6881094C00 EX500 EX600 EX560 XLS EX600 XLS Service Manual Level 1 and 2 Basic English 6881094C21 EX500 EX600 EX560 XLS EX600 XLS Service Manual Level 3 Detailed English ...

Page 77: ...C Kit 136 174 MHz 5W 16CH X PMHD4006 EX600 B C Kit 136 174 MHz 5W 128CH X PMHD4015 EX600 XLS B C Kit 136 174 MHz 5W 160CH X PMHD4000 EX500 Front Housing Kit 16CH X PMHD4001 EX600 Front Housing Kit 128CH Display DTMF X PMHD4013 EX600 XLS Front Housing Kit 160CH Display DTMF X X X PMAD4012 Antenna 136 155 MHz Stubby X X X PMAD4013 Antenna 155 174 MHz Stubby X X X PMAD4014 Antenna 136 155 MHz 14 cm X...

Page 78: ...37_ EX560 XLS Super Tanapa 136 174 MHz 5W 160CH IP67 X PMHD4031_ EX560 XLS B C Kit 136 174 MHz 5W 160CH IP67 X PMHD4044_ EX560 XLS Front Housing Kit 160CH IP67 X NAD6566_ Antenna 136 150 8 MHz IP67 X NAD6567_ Antenna 150 8 162 MHz IP67 X NAD6568_ Antenna 162 178 MHz IP67 X 6880309T53 EX560 XLS User Guide English French x Indicates one of each is required ...

Page 79: ...03 470 MHz 4W 160CH X JMHE4001 EX500 B C Kit 403 470 MHz 4W 16CH X PMHE4010 EX600 B C Kit 403 470 MHz 4W 128CH X PMHD4016 EX600 XLS B C Kit 403 470 MHz 4W 160CH X PMHE4000 EX500 Front Housing Kit 16CH X PMHE4001 EX600 Front Housing Kit 128CH Display DTMF X PMHE4018 EX600 XLS Front Housing Kit 160CH Display DTMF X X X NAE6483 Monopole Whip antenna 403 470 MHz X X X PMAE4002 UHF 9 cm antenna 403 433...

Page 80: ... 160CH LKP IP67 Item Description X PMUE2782_ EX560 XLS Super Tanapa 403 470 MHz 4W 160CH IP67 X PMHE4042_ EX560 XLS B C Kit 403 470 MHz 4W 160CH IP67 X PMHE4061_ EX560 XLS Front Housing Kit 160CH IP67 X PMAE4022_ Antenna 403 470 MHz IP67 X 6880309T53 EX560 XLS User Guide English French x Indicates one of each is required ...

Page 81: ...011 EX600 B C Kit 450 512 MHz 4W 128CH X PMHE4002 EX500 Front Housing Kit 16CH X PMHE4003 EX600 Front Housing Kit 128CH Display DTMF X X NAE6483 Monopole Whip antenna 403 470 MHz X X PMAE4008 Monopole Whip antenna 470 512 MHz X X PMAE4006 UHF 9 cm antenna 465 495 MHz X X PMAE4007 UHF 9 cm antenna 490 512 MHz X 6881093C98 EX500 User Guide English French X 6881094C70 EX600 User Guide English French ...

Page 82: ... 160CH LKP IP67 Item Description X PMUE2783_ EX560 XLS Super Tanapa 450 512 MHz 4W 160CH IP67 X PMHE4047_ EX560 XLS B C Kit 450 512 MHz 4W 160CH IP67 X PMHE4062_ EX560 XLS Front Housing Kit 160CH IP67 X PMAE4025_ Antenna 450 527 MHz IP67 X 6880309T53 EX560 XLS User Guide English French x Indicates one of each is required ...

Page 83: ...uty Cycle Standard High Capacity Lithium Battery Ultra High Capacity Lithium Battery IP67 Li ion Battery Low Power 10 hrs 14 hrs 14 hrs High Power 7 hrs 10 hrs 10 hrs Sealing IP67 Radios Others Meets MIL STD 810 C D E F and IPX7 Meets MIL STD 810 C D E and IPX4 Shock IP67 Radios Others Meets MIL STD 810 C D E F and TIA EIA 603 Meets MIL STD 810 C D E and TIA EIA 603 Vibration IP67 Radios Others Me...

Page 84: ...rs Harmonics 36 dBm 1GHz 30 dBm 1 GHz Audio Response from 6 dB oct Pre Emphasis 300 to 3000Hz 1 3 dB Audio Distortion 1000 Hz 60 Rated Max Dev 5 FM Noise 40 dB Receiver VHF UHF 1 UHF 2 12 5 kHz 20 25 kHz 12 5 kHz 20 25 kHz 12 5 kHz 20 25 kHz Frequency 136 174 MHz 403 470 MHz 450 512 MHz Sensitivity 12dB EIA SINAD 0 35 mV Adjacent Channel Selectivity ETS 60 dB 70 dB 60 dB 70 dB 60 dB 70 dB Intermod...

Page 85: ...from a subscriber unit to the central control unit LCD Liquid Crystal Display a module used to display the radio s current operating channel or system and scan status LH DATA Longhorn Data a bidirectional 0 5V RS 232 line that uses the Microcontroller s integrated RS 232 asynchronous serial communications interface SCI peripheral LLE Low Level Expander slight amount of volume expansion used to imp...

Page 86: ...table electronic attenuator Software Computer programs procedures rules documentation and data pertaining to the operation of a system SPI clock and data lines Serial Peripheral Interface how the Microcontroller communicates to modules and ICs through the CLOCK and DATA lines Squelch Muting of audio circuits when received signal levels fall below a pre determined value Standby Mode An operating mo...

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