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.
Table of Contents Foreword ......................ii Product Safety and RF Exposure Compliance ............... ii Computer Software Copyrights..................ii Document Copyrights ..................... ii Disclaimer ........................ii Trademarks........................ii List of Figures ....................ix List of Tables ....................xi Chapter 1 Introduction ....................1-1 1.1 Scope of Manual....................1-1 1.2 Warranty and Service Support................
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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 ..........3-2 3.5 Disassembling and Reassembling the Radio — General ........3-3 3.6 Detailed Radio Disassembly ................3-4 3.6.1 Front Cover from Chassis Disassembly ........... 3-4 3.6.2 Chassis Assembly/Disassembly...............
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3.8.16 HT1550•XLS Exploded View Parts List ..........3-30 3.8.17 MTX950 Exploded View................. 3-31 3.8.18 MTX950 Exploded View Parts List............3-32 3.8.19 MTX9250 Exploded View............... 3-33 3.8.20 MTX9250 Exploded View Parts List............3-34 3.9 Service Aids...................... 3-35 3.10 Test Equipment....................3-36 3.11 Configuring and Wiring the Programming/Test Cable ........
LIST OF TABLES Table 1-1: Radio Model Number (Example: AAH25KDC9AA3AN)......1-4 Table 3-11: Service Aids ................... 3-35 Table 3-12: Recommended Test Equipment ............3-36 Table 4-1: Test Environments (Side Button 1) ............4-4 Table 4-2: Test Environments (Models with “G” in location 10 of model number EX: AAH25RCH6GB6AN) ................
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.
*The Customer Care and Services Division (CCSD) was formerly known as the Accesso- ries and Aftermarket Division (AAD). Motorola Online: Motorola Online users can access our online catalog at https://www.motorola.com/businessonline To register for online access, please call 800-814-0601. Mail Orders:...
For service, contact the Service Depot in your area. If your area does not have a depot, please contact your Business Development Manager, Distributor, or contact Motorola Technical Support. When contacting Motorola Technical Support, keep the product model number and the unit’s serial number handy.
Introduction 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: AAH25KDC9AA3AN) Type of Model...
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 Intrinsically Safe, hazardous atmosphere capability and FM Approval labeling. Radios will not be “upgraded” or converted to Intrinsically safe, and or labeled in the field, after it has been shipped from the manufacturing location.
Intrinsically Safe Radio Information Modifications can only be made by the original product manufacturer (Motorola) at one of its FM audited manufacturing facilities. • Failure to use an FMRC Approved portable radio unit with an FMRC Approved battery or FMRC Approved accessories...
Intrinsically Safe Radio Information 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. This FM Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit.
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Intrinsically Safe Radio Information Notes...
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 Installation of Optional Retrofit Kit Installation of Option Boards Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...
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 the “Piece Parts” section of this manual...
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, section 1.2.4 Technical Support on page 1-3 for a list of authorized service centers.) The following disassembly procedures should be performed only if necessary: section 3.6.2 Chassis Assembly/Disassembly on page 3-6...
Maintenance Detailed Radio Disassembly 3.6.1 Front Cover from Chassis Disassembly 1. Turn off the radio. 2. Remove the battery: a. Pull down on the two battery-release buttons. b. With the buttons pulled down, the top of the battery will fall from the radio. c.
Maintenance 4. Separate the chassis from the internal electronics front cover assembly as follows: a. Insert a small, 3/16” flat-blade screwdriver, or similar instrument, in between the thin remaining wall and the chassis at the bottom of the radio. Do not mar the O-ring sealing area on the housing.
Maintenance NOTE: At this point, if necessary, the DTMF Retrofit Kit Procedure can be performed. (See section 3.7.7 DTMF Retrofit Kit Procedure (Optional Upgrade Procedure) on page 3-12). 3.6.2 Chassis Assembly/Disassembly 1. If disassembly of the chassis or the main board is required, then use a TORX™ screwdriver with a T6 head to remove the four screws holding the main board to the chassis.
Maintenance 3. To remove the keypad retainer shield: a. Insert the tip of a “penknife size,” flat blade screwdriver in the opening at the end of the keypad retainer arm tab. b. Pry the tab away from the side of the front cover until it moves past the ledges on the side wall.
Maintenance Retainer Display Module Keypad Option Board Keypad Radio Body Figure 3-5: Removing the Keypad Retainer and Other Boards from the Radio NOTE: At this point, the Option Board Installation Procedure should be performed, if necessary. (See page 3-13) 3.6.4 Speaker, Microphone, and Universal Connector Flex Disassembly 1.
Maintenance 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.
3-10 Maintenance Detailed Radio Reassembly 3.7.1 Control Top Reassembly 1. Replace transmit light pipe and control top seal. 2. Peel off the liners from a new control top escutcheon and place it in the recess in the front cover. Press the control top escutcheon firmly against the adhesive. 3.7.2 PTT Reassembly 1.
Maintenance 3-11 Catches Retainer Figure 3-8: Lock Retainer Catches to the Radio’s Body 3.7.5 Chassis Assembly Reassembly 1. Slide on the ground contact (if it was removed) on the top corner boss of the chassis. 2. Replace the O-ring. The tabs on the O-ring should reach into the chassis and point down. 3.
3-12 Maintenance 8. Reassemble the knobs, dust cover, antenna, and battery. Radio Chassis Figure 3-9: Fastening the Chassis 3.7.7 DTMF Retrofit Kit Procedure (Optional Upgrade Procedure) If you are performing an upgrade from a basic model to a DTMF model, replace the existing front cover kit with kit number HLN9984 and follow the reassembly steps to reassemble the upgraded radio.
Maintenance 3-13 NOTE: The CPS may display a warning dialog box when you attempt to write the codeplug back to the radio. It is safe to ignore this warning. Press the OK button. 3.7.8 Option Board Installation 1. With the keypad retainer removed the keypad backer board can be removed without the use of tools.
3-30 3.8.16 HT1550•XLS Exploded View Parts List Table 3-8. HT1550•XLS Parts List (Continued) Table 3-8. HT1550•XLS Parts List Motorola Part Item Description Number Motorola Part Item Description Number 6062884K01 Backup Battery See Section 7 in Antenna 0304726J04 Screw manual 3980667Z01...
Table 3-11 lists service aids recommended for working on the HT750/HT1250/HT1250•LS/ HT1250•LS /HT1550•XLS/MTX850/MTX950/MTX850•LS/MTX8250/MTX9250/MTX8250•LS radios. NOTE: 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.
3-36 Test Equipment 3.10 Test Equipment Table 3-12 lists test equipment required to service the HT750/HT1250/HT1250•LS/HT1250•LS HT1550•XLS/MTX850/MTX950/MTX850•LS/MTX8250/MTX9250/MTX8250•LS radios. Table 3-12:Recommended Test Equipment Motorola Part Description Characteristics Application R2000, R2600 Service Monitor This monitor will Frequency/deviation meter and sig- R2400, or R2001...
Configuring and Wiring the Programming/Test Cable 3-37 3.11 Configuring and Wiring the Programming/Test Cable Block Figure 3-22: Programming/Test Cable AARKN4074 Figure 3-23: Pin Configuration of the Cable Side Connector...
3-38 Configuring and Wiring the Programming/Test Cable TO RADIO TO RADIO UNIVERSAL TEST SET CONNECTOR RLN4460 EXT SPKR + AUDIO - EXT SPKR - AUDIO + OPTION B+ EXT MIC MIC AUDIO OPT SEL 2 OPT SEL 1 RX DATA VOL CTRL TX DATA DISC...
Chapter 4 Transceiver Performance Testing 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.
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Transceiver Performance Testing 8. Press ‘side button 1’ at the end of the Icon Test to activate the button test. Pressing any side button (except ‘side button 1’), or any keypad button during the LCD test or Icon test immediately activates this test. A good button press is verified by a chirp. 9.
Transceiver Performance Testing Annunciators Figure 4-3: Two-Line Display Annunciators Test Mode Information, Line 2 Figure 4-4: Four-Line Display (HT1550 XLS) • Table 4-1: Test Environments (Side Button 1) Number of Side No. of Display Description Function Button 1 Beeps Shows Presses Initial (No but- Carrier...
Transceiver Performance Testing Table 4-2: Test Environments (Models with “ ” in location 10 of model number EX: AAH25RCH6GB6AN) Item No. of Description Function Beeps Carrier Squelch RX: unsquelch if carrier detected TX: mic audio Tone RX: unsquelch if carrier and tone (192.8Hz) detected Private-Line TX: mic audio + tone (192.8Hz) Digital...
Transceiver Performance Testing Test Frequencies for Display and Non-Display Radios The radio channels and test frequencies are listed in Table 4-4. The channels are selected using the channel selector switch located on top of the radio, as shown in Figure 4-1 on page 4-3. The test environment and channel spacing for any particular frequency is selected using ‘side buttons 1 and 2’, as listed in Table 4-1 on page 4-4 and Table 4-2 on page 4-5.
Transceiver Performance Testing Receiver Performance Tests The receiver and transmitter performance tests are contained in Table 4-5 and Table 4-6 respectively. Refer to Chapter 5, Figure 5-1 on page 5-2, for test equipment setup. Note that all test measurements ° °...
Transceiver Performance Testing Table 4-6: Transmitter Performance Checks (Models with ”G” in location 10 of model number EX:AAH25RDH9GB6AN) Test Service Monitor Radio Test Set Comments Name Reference Mode: PWR MON TEST MODE, PTT to continu- Frequency error Frequency 4th channel test frequency* Test Channel ous (during the ±200 Hz VHF...
Chapter 5 Radio Tuning, Programming, Cloning, Lowband Antenna Cutting Procedure, PassPort Tone Options, and Diagnostic Functions Introduction This chapter provides an overview of the Customer Programming Software (CPS) and tuner program designed for use in a Windows NT, Windows 95, Windows 98, Windows 2000, and Windows ®...
Figure 5-1: Radio Tuning Test Equipment Setup 5.2.1 Initial Test Equipment Setup The supply voltage is connected to the radio using a Motorola battery eliminator, P/N AA0180305G54. The initial test equipment (Figure 5-1) control settings are listed in Table 5-2.
Radio Tuning, Programming, Cloning, Lowband Antenna Cutting Procedure, PassPort Tone Options, and Diagnostic Functions CPS Programming Setup The CPS programming setup, shown in Figure 5-2, is used to program the radio codeplug. NOTE: Refer to appropriate program on-line help files for the codeplug programming procedures. Radio Test Box Battery...
Radio Tuning, Programming, Cloning, Lowband Antenna Cutting Procedure, PassPort Tone Options, and Diagnostic Functions source radio produces a “clone-exit” tone and displays “Clone Complete”. 7. Turn both radios off. 8. Disconnect the cloning cable from both radios and turn them on for normal operation. On/Off Knob Side Button 1...
Radio Tuning, Programming, Cloning, Lowband Antenna Cutting Procedure, PassPort Tone Options, and Diagnostic Functions WARNING: Do NOT turn off the radio or disconnect it from the computer while attempting to PROGRAM the codeplug. Interrupting the programming process WILL DESTROY the code- plug contents and completely DISABLE the radio W A R N I N G Procedure:...
11 9/16 (29.369 cm) 11 7/16 (29.052 cm) 4. To replace the antenna cap, put a small bead NOTE: of #414 Loctite™ (Motorola part number 1110019B59) 10 5/8 (26.988 cm) Antenna length 10 (25.400 cm) around the inside walls of the antenna cap. Place measured from 9 3/8 (23.813 cm)
Radio Tuning, Programming, Cloning, Lowband Antenna Cutting Procedure, PassPort Tone Options, and Diagnostic Functions HT1250 PassPort Tone Options • In order to provide more detailed information about the radio’s state to a user or service technician various Tones and Display options are available. One Tone option is a short low pitched tone that sounds whenever the radio loses contact for any reason with its registered PassPort site and begins to search for another site.
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Radio Tuning, Programming, Cloning, Lowband Antenna Cutting Procedure, PassPort Tone Options, and Diagnostic Functions the “*” key for the decimal point, enter the desired Search Frequency in MHz. Press the Select key when the entry is complete or the Escape/Exit Key to exit the function without entering a search frequency.
Chapter 6 Power Up Self-Test Error Codes - Conventional and LTR Radios Turning on the radio starts a self-test routine that checks the RAM, ROM checksum, EEPROM hardware, and EEPROM checksum. If these checks are successful, the radio generates two high- pitched self-test pass tones, or a musical tone (selected in CPS).
Power Up Self-Test Error Codes - Privacy Plus At power-up, the radio performs cursory tests to determine if its basic electronics and software are in working order. Problems detected during these tests are presented as error codes on the radio display.
Power Up Self-Test Error Codes - PassPort For the purpose of this document the phrase “PassPort Trunking Controller Board” and its acronym “PTCB” are used. Table 6-3: Power-up Display Codes (PassPort Trunking Controller Board) If the error code then, there is To correct the problem...
Accessories 7.1.2 Carrying Accessories All Models/All Battery Chemistries: HLN9952 Carry Holder, Belt Clip-One size fits all HLN9714 Spring 2-1/2” Belt Clip HLN9701 Nylon Carry Case with Beltloop 7.1.3 Carry Cases HT750, MTX850, MTX950, Ultra-High and High Capacity Battery Carry Cases MTX850•LS (Standard Model Only) HLN9665 Standard Leather Case, Beltloop...
Accessories 7.1.4 Chargers AAHTN3000 120V Rapid Rate Single Unit Charger Kit, U.S. 3-Prong Plug (includes Xfmr, pocket, spacer, model box, and NA/LA manual) HTN9000 Rapid Rate Single Unit (Pocket Only) 25-04548T05 120V Transformer Only AAHTN3003 120V Multi-Unit Rapid Rate Charger, U.S. 3-Prong Plug (includes line cord and NA/LA manual) NLN7967 Wall Mount Kit for Multi-unit Charger...
Accessories 7.1.11 Option Boards (All option boards below are not compatible with HT1550•XLS) AAHLN9729 DTMF Decode Option Board with Manual (Field Install Only) 6881088C24 DTMF Decode Installation Sheet AAHLN9725 Voice Storage Option Board with Manual 6881088C22 Voice Storage User Manual AAENLN4150 Mandown board for HT1250 All option boards include the installation user manual.
Model Chart and Test Specifications UHF 403–470 MHz (Conventional/LTR) HT Series, UHF, 403–470 MHz (Conventional/LTR) Model Description AAH25RDN9DU8_N HT1550•XLS, 403-470 MHz, 4 Watt, 160 Channel Item Description X PMLE4215 HT1550•XLS Back Cover Kit (403-470 MHz) X PMLN4218 HT1550•XLS Front Housing Kit X NAE6483 Whip Antenna (403-520 MHz) X 6881093C95...
Model Chart and Test Specifications UHF 450–512 MHz (Conventional/LTR) HT Series, UHF, 450–512 MHz (Conventional/LTR) Model Description AAH25SDN9DU8_N HT1550•XLS, 450-512 MHz, 4 Watt, 160 Channel Item Description X PMLE4216 HT1550•XLS Back Cover Kit (450-512 MHz) X PMLN4218 HT1550•XLS Front Housing Kit X NAE6483 Whip Antenna (403-520 MHz) X 6881093C95...
Low Level Expander: slight amount of volume expansion; used to improve the signal to noise ratio. Low-Speed Handshake: 150 baud digital data sent to the radio during trunked operation while receiving audio. Trunked signaling protocol using low speed data. Registered trademark of E.F. Johnson Company. Motorola Digital Communication.
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Glossary-2 MRTI Motorola Radio-Telephone Interconnect: a system that provides a repeater connection to the Public Switched Telephone Network (PSTN). The MRTI allows the radio to access the telephone network when the proper access code is received. Minimum-Shift Keying. OMPAC Over-Molded Pad-Array Carrier: a Motorola custom package, distinguished by the presence of solder balls on the bottom pads.
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Glossary-3 Standby Mode An operating mode whereby the radio is muted but still continues to receive data. System Central Main control unit of the trunked dispatch system; handles ISW and OSW Controller messages to and from subscriber units (see ISW and OSW). System Select The act of selecting the desired operating system with the system-select switch (also, the name given to this switch).