PRO5350™

PRO5450™
PRO7350™

Professional Radio
Portable Radios
PRO Series™
Portable Radios

contact

contact

control control
C
A, Motorola, Professional Radio, PRO Series and PRO
Model numbers are marks of Motorola. LTR¨ is a registered
trademark of E.F. Johnson Company. Transcrypt¨ is a regis-
tered trademark of Transcrypt International, Inc. PassPort¨
is a registered trademark of Trident Microsystems, Inc.
© 2000 Motorola, Inc. All rights reserved. Printed in USA.
Basic
*6881088C45* Service Manual
68P81088C45-C
 MANUAL REVISION
¨
Professional Radioª
6881088C45-C
PRO Series
Basic Service Manual

This revision outlines changes that have occurred since the printing of your manual. Use this information to supple-
ment your manual. Installation of these changes in earlier equipment is not necessary except as recommended in
Motorola Service and Repair Notes (SRNs)

REVISION CHANGE:

Please use the following updated pages in place of the existing pages in your basic service manual. The table that
follows lists the pages attached to this FMR and their related basic service manual chapters along with a descrip-
tion of each change.

Discontinue Replace These Basic Service Manual

Using Manual Pages with FMR 6881088C45-C Chapter Description
Pages ... Pages... Number
1-4 1-4 1 Radio Model Information.
3-15, 3-16, 3-15, 3-16, 3 Exploded Mechanical View and
3-19, & 3-20 3-19, & 3-20 Parts List and Service Aids.
5-1 5-1 5 Software Installation Kits.
8-1 through 8-7 8.1 through 8.5 8 Model Charts
(Sections 8.1
through 8.10)

*FMR-1978A-1*
FMR-1978A-1
© 2000 by Motorola, Inc.
8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322 11-7-00
Printed in U. S. A. November, 2000. All Rights Reserved.
 This page intentionally left blank

November, 2000 2 FMR-1978A-1

Radio Model Information 1-4

1.3 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 speciÞc characteristics.

Table 1-1. Radio Model Number

Example: LAH25KDC9AA3
Type of Model Freq. Power Physical Channel Feature Model Model
Protocol
Unit Series Band Level Packages Spacing Level Revision Package

AA H 25 K C C 9 AA 2 A N
or VHF 2.5W No Display Program- Conventional 4F
LA (136- mable
H = Portable

174MHz)
AA or LA = Motorola Internal Use

R D D 6 DU 3
UHF1 4-5W Keypad 25kHz LTR 16F
(403-
470MHz)
S E H CK 6
UHF2 6W 1-Line Dis- MPT 128F
(450- play 256F LTR
527MHz)
B N GB 8
Low 4-Line Dis- Privacy Plus 160F
Band, R1 play
(29.7-
42.0MHz)
C GE
Low Privacy Plus
Band, R2 Roaming
(35.0-
50.0MHz)
U FC
800MHz Smart Zone
(806-824)
(851-869)
PRO5X50 Radio Exploded Mechanical View and Parts List 3-15

3.8 PRO5X50 Radio Exploded Mechanical View and Parts List

Ite Motorola Description Ite Motorola Description Ite Motorola Description
1 Please refer to Antenna HHLN4154A Nameplate, PRO5550 (Extended 21 5013920A04 Microphone
section 7.1 on Privacy Plus) 22 8480549Z01 Flex, Speaker-Microphone
page 7-1 HHLN4156A Nameplate, PRO5650 (Extended w/ 23 2113740A41 Capacitor, 33pF
1 2 3680529Z01 Knob, Volume Roaming) 24 4280504Z01 Retainer, Speaker
3 3680530Z02 Knob, Channel Selector HHLN4158A Nameplate, PRO5750 (Smart Zone) 25 0304726J04 Screw
3a 4285611Z01 Stop, Mechanical (4-Channel) 9 1586059A01 Dust Cover, Universal Connector 26 See detailed Ctrl/RF Board Assembly
4 1380525Z01 Escutcheon, Top 10 1386058A01 Escutcheon, Universal Flex service manual
4a 1380525Z04 Escutcheon, Top (4-Channel) 11 1580666Z03 Front Cover, Basic 27 8480475Z02 Flex, Keypad/Controller
5 3380644Z01 Escutcheon, Label 1580666Z04 Front Cover with Keypad (DTMF) 28 1480652Z01 Insulator, Antenna
2 12 Not Field Escutcheon, FM
6 3280533Z01 Seal, Control Top 29 7580556Z01 Pad, Thermal
Replaceable
7 6180527Z01 Litepipe, Tx 30 3280534Z01 Seal, Contact
3 13 7580532Z01 Keypad, Side Control
8 HLN9965A Nameplate, PRO5150 (Used with 31 3280536Z01 Gasket, O-Ring
Retro-Fit) 14 1380528Z01 Bezel, Side Control
32 3980698Z01 Contact, Ground, Compliant, VHF
3a HLN9995A Nameplate, PRO5150 (Wide) 15 7580620Z03 Keypad, Blank
33a 2780518Z01 Chassis
7580620Z04 Keypad, Full
HLN9987A Nameplate, PRO5150 (DTMF Retro- 33b 2780518Z03 Chassis
4 4a Fit) 16 0104007J99 Keypad Board Assembly
34 See section 7.5 Battery
5 HLN9966A Nameplate, PR5350 (Used with 17 4280498Z01 Retainer, Keypad PCB
on page 7-3
Retro-Fit) 18 3586057A01 Felt Speaker
35 HLN9714 Beltclip
6 HLN9996A Nameplate, PRO5350 (Wide) 19 1480577C01 Boot, Microphone
HLN9967A Nameplate, PRO5450 (MPT) 20 5085962A02 Speaker
7
14

8 13

15 18
16 20 800 MHz Only
24

26
800 MHz Only
28 30
31 33b
32
33a
11 34
19
9 12 21
35
10 17
23
22 25

PRO5X50 Exploded
View and Parts List
27
29
3-16 PRO7X50 Radio Exploded Mechanical View and Parts List

3.9 PRO7X50 Radio Exploded Mechanical View and Parts List

Motorola Motorola Motorola
Ite Ite Ite
Part Description Part Description Part Description
m m m
Number Number Number
1 Please refer to Antenna 11 1580666Z01 Front Cover with DTMF 26 2113740A41 Capacitor, 33pF
1 section 7.1 on 1580666Z02 Front Cover without DTMF 27 4280504Z01 Retainer, Speaker
page 7-1 12 Not Field Escutcheon, FM 28 1480503Z01 Boot, Backup Battery
2 3680529Z01 Knob, Volume Replaceable 29 6062884G01 Backup Battery
3 3680530Z01 Knob, Channel Selector 13 7580532Z01 Keypad, Side Control 30 0304726J04 Screw
4 1380525Z01 Escutcheon, Top 14 1380528Z01 Bezel, Side Control 31 3980667Z01 Contact, Finger
5 3380644Z01 Escutcheon, Label 15 7580620Z02 Keypad, Full 32 See detailed Ctrl/RF Board Assembly
2 7580620Z05 Keypad, Full, MPT
6 3280533Z01 Seal, Control Top manual
7585680Z07 Keypad, Full, Privacy Plus
7 6180527Z01 Litepipe, Tx 33 8480475Z02 Flex, Keypad/Controller
3 16 0104007J99 Keypad Board Assembly
8 HLN9969A Nameplate, PRO7150 34 1480652Z01 Insulator, Antenna
17 7580540Z01 Pad Display
HLN9979A Nameplate, PRO7350 (LTR) 35 7580556Z01 Pad, Thermal
18 5104949J05 LCD Module
4 HLN9980A Nameplate, PRO7450 (MPT) 36 3280534Z01 Seal, Contact
19 7580637Z01 Pad, LCD Back
5 HHLN4155A Nameplate, PRO7550 (Extended 37 3280536Z01 Gasket, O-Ring
Privacy Plus) 20 4280498Z01 Retainer, Keypad PCB
38 3980698Z01 Contact, Ground, Compliant
HHLN4157A Nameplate, PRO7650 (Extended w/ 21 3586057A01 Felt Speaker
6 39a 2780518Z01 Chassis
Roaming) 22 1480577C01 Boot, Microphone
39b 2780518Z03 Chassis
7 HHLN4159A Nameplate, PRO7750 (Smart Zone) 23 5085962A02 Speaker
40 See section 7.5 Battery
9 1586059A01 Dust Cover, Universal Connector 24 5013920A04 Microphone on page 7-3
14
10 1386058A01 Escutcheon, Universal Flex 25 8480549Z01 Flex, Speaker-Microphone 41 HLN9714 Beltclip
8 13

15
16 17
18 21
19 23 800 MHz Only
27
28 32 800 MHz Only
31
34 36
39b
37
38 39a
11
40
9 12
10 22 41
24
20
26
29
25 30

33
35 PRO7X50 Exploded
View and Parts List
3.11 Service Aids 3-19

3.11 Service Aids

Table 3-1 lists service aids recommended for working on the PRO Series 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.

Table 3-1. Service Aids

Motorola
Description Application
Part No.
RLN4460 Portable Test Set Enables connection to audio/accessory jack. Allows
switching for radio testing.

HVN9027 Customer Programming Soft- Programs customer option and channel data. Tunes
ware (CPS): CD ROM. hardware parameters, front end, power, deviation,
Includes images for high den- etc. Conventional and LTR products.
sity, 1.4 Mbyte, 3.5Ó ßoppy dis-
kettes.

HVN9030 Customer Programming Soft- Same as above (MPT protocol products).

ware (CPS).

HVN9045 Customer Programming Soft- Same as above (800 MHz LTR protocol products).
ware (CPS).

HVN9065 Customer Programming Soft- Same as above (Privacy Plus/Privacy Plus w/ Roam-
ware (CPS). ing protocol products).

HKVN4001 Customer Programming Soft- Same as above (Smart Zone protocol products).
ware (CPS).

AARKN4075 Programming Cable Includes radio interface box (RIB) capability.

AARKN4074 Programming Cable/Test Connects radio to RIB (RLN4008B).

Cable

AARKN4073 Radio to Radio Cloning Cable Allows radio to be duplicated from a master radio by
transferring programmed data from the master radio
to the other. (Only for Conventional and LTR models)

RLN4008 Radio Interface Box Enables communications between radio and com-
puterÕs serial communications adapter.

HLN9756 BNC Adaptor Adapts radio antenna port to BNC cabling of equip-
ment (VHF and UHF , B1 only)

5880313B69 SMA to BNC adapter Adapts radio antenna port to BNC cabling of equip-
ment (800 MHz radios)

HHLN4133A Rhombic tip adapter (Yellow) Adapts radio antenna port to BNC cabling of test
equipment.

HHLN4134A Cylindrical tip adapter (Blue) Adapts radio antenna port to BNC cabling of test
equipment.

RLN4510 Battery Eliminator 7.5V Regu- Works in combination with Shop Battery Block,
lator 0180305G54.
3-20 3.11 Service Aids

Motorola
Description Application
Part No.
AA0180305G54 Shop Battery Block Interconnects radio to power supply. Provides for
AA8180384F68 Bench Test Housing Eliminator troubleshooting of radio when housing is removed.
AA8180384F66 Bench Test Housing Eliminator For use with PRO9150 long frame radio.

0180357A57 Wall-Mounted Power Supply Used to supply power to RIB.

(120 VAC)

0180358A56 Wall-Mounted Power Supply Used to supply power to RIB.

(220 VAC; 2-prong)

3080369B72 Computer Interface Cable Connects computerÕs serial communications adapter

to RIB (RLN4008B).

6680702Z01 Service Tool Remove radio chassis and knobs.

 5-1

Chapter 5
Radio Tuning, Programming, Cloning, and Lowband
Antenna Cutting Procedure

5.1 Introduction
This chapter provides an overview of the Customer Programming Software (CPS) and tuner program
designed for use in a Windows 95/98 environment. These programs are available in separate kits as
listed in the Table 5-1. An installation instruction manual is also included with each kit.
Note: Refer to the appropriate program on-line help Þles for the programming procedures.
Table 5-1. Software Installation Kits Radio Tuning Setup

Description Kit Number

CPS, Conventional and UHF Radios HVN9027/H5197

CPS, 800MHz LTR HVN9045

CPS, Privacy Plus and Privacy Plus w/ Roaming HVN9065

CPS, MPT Trunking HVN9030

CPS, Smart Zone HKVN4001

5.2 Global Radio Tuning Setup

A personal computer (PC), Windows 95/98/NT, and a global 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 shown in Figure 5-1.
Service Monitor
30 dB Pad or Counter
Double Male Transmit
Battery
Eliminator 30 dB Pad Wattmeter
RF Adaptor
7.5V Reg. BNC
HLN9756
RLN4510 3.5 mm to
+12VDC RF Generator
Power Ferrule BNC Receive
Radio Audio In
Supply Tx Audio Generator
Test Box
RLN4460A
or B Rx Sinad Meter
Battery Block
Program/Test Cable
0180305G54
AARKN 4074
AC Voltmeter

DB15 DB9 Tx Data

AC Plug RIB
120/230 Vac Rx Data
RLN-4008 Gnd
Computer Interface
RIB Power Supply Cable 3080369B72
0180357A57 (120V)
0180358A56 (230V)

Figure 5-1. Radio Tuning Test Equipment Setup

 8-1

Chapter 8
Model Chart and Test SpeciÞcations

8.1 UHF 403-470 MHz

PRO Series, UHF, 403-470 MHz

Model Description
LAH25RDC9AA2 PRO5150, 403-470 MHz, 4W, 4-Ch (4-Frequency)
LAH25RDC9AA3 PRO5150, 403-470 MHz, 4W, 16-Ch
LAH25RDC9DU3 PRO5350, 403-470 MHz, 4W, (LTR)
LAH25RDC9CK3 PRO5450, 403-470 MHz, 4W, (MPT)
LAH25RCC6GC3 PRO5750, 403-470 MHz, 4W, 16-Ch (Smart Zone)
LAH25RDH9AA6 PRO7150, 403-470 MHz, 4W, 128-Ch
LAH25RDH9DU6 PRO7350, 403-470 MHz, 4W, (LTR)
LAH25RDH9CK6 PRO7450, 403-470 MHz, 4W, (MPT)
LAH25RCH6GC6 PRO7750, 403-470 MHz, 4W, 128-Ch (Smart Zone)
LAH25RDN9AA8 PRO9150, 403-470 MHz, 4W, 160-Ch
Item Description
X PMLE4171 PRO5150 Back Cover Kit (4-Frequency)
X PMLE4130 PRO5150 Back Cover Kit
X PMLE4148 PRO5350 Back Cover Kit
X PMLE4133 PRO5450 Back Cover Kit
X PMLE4192 PRO5750 Back Cover Kit
X PMLE4109 PRO7150 Back Cover Kit
X PMLE4149 PRO7350 Back Cover Kit
X PMLE4134 PRO7450 Back Cover Kit
X PMLE4193 PRO7750 Back Cover Kit
X PMLE4132 PRO9150 Back Cover Kit
X X X X X PMLN4216 PRO5X50 Series Radio Front Housing Kit
X PMLN4199 PRO7150 Front Housing Kit
X PMLN4365 PRO7350 Front Housing Kit
X PMLN4304 PRO7450 Front Housing Kit
X PMLN4373 PRO7750 Front Housing Kit
X PMLN4218 PRO9150 Front Housing Kit
X X HLN9995 PRO5150 Label
X HLN9996 PRO5350 Label
X HLN9967 PRO5450 Label
x = Indicates one of each is required.
8-2 UHF 403-470 MHz

PRO Series, UHF, 403-470 MHz

Model Description
LAH25RDC9AA2 PRO5150, 403-470 MHz, 4W, 4-Ch (4-Frequency)
LAH25RDC9AA3 PRO5150, 403-470 MHz, 4W, 16-Ch
LAH25RDC9DU3 PRO5350, 403-470 MHz, 4W, (LTR)
LAH25RDC9CK3 PRO5450, 403-470 MHz, 4W, (MPT)
LAH25RCC6GC3 PRO5750, 403-470 MHz, 4W, 16-Ch (Smart Zone)
LAH25RDH9AA6 PRO7150, 403-470 MHz, 4W, 128-Ch
LAH25RDH9DU6 PRO7350, 403-470 MHz, 4W, (LTR)
LAH25RDH9CK6 PRO7450, 403-470 MHz, 4W, (MPT)
LAH25RCH6GC6 PRO7750, 403-470 MHz, 4W, 128-Ch (Smart Zone)
LAH25RDN9AA8 PRO9150, 403-470 MHz, 4W, 160-Ch
Item Description
X HHLN4158 PRO5750 Label
X X X X X X X X X X NAE6483 Antenna, Whip, 403-520 MHz
X X 68P81089C96 PRO5150 User Guide
X 68P81088C40 PRO5350 User Guide
X 68P81089C39 PRO5450 User Guide
X 68P81093C87 PRO5750 User Guide
X 68P81088C38 PRO7150 User Guide
X 68P81088C43 PRO7350 User Guide
X 68P81091C15 PRO7450 User Guide
X 68P81093C88 PRO7750 User Guide
X 68P81089C99 PRO9150 User Guide
x = Indicates one of each is required.
UHF 450-527 MHz 8-3

8.2 UHF 450-527 MHz

PRO Series, UHF, 450-527 MHz

Model Description
LAH25SDC9AA2 PRO5150, 450-527 MHz, 4W, 4-Ch (4-Frequency)
LAH25SDC9AA3 PRO5150, 450-527 MHz, 4W, 16-Ch
LAH25SDC9DU3 PRO5350, 450-527 MHz, 4W, (LTR)
LAH25SDC9CK3 PRO5450, 450-527 MHz, 4W, (MPT)
LAH25SDH9AA6 PRO7150, 450-527 MHz, 4W, 128-Ch
LAH25SDH9DU6 PRO7350, 450-527 MHz, 4W, (LTR)
LAH25SDH9CK6 PRO7450, 450-527 MHz, 4W, (MPT)
LAH25SDN9AA8 PRO9150, 450-527 MHz, 4W, 160-Ch

Item Description

X PMLE4172 PRO5150 Back Cover Kit (4-Frequency)

X PMLE4118 PRO5150 Back Cover Kit
X PMLE4150 PRO5350 Back Cover Kit
X PMLE4122 PRO5450 Back Cover Kit
X PMLE4119 PRO7150 Back Cover Kit
X PMLE4151 PRO7350 Back Cover Kit
X PMLE4123 PRO7450 Back Cover Kit
X PMLE4121 PRO9150 Back Cover Kit
X X X X PMLN4216 PRO5X50 Series Radio Front Housing Kit
X PMLN4199 PRO7150 Front Housing Kit
X PMLN4365 PRO7350 Front Housing Kit
X PMLN4304 PRO7450 Front Housing Kit
X PMLN4218 PRO9150 Front Housing Kit
X X HLN9995 PRO5150 Label
X HLN9996 PRO5350 Label
X HLN9967 PRO5450 Label
X X X X X X X X NAE6483 Antenna, Whip, 403-520 MHz
X X 68P81089C96 PRO5150 User Guide
X 68P81088C40 PRO5350 User Guide
X 68P81089C39 PRO5450 User Guide
X 68P81088C38 PRO7150 User Guide
X 68P81088C43 PRO7350 User Guide
X 68P81093C15 PRO7450 User Guide
X 68P81089C99 PRO9150 User Guide
x = Indicates one of each is required.
8-4 VHF 136-174 MHz

8.3 VHF 136-174 MHz

PRO Series, VHF, 136-174 MHz

Model Description
LAH25KDC9AA2 PRO5150, 136-174 MHz, 5W, 4 -Ch (4-Frequency)
LAH25KDC9AA3 PRO5150, 136-174 MHz, 5W, 16 -Ch
LAH25KDH9AA6 PRO7150, 136-174 MHz, 5W, 128 -Ch
LAH25KDN9AA8 PRO9150, 136-174 MHz, 5W, 160 -Ch

Item Description

X PMLD4159 PRO5150 Back Cover Kit (4-Frequency)

X PMLD4109 PRO5150 Back Cover Kit
X PMLD4110 PRO7150 Back Cover Kit
X PMLD4112 PRO9150 Back Cover Kit
X X PMLN4216 PRO5150 Front Housing Kit
X PMLN4199 PRO7150 Front Housing Kit
X PMLN4218 PRO9150 Front Housing Kit
X X HLN9995 PRO5150 Label
X X X X PMAD4023 Antenna, Whip, 150-161 MHz
X X X X PMAD4014 Antenna, 136-155 MHz 14 cm
X X X X PMAD4015 Antenna, 155-174 MHz 14 cm
X X 68P81089C96 PRO5150 User Guide
X 68P81088C38 PRO7150 User Guide
X 68P81089C99 PRO9150 User Guide
x = Indicates one of each is required.

8.4 Low Band 29.7-42/35-50MHz

PRO Series, Lowband, 29.7- 42/35 - 50MHz

Model Description
LAH25BEC9AA3 PRO5150, 29.7-42 MHz, 6W, 16 -Ch
LAH25CEC9AA3 PRO5150, 35-50 MHz, 6W, 16 -Ch
Item Description
X PMLB4002 PRO5150 Back Cover Kit, 29.7-42 MHz
X PMLB4010 PRO5150 Back Cover Kit, 35-50 MHz
X X PMLN4216 PRO5150 Front Housing Kit
X X HLN9995 PRO5150 Label
X X NAB6064 Antenna, Molded, Cut to Frequency
X X 68P81089C96 PRO5150 User Manual
x = Indicates one of each is required.
800 MHz (806-870 MHz) 8-5

8.5 800 MHz (806-870 MHz)

PRO Series, 806-870 MHz

Model Description
LAH25UCC6DU3 PRO5350, 800MHz, 2.5W, (LTR)
LAH25UCC6GB3 PRO5550, 800 MHz, 2.5W, Non-Display (Privacy Plus)
LAH25UCC6GB3 PRO5650, 800MHz, 2.5W, Non-Display (Privacy Plus w/ Roaming)
LAH25UCC6FC3 PRO5750, 800MHz, 3W, (Smart Zone)
LAH25UCH6DU6 PRO7350, 800MHz, 2.5W, Display (LTR)
LAH25UCH6GC6 PRO7550, 800MHz, 2.5W, Display (Privacy Plus)
LAH25UCH6GB6 PRO7650, 800MHz, 2.5W, Display (Privacy Plus w/ Roaming)
LAH25UCH6FC6 PRO7750, 806-870MHz, 3W, (Smart Zone)
Item Description
X PMLF4012 PRO5350 Back Cover Kit
X X PMLF4016 PRO5550, PRO5650 Back Cover Kit
X PMLF4020 PRO5750 Back Cover Kit
X PMLF4013 PRO7350 Back Cover Kit
X X PMLF4017 PRO7550, PRO7650 Back Cover Kit
X PMLF4021 PRO7750 Back Cover Kit
X X X X PMLN4216 PRO5350,PRO5550,PR05650,PRO5750 Front Housing Kit
X PMLN4199 PRO7350 Front Housing Kit
X X X PMLN4373 PRO7550,PR07650,PRO7750 Front Housing Kit
X HLN9996 PRO5350 Label
X HHLN4154 PRO5550 Label
X HHLN4156 PRO5650 Label
X HHLN4158 PRO5750 Label
X X X X X X X X NAF5037 Antenna, Whip
X X X X X X X X NAF5042 Antenna, Quarter Wave, Stubby, 806-870 MHz
X 68P81088C40 PRO5350 User Guide
X X 68P81093C85 PRO5550/PRO5650 User Guide
X 68P81093C87 PRO5750 User Guide
X 68P81088C43 PRO7350 User Guide
X X 68P81093C86 PRO7550/PRO7650 User Guide
X 68P81093C88 PRO7750 User Guide
x = Indicates one of each is required.
 MANUAL REVISION
®
Professional Radio™
6881088C45-C
PRO Series
Basic Service Manual

This revision outlines changes that have occurred since the printing of your manual. Use this information to
supplement your manual.

REVISION CHANGE:

On page 8-15, the first row of the Transmitter table (in Section 8.14, Specifications - 800MHz Radio) should read as
follows:

Transmitter
Specification 800 MHz
RF Output Low High
NiMH @ 7.5V: 1W 2.5W @ 806-824 MHz
2.0W @ 851-869 MHz

*FMR-1978A-2*
© 2002 by Motorola, Inc. FMR-1978A-2
Commercial, Government and Industrial Solutions Sector
8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322 2-20-02
Printed in U. S. A. 2/02. All Rights Reserved.
 i

SAFETY INFORMATION

IMPORTANT INFORMATION ON SAFE AND EFFICIENT OPERATION

READ THIS INFORMATION BEFORE USING YOUR TWO-WAY RADIO
The information provided in this document supersedes the general safety information contained in user guides
published prior to July 2000. For information regarding radio use and hazardous atmosphere please refer to
the Factory Mutual (FM) Approval Manual Supplement or Instruction Card, which is included with radio
models that offer this capability.
RF Operational Characteristics
Your radio contains a transmitter and a receiver. When it is ON, it receives and transmits radio frequency (RF))
energy.
Exposure To Radio Frequency Energy
Your Motorola Two-Way Radio, is designed to comply with the following National and International Standards and
Guidelines regarding exposure of human beings to radio frequency electromagnetic energy (EME):
• United States Federal Communications Commission, Code of Federal Regulations
(47 CFR part 2 sub-part J)
• American National Standards Institute (ANSI)/Institute of Electrical and Electronic Engineers (IEEE)
(C95.1 - 1992)
• Institute of Electrical and Electronic Engineers (IEEE) (C95.1-1999 Edition)
• National Council on Radiation Protection and Measurements (NCRP) of the United States (Report 86,
1986)
• International Commission on Non-Ionizing Radiation Protection (ICNRP - 1998)
• National Radiological Protection Board of the United Kingdom (1995)
• Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radio frequency Electromag-
netic Fields in the Frequency Range from 3 kHz to 300 GHz (1999)
• Australian Communications Authority Radiocommunications (Electromagnetic Radiation - Human Expo-
sure) Standard (1999) (applicable to wireless phones only)

PORTABLE RADIO OPERATION AND EME EXPOSURE

To assure optimal radio performance and make sure human exposure to radio frequency electromagnetic
energy is within the guidelines set forth in the above standards, always adhere to the following procedures:
Antenna Care
Use only the supplied or an approved replacement antenna. Unauthorized antennas, modifications, or
attachments could damage the phone and may violate FCC regulations.
DO NOT hold the antenna when the two-way radio is “IN USE”. Holding the antenna affects call quality
and may cause the radio to operate at a higher power level than needed.
Two-Way Radio Operation
When using your radio as a traditional two-way radio, hold the radio in a vertical position with the
microphone one to two inches (2.5 to 5 cm) away from the lips.

MAN WITH RADIO

ii Safety Information

Body-Worn Operation
To maintain compliance with FCC RF exposure guidelines, if you wear a radio on your body when transmitting,
always place the radio in a Motorola supplied or approved clip, holder, holster, case, or body harness.
Use of non-Motorola-approved accessories may exceed FCC RF exposure guidelines. If you do not use a
body-worn accessory, ensure the antenna is at least one inch (2.5 cm) from your body when
transmitting.
Data Operation
When using any data feature of the radio, with or without an accessory cable, position the antenna of the
radio at least one inch (2.5 cm) from the body.
Approved Accessories
For a list of approved Motorola accessories look in the accessory section of this manual.
ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY

Note: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately
shielded, designed or otherwise configured for electromagnetic compatibility.

• FACILITIES
To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any facility where
posted notices instruct you to do so. Hospitals or health care facilities may be using equipment that is
sensitive to external RF energy.
• AIRCRAFT
When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in
accordance with applicable regulations per airline crew instructions.
• MEDICAL DEVICES
• Pacemakers
The Health Industry Manufacturers Association recommends that a minimum separation of 6 inches (15
cm) be maintained between a handheld wireless radio and a pacemaker.These recommendations are
consistent with the independent research by, and recommendations of, Wireless Technology Research.
Persons with pacemakers should:
• ALWAYS keep the radio more than six inches (15 cm) from their pacemaker when the radio is turned ON.
• not carry the radio in the breast pocket.
• use the ear opposite the pacemaker to minimize the potential for interference.
• turn the radio OFF immediately if you have any reason to suspect that interference is taking place.
• Hearing Aids
Some digital wireless radios may interfere with some hearing aids. In the event of such interference, you may
want to consult your hearing aid manufacturer to discuss alternatives.
• Other Medical Devices
If you use any other personal medical device, consult the manufacturer of your device to determine if it is
adequately shielded from RF energy. Your physician may be able to assist you in obtaining this information.
Safety Information iii

SAFETY AND GENERAL

• Use While Driving
Check the laws and regulations on the use of radios in the area where you drive. Always obey them
When using your radio while driving, please:
• Give full attention to driving and to the road.
• Use hands-free operation, if available.
• Pull off the road and park before making or answering a call if driving conditions so require.
OPERATIONAL WARNINGS
!
• FOR VEHICLES WITH AN AIR BAG WARNING

Do not place a portable radio in the area over an air bag or in the air bag deployment area. Air bags inflate
with great force. If a portable radio is placed in the air bag deployment area and the air bag inflates, the radio
may be propelled with great force and cause serious injury to occupants of the vehicle.

• POTENTIALLY EXPLOSIVE ATMOSPHERES

Turn off your radio prior to entering any area with a potentially explosive atmosphere, unless it is a radio type
especially qualified for use in such areas as “Intrinsically Safe” (for example, Factory Mutual, CSA, or UL
Approved). Do not remove, install, or charge batteries in such areas. Sparks in a potentially explosive
atmosphere can cause an explosion or fire resulting in bodily injury or even death.

Note: The areas with potentially explosive atmospheres referred to above include fueling areas such as
below decks on boats, fuel or chemical transfer or storage facilities, areas where the air contains
chemicals or particles, such as grain, dust or metal powders, and any other area where you would nor-
mally be advised to turn off your vehicle engine. Areas with potentially explosive atmospheres are
often but not always posted.

• BLASTING CAPS AND AREAS

To avoid possible interference with blasting operations, turn off your radio when you are near electrical
blasting caps, in a blasting area, or in areas posted: “Turn off two-way radio”. Obey all signs and instructions.
OPERATIONAL CAUTIONS
!
• ANTENNAS Caution

Do not use any portable radio that has a damaged antenna. If a damaged antenna comes into contact
with your skin, a minor burn can result.
• BATTERIES
All batteries can cause property damage and/or bodily injury such as burns if a conductive material such as
jewelry, keys, or beaded chains touch exposed terminals. The conductive material may complete an electrical
circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when
placing it inside a pocket, purse, or other container with metal objects.
iv Safety Information

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 v

Table of Contents
Chapter 1 Introduction

1.1 Scope of Manual ............................................................................................... 1-1

1.2 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................................................................................ 1-3
1.2.5 Warranty and Repairs.......................................................................... 1-3
1.3 Radio Model Information................................................................................... 1-4

Chapter 2 Intrinsically Safe Radio Information

2.1 FMRC Approved Equipment ............................................................................. 2-1

2.2 Repair of FMRC Approved Products ................................................................ 2-2
2.2.1 Repair .................................................................................................. 2-2
2.2.2 Relabeling............................................................................................ 2-2
2.2.3 Do Not Substitute Options or Accessories .......................................... 2-2

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 ............................................... 3-2
3.5 Disassembling and Reassembling the Radio — General ................................. 3-3
3.6 Radio Disassembly — Detailed ........................................................................ 3-4
3.6.1 Front Cover from Chassis Disassembly .............................................. 3-4
3.6.2 Chassis Assembly Disassembly.......................................................... 3-6
3.6.3 Keypad and Keypad/Option Board Disassembly................................. 3-7
3.6.4 Display Disassembly ........................................................................... 3-8
3.6.5 Speaker, Microphone, and Universal Connector Flex Disassembly.... 3-8
3.6.6 PTT Disassembly .............................................................................. 3-10
3.6.7 Control Top Disassembly .................................................................. 3-10
3.7 Radio Reassembly — Detailed ....................................................................... 3-10
3.7.1 Control Top Reassembly ................................................................... 3-10
3.7.2 PTT Reassembly ............................................................................... 3-10
vi

3.7.3 Speaker, Microphone, and Universal Connector Flex Reassembly...3-11

3.7.4 Keypad and Keypad Option Board Reassembly................................3-11
3.7.5 Chassis Assembly Reassembly.........................................................3-12
3.7.6 Chassis and Front Cover Reassembly ..............................................3-12
3.7.7 DTMF Retrofit Kit Procedure (Optional Upgrade Procedure) ............3-13
3.7.8 Option Board Installation....................................................................3-14
3.8 PRO5150/PRO5350/PRO5450 Radio Exploded Mechanical View and
Parts List..........................................................................................................3-15
3.9 PRO7150/PRO7350/PRO7450 Radio Exploded Mechanical View and
Parts List..........................................................................................................3-16
3.10 PRO9150/PRO9450 Radio Exploded Mechanical View and Parts List ..........3-17
3.11 Service Aids.....................................................................................................3-19
3.12 Test Equipment ...............................................................................................3-21
3.13 Configuring and Wiring the Programming/Test Cable .....................................3-22

Chapter 4 Transceiver Performance Testing

4.1 General..............................................................................................................4-1
4.2 RF Test Mode....................................................................................................4-1
4.3 Test Frequencies for Display and Non-Display Radios .....................................4-6
4.4 Receiver Performance Tests .............................................................................4-7

Chapter 5 Radio Tuning, Programming, Cloning, and Lowband Antenna Cutting

Procedure

5.1 Introduction........................................................................................................5-1
5.2 Global Radio Tuning Setup ...............................................................................5-1
5.2.1 Initial Test Equipment Setup ................................................................5-2
5.3 CPS Programming Setup ..................................................................................5-2
5.4 Cloning (Conventional Only)..............................................................................5-3
5.4.1 Error Codes (Display Radios Only)......................................................5-3
5.5 Lowband Molded Antenna Cut Chart ................................................................5-4

Chapter 6 Power Up Self-Test

6.1 Error Codes - Conventional Radios...................................................................6-1

6.2 Error Codes .......................................................................................................6-1
6.3 Operation Display Codes...................................................................................6-2
 vii

Chapter 7 Accessories

7.1 Antennas ............................................................................................. 7-1

7.2 Carrying Accessories........................................................................... 7-1
7.3 Carry Cases......................................................................................... 7-2
7.4 Chargers.............................................................................................. 7-2
7.5 Batteries .............................................................................................. 7-3
7.6 Adaptors .............................................................................................. 7-3
7.7 Miscellaneous...................................................................................... 7-3
7.8 Service Aids......................................................................................... 7-3
7.9 Audio Accessories ............................................................................... 7-4
7.10 Option Boards...................................................................................... 7-5
7.11 Remote Speaker Microphones ............................................................ 7-5
7.12 Manuals ............................................................................................... 7-5
7.13 Retrofit Front Cover Kits ...................................................................... 7-6

Chapter 8 Model Chart and Test Specifications

8.1 UHF 403-470 MHz ............................................................................................ 8-1

8.2 UHF 450-527 MHz ............................................................................................ 8-2
8.3 UHF 403-470 MHz (MPT) ................................................................................. 8-3
8.4 UHF 450-527 MHz (MPT) ................................................................................. 8-4
8.5 UHF 403-470 MHz (LTR).................................................................................. 8-4
8.6 UHF 450-527 MHz (LTR).................................................................................. 8-5
8.7 VHF 136-174 MHz ............................................................................................ 8-5
8.8 Low Band 29.7-42/35-50MHz ........................................................................... 8-6
8.9 800 MHz (LTR) ................................................................................................. 8-6
8.10 800 MHz (Privacy Plus) .................................................................................... 8-7
8.11 Specifications - PRO5150/PRO5350/PRO5450 Radios ................................... 8-7
8.12 Specifications - PRO7150/PRO7350/PRO7450 Radios ................................. 8-10
8.13 Specifications - PRO9150/PRO9450 Radios.................................................. 8-12
8.14 Specifications - 800 MHz Radio...................................................................... 8-14

Glossary of Terms .......................................................................................................... G-1

viii

Notes
 1-1

Chapter 1
Introduction

1.1 Scope of Manual

This manual is intended for use by service technicians familiar with similar types of equipment. It
contains service information required for the equipment described and is current as of the printing
date. Changes which occur after the printing date may be incorporated by a complete Manual revision
or alternatively as additions.
NOTE Before operating or testing these units, please read the Safety Information Section in the
front of this manual.

1.2 Warranty and Service Support

Motorola offers support which includes: full exchange and/or repair of the product during the warranty
period; and service/ repair or spare parts support out of warranty. Any “return for exchange” or “return
for repair” to an authorized Motorola Dealer must be accompanied by a Warranty Claim Form.
Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer. (See section 1.2.4
on page 1-3.)

1.2.1 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 subsections 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 (Please see page 2 and page 3 in this chapter.). All returns must be accompanied by a
Warranty Claim Form, available from your Customer Resources representative. Products should be
shipped back in the original packaging, or correctly packaged to ensure that no damage occurs in
transit.

1.2.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways:
1. Motorola's Radio Parts and Service Group (CGISS) offers repair service to users and dealers at
competitive prices.
2. RPSG supplies individual parts and modules that can be purchased by dealers who are capable
of performing fault analysis and repair.
1-2 Warranty and Service Support

1.2.3 Piece Parts Availability

Some replacement parts, spare parts, and/or product information can be ordered directly. If a
complete Motorola part number is assigned to the part, and it is not identified as Depot ONLY, it is
available from the Accessories and Aftermarket Division (AAD). If no part number is assigned, the
part is not normally available from Motorola. If the part number is appended with an asterisk, the part
is serviceable by a Motorola Depot only. If a parts list is not included, this generally means that no
user-serviceable parts are available for that kit or assembly.

To Order Parts in Latin America and the Caribbean:

7:00 A. M. to 7:00 P. M. (Central Standard Time)
Monday through Friday (Chicago, U. S. A.)
1-847-538-8023
Motorola Parts
Accessories and Aftermarket Division
Attention: Order Processing
1313 E. Algonquin Road
Schaumburg, IL 60196
Parts Identification
1-847-538-0021 (Voice)
1-847-538-8194 (Fax)
Warranty and Service Support 1-3

1.2.4 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, be prepared to provide the product model number and
the unit’s serial number.
Latin America and Caribbean Depots
(Motorola, Plantation, Florida, U. S. A.)
1-800-694-2161
1-954-723-3008

1.2.5 Warranty and Repairs

For warranty and repairs, contact Motorola Technical Support as listed below. Be prepared to provide
the product model number and the unit’s serial number.
Colombia Brazil
Motorola de Colombia Motorola Do Brasil
Diagonal 127A 17-64 Rua Bandeira Paulista, 580
Santa Fe de Bogota 04532-001 Sao Paulo - SP
Colombia Brazil
Phone: 571-615-5759 Phone: 5511-821-9991
Puerto Rico Fax: 5511-828-0157
Motorola de Puerto Rico Mexico
A Street #21 Motorola De Mexico
Mario Julia Industrial Park Huatabampo #50
Puerto Nuevo, Puerto Rico 00922 COL. Roma Sur
Phone: 787-273-2400 Mexico D.F. 06700
Fax: 787-782-3685 Mexico
Phone: 525-574-1513
Fax: 525-564-2188
1-4 Radio Model Information

1.3 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: LAH25KDC9AA3
Type of Model Freq. Power Physical Channel Feature Model Model
Protocol
Unit Series Band Level Packages Spacing Level Revision Package

AA H 25 K C C 9 AA 2 A N
or VHF 2.5W No Display Program- Conventional 2F
LA (136- mable
H = Portable

174MHz)
AA or LA = Motorola Internal Use

R D D 6 DU 3
UHF1 4-5W Keypad 25kHz LTR 16F
(403-
470MHz)
S E H CK 5
UHF2 6W 1-Line Dis- MPT 256F LTR
(450- play
520MHz)
B N GB 6
Low 4-Line Dis- Privacy Plus 128F
Band, R1 play 256F LTR
(29.7-
42.0MHz)
C GE 8
Low Privacy Plus 160F
Band, R2 Roaming
(35.0-
50.0MHz)
U
800MHz
(806-821)
(851-866)
 2-1

Chapter 2
Intrinsically Safe Radio Information

2.1 FMRC Approved Equipment

Anyone intending to use a radio in a location where hazardous concentrations of flammable material
exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and
with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500 (hazardous
[classified] locations).
An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers and
the products approved by FMRC for use in such locations. FMRC has also issued a voluntary
approval standard for repair service (“Class Number 3605”).
FMRC Approval labels are attached to the radio to identify the unit as being FM Approved for
specified hazardous atmospheres. This label specifies the hazardous Class/Division/Group along
with the part number of the battery that must be used. Depending on the design of the portable unit,
this FM label can be found on the back of the radio housing or the bottom of the radio housing.Their
Approval mark is shown below.

FM

APPROVED

WARNING: Do not operate radio communications equipment in a hazardous atmosphere

unless it is a type especially qualified (e.g. FMRC Approved) for such use. An explosion or
! fire may result.

WARNING: Do not operate the FMRC Approved Product in a hazardous atmosphere if it has
been physically damaged (e.g. cracked housing). An explosion or fire may result.
WARNING: Do not replace or charge batteries in a hazardous atmosphere. Contact sparking
may occur while installing or removing batteries and cause an explosion or fire.
WARNING: Do not replace or change accessories in a hazardous atmosphere. Contact
sparking may occur while installing or removing accessories and cause an explosion or fire.
WARNING: Do not operate the FMRC Approved Product unit in a hazardous location with the
accessory contacts exposed. Keep the connector cover in place when accessories are not
used.
WARNING: Turn radio off before removing or installing a battery or accessory.
WARNING: Do not disassemble the 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.
A modification changes the unit’s hardware from its original design configuration. Modifications can
only be done by the original product manufacturer at one of its FMRC audited manufacturing facilities.
2-2 Repair of FMRC Approved Products

WARNING: Failure to use an FMRC Approved Product unit with an FMRC Approved battery
or FMRC Approved accessories specifically approved for that product may result in the dan-
! gerously unsafe condition of an unapproved radio combination being used in a hazardous
location.

Unauthorized or incorrect modification of an FMRC Approved Product unit will negate the Approval
rating of the product.

2.2 Repair of FMRC Approved Products

REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS 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).
You may want to consider using a repair facility that operates under 3605 repair service approval.

WARNING: Incorrect repair or relabeling of any FMRC Approved Product unit could
! adversely affect the Approval rating of the unit.

WARNING: Use of a radio that is not intrinsically safe in a hazardous atmosphere could
result in serious injury or death.
FMRC’s Approval Standard Class Number 3605 is subject to change at any time without notice to
you, so you may want to obtain a current copy of 3605 from FMRC. Per the December, 1994
publication of 3605, some key definitions and service requirements are as follows:

2.2.1 Repair
A repair constitutes something done internally to the unit that would bring it back to its original
condition Approved by FMRC. A repair should be done in an FMRC Approved facility.
Items not considered as repairs are those in which an action is performed on a unit which does not
require 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 the
Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the
repair facility. An FMRC Approval label shall be ordered from the original manufacturer as needed to
repair a specific unit. Replacement labels may be obtained and applied by the repair facility providing
satisfactory evidence that the unit being relabeled was originally an FMRC Approved unit. Verification
may include, but is not limited to: a unit with a damaged Approval label, a unit with a defective housing
displaying an Approval label, or a customer invoice indicating the serial number of the unit and
purchase of an FMRC Approved model.

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 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. Approved configurations are listed in the FM Approval
guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped with FM
Repair of FMRC Approved Products 2-3

Approved radio and battery combination from the manufacturer. The Approval guide, or the Approval
standard Class Number 3605 document for repairs and service, can be ordered directly through
Factory Mutual Research Corporation located in Norwood, Massachusetts.
 3-1

Chapter 3
Maintenance

3.1 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
● Installation of Optional Retrofit Kit
● Installation of Option Boards

3.2 Preventive Maintenance

The radios do not require a scheduled preventive maintenance program; however, periodic visual
inspection and cleaning is recommended.

3.2.1 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.

3.2.2 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 (70% by volume).

CAUTION: Certain chemicals and their vapors can have harmful effects on certain plastics.
! Avoid using aerosol sprays, tuner cleaners, and other chemicals.

Cleaning External Plastic Surface

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 (70%) 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
3-2 Safe Handling of CMOS and LDMOS Devices

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).

3.3 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 following CAUTION
statement.

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 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 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.
● 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 RSX-4015.)
● Do not wear nylon clothing while handling CMOS devices.
● Do not insert or remove CMOS devices with power applied. Check all power supplies used
for testing CMOS devices to be certain that there are no voltage transients present.
● When straightening CMOS pins, provide ground straps for the apparatus used.
● When soldering, use a grounded soldering iron.
● If at all possible, handle CMOS 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.

3.4 Repair Procedures and Techniques — General

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 Communications parts center listed in Chapter 1 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 the 20-pin and 40-pin connectors:
● Avoid accidentally getting solder in the connector.
Disassembling and Reassembling the Radio — General 3-3

● Be careful not to form solder bridges between the connector pins.

● Examine your work closely for shorts due to solder bridges.
Flexible Circuits
The flexible circuits are made from a different material than the rigid boards, and require different
soldering techniques. Excessive prolonged heat on a flexible circuit can damage the material.
Therefore, avoid excessive heat and excessive bending.
For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700
degree tip, and use small diameter solder such as ST-633. The smaller size 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.

NOTE Do not attempt to puddle-out components. Prolonged application of heat may

damage the flexible circuit.

3.5 Disassembling and Reassembling the Radio — General

Since these radios may be 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/front cover disassembly tool
● Penknife-size screwdriver
● 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.)
3-4 Radio Disassembly — Detailed

3.6 Radio Disassembly — Detailed

The paragraph that follow describe how to disassemble the radio. This includes the following major
components:
● Front cover
● Chassis
● Keypad,
● Keypad/option board
● Display assembly
● Speaker, microphone, universal flex connector
● PTT assembly

3.6.1 Front Cover from Chassis Disassembly

1. Turn off the radio.
2. Pull down on the two battery-release buttons.
3. With the buttons pulled down, the top of the battery will fall from the radio.
4. Remove the battery completely from the radio.

Battery
Release
Buttons

Battery

Figure 3-1. Battery Removal

5. Remove the antenna.

6. Using the chassis and knob opener tool, remove the volume and channel selector knobs off of
their shafts as shown in Figure 3-2.

NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their
shafts.

7. Separate the chassis from the internal electronics front cover assembly by inserting the chassis
and knob opener tool in between the thin retaining wall and the chassis at the bottom of the radio
as shown in Figure 3-3. Do not mar the housing O-ring sealing area.
8. Slowly pry the bottom of the chassis from the cover by pushing the chassis and knob opener tool
back while rotating 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.
Radio Disassembly — Detailed 3-5

Chassis and
Knob Opener

ER
EN
OP
S
OB
KN
C
H

Knobs
A
S
6

Insert opener between

S
6

IS
C
8

O
0
7

knob and switch base,

0

E
2

N
Z

E
0

R
1

then pry off knob

Figure 3-2. Knob Removal

KNOB
S OP
ENER

Chassis and
Knob Opener

R
NE
PE
O
S 1
SI Z0
AS 02
CH 07
C8
66

Radio
Chassis

Figure 3-3. Chassis Removal

Marring the front cover O-ring sealing area will prevent the radio from sealing
! properly.

9. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis.

NOTE CAUTION: Flexible ribbon circuits (flexes) connecting the front cover assembly
and the chassis prevent you from completely separating the two units. Display
radios and radios with option boards have two flexes. The PRO9150 will not lay
flat with the two units separated.
3-6 Radio Disassembly — Detailed

10. Lift the latches on the main circuit board to release the flexes from their connectors as shown in
Figure 3-4.

Latches

Flex Connectors

Figure 3-4. Unlatching Flex Connectors

NOTE At this point, if necessary, the DTMF Retrofit Kit Procedure can be performed. (See
paragraph 3.7.7).

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.
2. Lift the main board from the chassis as shown in Figure 3-5.

Screws (4)

Compliant
Ground Main
Contact Board

Radio
Chassis

O-Ring
Retaining
Features

Figure 3-5. Main Board from Chassis Removal

Radio Disassembly — Detailed 3-7

CAUTION: Refer to the CMOS CAUTION in paragraph 3.3 before removing the main board.
! Be sure to use ESD protection when handling circuit boards.

3. Remove the small O-ring retainers from their slots in the chassis. Note the alignment of the
retainers for reassembly.
4. Remove the O-ring.
5. (VHF, UHF, and lowband only) If required in disassembly, slide off the ground contact from the top
corner boss of the radio chassis.

3.6.3 Keypad and Keypad/Option Board Disassembly

1. If the disassembly of the keypad or the keypad printed circuit board, is required, lift the
microphone flex circuit up, and carefully remove the microphone and its boot from the front cover
pocket as shown in Figure 3-6.
2. Lay this flex circuit to one side.

3. To remove the keypad retainer shield, Insert the tip of a “penknife size,” flat blade screwdriver in
the opening at the end of the keypad retainer arm tab. Pry the tab away from the side of the front
cover until it moves past the ledges on the side wall. Repeat this procedure for the four remaining
retainer arm tabs.

Flat Blade
Speaker-Microphone
Screwdriver
Flex Circuit Tail

Keypad Retainer
Arm Tabs (4)

Retainer
Top Hooks Retainer

Figure 3-6. Retainer Removal

4. Note that for the PRO series, with the exception of the PRO9150, the two “top hooks” are still held
underneath the front cover—right below the speaker. Lift the keypad retainer out of the front
cover, then lift and pivot the two hooks out of the front cover.
5. Lift latch on connector located on the keypad board to release the display flex.
6. The keypad/option board and the keypad can be removed without the use of tools

NOTE At this point, the Option Board Installation Procedure should be performed, if
necessary (See paragraph 3.7.8)
3-8 Radio Disassembly — Detailed

Retainer

Display
Module
Keypad
Option
Board

Keypad

Radio
Body

Figure 3-7. Keypad Retainer and Other Boards Removable

3.6.4 Display Disassembly
1. If disassembly involves the removal of the display module, with the keypad retainer removed,
disconnect the display flex from the keypad option board connector by lifting the latch on the
connector.

CAUTION: Take care not to damage the display. Do not cut, bend, or pinch the heat seal.
! Display modules contain CMOS devices. Be sure to use ESD protection.

2. For the PRO7150 and PRO7350, the display module is attached to the front cover with a double-
sided adhesive pad. Carefully pull up on the display module, lifting only at the bottom corners,
remove it from the front cover. Use a new piece of double-sided adhesive to re-mount the display
to the cover.
3. For the PRO9150 only, The display module snaps into the front cover assembly. Insert two flat
blade screwdrivers between the flexible beam at the top of the display module (one on each side).
Deflect the beam down until it moves past the hooks on the front cover. The display module is
hooked to the front cover at the base of the display. Lift the top of the display module past the
hooks and remove from front cover.

3.6.5 Speaker, Microphone, and Universal Connector Flex Disassembly

1. If disassembly of the speaker-microphone assembly is necessary, remove the dustcover by
turning the screw at the bottom of the dustcover counterclockwise with your fingers. Lift the
dustcover out of its pocket.

NOTE The dustcover must be removed to remove the speaker-microphone assembly flex
circuit.
Radio Disassembly — Detailed 3-9

NOTE The speaker is held in place with a two-legged retainer bracket. The bracket legs are
secured by slots in the front cover. Be careful not to damage the speaker when
removing the retainer bracket.
2. Using a screwdriver, push down on the portion of the speaker retainer bracket pointing toward the
bottom of the radio. Then, remove the retainer by slightly pushing it toward the top of the radio
until you slide it past the front cover slot.
3. Using care not to pull on the flex cable, pull the rubber microphone boot from its seated position.
Unless you are replacing the microphone, leave it in the boot.

NOTE The PRO9150 radio has a different microphone and microphone boot then is used in
the other PRO series models. These are NOT interchangeable.

NOTE The speaker-microphone assembly flex circuit goes through the front cover wall to
the outside wall. To replace this assembly, you must peel-off the universal connector
escutcheon label. The existing escutcheon cannot be reassembled; a new part must
be used. (See item number 10 on the exploded view drawing on paragraph 3.8).

4. Peel-off the universal connector flex circuit escutcheon (label).

5. Carefully pry the flex circuit (adhesive 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. 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.

Speaker Orientation
Speaker Tab (12:00 Position)
Universal
Connector
Tail

Microphone
Boot
Microphone
Note: PRO7150 radio shown
Speaker Microphone as an example only.
Flex Circuit Assembly

Figure 3-8. Speaker-Microphone Removal

3-10 Radio Reassembly — Detailed

3.6.6 PTT Disassembly

If required, the PTT bezel and the PTT seal assembly can be disassembled using a small screwdriver
as follows:
PTT T-Shaped
Bezel Retainer Tab
Tab
Tab

PTT
Seal

Figure 3-9. PTT Removal

1. Pry back the T-tab found inside the front cover (in between the four buttons on the PTT assembly).
2. Remove the PTT bezel by slightly bowing it until the top and bottom tabs are released from the
slots in the front cover.
3. The PTT seal can be easily lifted from the bezel without the use of tools.

3.6.7 Control Top Disassembly

1. To remove the control top assembly, place a screwdriver next to the antenna boss, then pry it
against the control top escutcheon. This lifts the control top escutcheon away from its
double-sided adhesive. Grab the double-sided adhesive near the volume potentiometer, then lift it
away.
2. Remove the integrated control top seal, emergency button, and remove the transmit light pipe.

3.7 Radio Reassembly — Detailed

The paragraph that follow describe how to reassemble the radio. This includes the following major
components:
● Control top
● Speaker, microphone, universal flex connector
● Keypad/option board
● Chassis and front cover

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. Put the PTT seal in the PTT bezel.
2. Place the bezel top tab in the top slot inside the front cover PTT opening. Slightly bow the bezel
so that the bottom tab can fall inside the bottom slot.
3. Press the PTT assembly against the front cover opening.

NOTE Look inside the front cover to make sure the T-tab is fully engaged with the front
cover. If necessary, press the T-tab toward the top of the radio until it becomes fully
engaged.
Radio Reassembly — Detailed 3-11

3.7.3 Speaker, Microphone, and Universal Connector Flex Reassembly

1. Feed the universal connector tail 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 tail of the flex circuit. Attach the
flex tail to the front cover using the guide pins for correct alignment.
3. Replace the universal connector escutcheon. Make sure that all the connector openings align
with the gold pads on the flex circuit.
4. Align the notch in the speaker at the twelve o’clock position with the tab on the front cover as
shown in Figure 3-8.
5. Place the speaker retainer bracket into the hole on the top of the front cover, and bend the
retainer down to fit underneath the boss below the speaker.
6. If display, keypad, or keypad option board are not involved, reinsert the microphone and boot into
the pocket in the front cover

3.7.4 Keypad and Keypad Option Board Reassembly

1. If you are replacing the PRO7150 or PRO7350 display, use a new double-sided adhesive display
pad (item number 17 on the exploded view diagram in paragraph 3-8). Take care to avoid touching
the display lens.
2. If you are replacing the PRO9150 display, place the tabs at the bottom of the display into the
reliefs in the front cover. Gently snap the beam at the top of the display under the hooks in the
front cover. Take care to avoid touching the front of the display or the display lens.
3. Replace the keypad, and the keypad/option board. Insert display module flex tail into connector
on keypad option board. Push down on latch, closing it securely.

CAUTION: Take care not to damage the display. Do not cut, bend, or pinch the heat seal.
! Display modules contain CMOS devices. Be sure to use ESD protection.

4. For PRO7150 or PRO7350, insert the “top hooks” of the keypad retainer into the slots below the
speaker (above the display) in the front cover. For all models, snap all four of the retainer arm tabs
in place in the front cover.

NOTE If speaker and microphone not removed, pull the speaker-microphone flex circuit out
of the way during reassembly.

5. Reinsert the microphone and boot into the pocket in the front cover (PRO5150 and PRO7150
cylinder, PRO9150 clam shell).
6. Lay the speaker-microphone flex on top of keypad/option board retainer.

Catches

Retainer

Figure 3-10. Lock Retainer Catches to Radio Body

3-12 Radio Reassembly — Detailed

3.7.5 Chassis Assembly Reassembly

Before assembling the main RF board to the chassis, ensure that the following steps are done to the
chassis.
1. Slide on the ground contact (if it was removed) on the top corner boss of the chassis. Do not bend
the fingers that extend from this contact.
2. Replace the O-ring. The tabs on the O-ring should reach into the chassis and point down.
3. Stretch the O-ring to place it into the retaining pocket at the bottom end of the chassis.

NOTE When properly assembled, the retainers on the O-ring should align with the slots on
the chassis. If this is not the case, remove and replace the O-ring until it is aligned
with the chassis and completely seated in place around the perimeter.

Before assembling the main RF board to the chassis, ensure that the following additional steps are
done to the chassis.
1. Ensure that the antenna nut insulator is correctly replaced by pushing it all the way to the top of
the antenna nut.
2. Replace the battery contact seal (if necessary) surrounding the battery contact.
3. Place the main circuit board straight down on top of the chassis.

NOTE Be sure the battery contact seal protrudes through the chassis and is not pinched
under the chassis.
4. Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis.
5. Do not over torque. Torque limit is 3 inch lbs.

3.7.6 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. Push down the latches on the connectors to hold the flex circuits to the main board.
4. Slide the volume potentiometer and frequency switch shafts into their respective holes in the front
cover.
5. Push the chassis assembly completely into the top of the front cover until it settles in place.
6. Be sure the O-ring is properly seated.
7. Snap the bottom of the chassis into the front cover.
8. Reassemble the knobs, dust cover, antenna, and battery.

Radio
Chassis

Figure 3-11. Fastening the Chassis

Radio Reassembly — Detailed 3-13

3.7.7 DTMF Retrofit Kit Procedure (Optional Upgrade Procedure)

If you are performing an upgrade from a PRO5150 or PRO5350 model with no keypad to a PRO5150
or PRO5350 DTMF model, replace the existing front cover kit with kit number HLN9987 and follow the
reassembly steps to reassemble the upgraded radio. (See paragraph 3.7 for details about
reassembly.)
To activate the retrofit using the radio software, follow these steps:
1. Start the Customer Programming Software (CPS).
2. Read the codeplug data by clicking on the READ icon in the menu bar, or by selecting READ
DEVICE in the pulldown menu.
3. Open the Radio Configuration dialog box. (See Figure 3-12.)

Figure 3-12. Activating the Retrofit

4. Change the Keypad Configuration from “No Keypad” to “Programmable/Numeric”.
5. Write the codeplug back to the radio by clicking on the WRITE icon in the menu bar, or by
selecting WRITE DEVICE in the pulldown menu.

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.
3-14 Radio Reassembly — Detailed

3.7.8 Option Board Installation

1. With the keypad retainer removed and the display flex disconnected as shown in Figure 3-13, the
keypad backer board can be removed without the use of tools.
2. Remove the jumper flex from the connector on the keypad board. Notice the orientation of the flex
to the connector. Arrows on the jumper flex point to the correct way of inserting the flex into the
connector.
3. Discard the keypad backer board.
4. The “breakaway” tab at the top of all option boards contains an extra row of keys and is used only
for PRO9150 models.
5. For other PRO series models, break-off and discard the option board tab, taking care not to
damage the option board. Trim any tab fragments that may remain on the option board.

Retainer
Jumper
Flex

Keypad/
Option
Board

TO KP

Display
Flex

Note: PRO7150 radio shown

as an example only.

Figure 3-13. Changing Keypad/Option Board

6. Reassemble the option board to the front cover assembly.

7. Insert the display flex circuit into the connector on the option board.
8. Insert the jumper flex circuit into the connector on the option board. Notice the orientation of the
flex circuit. Arrows on the jumper flex point to the correct way of inserting the flex into the
connector.
9. For other PRO series models, replace the retainer by placing the two top hooks into the slots
below the speaker in the front cover; then, pivot the retainer into the front cover. For all radio
models, ensure that all four tab arms snap correctly into the front cover.
10. With the speaker microphone/keypad option board, display, and retainer correctly in place, the
front cover assembly can now be reassembled per paragraph 3.7.6.