Motorola EX500 Expert Series User manual

Product Software License Agreement
THIS LICENSE AGREEMENT BETWEEN YOU, THE USER, AND MOTOROLA, APPLIES TO THE SOFT-
WARE EMBEDDED IN OR DELIVERED WITH THE ACCOMPANYING MOTOROLA PRODUCT (“SOFT-
WARE”), AND IS APPLICABLE UNLESS A SIGNED LICENSE AGREEMENT COVERING ITS SUBJECT
MATTER HAS BEEN EXECUTED BETWEEN YOU AND MOTOROLA. BY USING THE PRODUCT, YOU
ACKNOWLEDGE THAT THIS AGREEMENT HAS BEEN READ AND UNDERSTOOD AND THAT YOU
AGREE TO BE BOUND BY ITS TERMS AND CONDITIONS. IF YOU DO NOT AGREE, YOU ARE NOT
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Motorola grants to You a non-exclusive license to use the SOFTWARE in the manner described in the docu-
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You agree not to reverse engineer or create derivative works of the SOFTWARE; not to transmit the SOFT-
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MOTOROLA SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING
FROM THE USE OF THIS SOFTWARE.
With respect to the U.S. Government, if acquired under FAR policy (52.227-19), the SOFTWARE is provided
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with the commercial rights of this Agreement.
This license is effective until terminated. It will terminate immediately and automatically if You fail to comply
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Computer Software Copyrights
This manual may not be reproduced, in whole or in part, in any form whatsoever, without the express written per-
mission of Motorola, Inc.
The Motorola products described in this manual contain one or more computer programs. These computer
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of these programs, or any part thereof, may result in severe civil and criminal penalties, and will be prosecuted
to the maximum extent possible under the law. U.S. and international patents pending.

i
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
6881094C00-O Initial edition Mar 2001
6881094C00-B Updated model charts for UHF Band 1, UHF Band 2 and
VHF bands for EX560•XLS.
Added Disassembly and Reassembly, Mechanical View
and Parts List for EX560•XLS.
Added Ensuring Radio Immersibility section
Jan 2007

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Notes

iii
Table of Contents
Product Safety and RF Exposure Compliance .................................................................. v
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
1.3 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 .......................................................... 2-3
Chapter 3 Maintenance
3.1 Introduction ............................................................................................................ 3-1
3.2 Preventive Maintenance......................................................................................... 3-1
3.2.1 Inspection ............................................................................................................ 3-1
3.2.2 Cleaning Procedures........................................................................................... 3-1
3.3 Safe Handling of CMOS and LDMOS Devices ...................................................... 3-2
3.4 Repair Procedures and Techniques — General .................................................... 3-3
3.5 Servicing IP67 radios ............................................................................................. 3-4
3.6 Disassembling and Reassembling the Radio — General ...................................... 3-4
3.7 EX500 Radio Disassembly — Detailed.................................................................. 3-5
3.7.1 Front Cover from Chassis Disassembly .............................................................. 3-5
3.7.2 Chassis Assembly Disassembly.......................................................................... 3-7
3.7.3 Speaker, Microphone, and Universal Connector Flex Disassembly ................... 3-8
3.7.4 Controller Board Disassembly............................................................................. 3-9
3.7.5 Control Top Disassembly .................................................................................... 3-9
3.8 EX500 Radio Reassembly — Detailed .................................................................. 3-9
3.8.1 Control Top Reassembly..................................................................................... 3-9

iv
3.8.2 Speaker, Microphone, and Universal Connector Flex Reassembly.................... 3-9
3.8.3 Chassis Assembly Reassembly ........................................................................ 3-10
3.8.4 Chassis and Front Cover Reassembly.............................................................. 3-10
3.9 EX600 / EX600•XLS Radio Disassembly and Reassembly — General ...............3-11
3.10 EX600 / EX600•XLS Radio Disassembly — Detailed ..........................................3-11
3.10.1 Front Cover from Chassis Disassembly............................................................ 3-11
3.10.2 Chassis Assembly Disassembly ....................................................................... 3-14
3.10.3 Speaker, Microphone, and Universal Connector Flex Disassembly ................. 3-14
3.10.4 Controller Board, Display Module and Keypad Disassembly............................ 3-15
3.10.5 Control Top Disassembly .................................................................................. 3-17
3.11 EX600 / EX600•XLS Radio Reassembly — Detailed ...........................................3-17
3.11.1 Control Top Reassembly................................................................................... 3-17
3.11.2 Speaker, Microphone, and Universal Connector Flex Reassembly .................. 3-17
3.11.3 Chassis Assembly Reassembly ........................................................................ 3-17
3.11.4 Chassis and Front Cover Reassembly.............................................................. 3-17
3.12 EX560•XLS Radio Disassembly and Reassembly — General.............................3-18
3.13 EX560•XLS Radio Disassembly — Detailed ........................................................3-19
3.13.1 Front Cover from Chassis Disassembly............................................................ 3-19
3.13.2 Chassis Assembly Disassembly ....................................................................... 3-21
3.13.3 Speaker and Microphone Disassembly............................................................. 3-22
3.13.4 Controller Board, Display Module and Keypad Disassembly............................ 3-22
3.13.5 Control Top Disassembly .................................................................................. 3-24
3.14 EX560•XLS Radio Reassembly — Detailed.........................................................3-24
3.14.1 Control Top Reassembly................................................................................... 3-24
3.14.2 Speaker Reassembly ........................................................................................ 3-24
3.14.3 Chassis Assembly Reassembly ........................................................................ 3-24
3.14.4 Chassis and Front Cover Reassembly.............................................................. 3-24
3.15 Ensuring Radio Immersibility ................................................................................3-25
3.15.1 Servicing ........................................................................................................... 3-25
3.15.2 Accidental Immersion........................................................................................ 3-25
3.15.3 Specialized Test Equipment.............................................................................. 3-25
3.15.4 Vacuum Pump Kit NLN9839 ............................................................................. 3-26
3.15.5 Pressure Pump Kit NTN4265............................................................................ 3-26
3.15.6 Miscellaneous Hardware................................................................................... 3-26
3.15.7 Disassembly...................................................................................................... 3-26
3.15.8 Reassembly ...................................................................................................... 3-26
3.15.9 Vacuum Test ..................................................................................................... 3-27
3.15.10 Pressure Test.................................................................................................... 3-27
3.15.11 Troubleshooting Leak Areas ............................................................................. 3-28
3.15.12 Breathing Vent Membrane and Breathing Vent Label....................................... 3-30
3.15.13 Troubleshooting Charts..................................................................................... 3-31
3.16 Mechanical Views and Parts Lists ........................................................................3-33

v
3.16.1 EX500 Exploded View and Parts List................................................................ 3-33
3.16.2 EX560•XLS Exploded View and Parts List........................................................ 3-35
3.16.3 EX600 / EX600•XLS Exploded View and Parts List .......................................... 3-37
3.17 Service Aids ......................................................................................................... 3-39
3.18 Test Equipment.................................................................................................... 3-40
3.19 Programming/Test Cable ..................................................................................... 3-41
Chapter 4 Transceiver Performance Testing
4.1 Introduction ............................................................................................................ 4-1
4.2 Setup...................................................................................................................... 4-1
4.3 Test Mode .............................................................................................................. 4-2
4.3.1 RF Test Mode...................................................................................................... 4-2
Chapter 5 Radio Tuning and Programming
5.1 Introduction ............................................................................................................ 5-1
5.2 Radio Tuning Setup ............................................................................................... 5-1
5.3 CPS Programming Setup....................................................................................... 5-2
5.4 Cloning Information................................................................................................ 5-3
Chapter 6 Power Up Self-Test
6.1 Error Codes............................................................................................................ 6-1
Chapter 7 Accessories
7.1 Antennas................................................................................................................ 7-1
7.1.1 EX500 / EX600 / EX600•XLS.............................................................................. 7-1
7.1.2 EX560•XLS.......................................................................................................... 7-1
7.2 Carry Cases ........................................................................................................... 7-2
7.3 Chargers ............................................................................................................... 7-2
7.4 Batteries ................................................................................................................ 7-2
7.5 Audio Accessories.................................................................................................. 7-3
7.6 Microphones........................................................................................................... 7-3
7.7 Ear Microphone System......................................................................................... 7-3
7.8 Manuals ................................................................................................................. 7-4
Chapter 8 Model Chart and Test Specifications

vi
8.1 136-174 MHz ..........................................................................................................8-1
8.1.1 EX500/EX600/EX600•XLS.................................................................................. 8-1
8.1.2 EX560•XLS ......................................................................................................... 8-2
8.2 403-470 MHz ..........................................................................................................8-3
8.2.1 EX500/EX600/EX600•XLS.................................................................................. 8-3
8.2.2 EX560•XLS ......................................................................................................... 8-4
8.3 450-512 MHz ..........................................................................................................8-5
8.3.1 EX500/EX600/EX600•XLS.................................................................................. 8-5
8.3.2 EX560•XLS ......................................................................................................... 8-6
8.4 Specifications .........................................................................................................8-7
Glossary of Terms .......................................................................................................... G-1

Safety and General Information vii
Product Safety and RF Exposure Compliance
ATTENTION!
This radio is restricted to occupational use only to satisfy FCC RF energy exposure
requirements. Before using this product, read the RF energy awareness information and operating
instructions in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola
Publication part number 68P81095C98) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site
which lists approved accessories: http://www.motorola.com/cgiss/index.shtml.
NOTE Before using this product, read the operating instructions for safe usage contained
in the Product Safety and RF Exposure booklet enclosed with your radio.
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viii Safety and General Information
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 in this document and is current as
of the printing date. Changes which occur after the printing date will be incorporated in a complete
Manual Revision or alternatively as additions.
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 available from Authorized Motorola Dealers.
1.2.1 Warranty Period and Return Instructions
The terms and conditions of warranty are defined fully in the Motorola Dealer, 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. (See section 1.2.4 on page 1-3 of 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 offers repair service to users and dealers at competi-
tive prices.
2. The Motorola Accessories and Aftermarket Division (AAD) supplies individual parts and modules
that can be purchased by dealers who are capable of performing fault analysis and repair.
NOTE Before operating or testing these units, please read the Safety Information Section at the
beginning of this manual.

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.
Parts Order Entry:
7:00 A.M. to 7:00 P.M. (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
To Order Parts:
1-800-422-4210, or 847-538-8023
1-800-826-1913, or 410-712-4907 (U.S. Federal Government)
TELEX: 280127
FAX: [phone]
FAX: [phone] (U.S. Federal Government)
(U.S.A.) after hours or weekends:
1-800-925-4357
Motorola Parts
Accessories and Aftermarket Division
(United States and Canada)
Attention: Order Processing
2200 Galvin Dr.
Elgin, IL 60123
Parts Identification
1-800-422-4210 Menu 3
If... It Means That...
A complete Motorola part number is assigned to
the part, and it is not identified as Depot ONLY
The part is available from AAD.
No part number is assigned The part is not normally available from Motorola.
The part number is appended with an asterisk, The part is serviceable by a Motorola Depot
only.
A parts list is not included Generally, no user-serviceable parts are
available for that kit or assembly.

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, keep the product model number and the unit’s serial
number handy.
For service, contact one of the following Depots. Please call and confirm your return before sending
the unit to the depot for service.
Motorola Radio Support Center
3761 South Central Avenue
Rockford, IL 61102-4294
1-800-227-6772
1-815-489-1000
Motorola Toronto Service Center
400 Matheson Blvd. W
Mississauga, Ontario, Canada L5R 3M1
1-800-543-3222
1-416-756-5841
1-888-331-9872 (Fax)
Motorola U.S. Federal Government Depot
4395 Nicole Drive
Lanham, MD 20706
1-800-969-6680
1-301-731-6676

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: AAH38KDC9AA3)
Type of
Unit
Model
Series
Freq.
Band
Power
Level
Physical
Packages
Channel
Spacing Protocol Feature Level
Model
Revision
Model
Package
AA H 38 K
VHF
(136-
174MHz)
D
4-5W
C
EX500
No display
9
Program-
mable
AA
Conven-
tional
3
EX500
AN
R
UHF1
(403-
470MHz)
H
EX600 /
EX600•XLS
Full Keypad
with display
DU
LTR
6
EX600 /
EX600•XLS
S
UHF2
(450-512
MHz)
AA = Motorola Internal Use
Portable

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 or the bottom of the radio housing. The FM Approval mark is
shown below:
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.
WARNING: Do not operate radio communications equipment in a hazardous atmosphere
unless it is a type especially qualified for such use (e.g., FMRC Approved). An explosion
or fire may result.
WARNING: Do not operate an FMRC Approved 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 spark-
ing 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 an 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 a radio off before removing or installing a battery or accessory.
WARNING: Do not disassemble an FMRC Approved Product unit in any way that exposes
the internal electrical circuits of the unit.
FM
APPROVED
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2-2 Repair of FMRC Approved Products
A modification changes the unit’s hardware from its original design configuration. Modifications can
only be made by the original product manufacturer at one of its FMRC-audited manufacturing
facilities.
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 PRODUCTS WITH FMRC APPROVAL ARE THE RESPONSIBILITY
OF THE USER.
You should not repair or relabel any Motorola- manufactured communication equipment bearing the
FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC
Approval standard for repairs and service (“Class Number 3605”).
You may want to consider using a repair facility that operates under 3605 repair service approval.
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.
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
dangerously unsafe condition of an unapproved radio combination being used in a hazard-
ous location.
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.
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Repair of FMRC Approved Products 2-3
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. Approved configurations are listed in the FM Approval
Guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped from
the manufacturer with the FM Approved radio and battery combination. The Approval Guide, or the
Approval Standard Class Number 3605 document for repairs and service, can be ordered directly
from Factory Mutual Research Corporation located in Norwood, Massachusetts, USA.

2-4 Repair of FMRC Approved Products
Notes

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
•Repair procedures and techniques
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.
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).
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.
CAUTION: The effects of certain chemicals and their vapors can have
harmful results on certain plastics. Avoid using aerosol sprays, tuner
cleaners, and other chemicals.
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3-2 Safe Handling of CMOS and LDMOS Devices
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
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.
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.
NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
CAUTION: This radio contains static-sensitive devices. Do not open the radio
unless you are properly grounded. Take the following precautions when
working on this unit:
• Store and transport all CMOS devices in conductive material so that all
exposed leads are shorted together. Do not insert CMOS devices into con-
ventional plastic “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 Motor-
ola 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 volt-
age 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.
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