Motorola Xts1500 Xts2500 Basic 6881094c09 B Manual
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Disassembly/Assembly 53 Keypad and Keypad Option Board Reassembly1. Insert the keypad into the front cover. Align the keypad to the pins in the front cover. 2. Replace the board on the locator pins. 3. Replace the keypad retainer legs on the PTT side first. Then, press the retainer down and snap the other two legs into place on the universal connector side; make sure that all four legs snap into place. If necessary, use a small, flat-bladed screwdriver to put pressure on the corner bend of each retainer leg. Display Reassembly1. Slide the two bottom tabs of the display module, with the LCD facing the front housing lens, into the grooves located above the keypad assembly area in the front cover housing. Gently press on the upper portion of the display until it snaps into place past the two small hooks in the housing. 2. Connect the display flex to the keypad option board connector. Speaker, Microphone, and Universal Connector Flex Reassembly1. Insert the microphone boot into the pocket in the front cover housing. 2. Insert the microphone boot plastic retainer. Make sure the retainer is securely hooked to the front cover. 3. Center the speaker in the speaker recess. Make certain the speaker is correctly nested inside the front cover. 4. Before you replace the speaker retainer, be sure the retainer is placed between the speaker-microphone flex circuit and the speaker. Insert the flat end of the speaker retainer into the opening in the front cover. Press the other end of the retainer against the speaker. Hold the retainer in place with your thumb while pushing down on the retainer with a flat-bladed screwdriver. Use the screwdriver to push down on the portion of the speaker retainer that is pointing toward the bottom of the radio. Move the retainer by pushing it toward the bottom of the radio. Slide it into the front cover slot above the display. 5. Connect the universal flex to the pins and press into place.Figure 39. Lock Retainer Catches to Radio Body
Disassembly/Assembly 54 Chassis Assembly ReassemblyBefore you assemble the main board to the chassis, make sure that the following steps are done to the chassis. 1. Replace the O-ring. The tabs on the O-ring should reach into the chassis and point down. 2. 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. 3. Replace the battery contact seal (if necessary) surrounding the battery contact. NOTE:Be sure the battery contact seal protrudes through the chassis and is not pinched under the chassis. 4. Make sure the thermal pad is placed on top of the RF Power Amplifier on the main board. 5. Use the notch in the bottom of the main board and the protrusion at the bottom of the casting to align the board to the casting. Place the board against the casting. Make sure that the five screw holes are aligned. 6. Place the main shield assembly on the main board. Again, make sure that the five screw holes are aligned. 7. Use the TORX T7-IP screwdriver to fasten the screws holding the main board and shield to the chassis. Do not over torque. Torque limit is 4 inch-lbs. 8. Place the O-ring at the antenna connector over the antenna connector bushing. Backup Battery Reassembly1. Insert the backup battery (positive side up) into the battery holder, as shown in Figure 40. 2. Replace the retaining clip by sliding it into its recess on the board. Chassis and Front Cover Reassembly1. 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 Figure 40. Reassemble the Backup Battery
Disassembly/Assembly 55 chassis assembly. 3. Push down the latches on the connectors to hold the flex circuits to the main board. NOTE:Be sure the concentric lever is not in place on the frequency knob shaft when reassembling the chassis with the front cover assembly. 4. Align the volume knob shaft and the frequency switch shaft with their respective holes in the front cover. Slowly reassemble the chassis and front cover assemblies. Slowly slide the volume knob and frequency switch shafts into their respective holes in the front cover. NOTE:Make sure the flex circuits are correctly folded in place. Take special care to prevent pinching or excess binding of these flexes. 5. Push the chassis assembly completely into the top of the front cover until it settles in place. NOTE:Be sure the O-ring is properly seated. 6. Press down at the bottom of the chassis until the chassis snaps into place in the front cover. 7. Reassemble the concentric lever to the frequency knob shaft by aligning the protrusions in the lever with the openings in the shaft. The triangular-shaped side of the lever should point toward the back of the radio. 8. Reassemble the Teflon washer to the volume knob shaft. Reassemble the knobs, dust cover, antenna, and battery.Figure 41. Fastening the Chassis
57 Radio-Level Troubleshooting 9 Introduction to This SectionThis section of the manual contains troubleshooting charts and error codes that will help you to isolate problems. Level one troubleshooting will support only radio alignment, programming, battery replacement, and knob replacement. If the radio needs further troubleshooting, it must be sent to the depot. Board-level, component-level, and service information can be found in the ASTRO Digital XTS 2500 Portable Radios Detailed Service Manual, Motorola publication number 68P81094C10. Power-Up Error CodesWhen the radio is turned on (power-up), the radio performs cursory tests to determine if its basic electronics and software are in working order. Problems detected during these tests are presented as error codes on the radio’s display. For non-display radios, the problem is indicated at power-up by a single, low-frequency tone. If cycling power and code plug reprogramming do not fix the error, the radio should be sent to the depot for repair. The presence of an error should prompt the user that a problem exists and that a service technician should be contacted. Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user operation; non-fatal errors will not. Table 23. lists their descriptions and suggested corrective action.
Radio-Level Troubleshooting 58 Operational Error CodesDuring radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as error codes on the radio’s display. Ann error code indicates that a problem exists and that a service technician should be contacted. Operational error codes are listed in Table 24..Table 23. Power-Up Error Code Displays Error CodeDescriptionCorrective Action 01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug. 01/12 Security partition Checksum Non-Fatal Error Send Radio to Depot. 01/22 Tuning Codeplug Checksum Non-Fatal Error Send Radio to Depot. 01/81 Host ROM Checksum Fatal Error Send Radio to Depot. 01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug. 01/88 External RAM FATAL Error -- Note: not a checksum failure Send radio to depot. 01/90 General Hardware Failure Fatal Error Turn the radio off, then on. 01/92 Security Partition Checksum Fatal Error Send radio to depot. 01/93 Flashport AUTHENTIFICATION CODE failure Send radio to depot. 01/98 Internal RAM Fail Fatal Error Send radio to depot. 01/A0 ABACUS Tune failure Fatal Error Turn the radio off, then on. 01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot. 02/10 DSP Support IC Checksum Non-Fatal Error Turn the radio off, then on. 02/81 DSP ROM Checksum Fatal Error Send radio to depot. 02/88 DSP RAM Fatal Error -- Note: not a checksum failure Turn the radio off, then on. 02/90 General DSP Hardware Failure (DSP startup message not received correctly)Turn the radio off, then on. NOTE:If the corrective action does not fix the failure, send the radio to the depot. Table 24. Operational Error Code Displays Error CodeDescriptionCorrective Action FAIL 001 Synthesizer Out-of-Lock a. Reprogram external codeplug b. Send radio to depot FAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram external codeplug
Radio-Level Troubleshooting
59 Table 25. Receiver Troubleshooting Chart
SymptomPossible CauseCorrection or Test (Measurements
Ta k e n a t R o o m Te m p e r a t u r e )
Radio dead; Display does not
light up1. Dead Battery Replace with charged battery.
2. Blown Fuse Send radio to depot.
3. On/Off Switch
4. Regulators
Radio dead; display
lights up1. VOCON Send radio to depot.
2. RF
No receiver audio or receiver
does not unmeetProgramming a. Does the transmitted signal match the receiver
configuration (PL, DPL, etc.)?
b. With the monitor function enabled, can the radio
be unmuted?
Audio distorted or not loud
enoughSynthesizer Not On
FrequencyCheck synthesizer frequency by measuring the transmitter
frequency; if off by more than ±1000Hz, realign.
RF sensitivity poor 1. Synthesizer Not
On FrequencyCheck synthesizer frequency by measuring the transmitter
frequency; if off by more than ≤ ±1000Hz, realign.
2. Antenna Switch Send radio to depot.
3. Receiver Front-
End Tuning Check RF front-end tuning for optimum sensitivity using the CPS.
Radio will not turn off VOCON Send radio to depot.
Table 26. Transmitter Troubleshooting Chart
SymptomPossible CauseCorrection or Test (Measurements Taken
at Room Temperature)
No RF power out 1. TX Power Level or Frequency Check TX power level and frequency
programming (from CPS).
2. No PTT From Control Top Send radio to depot.
3. No Injection To Power Amplifier
No modulation;
Distorted modulation1. Programming Check deviation and compensation settings
using the CPS.
2. VOCON Send radio to depot.
Bad microphone sensitivity 1. Check Deviation and Compensation Realign if necessary.
2. Microphone Send radio to depot.
No/Low signalling
(PL, DPL, MDC)1. Programming Check programming.
2. VOCON Send radio to depot.
Cannot set deviation balance RF Send radio to depot.
61 Accessories 10 GeneralMotorola provides the following approved accessories to improve the productivity of your XTS 2500 portable two-way radio. Antennas Audio Headsets Earpieces Remote Speaker Microphones NAF5037 806-870 MHz Whip, Half-wave, 7 inch NAF5042 806-870 MHz Quarter Wave, 3 inch, Stubby NAF5080 764-870 MHz Whip, Half-wave, 6.5 inch BDN6635 Boom Mic Headset with VOX (Adapter BDN6673) BDN6636 Throat Mic Headset with VOX (Adapter BDN6673) BDN6645 Noise-Canceling Boom Mic Headset with PTT on earcup BDN6673 Headset Adapter Cable for use with BDN6645, BDN6635, and BDN6636 NMN6258 Over the Head Headset w/ In Line PTT NMN6259 Medium Weight Dual Headset with NC Mic RMN4049 Temple Transducer BDN6677 Ear mic, standard, noise up to 95dB, black (must order Interface module) BDN6641 Ear mic, high noise level up to 105dB, grey (must order interface module) NMN6193 Remote Speaker Microphone NMN6191 RSM Noise Cancelling Includes: 6.0 coiled cord assembly, 3.5mm earjack, swivel clip, quick disconnect
Accessories 62 Surveillance Batteries Belt Clips Carrying Cases BDN6671 PTT and VOX Interface Module for use with BDN6677, BDN6678, and BDN6641 BDN6677 Ear Microphone, Standard 95 dB (Black) BDN6678 Ear Microphone, Standard 95 dB (Beige) BDN6708 PTT Interface Module for use with BDN6677, BDN6678, and BDN6641 NTN9815 NiCd High Capacity NTN9816 NiCd High Capacity, Factory Mutual Intrinsically Safe NTN9857 NiMH Ultra-High Capacity, Factory Mutual Intrinsically Safe NTN9858 NiMH Ultra-High Capacity HLN6853 Belt Clip, 2 1/4 inch NNTN4115 Carrying case, Bonded leather with 3” Swivel Belt Loop and T- strap NNTN4116 Carrying case, Bonded leather with 2.5” Swivel Belt Loop and T- strap NNTN4117 Carrying case, Bonded leather with 3” Belt Loop and T-strap