XTL2500 FL01-90 Error Then Maintenance Mode

KG4LHQ · Post by **KG4LHQ** » Wed Nov 21, 2012 4:44 pm

Was writing a codeplug to a XTL2500 and got a FL01-90 Error and then it goes into Maintenance Mode. CPS will not write to it anymore, gives a Radio not acknowledge, tried to resync the head to the radio and still nothing.

Suggestions?

JeffFireRadio · Post by **JeffFireRadio** » Wed Nov 21, 2012 10:01 pm

My last experience with exactly those symptoms was about 45 days ago (June 2010 production unit, 14.xx.xx original firmware, XTL2500 remote, 700-800mhz) and ended up being a bad CHIB according to the depot sheet. They also noted that they loaded new firmware into the radio, which they normally do on a depot trip anyway, but don't usually list it as a specific line item on the repair ticket. Ironically, our NIB spare control head wouldn't work either that day on that radio, so I later wondered if a bad CHIB on the first head had really been the only issue. So, I'm still not convinced what I was really dealing with for a problem that day, just frustrated that a perfectly working radio now wasn't as a result of a simple reprogramming where there hadn't been a computer or power issue during the zap. Arghh. Regarding yours, if you are sure you've got good power to the drawer and both head wires (another source of the dreaded FL01-90, Maintenance Mode message...just not usually first seen during a programming session), it sounds like a trip to Texas might be in your radio's future. Best wishes.

KG4LHQ · Post by **KG4LHQ** » Thu Nov 22, 2012 7:41 am

Yeah, I was uploading some stuff into it and the programming worked fine in it at first then about 30 minutes later I programmed more stuff in it and it went half way through and then threw this error as I was writing.

I think I could like this radio but it has given nothing but headaches to me lately. Guess thats why I have a KW 5720 in my truck.

dasuriano · Post by **dasuriano** » Thu Nov 22, 2012 8:57 am

I had the same thing showing up on mine and it turned out to be that the ground wire was loose. Tightened up the ground and the issues completely went away.

KB2ZTX · Post by **KB2ZTX** » Thu Nov 22, 2012 2:02 pm

is this a dash mount or remote head ? I had this issue on a remote head unit. Plugging the programming cable into the deck instead of the head and reprogramming solved the issue.

KG4LHQ · Post by **KG4LHQ** » Thu Nov 22, 2012 3:34 pm

This is a dash mount radio.

How do I check that ground wire? Thanks!!

KB2ZTX · Post by **KB2ZTX** » Thu Nov 22, 2012 5:13 pm

I would check all your power connections, B+ and ground in addition to the ignition cable.

KG4LHQ · Post by **KG4LHQ** » Thu Nov 22, 2012 5:27 pm

Its not installed in a vehicle its as a base at the moment. What to check?

KG4LHQ · Post by **KG4LHQ** » Wed Nov 28, 2012 6:59 am

Any other ideas? Whats it going to cost me on a trip to depot

spectragod · Post by **spectragod** » Wed Nov 28, 2012 9:07 am

Bad flex, bad head?

KG4LHQ · Post by **KG4LHQ** » Wed Nov 28, 2012 10:02 am

Makes no sense. I programmed it once after I got it flashed so it would do P25 and it worked fine, added more stuff into it and it did this stuff while I was programming it.

Grr!

Post by **escomm** » Wed Nov 28, 2012 10:08 am

CPS 17? What is the firmware in the radio? Did this happen around block 13 or 14 of the write process? Flat rate on those radios is about $450. Good luck

MSS-Dave · Post by **MSS-Dave** » Wed Nov 28, 2012 10:22 am

Hey... I will take a whack at this...

I had a mobile do the exact same thing to me last year. It was a remote though. I was using the USB GCAI cable and could not clear the problem. It was suggested that I try the 26 pin serial programming cable. I uploaded the default saved codeplug and everything programmed fine and the head started working again. I know this is a dash mount but I have had NO problems in my fleet with dash mount like you are describing, just remotes. What cable are you using to program? If it is the GCAI, I'd be willing to say hitting it with the rear serial cable would fix it. If either that or the rear USB cable is being used now, it possibly needs to take a trip to Mexirola. Flat rate is high at $400+ though.....

EDIT>>> Just saw escomm's post so I will add that my issues happened at CPS 15 and Host/DSP 12. There was a updated control head sync program on MOL about the same time that CPS 17 showed.

Dave

KG4LHQ · Post by **KG4LHQ** » Wed Nov 28, 2012 3:04 pm

Yes CPS17 and probably half way through the program went unresponsive and thats when the radio threw the error.

com501 · Post by **com501** » Thu Nov 29, 2012 9:50 am

I was able to recover several remote mount radios with this issue by reflashing them. The radios were stuck in flashzap mode, so we reflashed them from the drawer GCAI connector.

After they were recovered, we reflashed with the ibutton using the normal procedure just to be sure and that also upgraded the codeplug version to match.

spectragod · Post by **spectragod** » Thu Nov 29, 2012 1:24 pm

com501 wrote:I was able to recover several remote mount radios with this issue by reflashing them. The radios were stuck in flashzap mode, so we reflashed them from the drawer GCAI connector.

After they were recovered, we reflashed with the ibutton using the normal procedure just to be sure and that also upgraded the codeplug version to match.

Had to use the same procedure on 3 2500 portables.

KG4LHQ · Post by **KG4LHQ** » Mon Dec 03, 2012 5:30 pm

Com501,

Friend tried this method and still nothing.

Any other suggestions?

com501 · Post by **com501** » Mon Dec 03, 2012 7:04 pm

There are 8 different programming cables for the XTL series.

Did you try them all?

You could always send it to a Motorola shop that knows what they are doing.

Did you check the control head bus fuse in the drawer?

Was the radio programmed so it can power up without 'control head required for power up' ??

KG4LHQ · Post by **KG4LHQ** » Tue Dec 04, 2012 10:00 pm

There are 8 different programming cables for the XTL series.

Did you try them all?

You could always send it to a Motorola shop that knows what they are doing.

Did you check the control head bus fuse in the drawer?

Was the radio programmed so it can power up without 'control head required for power up' ??

All I know is I sent it to a friend that took it to a friends shop and he tried what you suggested and even put a new head on it and still goes into this FL01-90 Maintenance Mode crap.

I don't know about 8 programming cables or anything like that.

I can not confirm if he checked the control head bus fuse.

The radio powers up again, I was writing to the radio, half way through CPS froze and then radio made a thump beep and then threw this error.

I have another person that says they can probably fix it so I'm hopeful. Good grief this will make someone's nerves and temper show.

MSS-Dave · Post by **MSS-Dave** » Wed Dec 05, 2012 4:20 am

What cable are YOU using?

KG4LHQ · Post by **KG4LHQ** » Wed Dec 05, 2012 5:59 am

I was using a OEM Serial to Mic Plug cable

t95mwp · Post by **t95mwp** » Wed Dec 05, 2012 11:44 am

You need to replace MUX PN#5114000C11,that is 99% of the time what goes wrong with the XTL2500 when you have FL01/90.

KG4LHQ · Post by **KG4LHQ** » Wed Dec 05, 2012 2:33 pm

What is that part number, how to install and cost?

t95mwp · Post by **t95mwp** » Wed Dec 05, 2012 2:58 pm

5114000C11,it is very small IC that you have to use magnifier to replace.

KG4LHQ · Post by **KG4LHQ** » Wed Dec 05, 2012 3:12 pm

Good grief!

I knew I should have stuck with Kenwood

t95mwp · Post by **t95mwp** » Wed Dec 05, 2012 3:54 pm

We in the state shop fixed them on daily bases, if isn't flex then go replace the head and if that does not help next is this part that like I said fails always.Actually it is not that hard to replace it.

KG4LHQ · Post by **KG4LHQ** » Wed Dec 05, 2012 7:09 pm

Pm sent asking for more info.

MSS-Dave · Post by **MSS-Dave** » Thu Dec 06, 2012 6:31 am

If you can get a hold of a rear connector serial cable (sorry, I can't find the P/N at the moment), that MAY work. That is what ended up working on my failures. I just happened to have the full complement of cables available at the time. I have had dead radios that got sent to the depot but either was a fuse in the control head or they just swapped the whole head under warranty. Never sent one out for 01/90 or Maintenance Mode.

At least with trying the cable, you don't have to dig into the guts of the thing.

mogman · Post by **mogman** » Thu Aug 11, 2016 2:23 pm

Can someone help me out here, I have looked and can not find the part number listed above anywhere in the basic or detailed manual, I do see reference to U0209, U0902 and U0606 as MUX chips but the numbers are not even close to the above referenced part #
I have a 2500 that cannot be read in any mode, front or rear, it boots into the fail1/90 then maintenance mode, can be put into the bootstrap mode but still cannot be read.

N4DES · Post by **N4DES** » Fri Aug 12, 2016 2:38 am

What were you doing with the radio at the time that the 01/90 showed up? I have had two radios previously that this occurred during a FW bump and all I did was to totally reboot everything, including the computers, and reload the FW into it using a valid flashkey. I walked away from them for the afternoon and when I returned a few hours later they and I were very happy campers.

mogman · Post by **mogman** » Fri Aug 12, 2016 12:33 pm

It came to me this way, it will not respond to any of the "tricks" cannot load a codeplug or firmware,,, zip zero nada
Have used front and rear USB and front and rear serial cables, multiple PCs
Cannot read or write in any fashion period..

Bigfella237 · Post by **Bigfella237** » Fri Aug 12, 2016 3:08 pm

There is an option in CPS called 'CH required to boot' (or something like that), if that was ticked and the connection to the CH is lost for any reason, then that may explain why you can't get anything from the rear connector?

mogman · Post by **mogman** » Sat Aug 13, 2016 1:38 pm

I can find no such setting.....

Bigfella237 · Post by **Bigfella237** » Sat Aug 13, 2016 6:36 pm

It's in the Radio Wide > Control Head tab...

mogman · Post by **mogman** » Sun Aug 14, 2016 5:39 am

I am confused, you have to have the codeplug loaded (read) to get into the radio wide settings, yes?
This option was not selected when I tried to force a codeplug into the radio.
I still don't think that would affect the radio when in the flash-zap mode.

mogman · Post by **mogman** » Fri Aug 19, 2016 4:27 am

OK I finally figured it out, the part number above supersedes the original number in the manual, looking at the schematic there is a VR (4 zeners in one package) that looks to be a likely suspect also, I have had quite a few of these go out in the Pro series radios.
Off to the bench..

Post by **Dispatch229** » Thu Sep 29, 2016 11:50 pm

Any luck?

MotoFAN · Post by **MotoFAN** » Tue Oct 25, 2016 3:51 pm

Hi all! There is no such P/N in SM as 5114000C11. Can somebody point me to right component accordinlgy to SM? There are a few MUX in radio. Is it U0606 5105109Z31 or something else?

I come across with very strange XTL2500 behavior. Sometimes it fails to boot, falls to FAIL 01/90, goes to MAINT MODE (orange backlight), produces very loud tones with (sometimes with rustle), and finally boots okay (with no any interventions). It can product very loud tones (like maximum radio volume) when VOL pot set fully CCW. After that it can boot and start working during a few days with no issues. It can be read and written, or even flashed. After that it can start 10 times with no issues, and on the next begin doing crazy things.

Radio was purchased NIB, used at home only. No wet, no vibration. Dash config. 3 small flexes in the head was reseated. Head has been replaced with new one, but same hell. Radio was R16 or something, but now R20.05/R19.50. No differencies.

It's a reason why I ask for component #.

t95mwp · Post by **t95mwp** » Tue Oct 25, 2016 5:31 pm

IC MOS TTL SPDT ANLG SC70, PB-FREE. The part is still current at MOl and it is only $5.

MotoFAN · Post by **MotoFAN** » Wed Oct 26, 2016 1:28 am

I know that this part in MOL and I see its description and pricing. But I am asking about P/N accordingly XTL service manual or component ID. There is not such part as 5114000C11 in XTL at all!!! This number is NOT from XTL radio as was stated above 3 times! This P/N is from programming cable.

But I need to know what to replace with this component in XTL. So I need P/N from XTL manual or other reference. Like U606.

tsunami_australia · Post by **tsunami_australia** » Thu Oct 27, 2016 2:35 pm

I've seen this behaviour with my XTL2500 base radio when programming one day. For some reason the USB adapter was NOT happy with the USB port of the laptop (USB3) and it just stalled half way through (FW12 CPS20.05 iirc).

I resurrected the radio through means I won't mention or describe but once resurrected, a simple change of the USB-RS232 adapter (genuine Moto serial-GCAI lead) to the USB2 port on the opposite side of the laptop and I've never had an issue since. What drove me to test the other port was I had been able to program my handheld fine and that night it went into stall mode and corrupted as well.

So not sure what's in USB3 ports that would cause this but I steer clear of them now.

MotoFAN · Post by **MotoFAN** » Fri Oct 28, 2016 12:07 am

Not my case indeed. Radio programmed many times with all genuine cables and programming cable has disconnected.

fineshot1 · Post by **fineshot1** » Fri Oct 28, 2016 7:14 am

FSB NUMBER: FSB10530A
APC: 500, 585, 514, 518
DATE: May 2011
EXPIRES: 31-December-2012
BULLETIN TYPE: Informational Only

Up-Issued to expand control head firmware versions affected

SUBJECT: XTL5000/XTL2500 Radio May Exhibit a “Maintenance Mode or Reset”
after upgrading to radio Host R14.00.00 with Control Head Version MCH R08.00.00 thru R11.00.03
MODEL / SYSTEM AFFECTED:
XTL5000 M20xxx9PWxAN or XTL2500 M21xxx9PWxAN mobiles using control head firmware version MCH
R08.00.00 thru R11.00.03
Note: W Series Configurations not affected.
SYMPTOM:
Radio will intermittently power cycle or display maintenance mode without user intervention.
CAUSE:
If the microphone HUB is not solidly grounded, an excessive number of interrupts can be generated, resulting in
processor overload and eventual reset/maintenance mode display.
RESOLUTION:
Please ensure the microphone HUB is properly grounded and, if the issue still persists, update radio firmware to
R15.00.09 or later.
Please contact Motorola System Support Center - TSO Subscriber Support team at 1-800-927-2744 with any questions
or if a firmware refresh form is needed.
SEVERITY RECOMMENDATION:
Medium - Perform at next scheduled maintenance
PARTS REQUIRED (HARDWARE/SOFTWARE):
NONE
LABOR ALLOWANCE
This is an informational bulletin. No labor warranty is implied, intended or authorized.

Page 1 of 1

The information contained in this bulletin is intended for use by trained, professional technicians who have the proper tools, equipment, and training to perform the
service described above. If applicable, enter this information or note this bulletin number and subject material in the appropriate equipment instruction manuals and
make necessary schematic diagram changes. Labor and/or parts warranty reference is limited to products sold and in use in the United States. For products sold and in
use Internationally, this bulletin is for informational purposes only. Radios that are Agency Approved must follow designated agency guidelines. MOTOROLA
SOLUTIONS and the Stylized M Logo are registered in the US Patent & Trademark Office. All other trademarks, product, or service names are the property of their
respective owners.

MotoFAN · Post by **MotoFAN** » Fri Oct 28, 2016 7:23 am

t95mwp wrote:IC MOS TTL SPDT ANLG SC70, PB-FREE. The part is still current at MOl and it is only $5.

Where you get info about this part if you even cannot point to component ID or original P/N?

Post by **Dispatch229** » Fri Oct 28, 2016 9:31 pm

Old Part number was 5162852A79. If you have an older service manual, this is what you'll find.

It has since been replaced by 5114000C11.

I am still trying to figure out what the reference designator number is, since there are multiple components with the same part number (maybe they all need to be replaced?)

If anyone can shed some light on this, it would be greatly appreciated

MotoFAN · Post by **MotoFAN** » Sun Oct 30, 2016 11:34 am

Dispatch229

Thanks for your input. Whit is exactly what I asked for. But you're right, there are 5 chips in radios: U0203, UC0208, U0209, U0210, U0401. And some of radio can contains U0703, U0704, U0705. Which one to replace - this is the quesion!

If I understand, they are just electronic switches. And in theory I can tryto analyze what's goes wrong and replace particular one. But it's not easy indeed.

Also I see, that mogman told about another component, VRs (4 Zener diodes in one case). It's absolutely different story, it's just a line protection. They also can be a problem, because bad Zeners can load lines.