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Motorola DSR-6400 Satellite Radio User Manual

1. Figure 7 16 EP450 Non Display Radio Exploded View 7 13 December 3 2003 Motorola Part Number See Section 6 Description Antenna 2 3680530Z02 Knob Frequency 3 1386440Z02 Escutcheon Top 16 Ch 4 5886627Z201 Antenna Adaptor Seal 5 1586391201 Housing ELP Plain 6 3586621201 Felt Speaker 7 3886489201 PTT Rubber 8 4586439201 PTT Plastic 9 5085738208 Speaker 10 4286620201 Retainer Speaker 11 3586621202 Felt Microphone 12 0780608V01 Boot Microphone 13 5085880L01 Microphone 14 3286431 Z02 Seal Main O ring 15 7586436201 Pad PA Interface 16 2786389201 Chassis 17 3286435201 Seal Battery Contact Block 18 0304726J05 Screws Chassis 4 Used 19 1586437201 Shroud Audio Jack 20 5586445202 Latch Assembly 21 4105944K01 Spring Latch 2 Used 22 3886441Z01 Cap Dust 23 3286432Z01 Seal Control Shaft 24 3386443Z01 Label Escutcheon Seal 25 6186446Z02 Lightpipe 26 3680529Z01 Knob Volume 27 0386434201 Screw Speaker Retainer NON REFERENCED ITEMS 3386625201 Nameplate Motorola Nameplate EP450 Mechanical View and Parts List Chapter 8 Troubleshooting Tables 8 1 Power Up Error Codes During radio power up the radio performs dynamic tests to determine if the radio is working properly Problems detected during these tests are presented as an error code on the radio s
2. Rx Res eet aay Sinad Meter Program Test Cable AAPMKN4004 AC Voltmeter Tx Data RIB H Rx run4oo8 Fu Eee NI Computer Interface Cable RIB Power Supply Figure 5 2 Radio Tuning Setup December 3 2003 HKLN4215A Radio Alignment Procedures Transmitter Alignment Options 5 3 5 3 1 Initial Test Equipment Control Settings The initial test equipment control settings are listed in Table 5 1 Table 5 1 Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode Power Monitor Speaker set A Voltage 13 2 Vdc RF Attenuation 70 Speaker load DC on standby Speaker Standby AM CW FM FM PTT OFF Volt Range 20 V Oscilloscope Source Mod Current 20 A Oscilloscope Horizontal 10 mSec Div Oscilloscope Vertical 2 5 kHz Div Oscilloscope Trigger Auto Monitor Image Hi Monitor BW Nar Monitor Squelch mid CW Monitor Volume 1 4 CW 5 4 Transmitter Alignment Options Note When checking the RF power output of the radio with a test set always use a pad of at least 30 dB attached to the radio end of the RF cable This will avoid an RF mismatch and ensure a stable RF reading that will not change with varying lengths of connecting cable 5 4 1 Reference Oscillator Warp This is an important operation which affects all dev
3. Motorola Part No Table 3 1 Recommended Test Equipment Description Characteristics Application R2600 series System analyzer This item will substitute for Frequency deviation meter and items with an asterisk signal generator for wide range troubleshooting and alignment R1074 Fluke 87 digital multi True RMS metering Digital voltmeter is recom meter 200 kHz frequency mended for AC DC voltage and counter 32 segment bar current measurements graph with backlit display Fluke 85 RF probe 500 MHz 30 VAC max Use with Fluke 87 digital multi meter for RF voltage measure ments R1377 AC voltmeter 1 mV to 300 mV 10 mega Audio voltage measurements ohm input impedance R1611 Dual channel Two channel 100 MHz Waveform measurements 100 MHz oscillo bandwidth 200 M sample scope Agillent rate sec 2 MB memory channel 1339 RF millivolt meter 100 uV to 3V RF 10 kHz to RF level measurements 1 GHz frequency range R1013 or SINAD meter or Without RMS audio volt Receiver sensitivity measure meter or ments R1370 SINAD meter with With RMS audio voltmeter RMS 3 2 3 2 Service Aids Test Equipment Service Aids and Service Tools Service Aids Table 3 2 lists service aids recommended for working on the EP450 Radios 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
4. 7 Exit the Squelch Tuning function 5 5 2 2 Auto Tune Note Proceed with caution since this procedure automatically programs the softpot value into your radio When you press the Auto Tune button the radio automatically returns an optimum squelch value After you press the button the radio may need time to produce an optimal setting for the squelch attenuation The following steps describe the auto tune process 1 Select current frequency point F1 being the first then press Auto Tune 2 Repeat Steps 3 4 of the Manual Squelch Tuning section for frequency points F2 F7 Note Auto Tune will automatically update your radio s codeplug Please be careful when using it 5 5 3 RSSI System Level Tuning i BER 14415 dBm Softpot 1 175 dem Softpot2 TT BI Update Frequency tuning pointis currently 454 025000 MHz Figure 5 11 RSSI Tuning Under the Rx Align menu select RSSI Tuning Figure 5 11 2 Inject an on channel signal to the radio at 47 dBm at the frequency listed Modulate the signal with a 1 kHz tone at 60 deviation 3 kHz to verify that the radio is receiving the desired fre quency RSSI tuning is only done at 25 kHz channel spacing 3 Change the level to the defined dBm level in the softpot box 115 dBm or 105 dBm Press the Update button for the soft spot to be tuned to the RSSI value correlating to the applied level The programmed RSSI value will be displayed HKLN4215A December 3 2003
5. Microphone Position Figure 7 10 Microphone Re assembly Locate the speaker tab and align it with the tab opening in the front housing Figure 7 11 Insert the speaker tab into the speaker recess in the housing Ensure the speaker is seated flush in the housing December 3 2003 HKLN4215A Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 9 Note Make sure the speaker and microphone wires are routed tightly between the speaker basket and the housing post 6 Insert one end of the speaker retainer into the slot in the front housing See Figure 7 11 Speaker Retainer Speaker Tab Speaker Front Housing Slot Figure 7 11 Speaker Re assembly Note When fastening the speaker retainer screw make sure the wires are out of the way to pre vent pinching by the retainer 7 Install the retainer screw using a T6 Torx screwdriver Torque to 2 3 2 5 Ib in 7 4 3 3 Chassis Assembly Re assembly Replace the battery contact seal if necessary surrounding the battery contact Figure 7 12 2 Remove the old Interface Pad from the chassis by scraping off the pad and adhesive with a straight razor Use rubbing alcohol and a cloth to completely remove the adhesive from the chas sis surface With the chassis clean and dry add a new Interface Pad to the chassis 3 Place the main circuit board straight down on top of the chassis with the fr
6. Optional 5 1586391203 Housing Full with Lens 6 3586621201 Speaker Felt 7 3886489201 PTT Rubber 8 4586439201 PTT Plastic 9 5085738Z08 Speaker 10 4286620Z01 Retainer Speaker 11 3586621Z202 Felt Microphone 12 0780608V01 Boot Microphone 13 5085880L01 Microphone 14 5104949J16 Display LCD Module 15 0104017J18 Keypad Board Assy 16 1586437Z01 Shroud Audio Jack 17 3286431202 Seal Main O ring 18 7586436Z01 Pad PA Interface 19 2786389201 Chassis 20 3286435201 Seal Battery Contact Block 21 0304726J05 Screws Chassis 4 Used 22 4286648201 Plate Retainer 23 0909059E19 Connector 28 pin 24 0986632202 9 Pin Connector 25 7586654Z03 Keypad Full 26 5586445Z02 Latch Assembly 27 4105944K01 Spring Latch 2 Used 28 3886441Z01 Cap Dust 29 3286432201 Seal Control Shaft 30 0386434Z01 Screw Speaker Retainer 31 3386443201 Label Escutcheon Seal 32 6186446202 Lightpipe 33 3680529201 Knob Volume December 3 2003 Display Model Disassembly and Re assembly Mechanical View and Parts List HKLN4215A Chapter 7 Non Display Model Disassembly and Re assembly 7 1 Introduction This section provides details about the following Preventive maintenance inspection and cleaning Safe handling of CMOS and LDMOS devices Disassembly and re assembly of the radio Repair procedures and techniques 7 2 Preventive Maintenance The radios do not require a scheduled preventive maintenance program however periodic visual inspectio
7. 9cm 146 162 MHz VHF Stubby Antenna 9cm 162 174 MHz UHF Heliflex Stubby Antenna 9cm 438 470 MHz Flexible Whip Antenna 403 520 MHz UHF Heliflex Stubby 470 520 MHz Carrying Accessories RLN5498 RLN5496 RLN5497 RLN5644 NTN5243 HLN9985 RLN5383 HLN9701 RLN5384 RLN5385 Chargers WPLN4137 WPLN4138 R WPLN4139 R WPLN4142 R WPLN4140 R WPLN4161 WPLN4162 WPLN4163 WPLN4164 Batteries NNTN4496 R NNTN4497 R NNTN4851 R NNTN4970 Hard Leather Case Full DTMF with Belt Loop Hard Leather Case Full DTMF with 3 inch Swivel Belt Loop Hard Leather Case Full DTMF attaches to D Shaped Rings on case 2 5 inch Spring Action Belt Clip Shoulder Strap for Hard Leather Cases attaches to D Shaped Rings on case Waterproof Bag Nylon Case with Belt Loop Non Display models Leather Case with Belt Loop Leather Case with 2 1 2 inch Swivel Belt Loop Non Display models Leather Case with 3 inch Swivel Belt Loop Non Display models Desktop Rapid Charger Base Only w NA LA Manual Rapid 90 Min Desktop Charger w US plug Rapid 90 Min Desktop Charger w Euro plug Rapid 90 Min Desktop Charger w Argentina plug Rapid 90 Min Desktop Charger w UK plug Rapid 90 Min Multi Unit Charger w US plug Rapid 90 Min Multi Unit Charger w Euro plug Rapid 90 Min Multi Unit Charger w UK plug Rapid 90 Min Multi Unit Charger w Argentina plug High Capacity Ni Cd 1100 mAH Ultra High Capacity Li lon 1800 mAH High Capacity NiMH 1400 mAH High
8. Both cover all the functions of the traditional Radio Service Software RSS package They are both available in the CPS Tuner CD ROM Kit RVN4195 CPS Programming Setup Refer to online help files for the CPS Programming procedures See Figure 5 1 for CPS Programming Setup Radio Test Box RLN4460 Battery NN Program Test Cable AAPMKN4004 Tx Data RIB Rx P Data RLN4008 pal a N 27 Computer Interface Cable RIB Power Supply e Figure 5 1 CPS Programming Setup 5 2 Radio Alignment Procedures Radio Tuning Setup 5 3 Radio Tuning Setup A Windows 98 NT4 2000 ME XP PC personal computer and Global Tuner are required to tune the radio To perform the tuning procedures the radio must be connected to the PC RIB Radio Interface Box and Universal Test Set as shown in Figure 5 2 below Refer to online help files for the tuning procedures gt 30 dB Pad Service Monitor or Counter Transmit Power Cable gt 30 dB Pad Ww RLN5410 Li attmeter BNC Lt 1 RF Generator Receive RF Adaptor Power Radi 5886564201 Supply adlo gae Audio 1D Tx Audio Generator Gees Test Box Battery RLN4460 Eliminator
9. December 3 2003 HKLN4215A Performance Checks RF Test Mode To enter test mode 1 Turn the radio on Within ten seconds after the self test is complete self test tone is heard press SB2 Side Button 2 in Figure 4 2 five times in succession If the self test complete tone is not heard see Error Codes information in Chapter 8 Entry into the test mode is indicated by a positive indicator tone followed by a good key chirp GKC Upon entering test mode the radio is in the carrier squelch mode 2 Press SB1 Side Button 1 and scroll through and access test environments as shown in Table 4 2 3 Press SB2 and scroll through the channel spacing available as shown in Table 4 3 Turn the channel selector knob to change the test channel for that environment as shown in Table 4 4 5 Press the PTT on a test channel to cause the radio to transmit at the test frequency for the channel Table 4 2 Test Environments 4 3 Ate Description Function Beeps 1 Carrier Squelch RX unsquelch if carrier detected GKC TX mic audio 1 Tone Private Line RX unsquelch if carrier and tone 192 8 Hz detected BKC TX mic audio tone 192 8 Hz 2 Digital Private Line RX unsquelch if carrier and digital code 131 detected BKC TX mic audio digital code 131 3 Dual Tone Multiple RX unsquelch if carrier detected BKC Frequency TX selected DTMF tone pair 5 Unsquelch Open RX constant unsquelch BKC TX mic audio 9 High Speed Sign
10. Press the handle on the opener downwards This pressing action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs n Knob Remover 2 17 Chassis Opener Figure 6 3 Chassis Removal CAUTION Marring the front cover O ring sealing area will prevent the radio from sealing properly If the O ring is damaged replace it with a new one 6 Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case Figure 6 4 December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 5 Note The speaker wire assembly microphone wire assembly and keypad flex cable connector connecting the front housing assembly and the chassis prevent the two units from being completely separated 7 Rotate the bottom of the chassis up about 20 to disconnect the keyboard flex cable connector Push down 2 end tabs to release flex connector at the bottom of the chassis Radio Chassis Flex Connector Figure 6 4 Keyboard Flex Connection 8 Rotate the chassis counterclockwise out of the housing and position next to the housing Take care not to damage the speaker and microphone wires that are still connected to the chassis Figure 6 5 Speaker Connector Figure 6 5 Micr
11. 2 Side Button Locations 4 2 Figure 5 1 CPS Programming Setup ccccescceceececeseeeeeeeeeeeeaaeseeneeecaaesseaaeeseeeesesaaeesseneeessaeeseeneess 5 1 Figure 5 2 Radio Tuning Getup 5 2 Figure 5 3 Reference Oscillator Warp Wimdow 5 3 Figure 5 4 Modulation Balance Window ccc cece e eee setae eeeee eee eee ae seta gee sees eeseaaeseaeeseneaeeneeeees 5 4 Figure 5 5 Transmit Power Window High Power 5 5 Figure 5 6 VCO Attenuation Window 12 5 KHZ rernnnnvrnnnnrvnrnnrrnnnnnvnnrnrrennnnrnnnerrensnnrnnnrnrensrrrrenennnennn 5 7 Figure 5 7 DTMF Deviation Tuning Window renasvvvnrnvvannnnvvnnnnvrrnnnvvnnnrrrennnvnnnnvrenersrennnvvnnersrrennnsenenn 5 9 Figure 5 8 MDC 1200 Deviation Tuning Window rsrrarvvnnvnvnrvvnnvnvvrnvvrnvverevrrsnvrrrarrvrrvrrrervrneennernne 5 10 Figure 5 9 Rated Volume Tuning Window rsrrrnnnnnnnvrvnnnnnnrvrnnnennnrrnnrrennrrrnnrennnrrnnrnsnnrrnnnrennnrrrensennnnn 5 11 Figure 5 10 Squelch Tuning Window 5 12 Figure 5 11 RSSI Tuning niian a EA je a eee ade beeen ie 5 13 Figure 5 12 Side Button Locations 5 15 Figure 6 1 Battery Removal i tn 0 ati Eed EE det Agia kina 6 3 Figure 6 2 Antenna and Knob Hemoval ee eee ects eee ee ee sees ee ee gee sneeeee sagas sseaaeeseaeeeeeageesnneas 6 4 Figure 6 3 Chassis REMOVAL eceeeeeeecenee eee cenee ease eaeeseeeseaeeseeeseaeeseaeseaaesnaeesaeesseesaeeseeeeseeeeaeees 6 4 Figure 6 4 Keyboard Flex Connection 6 5 Figure 6 5 Microphone and Spe
12. 4 RSS Display Tunings 4c cisc aia aii Aone aia deeded 5 14 fe lte geste a rere Eee 5 14 5 61 Program Serial NOs eresiaren aaea a naaa aaa Aa a aera a aata Teea e 5 14 5 6 2 Temp Comp Data Head 5 14 56 3 Temp Comp Data Wette sisarien eriin eae ede eh nati saesticien dean de 5 14 5 7 Radio to Radi Clonimg 5 14 Chapter6 Display Model Disassembly and Re assembly 6 1 DCH INTFOAUGHON sure Greer rattet eek Ue ev edel ege Shad dies AANS 6 1 6 2 Preventive Maintenance cccecececceeeeeeeenceeeeeeeeeeeeeeeeeseeeeeeaeeseenseaaesaesseaaeeeeeeeaaeseeseeseeneeeeeesseaeeees 6 1 6 21 1 INSPOCTION nd aa ae radar Lent 6 1 6 2 2 Cleaning Procedures A 6 1 6 3 Safe Handling of CMOS and LDMOS Devices rrnrrrnnnnvnnnonvvnnnnrnnnnnnnnrnnrrennnnnnnerrresnnrnnnerrrenennnnneennne 6 2 6 4 Disassembling and Re assembling the Radio General 6 3 6 4 1 Radio Disassembly Detailed AAA 6 3 6 4 1 1 Front Cover From Chassis Disassembiy 6 3 6 4 1 2 Dust Cover Disassembhy nenn nnne 6 6 6 4 1 3 Speaker and Microphone Disassembly ssseesseeeseeesneeireeinessrnesrrnssrnnssnnssne nee 6 6 6 4 1 4 Keyboard Removal mnnnrvrnnnnnnnvrvnnnnnnvvnnnnennvrvnnnrnrsvvnnnnsrrnnnnersrsnnnnserennrnnssrennnnnn 6 7 Dk FEI Lugeseermbl Aessen E erat dene angst 6 7 6 4 1 6 Chassis DisaSSembly i s ec2hetcisacacs eetecnevtatehave aaas aan aaraa n asiakir iias 6 8 6 4 2 Radio Re assembly Detailed rrrnnnnnnnnnnnvnnnnnnnnnv
13. Capacity Li lon 1600 mAH A 2 Accessories Audio Accessories HMN9752 HMN9727 RLN4894 HMN9754 RLN4895 RLN5198 P BDN6720 PMLN4443 HMN9036 PMLN4294 PMLN4442 HLN9132 NTN8370 5080384172 NTN8371 RLN4760 RLN4763 RLN4761 RLN4764 RLN4762 RLN4765 BDN6646 BDN6706 0180358B38 0180300E83 RLN5500 RLN5317 RLN5318 TDN9327 TDN9373 Headsets RLN5411 PMMN4001 HMN9013 RMN4016 RLN5238 HMN9021 HMN9022 December 3 2003 Earpiece with Volume Control 1 Wire plastic earloop Beige Earpiece without Volume Control 1 Wire plastic earloop Beige Earpiece without Volume Control 1 Wire plastic earloop Black Earpiece with Microphone amp PTT Combined 2 Wire Beige Earpiece with Microphone amp PTT Combined 2 Wire Black Earpiece with Microphone amp PTT Combined Black including Low Noise Kit 2 Wire Surveillance Kit w Clear Comfortable Acoustic Tube includes NTN8371 Flexible Ear Receiver RX only Flexible Ear Receiver with Microphone amp PTT Combined Earbud with Microphone amp PTT Combined 2 Wire Black Earbud with Microphone amp PTT Combined Earbud with Microphone amp PTT Combined Earbud Single Wire Receive Only Black Extreme Noise Kit Replacement Noise Attenuating Plug for NTN8370 Low Noise Kit Small Custom Clear Earpiece Right Ear Small Custom Clear Earpiece Left Ear Medium Custom Clear Earpiece Right Ear Medium Custom Clear Earpiece Left Ear Large Custom Clear Earpiece Rig
14. Information cannot be altered or reprogrammed FGU Frequency Generation Unit GaAs Gallium Arsenide a type of crystalline material used in some semiconductors GKC Good Key Chirp ISW Inbound Signalling Word data transmitted on the control channel from a sub scriber unit to the central control unit LH DATA Longhorn Data a bidirectional 0 5V RS 232 line protocol that uses the micro controller s integrated RS 232 asynchronous serial communications interface SCI peripheral LLE Low Level Expander slight amount of volume expansion used to improve the signal to noise ratio MCU Micro Controller Unit MRTI Motorola Radio Telephone Interconnect a system that provides a repeater con nection to the Public Switched Telephone Network PSTN The MRTI allows the radio to access the telephone network when the proper access code is received OMPAC Over Molded Pad Array Carrier a Motorola custom package distinguished by the presence of solder balls on the bottom pads PC Board Printed Circuit Board PL Private Line tone squelch a continuous sub audible tone that is transmitted along with the carrier G 2 Term Definition PLL Phase Locked Loop a circuit in which an oscillator is kept in phase with a refer ence usually after passing through a frequency divider PTT Push To Talk the switch located on the left side of the radio when pressed causes the radio to transmit RAM Random Access M
15. Off Transceiver Board Send radio to depot December 3 2003 HKLN4215A Troubleshooting Tables Troubleshooting Table for Transmitter 8 3 8 4 Troubleshooting Table for Transmitter Table Table 8 4 lists the possible causes of and corrections for transmitter problems Table 8 4 Transmitter Troubleshooting Table Symptom No RF Power Out Possible Causes 1 Tx Power Level or Fre quency Corrective or Test Measurements at Room Temperature Check Tx power level and frequency programming from tuner 2 No Injection To Power Amplifier Antenna Switch Connector Send radio to depot No Modulation Distortion Modulation 1 Programming Check deviation and compensation settings using the tuner 2 Transceiver Board Send radio to depot Bad Microphone Sensitivity 1 Check Deviation and Compensation Realign if necessary 2 Microphone Send radio to depot No Low Signaling PL DPL MDC 1 Programming Check programming 2 Transceiver Board Send radio to depot Cannot Set Deviation Balance RF Board Send radio to depot HKLN4215A December 3 2003 8 4 Troubleshooting Tables Troubleshooting Table for Transmitter Notes December 3 2003 HKLN4215A Appendix A Antennas NAD6502_R HAD9742 HAD9743 NAE6522 R NAE6483 R 8505816K26 Accessories VHF Heliflex Antenna 14cm 146 174 MHz VHF Stubby Antenna
16. PMLE4283_ EP450 Back Cover Kit 438 470 MHz X PMLN4601_ Non Display Front Housing Kit 16 Ch X PMLN4603_ Display Front Housing Kit 64 Ch X X NNTN4496_R Ni Cd Battery 1100 mAH X X NNTN4497 H Li lon Battery 1800 mAH X X NNTN4851 NiMH Battery 1400 mAH X X NNTN4970 Slim Li lon Battery 1600 mAH X X WPLN4138 H Rapid 90 Min Desktop Charger w US Plug X X WPLN4139 R Rapid 90 Min Desktop Charger w Euro Plug X X WPLN4142_R Rapid 90 Min Desktop Charger w Argentina Plug X X WPLN4140 R Rapid 90 Min Desktop Charger w UK Plug X X RLN5644 2 5 Belt Clip X X NAE6483 R Antenna 403 520 MHz Whip X X HKLN4212 E Series Interactive User CD X Indicates compatibility with model s December 3 2003 1 6 Model Charts and Test Specifications Model Chart for UHF 465 495 MHz 1 6 Model Chart for UHF 465 495 MHz EP450 UHF 465 495 MHz Model Description December 3 2003 LAH65SDC9AA2AN EP450 465 495 MHz 4 W 16 Ch Non Display Model LAH65SDH9AA4AN EP450 465 495 MHz 4 W 64 Ch Display Model Item Description X PMUE1978_ EP450 465 495 MHz 4 W 16 Ch Non Display Model X PMUE1980_ EP450 465 495 MHz 4 W 64 Ch Display Model X X PMLE4284_ EP450 Back Cover Kit 465 495 MHz 1 4W X PMLN4601_ Non Display Front Housing Kit 16 Ch X PMLN4603_ Display Front Housing Kit 64 Ch X X NNTN4496_R
17. 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 Computer Software Copyrights The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs including but not limited to the exclusive right to copy or reproduce in any form the copyrighted computer program Accordingly any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied reproduced modified reverse engineered or distributed in any manner without the express written permission of Motorola Furthermore the purchase of Motorola products shall not be deemed to grant either directly or by implication estoppel or otherwise any license under the copyrights patents or patent applications of Motorola except for the normal non exclusive license to use that arises by operation of law in the sale of a product Document Copyrights No duplication or distribution of this document or any portion thereof shall take place without the expre
18. Transmitter Troubleshooting Table 8 3 Related Publications E Series Detailed Service Manual HKLN4216 E Series Interactive User Ch HKLN4212 December 3 2003 HKLN4215A Chapter 1 1 1 Motorola Internal Use y 5 LA Model Charts and Test Specifications 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 Type of Unit Portable gt H Table 1 1 Radio Model Number Example LAH65KDC9AA2AN Model Series 65 Freq Band K VHF 146 174 MHz Q 403 440 MHz R UHF 438 470 MHz S UHF 465 495 MHz Power Level D A Wor 5W Physical Packages C Non Display H Full Display Channel Spacing 9 Pro gramma ble Protocol AA Conven tional Feature Level 2 16 CH 4 64 CH Model Revision A Model Package N 1 2 Model Charts and Test Specifications Model Chart for VHF 146 174 MHz 1 2 Model Chart for VHF 146 174 MHz EP450 VHF 146 174 MHz Model Description December 3 2003 LAH65KDC9AA2AN EP450 146 174 MHz 5 W 16 Ch Non Display Model LAH65KDH9AA4AN EP450 146 174 MHz 5
19. W 64 Ch Display Model Item Description X PMUD1857_ EP450 146 174 MHz 5 W 16 Ch Non Display Model X PMUD1859_ EP450 146 174 MHz 5 W 64 Ch Display Model X X PMLD4222 EP450 Back Cover Kit 146 174 MHz X PMLN4601_ Non Display Front Housing Kit 16 Ch X PMLN4603_ Full Display Front Housing Kit 64 Ch X X NNTN4496_R Ni Cd Battery 1100 mAH X X NNTN4497 R Li lon Battery 1800 mAH X X NNTN4851 NiMH Battery 1400 mAH X X NNTN4970 Slim Li lon Battery 1600 mAH X X WPLN4138 R Rapid 90 Min Desktop Charger w US Plug X X WPLN4139 R Rapid 90 Min Desktop Charger w Euro Plug X X WPLN4142_R Rapid 90 Min Desktop Charger w Argentina Plug X X WPLN4140 R Rapid 90 Min Desktop Charger w UK Plug X X RLN5644 2 5 Belt Clip X X NAD6502 R Antenna 146 174 MHz 14cm X X HKLN4212 E Series Interactive User CD X Indicates compatibility with model s HKLN4215A VHF Test Specifications 1 3 General Channel Capacity VHF Test Specifications VHF 16 or 64 Channels Power Supply 7 5 Volts 220 Dimensions HxWxD with Battery High Capacity Li lon 130 5mm x 62mm x 45mm 5 12 x 2 44 x 1 77 Weight with Battery High Capacity Li lon 397g 14 0 oz Average Battery Life 5 5 90 Duty Cycle High Capacity Li lon Model Number 17 hr low power 12 hr high power LAH65KDC9AA2 N LAH65KDH9AA4_N Frequency Range 146 174
20. 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 notes 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 After Warranty Period After the Warranty period Motorola continues to support its products in two ways 1 Motorola s Radio Products Services Division RPSD offers a repair service to both end users and dealers at competitive prices 2 Radio Products Services Division RPSD supplies individual parts and modules that can be pur chased by dealers who are technically capable of performing fault analysis and repair The Radio Products Services Division RPSD was formerly knows as the Accessories and Aftermarket Division AAD Replacement Parts Ordering Basic Ordering Information When ordering replacement parts or equipment information the complete identification number should be included This applied to all components kits and chassis If the component part number is not known the order should include the number of the chassis or kit of which it is a part a
21. antenna Rated Audio Mode GEN TEST MODE PTT to OFF Set volume control to Output level 1 0m V RF Test Channel 4 center meter 3 24Vrms 4th channel test frequency carrier squelch selector to Audio Mod 1 kHz tone at PA 3 kHz deviation Monitor DVM AC Volts Distortion As above except to distortion As above As above Distortion lt 5 0 Sensitivity As above except SINAD As above PTT to OFF RF input to be lt 0 30 SINAD lower the RF level for 12 dB center uV 0 25 uV typical SINAD Noise RF level set to 1 mV RF As above PTT to OFF Set volume control to Squelch center meter 3 24 Vrms Threshold selection to only radios Audio PA spkr with conven load to speaker Monat oyster As above except change fre out of TEST As above Unsquelch to occur at need to be tested quency to a conventional sys MODE select lt 0 25 uV tem Raise RF level from zero a conventional Preferred SINAD until radio unsquelches system 6 9 dB See Table 4 4 December 3 2003 HKLN4215A Performance Checks RF Test Mode Table 4 6 Transmitter Performance Checks 4 5 BW to narrow TPL DPL Test Name Communications Analyzer Radio Test Set Comments Reference Mode PWR MON TEST MODE PTT to continu Frequency error to be Frequency 4th channel test frequency Test Channel 4 ous during the 200 Hz VHF Monitor Frequency error carrier squelch performance 500 Hz UHF Input
22. for the item listed Table 3 2 Service Aids ag Part Description Application RLN4460 Portable Test Set Enables connection to the audio accessory jack Allows switching for radio testing RLN4510 Battery Interface Regulates DC current and voltage between radio and power supply RVN4195 Customer Programming Soft Program customer option and channel data ware and Tuner Software on CD ROM AAPMKN4004 Programming Test Cable Connects radio to RIB RLN4008 AAPMKN4003 Radio to Radio Cloning Cable Allows a radio to be duplicated from a master radio by transferring programmed data from the master radio to the other RLN4008 Radio Interface Box Enables communications between the radio and the computer s serial communications adapter 5886564201 RF Adaptor Adapts radio s antenna port to BNC cabling of test equipment 0180305K08 Shop Battery Eliminator Interconnects radio to power supply HSN9412 Wall Mounted Power Supply Used to supply power to the RIB 120 VAC 3080369B71 or Computer Interface Cable Use B72 for the IBM PC AT or newer 9 pin serial 3080369B72 port Use B71 for older models 25 pin serial port Connects the computer s serial communications adapter to the RIB PLN4008 6686533201 Knob Remover Chassis Opener Used to remove the front cover assembly HKN9216 IBM Computer Interface Cable Connection from computer to RIB 8180384N65 Housing Eliminator Allows testing
23. from being com pletely separated December 3 2003 HKLN4215A Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 5 6 Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case Figure 7 4 Rotate the chassis counterclockwise out of the housing and position next to the housing Take care not to damage the speaker and microphone wires that are still connected to the chassis Figure 7 4 Speaker Connector Shroud Microphone Connector Figure 7 4 Microphone and Speaker Connections 7 Unplug the speaker wire assembly from the 2 pin connector on the chassis 8 Unplug the microphone wire assembly from the socket on the chassis 9 Move the chassis away from the housing and place on a clean work surface 7 4 1 2 Dust Cover Disassembly 1 Gently pry the top of the dust cover away from the body of the radio See Figure 7 5 2 Rotate the dust cover 90 in a counterclockwise direction to allow the key to be removed 3 Separate the dust cover away from the body of the radio The dust cover key is fragile apply only light pressure to the key while removing the dust cover S a Pry dust cover from body b Rotate dust cover 90 to c Separate dust allow key to be removed cover from body Figure 7 5 Dust Cover
24. point will key the radio up at the first frequency point Inject 80 Hz at an amplitude of 1 78 V Record the deviation obtained Typical values should range from 1 70 2 30 kHz Modulation is only tuned in the 25 kHz channel spacing mode Inject 3 kHz Set the amplitude to 1 5 V Change the modulation balance attenuation setting until the Tx deviation is as recorded in step 4 Inject 80 Hz at an amplitude of 1 78 V Check the deviation again If the Tx deviation changes record the reading and repeat steps 5 8 until the Tx deviation remains the same PO DING 38 9 Press PTT Toggle to dekey the radio Choose the next frequency key up and repeat steps 3 to 8 until all seven tuning points are done 10 Program the softpot value by pressing the Program button 11 Exit the Modulation Balance Function Transmit Power Tuning Note The maximum available power level given in the table below must not be exceeded There are separate alignment procedures for High and Low power Note When checking the RF power output of the radio with a test set always use a pad of at least 30 dB attached to the radio end of the RF cable This will avoid an RF mismatch and ensure a stable RF reading that will not change with varying lengths of connecting cable BER Frequency Point MHz Default Softpot Working Softpot ri 450 025000 Ig mi is a md E Bam gj r De pl EO DEE SI E re a r 0 ome Be P
25. replace main board or send radio to depot 8 2 8 3 Troubleshooting Tables Troubleshooting Table for Receiver Troubleshooting Table for Receiver Table Table 8 3 lists the possible causes of and corrections for receiver problems Table 8 3 Receiver Troubleshooting Table Symptom Radio Dead Display Does Not Turn On Possible Causes 1 Dead Battery Corrective or Test Measurements at Room Temperature Replace with charged battery 2 Blown Fuse 3 On Off Switch 4 Regulators 5 Regulator fault Send radio to depot Radio Dead Display Turns On Transceiver Board Send radio to depot No Receive Audio or Receiver Does Not Unmute Programming 1 Does the transmitted signal match the receiver configu ration PL DPL etc 2 With the monitor function enabled can the radio be unmuted Audio Distorted or Not Loud Enough Synthesizer Not On Fre quency Check synthesizer frequency by measuring the transmit ter frequency realign it off by more than 150 Hz VHF 500 Hz UHF RF Sensitivity Poor 1 Synthesizer Not on Fre quency Check synthesizer frequency by measuring the transmit ter frequency realign it off by more than 150 Hz VHF 500 Hz UHF 2 Antenna Switch Connec tor Send radio to depot 3 Receiver Front End Tun ing Check RF front end tuning for optimum sensitivity using the tuner Radio Will Not Turn
26. slider spin or edit control press ENTER to confirm the selection send a softpot value until a deviation of 3 3 3 7 kHz is obtained Press PTT Toggle again to dekey the radio 5 Program the softpot value into the radio by pressing the Program 6 Exit the MDC 1200 Deviation function 5 5 Receiver Tuning The following sub sections contain the procedures to tune the radio receiver These procedures include Rated Volume e Squelch Tuning Front End Filter Tuning December 3 2003 HKLN4215A Radio Alignment Procedures Receiver Tuning 5 11 5 5 1 Rated Volume Tuning Note When using test box RLN4460 the received audio output is taken from the AC DC METER OUT terminals with the METER OUT rotary switch set to RX The rated audio tuning procedure automatically configures the radio for 25 KHz This means that a 3 kHz for 25 kHz channel spacing deviation must always be used irrespective of the radio channel bandwidth a EZ Yolume Tuning Carrier Squelch environment Frequency Point IMHz Default Softpot Working Softpot 454 025000 2047 DH E gt 204 K Frequency Tuning Point is currently selected Note Valid Softpot values will range from 0 255 Figure 5 9 Rated Volume Tuning Window Perform the rated volume tuning procedure as follows 1 Under the Rx Align menu select Rated Volume Figure 5 9 2 Inject a 47 dBm RF signal modulated with 1 kHz tone at 3 KHz for 25 kHz channel spacing 3 Adjust the softpo
27. so will result in the wrong deviation value being obtained while tuning the DTMF BER Frequency Point MHz Default Softpot Working Softpot je a pe is currently dekeyed Note Valid Softpot values will range from 0 31 Figure 5 7 DTMF Deviation Tuning Window Under Tx Align select DTMF Deviation Figure 5 7 2 Press PTT Toggle to key the radio Monitor the deviation obtained 3 Adjust the slider spin or edit control press ENTER to confirm your selection send a softpot value until a deviation of 3 1 3 4 kHz is obtained 4 Press PTT Toggle again to dekey the radio 5 Program the softpot value into the radio by pressing Program 6 Exitthe DTMF Deviation function HKLN4215A December 3 2003 5 10 Radio Alignment Procedures Receiver Tuning 5 4 6 MDC 1200 Deviation Tuning This tuning option controls the MDC 1200 Signaling deviation Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation Not doing so will result in the wrong deviation value being obtained while tuning this feature BER Frequency Foint IvIHz Default Softpot Working Softpot Se Cie Pr s is currently dekeyed Note Valid Softpot values will range from 0 31 Figure 5 8 MDC 1200 Deviation Tuning Window 1 Under the Tx Align select MDC 1200 Signaling Figure 5 8 2 Press PTT Toggle to key the radio up Monitor the deviation obtained 3 Adjust the
28. 40 Hz UHF Band 2 438 470 470 Hz UHF Band 3 465 495 495 Hz 5 4 2 Modulation Balance Attenuation Note When using test box RLN4460 e Inject the signal into the radio via the METER IN terminal and e Set the METER IN selector switch to VOL e Inject the signal into the radio via the AUDIO IN terminal e Set the METER OUT toggle switch to the MIC PORT position e Set the METER OUT selector switch to MIC BER Frequency Point MHz Default Softpot Working Softpot 438 00000 ao a 5 3 gt 3 D om D eme Bm Gi HS Radio is currently dekeyed Note Valid Softpot values will range from 0 63 Figure 5 4 Modulation Balance Window December 3 2003 HKLN4215A Radio Alignment Procedures Transmitter Alignment Options 5 5 5 4 3 Compensation alignment balances the modulation sensitivity of the VCO and reference modulation synthesizer low frequency port lines The compensation algorithm is critical to the operation of signaling schemes that have very low frequency components Digital Private Line and could result in distorted waveforms if improperly adjusted To perform Modulation Balance tuning follow the following steps 1 Under the Tx Align menu select Mod Balance Attn Figure 5 4 2 Begin with the lowest frequency i e the first frequency point from the top Pressing PTT Toggle without selecting any slider control at the corresponding frequency
29. 5 14 Radio Alignment Procedures Utilities 5 Adjust the input level to reflect the next soft spot value Repeat steps 3 and 4 to tune the next value 5 5 4 RSSI Display Tuning 5 6 5 6 1 5 7 1 Under the Rx Align menu select RSSI Display Tuning 2 Inject an on channel signal to the radio at 47 dBm at the frequency listed Modulated the signal with a 1 kHz tone at 60 deviation 3 kHz to verify the radio is receiving the desired frequency RSSI tuning is only done at 25 kHz channel spacing 3 Change the level to that which is needed to produce 12 SINAD approximately 119 dBm 4 Press the Update button for the soft spot to be tuned to the RSSI value correlating to the applied level The programmed RSSI value will be displayed 5 Adjust the input level to 90 dBm 6 Press the Update button for the soft spot to be tuned to the RSSI value correlating to the applied level The programmed RSSI value will be displayed Utilities Program Serial No The Program Serial No option under the Utilities heading allow the radio serial number to be programmed However the serial number of a particular radio can only be programmed if it was originally blank If the serial number of the radio was not blank then access to the screen will be denied Radio to Radio Cloning 1 Cloning is the process of copying the content of one radio source radio into another radio desti nation radio Radio content refers to system type featu
30. 50 403 440 MHz 4 W 64 Ch Display Model Item Description X PMUE1972_ EP450 403 440 MHz 4 W 16 Ch Non Display Model X PMUE1974_ EP450 403 440 MHz 4 W 64 Ch Display Model X X PMLE4288 EP450 Back Cover Kit 403 440 MHz X PMLN4601_ Non Keypad Front Housing Kit 16 Ch X PMLN4603_ Full Keypad Front Housing Kit 64 Ch X X NNTN4496 R Ni Cd Battery 1100 mAH X X NNTN4497 R Li lon Battery 1800 mAH X X NNTN4851 NiMH Battery 1400 mAH X X NNTN4970 Slim Li lon Battery 1600 mAH X X WPLN4138 R Rapid 90 Min Desktop Charger w US Plug X X WPLN4139 R Rapid 90 Min Desktop Charger w Euro Plug X X WPLN4142 R Rapid 90 Min Desktop Charger w Argentina Plug X X WPLN4140 R Rapid 90 Min Desktop Charger w UK Plug X X RLN5644 2 5 Belt Clip X X NAE6483 R Antenna 403 520 MHz Whip X X HKLN4212 E Series Interactive User CD X Indicates compatibility with model s HKLN4215A Model Charts and Test Specifications Model Chart for UHF 438 470 MHz 1 5 Model Chart for UHF 438 470 MHz EP450 UHF 438 470 MHz Model Description HKLN4215A LAH65RDC9AA2AN EP450 438 470 MHz 4 W 16 Ch Non Display Model LAH65RDH9AA4AN EP450 438 470 MHz 4 W 64 Ch Display Model Item Description X PMUE1966_ EP450 438 470 MHz 4 W 16 Ch Non Display Model X PMUE1968_ EP450 438 470 MHz 4 W 64 Ch Display Model X X
31. 6680332E96 PLCC 84 nozzle 6680334E67 QFP 160 nozzle 6680333E46 SOL 18 nozzle 6680332E84 SOIC 20 nozzle 6680332E87 SOL 20J nozzle 6680333E45 SOL 24 nozzle 6680333E55 TSOP 64 nozzle Included with ChipMaster packages HKLN4215A December 3 2003 3 4 Programming Test Cable 25 POSITION MALE CONNECTOR Test Equipment Service Aids and Service Tools Service Aids 25 POSITION FEMALE CONNECTOR offers oo fo 71 nt 36 0 CABLE 36 0 St CABLE Hen P3 Figure 3 1 Programming Test Cable P2 P1 25 pin Male D Connector bmm stereo nd Components molded inside 3 5mm 1 ee 3 Orange 3 5mm Tip 1 lt A Speaker 47 1 ohm 24 De Blue l 7 pa To Test Box i 33K White ep 20 25mmTip 5 lt C 8 Microphone 15 1UF 16V 5 16 2 5mm 3 lt Spiral 9 2 5mm a Yellow Center br P3 25 pin Female D Connector 1 S 15 To Test Box 3 5mm mono gt Car 4 2 5mm stereo gt 11 5 4 3 Figure 3 2 Wiring of the Connectors December 3 2003 HKLN4215A Chapter 4 Performance Checks 4 1 General These radios meet published specifications through their manufacturing process by utilizing high accuracy laboratory quality test equipment The recommended field service equipment is as accurate as the manufacturing equipment with few exceptions This accuracy must be mai
32. Blade Screwdriver PTT Seal Figure 6 9 PTT Removal 6 4 1 6 Chassis Disassembly CAUTION Refer to the CMOS CAUTION paragraph see 3 3 before removing the main board Be sure hi to use Electrostatic Discharge protection when handling circuit boards 1 Remove the O ring 2 Use a Torx screwdriver with a T6 bit to remove the four screws Figure 6 10 holding the main board to the chassis v Audio Jack Shroud I 1 Main Board Radio Chassis O Ring Figure 6 10 Removal of Main Board from Chassis 3 The audio jack shroud can be removed from the main board December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 9 4 Lift the main board from the chassis Figure 6 10 5 Remove the battery contact seal 6 4 2 Radio Re assembly Detailed 6 4 2 1 Dust Cover Re assembly 1 Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening Figure 6 11 2 Press the dust cap until the tail is fully into the hole Note Make sure the dust cap is placed between the keypad retainer mounting post and the side wall of the radio 3 Twist the dust cap counter clockwise until the cap is seated properly onto the recess 4 Press the cap again to ensure it fully covers the opening for the audio jack Figure 6 11 Dust Cap Re assembly 6 4 2 2 Microphone and Speaker
33. Chassis and Front Cover Re assembly 1 Dress and connect the speaker wires Note Care should be taken when dressing the speaker and microphone wires to avoid pinching them between the speaker magnet and shield or between the accessory connector and housing Note Ensure that the plug orientation is correct with the exposed pins in the wire casing facing upward and fully plugged in a Connect the speaker wire assembly into the 2 pin connector on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio Figure 6 18 b Connect the microphone wire assembly into the two hole socket on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio Figure 6 18 c Slide the audio jack shroud onto accessory connector Figure 6 17 HKLN4215A December 3 2003 6 14 Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General Speaker Connector Microphone Connector Shroud Figure 6 18 Microphone and Speaker Wires Re assembly 2 Position the radio Figure 6 19 and reconnect the flex connector from the keyboard into the con nector located on the bottom of the main board pushing up the 2 end tabs 3 Slide the volume potentiometer and frequency switch shafts into their respective holes in
34. Disassembly HKLN4215A December 3 2003 7 6 Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 4 1 3 Speaker and Microphone Disassembly Note The speaker is held in place with a retainer bracket Be careful not to damage the speaker when removing the retainer bracket Remove the screw from the speaker retainer using a T6 Torx screwdriver Figure 7 6 Lift the retainer off the speaker sliding end of retainer out of corner slot on the housing Lift the speaker out from the front housing Por a Carefully lift microphone assembly out of housing Retainer Bracket Wire Connector Radio Housing Microphone Assembly Figure 7 6 Removal Speaker Microphone Assembly 7 4 1 4 PTT Disassembly 1 If required the PTT Figure 7 7 can be disassembly using a small screwdriver as follows a Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab b Pry the PTT away from the radio housing c Inspect the two hooks If bent or broken the PTT must be replaced d Remove the PTT seal December 3 2003 HKLN4215A Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 7 Flat Blade Screwdriver PTT Seal Figure 7 7 PTT Removal 7 4 2 Chassis Disassembly CAUTION Refer to the CMOS CAUTION paragraph 7 3 before removing the main board Be sure to use Electrostatic Discharge protection when h
35. Figure 4 1 Initial equipment control settings should be as indicated in Table 4 1 and should be the same for all performance checks and tuner alignment procedures Table 4 1 Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode Power Monitor Spkr set C Voltage 7 5 Vdc RF Attenuation 70 Spkr load DC on standby Load Standby AM CW FM FM PTT OFF Volt Range 10 V Oscilloscope Source Mod Current 2 5 A Oscilloscope Horiz 1 0 mSec Div Oscilloscope Vert 2 5kHz Div Oscilloscope Trig Auto Monitor Image Hi Monitor BW Nar Monitor Squelch mid CW Monitor Vol 1 4 CW 4 3 RF Test Mode When the EP450 radio is operating in its normal environment the radio s microcomputer controls the RF channel selection transmitter key up and receiver muting according to the customer code plug configuration However when the unit is on the bench for testing alignment or repair it must be removed from its normal environment using a special routine called RF TEST MODE This mode allows bench testing of the radio at various test frequencies across the entire band at both high and low transmit power if applicable at various channel spacings and with different coded or carrier squelch types Any customer specific programming in the radio will not be changed or affected by use of the RF Test Mode Side Button 1 Side Button 2 Figure 4 2 Side Button Locations
36. List of Tables Table 1 1 Table 1 2 Table 3 1 Table 3 2 Table 3 3 Table 4 1 Table 4 2 Table 4 3 Table 4 4 Table 4 5 Table 4 6 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 8 1 Table 8 2 Table 8 3 Table 8 4 Radio Model Number Example LAHGPRDCOAAZAN 1 1 MIL STDS 810 C DE and F Applicable to UHF and VHF Specifications 2 2 1 8 Recommended Test Eoutpment 3 1 SELVICS te Linni enken 3 2 Recommended Service Tools ccccccccececceeeseeeeeeeeeeeeaeeeceeeeeseaeeeeeeeeeeaeeesaeeeseeeeesnaeeseaes 3 2 Initial Equipment Control Settings ccccceeesceeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeseaeeeeeaeeeseaeeeseeeeeeas 4 2 TeSt ENVION 3 cnet cdi ena ean ee a 4 3 Test Channel Spacing AANEREN 4 3 Test Frequencies 3 3 c0det eceteli eta nee ae ceded NEEN eee aden eddie eee apd adiea 4 4 Receiver Performance Checks 4 4 Transmitter Performance Checks 4 5 Initial Equipment Control Settings ccccceesceeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeesaeeeseaeeesecaeeeeeeeeeeas 5 3 Reference Oscillator Specifications vnr nrnnnrnrvnnnnrrnnnnnnnennrnennnnnnnerrrennnnnnnnenne 5 4 Transmit High Low Power Level 5 6 Deviation Specifications us etic ka dead 5 8 Squelch Deviation Values nnen nnn nnet 5 12 Power Up Error Code Display rrrarnrnnrnnrrnnnnnvnnnnrrnnnnnrnnnnnrnnnnnrannnnnnnrrrrnensnnnnnerrrenennnnnnenne 8 1 Operational Error Code Display 8 1 Receiver Troubleshooting Table 8 2
37. Low 500 1 1 500 2 2 500 3 2 500 4 1 Pressure High Temper 501 1 1 2 501 2 1 2 501 3 1 2 501 4 1 2 ature Low 502 1 1 502 2 1 2 502 3 1 2 502 4 1 2 Temperature Temperature 503 1 1 503 2 1 503 3 1 503 4 1 Shock Solar Radia 505 1 1 505 2 1 505 3 1 505 4 1 tion Rain 506 1 1 2 506 2 1 2 506 3 1 2 506 4 1 Humidity 507 1 2 507 2 2 3 507 3 2 3 507 4 3 Salt Fog 509 1 1 509 2 1 509 3 1 509 4 1 Dust 510 1 1 510 2 1 510 3 1 510 4 1 Vibration 514 2 8 10 514 3 1 514 4 1 514 5 1 Shock 516 2 1 2 5 516 3 1 4 516 4 1 4 516 5 1 December 3 2003 HKLN4215A Chapter 2 Theory Of Operation 2 1 2 2 2 2 1 Introduction This chapter provides a basic theory of operation for the radio components Major Assemblies e Transceiver Board contains all transmit receive and audio circuitry e Display Display models only 8 characters 14 segments star burst and 10 icons with back lighting liquid crystal display LCD Keypad Board Display models only Display model a 2 button menu keypad with 2 way navigation button and a 3 x 4 alphanumeric keypad Transceiver Board Figure 2 1 Antenna M140 Transceiver Board Battery ca J301 J460 Eo J491 J470 Keypad Board 28 J2 J1 Display Figure 2 1 Major Assemblies Block Diagram Receiver Incoming RF signals from the antenna are first routed through the harmonic filter and antenna switch part o
38. MHz Channel Spacing 12 5 20 25 kHz Temperature Range 30 to 60 C Frequency Stability 2 5 ppm FCC ABZ99FT3045 5 receive 5 transmit 90 standby 1 3 Transmitter VHF RF Output Low High Li lon 7 5 V 1W DW Frequency 146 174 MHz Channel Spacing 12 5 20 25 kHz Spurious Harmonics 36 dBm lt 1 GHz 30 dBm gt 1 GHz FM Noise 40 dB 12 5 kHz 45 dB 25 kHz Modulation Limitation 2 5 kHz 12 5 kHz 5 kHz 25 kHz Audio Response 1 to 3 dB from 6 dB oct Pre emphasis 300 to 3000 Hz Audio Distortion 3 1000 Hz 60 Rated Max Dev Receiver VHF VHF 12 5 kHz 25kHz Channel Spacing 12 5 20 25 kHz Sensitivity 0 25 uV typical 12 dB EIA SINAD Adjacent Channel 60 dB 70 dB Selectivity Intermodulation 70 dB Freq Stability 0 00025 30 C to 60 C Spur Rejection 75 dB Image and 1 2 F 70 dB Rejection Audio Output lt 5 Distortion 500 mW into 24Q Specifications subject to change without notice All electrical specifications and methods refer to EIA TIA 603 standards 1 4 Model Charts and Test Specifications Model Chart for UHF 403 440 MHz 1 4 Model Chart for UHF 403 440 MHz EP450 UHF 403 440 MHz Model Description December 3 2003 LAH65QDC9AA2AN EP450 403 440 MHz 4 W 16 Ch Non Display Model LAH65QDH9AA4AN EP4
39. Ni Cd Battery 1100 mAH X X NNTN4497 R Li lon Battery 1800 mAH X X NNTN4851 NiMH Battery 1400 mAH X X NNTN4970 Slim Li lon Battery 1600 mAH X X WPLN4138 R Rapid 90 Min Desktop Charger w US Plug X X WPLN4139 R Rapid 90 Min Desktop Charger w Euro Plug X X WPLN4142_R Rapid 90 Min Desktop Charger w Argentina Plug X X WPLN4140 R Rapid 90 Min Desktop Charger w UK Plug X X RLN5644 2 5 Belt Clip X X NAE6483 R Antenna 403 520 MHz Whip X X HKLN4212 E Series Interactive User CD X Indicates compatibility with model s HKLN4215A UHF Test Specifications 1 7 General Channel Capacity UHF Test Specifications UHF 16 or 64 Channels Power Supply Dimensions HxWxD with Battery High Capacity Li lon 7 5 Volts 220 130 5mm x 62mm x 45mm 5 12 x 2 44 x 1 77 Weight with Battery High Capacity Li lon 397g 14 0 oz Average Battery Life 5 5 90 Duty Cycle High Capacity Li lon 17 hr low power 12 hr high power Model Numbers LAH65QDC9AA2 N LAH65QDH9AA4_N LAH65RDC9AA2_N LAH65RDH9AA4_N LAH65SDC9AA2_N LAH65SDH9AA4_N Modulation Limitation 2 5 kHz 12 5 kHz 5 kHz 25 kHz Channel Spacing 12 5 20 25 kHz Temperature Range 30 to 60 C Frequency Stability 2 5 ppm FCC ABZ99F T4057 403 440MHz ABZ99F T4056 438 470MHz ABZ99F T4058 465 495MHz 5 receive 5 transmit 90 sta
40. Q MOTOROLA MOTOROLA The Stylized M logo are trademarks of Motorola Inc All other product or service names are the property of their respective owners 2003 Motorola Inc All rights reserved Printed in U S A HKLN4215A 2 MOTOROLA O MOTOROLA intelligence everywhere EP450 Portable Radio Basic Service Manual MOTOROLA intelligence everywhere Motorola Inc 1301 E Algonquin Road Schaumburg IL 60196 EP450 Portable Radio Basic Service Manual VHF 146 174 MHz UHF 403 440 MHz UHF 438 470 MHz UHF 465 495 MHz HKLN4215A Foreword 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 Product Safety and RF Exposure Compliance section Product Safety and RF Exposure Compliance Before using this product read the operating instructions for safe usage contained in the fi Product Safety and RF Exposure booklet enclosed with your radio Caution 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
41. R EARE ELER EAA RAEI MAEA AEF E AAAS EE T EALO E R etA DE ERE 1 1 1 2 Model Chart for VHF 146 174 MHZ msnnnnnnnrrnnnnvnnnonrennnnrnnnrnrnnrnnrrnnnnnnnrnnrrrsnnnnnrerrresrnrnnnerresnnrnnnennenn 1 2 t3 Non DBisplay Model su sie a ad ea a eek 1 3 1 4 Model Chart for UHF 403 440 MHZ enveenonrrnnnnvnnnenrvnrnnrnnnrnvnnrnnrrrnnnrnnrrnrrrsnnnnnrerrrrennrnnnenrresrsrnnnennenn 1 4 1 5 Model Chart for UHF 438 470 MHz annenrnnrrnnnnvnnnenrennnnrnnnrnrnnrnnrrnnnnvenrnnrresnnnnnrerrrrsnnrnnnenrresrnrnenennenn 1 5 1 6 Model Chart for UHF 465 495 MHz mnnnvnnnnrrnnnnvnnnenrennnnrnnnenrnnrnnrnrnnnrnnrsnrrrennnnnrerrressnrnnrenrresnnrnnnennenn 1 6 1 7 Display e EE EE 1 7 1 8 MIE Standards s cccca an diene hadi wiih a aati dina RA 1 8 Chapter 2 Theory Of Operation rnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnr 2 1 SL tt ue t Dee e eier ee ee nerdene 2 1 222 Major ASSEMDIIGS rira sia a ar A RE AE E E A 2 1 E E EE 2 1 2 212 eg El ul 2 2 Chapter3 Test Equipment Service Aids and Service Tools 3 1 3 1 Test Equipment erte edd bedere este den tended SERA dee 3 1 312 SEN le vinranker hr det 3 2 Chapter4 Performance Checks nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 4 1 4 1 G n rahuunssdusarterkurre E eh ctvele fruene tann dren unrated 4 1 4 2 PowerUp Self Test EE 4 1 43 JRE TestiMod usa 4 2 Chapter 5 Radio Alignment Procedures rr snssvnvvnnnnnnnnnnnnnnnnvnvnnnenennn 5 1 Bed Jotto
42. Re assembly Check that the mic and speaker felts are in position and not damaged If damaged replace felts 2 Insert the microphone sub assembly into the microphone boot 3 3 Insert the Boot and microphone sub assembly into the microphone recess in the housing and route wires as shown in Figure 6 12 HKLN4215A December 3 2003 6 10 Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General Figure 6 12 Microphone Re assembly 4 Locate the speaker tab and align it with the tab opening in the front housing Figure 6 13 5 Insert the speaker tab into the speaker recess in the housing Ensure the speaker is seated flush in the housing Note Make sure the speaker and microphone wires are routed tightly between the speaker basket and the housing post 6 Insert one end of the speaker retainer into the slot in the front housing See Figure 6 13 g Speaker Retainer aC ker Ti Speaker Speaker Tab Tab Opening Front Housing Slot a e e 880200 979099 90 A op a o o on 0978 Figure 6 13 Speaker Re assembly Note When fastening the speaker retainer screw make sure the wires are out of the way to pre vent pinching by the retainer 7 Install the retainer screw using a T6 Torx screwdriver Torque to 2 3 2 5 Ib in December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling th
43. Service Center See Appendix B for a list of authorized service centers The following disassembly procedures should be performed only if necessary e Chassis Disassembly e Speaker Disassembly PTT Disassembly 6 4 1 Radio Disassembly Detailed 6 4 1 1 Front Cover From Chassis Disassembly 1 Turn off the radio 2 Remove the battery Figure 6 1 a Slide the battery latch into the unlock position Disengage by pushing downward and holding the latch towards the front of the radio b With the battery latch disengaged slide the battery down from the top of the radio about 1 2 in Once the battery is free from the battery rails lift it directly away from the radio c Remove the battery from the radio CN Battery Latch Figure 6 1 Battery Removal HKLN4215A December 3 2003 6 4 Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 3 Remove the antenna 4 Pry off the volume and channel selector knobs from their shafts using the knob removal chassis opener tool Motorola part 6686533201 Figure 6 2 Figure 6 2 Antenna and Knob Removal Note Both knobs slide on and off However the knobs are designed to fit very tightly on the shaft 5 Separate the chassis from the front housing assembly by using the knob remover chassis opener too Place the broad side of the opener into the slots located at the base of the radio Figure 6 3
44. aker Connections seesseessseessiessisesiressrrssirnsrtsstnnetnnnrnnstnnnennnnnnnnt 6 5 Figure 6 6 Dust Cover Disassembly 0 cee cceeeeee cree cnet eee eter eeeaeseeeseaeesae egestas seaeesaeeseeeeseaeeeaeee 6 6 Figure 6 7 Removal Speaker Microphone Assembly ssesssssseesssesressrrssirnssrrsstrnstnnnstnnsnnsennnnrnene 6 6 Figure 6 8 Keypad Removal aen 6 7 Figure 6 9 PFE Removal oaan lua ras eel ae Re genio anna ates 6 8 Figure 6 10 Removal of Main Board from Chassis 6 8 Figure 6 11 Dust Cap He assemihy 6 9 Figure 6 12 Microphone He assembhy A 6 10 Figure 6 13 Speaker Re assembly esssssseesseeessessseessiessttssstrsstnnsrnssttnettnnennnntnnntnnnntnntnnnanstennnennnenn 6 10 Figure 6 14 Keypad Re assembly nnrannrrrnnrnonnrrnnnrrnnrrrnnnnnnnrrnnnrennrrrnnrennrnennrennrannsrennrannnnennnrrnnseennnnn 6 11 Figure 6 15 LCD Keypad Board He assembhy 6 11 Figure 6 16 Keyboard Retainer He zssembhy 6 12 Figure 6 17 Main Board onto Chassis Re assembly rsnrnnvnrnvnnnnvrnnvernvrrrnverrvrrrnrrnerrrrvrnrenrerrrnevnnn 6 13 Figure 6 18 Microphone and Speaker Wires Re assembly cccccccceesseneeeeeeeneeeeeecnaeeeeeesenaeeeeeseaas 6 14 Figure 6 19 Keyboard Flex Cable Connecton 6 14 Figure 6 20 Fastening the Chassis eccesceesscecseeseeceeeneeseeeeeneesseeeneceseessaeeneceseaeseaeesseeeeaneeeneeeees 6 15 Figure 6 21 PTT Re aSSOMDIY s c sscceciciasiecccasececsesdsuasoccavedectadiasaanediassq
45. al RX unsquelch if carrier detected BKC ing TX 1500 Hz tone BKC means Bad Key Chirp low pitched tone GKC means Good Key Chirp high pitched only HKLN4215A Table 4 3 Test Channel Spacing No of BKC Channel Spacing 1 25 kHz 12 5 kHz 20 kHz December 3 2003 4 4 Performance Checks RF Test Mode Table 4 4 Test Frequencies Channel Selector VHF R2 UHF R1 UHF R2 UHF R3 Switch Position Jest Channel MHz MHz MHz MHz 1 Low Power TX 1 or 8 8 High Power RX 1 or 8 146 625 403 625 438 625 465 625 2 Low Power TX 2 or 9 9 High Power RX 2 or 9 150 775 409 775 443 775 470 775 3 Low Power TX 3 or 10 10 High Power RX 3 or 10 155 275 415 275 448 275 475 275 4 Low Power TX 4 or 11 11 High Power RX 4 or 11 160 125 421 125 454 125 480 125 5 Low Power TX 5 or 12 12 High Power RX 5 or 12 164 475 427 475 459 475 485 475 6 Low Power TX 6 or 13 13 High Power RX 6 or 13 169 475 433 475 464 475 490 475 7 Low Power TX 7 or 14 14 High Power RX 7 or 14 173 875 439 875 469 875 494 875 Table 4 5 Receiver Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode PWR MON TEST MODE PTT to continu Frequency error to be Frequency 4th channel test frequency Test Channel 4 ous during the 200 Hz VHF Monitor Frequency error carrier squelch performance 500 Hz UHF Input at RF In Out output at check
46. alue using the spin control Press PTT Toggle again to key up the radio at the selected frequency point Repeat steps 3 5 for the remaining test frequencies F2 7 Press Program to store the softpot values into the radio s codeplug Exit the Transmit High Power function If the radio uses only high power channels proceed to adjust modulation If low power channels are used perform Transmit Low Power Tuning as defined 5 4 3 2 To Perform Transmit Low Power Tuning do the following 1 2 3 E Je Under the Tx Align menu select Transmit Power and then select Low Press PTT Toggle This will key the radio up at 1st test frequency F1 Adjust the power level to be as defined by country power level specifications by moving the slider spin control or keying in values in the edit control press ENTER to confirm your selection after typing in the softpot value Press PTT Toggle to dekey the radio go to the next frequency point by selecting the slider typing in the edit control box press ENTER to confirm your selection or toggling the softpot value using the spin control Press PTT Toggle again to key up the radio at the selected frequency point Repeat steps 3 5 for the remaining test frequencies F2 F7 Press Program to store the softpot values into the radio s codeplug Exit the Transmit Low Power function December 3 2003 HKLN4215A Radio Alignment Procedures Transmitter Alignment Options 5 7 5 4 4 VCO Attenua
47. andling circuit boards 1 Remove the O ring 2 Use a Torx screwdriver with a T6 bit to remove the four screws Figure 7 8 holding the main board to the chassis Main Board Radio Chassis O Ring Figure 7 8 Removal of Main Board from Chassis 3 The audio jack shroud can be removed from the main board 4 Lift the main board from the chassis 5 Remove the battery contact seal HKLN4215A December 3 2003 7 8 Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 4 3 Radio Re assembly Detailed 7 4 3 1 Dust Cover Re assembly B N Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening Figure 7 9 Press the dust cap until the tail is fully into the hole Twist the dust cap counter clockwise until the cap is seated properly onto the recess Press the cap again to ensure it fully covers the opening for the audio jack Figure 7 9 Dust Cap Re assembly 7 4 3 2 Microphone and Speaker Re assembly 1 2 3 4 5 Check that the speaker felt is in position and is not damaged If damaged replace felt Insert the microphone sub assembly into the microphone boot Insert the Boot and microphone sub assembly into the microphone recess in the housing and route the wires as shown in Figure 7 10 Microphone PRE Boot af Ny F GT E Microphone Recess
48. at RF In Out Output at check antenna Power RF As above As above As above Refer to Maintenance Specifications Voice Mode PWR MON As above As above meter Deviation Modulation Ath channel test frequency selector to mic VHF UHF atten to 70 input to RF In 2 4 0 kHz but 0 kHz Out 25 kHz Ch Sp Monitor DVM AC Volts Set 1 kHz Mod Out level for 0 025 Vrms at test set 80m Vrms at AC DC test set jack Voice Mode PWR MON TEST MODE Remove modula Press PTT switch on Modulation 4th channel test frequency Test Channel 4 tion input radio Say four loudly internal atten to 70 input to RF In carrier squelch into the radio mic Out Output at Measure deviation antenna VHF UHF 4 0 kHz but 5 0 kHz 25 kHz Ch Sp DTMF As above TEST MODE As above Deviation Modulation 4th channel test frequency Test Channel 4 VHF UHF gt 3 05 kHz DTMF but 3 45 kHz Output at 25 kHz Ch Sp antenna PL DPL As above TEST MODE As above Deviation Modulation 4th channel test frequency Test Channel 4 VHF UHF gt 500Hz but lt 1000 Hz 25 kHz Ch Sp See Table 4 4 HKLN4215A December 3 2003 4 6 Performance Checks RF Test Mode Notes December 3 2003 HKLN4215A Chapter 5 Radio Alignment Procedures 5 1 5 2 Introduction This chapter provides an overview of the Commercial Series Customer Programming Software CPS and the Global Tuner as designed for use in a Windows 98 NT4 2000 ME XP environment
49. cadoas ces aoi iieii aa ia 6 15 Figure 6 22 EP450 Full Keypad Radio Exploded View 6 16 Figure 7 1 Battery Removals osne ain mabe AAEE AES 7 3 Figure 7 2 Antenna and Knob Hemoval 7 4 Figure 7 3 Chassis Hemoval 7 4 Figure 7 4 Microphone and Speaker Connections seesseeessesssiessisssiessrresitnsrnsstnnetnnntnnstnnnennnnnnnn 7 5 Figure 7 5 Dust Cover Disassembly ccccccceeeceeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeseaeeeeeaeeesaeeeseaaeseceeeeesaaeeeenees 7 5 Figure 7 6 Removal Speaker Microphone Assembly esessessseesssssrsssrrssrrnssrnsstnnstnnntnnsnnnrnnnernnnt 7 6 Figure Tl RE EE 7 7 Figure 7 8 Removal of Main Board from Chassis eessseesseeesseessiessitessrnesrnnsrnnstnnntnnntnnstnnnnnnnnnnne 7 7 Figure 7 9 Dust Cap He assemihy 7 8 Figure 7 10 Microphone Re asSsSembly cescccccecesecceceeeesecceeeeeeeeeeeeeeseeceeeeensaeceeeesneeeeeeesnsneeeesentennaes 7 8 December 3 2003 HKLN4215A Table of Contents Figure 7 11 Figure 7 12 Figure 7 13 Figure 7 14 Figure 7 15 Figure 7 16 vii Speaker Re assembly A 7 9 Installation of Main Board onto Chassis 7 10 Microphone and Speaker Wires Re assembly rrrrnnnnnrnnnonvvnnnnrnnnnnrrnnnnrrnnnnnrenrrrrnnnnnnnnn 7 11 Fastening the Ghassis a rassqcaadsiarteime rad eatin aaa a Saadan er ane needa 7 11 ai REI le isete RATE nedi 7 12 EP450 Non Display Radio Exploded View 7 13 HKLN4215A December 3 2003 viii Table of Contents
50. display The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted Use Table 8 1 to aid in understanding particular operational error codes Table 8 1 Power Up Error Code Display Error Code Possible Causes Corrective Action RAM ERR RAM Test Failure Retest radio by turning if off and tuning it on again If message reoccurs replace main board or send radio to depot ROM ERR ROM checksum is wrong Reprogram FLASH memory and retest If message reoc curs replace main board or send radio to depot EPRM ERR EEPROM Hardware Error Reprogram codeplug with correct codeplug and retest If Codeplug structure mismatch message reoccurs replace main board or send radio to or non existence of code depot plug or EEPROM Checksum Error Codeplug checksum is wrong 8 2 Operational Error Codes During radio operation the radio performs dynamic tests to determine if the radio is working properly Problems detected during these tests are presented as an error code on the radio s display The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted Use Table 8 2 to aid in understanding particular operational error codes Table 8 2 Operational Error Code Display Possible Causes Corrective Action SYN UNLK Synthesizer Out of Lock Verify codeplug and reprogram if necessary If message reoccurs
51. e Radio General 6 11 6 4 2 3 Keypad and LCD Keyboard Re assembly 1 Attach the flex cable from the LCD module to the keyboard if not already attached Figure 6 15 2 Remove protective mylar from window and from keypad if present 3 Install the new keypad into the housing Use the two housing posts for keypad alignment Figure 6 14 Figure 6 14 Keypad Re assembly 4 Remove mylar from LCD if present i CAUTION Make sure the microphone and speaker wires are not trapped under the LCD module 5 Install the LCD Keypad sub assembly into the housing Figure 6 15 Flex Cable from LCD Module Flex Cable to Main PC Board Figure 6 15 LCD Keypad Board Re assembly HKLN4215A December 3 2003 6 12 Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 Attach the flex cable into the connector on the keypad board if not already connected 7 Bend the flex cable as shown Figure 6 15 6 4 2 4 Keyboard Retainer Re assembly 1 Insert the flex cable through the slot at the bottom of the keyboard retainer Figure 6 16 Figure 6 16 Keyboard Retainer Re assembly 2 Insert the two top tabs of the keyboard retainer into the two tab retainers located on each side of the speaker in the front housing Figure 6 16 3 Press the four keypad retainer locking tabs into the housing 4 Push the speaker and microphone wires into the top left hand corner of the housing 6 4 2 5 Chass
52. e battery down from the top of the radio about 1 2 in Once the battery is free from the battery rails lift it directly away from the radio c Remove the battery from the radio CN Battery Latch Figure 7 1 Battery Removal HKLN4215A December 3 2003 7 4 Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 3 Remove the antenna 4 Pry off the volume and channel selector knobs from their shafts using the knob removal chassis opener tool Motorola part 6686533201 Figure 7 2 Figure 7 2 Antenna and Knob Removal Note Both knobs slide on and off However the knobs are designed to fit very tightly on the shaft 5 Separate the chassis from the front housing assembly by using the knob remover chassis opener too Place the broad side of the opener into the slots located at the base of the radio Figure 7 3 Press the handle on the opener downwards This pressing action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs n Knob Remover 4 Chassis Opener Figure 7 3 Chassis Removal CAUTION Marring the front cover O ring sealing area will prevent the radio from sealing properly If the N O ring is damaged replace it with a new one Note The speaker wire assembly microphone wire assembly and keypad ribbon connector con necting the front housing assembly and the chassis prevent the two units
53. eduefeon gege ee a a eee 5 1 5 2 OPS Programming S 6tupx ushaeanudegnadlasdtmme dateres 5 1 5 3 Radio Funing Setupi urnuasarnunnat ser dugde a eed 5 2 5 3 1 Initial Test Equipment Control Gettings ner nstnretnnnnnnnnnsennnsrnnssrnssrnns 5 3 5 4 Transmitter Alignment Options urnrrnrnnrrnnnnnrnnrnrrnnnnrrnnrnnrennrrrnntnnnerrrrannnnnnerenrerennnnnsrnnenensnnesennnerenn 5 3 5 4 1 Reference Oscillator Wam 5 3 5 4 2 Modulation Balance Attenuation uarssvrvnnnnnnvvrrnnnnnnvvnnnnnrnrvvnnnnrrrnnnnnrnrrnnrnneernennrnensrennnnne 5 4 HKLN4215A December 3 2003 iv Table of Contents 5 4 3 Transmit Power TUNNO ek 5 5 5 4 3 1 To Perform Transmit High Power Tuning do the following 5 6 5 4 3 2 To Perform Transmit Low Power Tuning do the following 5 6 E e E E e EE 5 7 DAAT VCO Attenuation 25 KS 5 7 5 4 4 2 VCO Attenuation 123BkS A 5 8 5 4 4 3 VCO Attenuation 20 KS 5 8 5 4 5 DTME Deviation TUNMO e cia aka detected od 5 9 5 4 6 MDC 1200 Deviation Tuning 5 10 5 5 IRECSIVER TONN kle egene etched hen eieiei Ed R wel beevtawtvrst 5 10 5 5 1 Rated Volume Tuning iicceetebts cece hed ENER AER a dedised ee EOE 5 11 5 5 2 Squeleh TUNING WEE 5 12 5 5 2 1 Manual Squelch Tuning cc ccccceccceeeeeeeeeeeeeeeeeeeeaeeeeeeeeeseaeeeseaeeseeeeeeeaaeeeaes 5 12 5 5 2 2 AUO UE 5 13 5 5 3 RSSI System Level TUNING cccececeesceececeeeeeeeeceeeeeeaaeeeeeeeesaaeseeaeeesaaaesseneeesaaeeeeaeees 5 13 5 5
54. edures Radio to Radio Cloning December 3 2003 HKLN4215A Chapter 6 Display Model Disassembly and Re assembly 6 1 Introduction This section provides details about the following Preventive maintenance inspection and cleaning Safe handling of CMOS and LDMOS devices Disassembly and re assembly of the radio Repair procedures and techniques 6 2 Preventive Maintenance The radios do not require a scheduled preventive maintenance program however yearly verification of technical parameters and periodic visual inspection and cleaning is recommended 6 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 6 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 boa
55. emory the radio s RAM is loaded with a copy of the EEPROM data Registers Short term data storage circuits within the microcontroller RESET Reset line an input to the microcontroller that restarts execution RF PA Radio Frequency Power Amplifier RIB Radio Interface Box ROM Read Only Memory RSSI Received Signal Strength Indicator a dc voltage proportional to the received RF signal strength RPT TA Repeater Talk Around Softpot A computer adjustable electronic attenuator Software Computer programs procedures rules documentation and data pertaining to the operation of a system SPI clock and data lines Serial Peripheral Interface how the microcontroller communicates to modules and ICs through the CLOCK and DATA lines Squelch Muting of audio circuits when received signal levels fall below a pre determined value Standby Mode An operating mode whereby the radio is muted but still continues to receive data TOT Time Out Timer a timer that limits the length of a transmission TPL Tone Private line UC Microcontroller UHF Ultra High Frequency uP Microprocessor VCO Voltage Controlled Oscillator an oscillator whereby the frequency of oscillation can be varied by changing a control voltage VCOBIC Voltage Controlled Oscillator Buffer Integrated Circuit VHF Very High Frequency VSWR Voltage Standing Wave Ratio December 3 2003 HKLN4215A
56. equency and volume switches facing down 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 Tighten to 3 7 3 9 in lb 5 Replace the O ring by positioning it in the top groove by the volume frequency switches Stretch the O ring to place it into the retaining groove at the bottom end of the chassis 6 Check that the O ring is not twisted and is being held by the top and bottom chassis groves 7 Replace the audio jack shroud HKLN4215A December 3 2003 7 10 Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General Frequency amp v Audio Jack Shroud I 1 i J 1 Volume MS Replace after Plugging amp in Speaker and Mic gt pr e Main Board Interface Pad Battery Contact Seal Figure 7 12 Installation of Main Board onto Chassis 7 4 3 4 Chassis and Front Cover Re assembly 8 Dress and connect the speaker wires Note Care should be taken when dressing the speaker and microphone wires to avoid pinching them between the speaker magnet and shield or between the accessory connector and housing Note Ensure that the plug orientation is correct with the exposed pins in the wire casing facing upward and fully plugged in a Connect the speaker wire assembly into the 10 pin connector on the main board and bend the wire
57. erly seated If the O ring seal is pinched separate the chassis from the housing using the knob removal chassis opener and dress O ring properly 14 Snap the bottom of the chassis into the front cover 15 Check that O ring is visible at the corners 16 After closing the radio verify that the O ring is not visible if visible re assemble properly 17 Re assemble the knobs antenna and battery 7 4 3 5 PTT Re assembly 1 Place the PTT seal over the ridge around the top hole Press down to seat the seal around the ridge 2 Place the bottom tab in the slot inside the front housing PTT opening Slightly slide down the PTT and bow it by placing one finger under the middle of the PTT so that the top tab can be aligned and inserted into the top slot Figure 7 15a HKLN4215A December 3 2003 7 12 Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 3 Press the PTT assembly against the front cover opening Figure 7 15b EE f a Place bottom tab into bottom slot b Push down on PTT toward bottom Place top tab into top slot of radio so hooks do not get crushed Figure 7 15 PTT Re assembly December 3 2003 HKLN4215A Non Display Model Disassembly and Re assembly Mechanical View and Parts List 7 5 Mechanical View and Parts List 7 5 1 EP450 Non Display Exploded View and Parts List HKLN4215A gt
58. esonator provides phases vs frequency characteristic required by the quadrature detector with 90 degree phase shift occurring at 455 kHz The output of the IFIC is the recovered audio signal which is fed to the audio IC for amplification and signal conditioning The output of the audio IC is injecting into the audio PA which drives the 24 Ohm speaker 2 2 2 Transmitter e When the radio is transmitting microphone audio is passed through the audio IC where pre emphasis and low pass splatter filtering are done The output of the audio IC is used to modu late the TX VCO which creates the modulated carrier The modulated carrier is then amplified by the pre driver and power amplifier circuit which transmits the signal under dynamic power control Ref Osc Frac N Tx PA ae Predriver Module Tx Out el L GC VCOBIC Rx VCO ane Circuit i Audio PA T R Harmonie Switch Filter Spkr P q Audio IC Mic gt Filter Recovered Audio Preselector 6G Ceramic l Rx LNA Resonator f IF Amp Crystal Filter Image lt EE Filter Demodulator Figure 2 2 Transceiver Block Diagram December 3 2003 HKLN4215A Chapter 3 Test Equipment Service Aids and Service Tools 3 1 Test Equipment Table 3 1 lists test equipment required to service the EP450 Radios
59. f the transmitter circuitry before being applied to the receiver front end The receiver front end consists of a preselector filter RF amplifier interstage filter and a double balanced first mixer Figure 2 2 The mixer output is applied to a diplexer network which matches the 44 85 MHz IF signal to the crystal filter and terminates the mixer into 50 ohms at all other frequencies The receiver back end is a dual conversion design High IF selectivity is provided by a 4 pole fundamental mode 44 85 MHz crystal filter The output is matched to an IF amplifier stage The output of the IF amplifier is applied to the input of the receiver IFIC 2 2 Theory Of Operation Major Assemblies The IFIC is a low voltage monolithic FM IF system incorporating a mixer oscillator two limiting IF amplifiers quadrature detector logarithmic received signal strength indicator RSSI voltage regulator and audio and RSSI Op Amps The second LO frequency 44 395 MHz is determined by a crystal oscillator The second mixer converts the 44 85 MHz high IF frequency to 455 kHz Additional IF selectivity is provided by two ceramic filters The first ceramic filter is a 4 pole filter used between the second mixer and IF amp The second ceramic filter is a 6 pole filter and is used between the IF amp and the limiter input For the second ceramic filter a wider filter is used for 20 25 kHz channel spacing and a narrower filter is used for 12 5 kHz channels A ceramic r
60. ge 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 December 3 2003 HKLN4215A Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 3 7 4 Disassembling and Re assembling the Radio General Since these radios may be disassembled and re assembled 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 see 3 2 for a list of service aids knob remover chassis opener e 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 Appendix B for a list of authorized service centers The following disassembly procedures should be performed only if necessary e Chassis Disassembly e Speaker Disassembly PTT Disassembly 7 4 1 Radio Disassembly Detailed 7 4 1 1 Front Cover From Chassis Disassembly 1 Turn off the radio 2 Remove the battery Figure 7 1 a Slide the battery latch into the unlock position Disengage by pushing downward and holding the latch towards the front of the radio b With the battery latch disengaged slide th
61. ht Ear Large Custom Clear Earpiece Left Ear Standard 95 dB Ear Microphone with PTT Interface Module Standard 95 dB Ear Microphone with VOX amp PTT Interface Module Ring PTT Switch for Ear Microphone System Body PTT Switch for Ear Microphone System Accessory Retainer 2 Wire Comfort Earpiece wMic amp PTT Beige 2 Wire Comfort Earpiece w Mic amp PTT Black Portable Radio Hanger Portable Radio Hanger Ultra Lite Breeze Behind the Head Headset Ultra Lite Earset with Mic and PTT Lightweight Headset w o In line PTT Lightweight Headset with In line PTT Lightweight Headset with In line PTT NFL Style Medium Weight Over the Head Dual Muff Headset Medium Weight Behind the Head Dual Muff Headset HKLN4215A Accessories BDN6647 BDN6648 508037 1E66 RMN5015 REX4648 RKN4090 RMN4051 RMN4055 HLN9133 RKN4094 PMLN4445 A 3 Medium Weight Single Speaker Headset Heavy Duty Dual Muff Headset with Noise Canceling Microphone Replacement Ear Pad for BDN6647 Heavy Duty Dual Muff Racing Headset requires RKN4090 Headset Adapter Cable Ear Pad and Windscreen Kit Adapter Cable for use with RMN5015 Racing Headset 2 Way Hard Hat Mount Black Noise Reduction Rating 22db requires RKN4094 Adapter Cable Receive Only Headband Style Headset with 3 5mm Right Angle Plug VOX Adapter Kit for use with Headsets only In Line PTT Adapter for use with headsets RMN4051 RMN4052 and RMN4053 only Ultra Light Headset with Boom M
62. iation values such as DTMF MDC 1200 Signaling etc The frequency will drift if not warped properly Perform this operation prior to all other transmit tuning operations in order to minimize heating and because of the impact of warp on signaling operations Fgreference Oscillator Warp E lol xj Frequency Point IMiHz Default Softpot Working Softpot Pe sf E DIEE 470 000000 TE e Radio is currently dekeyed Note Valid Softpot values will range from 0 511 Figure 5 3 Reference Oscillator Warp Window HKLN4215A December 3 2003 5 4 Radio Alignment Procedures Transmitter Alignment Options 1 Under Tx Align menu select Reference Oscillator Warp Figure 5 3 2 There is only 1 frequency point shown which is always the last non 0 transmit frequency point which will normally be F7 3 Click on the slider thumb and press PTT Toggle to key up the radio at the corresponding fre quency point 4 Monitor the transmit frequency 5 Adjust the slider spin or edit control press ENTER to confirm selection send a softpot value until the frequency is as close as possible to the indicated transmit frequency Refer to Table 5 2 6 Dekey the radio by pressing PTT Toggle 7 Program the warp value into the radio by pressing the Program button 8 Exit the Reference Oscillator Warp function Table 5 2 Reference Oscillator Specifications RF Band Target VHF 146 174 174 Hz UHF Band 1 403 440 4
63. icrophone Remote Speaker Microphones HMN9030 RLN4904 HKN9094 PMMN4008 Manuals HKLN4212 HKLN4215 HKLN4216 HKLN4215A Remote Speaker Microphone Mic Jacket for HMN9030 Remote Speaker Microphone Replacement Cord for HMN9030 Remote Speaker Microphone E Series User Guide E Series Basic Service Manual E Series Detailed Service Manual December 3 2003 A 4 Accessories December 3 2003 HKLN4215A Appendix B Warranty Service Support and 1 1 1 2 1 2 1 1 2 2 1 3 1 3 1 Replacement Parts 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 Notes Before operating or testing these units please read the Product Safety and RF Exposure Compliance section in the front of this manual Warranty Motorola offers long term support for its products This support 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 by an authorized Motorola Dealer must be accompanied by a Warranty Claim Form Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer Warranty Period
64. ing Table for Transmitter eee cece ee eeeenee eee eeeeaeeeeeeeeeaeeeeeeeaaeeeeeneeaaeeeeeeeeaeeeeeeaaas 8 3 Appendix A Accessories asco ccte screens cece aes eek deena A 1 Appendix B Warranty Service Support and Replacement Parts B 1 14 Scope lU EE 1 1 tt A TLRs 1010 Ger pear ereeeerrerreecerer E E TSR 1 1 1 2 1 Warranty Period and Return Instruchons 1 1 IS After Warr nty Period accses a a eabedenchauehnoe cust ane enga koden athenernes ed 1 1 1 3 Replacement Parts Ordetng prinia erae a aaea da arean tS eai vetaa kanaa aaeh a aaas 1 1 1 3 1 Basic Ordering Information 1 1 1 3 2 MOtorola ONNE EEN 1 2 UE DC E Mal EE 1 2 1 3 4 Telephone Orders raaa anki akk Amsfoa kandidat 1 2 1 3 5 E le EE 1 2 V3 6 Parts identican riire eea EAE E esebianesteevbbeanecegiedane bogie eege dE 1 2 1 4 Technical Supportasiucsssonsdeskng aa haces EES aa a aai 1 3 GIOSSANY rn G 1 HKLN4215A December 3 2003 vi Table of Contents List of Figures Figure 2 1 Major Assemblies Block Diagram esessssssirsssssirsssrrirssstirrnnstinnnnstinnnnsttnnunstnnnnnntnennnnant 2 1 Figure 2 2 Transceiver Block Diagram rurrnnnvnnnnnnnnvrnnnnnnnnrrnnnernnnrnnnrnennrnnenrennnrnnsnnnnnnnessrennnrnessnennnnnn 2 2 Figure 3 1 Programming Test Cable A 3 4 Figure 3 2 Wiring of the Connectors 0 eee eee eeeee crete eee eeee teat seen eteeeteaeseaeeeaeeeaeeseaeesaeeseeeeseeeneaeee 3 4 Figure 4 1 Radio Tuning Getup 4 1 Figure 4
65. is Assembly Re assembly 1 Replace the battery contact seal if necessary surrounding the battery contact Figure 6 17 2 Remove the old Interface Pad from the chassis by scraping off the pad and adhesive with a straight razor Use rubbing alcohol and a cloth to completely remove the adhesive from the chas sis surface With the chassis clean and dry add a new Interface Pad to the chassis 3 Place the main circuit board straight down on top of the chassis with the frequency and volume switches facing down Figure 6 17 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 Tighten to 3 7 3 9 in lb 5 Replace the O ring by positioning it in the top groove by the volume frequency switches Stretch the O ring to place it into the retaining groove at the bottom end of the chassis 6 Check that the O ring is not twisted and being held by the top and bottom chassis groves December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 13 F Audio Jack Shroud Frequency amp i R In Replace after Plugging Volume MEN ee ih in Speaker and Mic gt a Main Board Interface Pad Flex Cable Connector Radio Chassis Battery Contact Seal O Ring Figure 6 17 Main Board onto Chassis Re assembly 6 4 2 6
66. lace the PTT seal over the ridge around the top hole Press down to seat the seal around the ridge 2 Place the bottom tab in the slot inside the front housing PTT opening Slightly slide down the PTT and bow it by placing one finger under the middle of the PTT so that the top tab can be aligned and inserted into the top slot Figure 6 21a 3 Press the PTT assembly against the front cover opening Figure 6 21b WA f a Place bottom tab into bottom slot b Push down on PTT toward bottom Place top tab into top slot of radio so hooks do not get crushed Figure 6 21 PTT Re assembly HKLN4215A December 3 2003 6 16 Display Model Disassembly and Re assembly Mechanical View and Parts List 6 5 Mechanical View and Parts List 6 5 1 EP450 Display Exploded View and Parts List Figure 6 22 EP450 Display Radio Exploded View December 3 2003 HKLN4215A Mechanical View and Parts List Motorola Part Number NON REFERENCED ITEMS Description 3386625201 Nameplate Motorola Nameplate EP450 Motorola Part Description Number 1 See Section6 Antenna 2 3680530202 Knob Frequency 3 1386440201 Escutcheon Top 4 Ch 1386440202 Escutcheon Top 16 Ch 4 5886627201 Antenna Adaptor Seal
67. lfunction which may be encountered Initial contact should be by telephone wherever possible When contacting Motorola Technical Support contact us MOL at https businessonline motorola com be prepared to provide the product model number and the unit s serial number Motorola de Colombia Service Center Carrera 7 No 71 52 Torre B Piso 13 Oficina 1301 Bogota Colombia 1 571 376 6990 Motorola de Mexico Service Center Bosques de Alisos 125 Col Bosques de las Lomas CP 05120 Mexico D F 1 525 257 6700 HKLN4215A December 3 2003 Appendix B 4 Warranty Service Support and Replacement Parts Technical Support December 3 2003 HKLN4215A Glossary of Terms Term Definition ALC Automatic Level Control a circuit in the transmit RF path that controls RF power amplifier output provides leveling over frequency and voltage and protects against high VSWR voltage standing wave ratio ASFIC Audio Signalling Filter Integrated Circuit BKC Bad Key Chirp CD Compact Disk CMP Compression CPS Customer Programming Software CSQ Carrier Squelch DTMF Dual Tone Multifrequency DPL Digital Private Line EEPROM Electronically Erasable Programmable Read Only Memory used by the radio to store its personality Firmware Software or a software hardware combination of computer programs and data with a fixed logic configuration stores in a read only memory
68. mber RSX 4015 e Do not wear nylon clothing while handling CMOS devices e 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 bk When straightening CMOS pins provide ground straps for the apparatus used When soldering use a grounded soldering iron e 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 December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 3 6 4 Disassembling and Re assembling the Radio General Since these radios may be disassembled and re assembled 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 see 3 2 for a list of service aids Knob remover chassis opener Penknife size screwdriver TORX T6 screwdriver e Scribe If a unit requires more complete testing or service than is customarily performed at the basic level send this unit to a Motorola Authorized
69. n and cleaning is recommended 7 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 7 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 The effects of certain chemicals and their vapors can have harmful results on certain plas hi tics Avoid using aerosol sprays tuner cleaners and other chemicals 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 en
70. ncy point until the deviation is within the range specified in Table 5 4 Press PTT Toggle to dekey the radio Program the softpot value by pressing the Program button Exit the VCO Attenuation 12 5 kHz function 5 4 4 3 VCO Attenuation 20 kHz Note Tuning of Modulation Balance Attn and VCO Attn for 25 kHz channel bandwidth must be done first Under the Tx Align menu select VCO Attenuation 20 kHz Press PTT Toggle to key up the radio at the last non 0 transmit frequency point normally F7 Inject 1 kHz at an appropriate level until 2 3V rms is measured at the AC DC METER radio input if using test box RLN4460 Record the deviation obtained Adjust the slider adjust the spin control or key in softpot values press ENTER to confirm for the frequency point until the deviation is within the range specified in Table 5 4 Press PTT Toggle to dekey the radio Program the softpot value by pressing the Program button Exit the VCO Attn 20 kHz function Table 5 4 Deviation Specifications Band Channel Spacing Deviation kHz UHF VHF 25 kHz 4 40 4 60 UHF VHF 12 5 kHz 2 20 2 30 UHF VHF 20 kHz 3 40 3 60 December 3 2003 HKLN4215A Radio Alignment Procedures Transmitter Alignment Options 5 9 5 4 5 DTMF Deviation Tuning This tuning option controls the Dual Tone Multi Frequency deviation Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation Not doing
71. ndby Transmitter 30 C to 60 C UHF RF Output Low High Li lon 7 5 V 1W 4W Frequency 403 440 MHz 438 470 MHz 465 495 MHz Channel Spacing 12 5 20 25 kHz Freq Stability 0 00025 Spurious Harmonics 36 dBm lt 1 GHz 30 dBm gt 1 GHz Rejection FM Noise 40 dB 12 5 kHz 45 dB 25 kHz Audio Response 1 to 3 dB from 6 dB oct Pre emphasis 300 to 3000 Hz Audio Distortion lt 3 1000 Hz 60 Rated Max Dev Receiver UHF UHF 12 5 kHz 25kHz Channel Spacing 12 5 20 25 kHz Frequency 403 440 MHz 438 470 MHz 465 495 MHz Sensitivity 0 25 uV typical 12 dB EIA SINAD Adjacent Channel 60 dB 70 dB Selectivity Intermodulation 70 dB Freq Stability 0 00025 30 C to 60 C Spur Rejection 75 dB Image and 1 2 F 70 dB Audio Output lt 5 Distortion 500 mW into 24Q Specifications subject to change without notice All electrical specifications and methods refer to EIA TIA 603 standards 1 8 Model Charts and Test Specifications MIL Standards 1 8 MIL Standards Table 1 2 MIL STDS 810 C DE and F Applicable to UHF and VHF Specifications 8 2 and 8 4 Military Standards 810 C D E amp F Parameters Methods Procedures 810C 810D 810E 810F Applicable Methods Procedures Methods Procedures Methods Procedures Methods Procedures MIL STD
72. nnnennennnnneeennnnnnneenennnenee 7 3 7 4 1 1 Front Cover From Chassis Disassembly sssesseesesesirsssrrssrnrsrrsrnnsennesrrresrnns 7 3 7 4 1 2 DustGover Disassembly rarr aaaea ae ia eias 7 5 7 4 1 3 Speaker and Microphone Disassembly cccccceeeeeeeeeeeeeeeeeeeeeeeeseaeeeeeneeeeeas 7 6 Tkt E AN RRE ue 7 6 7 4 2 Chassis Disassemblv ens 7 7 7 4 3 Radio Re assembly Detailed rsrnnnnnnnnvnnnnnnnnnvnnnnnnnnvnnnnnnnnnnnennnnnnnneennennnnneennnnnnneeenennnene 7 8 7 4 3 1 Dust Cover Re assembly rrrrnnnnvnnnnnvnnnervvnnnnvnnnrnvennnnrnnnnnnnnrnnrrennnnnnrrrrresnnnnenennn 7 8 7 4 3 2 Microphone and Speaker He assembhy 7 8 7 4 3 3 Chassis Assembly Re assembly sseseesseesneseinesirresrnsssrnstrnretnnsnnnsnnntnnnsnnn 7 9 7 4 3 4 Chassis and Front Cover Re assembly rannrrnnnnrnnnnnnvnnnrrrnnnnnnnnrrrrennnnrnnnrnnennn 7 10 TASS PTI Re assemnmb eorne a EE E R 7 11 7 5 Mechanical View and Parts Eistar Aaina aR N A aaa AEEA KANNE EASE TAE A 7 13 7 5 1 EP450 Non Display Exploded View and Parts List rrurrnnnrnnnnnonnnrnnnnrnnnrrnnnnnnnnrnnnnnrnnnnn 7 13 Chapter 8 Troubleshooting Tables nnnnnnnnnnnnnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnn 8 1 81 Power Up Error O OTOS a aTa a a a Reiret Loes iee ele 8 1 82 Operational Error Cod Snie ai ee i a ae dee i a ee 8 1 8 3 Troubleshooting Table for Heceiver cece eeeeeee eee eeeeneeeeeeeeaeeeeeeeeaaeeeeeeeaaeeeeeeeeaaeeeeeneiaeeeeeneaaas 8 2 8 4 Troubleshoot
73. nnnnnnnnnvnnnnnnnnennnnnnnnnennnnnnnennnnnnnnnennnnennne 6 9 6 4 2 1 Dust Cover Re assembly rrnrrnannvnnnnnvvnnnnrnnnnnnvnnnnrrnnnnnvnnerrrennnnvnnennrensnrnnannnenen 6 9 6 4 2 2 Microphone and Speaker He zssembhy 6 9 6 4 2 3 Keypad and LCD Keyboard Re assembly cccceeeeeeeeeeeeeeeneeseseeeesenaeessaes 6 11 6 4 2 4 Keyboard Retainer Re assembly rnnnnnnnnvrnnnnnnnrrnnnnnrnnrnnnnnrnnrrnnnrrnnnrnerrrrrnnnnn 6 12 6 4 2 5 Chassis Aesemblhv e assembiy 6 12 6 4 2 6 Chassis and Front Cover Re assembly ssssssessseesseseesesisssnesinssrrnssrnesens 6 13 6 4 2 7 PIT M ssel roue a eneeier eee 6 15 6 5 Mechanical View and Parteie 6 16 6 5 1 EP450 Display Model Exploded View and Parts Uert 6 16 Chapter 7 Non Display Model Disassembly and Re assembly 7 1 PAL IMtroduetion usnsuadusas dveler ENN EEN Ea aes NAE EEA TN ates 7 1 7 2 Preventive Maintenance eernrnnnnvnnnnnnnnnnonnnnnnnvennnnnnnnnnnnntnnannnennnnnnnnnnnsnnnnnnnnnsannennnnsannnnnnnnsannenesee 7 1 T amp L NSPOCUION csi ave ee e ei in A pe Ee 7 1 December 3 2003 HKLN4215A Table of Contents V 7 2 2 Cleaning Procedures cccccccceesnceceeeeeeeaeeeeeneeecaaeeseeaeeeceaeeeseaaesseneeesaeesseaeeeseeeeseaaeeesaes 7 1 7 3 Safe Handling of CMOS and LDMOS Devices nenene 7 2 7 4 Disassembling and Re assembling the Radio General 7 3 7 4 1 Radio Disassembly Detailed rmrnnnnnnnvnnnnnnnnvnnnnnnnnvnnnnnnnnnnnnennvnn
74. ntained in compliance with the manufacturer s recommended calibration schedule 30 dB Pad Service Monitor or Transmit GEL Power Cable el 30 dB Pad RLN5410 Wattmeter BNC lt q RF Generator Receive RF Adaptor 5886564Z01 lt H Audioln TX Audio Generator Test Box Battery a RLN4460 aoa N Rx Sinad Meter Program Test Cable AAPMKN4004 AC Voltmeter Tx Data m RIB Rx Data fi RLN4008 A CS Nr Computer Interface Cable RIB Power Supply FE Figure 4 1 Radio Tuning Setup 4 2 Power Up Self Test Applying power to the radio by using the on off volume control starts a self test routine which checks the RAM EEPROM hardware and EEPROM checksum Pressing and holding SB1 while turning on the radio causes the self test routine to check for the ROM checksum as well If these checks are successfully completed the radio will generate the Self Test Pass Tone If the self test is not successful a Self Test Fail Tone is heard 4 2 Performance Checks RF Test Mode Supply voltage can be connected from the battery eliminator The equipment required for alignment procedures is connected as shown in the Radio Performance Checks Setup diagram
75. of the radio outside of the housing RLN5583 Flashing Adapter Flashing CPS cable for authorized service centers Table 3 3 Recommended Service Tools vee Part Description Application RSX4043 TORX screwdriver Tighten and remove chassis screws 6680387A70 T6 TORX bit Removable TORX screwdriver bit R1453 Digital readout solder station Digitally controlled soldering iron RLN4062 Hot air workstation 120 V Tool for hot air soldering desoldering of surface mounted integrated circuits December 3 2003 HKLN4215A Test Equipment Service Aids and Service Tools Service Aids Motorola Part Table 3 3 Recommended Service Tools Continued 3 3 No Description 0180386A78 Illuminated magnifying glass with lens attachment Illumination and magnification of components 0180302E51 Master lens system 0180386A82 Anti static grounding kit Used during all radio assembly and disassembly pro 6684253C72 Straight prober 6680384A98 Brush 1010041A86 Solder RMA type 63 67 0 5mm diameter 1 Ib spool 0180303E45 SMD tool kit included with R1319A R1319 ChipMaster 110 V Surface mount removal and assembly of surface R1321 ChipMaster 220 V mounted integrated circuits and or rework station shields Includes 5 nozzles ChipMaster Nozzles Soldering and Un soldering IC s 6680332E83 PLCC 28 nozzle 6680332E82 PLCC 44 nozzle 6680332E94 PLCC 52 nozzle
76. ontrol can also be toggled via its up down arrow buttons The softpot value can also be typed into the edit control press ENTER to confirm your selection send a softpot value 3 Inject 1 kHz at an appropriate level until 2 3 V rms is measured at the AC DC METER radio input if using test box RLN4460 4 Record the deviation obtained 5 Adjust the slider adjust the spin control or key in softpot values press ENTER to confirm for the frequency point until the deviation is within the range specified in Table 5 4 6 Dekey the radio Press the PTT Toggle button Choose the next frequency key up and repeat steps 3 to 6 until all seven tuning points are done HKLN4215A December 3 2003 5 8 7 8 Radio Alignment Procedures Transmitter Alignment Options Program the softpot value by pressing the Program button Exit the VCO Attn 25 kHz function 5 4 4 2 VCO Attenuation 12 5 kHz Note Tuning of Modulation Balance Attenuation and VCO Attenuation for 25 kHz channel 6 7 8 bandwidth must be done first Under the Tx Align menu select VCO Attenuation 12 5 kHz Press PTT Toggle to key up the radio at the last non 0 transmit frequency point normally F7 Inject 1 kHz at an appropriate level until 2 3 V rms is measured at the AC DC METER radio input if using test box RLN4460 Record the deviation obtained Adjust the slider adjust the spin control or key in softpot values press ENTER to confirm for the freque
77. ophone and Speaker Connections 9 Unplug the speaker wire assembly from the 2 pin connector on the chassis 10 Unplug the microphone wire assembly from the socket on the chassis 11 Move the chassis away from the housing and place on a clean work surface HKLN4215A December 3 2003 6 6 Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 4 1 2 Dust Cover Disassembly 1 Gently pry the top of the dust cover away from the body of the radio See Figure 6 6 2 Rotate the dust cover 90 in a counterclockwise direction to allow the key to be removed 3 Separate the dust cover away from the body of the radio The dust cover key is fragile apply only light pressure to the key while removing the dust cover b Rotate dust cover 90 to c Separate dust a Pry dust cover from body 4 4 allow key to be removed cover from body Figure 6 6 Dust Cover Disassembly 6 4 1 3 Speaker and Microphone Disassembly Note The speaker is held in place with a retainer bracket Be careful not to damage the speaker when removing the retainer bracket Remove the screw from the speaker retainer using a T6 Torx screwdriver Figure 6 7 Lift the retainer off the speaker sliding end of retainer out of corner slot on the housing Lift the speaker out from the front housing Carefully lift microphone assembly out of housing G Retainer Bracket Re Speaker AEG Speaker Connect
78. or D Por 3 Microphone Radio Housing Microphone Connector Figure 6 7 Removal Speaker Microphone Assembly December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 7 6 4 1 4 Keyboard Removal 1 Carefully pry the four keypad retainer locking tabs free from the housing use a scribe Note Use care when removing the keypad retainer to prevent damage to the keyboard flex cable 2 Lift the keypad retainer up from the bottom and slide the top tabs out 3 Slide keypad retainer out of chassis carefully to prevent damage to flex cable CAUTION Refer to the CMOS CAUTION paragraph 6 3 before removing the main board Be sure to N use Electrostatic Discharge protection when handling circuit boards 4 Lift LCD keypad board out of housing Figure 6 8 5 Lift keypad out of housing Keypad Retainer Flex Cable Keypad Board Keypad Figure 6 8 Keypad Removal 6 4 1 5 PTT Disassembly 1 If required the PTT Figure 6 9 can be disassembly using a small screwdriver as follows a Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab b Pry the PTT away from the radio housing c Inspect the two hooks If bent or broken the PTT must be replaced d Remove the PTT seal HKLN4215A December 3 2003 6 8 Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General Flat
79. procedure as follows 1 Under the Rx Align menu select Squelch Attenuation Select Squelch Attenuation 12 5 kHz or Squelch Attenuation 25 kHz Channel Spacing variations Figure 5 10 2 Apply an RF signal modulated with a 1 kHz tone at 60 rated deviation listed in Table 5 5 for cur rent frequency point F1 being the first of 10 dB SINAD That is adjust the reference signal level until 10 dB SINAD is obtained at the SINAD meter Squelch tuning can either be done manually see Manual Squelch Tuning for procedure or by Auto Squelch see Manual Squelch Tuning for pro cedure To obtain 10 dB unmute the radio first by dragging the corresponding slider value to 1 Table 5 5 Squelch Deviation Values Channel Spacing Rated System Deviation Signal Generator Deviation 25 kHz 5 0 kHz 3 0 kHz 12 5 kHz 2 5 kHz 1 5 kHz 20 kHz 4 0 kHz 2 4 kHz December 3 2003 HKLN4215A Radio Alignment Procedures Receiver Tuning 5 13 3 Set softpot to its maximum value to mute the radio 4 Adjust the softpot value by using the slider keying in the edit box or using the spin controls Press ENTER to confirm the selection or use the spin controls Do this until the radio is totally unmuted Verify the squelch closing by inputting a signal level of 4 dB lower than that of the 10 dB SINAD level 5 Repeat Steps 2 through 4 of Manual Squelch Tuning for frequency points F2 F7 6 Press Program to commit the softpot values into the radio
80. rds and their components is isopropyl alcohol 70 by volume CAUTION The effects of certain chemicals and their vapors can have harmful results on certain plas hi tics Avoid using aerosol sprays tuner cleaners and other chemicals 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 6 2 6 3 AN Display Model Disassembly and Re assembly 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 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 afresh supply of alcohol and a clean container to prevent contamination b
81. res such as frequency squelch type options trunking etc Note The source radio s serial number cannot be blank Radio functionality inherent in one radio cannot be cloned to another radio that does not contain the same functionality Tuning and alignment information are not transferable and are not affected by cloning 1 Signaling Identification Numbers IDs are duplicated in the cloning process Unique IDs may be assigned with the CPS Note Unsuccessful cloning attempts generates a continuous tone and may be an indication that the destination radio s codeplug is corrupted December 3 2003 HKLN4215A Radio Alignment Procedures Radio to Radio Cloning 5 15 Procedure 1 2 3 4 HKLN4215A Turn source and target radios off Connect cloning cable AAPMKN4003 to the side connector of both radios Turn on the destination radio Press and hold the two side buttons at the same time on the source radio and then power up the source radio Figure 5 12 Both radios produce a clone entry tone Release both side buttons 1 and 2 When cloning is completed the source radio produce s a clone exit tone and both the source and destination radios reset Turn both radios off Disconnect the cloning cable from both radios and turn them on for normal operation B Side Button 1 Side Button 2 Figure 5 12 Side Button Locations December 3 2003 5 16 Radio Alignment Proc
82. rogam Radio is currently dekeyed Note Valid Softpot values will range from 0 127 Figure 5 5 Transmit Power Window High Power HKLN4215A December 3 2003 5 6 Radio Alignment Procedures Transmitter Alignment Options Table 5 3 Transmit High Low Power Level RF Band MHz Model Number High Power W Low Power W 16 Channel VHF 146 174 H65KDC9AA2AN 5 2 5 5 1 1 1 3 64 Channel VHF 146 174 H65KDH9AA4AN 5 2 5 5 1 1 1 3 16 Channel UHF 1 403 440 H65QDC9AA2AN 4 2 4 5 1 1 1 3 64 Channel UHF 1 403 440 H65QDH9AA4AN 4 2 4 5 1 1 1 3 16 Channel UHF 2 438 470 H65RDC9AA2AN 4 2 4 5 1 1 1 3 64 Channel UHF 2 438 470 H65RDHYAA4AN 4 2 4 5 1 1 1 3 16 Channel UHF 3 465 495 H65SDC9AA2AN 4 2 4 5 11 13 64 Channel UHF 3 465 495 H65SDH9AA4AN 4 2 4 5 1 1 1 3 5 4 3 1 To Perform Transmit High Power Tuning do the following 1 2 3 Dm Je Under the Tx Align menu select Transmit Power then select High Figure 5 5 Press PTT Toggle This will key the radio up at 1st test frequency F1 Adjust the high power level to be as defined by Table 5 3 Move the slider spin control or keying in values in the edit control press ENTER to confirm your selection after typing in the softpot value Press PTT Toggle to dekey the radio go to the next frequency point by selecting the slider typing in the edit control box press ENTER to confirm selection after typing in the softpot value or tog gling the softpot v
83. s at the board connector so the wires are positioned toward the top of the radio Figure 7 13 b Connect the microphone wire assembly into the two hole socket on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio Figure 7 13 c Slide the audio jack shroud onto accessory connector Figure 7 12 9 Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover Look through the accessory connector opening to make certain that the wires are not pinched 10 Push the topside of the board chassis upward until it touches the housing end Before snapping the board into the housing perform the following checks a Open the dust cap and ensure the wires are not pinched between the shroud and housing b Ensure the O ring is seated in the groove 11 c Ensure that the bottom side of the dust cap is fully pressed into the housing before the snap ping the board into place December 3 2003 HKLN4215A Non Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 7 11 Speaker Connector Microphone Connector Shroud Radio Chassis Figure 7 14 Fastening the Chassis 12 Snap chassis assembly completely into the top of the front cover Figure 7 14 until it settles in place 13 Make sure the O ring is prop
84. ss written permission of Motorola No part of this manual may be reproduced distributed or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Motorola Disclaimer The information in this document is carefully examined and is believed to be entirely reliable However no responsibility is assumed for inaccuracies Furthermore Motorola reserves the right to make changes to any products herein to improve readability function or design Motorola does not assume any liability arising out of the applications or use of any product or circuit described herein nor does it cover any license under its patent rights nor the rights of others MOTOROLA and the Stylized M logo are trademarks of Motorola Inc All other product or service names are the property of their respective owners 2003 Motorola Inc All rights reserved Printed in U S A Table of Contents iii Table of Contents ele te ME ii Product Safety and RF Exposure Compliance urrrrrnannnvnnerrrnnnnrnnnenvennnnrrnnnnnnnernnrnernnrnnrrrnnesnnnnnrenrresnnrnnneenn ii Computer Software Copvrigbts viesis isisi inii iiien iiaa ae ai aeii ini iaat iiaa ii Document Gopynghis ru ean suveren setra divide ay eaa Sraa Aaaa artene ii Ae TEE ii List of ale Ui vi Eist Of Tables kin viii Chapter 1 Model Charts and Test Specifications rrnnnnnnnnnnnnnnnnnnnnnn 1 1 1 1 Radio Model Intormaton ceccceeeeeeeneee ERAKA
85. sufficient description of the desired component to identify it Appendix B 2 Warranty Service Support and Replacement Parts Replacement Parts Ordering 1 3 2 Motorola Online Motorola online users can access our on line catalog at https businessonline motorola com 1 3 3 Mail Orders Send written orders to the following addresses International Orders Motorola Inc Customer Care and Services Division Attention Order Processing 2200 Galvin Dr Elgin IL 60123 U S A 1 3 4 Telephone Orders Radio Products Services Division RPSD United States and Canada 7 00 AM to 7 00 PM Central Standard Time Monday through Friday Chicago U S A 1 800 422 4210 1 847 538 8023 International Orders 1 3 5 Fax Orders Radio Products Services Division RPSD United States and Canada 1 800 622 6210 1 847 576 3023 International USFGMD Federal Government Orders 1 800 526 8641 For Parts and Equipment Purchased Orders 1 3 6 Parts Identification Radio Products Services Division RPSD United States and Canada 1 800 422 4210 menu 3 1 847 538 0021 International voice The Radio Products Services Division RPSD was formerly known as the Accessories and Aftermarket Division AAD December 3 2003 HKLN4215A Warranty Service Support and Replacement Parts Technical Support Appendix B 3 1 4 Technical Support Technical support is available to assist the dealer distributor in resolving any ma
86. t value by using the slider keying in the edit box press ENTER to confirm the selection or send a softpot value or via the spin controls Repeat this until 500 mW 3 24 V audio power is obtained Rated Audio tuning is only done for 25 kHz channel spacing 4 Press Program to commit the softpot value into the radio 5 Exit the rated volume tuning function HKLN4215A December 3 2003 5 12 Radio Alignment Procedures Receiver Tuning 5 5 2 Squelch Tuning Note 1 Squelch tuning can only be accomplished after reference oscillator warping 2 When using the test box RLN4460 the received audio output is taken from the AC DC METER OUT terminals with the METER OUT rotary switch set to RX It is recom mended that Rated Volume Tuning be performed so the correct 10 dB SINAD level can be obtained 3 This tuning method is performed for multiple squelch tuning channels and multiple channel spacings Flsquelch Attn 25KHz KE Frequency Point MHz Default Softpot Working Softpot er dia 4 amp Auto Ture l gt 4 4 amp AuoTwe gt o 4 amp AuoTue la H amp AutoTur gt 4 H amp Auto Ture gt o H amp AutoTu 38 025000 A Bl Ol e 469 975000 t g Program No Frequency Tuning Point is currently selected Note Valid Softpot values will range from 1 63 bal Figure 5 10 Squelch Tuning Window 5 5 2 1 Manual Squelch Tuning Perform the squelch tuning
87. the front cover Look through the accessory connector opening to make certain that the wires are not pinched between shroud and housing dio Chassis End Tabs o 00 9 o on 99 o on op Flex Cable Connector Figure 6 19 Keyboard Flex Cable Connection 4 Push the topside of the board chassis upward until it touches the housing end Before snapping the board into the housing perform the following checks a Open the dust cap and ensure the wires are not pinched between the shroud and housing b Ensure the O ring is seated in the groove c Ensure that the bottom side of the dust cap is fully pressed into the housing before the snapping the board into place December 3 2003 HKLN4215A Display Model Disassembly and Re assembly Disassembling and Re assembling the Radio General 6 15 5 Snap chassis assembly completely into the top of the front cover Figure 6 20 until it settles in place Radio Chassis Figure 6 20 Fastening the Chassis 6 Make sure the O ring is properly seated If the O ring seal is pinched separate the chassis from the housing using the knob removal chassis opener and dress O ring properly 7 Snap the bottom of the chassis into the front cover 8 Check that O ring is visible at the corners 9 After closing the radio verify that the O ring is not visible if visible re assemble properly 10 Re assemble the knobs antenna and battery 6 4 2 7 PTT Re assembly 1 P
88. tion Note Modulation Balance Tuning must be done first The Transmit Deviation Limit softpot sets the maximum deviation of the carrier Tuning is performed for all 12 5 kHz 20 kHz and 25 kHz channel bandwidths Tuning for 25 kHz channels must be done first for all frequency points Tuning for 12 5 and 20 kHz channels determines only the off set to the previously tuned deviation for 25 kHz tuning channel spacing For 12 5 and 20kHz channels only the last non 0 transmit frequency point normally F7 is used for tuning The 30 kHz channel bandwidths that use 5 0 kHz maximum system devia tion are covered by the 25 kHz tuning When using test box RLN4460 e Set the METER OUT toggle switch to the MIC PORT position e Set the METER OUT selector switch to MIC e Inject a 1 kHz tone with the levels given below for each radio model to AUDIO IN e Measure the level at the radio input at the AC DC meter 8 Attn 12 5kHz Frequency Point MHz Default Softpot Working Softpot laf Ae a k Radio is currently dekeyed Note Valid Softpot values will range from 0 127 Figure 5 6 VCO Attenuation Window 12 5 kHz 5 4 4 1 VCO Attenuation 25 kHz Under the Tx Align menu select VCO Attenuation 25 kHz Figure 5 6 2 Begin with the lowest frequency Select the thumb of the slider at the lowest frequency point and then press the PTT Toggle button to key up the radio at the corresponding frequency point The spin c
89. trapped near the connectors cracks or crevices 7 2 7 3 AN Non Display Model Disassembly and Re assembly 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 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 afresh supply of alcohol and a clean container to prevent contamination by dissolved material from previous usage 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 humidi
90. ty 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 e 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 e 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 anda floor mat e 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 e Do not wear nylon clothing while handling CMOS devices e 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 bk When straightening CMOS pins provide ground straps for the apparatus used When soldering use a grounded soldering iron e 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 char
91. y dissolved material from previous usage 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 e 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 e 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 anda floor mat e 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 nu

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