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Professional Radio

GM Series

Service Maintainability

Issue: September 2000

ii

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 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 or reproduced 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 royalty-free license to use that arises by operation of law in the sale of a product.

Table of Contents

Chapter 1 INTRODUCTION

1.0 Scope of Manual .................................................................................................. 1-1

2.0 Warranty and Service Support............................................................................. 1-1

2.1 Warranty Period and Return Instructions ....................................................... 1-1

2.2 After Warranty Period ..................................................................................... 1-1

2.3 European Radio Support Centre (ERSC)....................................................... 1-2

2.4 Piece Parts ..................................................................................................... 1-2

2.5 Technical Support........................................................................................... 1-3

2.6 Related Documents ........................................................................................ 1-3

3.0 Radio Model Information...................................................................................... 1-4

Chapter 2 MAINTENANCE

1.0 Introduction .......................................................................................................... 2-1

2.0 Preventive Maintenance ...................................................................................... 2-1

2.1 Inspection ....................................................................................................... 2-1

2.2 Cleaning ......................................................................................................... 2-1

3.0 Safe Handling of CMOS and LDMOS.................................................................. 2-2

4.0 General Repair Procedures and Techniques....................................................... 2-2

5.0 Notes For All Schematics and Circuit Boards ...................................................... 2-5

Chapter 3 SERVICE AIDS

1.0 Recommended Test Tools................................................................................... 3-1

2.0 Test Equipment.................................................................................................... 3-2 iii

iv

SAFETY AND GENERAL INFORMATION

Read this information before using your radio.

IMPORTANT INFORMATION ON SAFE AND EFFICIENT OPERATION

The information provided in this document supersedes the general safety information contained in user guides published prior to July 2000. For information regarding radio use in a hazardous atmosphere please refer to the

Factory Mutual (FM) Approval Manual Supplement or Instruction Card, which is included with radio models that offer this capability.

RF Operational Characteristics

Your radio/radio product contains a transmitter and a receiver. When it is ON, it receives and transmits radio frequency(RF) energy.

Exposure To Radio Frequency Energy

Your Motorola radio/radio product is designed to comply with the following national and international standards and guidelines regarding exposure of human beings to radio frequency electromagnetic energy:

United States Federal Communications Commission, Code of Federal Regulations; 47 CFR part 2 sub-part J

American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers (IEEE) C95.

1-1992

Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999 Edition

National Council on Radiation Protection and Measurements (NCRP) of the United States, Report 86, 1986

International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998

National Radiological Protection Board of the United Kingdom 1995

Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radiofrequency Electromagnetic

Fields in the Frequency Range from 3 kHz to 300 GHz, 1999

Australian Communications Authority Radiocommunications (Electromagnetic Radiation - Human Exposure)

Standard 1999 (applicable to wireless phones only)

To assure optimal radio/radio product performance and make sure human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards, always adhere to the following procedures:

ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY

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

Facilities

To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio product in any facility where posted notices instruct you to do so. Hospitals or health care facilities may be using equipment that is sensitive to external RF energy.

Medical Devices

Pacemakers

The Health Industry Manufacturers Association recommends that a minimum separation of 15 cms be maintained between a handheld wireless radio product and a pacemaker.These recommendations are consistent with the independent research by, and recommendations of, Wireless Technology Research.

Persons with pacemakers should:

ALWAYS keep the radio product more than 15 cms from their pacemaker when the radio product is turned ON.

● not carry the radio product in the breast pocket.

● use the ear opposite the pacemaker to minimize the potential for interference.

● turn the radio product OFF immediately if you have any reason to suspect that interference is taking place.

Hearing Aids

Some digital wireless radio products may interfere with some hearing aids. In the event of such interference, you may want to consult your hearing aid manufacturer to discuss alternatives.

v

vi SAFETY AND GENERAL INFORMATION

Other Medical Devices

If you use any other personal medical device, consult the manufacturer of your device to determine if it is adequately shielded from RF energy. Your physician may be able to assist you in obtaining this information.

Safety and General

Use While Driving

Check the laws and regulations on the use of radio products in the area where you drive. Always obey them.

When using your radio product while driving, please:

Give full attention to driving and to the road.

Use hands-free operation, if available.

Pull off the road and park before making or answering a call if driving conditions so require.

OPERATIONAL WARNINGS

Vehicles with an air bag

!

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

Potentially explosive atmospheres

!

WARNING: Turn off your radio product prior to entering any area with a potentially explosive atmosphere, unless it is a radio product type especially qualified for use in such areas as

"Intrinsically Safe" (for example, Factory Mutual, CSA, or UL Approved). Do not remove, install, or charge batteries in such areas. Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death.

Blasting caps and areas

!

WARNING: To avoid possible interference with blasting operations, turn off your radio when you are near electrical blasting caps, in a “ blasting area” or in areas posted

“ turn off two-way radio”. Obey all signs and instructions.

NOTE The areas with potentially explosive atmospheres referred to above include fueling areas such as below decks on boats, fuel or chemical transfer or storage facilities, areas where the air contains chemicals or particles, such as grain, dust or metal powders, and any other area where you would normally be advised to turn off your vehicle engine. Areas with potentially explosive atmospheres are often but not always posted.

SAFETY AND GENERAL INFORMATION

MOBILE RADIO OPERATION AND EME EXPOSURE

To assure optimal radio performance and that human exposure to radio frequency electromagnetic energy is within the guidelines referenced earlier in this document, transmit only when people outside the vehicle are at least the minimum distance away from a properly installed, externally-mounted antenna. Table 1 lists the minimum distance for several different ranges of rated radio power.

Table 1 Rated Power and Distance

Radiated Power of

Vehicle-installed Mobile

Two-way Radio

7 to 15 Watts

16 to 50 Watts

More than 50 Watts

Minimum Distance

From Transmitting

Antenna

30.5 cm (1 Ft)

61 cm (2 Ft)

91.5 cm (3 Ft) vii

ANTENNA INSTALLATION

Mobile Antennas

Recommended mobile antenna installations are limited to metal body vehicles at the center of the roof and center of the trunk deck locations.

The antenna installation must additionally be in accordance with:

1.

The requirements of the antenna manufacturer/supplier.

2.

Instructions in the Radio Installation Manual.

Fixed Site Antennas

Mobile radio equipment is sometimes installed at a fixed location and operated as a control station or as a fixed unit. In such cases the antenna installation must comply with the following requirements in order to assure optimal performance and make sure human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards:

The antenna must be mounted outside the building

Mount the antenna on a tower if at all possible

If the antenna is to be mounted on a building then it must be mounted on the roof.

As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in accordance with applicable regulatory requirements and may require additional compliance actions such as site survey measurements, signage, and site access restrictions in order to insure that exposure limits are not exceeded.

viii SAFETY AND GENERAL INFORMATION

Chapter 1

INTRODUCTION

1.0

Scope of Manual

This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the equipment described and is current as of the printing date. Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions.

NOTE

Before operating or testing these units, please read the Safety Information Section in the front of this manual.

2.0

Warranty and Service Support

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 authorised Motorola Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an

Authorised Motorola Dealer.

2.1

2.2

Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or

Reseller contract. These conditions may change from time to time and the following 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.

Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact

Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be accompanied by a Warranty Claim Form, available from your Customer Services representative.

Products should be shipped back in the original packaging, or correctly packaged to ensure no damage occurs in transit.

After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.

1.

Motorola's Radio Aftermarket and Accessory Division (AAD) offers a repair service to both end users and dealers at competitive prices.

2.

AAD supplies individual parts and modules that can be purchased by dealers who are technically capable of performing fault analysis and repair.

1-2

2.3

INTRODUCTION

European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:

Austria: 06 60 75 41 Italy: 16 78 77 387

Belgium:

Denmark:

08 00 72 471

80 01 55 72

Luxemburg:

Netherlands:

08 00 23 27

60 22 45 13

Finland:

France:

Germany:

Greece:

UK:

Ireland:

08 00 11 49 10

05 90 30 90

01 30 18 75 24

00 80 04 91 29 020

08 00 96 90 95

18 00 55 50 21

Norway:

Portugal:

Spain:

Sweden:

Switzerland:

Iceland:

80 01 11 15

05 05 49 35 70

90 09 84 902

02 07 94 307

1 55 30 82

80 08 147

2.4

Or dial Customer Care Centre:

Tel: +49 6128 70 2618

Please use these numbers for repair enquiries only.

Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly. If a complete Motorola part number is assigned to the part, it is available from Motorola Radio

Aftermarket and Accessory Division (AAD). If no part number is assigned, the part is not normally available from Motorola. If the part number is appended with an asterisk, the part is serviceable by

Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable parts are available for that kit or assembly.

All enquiries should be directed to your local Technical Support Team.

Warranty and Service Support

2.5

1-3

Technical Support

Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions which may be encountered.

UK/Ireland - Richard Russell

Telephone: +44 (0) 1256 488 082

Fax: +44 01256 488 080

Email: [email protected]

East Europe, Turkey and Central Asia

Siggy Punzenberger

Telephone: +49 (0) 6128 70 2342

Fax: +49 (0) 6128 95 1096

Email: [email protected]

Scandinavia - Bjorn Rambert

Telephone: +46 8 735 9282

Fax: +46 8 735 9280

Email: [email protected]

Central Europe (Germany, Benelux,

Austria & Switzerland) - Customer Connect

Telephone: +49 (0) 6128 70 2266

Fax: +49 (0) 6128 95 1685

Email: [email protected]

France - Armand Roy

Telephone: +33 1 6929 5715

Fax: +33 1 6929 5904

Email: [email protected]

Italy - Ugo Gentile

Telephone: +39 0 2822 0325

Fax: +39 0 2822 0334

Email: [email protected]

Middle East & Africa - Ralph Schubert

Telephone: +33 (0) 4 4230 5887

Fax: +33 (0) 4 4230 4784

Email: [email protected]

2.6

Related Documents

The following documents are directly related to the use and maintainability of this product.

Title

GM100 Series Product Manual

GM300 Series Product Manual

GM600/GM1200 Series Product Manual

Language

English

English

German

French

Italian

Spanish

Russian

English

German

French

Russian

Part Number

ENLN4147

ENLN4137

ENLN4138

ENLN4139

ENLN4140

ENLN4141

ENLN4142

ENLN4143

ENLN4144

ENLN4145

ENLN4146

1-4 INTRODUCTION

3.0

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 mobile radio model number and its specific characteristics.

Table 1-1 Radio Model Number (Example: MDM25KHC9AN1AE)

MD

Type of

Unit

Model

Series

M 25

Freq.

Band

Power

Level

K

VHF

(136-

174MHz)

H

1-25W

Physical

Packages

C

GM140,

GM340,

GM640

Channel

Spacing

Protocol

9

Programmable

AN

Conventional

5 Tone

Feature

Level

Model

Revision

Model

Package

1

GM140

GM340

GM640

A E

S

UHF 2

(450-

527MHz)

B

LB1

29-36MHz

C

LB2

36-42MHz

D

LB3

42-50MHz

R

UHF 1

(403-

470MHz)

K

25-40W

40-60W

N

GM380,

GM1280

F

GM160

GM360

GM660

A

Databox

AA

Conventional

MDC

O

Databox

(5Tone)

CK

MPT

5

GM160

GM360

GM660

8

GM380

GM1280

7

Databox

(MPT)

Chapter 2

MAINTENANCE

1.0

Introduction

This chapter of the manual describes: preventive maintenance safe handling of CMOS devices repair procedures and techniques

2.0

Preventive Maintenance

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

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.

2.2

!

Cleaning

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 servicing 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 plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided.

1.

Cleaning External Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff, non-metallic, shortbristled brush to work all loose dirt away from the radio. A soft, absorbent, lintless cloth or tissue should be used to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices.

2.

Cleaning Internal Circuit Boards and Components

Isopropyl alcohol 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. Upon completion of the cleaning process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or

2-2 MAINTENANCE back cover.

NOTE

Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).

3.0

Safe Handling of CMOS and LDMOS

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios.

CMOS characteristics make them 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 CMOS

CAUTION paragraph in the Disassembly and Reassembly section of the manual.

4.0

General Repair Procedures and Techniques

Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement component is not locally available, check the parts list for the proper Motorola part number and order the component from the nearest Motorola Communications parts center listed in the “Piece

Parts” section of this manual.

Rigid Circuit Boards

The family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not accessible, some special considerations are required when soldering and unsoldering components. The through-plated holes may interconnect multiple layers of the printed circuit.

Therefore, care should be exercised to avoid pulling the plated circuit out of the hole.

When soldering near the 18-pin and 40-pin connectors: avoid accidentally getting solder in the connector. be careful not to form solder bridges between the connector pins closely examine your work for shorts due to solder bridges.

General Repair Procedures and Techniques 2-3

Chip Components

Use either the RLN4062 Hot-Air Repair Station or the Motorola 0180381B45 Repair Station for chip component replacement. When using the 0180381B45 Repair Station, select the TJ-65 minithermojet hand piece. On either unit, adjust the temperature control to 370 °C (700 °F), and adjust the airflow to a minimum setting. Airflow can vary due to component density.

To remove a chip component:

1.

Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm

(1/8") above the component to be removed.

2.

Begin applying the hot air. Once the solder reflows, remove the component using a pair of tweezers.

3.

Using a solder wick and a soldering iron or a power desoldering station, remove the excess solder from the pads.

To replace a chip component using a soldering iron:

1.

Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the solder pads.

2.

Using a pair of tweezers, position the new chip component in place while heating the fresh solder.

3.

Once solder wicks onto the new component, remove the heat from the solder.

4.

Heat the remaining pad with the soldering iron and apply solder until it wicks to the component. If necessary, touch up the first side. All solder joints should be smooth and shiny.

To replace a chip component using hot air:

1.

Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.

2.

Apply a drop of solder paste flux to each pad.

3.

Using a pair of tweezers, position the new component in place.

4.

Position the hot-air hand piece approximately 0.3 cm (1/8” ) above the component and begin applying heat.

5.

Once the solder wicks to the component, remove the heat and inspect the repair. All joints should be smooth and shiny.

2-4 MAINTENANCE

Shields

Removing and replacing shields will be done with the R1070 station with the temperature control set to approximately 215

°

C (415

°

F) [230

°

C (445

°

F) maximum].

To remove the shield:

1.

Place the circuit board in the R1070 circuit board holder.

2.

Select the proper heat focus head and attach it to the heater chimney.

3.

Add solder paste flux around the base of the shield.

4.

Position the shield under the heat-focus head.

5.

Lower the vacuum tip and attach it to the shield by turning on the vacuum pump.

6.

Lower the focus head until it is approximately 0.3 cm (1/8”) above the shield.

7.

Turn on the heater and wait until the shield lifts off the circuit board.

8.

Once the shield is off, turn off the heat, grab the part with a pair of tweezers, and turn off the vacuum pump.

9.

Remove the circuit board from the R1070 circuit board holder.

To replace the shield:

1.

Add solder to the shield if necessary, using a micro-tipped soldering iron.

2.

Next, rub the soldering iron tip along the edge of the shield to smooth out any excess solder. Use solder wick and a soldering iron to remove excess solder from the solder pads on the circuit board.

3.

Place the circuit board back in the R1070 circuit board holder.

4.

Place the shield on the circuit board using a pair of tweezers.

5.

Position the heat-focus head over the shield and lower it to approximately 0.3 cm (1/8”) above the shield.

6.

Turn on the heater and wait for the solder to reflow.

7.

Once complete, turn off the heat, raise the heat-focus head and wait approximately one minute for the part to cool.

8.

Remove the circuit board and inspect the repair. No cleaning should be necessary.

Notes For All Schematics and Circuit Boards 2-5

5.0

Notes For All Schematics and Circuit Boards

* Component is frequency sensitive. Refer to the Electrical Parts List for value and usage.

1.

Unless otherwise stated, resistances are in Ohms (k = 1000), and capacitances are in picofarads

(pF) or microfarads (µF).

2.

DC voltages are measured from point indicated to chassis ground using a Motorola DC multimeter or equivalent. Transmitter measurements should be made with a 1.2 µH choke in series with the voltage probe to prevent circuit loading.

3.

Interconnect Tie Point Legend:

16_8MHz

3V3

5V

16.8MHz Reference Frequency

Regulated 3.3V Supply Voltage for Voice Storage

Regulated 5V Supply Voltage for RF Circuitry

Regulated 5V Supply Voltage (Control Head) 5V

5V RF

5V SOURCE

5VD

Regulated 5V Supply Voltage for RF Circuitry

5V Signal to Switch On Control Head

Regulated 5V Supply Voltage for Digital Circuitry

Regulated 9.3V Supply Voltage 9V3

9V3FLT

A+

ADDR

Filtered 9.3V Supply Voltage

13.2V Supply Voltage

*P Address Lines

Analog Lines to Analog to Digital Converter AN

ANALOG INPUT 2

ANALOG INPUT 3

BATTERY VOLTAGE

External Keypad Matrix Column Signal

External Keypad Matrix Row Signal

Battery Voltage Sense Line

Back Light Anode Green BL A GREEN

BL A RED

BL GREEN

BL K GREEN

Back Light Anode Red

Green Back Light Control

Back Light Cathode Green

Back Light Cathode Red BL K RED

BL KP Green

BL KP RED

BL LCD GREEN

Green Keypad Back Light Control

Red Keypad Back Light Control

Green Display Back Light Control

Red Display Back Light Control BL LCD RED

BL RED

BOOT CNTRL

BOOT MODE

Red Back Light Control

Bootstrap Mode Enable Signal

Boot Mode Select

Control Head Switch On Signal BOOT PWR ON

BOOT SCI RX

BOOT SCI TX

BOOT VPP

BUS+

BWSELECT

Serial Communication Interface Receive Line

Serial Communication Interface Transmit Line

Boot Mode Select

Bi-directional Serial Communication Line

Signal to select between the Ceramic Filter Pairs

2-6

CH ACT

CH KP ID

CH REQUEST

CLK

CNTLVLTG

CNTR AUDIO

COL x

CSX

DATA

DC POWER ON

DISCAUDIO

ECLK

EE CS

EMERGENCY CONTROL

EXP BD REQ

EXP1 CS

EXP2 CS

EXT KP COL

EXT KP ROW

EXT MIC

EXT SWB+

F1200

FECTRL 1

FECTRL 2

FLASH CE

FLASH OE

FLAT RX SND

FLAT TX RTN

FLT A+

GP x IN

GP x IN ACC y

GP x IN OUT ACC y y

GP x OUT

GP x OUT ACC y

GPIO

HANDSET AUDIO

HOOK

HSIO

IF

IGNITION CONTROL

MAINTENANCE

Channel Activity Indicator Signal (Fast Squelch)

Control Head Keypad ID (Data) Lines

Control Head Request from Control Head *P

Clock Signal

PA Power Control Voltage

Audio Lines of the Controller

Keypad Matrix Column x

Chip Select Line PCIC / FRACN

Data Signal

Electronic Switching On or Off of the Radio's Voltage Regulators

Audio Output Signal from the Receiver IC

Clock (not used)

EEPROM Chip Select

Emergency Line to switch on the Radio's Voltage Regulators

Service Request Line from Expansion Board

Expansion Board Chip Select 1

Expansion Board Chip Select 2

External Keypad Matrix Column Signal

External Keypad Matrix Row Signal

External (from Accessory Connector) Microphone Input

External Switched 13.2V Supply Voltage

Interrupt Line from ASFIC CMP

Control Voltage for Front End Filter

Control Voltage for Front End Attenuator Switch

Flash Chip Select

Flash Output Enable

Option Board Audio Output Signal

Flat TX Input from Option Board and Accessory Connector

Filtered 13.2 V Supply Voltage

General Purpose Input x

General Purpose Input x from Accessory Connector Pin y

General Purpose Input /Output x from Accessory Connector Pin

General Purpose Output x

General Purpose Input x from Accessory Connector Pin y

General Purpose Input Output Lines

Handset Audio Output

Hang-up Switch Input

High Speed Clock In / Data Out

First Intermediate Frequency Signal

Ignition Line to switch on the Radio's Voltage Regulators

Notes For All Schematics and Circuit Boards 2-7

IN 5V RF REG

INT KP COL

INT KP ROW

INT MIC

INT SWB

INT SWB+

IRQ

K9V1

KEYPAD ID

LCD A0

LCD CS

LCD DATA

LCD E RD

LCD RW WR

LED CNTRL

LED GREEN

LED RED

LED YELLOW

LOCK

LSIO

LVZIF CS

MIC

MISO

MODIN

MOSBIAS 2

MOSBIAS 3

NOISE BLNKR

ON OFF CONTROL

Supply Voltage for 5V Regulator in RF Section

Internal Keypad Matrix Column Signal

Internal Keypad Matrix Row Signal

Internal (from Control Head) Microphone Input

Internal Switched 13.2V Supply Voltage

Internal Switched 13.2V Supply Voltage

Interrupt Request from Control Head

9.1V in Transmit Mode

Keypad Identification Line

LCD Control / Display Data Select

LCD Chip Select

LCD Data Lines

LCD Enable Read

LCD Read Write Control

LED Control Lines

Green LED Control

Red LED Control

Yellow LED Control

Lock Detect Signal from Synthesizer

Low Speed Clock In / Data Out

LVZIF Chip Select (not used)

Microphone Input

Serial Peripheral Interface Receive Line

Modulation Signal into the Synthesizer

PA Bias Voltage for second Stage

PA Bias Voltage for third Stage

Noise Blanker Enable (Low Band only)

Service Request Line from Control Head / Manual Switching On of the Radio's Voltage Regulators

ON OFF SENSE (Control Head) On Off Sense Line to Control Head *P

ON OFF SENSE (Controller) Service Request Line from Control Head

OPT CS

OPT PTT

Option Board Chip Select

PTT from Option Board

PA PWR SET

PA SWB

PASUPVLTG

PCIC MOSBIAS 1

ASFIC Output Voltage to set the Transmitter Power

Switches Supply Voltage for PA Current Control Circuitry

13.2 V Supply Voltage of the Transmitter PA

PA Bias Voltage for first Stage

PRESC

PTT IRDEC

PTT IRDECODER

R W

Prescaler Signal from VCO to Synthesizer

Microphone PTT Input

Microphone PTT Input

Read Write Signal for RAM / Flash

2-8 MAINTENANCE

SQ DET

SYN

TEMP SENSE

TEMPSENSE

TRB

TX AUD RTN

TX AUD SND

TXINJ

U DRIVER

U PREDRIVER

UNSW 5V

URX SND

VAG

VCOBIAS 1

VCOBIAS 2

VCOMOD

RAM CS

RDY

REF CS

RESET

ROW x

RSSI

RX ADAPT

RX AUD RTN

RX FLAT FILTERED AUDIO

RXIN

RXINJ

SCI RX

SCI TX

SPI

SPKR-

SPKR+

VCTRL

VDDA

VOLTAGE SENSE

VOLUME

VOX

VPP

VS AUDIOSEL

VS GAINSEL

VS INT

RAM Ship Select

Service Request Line from Option Board

Reference Chip Select (not used)

Reset Line

Keypad Matrix Row x

Received Signal Strength Indicator

Flat TX Path Disable during Transmitter Key-up

Option Board Input / Output of Receiver Audio Path

Flat or Filtered Audio to Accessory Connector

RF Signal from Antenna Switch into the Receiver

RF Signal from the VCO into the Mixer

Serial Communication Interface Receive Line

Serial Communication Interface Transmit Line

Serial Peripheral Interface Bus

Negative Audio PA Speaker Output

Positive Audio PA Speaker Output

Squelch Detect Signal

*P Clock Signal

Temperature Sense Line for LCD

Temperature Sense Line from PA to *P

TX/RX VCO Switch Signal

Option Board Output to Transmit Audio Path

Microphone Audio to Option Board

RF Signal from the VCO into the Transmitter PA

Supply Voltage for PA Driver

Supply Voltage for PA Pre-driver

Permanent 5V Supply

Filtered Audio Signal to Option Board

2.5V Reference Voltage for Analog Circuitry

Switch Signal from Synthesizer

Switch Signal from Synthesizer

Modulation Signal into VCO

VCO Frequency Control Voltage

Regulated 5V for Digital Circuitry in RF Section

Voltage Sense Line from LCD

Volume Pot Output

Voice Operated Transmit Level

Boot Mode Select

Switch Signal to Enable Option Board Audio Output Signal

Voice Storage Gain Select Line

Voice Storage Interrupt Line

Notes For All Schematics and Circuit Boards

VS MIC

VS RAC

VSF

VSTBY

Voice Storage Audio Signal into Microphone Path

Voice Storage Row Address Clock Signal

Voltage Super Filtered (5V)

5V Supply for *P when the Radio is switched off

4-LAYER CIRCUIT BOARD DETAIL VIEWING

COPPER STEPS IN PROPER LAYER SEQUENCE

SIDE 1

LAYER 1 (L1)

LAYER 2 (L2)

LAYER 3 (L3)

LAYER 4 (L4)

INNER LAYERS

SIDE 2

2-9

2-10 MAINTENANCE

Chapter 3

SERVICE AIDS

1.0

Recommended Test Tools

Table 3-1 lists the service aids recommended for working on the radio. While all of these items are available from Motorola, most are standard workshop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.

Table 3-1 Service Aids

Motorola Part

Number

RLN4460_

Description Application

RKN4081_

RLN4853_

RKN4083_

GTF374_

RLN4008_

HLN8027_

GPN6133_

EPN4040_

EPN4041_

8180384J59

8180384L95

8180384J60

8180384J61

3080369B71

3080369B72

6686119B01

Portable Test Set Enables connection to audio/accessory jack.

Allows switching for radio testing.

Includes radio interface box (RIB) capability.

Programming Cable with

Internal RIB

10 to 20 Pin Adapter Connects RKN4081_ to the radio accessory connector.

Connects radio to RIB (RLN4008_).

Mobile Programming/Test

Cable

Program Cable

Radio Interface Box

Mini UHF to BNC Adaptor

Power Supply

Connects RIB to Radio microphone input

Enables communications between radio and computer’s serial communications adapter.

Adapts radio antenna port to BNC cabling of test equipment.

Provides the radio with power when bench testing.

Wall-Mounted Power Supply Used to supply power to the RIB (UK).

Wall-Mounted Power Supply Used to supply power to the RIB (Euro)

Housing Eliminator (short)

Housing Eliminator

(short + top)

Housing Eliminator

(medium)

Housing Eliminator (long)

Computer Interface Cable

Computer Interface Cable

Removal Tool

Test Fixture used to bench test the radio pcb

Test Fixture used to bench test the radio pcb.

(Radio using pressure pads to retain pcb)

Test Fixture used to bench test the radio pcb

Test Fixture used to bench test the radio pcb

Connects the RIB to the Computer (25-pin)

Connects the RIB to the Computer 9-pin

(Use for IBM PC AT - other IBM models use the B71 cable above)

Assists in the removal of radio control head.

3-2 SERVICE AIDS

2.0

Test Equipment

Table 3-2 lists test equipment required to service the radio and other two-way radios.

Table 3-2 Recommended Test Equipment

Motorola Part

Number

R2600_NT

Description

Comms System Analyzer

(non MPT)

Characteristics Application

R2680_NT

*R1072_

*R-1377_

WADN133

R1440_

0180305F17

0180305F31

0180305F39

RLN4610

Comms System Analyzer

( MPT1327) to be ordered with

RLN1022_ (H/W)

RLN1023_ (S/W)

Digital Multimeter

AC Voltmeter

Delay Oscilloscope

Wattmeter,

Plug-in Elements

Plug-in Elements

Plug-in Elements

Carry case

This monitor will substitute for items with an asterisk*

This monitor will substitute for items with an asterisk*.

Frequency/deviation meter and signal generator for widerange troubleshooting and alignment

Frequency/deviation meter and signal generator for widerange troubleshooting and alignment

AC/DC voltage and current measurements

Audio voltage measurements

100µV to 300V, 5Hz -

1MHz, 10Megohm input impedance

2 Channel 40MHz bandwidth,

5mV/cm - 20 V/cm

Thruline 50-Ohm,

±5% accuracy

100W, 25 - 60MHz

25W, 100-250MHz

10W, 200-250MHz

Wattmeter and

6 elements

Waveform measurements

Transmitter power output measurements

T1013_

S1339_

RF Dummy Load

RF Millivolt Meter

R1011_/220V 220V Power Supply

100mV to 3 VRF.

10kHz to 1.2GHz

0 - 40V 0 - 40A

RF level measurements

Programmable

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