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6816101H01-A
User Manual
62 pgs1.79 Mb0

Motorola 6816101H01-A User Manual

Mag One™ by Motorola
Radio Series
Basic Service Manual
6816101H01-A
Computer Software Copyrights
i
DOCUMENT HISTORY
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
6816101H01-A Initial edition Mar. 2007
ii
Notes
iii
Safety Information
Product Safety and RF Energy Exposure Booklet for Portable Two-Way Radios
The information provided in this document supersedes the general safety information contained in user guides published prior to February 2002.
BEFORE USING THIS RADIO, READ THE FOLLOWING INFORMATION WHICH CONTAINS IMPORTANT OPERATING INSTRUCTIONS FOR SAFE USAGE AND RF ENERGY AWARENESS AND CONTROL INFORMATION AND OPERATIONAL INSTRUCTIONS FOR COMPLIANCE WITH RF ENERGY EXPOSURE LIMITS IN APPLICABLE NATIONAL AND INTERNATIONAL STAN­DARDS. ALSO READ THE OPERATIONAL INSTRUCTIONS FOR SAFE USAGE. FOR RADIOS THAT HAVE BEEN APPROVED AS INTRINSICALLY SAFE, READ THE INSTRUCTIONS AND INFORMATION ON INTRINSIC SAFETY ON PAGE vii.
RF Energy Exposure Awareness and Control Information and Operational Instructions for Occupational Use
NOTICE: This radio is intended for use in occupational/controlled conditions where users
have full knowledge of their exposure and can exercise control over their exposure to meet the occupational limits in FCC and International standards. This radio device is NOT authorized for general population or consumer use.
This two-way radio uses electromagnetic energy in the radio frequency (RF) spectrum to provide communications between two or more users over a distance. It uses radio frequency (RF) energy or radio waves to send and receive calls. RF energy is one form of electromagnetic energy. Other forms include, but are not limited to, sunlight and x-rays. RF energy, however, should not be confused with these other forms of electromagnetic energy, which when used improperly, can cause biological damage. Very high levels of x-rays, for example, can damage tissues and genetic material.
Experts in science, engineering, medicine, health, and industry work with organizations to develop standards for safe exposure to RF energy. These standards provide recommended levels of RF exposure for both workers and the general public. These recommended RF exposure levels include substantial margins of protection.
All Motorola two-way radios are designed, manufactured, and tested to ensure they meet government-established RF exposure levels. In addition, manufacturers also recommend specific operating instructions to users of two-way radios. These instructions are important because they inform users about RF energy exposure and provide simple procedures on how to control it.
Please refer to the following websites for more information on what RF energy exposure is and how to control your exposure to assure compliance with established RF exposure limits: http://www.fcc.gov/oet/rfsafety/rf-faqs.html http://www.osha.gov/SLTC/radiofrequencyradiation/index.html
Federal Communication Commission (FCC) Regulations
The FCC rules require manufacturers to comply with the FCC RF energy exposure limits for portable two-way radios before they can be marketed in the U.S. When two-way radios are used as a consequence of employment, the FCC requires users to be fully aware of and able to control their exposure to meet occupational requirements.
iv
Exposure awareness can be facilitated by the use of a product label directing users to specific user awareness information. Your Motorola two-way radio has a RF exposure product label. Also, your Motorola user manual, or separate safety booklet includes information and operating instructions required to control your RF exposure and to satisfy compliance requirements.
Compliance with RF Exposure Standards
Your Motorola two-way radio is designed and tested to comply with a number of national and International standards and guidelines (listed below) for human exposure to radio frequency electromagnetic energy. This radio complies with the IEEE (FCC) and ICNIRP exposure limits for occupational/controlled RF exposure environments at operating duty factors of up to 50% talk-50% listen and is authorized by the FCC for occupational use only.
In terms of measuring RF energy for compliance with these exposure guidelines, your radio generates measurable RF energy only while it is transmitting (during talking), not when it is receiving (listening) or in standby mode.
NOTE: The approved batteries, supplied with this radio, are rated for a 5-5-90 duty factor (5% talk­ 5% listen-90% standby) even though this radio complies with FCC occupational exposure limits and may operate at duty factors of up to 50% talk.
Your Motorola two-way radio complies with the following RF energy exposure standards and guidelines:
• United States Federal Communications Commission, Code of Federal Regulations; 47CFR 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
• International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998
• Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radiofrequency Elec-
tromagnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999
• Australian Communications Authority Radiocommunications (Electromagnetic Radiation ­ Human Exposure) Standard, 2003
• ANATEL ANNEX to Resolution No. 303 of July 2, 2002 "Regulation of limitation of exposure to electrical, magnetic and electromagnetic fields in the radio frequency range between 9 KHz and 300 GHz" and "Attachment to resolution # 303 from July 2, 2002"
"Additional Requirements for SMR, Cellular and PCS Product Certification"
RF Exposure Compliance and Control Guidelines and Operating Instructions
To control your exposure and ensure compliance with the occupational/controlled environment exposure limits, always adhere to the following procedures.
Guidelines:
• Do not remove the RF Exposure Label from the device.
• User awareness instructions should accompany device when transferred to other users.
• Do not use this device if the operational requirements described herein are not met.
v
Operating Instructions
• Transmit no more than the rated duty factor of 50% of the time. To transmit (talk), push the Push­ To-Talk (PTT) button. To receive calls, release the PTT button. Transmitting 50% of the time, or less, is important because this radio generates measurable RF energy exposure only when transmitting (in terms of measuring for standards compliance).
• Hold the radio in a vertical position in front of the face with the microphone (and other parts of the radio including the antenna) at least one inch (2.5 centimeters) away from the nose or lips.
• Antenna should be kept away from the eye. Keeping the radio at a proper distance is important since RF exposures decrease with increasing distance from the antenna.
• When worn on the body, always place the radio in a Motorola-approved clip, holder, holster, case, or body harness for this product. Using approved body-worn accessories is important because the use of non-Motorola-approved accessories may result in exposure levels, which exceed the FCC occupational/controlled environment RF exposure limits.
• If you are not using a body-worn accessory and are not using the radio in the intended use posi­ tion in front of the face, ensure the antenna and the radio are kept at least one inch (2.5 centime­ ters) from the body when transmitting. Keeping the radio at a proper distance is important because RF exposures decrease with increasing distance from the antenna.
Approved Accessories
• Use only Motorola-approved supplied or replacement antennas, batteries, and accessories. Use of Non-Motorola approved antennas, batteries, and accessories may exceed the FCC (IEEE) and ICNIRP RF exposure guidelines.
• For a list of Motorola-approved accessories, visit the following website, which lists approved accessories for your radio model: http://www.motorola.com/governmentandenterprise.
Additional Information
For additional information on exposure requirements or other training information, visit http://www.motorola.com/rfhealth.
Electromagnetic Interference/Compatibility
NOTE: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if
inadequately shielded, designed, or otherwise configured for electromagnetic compatibility.
Facilities
To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio 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.
Aircraft
When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in accordance with applicable regulations per airline crew instructions.
Medical Devices Pacemakers
The Advanced Medical Technology Association (AdvaMed) recommends that a minimum separation of 6 inches (15 centimeters) be maintained between a handheld wireless radio and a pacemaker. These recommendations are consistent with those of the U.S. Food and Drug Administration.
vi
Persons with pacemakers should:
• ALWAYS keep the radio more than 6 inches (15 centimeters) from their pacemaker when the radio is turned ON.
• Not carry the radio in the breast pocket.
• Use the ear opposite the pacemaker to minimize the potential for interference.
• Turn the radio OFF immediately if there is any reason to suspect that interference is taking place.
Hearing Aids
Some digital wireless radios may interfere with some hearing aids. In the event of such interference, you may want to consult your hearing aid manufacturer to discuss alternatives.
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.
Use of communication devices while driving
Always check the laws and regulations on the use of radios in the areas where you drive.
• 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 or regulations
so require.
Operational Warnings
For vehicle with air bags Refer to vehicle manufacturer's manual prior to installation of electronic equipment to avoid
interference with air bag wiring. Do not place a portable radio in the area over an air bag or in the air bag deployment area. Air
bags inflate with great force. If a portable radio is placed in the air bag deployment area and the air bag inflates, the radio may be propelled with great force and cause serious injury to occupants of the vehicle.
Potentially Explosive Atmospheres (Explosive atmospheres refers to hazard classified locations that may contain hazardous gas,
vapors, or dusts.) Turn off your radio prior to entering any area with a potentially explosive atmosphere unless it is
a portable radio type especially qualified for use in such areas as Intrinsically Safe (for example, Factory Mutual, CSA, UL, or CENELEC).
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.
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, and areas where the air contains chemicals or particles such as grain, dust or metal powders. Areas with potentially explosive atmospheres are often, but not always, posted.
Blasting Caps And Blasting Areas 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.
vii
Operational Cautions
Antennas Do not use any portable radio that has a damaged antenna. If a damaged antenna comes into contact with
your skin, a minor burn can result.
Batteries All batteries can cause property damage and/or bodily injury, such as burns, if a conductive material
such as jewelry, keys, or beaded chains touches exposed terminals. The conductive material may complete an electrical circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when placing it inside a pocket, purse, or other container with metal objects.
Intrinsically Safe Radio Information
The Intrinsically safe approval unit refers to a product that has been approved as intrinsically safe by an approval agency (for example FM Approvals, CSA, UL, or Cenelec) and certifies that a particular product meets the Agency's applicable intrinsic safety standards for specific types of hazardous classified locations. A portable radio that has been approved for intrinsic safety will have Approval label attached to the radio to identify the unit as being Approved for specified hazardous atmospheres. This label specifies the hazardous Class/Division/Group along with the part number of the battery that must be used. The intrinsically safe approval label will be located on the portable radio unit.
Operational Cautions for Intrinsic Safe Equipment
• Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualified (for example, FM, UL, CSA, or CENELEC approved). An explosion or fire may result.
• Do not operate a radio unit that has been approved as intrinsically safe product in a hazardous atmosphere if it has been physically damaged (for example, cracked housing). An explosion or fire may result.
• Do not replace or charge batteries in a hazardous atmosphere. Contact sparking may occur while
installing or removing batteries and cause an explosion or fire.
Warnings for Radios Approved as Intrinsically Safe
Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and the intrinsic safety approval labelling (FM, UL, CSA, CENELEC). Radios will not be upgraded to this capability and labeled once they have been shipped to the field.
viii
A modification changes the unit's hardware from its original design configuration. Modifications can only be made by the original product manufacturer.
• Do not replace or change accessories in a hazardous atmosphere. Contact sparking may
occur while installing or removing accessories and cause an explosion or fire.
• Turn the radio off before removing or installing a battery or accessory.
• Do not disassemble an intrinsically safe product in any way that exposes the internal
circuits of the unit.
• Failure to use an intrinsically safe approved battery or Approved accessories specifically
approved for the radio unit may result in the dangerously unsafe condition of an unapproved radio combination being used in a hazardous location.
• Unauthorized or incorrect modification of the intrinsically safe approved Product will
negate the approval rating of the product.
• Incorrect repair or relabeling of any intrinsically safe Agency approved radio could
adversely affect the Approval rating of the unit.
• Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in
serious injury or death.
Repair
REPAIRS FOR MOTOROLA PRODUCTS WITH INTRINSICALLY SAFE APPROVAL ARE THE RESPONSIBILITY OF THE USER.
• Repairs to a Motorola FM approved radio product should only be done at a location that
has been FM audited under the FM 3605 repairs and service standard.
• Contact Motorola for assistance regarding repairs and service of Motorola intrinsically
safe equipment.
A repair constitutes something done internally to the unit that would bring it back to its original condition.
Items not considered as repairs are those in which an action is performed on a unit which does not require the outer casing of the unit to be opened in a manner that exposes the internal electrical circuits of the unit.
Do Not Substitute Options or Accessories
The Motorola communications equipment certified as intrinsically safe by the approving agency, (FM, UL, CSA, CENELEC) is tested as a complete system which consists of the listed agency Approved portable, Approved battery, and Approved accessories or options, or both. This Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit. Approved configurations are listed by the Approving Agency (FM, UL, CSA, CENELEC).
The intrinsically safe Approval label affixed to radio refers to the intrinsically safe classification of that radio product, and the approved batteries that can be used with that system.
The manual PN referenced on the intrinsically safe approval label identifies the approved Accessories and or options that can be used with that portable radio unit.
Using a non Motorola intrinsically safe battery and or accessory with the Motorola approved radio unit will void the intrinsically safe approval of that radio unit.
Table of Contents
Document History ... .............................................................................................. .i
Safety Information ... ........................................................................................... . iii
Section 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 ... ................................................................................... ..1-2
2.3 Piece Parts ... ................................................................................................... ...1-2
2.4 Technical Support ... .......................................................................................... .1-2
2.5 Further Assistance From Motorola ... ............................................................... ...1-2
3.0 Radio Model Information... ....................................................................................... .1-3
4.0 Radio Features ... .................................................................................................. ..1-4
Section 2 MAINTENANCE
1.0 Introduction ... ........................................................................................................ ...2-1
2.0 Preventive Maintenance ... ...................................................................................... .2-1
2.1 Inspection ... ...................................................................................................... ..2-1
2.2 Cleaning Procedures ... ................................................................................... ...2-1
3.0 Safe Handling of CMOS and LDMOS Devices ... .................................................. ...2-2
4.0 Repair Procedures and Techniques — General ... .................................................. .2-3
5.0 Disassembling and Reassembling the Radio — General ... ................................... ..2-4
6.0 Radio Disassembly — Detailed ... .......................................................................... ..2-5
6.1 Front Cover from Chassis Disassembly ... ......................................................... .2-5
6.2 PC Board Disassembly ... ................................................................................. ..2-8
7.0 Radio Reassembly — Detailed ... .......................................................................... ...2-8
7.1 PC Board Reassembly ... ................................................................................. ...2-8
7.2 Chassis and Front Cover Reassembly ... ......................................................... ..2-9
8.0 Mechanical View and Parts List ... ....................................................................... ...2-12
8.1 Exploded View and Parts List... ..................................................................... ...2-12
9.0 Service Aids ... ..................................................................................................... ...2-16
10.0 Test Equipment... ................................................................................................... .2-17
11.0 Programming Cable (PMDN4043_R) ... .............................................................. ...2-17
12.0 Cloning Cable (PMDN4060_R) ... .......................................................................... .2-18
13.0 Test Box (PMDN4040_R) ... ................................................................................ ...2-18
Section 3 RADIO TUNING
1.0 Introduction ... ........................................................................................................ ...3-1
2.0 Hardware Tuning Setup and Procedure ... .............................................................. .3-2
2.1 Tuning Frequency ... ....................................................................................... ...3-2
2.2 Preparation Before Tuning (refer to Figure 3-1) ... ............................................. .3-2
2.3 Transmitter Tuning ... ....................................................................................... ...3-3
2.4 Receiver Tuning ... ............................................................................................. .3-6
Section 4 RADIO PROGRAMMING
1.0 Introduction ... ........................................................................................................ ...4-1
2.0 Programming Your Radio ... ................................................................................... ..4-1
2.1 Overview of the Programming Process ... ........................................................ ..4-1
2.2 Cloning Radio Parameters to User Radios ... ................................................... ..4-1
2.3 Parameters which are cloned ... ....................................................................... ..4-1
2.4 Parameters which are not cloned ... ................................................................. ..4-1
2.5 To Clone a Radio ... .......................................................................................... ..4-1
2.6 Error Conditions ... ............................................................................................. .4-2
3.0 CPS Programming ... ............................................................................................... .4-2
3.1 To Read Radio Data to a PC... ........................................................................ ...4-3
3.2 To Write Data to a Radio ... ............................................................................. ...4-3
4.0 Factory Reset ... ...................................................................................................... ..4-3
Section 5 ACCESSORIES
1.0 Antennas... ............................................................................................................... .5-1
2.0 Carry Accessories ... ............................................................................................... ..5-1
3.0 Carry Cases ... ........................................................................................................ ..5-1
4.0 Chargers ... .............................................................................................................. .5-1
5.0 Batteries... ............................................................................................................... ..5-1
6.0 Audio Accessories ... ............................................................................................... .5-2
7.0 Publications ... ......................................................................................................... ..5-2
8.0 Service Kits ... ........................................................................................................ ...5-2
Section 6 MODEL CHART AND TEST SPECIFICATION
1.0 VHF Band 1 Information (136-150 MHz) ... ............................................................ .6-1
2.0 Specifications... ...................................................................................................... ...6-2
3.0 VHF Band 2 Information (150 - 174 MHz) ... ......................................................... ..6-3
4.0 Specifications... ...................................................................................................... ...6-4
5.0 UHF Band 1 Information (403-425MHz) ... ............................................................ ...6-5
6.0 Specifications... ...................................................................................................... ...6-6
7.0 UHF Band 2 Information (450 - 470MHz) ... ......................................................... ...6-7
8.0 Specifications... ...................................................................................................... ...6-8
9.0 UHF Band 4 Information (490 - 512 MHz) ... ......................................................... ...6-9
10.0 Specifications... ...................................................................................................... .6-10
Glossary of Terms ... .................................................................................... .G-1
Scope of Manual 1-1
Section 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 authorized Motorola Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer.
2.1 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.
NOTE
For service technicians in the Latin America Countries Region
For any warranty claims in the Latin America Countries region, please open a case using the "Contact Us" feature within Motorola Online at https://businessonline.motorola.com/ .
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact Customer Resources (Please see page 1-2). 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.
1-2 Warranty and Service Support
2.2 After Warranty Period
NOTE
For service technicians in the Latin America Countries Region
After Warranty Period claims in the Latin America Countries region are handled through the Motorola Authorized Service Provider (SAM) Network. To find the nearest SAM, please go to Motorola Resource Center in Motorola Online at https://businessonline.motorola.com/ .
After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola's Managed Technical Services (MTS) offers a repair service to both end users and dealers at competitive prices.
2. MTS supplies individual parts and modules that can be purchased by dealers who are techni­cally capable of performing fault analysis and repair.
2.3 Piece Parts
NOTE
For service technicians in the Latin America Countries Region
All part orders should be directed to your local Parts Distributors.
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‟s Managed Technical Services (MTS). 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 orders for parts/information should include the complete Motorola identification number. All part orders should be directed to your local MTS office. Please refer to your latest price pages.
2.4 Technical Support
NOTE
For service technicians in the Latin America Countries Region
For Technical Support in the Latin America Countries Region, please open a case using the "Contact Us" feature within Motorola Online at https://businessonline.motorola.com/ .
Technical support is available to assist the dealer/distributor in resolving any malfunction which may be encountered. Initial contact should be by telephone wherever possible. When contacting Motorola Technical Support, be prepared to provide the product model number and the unit‟s serial number.
2.5 Further Assistance From Motorola
You can also contact the Customer Help Desk through the following web address: http://www.motorola.com/governmentandenterprise/contactus
NOTE Only Motorola Service Centers or Approved Motorola Service Dealers can perform these
functions. Any tampering by non-authorized Motorola Service Centers voids the warranty of your radio. To find out more about Motorola and its approved Service Centers, please visit http://www.motorola.com/governmentandenterprise/public/functions/home/home.aspx
Series Freq. Band P
Radio Model Information 1-3
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 portable radio model number and its specific characteristics.
Table 1-1 Radio Model Number (Example: LAH84JDC8AA4)
Type
of
Unit
LA H
Model
84 J
(136-150 MHz)
ower Physical Channel
Level Packages Spacing
D C 8
5W 16-Channel 12.5/25K
Black
Feature
Protocol
Level
AA 4
Conventional A8
K
(150-174 MHz)
Q
(403-425 MHz)
R
(450-470 MHz)
T
(490-512 MHz)
H = Portable
LA = Latin America Regional Prefix
C
4W
1-4
Radio Features
4.0 Radio Features
The following are features your radio has. Normal Operation
• Rx/Tx
• Radio-CPS-Radio Cloning
• Radio-to-Radio Cloning
• Factory Reset
• Low Battery Indication
• Self Test
Programming Button
• Hi/Lo Power
• Volume Set
• Monitor
• Sticky Monitor
• Scan Activate
• Nuisance Channel Delete
• Repeater/Talkaround
• PL/DPL
• Button Lock
• Battery Save Mode
• Squelch
• Unassigned
CPS
• Rx Frequency
• Tx Frequency
• RX TPL/DPL/IDPL
• TX TPL/DPL/IDPL
• User Defined PL (TPL1, TPL2, TPL3)
• Squelch Type
• Unmute/Mute Rules
• Power Level (High/Low)
• TPL Reverse Burst
• Turn Off Code
• Rx Only
• Busy Channel Lock Out (BCLO)
• Channel Spacing (25KHz / 12.5KHz)
• Talkaround
• Time Out TImer
• Battery Save Mode
• Quick Key Override
• Password Protection
• Scan List
• Normal Scan
• Priority Scan
• Talkback Scan
2-1
Section 2 MAINTENANCE
1.0 Introduction
This chapter provides details about the following:
• Preventive Maintenance
• Safe Handling of CMOS and LDMOS Devices
• General Repair Procedures and Techniques
• Disassembling and Reassembling the Radio
2.0 Preventive Maintenance
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 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 plastics. 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.
2-2 Safe Handling of CMOS and LDMOS Devices
Cleaning Internal Circuit Boards and Components Isopropyl alcohol (70%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge
embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the dislodged material out and away from the inside of the radio. Make sure that controls or tunable components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process since this could cause the liquid to collect in unwanted places. After completing of the cleaning process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or back cover.
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 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:
• 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.
• Ground the working surface of the service bench to protect the CMOS device. We recommend using the Motorola Static Protection Assembly (part number 0180386A82), which includes a wrist strap, two ground cords, a table mat, and a floor mat.
• Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX-4015.)
• Do not wear nylon clothing while handling CMOS devices.
• Do not insert or remove CMOS devices with power applied. Check all power supplies used for
testing CMOS devices to be certain that there are no voltage transients present.
• When straightening CMOS pins, provide ground straps for the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS devices by the package and not by the leads. Prior to touching
the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.
Repair Procedures and Techniques — General 2-3
4.0 Repair Procedures and Techniques — General
Parts Replacement and Substitution When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part from the nearest Motorola Communications parts center listed in the Piece Parts section of this manual.
Rigid Circuit Boards This 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 printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise care to avoid pulling the plated circuit out of the hole.
When soldering near the 20-pin and 40-pin connectors:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges.
Flexible Circuits The flexible circuits are made from a different material than the rigid boards, and require different
soldering techniques. Excessive prolonged heat on a flexible circuit can damage the material. Therefore, avoid excessive heat and excessive bending.
For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700 degree F tip, and use small diameter solder such as ST-633. The smaller size solder will melt faster and require less heat to be applied to the circuit.
To replace a component on a flexible circuit:
1. Grasp with seizers (hemostats) the edge of the flexible circuit near the part to be removed.
2. Pull gently.
3. Apply the tip of the soldering iron to the component connections while pulling with the seizers.
NOTE Do not attempt to puddle-out components. Prolonged application of heat may damage the
flexible circuit.
Chip Components Use either the RLN-4062 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 700 degrees F. (370 degrees C), and adjust the airflow to a minimum setting. Airflow can vary due to component density.
• To remove a chip component, select a hot-air hand piece and position the nozzle of the hand
piece approximately 1/8” above the component to be removed. Begin applying the hot air. Once the solder reflows, remove the component using a pair of tweezers. Using solder wick and a soldering iron or a power desoldering station, remove the excess solder from the pads.
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