Motorola HKLN4204 Service Manual
™
PRO2150
Portable Radio
Detailed Service Manual
Table of Contents i
User Safety, Training, and General Information..........................................v
Chapter 1 Introduction ......................................................................... 1-1
1.1 Scope of Manual............................................................................................................................ 1-1
1.2 Warranty and Service Support....................................................................................................... 1-1
1.2.1 Warranty Period and Return Instructions.......................................................................... 1-1
1.2.2 After Warranty Period ....................................................................................................... 1-1
1.2.3 Piece Parts ....................................................................................................................... 1-2
1.2.4 Technical Support............................................................................................................. 1-2
1.2.5 Parts Identification ............................................................................................................ 1-2
1.3 Radio Model Information................................................................................................................ 1-3
1.4 Radio Features .............................................................................................................................. 1-4
Chapter 2 Maintenance ........................................................................ 2-1
2.1 Introduction .................................................................................................................................... 2-1
2.2 Preventive Maintenance ................................................................................................................ 2-1
2.2.1 Inspection ......................................................................................................................... 2-1
2.2.2 Cleaning Procedures ........................................................................................................2-1
2.3 Safe Handling of CMOS and LDMOS Devices.............................................................................. 2-2
2.4 Repair Procedures and Techniques — General............................................................................ 2-2
2.4.1 Parts Replacement and Substitution ................................................................................ 2-2
2.4.2 Rigid Circuit Boards .......................................................................................................... 2-2
2.4.3 Flexible Circuits ................................................................................................................ 2-3
2.4.4 Chip Components ............................................................................................................. 2-3
2.4.5 Shields .............................................................................................................................. 2-4
2.5 Disassembling and Reassembling the Radio — General.............................................................. 2-4
2.6 Radio Disassembly — Detailed ..................................................................................................... 2-5
2.6.1 Front Cover from Chassis Disassembly ........................................................................... 2-5
2.6.2 Control Board Disassembly .............................................................................................. 2-7
2.6.3 RF Board Disassembly ..................................................................................................... 2-7
2.7 Radio Reassembly — Detailed...................................................................................................... 2-8
2.7.1 RF Board Reassembly...................................................................................................... 2-8
2.7.2 Control Board Reassembly............................................................................................... 2-8
2.7.3 Chassis and Front Cover Reassembly ............................................................................. 2-8
2.8 Mechanical View and Parts List ................................................................................................... 2-12
2.8.1 Exploded View and Parts List ......................................................................................... 2-12
2.9 Service Aids................................................................................................................................. 2-14
2.10 Test Equipment............................................................................................................................ 2-15
2.11 Programming Cable (DSK001C706) ........................................................................................... 2-16
2.12 IF Test Box (DSK001C702) ......................................................................................................... 2-17
99R85452E01-O August 30, 2002
ii Table of Contents
Chapter 3 Radio Tuning ....................................................................... 3-1
3.1 Introduction .................................................................................................................................... 3-1
3.2 Software Tuning Setup .................................................................................................................. 3-1
3.3 Affixing Antenna Ground Plate....................................................................................................... 3-2
3.4 Hardware Tuning Setup and Procedure ........................................................................................ 3-3
3.4.1 Audio Modulation Tuning .................................................................................................. 3-3
3.4.2 Sub-Audio Modulation Tuning........................................................................................... 3-4
3.4.3 Tuning Frequency .............................................................................................................3-4
Chapter 4 Radio Programming............................................................ 4-1
4.1 Introduction .................................................................................................................................... 4-1
4.2 Programming Your Radio .............................................................................................................. 4-1
4.2.1 Overview of the Programming Process ............................................................................ 4-1
4.2.2 Cloning Radio Parameters to User Radios ....................................................................... 4-1
4.2.3 Parameters Which are Cloned.......................................................................................... 4-1
4.2.4 Parameters Which are Not Cloned ................................................................................... 4-1
4.2.5 To Clone a Radio .............................................................................................................. 4-1
4.2.6 Error Conditions ................................................................................................................ 4-2
4.3 CPS Programming ......................................................................................................................... 4-2
4.4 Programming ................................................................................................................................. 4-3
4.4.1 PL Frequencies and Codes .............................................................................................. 4-3
4.4.2 DPL Codes........................................................................................................................ 4-4
4.4.3 Examples .......................................................................................................................... 4-4
Chapter 5 Error Code Displays............................................................ 5-1
5.1 Error Codes.................................................................................................................................... 5-1
Chapter 6 Accessories ......................................................................... 6-1
6.1 Antennas........................................................................................................................................ 6-1
6.2 Carrying Accessories ..................................................................................................................... 6-1
6.3 Carry Cases ................................................................................................................................... 6-1
6.4 Chargers ........................................................................................................................................ 6-1
6.5 Batteries......................................................................................................................................... 6-1
6.6 Audio Accessories ......................................................................................................................... 6-1
6.7 Manuals ......................................................................................................................................... 6-2
6.8 Software......................................................................................................................................... 6-2
August 30, 2002 99R85452E01-O
Table of Contents iii
Chapter 7 VHF Band Information ........................................................ 7-1
7.1 Model Chart ................................................................................................................................... 7-1
7.2 Specifications................................................................................................................................. 7-2
7.3 Theory of Operation....................................................................................................................... 7-3
7.3.1 General Information .......................................................................................................... 7-3
7.3.2 Power Distribution............................................................................................................. 7-3
7.3.3 Power up Sequence ......................................................................................................... 7-3
7.3.4 CPU / Control Section....................................................................................................... 7-4
7.3.5 VCO / Synthesizer Section ............................................................................................... 7-4
7.3.6 Transmitter Section........................................................................................................... 7-5
7.3.7 Receiver Section............................................................................................................... 7-6
7.3.8 Battery Section ................................................................................................................. 7-7
7.4 Block Diagrams.............................................................................................................................. 7-8
7.4.1 Complete .......................................................................................................................... 7-8
7.4.2 Controller .......................................................................................................................... 7-9
7.4.3 VCO .................................................................................................................................. 7-9
7.4.4 Transmitter...................................................................................................................... 7-10
7.4.5 Receiver.......................................................................................................................... 7-10
7.5 Troubleshooting Charts ............................................................................................................... 7-11
Chapter 8 UHF Band Information ........................................................ 8-1
8.1 Model Charts ................................................................................................................................. 8-1
8.2 Specifications................................................................................................................................. 8-3
8.3 Theory of Operation....................................................................................................................... 8-4
8.3.1 General Information .......................................................................................................... 8-4
8.3.2 Power Distribution............................................................................................................. 8-4
8.3.3 Power up Sequence ......................................................................................................... 8-4
8.3.4 CPU / Control Section....................................................................................................... 8-5
8.3.5 VCO / Synthesizer Section ............................................................................................... 8-5
8.3.6 Transmitter Section........................................................................................................... 8-6
8.3.7 Receiver Section............................................................................................................... 8-7
8.3.8 Battery Section ................................................................................................................. 8-8
8.4 Block Diagrams.............................................................................................................................. 8-9
8.4.1 Complete .......................................................................................................................... 8-9
8.4.2 Controller ........................................................................................................................ 8-10
8.4.3 VCO ................................................................................................................................ 8-10
8.4.4 Transmitter...................................................................................................................... 8-11
8.4.5 Receiver.......................................................................................................................... 8-11
8.5 Troubleshooting Charts ............................................................................................................... 8-12
99R85452E01-O August 30, 2002
iv Table of Contents
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August 30, 2002 99R85452E01-O
User Safety, Training, and General Information
Product Safety and RF Exposure Compliance
CAUTION: Before using this product, read the operating instructions for safe usage contained in
the Product Safety and RF Exposure booklet enclosed with your radio.
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 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
.
vi : Product Safety and RF Exposure Compliance
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August 30, 2002 99R85452E01-O
Chapter 1 Introduction
1.1 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 User Safety, Training and General
Information Section in the front of this manual.
1.2 Warranty and Service Support
Motorola offers long term support for its products. This support includes repair of the product during
the warranty period, and service/repair or spare parts support out of warranty.
Motorola de Colombia Service Center
Carrera 7 No. 71-52
Torre B, Piso 13
Oficina 1301
Bogota - Colombia
Phone: 571-376-6990
Motorola de Mexico Service Center
Bosques de Alisos #125
Col. Bosques de las Lomas
CP 05120 Mexico D.F.
Phone: 525-257-6700
1.2.1 Warranty Period and Return Instructions
Where the product is covered under warranty, a check of the product should be performed prior to
shipping the unit. This is to ensure that the product has been correctly programmed or has not been
subjected to damage outside the terms of the warranty.
Products should be shipped back in the original packaging, or correctly packaged to ensure no
damage occurs in transit.
1.2.2 After Warranty Period
After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola’s authorized service centers offer 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
1.2.3 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’s Accessories
and Aftermarket 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 orders for parts/information should include the complete Motorola identification number. All part
orders should be directed to your local AAD office. Please refer to your latest price pages.
To order parts in Latin America and the Caribbean:
7:00 a.m. to 7:00 p.m. (Central Standard Time)
Monday through Friday (Chicago, USA)
1-847-538-8023
Motorola Parts (Accessories and Aftermarket Division AAD):
Attention: Order Processing
1313 E. Algonquin Road
Schaumburg, IL 60196
Introduction
: Warranty and Service Support
1.2.4 Technical Support
https://businessonline.motorola.com
Select: "Contact Us"
1.2.5 Parts Identification
1-847-538-0021 (Voice)
1-847-538-8194 (Fax)
August 30, 2002 99R85452E01-O
Introduction
: Radio Model Information 1-3
1.3 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: LAH49KDH8AA9)
Type
of
Unit
LA H 49 K
Model
Series
H = Portable
Motorola Internal Use
Frequency
Band
(136-174
MHz)
(403-440
MHz)
(435-480
MHz)
Power
Level
D
5W
Q
R
C
4W
Physical
Packages
H
Full Keypad
with Display
Channel
Spacing
8
12.5/25KAAConventional
Protocol
Feature
Level
9
Full
Keypad
99R85452E01-O August 30, 2002
1-4
1.4 Radio Features
Feature
Introduction
PRO2150
CPS User
: Radio Features
Accessibility Yes
Normal Operation
Rx/Tx XX
Cloning
Factory Reset
VFO
Squelch Level
Scan List 1
Scan List 2
Scan List 3
Special PL 1,2,3
Norm/Inv DPL
TOT
Battery Saver
Battery Type
Alert Tone Volume
Prime Ch
Prime Ch Return Hang Time
XX
X
X
XX
XX
XX
XX
X
X
XX
XX
XX
XX
XX
X
Yes
PTT ID (OFF, PRE, POST, BOTH)
PTT ID Sidetone
PTT Short Sidetone
Tx Pretime
Backlight Status
PTT ID
Button Programmability
Access/Deaccess Code
Telephone No
PL/DPL Type
Scan Interval Timer
Scan Hang Timer
Channel On/Off
Rx Freq
Tx Freq
Rx PL/DPL
X
X
X
X
XX
X
X
XX
XX
X
X
X
X
X
X
X
August 30, 2002 99R85452E01-O
Introduction
: Radio Features 1-5
PRO2150
Feature
CPS User
Tx PL/DPL
TOC
Power Level
BCL
Ch Alias
Ch Spacing
PTT ID On/Off
PL Required for Selcall
Scan Type Select
Scan List Select
Copy Ch
Scan Lower Limit
Scan Upper Limit
Freq Step Size
Rx Freq
Tx Freq
Offset Freq
Repeater Offset
Rx PL/DPL
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Tx PL/DPL
TOC
Power Level
BCL
Ch Spacing
PTT ID On/Off
Radio Information
Radio Configuration
Conventional Personality
VFO Status
Scan List
Phone Information
Signalling
Programmable Button
Reverse Burst
X = Indicates available
Blank = Indicates unavailable
X
X
X
X
X
X
XX
XX
XX
X
XX
XX
XX
XX
X
99R85452E01-O August 30, 2002
1-6
Introduction
: Radio Features
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August 30, 2002 99R85452E01-O
Chapter 2 Maintenance
2.1 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
2.2 Preventive Maintenance
The radio does not require a scheduled preventive maintenance program; however, periodic visual
inspection and cleaning is recommended.
2.2.1 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.
2.2.2 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 external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning 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.
2.2.2.1 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.
2.2.2.2 Cleaning Internal Circuit Boards and Components
Apply Isopropyl alcohol (70%) 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.
2-2
Maintenance
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
: Safe Handling of CMOS and LDMOS Devices
2.3 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.
2.4 Repair Procedures and Techniques — General
2.4.1 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.
2.4.2 Rigid Circuit Boards
This radio 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 printedthrough holes may interconnect multiple layers of the printed circuit. Therefore, exercise care to
avoid pulling the plated circuit out of the hole.
August 30, 2002 99R85452E01-O
Maintenance
: Repair Procedures and Techniques — General 2-3
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.
2.4.3 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.
2.4.4 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 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.
• To replace a chip component using a soldering iron, select the appropriate micro-tipped
soldering iron and apply fresh solder to one of the solder pads. Using a pair of tweezers,
position the new chip component in place while heating the fresh solder. Once solder wicks
onto the new component, remove the heat from the solder. 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, select the hot-air hand piece and reflow the solder
on the solder pads to smooth it. Apply a drop of solder paste flux to each pad. using a pair of
tweezers, position the new component in place. Position the hot-air hand piece approximately
1/8” above the component and begin applying heat. Once the solder wicks to the component,
remove the heat and inspect the repair. All joints should be smooth and shiny.
99R85452E01-O August 30, 2002
2-4
2.4.5 Shields
Removing and replacing shields will be done with the R-1070 station with the temperature control set
to approximately 415°F (215°C); 445°F (230°C) max.
• To remove the shield, place the circuit board in the R-1070’s holder. Select the proper heat
focus head and attach it to the heater chimney. Add solder paste flux around the base of the
shield. Position the shield under the heat-focus head. Lower the vacuum tip and attach it to the
shield by turning on the vacuum pump. Lower the focus head until it is approximately 1/8”
(0.3cm) above the shield. Turn on the heater and wait until the shield lifts off the circuit board.
Once the shield is off, turn off the heat, grab the part with a pair of tweezers, and turn off the
vacuum pump. Remove the circuit board from the R-1070’s circuit board holder.
• To replace the shield, add solder to the shield if necessary, using a micro-tipped soldering iron.
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. Place the circuit board back in the R1070’s circuit board holder. Place the shield
on the circuit board using a pair of tweezers. Position the heat-focus head over the shield and
lower it to approximately 1/8” above the shield. Turn on the heater and wait for the solder to
reflow.
Once complete, turn off the heat, raise the heat-focus head and wait approximately one minute
for the part to cool. Remove the circuit board and inspect the repair. No cleaning should be
necessary.
Maintenance
: Disassembling and Reassembling the Radio — General
2.5 Disassembling and Reassembling the Radio — General
Since these radios may be disassembled and reassembled 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:
• Phillips screwdriver
• 4mm socket wrench
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.
August 30, 2002 99R85452E01-O
Maintenance
: Radio Disassembly — Detailed 2-5
2.6 Radio Disassembly — Detailed
2.6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Slide the battery clasp away from the radio (
See Figure 2-1.
).
Figure 2-1.
b. Slide battery down and away from radio.
3. Remove the antenna.
4. Pull the On/Off Volume knob off of its shaft.
5. Remove the two screws at the back of the rear chassis (
See Figure 2-2.
Insert screwdriver here
to remove chassis.
).
Figure 2-2.
6. Insert a small flat-head screwdriver at the bottom of the radio, between the chassis and
housing (location marked in
the housing or the O-ring underneath.
99R85452E01-O August 30, 2002
Figure 2-2
), and lift the chassis gently. Be careful not to damage
2-6
Maintenance
: Radio Disassembly — Detailed
7. Lift the rear chassis away from the front cover (
See Figure 2-3.
). Be careful not to damage the
speaker wire underneath.
Figure 2-3.
8. Slide the rear chassis downwards, and away from the front cover.
9. Remove the speaker connector, which connects between RF Board and the internal speaker
on the front cover (
See Figure 2-4.
).
Figure 2-4.
August 30, 2002 99R85452E01-O
Maintenance
: Radio Disassembly — Detailed 2-7
2.6.2 Control Board Disassembly
1. Remove the screws which hold the control board to the RF board.
2. Remove the control board which is connected to the RF board through a board-to-board
connector (
Board-to-board
connector
See Figure 2-5.
2.6.3 RF Board Disassembly
).
Figure 2-5.
1. Remove the screws and the stud which hold the RF board to the rear diecast with the Phillips
head screwdriver and socket wrench respectively.
2. Gently remove the RF board from rear diecast. The completely disassembled radio is shown
Figure 2-6
in
.
Figure 2-6.
NOTE: The Control and RF boards are mounted with cross recess screws meeting the Phillips Cross
Slot number 1 standard. Using a Phillips 0 will damage the screw recesses as will a poorly
fitting Phillips 1 screwdriver. One example of a correct fitting screwdriver is manufactured by
PB Baumann (http://www.pbtools.ch/index_e.html) and is available from many electronic tool
dealers. The PB Baumann item number is 121/1-70. Other high quality manufacturer's
pruducts meeting the Phillips 1 standard are also acceptable.
99R85452E01-O August 30, 2002
2-8
2.7 Radio Reassembly — Detailed
2.7.1 RF Board Reassembly
1. Place the RF board on the rear diecast.
2. Tighten the screws and the stud.
2.7.2 Control Board Reassembly
1. Place the control board on the RF board.
2. Connect the control board to the RF board by pressing it firmly downwards at the board-toboard connector (
Board-to-board
Connector
See Figure 2-7.
).
Maintenance
: Radio Reassembly — Detailed
Figure 2-7.
3. Tighten the screws using a screwdriver to hold the control board in place.
2.7.3 Chassis and Front Cover Reassembly
1. Remove the metal retainer with a small flat head screwdriver (
Housing tab
Figure 2-8.
See Figure 2-11.
Retainer
).
August 30, 2002 99R85452E01-O
Maintenance
: Radio Reassembly — Detailed 2-9
2. Remove the rubber button insert behind the retainer (
Rubber button
Figure 2-9.
3. Push left hand side PTT hook until it releases (
See Figure 2-10.
PTT hooks
See Figure 2-9.
).
).
Figure 2-10.
4. Push right hand side PTT hook until PTT button is completely released.
5. Reinstall the rubber insert and metal retainer.
6. Connect the RF board to the internal speaker on the front cover with the speaker connector
(
See Figure 2-11.
).
Figure 2-11.
99R85452E01-O August 30, 2002
2-10
Maintenance
: Radio Reassembly — Detailed
7. Place the front cover over the tabs on the rear diecast.
8. Insert the On/Off Volume shaft into the front cover opening.
9. Lower the front cover until the bottom edges snap firmly into place on the rear diecast (
Figure 2-12.
).
Figure 2-12.
10. Tighten the two (2) screws at the bottom of rear diecast using a screwdriver (
2-13.
).
See Figure
See
Figure 2-13.
11. Reinsert the PTT button (
Press to insert
See Figure 2-15.
).
Large hook side
Figure 2-14.
August 30, 2002 99R85452E01-O
Maintenance
: Radio Reassembly — Detailed 2-11
12. Attach the battery.
13. Attach the On/Off Volume knob and the antenna.
Figure 2-15.
99R85452E01-O August 30, 2002
2-12
2.8 Mechanical View and Parts List
2.8.1 Exploded View and Parts List
14
Maintenance
2g
2f
8c
: Mechanical View and Parts List
10
2d
8b
15
12
11
2a
5
2e
2c
2b
6
4a
4b
9
7d
7c
7b
7a
17
3a
13
3b
16
1
8a
Figure 2-16.
August 30, 2002 99R85452E01-O
Maintenance
: Mechanical View and Parts List 2-13
Item
1 DS1M001110 Front Cover Kit
2 DS1M001120 Chassis Hardware Kit
2a Rod (M2)
2b Heatsink Tape
2c DSM4193013 Gasket (Screw M2.6)
2d DSM1B26051 Screw M2.6
2e PCB Bracket
2f Screw M2 Cfims
2g External Tape
3 DS1M001130 Knob Assembly
3a Knob
3b Spring (D4.75)
4 DS1M001140 External Cover Kit
4a External Cover
Part
Number
Description
4b External Cover Cap
5 Model Dependent Controller Board Assembly
6 Model Dependent RF Board Assembly
7 DS1M001170 LCD Kit
7a LCD Bracket
7b LCD
7c Interconnector
7d Reflector
8 DSM4193042 PRO2150 Nameplate
8a Label Nameplate
8b Label Serial
8c Label Tuning
9 DS1M001190 Speaker Assembly
10 PMNN4046 Battery
11 DSM2192004 Contact Gasket
12 DSM2192005 Main Gasket
13 DSM2192006 Volum e Gasket
14 HLN9844_ Beltclip
99R85452E01-O August 30, 2002
2-14
Maintenance
: Service Aids
Item
15 DSM5190001 Back Housing
16 DSM6189003 PTT Button
17 Frequency dependent. Please see
Part
Number
“6.1
Description
Antenna
Antennas” on page 6-1
2.9 Service Aids
Table 2-1
these items are available from Motorola, most are standard shop equipment items, and any
equivalent item capable of the same performance may be substituted for the item listed.
Motorola Part
No.
H5197
HKVN4002_
DSK001C706 Programming Cable (2.5mm) Connects radio and IF Test Box to Computer.
AAPMKN4003_ Cloning Cable (2.5mm) To clone programmable information from one radio to
lists service aids recommended for working on the PRO2150 Portable Radio. While all
Table 2-1.
Description Application
Customer Programming and
Tuning Software (CD)
Program customer options, channel data, and tuner
hardware parameters, front end, power, etc.
another radio.
DSK001C704 Test Cable Connects radio to IF Test Box.
DSK001C714 Interconnect Service Cable Connects RF board and CPU board.
DSK001C702 IF Test Box Enables connection to the audio/accessory jack. Allows
switching for radio testing.
DSK001C705 Battery Eliminator Interconnects radio to power supply (red-and-black power
cable included).
DSK001C719 Antenna Ground Plate To improve the grounding while tuning and doing conducted
measurement.
HLN8262_ BNC Adaptor Adapts radio’s antenna port to BNC cabling of test
equipment.
August 30, 2002 99R85452E01-O
Maintenance
: Test Equipment 2-15
2.10 Test Equipment
Table 2-2
lists test equipment required to service the PRO2150 Portable Radio and other two-way
radios.
Table 2-2.
Motorola Part
No.
*R1049 Digital Multimeter Two meters recommended for
*S1100 Audio Oscillator 67 to 200Hz tones Used with service monitor to
*S1053,
*SKN6009,
*SKN6001
R1053 Dual-trace
*S1350, *ST1215
(VHF)
*ST1223 (UHF)
*T1013
S1339 RF Millivolt Meter 100 µV to 3 VRF, 10 kHz
Description Characteristics Application
AC/DC voltage and current
measurements
inject PL tones
AC Voltmeter, Power
Cable for meter, Test
leads for meter
Oscilloscope
Wattmeter,
Plug-in Elements
(VHF & UHF), RF
Dummy Load
1 mV to 300 V,
10 Mega Ohm input
impedance
20 MHz bandwidth,
5 mV/cm - 20 V/cm
50-Ohm, ±5% accuracy
10 W, max. 0-1000 MHz,
300 W
to 1.2 GHz
Audio voltage measurements
Waveform measurements
Transmitter power output
measurements
RF level measurements
*R1013 SINAD Meter Receiver sensitivity
measurements
S1347 or
S1348 (prog)
*Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment
DC Power Supply 0-20 Vdc, 0-5 Amps Bench supply for 7.5Vdc
99R85452E01-O August 30, 2002
2-16
2.11 Programming Cable (DSK001C706)
To: PC
RS232C 9PD-SUB
1: DCD
2: RXD
3: TXD
4: DTR
5: GND
6: DSR
7: RTS
8: CTS
9: RI
Maintenance
D101
1SS362
D102
1SS362
R103
10k
: Programming Cable (DSK001C706)
C101
0.1
R101
10k
R102
10k
Q101
UMW1N
Q102
UMW1N
Figure 2-17.
543 2 1
987 6
Figure 2-18.
R104
10k
PROG
GND
August 30, 2002 99R85452E01-O
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