Motorola HT750, MTX950, HT1550XLS, MTX8250LS, MTX850LS User Manual 2
...
HT750 MTX850 MTX8250
HT1250 MTX850•LS MTX8250•LS
HT1250•LS HT1250•LS+ MTX950
HT1550•XLS MTX9250
Portable Radios
Professional Radio
Basic Service Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322
68P80906Z54-D
ii
C
n
Foreword
This manual provides sufficient information to enable qualified service technicians to troubleshoot and repair
CDM Series mobile radios to the component level.
Product Safety and RF Exposure Compliance
Before using this product, read the operating instructions
!
a u t i o
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 (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.
for safe usage contained in the Product Safety and RF
Exposure booklet.
ATTENTION!
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer pr ograms stored
in semiconductor memories or other media. Laws in the United States and other countries preserve for
Motorola certain exclusive rights for copyrighted computer programs, including, but not limited to, the
exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any
copyrighted Motorola computer programs contained in the Motorola products described in this manual may
not be copied, reproduced, modified, reverse- engineered, or distributed in any manner without the express
written permission of Motorola. Furthermore, the purchase of Motorola p roducts shall not be deemed to grant
either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or patent
applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in
the sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express
written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any
form or by any means, electronic or mechanical, for any purpose without the express written permission of
Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no
responsibility is assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any
products herein to improve readability, function, or design. Motorola does not assume any liability arising out
of the applications or use of any product or circuit described herein; nor does it cover any license under its
patent rights nor the rights of others.
Trademarks
MOTOROLA and the Stylized M logo are registered in the US Patent & Trademark Office. All other products
or service names are the property of their respective owners.
© Motorola, Inc. 2002.
Table of Contents
Foreword.........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................... ii
Computer Software Copyrights....................................................................................... ii
Document Copyrights..................................................................................................... ii
Disclaimer....................................................................................................................... ii
Trademarks..................................................................................................................... ii
List of Figures ...............................................................................................ix
List of Tables.................................................................................................xi
Chapter 1
Introduction ................................................................................................ 1-1
1.1 Scope of Manual................................................................................................. 1-1
iii
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 Availability............................................................................. 1-2
1.2.4 Technical Support.................................................................................... 1-3
1.3 Radio Model Information..................................................................................... 1-4
Chapter 2
Intrinsically Safe Radio Information......................................................... 2-1
2.1 FMRC Approved Equipment............................................................................... 2-1
2.2 Repair of FMRC Approved Products.................................................................. 2-2
2.2.1 Repair ...................................................................................................... 2-2
2.2.2 Relabeling................................................................................................ 2-2
2.2.3 Do Not Substitute Options or Accessories............................................... 2-3
Chapter 3
Maintenance ............................................................................................... 3-1
3.1 Introduction......................................................................................................... 3-1
3.2 Preventive Maintenance. .................................................................................... 3-1
3.2.1 Inspection................................................................................................. 3-1
iv
3.2.2 Cleaning Procedures................................................................................ 3-1
3.3 Safe Handling of CMOS and LDMOS Devices ................................................... 3-2
3.4 Repair Procedures and Techniques — General ................................................. 3-2
3.5 Disassembling and Reassembling the Radio — General ................................... 3-3
3.6 Detailed Radio Disassembly ............................................................................... 3-4
3.6.1 Front Cover from Chassis Disassembly................................................... 3-4
3.6.2 Chassis Assembly/Disassembly............................................................... 3-6
3.6.3 Keypad, Display, and Keypad/PassPort/Option Board Disassembly....... 3-6
3.6.4 Speaker, Microphone, and Universal Connector Flex Disassembly ........ 3-8
3.6.5 PTT Disassembly..................................................................................... 3-9
3.6.6 Control Top Disassembly......................................................................... 3-9
3.7 Detailed Radio Reassembly.............................................................................. 3-10
3.7.1 Control Top Reassembly........................................................................ 3-10
3.7.2 PTT Reassembly.................................................................................... 3-10
3.7.3 Speaker, Microphone, and Universal Connector Flex Reassembly....... 3-10
3.7.4 Keypad, Display, and Keypad/PassPort/Option Board Reassembly...... 3-10
3.7.5 Chassis Assembly Reassembly............................................................. 3-11
3.7.6 Chassis and Front Cover Reassembly................................................... 3-11
3.7.7 DTMF Retrofit Kit Procedure (Optional Upgrade Procedure)................. 3-12
3.7.8 Option Board Installation........................................................................ 3-13
3.8 HT750 Radio Exploded Mechanical View and Parts List................................. 3-15
3.8.1 HT750 Exploded View........................................................................... 3-15
3.8.2 HT750 Exploded View Parts List............................................................ 3-16
3.8.3 HT1250 and HT1250•LS Exploded View ............................................... 3-17
3.8.4 HT1250 and HT1250•LS Parts List........................................................ 3-18
3.8.5 HT1250•LS+ Exploded View.................................................................. 3-19
3.8.6 HT1250•LS+ Exploded View Parts List.................................................. 3-20
3.8.7 MTX850 Exploded View......................................................................... 3-21
3.8.8 MTX850 Exploded View Parts List......................................................... 3-22
3.8.9 MTX850•LS Exploded View ................................................................... 3-23
3.8.10 MTX850•LS Exploded View Parts List ................................................... 3-24
3.8.11 MTX8250 Exploded View....................................................................... 3-25
3.8.12 MTX8250 Exploded View Parts List....................................................... 3-26
3.8.13 MTX8250•LS Exploded View ................................................................. 3-27
3.8.14 MTX8250•LS Exploded View Parts List ................................................. 3-28
3.8.15 HT1550•XLS Exploded View.................................................................. 3-29
3.8.16 HT1550•XLS Exploded View Parts List ................................................. 3-30
3.8.17 MTX950 Exploded View......................................................................... 3-31
3.8.18 MTX950 Exploded View Parts List......................................................... 3-32
3.8.19 MTX9250 Exploded View....................................................................... 3-33
3.8.20 MTX9250 Exploded View Parts List....................................................... 3-34
3.9 Service Aids...................................................................................................... 3-35
3.10 Test Equipment................................................................................................. 3-36
3.11 Configuring and Wiring the Programming/Test Cable...................................... 3-37
Chapter 4
Transceiver Performance Testing ............................................................ 4-1
4.1 General............................................................................................................... 4-1
4.2 RF Test Mode..................................................................................................... 4-1
4.3 Test Frequencies for Display and Non-Display Radios...................................... 4-6
4.4 Receiver Performance Tests.............................................................................. 4-7
v
Chapter 5
Radio Tuning, Programming, Cloning, Lowband Antenna Cutting
Procedure, PassPort Tone Options, and Diagnostic Functions............ 5-1
5.1 Introduction......................................................................................................... 5-1
5.2 Global Radio Tuning Setup................................................................................. 5-2
5.2.1 Initial Test Equipment Setup.................................................................... 5-2
5.3 CPS Programming Setup ................................................................................... 5-3
5.4 Cloning (Conventional and LTR) ........................................................................ 5-3
5.4.1 Error Codes (Display Radios Only).......................................................... 5-4
5.5 Cloning (Privacy Plus) ........................................................................................ 5-4
5.6 Cloning (PassPort).............................................................................................. 5-5
5.7 Lowband Molded Antenna Cut Chart.................................................................. 5-6
5.8 HT1250•LS+ PassPort Tone Options................................................................. 5-7
5.9 HT1250•LS+ Special Diagnostic Functions........................................................ 5-7
Chapter 6
Power Up Self-Test..................................................................................... 6-1
6.1 Error Codes - Conventional and LTR Radios..................................................... 6-1
6.2 Error Codes - Privacy Plus ................................................................................. 6-2
vi
6.3 Error Codes - PassPort....................................................................................... 6-3
6.4 Operation Display Codes .................................................................................... 6-3
Chapter 7
Accessories................................................................................................7-1
7.1 HT750/HT1250/HT1250•LS/HT1250•LS+/HT1550•XLS/MTX850/MTX950/
MTX850•LS/MTX8250/MTX9250/MTX8250•LS Accessories............................. 7-1
7.1.1 Antennas.................................................................................................. 7-1
7.1.2 Carrying Accessories ............................................................................... 7-2
7.1.3 Carry Cases ............................................................................................. 7-2
7.1.4 Chargers .................................................................................................. 7-3
7.1.5 Vehicular Accessories.............................................................................. 7-3
7.1.6 Batteries .................................................................................................. 7-3
7.1.7 Adapters................................................................................................... 7-3
7.1.8 Miscellaneous........................................................................................... 7-3
7.1.9 Service Aids ............................................................................................. 7-4
7.1.10 Audio Accessories ................................................................................... 7-4
7.1.11 Option Boards* (All option boards below are not compatible with
HT1550•XLS) ........................................................................................... 7-5
7.1.12 Remote Speaker Microphones................................................................. 7-5
7.1.13 Manuals ................................................................................................... 7-5
7.1.14 Retrofit Front Cover Kits .......................................................................... 7-5
Chapter 8
Model Chart and Test Specifications ....................................................... 8-1
8.1 UHF 403–470 MHz (Conventional)..................................................................... 8-1
8.2 UHF 450–512 MHz (Conventional)..................................................................... 8-2
8.3 UHF 403–470 MHz (LTR and PassPort)............................................................. 8-3
8.4 UHF 450–512 MHz (LTR and PassPort)............................................................. 8-4
8.5 UHF 403–470 MHz (Conventional/LTR) ............................................................. 8-5
8.6 UHF 450–512 MHz (Conventional/LTR) ............................................................. 8-6
8.7 VHF 136–174 MHz.............................................................................................. 8-7
8.8 VHF 136–174 MHz (Conventional/LTR) ............................................................. 8-8
8.9 VHF, 136–174 MHz (LTR & PassPort) ............................................................... 8-9
8.10 LowBand 29.7–42/35–50 MHz.......................................................................... 8-10
8.11 800 MHz (LTR).................................................................................................. 8-11
vii
8.12 800 MHz (Privacy Plus).................................................................................... 8-11
8.13 900 MHz (Privacy Plus).................................................................................... 8-12
8.14 Specifications, HT750 Radio ............................................................................ 8-13
8.15 Specifications, HT1250 Radio .......................................................................... 8-15
8.16 Specifications, HT1250•LS+ Radio................................................................... 8-17
8.17 Specifications, HT1550•XLS Radio .................................................................. 8-19
8.18 Specifications, MTX850/MTX8250 (800 MHz),
MTX950/MTX9250 (900 MHz) Radios.............................................................. 8-21
8.19 Specifications, MTX850•LS and MTX8250•LS (800 MHz) Radios................... 8-23
Glossary.........................................................................................Glossary-1
viii
LIST OF FIGURES
Figure 3-1: Battery Removal..................................................................................... 3-4
Figure 3-2: Knob Removal........................................................................................ 3-4
Figure 3-3: Chassis Removal ................................................................................... 3-5
Figure 3-4: Unlatch Flex Connectors ........................................................................ 3-5
Figure 3-5: Remove Main Board from Chassis......................................................... 3-6
Figure 3-6: Remove Retainer.................................................................................... 3-7
Figure 3-5: Removing the Keypad Retainer and Other Boards from the Radio........ 3-8
Figure 3-6: Removal Speaker-Microphone Assembly .............................................. 3-9
Figure 3-7: PTT Removal.......................................................................................... 3-9
Figure 3-8: Lock Retainer Catches to the Radio’s Body......................................... 3-11
Figure 3-9: Fastening the Chassis.......................................................................... 3-12
ix
Figure 3-10: Activating the Retrofit ........................................................................... 3-12
Figure 3-11: Changing Keypad/PassPort Board /Option Boards.............................. 3-13
Figure 3-12: HT750 Exploded View.......................................................................... 3-15
Figure 3-22: Programming/Test Cable AARKN4074 ................................................ 3-37
Figure 3-23: Pin Configuration of the Cable Side Connector.................................... 3-37
Figure 3-24: Programming/Test Cable Schematic.................................................... 3-38
Figure 4-1: Radio Side Button Location.................................................................... 4-3
Figure 4-2: HT1550•XLS Radio Side Button Location.............................................. 4-3
Figure 4-3: Two-Line Display.................................................................................... 4-4
Figure 4-4: Four-Line Display (HT1550•XLS)........................................................... 4-4
Figure 5-1: Radio Tuning Test Equipment Setup...................................................... 5-2
Figure 5-2: CPS Programming Setup ....................................................................... 5-3
Figure 5-3: Radio Side Button Locations .................................................................. 5-4
Figure 5-4: HT1550•XLS Radio Side Button Locations ............................................ 5-4
x
Notes
LIST OF TABLES
Table 1-1: Radio Model Number (Example: AAH25KDC9AA3AN)........................... 1-4
Table 3-11:Service Aids........................................................................................... 3-35
Table 3-12:Recommended Test Equipment ............................................................ 3-36
Table 4-1: Test Environments (Side Button 1).......................................................... 4-4
Table 4-2: Test Environments (Models with “G” in location 10 of model number EX:
AAH25RCH6GB6AN) .............................................................................. 4-5
Table 4-3: Test Channel Spacing (Side Button 2)..................................................... 4-5
Table 4-4: Test Frequencies (Using the Channel Selector Switch) .......................... 4-6
Table 4-5: Receiver Performance Checks................................................................ 4-7
Table 4-6: Transmitter Performance Checks............................................................ 4-8
Table 5-1: Software Installation Kits Radio Tuning Setup......................................... 5-1
xi
Table 5-2: Initial Equipment Control Settings............................................................ 5-2
Table 6-1: Power-up Display Codes - (Conventional Radios)................................... 6-1
Table 6-2: Power-up Display Codes ......................................................................... 6-2
Table 6-3: Power-up Display Codes (PassPort Trunking Controller Board)............. 6-3
Table 6-4: Operational Display Codes...................................................................... 6-3
xii
Notes
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.
1.2 Warranty and Service Support
Motorola offers support which includes: full exchange and/or rep air 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” to an authorized Motorola Dealer must be accompanied by a Warranty Claim Form.
Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer. (See section 1.2.4
on page 1-3.)
1.2.1 Warranty Period and Return Instructions
1-1
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 subsections are for
guidance purposes only.
In instances where the product is covered under a “return for replacement” or “return for repair”
warranty , a chec k of the product should be performed prior to shipping the unit ba ck 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 co ntact 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 Resources representative. Products should be
shipped back in the
in transit.
original packaging, or correctly packag ed to ensure that no damage occurs
1.2.2 After Warranty Period
After the Warranty period, Motorola continues to support its products in two ways:
1. Motorola's Radio Parts and Service Group offers repair service to users and dealers at competitive prices.
2. The Motorola Customer Care and Services Division (CCSD) supplies individual parts and modules that can be purchased by dealers who are capable of performing fault analysis and repair.
1-2 Introduction
1.2.3 Piece Parts Availability
Some replacement parts, spare parts, and/or product information can be ordered directly.
If... It Means That...
A complete Motorola part number is
assigned to the part, and it is not identified
as Depot ONLY
No part number is assigned The part is not normally available from
The part number is appended with an
asterisk
A parts list is not included Generally, no us er-serviceable parts are
The part is available from the Customer Care
and Services Division (CCSD).*
Motorola.
The part is serviceable by a Motorola Depot
only.
available for that kit or assembly.
*The Customer Care and Services Division
(CCSD) was formerly known as the Accessories and Aftermarket Division (AAD).
Motorola Online:
Motorola Online users can access our online catalog at
https://www.motorola.com/businessonline
To register for online access, please call 800-814-0601.
Mail Orders:
Send written orders to the following addresses:
Replacement Parts/
Test Equipment/Manuals/
Crystal Service Items:
Federal Government Orders:
International Orders:
Motorola Inc.
Customer Care and Services
Division*
(United States and Canada)
Attention: Order Processing
1307 E. Algonquin Road
Schaumburg, IL 60196
Motorola Inc.
U.S. Federal Government
Markets Division
Attention: Order Processing
7230 Parkway Drive
Landover, MD 21076
Telephone Orders
Customer Care and Services Division*
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
1-847-538-8023 (International Orders)
U.S. Federal Government Markets Division (USFGMD)
1-800-826-1913 Federal Government Parts - Credit Cards Only
8:30 AM to 5:00 PM (Eastern Standard Time)
Motorola Inc.
Customer Care and Services
Division*
(United States and Canada)
Attention: Order Processing
1307 E. Algonquin Road
Schaumburg, IL 60196
Introduction 1-3
Fax Orders
Customer Care and Services Division*
1-800-622-6210
847-576-3023 (International)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchase Orders)
Parts Identification
Customer Care and Services Division*
(United States and Canada)
1-800-422-4210, menu 3
Product Customer Service
Customer Response Center
(Non-technical Issues)
1-800-247-2346
FAX:1-800-247-2347
*The Customer Care and Services Division (CCSD) was formerly known as the Accessories and
Aftermarket Division (AAD).
1.2.4 Technical Support
Technical support is available to ass ist th e de ale r/distributor in resolving any malfunction which may
be encountered. For service, contact the Service Depot in your area. If your area does not have a
depot, please contact your Business Development Manager, Distributor, or contact Motorola
Technical Support. When contacting Motorola Technical Support, keep the product model number
and the unit’s serial number handy.
For service, contact one of the following Depots. Pl ease call and confirm your return before sending
the unit to the depot for service.
Motorola Radio Support Center
2200 Galvin Dr.
Elgin, IL 60123
1-800-227-6772
Motorola Toronto Service Center
3900 Victoria Avenue
North York, Ontario, Canada M2H 3H7
1-800-543-3222
1-416-756-5841
1-888-331-9872 (Fax)
Motorola U.S. Federal Government Depot
4395 Nicole Drive
Lanham, MD 20706
1-800-969-6680
1-301-731-6676
1-4 Introduction
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: AAH25KDC9AA3AN)
T ype of
Unit
AA orLAH25 K
Model
Series
Freq.
Band
VHF
(136-174
MHz)
H = Portable
A or LA = Motorola Internal Use
R
UHF1
(403-470
MHz)
S
UHF2
(450-512
MHz)
B
Low Band,
R1 (29.7-
42.0 MHz)
C
Low Band,
R2 (35.0-
50.0 MHz)
U
800 MHz
(806-821)
(851-866)
W
900 MHz
(896-902)
(935-941)
Power
Level
C
1-3.9W
D
4-5W
E
5.1-6WNHT1550•XLS
Physical
Packages
C
HT750
MTX850
MTX850•LS
MTX950
(no display)
H
HT1250
HT1250•LS
MTX8250
MTX8250•LS
MTX9250
(1-Line Display)
(4-Line Display)
Channel
Spacing
9
Programma-
ble
6
25 kHz
4
12.5 kHz
Protocol
AA
Conventional
DU
LTR
DP
PassPort
CK
MPT
GB
Privacy Plus8HT1550•XLS
Feature
Level
3
HT750
MTX850
MTX850•LS
MTX950
(non-keypad)
5
HT1250
HT1250•LS
Limited
Keypad
6
HT1250
HT1250•LS
MTX8250
MTX8250•LS
MTX9250
Full Keypad
7
HT1250•LS
Limited
Keypad
MDC on Conv.
9
HT1250•LS
Full Keypad
MDC on Conv.
Revision
+
+
+
+
Model
Model
Package
AN
Chapter 2
W
G
Intrinsically Safe Radio Information
2.1 FMRC Approved Equipment
Anyone intending to use a radio in a location where hazardous concentrations of flammable
materials exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic
safety and with the National Electric Code NFP A 70 (National Fire Protection Association) Article 500
(hazardous [classified] locations).
An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers
and the products approved by FMRC for use in such locations. FMRC has also issued a voluntary
approval standard for repair service (“Class Number 3605”).
FMRC Approval labels are attached to the radio to identify the unit as being FM 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. Depending on the design of the portable unit,
this FM label can be found on the back or the bottom of the radio housing. The FM Approval mark is
shown below.
2-1
FM
APPROVED
• Do not operate radio communications equipment in a hazardous
!
!
A R N I N
Radios must ship from the Motorola manufacturing facility with the Intrinsically Safe, hazardous
atmosphere capability and FM Approval labeling. Radios will not be “upgraded” or converted to
Intrinsically safe, and or labeled in the field, after it has been shipped from the manufactu ring
location.
atmosphere unless it is a type especially qualified (for example,
FMRC Approved) for such use. An explosion or fire may result.
• Do not operate an FMRC Approved 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.
• 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 a radio off before removing or installing a battery or
accessory.
• Do not disassemble an FMRC Approved Product unit in any way
that exposes the internal electrical circuits of the unit.
2-2 Intrinsically Safe Radio Information
W
G
W
G
Modifications can only be made by the original product manufacturer (Motorola) at one of its FM
audited manufacturing facilities.
• Failure to use an FMRC Approved portable radio unit with an
!
!
A R N I N
FMRC Approved battery or FMRC Approved accessories
specifically Agency approved for that product may result in the
dangerously unsafe condition of an unapproved radio
combination being used in a hazardous location.
• Unauthorized or incorrect modification of an FMRC Approved
Product unit will negate the Approval rating of the product.
2.2 Repair of FMRC Approved Products
REPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL ARE THE RESPONSIBILITY
OF THE USER.
You should not repair or relabel any Motorola- manufactured communication equipment bearing the
FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC
Approval standard for repairs and service (“Class Number 3605”). Repairs and service to be done
FM audited locations.
!
!
A R N I N
The following are key definitions, from the FMRC’s Approval Standard Class Number 3605, 1994.
2.2.1 Repair
A repair constitutes something done internally to the unit that would bring it back to its original
condition-Approved by FMRC. A repair should be done in an FMRC audited facility. Items not
considered as repairs are those in which an a ction is perform ed on a unit which do es not require the
outer casing of the unit to be opened in a manner which exposes the internal electrical. You do not
have to be an FMRC audited Repair Facility to perform these actions.
2.2.2 Relabeling
The repair facility shall have a method by which the replacement of FMRC Approval labels are
controlled to ensure that any relabeling is limited to units that were originally shipped from the
Manufacturer with an FM Approval label in place. F MRC Ap pr oval labe ls sh all not be stocked by the
repair facility. An FMRC Approval label shall be ordered from the original manufacturer, as needed,
to repair a specific unit. Replacement labels may be obtained and applied by the repair facility,
provided there is satisfactory evidence that the unit being relabeled was originally an FMRC
Approved unit. Verification may include, but is not limited to: a unit with a damaged Approval label, a
unit with a defective housing displaying an Approval labe l, or a customer invoice indicating the serial
number of the unit and purchase of an FMRC Approved model.
• Incorrect repair or relabeling of any FMRC Approved Product unit
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.
Intrinsically Safe Radio Information 2-3
2.2.3 Do Not Substitute Options or Accessories
The Motorola communications equipment certified by Factory Mutual is tested as a system and
consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or
options, or both. This FM Approved portable and battery combination must be strictly observed. The re
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 in the FM Approval
Guide published by FMRC, or in the product FM product listing. This FM product listing is shipped
from the manufacturer with the FM Approved radio and battery combination.
2-4 Intrinsically Safe Radio Information
Notes
Chapter 3
C a u t i o n
Maintenance
3.1 Introduction
This chapter provides details about the following:
l Preventive maintenance (inspection and cleaning)
l Safe handling of CMOS and LDMOS devices
l Disassembly and reassembly of the radio
l Installation of Optional Retrofit Kit
l Installation of Option Boards
3.2 Preventive Maintenance
The radios do not require a scheduled preventive maintenance program; however, periodic visual
inspection and cleaning is recommended.
3-1
3.2.1 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.
3.2.2 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: Certain chemicals and their vapors can have harmful effects on certain
!
plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.
Cleaning External Plastic Surface
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
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 sh ould direct the
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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. Afte r 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).
3.3 Safe Handling of CMOS and LDMOS Devices
Complementary metal-oxide semico nductor (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 fir st referring to th e 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
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unit:
l 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.
l Ground the working surface of the service bench to protect the CMOS d evice. W e
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.
l 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.)
l Do not wear nylon clothing while handling CMOS devices.
l Do not insert or remove CMOS devices with power applied. Check all power
supplies used for testing CMOS devices to be certain that ther e ar e no voltage
transients present.
l When straightening CMOS pins, provide ground straps for the apparatus used.
l When soldering, use a grounded soldering iron.
l 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.
3.4 Repair Procedures and Techniques — General
Parts Replacement and Substitution
When damaged parts are r eplaced, identica l p art s sh ould be used. If the ide ntical replacement p art 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
(See page 1-2).
Maintenance 3-3
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:
l Avoid accidentally getting solder in the connector.
l Be careful not to form solder bridges between the connector pins.
l 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 mater ial.
Therefore, avoid excessive heat and excessive bending.
For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700
degree 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.
3.5 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 tab s, and how parts align with each
other.
The following tools are required for disassemb ling the radi o :
l 3/16” flat blade screwdriver
l Penknife-size screwdriver
l TORX™ T6 screwdriver
If a unit requires more complete testing or serv ic e than is customarily performed at the basic level,
send this unit to a Motorola Authorized Service Center. (See Chapter, section 1.2.4 Technical Support
on page 1-3 for a list of authorized service centers.)
The following disassembly procedures should be performed only if necessary:
section 3.6.2 Chassis Assembly/Disassembly on page 3-6
section 3.6.3 Keypad, Display, and Keypad/PassPort/Option Board Disassembly on page 3-6
section 3.6.4 Speaker, Microphone, and Universal Connector Flex Disassembly on page 3-8
section 3.6.5 PTT Disassembly on page 3-9
section 3.6.6 Control Top Disassembly on page 3-9
section 3.7.7 DTMF Retrofit Kit Procedure (Optional Upgrade Procedure) on page 3-12
section 3.7.8 Option Board Installation on page 3-13
3-4 Maintenance
3.6 Detailed Radio Disassembly
3.6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Pull down on the two battery-release buttons.
b. With the buttons pulled down, the top of the battery will fall from the radio.
c. Remove the battery completely from the radio.
Battery
Release
Buttons
Battery
Figure 3-1: Battery Removal
3. Remove the ante nn a.
3. Pull the volume and channel selector knobs off their shafts .
NOTE: Both knobs slide on and off. However, they are supposed to fit very tightly on their
shafts.
Figure 3-2: Knob Removal
Knobs
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4. Separate the chassis from the internal electronics front cover assembly as follows:
a. Insert a small, 3/16” flat-blade screwdriver, or similar instrument, in between the thin
remaining wall and the chassis at the bottom of the radio. Do not mar the O-ring se aling area
on the housing.
b. Slowly pry the bottom of the chassis from the cover by pushing the 3/16” flat-blade
screwdriver down, and rotating the handle of the tool over and behind the base of the rad io.
This prying action forces the thin inner plastic wall toward the base of the radio, releasing the
two chassis base tabs.
Radio
Figure 3-3: Chassis Removal
CAUTION: Marring the front cover O-ring sealing area will preve nt the r adio f rom
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sealing properly.
6. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis.
NOTE: Flexible ribbon circuits (flexes) connecting the front cover assembly and the
chassis prevent you from completely sep arating t he two unit s. Display radios an d
radios with option boards have two flexes.
5. Lift the latches on the main circuit board to release the flexes from their connectors.
Latches
Flex Connector
Figure 3-4: Unlatch Flex Connectors
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NOTE: At this point, if necessary, the DTMF Retrofit Kit Procedure can be performed.
(See section 3.7.7 DTMF Retrofit Kit Procedure ( Optional Upgrade Procedure) on page
3-12).
3.6.2 Chassis Assembly/Disassembly
1. If disassembly of the chassis or the main board is required, then use a TORX™ screwdriver with
a T6 head to remove the four screws holding the main board to the chassis.
Screws (4)
Compliant
Ground
Contact
Main
Board
Radio
Chassis
O-Ring
Retaining
Features
Figure 3-5: Remove Main Board from Chassis
CAUTION: Refer to the CMOS CAUTION in paragraph on page 3-2 before removing
the main board. Be sure to use electrost atic discharge (ESD) protection when
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handling circuit boards.
2. Lift the main board from the chassis (refer to Figure 3-5).
3. Remove the small O-ring retainers from their slots in the chassis. Note the alignment of the
retainers for reassembly.
4. Remove the O-ring.
5. If required in disassembly, slide off the ground contact from the top corner boss of the radio
chassis.
3.6.3 Keypad, Display, and Keypad/PassPort/Option Board Disassembly
1. If the disassembly of the keypad or the keypad printed circuit board, is required, lift the
microphone flex circuit up, and carefully remove the microphone and its boot from the front cover
pocket. (See Figure 3-6 on page 3-7).
2. Lay this flex circuit to one side.
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3. To remove the keypad retainer shield:
a. Insert the tip of a “penknife size,” flat blade screwdriver in the opening at the end of the
keypad retainer arm tab.
b. Pry the tab away from the side of the front cover until it moves past the ledges on the side
wall. Repeat this procedure for the four remaining retainer arm tabs.
Speaker-Microphone
Flex Circuit Tail
Keypad Retainer
Arm Tabs (4)
Flat Blade
Screwdriver
Retainer
Top Hooks
Retainer
Figure 3-6: Remove Retainer
4. Note that the two “top hooks” are still held underneath the front cover—right below the speaker.
Lift the keypad retainer out of the front cover, then lift and pivot the two hooks out of the front
cover.
5. If disassembly involves the removal of the display module, disconnect the display flex from the
keypad option board connector by lif ting the latch on the con nector. (This is similar to the process
for releasing the flexes.) (see page 3-5.)
6. The display module is attached to the front cover with a doub le-sided adhesive p ad. Carefully pull
up on the display module, using a small screwdriver, if necessary, and remove it from the front
cover. Use a new piece of double-sided adhesive to re-mount the display to the cover.
CAUTION Take care not to damage the display. Do not cut, bend, or pinch the heat
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seal. Display modules contain CMOS devices. Be sure to use ESD protection.
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7. The keypad/PassPort/option board can be removed without the use of tools.
3-8 Maintenance
Retainer
Display
Module
Keypad
Option
Board
Keypad
Radio
Body
Figure 3-5: Removing the Keypad Retainer and Other Boards from the Radio
NOTE: At this point, the Option Board Installation Procedure should be performed, if
necessary. (See page 3-13)
3.6.4 Speaker, Microphone, and Universal Connector Flex Disassembly
1. If disassembly of the speaker-microphone assembly is necessary, remove the dustcover by
turning the screw at the bottom of the dustcov e r counterclockwise with your fingers. Lift the
dustcover out of its pocket.
NOTE: The dustcover must be removed to remove the speaker-microphone assembly flex
circuit. The speaker is held in place with a two-legged retainer bracket. The bracket
legs are secured by the front cover slots. Be careful not to damage the speaker when
removing the retainer bracket.
2. Using a screwdriver, push down on the portion of the speaker retainer bracket pointing toward the
bottom of the radio. Then, remove the retainer by slightly pushing it toward the top of the radio
until you slide it past the front cover slot.
3. Pull the rubber microphone boot from its seated position. Unless you are replacing the
microphone, leave it in the boot.
NOTE: The speaker-microphone assembly flex circuit goes through the front cover wall to
the outside wall. To replace this assembly, you must peel-off the universal connector
escutcheon label. The existing escutcheon cannot be reassembled; a new part must
be used. (See item number 10 on the exploded view drawing on page 3-15).
4. Peel-off the universal connector flex circuit escutcheon (label).
5. Pry the flex circuit (adhesive held) backer board away from the front cover, and remove the
universal connector tail of the speaker-microphone assembly through its opening in the front
cover.
Maintenance 3-9
6. After the universal connector tail of the speaker-microphone assembly is removed, the assembly
can be completely removed. If it is necessary to replace the speaker or micr ophone, or bo th, do it
while the flex circuit is removed from the front cover. When reassembling the microphone in its
boot, make sure the microphone port faces the round hole in the bottom of the boot.
Speaker
Universal
Connector
Tail
Microphone
Boot
Microphone
Speaker Microphone
Flex Circuit Assembly
Speaker Orientation
Tab (12:00 Position)
Figure 3-6: Removal Speaker-Microphone Assembly
3.6.5 PTT Disassembly
If required, the PTT bezel and the PTT seal assembly can be d isassembled using a small screwdriver
as follows:
Tab
PTT
Bezel
PTT
Seal
1. Pry back the T-tab found inside the front cover (in between the four buttons on the PTT
assembly).
2. Remove the PTT bezel by slightly bowing it until the top and bottom tabs are released from the
slots in the front cover.
3. The PTT seal can be easily lifted from the bezel without the use of tools.
3.6.6 Control Top Disassembly
1. To remove the control top assembly, place a screwdriver next to the antenna boss, then pry it
against the control top escutcheon. This lifts the control top escutcheon away from its
double-sided adhesive. Grab the double-sided a dhesive near the volu me potentiometer , then lift it
away.
2. Remove the integrated control top seal, emergency button, and transmit light pipe.
T-Shaped
Retainer Tab
Tab
Figure 3-7: PTT Removal
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