Motorola P Basic Service Manual

Professional Radio

P Series

Basic Service Manual

68P64115B49

Issue: September 1999

Radio Communications Supply &

Installation Specialist

Website

www.radiotronics.co.uk

Email

[e-mail]

Telephone Numbers

0345 0 955 955

02087 190 180

Service Manual

ii

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored
in semiconductor memories or other media. Laws in the United States and other countries preserve for Motor­ola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or repro­duce in any form, the copyrighted computer program. Accordingly, any copyrighted Motorola computer
programs contained in the Motorola products described in this manual may not be copied or reproduced in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola prod­ucts shall not be deemed to grant, either directly or by implication, estoppel or otherwise, any license under
the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive royalty-free
license to use that arises by operation of law in the sale of a product.

iii

SAFETY INFORMATION

Read this information before using your radio.

SAFE AND EFFICIENT OPERATION OF MOTOROLA TWO-WAY RADIOS

This document provides information and instructions for the safe and efÞcient operation of Motorola Portable and
Mobile Two-Way Radios. The information provided in this document supersedes the general safety information
contained in user guides published prior to 1 January 1998.

For information regarding radio use in hazardous areas, please refer to the Factory Mutual (FM) approval manual
supplement.

EXPOSURE TO RADIO FREQUENCY ENERGY

Your Motorola Two-Way Radio, which generates and radiates radio frequency (RF) electromagnetic energy
(EME), is designed to comply with the following National and International Standards and Guidelines regarding
exposure of human beings to radio frequency electromagnetic energy:

●

Federal Communications Commission Report and Order No. FCC 96-326 (August 1996)

●

American National Standards Institute (C95.1 - 1992)

●

National Council on Radiation Protection and Measurements (NCRP-1986)

●

International Commission on Non-Ionizing Radiation Protection (ICNRP- 1986)

●

European Committee for Electrotechnical Standardization (CENELEC):

To assure optimal radio performance and to ensure that your exposure to radio frequency electromagnetic
energy is within the guidelines in the above standards, always adhere to the following procedures:

PORTABLE RADIO OPERATION AND EME EXPOSURE

●

When transmitting with a portable radio, hold radio in a vertical position with the
microphone 2.5 to 5.0 centimetres (one to two inches) away from the mouth. Keep
antenna at least 2.5 centimetres (one inch) from your head or body when
transmitting.

●

If you wear a portable two-way radio on your body, ensure that the antenna is at
least 2.5 centimetres (one inch) from the body when transmitting.

ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY

●

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

●

When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in
accordance with airline regulations or crew instructions.

- ENV 50166-1 1995 E Human exposure to electromagnetic Þelds Low
frequency (0 Hz to 10 kHz)

- ENV 50166-2 1995 E Human exposure to electromagnetic Þelds High
frequency (10 kHz to 300 GHz)

- Proceedings of SC211/B 1996 ÒSafety Considerations for Human Exposure to EMFs from
Mobile Telecommunication Equipment (MTE) in the
Frequency Range 30MHz - 6 GHz.Ó
(EMF - Electro-Magnetic Fields)

NOTE

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

2.5 to 5.0 cm
(1 to 2 in.)

iv SAFETY INFORMATION

OPERATIONAL WARNINGS

Vehicles with an air bag

Potentially explosive atmospheres

Batteries

Blasting caps and areas

OPERATIONAL CAUTIONS

Damaged antennas

Batteries

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

WARNING: Turn off your Two-Way radio when you are in any area with a potentially explosive
atmosphere, unless it is a radio type especially qualiÞed for use in such areas (e.g. FM).
Sparks in a potentially explosive atmosphere can cause an explosion or Þre resulting in
bodily injury or even death.

WARNING: Do not replace or recharge batteries in a potentially explosive atmosphere.
Contact sparking may occur while installing or removing batteries and cause an explosion.

WARNING: To avoid possible interference with blasting operations, turn off your radio when
you are near electrical blasting caps. In a Ò

blasting area

Ó or in areas posted Ò

turn off two-way

radio

Ó, obey all signs and instructions.

NOTE

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

CAUTION: Do not use any portable two-way radio that has a damaged antenna. If a damaged
antenna comes into contact with your skin, a minor burn can result.

CAUTION: All batteries can cause property damage and/or bodily injury such as burns if a
conductive material such as jewellery, keys or beaded chains touch 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.

!

!

!

!

!

!

v

Table of Contents

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..................................................................................... 1-1

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

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

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

3.0 Radio Model Information...................................................................................... 1-3

Section 2 INTRINSICALLY SAFE RADIO INFORMATION

1.0 FMRC Approved Equipment................................................................................ 2-1

2.0 Repair of FMRC Approved Products ................................................................... 2-2

2.1 Repair............................................................................................................. 2-2

2.2 Relabelling...................................................................................................... 2-2

2.3 Do Not Substitute Options or Accessories ..................................................... 2-3

Section 3 MAINTENANCE

1.0 Introduction ..........................................................................................................3-1

2.0 Preventive Maintenance ...................................................................................... 3-1

2.1 Inspection .......................................................................................................3-1

2.2 Cleaning Procedures...................................................................................... 3-1

3.0 Safe Handling of CMOS and LDMOS Devices.................................................... 3-2

4.0 Disassembling and Reassembling the Radio Ñ General.................................... 3-3

5.0 Radio Disassembly Ñ Detailed ........................................................................... 3-4

5.1 Front Cover from Chassis Disassembly .........................................................3-4

5.2 Chassis Assembly Disassembly..................................................................... 3-6

5.3 Keypad/Option Board and Display Module Disassembly ...............................3-7

5.4 Speaker, Microphone, and Wire Disassembly ...............................................3-8

5.5 PTT Disassembly ........................................................................................... 3-9

5.6 Control Top Disassembly ............................................................................. 3-10

6.0 Radio Reassembly Ñ Detailed.......................................................................... 3-10

6.1 Control Top Reassembly.............................................................................. 3-10

6.2 PTT Reassembly.......................................................................................... 3-10

6.3 Speaker Reassembly ................................................................................... 3-10

6.4 Keypad Option Board, Microphone and Wire Reassembly ..........................3-11

6.5 Chassis Assembly Reassembly ................................................................... 3-11

6.6 Chassis and Front Cover Reassembly......................................................... 3-12

vi

7.0 Option Board Installation....................................................................................3-12

7.1 Configuring the Radio after Option Board Installation ..................................3-14

7.2 Additional Configuration required by the DTMF Option Board .....................3-15

8.0 Mechanical View and Parts List .........................................................................3-16

8.1 P Series Radio Exploded View and Parts List ..............................................3-16

9.0 Service Aids .......................................................................................................3-18

10.0 Test Equipment ..................................................................................................3-19

11.0 Programming/Test Cable ...................................................................................3-20

Section 4 PERFORMANCE TESTING

1.0 Introduction ..........................................................................................................4-1

2.0 Setup....................................................................................................................4-1

3.0 Test Mode ............................................................................................................4-2

3.1 RF Test Mode .................................................................................................4-2

Section 5 RADIO TUNING AND PROGRAMMING

1.0 Introduction ..........................................................................................................5-1

2.0 Radio Tuning Setup .............................................................................................5-1

2.1 Initial Test Equipment Setup...........................................................................5-2

3.0 CPS Programming Setup.....................................................................................5-2

Section 6 POWER UP SELF-TEST

1.0 Error Codes..........................................................................................................6-1

Section 7 MODEL CHARTS AND TECHNICAL SPECIFICATIONS

1.0 Model Chart (VHF) ...............................................................................................7-1

2.0 Model Chart (UHF)...............................................................................................7-2

3.0 Model Chart (UHF2).............................................................................................7-3

4.0 Technical Specifications.......................................................................................7-4

Chapter 1

INTRODUCTION

1.0 Scope of Manual

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

2.0 Warranty and Service Support

Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warranty period, and service/ repair or spare parts support out of warranty.
Any "return for exchange" or "return for repair" by an authorised Motorola Dealer must be
accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an
Authorised Motorola Dealer.

2.1 Warranty Period and Return Instructions

The terms and conditions of warranty are deÞned fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only.

In instances where the product is covered under a "return for replacement" or "return for repair"
warranty, a check of the product should be performed prior to shipping the unit back to Motorola.
This is to ensure that the product has been correctly programmed or has not been subjected to
damage outside the terms of the warranty.

Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be
accompanied by a Warranty Claim Form, available from your Customer Services representative.
Products should be shipped back in the original packaging, or correctly packaged to ensure no
damage occurs in transit.

2.2 After Warranty Period

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

1.

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

2.

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

NOTE

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

1-2 INTRODUCTION

2.3 European Radio Support Centre (ERSC)

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

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

Belgium: 08 00 72 471 Luxemburg: 08 00 23 27

Denmark: 80 01 55 72 Netherlands: 60 22 45 13

Finland: 08 00 11 49 10 Norway: 80 01 11 15

France: 05 90 30 90 Portugal: 05 05 49 35 70

Germany: 01 30 18 75 24 Spain: 90 09 84 902

Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307

UK: 08 00 96 90 95 Switzerland: 1 55 30 82

Ireland: 18 00 55 50 21 Iceland: 80 08 147

Or dial Customer Care Centre:

Tel: [phone]

Please use these numbers for repair enquiries only

2.4 Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly. If a
complete Motorola part number is assigned to the part, it is available from Motorola Radio
Aftermarket and Accessory Division (AAD). If no part number is assigned, the part is not normally
available from Motorola. If the part number is appended with an asterisk, the part is serviceable by
Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable
parts are available for that kit or assembly.

All enquiries should be directed to:

Motorola GmbH
European Parts Department
65232 Taunusstein
Germany.

Radio Model Information 1-3

2.5 Technical Support

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

Central/East Europe - Siggy Punzenberger

Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Africa & Middle East - Michael Berberich

Telephone: [phone]
Fax: [phone]
Email: [e-mail]

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 speciÞc characteristics.

Table 1-1 Radio Model Number (Example: MDH34KDC9AA1AE)

Type of

Unit

Model
Series

Freq.
Band

Power

Level

Physical

Packages

Channel
Spacing

Protocol

Feature

Level

Model

Revision

Model

Package

MD H 34 K

VHF

(136-

174MHz)

D

4-5W

C

P040

9

Program-

mable

AA

Conventional

1

P040

AE

R

UHF

(403-

470MHz)

H

P080

6

P080

S

UHF2

(450-

527MHz)

MD = Motorola Internal Use

H = Portable

1-4 INTRODUCTION

Chapter 2

INTRINSICALLY SAFE RADIO INFORMATION

1.0 FMRC Approved Equipment

Anyone intending to use a radio in a location where hazardous concentrations of ßammable material
exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and
with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500
(hazardous [classiÞed] 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 (ÒClass Number 3605Ó).

FMRC Approval labels are attached to the radio to identify the unit as being FM
Approved for speciÞed hazardous atmospheres. This label speciÞes 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 of the radio housing or the bottom of the radio housing.Their Approval mark is shown above.

Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability
and FM Approval labeling. Radios will not be ÒupgradedÓ to this capability and labeled in the Þeld.

A modiÞcation changes the unitÕs hardware from its original design conÞguration. ModiÞcations can
only be done by the original product manufacturer at one of its FMRC audited manufacturing
facilities.

Unauthorized or incorrect modiÞcation of an FMRC Approved Product unit will negate the Approval
rating of the product.

WARNING: Do not operate radio communications equipment in a hazardous atmosphere
unless it is a type especially qualiÞed (e.g. FMRC Approved) for such use. An explosion or
Þre may result.

WARNING: Do not operate the FMRC Approved Product in a hazardous atmosphere if it has
been physically damaged (e.g. cracked housing). An explosion or Þre may result.

WARNING: Do not replace or charge batteries in a hazardous atmosphere. Contact sparking
may occur while installing or removing batteries and cause an explosion or Þre.

WARNING: Do not replace or change accessories in a hazardous atmosphere. Contact
sparking may occur while installing or removing accessories and cause an explosion or Þre.

WARNING: Do not operate the FMRC Approved Product unit in a hazardous location with the
accessory contacts exposed. Keep the connector cover in place when accessories are not
used.

WARNING: Turn radio off before removing or installing a battery or accessory.

WARNING: Do not disassemble the FMRC Approved Product unit in any way that exposes
the internal electrical circuits of the unit.

WARNING: Failure to use an FMRC Approved Product unit with an FMRC Approved battery
or FMRC Approved accessories speciÞcally approved for that product may result in the
dangerously unsafe condition of an unapproved radio combination being used in a
hazardous location.

FM

APPROVED

!

!

2-2 INTRINSICALLY SAFE RADIO INFORMATION

2.0 Repair of FMRC Approved Products

REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF
THE USER

You should not repair or relabel any Motorola manufactured communication equipment bearing the
FMRC Approval label (ÒFMRC Approved ProductÓ) unless you are familiar with the current FMRC
Approval standard for repairs and service (ÒClass Number 3605Ó).

You may want to consider using a repair facility that operates under 3605 repair service approval.

FMRCÕs Approval Standard Class Number 3605 is subject to change at any time without notice to
you, so you may want to obtain a current copy of 3605 from FMRC. Per the December, 1994
publication of 3605, some key deÞnitions and service requirements are as follows:

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 Approved facility.

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 which exposes the internal electrical
circuits of the unit. You do not have to be an FMRC Approved Repair Facility to perform these
actions.

2.2 Relabelling

The repair facility shall have a method by which the replacement of FMRC Approval labels are
controlled to ensure that any relabelling is limited to units that were originally shipped from the
Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the
repair facility. An FMRC Approval label shall be ordered from the original manufacturer as needed to
repair a speciÞc unit. Replacement labels may be obtained and applied by the repair facility
providing satisfactory evidence that the unit being relabelled was originally an FMRC Approved unit.

VeriÞcation may include, but is not limited to: a unit with a damaged Approval label, a unit with a
defective housing displaying an Approval label, or a customer invoice indicating the serial number of
the unit and purchase of an FMRC Approved model.

WARNING: Incorrect repair or relabeling of any FMRC Approved Product unit could
adversely affect the Approval rating of the unit.

WARNING: Use of a radio that is not intrinsically safe in a hazardous atmosphere could
result in serious injury or death.

!

Repair of FMRC Approved Products 2-3

2.3 Do Not Substitute Options or Accessories

The Motorola communications equipment certiÞed 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 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 conÞgurations are listed in the FM Approval
guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped with
FM Approved radio and battery combination from the manufacturer. The Approval guide, or the
Approval standard Class Number 3605 document for repairs and service, can be ordered directly
through Factory Mutual Research Corporation located in Norwood, Massachusetts.

2-4 INTRINSICALLY SAFE RADIO INFORMATION

Chapter 3

MAINTENANCE

1.0 Introduction

This chapter provides details about the following:

■

■

Preventive maintenance (inspection and cleaning)

■

■

Safe handling of CMOS and LDMOS devices

■

■

Disassembly and reassembly of the radio

■

■

Repair procedures and techniques

■

■

Installation of Option Boards

2.0 Preventive Maintenance

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

2.1 Inspection

Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.

2.2 Cleaning 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.

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).

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.

NOTE

Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.

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.

!

3-2 MAINTENANCE

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.

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 Þrst referring to the following
CAUTION statement.

NOTE

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

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
ÒsnowÓ 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
ßoor 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.

!

Disassembling and Reassembling the Radio Ñ General 3-3

4.0 Disassembling and Reassembling the Radio Ñ 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:

■

■

chassis opener

■

■

penknife-size screwdriver

■

■

TORXª T6 screwdriver

If a unit requires more complete testing or service than is customarily performed at the basic level,
send this unit to a Motorola Authorized Service Center (See Chapter 1 for a list of authorized service
centers).

The following disassembly procedures should be performed only if necessary:

Chassis Assembly Disassembly (Paragraph 5.2)

Keypad/Option Board and Display Module Disassembly (Paragraph 5.3)

Speaker, Microphone, and Wire Disassembly (Paragraph 5.4)

PTT Disassembly (Paragraph 5.5)

Control Top Disassembly (Paragraph 5.6)

3-4 MAINTENANCE

5.0 Radio Disassembly Ñ Detailed

5.1 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 from the radio.

3. Remove the antenna.

Figure 3-1 Battery Removal

Battery Release Button

Battery Release Button

Radio Disassembly Ñ Detailed 3-5

4. Pull the volume and channel selector knobs off of their shafts. Remove the dust cover.

5. Separate the chassis from the internal electronics front cover assembly by using the chassis

opener (part number 6680702Z01). Place the broad side of the opener into the slots located
at the base of the radio (see Figure 3-3). Press the handle of the opener downwards. This
pressing action forces the thin inner plastic wall toward the base of the radio, releasing the two

chassis base tabs.

Figure 3-2 Knob Removal

NOTE

Both knobs slide on and off. However, they are supposed to Þt very tightly on their shafts.

Figure 3-3 Chassis Removal

CAUTION: Marring the front cover O-ring sealing area will prevent the radio from sealing properly.

NOTE

The jumper ßex and wire assembly connecting the front cover assembly and the chassis
prevent you from completely separating the two units.

Knobs

Radio Chassis

chassis opener

!

3-6 MAINTENANCE

6. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis.

7. Lift the latch on the main circuit board to release the jumper ßex from its connector.

8. Unplug the wires from the 4-pin connector.

5.2 Chassis Assembly Disassembly

Use a TORXª screwdriver with a T6 head to remove the four screws holding the main board to the
chassis.

1. Lift the main board from the chassis (See Figure 3-5).

Figure 3-4 Unlatch Flex Connectors

Figure 3-5 Remove Main Board from Chassis

CAUTION: Refer to the CMOS CAUTION paragraph on Page 3-2 before removing the main board. Be
sure to use ESD protection when handling circuit boards.

Latch

Jumper Flex

4-Pin Connector

Wire Assembly

Main Board

Radio Chassis

O-Ring
Retaining Features

!

Radio Disassembly Ñ Detailed 3-7

2. Remove the six small O-ring retainers from their slots in the chassis. Note the alignment of

the retainers for reassembly.

3. Remove the O-ring.

5.3 Keypad/Option Board and Display Module Disassembly

1. If the disassembly of the keypad printed circuit board is required, open the catches on the

keypad retainer and lift the wire assembly up. (See Figure 3-6.)

2. Lay this wire assembly to one side.

3. To remove the keypad retainer shield:

a. Insert the tip of a Òpenknife size,Ó ßat 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. Duplicate this procedure for each of the four retainer arm tabs.

4. Note that the two Òtop hooksÓ are still held underneath the front coverÑright below the

speaker. Lift the keypad retainer out of the front cover; then, lift and pivot the two hooks out of
the front cover.

Figure 3-6 Remove Retainer

Retainer

Flat Blade
Screwdriver

Keypad Retainer
Arm Tabs (4)

Catches

Wire Assembly

3-8 MAINTENANCE

5. The keypad/option board, and the keypad, can be removed without the use of tools.

5.4 Speaker, Microphone, and Wire Disassembly

1. 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.

2. Pull the rubber microphone boot from its seated position. Unless you are replacing the

microphone, leave it in the boot.

Figure 3-7 Removing the Keypad Retainer, Display Module and Other Boards from the Radio Housing

NOTE

At this point, the Option Board Installation Procedure (Paragraph 7.0) should be performed,
if necessary.

NOTE

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.

Keypad

Radio Housing

Keypad/Option Board

Retainer

Display Module

Wire Assembly

Jumper Flex

Radio Disassembly Ñ Detailed 3-9

3. When reassembling the microphone in its boot, make sure the microphone port faces the

round hole in the bottom of the boot.

5.5 PTT Disassembly

1. If required, the PTT bezel, and the PTT seal assembly, can be disassembled using a small

screwdriver, as follows:

a. Insert the tip of a small screwdriver in between the bezel and side button 2

(refer to Figure 3-9).

b. Insert the tip of a small screwdriver in between side button 2 and PTT button

(refer to Figure 3-9).

c. Pry the PTT bezel away from the radio housing.

d. If required, the PTT seal can be easily lifted from the bezel without the use of tools.

Figure 3-8 Removal Speaker-Microphone Assembly

Figure 3-9 PTT Removal

Speaker Retainer

Speaker

Mic Boot

Radio Housing

Felt

Insulator

Wire Connector

Microphone

Flat Blade

Screwdriver

PTT Bezel

PTT Seal

Snaps

ÔTÕ Tab

3-10 MAINTENANCE

5.6 Control Top Disassembly

1. To remove the control top assembly, place a screwdriver next to the antenna boss, and pry it

against the top escutcheon. This will lift the top escutcheon away from the top of the front
housing.

2. Remove the control top seal and transmit light pipe.

6.0 Radio Reassembly Ñ Detailed

6.1 Control Top Reassembly

1. Replace transmit light pipe and control top seal.

2. Peel off the liners from a new top adhesive, and place it in the recess in the front cover. Press

the top escutcheon down uniformly.

6.2 PTT Reassembly

1. Put the PTT seal in the PTT bezel.

2. Place the bezel ÔTÕ tab in the ÔTÕ slot inside the front cover PTT opening. Slightly slide down

the bezel so that the two snaps can be aligned and inserted into the two rectangular slots.

3. Press the PTT assembly against the front cover opening.

6.3 Speaker Reassembly

1. Align the notch in the speaker at the six oÕclock position with the tab on the front cover.

2. Place the speaker retainer bracket into the hole on the top of the front cover, and bend the

retainer down to Þt underneath the boss below the speaker.

NOTE

Look inside the front cover to make sure the T-tab and snaps are fully engaged with the front
cover.

Radio Reassembly Ñ Detailed 3-11

6.4 Keypad Option Board, Microphone and Wire Reassembly

1. Replace the keypad/option board.

2. Insert the Òtop hooksÓ of the keypad retainer into the slots below the speaker (above the

display) in the front cover. Snap all four of the retainer arm tabs in place in the front cover.

3. Re-insert the microphone and boot into the pocket in the front cover.

4. Lay the speaker-microphone wire on top of the keypad/option board retainer, align them onto

the catches and close the catches.

6.5 Chassis Assembly Reassembly

1. Replace the O-ring. The tabs on the O-ring should reach around the chassis and point down.

2. Stretch the O-ring to place it into the retaining pocket at the bottom end of the chassis.

3. Replace the battery contact seal (if necessary) surrounding the battery contact.

4. Place the main circuit board straight down on top of the chassis.

5. Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis.

NOTE

Ensure the speaker-microphone wire is not damaged during reassembly.

Figure 3-10 Lock retainer catches to the radio housing

NOTE

When properly assembled, the retainers on the O-ring should align with the slots on the
chassis. If this is not the case, remove and replace the O-ring until it is aligned with the
chassis and completely seated in place around the perimeter.

NOTE

Be sure the battery contact seal protrudes through the chassis and is not pinched under the
chassis.

Retainer

Catches

Wire Assembly

3-12 MAINTENANCE

6.6 Chassis and Front Cover Reassembly

1. Align the chassis assembly end-to-end with the front cover assembly.

2. Insert the tails of the jumper ßex and wire assembly into their respective connectors at the

bottom of the front cover.

3. Push down the latches on the connectors to hold the ßex circuit to the main board.

4. Slide the volume potentiometer and frequency switch shafts into their respective holes in the

front cover.

5. Push the chassis assembly completely into the top of the front cover until it settles in place.

6. Be sure the O-ring is properly seated.

7. Snap the bottom of the chassis into the front cover.

8. Reassemble the knobs, dust cover, antenna, and battery.

7.0 Option Board Installation

1. With the keypad retainer removed, the keypad board can be removed without the use of tools.

2. Remove the jumper ßex from the connector on the keypad board. Notice the orientation of the

ßex to the connector. Arrows on the jumper ßex point to the correct way of inserting the ßex
into the connector.

3. Remove the keypad board.

Figure 3-11 Fastening the Chassis

Radio Chassis

Option Board Installation 3-13

4. Reassemble the option board to the front cover assembly.

5. Insert the display ßex circuit into the connector on the option board.

6. Insert the jumper ßex circuit into the connector on the option board. Notice the orientation of

the ßex circuit. Arrows on the jumper ßex point to the correct way of inserting the ßex into the
connector.

7. Replace the retainer by placing the two top hooks into the slots below the speaker in the front

cover; then, pivot the retainer into the front cover. Ensure that all four tab arms snap correctly
into the front cover.

8. With the keypad option board and retainer correctly in place, the front cover assembly can

now be reassembled as described in paragraph 6.6.

Figure 3-12 Changing the Keypad/Option Board

Jumper Flex

Retainer

Keypad/Option Board

Display
Module

Wire Assembly

3-14 MAINTENANCE

7.1 ConÞguring the Radio after Option Board Installation

1. Connect the radio to the computer following instructions outlined in Chapter 5.

2. Start up the CPS, and read the radioÕs codeplug.

3. Open the Radio ConÞguration dialog box, and proceed to the Option Board tab. From the

pull-down menu, choose the option board type that you just installed (choose Simple Decoder
for the DTMF option board).

4. Open the Personality dialog box. For every personality that you want the option board

features to be activated, click on the Option Board Feature check box of the Advanced tab.

Figure 3-13 Option Board tab of the Radio ConÞguration dialog box.

Figure 3-14 Advanced tab of the Personality dialog box.

Option Board Installation 3-15

7.2 Additional ConÞguration required by the DTMF Option Board

1. In the Tree View window of your CPS, expand the Signalling node. Also expand the DTMF

System node. Open each of the DTMF System dialog boxes under this node, and Þll in the
relevant information pertinent to your DTMF system.

Figure 3-15 DTMF System dialog box

3-16 MAINTENANCE

8.0 Mechanical View and Parts List

8.1 P Series Radio Exploded View and Parts List

Figure 3-16 P Series Radio Exploded View

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

26

27

28

29

30

31

32

33

34

36

37

38

39

35

25

Mechanical View and Parts List 3-17

* Not Þeld replaceable

Item

Motorola

Part

Number

Description

1 See Chapter 7 Antenna

2 3680529Z01 Knob, Volume

3 3680530Z02 Knob, Frequency

4 1385620Z01

1385620Z02

Escutcheon, Top (16 Ch.)
Escutcheon, Top (4 Ch.)

5 3385703Z01 Label, Escutcheon

6 3280722Z01 Seal, Control Shaft

7 6185621Z01 Lightpipe, Tx

8 3385629Z02

3385630Z01

Label, Name (P040)
Label, Name (P080)

9 3885617Z01 Cap, Dust

10 1385619Z01 Bezel, Side Control

11 7585618Z01 Keypad, Side Control

12 1585616Z01

1585616Z02

Housing, Front (P040)
Housing, Front (P080)

13 1380649Z03

* Escutcheon, FM

14 7585623Z01 Keypad, Front

15 0104009J11 Keypad Board Assembly

16 5104949J08 Display Module

17 4285609Z01 Retainer Plate

18 8480475Z02 Flex, Keypad/Controller

19 3585606Z02 Felt, Speaker

20 5085962A02 Speaker

21 1480577C01 Boot, Microphone

22 5013920A04 Microphone

23 8485687Z01 Flex, Microphone

24 2113740A55 Cap, 100pF

25 0980727Z01 Connector, Wire

26 4285601Z01 Retainer, Speaker

27 1480724Z01 Insulator, Speaker

28 3980667Z01 Contact Finger

29 1585608Z01 Shroud, Jack

30 0304726J04 Screw

31 0104008J60

0104008J90

Ctrl/RF Bd Assembly (VHF)
Ctrl/RF Bd Assembly (UHF)

32 7580556Z01 Pad, Thermal

33 3280534Z01 Seal, Contact

34 3380564Z01 Label, Warning

35 7585706Z01 Pad, Chassis

36 3280536Z01 Gasket, O-ring

37 2780518Z03 Chassis

38 See Chapter 7 Battery

39 HLN9714

HLN9844.

Beltclip, large (2in. wide belt)
Beltclip, medium (1,5in.belt)

Item

Motorola

Part

Number

Description

3-18 MAINTENANCE

9.0 Service Aids

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

Table 3-1 Service Aids

Motorola

Part No.

Description Application

RLN4460 Portable Test Set Enables connection to the audio/accessory jack.

Allows switching for radio testing.

RKN4075 Ribless Programming Cable Connects radio to Computer.

RKN4074 Programming Cable/Test Cable Connects radio to RIB (RLN4008).

RLN4008 Radio Interface Box (RIB) Enables communications between the radio and the

computerÕs serial communications adapter.

HLN9756 BNC Adaptor Adapts radioÕs antenna port to BNC cabling of test

equipment.

0180305G54
8180384F66

Shop Battery Eliminator
Bench Test Housing Eliminator

Interconnects radio to power supply. Provides for
troubleshooting of the radio when the housing is
removed.

RLN4510 Battery Eliminator 7.5V Interconnects radio to power supply.

EPN4040 Wall-Mounted Power Supply Used to supply power to the RIB (UK).

EPN4041 Wall-Mounted Power Supply Used to supply power to the RIB (Euro)

3080369B71
or
3080369B72

Computer Interface Cable Use B72 for the IBM PC AT. All other IBM models use

B71. Connects the computerÕs serial communications
adapter to the RIB. (RLN4008)

Test Equipment 3-19

10.0 Test Equipment

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

Table 3-2 Recommended Test Equipment

Motorola Part

No.

Description Characteristics Application

R2600CNT Comms System

Analyzer
(non MPT)

This monitor will
substitute for items with
an asterisk *

Frequency/deviation meter
and signal generator for
wide-range troubleshooting
and alignment

R2680ANT Comms System

Analyzer
(MPT1327) to be
ordered with
RLN1022A (H/W)
RLN1023A (S/W)

This monitor will
substitute for items with
an asterisk *

Frequency/deviation meter
and signal generator for
wide-range troubleshooting
and alignment

*R1072 Digital Multimeter AC/DC voltage and current

measurements

*R1377 AC Voltmeter 100 mV to 300 V,

5Hz-1MHz, 10 Megohm
input impedance

Audio voltage
measurements

WADN4133 Delay

Oscilloscope

2 Channel 40 MHz
bandwidth,
5 mV/cm - 20 V/cm

Waveform measurements

R1440A

0180305F14
0180305F30
0180305F39
RLN4610A

T1013

Wattmeter,

Plug-in Element
Plug-in Element
Plug-in Element
Carry case

RF Dummy Load

Thruline 50-Ohm, ±5%
accuracy
10W, 25 - 60 MHz
10W, 100 - 250 MHz
10W, 200 - 500 MHz
Wattmeter and
6 elements

Transmitter power output
measurements

S1339 RF Millivolt Meter 100mV to 3 VRF,

10 kHz to 1.2 GHz

RF level measurements

S1348 220V Power

Supply

20V 5A Programmable

3-20 MAINTENANCE

11.0 Programming/Test Cable

Figure 3-17 Programming/Test Cable

Figure 3-18 Wiring of the Connectors

25 POSITION

FEMALE CONNECTOR

25 POSITION

MALE CONNECTOR

1,000mm

CABLE

1,000mmÓ

CABLE

P1

P2 P3

P2

25 ways Female “D” Connector
Components molded inside

1
5

24
7

20
8
15
16
9

47

ohm

33K

+

1UF,16V 5%

Orange

Blue

White

Spiral

Yellow

P1

2.5mm stereo and

3.5mm
1

2

5

3
4

3.5mm Tip

(Speaker +)

3.5mm

Sleeve

2.5mm Tip

(Microphone)

2.5mm

2.5mm

Center

P3

25 ways Male “D”

1
15

4
11

1

2

3

4

5

3.5mm mono

2.5mm stereo

Programming/Test Cable 3-21

Figure 3-19 Front-end Filter Tuning Using 3rd Battery Contact

Figure 3-20 Battery Terminals

For front end
tuning use only

3-22 MAINTENANCE

Chapter 4

PERFORMANCE TESTING

1.0 Introduction

The radios have been prepared to meet published speciÞcations through their manufacturing
process, with the use of laboratory-quality test equipment of highest accuracy. The recommended
Þeld service equipment approaches the accuracy of the manufacturing equipment with a few
exceptions.

Accuracy of the equipment must be maintained in compliance with the manufacturerÕs
recommended calibration schedule.

2.0 Setup

Supply voltage can be connected from the battery eliminator. The equipment required for alignment
procedures is connected as shown in the Radio Alignment Test Setup diagram.

Initial equipment control settings should be as indicated in the following table and should hold for all
alignment procedures except as noted in Table 4-1.

Table 4-1 Initial Equipment Control Settings

Service Monitor Test Set Power Supply

Monitor Mode: Power Monitor Spkr set: A Voltage: 7.5Vdc

RF Attn: -70 Spkr/load:

Speaker

DC on/standby:
Standby

AM, CW, FM: FM PTT: OFF Volt Range: 10V

OÕscope Source: Mod
OÕscope Horiz: 10mSec/Div
OÕscope Vert: 2.5kHz/Div
OÕscope Trig: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: mid CW
Monitor Vol: 1/4 CW

Current: 2.5A

4-2 PERFORMANCE TESTING

3.0 Test Mode

3.1 RF Test Mode

When the radio is operating in its normal environment, the radioÕs microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting. However, when the unit is on the bench
for testing, alignment or repair, it is removed from its normal environment. It cannot receive
commands from its system and, therefore, the internal microcontroller will not key the transmitter nor
unmute the receiver. This prevents the use of normal tune-up procedures. To solve this problem a
special routine, called TEST MODE or Òair test,Ó has been incorporated in the radio.

To enter test mode:

■

■

Turn the radio on.

■

■

Within ten seconds after the self test is complete, press the side button 2, (SB2) Þve times in
succession.

■

■

After ÒCSQ XXÓ appears in the display, the radio is on channel XX, carrier squelch mode.

■

■

Pressing SB1 will scroll through and access test environments as shown in Table 4-2.

■

■

Pressing SB2 will scroll through the channel spacing available as shown in Table 4-3 and a
corresponding set of tones will be heard.

■

■

Pressing SB2 for 3 seconds will switch the radio to the Control Head Test mode. ÒLCDÓ
appears on the display.

■

■

Pressing SB1 will cause the radio to turn on all the segments of the Þrst character. Another
SB1 press will turn on all the segments of the next character and so on until the last character
(character 7).

■

■

Pressing SB1 at the end of the LCD test will activate the Icon Test. ÒICONÓ appears on the
display. The next SB1 press will turn on the Þrst icon.

■

■

Pressing SB1 at the end of the Icon test will activate the Button Test. ÒBUTTONÓ appears on
the display. Pressing any side button (except SB1) or any keypad button during the LCD test
of Icon test will immediately activate this test.

■

■

Pressing SB2 for 3 seconds in the Control Head Test mode will cause the radio to return to
the RF Test mode.

NOTE XX - channel number (01 - 14)

Table 4-2 Test Environments

Display

No. of
Beeps

Description Function

ÒCSQ XXÓ 1

GKC

Carrier Squelch RX: if carrier detected

TX: mic audio

ÒTPL XXÓ 1

BKC

Tone
Private-Line

RX: unsquelch if carrier and tone (192.8Hz) detected
TX: mic audio + tone (192.8Hz)

ÒDPL XXÓ 2

BKC

Digital
Private-Line

RX: unsquelch if carrier and digital code (131) detected
TX: mic audio + digital code (131)

Test Mode 4-3

ÒDTMF XXÓ 3

BKC

Dual-Tone
multiple
frequency

RX: unsquelch if carrier detected
TX: selected DTMF tone pair

ÒOPEN XXÓ 5

BKC

Unsquelch
Open

RX: constant unsquelch
TX: mic audio

ÒCMP XXÓ 11

BKC

CMP RX: if carrier detected

TX: mic audio

ÒLLE XXÓ 12

BKC

LLE RX: if carrier detected

TX: mic audio

Table 4-3 Test Channel Spacing

Display No. of BKC Channel Spacing

ÒSP 25Ó 1 25 kHz

ÒSP 12_5Ó 2 12.5 kHz

ÒSP 20Ó 3 20 kHz

Table 4-4 Test Frequencies

Channel

Selector Switch

Position

Test Channel VHF UHF

1 Low Power
8 High Power

TX#1 or #8
RX#1 or #8

136.025

136.025

403.025

403.025

2 Low Power
9 High Power

TX#2 or #9
RX#2 or #9

142.325

142.325

415.025

415.025

3 Low Power
10 High Power

TX#3 or #10
RX#3 or #10

148.625

148.625

425.025

425.025

4 Low Power
11 High Power

TX#4 or #11
RX#4 or #11

154.925

154.925

436.025

436.025

5 Low Power
12 High Power

TX#5 or #12
RX#5 or #12

161.225

161.225

449.025

449.025

6 Low Power
13 High Power

TX#6 or #13
RX#6 or #13

167.525

167.525

460.025

460.025

7 Low Power
14 High Power

TX#7 or #14
RX#7 or #14

173.825

173.825

469.975

469.975

Table 4-2 Test Environments

Display

No. of

Beeps

Description Function

4-4 PERFORMANCE TESTING

* See Table 4-4 Test Frequencies

Table 4-5 Receiver Performance Checks

Test Name

Communications

Analyzer

Radio Test Set Comments

Reference
Frequency

Mode: PWR MON
4th channel test frequency*
Monitor: Frequency error
Input at RF In/Out

TEST MODE,
Test
Channel 4
carrier
squelch
output at
antenna

PTT to
continuous
(during the
performance
check)

Frequency error to be
±200 Hz VHF
±600 Hz UHF

Rated Audio Mode: GEN

Output level: 1.0mV RF
4th channel test frequency*
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts

TEST MODE
Test
Channel 4
carrier
squelch

PTT to OFF
(center), meter
selector to
Audio PA

Set volume control to

3.16Vrms

Distortion As above, except to

distortion

As above As above Distortion <3.0%

Sensitivity
(SINAD)

As above, except SINAD,
lower the RF level for 12dB
SINAD.

As above PTT to OFF

(center)

RF input to be
<0.35mV

Noise
Squelch
Threshold
(only radios
with
conventional
system need
to be tested)

RF level set to 1mV RF As above PTT to OFF

(center), meter
selection to
Audio PA, spkr/
load to speaker

Set volume control to

3.16Vrms

As above, except change
frequency to a conventional
system. Raise RF level from
zero until radio unsquelches.

out of TEST
MODE;
select a
conventional
system

As above Unsquelch to occur at

<0.25mV.
Preferred SINAD =
9-10dB

Test Mode 4-5

* See Table 4-4 Test Frequencies

Table 4-6 Transmitter Performance Checks

Test Name

Communications

Analyzer

Radio Test Set Comments

Reference
Frequency

Mode: PWR MON
4th channel test frequency*
Monitor: Frequency error
Input at RF In/Out

TEST MODE,
Test
Channel 4
carrier
squelch
output at
antenna

PTT to
continuous
(during the
performance
check)

Frequency error to be
±200 Hz VHF
±600 Hz UHF

Power RF As above As above As above Refer to

Maintenance
SpeciÞcations

Voice
Modulation

Mode: PWR MON
4th channel test frequency*
atten to -70,
input to RF In/Out
Monitor: DVM, AC Volts
Set 1kHz Mod Out level for

0.025Vrms at test set,
80mVrms at AC/DC test set
jack

As above As above, meter

selector to mic

Deviation:
VHF, UHF
³ 4.0 kHz but £ 5.0
kHz (25 kHz Ch Sp).

Voice
Modulation
(internal)

Mode: PWR MON
4th channel test frequency*
atten to -70,
input to RF In/Out

TEST MODE,
Test
Channel 4
carrier
squelch
output at
antenna

Remove
modulation
input

Press PTT switch on
radio. Say ÒfourÓ
loudly into the radio
mic. Measure
deviation: VHF, UHF
³ 4.0 kHz but £ 5.0
kHz (25 kHz Ch Sp)

DTMF
Modulation

As above,
4th channel test frequency*

TEST MODE,
Test
Channel 4
DTMF output
at antenna

As above Deviation:

VHF, UHF ³ 3.05 kHz
but £ 3.45 kHz (25
kHz Ch Sp)

PL/DPL
Modulation

As above
4th channel test frequency*
BW to narrow

TEST MODE,
Test
Channel 4
TPL
DPL

As above Deviation:

VHF, UHF ³500Hz
but £ 1000Hz
(25 kHz Ch Sp).

4-6 PERFORMANCE TESTING

Chapter 5

RADIO TUNING AND PROGRAMMING

1.0 Introduction

This chapter provides an overview of the Customer Programming Software (CPS) and Tuner Software
which are designed for use in a Windows 95/98 environment. These programs are on the CD provided
with this manual. A Software Installation manual is also provided to guide through the installation
process.

Table 5-1 Software Installation and Radio Tuning Setup

2.0 Radio Tuning Setup

A personal computer (PC) using Windows 95/98 and a tuner program are required to tune the radio.
To perform the tuning procedures, the radio must be connected to the PC, radio interface box (RIB),
and test equipment shown in Figure 5-1.

Figure 5-1 Radio Tuning Test Equipment Setup

NOTE

Refer to the appropriate program on-line help Þles for the programming procedures.

Description Kit Number

Software CD

Customer Programmable Software
Tuner Software

ENLN4131_

ENVN4020_
ENVN4014_

Wattmeter

Audio Generator

Sinad Meter

AC Voltmeter

10 dB Pad

Battery Block

Power

Supply

Audio In

Tx

Rx

Receive

Transmit

RF Generator

RF Adaptor

RIB

RLN4008

RIB Power Supply

RLN4460

Test Box

Rx

Gnd

Data

Tx Data

Radio

Computer Interface
Cable 3080369B72

Program / Test Cable

PMKN4004

Service Monitor

or Counter

DB15 DB9

AC Plug

120/230 Vac

RLN4510

+12VDC

0180305H20

Battery
Eliminator

7.5V Reg.

HLN9756
3,5 mm to
Ferrule BNC

5-2 RADIO TUNING AND PROGRAMMING

2.1 Initial Test Equipment Setup

The supply voltage is connected to the radio using a Motorola battery eliminator, P/N 0180305H20.
The initial test equipment (Figure 5-1) control settings are listed in Table 5-2.

3.0 CPS Programming Setup

The CPS programming setup, shown in Figure 5-2, is used to program the radio codeplug.

Figure 5-2 CPS Programming Setup

NOTE

Refer to appropriate program on-line help Þles for the tuning procedures.

Table 5-2 Initial Equipment Control Settings

Service Monitor Test Set Power Supply

Monitor Mode: Power Monitor Speaker set: A Voltage: 7.5Vdc

RF Attenuation: -70 Speaker/load:

Speaker

DC on/standby:
Standby

AM, CW, FM: FM PTT: OFF Volt Range: 10V

Oscilloscope Source: Mod
Oscilloscope Horizontal: 10mSec/Div
Oscilloscope Vertical: 2.5kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: mid CW
Monitor Volume: 1/4 CW

Current: 2.5A

NOTE

Refer to appropriate program on-line help Þles for the codeplug programming procedures.

RIB

RLN4008

RIB Power Supply

RLN4460

Test Box

Rx

Gnd

Data

Tx Data

Radio

Battery

Computer Interface
Cable

Program/

PMKN4004

Test Cable

3080369B72

DB15

DB9

120/230 Vac

Power
Supply

RLN4510

+12VDC

Battery
Eliminator

7.5V Reg.

Block
0180305H20

Chapter 6

POWER UP SELF-TEST

1.0 Error Codes

Turning on the radio using the on/off volume control starts a self-test routine which checks the RAM,
ROM checksum, EEPROM hardware and EEPROM checksum. If these checks are successfully
completed, the radio will generate the Self-Test Pass Tone. If the self-test is not successful one of
the following error messages will be displayed and a 300 Hz tone is heard.

■

■

ÒRAM ERRÓ for <RAM Test Error>

■

■

ÒROM CSÓ for <ROM Checksum Error>

■

■

ÒEPM ERRÓ for <EEPROM Hardware Test Error>

■

■

ÒEPM CSÓ for <EEPROM Checksum Error>

NOTE A radio without a display emits only the 300 Hz tone if it fails the self-test.

Error Code Explanation Corrective Action

ÒRAM ERRÓ RAM Test Failure Retest radio by turning it off and turning it on again. If

message re-occurs, replace main board or send radio to
nearest Motorola Depot.

ÒROM CSÓ ROM Checksum is

wrong.

Reprogram FLASH Memory, then retest. If message
re-occurs, replace main board or send radio to nearest
Motorola Depot.

ÒEPM ERRÓ Codeplug structure

mismatch, non
existence of
codeplug.

Reprogram codeplug with correct version and retest radio. If
message re-occurs, replace main board or send radio to
nearest Motorola Depot.

ÒEPM CSÓ Codeplug

checksum is wrong.

Reprogram codeplug.

No Display Display module is

not connected
properly.
Display module is
damaged.

Check connection between main board and display module.

Replace with new display module.

300Hz Tone
(Radio without
display)

1. RAM Test Failure

2.Codeplug Check
sum is wrong.

3. ROM Checksum
is wrong

Retest radio by turning it off and turning it on again.

Reprogram Codeplug and retest.

Reprogram FLASH Memory, then retest.

If message re-occurs, replace main board or send the radio to
the nearest Motorola Depot.

6-2 POWER UP SELF-TEST

Chapter 7

MODEL CHARTS AND TECHNICAL SPECIFICATIONS

1.0 Model Chart (VHF)

P040 /P080 VHF (136 - 174 MHz)

Model Description

MDH34KDC9AA1AE P040 VHF 136 - 174 MHz 4W

MDH34KDH9AA6AE P080 VHF 136 - 174 MHz 4W

Item Description

X PMLD4167_ P040 Back Cover Kit

X PMLD4169_ P080 Back Cover Kit

X PMUD1623_ P040 Tanapa

X PMUD1626_ P080 Tanapa

X PMLN4351_ P040 Front Housing Kit

X PMLN4353_ P080 Front Housing Kit

X 6864110B67 P040 Basic User Guide

X 6864110B68 P080 Basic User Guide

X X PMAD4023_ VHF 150-161 MHz Antenna

X X PMNN4018_ Battery, NiMH Standard

x = Indicates one of each is required.

7-2 MODEL CHARTS AND TECHNICAL SPECIFICATIONS

2.0 Model Chart (UHF)

P040 / P080 UHF (403 - 470 MHz)

Model Description

MDH34RDC9AA1AE P040 UHF 403-470MHz 4W

MDH34RDH9AA6AE P080 UHF 403-470MHz 4W

Item Description

X PMLE4182_ P040 UHF Back Cover Kit

X PMLE4184_ P080 UHF Back Cover Kit

X PMUE1626_ P040 Tanapa

X PMUE1629_ P080 Tanapa

X PMLN4351_ P040 Front Housing Kit

X PMLN4353_ P080 Front Housing Kit

X 6864110B67 P040 Basic User Guide

X 6864110B68 P080 Basic User Guide

X X NAE6483_ UHF Whip (403-470 MHz) Antenna

X X PMNN4018_ Battery, NiMH Standard

x = Indicates one of each is required.

Model Chart (UHF2) 7-3

3.0 Model Chart (UHF2)

P040 / P080 UHF2 (450 - 527 MHz)

Model Description

MDH34SDC9AA1AE P040 UHF2 450-527MHz 4W

MDH34SDH9AA6AE P080 UHF2 450-527MHz 4W

Item Description

X PMLE4185_ P040 Back Cover Kit

X PMLE4187_ P080 Back Cover Kit

X PMUE1630_ P040 Tanapa

X PMUE1632_ P080 Tanapa

X PMLN4351_ P040 Front Housing Kit

X PMLN4353_ P080 Front Housing Kit

X 6864110B67 P040 Basic User Guide

X 6864110B68 P080 Basic User Guide

X X PMAE4008_ UHF 14cm (465-527MHz) Antenna

X X PMNN4018_ Battery, NiMH Standard

x = Indicates one of each is required.

7-4 MODEL CHARTS AND TECHNICAL SPECIFICATIONS

4.0 Technical SpeciÞcations

Data is speciÞed for +25¡C unless otherwise stated.

General SpeciÞcations VHF/UHF/UHF2

Channel Capacity

P040
P080

4
16

Power Supply 7.5v ± 20%

Dimensions: H x W x D (mm)

With standard high capacity NiMH battery
With NiCD battery

137 x 57.5 x 37.5
137 x 57.5 x 40

Weight: (gm)

With Standard high capacity NiMH battery
With NiCD battery

429
454

Average Battery Life @5/5/90 Duty Cycle:

With Standard high capacity NiMH battery
With NiCD battery

Low Power High Power
10 hours 8 hours

10 hours 8 hours

Sealing: Withstands rain testing per

MIL STD 810 C/D /E and IP54

Shock and Vibration: Protection provided via impact

resistant housing exceeding MIL STD
810-C/D /E and TIA/EIA 603

Dust and Humidity: Protection provided via environment

resistant housing exceeding MIL STD
810 C/D /E and TIA/EIA 603

Technical Specifications 7-5

Transmitter

*Frequencies - Full Bandsplit

VHF 136 - 174 MHz
UHF1 403 - 470MHz
UHF2 450 - 527MHz

Channel Spacing 12.5/20/25 kHz

Frequency Stability
(-30¡C to +60¡C) (+25¡C reference)

0.00025%

Powe r
(NiMH @ 7.5V)

Low High

1W 5W

Modulation Limiting

±2.5 @12.5kHz

±4.0 @20kHz
±5.0 @25kHz

FM Hum & Noise -40 dB typical

Conducted/Radiated Emission -66 dBw

Audio Response: (From 6dB/Octave
pre-emphasis, 300 - 3000 Hz)

+1 to -3 dB

Audio Distortion:
@ 1000 Hz, 60% Rated Maximum Dev.

3% typical

7-6 MODEL CHARTS AND TECHNICAL SPECIFICATIONS

*Availability subject to the laws and regulations of individual countries.

All speciÞcations shown are typical. Radios meet applicable regulatory requirements.

Receiver

*Frequencies - Full Bandsplit

VHF 136 - 174 MHz
UHF1 403 - 470MHz
UHF2 450 - 527MHz

Frequency Stability
(-30¡C to +60¡C) (+25¡C reference)

0.00025%

Sensitivity (12 dB SINAD) EIA 0.25 µV

Intermodulation EIA 70 dB

Adjacent Channel Selectivity

60 dB @ 12.5 kHz

70 dB @ 20/25 kHz

Spurious Rejection -70 dB

Rated Audio 0.5W

Audio Distortion @ Rated Audio 3%

Hum and Noise

-45dB@ 12.5kHz

-50dB@25kHz

Audio Response (300-3000Hz) +1 to -3dB

Conducted Spurious Emission

-57dBm<1GHz

-47dBm>1GHz