Motorola Astro Digitalport Saber Basic 68p81076c05 Manual

							ASTRO Digital SABER 
						

							FOREWORD
The information contained in this manual relates to all ASTRO Digital SABER radios, unless otherwise
specified.
SAFETY INFORMATION
The Federal Communications Commission (FCC), with its action in General Docket 79-144, March 13, 1985,
has adopted a safety standard for human exposure to radio frequency (RF) electromagnetic energy emitted by
FCC-regulated equipment. Motorola subscribes to the same safety standard for the use of its products. Proper
operation of this radio will result in user exposure substantially below FCC recommended limits.
¥ DO NOT hold the radio with the antenna very close to, or touching, exposed parts of the body, especially the
face, ears, or eyes, while transmitting. Hold the radio in a vertical position with the microphone two to three
inches away from the lips.
¥ DO NOT hold the transmit switch (PTT) on when not actually desiring to transmit.
¥ DO NOT allow children to play with any radio equipment containing a transmitter.
¥DO NOToperate this equipment near electrical blasting caps or in an explosive
atmosphere. Under certain conditions, radios can interfere with blasting operations.
When you are in the vicinity of construction work, look for, and observe, signs cautioning
against radio transmissions. If radio transmission is prohibited, you must not transmit until
out of the area. Furthermore, 
you must turn offyour radio to prevent any accidental
transmission.
¥DO NOTreplace or charge batteries in a hazardous atmosphere. Contact sparking may
occur while installing or removing batteries and cause an explosion.
¥TURN THE RADIO OFFwhen removing or installing a battery.
Anyone intending to use a radio in a hazardous area is advised to become familiar with the subject of intrinsic
safety and with Section 70 of the National Fire Code, which is commonly referred to as Article 500 of the National
Electric Code. Use of anything but factory supplied components may affect the approval and safety of the radio.
Likewise, it is advised that servicing should be performed only by qualified personnel who adhere to the following
Factory Mutual (FM) required warning:
MANUAL REVISIONS
Changes which occur after this manual is printed are described in ÒFMRs.Ó These FMRs provide complete
information on changes including pertinent parts listing data.
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.
MAEPF-1781MAEPF-17813-A
WARNING 
Modification of FM approved intrinsically safe radios will negate Factory Mutual Research
Corporation (FMRC) approval. 
						

							Basic Service Manual
68P81076C05-O
CONTENTS
© 1993 by Motorola, Inc., Radio Products Group
8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322
Printed in U.S.A. 5/93. All Rights Reserved.
, Motorola, ASTRO, SABER, FLASHport, SMARTNET, Stat-Alert, SABER SI, CoveragePLUS, Private-Line, 
and Digital Private Line are trademarks of Motorola, Inc.
TITLEPAGE
FOREWORD...................................................................................................................................................inside front cover
LIST OF TABLES .....................................................................................................................................................................ii
LIST OF ILLUSTRATIONS .......................................................................................................................................................ii
RELATED PUBLICATIONS AVAILABLE SEPARATELY .........................................................................................................ii
PORTABLE RADIO MODEL NUMBERING SYSTEM .............................................................................................................iii
SPECIFICATIONS FOR VHF RADIOS ...................................................................................................................................iv
SPECIFICATIONS FOR UHF RADIOS ....................................................................................................................................v
SPECIFICATIONS FOR 800MHz RADIOS .............................................................................................................................vi
SECTION I. INTRODUCTION
A. General ...........................................................................................................................................................1
B. Radio Description............................................................................................................................................1
C. ...............................................................................................................................................1
SECTION II. BASIC MAINTENANCE
A. Introduction to This Section ............................................................................................................................3
B. Preventive Maintenance .................................................................................................................................3
C. Handling Precautions ......................................................................................................................................3
SECTION III. RECOMMENDED TEST EQUIPMENT, 
SERVICE AIDS, AND TOOLS
A. Recommended Test Equipment .....................................................................................................................5
B. Service Aids and Recommended Tools ..........................................................................................................6
C. Field Programming Equipment .......................................................................................................................6
SECTION IV. PERFORMANCE CHECKS
A. Introduction to This Section ............................................................................................................................7
B. Setup...............................................................................................................................................................7
C. Test Mode .......................................................................................................................................................7
SECTION V. RADIO ALIGNMENT PROCEDURE
A. Introduction to This Section ..........................................................................................................................11
B. General .........................................................................................................................................................11
C. Reference Oscillator Alignment ....................................................................................................................13
D. Transmit Power Alignment ............................................................................................................................14
E. Transmit Deviation Balance (Compensation) Alignment ..............................................................................15
F. Transmit Deviation Limit Alignment ..............................................................................................................16
G. Front-End Filter Alignment (VHF/UHF Only).................................................................................................17
SECTION VI. DISASSEMBLY/REASSEMBLY PROCEDURES
A. Disassembly..................................................................................................................................................19
B. Servicing Major Subassemblies ....................................................................................................................21
C. Reassembly ..................................................................................................................................................22
ªDigital SABERª
Portable Radios
TM
TM 
						

							RELATED PUBLICATIONS AVAILABLE SEPARATELY
ASTRO Digital SABER UserÕs Guide ..........................................................................................................................68P81072C80
ASTRO Digital SABER Portable Radios Detailed Service Manual .............................................................................68P81076C10
TABLE TITLEPAGE
FIGURE TITLEPAGE
TYPE OF MANUALMANUAL NUMBER
LIST OF TABLES
LIST OF ILLUSTRATIONS
1 Radio Alignment Test Setup ................................................................................................................................11
2 RSS Service Menu Layout ...................................................................................................................................12
3 Softpot Concept ...................................................................................................................................................12
4 Reference Oscillator Alignment Screen ............................................................................................................13
5 Transmit Power Alignment Screen ...................................................................................................................14
6 Transmit Deviation Balance (Compensation) Alignment Screen ......................................................................15
7 Transmit Deviation Limit Alignment Screen ......................................................................................................16
8 Front-End Filter Alignment Screen ...................................................................................................................17
9 Functional Block Diagram .................................................................................................................................29
10 Connector Location Details...............................................................................................................................30
11 Control Top/PTT Flex and Connector Information ............................................................................................31
12 Display Flex and Connector Information...........................................................................................................31
13 Speaker/Microphone Flex and Connector Information .....................................................................................32
14 Universal Flex and Connector Information .......................................................................................................32
15 Controller Board/RF Board Connector Information...........................................................................................33
16 Controller Board/Encryption Board Connector Information ..............................................................................33
17 Exploded View Diagram and Parts List ............................................................................................................34
SECTION VII. BASIC THEORY OF OPERATION
A. Introduction to This Section ..........................................................................................................................23
B. General Overview .........................................................................................................................................23
C. Analog Mode of Operation ............................................................................................................................23
D. ASTRO Mode of Operation ...........................................................................................................................23
E. RF Board Basic Theory of Operation ............................................................................................................23
F. Controller Board Basic Theory of Operation .................................................................................................24
SECTION VIII. BOARD-LEVEL TROUBLESHOOTING
A. Introduction to This Section ..........................................................................................................................25
B. Replacement Board Procedures ...................................................................................................................25
C. Power-Up Error Codes..................................................................................................................................25
D. Operational Error Codes ...............................................................................................................................26
REPLACEMENT PARTS ORDERING ...........................................................................................................
inside back cover
CONTENTS (cont.)
TITLEPAGE
ii
1 ASTRO Digital SABER Basic Features..................................................................................................................1
2 Recommended Test Equipment.............................................................................................................................5
3 Service Aids for Board-Level Troubleshooting .......................................................................................................6
4 Recommended Tools for Board-Level Troubleshooting.........................................................................................6
5 Initial Equipment Control Settings ..........................................................................................................................7
6 Test Environments .................................................................................................................................................7
7 Test Frequencies ...................................................................................................................................................8
8 Receiver Performance Checks ..............................................................................................................................9
9 Transmitter Performance Checks ........................................................................................................................10
10 Reference Oscillator Alignment............................................................................................................................13
11 Transmit Power Setting ........................................................................................................................................14
12 Transmit Deviation Limit.......................................................................................................................................16
13 Torque Specifications...........................................................................................................................................22
14 Local Oscillator and First IF Frequencies.............................................................................................................24
15 Power-Up Error Code Displays ............................................................................................................................25
16 Operational Error Code Displays .........................................................................................................................26
17 Receiver Troubleshooting Chart ..........................................................................................................................26
18 Transmitter Troubleshooting Chart ......................................................................................................................27 
						

							iii
Typical Model Number:H04 U C F 9 P W 7 A N S P 0 1
Position:1 2 3 4 5 6 7 8 9 10 11 1213 141516
Position 1 - Type of Unit
H=Hand-Held Portable
Positions 2 & 3 - Model Series
04=ASTRO
Position 4 - Frequency Band
A=Less than 29.7MHz P=336 to 410MHz
B=29.7 to 35.99MHz Q=403 to 437MHz
C=36 to 41.99MHz R=438 to 482MHz
D=42 to 50MHz S=470 to 520MHz
F=66 to 80MHz T=Product Specific
G=74 to 90MHz U=806 to 870MHz
H=Product Specific V=825 to 870MHz
J=136 to162MHz W=896 to 941MHz
K=146 to178MHz Y=1.0 to 1.6GHz
L=174 to 210MHz Z=1.5 to 2.0GHz
M=190 to 235MHz
* Values given represent range only; they are
not absolute.
Position 5 - Power Level
A=0 to 0.7 Watts
B=0.7 to 0.9 Watts
C=1.0 to 3.9 Watts
D=4.0 to 5.0 Watts
E=5.1 to 6.0 Watts
F=6.1 to 10 Watts
Position 6 - Physical Packages
A=RF Modem Operation
B=Receiver Only
C=Standard Control; No Display
D=Standard Control; With Display
E=Limited Keypad; No Display
F=Limited Keypad; With Display
G=Full Keypad; No Display
H=Full Keypad; With Display
J=Limited Controls; No Display
K=Limited Controls; Basic Display
L=Limited Controls; Limited Display
M=Rotary Controls; Standard Display
N=Enhanced Controls; Enhanced Display
P=Low Profile; No Display
Q=Low Profile; Basic Display
R=Low Profile; Basic Display, Full Keypad
Position 7 - Channel Spacing
1=5kHz 5=15kHz
2=6.25kHz 6=20/25kHz
3=10kHz 7=30kHz
4=12.5kHz 9=Variable/Programmable
Position 8 - Primary Operation
A=Conventional/Simplex
B=Conventional/Duplex
C=Trunked Twin Type
D=Dual Mode Trunked
E=Dual Mode Trunked/Duplex
F=Trunked Type I
G=Trunked Type II
H=FDMA* Digital Dual Mode
J=TDMA** Digital Dual Mode
K=Single Sideband
L=Global Positioning Satellite Capable
M=Amplitude Companded Sideband (ACSB)
P=Programmable
* FDMA=Frequency Division Multiple Access
**TDMA=Time Division Multiple Access
Position 9 - Primary System Type
A=Conventional
B=Privacy Plus¨
C=Clear SMARTNETª
D=Advanced Conventional Stat-Alertª
E=Enhanced Privacy Plus¨
F=Nauganet 888 Series
G=Japan Specialized Mobile Radio (JSMR)
H=Multi-Channel Access (MCA)
J=CoveragePLUSª
K=MPT1327*-Public
L=MPT1327*-Private
M=Radiocom
N=Tone Signalling
P=Binary Signalling
Q=Phonenet¨
W=Programmable
X=Secure Conventional
Y=Secure SMARTNETª
* MPT=Ministry of Posts and Telecommunications
Position 10 - Feature Level
1=Basic 6=Standard Plus
2=Limited Package 7=Expanded Package
3=Limited Plus 8=Expanded Plus
4=Intermediate 9=Full Feature/
5=Standard Package Programmable
Position 11 - Version
Version Letter (Alpha)-Major Change
Position 12 - 
Unique Model Variations
C=Cenelec
N=Standard Package
Positions 13 - 16
ÒSPÓ Model Suffix 
PORTABLE RADIO MODEL NUMBERING SYSTEM 
						

							SPECIFICATIONS FOR VHF RADIOS
All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.
RF Power: 
136-174MHz1Watt/5 Watts
174-178MHz1Watt/4 Watts
Frequency Range:136Ð178MHz
 
Frequency Stability
(Ð30 to +60¡C;  25¡C ref.):± .00025%
Emission (Conducted and Radiated):Ð66dBw
FM Hum and Noise
(Companion Receiver):Ð45dB Typical
Distortion:3% Typical
Modulation Limiting:±5kHz
Emissions Designators:
20K0F1E, 16K0F3E, 15K0F2D, 
15K0F1D, and 8K10F1E Frequency Range:136Ð178MHz
Bandwidth:42MHz
Quieting Sensitivity (20dBQ):0.5µV Max.
Usable Sensitivity
(12dB SINAD):0.35µV Max.
Intermodulation:Ð70dB
Selectivity
(30kHz Adjacent Channel):Ð70dB
Spurious Rejection:Ð70dB 
Frequency Stability
(Ð30  to +60¡C; 25¡C reference):± .00025%
Rated Audio:500mW
Distortion (At Rated Audio):3% Typical
Channel Spacing:30kHz
GENERAL RECEIVER TRANSMITTER
Specifications subject to change without notice.
FCC Designation:    AZ489FT3770
Temperature Range:
Operating:Ð30¡C to +60¡C
Storage:Ð40¡C to +85¡C
Power Supply: Nickel-Cadmium Battery (NiCd)
or  Nickel-Metal-Hydride Battery (NiMH)
Battery Voltage:
Nominal:7.5 Volts
Range:6 to 9 Volts
Recommended Battery:
Medium Capacity NiCd:NTN4593**
orUltraÐHigh Capacity NiCd:NTN4595**
orMedium Capacity NiMH:NTN7014
orHigh Capacity NiMH:NTN7251
Optional FM (Factory Mutual) Battery :
High Capacity FM:NTN4538*/**
orUltra-High Capacity FM:NTN4596*/**
* FM Intrinsically Safe: Class I, II, III, Division 1, 
Groups D, F, and G
** FM Nonincendive: Class I, Division 2, 
Groups A, B, C, and D
Dimensions (H x W x D)
Note: 2.64 = width at PTT; 2.94 = width at top
Less Battery:
5.20 x 2.64/2.94x 1.23
(131.32mm x 67.05/74.67mm x 31.24mm)
With  Medium Capacity NiCd Battery:    
8.34 x 2.94 x 1.28
(211.82mm x 74.67mm x 31.24mm)
With Ultra-High Capacity NiCd Battery:
9.10 x 2.94 x 1.23
(231.12mm x 74.67mm x 31.24mm)
With High Capacity NiMH Battery:
8.34 x 2.94 x 1.23
(211.82mm x 74.67mm x 31.24mm)
Weight:  (w/Helical Antenna)
Less Battery:12.8oz. (366gm)
With  Medium Cap. NiCd :26.81oz. (759gm)
With Ultra-High Cap. NiCd:29.95oz. (849gm)
With High Cap. NiMH:26.3oz. (746gm)
iv 
						

							SPECIFICATIONS FOR UHF RADIOS
All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.
RF Power:
450-512MHz1Watt/4 Watts
512-520MHz1Watt/3 Watts
Frequency Range:450-520MHz
 
Frequency Stability
(Ð30 to +60¡C;  25¡C ref.):± .00025%
Emission (Conducted and Radiated):Ð66dBw
FM Hum and Noise
(Companion Receiver):Ð45dB Typical
Distortion:3% Typical
Modulation Limiting:±5kHz
Emissions Designators:
20K0F1E, 16K0F3E, 15K0F2D, 
15K0F1D, and 8K10F1E Frequency Range:403-520MHz
Bandwidth:70MHz Max.
Quieting Sensitivity (20dBQ):0.5µV Max.
Usable Sensitivity
(12dB SINAD):0.35µV Max.
Intermodulation:Ð70dB
Selectivity
(25kHz Adjacent Channel):Ð70dB 
Spurious Rejection:
450-512MHzÐ70dB 
512-520MHzÐ65dB 
Frequency Stability
(Ð30  to +60¡C; 25¡C reference):± .00025%
Rated Audio:500mW
Distortion (At Rated Audio):3% Typical
Channel Spacing:25kHz FCC Designation:    AZ489FT4783
Temperature Range:
Operating:Ð30¡C to +60¡C
Storage:Ð40¡C to +85¡C
Power Supply: Nickel-Cadmium Battery (NiCd)or  Nickel-Metal-Hydride Battery (NiMH)
Battery Voltage:
Nominal:7.5 Volts
Range:6 to 9 Volts
Recommended Battery:
Medium Capacity NiCd:NTN4593**
orUltraÐHigh Capacity NiCd:NTN4595**
orMedium Capacity NiMH:NTN7014
orHigh Capacity NiMH:NTN7251
Optional FM (Factory Mutual) Battery :
High Capacity FM:NTN4538*/**
orUltra-High Capacity FM:NTN4596*/**
* FM Intrinsically Safe: Class I, II, III, Division 1, 
Groups D, F, and G
** FM Nonincendive: Class I, Division 2, 
Groups A, B, C, and D
Dimensions (H x W x D)
Note: 2.64 = width at PTT; 2.94 = width at top
Less Battery:
5.20 x 2.64/2.94x 1.23
(131.32mm x 67.05/74.67mm x 31.24mm)
With  Medium Capacity NiCd Battery:    
8.34 x 2.94 x 1.28
(211.82mm x 74.67mm x 31.24mm)
With Ultra-High Capacity NiCd Battery:
9.10 x 2.94 x 1.23
(231.12mm x 74.67mm x 31.24mm)
With High Capacity NiMH Battery:
8.34 x 2.94 x 1.23
(211.82mm x 74.67mm x 31.24mm)
Weight:  (w/Helical Antenna)
Less Battery:12.8oz. (366gm)
With  Medium Cap. NiCd :26.81oz. (759gm)
With Ultra-High Cap. NiCd:29.95oz. (849gm)
With High Cap. NiMH:26.3oz. (746gm)
GENERAL RECEIVER TRANSMITTER
Specifications subject to change without notice.
v 
						

							SPECIFICATIONS FOR 800MHz RADIOS
All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.
RF Power: 3 Watts
Frequency Range:806Ð825MHz
851Ð870MHz
Frequency Stability
(Ð30 to +60¡C;  25¡C ref.):± .00015%
Emission (Conducted and Radiated):Ð46dBw
FM Hum and Noise
(Companion Receiver):Ð40dB
Distortion:3% Typical
Modulation Limiting:±5kHz
(821-824MHz):±4kHz
Emissions Designators:
20K0F1E, 16K0F3E, 15K0F2D, 
15K0F1D, and 8K10F1E Frequency Range:851Ð870MHz
Bandwidth:19MHz
Quieting Sensitivity (20dBQ):0.5µV Max.
Usable Sensitivity
(12dB SINAD):0.35µV Max.
Intermodulation:Ð70dB 
Selectivity
(25kHz Adjacent Channel):Ð70dB 
Spurious Rejection:Ð70dB 
Frequency Stability
(Ð30+60¡C; 25¡C reference):±.00015%
Rated Audio:500mW
Distortion (At Rated Audio):3% Typical
Channel Spacing:25kHz FCC Designation:    AZ489FT5750
Temperature Range:
Operating:Ð30¡C to +60¡C
Storage:Ð40¡C to +85¡C
Power Supply: Nickel-Cadmium Battery (NiCd)
or  Nickel-Metal-Hydride Battery (NiMH)
Battery Voltage:
Nominal:7.5 Volts
Range:6 to 9 Volts
Recommended Battery:
Medium Capacity NiCd:NTN4593**
orUltraÐHigh Capacity NiCd:NTN4595**
orMedium Capacity NiMH:NTN7014
orHigh Capacity NiMH:NTN7251
Optional FM (Factory Mutual) Battery:
High Capacity FM:NTN4538*/**
orUltra-High Capacity FM:NTN4596*/**
* FM Intrinsically Safe: Class I, II, III, Division 1, 
Groups D, F, and G
** FM Nonincendive: Class I, Division 2, 
Groups A, B, C, and D
Dimensions (H x W x D)
Note: 2.64 = width at PTT; 2.94 = width at top
Less Battery:
5.20 x 2.64/2.94x 1.23
(131.32mm x 67.05/74.67mm x 31.24mm)
With  Medium Capacity NiCd Battery:    
8.34 x 2.94 x 1.28
(211.82mm x 74.67mm x 31.24mm)
With Ultra-High Capacity NiCd Battery:
9.10 x 2.94 x 1.23
(231.12mm x 74.67mm x 31.24mm)
With High Capacity NiMH Battery:
8.34 x 2.94 x 1.23
(211.82mm x 74.67mm x 31.24mm)
Weight:  (w/Helical Antenna)
Less Battery:12.8oz. (366gm)
With  Medium Cap. NiCd :26.81oz. (759gm)
With Ultra-High Cap. NiCd:29.95oz. (849gm)
With High Cap. NiMH:26.3oz. (746gm)
GENERAL RECEIVER TRANSMITTER
Specifications subject to change without notice.
vi 
						

							A. General
This manual includes all the information necessary
to maintain peak product performance and maximum
working-time using the board-replacement service
approach. This basic level of service (board-level) is
typical of some local service centers, self-maintained
customers, and some distributors. Included in this
manual are: radio specifications for each frequency
band; a general description of ASTROª Digital
SABERª models; basic theory of operation; recom-
mended test equipment, service aids, and tools; radio
alignment procedures; fundamental disassembly/
reassembly procedures; general maintenance recom-
mendations; board-level troubleshooting information;
functional block diagram, connector information; and
an exploded view diagram with parts list of the ASTRO
Digital SABER portable radio. For details on the oper-
ation of the radio or component-level troubleshooting,
refer to the applicable manuals available separately.
To help you with your selection, a list is provided in
this manual, titled ÒRelated Publications Available
Separately.Ó
Throughout the text in this publication, you will
notice the use of warnings, cautions, and notes. These
notations are used to emphasize that safety hazards
exist, and care must be taken and observed.
NOTE
An operational procedure, practice, or condition,
etc., which is essential to emphasize.
B. Radio Description
The ASTRO Digital SABER radios are among the
most sophisticated two-way radios available. They are
available on VHF, UHF, and 800MHz bands.
One of the newest in a long line of quality 
Motorola products, the ASTRO Digital SABER radio
provides improved voice quality across more coverage
area. The digital process called Òembedded signallingÓ
intermixes system signalling information with digital
voice, resulting in improved system reliability and the
capability of supporting a multitude of advanced fea-
tures. Such features add up to better, more
cost-effective two-way radio communications.
ASTRO Digital SABER radios are available in
three basic models. Table 1 provides a description of
their basic features.
C.
The ASTRO Digital SABER radio utilizes 
MotorolaÕs revolutionary FLASHport technology.
FLASHport makes it possible to add software that
drives the radioÕs capabilities both at the time of pur-
chase and later on. Previously, changing a radioÕs
features and capabilities meant significant modifica-
tions, or buying a new radio. But now, similar to how a
computer can be loaded with different software, the
radioÕs features and capabilities can be upgraded with
FLASHport software.
1
SECTION I.  INTRODUCTION
Displaynone 2 lines/ 2 lines/
14 characters 14 characters
per line LCD per line LCD
Keypadnone 3 x 2 button 3 x 6 button
Channel Capability16/32 255 255
Dialing Fromnot available available available
Prestored List
Programmablenot available available available
Soft Keys
Feature Model I Model II Model III
Table 1. ASTRO Digital SABER Basic Features
WARNING
An operational procedure, practice, or condi-
tion, etc., which may result in injury or death
if not carefully observed.
CAUTION
An operational procedure, practice, or condition,
etc., which may result in damage to the equip-
ment if not carefully observed.
TM 
						

							2
NOTES