Motorola Bpr40 Magone 6816986h01 B Manual

							Mechanical View and Parts List2-13
8.0 Mechanical View and Parts List
8.1 Exploded View and Parts List
Figure 2-14 Exploded View
Table 2-1 Parts List
Reference 
NoPart NoPart NameQty
1§PMDN4001_RFront Housing 1
2§Lightpipe1
3PMDN4002_RMag One By Motorola Nameplate1
4PMDN4005_RBPR 40 Nameplate1
5PMDN4008_RPTT Escutcheon 1
6PMDN4007_RPTT Rubber1
14 3 2 6 57
21 23221413
15
16
1289 1110
43
41171819
20
30
29 48
4549
50
34
3332
28
3837
31
51
36 46
7
4
27 53
44 39
40 35
25 24
26
42
52 
						

							2-14Mechanical View and Parts List
7PMDN4010_RPTT Bezel1
8§PMDN4011_RSpeaker & Cable (non-EPP) 1
PMDN4067_RSpeaker & Cable (EPP) 1
9§PMDN4012_RSpeaker Bracket1
10§Speaker Bracket Screw1
11§PMDN4013_RSpeaker Poron Pad1
12§PMDN4046_RSp ea ke r F elt1
13PMDN4014_RVo l u m e  K n o b1
14Volume Knob D-Clip (D: 6.0)1
15PMDN4015_RChannel Knob1
16Channel Knob D-Clip (D: 3.5)1
17PMDN4016_RVolume Potentiometer1
18Crab-Eye Knob Nut1
19PMDN4017_RChannel Potentiometer1
20Crab-Eye Knob Nut1
21PMDN4018_RChannel & Volume Top Seal1
22PMDN4021_RTop Escutcheon 8 Channels1
PMDN4020_RTop Escutcheon 16 Channels1
23Top Adhesive1
24PMDN4022_RBattery Latch1
25Battery Latch Shaft1
26Battery Latch Tape1
27PMDD4001_R*150 – 174 MHz 5W PC Board (non-EPP) 1
PMDD4005_R†150 – 174 MHz 5W PC Board (EPP) 1
PMDE4001_R*450 – 470 MHz 4W PC Board (non-EPP) 1
PMDE4005_R†450 – 470 MHz 4W PC Board (EPP) 1
28PMDN4068_RRadio Chassis (EPP) 1
PMDN4024_RRadio Chassis (non-EPP) 1
29Thermal Pad1
30PTT Insulation Tape1
31Insulation Tape2
32PMDN4028_RTuning Hole Sticker (Small)2
Table 2-1 Parts List
Reference 
NoPart No Part Name Qty 
						

							Mechanical View and Parts List2-15
33PMDN4029_RTuning Hole Sticker (Big)2
34PMDN4047_RMotorola Caution Label1
35PMDN4030_RDust Cover1
36PMDN4031_RAudio Jack1
37Audio Bracket1
38PMDN4032_RAudio Jack Seal1
39PMDN4033_RMicrophone1
40Microphone Boot1
41PMDN4034_RAntenna Bracket1
42PMDN4035_RPTT Tact Switch1
43PMDN4056_RProgramming Button Tact Switch2
44PMDN4036_RSpeaker Connector1
45PMDN4037_RPogo Pin Seal1
46Pogo Pin Housing1
47Pogo Pin2
48PMAD4051_RMag One™ 150-174MHz Antenna 1
PMAE4020_RMag One™ 450-470MHz Antenna 1
49PMLN4743_Mag One™ Spring Belt Clip1
50PMNN4071_RMag One™ NiMH Battery 1200mAh1
PMNN4075_RMag One™ LiIon Battery 1500mAh1
51PMDN4058_R PCB-Chassis Tape for PMUD2086A_, 
PMUE2385A_1
PCB-Chassis Tape for PMUD2086B_2
PCB-Chassis Tape for PMUE2385B_3
52PMDN4025_RO-Ring1
53PMDN4027_RPCB Screw11
§Items are also available as PMDN4051_R.
*Non-EPP compliant boards must be used with PMDN4011_R and PMDN4024_R.
†EPP compliant boards must be used with PMDN4067_R and PMDN4068_R. 
Table 2-1 Parts List
Reference 
NoPart No Part Name Qty 
						

							2-16Service Aid
9.0 Service Aid
Table 2-2 lists service aids recommended for working on the Mag One by Motorola Radios. While all 
of these items are available from Motorola, most are standard shop equipment items, and any 
equivalent item capable of the same performance may be substituted for the item listed. 
Table 2-2   Service Aids
Motorola Part 
No.DescriptionApplication
PMDN4038_RChassis OpenerTo disassemble the radio
PMDN4039_RCrab Eye Nut OpenerTo fasten or remove crab-eye nut.
PMDN4040_RTest BoxEnables connection to the audio/accessory jack.
PMDN4041_RRF AdapterAdapts radio antenna port to BNC cabling of test 
equipment.
PMDN4043_RProgramming/Test 
CableConnects radio to Computer.
PMDN4060_RCloning CableAllows a radio to be duplicated from a master radio by 
transferring programmed data from the master radio 
to the other.
PMDN4042_RBattery EliminatorInterconnects radio to power supply (red-and-black 
power cable included).
PMDN4054_RAntenna Ground PlateTo improve grounding while conducting tuning and  
measurement.
PMDN4044_RT-Head Ceramic  
Tuning Tool
To tune the variable resistor for audio and sub-audio  
modulation adjustment; tuning points accessible via  
battery-chassis area.
PMDN4026_RFlat Ceramic Tuning 
Tool (1.8mm)To tune the variable resistor for audio and sub-audio  
modulation adjustment; requires disassembly of PCB 
from chassis to get access to tuning point.
PMDN4053_RFlat Ceramic Tuning 
Tool (0.9mm)
–Phillips Head  
Screwdriver
To remove M2 and M2.6 Phillips screws.
–Flat Head ScrewdriverTo remove speaker from speaker felt.
–TweezersTo remove smaller components i.e. latch pad and 
speaker connector.
TT907A National 
Service Technical 
GuideRepairing Leadless 
Component 
 
Assemblies
Guide on how to successfully remove and replace 
surface mount devices. 
						

							Test Equipment2-17
10.0 Test Equipment
Table 2-3 lists test equipment required to service the Mag One by Motorola Radios and other two-way 
radios. 
11.0 Programming Cable (PMDN4043_R) 
Table 2-3   Recommended Test Equipment
Motorola 
Part No.DescriptionCharacteristicsApplication
R2600Communication 
AnalyzerFrequency/deviation meter and signal  
generator for wide-range troubleshooting 
and alignment
R1038Handheld MultimeterAC/DC Voltage and current measure-
ments
S1339A/220RF Millivolt Meter 
220V100mv to 3VRF  
100kHz to 1.2GHz
RF Level Measurements
Figure 2-15 Programming Cable Schematic 
						

							2-18Cloning Cable (PMDN4060_R)
12.0 Cloning Cable (PMDN4060_R)
13.0 Test Box (PMDN4040_R)
Figure 2-16 Cloning Cable Schematic
Figure 2-17 Test Box Schematic
e i p 5 . 2e i p 5 . 2
5 . 2ei p 5 . 3ei p
1   O I D U A
1   O I D U A
O I D U A   X T
o M 1mho M 1mh0 0 1Fu
0 0 1Fuo 8mh
4 2mh o
o 8mh
2   r omh o 4 S1W
S2W
S3W K 2 . 2mh o 
						

							3-1
Section 3
RADIO TUNING
1.0 Introduction
This chapter provides an overview of the hardware tuning for this Mag One by Motorola Series 
radio. There is no software tuning required. 
In order to perform the manual tuning procedures, the radio needs to be disassembled to the PC 
Board. 
Following are the parameters that can be tuned:-
1.Transmitter Tuning
a. High Power Tuning 
b. Low Power Tuning
c. Frequency Tuning
d. Modulation Balancing
e. Maximum Modulation
f. Subtone Modulation
2.Receiver Tuning 
a. Wide Band Sinad Tuning
b. Narrow Band Sinad Tuning
3.PLL Synthesizer Tuning
a. Rx PLL Frequency Tuning
b. Tx PLL Frequency Tuning
For a list of Service Aids required, refer to Table 2-2 on page 2-16 
						

							3-2Hardware Tuning Setup and Procedure
2.0 Hardware Tuning Setup and Procedure
2.1 Tuning Frequency
2.2 Preparation Before Tuning (refer to Figure 3-1)
1.Set Power Supply to 7.5V and then connect to the radio.
2.Connect the connector and ground plate to the radio antenna port.
3.Connect the radio to the test equipment.
Table 3-1   Frequencies Used for Tuning.
BandTuning ParameterFrequency (MHz)
VHF 150 - 174 MHz
PLL Synthesizer 173.975
Transmitter150.025
Receiver150.025
UHF 450 - 470 MHz
PLL Synthesizer 469.975
Transmitter450.025
Receiver450.025
Figure 3-1 Radio Tuning Setup
NOTEOn the Test Box, select 8 ohm resistance when using with PMUD2086A_, and 
PMUE2386A_. For all other kits, please select 24 ohm resistance.
NOTEThe radio may need to be disassembled to the PC board level to access certain tuning 
ports. For disassembly, refer to 
Radio Disassembly — Detailed  on page 2-6
Ground Contact Finger
Radio
Antenna Port
     Acc
     Jack
TEST EQUIPMENTN Type
BNC
Input
LoHiTx8 ohm 24 ohm
Rx
TEST BOX
Output BNCBNC BNC 
						

							Hardware Tuning Setup and Procedure3-3
2.3 Transmitter Tuning 
2.3.1 High Power
1.Connect the radio to power meter. 
2.Set the radio to the appropriate tuning frequency (refer to Table 3-1).
3.Key up the radio.
4.Using the ceramic tool, adjust R425 to tune high power (refer to Figure 3-2).
2.3.2 Low Power
1.Connect the radio to power meter. 
2.Set the radio to the appropriate tuning frequency (refer to Table 3-1).
3.Key up the radio.
4.Using the ceramic tool, adjust R426 to tune low power (refer to Figure 3-2). 
2.3.3 Frequency Tuning
1.Set the radio to the appropriate tuning frequency (refer to Table 3-1). 
2.Using the ceramic tool, adjust FL701 to tune the frequency (refer to Figure 3-2).
2.3.4 Modulation Balancing
1.Set the radio to the appropriate tuning frequency (refer to Table 3-1). 
2.On the test equipment, set the following configurations:
Audio bandwidth: 0.25Hz to 15,000Hz.
De-emphasis: Off.
FM: Peak negative.
3.Using the Audio Analyzer, inject a 1 kHz tone to the radio through the test box.
4.Key up the radio.
5.Set the desired modulation balance at the output level of the Audio Analyzer.
Figure 3-2 Tuning Ports
R425
R426
FL701
R216
R215 
						

							3-4Hardware Tuning Setup and Procedure
6.Using the ceramic tool, adjust R174 to tune to 100% of the maximum deviation (refer to 
Figure 3-3).  
2.3.5 Maximum Modulation
1.Set the radio to the appropriate tuning frequency (refer to Table 3-1).
2.On the test equipment, set the following configurations:
Audio bandwidth: 0.25Hz to 15,000Hz
De-emphasis: Off
FM: Peak negative
3.Using the Audio Analyzer, input a 1 kHz tone + 67Hz subtone, 120mV to the radio through the 
test box.
4.Key up the radio. 
5.Using the ceramic tool, adjust R159 to tune maximum modulation between 2.4±0.02KHz for 
narrow band or under 5KHz for wide band (refer to 
Figure 3-3).
2.3.6 Subtone Modulation
1.Set the radio to the appropriate tuning frequency (refer to table3-1).
2.On the test equipment set the following configuration
Audio bandwidth: 0.25Hz to 15,000Hz
De-emphasis: Off
FM: Peak negative
3.Program radio subtone to 67Hz (CTCSS).
4.Key up the radio.
5.Using the ceramic tool, adjust R172 to tune subtone modulation between 0.42 ± 0.02KHz at 
narrow band. (refer to 
Figure 3-3)
Figure 3-3 Top Side of PCB
R159TP1
R174
R172