Motorola Magone Basic 6816101h01 A Manual
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Table of Contents Document History ... .............................................................................................. .i Safety Information ... ........................................................................................... . iii 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 ... ................................................................................... ..1-2 2.3 Piece Parts ... ................................................................................................... ...1-2 2.4 Technical Support ... .......................................................................................... .1-2 2.5 Further Assistance From Motorola ... ............................................................... ...1-2 3.0 Radio Model Information... ....................................................................................... .1-3 4.0 Radio Features ... .................................................................................................. ..1-4 Section 2 MAINTENANCE 1.0 Introduction ... ........................................................................................................ ...2-1 2.0 Preventive Maintenance ... ...................................................................................... .2-1 2.1 Inspection ... ...................................................................................................... ..2-1 2.2 Cleaning Procedures ... ................................................................................... ...2-1 3.0 Safe Handling of CMOS and LDMOS Devices ... .................................................. ...2-2 4.0 Repair Procedures and Techniques — General ... .................................................. .2-3 5.0 Disassembling and Reassembling the Radio — General ... ................................... ..2-4 6.0 Radio Disassembly — Detailed ... .......................................................................... ..2-5 6.1 Front Cover from Chassis Disassembly ... ......................................................... .2-5 6.2 PC Board Disassembly ... ................................................................................. ..2-8 7.0 Radio Reassembly — Detailed ... .......................................................................... ...2-8 7.1 PC Board Reassembly ... ................................................................................. ...2-8 7.2 Chassis and Front Cover Reassembly ... ......................................................... ..2-9 8.0 Mechanical View and Parts List ... ....................................................................... ...2-12 8.1 Exploded View and Parts List... ..................................................................... ...2-12 9.0 Service Aids ... ..................................................................................................... ...2-16 10.0 Test Equipment... ................................................................................................... .2-17 11.0 Programming Cable (PMDN4043_R) ... .............................................................. ...2-17 12.0 Cloning Cable (PMDN4060_R) ... .......................................................................... .2-18 13.0 Test Box (PMDN4040_R) ... ................................................................................ ...2-18 Section 3 RADIO TUNING 1.0 Introduction ... ........................................................................................................ ...3-1 2.0 Hardware Tuning Setup and Procedure ... .............................................................. .3-2
2.1 Tuning Frequency ... ....................................................................................... ...3-2 2.2 Preparation Before Tuning (refer to Figure 3-1) ... ............................................. .3-2 2.3 Transmitter Tuning ... ....................................................................................... ...3-3 2.4 Receiver Tuning ... ............................................................................................. .3-6 Section 4 RADIO PROGRAMMING 1.0 Introduction ... ........................................................................................................ ...4-1 2.0 Programming Your Radio ... ................................................................................... ..4-1 2.1 Overview of the Programming Process ... ........................................................ ..4-1 2.2 Cloning Radio Parameters to User Radios ... ................................................... ..4-1 2.3 Parameters which are cloned ... ....................................................................... ..4-1 2.4 Parameters which are not cloned ... ................................................................. ..4-1 2.5 To Clone a Radio ... .......................................................................................... ..4-1 2.6 Error Conditions ... ............................................................................................. .4-2 3.0 CPS Programming ... ............................................................................................... .4-2 3.1 To Read Radio Data to a PC... ........................................................................ ...4-3 3.2 To Write Data to a Radio ... ............................................................................. ...4-3 4.0 Factory Reset ... ...................................................................................................... ..4-3 Section 5 ACCESSORIES 1.0 Antennas... ............................................................................................................... .5-1 2.0 Carry Accessories ... ............................................................................................... ..5-1 3.0 Carry Cases ... ........................................................................................................ ..5-1 4.0 Chargers ... .............................................................................................................. .5-1 5.0 Batteries... ............................................................................................................... ..5-1 6.0 Audio Accessories ... ............................................................................................... .5-2 7.0 Publications ... ......................................................................................................... ..5-2 8.0 Service Kits ... ........................................................................................................ ...5-2 Section 6 MODEL CHART AND TEST SPECIFICATION 1.0 VHF Band 1 Information (136-150 MHz) ... ............................................................ .6-1 2.0 Specifications... ...................................................................................................... ...6-2 3.0 VHF Band 2 Information (150 - 174 MHz) ... ......................................................... ..6-3 4.0 Specifications... ...................................................................................................... ...6-4 5.0 UHF Band 1 Information (403-425MHz) ... ............................................................ ...6-5 6.0 Specifications... ...................................................................................................... ...6-6 7.0 UHF Band 2 Information (450 - 470MHz) ... ......................................................... ...6-7 8.0 Specifications... ...................................................................................................... ...6-8 9.0 UHF Band 4 Information (490 - 512 MHz) ... ......................................................... ...6-9 10.0 Specifications... ...................................................................................................... .6-10 Glossary of Terms ... .................................................................................... .G-1
Scope of Manual 1-1 Section 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. NOTE Before operating or testing these units, please read the Safety Information Section in the front of this manual. 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 authorized Motorola Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer. 2.1 Warranty Period and Return Instructions The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or Reseller contract. These conditions may change from time to time and the following 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. NOTE For service technicians in the Latin America Countries Region For any warranty claims in the Latin America Countries region, please open a case using the Contact Us feature within Motorola Online at https://businessonline.motorola.com/ . Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact Customer Resources (Please see page 1-2). 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.
1-2 Warranty and Service Support 2.2 After Warranty Period NOTE For service technicians in the Latin America Countries Region After Warranty Period claims in the Latin America Countries region are handled through the Motorola Authorized Service Provider (SAM) Network. To find the nearest SAM, please go to Motorola Resource Center in Motorola Online at https://businessonline.motorola.com/ . After the Warranty period, Motorola continues to support its products in two ways. 1. Motorolas Managed Technical Services (MTS) offers a repair service to both end users and dealers at competitive prices. 2. MTS supplies individual parts and modules that can be purchased by dealers who are techni- cally capable of performing fault analysis and repair. 2.3 Piece Parts NOTE For service technicians in the Latin America Countries Region All part orders should be directed to your local Parts Distributors. Some replacement parts, spare parts, and/or product information can be ordered directly. If a complete Motorola part number is assigned to the part, it is available from Motorola‟s Managed Technical Services (MTS). If no part number is assigned, the part is not normally available from Motorola. If the part number is appended with an asterisk, the part is serviceable by Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable parts are available for that kit or assembly. All orders for parts/information should include the complete Motorola identification number. All part orders should be directed to your local MTS office. Please refer to your latest price pages. 2.4 Technical Support NOTE For service technicians in the Latin America Countries Region For Technical Support in the Latin America Countries Region, please open a case using the Contact Us feature within Motorola Online at https://businessonline.motorola.com/ . Technical support is available to assist the dealer/distributor in resolving any malfunction which may be encountered. Initial contact should be by telephone wherever possible. When contacting Motorola Technical Support, be prepared to provide the product model number and the unit‟s serial number. 2.5 Further Assistance From Motorola You can also contact the Customer Help Desk through the following web address: http://www.motorola.com/governmentandenterprise/contactus NOTE Only Motorola Service Centers or Approved Motorola Service Dealers can perform these functions. Any tampering by non-authorized Motorola Service Centers voids the warranty of your radio. To find out more about Motorola and its approved Service Centers, please visit http://www.motorola.com/governmentandenterprise/public/functions/home/home.aspx
Series Freq. Band P Radio Model Information 1-3 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 specific characteristics. Table 1-1 Radio Model Number (Example: LAH84JDC8AA4) Type of Unit LA H Model 84 J (136-150 MHz) K (150-174 MHz) Q (403-425 MHz) R (450-470 MHz) T (490-512 MHz) H = Portable ower Physical Channel Level Packages Spacing D C 8 5W 16-Channel 12.5/25K Black C 4W Feature Protocol Level AA 4 Conventional A8 LA = Latin America Regional Prefix
1-4 4.0 Radio Features The following are features your radio has. Normal Operation • Rx/Tx • Radio-CPS-Radio Cloning • Radio-to-Radio Cloning • Factory Reset • Low Battery Indication • Self Test Programming Button • Hi/Lo Power • Volume Set • Monitor • Sticky Monitor • Scan Activate • Nuisance Channel Delete • Repeater/Talkaround • PL/DPL • Button Lock • Battery Save Mode • Squelch • Unassigned Radio Features CPS • Rx Frequency • Tx Frequency • RX TPL/DPL/IDPL • TX TPL/DPL/IDPL • User Defined PL (TPL1, TPL2, TPL3) • Squelch Type • Unmute/Mute Rules • Power Level (High/Low) • TPL Reverse Burst • Turn Off Code • Rx Only • Busy Channel Lock Out (BCLO) • Channel Spacing (25KHz / 12.5KHz) • Talkaround • Time Out TImer • Battery Save Mode • Quick Key Override • Password Protection • Scan List • Normal Scan • Priority Scan • Talkback Scan
2-1 Section 2 MAINTENANCE 1.0 Introduction This chapter provides details about the following: • Preventive Maintenance • Safe Handling of CMOS and LDMOS Devices • General Repair Procedures and Techniques • Disassembling and Reassembling the Radio 2.0 Preventive Maintenance 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. NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or repair. The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (70% by volume). CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals. Cleaning External Plastic Surfaces Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices.
2-2 Safe Handling of CMOS and LDMOS Devices 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. NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage). 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 first referring to the following CAUTION statement. CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are properly grounded. Take the following precautions when working on this unit: • Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together. Do not insert CMOS devices into conventional plastic “snow” trays used for storage and transportation of other semiconductor devices. • Ground the working surface of the service bench to protect the CMOS device. We recommend using the Motorola Static Protection Assembly (part number 0180386A82), which includes a wrist strap, two ground cords, a table mat, and a floor mat. • Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX-4015.) • Do not wear nylon clothing while handling CMOS devices. • Do not insert or remove CMOS devices with power applied. Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present. • When straightening CMOS pins, provide ground straps for the apparatus used. • When soldering, use a grounded soldering iron. • If at all possible, handle CMOS devices by the package and not by the leads. Prior to touching the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.
Repair Procedures and Techniques — General 2-3 4.0 Repair Procedures and Techniques — General Parts Replacement and Substitution When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number and order the part from the nearest Motorola Communications parts center listed in the Piece Parts section of this manual. Rigid Circuit Boards This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not accessible, some special considerations are required when soldering and unsoldering components. The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise care to avoid pulling the plated circuit out of the hole. When soldering near the 20-pin and 40-pin connectors: • Avoid accidentally getting solder in the connector. • Be careful not to form solder bridges between the connector pins. • Examine your work closely for shorts due to solder bridges. Flexible Circuits The flexible circuits are made from a different material than the rigid boards, and require different soldering techniques. Excessive prolonged heat on a flexible circuit can damage the material. Therefore, avoid excessive heat and excessive bending. For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700 degree F tip, and use small diameter solder such as ST-633. The smaller size solder will melt faster and require less heat to be applied to the circuit. To replace a component on a flexible circuit: 1. Grasp with seizers (hemostats) the edge of the flexible circuit near the part to be removed. 2. Pull gently. 3. Apply the tip of the soldering iron to the component connections while pulling with the seizers. NOTE Do not attempt to puddle-out components. Prolonged application of heat may damage the flexible circuit. Chip Components Use either the RLN-4062 Hot-Air Repair Station or the Motorola 0180381B45 Repair Station for chip component replacement. When using the 0180381B45 Repair Station, select the TJ-65 mini- thermojet hand piece. On either unit, adjust the temperature control to 700 degrees F. (370 degrees C), and adjust the airflow to a minimum setting. Airflow can vary due to component density. • To remove a chip component, select a hot-air hand piece and position the nozzle of the hand piece approximately 1/8” above the component to be removed. Begin applying the hot air. Once the solder reflows, remove the component using a pair of tweezers. Using solder wick and a soldering iron or a power desoldering station, remove the excess solder from the pads.
2-4 Disassembling and Reassembling the Radio — General • To replace a chip component using a soldering iron, select the appropriate micro-tipped soldering iron and apply fresh solder to one of the solder pads. Using a pair of tweezers, position the new chip component in place while heating the fresh solder. Once solder wicks onto the new component, remove the heat from the solder. Heat the remaining pad with the soldering iron and apply solder until it wicks to the component. If necessary, touch up the first side. All solder joints should be smooth and shiny. • To replace a chip component using hot air, select the hot-air hand piece and reflow the solder on the solder pads to smooth it. Apply a drop of solder paste flux to each pad. using a pair of tweezers, position the new component in place. Position the hot-air hand piece approximately 1/8” above the component and begin applying heat. Once the solder wicks to the component, remove the heat and inspect the repair. All joints should be smooth and shiny. 5.0 Disassembling and Reassembling the Radio — General For disassembly or reassembly of the radio, it is important to pay particular attention to all the snaps and tabs, and how parts align with each other. The following tools are required for disassembling the radio: • Phillips screwdriver • Flat head screwdriver • Chassis Opener • Crab Eye Nut Opener • Tweezers 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.