Motorola Portable Radio Ep450 Basic Hkln4215a Manual

							MOTOROLA, The Stylized M logo are trademarks of Motorola, Inc.All other product or service names are the property of their respective owners.© 2003 Motorola, Inc. All rights reserved. Printed in U.S.A.
HKLN4215A
HKLN4215A
EP450™
Portable Radio 
Basic Service Manual 
						

							EP450 Portable Radio
Basic Service Manual
 VHF 146-174 MHz
UHF 403-440 MHz
UHF 438-470 MHz
UHF 465-495 MHz
Motorola, Inc.
1301 E. Algonquin Road
Schaumburg, IL 60196
HKLN4215A 
						

							ii
Foreword
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.
Product Safety and RF Exposure Compliance
AT T E N T I O N !
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements. 
Before using this product, read the RF energy awareness information and operating instructions in the 
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 
68P81095C98) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which 
lists approved accessories: http://www.motorola.com/cgiss/index.shtml.
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, but not limited to, the  
exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any  
copyrighted Motorola computer programs contained in the Motorola products described in this manual may  
not be copied, reproduced, modified, reverse-engineered, or distributed in any manner without the express  
written permission of Motorola. Furthermore, the purchase of Motorola 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 license to use that arises by operation of law in  
the sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express  
written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any  
form or by any means, electronic or mechanical, for any purpose without the express written permission of  
Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no  
responsibility is assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any  
products herein to improve readability, function, or design. Motorola does not assume any liability arising out 
of the applications or use of any product or circuit described herein; nor does it cover any license under its  
patent rights nor the rights of others.
MOTOROLA, and the Stylized M logo are trademarks of Motorola, Inc.
All other product or service names are the property of their respective owners.
© 2003 Motorola, Inc. All rights reserved. Printed in U.S.A.Note:
Before operating or testing these units, please read the Product Safety and RF Exposure
Compliance section.
Note:
Before using this product, read the operating instructions for safe usage contained in the 
Product Safety and RF Exposure booklet enclosed with your radio.
!
C a u t i o n 
						

							Table of Contentsiii
HKLN4215ADecember 3, 2003
Table of Contents
Foreword ..................................................................................................................................................... ii
Product Safety and RF Exposure Compliance ............................................................................................ ii
Computer Software Copyrights ................................................................................................................... ii
Document Copyrights .................................................................................................................................. ii
Disclaimer .................................................................................................................................................... ii
List of Figures ...............................................................................................vi
List of Tables ...............................................................................................viii
Chapter 1 Model Charts and Test Specifications.............................. 1-1
1.1 Radio Model Information................................................................................................................ 1-1
1.2 Model Chart for VHF 146-174 MHz ............................................................................................... 1-2
1.3 Non-Display Model ........................................................................................................................ 1-3
1.4 Model Chart for UHF 403-440 MHz ............................................................................................... 1-4
1.5 Model Chart for UHF 438-470 MHz ............................................................................................... 1-5
1.6 Model Chart for UHF 465-495 MHz ............................................................................................... 1-6
1.7 Display Model ................................................................................................................................ 1-7
1.8 MIL Standards ............................................................................................................................... 1-8
Chapter 2 Theory Of Operation ........................................................... 2-1
2.1 Introduction .................................................................................................................................... 2-1
2.2 Major Assemblies .......................................................................................................................... 2-1
2.2.1 Receiver............................................................................................................................ 2-1
2.2.2 Transmitter........................................................................................................................ 2-2
Chapter 3 Test Equipment, Service Aids, and Service Tools ........... 3-1
3.1 Test Equipment.............................................................................................................................. 3-1
3.2 Service Aids ................................................................................................................................... 3-2
Chapter 4 Performance Checks .......................................................... 4-1
4.1 General .......................................................................................................................................... 4-1
4.2 Power-Up Self Test........................................................................................................................ 4-1
4.3 RF Test Mode ................................................................................................................................ 4-2
Chapter 5 Radio Alignment Procedures ............................................. 5-1
5.1 Introduction .................................................................................................................................... 5-1
5.2 CPS Programming Setup .............................................................................................................. 5-1
5.3 Radio Tuning Setup ....................................................................................................................... 5-2
5.3.1 Initial Test Equipment Control Settings............................................................................. 5-3
5.4 Transmitter Alignment Options ...................................................................................................... 5-3
5.4.1 Reference Oscillator Warp................................................................................................ 5-3
5.4.2 Modulation Balance Attenuation ....................................................................................... 5-4 
						

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December 3, 2003HKLN4215A
5.4.3 Transmit Power Tuning .....................................................................................................5-5
5.4.3.1 To Perform Transmit High Power Tuning, do the following: .............................. 5-6
5.4.3.2 To Perform Transmit Low Power Tuning, do the following:  .............................. 5-6
5.4.4 VCO Attenuation ............................................................................................................... 5-7
5.4.4.1 VCO Attenuation 25 kHz .................................................................................... 5-7
5.4.4.2 VCO Attenuation 12.5 kHz ................................................................................. 5-8
5.4.4.3 VCO Attenuation 20 kHz .................................................................................... 5-8
5.4.5 DTMF Deviation Tuning .................................................................................................... 5-9
5.4.6 MDC-1200 Deviation Tuning........................................................................................... 5-10
5.5 Receiver Tuning ........................................................................................................................... 5-10
5.5.1 Rated Volume Tuning ..................................................................................................... 5-11
5.5.2 Squelch Tuning ............................................................................................................... 5-12
5.5.2.1 Manual Squelch Tuning ................................................................................... 5-12
5.5.2.2 Auto Tune ........................................................................................................ 5-13
5.5.3 RSSI System Level Tuning ............................................................................................. 5-13
5.5.4 RSSI Display Tuning .......................................................................................................5-14
5.6 Utilities ......................................................................................................................................... 5-14
5.6.1 Program Serial No. .........................................................................................................5-14
5.6.2 Temp Comp Data Read .................................................................................................. 5-14
5.6.3 Temp Comp Data Write .................................................................................................. 5-14
5.7 Radio-to-Radio Cloning................................................................................................................ 5-14
Chapter 6 Display Model Disassembly and Re-assembly ................ 6-1
6.1 Introduction .................................................................................................................................... 6-1
6.2 Preventive Maintenance ................................................................................................................ 6-1
6.2.1 Inspection.......................................................................................................................... 6-1
6.2.2 Cleaning Procedures ........................................................................................................6-1
6.3 Safe Handling of CMOS and LDMOS Devices .............................................................................. 6-2
6.4 Disassembling and Re-assembling the Radio — General ............................................................. 6-3
6.4.1 Radio Disassembly — Detailed ........................................................................................ 6-3
6.4.1.1 Front Cover From Chassis Disassembly ........................................................... 6-3
6.4.1.2 Dust Cover Disassembly.................................................................................... 6-6
6.4.1.3 Speaker and Microphone Disassembly ............................................................. 6-6
6.4.1.4 Keyboard Removal ............................................................................................ 6-7
6.4.1.5 PTT Disassembly ............................................................................................... 6-7
6.4.1.6 Chassis Disassembly ......................................................................................... 6-8
6.4.2 Radio Re-assembly - Detailed .......................................................................................... 6-9
6.4.2.1 Dust Cover Re-assembly ................................................................................... 6-9
6.4.2.2 Microphone and Speaker Re-assembly ............................................................. 6-9
6.4.2.3 Keypad and LCD/Keyboard Re-assembly ....................................................... 6-11
6.4.2.4 Keyboard Retainer Re-assembly ..................................................................... 6-12
6.4.2.5 Chassis Assembly/Re-assembly...................................................................... 6-12
6.4.2.6 Chassis and Front Cover Re-assembly ........................................................... 6-13
6.4.2.7 PTT Re-assembly ............................................................................................ 6-15
6.5 Mechanical View and Parts List ................................................................................................... 6-16
6.5.1 EP450 Display Model Exploded View and Parts List ...................................................... 6-16
Chapter 7 Non-Display Model Disassembly and Re-assembly ........ 7-1
7.1 Introduction .................................................................................................................................... 7-1
7.2 Preventive Maintenance ................................................................................................................ 7-1
7.2.1 Inspection.......................................................................................................................... 7-1 
						

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HKLN4215ADecember 3, 2003
7.2.2 Cleaning Procedures ........................................................................................................7-1
7.3 Safe Handling of CMOS and LDMOS Devices .............................................................................. 7-2
7.4 Disassembling and Re-assembling the Radio — General............................................................. 7-3
7.4.1 Radio Disassembly — Detailed ........................................................................................ 7-3
7.4.1.1 Front Cover From Chassis Disassembly ........................................................... 7-3
7.4.1.2 Dust Cover Disassembly ................................................................................... 7-5
7.4.1.3 Speaker and Microphone Disassembly ............................................................. 7-6
7.4.1.4 PTT Disassembly............................................................................................... 7-6
7.4.2 Chassis Disassembly........................................................................................................7-7
7.4.3 Radio Re-assembly - Detailed .......................................................................................... 7-8
7.4.3.1 Dust Cover Re-assembly ................................................................................... 7-8
7.4.3.2 Microphone and Speaker Re-assembly............................................................. 7-8
7.4.3.3 Chassis Assembly/Re-assembly ....................................................................... 7-9
7.4.3.4 Chassis and Front Cover Re-assembly ........................................................... 7-10
7.4.3.5 PTT Re-assembly ............................................................................................ 7-11
7.5 Mechanical View and Parts List ................................................................................................... 7-13
7.5.1 EP450 Non-Display Exploded View and Parts List......................................................... 7-13
Chapter 8 Troubleshooting Tables ..................................................... 8-1
8.1 Power-Up Error Codes .................................................................................................................. 8-1
8.2 Operational Error Codes ................................................................................................................ 8-1
8.3 Troubleshooting Table for Receiver............................................................................................... 8-2
8.4 Troubleshooting Table for Transmitter........................................................................................... 8-3
Appendix A Accessories ......................................................................... A-1
Appendix B Warranty, Service Support, and Replacement Parts ....... B-1
1.1 Scope of Manual ............................................................................................................................ 1-1
1.2 Warranty ........................................................................................................................................ 1-1
1.2.1 Warranty Period and Return Instructions .......................................................................... 1-1
1.2.2 After Warranty Period ....................................................................................................... 1-1
1.3 Replacement Parts Ordering ......................................................................................................... 1-1
1.3.1 Basic Ordering Information ............................................................................................... 1-1
1.3.2 Motorola Online ................................................................................................................ 1-2
1.3.3 Mail Orders ....................................................................................................................... 1-2
1.3.4 Telephone Orders ............................................................................................................. 1-2
1.3.5 Fax Orders ........................................................................................................................ 1-2
1.3.6 Parts Identification ............................................................................................................ 1-2
1.4 Technical Support .......................................................................................................................... 1-3
Glossary ......................................................................................................G-1 
						

							viTable of Contents
December 3, 2003HKLN4215A
List of Figures
Figure 2-1. Major Assemblies Block Diagram ..................................................................................... 2-1
Figure 2-2. Transceiver Block Diagram .............................................................................................. 2-2
Figure 3-1. Programming/Test Cable.................................................................................................. 3-4
Figure 3-2. Wiring of the Connectors .................................................................................................. 3-4
Figure 4-1. Radio Tuning Setup .......................................................................................................... 4-1
Figure 4-2. Side Button Locations....................................................................................................... 4-2
Figure 5-1. CPS Programming Setup ................................................................................................. 5-1
Figure 5-2. Radio Tuning Setup .......................................................................................................... 5-2
Figure 5-3. Reference Oscillator Warp Window.................................................................................. 5-3
Figure 5-4. Modulation Balance Window ............................................................................................5-4
Figure 5-5. Transmit Power Window (High Power)............................................................................. 5-5
Figure 5-6. VCO Attenuation Window (12.5 kHz) ............................................................................... 5-7
Figure 5-7. DTMF Deviation Tuning Window ...................................................................................... 5-9
Figure 5-8. MDC-1200 Deviation Tuning Window ............................................................................ 5-10
Figure 5-9. Rated Volume Tuning Window ....................................................................................... 5-11
Figure 5-10. Squelch Tuning Window ................................................................................................. 5-12
Figure 5-11. RSSI Tuning ................................................................................................................... 5-13
Figure 5-12. Side Button Locations..................................................................................................... 5-15
Figure 6-1. Battery Removal ............................................................................................................... 6-3
Figure 6-2. Antenna and Knob Removal.............................................................................................6-4
Figure 6-3. Chassis Removal.............................................................................................................. 6-4
Figure 6-4. Keyboard Flex Connection ............................................................................................... 6-5
Figure 6-5. Microphone and Speaker Connections ............................................................................ 6-5
Figure 6-6. Dust Cover Disassembly .................................................................................................. 6-6
Figure 6-7. Removal Speaker-Microphone Assembly ........................................................................ 6-6
Figure 6-8. Keypad Removal .............................................................................................................. 6-7
Figure 6-9. PTT Removal.................................................................................................................... 6-8
Figure 6-10. Removal of Main Board from Chassis .............................................................................. 6-8
Figure 6-11. Dust Cap Re-assembly..................................................................................................... 6-9
Figure 6-12. Microphone Re-assembly ............................................................................................... 6-10
Figure 6-13. Speaker Re-assembly .................................................................................................... 6-10
Figure 6-14. Keypad Re-assembly ..................................................................................................... 6-11
Figure 6-15. LCD/Keypad Board Re-assembly................................................................................... 6-11
Figure 6-16. Keyboard Retainer Re-assembly.................................................................................... 6-12
Figure 6-17. Main Board onto Chassis Re-assembly ......................................................................... 6-13
Figure 6-18. Microphone and Speaker Wires Re-assembly ............................................................... 6-14
Figure 6-19. Keyboard Flex Cable Connection ................................................................................... 6-14
Figure 6-20. Fastening the Chassis .................................................................................................... 6-15
Figure 6-21. PTT Re-assembly ........................................................................................................... 6-15
Figure 6-22. EP450 Full Keypad Radio Exploded View...................................................................... 6-16
Figure 7-1. Battery Removal ............................................................................................................... 7-3
Figure 7-2. Antenna and Knob Removal.............................................................................................7-4
Figure 7-3. Chassis Removal.............................................................................................................. 7-4
Figure 7-4. Microphone and Speaker Connections ............................................................................ 7-5
Figure 7-5. Dust Cover Disassembly .................................................................................................. 7-5
Figure 7-6. Removal Speaker-Microphone Assembly ........................................................................ 7-6
Figure 7-7. PTT Removal.................................................................................................................... 7-7
Figure 7-8. Removal of Main Board from Chassis .............................................................................. 7-7
Figure 7-9. Dust Cap Re-assembly..................................................................................................... 7-8
Figure 7-10. Microphone Re-assembly ................................................................................................. 7-8 
						

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HKLN4215ADecember 3, 2003
Figure 7-11. Speaker Re-assembly ...................................................................................................... 7-9
Figure 7-12. Installation of Main Board onto Chassis ......................................................................... 7-10
Figure 7-13. Microphone and Speaker Wires Re-assembly ............................................................... 7-11
Figure 7-14. Fastening the Chassis .................................................................................................... 7-11
Figure 7-15. PTT Re-assembly........................................................................................................... 7-12
Figure 7-16. EP450 Non-Display Radio Exploded View ..................................................................... 7-13 
						

							viiiTable of Contents
December 3, 2003HKLN4215A
List of Tables
Table 1-1. Radio Model Number (Example: LAH65KDC9AA2AN) .................................................... 1-1
Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications ..................... 1-8
Table 3-1. Recommended Test Equipment ....................................................................................... 3-1
Table 3-2. Service Aids...................................................................................................................... 3-2
Table 3-3. Recommended Service Tools .......................................................................................... 3-2
Table 4-1. Initial Equipment Control Settings ....................................................................................4-2
Table 4-2. Test Environments............................................................................................................ 4-3
Table 4-3. Test Channel Spacing ...................................................................................................... 4-3
Table 4-4. Test Frequencies .............................................................................................................. 4-4
Table 4-5. Receiver Performance Checks ......................................................................................... 4-4
Table 4-6. Transmitter Performance Checks ..................................................................................... 4-5
Table 5-1. Initial Equipment Control Settings ....................................................................................5-3
Table 5-2. Reference Oscillator Specifications ..................................................................................5-4
Table 5-3. Transmit High/Low Power Level ....................................................................................... 5-6
Table 5-4. Deviation Specifications  .................................................................................................. 5-8
Table 5-5. Squelch Deviation Values............................................................................................... 5-12
Table 8-1. Power-Up Error Code Display ..........................................................................................8-1
Table 8-2. Operational Error Code Display........................................................................................8-1
Table 8-3. Receiver Troubleshooting Table.......................................................................................8-2
Table 8-4. Transmitter Troubleshooting Table................................................................................... 8-3
Related Publications
E-Series Detailed Service Manual ........................................................................HKLN4216
E-Series Interactive User CD ...............................................................................HKLN4212 
						

							Chapter 1 Model Charts and Test Specifications
1.1 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: LAH65KDC9AA2AN)
Type of 
UnitModel 
SeriesFreq. 
BandPower 
LevelPhysical 
Packages
Channel 
SpacingProtocolFeature 
LevelModel 
RevisionModel 
Package
LA H 65 K
VHF
(146-174 
MHz)
Q
(403-440 
MHz)
R
UHF 
(438-470 
MHz)
S
UHF
(465-495 
MHz)D
4 W or
5 WC
Non
Display
H
Full
Display9
Pro-
gramma-
bleAA
Conven-
tional2
16 CH
4
64 CHAN
LA = Motorola Internal Use
H = Portable