Motorola Portable Radio Ep450 Basic Hkln4215a Manual
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December 3, 2003HKLN4215A 7-8Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.3 Radio Re-assembly - Detailed 7.4.3.1 Dust Cover Re-assembly 1.Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 7-9). 2.Press the dust cap until the tail is fully into the hole. 3.Twist the dust cap counter-clockwise until the cap is seated properly onto the recess. 4.Press the cap again to ensure it fully covers the opening for the audio jack. 7.4.3.2 Microphone and Speaker Re-assembly 1.Check that the speaker felt is in position and is not damaged. If damaged replace felt. 2.Insert the microphone sub-assembly into the microphone boot. 3.Insert the Boot and microphone sub-assembly into the microphone recess in the housing and route the wires as shown in Figure 7-10. 4.Locate the speaker tab and align it with the tab opening in the front housing (Figure 7-11). 5.Insert the speaker tab into the speaker recess in the housing. Ensure the speaker is seated flush in the housingFigure 7-9. Dust Cap Re-assembly Figure 7-10. Microphone Re-assembly 12 34 Microphone Boot Microphone Recess Microphone Position
HKLN4215ADecember 3, 2003 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-9 . 6.Insert one end of the speaker retainer into the slot in the front housing (See Figure 7-11).. 7.Install the retainer screw using a T6 Torx screwdriver. Torque to 2.3 - 2.5 lb/in. 7.4.3.3 Chassis Assembly/Re-assembly 1.Replace the battery contact seal (if necessary) surrounding the battery contact (Figure 7-12). 2.Remove the old Interface Pad from the chassis by scraping off the pad and adhesive with a straight razor. Use rubbing alcohol and a cloth to completely remove the adhesive from the chas- sis surface. With the chassis clean and dry, add a new Interface Pad to the chassis. 3.Place the main circuit board straight down on top of the chassis with the frequency and volume switches facing down. 4.Use the T6 Torx screwdriver to fasten the screws holding the main board to the chassis. Tighten to 3.7 - 3.9 in/lb. 5.Replace the O-ring by positioning it in the top groove by the volume/frequency switches. Stretch the O-ring to place it into the retaining groove at the bottom end of the chassis. 6.Check that the O-ring is not twisted and is being held by the top and bottom chassis groves. 7.Replace the audio jack shroud. Note: Make sure the speaker and microphone wires are routed tightly between the speaker basket and the housing post Figure 7-11. Speaker Re-assembly Note: When fastening the speaker retainer screw, make sure the wires are out of the way to pre- vent pinching by the retainer. Note: Be sure the battery contact seal protrudes through the chassis and is not pinched under the chassis. Speaker Retainer Speaker Front Housing Slot Speaker Tab Tab Opening
December 3, 2003HKLN4215A 7-10Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General . 7.4.3.4 Chassis and Front Cover Re-assembly 8.Dress and connect the speaker wires. a. Connect the speaker wire assembly into the 10-pin connector on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio (Figure 7-13). b. Connect the microphone wire assembly into the two hole socket on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio (Figure 7-13). c.Slide the audio jack shroud onto accessory connector (Figure 7-12). 9.Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover. Look through the accessory connector opening to make certain that the wires are not pinched. 10.Push the topside of the board chassis upward until it touches the housing end. Before snapping the board into the housing, perform the following checks.: a. Open the dust cap and ensure the wires are not pinched between the shroud and housing. b. Ensure the O-ring is seated in the groove. 11.c. Ensure that the bottom side of the dust cap is fully pressed into the housing before the snap- ping the board into place .Figure 7-12. Installation of Main Board onto Chassis Note: Care should be taken when dressing the speaker and microphone wires to avoid pinching them between the speaker magnet and shield, or between the accessory connector and housing. Note: Ensure that the plug orientation is correct with the exposed pins in the wire casing facing upward and fully plugged in. Main Board Radio Chassis Battery Contact Seal Interface Pad Frequency & Volume SwitchesAudio Jack Shroud (Replace after Plugging in Speaker and Mic) O-ring
HKLN4215ADecember 3, 2003 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-11 12.Snap chassis assembly completely into the top of the front cover (Figure 7-14) until it settles in place. 13.Make sure the O-ring is properly seated. If the O-ring seal is pinched, separate the chassis from the housing using the knob removal/chassis opener and dress O-ring properly. 14.Snap the bottom of the chassis into the front cover. 15.Check that O-ring is visible at the corners. 16.After closing the radio, verify that the O-ring is not visible; if visible, re-assemble properly. 17.Re-assemble the knobs, antenna, and battery. 7.4.3.5 PTT Re-assembly 1.Place the PTT seal over the ridge around the top hole. Press down to seat the seal around the ridge. 2.Place the bottom tab in the slot inside the front housing PTT opening. Slightly slide down the PTT and bow it by placing one finger under the middle of the PTT, so that the top tab can be aligned and inserted into the top slot (Figure 7-15a). Figure 7-13. Microphone and Speaker Wires Re-assembly Figure 7-14. Fastening the Chassis Speaker Connector Microphone Connector Shroud Radio Chassis
December 3, 2003HKLN4215A 7-12Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3.Press the PTT assembly against the front cover opening (Figure 7-15b). Figure 7-15. PTT Re-assembly a. Place bottom tab into bottom slot. Place top tab into top slot.b. Push down on PTT toward bottom of radio so hooks do not get crushed.
HKLN4215ADecember 3, 2003 Non-Display Model Disassembly and Re-assembly: Mechanical View and Parts List 7-13 7.5 Mechanical View and Parts List 7.5.1 EP450 Non-Display Exploded View and Parts List Figure 7-16. EP450 Non-Display Radio Exploded View 1 2223 26 2 3 4 5 6 78 9 1011 12 13 14 15 16 1 7 18 19 20 2425 21 30
7-14Mechanical View and Parts List ItemMotorola Part NumberDescription 1See Section 6Antenna 2 3680530Z02 Knob, Frequency 31386440Z02Escutcheon, Top; 16 Ch. 4 5886627Z01 Antenna Adaptor / Seal 51586391Z01Housing, ELP+, Plain 6 3586621Z01 Felt, Speaker 73886489Z01PTT, Rubber 8 4586439Z01 PTT, Plastic 95085738Z08Speaker 10 4286620Z01 Retainer, Speaker 113586621Z02Felt, Microphone 12 0780608V01 Boot, Microphone 135085880L01Microphone 14 3286431Z02 Seal, Main O-ring 157586436Z01Pad, PA Interface 16 2786389Z01 Chassis 173286435Z01Seal, Battery Contact Block 18 0304726J05 Screws, Chassis; 4 Used 191586437Z01Shroud, Audio Jack 20 5586445Z02 Latch Assembly 214105944K01Spring, Latch; 2 Used 22 3886441Z01 Cap, Dust 233286432Z01Seal, Control Shaft 24 3386443Z01 Label, Escutcheon Seal 256186446Z02Lightpipe 26 3680529Z01 Knob, Volume 270386434Z01Screw, Speaker Retainer NON-REFERENCED ITEMS 3386625Z01Nameplate, Motorola Nameplate, EP450
Chapter 8 Troubleshooting Tables 8.1 Power-Up Error Codes During radio power-up, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as an error code on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Ta b l e 8 - 1 to aid in understanding particular operational error codes. 8.2 Operational Error Codes During radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as an error code on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Ta b l e 8 - 2 to aid in understanding particular operational error codes. Table 8-1. Power-Up Error Code Display Error Code Possible Causes Corrective Action RAM ERRRAM Test FailureRetest radio by turning if off and tuning it on again. If message reoccurs, replace main board or send radio to depot. ROM ERR ROM checksum is wrong Reprogram FLASH memory and retest. If message reoc- curs, replace main board or send radio to depot. EPRM ERR EEPROM Hardware Error – Codeplug structure mismatch or non-existence of code- plug or, EEPROM Checksum Error – Codeplug checksum is wrongReprogram codeplug with correct codeplug and retest. If message reoccurs, replace main board or send radio to depot. Table 8-2. Operational Error Code Display Error Code Possible Causes Corrective Action SYN UNLKSynthesizer Out-of-LockVerify codeplug and reprogram if necessary. If message reoccurs, replace main board or send radio to depot.
December 3, 2003HKLN4215A 8-2Troubleshooting Tables: Troubleshooting Table for Receiver 8.3 Troubleshooting Table for Receiver Ta b l e Ta b l e 8 - 3 lists the possible causes of, and corrections for, receiver problems. Table 8-3. Receiver Troubleshooting Table Symptom Possible CausesCorrective or Test (Measurements at Room Temperature) Radio Dead; Display Does Not Turn On1. Dead Battery.Replace with charged battery. 2. Blown Fuse Send radio to depot. 3. On/Off Switch 4. Regulators 5. Regulator fault Radio Dead; Display Turns OnTransceiver Board Send radio to depot. No Receive Audio, or Receiver Does Not Unmute Programming1. Does the transmitted signal match the receiver configu- ration (PL, DPL, etc.)? 2. With the monitor function enabled, can the radio be unmuted? Audio Distorted or Not Loud EnoughSynthesizer Not On Fre- quencyCheck synthesizer frequency by measuring the transmit- ter frequency; realign it off by more than ±150 Hz (VHF), ±500 Hz (UHF) RF Sensitivity Poor 1. Synthesizer Not on Fre- quencyCheck synthesizer frequency by measuring the transmit- ter frequency; realign it off by more than ±150 Hz (VHF), ±500 Hz (UHF) 2. Antenna Switch/Connec- torSend radio to depot. 3. Receiver Front End Tun- ingCheck RF front-end tuning for optimum sensitivity using the tuner. Radio Will Not Turn Off Transceiver Board Send radio to depot.
HKLN4215ADecember 3, 2003 Troubleshooting Tables: Troubleshooting Table for Transmitter 8-3 8.4 Troubleshooting Table for Transmitter Table Table 8-4 lists the possible causes of, and corrections for, transmitter problems. Table 8-4. Transmitter Troubleshooting Table Symptom Possible CausesCorrective or Test (Measurements at Room Temperature) No RF Power Out1. Tx Power Level or Fre- quencyCheck Tx power level and frequency programming (from tuner). 2. No Injection To Power AmplifierSend radio to depot. Antenna Switch/Connector No Modulation; Distortion Modulation1. Programming Check deviation and compensation settings using the tuner. 2. Transceiver BoardSend radio to depot. Bad Microphone Sensitivity 1. Check Deviation and CompensationRealign if necessary. 2. MicrophoneSend radio to depot. No/Low Signaling (PL, DPL, MDC)1. Programming Check programming. 2. Transceiver BoardSend radio to depot. Cannot Set Deviation BalanceRF Board Send radio to depot.