Motorola Radio Mcs2000 Vol 1 68p81083c20 A Manual

							 
Test Equipment, Service Aids, and Tools3-3 
*  Available through Taunusstein Parts only. 
The following table lists the tools recommended for working on the radio; 
these also are available from Motorola. Note that the R-1070A workstation 
requires the use of a speciÞc heat focus head for each of the components on 
which this item is used. Each of these heat focus heads must be ordered 
separately.  
The use of Mini UHF Adapters will have damaging effects on the RF 
Antenna Connector which might lead to radio failure. 
TKN9152ASecurenet Keyload AdapterConnects radio to Securenet Keyloader
3080370E05Securenet Extender CableConnects the control head to the secure board.
RVN4113Radio Service Software
MCS 2000 Series For programming of MCS 2000 radios with SmartNet/Zone, STARTSITE and 
Conventional StatAlert software. (3 1/2Ó ßoppy disc, English version)
GVN6011* (Eng)
GVN6012* (Ger)
GVN6013* (Fren)
GVN6015* (Spa)Radio Service Software
2000 & 2100 Series Select 5For programming of MCS 2000 radios with Conventional Select 5 software. 
Only compatible with VHF and UHF 1-25 Watt models. (3 1/2Ó ßoppy disc) 
Table 3-2   Service Aids 
 Part Number
DescriptionApplication
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Table 3-3   Recommended Service Tools 
Part Number
DescriptionApplication  
0180381B45   110VAC
   or
0180300E06   220VACMBT250 Surface-mount/throu-hole repair stationTemperature-controlled, self-contained soldering/
desoldering repair station for installation and removal of 
surface-mounted devices.
8180369E97Flux holder/applicatorAllows for the proper amount of ßux to be applied to pad 
grid arrays for repair.
1105139W0230cc plastic syringe and ßux pasteFor use with ßux holder/applicator 8180369E97.
0180386A81Miniature digital read-out soldering station (incl. 
1/64Ó micropoint tip)
0180386A78Illuminated magnifying glass with lens 
attachment
0180386A82Anti-static grounding kitUsed during all radio assembly and disassembly 
procedures
6684253C72Straight prober
6680384A98Brush
1010041A86Solder (RMA type), 63/37, 0.020 diameter,1 lb. 
spool
R-1070A
(superseded by R1319A)Shields and surface-mounted component -  IC 
removal/rework stationRemoval of surface-mounted integrated circuits
R1319A
(supersedes R1070A)
6680332E82
6680332E83
6680332E84Surface-Mounted Device Rework Station
R1319A Reßow Nozzle
R1319A Reßow Nozzle
R1319A Reßow NozzleRemoval of surface-mounted integrated circuits
For IC removal (approximate size 0.8 in. x 0.8 in.)
For IC removal (approximate size 0.6 in. x 0.6 in.)
For IC removal (approximate size 0.5 in. x 0.5 in.)
6685629A01End CutterExtraction tool for removable control head buttons.
HLN6621Plug, coaxial Mini UHF male connector.  
Note  
: this connector is delivered with the radio. 
Prior to installation, replace the RF connector 
provided with the antenna with this connector.Recommended RF connector to interface with 
MCS 2000 radios. For use during bench test and 
tuning. 
						

							 
3-4Test Equipment, Service Aids, and Tools 
  
Connection of Control Head Extender Cable 
Failure to follow these instructions may cause severe damage to the 
control head. 
Mid Power Chassis 
1.Place radio on bench with Þns facing downward and away.
2.Remove the plastic cover. This position leaves the top side of the PC 
boards fully exposed and the 18 pin connector (see Table 3-4) facing the 
operator. Note that the 18 pin connector is offset left of center.
3.Place the control head directly in front of the chassis with the control 
head and chassis sides aligned to each other. The two 18 pin connectors 
MUST also be aligned. This means that the control head is sitting upright.  
If the cable is plugged in upside down the control head will burn out.  
4.With the colored side of the control head extender cable facing upward 
all the way between the control head and the chassis connect the cable 
to both control head and chassis 18 pin connectors. 
High Power 
Chassis 
1.Place radio on bench with Þns facing downward and away.
2.Remove the polycarbonate cover. This position leaves the top side of the 
PC boards fully exposed and the 18 pin connector (see Table 3-4) facing 
the operator. Note that the 18 pin connector is offset right of center.
3.Place the control head directly in front of the chassis with the control 
head and chassis sides aligned to each other. The two 18 pin connectors 
MUST also be aligned. This means that the control head is upside-down 
on the bench.  
If the cable is plugged in upside down the control head will burn out.  
4.With the colored side of the control head extender cable facing upward 
all the way between the control head and the chassis connect the cable 
to both control head and chassis 18 pin connectors. After the cable is 
connected the control head can be uprighted.
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Table 3-4   Control Head Connector Pin Signals 
PIN NUMBER 
CONTROLLER SIGNALPIN NUMBER  CONTROLLER SIGNAL
 
1INTERNAL SPKR+10DVP WE
2SPKRÐ11KEY/FAIL
3RESET12KID
4SB9600_BUSÐ13DIGITAL_GND
5not used14SB9600_BUSY
6not used15SB9600_BUS+
7ANALOG_GND16not used
8HANDSET_AUDIO17A+
9MIC/ON_OFF18SW_B+ 
						

							 
Test Mode and Error Codes 4-1 
Test Mode and Error Codes 
4 
Test Mode 
General 
The test mode allows the technician to monitor a set of radio parameters, to 
conÞgure the radio hardware in a number of predeÞned ways, and have access 
to a number of test procedures. Two basic areas of functionality are provided 
by the Test Mode:
¥  
RF  
 test mode - allows the RF functionality of the radio to be tested.
¥  
CH  
 (Control Head) test mode - allows the radio display, buttons and 
switches to be tested.
The purpose of the test mode is to test the radio unit and its interfaces, but not 
to test the various accessories. However, the mobile radio is incapable of 
operating in isolation without a minimum set of accessories. The following 
accessories are assumed:
¥ Keypad or noise cancelling microphone
¥ External speaker (only models II and III)
¥ Control head model I, II or III
If an accessory is subsequently connected to the radio after the test mode 
application has already been invoked, the radio will ignore any resulting 
power up messages received on the serial bus. 
Test Mode 
Features 
On entering Test Mode the radio will be in an idle state, all indicators are 
extinguished and the   
RF TEST  
 Mode Select menu message will be displayed.
Test mode control is provided by a set of menus which may be scrolled 
through and selected. The dedicated buttons   
TM1 (Select)  
 and   
TM2 (Scroll)  
 
(see Figure 4-1 on page 2) are used to navigate through these menus. 
Test Mode Entry 
and Exit 
1. Turn the radio on.
2. Within Þve seconds after power on press the   
TM1  
 Þve (5) times.
3. On entry, the   
SERVICE  
 test mode message is displayed for 2 seconds. 
Following this, each of the following is displayed in sequence:
- radio software part number
- control head part number
- radio model number
- radio serial number
Each of these Òtemporary messagesÓ lasts for 2 seconds. After the radio 
serial number has been displayed for 2 seconds, the message   
RF TEST  
 
will show in the display after 2 seconds. 
						

							 
4-2Test Mode and Error Codes 
4.To exit either the RF Test Mode or the CH Test Mode turn the radio off.  
Figure 4-1    Dedicated Test Mode Keys on Models I, II and III 
RF/CH Test Mode 
Select 
Pressing the scroll key alternates between the two Mode Select menus   
RF TEST  
 and   
CH TEST  
. To select either the RF or CH test menu press the 
dedicated select key while the desired menu is being displayed.  
RF Test Mode 
On entry into the RF test mode the radio hardware will be conÞgured for the 
default carrier squelch (  
CSQ  
) test mode environment. The test mode 
application will examine the following personality parameters in the radio 
codeplug:
¥Tx Channel Number.
¥Rx Channel Number.
When the radio is in RF test mode the PTT button is used to key and dekey the 
transmitter. Whenever the transmitter keys up, the test mode application 
illuminates the front panel red LED and whenever the transmitter keys down 
the application extinguishes the front panel red LED.  
Test Mode Environments  
When the   
RF TEST  
 menu is displayed, press the   
TM1  
 key to gain access to the 
RF test mode environments:
¥  
CSQ  
 (Carrier Squelch). . . (Default)
123
456
789
*0#
MODEL I
M
ODEL III M
ODEL II
TM1
TM2
TM1TM2
TM1
TM2
¥Button TM1:used as Select Key and for Test Mode Entry
¥Button 
TM2:used as Scroll Key 
						

							 
Test Mode and Error Codes4-3  
¥ 
TPL 
 (Tone Private Line)
¥ 
DPL 
 (Digital Private Line 
)  
¥ 
TLS  
(Trunking Low Speed)
¥ 
THS 
 (Trunking high speed)
¥ 
DTM 
 (Dual Tone Modulation Frequency)
¥ 
M12  
(MDC 1200)
When the appropriate environment is selected the test mode application will 
conÞgure the radio hardware for this environment. 
Channel Numbers 
When the cursor is blinking on the channel number Þeld,   
TM2  
 will scroll 
through channels:  
1  
,  
   
2  
,  
   
...n  
 (n is the highest channel number speciÞed by the 
Tx/Rx pairs Þeld). The test mode application will examine the number of Tx/
Rx pairs Þeld contained in the personality area of the radio codeplug in order 
to determine how many different channel number menu messages to display. 
Selecting one of the channel numbers will reconÞgure the radio hardware with 
the speciÞc transmit/receive frequency.
The resulting frequencies will be as follows:
¥Transmit frequency: Offset frequency + (Tx channel number #n * Channel 
step size).
¥Receive frequency: Offset frequency + (Rx channel number #n * Channel 
step size).
The Rx/Tx channel number #n and Channel step size values are extracted from 
the personality area of the radio codeplug and the offset frequency is derived 
from the offset frequency calculation performed on entry into RF test mode.  
CH Test Mode 
On entry into the Control Head test mode, all front panel indicators and 
display segments are displayed for a period of 2 seconds, and then 
extinguished.
When the radio is in Control Head test mode, all front panel momentary 
button presses/releases (apart from the dedicated scroll and select keys and the 
volume control), static switch activations and free revolving rotary activations 
are monitored. When any one of these is detected a short tone will be heard 
and the associated button code (in decimal) and state will be displayed on the 
front panel. 
Error Code 
Displays 
Power-up Display 
Codes 
At power-up, the radio performs cursory tests to determine if its basic 
electronics and software are in working order. Problems detected during these 
tests are presented as error codes on the radio display. The presence of an error 
code should prompt the user that a problem exists and that a service 
technician should be contacted. 
						

							 
4-4Test Mode and Error Codes 
Self-test errors are classiÞed as either fatal or non-fatal. Fatal errors will inhibit 
user operation, while non-fatal errors will not. Use Table 4-1 to aid in 
understanding particular power-up error code displays.
Due to the nature of fatal ROM & RAM errors, it may not be possible to present 
an error code on the display. In these cases the radio will attempt to display 
the appropriate error code, generate an illegal mode tone for one second and 
then reset its microcontroller. 
Operational 
Display Codes 
During operation, the radio performs dynamic tests to determine if it is 
working properly. Problems detected during these tests are presented as error 
codes on the radio display. The presence of an error code should prompt a user 
that a problem exists and that a service technician should be contacted. Use 
Table 4-2 to aid in understanding particular operational error code displays. 
FAILURE DISPLAY
TYPE OF 
FAILUREDESCRIPTIONPOSSIBLE SOURCE
 
FAIL 01/81FATALExternal ROM/Flash checksum errorBad ROM data, Defective ROM
FAIL 01/82FATALExternal EEPROM checksum errorBad external codeplug data, 
Defective external EEPROM
ERROR 01/02NON-FATALExternal EEPROM checksum errorBad external codeplug data
FAIL 01/84FATALExternal EEPROM checksum blankUnprogrammed external codeplug data
FAIL 01/88FATALExternal RAM errorDefective RAM
FAIL 01/90FATALHardware failureDefective IC
FAIL 01/92FATALInternal EEPROM checksum errorBad internal codeplug data, 
Defective microcontroller
FAIL 01/93NON-FATALInternal EEPROM checksum blankFailure of Flashport authorization code
FAIL 01/94FATALInternal EEPROM checksum blankUnprogrammed internal codeplug data
FAIL 01/98FATALInternal RAM errorDefective microcontroller
ERROR 01/12NON-FATALInternal EEPROM checksum errorBad internal codeplug data
ERROR 09/10FATALHardware failureDefective secure board, Missing secure board 
Table 4-1   Power Up Display Codes
Note
 
FAILURE CODE
DESCRIPTIONPOSSIBLE SOURCE
 
FAIL 001Synthesizer out of lockBad frequency data in codeplug; defective synthesizer
FAIL 002Selected Mode (Zone/Channel) codeplug 
checksum errorBad codeplug data  
Table 4-2   Operational Display Codes 
						

							 
Disassembly & Reassembly and Replacement Procedures 5-1 
Disassembly & Reassembly
and Replacement Procedures 
5 
General 
The disassembly/reassembly procedure covers all radio models. SpeciÞc model 
information is included in the procedure where relevant. Where nothing is 
indicated, the procedure will be valid for all models.  
DO NOT attempt to disassemble the radio without Þrst referring to the 
CMOS Precautions paragraph on page 2-2 in the Maintenance section. 
Disassembly to Transceiver Board Level
Low and Mid Power Models 
Remove the 
Control Head 
Steps 1 and 2, Removal of the Retention Frame, are only 
valid for Models II and III, Low and Mid Power Dash Mount 
version radios.
1.  
On Models II & III, Dash Mount only  
: Prior to removing the control 
head, remove the retention frame by inserting a small ßat blade 
screwdriver in the cut outs provided.
2.  
On Models II & III, Dash Mount only  
: Slide the retention frame away 
from the control head groove.
3. Insert a small blade screw driver or like instrument in the side groove at the 
interface between the control head and the transceiver (see Figure 5-1). While 
pulling the control head away from the transceiver press until the control 
head side releases, and then repeat the operation on the opposite side.  
Figure 5-1   Removing the Control Head
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Note
See Detail A
Depress Snap Here
Detail AControl Head I
Transceiver 
						

							 
5-2 Disassembly & Reassembly and Replacement Procedures 
The control head must be removed before removing the transceiver top 
cover.  
4. Pull the control head off of the transceiver while pressing the snaps. (Go 
to ÒRemove the Top CoverÓ section below). 
Remove Front 
Housing 
R 
EMOTE 
 M 
OUNT 
 
V 
ERSION 
 M 
ODELS 
 O 
NLY 
1. Disconnect the Remote Mount Cable by squeezing the top and bottom 
of the connector together, disengaging the bottom snap then the top 
and pulling straight out.
2. Insert a small ßat-blade screwdriver or like instrument in the side groove 
at the interface between the remote front housing and the transceiver 
(see Figure 5-1). Press while pulling the housing away from the 
transceiver until the snap releases. Repeat the operation on the opposite 
side.
3. Remove the 18 position connector from the front of the transceiver.
4. Pull housing off the transceiver. 
Remove the Top 
Cover  
L 
OW 
 P 
OWER 
 M 
ODELS 
1. Pry the cover free from the chassis by inserting a small ßat-blade 
screwdriver or like instrument into the area shown in Figure 5-2 and 
rotating the handle of the screwdriver over the top of the radio. This will 
disengage the snap between the cover and chassis. Rotate the cover away 
from the chassis and pull off. (Go to ÒRemove the Cavity ShieldÓ 
paragraph, page 5-3).   
Figure 5-2   Removing the Top Cover - Low Power Models  
M 
ID 
 P 
OWER 
 M 
ODELS 
1. Insert a wide ßat-blade screwdriver or like instrument in the recess area 
on the side of the radio near the RF and DC connector end (see Figure 5-
3).
2. Pry the cover off the chassis by pushing the handle of the screwdriver up 
and toward the radio. This will disengage the snap between the cover 
and chassis.
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Disengage Snap Here 
						

							 
Disassembly & Reassembly and Replacement Procedures 5-3  
3. Repeat Step 1. and Step 2. for the opposite side of the radio.  
Figure 5-3   Removing the Top Cover - Mid Power Models 
Remove the Cavity 
Shield 
L 
OW 
 P 
OWER 
 M 
ODELS 
 
O 
NLY 
Eight tabs hold the cavity shield to the chassis. The cavity 
shield is the retaining device for the transceiver board and 
also provides the pressure to heat dissipating devices 
attached to the chassis.
1. Remove the cover gasket from the chassis.
2. Loosen the cavity shield by prying each of the eight tabs away from the 
chassis. Release the four tabs on one side Þrst and then repeat the 
operation on the other. Be careful not to pry the tabs any more than is 
necessary to free them from their respective retaining posts (see Figure 5-
4).
3. Pull straight up on the cavity shield. 
Figure 5-4   Removing the Cavity Shield
Disengage Snap here 
and on other side
Note
Cavity Shield Tabs 
						

							 
5-4 Disassembly & Reassembly and Replacement Procedures 
Remove the PA 
Shield 
L 
OW 
  
AND 
 M 
ID 
 P 
OWER 
 
M 
ODELS 
1. Unscrew the three screws that hold the PA shield with T-10 TORX driver.
2. Remove the PA shield by pulling straight up on the attached handle. 
Figure 5-5   Removing the PA Shield (Low and Mid Power Models) 
Remove the 
Transceiver Board 
E 
XCEPT 
 800 MH 
Z 
  
AND 
 
900 MH 
Z 
For 800 MHz and 900 MHz radios go to page 5-6. 
L 
OW 
 P 
OWER 
 M 
ODELS 
1. Remove the Accessory Connector by sliding a Þnger into the recess on 
the chassis and pushing up on the connector tab to loosen the 
connection. Lift the connector out of the recess.
2. Remove all screws using a T-10 TORX driver. Remove the power and 
antenna connector retaining clips by inserting a small ßat blade 
screwdriver between the clip and the top of the chassis wall and gently 
prying upwards (see Figure 5-6).
Thermal grease can act as an adhesive and cause the leads of the the power 
ampliÞer devices to be over stressed if the board is lifted too quickly. 
Figure 5-6   Removing the Transceiver Board - Low Power Models 
(except 800 MHz and 900 MHz)
PA Section & PCB
Holding Screws (3)
Note
Note
Front
Pry Clip Off Here