E.F. Johnson Company 5100 ES Page 3 Service Manual Download

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2007 by the E.F. Johnson Company

The EFJohnson logo, PC Configure

™

, Trunked IP25

™

, and Call Guard

are trademarks of EFJohnson. All

other company and/or product names used in this manual are trademarks and/or registered trademarks of

their respective manufacturers.

Information in this manual is subject to change without notice.

5100 ES Series Portable Radio Service Manual

January 2007

Summary of Contents for 5100 ES

Page 1: ...table Radio Service Manual UHF 700 800 MHz Project 25 Conventional and Trunked Analog and Digital Conventional SMARTNET SmartZone 7 2 VDC 4 Watt UHF 2 5 Watt 700 MHz 3 Watt 800 MHz Part Number 001 5100 60001 January 2007 ...

Page 2: ......

Page 3: ...ll Guard are trademarks of EFJohnson All other company and or product names used in this manual are trademarks and or registered trademarks of their respective manufacturers Information in this manual is subject to change without notice 5100 ES Series Portable Radio Service Manual January 2007 ...

Page 4: ......

Page 5: ...ation 1 9 Introduction 1 9 Definitions 1 10 Possible Ignition Sources 1 10 Intrinsically Safe and Nonincendive Ratings 1 11 Classification of Hazardous Areas and Atmospheres 1 11 Classification of Hazardous Areas Division 1 12 Atmosphere Classification Class Group 1 12 Secure Communication 1 13 Typical Performance Specifications 1 14 2 Battery Accessory and Disassembly Information 2 1 Battery Info...

Page 6: ...nfigure Software 4 2 Firmware Upgrade Instructions 4 2 Upgrade Utility Compatibility 4 2 Firmware Upgrade instructions 4 3 Requirements 4 3 PC Configure Upgrade Instructions 4 4 Initial Setup 4 4 Firmware Upgrade Procedure 4 5 Cloning Procedure 4 6 5 Circuit Description 5 1 General Overview 5 1 Introduction 5 1 PC Boards 5 1 Analog Mode 5 2 Receive Mode 5 2 Transmit Mode 5 2 Project 25 Digital Mod...

Page 7: ...d Amplifier 5 11 Back End IC 5 11 Synthesizer 5 12 PLL IC 5 12 Reference Oscillator 5 12 Analog Switches and PLL Loop Filters 5 12 VCOs 5 12 Transmitter 5 13 Modulation 5 13 Power Amplifier 5 13 ALC 5 13 T R Switching and Harmonic Filter 5 13 User Interface Board 5 14 Power Supplies 5 14 MPC870 Processor 5 15 Flash Memory 5 15 SRAM 5 15 HPI Bus Multiplexer 5 16 Bus Configuration Logic 5 16 HC08 Mi...

Page 8: ...tions 7 1 User Troubleshooting 7 2 Low Battery Indicators 7 2 Battery Replacement 7 2 Additional Information 7 3 Contact Information 7 3 8 Service Information 8 1 Product Warranty 8 1 Factory Customer Service 8 2 Returns for Repairs 8 2 Replacement Parts 8 3 Internet Home Page 8 4 9 Parts List 9 1 Parts 9 1 Exploded Views 9 44 10 Schematic Diagrams and Component Layouts 10 1 ...

Page 9: ...ly Model I 9 53 9 11 Front Cover Assembly Model II III 9 54 9 12 Front Cover Assembly Model I 9 55 9 13 Front Cover Assembly Detail 9 56 10 1 Interconnect Schematic 10 2 10 2 UHF RF Board Schematic Page 1 of 5 10 3 10 3 UHF RF Board Schematic Page 2 of 5 10 4 10 4 UHF RF Board Schematic Page 3 of 5 10 5 10 5 UHF RF Board Schematic Page 4 of 5 10 6 10 6 UHF RF Board Schematic Page 5 of 5 10 7 10 7 ...

Page 10: ...0 10 30 10 30 023 5500 480 485 User Interface Board Schematic Page 9 of 10 10 31 10 31 023 5500 480 485 User Interface Board Schematic Page 10 of 10 10 32 10 32 023 5500 480 485 User Interface Board Assembly 10 33 10 33 023 5500 480 01 487 User Interface Board Schematic Page 1 of 10 10 34 10 34 023 5500 480 01 487 User Interface Board Schematic Page 2 of 10 10 35 10 35 023 5500 480 01 487 User Int...

Page 11: ... 1 3 Material Classification 1 12 1 4 5100 ES Portable Radio General Specifications 1 14 1 5 5100 ES Portable Radio Transmitter Specifications 1 15 1 6 5100 ES Portable Radio Receiver Specifications 1 15 1 7 5100 ES Portable Radio Batteries Specifications 1 16 5 1 Multiplexer Logic Operation 5 16 7 1 Start Up Failure LED Indications 7 1 ...

Page 12: ...viii 5100 ES Series Portable Radio Service Manual January 2007 List of Tables continued Table Page ...

Page 13: ...al This service manual contains operation programming alignment and service information for the EFJohnson 5100 ES Portable Radio Model I II III The distinguishing characteristics of the 5100 ES Portable Radio Model I II III are shown in Figure 1 1 Figure 1 1 5100 ES Portable Radio Model I II III Model II Model I Model III ...

Page 14: ...ion 1 2 1 General The 5100 ES portable transceivers have multiple system programming capability to allow operation in various types of radio systems described in the following information Models are available for operation in the following frequency ranges Repeater talk around which allows transmitting on the receive frequency is available with all bands UHF Low 380 470 MHz 700 800 MHz 762 806 and...

Page 15: ...digital This mode uses a channel spacing of 12 5 kHz 1 2 3 Operating Protocols Standard 5100 ES transceivers can be programmed for any or all the following operating protocols The conventional analog protocol is standard and the others are optional and therefore must be enabled by factory programming Refer to Operation on page 3 1 for more operation information APCO Project 25 digital conventional...

Page 16: ... than a conventional system the total number of channels decreases as the number of SMARTNET systems increases The programming software displays a bar graph which shows the amount of available memory space that is used by the current data Refer to Transceiver Programming on page 4 1 for more information 1 2 4 3 Zones A zone is a collection of up to 16 channels of any type For example a zone could ...

Page 17: ...el II C DTMF Keypad Model III D I S No Display No Keypad Model I E I S Non DTMF Keypad Model II F I S DTMF Keypad Model III A Antenna 0 No Antenna 4 UHF 403 520 MHz 8 800 MHz 1 2 Wavelength 9 800 MHz 1 4 Wavelength B Battery 0 No Battery Pack 1 Ultra High Capacity NiMH 2 Alkaline Battery Clamshell 3 Ultra High Capacity NiMH Submersible 6 I S Ultra High Capacity NiMH 7 I S Ultra High Capacity NiMH ...

Page 18: ...d in the identification number 1 5 Accessories The accessories available for this transceiver are listed in Table 1 1 51xx 0 A 12 04 A 1234 Model Revision Letter Manufacture Date Warranty Number Week No of Year Last Two Digits of Year Plant From P N Table 1 1 Accessories Accessory Part No Batteries 3600 mAH NiMH standard 587 5100 360 3600 mAH NiMH std intrin safe 587 5100 361 3600 mAH NiMH Immersi...

Page 19: ...17 100 136 151 MHz helical yellow core 501 0017 101 151 166 MHz helical black core 501 0017 103 166 174 MHz helical blue core 501 0017 105 403 520 MHz whip dipole 501 0017 107 800 MHz half wave red core 501 0105 013 800 MHz 1 4 wave white core 501 0105 012 Carrying Accessories Nylon Case Model I Military LBE Strap Black 585 5100 15005 Nylon Case Model I B Clip Black 585 5100 15003 Nylon Case Model...

Page 20: ...ter 589 5100 055 Programming Accessories 5100 Programming Kit 488 software 920 cable CD manual 250 5100 003 5100 Programming Cable 023 5100 920 5100 Cloning Cable 023 5100 930 PC Configure programming software CD 023 9998 488 Adapter DB9M DB25F 515 9000 015 Test Cables and Accessories PC Tune radio tuning software 023 9998 499 PC Tune cable w 2 5mm audio out jack 023 5100 940 Patch cord 2 5 mm pho...

Page 21: ...rized by the Factory Mutual Research Corporation to service EFJohnson intrinsically safe transceivers Contact Factory Mutual at the following address for information concerning their auditing procedure Contact the EFJohnson Customer Service Depart ment as described in Section 8 2 if you have questions Factory Mutual Research Corporation 1151 Boston Providence Turnpike P O Box 9102 Norwood Massachu...

Page 22: ...rtain flammable atmospheres Fault A defect or electrical breakdown of any component spacing or insulation which alone or in combination with other faults may adversely affect the electrical or thermal characteristics of the intrinsically safe circuit for example a shorted transistor 1 6 3 Possible Ignition Sources When a transceiver is evaluated by Factory Mutual possible sources of ignition are c...

Page 23: ... faults specified in the testing procedure occur In other words it must be able to withstand two simultaneous unrelated breakdowns without causing ignition To receive a nonincendive rating the transceiver needs to withstand only a single fault without causing ignition of a particular atmosphere 1 6 5 Classification of Hazardous Areas and Atmospheres This transceiver has been submitted for approval...

Page 24: ...nd Class III materials include ignitable fibers or flyings The typical hazardous materials in each group and class are shown in Table 1 3 Table 1 2 Area Classification Division Area Class I and II Materials Gases Vapors and Dusts 1 An area where there is or could be an explosive atmosphere most of the time in normal operation 2 An area where an explosive atmosphere exists only as a result of a fau...

Page 25: ...erating Manual for more information FIPS 140 2 Approved Encryption DES OFB and AES encryption is FIPS 140 2 approved in 5100 ES models equipped with the SEM Over The Air Rekeying OTAR Encryption keys are loaded into the radio by OTAR Over The Air Rekeying using a KMF Key Management Facility and or a handheld keyloader such as the EFJohnson SMA Subscriber Management Assistant or Motorola KVL 3000 P...

Page 26: ...II and SmartZone trunking protocols Encryption Protocols Industry standard encryption capabilities such as AES DES OFB and DES Table 1 4 5100 ES Portable Radio General Specifications Characteristic 800 Only 700 800 UHF Low Frequency Range 806 870 MHz 700 762 806 MHz 800 806 870 MHz 380 470 MHz Channel Spacing 12 5 kHz 25 kHz 12 5 kHz 25 kHz 12 5 kHz 25 kHz Pressure Maximum Frequency Separation Ful...

Page 27: ...ed Radiated 75 dBc 75 dBc 75 dBc Audio Response 1 3dB 1 3dB 1 3dB FM Hum and Noise 25 kHz Channels 40 dB 40 dB 40 dB 12 5 kHz Channels 35 dB 35 dB 35 dB Audio Distortion 3 3 3 Table 1 6 5100 ES Portable Radio Receiver Specifications Characteristic 800 Only 700 800 UHF Low Audio Output Power 500 mW 500 mW 500 mW Frequency Stability 22 F to 140 F 30 C to 60 C 1 5 ppm 1 5 ppm 1 5 ppm Sensitivity Anal...

Page 28: ...ct to change without notice Table 1 7 5100 ES Portable Radio Batteries Specifications Battery Type Dimensions HxWxD Weight Approximate Life 5 5 90 Extra High Capacity NiMH 6 0 x 2 3 x 0 85 inches 153 x 59 x 22 mm 0 81 lbs 0 37 kg UHF Minimum 10 hours 700 800 MHz Minimum 12 hours Extra High Capacity NiMH IS 6 0 x 2 3 x 0 85 inches 153 x 59 x 22 mm 0 81 lbs 0 37 kg UHF Minimum 10 hours 700 800 MHz M...

Page 29: ...ly Information 2 1 Battery Information 2 1 1 Battery Removal Installation To remove the battery from the radio for recharging or replacement press the release button see Figure 2 1 and then rotate it upward to the approximate point shown and remove it from the radio Figure 2 1 Battery Removal Battery Release Button ...

Page 30: ...nite Key Retention is not programmed the transceiver must be connected to a constant power source to preserve the encryption keys in memory Storage capacitors maintain the supply voltage and these keys for approximately 30 seconds to allow the battery to be changed Therefore when changing the battery of a transceiver containing keys make sure to reattach another battery within 30 seconds Models wi...

Page 31: ...tery and slide the belt clip into the slot on the battery as shown in Figure 2 2 To remove the clip simply slide it out It is held in place by the chassis when the battery is installed on the radio 2 3 Accessory Installation To connect an accessory such as a speaker microphone to the transceiver refer to Figure 2 3 and proceed as follows 1 Remove the dust cover over the accessory jack on the side ...

Page 32: ...e lines function as follows Opt Sel 1 and 2 High 3 3V This is the normal operating condition in which no accessory is connected Both lines are pulled high 3 3V by internal pull up resistors Opt Sel 1 Low A speaker microphone or some other accessory is connected Opt Sel 2 then functions as an external PTT line low PTT and the radio PTT switch is also functional The internal speaker and microphone a...

Page 33: ...ely the point shown in the next illustration 3 Slide the chassis out of the top part of the front cover Note Before reassembling the front cover and chassis make sure the UDC accessory connector flex circuit is flat against the side of the front cover If it is not the RF board shield clip may catch and damage it 4 When reassembling make sure the perimeter gasket is in place and then use the screwd...

Page 34: ...he chassis and then clip to the other side of the chassis These shields also hold the boards in place 7 Unplug the antenna cable from the RF board using a plier or similar tool at the location shown below Unlock the logic board flex circuit by sliding the tab on the connector outward The RF and logic boards can now be removed 8 When handling these boards minimize bending of the flex circuit to pre...

Page 35: ... UI board out of the radio 13 When reinstalling the UI board the display assembly on the bottom of the board must slide into the area above the keypad see following illustration If the UI board does not lie flat against the keypad after it is installed the display is probably hanging up on the keypad Do not force it in place Reorient the keypad and UI board as required until the display slides int...

Page 36: ...ator ring under the channel knob turn the channel switch so that the flat part of the shaft is toward one of the tangs see below Then insert a tweezers or similar tool under both tangs and push it inward to release the tangs from the groove in the shaft 17 Remove the spanner nut on each shaft and slide the switch assembly out of the cover ...

Page 37: ...e Manual 3 1 S E C T I O N Chapter3Operation 3 1 General The operation of the 5100 ES transceiver is described in the 5100 ES Model I Operating Manual and the 5100 ES Model II III Operation Manual These manuals are available from your EFJohnson dealer ...

Page 38: ...3 2 5100 ES Series Portable Radio Service Manual January 2007 Operation ...

Page 39: ...the transceiver The part numbers of this equipment are shown in the accessories listing in Table 1 1 The programming set up is shown in Figure 4 1 Computer running Windows software 5100 Programming Cable Part No 023 5100 920 PC Configure programming software Part No 023 9998 527 Figure 4 1 Programming Setup 5100 Programming Cable Connect To Serial Port Part No 023 5100 920 ...

Page 40: ...channel frequencies are located in the back of the above manual 4 4 Firmware Upgrade Instructions 4 4 1 Upgrade Utility Compatibility PC Configure 2 4 x supports 5100 ES Portable Radios that have 4 8 x firmware This firmware has a revised memory configuration for storing the radio operating program Firmware versions utilizing this new memory configuration are as follows Non SEM Version 1 14 0 or l...

Page 41: ...ier versions of firmware 4 4 2 Firmware Upgrade instructions Note If upgrading to the version of firmware described in the preceding section the Boot Code must also be upgraded and it must be done before upgrading the PPC code 4 4 2 1 Requirements 4 4 2 1 1 Firmware Versions Note The firmware Flash operating software version number is briefly displayed when the radio powers up It is also indicated...

Page 42: ...er end of the programming cable to this jack 2 Start the PC Configure program 3 From PC Configure open the Radio menu and select Series 5100 Portable Then open the Transfer menu and select Baud Rates 115200 baud Note If a communication error occurs try selecting a lower baud rate 4 From PC Configure verify the current code version by opening the Transfer menu and selecting Read Version Info from R...

Page 43: ...ly above the PTT switch and then turn power on Release the button and the display will indicate Bootload Waiting for serial bus command 5 Click the Start button and the progress bar should begin advancing to the right If downloading does not start wait until the Communication Problem During Code Download message appears and then click Start again Typically if a sync failure occurs on the first att...

Page 44: ... select Write Parameters to Radio The Progress bar at the bottom of the screen advances as the parameters are written Radio power automatically cycles after the parameters are written 9 To verify that the new code version has been loaded open the Transfer menu and select Read Version Info From Radio Note the Controller Version number to verify that the new code version has been loaded Click the OK...

Page 45: ... this mode Wideband Analog FM modulation with a maximum deviation of 5 kHz This mode is usually used in systems where the channel spacing is 25 kHz or 30 kHz Call Guard CTCSS or DCS subaudible squelch signaling can be used in this mode Project 25 Digital The voice is digitized error corrected optionally encrypted and transmitted using C4FM modulation according to the Project 25 standard This mode ...

Page 46: ...local oscillator frequency to create a second IF signal The second IF signal is then sampled and downconverted to baseband The baseband signal is then decimated to a lower sample rate that is selectable at 20 kHz This signal is then routed via a serial interface from the IF chip to the DSP on the logic board On the logic board the DSP digitally filters the input signal and performs frequency discr...

Page 47: ... kHz The sampled voice signal is sent to a D A in the CODEC to produce an analog signal for output to the audio power amplifier and speaker 5 1 3 2 Transmit Mode The microphone signal is processed as in the analog mode until it reaches the DSP At this point the audio signal is processed by a voice encoding routine to digitize the information The resulting samples are then converted to a bit stream...

Page 48: ...January 2007 5100 ES Series Portable Radio Service Manual 5 4 Circuit Description Figure 5 1 UHF RF Board Block Diagram ...

Page 49: ...ront end filters previously described RF switches U42 and U40 are used to select between the two bands These filters provide additional image rejection 5 2 1 4 Mixer and LO Filter A double balanced low level ADEX 10L mixer MX1 with a LO drive level of 4 dBm is used for the first conversion This mixer provides good dynamic range with a 3 dB lower LO drive than the more traditional 7 dBm drive mixer...

Page 50: ...se detector frequency of 15 kHz Second Conversion Mixer and Filtering A mixer inside the AD9864 converts from the first IF of 64 455 MHz to the second IF of 2 1 MHz External filters L29 and L30 provide IF bandpass filtering Additional filtering is provided by the inherent operation of the sigma delta analog digital converters Gain Control This device provides up to 12 dB of AGC range via a combina...

Page 51: ...h oscillator s modulation port from the digital board A RF2361 buffer amplifier U6 provides the required level of drive for the receiver mixer s local oscillator signal as discussed above 5 2 3 Transmitter 5 2 3 1 Modulation A dual port modulation scheme is used in order to provide DC coupling of the signal required for data modulation applications Modulation applied to the PLL s frequency referen...

Page 52: ...plifier module Transmitter on off splatter filtering is provided by an RC network R76 R109 C267 and C141 5 2 3 4 T R Switching and Harmonic Filter The output of the power amplifier is applied to the transmit receive RF PIN switch D12 D13 This is a high dynamic range switch that is capable of passing the desired transmit power with minimal compression Any harmonics generated by the PA module and th...

Page 53: ...January 2007 5100 ES Series Portable Radio Service Manual 5 9 Circuit Description Figure 5 2 700 800 MHz RF Board Block Diagram ...

Page 54: ...pass Filters Additional bandpass filters are used after the LNA These filters are fixed tuned since varactor tuned filters would have an excessive third order intercept point One filter bank is tuned to the 700 MHz receive band and the other bank to the 800 MHz receive band RF switches U8 and U7 select the desired band These filters have better selectivity and more loss than the front end filters ...

Page 55: ...vides the following receiver functions Second Local Oscillator A varactor tuned transistor Q2 oscillator is phase locked to a fixed frequency of 62 355 MHz in order to convert the first IF of 64 455 MHz to a second IF frequency of 2 1 MHz Phase Locked Loop circuitry inside of the AD9864 operates with a phase detector frequency of 15 kHz Second Conversion Mixer and Filtering A mixer inside the AD98...

Page 56: ... MHz oscillator Y1 provides the frequency reference for the synthesizer and receiver backend IC The center frequency of this oscillator is corrected using a DC tuning voltage from the digital board during receive and it is modulated with voice or data during transmit 5 3 2 3 Analog Switches and PLL Loop Filters Analog switches U16 U17 and U18 provide faster channel switching by changing the time c...

Page 57: ...ut power The PA is turned on and off by switching the power to this driver via transistor D10 5 3 3 3 ALC To maintain the specified Transmitter output power level Automatic Level Control ALC is provided to control the drive level to the PA The detected forward power is compared to a reference level provided by the digital board via op amp U21A The resulting error voltage is applied to a power leve...

Page 58: ...r TI Document TMS320VC5510 PDf HCS08 Microcontrollers Freescale Document MC9S08GB60 PDF Functional Description A functional description of the UI Board is provided in the following paragraphs A block diagram of the UI Board is shown in Figure 5 3 5 4 1 Power Supplies All power used by the UI Board is provided by voltage regulators located on the Logic Board The six supply voltages are as follows 5...

Page 59: ...ough internal peripheral devices controllers The device controllers provide the following functions SPI Bus Controller Communication link to volume control DAC HC08 Microcontroller SPI FLASH Logic Board SEM and LCD display RS232 Controller UDC RS232 link I2C Bus Controller I2C bus control link to the Logic Board Codec Memory Controller SRAM FLASH and HPI data interface and timing General Purpose I...

Page 60: ... at U5 sets the initial operating configuration of the MPC870 by driving selected signals on the MPC870 data bus signals EB_D0 15 high Two different configurations can be selected depending on the state of the nTAP test point TP56 signal line to the CPLD If nTAP is left floating normal configuration the MPC870 JTAG BDM port is set for BDM operation If nTAP is pulled low the MPC870 JTAG BDM port is...

Page 61: ... buffered by U41B on the UI board This voltage is then applied to an 8 bit A D converter in the HC08 microcontroller The HC08 forwards the voltage reading to the MPC870 via the SPI bus This allows the MPC870 to determine the volume level that is currently set by the user The MPC870 then programs D A converter U7 to produce a DC output voltage that sets the desired volume level The volume control v...

Page 62: ...January 2007 5100 ES Series Portable Radio Service Manual 5 18 Circuit Description Figure 5 3 User Interface Board Block Diagram ...

Page 63: ...320AIC21 Data Manual TI Document TLV320AIC21 PDF Functional Description A functional description of the Logic Board is provided in the following paragraphs A block diagram of the Logic Board is shown in Figure 5 4 5 5 1 Power Supplies The power supply section of the Logic board receives power from the battery and converts it through linear and switching regulators into various other voltages that ...

Page 64: ...witching regulators U49 U46 and U47 are synchronized to a 768Khz clock from the CPLD U20 that is derived from the 12 288 TCXO Y2 5 5 1 2 Analog Two linear regulators U11 U45 provide power to the analog circuitry op amps Codec on the Logic and UI boards The 5Vdc analog supply U11 powers the audio out section U9 U10 and Codec 3 3Vdc linear regulator U45 on the Logic Board Additionally the 5Vdc suppl...

Page 65: ...s The DSP processes the incoming data and sends the digitized modulation signals for the RF Deck VCO and TCXO back to the Codec via the SSI bus The Codec converts the digitized modulation signals into analog signals which are level shifted by an op amp U26 to derive the TXMOD1 and TXMOD2 signals for the RF Deck 5 5 2 3 Receive Operation In receive mode the DSP receives I Q data from the Rx Backend...

Page 66: ...on of the multiplexer logic is shown in the table below 5 5 4 Codec The Codec U27 is a support chip for the DSP It provides the A D and D A conversion between the DSP and the microphone and speaker audio signals and between the DSP and the RF Deck modulation signals The operation of the Codec is determined by fourteen internal registers These registers are configured by the MPC870 on the UI Board ...

Page 67: ... 0 6 printed circuit board that in turn is mounted on the Logic Board The application code resides in the EEPROM and is downloaded into the 5416 DSP after reset Operation of the SEM is controlled by the MPC870 on the UI Board through a SPI bus interface on the 5416 DSP Data to be encrypted or decrypted is passed to the SEM through an SSI bus that is connected to the Logic Board 5510 DSP ...

Page 68: ...January 2007 5100 ES Series Portable Radio Service Manual 5 24 Circuit Description Figure 5 4 Logic Board Block Diagram ...

Page 69: ...are set digitally using the computer It is not necessary to disassemble the transceiver to access adjustment points In addition audio test signals are generated internally so an audio generator is not required To verify radio operation perform the Digital Performance Tests and the Analog Performance Tests in the PC Tune manual included on the PC Tune CD Figure 6 1 Alignment Setup 5100 Test Cable D...

Page 70: ...6 2 5100 ES Series Portable Radio Service Manual January 2007 Alignment Procedure ...

Page 71: ...The backup copy of the parameters stored in the SPI flash device is invalid To remove this error use PC Configure to write the parameter file 4 Bad Band The radio band in the parameter file does not match the radio band in the tuning parameters This error message displays if a parameter file for the wrong band is downloaded to the radio 5 Corrupt Parms This error message appears if the parameters ...

Page 72: ...oving to higher ground or away from shielding objects such as tall buildings or hills If some other problem is occurring turn power off and then on again to reset the control logic Also make sure that the controls are properly set If the radio still does not operate correctly return it for service 7 3 Low Battery Indicators A Low Battery Beep sounds once a minute in the standby and transmit modes ...

Page 73: ...vides information about the tones used in the 5100 ES Portable Radio Quick Reference Guide Each radio comes with a quick reference guide This guide includes descriptions and graphics of the 5100 ES Portable Radio hardware features Operator s Manual Please refer to the 5100 ES Model I Operating Manual or the 5100 ES Models II III Operating Manual for technical information 7 5 Contact Information Co...

Page 74: ...7 4 5100 ES Series Portable Radio Service Manual January 2007 Troubleshooting ...

Page 75: ...e warranty statement for this equipment is available from your product supplier or from Warranty Department EFJohnson 1440 Corporate Drive Irving TX 75038 2401 This information may also be requested from the Warranty Department by phone at the numbers listed in Section 8 2 The Warranty Department may also be contacted for warranty service reports claim forms or any other questions concerning warra...

Page 76: ... message informing you of numbers that can be entered to reach various departments This number may be entered during or after the message using a tone type telephone If you have a pulse type telephone wait until the message is finished and an operator will come on the line to assist you When you enter some numbers another number is requested to further categorize the type of information you need Y...

Page 77: ...horization RA numbers are not necessary unless you have been given one by the Field Service Department RA numbers are required for exchange units or if the Field Service Department wants to be aware of a specific problem If you have been given an RA number reference this number on the Factory Repair Request Form sent with the unit The repair lab will then contact the Field Service Department when ...

Page 78: ...ual January 2007 Service Information 8 5 Internet Home Page EFJohnson has a site on the World Wide Web that can be accessed for information on the company about such things as products systems and regulations The address is http www efjohnson com ...

Page 79: ... Series Portable Radio Service Manual 9 1 S E C T I O N Chapter9Parts List 9 1 Parts This section lists the 5100 ES Model I II III Portable Radio component descriptions reference designators Ref No and part numbers Part No ...

Page 80: ...t UI PCB Plain Black 023 5100 341 A 040 ASSEMBLY CONTROLS 5100 See separate listing on Page 9 2 023 5100 045 A 060 ASSEMBLY FRONT HOUSING BLACK PLAIN 587 5100 06104 HW 102 SPNR NUT M6 75 6H MET 013 1313 005 HW 105 SPNR NUT M6 75 6H MET 013 1313 005 MP 006 LIGHTPIPE SLEEVE ASSEMBLY 032 0431 194 MP 104 BUTTON EMERGENCY 320 4312 0801 MP 105 5100 3 POS SELECTOR RING 015 0805 653 MP 106 SPACER SELECTOR...

Page 81: ...ON NI C BLACK ORING 301 X 070 574 2510 001 HW 103 SCREW THREAD FORMING M1 8 X 6 575 7800 10001 MK 101 MIC CARTRIDGE 589 0301 003 ML 000 36 YD x 1 4 ROLL POLYMIDE TAPE 042 0241 241 ML 003 020 62 36 2RA44CORE58 042 0211 234 MP 113 BRACKET SPEAKER 172 2295 6201 MP 120 CLIP SHIELD REAR HOUSING 172 2295 8101 MP 201 CONDUCTIVE COMPRESSION SPACER 574 5100 005 NP 002 WINDRIVER VXWORKS LICENSE LABEL 5100 5...

Page 82: ...1 103 C 026 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 027 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 059 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 063 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 064 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 065 4 7 µF 10V SMD TANT RL 510 2624 479 C 066 CERAMIC CAPACITOR 10 µF 1206 10V 510 3755 106 C 067 CAP 22 µF 10 16V X5R 1210 510 3607 226 C 070 CERAMIC CAPACITOR 1 0 ...

Page 83: ...4 C 128 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 129 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 130 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 132 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 133 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 134 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 135 10 µF 16V 10 TANTALUM CAPACITOR LOW ESR T494 510 2642 100 C 137 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 138 CAP 0 01 µF ...

Page 84: ... SMD INDUCTOR 542 9017 274 L 010 270 nH 0603 SMD INDUCTOR 542 9017 274 L 011 INDUCTOR 27 µH 1 2A SMD 542 5010 019 L 013 270 nH 0603 SMD INDUCTOR 542 9017 274 L 014 270 nH 0603 SMD INDUCTOR 542 9017 274 L 015 270 nH 0603 SMD INDUCTOR 542 9017 274 L 016 10 µH SMT POWER INDUCTOR SD12 100 542 9009 100 PC 001 PCB 5100G LOGIC BOARD 035 5500 180 Q 001 POWER MOSFET N P PAIR 20 V SC 70 576 0006 244 Q 002 G...

Page 85: ... 569 0165 103 R 092 RES 10K 5 402 569 0165 103 R 097 RES 10K 5 402 569 0165 103 R 098 RES 10K 5 402 569 0165 103 R 100 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 101 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 102 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 103 RESISTOR 1 0603 13K OHM 569 0151 412 R 105 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 106 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 107 RESISTOR 1 0603 20...

Page 86: ...9 0165 102 R 268 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 269 RES 100K 0 06W 5 402 569 0165 104 R 270 RES 100K 0 06W 5 402 569 0165 104 R 271 RES 100K 0 06W 5 402 569 0165 104 R 272 RES 100K 0 06W 5 402 569 0165 104 R 273 RES 100K 0 06W 5 402 569 0165 104 R 274 CHIP RESISTOR 0402 569 0165 100 R 275 CHIP RESISTOR 0402 569 0165 100 R 276 RES 100K 0 06W 5 402 569 0165 104 R 277 RES 0 ohm 5 402 569 016...

Page 87: ...16 057 U 042 REGULATOR LDO ADJ TO 5 5V 500mA MSOP 8 544 2603 057 U 043 REGULATOR LDO ADJ TO 5 5V 500mA MSOP 8 544 2603 057 U 045 IC LDO 3 3V 150MA SOT23 TPS73133 544 2603 068 U 046 CONV SYNC STEP DOWN 2 7 10V IN 1 8V OUT 544 4006 012 U 047 CONV SYNC STEP DOWN V REG 2 7 10V IN 3 3V OUT 544 4006 014 U 049 CONV SYNC STEP DOWN 2 7 10V IN VAR OUT 544 4006 010 Y 002 TCXO 12 288 MHz 2PPM HCMOS 518 7012 2...

Page 88: ...6V 10 X7R 0402 510 3687 104 C 093 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 094 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 095 CAP 1 µF 25V 0603 X5S 20 510 3693 105 C 097 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 098 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 099 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 100 CAP 2200 µF 0402 SMD 10V 10 510 3681 222 C 101 CAP 270 µF 10 50V X7R 0402 510 3685 271 C 112...

Page 89: ... 3681 103 C 227 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 228 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 229 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 230 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 231 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 232 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 233 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 234 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 235 CAP 0 1 µF 16V 10 X7R 0402 510 ...

Page 90: ...5 471 C 271 CAP 470 µF 10 50V X7R 0402 510 3685 471 C 272 CAP 470 µF 10 50V X7R 0402 510 3685 471 C 273 CAP 470 µF 10 50V X7R 0402 510 3685 471 C 274 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 275 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 276 CAP 100 µF 402 25V 10 510 3681 101 C 277 CAP 100 µF 402 25V 10 510 3681 101 C 278 CAP 100 µF 402 25V 10 510 3681 101 C 279 CAP 100 µF 402 25V 10 510 3681 101 C 280 ...

Page 91: ...Y SMD 523 2909 005 CR 002 TVS 5V 5 LINE ARRAY SMD 523 2909 005 CR 003 ZENER REG 5 6V SOT23 T R 523 2016 569 CR 005 ZDIO MMBZ5V6ALT1 SOT23 523 2602 001 CR 008 DUAL COLOR RED GRN LED SMD 549 4001 215 CR 009 ZDIO MMBZ5V6ALT1 SOT23 523 2602 001 CR 033 DUAL DIODES COM ANODES 523 1504 024 CR 044 DIODE DUAL COMMON ANODE 7 5V SC89 523 1508 105 CR 045 DIODE DUAL COMMON ANODE 7 5V SC89 523 1508 105 F 001 FU...

Page 92: ... 330 Q 017 XSTR P CHNL MOSFET 30V SOT23 576 0006 330 R 005 CHIP RESISTOR 0402 569 0165 100 R 055 RESISTOR 1 0402 100K OHM 569 0161 501 R 057 RESISTOR 1 0402 100K OHM 569 0161 501 R 058 RESISTOR 1 0402 100K OHM 569 0161 501 R 060 RES 1K OHM 1 0402 SIZE SMT 569 0161 301 R 067 RES 47K OHM 5 402 569 0165 473 R 075 RES 10K 5 402 569 0165 103 R 076 RESISTOR 1 0402 2 21K OHM 569 0161 334 R 080 RESISTOR 1...

Page 93: ...65 471 R 123 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 128 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 129 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 130 RES 47K OHM 5 402 569 0165 473 R 131 RES 47K OHM 5 402 569 0165 473 R 132 RES 47K OHM 5 402 569 0165 473 R 135 RES 47K OHM 5 402 569 0165 473 R 136 RES 47K OHM 5 402 569 0165 473 R 137 RES 47K OHM 5 402 569 0165 473 R 138 RES 47K OHM 5 402 569 0165 473...

Page 94: ...OR 1 0402 100K OHM 569 0161 501 R 305 RES 10K 5 402 569 0165 103 R 306 RES 10K 5 402 569 0165 103 R 307 RES 1K OHM 1 0402 SIZE SMT 569 0161 301 R 308 RES 10K 5 402 569 0165 103 R 309 RES 10K 5 402 569 0165 103 R 311 RES 10K 5 402 569 0165 103 R 312 RES 10K 5 402 569 0165 103 R 313 RES 10K 5 402 569 0165 103 R 314 RES 10K 5 402 569 0165 103 R 315 RES 10K 5 402 569 0165 103 R 316 RES 10K 5 402 569 0...

Page 95: ...3 R 348 RES 10K 5 402 569 0165 103 R 349 RES 10K 5 402 569 0165 103 R 350 RES 10K 5 402 569 0165 103 R 360 RES 10K 5 402 569 0165 103 R 361 RES 10K 5 402 569 0165 103 R 362 RES 10K 5 402 569 0165 103 R 363 RES 10K 5 402 569 0165 103 R 364 RES 10K 5 402 569 0165 103 R 365 RES 10K 5 402 569 0165 103 R 367 RES 10K 5 402 569 0165 103 R 376 RESISTOR 255K 1 0402 569 0161 540 R 377 RES 10K 5 402 569 0165...

Page 96: ...8 U 007 IC DAC 8 BIT LOW PWR SC 70 2 7 TO 5 5V 544 2031 020 U 008 AMP AUDIO POWER 150 mW SOIC TPA122 544 2006 030 U 017 OpAmp Dual single sply 8p 544 2018 015 U 018 OpAmp Dual single sply 8p 544 2018 015 U 019 OPAMP QUAD SINGLE SPLY SSOP 544 2020 013 U 021 AMP AUDIO POWER 150 mW SOIC TPA122 544 2006 030 U 022 TRI ST BUFR 3 3V SINGLE GATE 5 P T R 544 3914 125 U 023 SINGLE D F F WITH PR CLR LOW POWE...

Page 97: ...7 104 C 080 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 083 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 084 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 086 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 087 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 088 CAP 22 µF 16V 20 X5R 1206 510 3804 226 C 089 CAP 220 pF 10 50V X7R 0402 t r 510 3685 221 C 092 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 093 CAP 0 1 µF 16V...

Page 98: ...0 pF 10 50V X7R 0402 510 3685 471 C 220 CAP 470 pF 10 50V X7R 0402 510 3685 471 C 221 CAP 470 pF 10 50V X7R 0402 510 3685 471 C 222 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 223 CAP 100 pF 402 25V 10 510 3681 101 C 224 CAP 100 pF 402 25V 10 510 3681 101 C 226 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 227 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 228 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 229 CAP 0 1...

Page 99: ...85 102 C 263 CAP 1 0 µF 6 3V 10 X5R 0402 510 3604 105 C 265 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 266 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 267 CAP 470 pF 10 50V X7R 0402 510 3685 471 C 268 CAP 470 pF 10 50V X7R 0402 510 3685 471 C 269 CAP 680 pF 10 50V X7R 0402 t r 510 3685 681 C 270 CAP 470 pF 10 50V X7R 0402 510 3685 471 C 271 CAP 470 pF 10 50V X7R 0402 510 3685 471 C 272 CAP 470 pF 10 50V X7...

Page 100: ...X5R 0402 510 3604 105 C 311 CAP 1 0 µF 6 3V 10 X5R 0402 510 3604 105 C 315 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 316 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 317 CAP 33 pF 10 402 25V 510 3681 330 C 318 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 321 CAP 0 01 µF 0402 10 TOL 510 3681 103 CR 001 TVS 5V 5 LINE ARRAY SMD 523 2909 005 CR 002 TVS 5V 5 LINE ARRAY SMD 523 2909 005 CR 003 ZENER REG 5 6V SOT23 T R...

Page 101: ...RPOSE 3904 BST SC 75 576 0001 029 Q 013 GEN PURPOSE 3904 BST SC 75 576 0001 029 Q 014 GEN PURPOSE 3904 BST SC 75 576 0001 029 Q 015 MOSFET 20V 238mA N CH ESD SC75 SOT416 NTA4001N 576 0010 001 Q 016 XSTR P CHNL MOSFET 30V SOT23 576 0006 330 Q 017 XSTR P CHNL MOSFET 30V SOT23 576 0006 330 R 005 CHIP RESISTOR TAPE REEL 0402 569 0165 100 R 055 RESISTOR 1 0402 100K OHM 569 0161 501 R 057 RESISTOR 1 040...

Page 102: ...117 RESISTOR 1 0402 100K OHM 569 0161 501 R 118 RESISTOR 1 0402 100K OHM 569 0161 501 R 119 RESISTOR 1 0402 100K OHM 569 0161 501 R 120 RESISTOR 1 0402 49 9K OHM T R 569 0161 468 R 122 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 123 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 128 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 129 RESISTOR 470 OHM 0402 SMT 569 0165 471 R 130 RES 47K OHM 5 402 569 0165 473 R 13...

Page 103: ...02 569 0165 103 R 294 RES 10K 5 402 569 0165 103 R 295 RES 1K OHM 1 0402 SIZE SMT 569 0161 301 R 296 RES 10K 5 402 569 0165 103 R 297 RES 10K 5 402 569 0165 103 R 300 RES 10K 5 402 569 0165 103 R 303 RESISTOR 1 0402 100K OHM 569 0161 501 R 304 RESISTOR 1 0402 100K OHM 569 0161 501 R 305 RES 10K 5 402 569 0165 103 R 306 RES 10K 5 402 569 0165 103 R 307 RES 1K OHM 1 0402 SIZE SMT 569 0161 301 R 308 ...

Page 104: ...1 0402 49 9K OHM T R 569 0161 468 R 341 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 343 RES 4 7K 5 402 569 0165 472 R 344 RES 4 7K 5 402 569 0165 472 R 345 RES 4 7K 5 402 569 0165 472 R 346 RES 10K 5 402 569 0165 103 R 347 RES 10K 5 402 569 0165 103 R 348 RES 10K 5 402 569 0165 103 R 349 RES 10K 5 402 569 0165 103 R 350 RES 10K 5 402 569 0165 103 R 360 RES 10K 5 402 569 0165 103 R 361 RES 10K 5 402 56...

Page 105: ... CELL 45 IO MIXED IO VOLTAGE 544 5001 421 U 006 SRAM 1Mx16 70ns 3 3v T R 544 1028 198 U 007 IC DAC 8 BIT LOW PWR SC 70 2 7 TO 5 5V 544 2031 020 U 008 AMP AUDIO PWR BTL VOL CTRL 8 PIN SOIC 544 2006 035 U 017 OpAmp Dual single sply 8p regA T R 544 2018 015 U 018 OpAmp Dual single sply 8p regA T R 544 2018 015 U 019 OPAMP QUAD SINGLE SPLY SSOP regAT R 544 2020 013 U 021 AMP AUDIO PWR BTL VOL CTRL 8 P...

Page 106: ... 10 TOL 510 3681 103 C 017 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 018 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 019 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 020 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 021 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 022 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 023 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 024 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 025 CAP 0 01 µF 0402 ...

Page 107: ...0402 10 TOL 510 3681 103 C 114 CAP 10 µF 10 402 25V 510 3681 100 C 115 CAP 10 µF 10 402 25V 510 3681 100 C 117 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 118 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 119 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 120 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 121 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 122 CAP 0 1 µF 16V 10 X7R 0402 510 3687 104 C 123 CERAMIC CAPACITOR 1...

Page 108: ...µF 0402 10 TOL 510 3681 103 CR 001 DUAL DIODES COM ANODES 523 1504 024 CR 004 SILICON SWITCHING DIODE SC 75 523 1004 021 CR 008 DUAL DIODES COM ANODES 523 1504 024 J 001 CONN 26 P ZIF 0 5MM PITCH SMD 515 7111 526 J 002 FINE PITCH SMD BD TO BD RECEP 60 PIN TR 515 7111 650 J 003 SINGLE SPRING CLIP BRIGHT TINNED 75RC 05 08 537 5001 014 J 004 SINGLE SPRING CLIP BRIGHT TINNED 75RC 05 08 537 5001 014 L ...

Page 109: ... 0161 501 R 062 RESISTOR 1 0402 100K OHM 569 0161 501 R 063 RESISTOR 1 0402 100K OHM 569 0161 501 R 064 RES 100K 0 06W 5 402 569 0165 104 R 065 RES 100K 0 06W 5 402 569 0165 104 R 068 RES 100K 0 06W 5 402 569 0165 104 R 069 RES 100K 0 06W 5 402 569 0165 104 R 074 CHIP RESISTOR 0402 569 0165 100 R 075 RESISTOR 100 OHM 402 SIZE 5 569 0165 101 R 078 RESISTOR 1 221K 0402 569 0161 534 R 081 RESISTOR 1 ...

Page 110: ...03 R 249 RES 10K 5 402 569 0165 103 R 253 RES 100K 0 06W 5 402 569 0165 104 R 254 RES 100K 0 06W 5 402 569 0165 104 R 255 CHIP RESISTOR 0402 569 0165 100 R 259 CHIP RESISTOR 0402 569 0165 100 R 260 CHIP RESISTOR 0402 569 0165 100 R 261 CHIP RESISTOR 0402 569 0165 100 R 262 RES 100K 0 06W 5 402 569 0165 104 R 263 RES 100K 0 06W 5 402 569 0165 104 R 264 RES 0 ohm 5 402 569 0165 001 R 265 RESISTOR 1K...

Page 111: ...9 SINGLE SUPPLY SPDT ANALOG SWITCH SC 70 544 4002 007 U 011 LDO DMOS400MA 5V 8P MSOP 544 2603 055 U 013 Reg L LDO 3 8V 50MA SOT23 5pin T R 544 5001 335 U 015 DSP TMS3205510AGGWA1 160MHz BGA trays 544 5003 133 U 016 SINGLE SUPPLY SPDT ANALOG SWITCH SC 70 544 4002 007 U 017 SINGLE SUPPLY SPDT ANALOG SWITCH SC 70 544 4002 007 U 018 LDO DMOS400MA 5V 8P MSOP 544 2603 055 U 020 IC CPLD 64 CELL 45 IO MIX...

Page 112: ...SEMBLY CONTROLS 5100 See separate listing on Page 9 2 023 5100 045 A 060 ASSEMBLY FR HOUSING BLACK 587 5100 06101 HW 102 SPNR NUT M6 75 6H MET 013 1313 005 HW 105 SPNR NUT M6 75 6H MET 013 1313 005 MP 006 LIGHTPIPE SLEEVE ASSEMBLY 032 0431 194 MP 104 BUTTON EMERGENCY 320 4312 0801 MP 105 5100 3 POS SELECTOR RING 015 0805 653 MP 106 SPACER SELECTOR SWITCH 5100 032 0431 166 MP 107 KNOB SELECTOR 5100...

Page 113: ...170 163 A 050 ASSEMBLY FR HOUSING W O UI PCB DTMF BLACK See separate listing on Page 9 35 023 5100 361 A 080 COMMON PARTS FINAL ASSEMBLY See separate listing on Page 9 3 023 5100 085 A 100 5100G LOGIC BD NON ENCRYPTED See separate listing on Page 9 4 023 5500 185 A 200 RF MODULE 700 800 MHz ONLY CALAMP 6A830 585 5500 710 A 400 ASSEMBLY UI PCB DTMF See separate listing on Page 9 36 023 5100 480 Ref...

Page 114: ...D 585 5100 02101 MP 100 SPACER LIGHT PIPE 574 3500 11701 MP 132 COMPRESSION PAD UI PCB 574 5100 13201 S 010 DOME ARRAY TOP 583 9511 02101 S 012 DOME ARRAY BOTTOM 583 9511 02201 Ref Number Description Part Number Model III 7 800 MHz SEM Black DTMF 023 5170 063 A 050 ASSEMBLY FR HOUSING W O UI PCB DTMF BLACK See separate listing on Page 9 35 023 5100 361 A 080 COMMON PARTS FINAL ASSEMBLY See separat...

Page 115: ... 3681 103 C 016 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 017 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 018 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 019 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 020 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 021 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 022 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 023 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 024 CAP 0 01 µF ...

Page 116: ...10 510 3607 226 C 110 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 111 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 114 CAP 10 µF 10 402 25V 510 3681 100 C 115 CAP 10 µF 10 402 25V 510 3681 100 C 117 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 118 CAP 0 1 µF 16V 10 X7R 0402 t r 510 3687 104 C 119 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 120 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 121 CAP 0 1 µF 16V 10 X7R 0402...

Page 117: ...10 TOL 510 3681 103 C 157 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 158 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 159 CAP 0 01 µF 0402 10 TOL 510 3681 103 C 160 CAP 0 01 µF 0402 10 TOL 510 3681 103 CR 001 DUAL DIODES COM ANODES 523 1504 024 CR 004 SILICON SWITCHING DIODE SC 75 523 1004 021 CR 008 DUAL DIODES COM ANODES 523 1504 024 J 001 CONN 26 P ZIF 0 5MM PITCH SMD see notes 515 7111 526 J 002 FINE PI...

Page 118: ...K 1 0402 569 0161 447 R 032 RES 30 1K 1 0402 569 0161 447 R 033 SURFACE MOUNT 20K 0402 RESISTOR 569 0165 203 R 059 RESISTOR 1 0402 100K OHM 569 0161 501 R 060 RESISTOR 1 0402 100K OHM 569 0161 501 R 061 RESISTOR 1 0402 100K OHM 569 0161 501 R 062 RESISTOR 1 0402 100K OHM 569 0161 501 R 063 RESISTOR 1 0402 100K OHM 569 0161 501 R 064 RES 100K 06W 5 402 569 0165 104 R 065 RES 100K 06W 5 402 569 0165...

Page 119: ... 0165 102 R 240 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 241 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 242 RESISTOR 1K OHM 0402 SMT 569 0165 102 R 243 RES 10K 5 402 569 0165 103 R 244 RES 10K 5 402 569 0165 103 R 245 RES 10K 5 402 569 0165 103 R 249 RES 10K 5 402 569 0165 103 R 253 RES 100K 06W 5 402 569 0165 104 R 254 RES 100K 06W 5 402 569 0165 104 R 255 CHIP RESISTOR TAPE REEL 0402 569 0165 100 R ...

Page 120: ...01 CHIP RESISTOR TAPE REEL 0402 569 0165 100 R 302 CHIP RESISTOR TAPE REEL 0402 569 0165 100 R 303 CHIP RESISTOR TAPE REEL 0402 569 0165 100 R 306 CHIP RESISTOR TAPE REEL 0402 569 0165 100 R 307 RES 100K 06W 5 402 569 0165 104 U 008 OPAMP QUAD SINGLE SPLY SSOP regAT R 544 2020 013 U 009 SINGLE SUPPLY SPDT ANALOG SWITCH SC 70 544 4002 007 U 011 LDO DMOS400MA 5V 8P MSOP regAT R 544 2603 055 U 013 Re...

Page 121: ... 046 CONV SYNC STEP DOWN 2 7 10V IN 1 8V OUT 544 4006 012 U 047 CONV SYNC STEP DOWN V REG 2 7 10V IN 3 3V OUT 544 4006 014 U 049 CONV SYNC STEP DOWN 2 7 10V IN VAR OUT 544 4006 010 Y 001 OSC 20 000 MHz SMD 3 3V 40 85C 561 9004 200 Y 002 TCXO 12 288 MHz 2PPM HCMOS 518 7012 210 Ref Number Description Part Number ...

Page 122: ...January 2007 5100 ES Series Portable Radio Service Manual 9 44 Parts List 9 2 Exploded Views Figure 9 1 5100 ES Portable Radio Model III Assembly ...

Page 123: ...January 2007 5100 ES Series Portable Radio Service Manual 9 45 Parts List Figure 9 2 5100 ES Portable Radio Model II Assembly ...

Page 124: ...January 2007 5100 ES Series Portable Radio Service Manual 9 46 Parts List Figure 9 3 5100 ES Portable Radio Model I Assembly ...

Page 125: ...January 2007 5100 ES Series Portable Radio Service Manual 9 47 Parts List Figure 9 4 Front Housing Assembly Model III ...

Page 126: ...January 2007 5100 ES Series Portable Radio Service Manual 9 48 Parts List Figure 9 5 Front Housing Assembly Model II ...

Page 127: ...January 2007 5100 ES Series Portable Radio Service Manual 9 49 Parts List Figure 9 6 Front Housing Assembly Model I ...

Page 128: ...January 2007 5100 ES Series Portable Radio Service Manual 9 50 Parts List Figure 9 7 Rear Housing Assembly Model I II III ...

Page 129: ...January 2007 5100 ES Series Portable Radio Service Manual 9 51 Parts List Figure 9 8 User Interface PCB Assembly Model III ...

Page 130: ...January 2007 5100 ES Series Portable Radio Service Manual 9 52 Parts List Figure 9 9 User Interface PCB Assembly Model II ...

Page 131: ...January 2007 5100 ES Series Portable Radio Service Manual 9 53 Parts List Figure 9 10 User Interface PCB Assembly Model I ...

Page 132: ...January 2007 5100 ES Series Portable Radio Service Manual 9 54 Parts List Figure 9 11 Front Cover Assembly Model II III ...

Page 133: ...January 2007 5100 ES Series Portable Radio Service Manual 9 55 Parts List Figure 9 12 Front Cover Assembly Model I ...

Page 134: ...January 2007 5100 ES Series Portable Radio Service Manual 9 56 Parts List Figure 9 13 Front Cover Assembly Detail ...

Page 135: ... Series Portable Radio Service Manual 10 1 S E C T I O N Chapter10Schematic Diagrams and Component Layouts This section contains schematic diagrams and layout illustrations of most components for the 5100 ES Portable Radio ...

Page 136: ...January 2007 5100 ES Series Portable Radio Service Manual 10 2 Schematic Diagrams and Component Layouts Figure 10 1 Interconnect Schematic 1 2 13 12 1 2 13 12 ...

Page 137: ...January 2007 5100 ES Series Portable Radio Service Manual 10 3 Schematic Diagrams and Component Layouts Figure 10 2 UHF RF Board Schematic Page 1 of 5 ...

Page 138: ...January 2007 5100 ES Series Portable Radio Service Manual 10 4 Schematic Diagrams and Component Layouts Figure 10 3 UHF RF Board Schematic Page 2 of 5 ...

Page 139: ...January 2007 5100 ES Series Portable Radio Service Manual 10 5 Schematic Diagrams and Component Layouts Figure 10 4 UHF RF Board Schematic Page 3 of 5 ...

Page 140: ...January 2007 5100 ES Series Portable Radio Service Manual 10 6 Schematic Diagrams and Component Layouts Figure 10 5 UHF RF Board Schematic Page 4 of 5 ...

Page 141: ...January 2007 5100 ES Series Portable Radio Service Manual 10 7 Schematic Diagrams and Component Layouts Figure 10 6 UHF RF Board Schematic Page 5 of 5 ...

Page 142: ...January 2007 5100 ES Series Portable Radio Service Manual 10 8 Schematic Diagrams and Component Layouts Figure 10 7 UHF RF Board Layout BOTTOM VIEW TOP VIEW ...

Page 143: ...o Service Manual 10 9 Schematic Diagrams and Component Layouts Figure 10 8 700 800 MHz RF Board Schematic Page 1 of 5 Note Individual replacement parts are not available for the RF board so the entire board must be replaced if it is defective ...

Page 144: ...January 2007 5100 ES Series Portable Radio Service Manual 10 10 Schematic Diagrams and Component Layouts Figure 10 9 700 800 MHz RF Board Schematic Page 2 of 5 ...

Page 145: ...January 2007 5100 ES Series Portable Radio Service Manual 10 11 Schematic Diagrams and Component Layouts Figure 10 10 700 800 MHz RF Board Schematic Page 3 of 5 ...

Page 146: ...January 2007 5100 ES Series Portable Radio Service Manual 10 12 Schematic Diagrams and Component Layouts Figure 10 11 700 800 MHz RF Board Schematic Page 4 of 5 ...

Page 147: ...January 2007 5100 ES Series Portable Radio Service Manual 10 13 Schematic Diagrams and Component Layouts Figure 10 12 700 800 MHz RF Board Schematic Page 5 of 5 ...

Page 148: ...January 2007 5100 ES Series Portable Radio Service Manual 10 14 Schematic Diagrams and Component Layouts Figure 10 13 700 800 MHz RF Board Layout Bottom View Top View ...

Page 149: ...l 10 15 Schematic Diagrams and Component Layouts Figure 10 14 023 5500 180 182 185 Logic Board Schematic Page 1 of 7 Note The number from 3 11 next to a node label indicates the page number of the circuit to which it connects Note Pages 1 and 2 are not used ...

Page 150: ...January 2007 5100 ES Series Portable Radio Service Manual 10 16 Schematic Diagrams and Component Layouts Figure 10 15 023 5500 180 182 185 Logic Board Schematic Page 2 of 7 ...

Page 151: ...January 2007 5100 ES Series Portable Radio Service Manual 10 17 Schematic Diagrams and Component Layouts Figure 10 16 023 5500 180 182 185 Logic Board Schematic Page 3 of 7 ...

Page 152: ...January 2007 5100 ES Series Portable Radio Service Manual 10 18 Schematic Diagrams and Component Layouts Figure 10 17 023 5500 180 182 185 Logic Board Schematic Page 4 of 7 ...

Page 153: ...January 2007 5100 ES Series Portable Radio Service Manual 10 19 Schematic Diagrams and Component Layouts Figure 10 18 023 5500 180 182 185 Logic Board Schematic Page 5 of 7 ...

Page 154: ...January 2007 5100 ES Series Portable Radio Service Manual 10 20 Schematic Diagrams and Component Layouts Figure 10 19 023 5500 180 182 185 Logic Board Schematic Page 6 of 7 ...

Page 155: ...January 2007 5100 ES Series Portable Radio Service Manual 10 21 Schematic Diagrams and Component Layouts Figure 10 20 023 5500 180 182 185 Logic Board Schematic Page 7 of 7 ...

Page 156: ...January 2007 5100 ES Series Portable Radio Service Manual 10 22 Schematic Diagrams and Component Layouts Figure 10 21 023 5500 180 182 185 Logic Board Assembly Bottom View Top View ...

Page 157: ...0 23 Schematic Diagrams and Component Layouts Figure 10 22 023 5500 480 485 User Interface Board Schematic Page 1 of 10 Note The number from 3 12 next to a node label indicates the page number of the circuit to which it connects Note Pages 1 and 2 are not used ...

Page 158: ...January 2007 5100 ES Series Portable Radio Service Manual 10 24 Schematic Diagrams and Component Layouts Figure 10 23 023 5500 480 485 User Interface Board Schematic Page 2 of 10 ...

Page 159: ...January 2007 5100 ES Series Portable Radio Service Manual 10 25 Schematic Diagrams and Component Layouts Figure 10 24 023 5500 480 485 User Interface Board Schematic Page 3 of 10 ...

Page 160: ...January 2007 5100 ES Series Portable Radio Service Manual 10 26 Schematic Diagrams and Component Layouts Figure 10 25 023 5500 480 485 User Interface Board Schematic Page 4 of 10 ...

Page 161: ...January 2007 5100 ES Series Portable Radio Service Manual 10 27 Schematic Diagrams and Component Layouts Figure 10 26 023 5500 480 485 User Interface Board Schematic Page 5 of 10 ...

Page 162: ...January 2007 5100 ES Series Portable Radio Service Manual 10 28 Schematic Diagrams and Component Layouts Figure 10 27 023 5500 480 485 User Interface Board Schematic Page 6 of 10 ...

Page 163: ...January 2007 5100 ES Series Portable Radio Service Manual 10 29 Schematic Diagrams and Component Layouts Figure 10 28 023 5500 480 485 User Interface Board Schematic Page 7 of 10 ...

Page 164: ...January 2007 5100 ES Series Portable Radio Service Manual 10 30 Schematic Diagrams and Component Layouts Figure 10 29 023 5500 480 485 User Interface Board Schematic Page 8 of 10 ...

Page 165: ...January 2007 5100 ES Series Portable Radio Service Manual 10 31 Schematic Diagrams and Component Layouts Figure 10 30 023 5500 480 485 User Interface Board Schematic Page 9 of 10 ...

Page 166: ...January 2007 5100 ES Series Portable Radio Service Manual 10 32 Schematic Diagrams and Component Layouts Figure 10 31 023 5500 480 485 User Interface Board Schematic Page 10 of 10 ...

Page 167: ...January 2007 5100 ES Series Portable Radio Service Manual 10 33 Schematic Diagrams and Component Layouts Figure 10 32 023 5500 480 485 User Interface Board Assembly Top View Bottom View ...

Page 168: ... 34 Schematic Diagrams and Component Layouts Figure 10 33 023 5500 480 01 487 User Interface Board Schematic Page 1 of 10 Note The number from 3 12 next to a node label indicates the page number of the circuit to which it connects Note Pages 1 and 2 are not used ...

Page 169: ...January 2007 5100 ES Series Portable Radio Service Manual 10 35 Schematic Diagrams and Component Layouts Figure 10 34 023 5500 480 01 487 User Interface Board Schematic Page 2 of 10 ...

Page 170: ...January 2007 5100 ES Series Portable Radio Service Manual 10 36 Schematic Diagrams and Component Layouts Figure 10 35 023 5500 480 01 487 User Interface Board Schematic Page 3 of 10 ...

Page 171: ...January 2007 5100 ES Series Portable Radio Service Manual 10 37 Schematic Diagrams and Component Layouts Figure 10 36 023 5500 480 01 487 User Interface Board Schematic Page 4 of 10 ...

Page 172: ...January 2007 5100 ES Series Portable Radio Service Manual 10 38 Schematic Diagrams and Component Layouts Figure 10 37 023 5500 480 01 487 User Interface Board Schematic Page 5 of 10 ...

Page 173: ...January 2007 5100 ES Series Portable Radio Service Manual 10 39 Schematic Diagrams and Component Layouts Figure 10 38 023 5500 480 01 487 User Interface Board Schematic Page 6 of 10 ...

Page 174: ...January 2007 5100 ES Series Portable Radio Service Manual 10 40 Schematic Diagrams and Component Layouts Figure 10 39 023 5500 480 01 487 User Interface Board Schematic Page 7 of 10 ...

Page 175: ...January 2007 5100 ES Series Portable Radio Service Manual 10 41 Schematic Diagrams and Component Layouts Figure 10 40 023 5500 480 01 487 User Interface Board Schematic Page 8 of 10 ...

Page 176: ...January 2007 5100 ES Series Portable Radio Service Manual 10 42 Schematic Diagrams and Component Layouts Figure 10 41 023 5500 480 01 487 User Interface Board Schematic Page 9 of 10 ...

Page 177: ...January 2007 5100 ES Series Portable Radio Service Manual 10 43 Schematic Diagrams and Component Layouts Figure 10 42 023 5500 480 01 487 User Interface Board Schematic Page 10 of 10 ...

Page 178: ...January 2007 5100 ES Series Portable Radio Service Manual 10 44 Schematic Diagrams and Component Layouts Figure 10 43 023 5500 480 01 487 User Interface Board Assembly Top View Bottom View ...

Page 179: ...io Service Manual 10 45 Schematic Diagrams and Component Layouts Figure 10 44 Cable Schematics 1 5 9 6 1 2 12 13 UDC Pin Numbering DB9 F Pin Numbering Programming Cable Schematic Part No 023 5100 920 Test Cable Schematic Part No 023 5100 940 ...

Page 180: ...10 46 5100 ES Series Portable Radio Service Manual January 2007 Schematic Diagrams and Component Layouts ...

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