Motorola P Series Basic Service Manual Download Page 1

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Professional Radio

P Series

Basic Service Manual

68P64115B49

Issue: September 1999

Summary of Contents for P Series

Page 1: ...Professional Radio P Series Basic Service Manual 68P64115B49 Issue September 1999 ...

Page 2: ...Radio Communications Supply Installation Specialist Website www radiotronics co uk Email sales radiotronics co uk Telephone Numbers 0345 0 955 955 02087 190 180 Service Manual ...

Page 3: ...he copyrighted computer program Accordingly any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied or reproduced in any manner without the express written permission of Motorola Furthermore the purchase of Motorola prod ucts shall not be deemed to grant either directly or by implication estoppel or otherwise any license under the co...

Page 4: ... the above standards always adhere to the following procedures PORTABLE RADIO OPERATION AND EME EXPOSURE When transmitting with a portable radio hold radio in a vertical position with the microphone 2 5 to 5 0 centimetres one to two inches away from the mouth Keep antenna at least 2 5 centimetres one inch from your head or body when transmitting If you wear a portable two way radio on your body en...

Page 5: ...sible interference with blasting operations turn off your radio when you are near electrical blasting caps In a Òblasting areaÓ or in areas posted Òturn off two way radioÓ obey all signs and instructions NOTE The areas with potentially explosive atmospheres referred to above include fuelling areas such as below decks on boats fuel or chemical transfer or storage facilities areas where the air cont...

Page 6: ...uction 3 1 2 0 Preventive Maintenance 3 1 2 1 Inspection 3 1 2 2 Cleaning Procedures 3 1 3 0 Safe Handling of CMOS and LDMOS Devices 3 2 4 0 Disassembling and Reassembling the Radio Ñ General 3 3 5 0 Radio Disassembly Ñ Detailed 3 4 5 1 Front Cover from Chassis Disassembly 3 4 5 2 Chassis Assembly Disassembly 3 6 5 3 Keypad Option Board and Display Module Disassembly 3 7 5 4 Speaker Microphone and...

Page 7: ...t 3 19 11 0 Programming Test Cable 3 20 Section 4 PERFORMANCE TESTING 1 0 Introduction 4 1 2 0 Setup 4 1 3 0 Test Mode 4 2 3 1 RF Test Mode 4 2 Section 5 RADIO TUNING AND PROGRAMMING 1 0 Introduction 5 1 2 0 Radio Tuning Setup 5 1 2 1 Initial Test Equipment Setup 5 2 3 0 CPS Programming Setup 5 2 Section 6 POWER UP SELF TEST 1 0 Error Codes 6 1 Section 7 MODEL CHARTS AND TECHNICAL SPECIFICATIONS 1...

Page 8: ... for guidance purposes only In instances where the product is covered under a return for replacement or return for repair warranty a check of the product should be performed prior to shipping the unit back to Motorola This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty Prior to shipping any radio back to the appropr...

Page 9: ...l Customer Care Centre Tel 0049 6128 70 2618 Please use these numbers for repair enquiries only 2 4 Piece Parts Some replacement parts spare parts and or product information can be ordered directly If a complete Motorola part number is assigned to the part it is available from Motorola Radio Aftermarket and Accessory Division AAD If no part number is assigned the part is not normally available fro...

Page 10: ...formation 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 speciÞc characteristics Table 1 1 Radio Model Number Example MDH34KDC9AA1AE Type of Unit Model Series Freq Band Power Level Physical Packages Channe...

Page 11: ...1 4 INTRODUCTION ...

Page 12: ...done by the original product manufacturer at one of its FMRC audited manufacturing facilities Unauthorized or incorrect modiÞcation of an FMRC Approved Product unit will negate the Approval rating of the product WARNING Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualiÞed e g FMRC Approved for such use An explosion or Þre may result WARNIN...

Page 13: ...sing of the unit to be opened in a manner which exposes the internal electrical circuits of the unit You do not have to be an FMRC Approved Repair Facility to perform these actions 2 2 Relabelling The repair facility shall have a method by which the replacement of FMRC Approval labels are controlled to ensure that any relabelling is limited to units that were originally shipped from the Manufactur...

Page 14: ... There must be no substitution of items even if the substitute has been previously Approved with a different Motorola communications equipment unit Approved conÞgurations are listed in the FM Approval guide published by FMRC or in the product FM Supplement This FM Supplement is shipped with FM Approved radio and battery combination from the manufacturer The Approval guide or the Approval standard ...

Page 15: ...2 4 INTRINSICALLY SAFE RADIO INFORMATION ...

Page 16: ...de the front cover housing assembly and battery case These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges grease and or grime The only recommended agent for cleaning the external radio surfaces is a 0 5 solution of a mild dishwashing detergent in water The only factory recommended liquid for cleaning the printed circuit boards and their components ...

Page 17: ...to prevent contamination by dissolved material from previous usage CAUTION This radio contains static sensitive devices Do not open the radio unless you are properly grounded Take the following precautions when working on this unit Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert CMOS devices into conventional plastic ÒsnowÓ t...

Page 18: ... chassis opener penknife size screwdriver TORXª T6 screwdriver If a unit requires more complete testing or service than is customarily performed at the basic level send this unit to a Motorola Authorized Service Center See Chapter 1 for a list of authorized service centers The following disassembly procedures should be performed only if necessary Chassis Assembly Disassembly Paragraph 5 2 Keypad O...

Page 19: ...urn off the radio 2 Remove the battery a Pull down on the two battery release buttons b With the buttons pulled down the top of the battery will fall from the radio c Remove the battery from the radio 3 Remove the antenna Figure 3 1 Battery Removal Battery Release Button Battery Release Button ...

Page 20: ...f the opener downwards This pressing action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs Figure 3 2 Knob Removal NOTE Both knobs slide on and off However they are supposed to Þt very tightly on their shafts Figure 3 3 Chassis Removal CAUTION Marring the front cover O ring sealing area will prevent the radio from sealing properly NOTE The jumpe...

Page 21: ... a TORXª screwdriver with a T6 head to remove the four screws holding the main board to the chassis 1 Lift the main board from the chassis See Figure 3 5 Figure 3 4 Unlatch Flex Connectors Figure 3 5 Remove Main Board from Chassis CAUTION Refer to the CMOS CAUTION paragraph on Page 3 2 before removing the main board Be sure to use ESD protection when handling circuit boards Latch Jumper Flex 4 Pin...

Page 22: ... remove the keypad retainer shield a Insert the tip of a Òpenknife size Ó ßat blade screwdriver in the opening at the end of the keypad retainer arm tab b Pry the tab away from the side of the front cover until it moves past the ledges on the side wall Duplicate this procedure for each of the four retainer arm tabs 4 Note that the two Òtop hooksÓ are still held underneath the front coverÑright bel...

Page 23: ...ubber microphone boot from its seated position Unless you are replacing the microphone leave it in the boot Figure 3 7 Removing the Keypad Retainer Display Module and Other Boards from the Radio Housing NOTE At this point the Option Board Installation Procedure Paragraph 7 0 should be performed if necessary NOTE The speaker is held in place with a two legged retainer bracket The bracket legs are s...

Page 24: ...rewdriver in between the bezel and side button 2 refer to Figure 3 9 b Insert the tip of a small screwdriver in between side button 2 and PTT button refer to Figure 3 9 c Pry the PTT bezel away from the radio housing d If required the PTT seal can be easily lifted from the bezel without the use of tools Figure 3 8 Removal Speaker Microphone Assembly Figure 3 9 PTT Removal Speaker Retainer Speaker ...

Page 25: ...e top escutcheon down uniformly 6 2 PTT Reassembly 1 Put the PTT seal in the PTT bezel 2 Place the bezel ÔTÕ tab in the ÔTÕ slot inside the front cover PTT opening Slightly slide down the bezel so that the two snaps can be aligned and inserted into the two rectangular slots 3 Press the PTT assembly against the front cover opening 6 3 Speaker Reassembly 1 Align the notch in the speaker at the six o...

Page 26: ...Stretch the O ring to place it into the retaining pocket at the bottom end of the chassis 3 Replace the battery contact seal if necessary surrounding the battery contact 4 Place the main circuit board straight down on top of the chassis 5 Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis NOTE Ensure the speaker microphone wire is not damaged during reassembly F...

Page 27: ...Push the chassis assembly completely into the top of the front cover until it settles in place 6 Be sure the O ring is properly seated 7 Snap the bottom of the chassis into the front cover 8 Reassemble the knobs dust cover antenna and battery 7 0 Option Board Installation 1 With the keypad retainer removed the keypad board can be removed without the use of tools 2 Remove the jumper ßex from the co...

Page 28: ...ect way of inserting the ßex into the connector 7 Replace the retainer by placing the two top hooks into the slots below the speaker in the front cover then pivot the retainer into the front cover Ensure that all four tab arms snap correctly into the front cover 8 With the keypad option board and retainer correctly in place the front cover assembly can now be reassembled as described in paragraph ...

Page 29: ...roceed to the Option Board tab From the pull down menu choose the option board type that you just installed choose Simple Decoder for the DTMF option board 4 Open the Personality dialog box For every personality that you want the option board features to be activated click on the Option Board Feature check box of the Advanced tab Figure 3 13 Option Board tab of the Radio ConÞguration dialog box Fi...

Page 30: ... DTMF Option Board 1 In the Tree View window of your CPS expand the Signalling node Also expand the DTMF System node Open each of the DTMF System dialog boxes under this node and Þll in the relevant information pertinent to your DTMF system Figure 3 15 DTMF System dialog box ...

Page 31: ...chanical View and Parts List 8 1 P Series Radio Exploded View and Parts List Figure 3 16 P Series Radio Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 33 34 36 37 38 39 35 25 ...

Page 32: ...pad Board Assembly 16 5104949J08 Display Module 17 4285609Z01 Retainer Plate 18 8480475Z02 Flex Keypad Controller 19 3585606Z02 Felt Speaker 20 5085962A02 Speaker 21 1480577C01 Boot Microphone 22 5013920A04 Microphone 23 8485687Z01 Flex Microphone 24 2113740A55 Cap 100pF 25 0980727Z01 Connector Wire 26 4285601Z01 Retainer Speaker 27 1480724Z01 Insulator Speaker 28 3980667Z01 Contact Finger 29 1585...

Page 33: ... to RIB RLN4008 RLN4008 Radio Interface Box RIB Enables communications between the radio and the computerÕs serial communications adapter HLN9756 BNC Adaptor Adapts radioÕs antenna port to BNC cabling of test equipment 0180305G54 8180384F66 Shop Battery Eliminator Bench Test Housing Eliminator Interconnects radio to power supply Provides for troubleshooting of the radio when the housing is removed...

Page 34: ...sterisk Frequency deviation meter and signal generator for wide range troubleshooting and alignment R1072 Digital Multimeter AC DC voltage and current measurements R1377 AC Voltmeter 100 mV to 300 V 5Hz 1MHz 10 Megohm input impedance Audio voltage measurements WADN4133 Delay Oscilloscope 2 Channel 40 MHz bandwidth 5 mV cm 20 V cm Waveform measurements R1440A 0180305F14 0180305F30 0180305F39 RLN461...

Page 35: ...ION MALE CONNECTOR 1 000mm CABLE 1 000mmÓ CABLE P1 P2 P3 P2 25 ways Female D Connector Components molded inside 1 5 24 7 20 8 15 16 9 47 ohm 33K 1UF 16V 5 Orange Blue White Spiral Yellow P1 2 5mm stereo and 3 5mm 1 2 5 3 4 3 5mm Tip Speaker 3 5mm Sleeve 2 5mm Tip Microphone 2 5mm 2 5mm Center P3 25 ways Male D 1 15 4 11 1 2 3 4 5 3 5mm mono 2 5mm stereo ...

Page 36: ...Programming Test Cable 3 21 Figure 3 19 Front end Filter Tuning Using 3rd Battery Contact Figure 3 20 Battery Terminals For front end tuning use only ...

Page 37: ...3 22 MAINTENANCE ...

Page 38: ... from the battery eliminator The equipment required for alignment procedures is connected as shown in the Radio Alignment Test Setup diagram Initial equipment control settings should be as indicated in the following table and should hold for all alignment procedures except as noted in Table 4 1 Table 4 1 Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode Power Mo...

Page 39: ...orresponding set of tones will be heard Pressing SB2 for 3 seconds will switch the radio to the Control Head Test mode ÒLCDÓ appears on the display Pressing SB1 will cause the radio to turn on all the segments of the Þrst character Another SB1 press will turn on all the segments of the next character and so on until the last character character 7 Pressing SB1 at the end of the LCD test will activa...

Page 40: ...r Switch Position Test Channel VHF UHF 1 Low Power 8 High Power TX 1 or 8 RX 1 or 8 136 025 136 025 403 025 403 025 2 Low Power 9 High Power TX 2 or 9 RX 2 or 9 142 325 142 325 415 025 415 025 3 Low Power 10 High Power TX 3 or 10 RX 3 or 10 148 625 148 625 425 025 425 025 4 Low Power 11 High Power TX 4 or 11 RX 4 or 11 154 925 154 925 436 025 436 025 5 Low Power 12 High Power TX 5 or 12 RX 5 or 12...

Page 41: ... MODE Test Channel 4 carrier squelch PTT to OFF center meter selector to Audio PA Set volume control to 3 16Vrms Distortion As above except to distortion As above As above Distortion 3 0 Sensitivity SINAD As above except SINAD lower the RF level for 12dB SINAD As above PTT to OFF center RF input to be 0 35mV Noise Squelch Threshold only radios with conventional system need to be tested RF level se...

Page 42: ...Hz Mod Out level for 0 025Vrms at test set 80mVrms at AC DC test set jack As above As above meter selector to mic Deviation VHF UHF 4 0 kHz but 5 0 kHz 25 kHz Ch Sp Voice Modulation internal Mode PWR MON 4th channel test frequency atten to 70 input to RF In Out TEST MODE Test Channel 4 carrier squelch output at antenna Remove modulation input Press PTT switch on radio Say ÒfourÓ loudly into the ra...

Page 43: ...4 6 PERFORMANCE TESTING ...

Page 44: ...e radio must be connected to the PC radio interface box RIB and test equipment shown in Figure 5 1 Figure 5 1 Radio Tuning Test Equipment Setup NOTE Refer to the appropriate program on line help Þles for the programming procedures Description Kit Number Software CD Customer Programmable Software Tuner Software ENLN4131_ ENVN4020_ ENVN4014_ Wattmeter Audio Generator Sinad Meter AC Voltmeter 10 dB P...

Page 45: ...onitor Test Set Power Supply Monitor Mode Power Monitor Speaker set A Voltage 7 5Vdc RF Attenuation 70 Speaker load Speaker DC on standby Standby AM CW FM FM PTT OFF Volt Range 10V Oscilloscope Source Mod Oscilloscope Horizontal 10mSec Div Oscilloscope Vertical 2 5kHz Div Oscilloscope Trigger Auto Monitor Image Hi Monitor BW Nar Monitor Squelch mid CW Monitor Volume 1 4 CW Current 2 5A NOTE Refer ...

Page 46: ...sage re occurs replace main board or send radio to nearest Motorola Depot ÒROM CSÓ ROM Checksum is wrong Reprogram FLASH Memory then retest If message re occurs replace main board or send radio to nearest Motorola Depot ÒEPM ERRÓ Codeplug structure mismatch non existence of codeplug Reprogram codeplug with correct version and retest radio If message re occurs replace main board or send radio to ne...

Page 47: ...6 2 POWER UP SELF TEST ...

Page 48: ...4 MHz 4W Item Description X PMLD4167_ P040 Back Cover Kit X PMLD4169_ P080 Back Cover Kit X PMUD1623_ P040 Tanapa X PMUD1626_ P080 Tanapa X PMLN4351_ P040 Front Housing Kit X PMLN4353_ P080 Front Housing Kit X 6864110B67 P040 Basic User Guide X 6864110B68 P080 Basic User Guide X X PMAD4023_ VHF 150 161 MHz Antenna X X PMNN4018_ Battery NiMH Standard x Indicates one of each is required ...

Page 49: ...tem Description X PMLE4182_ P040 UHF Back Cover Kit X PMLE4184_ P080 UHF Back Cover Kit X PMUE1626_ P040 Tanapa X PMUE1629_ P080 Tanapa X PMLN4351_ P040 Front Housing Kit X PMLN4353_ P080 Front Housing Kit X 6864110B67 P040 Basic User Guide X 6864110B68 P080 Basic User Guide X X NAE6483_ UHF Whip 403 470 MHz Antenna X X PMNN4018_ Battery NiMH Standard x Indicates one of each is required ...

Page 50: ...cription X PMLE4185_ P040 Back Cover Kit X PMLE4187_ P080 Back Cover Kit X PMUE1630_ P040 Tanapa X PMUE1632_ P080 Tanapa X PMLN4351_ P040 Front Housing Kit X PMLN4353_ P080 Front Housing Kit X 6864110B67 P040 Basic User Guide X 6864110B68 P080 Basic User Guide X X PMAE4008_ UHF 14cm 465 527MHz Antenna X X PMNN4018_ Battery NiMH Standard x Indicates one of each is required ...

Page 51: ...x 40 Weight gm With Standard high capacity NiMH battery With NiCD battery 429 454 Average Battery Life 5 5 90 Duty Cycle With Standard high capacity NiMH battery With NiCD battery Low Power High Power 10 hours 8 hours 10 hours 8 hours Sealing Withstands rain testing per MIL STD 810 C D E and IP54 Shock and Vibration Protection provided via impact resistant housing exceeding MIL STD 810 C D E and T...

Page 52: ... 5 20 25 kHz Frequency Stability 30 C to 60 C 25 C reference 0 00025 Power NiMH 7 5V Low High 1W 5W Modulation Limiting 2 5 12 5kHz 4 0 20kHz 5 0 25kHz FM Hum Noise 40 dB typical Conducted Radiated Emission 66 dBw Audio Response From 6dB Octave pre emphasis 300 3000 Hz 1 to 3 dB Audio Distortion 1000 Hz 60 Rated Maximum Dev 3 typical ...

Page 53: ...andsplit VHF 136 174 MHz UHF1 403 470MHz UHF2 450 527MHz Frequency Stability 30 C to 60 C 25 C reference 0 00025 Sensitivity 12 dB SINAD EIA 0 25 µV Intermodulation EIA 70 dB Adjacent Channel Selectivity 60 dB 12 5 kHz 70 dB 20 25 kHz Spurious Rejection 70 dB Rated Audio 0 5W Audio Distortion Rated Audio 3 Hum and Noise 45dB 12 5kHz 50dB 25kHz Audio Response 300 3000Hz 1 to 3dB Conducted Spurious ...

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