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Repair Procedures and Techniques – General

2-3

4.0

Repair Procedures and Techniques – General

Any rework or repair on Environmentally Preferred Products must be done using the appropriate
lead-free solder wire and lead-free solder paste as stated in the following table:

Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
from the nearest center listed under

Replacement Parts Ordering

on page A-1.

Rigid Circuit Boards

This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.

When soldering near the 20-pin and 40-pin connectors:

•

Avoid accidentally getting solder in the connector.

•

Be careful not to form solder bridges between the connector pins.

•

Examine your work closely for shorts due to solder bridges.

NOTE

Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards — examples shown below) were developed and assembled using environmen-
tally preferred components and solder assembly techniques to comply with the Euro-
pean Union’s

Restriction of Hazardous Substances (ROHS) Directive 2002/95/EC

and

Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC

. To

maintain product compliance and reliability, use only the Motorola specified parts in this
manual.

Table 2-1. Lead Free Solder Wire Part Number List

Motorola

Part Number

Alloy

Flux Type

Flux Content

by Weight

Melting

Point

Supplier Part

number

Diameter

Weight

1088929Y01

95.5Sn/3.8Ag/0.7Cu

RMA Version

2.7-3.2%

217°C

52171

0.015”

1lb spool

Table 2-2. Lead Free Solder Paste Part Number List

Motorola Part

Number

Manufacturer Part

Number

Viscosity

Type

Composition & Percent Metal

Liquid

Temperature

1085674C03

NC-SMQ230

900-1000KCPs

Brookfield (5rpm)

Type 3

(-325/+500)

(95.5%Sn-3.8%Ag-0.7%Cu)

89.3%

217°C

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Содержание BPR 40

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Страница 3: ...not be copied reproduced modified reverse engineered or distributed in any manner without the express written permission of Motorola Furthermore the purchase of Motorola products shall not be deemed to grant either directly or by implication estoppel or otherwise any license under the copyrights patents or patent applications of Motorola except for the normal non exclusive license to use that aris...

Страница 4: ...ii Notes ...

Страница 5: ...d Radio Model Information Section 2 Maintenance Updated mechanical parts list Section 5 Accessories Updated items listed under Carry Accessories Chargers Publications and Batteries Added Appendix A Replacement Parts Ordering and Appendix B Motorola Service Centers June 2007 6816986H01 C Added Serial Number Programming to Section 4 Radio Programming Updated Safety Information section with new relea...

Страница 6: ...iv Notes ...

Страница 7: ...for both workers and the general public These recommended RF exposure levels include substantial margins of protection All Motorola two way radios are designed manufactured and tested to ensure they meet government established RF exposure levels In addition manufacturers also recommend specific operating instructions to users of two way radios These instructions are important because they inform u...

Страница 8: ...ines United States Federal Communications Commission FCC Code of Federal Regulations 47 CFR et seq FCC OET Bulletin 65 Institute of Electrical and Electronic Engineers IEEE C95 1 International Commission on Non Ionizing Radiation Protection ICNIRP Ministry of Health Canada Safety Code 6 Industry Canada RSS 102 Australian Communications Authority Radiocommunications Standard et seq ANATEL ANNEX to ...

Страница 9: ...ts or other training information visit http www motorola com rfhealth Electromagnetic Interference Compatibility NOTE Nearly every electronic device is susceptible to electromagnetic interference EMI if inadequately shielded designed or otherwise configured for electromagnetic compatibility Facilities To avoid electromagnetic interference and or compatibility conflicts turn off your radio in any f...

Страница 10: ... operation if available Pull off the road and park before making or answering a call if driving conditions or regulations so require Acoustic Safety Exposure to loud noises from any source for extended periods of time may temporarily or permanently affect your hearing The louder the radio s volume the less time is required before your hearing could be affected Hearing damage from loud noise is som...

Страница 11: ...rdous gas vapors or dusts Turn off your radio prior to entering any area with a potentially explosive atmosphere unless it is a portable radio type especially qualified for use in such areas as Intrinsically Safe for example Factory Mutual CSA UL ATEX IEC Do not remove install or charge batteries in such areas Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in...

Страница 12: ...e or charge batteries in a hazardous atmosphere Contact sparking may occur while installing or removing batteries and cause an explosion or fire Do not replace or change accessories in a hazardous atmosphere Contact sparking may occur while installing or removing accessories and cause an explosion or fire Turn the radio off before removing or installing a battery or accessory Do not disassemble an...

Страница 13: ...y Approved with a different Motorola communications equipment unit Approved configurations are listed by the Approving Agency FM UL CSA ATEX IEC The Intrinsically Safe Approval Label affixed to radio refers to the intrinsically safe classification of that radio product and the approved batteries that can be used with that system The manual PN referenced on the Intrinsically Safe Approval Label ide...

Страница 14: ...xii Notes ...

Страница 15: ... 2 1 Inspection 2 1 2 2 Cleaning Procedures 2 1 3 0 Safe Handling of CMOS and LDMOS Devices 2 2 4 0 Repair Procedures and Techniques General 2 3 5 0 Disassembling and Reassembling the Radio General 2 5 6 0 Radio Disassembly Detailed 2 6 6 1 Front Cover from Chassis Disassembly 2 6 6 2 PC Board Disassembly 2 9 7 0 Radio Reassembly Detailed 2 9 7 1 PC Board Reassembly 2 9 7 2 Chassis and Front Cover...

Страница 16: ...re cloned 4 1 2 4 Parameters which are not cloned 4 1 2 5 To Clone a Radio 4 1 2 6 Error Conditions 4 2 3 0 CPS Programming 4 2 3 1 To Read Radio Data to a PC 4 3 3 2 To Write Data to a Radio 4 3 4 0 Serial Number Programming 4 4 4 1 To read the Radio Serial Number to a PC 4 4 4 2 To Reprogram a Serial Number to a Radio 4 4 5 0 Factory Reset 4 5 Section 5 ACCESSORIES 1 0 Antennas 5 1 2 0 Carry Acc...

Страница 17: ...e and the following notes are 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 ...

Страница 18: ...t be prepared to provide the product model number and the unit s serial number For service do contact one of the service depots listed in Appendix B Motorola Service Centers on page B 1 of this manual Please call and confirm your return before sending the unit to the depot for service 2 5 Further Assistance From Motorola You can also contact the Customer Help Desk through the following web address...

Страница 19: ...ple below shows one portable radio model number and its specific characteristics Table 1 1 Radio Model Number Example AAH84KDS8AA1AN Type of Unit Model Serie s Freq Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package AA H 84 K 150 174 MHz D 5W S 8 Channel Navy 8 12 5 25K AA Conventional 1 BPR 40 NiMH A N R 450 470 MHz C 4W J 16 Channel Navy 2 BPR ...

Страница 20: ...ate Nuisance Channel Delete Repeater Talkaround PL DPL Button Lock Battery Save Mode Squelch Unassigned CPS Rx Frequency Tx Frequency RX TPL DPL IDPL TX TPL DPL IDPL User Defined PL TPL1 TPL2 TPL3 Squelch Type Unmute Mute Rules Power Level High Low TPL Reverse Burst Turn Off Code Rx Only Busy Channel Lock Out BCLO Channel Spacing 22KHz 12 5KHz Talkaround Time Out TImer Battery Save Mode Quick Key ...

Страница 21: ...urfaces 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 is isopropyl alcohol 100 by volume Cleaning External Plastic...

Страница 22: ...hol and a clean container 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 con...

Страница 23: ... and 40 pin connectors Avoid accidentally getting solder in the connector Be careful not to form solder bridges between the connector pins Examine your work closely for shorts due to solder bridges NOTE Environmentally Preferred Products EPP refer to the marking on the printed circuit boards examples shown below were developed and assembled using environmen tally preferred components and solder as...

Страница 24: ...0 3 cm 1 8 above the component to be removed 2 Begin applying the hot air Once the solder reflows remove the component using a pair of tweezers 3 Using a solder wick and a soldering iron or a power desoldering station remove the excess solder from the pads To replace a chip component using a soldering iron 1 Select the appropriate micro tipped soldering iron and apply fresh solder to one of the so...

Страница 25: ... tabs and how parts align with each other The following tools are required for disassembling the radio Phillips screwdriver Flat head screwdriver Chassis Opener Crab Eye Nut Opener Tweezers 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 section 2 4 on page 1 2 for a list of authorized s...

Страница 26: ...dio see Figure 2 1 Remove the battery by gently lifting the hilt of the battery nearest to the battery latch away from the housing 3 Slide the battery downwards to remove the battery 4 Remove the antenna by unscrewing it see Figure 2 2 5 Pull the On Off Volume and Channel knobs out of their shafts using the Chassis Opener see Figure 2 2 Figure 2 1 Figure 2 2 2a 2a 3 2b 6 4 5 ...

Страница 27: ...ker wire under neath 8 Slide the rear chassis downwards and away from the front cover 9 Remove the speaker connector which connects between the PC Board and the internal speaker on front cover see Figure 2 4 10 Remove the latch pad from right slot space 11 With the battery latch on the housing push the shaft in the housing slot to the right see Fig ure 2 5 Figure 2 3 Figure 2 4 NOTE Proceed to per...

Страница 28: ...he speaker bracket from the housing see Figure 2 6 14 Remove the speaker from on top of the speaker felt 15 Remove the speaker felt from the grille area Figure 2 5 NOTE Proceed to perform steps 13 14 and 15 only if there is a need to replace the speaker speaker bracket or speaker felt Figure 2 6 ...

Страница 29: ...cast 5 The completely disassembly PC board is shown in Figure 2 7 7 0 Radio Reassembly Detailed 7 1 PC Board Reassembly 1 Place the PC board on the rear diecast 2 Tighten the screws and the nuts on the two knobs Figure 2 7 Completely Disassembled PC Board Stickers for Tuning Holes O ring Radio Chasis PCB Antenna Bracket Crab eye Knob Nut Audio Jack Seal Microphone Boot POGO Pin Housing Audio Brack...

Страница 30: ...aker bracket and screw the bracket to the housing 5 Slot the battery latch shaft into the latch see Figure 2 9 6 Place the latch onto the housing with the shaft protruding on the right side of the latch see Figure 2 10 NOTE Proceed to perform steps 1 2 3 and 4 only if there is a need to replace the speaker speaker bracket or speaker felt Figure 2 8 NOTE Proceed to perform steps 5 6 7 and 8 only if...

Страница 31: ... Detailed 2 11 7 With the battery latch placed on the housing push the shaft in the housing slot to the left see Figure 2 11 8 Place the small latch pad onto the right slot space see Figure 2 11 Figure 2 10 Figure 2 11 ...

Страница 32: ...e PC board see Figure 2 12 10 Place the diecast into the front housing see Figure 2 13 11 Snap the front housing cover firmly into place on the rear diecast 12 Attach the battery 13 Attach the On Off Volume Knob Channel Knob and Antenna Figure 2 12 Figure 2 13 Speaker Connector ...

Страница 33: ...rence No Part No Part Name Qty 1 PMDN4001_R Front Housing 1 2 Lightpipe 1 3 PMDN4002_R Mag One By Motorola Nameplate 1 4 PMDN4005_R BPR 40 Nameplate 1 5 PMDN4008_R PTT Escutcheon 1 6 PMDN4007_R PTT Rubber 1 1 4 3 2 6 5 7 21 23 22 14 13 15 16 12 8 9 11 10 43 41 17 18 19 20 30 29 48 45 49 50 34 33 32 28 38 37 31 51 36 46 7 4 27 53 44 39 40 35 25 24 26 42 52 ...

Страница 34: ...tiometer 1 20 Crab Eye Knob Nut 1 21 PMDN4018_R Channel Volume Top Seal 1 22 PMDN4021_R Top Escutcheon 8 Channels 1 PMDN4020_R Top Escutcheon 16 Channels 1 23 Top Adhesive 1 24 PMDN4022_R Battery Latch 1 25 Battery Latch Shaft 1 26 Battery Latch Tape 1 27 PMDD4001_R 150 174 MHz 5W PC Board non EPP 1 PMDD4005_R 150 174 MHz 5W PC Board EPP 1 PMDE4001_R 450 470 MHz 4W PC Board non EPP 1 PMDE4005_R 45...

Страница 35: ...go Pin Housing 1 47 Pogo Pin 2 48 PMAD4051_R Mag One 150 174 MHz Antenna 1 PMAE4020_R Mag One 450 470 MHz Antenna 1 49 PMLN4743_ Mag One Spring Belt Clip 1 50 PMNN4071_R Mag One NiMH Battery 1200mAh 1 PMNN4075_R Mag One LiIon Battery 1500mAh 1 51 PMDN4058_R PCB Chassis Tape for PMUD2086A_ PMUE2385A_ 1 PCB Chassis Tape for PMUD2086B_ 2 PCB Chassis Tape for PMUE2385B_ 3 52 PMDN4025_R O Ring 1 53 PMD...

Страница 36: ...g programmed data from the master radio to the other PMDN4042_R Battery Eliminator Interconnects radio to power supply red and black power cable included PMDN4054_R Antenna Ground Plate To improve grounding while conducting tuning and measurement PMDN4044_R T Head Ceramic Tuning Tool To tune the variable resistor for audio and sub audio modulation adjustment tuning points accessible via battery ch...

Страница 37: ...ommended Test Equipment Motorola Part No Description Characteristics Application R2600 Communication Analyzer Frequency deviation meter and signal generator for wide range troubleshooting and alignment R1038 Handheld Multimeter AC DC Voltage and current measure ments S1339A 220 RF Millivolt Meter 220V 100mv to 3VRF 100kHz to 1 2GHz RF Level Measurements Figure 2 15 Programming Cable Schematic ...

Страница 38: ... Box PMDN4040_R Figure 2 16 Cloning Cable Schematic Figure 2 17 Test Box Schematic e i p 5 2 e i p 5 2 5 2 e i p 5 3 e i p 1 O I D U A 1 O I D U A O I D U A X T o M 1 m h o M 1 m h 0 0 1 F u 0 0 1 F u o 8 m h 4 2 m h o o 8 m h 2 r o m h o 4 S 1 W S 2 W S 3 W K 2 2 m h o ...

Страница 39: ...ds to be disassembled to the PC Board Following are the parameters that can be tuned 1 Transmitter Tuning a High Power Tuning b Low Power Tuning c Frequency Tuning d Modulation Balancing e Maximum Modulation f Subtone Modulation 2 Receiver Tuning a Wide Band Sinad Tuning b Narrow Band Sinad Tuning 3 PLL Synthesizer Tuning a Rx PLL Frequency Tuning b Tx PLL Frequency Tuning For a list of Service Ai...

Страница 40: ...MHz PLL Synthesizer 173 975 Transmitter 150 025 Receiver 150 025 UHF 450 470 MHz PLL Synthesizer 469 975 Transmitter 450 025 Receiver 450 025 Figure 3 1 Radio Tuning Setup NOTE On the Test Box select 8 ohm resistance when using with PMUD2086A_ and PMUE2386A_ For all other kits please select 24 ohm resistance NOTE The radio may need to be disassembled to the PC board level to access certain tuning ...

Страница 41: ...o tune low power refer to Figure 3 2 2 3 3 Frequency Tuning 1 Set the radio to the appropriate tuning frequency refer to Table 3 1 2 Using the ceramic tool adjust FL701 to tune the frequency refer to Figure 3 2 2 3 4 Modulation Balancing 1 Set the radio to the appropriate tuning frequency refer to Table 3 1 2 On the test equipment set the following configurations Audio bandwidth 0 25Hz to 15 000Hz...

Страница 42: ...dio through the test box 4 Key up the radio 5 Using the ceramic tool adjust R159 to tune maximum modulation between 2 4 0 02KHz for narrow band or under 5KHz for wide band refer to Figure 3 3 2 3 6 Subtone Modulation 1 Set the radio to the appropriate tuning frequency refer to table3 1 2 On the test equipment set the following configuration Audio bandwidth 0 25Hz to 15 000Hz De emphasis Off FM Pea...

Страница 43: ...e radio to the appropriate tuning frequency refer to Table 3 1 2 Set RF Signal Generator level to 47dBm at 1 kHz tone 60 of the deviation 3 Find the SINAD level 7 of the radio to decrease RF Signal Generator level 4 Using the ceramic tool adjust R216 clockwise to off the audio output refer to Figure 3 2 5 Then adjust R216 counterclockwise at the point where the Audio Frequency signal appears 2 4 3...

Страница 44: ...ocedure Tx PLL Frequency Tuning 1 Set the radio to the appropriate tuning frequency refer Table 3 1 2 Detect output voltage at test point TP1 3 Using the ceramic tool adjust C722 to tune the voltage below 5 0V 0 1V refer to Figure 3 4 ...

Страница 45: ...s the contents of Radio 1 master radio into Radio 2 slave radio 2 3 Parameters which are cloned Radio Configuration parameters Conventional Personality parameters 2 4 Parameters which are not cloned Unit Serial Number Model Number 2 5 To Clone a Radio Cloning duplicates the contents of your radio master radio into your customer s radio slave radio Tuning and alignment information are not affected ...

Страница 46: ...ng cloning 5 Once cloning is completed an Out Chirp alert tone can be heard from both radios 6 Disconnect radios from the cloning cable They are now ready for operation 2 6 Error Conditions An error may occur when cloning a radio When this happens the radio sounds a Faulty Condition Alert tone and shows a Flashing Orange LED momentarily 3 0 CPS Programming The CPS is designed for use in the Window...

Страница 47: ...s LED illuminates in orange 5 Click the Read button on the CPS 6 The CPS shows a reading progress bar 3 2 To Write Data to a Radio 1 Turn off the radio 2 Connect the programming cable to the radio 3 Press and hold Programmable Button 1 top side button on radio then turn on the radio 4 The radio beeps once Immediately release Programmable Button 1 The radio s LED illuminates in orange 5 Click the W...

Страница 48: ...serial number This means this board can be reprogrammed a grayed un editable serial number field if it is already programmed with a 10 digit serial number This means this board cannot be reprogrammed 4 2 To Reprogram a Serial Number to a Radio NOTE Only radios whose boards have been replaced with service boards as listed in Table 4 1 below can have the serial number reprogrammed See Disassembling ...

Страница 49: ...r the correct 10 digit serial number as noted at step 1 above The tool does not allow the user to write the serial number to the radio unless a complete 10 digit serial number is entered 7 Click the Write button The tool shows a writing progress bar 5 0 Factory Reset This feature allows the user to restore the radio to the factory default settings 1 Press and hold both the PTT and Programmable But...

Страница 50: ...4 6 Factory Reset Notes ...

Страница 51: ...arger Base PMLN 5048_R Mag One Tri Chem SUC with Switching PS US 2 pin EPNN9288_ Switching Power Supply with AC Cord US 2 pin 90 264 VAC 5 0 Publications 6881098C61 BPR 40 User Guide English French Canadian 6816986H01 Mag One by Motorola Series Radio Service Manual English French Canadian 6871916T01 Mag One Tri Chem Charger User Guide English Simplified Chinese Bahasa Indonesia French Canadian Rus...

Страница 52: ...t with Clear Acoustic Tube PMLN4658_ D Shell Earset with Boom Microphone with PTT VOX Switch Caution Your radio does not support the VOX feature Please set the accessory switch to PTT If the accessory switch is set to VOX your radio transmits constantly and never receives 8 0 Service Kits PMDN4038_R Chassis Opener PMDN4039_R Crab Eye Nut Opener PMDN4040_R Test Box PMDN4041_R RF Adapter PMDN4042_R ...

Страница 53: ...ers only International customers can obtain assistance at http motorola com businessonline A 3 Mail Orders Mail orders are only accepted by the U S Federal Government Markets Division USFGMD Motorola Inc 7031 Columbia Gateway Drive 3rd Floor Order Processing Columbia MD 21046 U S A A 4 Telephone Orders Radio Products and Solutions Organization United States and Canada 7 00 AM to 7 00 PM Central St...

Страница 54: ...s and Canada 1 800 422 4210 A 7 Product Customer Service Radio Products and Solutions Organization United States and Canada 1 800 927 2744 The Radio Products and Solutions Organization RPSO was formerly known as the Radio Products Services Division RPSD and or the Accessories and Aftermarket Division AAD ...

Страница 55: ... please send the radio to a Motorola Service Center as listed below B 2 Motorola Service Center 45D Butterfield Trail El Paso TX 79906 Tel 1 800 227 6772 B 3 Motorola Federal Technical Center 4395 Nicole Drive Lanham MD 20706 Tel 1 800 969 6680 Fax 1 800 784 4133 B 4 Motorola Canadian Technical Logistics Center Motorola Canada Ltd 8133 Warden Avenue Markham Ontario L6G 1B3 Tel 1 800 543 3222 Fax 1...

Страница 56: ...B 2 Motorola Canadian Technical Logistics Center Notes ...

Страница 57: ...ured in Megahertz MHz Model Number The model number identifies the type of radio This information is stored in the radio s codeplug Normal Scan For Normal Scan the radio assigns equal priority to all members in the Scan List selected for the current channel When the radio is scanning a Scan List Active Scan all scan list members including the Home Channel will be allo cated equal time to be scanne...

Страница 58: ...16 Scan List Members Scan List Member scanning priority is definable Scan Mode When the radio is in one of the two Scan States Active Scan and Landed Scan This mode is initiated when the programmable SCAN button is pressed Serial Number Each radio has its own unique serial number This information is stored in the radio s codeplug Software Computer programs procedures rules documentation and data p...

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