Page 2
DOCUMENT HISTORY The following major changes have been implemented in this manual since the previous edition: Edition Description Date 6881094C21-O Initial edition Dec. 2001 6881094C21-B Added changes from FMR2027-1 into manual. Jan. 2007 Added Full keypad (FKP) controller board, sche- matics and parts lists (PCB no.8471678L01).
Page 4
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 68P81095C98) to ensure compliance with RF energy exposure limits. For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which lists approved accessories: http://www.motorola.com/cgiss/index.shtml.
Table of Contents Product Safety and RF Exposure Compliance ...........iii Chapter 1 Introduction................1-1 Scope of Manual..........................1-1 Warranty and Service Support....................... 1-1 1.2.1 Warranty Period ........................ 1-1 1.2.2 Return Instructions......................1-1 1.2.3 After Warranty Period ....................... 1-1 Related Documents ........................1-2 Technical Support..........................
Page 7
Chapter 3 Maintenance ................3-1 Introduction ............................ 3-1 Preventive Maintenance ........................ 3-1 3.2.1 Inspection.......................... 3-1 3.2.2 Cleaning..........................3-1 Safe Handling of CMOS and LDMOS.................... 3-2 General Repair Procedures and Techniques................. 3-2 Shields ............................3-3 Recommended Test Tools......................3-4 Replacing the Circuit Board Fuse....................3-6 Removing and Reinstalling the Circuit Board ................
Page 8
UHF Band 1 Radio Parts List ......................7-9 UHF Band 1, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471441L01)..7-11 UHF Band 1 Radio Parts List (PCB No. 8471441L01) ..............7-20 UHF Band 2, Circuit Board/Schematic Diagrams and Parts List ........... 8-1 UHF Band 2 Radio Parts List ......................
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.
Motorola. If the part number is appended with an asterisk, the part is serviceable by a Motorola depot only. If a parts list is not included, this generally means that no user-serviceable parts are available for that kit or assembly.
Radio Model Chart and Specifications Radio Model Chart and Specifications The radio model charts and specifications are located in the Basic Service Manual listed under the Related Documents paragraph of this chapter. Radio Model Information 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 from these numbers.
Chapter 2 Theory of Operation Introduction This section provides a detailed theory of operation for the radio and its components. Radio Power Distribution Audio Power Amplifier Vdda Vdda Regulator UNSWB+ SWB+ Vddd 7.5V Vddd Battery Regulator Fuse FRACTN ASFIC_CMP MCU, MicroP, ROM LVZIF Driver VCOBIC...
Keypad Table 2-1. Vdd Regulator Band and Radio Jumpers Dual Vdd Regulator Single Vdd Regulator Jumpers Scheme Scheme Vdda SW. Reg. Keypad The keypad block diagram is shown in Figure 2-2. The LED_EN setting is set by the codeplug. When the value is set to high, the LED will not light up during power up and vice versa.
The controller board is the central interface between the various subsytems of the radio. It is separated into digital and audio architectures. The digital portion consists of a special Motorola microcontroller (HC11FL0). The audio power amplifier (Audio PA) and audio/signalling/filter/ companding IC (ASFIC_CMP) form the backbone of the audio/signalling architecture.
Keypad 2.4.1 MCU Configuration There is one common MCU architecture for low-tier as well as for the high-tier products. It covers the Conventional and Trunking portables. An open architecture system with the new HC11FL0 as the processor is used. Combinations of different size RAM, ROM and EEPROM are available for various application software.
VHF Transmitter 2.4.4 ModB/Vstby Supply The supply to the ModB/Vstby pin varies depending on the conditions listed in Table 2-2 Table 2-2. ModB/Vstby Supply Modes Condition Circuit Operation Radio On Vdd supply voltage via CR411 Radio Off • Vdd turned off •...
VHF Transmitter 2.5.1 Power Amplifier The power amplifier consists of two devices: • 9Z67 LDMOS driver IC (U3501) and • PRF1507 LDMOS PA (Q3501). The 9Z67 LDMOS driver IC contains a 2 stage amplification with a supply voltage of 7.3V. This RF power amplifier is capable of supplying an output power of 0.3W (pin 6 and 7) with an input signal of 2mW (3dBm) (pin16).
VHF Transmitter 2.5.6 VHF Receiver The VHF receiver consists of a front end, back end, and automatic gain control circuits. A block diagram of the VHF receiver is shown in Figure 2-6. Detailed descriptions of these features are contained in the paragraphs that follow. Antenna Pin Diode Varactor...
VHF Transmitter The output of the post-RF amplifier filter is connected to the passive double balanced mixer which consists of T3301, T3302 and CR3301. Matching of the filter to the mixer is provided by C3317, C3318 and L3308. After mixing with the first LO signal from the voltage controlled oscillator (VCO) using high side injection, the RF signal is down-converted to the 45.1 MHz IF signal.
VHF Transmitter Resistors R3304 and R3305 are voltage dividers designed to turn on Q3301 at certain RSSI levels. In order to turn on Q3301 the voltage across R3305 must be greater or equal to the voltage across R3324, plus the base-emitter voltage (Vbe) present at Q3301. Capacitor C3209 is used to dampen any instability while the AGC is turning on.
2-10 VHF Transmitter 2.5.11 Synthesizer The Fractional-N Synthesizer, shown in Figure 2-8, uses a 16.8MHz crystal (Y3761) to provide a reference for the system. The LVFractN IC (U3701) further divides this to 2.1MHz, 2.225MHz, and 2.4MHz as reference frequencies. Together with C3761, C3762, C3763, R3761 and D3761, they build up the reference oscillator which is capable of 2.5ppm stability over temperatures of -30 to 85°C.
2-12 UHF Transmitter (Band 1 and Band 2) The RF section of the VCOBIC (U3801) is operated at 4.54 V (VSF), while the control section of the VCOBIC and Fractional-N synthesizer (U3701) is operated at 3.3V. The operation logic is shown in Table 2-3.
UHF Transmitter (Band 1 and Band 2) 2-13 2.6.1 Power Amplifier The power amplifier consists of two devices: • 9Z67 LDMOS driver IC (U101) and • PRF1507 LDMOS PA (Q110). The 9Z67 LDMOS driver IC contains a 2 stage amplification with a supply voltage of 7.3V. This RF power amplifier is capable of supplying an output power of 0.3W (pins 6 and 7) with an input signal of 2mW (3dBm) (pin 16).
2-14 UHF Transmitter (Band 1 and Band 2) 2.6.6 UHF Receiver (Band 1 and Band 2) The UHF receiver consists of a front end, back end, and automatic gain control circuits. a block diagram of the receiver is shown in Figure 2-11. Antenna Pin Diode Varactor...
UHF Transmitter (Band 1 and Band 2) 2-15 The output of the post-RF amplifier filter which is connected to the passive double balanced mixer consists of T301, T302 and CR306. Matching of the filter to the mixer is provided by C381. After mixing with the first LO signal from the voltage controlled oscillator (VCO) using low side injection, the RF signal is down-converted to the 45.1MHz IF signal.
2-16 UHF Transmitter (Band 1 and Band 2) Resistor network at the input to the base of Q315 is scaled to turn on Q315, hence activating the AGC, at certain RSSI levels. In order to turn on Q315, the voltage across the transistor’s base to ground must be greater or equal to the voltage across R319, plus the base-emitter voltage (Vbe) present at Q315.
Page 30
UHF Transmitter (Band 1 and Band 2) 2-17 In achieving fast locking for the synthesizer, an internal adapt charge pump provides higher current at pin 45 of U201 to put synthesizer within the lock range. The required frequency is then locked by normal mode charge pump at pin 43.
2-18 UHF Transmitter (Band 1 and Band 2) 2.6.12 Voltage Controlled Oscillator - (VCO) AUX3 (U201 Pin2) Level Shifter AUX4 (U201 Pin3) Network U201 Pin 32 Prescaler Out TRB_IN Pin 20 Pin 19 Pin 12 Pin7 Rx-SW TX/RX/BS Pin13 Tx-SW Switching Network LO RF INJECTION Presc...
Page 32
UHF Transmitter (Band 1 and Band 2) 2-19 Table 2-4. Level Shifter Logic Desired Mode AUX 4 AUX 3 High (@3.2V) High (@4.8V) High Battery Saver Hi-Z/Float (@2.5V) In the receive mode, U241 pin 19 is low or grounded. This activates the receive VCO by enabling the receive oscillator and the receive buffer of U241.
Page 33
2-20 UHF Transmitter (Band 1 and Band 2) Notes...
Chapter 3 Maintenance Introduction This chapter of the manual describes: • Preventive maintenance • Safe handling of CMOS devices • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 3.2.1 Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional.
When damaged parts are replaced, identical parts should be used. If the identical replacement component is not locally available, check the parts list for the proper Motorola part number and order the component from the nearest Motorola Communications parts center listed in the “Piece Parts”...
Shields • Begin applying the hot air. Once the solder reflows, remove the component using a pair of twee- zers. • Using a solder wick and a soldering iron or a power desoldering station, remove the excess solder the pads. •...
Recommended Test Tools Recommended Test Tools Table 3-1 lists the tools recommended for working on this family of radios. These tools are also available from Motorola. Recommended Test Tools Table 3-1. MotorolaPart Number Description: Application: RSX4043A Torx Driver Tighten and remove chassis screws...
Removing and Reinstalling the Circuit Board Removing and Reinstalling the Circuit Board Both the UHF and VHF circuit boards are removed from the radio chassis in the following manner: 1. Refer to the Basic Service Manual (see Chapter 3- Related Documents) for radio disassembly, then use a philips screwdriver and to remove the four M2X4 screws shown in Figure 3-2.
Page 42
Error Codes *Error Code Explanation Corrective Action “EEPRM CS ERROR” Codeplug check- Reprogram codeplug. sum is wrong. No Display Display module is Check connection between main board and display not connected module. properly. Display module is Replace with new display module. damaged.
3-10 VHF Troubleshooting Charts 3.10 VHF Troubleshooting Charts MCU Check Press PTT. Red LED does not Before replacing light up Power Up Not able to pro- MCU, check SPI Alert Tone Audio at gram RF Board AUDIO clock, SPI data, AudioPA J403 Audio and RF IC select...
VHF Troubleshooting Charts 3-11 START Bad SINAD Bad 20dB Quieting No Recovered Audio Audio at pin 27 of Check Controller U3220? Spray of inject 1st IF into XTAL Filter IF Freq: 45.1MHz Check Q3270 bias circuitry for faults. Audio heard? Rotate Freq.
3-12 VHF Troubleshooting Charts Inject RF into J3501 Q3200 collector Trace IF signal from IF Signal at C3200 to Q3200. Check C3200? IF signal present? for bad XTAL filter. Before replacing U3220, check U3220 1st LO O/P OK? voltages; trace IF sig- RF Signal at Locked? nal path.
VHF Troubleshooting Charts 3-13 START No Power Is There B+ Bias for Check Q3561 Ant switch Is Control Voltage High Is Current OK? Check PCIC or Low High Check Drive to Mod- 1. Check Pin Diodes 2. Check Harmonic Filter Is Drive OK? Troubleshoot VCO Inspect/Repair Tx.
3-14 VHF Troubleshooting Charts 3.3V at Check U3701 pins Start U3201, 5, 20, 34 & L3731 Visual Check D3701, Correct D3702, U3701, check of the Problem C3701 - C3707 Board OK? Is U3701 Pin 16.8MHz Is 16.8MHz at pin 6 signal at Signal at Replace...
3-16 UHF (Band 1 and Band 2) Troubleshooting Charts 3.11 UHF (Band 1 and Band 2) Troubleshooting Charts MCU Check Press PTT. Red LED does not Before replacing light up Power Up Not able to pro- MCU, check SPI Alert Tone Audio at gram RF Board AUDIO...
UHF (Band 1 and Band 2) Troubleshooting Charts 3-17 START Bad SINAD Bad 20dB Quieting No Recovered Audio Check Controller Audio at pin 27 of U301? Spray of inject 1st IF into XTAL Filter IF Freq: 45.1MHz Check Q320 bias circuitry for faults.
3-18 UHF (Band 1 and Band 2) Troubleshooting Charts Inject RF into J101 Trace IF signal from IF Signal at L311 to Q302. Check Q302 collector OK? L311? for bad XTAL filter. IF signal present? Before replacing U301, check U301 voltages; trace IF signal path.
UHF (Band 1 and Band 2) Troubleshooting Charts 3-19 START No Power Is There B+ Bias for Ant switch Check Q111 Is Control Voltage High Check PCIC Is Current OK? or Low High Check Drive to Mod- 1. Check Pin Diodes 2.
3-22 Keypad Troubleshooting Chart 3.12 Keypad Troubleshooting Chart Disconnect and reconnect Display 18-pin flex IF STILL OFF Disconnect and reconnect Keypad LED 40-pin flex...
1. Unless otherwise stated, resistances are in Ohms (k = 1000), and capacitances are in picofarads (pF) or microfarads (µF). 2. DC voltages are measured from point indicated to chassis ground using a Motorola DC multime- ter or equivalent. Transmitter measurements should be made with a 1.2 µH choke in series with the voltage probe to prevent circuit loading.
RF - Controller Interconnect Flex 4.2.5 Universal Connector Flex Plain J404 J405 J406 J407 J408 J409 J410 J411 J412 J413 M401 J414 J415 J416 C402 J403 Front Metal Back Metal View From Top Side View From Top Side Figure 4-5. Universal Flex Connector Plain...
Page 60
RF - Controller Interconnect Flex M 4 0 0 P 4 0 3 Front Metal Back Metal View From Top Side View From Back Side (for 8471612L01) (for 8471612L01) Figure 4-6. Universal Flex Connector Plain (for 8471612L01)
VHF Circuit Board/ Schematic Diagrams and Parts List VHF Radio Parts List Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Part No. Part No. Part No. Circuit Motorola C3280 2113743L41 0.01uF C3525 2113740F27 10pF C3727 2113743N50 100pF Description Part No.
Page 101
6-10 VHF Circuit Board/ Schematic Diagrams and Parts List Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. C409 2113743M24 0.1uF +80-20% C505 2113743N50 100pF C721 2113743L09 470 pF 10%...
Page 102
VHF Circuit Board/ Schematic Diagrams and Parts List 6-11 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. Q3561 4813824A17 R3316 0662057M66 R3817 0662057M01 R476 0662057N08 Q3721 4802245J50 UMC5N...
6-22 Circuit Board/ Schematic Diagrams and Parts List (VHF: PCB No. 8471021L01) Parts List for VHF (for PCB No. Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description 8471021L01) Part No. Part No. Part No. C3278 2113945D04 CAP CER CHP 100,000PF...
Page 114
Circuit Board/ Schematic Diagrams and Parts List (VHF: PCB No. 8471021L01) 6-23 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. C3544 2113945A03 CAP CER CHP 330PF 50V C3708 2113946B04 CAP CER CHP 0.10UF 10V...
Page 115
6-24 Circuit Board/ Schematic Diagrams and Parts List (VHF: PCB No. 8471021L01) Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. C529 2113945A05 CAP CER CHP 470PF 50V C555...
Page 116
Circuit Board/ Schematic Diagrams and Parts List (VHF: PCB No. 8471021L01) 6-25 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. Q505 4813973M07 XSTR,BIP GP SS,NPN,TO- R3274 0613952Q79 CER CHIP RES 1800 OHM 5...
Page 117
CER CHIP RES 220 OHM 5 SH3303 2615144H06 SHIELD FOR GSM Y3761 4805875Z04 CRYSTAL 16.8 MHZ 0402 PLACEMENT * Motorola Depot Servicing only R3822 0613952Q41 CER CHIP RES 47.0 OHM 5 SH3501 2615144H03 SHIELD FOR GSM ** Not Servicable 0402...
Page 126
UHF Band 1, Circuit Board/Schematic Diagrams and Parts List UHF Band 1 Radio Parts List Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Part No. Part No. Part No. Circuit Motorola Description C171 2113743N50 100pF C264 2113743N50 100pF C339 2180478Z20 1.0UF...
7-20 UHF Band 1, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471441L01) UHF Band 1 Radio Parts List (PCB No. Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description 8471441L01) Part No. Part No. Part No. C122 2113944A40 CAP CER CHP 100.0PF 50V...
UHF Band 1, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471441L01) 7-21 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. C279 2113946N03 CAP CER CHP 2.2UF 16V...
Page 139
7-22 UHF Band 1, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471441L01) Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. C546 2113944A40 CAP CER CHP 100.0PF 50V...
Page 140
UHF Band 1, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471441L01) 7-23 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. R101 0613952H58 CER CHIP RES 240 OHM 5...
Page 141
2680511Z02 SHIELD, SYNTHESIZER TEF RESN SH202 2680511Z02 SHIELD, SYNTHESIZER 2880658Z08 SMA CONNECTOR SH241 2604120G02 AOBA VCO SHIELD * Motorola Depot Servicing only SH242 2680514Z02 SHIELD, VCO BOTTOM/ ** Not Servicable LVZIF SH301 2686583Z02 SHIELD, RECEIVER FRONT END TOP SH302 2680555Z02...
UHF Band 2, Circuit Board/Schematic Diagrams and Parts List UHF Band 2 Radio Parts List Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Part No. Part No. Part No. Circuit Motorola Description C171 2113743N50 100pF C271 2113743N03 1.0 PF...
Page 161
8-20 UHF Band 2, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471475L01) UHF Band 2 Radio Parts List (PCB No. Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description 8471475L01) Part No. Part No. Part No. C123 2313960F04...
Page 162
UHF Band 2, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471475L01) 8-21 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. C289 2113944A40 CAP CER CHP 100.0PF 50V...
Page 163
8-22 UHF Band 2, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471475L01) Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. CR306 4815923H02 SCHOTTKY DIODE-NEW L117 2414017P17...
Page 164
R303 0613952Q77 CER CHIP RES 1500 OHM 5 R346 0613952R05 CER CHIP RES 15K OHM 5% SH201 2680511Z02 SHIELD, SYNTHESIZER * Motorola Depot Servicing only 0402 0402 SH202 2680511Z02 SHIELD, SYNTHESIZER ** Not Servicable R304 0613952R03 CER CHIP RES 12K OHM 5%...
Page 165
8-24 UHF Band 2, Circuit Board/ Schematic Diagrams and Parts List (PCB No. 8471475L01) Notes...