MCS2000/MCS2000 Service Manual Vol 1 6881083C20 A MCS2000

User Manual: -MCS2000/MCS2000 service manual vol-1 6881083C20-A

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MCS 2000 Mobile Radio
Service Instructions
Volume 1
Non-Frequency Range Specific

68P81083C20-A, Issued: 02.97.

Computer Software Copyrights

Safety Information

The Motorola products described in this manual may
include copyrighted Motorola computer programs
stored in semiconductor memories or other media. Laws
in the United States and other countries preserve for
Motorola certain exclusive rights for copyrighted
computer programs, including the exclusive right to
copy or reproduce in any form the 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 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 nonexclusive royalty free license to use that arises by
operation of law in the sale of a product.

Every radio, when transmitting, radiates
energy into the atmosphere which may,
under certain conditions, cause the
generation of a spark. All users of vehicles
W A R N I N G fitted with radios should be aware of the
following warnings (see also “Important
Electromagnetic Emission Information”
below).

Notes, Cautions, Warnings, Danger
Throughout this guide, you will notice the use of
NOTES, CAUTIONS, WARNINGS, and DANGERS. Their
use is explained below.

Note

NOTE: A clarifying statement that
expands on the text that follows.

!

• Do not operate radio near flammable liquids or in
the vicinity of explosive devices.
During normal use, the radio will subject you to radio
energy substantially below the level where any kind of
harm is reported. To ensure personal safety, please
observe the following simple rules:
• Do not transmit when the antenna is very close to,
or touching, exposed parts of the body, especially the
face and eyes.
• Do not hold the transmit (PTT) key in when not
desiring to transmit.
• Check the laws and regulations on the use of twoway mobile radios in the areas where you drive.
Always obey them. Also, when using your phone
while driving, please:
- give full attention to driving,
- use hands-free operation, if available, and
- pull off the road and park before making or
answering a call if driving conditions so require.

!
Caution

CAUTION indicates a potentially
hazardous situation which, if not
avoided, may result in equipment
damage.

WARNING indicates a potentially
hazardous situation which, if not
W A R N I N G avoided, could result in death or injury.

DANGER

ii

An air bag inflates with great force.
Do not place objects, including
communication equipment, in the area
over the air bag or in the air bag
WARNING
deployment area. If the communication
equipment is improperly installed and
the air bag inflates, this could cause
serious injury.

!

!

!

Airbag Warning

DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.

Installation of vehicle communication equipment
should be performed by a professional installer/
technician qualified in the requirements for such
installations.
An air bag’s size, shape and deployment area can vary by
vehicle make, model and front compartment
configuration (e.g., bench seat vs. bucket seats). Contact
the vehicle manufacturer’s corporate headquarters, if
necessary, for specific air bag information for the vehicle
make, model and front compartment configuration
involved in your communication equipment
installation.

Operational Safety Warnings
For vehicles equipped with Electronic
Ignition Systems, check the vehicle
service manual for warnings about the
use of two-way radio equipment in the
W A R N I N G vehicle.

!

The radio may switch into transmit mode, immediately
upon being connected to power, if an open circuit exists
between pins 4 and 9 of the Accessory Connector. To
avoid personal injury and/or damage to the radio,
ensure that a jumper wire or an emergency switch that
has normally closed contacts is connected between pins
4 and 9 of the accessory connector before the radio is
connected to vehicle battery power or any other power
supply.

Radio Care / Handling Cautions
• Avoid physical abuse; do not pound, drop, or throw
the radio. It may damage exposed parts such as
controls and connectors.
• Do not connect accessories other than Motorola
compatible equipment, as it may damage the radio.
For a list of available compatible accessories consult
the Mobius Accessories Guide part number
68P02058U52, or the MCS 2000 Accessories Guide
part number 68P81080C47, or check with your local
Motorola representative.
• The use of a Mini UHF Adaptor can damage the RF
Antenna Connector and lead to radio failure, and is
grounds for voiding warranty.
• Operating the radio without an antenna cable
attached may lead to radio failure and is grounds for
voiding warranty.

Important Electromagnetic
Emission Information
In August, 1996, The Federal Communications
Commission (FCC) adopted an updated safety standard
for human exposure to radio frequency electromagnetic
energy emitted by FCC regulated equipment. Motorola
subscribes to this same updated safety standard for the
use of its products.
In keeping with sound installation practice and to
maximize radiation efficiency, a one-quarter (1/4) wave
length antenna should be installed at the center of the
vehicle roof. If it is necessary to mount the antenna on
the vehicle's trunk lid, an appropriate 3db gain antenna
should be used. This installation procedure will assure
that vehicle occupants will be exposed to radio
frequency energy levels lower than the limits specified in
the standard adopted by the FCC in General Docket
79144.
To assure that radio frequency (RF) energy exposure to
bystanders external to a vehicle is lower than that
recommended by FCC adopted standard, transmit with
any mobile radio only when bystanders are at least two
(2) feet/60 cm away from a properly installed externally
mounted antenna for radios with less than 50 watts of
output power, or three (3) feet/90 cm away for radios
with 50 watts or greater power.

Control Station Operation
In the event of Control Station operation, to assure
operators and bystanders are exposed to radio frequency
(RF) energy levels lower than the limits specified in the
FCC adopted standard, the antenna should be installed
outside of any building, but in no instance shall the
antenna be within two feet/60 cm (less than 50 watts
power output) or within three feet/90 cm (50 watts or
higher power output) of station operators or bystanders.

iii

LP Gas Warning
It is mandatory that radios installed in
vehicles fuelled by liquefied petroleum
gas conform to the National Fire
Protection Association standard NFPA 58,
W A R N I N G which applies to vehicles with a liquid
propane (LP) gas container in the trunk or
other sealed off space within the interior
of the vehicle. The NFPA58 requires the
following:

!

Braking System Tests
The following procedure checks for the most common
types of interference that may be caused to vehicle
braking system by a radio transmitter.
1.

• Any space containing radio equipment shall be
isolated by a seal from the space in which the LP gas
container and its fittings are located.

Run vehicle engine at idle speed and set vehicle
transmission selector to PARK. Release brake pedal
completely and key radio transmitter. Verify that
there are no unusual effects (visual or audible) to
vehicle lights or other electrical equipment and
accessories while microphone is NOT being
spoken into.

2.

Repeat Step 1. except do so while microphone IS
being spoken into.

• Removable (outside) filling connections shall be
used.

3.

Press vehicle brake pedal slightly just enough to
light vehicle brake light(s). Then repeat Step 1.
and Step 2.

4.

Press the vehicle brake pedal firmly and repeat
Step 1. and Step 2.

5.

Ensure that there is a minimum of two vehicle
lengths between front of vehicle and any object in
vehicle’s forward path. Then, set vehicle
transmission selector to DRIVE. Press brake pedal
just far enough to stop vehicle motion completely.
Key radio transmitter. Verify that vehicle does not
start to move while microphone is NOT being
spoken into.

6.

Repeat Step 5. except do so while microphone IS
being spoken into.

7.

Release brake pedal completely and accelerate
vehicle to a speed between 15 and 25 miles/25 and
40 kilometers per hour. Ensure that a minimum of
two vehicle lengths is maintained between front of
vehicle and any object in vehicle’s forward path.
Have another person key radio transmitter and
verify that vehicle can be braked normally to a
moderate stop while microphone is NOT being
spoken into.

8.

Repeat Step 7. except do so while microphone IS
being spoken into.

9.

Release brake pedal completely and accelerate
vehicle to a speed of 20 miles/30 kilometers per
hour. Ensure that a minimum of two vehicle
lengths is maintained between front of vehicle and
any object in vehicle’s forward path. Have another
person key radio transmitter and verify that
vehicle can be braked properly to a sudden (panic)
stop while microphone is NOT being spoken into.

• The container space shall be vented to the outside.

Anti-Lock Braking System (ABS)
and Anti-Skid Braking System
Precautions

!

Disruption of the anti-skid/anti-lock
braking system by the radio transmitter
may result in unexpected vehicle motion.

WARNING
Motorola recommends the following radio installation
precautions and vehicle braking system test procedures
to ensure that the radio, when transmitting, does not
interfere with operation of the vehicle braking system.

Installation Precautions
Always provide as much distance as possible between
braking modulator unit and radio, and between braking
modulator unit and radio antenna and associated
antenna transmission line. Before installing radio,
determine location of braking modulator unit in vehicle.
Depending on make and model of vehicle, braking
modulator unit may be located in trunk, under
dashboard, in engine compartment, or in some other
cargo area. If you cannot determine location of braking
modulator unit, refer to vehicle service manual or
contact a dealer for the particular make of vehicle.
If braking modulator unit is located on left side of the
vehicle, install radio on right side of vehicle, and
conversely.
Route all radio wiring including antenna transmission
line as far away as possible from braking modulator unit
and associated braking system wiring.
Never activate radio transmitter while vehicle is in
motion and vehicle trunk lid is open.

iv

10. Repeat Step 9. except do so while microphone IS
being spoken into.
11. Repeat Step 9. and Step 10. except use a vehicle
speed of 30 miles/50 kilometers per hour.

Table of Contents

1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scope of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Numbering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Kit-To-Model Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safe Handling of CMOS Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Parts Replacement and Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Rigid Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Audio PA Component Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
For High Power Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Antenna/Power Connector Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
For Low, Mid, and High Power Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3 - Test Equipment, Service Aids, and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service Aids and Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Field Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Connection of Control Head Extender Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Mid Power Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
High Power Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4 - Test Mode and Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Test Mode Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Test Mode Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power-up Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operational Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
5 - Disassembly & Reassembly and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Disassembly to Transceiver Board Level Low and Mid Power Models . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Remove the Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Remove Front Housing REMOTE MOUNT VERSION MODELS ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Remove the Top Cover LOW POWER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
MID POWER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Remove the Cavity Shield LOW POWER MODELS ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
v

Remove the PA Shield LOW AND MID POWER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Remove the Transceiver Board EXCEPT 800 MHZ AND 900 MHZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Remove the Transceiver Board 800 MHZ AND 900 MHZ MODELS ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Disassembly to Transceiver Board Level High Power Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Remove the Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Remove the RF Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Remove the PA Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Remove the PA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Remove the RF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Disassembly of the Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Remote Mount Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Model I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Models II & III STANDARD KEYPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Models II & III KEYPAD WITH REPLACEABLE PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Reassembly of the Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Model I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Models II and III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Transceiver Reassembly Low and Mid Power Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Transceiver Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Assembly of Control Head to Transceiver DASH MOUNT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
REMOTE MOUNT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Transceiver Reassembly High Power Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Replaceable Pushbuttons Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Models II & III KEYPAD WITH REPLACEABLE PUSHBUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
6 - Radio Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Transmitter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Transmit Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Transmit Deviation Balance (Compensation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Transmit Deviation Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Transmit Deviation Limit Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Signaling Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Squelch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Rated Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Front-End Pre-Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
7 - Controller Section Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Theory Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Voltage Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electronic On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Mechanical On/Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Protection features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Interfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Microprocessor Clock Synthesizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Serial Peripheral Interface (SPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
SB9600 Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
General Purpose Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Microprocessor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Normal (=Expanded) Microprocessor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
vi

Bootstrap Microprocessor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Audio and Signalling Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Audio Signalling Filter IC (ASFIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Audio Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Transmit Audio Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Transmit Signalling Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Receive Audio Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Receive Signalling Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
8 - Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Model I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Audio configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Volume Control/On-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Micro-controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Xtal Oscillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Mode Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Multiplexer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Models II and III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Audio Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Volume Control/On-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Micro-controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Xtal Oscillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Mode Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
9 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Troubleshooting Chart 1-1, Overall Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Troubleshooting Chart 1-2 (1 of 3), Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Troubleshooting Chart 1-2 (2 of 3), Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
Troubleshooting Chart 1-2 (3 of 3), Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
Troubleshooting Chart 1-3, On/Off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Troubleshooting Chart 1-4, TX Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
TX Audio Routing, Simplified Schematic for Chart 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Troubleshooting Chart 1-5, RX Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
RX Audio Routing, Simplified Schematic for Chart 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Troubleshooting Chart 1-6, Signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Troubleshooting Chart 1-7, DC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Radio Voltage, Simplified Schematic For Chart 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Troubleshooting Chart 1-8A, Control Head Model I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Numbers in brackets refer to accompanying troubleshooting procedure overleaf. . . . . . . . . . . 9-13
Control Head I Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Troubleshooting Chart 1-8B, Control Head Models II & III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Numbers in brackets refer to accompanying troubleshooting procedure overleaf . . . . . . . . . . . 9-18
Control Heads II and III Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Troubleshooting Chart 1-9, Clock Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Troubleshooting Chart 1-10, SB9600 BUS RX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Troubleshooting Chart 1-11, SB9600 BUS RX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
SB9600 Voltage Table for Charts 1-10 & 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
SB9600 BUSY, Simplified Schematic for Charts 1-10 & 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
vii

SB9600, Simplified Schematic for Charts 1-10 & 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Troubleshooting Chart 1-12, GPIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Troubleshooting Chart 1-13 (1 of 2), Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Troubleshooting Chart 1-13 (2 of 2), Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
10 - Diagrams and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Notes on Sheet Port Connections, Circuit Block Port Connections and Physical Connectors . . . . 10-2
Schematic Hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Low Power Radios Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Mid Power Radios Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
High Power Radios Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Control Head Model I Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Control Head Model II Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Control Head Model III Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Control Head Model I Component Locations and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Control Head Model I Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Control Head Model II Component Locations and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Control Head Model II Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Control Head Model III Component Locations and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Control Head Model III Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Main Controller and Audio Power Amplifier and Voltage Regulators Component Locations . . 10-16
Controller Hierarchy Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Main Controller Blocks Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Controller, Microprocessor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Controller, Power Control Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Controller, Audio Blocks Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Controller, Hear Clear Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Controller, ASFIC Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Controller, Interface Blocks Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Controller, IO RSSI Buffers Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Controller, Emergency Ignition Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Controller, SCI Drivers Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Controller, IO Buffers Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Controller, Audio Power Amplifier and Voltage Regulators, Low and Mid Power Schematic Diagram .10-29
Controller, Audio Power Amplifier and Voltage Regulators, High Power Schematic Diagram . . 10-30
Controller Parts List, Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Controller Parts List, Common Parts, Continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Controller Parts List, 800 MHz 15W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Controller Parts List, 800 MHz 35W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Controller Parts List, 900 MHz 12W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Controller Parts List, VHF 110W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Controller Parts List, UHF1 110 W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Controller Parts List, Non-Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Over Molded Pad Array Carriers (OMPACs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Integrated Circuits with Pin-Out Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
A - Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

viii

List of Figures

RF and Power Connector Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Install Connector Retaining Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Replace PA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Dedicated Test Mode Keys on Models I, II and III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removing the Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Removing the Top Cover - Low Power Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Removing the Top Cover - Mid Power Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Removing the Cavity Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Removing the PA Shield (Low and Mid Power Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Removing the Transceiver Board - Low Power Models (except 800 MHz and 900 MHz) . . . . . . 5-4
Removing the Transceiver Board - Mid Power Models (except 800 MHz and 900 MHz) . . . . . . . 5-5
Removing the Transceiver Board (800 MHz and 900 MHz only) . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Direction Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Removing the Accessory Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Removing the Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Removing the RF Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Removing the PA Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Removing the PA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Removing the RF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Wakefield / Thermal Compound Application Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Inserting Transceiver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Reassembly Screw Down Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Inserting Audio PA Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Installing Cover Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Model I Replaceable Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Model II Replaceable Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Model III Replaceable Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Grasping Pushbutton with Flat End Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Pulling Pushbutton Away from Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Radio Alignment Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Service Menu Structure for RVN4113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Softpot Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Clock Distribution Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Transmit Audio Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Transmit Signalling Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Receive Audio Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Receive Signalling Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Troubleshooting Charts Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Schematic Diagram Hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Example of Transceiver Board Block Connection Diagram (110 Watt Radio) . . . . . . . . . . . . . . 10-3

ix

List of Tables

Kit-to-Model Structure for VHF and UHF Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Kit-to-Model Structure for 800 and 900 MHz Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Recommended Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Control Head Connector Pin Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Power Up Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Operational Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Replaceable Pushbutton Graphics and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Transmit Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Current Limit Step Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Signaling Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Conventional/MDC/SmartNet/SmartZone Ignition Sense Function . . . . . . . . . . . Operator Action vs Resultant Radio States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Secondary I/O Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Hear Clear Enable Lines Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

x

Introduction
Scope of this
Manual

1

This manual includes model/kit information, specifications, fundamental
disassembly/reassembly procedures, maintenance, alignment,
troubleshooting; and all theory, schematic diagrams, printed circuit board
details and parts lists for all Non-Frequency Range Specific parts in the
equipment listed.
This manual is NOT a stand-alone manual, but requires the companionship of
an appropriate Volume 2 manual in order to have all service information for a
particular model of the radio. For every frequency band a band specific
Volume 2 manual will be available.
By ordering the Complete Service Instructions, Motorola Publication Number
68P81080C40, you will receive Volume 1 as well as all Volume 2 band specific
manuals available at the time of ordering. In addition, for radios that are
equipped with the Motorola SECURENET option, the SECURENET Service
manual, Motorola Publication Number 68P81083C25, is required.

Related
Publications

• 68P02058U20: Installation Instructions covering mobile series 900 / 1200
/ 2000 / 2100.
• 68P81080C40: MCS 2000 Mobile Radio Complete Service Instructions. All
Frequency Ranges, includes all volume 2s.
• 68P81083C20: MCS 2000 Mobile Radio Service Instructions - Volume 1.
Non-Frequency Range Specific (this publication).
• 68P81080C43: MCS 2000 Mobile Radio Service Instructions - Volume 2a.
800 MHz Frequency Range Specific.
• 68P81080C41: MCS 2000 Mobile Radio Service Instructions - Volume 2b.
VHF Frequency Range Specific.
• 68P81080C42: MCS 2000 Mobile Radio Service Instructions - Volume 2c.
UHF Frequency Range Specific.
• 68P81080C44: MCS 2000 Mobile Radio Service Instructions - Volume 2d.
900 MHz Frequency Range Specific.
• 68P81083C25: MCS 2000 Mobile Radio SECURENET Service Instructions.
• 68P81080C47: MCS 2000 Accessory Guide.
• 68P81080C35: MCS 2000 Mobile Radio Detailed User Reference Guide full
operating instruction covering models I, II and III.
• 68P81080C05: MCS 2000 Short Form User Guide for Model I.
• 68P81080C10: MCS 2000 Short Form User Guide for Models II and III.
• 68P81077C65: FlashPort User’s Guide.
• 68P81077C15: SmartZone RSS Manual.

Manual Revisions

Changes which occur after this manual is printed are described in Manual
Revisions. These Manual Revisions provide complete information on changes
including pertinent parts listing data.

Introduction

1-1

Model Numbering System

Typical Model Number: M
Position: 1

0
2

1
3

K
4

L
5

Position 1 - Type of Unit
M = Mobile Radio
Positions 2 & 3 - Model Series

Position 4 - Frequency Band
F = 66 to 88MHz
(Mid Band)
J = 136 to 174MHz (VHF1)
K = 146 to 174MHz (VHF2)
R = 403 to 470MHz (UHF1)
S = 450 to 512MHz (UHF2)*
U = 806 to 870MHz (800MHz))
W = 896 to 941MHz (900MHz)

* 450 to 520 on some models
Values given represent range only; they are
not absolute.
Position 5 - Power Level
F = 1 to 10 Watts
G = 10 to 15 Watts
H = 25 Watts
J = 30 to 35 Watts
K = 40 to 50 Watts
L = 100 to 110 Watts

Position 6 - Control Head
D = Duplex
H = Hand-Held Control
L = Limited Control; Limited Display (Model I)
M = Rotary Knob; Standard Display (Model II)
N = Keypad; Standard Display
(Model III)

M
6

9
7

P
8

W
9

6
10

A
11

N
12

S
13

P
14

0
15

1
16

Positions 13 - 16
“SP” Model Suffix
Position 12 Unique Model Variations
N = Standard Package

Position 11 - Version
Version Letter (Alpha) - Major Change
Position 10 - Specification Level
4 = Standard Specifications (Model I)
5 = Standard Specifications (Models II & III)
6 = High Specifications
Position 9 - Primary System Type
A = Conventional
B = Privacy Plus®
C = Clear SMARTNET™
D = Advanced Conventional Stat-Alert™
E = Enhanced Privacy Plus®
F = Nauganet 888 Series
G = Japan Specialized Mobile Radio (JSMR)
H = Multi-Channel Access (MCA)
J = CoveragePLUS™
K = MPT1327* - Public
L = MPT1327* - Private
M = Radiocom
N = Tone Signalling
P = Binary Signalling
Q = Phonenet®
W = Programmable
X = Secure Conventional
Y = Secure SMARTNET™

* MPT = Ministry of Posts and Telecommunications
Position 7 - Channel Spacing
1 = 5kHz
5 = 15kHz
2 = 6.25kHz 6 = 20/25kHz
3 = 10kHz
7 = 30kHz
4 = 12.5kHz 9 = Variable/Programmable

MEPC-95040-B/GB

1-2

Introduction

Position 8 - Primary Operation
A = Conventinal/Simplex
B = Conventional/Duplex
C = Trunked Twin Type
D = Dual Mode Trunked
E = Dual Mode Trunked/Duplex
F = Trunked Type I
G = Trunked Type II
H = FDMA* Digital Dual Mode
J = TDMA** Digital Dual Mode
K = Single Sideband
L = Global Positioning Satellite Capable
M = Amplitude Companded Sideband (ACSB)
P = Programmable

* FDMA = Frequency Division Multiple Access
** TDMA = Time Division Multiple Access

List of Models
PRIVATE SYSTEMS RADIOS
MCS 2000 Model Family
Model Number

Frequency Range

Power Level

Control Head Model

Channel Spacing

No. of Modes

M01JLM9PW6_N

136 - 162 MHz

50-110 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01JLN9PW6A_N

136 - 162 MHz

50-110 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01JLH9PW6A_N

136 - 162 MHz

50-110 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01KHL9PW4_N

136 - 174 MHz

1-25 Watts

Model I, 8 digits

25/20/12.5 kHz

48

M01KHM9PW5_N

136 - 174 MHz

1-25 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01KHN9PW5_N

136 - 174 MHz

1-25 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01KHH9PW5_N

136 - 174 MHz

1-25 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01KKM9PW6_N

136 - 174 MHz

25-50 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01KKN9PW6_N

136 - 174 MHz

25-50 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01KKH9PW6_N

136 - 174 MHz

25-50 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01KLM9PW6_N

146 - 174 MHz

50-110 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01KLN9PW6_N

146 - 174 MHz

50-110 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01KLH9PW6_N

146 - 174 MHz

50-110 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01RFL9PW4_N

403 - 470 MHz

1-10 Watts

Model I, 8 digits

25/20/12.5 kHz

48

M01RFM9PW5_N

403 - 470 MHz

1-10 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01RFN9PW5_N

403 - 470 MHz

1-10 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01RFH9PW5_N

403 - 470 MHz

1-10 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01RHL9PW4_N

403 - 470 MHz

10-25 Watts

Model I, 8 digits

25/20/12.5 kHz

48

M01RHM9PW5_N

403 - 470 MHz

10-25 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01RHN9PW5_N

403 - 470 MHz

10-25 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01RHH9PW5_N

403 - 470 MHz

10-25 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01RKM9PW6_N

*

403 - 470 MHz

25-50 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01RKN9PW6_N

403 - 470 MHz*

25-50 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01RKH9PW6_N

403 - 470 MHz*

25-50 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01RLM9PW6_N

403 - 470 MHz*

50-110 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01RLN9PW6_N

403 - 470 MHz*

50-110 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01RLH9PW6_N

403 - 470 MHz*

50-110 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01SHM9PW5_N

450 - 512 MHz

10-25 Watts

Model I, 8 digits

25/20/12.5 kHz

48

M01SHM9PW5_N

450 - 512 MHz

10-25 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01SHM9PW5_N

450 - 512 MHz

10-25 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01SLM9PW6_N

450 - 512 MHz

50-110 Watts

Model II, 1x14 digits

25/20/12.5 kHz

160

M01SLN9PW6_N

450 - 512 MHz

50-110 Watts

Model III, 2x14 digits

25/20/12.5 kHz

160

M01SLH9PW6_N

450 - 512 MHz

50-110 Watts

Hand-held Control Head

25/20/12.5 kHz

160

M01UGL6PW4_N

806 - 870 MHz

15 Watts

Model I, 8 digits

20/25 kHz

48

M01UGM6PW5_N

806 - 870 MHz

15 Watts

Model II, 1x14 digits

20/25 kHz

160

M01UGM6PW6_N

806 - 870 MHz

15 Watts

Model II, 1x14 digits

20/25 kHz

160

Introduction

1-3

PRIVATE SYSTEMS RADIOS
MCS 2000 Model Family
Model Number

Frequency Range

Power Level

Control Head Model

Channel Spacing

No. of Modes

M01UGN6PW6_N

806 - 870 MHz

15 Watts

Model III, 2X14 digits

20/25 kHz

160

M01UGH6PW6_N

806 - 870 MHz

15 Watts

Hand-held Control Head

20/25 kHz

160

M01UJL6PW4_N

806 - 870 MHz

30-35 Watts

Model I, 8 digits

20/25 kHz

48

M01UJM6PW6_N

806 - 870 MHz

30-35 Watts

Model II, 1x14 digits

20/25 kHz

160

M01UJN6PW6_N

806 - 870 MHz

30-35 Watts

Model III, 2X14 digits

20/25 kHz

160

M01UJH6PW6_N

806 - 870 MHz

30-35 Watts

Hand-held Control Head

20/25 kHz

160

M01WGL4PW4_N

896-941 MHz

12 Watts

Model I, 8 digits

12.5 kHz

48

M01WGM4PW6_N

896-941 MHz

12 Watts

Model II, 1x14 digits

12.5 kHz

160

M01WGN4PW6_N

896-941 MHz

12 Watts

Model III, 2X14 digits

12.5 kHz

160

M01WGH4PW6_N

896-941 MHz

12 Watts

Hand-held Control Head

12.5 kHz

160

M01WJL4PW4_N

896-941 MHz

30 Watts

Model I, 8 digits

12.5 kHz

48

M01WJM4PW6_N

896-941 MHz

30 Watts

Model II, 1x14 digits

12.5 kHz

160

M01WJN4PW6_N

896-941 MHz

30 Watts

Model III, 2X14 digits

12.5 kHz

160

M01WJH4PW6_N

896-941 MHz

30 Watts

Hand-held Control Head

12.5 kHz

160

* The radio will operate with some degradation in receiver performance in 433-438 MHz frequencies.

1-4

Introduction

Kit-To-Model
Structure

The cross-reference charts below show the kit breakdown for each of the
MCS 2000 models. Table 1-1 covers the VHF and UHF models and Table 1-2
covers the 800 MHz and 900 MHz models.

HLN6353A Trstr Hw kit U2 25W

HLN6572A Trstr Hw kit VHF 100W

HLN6357A Trstr Hw kit VHF 50W

HLN6354A Trstr Hw kit V/U 25W

HHN4042A Housing, HP (110W)

HHN4041A Housing, MP (25-50W)

HLN6544A Housing, LP (≥25W), VHF/UHF

HCN1093B Ctrl Hd III

HCN1091B Ctrl Hd I

HCN1092B Ctrl Hd II

HUE4017A RF/Ctrl Bd, UHF, 110W

HUE4018A PA, UHF, 110W

NLE4248A RF/Ctrl Bd, UHF, 50 W

HUE4019A RF/Ctrl Bd, UHF2, 110W

HUE4020A PA, UHF2, 110W

HUE4011B2 RF/Ctrl Bd, UHF2, 10-25W

HUE4012C1 RF/Ctrl Bd, UHF1, 10-25W

HUE4021B RF/Ctrl Bd, UHF1, 1-10W

HUD4016A PA VHF2,110W

HUD4021A PA VHF1, 110W

HUD4015A RF/Ctrl Bd, VHF1/VHF2, 110W

HUD4006A RF/Ctrl Bd, VHF, 25-50W

Description
Item

HUD4012D RF/Ctrl Bd, VHF, 1-25W

Table 1-1 Kit-to-Model Structure for VHF and UHF Radios

Model

•
•
•

•

• •
• •
• •
•
•
•

•
•
•
•

•
•
• •
• •
• •
•
•
•
•
•
•

•
•
•
•
•
•
•
•
•

•
•
•
•
•
•
•
•
•

•

•
• •
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
• • •
•
• •
•
•
• •
•

•
•
•
•

M01KHN9PW5_N, VHF1, 25W, Mod. III
M01KHH9PW5_N, VHF1, 25W, Hand held
M01KKM9PW6_N, VHF1, 50W, Mod. II
M01KKN9PW6_N, VHF1, 50W, Mod. III
M01KKH9PW6_N, VHF1, 50W, Hand held

•
•
•
•
•
•
•
•
•
•
•
•
•

Description

M01KHM9PW5_N, VHF1, 25W, Mod. II

M01JLM9PW6_N, VHF1, 110W, Mod. II
M01JLN9PW6_N, VHF1, 110W, Mod. III
M01JLH9PW6_N, VHF1, 110W, Hand held
M01KLM9PW6_N, VHF2, 110W, Mod. II
M01KLN9PW6_N, VHF2, 110W, Mod. III
M01KLH9PW6_N, VHF2, 110W, Hand held
M01RFM9PW5_N, UHF1, 10W, Mod. II
M01RFN9PW5_N, UHF1, 10W, Mod. III
M01RFH9PW5_N, UHF1, 10W, Hand held
M01RHL9PW4_N, UHF1, 10-25W, Mod. I
M01RHM9PW5_N, UHF1, 10-25W, Mod. II
M01RHN9PW5_N, UHF1, 10-25W, Mod. III
M01RHH9PW5_N, UHF1, 10-25W, Hand
M01RKM9PW6_N, UHF1, 50W, Mod. II
M01KHN9PW6_N, UHF1, 50W, Mod. III
M01RKH9PW6_N, UHF1, 50W, Hand held
M01RLM9PW6_N, UHF1, 110W, Mod. II
M01RLN9PW6_N, UHF1, 110W, Mod. III
M01RLH9PW6_N, UHF1, 110W, Hand held
M01SHM9PW5_N, UHF2, 25W, Mod. II

• •
• •
• •

•
•

•
•
•

M01SLM9PW5_N, UHF2, 110W, Mod. II
M01SLN9PW5_N, UHF2, 110W, Mod. III
M01SLH9PW5_N, UHF2, 110W, Hand held

Introduction

1-5

FLN8182A Trstr Hw kit 8/900MHz 15/12W

HLN6572A Trstr Hw kit VHF 100W

HLN6357A Trstr Hw kit VHF 50W

HLN6354A Trstr Hw kit V/U 25W

HHN4042A Housing, HP (110W)

HHN4041A Housing, MP (25-50W)

HLN6544A Housing, LP (≥25W), VHF/UHF

HHN4037A Housing, LP (≥25W), 8/900 MHz

HCN1093B Ctrl Hd III

HCN1091B Ctrl Hd I

HCN1092B Ctrl Hd II

FLF5592A RF/Ctrl Bd, 900 MHz, 30W

HUF4006A RF/Ctrl Bd, 900 MHz, 12W

FLF5574C RF/Ctrl Bd, 800 MHz, 35W

Description
Item

FLF5579C RF/Ctrl Bd, 800 MHz, 15W

Table 1-2 Kit-to-Model Structure for 800 and 900 MHz Radios

Model

•
•
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Description

M01UGL6PW4_N, 800MHz, 15W, Mod. I
M01UGM6PW6_N, 800MHz, 15W, Mod. II
M01UGN6PW6_N, 800MHz, 15W, Mod. III
M01UGH6PW6_N, 800MHz, 15W,Hand hld

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Introduction

M01UJL6PW4_N, 800MHz, 35W, Mod. I
M01UJM6PW6_N, 800MHz, 35W, Mod. II
M01UJN6PW6_N, 800MHz, 35W, Mod. III

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1-6

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M01UGH6PW6_N, 800MHz, 35W, Hand hld

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M01UGM6PW5_N, 800MHz, 15W, Mod. II

M01WGL4PW4_N, 900MHz, 12W, Mod. I
M01WGM4PW6_N, 900MHz, 12W, Mod. II
M01WGN4PW6_N, 900MHz, 12W, Mod. III
M01WGH4PW6_N, 900MHz, 12W, Hand hld
M01WJL4PW6_N, 900MHz, 30W, Mod. I
M01WJM4PW6_N, 900MHz, 30W, Mod. II
M01WJN4PW6_N, 900MHz, 30W, Mod. III
M01WJH4PW6_N, 900MHz, 30W, Hand hld

SPECIFICATIONS FOR VHF, 1-25 WATT RADIOS
All specifications are per European Telecommunication Standard (ETS) 300-086 unless otherwise noted.

Temperature Range:
Operating:
Storage:

Frequency Range:
-25 to +55°C
-40 to +85°C

Power Supply:
Nominal Voltage:
13.6 V
Operating Voltage:
10.8-15.6 V
Current Drain, maximum values:
Stand-by:
0.45 A
Receive:
1.7 A with 7.5 W speaker
2.5 A with 13 W speaker
1.5 A with 4 W speaker
Transmit:
8.75 A
Off
35 mA
Number of Modes:
Model I:
Standard 48, optional 150
Model II, III:
Standard 160, optional 250
Channel Spacing:

12.5, 20, 25 kHz

Mode of Operation:
Simplex/Half-Duplex
Modulation:

TRANSMITTER

RECEIVER

GENERAL

FM/PM

Antenna Impedance:

50 Ω

Frequency Stability:

±5.0 ppm

136-174MHz

Maximum Frequency Separation:
Sensitivity:
20dB SINAD:
12.5 kHz:
20/25 kHz:
12dB SINAD:

38 MHz

0.45 uV
0.35 uV
0.30 uV

Frequency Range:
RF Power:

136-174MHz
1 - 25 Watts variable

Deviation, Maximum:
12.5 kHz channel spacing:
20 kHz channel spacing:
25 kHz channel spacing:
Spurious & Harmonics:

Adjacent Channel Selectivity:
12.5 kHz:
20 kHz:
25 kHz:

>70 dB
>75 dB
>80 dB

Spurious / Image Rejection:

>80 dB

Intermodulation:

(uVemf)>70 dB

Conducted Spurious Emission:

<2 nW

±2.5 kHz
±4.0 kHz
±5.0 kHz
<0.25 uW

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
<3% @ 60% of maximum deviation
Adjacent Channel Power (CEPT):
12.5 kHz:
20/25 kHz:

<60 dB
<-70 dB

Audio Output:
12.5 kHz:
4 W (internal, 16 Ω)
20/25 kHz: 7.5/13 W (external, 8 Ω/3.2 Ω)
Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
EIA:
CEPT:

<3%
<5%

Dimensions (H/W/D):
1-25 Watt Transceiver:
44x168x180 mm / 1.73”x6.61”x7.09”
Control Head I, Dash Mt.:
44x168x30 mm / 1.73”x6.61”x1.18”
Control Head II, III, Dash Mt.:
60x190x30 mm / 2.36”x7.48”x1.18”
Control Head II, III, Remote Mt.:
60x190x71 mm / 2.36”x7.48”x2.80”
Weight:
1-25 Watt Transceivers: 1.6 kg / 3.53 lbs
Control Head I, Dash Mt.: 152 g / 0.33 lbs
Control Head II, Dash Mt.: 233 g / 0.51 lbs
Control Head III, Dash Mt.:229 g / 0.50 lbs

Specifications subject to change without notice.

Introduction

1-7

SPECIFICATIONS FOR VHF, 25-50 WATT AND 50-110 WATT RADIOS
All specifications are per Electronic Industries Association (EIA) 603 unless otherwise noted.

(FCC Designation:
136-174 MHz, 110 W

Frequency Range:
AZ492FT3781)

Temperature Range:
Operating:
Storage:

-30 to +60°C
-40 to +85°C

Power Supply:
Nominal Voltage:
13.6 V
Operating Voltage:
10.8-16.3 V
Current Drain, maximum values:
Stand-by:
0.45 A
Receive:
1.7 A with 7.5 W speaker
2.5 A with 13 W speaker
1.5 A with 4 W speaker
Transmit (25-50W):
15 A
Transmit (110W):
27 A
Off:
35 mA
Number of Modes:
Model I:
Standard 48, optional 150
Model II, III:
Standard 160, optional 250
Channel Spacing:
Mode of Operation:

12.5/30 kHz
Semi-Duplex

Modulation:

TRANSMITTER

RECEIVER

GENERAL

FM

Antenna Impedance:

50 Ω

Frequency Stability:

±2.0 ppm

Dimensions (H/W/D):
25-50W Transceivers:
44x168x230 mm / 1.97”x6.61”x7.76”
50-110 Watt Transceivers:
56x168x360 mm / 2.30”x6.61”x11.66”
Control Head I, Dash Mt.:
44x168x30 mm / 1.75”x6.61”x1.81”
Control Head II, III, Dash Mt.:
60x186x30 mm / 2.35”x7.33”x1.83”
Control Head II, III, Remote Mt.:
60x186x71 mm / 2.35”x7.33”x2.78”

(50-110 W) 136-162MHz
(50-110 W) 136-174 MHz
(25-50W) 146-174MHz

Maximum Frequency Separation:
25-50 W
50-110 W
136-162 MHz
146-174 MHz

38 MHz
26 MHz
28 MHz

Maximum Frequency Separation:
25-50 W
50-110 W
136-162 MHz
146-174 MHz
RF Power:

Adjacent Channel Selectivity:
@12.5 kHz:
@30 kHz:

-65 dB
-95 dB

Deviation, Maximum:
12.5 kHz channel spacing:
25 kHz channel spacing:

Image Rejection:

-90 dB

Spurious & Harmonics:

Spurious Rejection:
or with preamp
Intermodulation:
or with preamp

*

-100 dB
-90 dB
-85 dB
-80 dB

Conducted Spurious Emission:
per FCC part 90
Audio Output:
4 W (internal, 16 Ω)
7.5 W or 13 W (external, 8 Ω/3.2 Ω)
Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
7.5 W @:
(optional spkr) 13 W @

*.

<3%
<5%

-100 dB is not applicable to all
spurious frequencies.

Specifications subject to change without notice.

Introduction

(50-110 W) 136-162MHz
(50-110 W) 136-174 MHz
(25-50W) 146-174MHz

Sensitivity:
20dB SINAD:0.50 uV or 0.30 uV w/ preamp
12dB SINAD:0.35 uV 0r 0.20 uV w/ preamp

Weight:
25-50 Watt Transceivers: 1.8 kg / 4.04 lbs
50-110 Watt Transceivers: 2.5 kg / 5.50 lbs
Control Head I, Dash Mt.: 152 g / 0.33 lbs
Control Head II, Dash Mt.: 233 g / 0.51 lbs
Control Head III, Dash Mt.:229 g / 0.50 lbs

1-8

Frequency Range:

38 MHz
26 MHz
28 MHz

136-174MHz: 25-50 Watts
136-162 MHz: 50-110 Watts
146-174MHz: 50-110 Watts

±2.5 kHz
±5.0 kHz
-85 dBc

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
<3% @ 60% of maximum deviation
Adjacent Channel Power (CEPT):
12.5 kHz:
20/25/30 kHz:

-60 dBc
-70 dBc

SPECIFICATIONS FOR UHF, 1-10 WATT AND 10-25 WATT RADIOS
All specifications are per European Telecommunication Standard (ETS) 300-086 unless otherwise noted.

Temperature Range:
Operating:
Storage:

Frequency Range:
-25 to +55°C
-40 to +85°C

Power Supply:
Nominal Voltage:
13.6 V
Operating Voltage:
10.8-15.6 V
Current Drain, maximum values:
Stand-by:
0.45 A
Receive:
1.7 A with 7.5 W speaker
2.5 A with 13 W speaker
1.5 A with 4 W speaker
Transmit (25W):
8.75 A
Off:
35 mA
Number of Modes:
Model I:
Standard 48, optional 150
Model II, III:
Standard 160, optional 250
Channel Spacing:

12.5, 20, 25 kHz

Mode of Operation:
Simplex/Half-Duplex
Modulation:

TRANSMITTER

RECEIVER

GENERAL

FM/PM

Antenna Impedance:

50 Ω

Frequency Stability:

±4.0 ppm

Dimensions (H/W/D):
1-25 Watt Transceiver:
44x168x180 mm / 1.73”x6.61”x7.09”
Control Head I, Dash Mt.:
44x168x30 mm / 1.73”x6.61”x1.18”
Control Head II, III, Dash Mt.:
60x190x30 mm / 2.36”x7.48”x1.18”
Control Head II, III, Remote Mt.:
60x190x71 mm / 2.36”x7.48”x2.80”

403-470 MHz

Maximum Frequency Separation:
Sensitivity:
20dB SINAD:
12.5 kHz:
20/25 kHz:
12dB SINAD:
12.5 kHz:
20/25 kHz:

RF Power:

0.45 uV
0.35 uV

Deviation, Maximum:
12.5 kHz channel spacing:
20 kHz channel spacing:
25 kHz channel spacing:

0.35 uV
0.30 uV

Spurious & Harmonics:

>65 dB
>70 dB
>75 dB

Spurious / Image Rejection:

>80 dB
(uVemf)>70 dB

Conducted Spurious Emission:

403-470 MHz

67 MHz

Adjacent Channel Selectivity:
12.5 kHz:
20 kHz:
25 kHz:

Intermodulation:

Frequency Range:

1 - 10 Watts variable
10-25 Watts variable

±2.5 kHz
±4.0 kHz
±5.0 kHz
<0.25 uW

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
<3% @ 60% of maximum deviation
Adjacent Channel Power (CEPT):
12.5 kHz:
20/25 kHz:

<60 dB
<-70 dB

<2 nW

Audio Output:
12.5 kHz:
4 W (internal, 16 Ω)
20/25 kHz: 7.5/13 W (external, 8 Ω/3.2 Ω)
Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
EIA:
CEPT:

<3%
<5%

Weight:
1-25 Watt Transceivers: 1.6 kg / 3.53 lbs
Control Head I, Dash Mt.: 152 g / 0.33 lbs
Control Head II, Dash Mt.: 233 g / 0.51 lbs
Control Head III, Dash Mt.:229 g / 0.50 lbs

Specifications subject to change without notice.

Introduction

1-9

SPECIFICATIONS FOR UHF, 25-40 WATT, 50-110 WATT RADIOS
All specifications are per Electronic Industries Association (EIA) 603 unless otherwise noted.

(FCC Designation:
403-470 MHz, 110 W

Frequency Range:

Frequency Range:
403-470*MHz
450-512MHz

AZ492FT54797)

Temperature Range:
Operating:
Storage:

-30 to +60°C
-40 to +85°C

Power Supply:
Nominal Voltage:
13.6 V
Operating Voltage:
10.8-16.3 V
Current Drain, maximum values:
Stand-by:
0.5 A
Receive:
1.7 A with 7.5 W speaker
2.5 A with 13 W speaker
1.5 A with 4 W speaker
Transmit (25-40W):
13.0 A
Transmit (50-110W):
31.0 A
Off:
35 mA
Number of Modes:
Model I:
Standard 48, optional 150
Model II, III:
Standard 160, optional 250
Channel Spacing:
Mode of Operation:

TRANSMITTER

RECEIVER

GENERAL

12.5/25 kHz
Semi-Duplex

Modulation:

FM

Antenna Impedance:

50 Ω

Frequency Stability:

±2.0 ppm

Maximum Frequency Separation:

67 MHz

Sensitivity:
20dB SINAD:0.50 uV or 0.30 uV w/ preamp
12dB SINAD:0.35 uV 0r 0.20 uV w/ preamp

403-470*MHz
450-512MHz
RF Power:
403-470 MHz:
450-512 MHz

Adjacent Channel Selectivity:
@12.5 kHz:
@25 kHz:

-65 dB
-82 dB

Deviation, Maximum:
12.5 kHz channel spacing:
25 kHz channel spacing:

Spurious / Image Rejection:
or with preamp

-95 dB
-90 dB

Spurious & Harmonics:

Intermodulation:(uVemf)
or with preamp

-85 dB
-80 dB

25-40 Watts
50-110 Watts
25-40 Watts
50-110 Watts*

±2.5 kHz
±5.0 kHz
-80 dBc

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:

Conducted Spurious Emission:
per FCC part 90
Audio Output:
7.5 W or 13 W (external, 8 Ω/3.2 Ω)

<3% @ 60% of maximum deviation
Adjacent Channel Power (CEPT):
12.5 kHz:
20/25/30 kHz:

-60 dBc
-70 dBc

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
7.5 W @:
(optional spkr) 13 W @

<3%
<5%

Dimensions (H/W/D):
25-50W Transceivers:
44x168x230 mm / 1.97”x6.61”x7.76”
50-110 Watt Transceivers:
56x168x360 mm / 2.30”x6.61”x11.66”
Control Head I, Dash Mt.:
44x168x30 mm / 1.75”x6.61”x1.81”
Control Head II, III, Dash Mt.:
60x186x30 mm / 2.35”x7.33”x1.83”
Control Head II, III, Remote Mt.:
60x186x71 mm / 2.35”x7.33”x2.78”
Weight:
25-50 Watt Transceivers: 1.8 kg / 4.04 lbs
50-110 Watt Transceivers: 2.5 kg / 5.50 lbs
Control Head I, Dash Mt.: 152 g / 0.33 lbs
Control Head II, Dash Mt.: 233 g / 0.51 lbs
Control Head III, Dash Mt.:229 g / 0.50 lbs

*.

The radio will operate with
some degradation in receiver
performance in 433-438 MHz
frequencies.

Specifications subject to change without notice.

1-10

Introduction

*.

Limited to 78 Watts above
470 MHz in the USA.

SPECIFICATIONS FOR 800 MHZ, 15 WATT AND 30-35 WATT RADIOS
All specifications are per Electronic Industries Association (EIA) 603 unless otherwise noted.

FCC Designation:

TRANSMITTER

RECEIVER

GENERAL
30-35W: AZ492FT5773
15W: AZ492FT5765

Frequency Range:

851-866MHz
866-870MHz

Frequency Range:
(Talkaround)

Temperature Range:
Operating:
Storage:

Maximum Frequency Separation:
-30 to +60°C
-40 to +85°C

Power Supply:
Nominal Voltage:
13.6 V
Operating Voltage:
10.8-16.3 V
Current Drain, maximum values:
Stand-by:
0.45 A
Receive:
1.7 A with 7.5 W speaker
2.5 A with 13 W speaker
1.5 A with 4 W speaker
Transmit (15W):
6.5 A
Transmit (35W):
13.5 A
Off:
30 mA
Number of Modes:
Model I:
Standard 48, optional 150
Model II, III:
Standard 160, optional 250

18 MHz
Maximum Frequency Separation:

Sensitivity:
20dB SINAD:
12dB SINAD:

0.40 uV
0.30 uV

Adjacent Channel Selectivity:
Model I:
Models II & III:

-75 dB
-80 dB

Spurious & Image Rejection:
Model I:
Models II & III:

-75 dB
-90 dB

Intermodulation: (uVemf)
Model I:
Models II & III:

-75 dB
-80 dB

RF Power:

15 Watts
30 or 35 Watts

Deviation, Maximum:
@806-821 & 851-866MHz:
@821-825 & 866-870MHz:
Spurious & Harmonics:

Conducted Spurious Emission:
per FCC part 90

63 MHz

5 kHz
4 kHz
-70 dBc

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
<3% @ 60% of maximum deviation
Adjacent Channel Power (CEPT):
>-60 dBc

Audio Output:

Channel Spacing:
806-821 & 851-866MHz:
821-825 & 866-870MHz:
Mode of Operation:

806-821 & 821-825MHz
851-866 & 866-870MHz

4 W (internal, 16 Ω)
7.5 W or 13 W (external, 8 Ω/3.2 Ω)

25 kHz
20 kHz
Semi-Duplex

Modulation:
Antenna Impedance:
Frequency Stability:
806-821 MHz & 851-866 MHz:
821-825 MHz & 866-870 MHz:

FM

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:

4/7.5/13 W @:<5%

50 Ω

±2.5 ppm
±1.5 ppm

Dimensions (H/W/D):
1-25W Transceivers:
44x168x180 mm / 1.73”x6.61”x7.09”
25-50W Transceivers:
44x168x230 mm / 1.97”x6.61”x7.76”
Control Head I, Dash Mt.:
44x168x30 mm / 1.75”x6.61”x1.81”
Control Head II, III, Dash Mt.:
60x186x30 mm / 2.35”x7.33”x1.83”
Control Head II, III, Remote Mt.:
60x186x71 mm / 2.35”x7.33”x2.78”
Weight:
1-25 Watt Transceivers: 1.6 kg / 3.53 lbs
25-50 Watt Transceivers: 1.8 kg / 4.04 lbs
Control Head I, Dash Mt.: 152 g / 0.33 lbs
Control Head II, Dash Mt.: 233 g / 0.51 lbs
Control Head III, Dash Mt.:229 g / 0.50 lbs

Specifications subject to change without notice.

Introduction

1-11

SPECIFICATIONS FOR 900 MHZ, 12 WATT AND 30 WATT RADIOS
All specifications are per Electronic Industries Association (EIA) 603 unless otherwise noted.

FCC Designation:

30W: AZ492FT5773
12W: AZ492FT5765

Frequency Range:

896-941MHz

Maximum Frequency Separation:
Temperature Range:
Operating:
Storage:

-30 to +60°C
-40 to +85°C

Power Supply:
Nominal Voltage:
13.6 V
Operating Voltage:
10.8-16.3 V
Current Drain, maximum values:
Stand-by:
0.45 A
Receive:
1.7 A with 7.5 W speaker
2.5 A with 13 W speaker
1.5 A with 4 W speaker
Transmit (12W):
6.5 A
Transmit (30W):
14.5 A
Off:
30 mA
Number of Modes:
Model I:
Standard 48, optional 150
Model II, III:
Standard 160, optional 250
Channel Spacing:
Mode of Operation:

Semi-Duplex
FM

Antenna Impedance:

50 Ω

Frequency Stability:

±1.5 ppm

6 MHz

-65 dB
-70 dB

Spurious & Image Rejection:
Model I:
Models II & III:

-70 dB
-90 dB

Intermodulation: (uVemf)
Model I:
Models II & III:

-65 dB
-70 dB

Conducted Spurious Emission:
per FCC part 90
Audio Output:
4 W (internal, 16 Ω)
7.5 W or 13 W (external, 8 Ω/3.2 Ω)
Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
4/7.5/13 W @:<5%

Dimensions (H/W/D):
1-25W Transceivers:
44x168x180 mm / 1.73”x6.61”x7.09”
25-50W Transceivers:
44x168x230 mm / 1.97”x6.61”x7.76”
Control Head I, Dash Mt.:
44x168x30 mm / 1.75”x6.61”x1.81”
Control Head II, III, Dash Mt.:
60x186x30 mm / 2.35”x7.33”x1.83”
Control Head II, III, Remote Mt.:
60x186x71 mm / 2.35”x7.33”x2.78”
Weight:
1-25 Watt Transceivers: 1.6 kg / 3.53 lbs
25-50 Watt Transceivers: 1.8 kg / 4.04 lbs
Control Head I, Dash Mt.: 152 g / 0.33 lbs
Control Head II, Dash Mt.: 233 g / 0.51 lbs
Control Head III, Dash Mt.:229 g / 0.50 lbs

Specifications subject to change without notice.

1-12

Introduction

896-941MHz

Maximum Frequency Separation:

45 MHz
12 Watts
30 Watts

0.40 uV
0.30 uV

Adjacent Channel Selectivity:
Model I:
Models II & III:

Distortion:

Frequency Range:

RF Power:

Sensitivity:
20dB SINAD:
12dB SINAD:

12.5 kHz

Modulation:

TRANSMITTER

RECEIVER

GENERAL

Deviation, Maximum:

2.5 kHz

Spurious & Harmonics:

-70 dBc

Audio Response:
6 dB/octave +1/-3 dB at 300-3000 Hz
Distortion:
<3% @ 60% of maximum deviation
Adjacent Channel Power (CEPT):
>-60 dBc

Basic Maintenance

2

Introduction

This chapter of the manual describes preventive maintenance, safe handling
of CMOS devices, and repair procedures and techniques. Each of these topics
provides information vital to the successful operation and maintenance of
your radio.

Preventive
Maintenance

The radios do not require a scheduled preventive maintenance program;
however, periodic visual inspection and cleaning is recommended.

Inspection

Check that the external surfaces of the radio are clean, and that all external
controls and switches are functional. A detailed inspection of the interior
electronic circuitry is not needed or desired.

Cleaning

The following procedures describe the recommended cleaning agents and the
methods to be used when cleaning the external and internal surfaces of the
radio. External surfaces include the front cover, housing and assembly. These
surfaces should be cleaned whenever a periodic visual inspection reveals the
presence of smudges, grease, and/or grime. Internal surfaces should be cleaned
only when the radio is disassembled for servicing or repair.
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 (70% by volume).

!
Caution

The effects of certain chemicals and their vapors can have harmful results
on certain plastics. Aerosol sprays, tuner cleaners, and other chemicals
should be avoided.

Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff,
nonmetallic, short-bristled brush to work all loose dirt away from the radio. A
soft, absorbent, lint-free cloth or tissue should be used to remove the solution
and dry the radio. Make sure that no water remains entrapped near the
connectors, cracks, or crevices.

Circuit Boards and
Components

Isopropyl alcohol may be applied with a stiff, nonmetallic, short-bristled
brush to dislodge embedded or caked materials located in hard-to-reach areas.
The brush stroke should direct the dislodged material out and away from the
inside of the radio.
Alcohol is a high-wetting liquid and can carry contamination into unwanted
places if an excessive quantity is used. Make sure that controls or tuneable
components are not soaked with the liquid. Do not use high-pressure air to
hasten the drying process, since this could cause the liquid to puddle and
collect in unwanted places.

Basic Maintenance

2-1

Upon completion of the cleaning process, use a soft, absorbent, lint-free cloth
to dry the area. Do not brush or apply any isopropyl alcohol to the frame,
front cover, or back cover.
Note

Always use a fresh supply of alcohol and a clean container to prevent
contamination by dissolved material (from previous usage).

Safe Handling
of CMOS
Devices

!
Caution

Precautions

Complementary metal-oxide semiconductor (CMOS) devices are used in
this family of radios. While the attributes of CMOS are many, their
characteristics make them susceptible to damage by electrostatic or high
voltage charges. Damage can be latent, resulting in failures occurring
weeks or months later. Therefore, special precautions must be taken to
prevent device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits, and are especially
important in low humidity conditions. DO NOT attempt to disassemble
the radio without observing the following handling precautions.
12. Eliminate static generators (plastics, styrofoam, etc.) in the work area.
13. Remove nylon or double-knit polyester jackets, roll up long sleeves, and
remove or tie back loose hanging neckties
14. Store and transport all static-sensitive devices in ESD-protective
containers.
15. If at all possible, handle CMOS devices by the package and not by the
leads. Prior to touching the unit, touch an electrical ground to remove
any static charge that you may have accumulated. The package and
substrate may be electrically common. If so, the reaction of a discharge
to the case would cause the same damage as touching the leads.
16. Disconnect all power from the unit before ESD-sensitive components are
removed or inserted unless otherwise noted.
17. Use a static-safeguarded workstation, which can be accomplished
through the use of an anti-static kit (Motorola part number 0180386A82). This kit includes a wrist strap, two ground cords, a staticcontrol table mat and a static-control floor mat. For additional
information, refer to Service and Repair Note SRN F1052, “Static Control
Equipment for Servicing ESD Sensitive Products”, available from
Motorola Literature Distribution 2290 Hammond Drive Schaumburg, IL
60173 (847) 576-2826
When these items are not readily available, observing the following
techniques will minimize chance of damage.

2-2

Basic Maintenance

-

If a static-sensitive device is to be temporarily set down, use a
conductive surface for placement of the device.

-

Make skin contact with a conductive work surface first and maintain
this contact when the device is set down or picked up.

18. Always wear a conductive wrist strap when servicing this equipment.
The Motorola part number for a replacement wrist strap that connects to
the table mat is 42-80385A59.
19. When straightening CMOS pins, provide ground straps for apparatus used.
20. When soldering, use a grounded soldering iron.

Parts
Replacement
and
Substitution

Special care should be taken to be as certain as possible that a suspected
component is actually the one at fault. This special care will eliminate
unnecessary unsoldering and removal of parts, which could damage or
weaken other components or the printed circuit board itself.
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 office.

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, care should be
exercised to avoid pulling the plated circuit out of the hole.
When soldering near the module socket pins, use care to avoid accidentally
getting solder in the socket. Also, be careful not to form solder bridges between
the module socket pins. Closely examine your work for shorts due to solder
bridges. When removing modules with metal enclosures, be sure to desolder
the enclosure ground tabs as well as the module pins.

Specific

During all repair procedures, heating neighbouring components can be
minimized by:
• using upper heat only.
• using the correct size heat focus head approximately the same size as the
carrier being replaced
• keeping the heat focus head approximately1/8” or 3-6 mm above the
printed circuit board when removing or replacing the device.

!
Caution

If neighbouring OMPAC components are heated above 365 degrees F or
185 degrees C they will suffer die-bond delamination and possible
“popcorn” failure.

Basic Maintenance

2-3

Audio PA Component Replacement Procedure
For High Power Models

!

This procedure must be used when replacing these components to ensure
proper alignment and heatsinking.

Caution

2-4

1.

Remove the main board from the chassis per disassembly instructions in
Chapter 5.

2.

Remove the faulty component in the Audio PA section of the main
board. Ensure that the through-holes are free of solder.

3.

Place the main board in a chassis eliminator (Motorola Part Number
2705815W03). Assemble the screws based on the Screw-Down sequence
in Figure 5-19.

4.

Place new component(s) in the proper location. Assemble the Audio PA
Clip per the reassembly instructions Step 8. on page 5-22.

5.

Flip the chassis eliminator over.

6.

Using a large tip soldering iron set to 750°F max, heat ground plane
around through holes for approximately 15 seconds. Dispense 6337 Tin
Lead solder wire until a uniform solder fillet exists. Repeat this operation
for all leads.

7.

Inspect solder joints. There should be a uniform fillet. The joints should
be shiny and not dull in appearance.

8.

Remove the Audio PA clip per disassembly instructions Step 2. on page 514. Remove all screws. Pull board out of chassis eliminator.

Basic Maintenance

Antenna/Power Connector Replacement Procedure
For Low, Mid, and High Power Models
Note that Figures show High Power Chassis, but apply to all power levels.
1.

Remove damaged connector by heating the solder
joints until they reflow. Pull connector from board
with small pliers or like instrument.

2.

Place new connector (either Power or RF) in
opening in chassis (See Figure 2-1.). Connector
Part Numbers can be found in Chapter 10.

3.

Install connector retaining clip over connector
and chassis wall (See Figure 2-2.).

4.

Install PA Board, aligning connector holes over
connector pins per orientation in Figure 2-3.
Ensure that the undamaged connector has a
retaining clip installed.

5.

Screw down board using Torx drivers per the
Assembly Section of Chapter 5. For High Power
radios, follow the screw-down sequence found in
Figure 5-19.

6.

Using a large tip soldering iron set to maximum
750°F/400°C, heat ground leads on connector for
approximately 15 seconds. Dispense 6337 Tin
Lead solder wire until a uniform solder fillet exists.
Using temperatures higher than 750°F/
400°C will cause the modular ground
rings to pull off the board around pins
and cause the board irreparable
Caution
damage.

!

7.

Inspect solder joints. The solder should not “ballup” over leads. There should be a uniform fillet.
The joints should be shiny and not dull in
appearance.
If solder joint does not exhibit these
characteristics, the joint will contain a
cold solder and/or voids that could
damage the Power Amplifier portion of
Caution
the radio.

RF Connector
Opening

Power Connector
Opening

MEPC-96587-O

Figure 2-1 RF and Power Connector Openings

Retaining
Clip
Chassis
Wall

Connector

MEPC-96588-O

Figure 2-2 Install Connector Retaining Clip

!

8.

Remove retaining clips. Unscrew board. Take
board out of chassis.

9.

Inspect for uniform solder fillet around leads on
heavy side of board. Ensure that there is not
excessive solder around leads. If excessive solder
exists, carefully remove it with the soldering iron.

10. Reassemble board into chassis per the Reassembly/
Assembly procedure on the previous pages based
on the power level being repaired.

PA Board

Ground Leads
MEPC-96589-O

Figure 2-3 Replace PA Board

Basic Maintenance

2-5

NOTES

2-6

Basic Maintenance

3

Test Equipment,
Service Aids, and Tools
Recommended
Test
Equipment

The list of equipment contained in the table below includes all of the standard
test equipment required for servicing two-way mobile radios, as well as several
unique items designed specifically for servicing the radio. Battery-operated test
equipment is recommended when available. The “Characteristics” column is
included so that equivalent equipment may be substituted; however, when no
information is provided in this column, the specific Motorola model listed is
either a unique item or no substitution is recommended.
Table 3-1

Motorola
Model Number

Description

Recommended Test Equipment
Characteristics
This monitor will substitute for
items with an asterisk (*)

Application

R2000 Series

System Analyzer

Frequency/deviation meter and signal
generator for wide-range
troubleshooting and alignment.

R1150C*

Code Synthesizer

S1053D*
HM-203-7*
SKN6008A*
SKN6001A*

220 VAC Voltmeter
110 VAC Voltmeter
Power Cable for Meter
Test Leads for Meter

1mV to 300V, 10-Mohm input
impedance

Audio voltage measurements.

S1350C*

Watt Meter

ST1213B (VHF)*
(Superseded by ST1217B)

Plug-in Element

50 ohm, ±5% accuracy
10 Watts, maximum
0-1000 MHz, 300W

Transmitter power output
measurements.

ST1217B (VHF)*

Plug-in Element

ST1223B (UHF)*
(Superseded by ST1237B
and ST1227B)

RF Dummy Load

ST1237B (UHF R1)*

Plug-in Element

ST1227B (UHF R2)*

Plug-in Element

T1013A
(Supersedes R1065A)

Load Resistor

0-1000MHz, 300W

For use with Wattmeter.

R1065A
(Superseded by T1013A)

Load Resistor

10-watt Broadband

For use with Wattmeter.

S1339A

RF Millivolt Meter
10kHz to 1.2 GHz

100µV to 3V rf

RF level measurements.

R1013A*

SINAD Meter

R1011B
(Supersedes S1347D &
S1348D)

DC Power Supply

0-40Vdc, 0-30 Amps

Current limited bench power supply.

S1347D or
S1348D (programmable)
(Superseded by R1011B)

DC Power Supply

0-20Vdc, 0-5 Amps

Current limited bench power supply.

Injection of audio and digital signalling
codes.

Receiver sensitivity measurement.

* Any of the R2000 Series system analyzers will substitute for items with an asterisk (*)

Test Equipment, Service Aids, and Tools

3-1

Service Aids
and
Recommended
Tools

Refer to the “SERVICE AIDS” and “RECOMMENDED TOOLS LIST” for a listing
and description of the service aids and tools designed specifically for servicing
the radio, as well as the more common tools required to disassemble and
properly maintain the radio. These kits and/or parts are available from
Motorola.
The following table lists service aids recommended for working on the radio.
While all of these items are available from Motorola, most are standard shop
equipment items, and any equivalent item capable of the same performance
may be substituted for the item listed.

Field
Programming

The radio can be aligned and programmed in the field. This requires specific
equipment and special instructions. Refer to the “Radio Service Software User’s
Manual” for complete field programming information.
Table 3-2 Service Aids
Description

Part Number

Application

RKN4062B

Programming and Cloning Cable

Connects the RIB RLN4008B to the microphone connector. Cloning is the
act of transferring programmed data from one radio to another.

RKN4063A

FLASH, Programming and
Cloning Cable with Test Box

Connects the RIB RLN4008B to the accessory connector. Cloning is the act
of transferring programmed data from one radio to another. FLASHing is the
act of adding new software to the radio.

3080376E36

Control Head Extender Cable

Connects the control head to the 18 pin connector.
(see page 4 for correct use of this cable).

GTF373A*

Test Box Cable

Connects radio to GTF180B test box.

GTF372A*

Combined Interface Cable

Connects radio to RLN4008B RIB and Microphone Port and Accessory
Connector.

HKN4191A

DC Power Cable for radios

Interconnects radio below 50 W to power supply.

HKN6110

DC Power Cable for radios

Interconnects radio of over 50 W to power supply.

RLN4460A or
GTF180B*

Test Box

Allows switching for radio testing.

RLN4008B

Radio Interface Box

Enables communications between the radio and the computer’s serial
communications adapter.

0180358A56 or
EPN4041A*

Power Supply

Used to supply power to the RIB (220 VAC).

0180357A57

Power Supply

Used to supply power to the RIB (110 VAC).

EPN4040A*

Power Supply

Used to supply power to the RIB (240 VAC).

3080369B71 or
3080369B72

Computer Interface Cable

Use B72 for the IBM PC AT. All other IBM models use B71. Connects the
computer’s serial communications adapter to the RIB.

RLN4438A

Adapter

25 pin (F) to 9 pin (M) adapter, for use with 3080369B72 for AT applications.

RLN1015B

Smart Radio Interface Box (SRIB)

Enables communications between the radio and the computer’s serial
communications adapter. For FLASHing, programming and cloning.

0180302E27

SRIB Power Supply

Used to supply power to the SRIB (120 VAC).

2580373E86

SRIB Power Supply

Used to supply power to the SRIB (220 VAC).

RLN4488A

SRIB Battery Pack

Used to power the SRIB from a battery.

3080390B48 or
3080390B49

Computer Interface Cable

Use B49 for the IBM PC AT. All other IBM models use B48. Connects the
computer’s serial communications adapter to the SRIB only.

2705438Y01
2705816W03
2705815W03

Chassis Eliminator
Chassis Eliminator
Chassis Eliminator

For Low Power radios.
For Mid Power radios.
For High Power radios.

3-2

Test Equipment, Service Aids, and Tools

Table 3-2 Service Aids
Part Number

Description

Application

TKN9152A

Securenet Keyload Adapter

Connects radio to Securenet Keyloader

3080370E05

Securenet Extender Cable

Connects the control head to the secure board.

RVN4113

Radio Service Software
MCS 2000 Series

For programming of MCS 2000 radios with SmartNet/Zone, STARTSITE and
Conventional StatAlert software. (3 1/2” floppy disc, English version)

GVN6011* (Eng)
GVN6012* (Ger)
GVN6013* (Fren)
GVN6015* (Spa)

Radio Service Software
2000 & 2100 Series Select 5

For programming of MCS 2000 radios with Conventional Select 5 software.
Only compatible with VHF and UHF 1-25 Watt models. (3 1/2” floppy disc)

* Available through Taunusstein Parts only.

The following table lists the tools recommended for working on the radio;
these also are available from Motorola. Note that the R-1070A workstation
requires the use of a specific "heat focus head" for each of the components on
which this item is used. Each of these heat focus heads must be ordered
separately.

!

The use of Mini UHF Adapters will have damaging effects on the RF
Antenna Connector which might lead to radio failure.

Caution
Table 3-3 Recommended Service Tools
Part Number

Description

Application

0180381B45 110VAC
or
0180300E06 220VAC

MBT250 Surface-mount/throu-hole repair station

Temperature-controlled, self-contained soldering/
desoldering repair station for installation and removal of
surface-mounted devices.

8180369E97

Flux holder/applicator

Allows for the proper amount of flux to be applied to pad
grid arrays for repair.

1105139W02

30cc plastic syringe and flux paste

For use with flux holder/applicator 8180369E97.

0180386A81

Miniature digital read-out soldering station (incl.
1/64” micropoint tip)

0180386A78

Illuminated magnifying glass with lens
attachment

0180386A82

Anti-static grounding kit

6684253C72

Straight prober

6680384A98

Brush

1010041A86

Solder (RMA type), 63/37, 0.020" diameter,1 lb.
spool

R-1070A
(superseded by R1319A)

Shields and surface-mounted component - IC
removal/rework station

Removal of surface-mounted integrated circuits

R1319A
(supersedes R1070A)
6680332E82
6680332E83
6680332E84

Surface-Mounted Device Rework Station

Removal of surface-mounted integrated circuits

R1319A Reflow Nozzle
R1319A Reflow Nozzle
R1319A Reflow Nozzle

For IC removal (approximate size 0.8 in. x 0.8 in.)
For IC removal (approximate size 0.6 in. x 0.6 in.)
For IC removal (approximate size 0.5 in. x 0.5 in.)

6685629A01

End Cutter

Extraction tool for removable control head buttons.

HLN6621

Plug, coaxial Mini UHF male connector.
Note: this connector is delivered with the radio.
Prior to installation, replace the RF connector
provided with the antenna with this connector.

Recommended RF connector to interface with
MCS 2000 radios. For use during bench test and
tuning.

Used during all radio assembly and disassembly
procedures

Test Equipment, Service Aids, and Tools

3-3

Connection of Control Head Extender Cable

!

Failure to follow these instructions may cause severe damage to the
control head.

Caution

Mid Power Chassis

!
Caution

High Power
Chassis

!
Caution

1.

Place radio on bench with fins facing downward and away.

2.

Remove the plastic cover. This position leaves the top side of the PC
boards fully exposed and the 18 pin connector (see Table 3-4) facing the
operator. Note that the 18 pin connector is offset left of center.

3.

Place the control head directly in front of the chassis with the control
head and chassis sides aligned to each other. The two 18 pin connectors
MUST also be aligned. This means that the control head is sitting upright.

If the cable is plugged in upside down the control head will burn out.
4.

With the colored side of the control head extender cable facing upward
all the way between the control head and the chassis connect the cable
to both control head and chassis 18 pin connectors.

1.

Place radio on bench with fins facing downward and away.

2.

Remove the polycarbonate cover. This position leaves the top side of the
PC boards fully exposed and the 18 pin connector (see Table 3-4) facing
the operator. Note that the 18 pin connector is offset right of center.

3.

Place the control head directly in front of the chassis with the control
head and chassis sides aligned to each other. The two 18 pin connectors
MUST also be aligned. This means that the control head is upside-down
on the bench.

If the cable is plugged in upside down the control head will burn out.
4.

With the colored side of the control head extender cable facing upward
all the way between the control head and the chassis connect the cable
to both control head and chassis 18 pin connectors. After the cable is
connected the control head can be uprighted.
Table 3-4 Control Head Connector Pin Signals

3-4

PIN NUMBER

CONTROLLER SIGNAL

PIN NUMBER

CONTROLLER SIGNAL

1

INTERNAL SPKR+

10

DVP WE

2

SPKR–

11

KEY/FAIL

3

RESET

12

KID

4

SB9600_BUS–

13

DIGITAL_GND

5

not used

14

SB9600_BUSY

6

not used

15

SB9600_BUS+

7

ANALOG_GND

16

not used

8

HANDSET_AUDIO

17

A+

9

MIC/ON_OFF

18

SW_B+

Test Equipment, Service Aids, and Tools

Test Mode and Error Codes

4

Test Mode
General

The test mode allows the technician to monitor a set of radio parameters, to
configure the radio hardware in a number of predefined ways, and have access
to a number of test procedures. Two basic areas of functionality are provided
by the Test Mode:
• RF test mode - allows the RF functionality of the radio to be tested.
• CH (Control Head) test mode - allows the radio display, buttons and
switches to be tested.
The purpose of the test mode is to test the radio unit and its interfaces, but not
to test the various accessories. However, the mobile radio is incapable of
operating in isolation without a minimum set of accessories. The following
accessories are assumed:
• Keypad or noise cancelling microphone
• External speaker (only models II and III)
• Control head model I, II or III
If an accessory is subsequently connected to the radio after the test mode
application has already been invoked, the radio will ignore any resulting
power up messages received on the serial bus.

Test Mode
Features

On entering Test Mode the radio will be in an idle state, all indicators are
extinguished and the RF TEST Mode Select menu message will be displayed.
Test mode control is provided by a set of menus which may be scrolled
through and selected. The dedicated buttons TM1 (Select) and TM2 (Scroll)
(see Figure 4-1 on page 2) are used to navigate through these menus.

Test Mode Entry
and Exit

1.

Turn the radio on.

2.

Within five seconds after power on press the TM1 five (5) times.

3.

On entry, the SERVICE test mode message is displayed for 2 seconds.
Following this, each of the following is displayed in sequence:
-

radio software part number

-

control head part number

-

radio model number

-

radio serial number

Each of these “temporary messages” lasts for 2 seconds. After the radio
serial number has been displayed for 2 seconds, the message RF TEST
will show in the display after 2 seconds.
Test Mode and Error Codes

4-1

4.

To exit either the RF Test Mode or the CH Test Mode turn the radio off.
•

Button TM1: used as Select Key and for Test Mode Entry

•

Button TM2: used as Scroll Key

MODEL I

TM1

TM2

MODEL II

TM1

TM2

TM2

MODEL III

1

2

3

4

5

6

7

8

9

*

0

#

TM1

Figure 4-1

Dedicated Test Mode Keys on Models I, II and III

RF/CH Test Mode
Select

Pressing the scroll key alternates between the two Mode Select menus
RF TEST and CH TEST. To select either the RF or CH test menu press the
dedicated select key while the desired menu is being displayed.

RF Test Mode

On entry into the RF test mode the radio hardware will be configured for the
default carrier squelch (CSQ) test mode environment. The test mode
application will examine the following personality parameters in the radio
codeplug:
• Tx Channel Number.
• Rx Channel Number.
When the radio is in RF test mode the PTT button is used to key and dekey the
transmitter. Whenever the transmitter keys up, the test mode application
illuminates the front panel red LED and whenever the transmitter keys down
the application extinguishes the front panel red LED.
Test Mode Environments
When the RF TEST menu is displayed, press the TM1 key to gain access to the
RF test mode environments:
• CSQ (Carrier Squelch). . . (Default)

4-2

Test Mode and Error Codes

• TPL (Tone Private Line)
• DPL (Digital Private Line)
• TLS (Trunking Low Speed)
• THS (Trunking high speed)
• DTM (Dual Tone Modulation Frequency)
• M12 (MDC 1200)
When the appropriate environment is selected the test mode application will
configure the radio hardware for this environment.
Channel Numbers
When the cursor is blinking on the channel number field, TM2 will scroll
through channels: 1, 2, ...n (n is the highest channel number specified by the
Tx/Rx pairs field). The test mode application will examine the number of Tx/
Rx pairs field contained in the personality area of the radio codeplug in order
to determine how many different channel number menu messages to display.
Selecting one of the channel numbers will reconfigure the radio hardware with
the specific transmit/receive frequency.
The resulting frequencies will be as follows:
• Transmit frequency: Offset frequency + (Tx channel number #n * Channel
step size).
• Receive frequency: Offset frequency + (Rx channel number #n * Channel
step size).
The Rx/Tx channel number #n and Channel step size values are extracted from
the personality area of the radio codeplug and the offset frequency is derived
from the offset frequency calculation performed on entry into RF test mode.
CH Test Mode

On entry into the Control Head test mode, all front panel indicators and
display segments are displayed for a period of 2 seconds, and then
extinguished.
When the radio is in Control Head test mode, all front panel momentary
button presses/releases (apart from the dedicated scroll and select keys and the
volume control), static switch activations and free revolving rotary activations
are monitored. When any one of these is detected a short tone will be heard
and the associated button code (in decimal) and state will be displayed on the
front panel.

Error Code
Displays
Power-up Display
Codes

At power-up, the radio performs cursory tests to determine if its basic
electronics and software are in working order. Problems detected during these
tests are presented as error codes on the radio display. The presence of an error
code should prompt the user that a problem exists and that a service
technician should be contacted.

Test Mode and Error Codes

4-3

Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit
user operation, while non-fatal errors will not. Use Table 4-1 to aid in
understanding particular power-up error code displays.

FAILURE DISPLAY

TYPE OF
FAILURE

FAIL 01/81

FATAL

External ROM/Flash checksum error

Bad ROM data, Defective ROM

FAIL 01/82

FATAL

External EEPROM checksum error

Bad external codeplug data,
Defective external EEPROM

ERROR 01/02

NON-FATAL

External EEPROM checksum error

Bad external codeplug data

FAIL 01/84

FATAL

External EEPROM checksum blank

Unprogrammed external codeplug data

FAIL 01/88

FATAL

External RAM error

Defective RAM

FAIL 01/90

FATAL

Hardware failure

Defective IC

FAIL 01/92

FATAL

Internal EEPROM checksum error

Bad internal codeplug data,
Defective microcontroller

FAIL 01/93

NON-FATAL

Internal EEPROM checksum blank

Failure of Flashport authorization code

FAIL 01/94

FATAL

Internal EEPROM checksum blank

Unprogrammed internal codeplug data

FAIL 01/98

FATAL

Internal RAM error

Defective microcontroller

ERROR 01/12

NON-FATAL

Internal EEPROM checksum error

Bad internal codeplug data

ERROR 09/10

FATAL

Hardware failure

Defective secure board, Missing secure board

DESCRIPTION

POSSIBLE SOURCE

Table 4-1 Power Up Display Codes

Note

Operational
Display Codes

FAILURE CODE

Due to the nature of fatal ROM & RAM errors, it may not be possible to present
an error code on the display. In these cases the radio will attempt to display
the appropriate error code, generate an illegal mode tone for one second and
then reset its microcontroller.
During operation, the radio performs dynamic tests to determine if it is
working properly. Problems detected during these tests are presented as error
codes on the radio display. The presence of an error code should prompt a user
that a problem exists and that a service technician should be contacted. Use
Table 4-2 to aid in understanding particular operational error code displays.

DESCRIPTION

POSSIBLE SOURCE

FAIL 001

Synthesizer out of lock

Bad frequency data in codeplug; defective synthesizer

FAIL 002

Selected Mode (Zone/Channel) codeplug
checksum error

Bad codeplug data

Table 4-2 Operational Display Codes

4-4

Test Mode and Error Codes

Disassembly & Reassembly
and Replacement Procedures
General

5

The disassembly/reassembly procedure covers all radio models. Specific model
information is included in the procedure where relevant. Where nothing is
indicated, the procedure will be valid for all models.

!

DO NOT attempt to disassemble the radio without first referring to the
CMOS Precautions paragraph on page 2-2 in the Maintenance section.

Caution

Disassembly to Transceiver Board Level
Low and Mid Power Models
Remove the
Control Head

Note

Steps 1 and 2, Removal of the Retention Frame, are only
valid for Models II and III, Low and Mid Power Dash Mount
version radios.

1.

On Models II & III, Dash Mount only: Prior to removing the control
head, remove the retention frame by inserting a small flat blade
screwdriver in the cut outs provided.

2.

On Models II & III, Dash Mount only: Slide the retention frame away
from the control head groove.

3.

Insert a small blade screw driver or like instrument in the side groove at the
interface between the control head and the transceiver (see Figure 5-1). While
pulling the control head away from the transceiver press until the control
head side releases, and then repeat the operation on the opposite side.

Control Head I

Transceiver

See Detail "A"

Depress Snap Here
Detail "A"

Figure 5-1 Removing the Control Head
Disassembly & Reassembly and Replacement Procedures

5-1

!

The control head must be removed before removing the transceiver top
cover.

Caution

Remove Front
Housing
REMOTE MOUNT
VERSION MODELS ONLY

Remove the Top
Cover

4.

Pull the control head off of the transceiver while pressing the snaps. (Go
to “Remove the Top Cover” section below).

1.

Disconnect the Remote Mount Cable by squeezing the top and bottom
of the connector together, disengaging the bottom snap then the top
and pulling straight out.

2.

Insert a small flat-blade screwdriver or like instrument in the side groove
at the interface between the remote front housing and the transceiver
(see Figure 5-1). Press while pulling the housing away from the
transceiver until the snap releases. Repeat the operation on the opposite
side.

3.

Remove the 18 position connector from the front of the transceiver.

4.

Pull housing off the transceiver.

1.

Pry the cover free from the chassis by inserting a small flat-blade
screwdriver or like instrument into the area shown in Figure 5-2 and
rotating the handle of the screwdriver over the top of the radio. This will
disengage the snap between the cover and chassis. Rotate the cover away
from the chassis and pull off. (Go to “Remove the Cavity Shield”
paragraph, page 5-3).

LOW POWER MODELS

Disengage Snap Here

Figure 5-2 Removing the Top Cover - Low Power Models
MID POWER MODELS

5-2

1.

Insert a wide flat-blade screwdriver or like instrument in the recess area
on the side of the radio near the RF and DC connector end (see Figure 53).

2.

Pry the cover off the chassis by pushing the handle of the screwdriver up
and toward the radio. This will disengage the snap between the cover
and chassis.

Disassembly & Reassembly and Replacement Procedures

3.

Repeat Step 1. and Step 2. for the opposite side of the radio.

Disengage Snap here
and on other side

Figure 5-3 Removing the Top Cover - Mid Power Models

Remove the Cavity
Shield

Note

LOW POWER MODELS
ONLY

Eight tabs hold the cavity shield to the chassis. The cavity
shield is the retaining device for the transceiver board and
also provides the pressure to heat dissipating devices
attached to the chassis.

1.

Remove the cover gasket from the chassis.

2.

Loosen the cavity shield by prying each of the eight tabs away from the
chassis. Release the four tabs on one side first and then repeat the
operation on the other. Be careful not to pry the tabs any more than is
necessary to free them from their respective retaining posts (see Figure 54).

3.

Pull straight up on the cavity shield.

Cavity Shield Tabs

Figure 5-4 Removing the Cavity Shield
Disassembly & Reassembly and Replacement Procedures

5-3

Remove the PA
Shield

1.

Unscrew the three screws that hold the PA shield with T-10 TORX driver.

2.

Remove the PA shield by pulling straight up on the attached handle.

LOW AND MID POWER
MODELS
PA Section & PCB
Holding Screws (3)

Figure 5-5 Removing the PA Shield (Low and Mid Power Models)

Remove the
Transceiver Board

Note

For 800 MHz and 900 MHz radios go to page 5-6.

EXCEPT 800 MHZ AND
900 MHZ
LOW POWER MODELS

Note

1.

Remove the Accessory Connector by sliding a finger into the recess on
the chassis and pushing up on the connector tab to loosen the
connection. Lift the connector out of the recess.

2.

Remove all screws using a T-10 TORX driver. Remove the power and
antenna connector retaining clips by inserting a small flat blade
screwdriver between the clip and the top of the chassis wall and gently
prying upwards (see Figure 5-6).

Thermal grease can act as an adhesive and cause the leads of the the power
amplifier devices to be over stressed if the board is lifted too quickly.

Front

Pry Clip Off Here

Figure 5-6 Removing the Transceiver Board - Low Power Models
(except 800 MHz and 900 MHz)
5-4

Disassembly & Reassembly and Replacement Procedures

MID POWER MODELS

3.

Carefully remove the transceiver board by rotating it out of the chassis.
Slowly lift the board on the front edge while pushing up on the board
through the accessory connector opening. Pull the board forward out of
the chassis.

1.

Remove the Accessory Connector by sliding a finger into the recess on
the chassis and pushing up on the connector tab to loosen the
connection. Lift the connector out of the recess.

2.

Remove the power and antenna connector retaining clips by inserting a
small flat-blade screwdriver or like instrument between the clip and the
top of the cavity wall per area shown inFigure 5-6. Gently prying
upwards.

3.

Remove the PCB Clip and the Audio PA clip by inserting a flat-blace
screwdriver or like instrument between the clip and the side wall. Prying
the clip upward to disengage with the tabs on the wall.

4.

Remove the four recessed Power Amplifier Device screws using a T-8 Torx
Driver (see Figure 5-7).

5.

Remove the remaining screws with a T-10 Torx Driver.

6.

Carefully remove the transceiver board by rotating it out of the chassis.
Slowly lift the board on the front edge while pushing up on the board
through the accessory connector opening. Pull the board forward out of
the chassis.

Note

Thermal Grease can act as an adhesive and cause the leads
of the power amplifier devices to be over stressed if the
board is lifted too quickly.

Four Recessed Power
Amplifier Screws

Antenna Connector
Clip

Power Connector
Clip

Audio PA Clip

PCB Mount Clip

Figure 5-7 Removing the Transceiver Board - Mid Power Models
(except 800 MHz and 900 MHz)

Disassembly & Reassembly and Replacement Procedures

5-5

Remove the
Transceiver Board
800 MHZ AND 900 MHZ
MODELS ONLY

1.

Remove the Accessory Connector by sliding a finger into the recess on
the chassis and pushing up on the connector tab to loosen the
connection. Lift the connector out of the recess.

2.

Remove all screws using a T-10 TORX driver.

3.

Remove the power and antenna connector retaining clips by inserting a
small flat blade screwdriver between the clip and the top of the cavity
wall and gently prying the clip upwards.
On Mid Power models: Remove the PCB clip and the Audio PA clip by
inserting a flat-blace screwdriver or like instrument between the clip and
the side wall. Prying the clip upward to disengage with the tabs on the
wall.

4.

Press on the 25 pin connector through the bottom of the chassis until
the board is released from the chassis.

5.

Carefully remove the transceiver board by rotating it out of the chassis.
Slowly lift the board on the front edge while pushing up on the board
through the accessory connector opening (see Figure 5-8).

Front

Board Holding Screw
(To be removed last)
Power Connector
Retaining Clip

Antenna Connector
Retaining Clip

PA Holding Screws (2)

Figure 5-8 Removing the Transceiver Board (800 MHz and 900 MHz only)

5-6

Disassembly & Reassembly and Replacement Procedures

Disassembly to Transceiver Board Level
High Power Models

!

DO NOT attempt to disassemble the radio without first referring to the
CMOS Precautions paragraph on page 2-2 in the Maintenance section.

Caution

Remove the
Bottom Cover

1.

Disconnect the Remote Mount Cable by squeezing the top and bottom
of the connector together, disengaging the bottom snap then the top,
and pulling straight out.

2.

Flip the unit over so that the Bottom Cover is facing up.

Back

Top

Bottom

Front

Figure 5-9
3.

Direction Conventions

Remove the Accessory Connector by sliding a finger into the recess on
the bottom cover and pushing up on the connector tab to loosen the
connection. Lift the connector out of the recess. See Figure 5-10.
2) Pull connector
straight out

1) Slide finger
under tab

Bottom Cover

Accessory Connector

Figure 5-10

Removing the Accessory Connector

Disassembly & Reassembly and Replacement Procedures

5-7

4.

Insert a wide flat-blade screwdriver or like instrument in the recess area
on the side of the radio near the antenna and power connector ends (see
Figure 5-11).

5.

Pry the bottom cover off the chassis by pushing the handle of a
screwdriver up and toward the radio. This will disengage the snap
between the bottom cover and the chassis.

6.

Repeat Step 4. and Step 5. for the other side of the radio.

7.

Rotate the bottom cover out and away from the chassis until it is
completely free of the chassis taking care not to damage the 18 position
connector in the process.

Rotate Cover
Out and Away
in this Direction

Disengage Snap here
and on other side

18 Position Connector

Figure 5-11

Remove the RF
Shield

Removing the Bottom Cover

8.

Remove the cover gasket from the chassis.

1.

Pull straight up on the RF shield using the supplied handle.

Handle

RF Shield

Figure 5-12 Removing the RF Shield

5-8

Disassembly & Reassembly and Replacement Procedures

Remove the PA
Shield

1.

Pull straight up on the PA shield using the supplied handle.

PA Shield

Handle

Figure 5-13

Remove the PA
Board

Removing the PA Shield

1.

Unscrew the 6 recessed, PA device screws using a T-8 Torx driver.
Unscrew the remaining screws (9 for VHF, 11 for UHF) using a T-10 Torx
driver.

2.

Remove the power and antenna connector retaining clips by inserting a
small flat-blade screwdriver between the clip and the underlying cavity
wall and by gently prying the clip upwards.

3.

Gently disconnect the 2 and 12 position connectors from the RF board
by rotating the PA Board toward the chassis fins.

4.

Once the connectors are disengaged, remove the PA Board from the
chassis by pulling edge of board up and away from fin (back) side of
radio.

Pry Clip off here

Pry Clip off here

Disconnect PA board
from these two RF
connectors

Figure 5-14

Removing the PA Board

Disassembly & Reassembly and Replacement Procedures

5-9

Remove the RF
Board

1.

Remove the 18 position connector by pulling it straight out from the
chassis taking care not the bend the leads.

2.

Remove the Audio PA Clip by inserting a flat-blade screwdriver under the
clip´s extended tab, pivoting off the top of the underlying wall, and
gently prying the clip upward.

3.

Unscrew the 7 screws that hold the RF board in place using a T-10 Torx
driver.

4.

Carefully remove the RF board from the chassis by pulling straight up on
the 25 D connector.

Pull Board
straight up
25 D Connector

Pry off Audio PA clip here
Pull Connector
straight out

18 Position Connector

Figure 5-15

5-10

Removing the RF Board

Disassembly & Reassembly and Replacement Procedures

Disassembly of the Control Head
Remote Mount
Versions

1.

Disconnect the Remote Mount Cable by squeezing the top and bottom
of the connector together, disengaging the bottom snap then the top,
and pulling straight out.

2.

Remove the back housing by inserting a small flat-blade screwdriver or
like instrument into the recess on the short side of the control head
exterior, taking care not to mar the surface. Rotate the screwdriver so
that the tab deflects out and disengages from the control head housing.

3.

Repeat the operation in Step 2. for the opposite side.

1.

Remove the internal spacer by inserting a small flat-blade screwdriver or
like instrument into one of the eight recesses around the perimeter of
the spacer. Rotate the screwdriver so that the spacer deflects in and the
tab disengages from the control head housing.

2.

Repeat Step 1. for the remaining seven recesses.

3.

Pull the control head board straight out from the control head housing,
removing the control head board, the speaker, and the keypad together.

4.

Remove the keypad from the PCB by pulling up on the keypad. Care is
required in removing the keypad from around the volume
potentiometer and the microphone connector to keep from
overstressing the leads. Care should be taken not to touch or get other
contaminants on the conductive pads on the underside of the keypad.

5.

To remove the LCD gasket, first remove the elastomeric connector, the
LCD frame, the colour sheet and the LCD itself from the housing.

6.

Disconnect the speaker lead from the connector on the control head
board.

Models II & III

1.

Pull the back housing straight off.

STANDARD KEYPAD

2.

On Model II, also remove the rotary knob on the right side of the unit
by pulling away from the control head.

3.

Remove the control head board by prying back on the four visible light
pipe snaps. Carefully remove the board from the housing. Gently pull
the board straight up so not to damage the volume potentiometer and
the microphone connector leads.

4.

The light pipe can be removed by prying back on its plastic snaps from
the recesses in the control head housing. This step is only required to
gain access to the keypad.

5.

With the light pipe removed, the keypad can be pulled from the
housing. Care should be taken not to touch or get other contaminants
on the conductive pads on the under side of the keypad.

1.

Remove the back housing by inserting a small flat-blade screwdriver or
like instrument into the recess on the short side of the control head
exterior, taking care not to mar the surface. Rotate the screwdriver so
that the tab deflects out and disengages from the control head housing.

2.

Repeat the operation in Step 1. for the opposite side.

3.

Pull the back housing straight off.

Model I

Models II & III
KEYPAD WITH
REPLACEABLE PUSH
BUTTONS

Disassembly & Reassembly and Replacement Procedures

5-11

Note

4.

On Model II, also remove the rotary knob on the right side of the unit
by pulling straight up.

5.

Remove the control head board by prying back on the four visible light
pipe snaps. Carefully remove the board from the housing. Gently pull
the board straight up so not to damage the volume potentiometer and
the microphone connector leads.

6.

The light pipe can be removed by prying back on its plastic snaps from
the recesses in the control head housing. This step is only required to
gain access to the keypad.

Care should be taken when removing the light pipe from control heads
equipped with replaceable pushbuttons as the buttons are loose in the housing
under the keypad.
7.

5-12

With the light pipe removed, the keypad can be pulled from the
housing. Care should be taken not to touch or get other contaminants
on the conductive pads on the underside of the keypad.

Disassembly & Reassembly and Replacement Procedures

Reassembly of the Control Head
Model I

Models II and III

1.

Place the LCD, colour sheet, LCD frame, and elastomeric connector into
the housing. Make sure that the LCD aligns with the gasket in the
housing.

2.

Place the keypad into the board assembly, making sure that the keypad is
flush with the board.

3.

Make sure that both the volume knob and potentiometer are both fully
in the counter clockwise position before assembling the board into the
housing.

4.

Also make sure that the speaker is aligned with the speaker gasket and
connected to the board assembly.

5.

During the installation of the internal speaker be sure that all eight snaps
are engaged. Be sure not to crimp the speaker wire.

1.

Place the keypad into the control head housing.

2.

Snap the light pipe into the housing. Alternate engaging snaps on each
side for best result.

3.

Make sure that both the volume knob and potentiometer are both fully
in the counter clockwise position before assembling the board into the
housing.

4.

Snap the board assembly into the housing.

5.

For model “II” only, attach the large rotary knob.

Disassembly & Reassembly and Replacement Procedures

5-13

Transceiver Reassembly
Low and Mid Power Models
Transceiver Reassembly
Notes

• Replace all gaskets at each servicing to ensure proper sealing of unit.
• Be careful to use only very little thermal grease as an excessive quantity
will deteriorate the conductivity.
1.

Inspect and reapply thermal grease as needed to the areas shown in
Figure 5-16.

Apply Thermal Grease
to these raised surfaces

Audio PA and Regulator Pedestals
Board Slot Shield
Diode Spring

Chassis PA Pedestal
Apply Thermal Grease
to this raised surface

Figure 5-16

5-14

Reassembly

2.

Insert the diode spring.

3.

Install a new gasket to the 25 pin connector, Antenna connector and
Power connector gaskets located on the board.

4.

On 800/900 MHz Models only: Insert board slot shield.

5.

Replace the thermal pad attached to the large heatsink (designator
B6501) on the bottom side of the board in the PA section.

6.

Insert the main board carefully at an appropriate angle (approximately
30°) into the chassis.

7.

Install the antenna and power connector retaining clips.

8.

On Low Power Models Only: Install all screws (except the three screws
that retain the PA shield) with 12 in lbs of torque using a T-10 Torx
driver.
On Mid Power 800/900 MHz Models: Install all screws (except the
three screws that retain the PA shield) with 12 in lbs of torque using a T10 Torx driver.
On Mid Power Models (Excluding 800/900 MHz): Install the four
screws in the recessed PA devices with 12 in lbs of torque using a T-8 Torx

Disassembly & Reassembly and Replacement Procedures

driver (see Figure 5-7). Install the remaining screws (except the three
screws that retain the PA shield) with 6-8 in lbs of torque using a T-10
Torx driver.
9.

On Mid Power Models Only: Install the PCB and Audio PA clips.

10. Insert the PA shield. Tighten the three screws that hold it to the PCB and
the one screw in the middle of the board with 6-8 in lbs of torque using a
T-10 Torx driver.
11. On Low Power Models: Install the Cavity Shield and press down until it
locks on the chassis tabs.

!
Caution

Ensure that ALL cavity shield tabs engage properly. Failure to do this may
inhibit the top cover from engaging properly and could damage the top
cover.

12. Place a new cover gasket around the chassis ensuring that it is placed
under the locking tabs and ledge at the front of the chassis. To ensure
that the gasket remains seated along the groove, twist the gasket between
fingers down and toward the chassis on both sides of the chassis.
13. Install the top cover by engaging the hooks on front of the chassis and
rotating the cover back. Ensure that the side snaps on the cover are
engaged.
14. Install the front cover gasket over the front of the transceiver ensuring
that the rectangular hole in the transceiver aligns with the rectangular
hole in the gasket. Press the gasket flush against the transceiver to ensure
proper sealing.

Assembly of Control Head to Transceiver
DASH MOUNT MODELS
1.

For Model I: Install dash mount configured control head onto the
transceiver. Ensure that the side snaps are engaged.
For Models II and III: Install the retention frame over the front of the
transceiver. Install the dash mount configured control head onto the
transceiver. Slide the retention frame toward the control head until both
snaps engage.

1.

Install the 18 position connector into the female connector (mounted
on the PC board) through the hole in the front of the chassis.

2.

Install the remote header retainer into the recess for the rectangular
cutout in the remote front housing.

3.

Install the remote front housing over the 18 position connector onto the
front of the transceiver ensuring that both snaps are engaged.

4.

Connect the remote mount cable to the transceiver and to the remote
mount configured control head.

REMOTE MOUNT MODELS

Disassembly & Reassembly and Replacement Procedures

5-15

Transceiver Reassembly
High Power Models

Note

Replace all gaskets at each servicing to ensure proper sealing of unit.
1.

Inspect and reapply a thin coat of thermal compound as necessary to the
heatsinking pads, voltage regulator and Audio PA areas in the chassis per
Figure 5-17. A thick coat of thermal compound may negatively effect
heat sinking.
Apply Thermal Compound
to these raised areas

Apply Thermal Compound
to this portion of
chassis wall

Figure 5-17
2.

Wakefield / Thermal Compound Application Area

Insert the transceiver board placing board slots over locating features in
chassis. Be sure the board is sitting flush on the chassis mounting
surface.

Spring Diode
Chassis locating features

Transceiver board

Figure 5-18

5-16

Inserting Transceiver Board

Disassembly & Reassembly and Replacement Procedures

3.

Replace the 25-D connector gasket on the transceiver board.

4.

Replace the RF and power connector gaskets on the PA board.

5.

Install the PA board carefully at an appropriate angle (approximately 30o)
to the chassis connecting the 2 and 12 pin connectors to the RF board.

6.

Install the 2 PA connector retaining clips over the RF and power
connectors and chassis wall.

Observe the screw-down sequence in Figure 5-19 when installing screws.
Proper alignment of boards depend on following this sequence.

Note

7.

Fasten screws #1-6 to 12 in lbs of torque using a T-8 Torx driver. Fasten
the remaining screws (#7-20 for VHF models, #7-22 for UHF models) to
6-8 in lbs of torque using a T-10 Torx driver following the screw down
sequence in Figure 5-19.

13
13

14
14

5

2

1

1

10
11 10
11

12
12

21
21

4
1

4

6
6

33

99

2

2

2

6
6

33

11
12
11
12

7

8

15
15

18
18

14
14

10
10

8

8

20
23

16
16

17
17

5

1

1

7

8

22
22

15
15

16
16

20
20

2

99

7

2

7
17
17

13
13

20
24

20
20

18
18

19

19

4
1

4

22
22

21
21

UHF

VHF

Figure 5-19

Reassembly Screw Down Sequence

Disassembly & Reassembly and Replacement Procedures

5-17

8.

Install the Audio PA clip to the corner of the chassis (per Figure 5-20) by
applying downward, equal pressure to the side and main tab of the clip.
Side pressure on the clip will negatively impact heat sinking of the 5 V
Regulator and Audio PA. The placement tab should rest flush against the
top of the chassis wall.

Pressure Points

Guide Rail
Audio PA Clip
18 Position Connector,
Female

Figure 5-20
9.

Inserting Audio PA Clip

Install the RF shield by placing it over the chassis with the front and
back tabs inside the chassis and side tabs outside the chassis walls. Push
straight down applying even pressure to the edges of the shield until
they rest flush on the chassis wall. Repeat the same operation for the PA
shield.

10. Insert the 18 position connector (black side) through the opening in the
chassis into the female connector on the RF board.

Note

The 18 position connector is not symmetrical, therefore the black side must
mate to the connector on the transceiver board.
11. Place a new cover gasket around the chassis being sure it is placed under
the locking tabs and the v-shaped rail shown in Figure 5-21. To ensure
that the gasket remains seated under the rail, twist the gasket up and
toward chassis between the fingers at the location of the lowest point of
“V”. Position the gasket under the rail and release.
12. Insert the 18 position connector (white side) into the female connector
through the hole in the front of the chassis.
13. Carefully guide the bottom cover front hole opening over the 18
position connector. Engage the bottom cover over the hooks at the front
of the chassis, rotate the cover back over the chassis, and press down
until the sides snap into place.

5-18

Disassembly & Reassembly and Replacement Procedures

Locking Tab
(other tab on opposite
side of chassis)
Gasket twist
direction
Lowest point of gasket locating feature “V”

Figure 5-21

Installing Cover Gasket

14. Install the accessory connector assembly through the bottom side of the
radio. Be sure to install the connector straight down into the unit
because otherwise it will catch on the housing and no connection will be
made.

Note

The radio will not function without the accessory connector.

Disassembly & Reassembly and Replacement Procedures

5-19

Replaceable Pushbuttons Replacement Procedure

Note

Availability of replaceable pushbutton control heads depends upon date
order was placed, shipped and based upon options ordered. Contact your
Parts division for aftermarket kits and parts.

Models II & III
KEYPAD WITH REPLACEABLE PUSHBUTTONS
There are five sizes of replaceable pushbuttons, which are designated sizes A,
B, C, and D. The locations and sizes of the Model I, II and III replaceable
pushbuttons are shown in Figure 5-22, Figure 5-23 and Figure 5-24,
respectively. All available replaceable pushbuttons, cross-referenced to their
legend descriptions, colors, sizes and part numbers are listed in see Table 5-1
on page 523

E

E

E

E

E

Figure 5-22 Model I Replaceable Pushbuttons

C

C

C

C

A
A
A

B

B

B

B

B

B

Figure 5-23 Model II Replaceable Pushbuttons

A

D

D

D

A

D

D

D

A

D

D

D

A

D

D

D

A

A
A

B

B

B

B

B

B

Figure 5-24 Model III Replaceable Pushbuttons
5-20

Disassembly & Reassembly and Replacement Procedures

Replaceable pushbuttons can be replaced in two ways:
• while the control head is disassembled or
• while the control heads is assembled.

Replacement in
Disassembled
Control Head

Replacement in
Assembled
Control Head

To replace buttons in a control head that is already disassembled, follow the
procedure below.
1.

Pull replaceable pushbutton up and out of housing.

2.

Replace buttons as necessary per Table 5-1, “Replaceable Pushbutton
Graphics and Part Numbers,” on page 5-23.

3.

Place the keypad into the control head housing.

4.

Snap the light pipe into the housing. Alternate engaging snaps on each
side for best result.

5.

Make sure that both the volume knob and potentiometer are both fully
in the counter clockwise position before assembling the board into the
housing.

6.

Snap the board assembly into the housing.

7.

For model “II” only, attach the large rotary knob.

To replace buttons in a control head that is already assembled, follow the
procedure below:
The replaceable style pushbuttons have two expandable tabs on the inside
edge, one on the top and one on the bottom. When expanded, these tabs press
against the inside surface of the control head faceplate and hold the
pushbutton in place. To replace a pushbutton, refer to Figure 5-25 and Figure
5-26 and proceed as follows:

!

Be careful to avoid damaging surface of control head front panel when
using flat end pliers to grasp pushbutton to be removed.

Caution
1.

!
Caution

Note

Grasp pushbutton to be removed with flat end pliers (Motorola Part
Number 6685629A01) as close as possible to control head faceplate.

In step 2 below, to avoid damage to pushbutton, compress pushbutton
only enough to allow tabs on pushbutton to clear edges of hole in
faceplate.
2.

Compress pushbutton just enough so that the tabs can clear the control
head faceplate. Then pull pushbutton away from control head.

3.

Orient the new pushbutton so that legend is oriented correctly.

No tools are required to perform Step 4. below.
4.

Snap replacement pushbutton into opening in control panel faceplate.

Disassembly & Reassembly and Replacement Procedures

5-21

5.

Verify that tabs on replacement pushbutton are engaged behind control
head faceplate and that pushbutton operates freely.

6.

Using RSS software and manual, reprogram the radio so that replaced
pushbutton has the desired function.

MCS

2000

MEPC-96618-O/None

Figure 5-25 Grasping Pushbutton with Flat End Pliers

MCS

Tab

2000

Control Head
Faceplate

Pushbutton
Plier
Nibs

Tab
MEPC-96619-O/GB

Figure 5-26 Pulling Pushbutton Away from Control Head

5-22

Disassembly & Reassembly and Replacement Procedures

Table 5-1 Replaceable Pushbutton Graphics and Part Numbers
Graphic
Legend

Description

Pushbutton Part Number
Color

Size A

Size B

Size C

Size D

Size E

BLANK

Blank

White

3805230Z01

3805231Z01

3805232Z01

3805233Z01

3805234Z01

BLANK

Blank

Orange

3805230Z18

3805231Z14

3805232Z10

N/A

3805234Z10

A

A

Black

3805230Z42

3805231Z42

3805232Z42

N/A

3805234Z40

B

B

Black

3805230Z43

3805231Z43

3805232Z43

N/A

3805234Z41

C

C

Black

3805230Z44

3805231Z44

3805232Z44

N/A

3805234Z42

Call

Black

3805230Z21

3805231Z07

3805232Z13

N/A

3805234Z13

D

Black

3805230Z45

3805231Z45

3805232Z45

N/A

3805234Z43

Del

Delete

Black

3805230Z35

3805231Z35

3805232Z35

N/A

3805234Z14

Dim

Dim

Black

3805230Z12

3805231Z17

3805232Z14

N/A

3805234Z15

Dir

Dir

Black

3805230Z38

3805231Z38

3805232Z38

N/A

3805234Z36

Emer

Emergency

White

3805230Z22

3805231Z09

3805232Z15

N/A

3805234Z16

Emer

Emergency

Orange

3805230Z20

3805231Z16

3805232Z12

N/A

3805234Z12

H/L

Horn/Light

Black

3805230Z23

3805231Z04

3805232Z16

N/A

3805234Z17

Home

Home

Black

3805230Z10

3805231Z18

3805232Z03

N/A

3805234Z18

Menu

Menu

Black

3805230Z09

3805231Z19

3805232Z04

N/A

3805234Z05

Mess

Message

Black

3805230Z46

3805231Z46

N/A

N/A

N/A

Mon

Monitor

Black

3805230Z33

3805231Z33

3805232Z33

N/A

3805234Z19

Mpl

Mpl

Black

3805230Z41

3805231Z41

3805232Z41

N/A

3805234Z39

Opt

Option

Black

3805230Z05

3805231Z20

3805232Z02

N/A

3805234Z20

Page

Page

Black

3805230Z03

3805231Z08

3805232Z17

N/A

3805234Z21

Phon

Phone

Black

3805230Z24

3805231Z05

3805232Z18

N/A

3805234Z22

Pwr

Power

Black

3805230Z39

3805231Z39

3805232Z39

N/A

3805234Z37

Read

Read

Black

3805230Z48

3805231Z48

N/A

N/A

N/A

Rcl

Recall

Black

3805230Z36

3805231Z36

3805232Z36

N/A

3805234Z34

S

Menu

Black

3805230Z16

3805231Z21

3805232Z06

N/A

3805234Z08

Scan

Scan

Black

3805230Z25

3805231Z06

3805232Z19

N/A

3805234Z23

Sec

Secure

Black

3805230Z34

3805231Z34

3805232Z34

N/A

3805234Z24

Sel

Select

Black

3805230Z08

3805231Z22

3805232Z05

N/A

3805234Z06

Site

Site

Black

3805230Z37

3805231Z37

3805232Z37

N/A

3805234Z35

Srch

Search

Black

3805230Z11

3805231Z23

3805232Z20

N/A

3805234Z25

Stat

Status

Black

3805230Z47

3805231Z47

N/A

N/A

N/A

Sys

System

Black

3805230Z40

3805231Z40

3805232Z40

N/A

3805234Z38

Zone

Black

3805230Z02

3805231Z24

3805232Z21

N/A

3805234Z26

Call
D

Zone

Disassembly & Reassembly and Replacement Procedures

5-23

Graphic
Legend

5-24

Description

Pushbutton Part Number
Color

Size A

Size B

Size C

Size D

Size E

Call Symbol

Black

3805230Z26

3805231Z13

3805232Z22

N/A

3805234Z07

Emergency
Symbol

White

3805230Z27

3805231Z02

3805232Z23

N/A

3805234Z02

Emergency
Symbol

Orange

3805230Z19

3805231Z15

3805232Z11

N/A

3805234Z11

Horn/Light
Symbol

Black

3805230Z28

3805231Z10

3805232Z24

N/A

3805234Z27

Home
Symbol

Black

3805230Z29

3805231Z25

3805232Z09

N/A

3805234Z28

Monitor
Symbol

Black

3805230Z04

3805231Z26

3805232Z25

N/A

380523´4Z29

Option
Symbol

Black

3805230Z15

3805231Z27

3805232Z08

N/A

3805234Z30

Page
Symbol

Black

3805230Z14

3805231Z28

3805232Z26

N/A

3805234Z31

Phone
Symbol

Black

3805230Z30

3805231Z11

3805232Z27

N/A

3805234Z04

Scan
Symbol

Black

3805230Z31

3805231Z12

3805232Z28

N/A

3805234Z03

Secure
Symbol

Black

3805230Z32

3805231Z03

3805232Z29

N/A

3805234Z32

Select
Symbol

Black

3805230Z17

3805231Z29

3805232Z07

N/A

3805234Z09

Up Arrow
Symbol

Black

3805230Z06

3805231Z30

3805232Z30

N/A

N/A

Down Arrow
Symbol

Black

3805230Z07

3805231Z31

3805232Z31

N/A

N/A

Zone
Symbol

Black

3805230Z13

3805231Z32

3805232Z32

N/A

3805234Z33

Disassembly & Reassembly and Replacement Procedures

Graphic

Pushbutton Part Number

Legend

Description

Color

Size A

Size B

Size C

Size D

Size E

1

Decimal
Number

Black

N/A

N/A

N/A

3805233Z02

N/A

2

Decimal
Number

Black

N/A

N/A

N/A

3805233Z03

N/A

3

Decimal
Number

Black

N/A

N/A

N/A

3805233Z04

N/A

4

Decimal
Number

Black

N/A

N/A

N/A

3805233Z05

N/A

5

Decimal
Number

Black

N/A

N/A

N/A

3805233Z06

N/A

6

Decimal
Number

Black

N/A

N/A

N/A

3805233Z07

N/A

7

Decimal
Number

Black

N/A

N/A

N/A

3805233Z08

N/A

8

Decimal
Number

Black

N/A

N/A

N/A

3805233Z09

N/A

9

Decimal
Number

Black

N/A

N/A

N/A

3805233Z10

N/A

*

Special
Character

Black

N/A

N/A

N/A

3805233Z11

N/A

0

Decimal
Number

Black

N/A

N/A

N/A

3805233Z12

N/A

#

Special
Character

Black

N/A

N/A

N/A

3805233Z13

N/A

2ABC

NumeralLetter

Black

N/A

N/A

N/A

3805233Z14

N/A

3DEF

NumeralLetter

Black

N/A

N/A

N/A

3805233Z15

N/A

4GHI

NumeralLetter

Black

N/A

N/A

N/A

3805233Z16

N/A

5JKL

NumeralLetter

Black

N/A

N/A

N/A

3805233Z17

N/A

6MNO

NumeralLetter

Black

N/A

N/A

N/A

3805233Z18

N/A

7PRS

NumeralLetter

Black

N/A

N/A

N/A

3805233Z19

N/A

8TUV

NumeralLetter

Black

N/A

N/A

N/A

3805233Z20

N/A

9WXY

NumeralLetter

Black

N/A

N/A

N/A

3805233Z21

N/A

Disassembly & Reassembly and Replacement Procedures

5-25

NOTES

5-26

Disassembly & Reassembly and Replacement Procedures

6

Radio Tuning Procedure
General

An IBM PC (personal computer) and RSS (Radio Service Software) are required
to align the radio. Refer to the applicable RSS Manual for installation, setup
procedures for the software and minimum computer requirements.
To perform the alignment procedures, the radio must be connected to the PC,
RIB (Radio Interface Box), and Test Set as shown in Figure 6-1.

!

The use of Mini UHF Adapters will have damaging effects on the RF
Antenna Connector which might lead to radio failure.

Caution

30 dB PAD

SERVICE MONITOR
OR COUNTER

30 dB PAD

WATTMETER

TRANSMIT

BNC
RF GENERATOR
RECEIVE

DC/BATTERY
HKN4191 or
HKN6110

AUDIO IN

TX
AUDIO GENERATOR

TEST SET
RLN4460A or
GTF180B

RADIO

RX

SINAD METER
AC VOLTMETER

PROGRAM/TEST CABLE
RKN4062A, RKN4063A or GTF372A

COMPUTER
DATA
BUSY
GND

RIB RLN4008
or
SRIB RLN1015

COMPUTER INTERFACE RIB CABLE
30-80369B71/72
or
COMPUTER INTERFACE SRIB CABLE
30-80390B48/49
RIB POWER SUPPLY
0180357A57 (110VAC)
0180357A56 or EPN4041A (220 VAC.)/
EPN4040A (240 VAC.)

Figure 6-1

MEPC-95029-A/GB

Radio Alignment Test Setup

Radio Tuning Procedure

6-1

As listed in the Service Aids table in Chapter 3 two different RSS packages are
available for field programming of the MCS 2000 radios:
• RVN4113 for SmartNet/Zone, STARTSITE and Conventional StatAlert
operation
• GVN6011 for Conventional Select 5 operation.
In RVN4113 all service and tuning procedures are performed from the
SERVICE menu, which is selected by pressing F2 from the MAIN MENU. Figure
6-2 illustrates how the MCS 2000 RSS SERVICE screens are organized.
In GVN6011 all service and tuning procedures are performed from the TUNE
RADIO menu which is entered by pressing F2, F5 from the MAIN MENU. The
structure of the TUNE RADIO menu is the same one as shown for the SERVICE
menu in RVN4113 illustrated in Figure 6-2.
The two RSS packages are very similar. The following tuning procedure is
mainly described as seen from within the RVN4113 package.
Service
Menu

F2

F3
Receicer
Alignment
Menu

Transmitter
Alignment
Menu

F2
F3
F4
F5
F6

Reference Oscillator
TX Power
TX Deviation Balance (Comp)
TX Deviation Limit
TX Dev. Limit: Reference
F8 Secure Tx Deviation
F9 TX Current Limit

Figure 6-2

F4

F2
F3
F4
F5
F6

Front End Bandpass Filter
Rated Audio Calibration
Squelch Attenuator (12.5 kHz)
Squelch Attenuator (20 kHz)
Squelch Attenuator (25 kHz)
F8 SECURE Rx Discriminator Level

Signaling
Alignment
Menu

F2 DTMF
F3 High Speed
F4 MDC1200

Service Menu Structure for RVN4113

Before going into the Service Aids menu, the radio must first be read using the
GET/SAVE/PROGRAM Radio Data menu (if the radio has just been
programmed with data loaded from disk or from a newly created codeplug,
then it must still be read so that the RSS will have the radio’s actual tuning
values).
All SERVICE screens read and program the radio codeplug directly; you do
NOT have to use the RSS GET/SAVE functions to program new tuning values.

!
Caution

Do NOT switch radios in the middle of any SERVICE procedure. Always
use the EXIT key to return to the MAIN menu screen before disconnecting
the radio. Improper exits from the SERVICE screens may leave the radio
in an improperly configured state and result in seriously degraded radio
or system performance.
The SERVICE screens use the concept of the “Softpot”, an analog SOFTware
controlled POTentiometer used for adjusting all transceiver alignment
controls.
Each SERVICE screen provides the capability to increase or decrease the
‘softpot’ value with the keyboard UP/DOWN arrow keys respectively. A

6-2

Radio Tuning Procedure

graphical scale is displayed indicating the minimum, maximum, and
proposed value of the softpot, as shown in Figure 6-3.
Adjusting the softpot value sends information to the radio to increase (or
decrease) a DC voltage in the corresponding circuit. For example, pressing the
UP arrow key at the Reference Oscillator screen instructs the radio
microprocessor to decrease the voltage across a varactor in the reference
oscillator, which decreases the frequency.

0

15

Min.
Value

Max.
Value
MAEPF-22858-O

Figure 6-3

Softpot Concept

In ALL cases, the softpot value is just a relative number corresponding to a D/
A (Digital-to-Analog) generated voltage in the radio.

Tuning
Procedure
Reference
Oscillator
Alignment

Perform the following procedures in the sequence indicated
Note
Adjustment of the reference oscillator is critical for proper radio operation.
Improper adjustment will not only result in poor operation, but also a
misaligned radio that will interfere with other users operating on adjacent
channels. For this reason, the reference oscillator should be checked every
time the radio is serviced. The frequency counter used for this procedure must
have a stability of 0.1 ppm (or better).
1.

From the SERVICE menu, press F2 to select TRANSMITTER alignment.

2.

Press F2 again to select the REFERENCE OSCILLATOR softpot.

3.

Press F6 to key the radio. The screen will indicate that the radio is
transmitting.

4.

Measure the transmit frequency on your frequency counter.

5.

Use the UP/DOWN arrow keys to adjust the reference oscillator per the
targets shown in Table 6-1.

Band

Target

VHF

±150 Hz

UHF

±150 Hz

800 MHz / 900 MHz

0.3 ppm

Table 6-1

Reference Oscillator Alignment

6.

Press F6 again to dekey the radio and then press F8 to program the
softpot value.

7.

Press F10, F10 to return to SERVICE menu.

Radio Tuning Procedure

6-3

Transmitter Power

Note

The radio requires two power level adjustments, a high power or rated power
adjustment, and a low power adjustment.
• After POWER tuning, measure and note the DC current to the radio on
each channel in the high power level. These values are needed for the
Current Limit tuning.
• The larger the softpot values, the lower the transmit power.

Radio Model

VHF 25W

VHF 110W R1

VHF 110W R2

UHF 25W

UHF 10W
UHF 40W
UHF 110W R1

800 MHz 15W

800 MHz 35W

900 MHz 12W

900 MHz 30W

Power
Level

Test
Frequency
Range

Transmit Power Setting

25 Watts

136-178 MHz

24-26 Watts

5 Watts

136-174 MHz

5-7 Watts

110 Watts

136-162 MHz

108-112 Watts

55 Watts

136-162 MHz

53-57 Watts

110 Watts

146-174 MHz

108-112 Watts

55 Watts

146-174 MHz

53-57 Watts

25 Watts

403-470 MHz

24-26 Watts

10 Watts

403-470 MHz

9-11 Watts

10 Watts

403-470 MHz

9-11 Watts

5 Watts

403-470 MHz

5-7 Watts

40 Watts

403-470 MHz

43-47 Watts

110 Watts

403-470 MHz

108-112 Watts
(98-103 Watts for test freq. F7)

55 Watts

403-470 MHz

53-57 Watts

15 Watts

806-870 MHz

16-18 Watts

7.5 Watts

806-870 MHz

8-9.5 Watts

3.75 Watts

806-870 MHz

4-5 Watts

35 Watts

806-870 MHz

37.5-39.5 Watts for test freqs. F1-F3
33-34.4 Watts for test freqs. F4-F7

17.5 Watts

806-870 MHz

19-20.5 Watts

8.75 Watts

806-870 MHz

9-10 Watts

13.5 Watts

896-941 MHz

13.5-15.5 Watts

6.0 Watts

896-941 MHz

6.5-8 Watts

3.5 Watts

896-941 MHz

3-4 Watts

30 Watts

896-941 MHz

33-34.5 Watts

6.0 Watts

896-941 MHz

8-9 Watts

Table 6-2 Transmit Power Setting

6-4

1.

From the SERVICE menu, press F2 to select TRANSMITTER alignment.

2.

Press F9 to select CURRENT LIMIT. Use the UP/DOWN arrow keys to set
the softpot to zero. Press F8 to program the new value and press F10 to
return to the TRANSMITTER alignment menu.

3.

Press F3 to select the TRANSMIT POWER softpot. The screen will indicate
the transmit test frequencies to be used.

Radio Tuning Procedure

4.

Press F6 to key the radio, and use the UP/DOWN arrow keys to adjust the
transmit power per the value shown in Table 6-2.

5.

Press F6 to dekey the radio, and then press F8 to program the value. Press
ENTER to select next softpot frequency.

6.

Repeat steps 4 and 5 for the remaining test frequencies.

7.

Press F10 to return to the TRANSMIT menu.

Transmit Current
Limit

Note

After POWER tuning, measure and note the DC current to the
radio on each channel in the high power level. These values
are needed for the Current Limit tuning.
Larger Softpot Values yield increased Cutback resulting in
Lower Power.
For 800/900 MHz radios tuning is done with three voltages:
11.8 V, 13.8 V and 15.5 V.

1.

Press F9 to select the Current Limit softpot. The screen will indicate the
transmit test frequencies to be used.

2.

Select the frequency with the highest DC current drain as measured
during the power tuning procedure.

3.

Press F6 to key the radio and use the UP/DOWN arrow keys to adjust the
transmit Current Limit until the power has reached the maximum
nominal power of the radio (10, 12, 15, 25, 30, 35, 40, 55 or 110 Watts).
If the value cannot be exactly tuned set the output power one step above
the nominal value.

4.

Increase the current limit setting by number of steps defined in Table 63.

5.

Press F6 to dekey the radio.

6.

Press F8 to program the value. (The six other softpot values do not need
tuning because only one Current Limit value is held in the radio).

7.

Press F10 twice to return to the SERVICE menu.

Model

Power

Steps

VHF

all power levels

3

UHF

all power levels

0

800 MHz/900 MHz

all power levels

3

Table 6-3

Transmit
Deviation Balance
(Compensation)

Current Limit Step Adjustment

Compensation alignment balances the modulation sensitivity of the VCO and
reference modulation (synthesizer low frequency port) lines. Compensation
algorithm is critical to the operation of signaling schemes that have very low
frequency components (e.g. DPL) and could result in distorted waveforms if
improperly adjusted.
1.

Press F4 to select the TRANSMIT DEVIATION BALANCE softpot. The
screen will indicate the transmit test frequencies to be used.

Radio Tuning Procedure

6-5

Note

Transmit
Deviation Limit

Note

6-6

2.

Begin with the lowest test frequency shown on the screen.

3.

With Test Box RLN4460A: Set the test box METER OUT switch to the
AUDIO IN position, and inject a 80 Hz tone at 100 mVrms into the
AUDIO IN BNC connector. To ensure proper signal level measure on
METER OUT jack with AC voltmeter.
With Test Box GTF180B: Set the Test Box meter selector switch to the
“GEN” position, and inject a 80 Hz tone at 100 mVrms into the “Audio
In” port. Connect an AC meter to the meter port to ensure the proper
input signal level.

4.

Press F6 to key the radio, then press F8 and measure deviation. Record
this measurement.

5.

Press F6 again to dekey the radio, and change the input tone to 3 kHz,
100 mVrms.

6.

Press F6 to key the radio, then press F8 and use the UP/DOWN arrow
keys to adjust the deviation to within ±0.15 kHz of the value recorded in
Step 4.

7.

Press F6 to dekey the radio, and press F8 to program the softpot value.
Press ENTER to move to next softpot value.

8.

Repeat steps 3 - 7 for the remaining test frequencies.

9.

Press F10 to return to the TRANSMIT menu.

The step size change for step 6 is approximately 2.5% softpot value.

The transmit deviation limit softpot sets the maximum deviation of the
carrier. Tuning is performed for 25 kHz channel spacing. Values for other
channel spacings are calculated by the radio software.
1.

Press F5 to select the TRANSMIT DEVIATION LIMIT softpot. The screen
will indicate the transmit test frequencies to be used.

2.

Begin with the lowest test frequency shown on the screen.

3.

With Test Box RLN4460A: With the METER OUT switch set to MIC
PORT, and METER OUT selector to MIC, inject a 1 kHz tone, 800 mVrms
as measured on the AC/DC METER port.
With Test Box GTF180B: With the meter selector switch set to GEN,
inject a 1 kHz tone, 800 mVrms as measured on the METER port. Where
ever possible tune for the top of the range.

4.

Press F6 to key the radio, and use the UP/DOWN arrow keys to adjust the
deviation until 4.6 kHz is just exceeded, then step down 1 kHz.

5.

Press F6 to dekey the radio, and press F8 to program the softpot value.
Press ENTER to move to the next softpot value.

6.

Repeat steps 3 - 5 for the remaining frequencies shown on the screen.

7.

Press F10 to return to the TRANSMIT menu.

For SELECT 5 radios it is currently ESSENTIAL that the programming of the 25/
30 kHz channel spacing is the last action before exiting this menu. The limit
is 4.3 - 4.6 kHz, and although the softpot value will not normally need
adjusting, the value must be programmed using the F8 key.

Radio Tuning Procedure

Transmit
Deviation Limit
Reference

Note

These softpots set the deviation reduction ratio to transmit at 20 kHz or 12.5
kHz channel spacing.
1.

Press F6 to select the TRANSMIT DEVIATION LIMIT 12.5/20 kHz softpot.

2.

With Test Box RLN4460A: With the meter selector switch set to MIC,
inject a 1 kHz tone on the AUDIO IN terminal on the test set, 400
mVrms as measured on the AC/DC MTR port.
With Test Box GTF180B: With the meter selector switch set to GEN,
inject a 1 kHz tone, 400 mVrms as measured on the METER port.

3.

Press F6 to key the radio, then press F8 and use the UP/DOWN arrow
keys to adjust the deviation until 4.6 kHz is just exceeded, then step
down 1 kHz. Tune as close to the upper range as possible

4.

Press F6 to dekey the radio, and press F8 to program the softpot value.
Press Enter to move to next softpot value.

5.

Repeat steps 2 - 4 for the remaining channel spacings.

6.

Press F10 to return to the TRANSMIT menu.

For radios with Conventional Select 5 Signaling software it is currently
ESSENTIAL that the programming of the 25/30 kHz channel spacing is the last
action before exiting this menu. The limit is 4.3 - 4.6 kHz and although the
softpot value will not normally need adjusting the value must be programmed
using the F8 key.

Signaling
Deviation

DTMF Transmit
Deviation

This procedure is only required for VHF and UHF models with
20 kHz and 12.5 kHz channel spacing.

Note

On radios with Conventional Select 5 Signaling software skip
the next three steps and go to “DTMF Transmit Deviation
(GVN6011 only)” on page 6-8 and “Select 5 Transmit
Deviation (GVN6011 only)” on page 6-9.

Note

The DTMF Deviation Softpot is used to tune the FFSK signaling deviation.
1.

From the SERVICE menu, press F4 to select SIGNALING alignment.

2.

Press F2 again to select the DTMF softpot.

3.

Press F6 to key the radio on the test frequency. The screen will indicate
that the radio is transmitting.

4.

Measure the DTMF deviation on your service monitor.

5.

Use the UP/DOWN arrow keys to adjust the DTMF deviation per Table 64.

Channel Spacing (kHz)

DTMF

Trunking

MDC

25 / 30

3.05-3.40

2.5-3.5

3.25-3.75

20 (VHF/UHF)

2.44-2.76

2.0-2.8

2.6-3.0

12.5

1.55-1.85

1.25-1.75

1.62-1.88

Table 6-4 Signaling Deviation
Radio Tuning Procedure

6-7

High Speed
Deviation

MDC 1200
Deviation

6.

Press F6 again to dekey the radio.

7.

Press F8 to program the softpot value; press F10 twice to return to the
SERVICE menu.

1.

From the SERVICE menu, press F4 to select SIGNALING alignment

2.

Press F3 to select the TRUNKING HIGH SPEED softpot.

3.

Press F6 to key the radio on the test frequency. The screen will indicate
that the radio is transmitting.

4.

Measure the TRUNKING HIGH SPEED deviation on your service
monitor.

5.

Use the UP/DOWN arrow keys to adjust the TRUNKING HIGH SPEED
deviation per Table 6-4.

6.

Press F6 again to dekey the radio.

7.

Press F8 to program the softpot value; press F10 twice to return to the
SERVICE menu.

1.

From the SERVICE menu, press F4 to select SIGNALING alignment

2.

Press F4 again to select the MDC softpot.

3.

Press F6 to key the radio on the test frequency. The screen will indicate
that the radio is transmitting.

4.

Measure the MDC deviation on your service monitor.

5.

Use the UP/DOWN arrow keys to adjust the MDC deviation per Table 64.

6.

Press F6 again to dekey the radio.

7.

Press F8 to program the softpot value; press F10 twice to return to the
SERVICE menu.

DTMF Transmit
Deviation
(GVN6011 only)

Note

This tuning sequence is ONLY for radios with Conventional
Select 5 Signaling software being tuned with the RSS
GVN6011.

The DTMF Deviation Softpot is used to tune the FFSK signaling deviation.
Tuning is performed at one frequency and for 25 kHz channel spacing. The
radio generates a DTMF signal for tuning. Values for other frequencies and
channel spacings are calculated by the radio software.

6-8

1.

From the RADIO TUNE menu, press F4 to select SIGNALING alignment.

2.

Press F4 again to select the DTMF softpot.

3.

Press F6 to key the radio on the test frequency. The screen will indicate
that the radio is transmitting.

4.

Measure the DTMF deviation on your service monitor.

5.

Use the UP/DOWN arrow keys to adjust the DTMF deviation to be
within 3.05 and 3.45 kHz.

6.

Press F6 again to dekey the radio.

7.

Press F8 to program the softpot value; press F10 to return to the
SIGNALING menu.

Radio Tuning Procedure

Select 5 Transmit
Deviation
(GVN6011 only)

Note

This tuning sequence is ONLY for radios with Conventional
Select 5 Signaling software being tuned with the RSS
GVN6011.

The Select 5 Deviation Softpot is used to tune the FFSK signaling deviation.
Tuning is performed at one frequency and for 25 kHz channel spacing. The
radio generates a Select 5 signal for tuning. Values for other frequencies and
channel spacings are calculated by the radio software.
Note

Squelch

Alignment of the Transmit Deviation Limit Reference MUST immediately
PRECEDE the Select 5 Alignment Procedure.
1.

From the RADIO TUNE menu, press F4 to select SIGNALING alignment.

2.

Press F5 again to select the Select 5 softpot.

3.

Press F6 to key the radio on the test frequency. The screen will indicate
that the radio is transmitting.

4.

Measure the Select 5 deviation on your service monitor.

5.

Use the UP/DOWN arrow keys to adjust the Select 5 deviation to be
between 3.30 and 3.70 kHz.

6.

Press F6 again to dekey the radio.

7.

Press F8 to program the softpot value; press F10 twice to return to the
SERVICE menu.

The squelch softpots set the signal to noise ratio at which the squelch opens.
The 25/30 kHz squelch value needs to be set at 7 frequencies across the
frequency range. In 800 MHz and 900 MHz radios the 6th and 7th frequency
are always the same, so only 6 frequencies are being tuned. For some models,
the 20 kHz and 12.5 kHz values are then set at one frequency and the other
frequency settings are calculated by the radio software. For other models the
20 kHz and 12.5 kHz squelch settings are also tuned for all 7 frequencies across
the band.
1.

From the SERVICE menu, press F3 to select RECEIVER alignment.

2.

Channel spacing determines the next key press. Press F4, F5, or F6 (as
applicable) to select the SQUELCH softpot.

3.

Select the first test frequency shown, and adjust the UP/DOWN arrow
key to the minimum squelch value.

4.

With Test Box RLN4460A: Set the RF test generator to the test frequency
plus the following offset: VHF: +200 Hz, UHF: +200 Hz, 800 MHz:
+500 Hz.
With Test Box GTF180B: Set the RF test generator to the test frequency
and modulate the signal generator at 3.0 kHz deviation, 1 kHz tone.
Adjust the generator for an 8-10 dB SINAD level.

5.

Adjust the UP/DOWN arrow key until the squelch just closes.

6.

Monitor for squelch chatter; if chatter is present, repeat step 4.

7.

When no chatter is detected, press F8 to program this value. Press
“ENTER” to select next softpot adjustment.

8.

Repeat steps 3 - 6 for all test frequencies shown on the screen.

9.

Press F10, F10 to return to the Service menu.
Radio Tuning Procedure

6-9

Rated Audio

Alignment of the Rated Audio is not required on these radios.

Front-End PreSelector

Alignment of the front-end pre-selector is not required on these radios.

6-10

Radio Tuning Procedure

7

Controller Section
Theory of Operation
Introduction

The radio is a microcontroller-based dual mode (trunked/conventional)
transceiver. The microcontroller determines the active state of the radio
(transmit/receive), monitors radio status, and processes operator commands
entered from the keypad or the other radio controls.
In the Low and Mid Power versions of the radio all radio circuitry is contained
on a single rigid printed circuit board (PCB). In the High Power version of the
radio, the physical arrangement of the circuitry is the same except the power
amplifier (PA) part of the transmitter is contained on a separate PCB.
The radio is composed of the following three major functions:
• RF (Receiver and Transmitter)
• Controller (Main Controller and DC Power Control and Regulation
• Control Head
The RF section is band specific circuitry described in one of the frequency
range specific Volume 2s depending on the band split (See “Related
Publications” on page 1-1).
The Control Head connects to the radio via an 18 pin connector. There are
three different control head types of varying complexity: Model I, Model II
and Model III. Control Head information is covered in this volume of the
manual.

Theory
Overview

The Controller section is physically separated into two functional sections, i.e.
the Main Controller and the DC Power Control and Regulation.
The controller section of the radio is a microcomputer-based processor that
controls the radio in accordance with its built in programming as well as
commands input manually by the radio operator. The radio operator inputs
manual commands to the controller section using the push-button and other
controls located on the radio control head. In addition to its controlling
functions, the controller section provides audio amplification of the audio
output signal from the receiver section. It also controls and processes a squelch
signal output from the receiver back end section to control the receiver’s audio
squelch function.

Controller Section Theory of Operation

7-1

The radio controller consists of 5 main functional sections. These are:
• voltage regulation
• power control
• interfacing
• microprocessor operation
• audio and signalling processing
The controller is based on the Motorola 68HC11F1 microprocessor (U0103).
In addition to the microprocessor, the controller has 3 external memory
devices, signal MUX IC (U0105), and a Support Logic IC (SLIC IV, SLIC IVa, or
SLIC V, U0104). The 3 memory devices consist of a 32 Kbyte EEPROM (U0100),
32 Kbyte SRAM (U0101), and a 256Kbyte or 1MByte FLASH EEPROM (U0102).
The digital section consists of a microprocessor, support memory, support
logic, signal MUX ICs, the On/Off circuit, and General Purpose Input/Output
circuitry.

Voltage
Regulation

(Refer to schematic page 10-29 or 10-30 for reference)

Voltage Regulators

Voltage regulation for the controller is provided by 4 separate devices; U0500
(LM2925) +5V, U0501 (LM2941) +9.3 V, U0502 +8V, and UNSW 5V (a
combination of R0004 and VR0001). Additional regulators are located in the
RF section and the control head/handset.
Voltage regulation providing 5V for the digital circuitry is done by U500. Input
and output capacitors (C0500/0501 and C0503/0504) are used to reduce high
frequency noise and provide proper operation during battery transients. This
regulator provides a reset output (pin 5) that goes to 0 volts if the regulator
output goes out of regulation. This is used to reset the controller during power
on to prevent improper operation. C0502 sets the duration of this reset signal
to a minimum of about 12 ms.
Regulator U0501 is used to generate the 9.3 volts required by some audio
circuits, the RF circuitry and power control circuitry. Input and output
capacitors (C0505/0506 and C0508/0509) are used to reduce high frequency
noise. R0503/R0504 sets the output voltage of the regulator. If the voltage at
pin 1 is greater than 1.2 volts the regulator output decreases and if the voltage
is less than 1.2 volts the regulator output increases. This regulator output is
electronically enabled by a 0 volt signal on pin 2. Q0500 and associated
circuitry (R0500/0501/0502 and C0507) are used to disable the regulator when
the radio is turned off.
Regulated 8V is provided by U0502. It provides a separate supply to the
microphone circuitry. The microphone cannot be supported directly from A+/
SWB+ because any fluctuation on A+ would be impressed on the microphone
line and affect transmitted audio. The microphone circuitry can not be
connected to the other regulators because, there is a function which allows the
radio to be switched on by momentarily grounding the microphone line (see
Electronic On/Off).

7-2

Controller Section Theory of Operation

UNSW 5V is only used in a few areas which draw low current and requires 5 V
while the radio is off.

Electronic On/Off

Unlike older radios whose on/off feature was controlled only by the
mechanical on/off switch, this radio has circuitry which allow radio software
and/or external triggers to turn the radio on or off without direct user action.
Some examples of this usage are 1) automatic turn on when emergency switch
is engaged; 2) automatic turn on when ignition is sensed and off when
ignition is off; 3) radio deaffiliation, with certain features the radio can be
programmed to stay on for a brief period after the user has “turned it off”.
During this “extra on” period the radio may transmit a signal to a base station
letting the station know that the radio has been turned off.
Q0511 is used to provide SW B+ to the various radio circuits. Q0511 acts as an
electronic on/off switch where pin 4 acts as the control pin. The switch is on
when pin 4 is low and off when pin 4 is high. When the radio is off Q0510 is
cutoff and the voltage at Q0511-4 is at A+. This effectively prevents current
flow through Q0511 from pins 2/3 to 5/6/7/8. When the radio is turned on the
voltage at the base of Q0510 is high (at least above 3V) and Q0510 switches on
(saturation) and pulls down the voltage at Q0511-4 to ~0.07V. With FET
Q0511 now “enabled” current flows through the device. This path has a very
low impedance (less than 1 ohm) from pins 2/3 to 5/6/7/8. This effectively
provides the same voltage level at SWB+ as at A+.
The electronic on/off circuitry can be enabled by the microprocessor, the
emergency switch, the mechanical On/Off switch on the control head, or the
ignition sense circuitry. If any of the 4 paths leading to the base of Q0510
provides a high voltage through diodes CR0510 or CR0511, the electronic
“ON” is engaged.

Emergency
(Refer to schematic
Page 10-26 for
reference)

The emergency switch, when not engaged, normally grounds the base of
Q0414. When the emergency switch is pressed this connection is opened and
the base of Q0414 is pulled high by R0437. This causes the collector of
transistor Q0414 to go low (.2V), thereby setting the EMERGENCY IN input of
U0510 low. U0510 is a dual 555 timer configured as two “pulse stretchers”, one
for the Emergency input to electronically turn on the radio and the other for
the mechanical On/Off switch on the control head to cause the radio to
electronically switch on.
With regard to emergency, when U0510-8 EMERGENCY IN is above 1/3 of the
supply voltage at U0510-14, that causes the device to internally ground
U0510-13, which in turn holds capacitor C0513 in a discharged state. The
device also keeps U0510-9 EMER TRIG at a low voltage. When EMERGENCY
IN goes below 1/3 of the device supply voltage, U0510 disables the discharge
mechanism at pin 13 allowing the capacitor C0513 to charge through R0513.
The charging rate is set by the values of R0513 and C0513. When the voltage
at pin 12 goes above 2/3 supply voltage, the device sets pin 9 EMER TRIG high
which in turn switches on Q0510 enabling the radio to turn on to begin
emergency operation. U0510 will keep pin 12 high for a period set by R0513
and C0513 which for 200K/1 uF equals 220 ms.
While SW B+ is on for 220 ms, the microprocessor starts execution, reads that
the emergency input is active, and sets the B+ CNTL output to a logic high.
This high will keep Q0510 switched on through CR0510 beyond the 220 ms
period after which U0510-9 will return to a low level. This operation allows a
momentary press of the emergency switch to power up the radio. When the

Controller Section Theory of Operation

7-3

microprocessor has finished processing the emergency press, it sets the B+
CNTL output to a logic 0. This turns off Q0511 and the radio turns off. Notice
that EMER TRIG also goes to U0104-D5 and U0003-F2. This is where the
appropriate microprocessor is alerted to the emergency condition. If the radio
was already on when emergency was triggered then B+ CTRL would already be
high and EMER TRIG going high due to the emergency condition would have
no effect on Q0510, i.e. switching on Q0511 when it is already on.

Mechanical
On/Off

This refers to the typical on/off switch, located on the control head, and which
turns the radio on and off.

(Refer to schematic
Page 10-26 for
reference)

U0502 is fed by A+, and is therefore always on and providing 8 V on MIC
VOLTAGE. When the Mechanical on/off switch is pressed, the MIC IN line is
momentarily grounded setting the ON/OFF input of U0510-6 low.
Similar to the emergency operation described previously, when U0510-6 ON/
OFF is above 1/3 of the supply voltage at U0510-14, it will cause the device to
internally ground U0510-1, which in turn holds capacitor C0511 in a
discharged state. The device also keeps U0510-5 SW B+ SENSE at a low voltage.
When ON/OFF goes below 1/3 of the device supply voltage, U0510 disables
the discharge mechanism at pin 1 allowing the capacitor C0511 to charge
through R0512. The charging rate is set by the values of R0512 and C0511.
When the voltage at pin 2 goes above 2/3 supply voltage, the device sets pin
5 SW B+ SENSE high which in turn switches on Q0510 enabling the radio to
turn on to begin operation. U0510 will keep pin 5 high for a period set by
R0512 and C0511 which for 200K/1 uF equals 220 ms.
While SW B+ SENSE is on for 220 ms, the microprocessor starts execution,
reads that the SW B+ SENSE is active, and sets the B+ CNTL output to a logic
high to keep Q0510 switched on through CR0510 beyond the 220 ms period.
After this U0510-5 will return to a low level. This operation allows a
momentary press of the Mechanical on/off switch to power up the radio.
Notice that SW B+ SENSE also goes to U0104-B4 or U0003-H2. This is where
the appropriate microprocessor is alerted to the turn on/off condition.
If the radio is already on when the switch was pressed then B+ CTRL is already
high and SW B+ SENSE going high due to the switch being pressed will have
no effect on Q0510. However, since SW B+ SENSE also goes to U0104-B4 or
U0003-H2, the software can detect the line changing from low to high state
momentarily, indicating that the radio must now turn off. In this case the
software asserts B+ CTRL low which switches off Q0510 and Q0511, turning
off the radio.
Resistor R0518 and capacitor C0518 form a filter to roll off any audio on the
line. This prevents audio signal swing on the MIC IN line from triggering the
on/off function at U0510-6.

Ignition
(Refer to schematic
Page 10-29 for
reference)

Ignition sense is used to prevent the radio from draining the vehicle’s battery
because the engine is not running. The radio can be programmed to keep the
unit entirely off, preventing RX and TX; or programmed to only prevent TX,
while the vehicle’s engine is off. See for functional operation.
When the IGNITION input goes above 6 volts Q0430 turns on. This turns
Q0517 off and turns Q0519 on, turning on SW B+ by directly forcing Q05114 low. The logic 0 output of Q0430 also turns on Q0431 providing an input to
the microprocessor. The microprocessor starts execution, reads that the

7-4

Controller Section Theory of Operation

Ignition input is active and sets the B+ CNTL output to a logic 1 to latch on
SW B+. If the software determines that the radio should not be operating, it
will set the CLEAR output to a logic 1 and the B+ CNTL output to a logic 0.
This sets a latch composed of Q0514 - Q0517, R0519 and R0521. The latch
output (at the collector of Q0517) will go to a logic 0 (at Q0517) and turn off
Q0519, which allows R0514 to pull Q0511-4 high, switching the FET off. The
latch output will remain at a logic 0 state until the IGNITION input has gone
below 6 volts. The next time the IGNITION input goes above 6 volts the above
process will be repeated. The microprocessor uses the ignition sense input
along with codeplug data to determine if the radio is allowed to transmit.

Table 7-1 Conventional/MDC/SmartNet/SmartZone Ignition Sense Function Operator Action vs Resultant Radio States
This Action During This State of Radio

Causes The Following Radio States to Occur

Present State of Radio

Functions Available Through Ignition Sense Programmed in RSS

Action

On/
Off

Receive/
Stand-by/
Emergency

Ignition

Blank
(Default from
Factory*)

Soft Power Off
Default from
Factory

TX Inhibit

PTT Inhibit

Press On/Off Button

On

Receive/
Stand-by

On

Off

Off

Off

Off

Press On/Off Button †

On

Emer

On

Off

Off

Off

Off

Press On/Off Button

Off

Off

On

On

On

On

On

Press On/Off Button

On

Receive/
Stand-by

Off

Off

Off

Off

Off

Press On/Off Button

On

Emer

Off

Off

Off

Off

Off

Press On/Off Button

Off

Off

Off

On

On (Off ‡)

On - RX or
Standby

On -RX or
Standby

Short Press Emer
Button

On

Receive/
Stand-by

On

On - Emer TX

On - Emer TX

On - Emer TX

On - Emer TX

Long Press Emer
Button

On

Emer

On

On

On

On

On

Short Press Emer
Button 2

Off

Off

On

Off

Off

Off

Off

Short Press Emer
Button 2

On

Receive/
Stand-by

Off

On - Emer TX

Off

Emer Displayed On - Emer TX
for 3 Seconds
then No Ack
Displayed - No
TX
(All of the above
plus sidetones 3)

Long Press Emer
Button

On

Emer

Off

On

Off

On

On

Short Press Emer
Button 2

Off

Off

Off

Off

Off

Off

Off

Turn Ignition On

On

Receive/
Stand-by

Off

On

On

On

On - No PTT TX

Turn Ignition On 2

On

Emer

Off

On - Emer TX

On

On - Emer TX

On - Emer TX

Controller Section Theory of Operation

7-5

This Action During This State of Radio

Causes The Following Radio States to Occur

Present State of Radio

Functions Available Through Ignition Sense Programmed in RSS

Action

On/
Off

Receive/
Stand-by/
Emergency

Ignition

Blank
(Default from
Factory*)

Soft Power Off
Default from
Factory

TX Inhibit

PTT Inhibit

Turn Ignition On

Off

Off

Off

Off

On

Off

Off

Turn Ignition Off

On

Receive/
Stand-by

On

On

Off

On - No TX

On - No TX

Turn Ignition Off 2

On

Emer

On

On - Emer TX

Off

On - Emer TX

On -Emer TX

Turn Ignition Off

Off

Off

On

Off

Off

Off

Off

Data PTT

On

Data Mode

Off

TX

Off

No TX

No TX

Press On/Off Button

On

Data Mode

On

Off

Off

Off

Off

Press On/Off Button

On

Data Mode

Off

Off

Off

Off

Off

Short Press Emer
Button

On

Data Mode

On

On - Emer TX

On - Emer TX

On - Emer TX

On - Emer TX

Short Press Emer
Button 2

On

Data Mode

Off

On - Emer TX

Off

Emer
Displayed
for 3
Seconds
then No
Ack
Displayed No TX

On - Emer TX

Turn Ignition On

On

Data Mode

Off

On

N/A

On

On - No PTT TX

Turn Ignition Off

On

Data Mode

On

On

Off

On - No TX

On - No TX

* The “Default from Factory” was changed in Release 4.01.
† Take special note of Emergency operation (shown in oversize bold print) under these conditions.
‡ For firmware versions older than Release 4.0, the feature will operate as shown in parenthesis. To determine firmware version present in radio, proceed as follows:
Within 10 Seconds after powering on the radio, press the test mode entry button five times. On Model I
radio, test mode entry button is third button from left on bottom row of buttons. On radio Models II and
III, test mode entry button is first button on left side of bottom row of buttons. When the test mode entry
button is pressed five times, the radio will scroll sequentially through six displays. The first display in the
sequence is SERVICE. The second display is the radio firmware version (e.g., R03.11).

Power Control
(Refer to schematic
Page 10-20 for
reference)

7-6

The power control loop regulates power with an automatic level control (ALC)
loop and provides protection features against overcurrent, excessive control
voltage, and high operating temperatures. Power and current limit are
adjusted under microprocessor control using a Digital to Analog (D/A)
converter (U0551). Control voltage limit is set by resistor ratio on the
transmitter, or D/A output for those radios that must minimize adjacent
channel splatter. The D/A adjustable control voltage limit increases
transmitter rise time and reduces adjacent channel splatter as it is adjusted
closer to the actual operating control voltage.

Controller Section Theory of Operation

The microprocessor controls K9.1 enable (K9.1 ENB) to bias the PA and
antenna switch, PA disable (PA DIS) to disable the PA control voltage, and
power range (PWR RANGE) to adjust the number of D/A steps per watt.
Note

The Power Range Mode is not used on all models.
The ALC loop regulates power by adjusting the PA control line PA CNTL to
keep the forward power voltage V FORWARD at a constant level. V FORWARD
is amplified with a gain of set by the PWR RANGE signal (described below) and
added to the PA PWR SET output U0551 pin 2 through resistors R0577, R0553
and R0554. The result is connected to opamp inverting input U0550 pin 9
which is compared with a 4.65 volt reference present at noninverting input
U0550 pin 10. The 4.65 volt reference is set by a divider circuit connected to
ground and 9.3 volts by resistors R0567 and R0569.
The power range line PWR RANGE controls the gain of the V FORWARD
amplifier. For high power mode operation (i.e. VHF/UHF 110W models, high
power mode is 110W. For VHF/UHF 40W models, high power mode is 40W)
the PWR RANGE line is set to a logic 0 (<1.0V) and the resulting V FORWARD
gain is 1+(R0564/R0573). For low power mode operation (i.e. VHF/UHF 110W
models, low power mode is 50W. For VHF/UHF 40W models, low power mode
is 25W) the PWR RANGE line is set to a logic 1 (>4.0V) and the resulting
V FORWARD gain is 1+(R0564/RP) where RP equals R0563 in parallel with
R0573.
The PA disable line PA DIS prevents transmitter operation by keeping the PA
control voltage PA CNTL near zero volts. On radios that are required to
minimize adjacent channel splatter, a control voltage limit line PA CNTL LIM
is pulled to ground by transistor Q0556 when PA disable is high. This
effectively makes the control voltage limit equal to zero and pulls the 4.65 volt
reference at noninverting input U0550 pin 10 to ground through transistor
Q0551. The ALC opamp output at U0550 pin 8 is prevented from rising above
zero since the noninverting input is grounded. On radios that are not required
to minimize adjacent channel splatter the transmitter is disabled through
transistor Q0551 which pulls the PA control voltage PA CNTL directly to
ground.
During normal transmitter operation the voltages at the opamp inputs U0550
pins 9 and 10 should be equal to 4.65 volts and the PA control voltage output
at pin 8 should be between 4 and 7 volts. If power falls below the desired
setting, V FORWARD decreases, causing the inverting input at U0550 pin 9 to
decrease, increasing the opamp output at U0550 pin 8 and increasing the PA
control voltage PA CNTL until V FORWARD increases to the desired level. The
D/A output voltage PA PWR SET at U0551 pin 2 adjusts the power set point.
V FORWARD reaches a steady state voltage such that the current through the
R0554 branch equals the current through the R0553-R0577 branch. As PA
PWR SET decreases, transmitted power must increase to make V FORWARD
larger and keep the inverting input U0550 pin 9 at 4.65 volts.
Loop frequency response is controlled by opamp feedback components R0570
and C0568 and the output lowpass filter R0571 and C0569.
Rise and fall time is controlled by the D/A adjustable control voltage limit
circuit attached to the reference voltage at U0550 pin 10 via transistor Q0555.
The reference voltage at U0550 pin 10 is pulled low by Q0555 when the PA
control voltage approaches the limit set by the D/A output PA CNTL LIM,
Controller Section Theory of Operation

7-7

U0551 pin 13. The PA control voltage at U0550 pin 8 connects to opamp
noninverting input U0202 pin 3 through the voltage divider formed by R0592
and R0591 and lowpass capacitor C0572. Control voltage limit is set by the D/
A output PA CNTL LIM at U0551 pin 13 which connects to inverting input
U0202 pin 2 through R0584, Q0556 and R0590. Transistor Q0556 is connected
to the PA disable line, PA DIS which effectively pulls the control voltage limit
to zero volts, and activates Q0555 to pull the reference voltage to zero when
control voltage is greater than zero.

Protection features

The transmit power control circuit has three protection mechanisms. They are
1) thermal cutback, 2) current limit and 3) PA control voltage limit. These
features operate by adding current to the ALC loop inverting input at U0550
pin 9 through diodes CR0550 and CR0551 and decreasing the PA control
voltage. When the voltage exceeds 4.65 volts plus one diode drop at any
cathode of diodes CR0550 and CR0551, current begins to flow into the ALC
loop increasing the voltage at the inverting input U0550 pin 9. As a result the
PA control voltage at U0550 pin 8 decreases in response to excessive PA
control voltage, final device temperature, and final device current.
Thermal cutback limits the PA temperature by reducing the PA control voltage
as temperature increases during extended periods of transmitter operation or
high ambient temperatures.
PA TEMP connects to an inverting amplifier through resistor R0550 to
inverting input U0550 pin 2. The noninverting input U0550 pin 3 is
connected to a 4.65 volt reference formed by voltage divider resistors R0576
and R0582 which connect to ground and the 9.3 volt supply. The output of
the inverting amplifier at U0550 pin 1 is the product of the amplifier gain as
determined by the ratio of R0551 divided by R0550 and the difference between
the amplifier inputs pins 2 and 3. When the PA TEMP input is greater than
4.65 volts the amplifier output is less than 5 volt.
As temperature rises the voltage on PA TEMP falls, the inverting amplifier
output at U0550 pin 1 rises, current begins to flow through R0552 and CR0550
into the ALC loop at the inverting input of U0550 pin 9, decreasing the PA
control voltage PA CNTL and reducing transmitter output.
Current limit is provided to protect the PA final device (Q5540) from
overcurrent caused by low line voltage and/or mismatched antennas.
Voltage dividers on the current sense lines, CURRENT SENSE+/ CURRENT
SENSE-, formed by resistors R0557, R0558, R0559, and R0560 protect the
inputs of U0550 (pins 5 and 6) from excessive voltages. CURRENT SENSE+
connects to the noninverting input U0550 pin 5 through resistors R0557 and
R0558. CURRENT SENSE- connects to the inverting input U0550 pin 6
through resistors R0559 and R0560. As current through the final device
increases, voltage drop through R5612 increases and CURRENT SENSEdecreases with respect to CURRENT SENSE+, increasing the difference between
inverting and noninverting inputs, causing the amplifier output at U0550 pin
7 to increase to over 4.65 volts plus one diode drop. As the amplifier output
increases to over 5 volts, the current through resistor R0556 and diode CR0550
becomes sufficient to reduce the PA control voltage reducing the PA device
current.
The D/A line CUR LIM SET at U0551 pin 4 adjusts the maximum allowed
current by creating an offset voltage at the noninverting input U0550 pin 5

7-8

Controller Section Theory of Operation

that is approximately equal to the voltage present at the inverting input
during the maximum current voltage drop through R5612.
PA control voltage limit consists of a portion of the control voltage fed back to
the power control loop. PA_CNTL_LIM is produced by a voltage divider
network on the PA board. When PA_CNTL_LIM goes above the reference
voltage of 4.65 V plus one diode voltage drop (i.e. 0.7 V) then protection
begins. At this point the control voltage PA_CNTL is clamped. This protects
the PA from being driven too hard by PA_CNTL which could cause excessively
high output power

Interfacing

(Refer to “Clock Distribution Block Diagram” on page 7-10, and Interface
schematic page 10-24 for general reference)

Microprocessor
Clock Synthesizer

(Refer to ASFIC schematic page 10-23 for reference)
The clock source for the microprocessor system is generated by the ASFIC
(U0200). Upon power-up the reference oscillator U5800 (Pendulum) provides
a 16.8 MHz reference. Based on this reference the synthesizer (U5801)
generates a 2.1 MHz waveform that is routed from the RF section (via C0403)
to the ASFIC (on U0200-E1) and the option connectors (J0401-3 and J0408-3).
At the option connectors the 2.1 MHz may be used as a reference for any
option boards that are attached. For the main board controller the ASFIC uses
2.1 MHz as a reference input clock signal for its internal synthesizer. The
ASFIC, in addition to audio circuitry, has a programmable synthesizer which
can generate a synthesized signal ranging from 1200 Hz to 32.769 MHz in
1200 Hz steps.
When power is first applied, the ASFIC will generate its default 3.6864 MHz
CMOS square wave µ P CLK (on U0200-D1) and this is routed to the
microprocessor (U0103-36/U0003-E3) and SLIC (U0104-A3). After the
microprocessor starts operation, it reprograms the ASFIC clock synthesizer to
a higher µ P CLK frequency (usually 7.3728 or 14.7456 MHz) and continues
operation.
The ASFIC synthesizer loop uses C0208, C0209 and R0204 to set the switching
time and jitter of the clock output. If the synthesizer cannot generate the
required clock frequency it will switch back to its default 3.6864 MHz output.
Because the ASFIC synthesizer and the µ P system will not operate without the
2.1 MHz reference clock it (and the voltage regulators) should be checked first
in debugging the system.

Serial Peripheral
Interface (SPI)

(Refer to Controller schematic page 10-19 for reference)
The µ P communicates to many of the ICs through its SPI port. This port
consists of SPI TX DATA (U0103-66/U0003-B2), SPI RX DATA (U0103-65/
U0003-B1), CLK (U0103-67/U0003-A2) and chip select lines going to the
various ICs, connected on the SPI PORT (BUS). This BUS is a synchronous bus,
in that the timing clock signal CLK is sent while SPI data (SPI TX DATA or SPI
RX DATA) is sent. Therefore, whenever there is activity on either SPI TX DATA
or SPI RX DATA there should be a uniform signal on CLK. The SPI TX DATA is
used to send serial from a µ P to a device, and SPI RX DATA is used to send data
from a device to a µ P.

Controller Section Theory of Operation

7-9

TRANSCEIVER
FRACTIONAL DIVISION SYNTHESIZER
PENDULUM

ELECTRONIC CLOCK GENERATION
2.1 MHz

QUARTZ
CRYSTAL
16.8 MHZ

ZERO I.F.
SPI-CLOCK

F REF OUT

SPI-CLOCK

AUDIO SIGNALLING FILTER IC
ELECTRONIC CLOCK GENERATION,
PROGRAMMABLE RANGE:
1200 Hz to 32.769 MHz (1200 Hz STEPS)
uP-CLOCK

MC68HC11F1 MICRO
CONTROLLER
ELECTRONIC GENERATION
OF E AND SPI CLOCKS

SLIC IVa OR
SLIC V

68HC11K4 uP
(not placed in
this application)

D/A

E-CLOCK
SPI-CLOCK

CONTROLLER
Figure 7-1 Clock Distribution Block Diagram
On the controller there are 2 ICs on the SPI BUS, ASFIC (U0200-F2) and D/A
(U0551-6). In the UHF and VHF RF sections there are 3 ICs on the SPI BUS, ZIF
(U3201-21), Pendulum (Reference Oscillator U5800-23) and FRAC/N (U58014). For the 800 and 900 MHz radios the 3 ICs on the SPI BUS are: ZIF (U6201),
Pendulum (Reference Oscillator U6704) and FRAC/N (U6702). The SPI TX
DATA and CLK lines going to the RF section are filtered by R0403 and R0404
to minimize noise.
There are 2 chip select lines going to each of the 2 Option boards (J0401-21
and J0401-23 /and J0408-21 and J0408-23).
When the µ P needs to program any of these ICs it brings the chip select line
for that IC to a logic 0 and then sends the proper data and clock signals. The
amount of data sent to the various ICs are different, for example the ASFIC can
receive up to 21 bytes (168 bits) while the ZIF can receive up to 5 bytes (40
bits). After the data has been sent the chip select line is returned to a logic 1.
The Option board interfaces are different in that the µ P can also read data back
from devices connected. Two additional interrupt lines are provided to each of
the 2 option boards ASN INT (J0401-22 and J0408-22) and JABBA INT(J040120 J0408-20) are provided to allow an option to signal the µ P that there is data
to transfer.

7-10

Controller Section Theory of Operation

The timing and operation of this interface is specific to the option connected,
but generally follows the pattern 1) an option board device generates the
interrupt, 2) main board asserts a chip for that option board device, 3) the
main board µ P generates the CLK, and 4) when data transfer is complete the
main board terminates the chip select and CLK activity. Typical Data rate for
the SPI BUS is 1 Megabit/sec.

SB9600 Serial
Interface

(Refer to schematics on page 10-27 and 10-19 for reference and to SB9600 BUSY
Simplified Schematic on page 9-27)
The SB9600 serial interface allows the radio to communicate with external
radio options (like a control head) and Radio Service Software (RSS). This
interface connects to both the Control Head connector (J0405) and the
Accessory connector (J0403) and comprises BUS+ (J0405-15/J0403-6), BUS(J0405-4/J0403-18), BUSY (J0405-14/J0403-5) and RESET (J0405-3/J0403-17).
All of these lines are bidirectional, meaning that either the radio or an option
can drive the line.
When the radio needs to send a message (for example to update the Control
Head display) it first checks BUSY IN (U0103-76/U0003-A4) to make sure the
interface is not currently being used. If this input is a logic 1 the interface is
available and the µ P will change BUSY OUT (U0104-G4/U0003-29) to a logic
0. This drives the BUSY line to a logic 1 through buffer transistor Q0406
informing the radio and all connected devices that a data transmission is
starting.
The radio’s µ P then starts sending serial data on SCI TX (U0103-64/U0003- 83).
This data is buffered by Q0402 and drives the differential bus signals (BUS+/
BUS-) through Q0401 and Q0400. The BUS+ line normally sits at +5 volts
because of pull-up resistor R0407. The BUS- line normally sits at 0 Volts
because of pull-down resistor R0412.
While the radio is sending serial data on SCI TX it receives an “echo” of the
same data on the SCI RX (U0103-63/U0003-82) line. The BUS-, BUS+ lines go
to U0401 which acts as a comparator. When the BUS+ voltage is greater than
the BUS- voltage the output (at U0401-7) is a logic 1. If it is less, the output is
a logic 0. This is routed through U0105 to µ P (U0103). Note that the SCI
SELECT input to U0105-11 is at a logic 1 to allow the routing to the controller
on BUS SCI (U0105- 13).
A total of 5 bytes of data are sent for each standard message. After the data is
sent the BUSY line is released to its default state (a logic 0). Other devices are
now free to use the interface to send data.
The same method of operation occurs when an option sends data to the radio
on this interface. The data is received through U0401 and U0105 (or R0020/
R0021) to the SCI RX input of the µ P.
The sender receives back an “echo” of each byte and compares this to what
was sent. If the echo does not agree then the transmission is repeated at a later
time.
If excessive transmission errors occur, the µ P will reset the interface by setting
the RESET OUT (U0104-B7/U0003-43) line to a logic 0. This drives the RESET
line to a logic 1 through buffer transistor Q0408 resetting all SCI devices
connected.

Controller Section Theory of Operation

7-11

An option can reset the radio by driving the LH RESET line to a logic 1. This
gets buffered by Q0409 and Q0425 and goes to the reset input of SLIC (U0104A8). This then causes the reset input of the µ P (U0103-50) RESET to go to a
logic 0 resulting in the µ P restarting operation.

General Purpose
Input/Output

(Refer to IO Buffers schematic page 10-28 for reference)
Five general purpose I/O lines (GP I/O 2 through GP I/O 6) are provided to
interface to external options. Each of these lines is configured under software
control to be either an input or an “open collector” output. To make an I/O
line an input the corresponding output line is set to a logic 0; for example to
make GP I/O 6 (J0403-7) an input pin, OUT 6 (U0104-K8/U0003-24) is set to a
logic 0. This turns off Q0423 and allows an external device to either turn on
or off Q0424 which is sensed by U0104-H2/U0003-36 IN6/RTSB.
The GP I/O 2 line is different to the other 4 GP I/O lines. The output transistor
(Q0425) can drive an external relay (HLN4435 or similar) for use with the
vehicle horn or lights. This can also drive a non relay device, but the device
must be designed to take a SW B+ input.
Selected GP I/O lines have secondary functions. If the line is used for the
secondary function then it can not be used as an I/O line. The following
secondary functions are supported (not all radio models support the RS-232
function, refer to the description for your radio).
Table 7-2

Secondary I/O Functions

I/O line

Standard

VRM500

VRM100

Alternate

Flashport

GP I/O 2

Horn/Lights

Horn/Lights

Horn/Lights

External
Alarm Out

n/a

GP I/O 3

PTT

Data PTT

Data PTT

n/a

Bootstrap Vpp

GP I/O 4

Not Used

Not used

Data Mode
Request
(Modem)

RS-232
TX Data

Bootstrap Data

GP I/O 5

Car Radio
Mute

Not used

Transmit
Enable
(Modem)

RS-232
CTS

n/a

GP I/O 6

Hub-Monitor Not used

Channel
Grant
(Modem)

RS-232
RTS

n/a

The 470 pF and 10 nF capacitors serve to filter out any AC noise which may
ride on the GPIO lines.

Microprocesso
r Operation
(Refer to schematic
page 10-19 for
reference)

7-12

For this radio, the µ P, U0103, is configured to operate in one of two modes,
expanded and bootstrap. In expanded mode the µ P uses external memory
devices to operate, whereas in bootstrap operation the µ P uses only its internal
memory. In normal operation of the radio the µ P is operating in expanded
mode as described below. See “Bootstrap Microprocessor Operation” on
page 7-16 for bootstrap information.

Controller Section Theory of Operation

Normal
(=Expanded)
Microprocessor
Operation

In expanded mode on this radio, the µ P has access to 3 external memory
devices; U0100 (EEPROM), U0101 (SRAM) U0102 (FLASH EEPROM). In
addition the µ P has access to U0104 (SLIC). Also, within the µ P there are 1
Kbytes of internal RAM and 512 bytes of internal EEPROM, as well as logic to
select external memory devices.
The external EEPROM (U0100) as well as the µ P’s own internal EEPROM space
contain the information in the radio which is customer specific, referred to as
the codeplug. This information consists of items such as: 1)what band the
radio operates in, 2)what frequencies are assigned to what channel, and 3)
tuning information. In general, tuning information and other more
frequently accessed items are stored in the internal EEPROM (space within the
68HC11F1), while the remaining data is stored in the external EEPROM. (See
the particular device subsection for more details.)
The external SRAM (U0101) as well as the µ P’s own internal RAM space are
used for temporary calculations required by the software during execution. All
of the data stored in both of these locations is lost when the radio powers off
(See the particular device subsection for more details).
The FLASH EEPROM (U0102) contains the actual Radio Operating Software.
This software is common to all radios within a given model type. For example
Securenet radios may have a different version of software in the FLASH ROM
than a non-secure radio (See the particular device subsection for more details).
The µ P provides an address bus of 16 address lines (A0-A15), and a data bus of
8 data lines (D0-D7). There are also 5 control lines; CSPROG (U0103-53),
CSGEN (U0103-54), CSI01 (U0103-55), E CLK (U0103-34), and RWBIN
(U0103-35). CSPROG and CSI01 are used to chip select the SLIC, CSGEN is
used to chip select the SRAM. E CLK and RWBIN are used to generate the
proper timed control signals to the memory devices. E CLK is generated by the
microprocessor based on µ P CLK and is always 1/4 the frequency of µ P CLK,
e.g. if µ P CLK is 7.3728 MHz, then E CLK will be 1.8432 MHz.
When the µ P is functioning normally, the address and data lines should be
toggling at CMOS logic levels. Specifically, the logic high levels should be
between 4.8 and 5.0 V, and the logic low levels should be between 0 and 0.2 V.
No other intermediate levels should be observed, and the rise and fall times
should be <30 ns.
The low-order address lines (A0-A4) and the data lines (D0-D7) should be
toggling at a high rate, e. g., you should set your oscilloscope sweep to 1 us/
div. or faster to observe individual pulses. High speed CMOS transitions
should also be observed on the µ P control lines.
On the µ P the lines XIRQ (U0103-51), BOOTSTRAP (U0103-58) and RESET
(U0103-50) should be high at all times during normal operation. However, the
XIRQ line is a non maskable interrupt and can be low during interrupt.
Whenever a data or address line becomes open or shorted to an adjacent line,
a common symptom is that the RESET line goes low periodically, with the
period being in the order of 20 msecs. In the case of shorted lines you may also
detect the line periodically at an intermediate level, i.e. around 2.5 V when 2
shorted lines attempt to drive to opposite rails.
The MODA (U0103-33) and MODB (U0103-32) inputs to the µ P must be at a
logic 1 for it to start executing correctly. After the µ P starts execution it will
periodically pulse these lines. While the Central Processing Unit (CPU) is
Controller Section Theory of Operation

7-13

running, this signal is an open-drain CMOS output which goes low whenever
the µ P begins a new instruction (an instruction typically requires 2-4 external
bus cycles, or memory fetches). However, since it is an open-drain output, the
waveform rise assumes an exponential shape similar to an RC circuit.
There are 8 analog to digital converter ports (A/D) on U0103. They are labelled
within the device block as PE0-PE7. These lines sense the voltage level ranging
from 0 to 5 V of the input line and convert that level to a number ranging
from 0 to 255 which can be read by the software to take appropriate action.
For example U0103-23 is the battery voltage detect line. R0417 and R0416
form a resistor divider on SWB+. With 68K and 22K and a voltage range of 11 V
to 17 V, that A/D port would see 2.68 V to 4.15 V which would then be
converted to ~136 to 211 respectively.
U0103-30 is the high reference voltage for the A/D ports on the µ P. Resistor
R0112 and capacitor C0104 filter the +5 V reference. If this voltage is lower
than +5 V the A/D readings will be incorrect. Likewise U0103-29 is the low
reference for the A/D ports. This line is normally tied to ground. If this line is
not connected to ground, the A/D readings will be incorrect.
Capacitor C0105 serves to filter out any AC noise which may ride on +5V at
U0103.

Support Logic IC
(SLIC)

The SLIC (U0104) provides 3 primary functions, I/O port expansion, memory
address expansion, and some signalling decoding.
There are 32 I/O lines within the SLIC which are under µ P control. They are
grouped in 4 blocks of 8 and labelled as SLIC ports H, J, K, and L. Ports J, K,
and L each have a DDR memory register and a “value” register. Port H only has
a “value” register. These ports are accessed by the µP by placing the correct
address for the I/O registers on the address bus and either reading or writing
the data on the data bus. Changing bits in the DDR registers configures specific
port bits to be either input sensors or output drivers. The “value” registers
either report the state of the sensed input or provide the logic level to be
driven on a line configured as an output.
Since the 68HC11F1 only has 16 address lines (A0-A15), it can only directly
address 64 Kbytes(=2^16) of external memory. The radio architecture is
designed to accommodate over 2 Mbytes of memory. The SLIC contains logic
which allows addressing of the memory which would otherwise be
unavailable to the µP on its own. The SLIC monitors address lines A0, A1, A2,
A3, A4, A14, and A15. Depending on what combinations appear on those
lines, the SLIC may or may not assist the µP with addressing. When the µP is
addressing a device on its own then address lines A0-A15 are used and valid.
If instead the SLIC is assisting with the addressing then address lines A0-A13
from the µP are valid, but the upper order address lines A14 OUT, A15 OUT,
A16, A17, A18, and if necessary A19 are provided from the SLIC. There is no
conflict with A14 and A14 OUT or with A15 and A15 OUT. Notice for example
that SRAM U0101 uses A14 meaning that line is always provided from the µP
directly. Notice also that EEPROM U0100 and FLASH ROM U0102 use A14
OUT, meaning that their address lines come from the SLIC. On the SLIC itself,
line A14 going to A14IN and A15 going to A15IN are address input lines TO
the SLIC. Whereas A14 OUT and A15 OUT are address output lines FROM the
SLIC.
The SLIC also generates chip select signals UV CS for U0102 and EE CS for
U0101, as well as memory timing signals MEMRWB and OE.

7-14

Controller Section Theory of Operation

The circuitry in the SLIC is reset when either the RESET IN (U0104-A8) is a
logic 1, or RESET* (U0104-E4) is a logic 0, or PWR RST is a logic 0. These lines
must be in the opposite logic state for the SLIC to function normally.
The SLIC supports hardware signalling decoding for certain signalling
standards such as MPT 1327 and Trunking (OSW). There are different versions
of SLIC each having a different decoder. Currently there are no SLIC devices
which have more than 1 decoder.
The incoming data received by the radio and filtered by the ASFIC exits the
ASFIC at U0200-G4 RX DATA, and enters the SLIC at U0104-B6. Based on the
data the SLIC updates internal status registers which the µP can read using the
address and data bus, and act upon it.
Notice that RX data also goes to U0103-77/U0003-C5. This implies that the
radio can be configured to perform software decoding if desired, even if the
radio has a SLIC with a hardware decoder in it.
Capacitor C0108 serves to filter out any AC noise which may ride on +5V at
U0104.

FLASH Electrically
Erasable
Programmable
Memory (FLASH
EEPROM)

The FLASH EEPROM (U0106) contains the radio’s operating software. This
software is common to all radios within a given model type. For example
Securenet radios may have a different version of software in the FLASH ROM
than a non-secure radio. This is, as opposed to the codeplug information
stored in EEPROM (U0100) which could be different from one user to another
in the same company.
In normal operating mode, this memory is only read, not written to. In
bootstrap mode the Vpp pin (U0106-11) is brought to 12 V to allow the device
to be written to. The memory access signals (UV CS, OE and MEMRWB) are
generated by the SLIC. To upgrade/reprogram the FLASH software, the µP must
be set in bootstrap operating mode, and the FLASH device pin (U0106-11) Vpp
must be between 11.4 and 12.6 V.
Taking diode CR0105 into account, the voltage at J0403-21 to enable FLASH
programming may range between 12.1 and 13.1 V. Resistor divider pair R0104
and R0105 set up 4.1 V on U0106-11 which reduces the chance of logic
transitions on I/O3 used as a GPIO from affecting the FLASH Vpp port. The
FLASH device may be reprogrammed 1,000 times without issue. It is not
recommended to reprogram the FLASH device at a temperature below 0°C.
(See “Bootstrap Microprocessor Operation” on page 7-16 for further details on
reprogramming of the FLASH EEPROM)
Capacitor C0102 serves to filter out any AC noise which may ride on +5V at
U0102, and C0107 filters out any AC noise on Vpp.

Electrically
Erasable
Programmable
Memory (EEPROM)

The EEPROM (U0100) contains the radio’s operating parameters such as
operating frequency and signalling features, commonly know as the codeplug.
It is also used to store radio operating state parameters such as current mode
and volume. U0100 is a 32 Kbyte device. This memory can be written to in
excess of 100,000 times and will retain the data when power is removed from
the radio. The memory access signals (EE CS, OE and MEMRWB) are generated
by the SLIC.

Controller Section Theory of Operation

7-15

Additional EEPROM is contained in the µP (U0103). This EEPROM is used to
store radio tuning and alignment data. Like the external EEPROM this
memory can be programmed multiple times and will retain the data when
power is removed from the radio.
Note: the external EEPROM plus the 512 bytes of internal EEPROM in the
68HC11F1 comprise the complete codeplug.

Static Random
Access Memory
(SRAM)

The SRAM (U0101) contains temporary radio calculations or parameters that
can change very frequently, and which are generated and stored by the
software during its normal operation. The information is lost when the radio
is turned off. The device allows an unlimited number of write cycles. SRAM
accesses are indicated by the CSGEN signal U101-20 (which comes from
U0103-54) going low. U0101 is commonly referred to as the external RAM as
opposed to the internal RAM which is the 1 K (1024) bytes of RAM which is
part of the µP. Both RAM spaces serve the purpose. However, the internal RAM
is used for the calculated values which are accessed most often.
Resistors R0100, R0101, and R0102 allow the board to be configured to accept
either an 8 K or 32 K byte EEPROM. For a 32 K device, R0100 is placed, and
R0102 and R0101 are NOT placed. For an 8 K device R0100 is NOT placed, and
R0102 and R0101 are placed.
Capacitor C0100 serves to filter out any ac noise which may ride on +5 V at
U0101

Bootstrap
Microprocessor
Operation

7-16

The bootstrap mode of operation is only used to load new software into the
FLASH EEPROM (U0106 or U0102). The MODA (U0103-33) and MODB
(U0103-32) inputs must be a logic 0 when the microprocessor comes out of
reset. The microprocessor will wait to receive data on its SCI RX (U0103-63)
line and as data is received, it will be echoed on the SCI TX (U0103-64) line.
For example, when the Smart RIB (SRIB) is used to load new software into the
FLASH EEPROM, the signals to the microprocessor are automatically
controlled by the SRIB to enter this mode. First the SRIB brings the SCI RX
DATA (J0403-19) above 12 volts. This turns on dual transistor Q0103 to bring
the MODA and MODB lines and the SCI SELECT line to a logic 0. The SRIB
then releases the LH RESET (J0403-17) line and begins transferring the data to
the radio. Data from the SRIB goes to GP I/O 4 (J0403-20) and data to the SRIB
comes from the BUS+ and BUS- lines (J0403-6 and J0403-18). After an initial
data transfer, the SRIB will bring the Vpp line (J0403-21) to 12.5 volts and start
loading the data to be stored in the FLASH. The microprocessor will verify that
each of the FLASH EEPROM memory locations are programmed correctly.

Controller Section Theory of Operation

Audio and
Signalling
Circuits

(Refer to ASFIC schematic page 10-23 for reference)

Audio Signalling
Filter IC (ASFIC)

The ASFIC has 4 functions;
1.

RX/TX audio shaping, i.e. filtering, amplification, attenuation

2.

RX/TX signalling, PL/DPL/HST/MDC/MPT

3.

Squelch detection

4.

Microprocessor clock signal generation (see Microprocessor Clock
Synthesizer Description Block).

The ASFIC is programmable through the SPI BUS (U0200-E3/F1/F2), normally
receiving 21 bytes. This programming sets up various paths within the ASFIC
to route audio and/or signalling signals through the appropriate filtering, gain
and attenuator blocks. The ASFIC also has 6 General Control Bits GCB0-5
which are CMOS level outputs. In this radio all, except GCB2 used for AUX TX
IN2 (see Aux TX), are used to control the Hear Clear IC. (See Hear Clear
Description Block for details).

Audio Ground
(Refer to schematic
page 10-25 for
reference)

Transmit Audio
Circuits
(Refer to schematic
page 10-23 for
reference)

VAG is the dc bias used as an audio ground for the op-amps that are external
to the Audio Signalling Filter IC (ASFIC). U0201 forms this bias by dividing
9.3 V with R0206 and R0207 and buffering the 4.65 V result with a voltage
follower. VAG emerges at pin 1 of U0201. C0235 is a bypass capacitor for VAG.
The ASFIC generates its own 2.5 V bias for its internal circuitry. C0210 is the
bypass for the ASFIC’s audio ground dc bias. Note that while there are ASFIC
VAG, BOARD VAG (U0201), and Hear Clear VAG, each of these are separate.
They do not connect together.
(Refer to Figure 7-2 for reference for the following sections)
The radio supports 2 distinct microphone paths known as internal and
external mic. The microphones used for the radio require a DC biasing voltage
provided by R0222 and R0223 for internal, and R0231 and R0230 for external.
These two microphone audio input paths enter the ASFIC at U0200-A7
(external mic) and U0200-B8 (internal mic). Following the internal mic path;
the microphone is plugged into the radio control head and is connected to the
controller board via J0405-9.
From here the signal is routed to R0224. R0222 and R0223 provide the
9.3 VDC bias and R0224 provides input protection for the CMOS amplifier
input. R0223 and C0219 provide a 560 ohm AC path to ground that sets the
input impedance for the microphone and determines the gain based on the
emitter resistor in the microphone’s amplifier circuit.
Filter capacitor C0224 provides lowpass filtering to eliminate frequency
components above 3 kHz, and C0218 serves as a DC blocking capacitor. C0427
bypasses RF interference which may couple onto the line to ground. The audio
signal at U0200-B8 should be approximately 80 mV to achieve 60% of
maximum system deviation.
The ASFIC has an internal AGC that can control the gain in the mic audio
path. The AGC can be disabled/enabled by the µP. Another feature that can be
Controller Section Theory of Operation

7-17

enabled or disabled in the ASFIC is the VOX. This circuit, along with C0205,
provides a DC voltage that can allow the µP to detect microphone audio. The
ASFIC can also be programmed to route the microphone audio to the speaker
for public address operation.

External Mic Path

The external microphone signal enters the radio on accessory connector J0403
pin 23. It is then routed to the ASFIC through resistor R0229 and capacitors
C0223 and C0221, with DC bias provided by R0231/R0230

PTT Sensing and
TX Audio
Processing

Mic PTT is sensed via SB9600. An external PTT can be generated by
programming one of the digital I/O lines on the accessory connector for PTT
and grounding that pin. When microphone PTT is sensed, the µP will always
configure the ASFIC for the “internal” mic audio path, and external PTT will
result in the external mic audio path being selected.

.
J405

D3 COMP BUF IN

HEARCLEAR - I
IC
U0250

HPF

9

MIC

COMP OUT

CONTROL HEAD
CONNECTOR

F3

J403

A6

13

C7
TX IN

MIC AMP OUT
23

EXT MIC

B8

MIC IN

FILTERS AND
PREEMPHASIS

24

AUX TX

A7

EXT MIC IN

ACCESSORY
CONNECTOR

LS SUMMER

J401
14

AUX TX

ASFIC
U0200

D7

SPLATTER
FILTER

AUX TX IN

HS SUMMER
LIMITER

INTERNAL OPTION
CONNECTOR

PRE EMP OUT

VCO ATN H8
ATTENUATOR

AUDIO MOD

TO
RF
SECTION
(VCO)

LIM IN

C8

E8

J408
AUX TX

14

INTERNAL OPTION
CONNECTOR

Figure 7-2

Transmit Audio Paths

Inside the ASFIC, the mic audio is filtered to eliminate components outside the
300-3000 Hz voice band, and pre-emphasized if pre-emphasis is enabled. The
7-18

Controller Section Theory of Operation

capacitor between ASFIC pre-emphasis out U0200-C8 and ASFIC limiter in
U0200-E8 AC couples the signal between ASFIC blocks and prevents the DC
bias at the ASFIC output U0200-H8 from shifting when the ASFIC transmit
circuits are powered up. The signal is then limited to prevent the transmitter
from over deviating. The limited mic audio is then routed through a summer,
used to add in signalling data, and then to a splatter filter to eliminate high
frequency spectral components that could be generated by the limiter. The
audio is then routed to two attenuators, which are tuned in the factory or the
field to set the proper amount of FM deviation. The TX audio emerges from
the ASFIC at U0200-H8 AUDIO MOD, at which point it is routed to the RF
section.

Auxiliary TX Audio
Paths

There are three auxiliary transmit audio inputs that are routed to the auxiliary
transmit path in the ASFIC. These are AUX TX IN1, AUX TX IN2, and AUX TX
IN3. The 3 paths, only one of which can be active at a time, are buffered by
U0202.
AUX TX IN2 is special in that it can “change” input impedance. The “voltage
mode” signal to U0400 is 9.3 V if the source for the auxiliary transmit audio
from J0403 is a current source. The “voltage mode” signal is 0 V if the auxiliary
transmit source is a voltage source. The difference being R0219 is bypassed by
the transmission gate or not. Typically current source mode will apply for
SB9600 based devices.
C0217 sets the lower frequency (high pass) signal of approximately 1 Hz. The
processing of the signal on the auxiliary transmit path depends on how the
ASFIC is configured. It can bypass filters, pre-emphasis, limiter, and/or splatter
filter.

TX Secure Audio
(AUX TX IN1 and
AUX TX IN3)

The audio follows the normal transmit audio processing until it emerges from
the ASFIC pre-emphasis out pin (U0200-C8), which is fed to the secure board
residing at either option connector J0401-7 / J0403-7. The Secure board
contains circuitry to amplify, digitize, encrypt, and filter the audio. The
encrypted signal is then fed back from J0401-14 / J0408-14 to the AUX TX
buffer through R0217 or R0218, and then to the ASFIC AUX TX input (U0200D7). The signal level at this pin should be about 1 Vpp. The signal is then
routed through the AUX TX path in the ASFIC (which bypasses everything
before including the ASFIC splatter filter) and summed into the main
modulation path. After the summer, it runs through the modulation
attenuator and then to the AUDIO MOD port U0200-H8.

Transmit
Signalling Circuits

(Refer to Figure 7-3 for reference for the following sections)
There are four types of transmit data:
1.

Sub-audible data (PL/DPL/Connect Tone) that gets summed with
transmit voice or signalling,

2.

High speed (3600 baud) data for trunking control channel
communication

3.

DTMF data for telephone communication in trunked and conventional
systems, and

4.

MDC data for use in Motorola proprietary MDC systems. Select 5 and
MPT-1327 signalling can be supported by the MDC signaling hardware.

Controller Section Theory of Operation

7-19

Sub-audible Data
(PL/DPL)

Sub-audible data implies signalling whose bandwidth is below 300 Hz. PL and
DPL waveforms are used for conventional operation and connect tones for
trunked voice channel operation. The trunking connect tone is simply a PL
tone at a higher deviation level than PL in a conventional system. Although it
is referred to as “sub-audible data,” the actual frequency spectrum of these
waveforms may be as high as 250 Hz, which is audible to the human ear.
However, the radio receiver filters out any audio below 300 Hz, so these tones
are never heard in the actual system.
Only one type of sub-audible data can be generated by U0200 at any one time.
The process is as follows, using the SPI BUS, the µP programs the ASFIC
(U0200) to set up the proper low-speed data deviation and select the PL or DPL
filters. The µP then generates a square wave which strobes the ASFIC PL/DPL
encode input PL CLK U0200-C3 at twelve times the desired data rate. For
example, for a PL frequency of 103 Hz, the frequency of the square wave would
be 1236 Hz.
This drives a tone generator inside U0200 which generates a staircase
approximation to a PL sine wave or DPL data pattern. This internal waveform
is then lowpass filtered and summed with voice or data. The resulting summed
waveform then appears on U0200-H8 (AUDIO MOD), where it is sent to the
RF board as previously described for transmit audio. A trunking connect tone
would be generated in the same manner as a PL tone.

High Speed Data

High speed data refers to the 3600 baud data waveforms, known as Inbound
Signalling Words (ISWs) used in a trunking system for high speed
communication between the central controller and the radio. To generate an
ISW, the uP first programs the ASFIC (U0200) to the proper filter and gain
settings. It then begins strobing U0200-G1 (TX DATA) with a pulse

HS
SUMMER

G1 HIGH SPEED
CLOCK IN
MICRO
CONTROLLER

G2 DTMF
CLOCK

5-3-2 STATE
ENCODER
DTMF
ENCODER

SPLATTER
FILTER

ASFIC
U0200
C3 LOW SPEED
CLOCK

PL
ENCODER

LS
SUMMER
ATTENUATOR

Figure 7-3

H8

AUDIO MOD

TO RF
SECTION
(VCO)

Transmit Signalling Paths

when the data is supposed to change states. U0200’s 5-3-2 State Encoder
(which is in a 2-state mode) is then fed to the post-limiter summer block and
then the splatter filter. From that point it is routed through the modulation
attenuators and then out of the ASFIC to the RF board. MPT 1327 and MDC
are generated in much the same way as Trunking ISW. However, in some cases
7-20

Controller Section Theory of Operation

these signals may also pass through a data pre-emphasis block in the ASFIC.
Also these signalling schemes are based on sending a combination of 1200 Hz
and 1800 Hz tones only. Microphone audio is muted during High Speed Data
signalling.

Dual Tone
Multiple
Frequency (DTMF)
Data

DTMF data is a dual tone waveform used during phone interconnect
operation. It is the same type of tones which are heard when using a “Touch
Tone” telephone.
There are seven frequencies, with four in the low group (697, 770, 852, 941 Hz)
and three in the high group (1209, 1336, 1477 Hz).
The high-group tone is generated by the µP (U0103-74 /U0003-B4) strobing
U0200-G1 at six times the tone frequency for tones less than 1440 Hz or twice
the frequency for tones greater than 1440 Hz. The low group tone is generated
by the µP (U0103-73/U0003-C4) strobing U0200-G2 (DTMF CLOCK) at six
times the tone frequency. Inside U0200 the low-group and high-group tones
are summed (with the amplitude of the high group tone being approximately
2 dB greater than that of the low group tone) and then pre-emphasized before
being routed to the summer and splatter filter. The DTMF waveform then
follows the same path as was described for high-speed data.

MDC Data

The MDC signal follows exactly the same path as the DTMF high group tone.
MDC data utilizes MSK modulation, in which a logic zero is represented by
one cycle of a 1200 Hz, and a logic one by 1.5 cycles of an 1800 Hz. To generate
the data, the microcontroller first programs the ASFIC (U0200) with TXSG1
and TXSG0 control lines to the proper filter and gain settings. It then begins
strobing U0200/Trunking Clock In with a pulse every time there should be a
transition in the MDC waveform. The output waveform from U0200's 5-3-2
State Encoder is then fed to the post-limiter summer block and then the
splatter filter. From that point it is routed through the modulation attenuators
and then out of the ASFIC to the RF board. Microphone audio is muted during
MDC signalling.

Receive Audio
Circuits

(Refer to Figure 7-4 for reference for the following sections)

Squelch Detect

The radio’s RF circuits are constantly producing an output at the discriminator.
In addition to the raw discriminator signal DISC (IF1-3-2-1), the RF board’s
Zero IF IC also provides a separate buffered version of the discriminator signal
that is dedicated to the ASFIC’s squelch detect circuitry SQUELCH (IF1-2-171). This signal enters the controller board and is routed to the ASFIC on
U0200-H7. All of the squelch detect circuitry is contained within the ASFIC.
Therefore from a user’s point of view, SQUELCH enters the ASFIC, and the
ASFIC produces to CMOS logic outputs based on the result. They are CH ACT
(U0200-H1) and SQ DET (U0200-H1).
The squelch signal entering the ASFIC is amplified, filtered, attenuated, and
rectified. It is then sent to a comparator to produce an active high signal on
CH ACT. A squelch tail circuit is used to produce SQ DET (U0200-H1) from CH
ACT. The state of CH ACT and SQ DET is high (logic 1) when carrier is
detected, otherwise low (logic 0). Both CH ACT and SQ DET are routed to the
SLIC (U0104-F4/H1).

Controller Section Theory of Operation

7-21

SQ DET is used to determine all audio mute/unmute decisions except for
Conventional Scan. In this case CH ACT is a pre-indicator as it occurs slightly
faster than SQ DET.

Audio Processing
and Digital Volume
Control

The signal enters the controller section from the ZIF on DISC (IF1-3-2-1) and
passes through RC filter R0245 and C0236 which filters out ZIF sampling
noise. The signal is AC coupled by C0202 and enters the ASFIC via the PL IN
pin U0200-J7. Inside the IC, the signal goes through 2 paths in parallel.

J403
J401
9 AUX RX

12
11
25

10 DISC (GAIN CONTROLLED)
1

5 DISC

J408
9
10
5

AUX RX
FILTERED AUDIO
UNIV IO OUT

AUDIO 4
PA
U0203 6

SPKR -

3

SPKR +

1

EXTERNAL
SPEAKER

9

AUX RX

2

DISC (GAIN CONTROLLED)
ACCESSORY
CONNECTOR

DISC

INTERNAL
OPTION
CONNECTORS

INT
SPKR+

ATTEN.

J405
1

INTERNAL
SPEAKER

2
8

C1
EXP
IN

H5
UNAT
RX OUT

HEARCLEAR - I
IC
U0250

EXP OUT A2
FF OUT F4

J5 EXP AUD IN
H6 RX IN

FFIN

E4

J7

B2
UNIV
IO

CONTROL
HEAD
CONNECTOR

J4
RX AUD
OUT

VOLUME
ATTEN.

FILTER AND
DEEMPHASIS

PL IN

HANDSET
AUDIO

ASFIC
U0200

J6 AUX RX IN
LIMITER, RECTIFIER
FILTER, COMPARATOR
SQ IN

H7

DISC (DISCRIMINATOR AUDIO)
FROM
RF
SECTION
(ZIF)

SQUELCH
CIRCUIT
CH
ACT

H2

SQ
DET

H1

MICRO
CONTROLLER

SQUELCH

Figure 7-4

Receive Audio Paths

The audio path has a programmable amplifier, whose setting is based on the
channel bandwidth being received, then a LPF filter to remove any frequency
components above 3000 Hz and then an HPF to strip off any sub-audible data
below 300 Hz. Next, the recovered audio passes through a de-emphasis filter if
it is enabled (to compensate for Pre-emphasis which is used to reduce the
effects of FM noise). The IC then passes the audio through the 8-bit
7-22

Controller Section Theory of Operation

programmable attenuator whose level is set depending on the value of the
volume control. Finally the filtered audio signal passes through an output
buffer within the ASFIC. The audio signal exits the ASFIC at RX AUDIO
(U0200-J4).
The µP programs the attenuator, using the SPI BUS, based on SB9600 messages
from the control head. The minimum /maximum settings of the attenuator
are set by codeplug parameters.
Since sub-audible signalling is summed with voice information on transmit, it
must be separated from the voice information before processing. Any subaudible signalling enters the ASFIC from the ZIF at PL IN U0200-J7. Once
inside it goes through the PL/DPL path. The signal first passes through one of
2 low pass filters, either PL low pass filter or DPL/LST low pass filter. Either
signal is then filtered and goes through a limiter and exits the ASFIC as PL RX
(U0200-A4). At this point the signal will appear as a square wave version of the
sub-audible signal which the radio received. This signal then goes to the SLIC
(U0104-E7). The SLIC must be poled periodically by the microprocessor to
determine the state of bit 0 for port L (see SLIC description block for details).
The microprocessor will then use that information to decode the signal.
Note these paths are somewhat different for radios using Hear Clear (See Hear
Clear description block for details).

Audio
Amplification
Speaker (+) / (-)
(Refer to schematic
page 10-29 for
reference)

The output of the ASFIC’s digital volume pot, U0204-J4 is routed through a
voltage divider formed by R0234 and R0235 to set the correct input level to
the audio PA (U0203). This is necessary because the gain of the audio PA is 46
dB, and the ASFIC output is capable of overdriving the PA unless the
maximum volume is limited.
The audio then passes through C0240 which provides AC coupling and low
frequency roll-off. C0242 provides high frequency roll-off as the audio signal
is routed to pins 1 and 9 of the audio power amplifier U0203.
The audio power amplifier has one inverted and one non-inverted output that
produces the differential audio output SPK+/SPK- (U0203-4/6). The inputs for
each of these amplifiers are pins 1 and 9 respectively; these inputs are both tied
to the received audio. The audio PA’s DC biases are not activated until the
audio PA is enabled at pin 8.
The audio PA is enabled via AUPA EN signal from the SLIC (U0104-F7). When
the base of Q0200 is low, the transistor is off and U0203-8 is high, using pull
up resistor R0236 — Audio PA is ON. The U0203-8 must be above 8.5 VDC to
properly enable the device. If the voltage is between 3.3 and 6.4 V, the device
will be active but has its input (U0203-1/9) off. This a mute condition which
is not employed in this radio design. R0202 ensures that the base of Q0202 is
high on power up. Otherwise there may be an audio pop due to R0236 pulling
U0203-8 high before the software can switch on Q0200.
The SPK+ and SPK- outputs of the audio PA have a DC bias which varies
proportionately with A+ CONT (U0200-7). A+ CONT of 11 V yields a DC offset
of 5 V, and A+ CONT of 17 V yields a DC offset of 8.5 V. If either of these lines
is shorted to ground, it is possible that the audio PA will be damaged. SPK+ and
SPK- are routed to the accessory connector (J0403-1 and 3). Only the SPK- is
routed to the control head. For the internal (control head) speaker to be
enabled, a jumper must be placed on the accessory connector between pins 1
and 2; this connects SPK+ to the control head’s INT SPK+.
Controller Section Theory of Operation

7-23

Handset Audio
(Refer to schematic
page 10-29 for
reference)

Filtered Audio
(Refer to schematic
page 10-25 for
reference)

Discriminator
Audio (Unfiltered)
(Refer to schematic
page 10-23 for
reference)

Certain hand held accessories have a speaker within them which require a
different voltage level than that provided by U0203. For those devices RX HI
is available at J0405-8.
The received audio from the output of the ASFIC’s digital volume attenuator
is also routed to U0202 pin 6 where it is amplified 15 dB; this is set by the 10k/
68k combination of R0238 and R0237. This signal is routed directly from the
output of the op amp U202 pin 7 to J0405-8. The control head sends this
signal directly out to the microphone jack. The maximum value of this output
is 6.6 Vpp. If the handset is Off-Hook, the audio PA (U0203) is disabled. C0434
is for RF bypass and VR0418 is for static protection.
This signal sources receive audio or Public Address audio to a large Siren PA
accessory.
The ASFIC has an audio whose output at U0200-H5 has been filtered and deemphasized, but has not gone through the digital volume attenuator. This
signal is buffered with an op amp with a gain of 0 dB, within the ASFIC. The
maximum level for this signal is 1.06 Vpp. From ASFIC U0200-H5 the signal is
AC coupled to U0201-6 by capacitor C0214. R0209 and R0203 being equal
value set up the op amp as a unity gain device, i.e. a buffer. The output at
U0201-7 is then routed to J0403-11 FIL AUD OUT. Note that any volume
adjustment of the signal on this path must be done by the accessory.
Note that discriminator audio DISC from the ZIF, in addition to being routed
to the ASFIC, is also routed to the Hear Clear (U0250) and both option
connectors J0408-5 and J0401-5 (See “Hear Clear IC (Refer to schematic page
10-22 for reference)” on page 7-26 and “Secure Receive Audio” on page 7-24 for
further information).

Auxiliary RX
Audio Paths

There are three auxiliary receive audio inputs that are buffered by U202 and
routed to the auxiliary receive path in the ASFIC U0200-J6. The processing for
this input is identical to that of normal received audio or it can bypass the
filtering and de-emphasis. The auxiliary inputs come from the two option
connectors J0408-9 and J0401-9 and from the accessory connector J0403-15.
The “voltage mode” signal to U0400 is 9.3 V if the source for the auxiliary
receive audio from J0403 is a current source. The “voltage mode” signal is 0 V
if the auxiliary receive source is a voltage source. Typically current source
mode will apply for SB9600 based devices. Note that the enable line for
transmission gate U0400-12/10 is the same line VOLTAGE MODE as that
which controls the Auxiliary TX path AUX TX IN2. The VOLTAGE MODE line
is driven by Q0202 which is turned on and off by ASFIC GCB2. In order to
change the state of VOLTAGE MODE the ASFIC (U0200) must be programmed
by the SPI BUS to do so.

Secure Receive
Audio

Discriminator audio, which is now coded audio, enters the ASFIC at U0200-J7.
Inside the ASFIC a path is set up to route the coded audio to a programmable
7 bit attenuator, where the signal level is adjusted, and then out of the ASFIC
at UNIV IO (U0200-B2). This path bypasses the ASFIC RX filtering and
Deemphasis. From U0200-B2 the coded audio goes to Option connectors
J0401-10 / J0408-10.
On the secure board, the coded signal is converted back to analog format, and
then fed back through (J0401-9 / J0408-9) to the Aux Rx buffer U0202. The
clear audio signal is then routed to the ASFIC pin U0200-J6; from then on it

7-24

Controller Section Theory of Operation

follows a path identical to conventional receive audio, where it is filtered (3003 kHz) and deemphasis.

Receive Signalling
Circuits

(Refer to Figure 7-5 for reference for the following sections)
The ASFIC (U0200) is used to filter and limit all received data. The data enters
the ASFIC at U0200-J7. Inside U0200 the data is filtered according to data type
(HS or LS), then it is limited to a 0-5 V digital level. The MDC and trunking
high speed data appear at U0200-G4, where it connects to the µP U0103-77,
software decoder, and U0104-B8, hardware decoder (see SLIC description
block for further details)
The low speed limited data output (PL, DPL, and trunking LS) appears at
U0200-A4, where it connects to the SLIC. While receiving low speed data, the
µP may output a sampling waveform, depending on the sampling technique,
to U0200-C3 of between 1 and 2 kHz.
The low speed data is read by the µP at twice the frequency of the sampling
waveform; a latch configuration in the ASFIC stores one bit every clock cycle.
The external capacitors C0211, C0212, and C0203 set the low frequency pole
for a zero crossings detector in the limiters for PL and HS data. The hysteresis
of these limiters is programmed based on the type of received data. Note that
during HS data the µP may generate a sampling waveform seen at U0200-G1.

C3

G1

LOW SPEED
CLOCK

HIGH SPEED
CLOCK
DATA FILTER
AND DEEMPHASIS
DISC
(DISCRIMINATOR AUDIO
FROM RF SECTION)

J7

PL
IN

RX
G4
LIM OUT

MICRO
CONTROLLER

ASFIC
U0200
FILTER

LOW SPEED
LIM CAP
C5

Figure 7-5

Alert Tone Circuits

LIMITER

PL A4
LIM

LIMITER

RX LIM
CAP
J3

Receive Signalling Paths

When the software determines that it needs to give the operator an audible
feedback (for a good key press, or for a bad key press), or radio status (trunked
system busy, phone call, circuit failures), it sends an alert tone to the speaker.
It does so by sending SPI BUS data to U0200 which sets up the audio path to
the speaker for alert tones. The alert tone itself can be generated in one of two
ways: internally by the ASFIC, or externally using the µP and the ASFIC.

Controller Section Theory of Operation

7-25

The allowable internal alert tones are 304, 608, 911, and 1823 Hz. In this case
a code contained within the SPI BUS load to the ASFIC sets up the path and
determines the tone frequency, and at what volume level to generate the tone.
(It does not have to be related to the setting of the volume knob).
For external alert tones, the µP can generate any tone within the 100-3000 Hz
audio band. This is accomplished by the µP generating a square wave which
enters the ASFIC at U0200-C3.
Inside the ASFIC, this signal is routed to the alert tone generator; the output
of the generator is summed into the audio chain just after the RX audio deemphasis block. Inside U0200 the tone is amplified and filtered, then passed
through the 8-bit digital volume attenuator, which is typically loaded with a
special value for alert tone audio. Note that the Hear Clear expander is
bypassed even if U0250 is present. The tone exits at U0200-J4, then is routed
to the audio PA like receive audio.

Hear Clear IC
(Refer to schematic
page 10-22 for
reference)

The Hear Clear (HC) is typically used for 900 MHz radios. The HC has 3 main
circuit blocks within the IC which are used by this radio; 1) Compressor, 2)
Flutter Fighter, and 3) Expander circuits. There are 6 enable lines on the Hear
Clear IC which determine its mode of operation. The IC ENAB line U0250-C4
is tied to SW B+, so whenever the IC is placed it is always active. The remaining
5 lines are controlled by the ASFIC General Control Bit lines, GCB0, GCB1,
GCB3, GCB4, and GCB5. The table below summarizes their logic states.
Table 7-3 Hear Clear Enable Lines Configuration
Logic State
Name

Ref. Des

Set By

TX1

RX1

TX2

RX2

Ic Enable

U0250-C4

SW B+

1

1

X

1

Flutter Fighter Enable

U0200-B5

U0200-B5

X

1

X

0

LO Clamp Disable

U0250-A5

U0200-B3

1

1

1

X

Hi Clamp Enable

U0250-C2

U0200-C4

0

0

X

0

HCI Disable

U0250-B6

U0200-A3

1

1

X

1

Compander Enable

U0250-D1

U0200-A2

1

1

X

0

TX1: transmit mode with carrier squelch, PL or DPL.
RX1: receive voice with carrier squelch, PL or DPL.
TX2: transmit mode with all other data HST/MDC/MPT/DTMF etc.
RX2: refers to receive mode with all other data HST/MDC/MPT/DTMF
Logic State “X” means either 1 or a 0, i.e. “don’t care”.

Transmit Path for
Radios with Hear
Clear

For transmit, the signal comes from the appropriate microphone and enters
the ASFIC at U0200-A7 or U0200-B6 as would standard TX audio. After
entering the ASFIC, the signal is internally routed to U0200-A6 ASFIC MIC
AMP OUT, where it leaves the ASFIC and enters the Hear Clear compressor at
U0250-D3. The signal then exits the compressor at U0250-F3, where it is
routed back to the ASFIC (U0200-C7). C0261 provides AC coupling. Inside the
ASFIC the signal goes through an LPF and HPF which band limit the signal
between 300 - 3 kHz. The signal is then pre-emphasized and exits the ASFIC at
U0250-C8, passes through a coupling cap and enters the ASFIC at U0200-E8.
Again inside the ASFIC the signal goes through a limiter, splatter filter, and a
pair of attenuators which set the amplitude (deviation level) of the signal.
The Compressor is used in transmit mode. The purpose of this circuit is
twofold; 1) improve S/N ratio for low level audio, and 2) maintain the same

7-26

Controller Section Theory of Operation

dynamic range of a 12.5 kHz bandwidth channel as is obtained in a 25 kHz
bandwidth channel.
The compressor raises low level signals and lowers high level signals. The
compressor circuit produces a signal whose output voltage (U0250-F3) is based
on the input voltage level (U0200-A6) of the signal. It is NOT a function of
frequency (as is Preemphasis). The voltage transfer function is:
COMPOUT == SQRT[ 80*ASFICMICAUDOUT ]
Notice that 80 mV in yields 80 mV out. Some example levels are:

Receive Path for
Radios with Hear
Clear

-

20 mV input == 40 mV output

-

80 mV input == 80 mV output

-

150 mV input == 110 mV output

The audio signal enters the controller from the ZIF on DISC. The discriminated
audio DISC enters the Hear Clear Flutter Fighter through C0200 and C0267.
C0200 connects the signal to FF IN (U0250-E4). C0267 is the beginning of a
noise sampling circuit consisting of components C0267, R0256, R0253,
C0264, C0263, R0254, R0255, R0257, and C0265; and Hear Clear ports Clip
Ref, Noise Filter In, and Noise Filter Out, Noise Hold.
After exiting the HC at FF OUT (U0250-F4), the signal enters the ASFIC at RX
IN (U0200-H6). Within the ASFIC the signal passes through a low pass filter
and a high pass filter limiting the audio band width to 300-3 kHz. It then goes
through deemphasis and exits the ASFIC at U0200-H5 FILTERED AUDIO.
Upon exiting the ASFIC at FILTERED AUDIO, the signal passes through
capacitor C0250, which provides AC coupling. The signal then enters the Hear
Clear at EXP IN (U0250-C1) and exits the Hear Clear Expander at EXP OUT
(U0250-A2). The normalized signal is the routed back to the ASFIC through
C0260 for volume adjustment, entering at U0200-J5 and exiting the ASFIC at
U0200-J4 as RX AUDIO. The audio is then routed to the Audio PA in the same
manner as standard receive audio.
The Flutter Fighter is for receive only. It samples the amount of Noise in the
receive audio between 10 kHz and 20 kHz, using the Noise filter in (U0250-B5),
Noise filter out (U0250-C6), and Noise hold (U0250-D5) ports. In addition, it
monitors the rate of change of RSSI (Receive Signal Strength In) (U0250-F5).
The discriminated audio DISC enters the HC at FF IN (U0250-E4) and the
circuit then reduces the amount of popping Noise associated with fading. The
improved audio exits the IC at FF OUT (U0250-F4).
The Expander is used after deemphasis but before the ASFIC volume
attenuator.
The purpose of the expander is to transpose compressed audio back to
“normal” audio. As with the compressor circuit, the expander circuit adjusts
the amplitude of a signal based upon its input amplitude, NOT its frequency.
The voltage transfer function is: EXPOUT= 0.41*(EXPIN/0.28)2.
The importance here is to notice that an input signal of 191 mV will exit as
191 mV. A smaller signal will be made even smaller and a signal larger than
191 mV will exit EXP OUT even larger.
Controller Section Theory of Operation

7-27

Some example levels are:
-

100 mV EXP IN == 52 mV EXP OUT

-

191 mV EXP IN == 191 mV EXP OUT

-

250 mV EXP IN == 327 mV EXP OUT

Again this operation is NOT A FUNCTION OF FREQUENCY between 300 Hz
and 3 kHz.

Hear Clear
Routing of Data/
Signalling

All signalling for transmit enters the transmit stream after the Hear Clear
Compressor and therefore does not pass through the compressor.
In receive, subaudible signalling PL/DPL goes through the Flutter Fighter
along with audio, and is unaffected by the Flutter Fighter operation. After the
Flutter Fighter, upon entering the ASFIC, the sub-audible signalling is
separated from the audio and decoded. Subaudible signalling never passes
through the expander.
In receive, for all other signalling HST/MDC/MPT etc. (not sub-audible), the
Flutter Fighter is set to “Pass Through Mode”. In this mode the Flutter Fighter
passes signals from FF IN to FF OUT without any adjustment.

7-28

Controller Section Theory of Operation

Control Heads

8

Model I
Introduction

The Control Head forms the interface between the radio and the user. It
contains an LCD display, on/off and volume switch, keypad and control keys.
The microprocessor controlled Control Head interfaces to the radio control
logic board J0650 via an 18-pin connector on the back of the unit. An external
microphone/speaker is connected to the Control Head via the front mounted
microphone connector P0651.

Power supplies

Power supply A+ (pin 17) is routed directly from the radio battery and is used
for LCD and keypad backlight LEDs and indicator LEDs.
Power supply B+ (pin 18) is routed from the radio battery via the radio on/off
switch and provides Vcc via regulator U0654.
Option SW B+ (pin 1) is the power supply output to the connected accessory.
The current is monitored by the Control Head to operate the multiplexer.
(Refer to Mode Select)

Audio
configuration

The Control Head can be configured for Handset audio or Speaker+ which is a
balanced output from the radio. Handset audio is configured by inserting
R0676 in the line from pin 8 to the microphone connector. Speaker + audio is
configured by inserting R0675 in the line from pin 1 to the microphone
connector. Note that only one resistor R0676 or R0675 must be fitted.

Volume Control /
on-off

Front panel switch/potentiometer R0698 controls the volume via A/D
converter PD0 (pin 14) in micro-controller (µ C) U0653. The centre of the
potentiometer is a push button switch used for microphone input and power
on-off. When activated the microphone line (pin 9) is connected to ground.

Micro-controller

Micro-controller U0653 controls the operation of the Control Head. The µ C
exchanges data with the radio via the SB9600 bus (TD0 and RD1) and
monitors inputs from the microphone connector via the A/D port (PD0-PD7).
The µ C is reset from the radio via the reset line (pin 3) and Q0652.The µ C is
also reset by under voltage detector U0657 when Vcc drops below 4.6V.

Xtal Oscillator

The xtal oscillator is built using on chip oscillator gates of the microprocessor.
The xtal is a standard 4 MHz ceramic resonator.

LCD
Backlight

The backlight consists of 10 LEDs. Light intensity is in 3 levels including off
and is software controlled by bus commands via µ C U0653.

Control Heads

8-1

Driver

The LCD driver U0651 contains the default character set. Its interface is a four
line serial interface. The LCD driver is connected to the µ C on pins PA0 - PA3.
The driver has a built in oscillator with one external resistor, R0700, defining
the clock frequency. The oscillator runs at approx. 25 kHz giving an LCD frame
frequency of approx. 48 Hz.

Power Supplies

The LCD driver and bias voltages are powered either from 5.0 V or 5.7 V. The
LCD bias voltage levels are created by the voltage divider R0701, R0702 and
R0703. This gives four voltages: supply voltage (VDD), V1, V2 and V3=GND.
The COM and SEG outputs from U651 jump between these 4 bias voltage
levels, which create the on and off AC voltage for each LCD segment.
Resistors R0715 and R0716 prevent U0651 from going into test mode during
power up.
The LCD supply voltage is controlled by the microcontroller U0653 PA6.

Display

Display (H0650) is a transmissive/reflective positive LCD display. The Control
Head has one line of 8 characters with fixed symbols on top, four key-related
symbols on the bottom and three colour indicators.

Color Indicators

The three color indicators are 4 LEDs D0679, D0680, D0681 and D0682. There
are two yellow LEDs in order to increase the colour intensity.

Keypad
Backlight

The keypad backlight is turned on and controlled along with the LCD
backlight.

Keypad

The keypad is a static input with 10 kohms pull-up resistors. There is no
scanning, but simply one input for each key. Debouncing control is handled
by the software.

Mode Select

To reduce the number of pins on the microphone connector multiplexing is
utilised to switch between the 3 different modes, Normal mode, SB9600 mode
and Keyload mode.

Multiplexer
Operation

The multiplexer comprises U0655 and U0656. Inputs to the multiplexer are
from the microphone connector pins 3, 6 and 7. The multiplexer is switched
either by a current sensing device (Q0662, Q0663), for Normal and SB9600 Bus
modes, or by software for keyload mode. Pin 1 of the microphone connector
carries the output current of the connected device.
When the output current is below 30 µ A, the multiplexer is switched to the
Normal mode.
When the connected device is an SB9600 device, the current is greater than 2
mA and the multiplexer is switched to SB9600 mode. Note that when an
SB9600 device is self-powered, i.e. no current consumption from the
microphone connector, a dummy load must be connected to pin 1 to ensure
a minimum current of 2 mA and force the multiplexer into the SB9600 mode.
A field programmer is an example of such a device.
In the Secure keyload mode, an A/D input on the µ C U0653 (PD6) monitors
the Speaker-output dc voltage.

8-2

Control Heads

If the output is short circuit to ground for more than 1 second, the µ C senses
this and switches to keyload mode (via PC7 output).

Normal Mode

Typically a microphone with no microprocessor is connected to the
microphone connector. Inputs in this mode include PTT, Monitor and
Auxiliary. In Normal mode these inputs are routed to the µ C A/D port where
the analogue voltage is measured and decoded for all possible combinations of
PTT, Monitor and Auxiliary.

SB9600 Bus Mode

Typically a control microphone, intelligent handset or field programmer is
connected to the microphone connector. Inputs include Bus+, Bus- and Busy.
On selection of this mode Bus+ and Bus- are routed from the multiplexer via
the bus comparator circuit (Q0655, Q0656 and U0658) to the µ C bus interface
(RD1/TD0). Busy is routed to the radio via the Busy line (pin 14).

Secure Mode

This is the secure keyload mode. The inputs in this mode include WE (Write
Enable), KID (Key Insert Data) and Key Fail. On selection of this mode these
inputs are routed from the multiplexer to the radio via pin 10 (WE), pin 12
(KID) and pin 11(Key Fail).

Models II
and III
Introduction

The Control Head forms the interface between the radio and the user. It
contains an LCD display, on/off and volume switch, keypad and control keys.
Control Head model II contains a rotary switch in place of a full keypad.
The microprocessor controlled Control Head interfaces to the radio control
logic board J0650 via an 18-pin connector on the back of the unit. An external
microphone/speaker is connected to the Control Head via the front mounted
microphone connector P0651.

Power Supplies

Power supply A+ (pin 17) is routed directly from the radio battery and is used
for LCD and keypad backlight LEDs and indicator LEDs.
Power supply B+ (pin 18) is routed from the radio battery via the radio on/off
switch. It is routed to the microphone connector current sensor device
(Q0664) and provides Vcc via regulator U0650.
Option SW B+ (pin 1) is the power supply output to the connected accessory.
The current is monitored by the Control Head to operate the multiplexer.
(Refer to Mode Select)

Audio
Configuration

The Control Head can be configured for Handset audio or Speaker+ which is a
balanced output from the radio. Handset audio is configured by inserting
R0665 in the line from pin 8 to the microphone connector. Speaker + audio is
configured by inserting R0664 in the line from pin 1 to the microphone
connector. Note that only one resistor R0655 or R0644 must be fitted.

Volume Control/
Cn-Off

Front panel switch/potentiometer R0696 controls the volume via A/D
converter PD0 (pin 14) in micro-controller (µ C) U0653. The centre of the
potentiometer is a push button switch used for microphone input and power
on-off. When activated the microphone line (pin 9) is connected to ground.
Control Heads

8-3

Micro-controller

Micro-controller U0653 and Data Expander U0654 control the operation of
the Control Head. The µ C exchanges data with the radio via the SB9600 bus
(TD0 and RD1) and monitors inputs from the microphone connector via the
A/D port (PD0-PD7). In addition keypad and LCD data is processed via ports
A, B and C. Both the µ C and the Expander are reset by under voltage detector
U0660 when Vcc drops below 4.6 V. Both devices can also be reset from the
radio via the reset line (pin 3) and Q0655.

Xtal Oscillator

The xtal oscillator is built using on chip oscillator gates of the microprocessor.
The xtal is a standard 4 MHz ceramic resonator.

LCD
Backlight

The backlight consists of 36 LEDs in model I and 48 LEDs in model J. Light
intensity is in 4 levels including off and is software controlled by bus
commands via Expander U0654 (Q6, Q7). A temperature condition in the
Control Head overrides the software commands such that on rising to 78°C or
above the lowest light level or off is selected.

Controller

LCD controller U0651 contains the default character set. On Control Head
model J the controller is expanded by the use of an LCD driver U0652. The
LCD controller is connected to the µ C via data bus PA0-PA7, while the control
and read/write (R/W) lines are connected via PB5 and PB7 respectively.

Power Supplies

The LCD bias voltage drives the display segments. The bias voltage is divided
into 5 levels by R0707 to R0711 and routed to the LCD controller (and LCD
driver in Control Head model J) under µ C control via U0655. The µ C measures
the bias voltage with respect to Vcc (TP3) at A/D port PD3. Another function
of the bias voltage is temperature which is measured across R0742 at A/D port
PD7. The µ C calculates the correction to the bias voltage and adjusts the duty
cycle of the PLMA output to U0655 accordingly.

Display

Display (H0650) is a double layer super twist LCD display. Control Head model
I has one line of 14 characters with fixed symbols on top, six key-related
symbols on the bottom and RSSI symbol on the right-hand side. Control Head
model J is similar but has two lines of 14 characters. The presence of a rotary
switch tells the software that the display is a one-line display.

Temperature
Sensor

µ C U0653 measures voltage on PD7 which is controlled by dividers R0741 and
R0742. R0742 is an NTC resistor which is placed in close proximity to the LCD
display. The temperature sensor protects the backlight LEDs from failure and
is also used to compensate the LCD bias voltage dependent on the LCD glass
temperature. The protection temperature is 77°C ±6°C.

Keypad
Backlight

The backlight consists of 7 LEDs in model I and 13 LEDs in model J. The
backlight can be switched on/off by the radio software, controlled via µ C
U0653 TCMP1 and TCMP2. A high pulse on TCMP1 turns on the backlight
and a low pulse on TCMP2 turns it off. If the temperature rises above 78°C in
the Control Head the µ C turns off the backlight utilising the Temperature
Sensor input.

Keypad

The keypad is a passive input scanning matrix such that each key has 3 poles.
When a key is pressed a row and column are connected to ground and sensed

8-4

Control Heads

by the µ C (PB0-PB4/PC0-PC4). Only Control Head model J contains a full
keypad.

Rotary Switch

Rotary switch R0697 (Control Head model I only) is a double wiper
continuous turn 16-step potentiometer. The two wipers are connected to two
A/D inputs on the µ C U0653 (PD1, PD2). One input covers 8 steps from 0° to
180° and the other the 8 steps from 180° to 360°. The switch function is
software programmable and may be used for example to select shortform call
numbers.

Mode Select

To reduce the number of pins on the microphone connector multiplexing is
utilised to switch between the 3 different modes, Normal mode, SB9600 mode
and Keyload mode.

Multiplexer
Operation

The multiplexer comprises U0657, U0658 and U0659. Inputs to the
multiplexer are from the microphone connector pins 3, 6 and 7. The
multiplexer is switched
either by a current sensing device (Q0664, Q0665), for Normal and SB9600 Bus
modes, or by software for keyload mode. Pin 1 of the microphone connector
carries the output current of the connected device.
When the output current is below 30 µ A, the multiplexer is switched to the
Normal mode.
When the connected device is an SB9600 device, the current is greater than 2
mA and the multiplexer is switched to SB9600 mode. Note that when an
SB9600 device is self-powered, i.e. no current consumption from the
microphone connector, a dummy load must be connected to pin 1 to ensure
a minimum current of 2 mA and force the multiplexer into the SB9600 mode.
A field programmer is an example of such a device.
In the Secure keyload mode, an A/D input on the µ C U0653 (PD6) monitors
the Speaker-output dc voltage. If the output is short circuit to ground for more
than 1 second, the µ C senses this via R0689/R0690 network and switches the
multiplexer to keyload mode via U0654 (Q1). This action overrides the current
sensor device.

Normal Mode

Typically a microphone with no microprocessor is connected to the
microphone connector. Inputs in this mode include PTT, Monitor and
Auxiliary. In Normal mode these inputs are routed via the multiplexer to the
µ C A/D port where the analogue voltage is measured and decoded for all four
possible combinations of PTT/Monitor and the 4 Auxiliary levels.

SB9600 Bus Mode

Typically a control microphone, intelligent handset or field programmer is
connected to the microphone connector. Inputs include Bus+, Bus- and Busy.
On selection of this mode Bus+ and Bus- are routed from the multiplexer via
the bus comparator circuit (Q0660, Q0661 and U0656) to the µ C bus interface
(RD1/TD0). Busy is routed to the radio via the Busy line (pin 14).

Secure Mode

This is the secure keyload mode. The inputs in this mode include DVP WE
(DVP Write Enable), KID (Key Insert Data) and Key/Fail. On selection of this
mode these inputs are routed from the multiplexer to the radio via pin 10
(DVP WE), pin 12 (KID) and pin 11 (Key/Fail).

Control Heads

8-5

NOTES

8-6

Control Heads

9

Troubleshooting

This chapter contains the troubleshooting flowchart diagrams for the Overall
radio and for the Controller section of the radio as well as the Control Heads.
Troubleshooting flowcharts for the RF section will be found in Volume 2a, 2b,
2c, 2d or 2e of this manual depending on the frequency range.
Refer to the SECURENET option service manual (part number 68P81083C25)
for troubleshooting information and troubleshooting flowchart diagrams for
the SECURENET Option for the radio.
The following chart will give you an overview of the complete set of
troubleshooting charts available for serviceing a radio.

CHART 1-1
OVERALL RADIO

RF BAND
SPECIFIC
CHARTS
(VOL 2)

CHART 1-13
POWER
CONTROL

CHART 1-2
FAILURE CODES
3 SHEETS

CHART 1-12
GPIO

CHART 1-5
RX AUDIO

RX AUDIO
ROUTING
SIMPLIFIED
SCHEMATIC

CHART 1-9
CLOCK
DISTRIBUTION

Refer to the IC Troubleshooting
Procedure before replacing any ICs.

CHART 1-6
SIGNALLING

CHART 1-4
TX AUDIO

CHART 1-7
DC
DISTRIBUTION

TX AUDIO
ROUTING
SIMPLIFIED
SCHEMATIC

SB9600
CHART 1-10 CHART 1-11
BUSY
SB9600
SB9600
SIMPLIFIED
BUS TX
BUS RX
SCHEMATIC

SB9600
VOLTAGE
TABLE

CHART 1-8
CONTROL
HEADS

SB9600
SIMPLIFIED
SCHEMATIC

CHART 1-8A
MODEL I

CHART 1-8B
MODELS II
AND III

CHART 1-3
ON/OFF
CIRCUIT

RADIO VOLTAGE
SIMPLIFIED
SCHEMATIC

CHART 1-9
CLOCK
DISTRIBUTION

Figure 9-1 Troubleshooting Charts Overview

Troubleshooting

9-1

Troubleshooting Chart 1-1, Overall Radio
CHART 1-1 OVERALL RADIO

START

Radio Setup
A+ = 13.6V, Accessory Connector
plugged in, Control Head plugged in,
Emergency Jumper in place
(Speaker Jumper in place Model 1 only)

Yes
Errors

GOTO
Failure Code
Chart 1-2

Pressing
On/Off Button, errors
on display?

No
Display

Attach known good
control head using
control head
extender cable

Display
OK?

No
Errors

Yes

Put the radio
in CSQ test mode
(Note 1 and 2)

Replace
Cable

No

IF remote
cable, do all lines
have continuity and all
lines free of shorts
to other lines
Yes

Check TX power
tuning with RSS.
GOTO Power Control
Chart 1-13.

No

Repair or
Replace
J0405

TX power
OK?

Yes

No

J0405
OK?

Yes

No

TX deviation
OK?

GOTO
TX Audio
Chart 1-4

GOTO
Control Head
Chart 1-8

No

13.4V on
J0405-18?

No

13.4V on
J0405-17?

Pressing
On/Off Button
creates pulse on
J0405-9?
Yes

GOTO
SB9600 Bus RX
Chart 1-10

Note 1. Power up the radio and press the
monitor button five times.
Note 2. See Band Specific TX Troubleshooting
Chart for proper setup.

Connect signal generator
to antenna connector.
Set to channel frequency.

Press
monitor button
on control head. Audio
from speaker?
Yes

No

GOTO
RX Audio
Chart 1-5

NOTE: Button press is to defeat squelch. Audio may come through
without button press depending on squelch level set.

Sensitivity
OK?

No

GOTO
Band Specific
RX Front End

Yes

Audio distortion
<5%?

No

GOTO
Band Specific
RX IF

Yes

Radio
decoding
PL/DPL?

No

GOTO
Signalling
Chart 1-6

Yes

Emergency
Horn and Lights
OK?
Yes
END

9-2

Troubleshooting

No

GOTO
GPIO
Chart 1-12

No

GOTO
DC Distribution
Chart 1-7

No

GOTO
On/Off
Chart 1-3

Yes

Check frequency
tuning using RSS.
GOTO Band Specific
Synthesizer Chart

Yes

GOTO
DC Distribution
Chart 1-7

Yes

Yes

TX output
centered on
frequency?

No

Troubleshooting

9

Troubleshooting Chart 1-2 (1 of 3), Failure Codes

CHART 1-2 FAILURE CODES (1 of 3)

Radio
power up

GOTO Band Specific
Synthesizer Chart

No

Fail
001

No

No

Fail
01/92

Fail
01/88

No

Fail
01/98

No

Fail
01/82

No

Fail
01/81

No

1

Note 1

To Sheet 2

Program
codeplug using
depot tool

5V
R0101

Yes

Yes

Yes

Yes

No

Repair or
Replace R0101

No

Repair or
Replace U0103

Check
U0103

Yes

Program
codeplug

Program firmware
Note 1

Yes
Problem
Fixed

No

U0103
OK?

Fail
01/92

Fail
01/82

Yes

Yes

Check
U0101

No

DATA on
U0105-13
Yes

No

DATA on
U0103-63

Yes

Problem
Fixed

GOTO SB9600
Bus Rx Chart 1-10

No

DATA on
U0105-13

No

Note 1
This level of troubleshooting must be
performed by an authorized DEPOT center.

Check
U0105

WARNING
Refer to the IC Troubleshooting
Procedure before replacing any ICs.

U0106
OK?

DATA on
U0103-63

U0104
OK?

No

Repair or
Replace U0104

Yes
Check
U0103

Yes

U0108
OK?

No

Problem
Fixed

No

Repair or
Replace U0106

No

Repair or
Replace U0106

No

Repair or
Replace U0104

Yes

Yes

Check
U0105

Check
U0103

Fail
01/81
Yes

Yes

Yes
GOTO SB9600
Bus RX Chart 1-10

No

U0103
OK?
Yes

No

Repair or
Replace U0108

U0104
OK?
Yes
Check
CR0105

Troubleshooting

9-3

Troubleshooting Chart 1-2 (2 of 3), Failure Codes

1
From Sheet 1

Fail
01/90

No

Error
01/02

Fail
01/84

No

Fail
01/94

Yes
Yes

J0405
OK?

GOTO
Control Head
Chart 1-8

Yes

Repair or
Replace J0405

Yes

Yes

Program
codeplug

Program
codeplug

Program
codeplug

Fail
01/84

No

Problem
Fixed

Fail
01/94

Yes
No

GOTO
Clock Distribution
Chart 1-9

Problem
Fixed

No

Yes

U0103
OK?

Error
01/02

DATA on
U0103-63

Yes
No

Repair or
Replace U0103

Repair or
Replace U0104

No

Repair or
Replace U0104

DATA on
U0105-13

No

GOTO SB9600
Bus Rx Chart 1-10

Yes
Check
U0105

U0104
OK?

U0108
OK?

No

DATA on
U0105-13

No

Yes
Yes

Check
U0105

DATA on
U0103-63

No

Repair or
Replace U0108

Check
U0103

Yes

Check
U0105

U0104
OK?

No

No

Repair or
Replace U0104

WARNING
Refer to the IC Troubleshooting
Procedure before replacing any ICs.

Yes
Check
U0103

Yes

U0108
OK?

No

Repair or
Replace U0108

9-4

DATA on
U0103-63

Problem
Fixed

Yes

Check
U0103

Yes

Check
U0105

No
DATA on
U0105-13
No

Yes
GOTO SB9600
Bus Rx Chart 1-10

GOTO SB9600
Bus Rx Chart 1-10

No

Yes

Yes

DATA on
U0105-13

No

No

Yes

Yes

Yes

U0104
OK?

2

No

No

Clock
signal on
U0103-34

No

To Sheet 3

Yes
Voltages
on J0403-5, 6,18
per Chart
14

No

Troubleshooting

GOTO SB9600
Bus Rx Chart 1-10

9

Troubleshooting

Troubleshooting Chart 1-2 (3 of 3), Failure Codes

Fail
002

2

No

Error
01/01

From Sheet 2
Yes

Yes
No
GOTO SB9600
Bus Rx Chart 1-10

Program
codeplug

DATA on
U0105-13

No

DATA on
U0103-63

Yes

Check
U0103

Yes
Fail
002

No

Problem
Fixed

Check
U0105

Yes
GOTO SB9600
Bus Rx Chart 1-10

No

DATA on
U0105-13

No

Yes

DATA on
U0103-63

WARNING
Refer to the IC Troubleshooting
Procedure before replacing any ICs.

Yes

Check
U0105

U0104
OK?

No

Repair or
Replace U0104

No

Repair or
Replace U0108

Yes
Check
U0103

Yes

U0108
OK?

Troubleshooting

9-5

Troubleshooting Chart 1-3, On/Off Circuit

CHART 1-3 ON/OFF CIRCUIT TROUBLESHOOTING
START

Press
On/Off Switch

0V
on U0510-6

Note:
Refer to IC Troubleshooting Procedure
before replacing any IC’s.

No

R0518
OK?

No

Repair or
Replace R0518

No

Check U0501, Q0500,
C0508, R0503, R0504

Yes
GOTO
Control Head
Chart 1-8

Yes
Pulse
on U0510-5

No

Check U0510,
R0512, C0511

No

Check CR0510,
Q0510, Q0511

Yes
13.6V
on Q0511-6
Yes
5V
on U0500-2
No
Check U0500,
CR0500, C0503

9-6

Troubleshooting

Yes

9.3V
on U0501-5
Yes
GOTO
Clock Distribution
Chart 1-9

Troubleshooting Chart 1-4, TX Audio
START

Inj: 1KHz Tone, 80mVrms
at the Internal Microphone
1KHz
45mVrms on
U0200-B8

No

Check for solder defects
on U0200, C0218,
R0224, R0233

Ref: TX Audio Simplified Schematic
~ = Approximately

Yes

TP5800 has
1KHz ~114mVrms
AC with ~2.5VDC
offset

SPI lines
activity at
U0200-E3, F1

No

Yes

Yes

Check
U0200 all bands,
U0250 for 900MHz

No

Check
U0103

No

GOTO Band Specific
RF Transmitter
Chart

SPI activity
on pins 66, 67
of U0103
Yes
Check
R0403, R0404,
R0405

TX Audio Routing, Simplified Schematic for Chart 1-4
9.3V

25KHz, 80mVrms, 1KHz tone

MIC
VOLTAGE

12.5KHz, 80mVrms, 1KHz tone

HEAR CLEAR
U0250

R0231
100

COMP
BUF IN

COMP
BUF OUT

D3

1.5Vdc
46mVrms
152mVpp

2.5Vdc
45mVrms
145mVpp

J0403-13

C0254
10nF

C0222
10µF 2.5Vdc

1.5Vdc
45mVrms 46mVrms
139mVpp 152mVpp

R0230
1K

C0421
470pF

VR0412
14V

R0229
470

A6

R0223
1K

45mVrms
145mVpp

2.5Vdc
45mVrms
145mVpp

1.5Vdc
46mVrms
152mVpp

2.5Vdc
1.5Vdc
45mVrms 46mVrms
139mVpp 152mVpp

A7

C0427
470pF

VR0411
14V

TX
IN

EXT
MIC
IN

PREMP
LIM
IN

C0218
0.1µF

INT MIC
R0224
470

C7

MIC AMP
OUT

46mVrms
152mVpp

C0219
10µF

R0252
47.5K

C0257
10nF

C0223
0.022µF

R0222
100

PLACED
900 MHz
ONLY

F3

C0251
0.1µF

C0221
0.1µF

EXT MIC

MIC
VOLTAGE

J0405-9

F2

COMP
OUT

C0224
0.022µF

45mVrms
145mVpp

46mVrms
152mVpp

B8

INT
MIC
IN

ASFIC
U0200

C8

C0243
10nF
E8
2.5Vdc
114mVrms
372mVpp

VCO MOD
VCO
ATTN H8 1.5Vdc
57mVrms
172mVpp

Troubleshooting

9-7

Troubleshooting Chart 1-5, RX Audio
CHART 1-5 RX AUDIO
START

Inj: 1kHz Tone, 3kHz deviation at the appropriate
RX frequency into the antenna connector.
~800mVpp
on U0200-J7

No

Volume set to ~7.5 Vrms

GOTO Band Specific
IF Receiver Chart

Ref: RX Audio Simplified Schematic
~ = Approximately

Yes

~375mVpp
on U0200-J4

No

SPI activity at
U0200-E3, F1

SPI activity
on pins 66, 67
of U0103
Yes

Check
R0403, R0404,
R0405

No

Check R0234,
C0240, R0239

No

Check
U0203

Yes

~5.4 Vpp
on
U0203-6, 4
Yes

Check speakers

9-8

Troubleshooting

Check
U0200

No

Check
U0103

No

Yes

~68mVpp
on U0203-J9

Yes

RX Audio Routing, Simplified Schematic for Chart 1-5

CONTROLLER BOARD RX AUDIO ROUTING SIMPLIFIED SCHEMATIC
260mVrms
800mVpp

260mVrms
800mVpp

R0245
10K

109mVrms
348mVpp

107mVrms
324mVpp

C0236
330pF

25KHz
12.5KHz

260mVrms 107mVrms
800mVpp 324mVpp

J7

C0202
0.22µF

PL IN

C0256
0.1µF

ASFIC
U0200

RX IN

DISC
C0415
470pF

FLUTTER
FIGHTER
SUPPORT
COMPONENTS

E4

H6

F4
FFOUT
FFIN

240mVrms
679mVpp

UNAT
RX
OUT

HEAR CLEAR i
U0250

H5

SPK+
SPK-

ACC 3
CONN
J0403

EXT
SPKR

EXP IN
A2

J5

C1

EXP OUT

C0250
0.1µF

C0260
0.1µF

R0234
4.7KΩ
40mVrms

6Vdc

6Vdc

INT
SPKR

6

SPK7.5V

2

4 7.88V
SPK+

1
6Vdc

AMP 1 RX_AUDIO
IN

APA
U0203

C0229

254mVrms
718mVpp

RX J4
AUD
OUT

EXP
AUD
IN

9

C0240
33nF

40mVrms
113mVpp
45mVrms
127mVpp

40mVrms

C0242
3.3nF

R0235
1KΩ

C0999
.0033µF

33pF

U0200-H5
R0232
0

J0403-11

FILTERED
AUDIO

J0405-8

R0238 68K
--

RX_ HI

HANDSET
AUDIO

C0228
0.1µF

VR0418
20V

C0434
470pF
680mVrms
670mVrms

+

R0237
10K
VAG

900MHZ ONLY
PLACED ONLY
FOR iDEN
HANDSET

Troubleshooting

9-9

Troubleshooting Chart 1-6, Signalling
CHART 1-6 SIGNALLING

START

Radio mutes
if proper PL/DPL is
not present
Yes

Yes

During TX
is there a 1 or 2kHz
signal at
U0200-C3?
No

Check for solder
defects on
U0200

9-10

Troubleshooting

Check
U0103

No

DATA ON
U0200-A4

No

Check
U0200-01

Yes

Check
U0104

Troubleshooting Chart 1-7, DC Distribution
CHART 1-7 DC DISTRIBUTION
START

Ref: Chart 1-3 and DC Voltage Distribution Simplified Schematic

13.6V on
connector J1

No

Check DC
input and fuse

No

Check C5613,
C5617, L5611,
R0432, J5500-1, 2

No

Check
U0502

No

GOTO
On/Off Circuit
Chart 1-3

Yes

13.6V on
U0502-8

Yes

8V on
U0502-1

Yes

~13.0V on
U0501-1

Yes

9.3V on
U0501-5

No

Check
U0501,
Q0500, C0508,
R0503, R0504

Yes

5V on
U0500-2

No

Check
U0500,
CR0500, C0501,
C0504

Yes

5V on
U5802-3

No

Check
U5802,
L5765, C5766,
C5767

Yes
Check
U5801,
Q5770, C5770,
C5810

Troubleshooting

9-11

Radio Voltage, Simplified Schematic For Chart 1-7
RADIO VOLTAGE SIMPLIFIED SCHEMATIC
MAIN SHIELD

A+
CONT

CONTROLLER

TRANSMITTER

TX
P/A

K 9.1V

9.3V
REG
Q0553 U0501

5V
REG

B
A
T
T
E
R
Y

A
L
T
E
R
N
A
T
O
R

OPTIONS
J0401
J0408

HEAR
CLEAR
U0250

8V
REG
U0502

AUDIO
PA
U0203

Q0552

5V
REG
U5802

CONTROL
HEAD

A+
J0405-17

UN
SW
5V

MIC
VOLT

K4 µP

FRAC N
U5801
ELEC ON/OFF
PWR OFF DLY
U0510/Q0510/Q0511

SLIC IVA
U0104

PEND
U5800
Q5770

ZIF
U3201
VCO

RECEIVER /
SYNTHESIZER

F1 µP
U0103
ROM
U0106
RAM
U0101

J0405-16
5V
REG
U0500

EEPROM
U0108
ASFIC
U0200

S
W
B
+

J0405-18

J0405-7, 13
SWB+

ACC CONNECTOR

CASTING
NOT PLACED

9-12

Troubleshooting

Troubleshooting Chart 1-8A, Control Head Model I
Numbers in brackets refer to accompanying troubleshooting procedure overleaf.

Control Head Model C Troubleshooting Chart
START
SW B+ and
multiplexing of MIC No
connector OK?

Radio
can turn on/off?
(1.1)

No

Check on/off switch (1.1)

Check the following:
SW B+ voltage in normal mode (5.1)
Multiplexer in normal position (5.2)
PTT input (5.3)
Monitor input (5.4)
AUX input (5.5)
SW B+ in SB9600 Mode (5.6)
SW B+ in SB9600 Mode (high load) (5.7)
Multiplexer in SB9600 Position (5.8)

Yes

Yes
Volume
control OK?
(6)

5VDC
OK?
(1.2)

No

Check 5V supply (1.2)

No

Check R0698 (6)

Yes

Yes

Radio
resets control
head?
(2.1)

Keypad
OK?
(7)

No

Error in radio!

No

Check electrical connection to µP
Clean PCB or replace keypad (7)

Yes

Yes

Keypad backlight:
See LCD backlight (10)

Reset
circuit works?
(2.2)

No

Check Q0652, U0657,
D0674 (2.2)
LED
indicators
OK?

Yes

Undervoltage detector
works?
(2.3)

Check U0653, Q0659, Q0660,
Q0661 and LEDs (9)

Yes
No

Replace U0657 (2.3)
LCD
backlight
OK?

Yes

Microprocessor clock
runs?
(3)

No

No

Yes

Yes
No

Check Y0650 and U0653
(3)
Check U0653, Q0651
and U0652 (10.1)

Yes

All LEDs?

No

Check the LEDs
(10.2)

(Communication not OK)
Check the following:
BUS + (4.1)
BUS- (4.2)
BUSY (4.3)
"FL 01/90"
Radio never starts BUS+/BUS- Comparator (4.4)

Serial bus
communication
OK? (4)

Yes

No

after power on

Text in
LCD display
OK?

No

Yes

Communication
stops only with accessory Yes
on MIC Conn?
(4.5)

No

Accessory is defect!

Secure
keyloading
OK?

No

Yes

Microprocessor
OK?

No

Check the following:
Defect outside segment area (11.1)
Missing segments? (11.2)
Weak segments? (11.3)
LCD bias voltage (5 or 5.6 volts)? (12)

Check the following:
Check input from P0651 to µP U0653 (13.1)
Check multiplexer position (13.2)
Check connections through multiplexer
including ESD protection diodes (13.3)

Replace and factory programming
and alignment necessary

Yes

END

MAEPF-25121-O

Troubleshooting

9-13

Control Head I Troubleshooting Procedure
1

Power Supply
Check that the radio is connected to a power supply.
1.1

ON/OFF switch
-

Check that radio turns on. I.e. SW B+ is 12V DC. If not, press the ON/OFF switch to turn the radio off
again.

-

If the radio does not turn ON, verify that there is DC voltage on the MIC-HI/ON_OFF line and that this
voltage goes to ground when pressing the ON/OFF switch.

-

If DC voltage is present, but does not go low, check J0650 and R0698.

1.2

5V DC supply
12VDC is now assumed to be present both on A+ and SW B+.
-

2

Reset
2.1
-

Monitor uP reset on U0653 pin 18 with an oscilloscope. Turn radio off and on.

-

Check that the uP reset goes from low to high (5 VDC) after power up and stays high.
Check reset circuit

-

If U0653 is not reset check Q0652 and U0657.

-

Check that D0674 is not shorted.

2.3

Check the undervoltage detector IC U0657
-

Disconnect the control head from the radio and connect J0650 pins 7 and 13 to ground and pins 17 and
18 to a variable DC supply.

-

Measure the DC voltage at U0654 pin 3.

-

Monitor U0657 pin 1.

-

Increase slowly the DC supply starting from 4 V.

-

Check that U0657 pin 1 changes from 0V to 5 VDC when TP3 is approx. 4.3 V. If not replace U0657.

-

Connect J0650 pin 3 to U0654 pin 3 (VCC). Check that U0657 pin 1 goes low.

-

If not replace Q0652.

2.4

Continuous reset
-

4

Check that the control head reset is functional.
Radio resets control head

2.2

3

Check that there is 5 VDC on U0654 pin 3. If not check R0673 and U0654.

If the control head is continuously reset by the radio it may be due to a bus communication problem or
the microprocessor not working.

Microprocessor Clock
-

Check that the microprocessor oscillator is working (4 MHz square wave on TP2). If not, check Y0650
and U0653.

-

Clean PCB area round Y0650.

Serial Bus Communication
A general serial bus communication problem in the radio is typically indicated by the radio remaining
inactive on power up, and the display showing "FL 01/90".
Make sure that no accessory is connected to P0651 (MIC Connector) and check the following lines with
an Oscilloscope while turning the radio on and off.
4.1

SB9600 BUS+, J650 pin 15
-

9-14

This signal is normally 5 VDC with short pulses to 0V when data are sent on the bus. If it is constantly 0
V or 5 VDC check D0677 (most common error), Q0655 and Q0656.

Troubleshooting

-

4.2

SB9600 BUS-, J650 pin 4
-

This signal is normally 0 V with short pulses to 5 VDC when data are sent on the bus. If it is constantly 5
VDC or 0 V, check D0678 (most common error), Q0657 and Q0656.

-

Check that U0653 pin 52 is 5 VDC with pulses to ground while transmitting data. Then check U0655
(disconnect pin 12). If problem disappears and OPTION SW B+ circuit is OK (see 5.), replace U0655. If
the OPTION SW B+ circuit is defect, D0683 should also be checked.

4.3

SB9600 BUSY, J650 pin 14
-

This signal is 0 V with pulses to 5 VDC when data are sent on the bus. If it is constantly 5 VDC or 0 V,
check D0675 (most common error) and Q0653. Check that U0653 pin 43 is 5 VDC with pulses to ground
while sending data.

-

Then check U0656 (disconnect pins 1 and 12). If problem disappears and OPTION SW B+ circuit is OK
(see 5.), replace U0656. If the OPTION SW B+ circuit is defect, D0685 should also be checked.

4.4

SB9600 data in comparator
-

4.5

If the above voltages are correct, check U0652, Q0658 and Q0656. Finally check U0653.
Communications stops only with accessory on MIC Conn

5

Check that U0653 pin 52 is 5 VDC with pulses to ground while transmitting data. Then check U0655
(disconnect pin 1). If problem disappears and OPTION SW B+ circuit is OK (see 5.), replace U0655. If the
OPTION SW B+ circuit is defect, D0684 should also be checked.

If bus communication stops working only when an accessory is connected to the MIC Connector
(P0651), check the OPTION SW B+ circuit (See 5.). The accessory is either defect or incompatible.

OPTION SW B+/Multiplexing of MIC Connector
Normal mode = No or simple microphone connected.
SB9600 mode = Smart accessory with serial bus connected.
5.1

SW B+ in Normal mode
-

Make sure no accessory is connected to the MIC Connector (P0651).

-

With power connected to the control head on J0650 pins 17 and 18, check that the DC voltage on P0651
pin 1 is approx. 12 VDC. If not check Q0662.

5.2

Multiplexer in normal position
-

5.3

PTT input
-

Check that the voltage on U0653 pin 46 changes from 5 VDC to 0 V when P0651 pin 6 is connected to
ground (equivalent to pressing PTT on a standard microphone).

-

If this fails, check U0655.

5.4

Monitor input
-

Check that the voltage on U0653 pin 45 changes from 5 VDC to 0 V when P0651 pin 3 is connected to
ground.

-

If this fails check U0656.

5.5

AUX input
-

Check that the voltage on U0653 pin 5 changes from 5 VDC to approx. 0 VDC when P0651 pin 7 is
connected to ground.

-

If this fails check U0655.

5.6

5.7

Check that the voltage on U0655/U0656 pin 10 is 5 VDC. If this fails, check Q0662 and Q0663.

SW B+ in SB9600 mode
-

Connect a 5.6 kohm resistor from P0651 pin 1 to ground (a keypad microphone can be used instead).

-

Check that the DC voltage on P0651 pin 1 is still approx. 12 VDC.

-

If not check Q0662.
SW B+ in SB9600 mode (high load)

Troubleshooting

9-15

-

Connect a 68 ohm resistor from P0651 pin 1 to ground.

-

Check that the DC voltage on P0651 pin 1 is still approx. 12 VDC.

-

If not check Q0662.

5.8

6

7

8

Multiplexer in SB9600 position
-

Connect a 5.6 kohm resistor from P0651 pin 1 to ground (a keypad microphone can be used instead).

-

Check that the voltage on U0655/U0656 pin 10 is 0 VDC.

-

If this fails check Q0662 and Q0663.

Volume Control
-

Turn R0698 fully counter clockwise and then fully clockwise and verify the voltage on U0653 pin 14 goes
from 0 V to 5 VDC.

-

If not, check R0698.

Keypad
-

Check that when pressing a key, the correct input to U0653 pins 33-39 goes low. The actual pins can be
found on the schematic diagram.

-

Clean the carbon pads with alcohol.

-

Check carbon on rubber keypad. If defect, replace keypad.

Key backlight
See LCD backlight.

9

10

LED indicators
-

Check that the outputs from U0653 pin 49 (yellow), pin 48 (red) and pin 47 (green) changes to 5 VDC
when LED must go ON.

-

Check Q0659 (yellow), Q0660 (red) and Q0661 (green).

-

Check the LEDs.

LCD backlight
10.1

All LEDs
If backlight cannot be turned on or off.

9-16

-

Check that U0653 pins 26 and 27 are 5 VDC. If not check U0653.

-

Check that the voltage of base on Q0651 is approx 1.5 VDC.

-

Check Q0651 and U0652.

Troubleshooting

10.2

11

One/some LEDs

-

One LED is off. Check the LED.

-

One row of LEDs is off. Find the LED that makes the short circuit.

LCD
11.1
11.2

Defect outside segments of display
If the LCD has either light or dark areas outside the segment, the LCD glass is defect and must be
replaced.
Missing segments

-

Missing segments. Most likely a bad connection between PCB and LCD. Disassemble and clean PCB and
zebra connector with alcohol. LCD glass surfaces can be cleaned with distilled water with 3%
ammonium chloride; never use alcohol on the LCD glass.

-

If necessary replace the zebra connector or LCD.

11.3

Weak segments

-

Segment brightness depends on the text displayed. Most likely a short between the lines from display
controller/driver to LCD. Disassemble and clean PCB and zebra connector with alcohol. If necessary
replace the zebra connector.

-

Check U0651.
NOTE: When monitoring the signal on the LCD controller/driver outputs, a complex signal pattern is
seen that jumps in 4 discrete voltage from 0V to + 5V. Waveform depends on the contents of the display.
Outputs are never steady. A signal can always be seen on a scope unless there is a short, or the LCD driver
is defect.

12

LCD bias voltage
If segments that should be on are weak or segments that should be off are partly lit, the problem may be
the bias voltage.

13

-

Measure the LCD bias voltage (DC) between TP1 (+) and GND.

-

The voltage should be approx. 5 VDC or 5.6 VDC depending on the viewing angle setting.

-

Check Q0650.

Secure keyloading
13.1
13.2
13.3

14

Secure keyloader sensing
Connect P0651 pin 2 to ground. Check that DC voltage on U0653 pin 4 goes to 0 V. If not, check P0651,
R0679, R0678 and C0668.
Multiplexer in keyload position
Check that U0653 pin 42 goes to 5 VDC. If not check U0653.
Connections through multiplexer

-

Check that P0651 pins 6, 3 and 7 are connected to J0650 pins 10, 12 and 11 respectively. If not check
U0655 and U0656.

-

Also check D0683, D0684, D0685 and D0676.

Microprocessor U0653
Replacement of U0653 requires special factory programming and alignment (currently not available in
the radio service software).

Troubleshooting

9-17

Troubleshooting Chart 1-8B, Control Head Models II & III
Numbers in brackets refer to accompanying troubleshooting procedure overleaf
START
Volume
control OK?
(6)
Radio
can turn on/off?
(1.1)

No

Check on/off switch (1.1)

5VDC
on TP3?
(1.2)

No

No

Yes

Yes

Error in radio!

Yes

All LEDs?

No

Check Q0655, U0660,
D0660 (2.2)
LED
indicators
OK?

Yes

Undervoltage detector
works?
(2.3)

No

LCD
backlight
OK?

No

No

Check U0654, Q0657,
Q0658, Q0659 and LEDs (9)

Yes

Replace U0660 (2.3)

Yes

Microprocessor clock
runs?
(3)

Check Y0650 and U0653
(3)

No

Yes

Yes

Yes

All LEDs?

Check U0654, Q0666,
Q0667 and U0656 (10.1)

Serial bus
communication
OK? (4)

No

"FAIL 01/90"

Check the following:
BUS + (4.1)
BUS- (4.2)
BUSY (4.3)
BUS+/BUS- Comparator (4.4)

Yes Radio never starts

Text in
LCD display
OK?

after power on

Communication
stops only with accessory Yes
on MIC Conn?
(4.5)

No

SW B+ and
multiplexing of MIC
connector OK?

No

No

Check the LEDs
(8.2)

Check Q0650, Q0651
and Q0652 (8.1)

Reset
circuit works?
(2.2)

Yes

Check electrical connection to µP.
Clean PCB or replace keypad (7)

Yes

Keypad
backlight
OK?

No

No

Check 5V supply (1.2)

Yes

Radio
resets control
head?
(2.1)

Check R0696 (6)

Yes

Keypad
OK?
(7)

Yes

No

Accessory is defect!

Check the following:
SW B+ voltage in normal mode (5.1)
Multiplexer in normal position (5.2)
PTT input (5.3)
Monitor input (5.4)
AUX input (5.5)
SW B+ in SB9600 Mode (5.6)
SW B+ in SB9600 Mode (high load) (5.7)
Multiplexer in SB9600 Position (5.8)

No

Yes

Secure
keyloading
OK?

No

Yes

No

Check the LEDs
(10.2)

Check the following:
Defect outside segment area (11.1)
Missing segments? (11.2)
Weak segments? (11.3)
LCD bias voltage (8 volts)? (12)

Check the following:
Check input from P0651 to µP U0653 (13.1)
Check multiplexer position (13.2)
Check connections through multiplexer
including ESD protection diodes (13.3)

Replace U0660 (2.3)
Rotary
switch OK?
(14)(model II

No

Check R0697 (14)

only)

Yes

Microprocessor
OK?

No

Replace and factory programming
and alignment necessary

Yes

END

9-18

Troubleshooting

MAEPF-25122-O

Control Heads
II and III Troubleshooting Procedure
1

Power Supply
Check that the radio is connected to a power supply.
1.1

ON/OFF switch
-

Check that radio turns on. I.e. SW B+ is 12V DC. If not, press the ON/OFF switch to turn off radio.

-

If the radio does not turn on, verify that there is DC voltage on the MIC-HI/ON_OFF line and that this
voltage goes to ground when pressing the ON/OFF switch.

-

If the DC voltage is present but does not go low check J0650 and R0696.

1.2

2

5V DC supply
-

12VDC is now assumed to be present both on A+ and SW B+.

-

Check that there is 5 VDC on TP3. If not check R0651 and U0650.

Reset
2.1

Radio resets control head
-

Monitor uP reset on U0653 pin 18 with an oscilloscope. Turn radio off and on.

-

Check that the uP reset goes from low to high (5 VDC) after power up and stays high.

2.2

Check reset circuit
-

If U0653 is not reset check Q0655 and U0660.

-

Check that D0660 is not shorted.

2.3

Check the undervoltage detector IC U0660
-

Disconnect the control head from the radio and connect J0650 pins 7 and 13 to ground and pins 17 and
18 to a variable DC supply.

-

Measure the DC voltage at TP3.

-

Monitor U0660 pin 1.

-

Increase slowly the DC supply starting from 4 V.

-

Check that U0660 pin 1 changes from 0V to 5 VDC when TP3 is approx. 4.3 V. If not replace U0660.

-

Connect J0650 pin 3 to TP3. Check that U0660 pin 1 goes low. If not replace Q0665.

2.4

Continuous reset
-

3

4

Check that the control head reset is functional.

If the control head is continuously reset by the radio it may be due to a bus communication problem or
the microprocessor not working.

Microprocessor Clock
-

Check that the microprocessor oscillator is working (4 MHz square wave on TP2). If not check Y0650 and
U0653.

-

Clean PCB area round Y0650.

Serial Bus Communication
A general serial bus communication problem in the radio, when the control head is connected, is
typically indicated by an inactive radio on power up or the display showing "FAIL 01/90".
Make sure no accessory is connected to P0651 (MIC Connector). Check the following lines with an
Oscilloscope while turning the radio on and off.

Troubleshooting

9-19

4.1

SB9600 BUS+, J650 pin 15
-

This signal is normally 5 VDC with short pulses to 0V when data are sent on the bus. If it is constantly 0
V or 5 VDC check D0665 (most common error), Q0663 and Q0662. Check that U0653 pin 52 is 5 VDC
with pulses to ground while sending data.

-

Then check U0659 (disconnect pins 1 and 12). If problem disappears and OPTION SW B+ circuit is OK
(see 5.), replace U0659.

-

If the OPTION SW B+ circuit is defect, D0669 should also be checked.

4.2

SB9600 BUS-, J650 pin 4
-

This signal is normally 0 V with short pulses to 5 VDC when data are sent on the bus. If it is constantly 5
VDC or 0 V, check D0664 (most common error), Q0661 and Q0662. Check that U0653 pin 52 is 5 VDC
with pulses to ground while sending data.

-

Then check U0657 (disconnect pins 1 and 12). If problem disappears and OPTION BW B+ circuit is OK
(see 5.), replace U0657.

-

If the OPTION SW B+ circuit is defect, D0667 should also be checked.

4.3

SB9600 BUSY, J650 pin 14
-

This signal is normally 0 V with pulses to 5 VDC when data are sent on the bus. If it is constantly 5 VDC,
check D0659 (most common error) and Q0653. Check that U0653 pin 43 is 5 VDC with pulses to ground
while sending data.

-

Then check U0658 (disconnect pins 1 and 12). If problem disappears and OPTION BW B+ circuit is OK
(see 5.), replace U0658.

-

If the OPTION SW B+ circuit is defect, D0668 should also be checked.

4.4

SB9600 data in comparator
-

If the above voltages are correct, check U0656, Q0660 and Q0662.

-

Finally check U0653.

4.5

Communication stops only with accessory on MIC Conn
-

5

If bus communication stops only when an accessory is connected to the MIC Connector (P0651), check
the OPTION SW B+ circuit (See 5.). The accessory is either defect or incompatible.

OPTION SW B+/Multiplexing of MIC Connector
Normal mode = No or simple microphone connected.
SB9600 mode = Smart accessory with serial bus connected.
5.1

SW B+ in Normal mode
-

Make sure no accessory is connected to the MIC Connector (P0651).

-

With power connected to the control head on J0650 pin 17 and 18, check that the DC voltage on P0651
pin 1 is approx. 12 VDC. If not check Q0664.

5.2

Multiplexer in normal position
-

Check that the voltage on U0657/U0658/U0659 pin 10 is 5 VDC.

-

If this fails check Q0664 and Q0665.

5.3

9-20

PTT input
-

Check that the voltage on U0653 pin 9 changes from 5 VDC to approx. 1.7 VDC when P0651 pin 6 is
connected to ground (equivalent to pressing PTT on a standard microphone).

-

If this fails, check U0657.

Troubleshooting

5.4

Monitor input
-

Check that the voltage on U0653 pin 9 changes from 5 VDC to approx. 3.3 VDC when P0651 pin 3 is
connected to ground.

-

If this fails check U0658.

5.5

AUX input
-

Check that the voltage on U0653 pin 5 changes from 5 VDC to approx. 0 VDC when P0651 pin 7 is
connected to ground.

-

If this fails check U0659.

5.6

SW B+ in SB9600 mode
-

Connect a 5.6 kohm resistor from P0651 pin 1 to ground (a keypad microphone can be used instead).

-

Check that the DC voltage on P0651 pin 1 is still approx. 12 VDC.

-

If not check Q0664.

5.7

SW B+ in SB9600 mode (high load)
-

Connect a 68 ohms resistor from P0651 pin 1 to ground.

-

Check that the DC voltage on P0651 pin 1 is still approx. 12 VDC.

-

If not check Q0664.

5.8

6

7

8

Multiplexer in SB9600 position
-

Connect a 5.6 kohm resistor from P0651 pin 1 to ground (a keypad microphone can be used instead).

-

Check that the voltage on U0657/U0658/U0659 pin 10 is 0 VDC.

-

If this fails check Q0664 and Q0665.

Volume Control
-

Turn R0696 fully counter clockwise and then fully clockwise and verify the voltage on U0653 pin 14 goes
from 0 V to 5 VDC.

-

If not, check R0696.

Keypad
-

Check that when pressing a key, both a column and a row input to U0653 pins 35-39 (rows) and 45-49
(columns) go low. The actual pins can be found on the schematic diagram.

-

Clean the carbon pads with alcohol.

-

Check carbon on rubber keypad. If defect, replace keypad.

Keypad backlight
8.1

All LEDs off or always on
-

If all keypad LEDs are OFF (or ON but never turns off), check Q0650, Q0651 and Q0652.

-

The backlight flip-flop can be turned on by connecting the base of Q0651 through a 4k7 ohms resistor to
5 VDC and turned off by connecting the base of Q0652 through a 4k7 ohms resistor to 5 VDC.

8.2

Light missing from some LEDS
-

9

Check the LEDs.

LED indicators
-

Check that the outputs from U0654 pin 6 (yellow), pin 9 (red) and pin 12 (green) change to 5 VDC when
LED should go ON.

Troubleshooting

9-21

10

-

Check Q0657 (yellow), Q0658 (red) and Q0659 (green).

-

Check LEDs.

LCD backlight
10.1

All LEDs
If backlight cannot be turned on or off.

-

Check that U0654 pins 16 and 19 are 5 VDC.

-

If not, check U0654.

-

Check that the voltage of base on Q0666 is 5 VDC.

-

Check that the DC voltage of U0656 pin 1 is approx. 4.3 V.

-

Check Q0667 and U0656.

10.2

11

One/some LEDs

-

One LED is off. Check the LED.

-

One row of LEDs is off. Find the LED that makes the short circuit.

LCD
11.1
11.2
-

11.3

Defect outside segments of display
If the LCD has either light or dark areas outside the segment, the LCD glass is defect and must be
replaced.
Missing segments
Most likely caused by a bad connection between PCB and LCD. Disassemble and clean PCB and zebra
connector with alcohol. LCD glass surfaces can be cleaned with distilled water with 3% ammonium
chloride; never use alcohol on the LCD glass. If necessary replace the zebra connector or LCD.
Weak segments

-

Segment brightness depends on the text displayed. Most likely caused by a short between the lines from
display controller/driver to LCD. Disassemble and clean PCB and zebra connector with alcohol. If
necessary replace the zebra connector.

-

Check U0651.

-

Check U0652 (model III only).
NOTE: When monitoring the signal on the LCD controller/driver outputs, a complex signal pattern is
seen that jumps in 6 discrete voltages from -3V to + 5V. Waveform depends on the contents of the
display. Outputs are never steady. A signal can always be seen on a scope unless there is a short, or the
LCD controller or driver is defect.

12

LCD bias voltage
If segments that should be on are weak, or segments that should be off are partly lit, the problem may be
the bias voltage.

13

9-22

-

Measure the LCD bias voltage (DC) between TP3 (+) and TP1 (-).

-

The voltage should be approx. 8 VDC at ambient temperature.

-

Check that U0654 pin 15 is high. If not check U0654.

-

Check that U0655 pin 8 is approx. -5 VDC. If not check U0655.

-

Check that U0653 pin 3 is approx. 2.5 VDC at ambient temperature. If not check R0742.

-

Check that U0653 pin 20 is a square wave with a DC mean of approx. 3 VDC.

-

If the bias regulation seems to run but the bias is too high or low this may be due to one of the following:

-

1) Microprocessor has lost its factory adjustment parameters.

-

2) Microprocessor is defect.

-

Reprogramming of microprocessor or replacement of microprocessor requires a new factory adjustment
currently not available in the RSS.

Secure keyloading

Troubleshooting

13.1
13.2
13.3

14

15

Secure keyloader sensing
Connect P0651 pin 2 to ground. Check that DC voltage on U0653 pin 4 goes to 0 V. If not, check P0651,
R0690, R0691 and C0667.
Multiplexer in keyload position
Check that U0654 pin 5 goes to 5 VDC. If not check U0654.
Connections through multiplexer

-

Check that P0651 pins 6, 3 and 7 are connected to J0650 pins 10, 12 and 11 respectively. If not check
U0657, U0658 and U0659.

-

Also check D0666, D0661, D0667, D0668, D0669, D0721 and D0722.

Rotary Switch (model II only)
-

Turn rotary while monitoring normal radio operation.

-

If rotary misses steps or jumps more than one step, replace R0697.

Microprocessor U0653
Replacement of U0653 requires a special factory programming and alignment (currently not available in
the RSS (radio service software).

Troubleshooting

9-23

Troubleshooting Chart 1-9, Clock Distribution
CHART 1-9 CLOCK DISTRIBUTION
START

16.8MHz
on U5801-14

No

Check
U5800,
C5754, R5750

No

Check
U5801,
R5759, C5768

Yes

2.1MHz
on U0200-E1

Yes

3.68MHz,
or 7MHz, or 14 MHz
on U0200-D1

No

Check
U0200,
R0204, L0200,
C0208, R0200

Yes

Frequency
on U0200-D1 divided
by 4 on
U0103-34

No

Check
U0103

Yes

Frequency on
No
U0200-D1 on U0104-A3
and Frequency on U0200-D1
divided by 4 on
U0104-A4
Yes

Check
U0104

9-24

Troubleshooting

Check
U0103

Troubleshooting Chart 1-10, SB9600 BUS RX
CHART 1-10 SB9600 BUS RX
START

Perform the following while sending data.
i.e. Control Head button press,
Channel Change, Radio OFF/ON.

Voltages on
SB9600 Voltage
Table correct?

No

Note: For SB 9600 operation the SCI RX,
SCI TX, and Busy paths must all function.

Correct as required.
Suggestion: Check for
shorted zener diodes.

Yes

Data
J0403-6,
J0403-18?

No

Check VR0420,
VR0419

No

Check R0410,
R0411, C0437

No

Check
R0130, U0401

Yes
Data
U0401-2 pin 6,
U0401-2 pin 5?

Yes

Data
U0105-13?
Yes

Data
U0105-14?

No

U0105
OK?

Yes

Check
Q0103, VR0428

No

Yes

Repair or replace
U0105

Data
U0103-63?

No

Check
R0129

No

Problem
Fixed

Yes
Check
U0103

Failure
persists?
Yes
GOTO SB9600
Tx Chart 1-11

Troubleshooting

9-25

Troubleshooting Chart 1-11, SB9600 BUS RX
START

Note: Verify Voltages per
SB9600 Busy Simplified Schematic.
Perform the following while sending data.
i.e. Control Head button press,
Channel Change, Radio OFF/ON.

Data
U0103-64?

Busy
Voltage OK per
SB9600 Voltage
Table

No

Yes

Yes
Check Q0401,
R0413, R0415,
R0414, Q0402

No

No

Check
U0103

Data
J0403-6?
Yes
Check
J0403

SB9600 Voltage Table for Charts 1-10 & 1-11
SB9600 VOLTAGE TABLE
NOMINAL
VOLTAGE

PIN

VOLTAGE DURING
MESSAGING

FUNCTION

5V

J0403-18

0

J0403-6

5

BUS -

0V

BUS +
OPPOSITE POLARITY OF J0403-18

J0403-5

5

J0403-19

5

5

Not Used in
Normal Operation

U0401-2, PIN 8

5

5

OP Amp Vdd

PIN 4

0

0

OP Amp GND

PIN 6

0

PIN 5

5

BUSY

BUS BUS +
OPPOSITE POLARITY OF PIN 6

PIN 7

5
TRACKS STATE OF PIN 5

U0105-11

5

U0105-13
-14

5

U0103-63

5

5

BUS_SCI
U0105 SCI_SELECT
(Flash Prog/Normal Mode Select)

SCI
TRACKS STATE OF
U0401-7 AND J0403-6

SCI_RX
TRACKS STATE OF U0401-7,
J0403-6 AND U0105-13

R0129

9-26

Troubleshooting

5

SCI_RX

Check
U0104

SB9600 BUSY, Simplified Schematic for Charts 1-10 & 1-11
+5
SLIC
BUSY_OUT
U0104-G4

R0424

(5V)
[0.06V]

(5V)
[4.25V]

4.7K

Q0406
(0V)
[4.9V]

BUSY
J0403-5

(0V)
[4.9V]

R0426
4.7K
(5V)
[0V]

R0425
4.7K

C0438
470pf

VR0421

+5

(0V)
[1.5V]
R0427
2K

( V ) - Voltages when radio is in STEADY STATE
[ V ] - Voltages when radio is asserting busy
in order to take control of SB9600 BUS

BUSY_IN
U0103-76

Q0407
C0439
470pf

SB9600, Simplified Schematic for Charts 1-10 & 1-11
VDD
R0408
10K

J0405
C/H CONN
4
15
R0113
0

VDD
= NOT PLACED

SCI_ECHO
TP0002
TP0004

R0409
2.2K

Q0400
18

CLOSED ONLY

BUS -

R0111
0
VR0419
10V

VDD

R0412
4.7K

C0435
470pf

R0410
100

VDD

R0414
22K

BUS +

Q0402
VR0420
10V

Q0401

C0436
470pf

-U0401-2

5

R0407
4.7K
6

6
C0437
33pf

R0411
100

+

7
BUS SCI

R0130
0

4

K4
SCI RX
U0003

R0020
10K

R0021
10K

OPEN ONLY
13 X1
14
X
12

R0129
0

63

U0105

SCI TX

11
TP0005

R0413
10K

R0415
2.2K

VDD
64

J0403

U0104
IN-4 C6
R0452
10K

R0451
4.7K

VDD

K4
SCI TX
U0003

BOOT_SCI
Q0100

C0455
0.1µf

I/O 4

Q0420
VR0429
14V

R0106
10K

C0453
470pf

Q0103

U0103
SCI SELECT

Z

MICRO
PROCESSOR

4.7K

SCI_RX_DATA

5V NORMALLY

VDD

VDD

19

47K

0V NORMALLY
R0421 VR0428
4.7K
10V

R0402
10K
C MOD B / O MOD A/B

VR0427
14V

SCI TX

R0126
47K

VDD

R0449
4.7K
20

SCI RX

X0

33
32

4.7K

C0462
470pf

A

B2

U0104

MOD B

K4
MOD B
U0003

47K
R0433
47K
DATA

MOD A

G4

J0405
C/H CONN

BUSY_OUT

SLICIVA
U0104

Q0426

5

BUSY

R0127
0

76

BUSY BUFFER

BUSY_ IN

SEE "SCI DRIVER" SCHEMATIC

Troubleshooting

9-27

Troubleshooting Chart 1-12, GPIO

CHART 1-12 GPIO
START

Note: Verify RSS programming for
the GPIO function to be correct.
Input

Check cable
used to interface
to the radio

Are
J0403-7,8,16,
20, 21 at the right
voltage
(0 or 5V)?

No

Yes

Repair or replace
defective device

Are
VR0424,VR0425,
VR0426,VR0429,
VR0430,VR0431
OK?

No

Yes

Repair or replace
defective device

Are
Q0414, Q0416,
Q0418, Q0420,
Q0422, Q0424
OK?

No

Yes

Repair or replace
defective component

No

Are
R0437, R0439,
R0440, R0443, R0444,
R0447, R0448, R0451, R0452,
R0455, R0456, R0459,
R0460, R0506
OK?

Yes
Check U0104
and for emergency
check U0510

9-28

Troubleshooting

GPIO
Function?

Output

Are
J0403-7,8,16,
20, 21 at the right
voltage
(0 or 5V)?

Yes

Check cable
used to interface
to the radio

No

Repair or replace
defective device

No

Repair or replace
defective device

No

Repair or replace
defective component

No
Are
VR0425,
VR0426, VR0429,
VR0430, VR0431
OK?
Yes
Are
Q0428, Q0429,
Q0417, Q0419,
Q0421, Q0423
OK?
Yes

Are
R0446, R0450,
R0454, R0458
OK?
Yes
Check
U0104

Troubleshooting Chart 1-13 (1 of 2), Power Control

START

Using RSS, check
personality for the
channel of interest

See Band Specific
TX Troubleshooting
Chart for proper setup

Is it set to
Low Power?

Yes

Set to
High Power
and retest

No
Using RSS, set current limit
values to zero and program
into radio (F8). Go into
Transmitter Power Tuning Screen.

Tuning
values per
Table 1?

No

Is
k9.1_ENB
~5V?

No

k9.1
~9V?
Yes

Yes

Is
PA_PWR_SET
(U0551 pin 2)
voltage per
Table 2?

Check Q0553,
Q0552, R0586,
R0585 or (R0528)

No

Check
U0103

No

SPI_CLK
on pin 67 or
U0103?

Set to values
within range
specified in Table 1
and retest

Yes

During TX

Check Port K1
(pin H9) of U0104

No

No

Yes

SPI_CLK
at U0551 pin 10
during tuning?
Yes

Yes

Is
PA_CNTL
(TP0400)
<1.0V?

No

To Sheet 2
Yes

Q0551
OK?

No

Repair
or replace
Q0551

Yes

Check R0567,
R0569, and
C0562

Yes

Is
U0550 pin 10
<4.0V?

Check
R0404

1

No

Check
pin K7 of U0104

No

DA_SEL
(U0551 pin 6) goes
low during
tuning?
Yes

Check
U0103

No

SPI_DATA
on pin 66 of
U0103?
Yes

Check
R0403

No

SPI_DATA
at U0551 pin 1
during tuning?
Yes

Check
U0551

Is
U0550 pin 9
>5.0V?

No

Check U0550, R0570,
C0568, CR0550, C0554,
C0553, CR0551, C0555

Yes
Is
V_FORWARD
(U0550 pin 12)
>max band specific
values in Table
3?

Yes

GOTO
Band Specific
TX Troubleshooting
Chart

No

Check U0550, R0571,
C0569, CR0551, CR0550,
C0553, C0554, R0570,
R0554, R0564, R0573

Troubleshooting

9-29

Troubleshooting Chart 1-13 (2 of 2), Power Control

CHART 1-13 POWER CONTROL

1
From Sheet 1

Is
PA_CNTL (TP0400)
4.0V?

Is
U0550 pin 3
near 4.65V?

Yes

No

Is
U0550 pin 7
>4.0V?

No

No

GOTO Band Specific
TX Troubleshooting
Chart

Check
R0576, R0582,
C0551 and 9.3V
Supply

Yes
Is
CUR_LIM_SET
(U0551 pin 4)
>7.0V?

No

Check U0550, R0546, R0547,
R0548, R0549, R0557, R0558,
R0559, R0560, R0580, R0583,
R0589, R0598, and C0557

Yes

SPI_CLK
at U0551 pin 10
during tuning?

No

Yes

SPI_CLK
on pin 67 or
U0103?

No

Check
U0103

No

Check
U0103

Yes

Check
R0404

DA_SEL
(U0551 pin 6) goes
low during
tuning?

No

Check
pin K7 of U0104

Yes

SPI_DATA
at U0551 pin 1
during tuning?
Yes

Check
U0551

9-30

Troubleshooting

No

SPI_DATA
on pin 66 of
U0103?
Yes

Check
R0403

Yes

Check R0587, R0550,
C0551, R0551, U0550,
C0231, RT5610,
CR0550, CR0551,
C0555, C0553, C0554

Diagrams and Parts Lists

10

Notes on Sheet Port Connections, Circuit Block Port Connections and Physical Connectors . . . . . . . 10-2
Notes on Sheet Port Connections, Circuit Block Port Connections and Physical Connectors . . . . . . . 10-2
Example of Transceiver Board Block Connection Diagram (110 Watt Radio) . . . . . . . . . . . . . . . . . . . . 10-3
Low Power Radios Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Mid Power Radios Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
High Power Radios Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Control Head Model I Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Control Head Model II Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Control Head Model III Exploded View Diagram and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Control Head Model I Component Locations and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Control Head Model I Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Control Head Model II Component Locations and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Control Head Model II Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Control Head Model III Component Locations and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Control Head Model III Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Main Controller and Audio Power Amplifier and Voltage Regulators Component Locations . . . . . . 10-16
Controller Hierarchy Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Main Controller Blocks Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Controller, Microprocessor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Controller, Power Control Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Controller, Audio Blocks Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Controller, Hear Clear Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Controller, ASFIC Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Controller, Interface Blocks Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Controller, IO RSSI Buffers Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Controller, Emergency Ignition Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Controller, SCI Drivers Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Controller, IO Buffers Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Controller, Audio Power Amplifier and Voltage Regulators, Low and Mid Power Schematic Diagram . 10-29
Controller, Audio Power Amplifier and Voltage Regulators, High Power Schematic Diagram . . . . . . 10-30
Controller Parts List, Common Parts, Continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32
Controller Parts List 800 MHz, 15W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Controller Parts List, 800 MHz 35W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Controller Parts List, 900 MHz 12W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Controller Parts List, VHF 110W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Controller Parts List, UHF1 110 W Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Controller Parts List, Non-Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Integrated Circuits with Pin-Out Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

10-1

Notes on Sheet Port Connections, Circuit Block Port Connections
and Physical Connectors
On the schematic drawings there are three different signal connection markers as described below.

Sheet Port Connection
The Sheet connection appear as
or
. These markers indicate that the signal shown on a given page
continues to another schematic page. Typically the arrow direction indicates whether it is an input of output. These
are used because the complete circuit scheme could not fit on one schematic sheet.

Circuit Block Port Connection
Besides the need to show page to page connections, the schematics also indicate interblock connections. While the
radio is fabricated on one or two PCBs, it is actually composed of several functional circuit blocks which are
interconnected. For example some signals from the receive front end block are connected to the Synthesizer circuit
block. While there is no connector, and these two blocks are connected only by copper traces, the schematic system
creates an imaginary point at which a runner for a given signal from the two blocks meet and assigns a connection
number. This number typically appears on the schematic as IF#### with a
symbol shown. The interconnect
diagram shows many of these blocks which are connected.

Physical Connector
Actual connectors such as the Accessory connector are shown with reference designators Jxxx or Pxxx. These represent
physical connectors.

Schematic Hierarchy
Many of the MCS 2000 schematics are created in a hierarchical fashion. This is similar to a computer directory/
subdirectory format. Like in a computer where there can be a mix of files and subdirectories under a given directory,
some schematic sheets in the manual contain blocks or components, or both, in various sheets.
Pages that follow contain the component level breakdown of the blocks. Components refer to discrete electrical
elements like resistors and capacitors. Blocks refer to a logical grouping of schematic components which appear in
detail on following schematic sheets. This representation allows the reader to start with an overview of the schematic/
circuit topology and navigate into more and more component level detail. Schematic blocks are represented by
rectangular blocks shown by dashed outlines and contain the title of the schematic sheet which they represent.

RF
See Volume:
2a: 800 MHz
2b: VHF
2c: UHF
2d: 900 MHz

Control Head

Controller

(Model I, Model II or Model III)

Regulator and
Audio Power Amplifier

Main Controller

Audio

Microprocessor

Hear Clear

ASFIC

Interface

I/O and
RSSI Buffer

Emergency
Ignition

Figure 10-1 Schematic Diagram Hierarchy
10-2

Power Control

SCI Drivers

I/O Buffers

CONTROLLER
COMMON
(LOGIC)
SECTION
(REFER TO
VOLUME I)

GND
AUD MOD
SYN SEL
LOCK DET
ROSC SEL
9.3
CLK
SPI TX DATA
2.1MHz
RX CNTL SRC
ZIF SEL
DISC
SQUELCH
RSSI

INTERCON 4

GND
GNDD
A+
PA CNTL
CURR SENSE +
CURR SENSE PA TEMP
K 9.1V
V FORWARD
V DRIVE

AUDIO MOD
SYN SEL
LOCK DET
ROSC SEL
9.3
CLK
SPI TX DATA
2.1 MHz
RF REG 5V

LO INJ

RECEIVER IF

RECEIVER
BACK END

IF IN

INTERCONNECT 5

RECEIVER FRONT END

J9601

GND

GND

INT 8

SYNTHESIZER
SECTION

INTERCONNECT 1

6 5

RX IN

9.3

INTERCONNECT 2

INTERCON 3

Block
Interconnect

INTERCONNECT 7

AUDIO AND POWER
REGULATION
SECTION
(REFER TO VOLUME I)

VSUM
VFWD BUF
SPK SPK +
CL UNSW 5V
UNSW 5V
Vaud
Vdd
+5V
PWR RST
SWB+
A+
B+ ON/OFF
CLEAR
AUPA EN
B+ IGNITION
RX AUDIO
GND
GNDD
A+ CNTL
PA CNTL
CURR SENSE +
CURR SENSE PA TEMP
K 9.1V
V FORWARD
V CNTL

4 3 1 8 2 10 9 1112 77
TX INJ

2

1

2

1

J9500

Physical
Connector
J3500

6 5 4

3

1

8

2 10 9 11 12 7

J3501

+

PA BOARD

-

BATTERY

MEPC-97057-O/None

ANTENNA

Figure 10-2 Example of Transceiver Board Block Connection Diagram (110 Watt Radio)

10-3

Exploded View Parts List, Low Power
ITEM
NO.

MOTOROLA
PART NO.

1

3205931V01

Gasket, Front Cover

2

1505908V02

Top Cover

3

3205934V01

Gasket, Top Cover

4

2605652W02

Pressure Plate

5

5584300B04

Handle, 800 MHz only

6

2604802K01

PA Shield, 800 MHz only

1

DESCRIPTION

7

4205938V01

Clip Spring, 2 pcs.

8

0310907C69

Screw, M3X0.5X10,6 pcs*.

9

0905902V01

Power Connector

10

3205457Z02

Gasket, Power Connector

11

0905901V01

Antenna Connector

12

320547Z01

13

4105783W01

Spring Diode

14

2705920V04

Chassis, Low Power

15

4205940V01

Retainer, Accessory Connector Cable

16

HLN6412

17

5405942V01

Label

18

3205935V01

Gasket, 25 D connector

19

2604555E01

Board Slot Shield,
800 MHz only

2

3
4

Gasket, Antenna Connector

5
6
8

Accessory Connector

7

* Number of screws can vary depending on the model.

8
9
10
11
12
13
19

18
14
15

17
16

10-4

Low Power Radios
Exploded View Diagram and Parts List

Exploded View Parts List, Mid Power
ITEM
NO.

MOTOROLA
PART NO.

1

3205931V02

Gasket, Front Cover

2

1505764X01

Top Cover Assembly

3

3205082E97

Gasket, Top Cover

4

5584300B04

Handle

5

2605625X03

PA Shield

6

4205938V01

Clip Spring, 2 pcs.

7

0905902V04

Power Connector

8

3205457Z04

Gasket, Power Connector

9

0905901V06

Antenna Connector

10

3205457Z03

Gasket, Antenna Connector

11

2604693P01

Board Slot Shield,
800 MHz only

12

4205727X01

Clip, Audio PA

13

4105783W01

Spring Diode

14

4205627X01

Retainer, Accessory Connector Cable

15

HLN6412

1
DESCRIPTION

2

3

4

5

Accessory Connector

16

3305873U04

Label, Rear Cover

17

2705816W01

Chassis, Mid Power

18

3205935V01

Gasket, 25 D connector

19

4205496Y01

Clip, PCB

6

20

7
8

pcs.*

20

0310907A20

Screw M3X0.5X10, 12

21

0310911A12

Screw M3x0.5x10, 6 pcs.*

9
10

* Number of screws can vary depending on the model.

19

11
12

18
13
17

16

14

15
MEPC-95410-A

Mid Power Radios
Exploded View Diagram and Parts List

10-5

Exploded View Parts List, High Power
ITEM
NO.

MOTOROLA
PART NO.

1

2705815W02

Chassis, High Power

2

3305179X01

Name Plate

3

4205938V01

Clip, Spring

4

0905902V04

Power Connector

4a

3205457Z04

Gasket, Power Connector

DESCRIPTION

5

0905901V08

RF Connector

5a

3205457Z03

Gasket, RF Connector

6

HUD4021

PA Board, VHF R1

or HUD4016

PA Board, VHF R2

or HUE4018

PA Board, UHF R1

or HUE4020

PA Board, UHF R2

7

0310911A12

Screw M3X0.5X10, 6 pcs.

7a

0310907A20

Screw M3X0.5X10,
VHF 16 pcs./UHF 18 pcs.

8

2605387Z02

PA Shield with Handle

9

1505849X01

Bottom Cover

10

HLN6412

11

3305873U04

12

1

2

3
19
18

17

4

5

6

16

Accessory Connector
Label, Rear Cover

15

7

32059789W01 Gasket, Remote Cable

13

2605265Y02

RF Shield with Handle

14

3205935V01

Gasket, 25 D Connector

15

4205169Y01

Audio PA Clip

16

2805347X02

Plug, High Spec.

17

HUD4019

Transceiver Board, VHF

or HUE4017

Transceiver Board, UHF

18

3205934V01

Gasket, Top Cover

19

4105783W01

Spring Diode

14
8

13
9

12
11
10

10-6

High Power Radios
Exploded View Diagram and Parts List

1

2

3
13
4

12

5
6
7

11

8

10

9

14

MEPC-95406-A/None

Exploded View Parts List, Control Head Model I
ITEM
NO.

MOTOROLA
PART NO.

1

0702103U01

Frame Lock

2

0180757T74

Front End

3

7502101U05

Keypad, Elastomeric

4

2802102U01

Connector, Elastomeric

5

0702103U01

Frame, LCD

6

9102100U01

Colour Sheet, LCD

7

1502102U03

Housing, Control Head Model I

8

3605893W02

Volume Knob

9

7202100U02

LCD Glass

10

3205932V01

Gasket, Speaker

11

5005156Z02

Speaker

12

7608133K01

Ferrite Plate*

13

1580365K01

Shroud, white*

14

see Chapter 5

DESCRIPTION

Replaceable Pushbutton

* Parts have been obsoleted on newer kits.

Control Head Model I
Exploded View Diagram and Parts List

10-7

1
2
19
3
4
5
12

6
7
11

8

58%

10
LCD: see
detail below

20

Exploded View, Control Head Model II
MEPC-95407-A/None

9
LCD Detail

13
14
15
16

ITEM
NO.

MOTOROLA
PART NO.

1

1502455Y04

Housing, Back

2

3202462Y03

Gasket, Housing

3

4602100U01

PCB Retainer

4

HCN4058

5

6102082U04

Light Guide

6

7502565Y04

Keypad, std. with Text

6a

7505241Z03

Keypad, for use with Replaceable
Pushbuttons

7

1502100U10

Housing, Control Head Model II

8

3605893W02

Volume Knob

9

3602100U01

Rotary Knob

10

7608133K01

Ferrite Plate†

11

1580365K01

Shroud, white2

12

0704779P01

Retention Frame

13

2802102U01

Connector, Elastomeric - Gray

14

2802101U01

Connector, Elastomeric - Pink

15

0702103U03

Frame, LCD

16

9102102U01

Reflector Sheet

17

7202076U04

Display Glass

18

1302100U01

Bezel

19

3280542K01

Adhesive Pad

20

see Chapter 5

17
18

DESCRIPTION

PCB Assembly*

Replaceable Pushbutton

* Radios with SDLN4192 may use HCN4058 as replacement
† Parts have been eliminated

10-8

Control Head Model II
Exploded View Diagram and Parts List

1
2
18
3
4
5
6

11

7
8

10
9
LCD: see
detail below

19

MEPC-95408-A/None

Exploded View Parts List, Control Head Model III
ITEM
NO.

MOTOROLA
PART NO.

1

1502455Y04

Housing, Back

2

3202462Y03

Gasket, Housing

3

4602100U01

PCB Retainer

12

4

HCN4059

13

5

6102082U04

Light Guide

6

7502566Y04

Keypad

6a

7505242Z03

Keypad, use with Replaceable
Pushbuttons

7

1502100U08

Housing, Control Head Model III

8

3605893W02

Volume Knob

9

7608133K01

Ferrite Plate2

10

1580365K01

Shroud, white2

11

0704779P01

Retention Frame

12

2802102U01

Connector, Elastomeric - Gray

13

2802101U01

Connector, Elastomeric - Pink

14

0702084U02

Frame, LCD

15

9102102U01

Reflector Sheet

16

7202076U03

Display Glass

17

1302085U01

Bezel

18

3280542K01

Adhesive Pad

19

see Chapter 5

LCD Detail

14
15
16
17

1
2

DESCRIPTION

PCB Assembly1

Replaceable Pushbutton

Radios with SDLN4193 may use HCN40589 as replacement
Parts have been eliminated

Control Head Model III
Exploded View Diagram and Parts List

10-9

LIGHT COMPONENTS SIDE

Control Head Model I Parts List
Reference
Symbol

MOTOROLA
Part Number

11/95

1

36

H0650

7

1

D0661

D0666

D0664

D0662

D0658

D0660

D0667

D0665

D0663

1
3
S0651

2

3

5

2

4

3

6

1

S0663

5

2

4

3

6

1

5

2

4

3

S0664
6

1

5

2

4

3

6

D0671

1

D0669

2

6

D0670

D0668

1

S0662

S0661

S0660

P0651

D0672

8

S0650

D0673

D0682

5

D0659

D0679

135%

3

D0680

R0698

2

1

3

D0681

1

5
4

DEPC-95366-A/None

HEAVY COMPONENTS SIDE

C0650
C0651
C0652
C0653
C0654
C0655
C0656
C0657
C0658
C0659
C0660
C0661
C0662
C0663
C0664
C0665
C0666
C0667
C0668
C0669
C0670
C0671
C0672
C0673
C0674
C0675
C06901

2311049J23
2113743K15
2113741F17
2113741F49
2113743A23
2311049J23
2113741F17
2113741F17
2113741F17
2113741F17
2113741F17
2113741F17
2113741F17
2311049J12
2113740F39
2113740F39
2311049J23
2113743K15
2113741F17
2113741F17
2113741F17
2113741F17
2113741F17
2113741F17
2113741F17
2113743A23
2311049A95

Description

unless otherwise
stated
10uF
0.1uF
470pF
.01uF
0.22uF
10uF
470pF
470pF
470pF
470pF
470pF
470pF
470pF
4.7uF
33pF
33pF
10uF
0.1uF
470pF
470pF
470pF
470pF
470pF
470pF
470pF
.220uF
10uF

R0658

Note: Only one of these are placed:
R0675 only mounted in Speaker Microphone Configurations
R0676 only mounted in Handset Configurations

8

1

Q0657

C0651

R0655

1
2

R0680

9
1

8

C0669

C0674

D0683

C0673

Q0662
1

C0670

C0668
3
D0676

2

U0656
Q0651

3

3
C0671

R0678
D0685
R0679

R0677

R0695

Q0661

R0696

3

1

2

C0672

R0709

R0664

1

D0684

1

C0655

16

3

C0690

R0673 C0654
R0663

R0675

D0674

3

2

1

3

2

2
3

1

Q0663
2

3
C0675

1

R0652

R0681

3

Q0655

3

3
2
2 1 Q0659

R0705

2

R0653

1

3

1

2

R0704

1

U0654

3

R0706 R0707

2 1

R0654

1

U0652

2
1
2

R0687

Q0658
2
1 2
R0690
3
4
5
1

3
8

R0676 R0674

3

3
C0661

3

D0678

1

R0682

3

1
Q0652 R0666

R0701
R0715

1

9

R0689
R0650
R0685 R0691
R0651
R0688

C0653

U0655

C0652
2

1

R0684
Q0656

TP2

R0667

18

J0650
Q0650

9

R0710

Y0650

C0665

C0667

J0652

C0666

C0664 R0692

16

TP1
C0650 2

R0683
R0713

21
20

8

2

3

10

13
12

R0686

7

R0665 R0712

R0716

R0672

R0703

1
R0700 48

R0656
R0711
R0702

U0653

1

C0656

1

3

3
R0657

2
R0671

U0651

1

R0699

C0663

R0697

R0694
2

Q0654
1

Q0660
2

D0677
2 1

D0730 R0693

D0675
2 1

R0708

33

C0662

4

34

C0659

46
47

25
24

36
37

C0658

U0657

C0657

R0660
R0659

R0661

R0662

R0670

1

3 Q0653

5

1

2

TP3 TP4

C0660

8

R0668

R0669

DIDODES:

DEPC-95367-A/None

D0658
D0659
D0660
D0661
D0662
D0663
D0664
D0665
D0666
D0667
D0668
D0669
D0670
D0671
D0672
D0673
D0674
D0675
D0676
D0677
D0678
D0679
D0680
D0681
D0682
D0683
D0684
D0685
D07301

4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4805729G75
4813830A15
4813830A15
4813830A33
4813830A15
4813830A15
4805729G73
4805729G73
4805729G74
4805729G75
4813830A15
4813830A15
4813830A15
4805129M12

10-10

MOTOROLA
Part Number

Description
CONNECTORS:

CAPACITORS, Fixed:

4

Reference
Symbol

LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
LED GREEN
DIODE 5.6V
DIODE 5.6V
DIODE 20V
DIODE 5.6V
DIODE 5.6V
LED YEL
LED YEL
LED RED
LED GREEN
DIODE 5.6V
DIODE 5.6V
DIODE 5.6V
DIODE

J0650
J0652
P0651

2805922V01
2809926G01
2805924V01

PLUG VERT
CONN SUR MT HDR
CONNECTOR MIC

Q0650
Q0651
Q0652
Q0653
Q0654
Q0655
Q0656
Q0657
Q0658
Q0659
Q0660
Q0661
Q0662
Q0663

4813824A17
4813822A20
4813824A10
4813824A17
4813824A10
4813824A10
4813824A17
4813824A17
4813824A10
4813824A10
4813824A10
4813824A10
4813822A08
4813824A10

PNP
NPN
NPN
PNP
NPN
NPN
PNP
PNP
NPN
NPN
NPN
NPN
PNP
NPN

TRANSISTORS:

RESISTORS, Fixed: Ω

R0650
R0651
R0652
R0653
R0654
R0655
R0656
R0657
R0658
R0659
R0660
R0661
R0662
R0663
R0664
R0665
R0666
R0667
R0668
R0669
R0670
R0671
R0672
R0673
R0674
R0676
R0677
R0678
R0679
R0680
R0681
R0682
R0683
R0684
R0685
R0686
R0687
R0688
R0689

0662057A59
0662057A77
0662057A73
0662057A09
0662057A73
0662057A61
0662057A85
0662057A85
0662057A73
0662057A73
0662057A73
0662057A73
0662057A73
0662057A73
0662057A73
0662057A89
0662057A81
0662057A73
0662057A73
0662057A65
0662057A65
0662057A65
0662057A56
0662057A01
0662057A01
0662057B47
0662057A89
0662057A97
0662057A65
0680194M18
0662057A57
0662057A73
0662057A65
0662057A73
0662057A73
0662057A57
0662057A73
0662057A73
0662057A73

Control Head Model I
Component Locations and Parts List

unless otherwise
stated
2.7K
15K
10K
220
10K
3.3K
33K
33K
10K
10K
10K
10K
10K
10K
10K
47K
22K
10K
10K
4.7K
4.7K
4.7K
2K
10
10
0
47K
100K
4.7K
51
2.2K
10K
4.7K
10K
10K
2.2K
10K
10K
10K

Reference
Symbol

MOTOROLA
Part Number

Description

R0690
R0691
R0692
R0693
R0694
R0695
R0696
R0697
R0698
R0699
R0700
R0701
R0702
R0703
R0704
R0705
R0706
R0707
R0708
R0709
R0710
R0711
R0712
R0713
R0715
R0716

0662057A97
0662057A73
0662057B22
0662057A39
0662057A41
0662057A39
0662057A37
0662057A37
1805911V01
0662057A73
0662057B16
0662057A73
0662057A73
0662057A73
0662057A73
0662057A41
0662057A89
0662057A81
0662057A65
0662057A65
0662057A65
0662057A65
0662057A73
0662057A53
0662057A97
0662057A97

100K
10K
1M
390
470
390
330
330
Pot Vol
10K
560K
10K
10K
10K
10K
470
47K
22K
4.7K
4.7K
4.7K
4.7K
10K
1.5K
100K
100K

U0651
U0652
U0653

5102109U01
5113818A03
5102110U03

U0654

5113816A07

U0655

5113805A84

U0656

5113805A84

LCD Segments driver
High Performance
IC UP OTP Prog.
RCH C
Reg. 5V Pos.500MA
MC78M05BD
IC Mux/Demux Dual
4-ch analog
IC Mux/Demux Dual
4-ch analog

Y0650

4880065M01

4.00 MHZ

8405410Z01
or
8402112U01

BOARD P.W.

INTEGRATED CIRCUITS:

FILTERS:

NON REFERENCED ITEMS

1

Not used on 8402112U01

For optimum performance, order replacement diodes, transistors, and circuit modules by Motorola part number only.
•
When ordering crystals, specify carrier frequency, crystal frequency, crystal type number, and Motorola part
number.
•
Part value notations: p=10-12, n=10-9, µ=10-6, m=10-3,
k=103 ,M=106

95%

DEPC-95368-A/None

Control Head Model I
Schematic Diagram

10-11

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MCS2000/MCS2000 Service Manual Vol 1 6881083C20 A MCS2000

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