PRO Series Portable Radios Basic Service Manual
Contents
1. WARNING Do not replace or charge batteries in a hazardous atmosphere Contact sparking may occur while installing or removing batteries and cause an explosion or fire WARNING Do not replace or change accessories in a hazardous atmosphere Contact sparking may occur while installing or removing accessories and cause an explosion or fire WARNING Do not operate the FMRC Approved Product unit in a hazardous location with the accessory contacts exposed Keep the connector cover in place when accessories are not used WARNING Turn radio off before removing or installing a battery or accessory WARNING Do not disassemble the FMRC Approved Product unit in any way that exposes the internal electrical circuits of the unit Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling Radios will not be upgraded to this capability and labeled in the field A modification changes the unit s hardware from its original design configuration Modifications can only be done by the original product manufacturer at one of its FMRC audited manufacturing facilities 2 2 2 2 A 2 2 1 2 2 2 2 2 3 Repair of FMRC Approved Products WARNING Failure to use an FMRC Approved Product unit with an FMRC Approved battery or FMRC Approved accessories specifically approved for that product may result in the dan gerously unsafe condition of an unapproved radio combination being use2. Take care not to damage the display Do not cut bend or pinch the heat seal Display modules contain CMOS devices Be sure to use ESD protection 2 For the PRO7150 and PRO7350 the display module is attached to the front cover with a double sided adhesive pad Carefully pull up on the display module lifting only at the bottom corners remove it from the front cover Use a new piece of double sided adhesive to re mount the display to the cover 3 For the PRO9150 only The display module snaps into the front cover assembly Insert two flat blade screwdrivers between the flexible beam at the top of the display module one on each side Deflect the beam down until it moves past the hooks on the front cover The display module is hooked to the front cover at the base of the display Lift the top of the display module past the hooks and remove from front cover 3 6 5 Speaker Microphone and Universal Connector Flex Disassembly 1 If disassembly of the speaker microphone assembly is necessary remove the dustcover by turning the screw at the bottom of the dustcover counterclockwise with your fingers Lift the dustcover out of its pocket NOTE The dustcover must be removed to remove the speaker microphone assembly flex circuit Radio Disassembly Detailed 3 9 NOTE The speaker is held in place with a two legged retainer bracket The bracket legs are secured by slots in the front cover Be careful not to damage the speaker when removing
3. visual inspection reveals the presence of smudges grease and or grime NOTE Internal surfaces should be cleaned only when the radio is disassembled for service 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 Certain chemicals and their vapors can have harmful effects on certain plastics Avoid using aerosol sprays tuner cleaners and other chemicals Cleaning External Plastic Surface Apply the 0 5 detergent water solution sparingly with a stiff non metallic short bristled brush to work all loose dirt away from the radio Use a soft absorbent lintless cloth or tissue to remove the solution and dry the radio Make sure that no water remains entrapped near the connectors cracks or crevices Cleaning Internal Circuit Boards and Components Isopropyl alcohol 70 may be applied with a stiff non metallic 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 Make sure that controls or tunable components are not soaked with alcohol Do not use high pressure air to hasten the drying process 3 2 3 3 A 3 4 Safe Handling of CMOS and LDMOS Devices since this coul
4. Blue Adapts radio antenna port to BNC cabling of test equipment RLN4510 Battery Eliminator 7 5V Regu Works in combination with Shop Battery Block lator 0180305G54 3 20 3 11 Service Aids Motorola Part No Description Application AA0180305G54 Shop Battery Block Interconnects radio to power supply Provides for AA8180384F68 Bench Test Housing Eliminator troubleshooting of radio when housing is removed AA8180384F66 Bench Test Housing Eliminator For use with PRO9150 long frame radio 0180357A57 Wall Mounted Power Supply Used to supply power to RIB 120 VAC 0180358A56 Wall Mounted Power Supply Used to supply power to RIB 220 VAC 2 prong 3080369B72 Computer Interface Cable Connects computer s serial communications adapter to RIB RLN4008B 6680702Z01 Service Tool Remove radio chassis and knobs Chapter 5 Radio Tuning Programming Cloning and Lowband Antenna Cutting Procedure 5 1 Introduction This chapter provides an overview of the Customer Programming Software CPS and tuner program designed for use in a Windows 95 98 environment These programs are available in separate kits as listed in the Table 5 1 An installation instruction manual is also included with each kit Note Refer to the appropriate program on line help files for the programming procedures Table 5 1 Software Installation Kits Radio Tuning Setup CPS Conventional and UHF Radios HVN902
5. a label attached to the back of your radio You can determine the RF output power frequency band protocols and physical packages The example below shows one portable radio model number and its specific characteristics Table 1 1 Example LAH25KDC9AA3 Radio Model Number Physical Channel Protocol Feature Model Model Packages Spacing Level Revision Package AA H 25 K Cc C 9 AA 2 A N or VHF 2 5W No Display Program Conventional 4F LA 136 mable A 2 174MHz Te g 818 2 E I amp O 2 O Il lt q l En o q lt R D D 6 DU 3 UHF1 4 5W Keypad 25kHz LTR 16F 403 470MHz S E H CK 6 UHF2 6W 1 Line Dis MPT 128F 450 play 256F LTR 527MHz B N GB 8 Low 4 Line Dis Privacy Plus 160F Band R1 play 29 7 42 0MHz c GE Low Privacy Plus Band R2 Roaming 35 0 50 0MHz U FC 800MHz Smart Zone 806 824 851 869 PROSX50 Radio Exploded Mechanical View and Parts List 3 8 PRO5X50 Radio Exploded Mechanical View and Parts List TITA WAY Motorola Please refer to section 7 1 on page 7 1 3680529Z01 3680530Z02 4285611Z01 1380525Z01 1380525Z04 3380644Z01 3280533201 6180527201 HLN9965A HLN9995A HLN9987A HLN9966A HLN9996A HLN9967A Ite 21 22 23 24 25 26 27 28 29 30 31 32 33a 33b 34 35 Motorola 5013920A04 8480549201 211
6. in the front cover PRO5150 and PRO7150 cylinder PRO9150 clam shell Lay the speaker microphone flex on top of keypad option board retainer Catches Retainer Figure 3 10 Lock Retainer Catches to Radio Body 3 12 3 7 5 3 7 6 Radio Reassembly Detailed Chassis Assembly Reassembly Before assembling the main RF board to the chassis ensure that the following steps are done to the chassis 1 Slide on the ground contact if it was removed on the top corner boss of the chassis Do not bend the fingers that extend from this contact 2 Replace the O ring The tabs on the O ring should reach into the chassis and point down 3 Stretch the O ring to place it into the retaining pocket at the bottom end of the chassis NOTE When properly assembled the retainers on the O ring should align with the slots on the chassis If this is not the case remove and replace the O ring until it is aligned with the chassis and completely seated in place around the perimeter Before assembling the main RF board to the chassis ensure that the following additional steps are done to the chassis 1 Ensure that the antenna nut insulator is correctly replaced by pushing it all the way to the top of the antenna nut Replace the battery contact seal if necessary surrounding the battery contact Place the main circuit board straight down on top of the chassis NOTE Be sure the battery contact seal protrudes through the chassis and is n
7. menu bar or by selecting READ DEVICE in the pulldown menu 3 Open the Radio Configuration dialog box See Figure 3 12 EA Device 00141 Fori Aladin Information Bl ndo Configaratica e Tat Hamia pen Beard WeicaSterasa ga Corentine Pazo Base LohiotED Abt Tones Scan Maru 2 Al Signaling q al FP Hesctet I Ta inhib Gaick Eep Oea ride ga Scan Lit F Hiken Fdo Processing Fie PF EA Personal Asadoran 162 ons Fe urs Pare ode al fisco q cos Hon Figure 3 12 Activating the Retrofit 4 Change the Keypad Configuration from No Keypad to Programmable Numeric 5 Write the codeplug back to the radio by clicking on the WRITE icon in the menu bar or by selecting WRITE DEVICE in the pulldown menu NOTE The CPS may display a warning dialog box when you attempt to write the codeplug back to the radio It is safe to ignore this warning Press the OK button 3 14 Radio Reassembly Detailed 3 7 8 Option Board Installation 1 With the keypad retainer removed and the display flex disconnected as shown in Figure 3 13 the keypad backer board can be removed without the use of tools Remove the jumper flex from the connector on the keypad board Notice the orientation of the flex to the connector Arrows on the jumper flex point to the correct way of inserting the flex into the connector Discard the keypad backer board The breakaway tab at the top of all option boards contains an extra
8. the retainer bracket 2 Using a screwdriver push down on the portion of the speaker retainer bracket pointing toward the bottom of the radio Then remove the retainer by slightly pushing it toward the top of the radio until you slide it past the front cover slot 3 Using care not to pull on the flex cable pull the rubber microphone boot from its seated position Unless you are replacing the microphone leave it in the boot NOTE The PRO9150 radio has a different microphone and microphone boot then is used in the other PRO series models These are NOT interchangeable NOTE The speaker microphone assembly flex circuit goes through the front cover wall to the outside wall To replace this assembly you must peel off the universal connector escutcheon label The existing escutcheon cannot be reassembled a new part must be used See item number 10 on the exploded view drawing on paragraph 3 8 4 Peel off the universal connector flex circuit escutcheon label 5 Carefully pry the flex circuit adhesive held backer board away from the front cover and remove the universal connector tail of the speaker microphone assembly through its opening in the front cover After the universal connector tail of the speaker microphone assembly is removed the assembly can be completely removed If it is necessary to replace the speaker or microphone or both do it while the flex circuit is removed from the front cover Speaker Orientation Tab 12 00 P
9. unit Approved configurations are listed in the FM Approval guide published by FMRC or in the product FM Supplement This FM Supplement is shipped with FM Repair of FMRC Approved Products 2 3 Approved radio and battery combination from the manufacturer The Approval guide or the Approval standard Class Number 3605 document for repairs and service can be ordered directly through Factory Mutual Research Corporation located in Norwood Massachusetts 3 1 Chapter 3 Maintenance 3 1 3 2 3 2 1 3 2 2 Introduction This chapter provides details about the following e Preventive maintenance inspection and cleaning e Safe handling of CMOS and LDMOS devices e Disassembly and reassembly of the radio e Installation of Optional Retrofit Kit e Installation of Option Boards 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 It is not recommended to inspect the interior electronic circuitry Cleaning Procedures 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 assembly and battery case These surfaces should be cleaned whenever a periodic
10. 3740A41 4280504201 0304726J04 See detailed service manual 8480475Z02 1480652Z01 7580556201 3280534201 3280536201 3980698201 2780518Z01 2780518Z03 See section 7 5 on page 7 3 HLN9714 Description Microphone Flex Speaker Microphone Capacitor 33pF Retainer Speaker Screw Ctrl RF Board Assembly Flex Keypad Controller Insulator Antenna Pad Thermal Seal Contact Gasket O Ring Contact Ground Compliant VHF Chassis Chassis Battery Beltclip Description Ite Motorola Description Antenna HHLN4154A Nameplate PRO5550 Extended Privacy Plus HHLN4156A Nameplate PRO5650 Extended w Knob Volume Roaming Knob Channel Selector HHLN4158A Nameplate PRO5750 Smart Zone Stop Mechanical 4 Channel 9 1586059401 Dust Cover Universal Connector Escutcheon Top 10 1386058A01 Escutcheon Universal Flex Escutcheon Top 4 Channel 11 1580666Z03 Front Cover Basic Escutcheon Label 1580666Z04 Front Cover with Keypad DTMF Seal Control Top 12 Not Field Escutcheon FM nE Replaceable Litepipe Tx 7 Nameplate PRO5150 Used with 13 7580532Z01 Keypad Side Control Retro Fit 14 1380528Z01 Bezel Side Control Nameplate PRO5150 Wide 15 7580620Z03 Keypad Blank Nameplate PRO5150 DTMF Retro Ser aA EEC Ml Fit 16 0104007J99 Keypad Board Assembly Nameplate PR5350 Used with 17 4280498Z01 Retainer Keypad PCB Retro Fit 18 3586057A01 Felt Speaker Nameplate PRO5350 Wide 19 1480577C01 Boot Mi
11. 5150 403 470 MHz 4W 16 Ch LAH25RDC9DU3 PRO5350 403 470 MHz 4W LTR LAH25RDC9CK3 PRO5450 403 470 MHz 4W MPT LAH25RCC6GC3 PRO5750 403 470 MHz 4W 16 Ch Smart Zone LAH25RDH9AA6 PRO7150 403 470 MHz 4W 128 Ch LAH25RDH9DU6 PRO7350 403 470 MHz 4W LTR LAH25RDH9CK6 PRO7450 403 470 MHz 4W MPT LAH25RCH6GC6 PRO7750 403 470 MHz 4W 128 Ch Smart Zone LAH25RDN9AA8 PRO9150 403 470 MHz 4W 160 Ch Item Description Xx HHLN4158 PRO5750 Label Xx X X X X X X X X NAE6483 Antenna Whip 403 520 MHz X 68P81089C96 PRO5150 User Guide X 68P81088C40 PRO5350 User Guide X 68P81089C39 PRO5450 User Guide X 68P81093C87 PRO5750 User Guide X 68P81088C38 PRO7150 User Guide X 68P81088C43 PRO7350 User Guide X 68P81091C15 PRO7450 User Guide X 68P81093C88 PRO7750 User Guide X 68P81089C99 PRO9150 User Guide x Indicates one of each is required UHF 450 527 MHz 8 2 UHF 450 527 MHz PRO Series UHF 450 527 MHz 8 3 Model Description x Indicates one of each is required LAH25SDC9AA2 PRO5150 450 527 MHz 4W 4 Ch 4 Frequency LAH25SDC9AA3 PRO5150 450 527 MHz 4W 16 Ch LAH25SDC9DU3 PRO5350 450 527 MHz 4W LTR LAH25SDC9CK3 PRO5450 450 527 MHz 4W MPT LAH25SDH9AA6 PRO7150 450 527 MHz 4W 128 Ch LAH25SDH9DU6 PRO7350 450 527 MHz 4W LTR LAH25SDH9CK6 PRO7450 450 527 MHz 4
12. 7 H5197 CPS 800MHz LTR HVN9045 CPS Privacy Plus and Privacy Plus w Roaming HVN9065 CPS MPT Trunking HVN9030 CPS Smart Zone HKVN4001 5 2 Global Radio Tuning Setup A personal computer PC Windows 95 98 NT and a global tuner program are required to tune the radio To perform the tuning procedures the radio must be connected to the PC radio interface box RIB and test equipment shown in Figure 5 1 Service Monitor gt 30 dB Pad or Counter Double Male Transmit Battery Eliminator RF Adaptor axe i a 30 dB Pad Wattmeter N i HLN9756 12VDC 310 3 5 mm to RF Generator Power Ferrule BNC Receive Supply Pady lt a Audio In TX Audio Generator ES Test Box il RLN4460A Battery Block gt or B RX Sinad Meter o180305G54 Program Test Cable AARKN 4074 Ba AC Voltmeter DB15 DB9 Tx Data AC Plug RIB 14 120 230 Vac RLN 4008 7 H zed cal a ax c Computer Interface Lol RIB Power Supply Cable 3080369872 0180357A57 120V 0180358A56 230V Figure 5 1 Radio Tuning Test Equipment Setup Chapter 8 8 1 Model Chart and Test Specifications 8 1 UHF 403 470 MHz PRO Series UHF 403 470 MHz Model Description LAH25RD
13. AA MOTOROLA PRO Series Protessional Radio MANUAL REVISION AA MOTOROLA Professional Radio 6881088C45 C PRO Series Basic Service Manual This revision outlines changes that have occurred since the printing of your manual Use this information to supple ment your manual Installation of these changes in earlier equipment is not necessary except as recommended in Motorola Service and Repair Notes SRNs REVISION CHANGE Please use the following updated pages in place of the existing pages in your basic service manual The table that follows lists the pages attached to this FMR and their related basic service manual chapters along with a descrip tion of each change Discontinue Replace These Basic Service Manual Using Manual Pages with FMR 6881088C45 C Chapter Description Pages Pages Number 1 4 1 4 1 Radio Model Information 3 15 3 16 3 15 3 16 3 Exploded Mechanical View and 3 19 amp 3 20 3 19 amp 3 20 Parts List and Service Aids 5 1 5 1 5 Software Installation Kits 8 1 through 8 7 8 1 through 8 5 8 Model Charts Sections 8 1 through 8 10 2000 by Motorola Inc FMR 1978A 1 8000 W Sunrise Blvd Ft Lauderdale FL 33322 11 7 Printed in U S A November 2000 All Rights Reserved o9 This page intentionally left blank November 2000 2 FMR 1978A 1 Radio Model Information 1 3 Radio Model Information The model number and serial number are located on
14. C9AA2 PRO5150 403 470 MHz 4W 4 Ch 4 Frequency LAH25RDC9AA3 PRO5150 403 470 MHz 4W 16 Ch LAH25RDC9DU3 PRO5350 403 470 MHz 4W LTR LAH25RDC9CK3 PRO5450 403 470 MHz 4W MPT LAH25RCC6GC3 PRO5750 403 470 MHz 4W 16 Ch Smart Zone LAH25RDH9AA6 PRO7150 403 470 MHz 4W 128 Ch LAH25RDH9DU6 PRO7350 403 470 MHz 4W LTR LAH25RDH9CK6 PRO7450 403 470 MHz 4W MPT LAH25RCH6GC6 PRO7750 403 470 MHz 4W 128 Ch Smart Zone LAH25RDN9AA8 PRO9150 403 470 MHz 4W 160 Ch Item Description xX PMLE4171 PRO5150 Back Cover Kit 4 Frequency X PMLE4130 PRO5150 Back Cover Kit X PMLE4148 PRO5350 Back Cover Kit X PMLE4133 PRO5450 Back Cover Kit xX PMLE4192 PRO5750 Back Cover Kit X PMLE4109 PRO7150 Back Cover Kit X PMLE4149 PRO7350 Back Cover Kit X PMLE4134 PRO7450 Back Cover Kit X PMLE4193 PRO7750 Back Cover Kit X PMLE4132 PRO9150 Back Cover Kit X X X X X PMLN4216 PRO5X50 Series Radio Front Housing Kit X PMLN4199 PRO7150 Front Housing Kit X PMLN4365 PRO7350 Front Housing Kit X PMLN4304 PRO7450 Front Housing Kit X PMLN4373 PRO7750 Front Housing Kit X PMLN4218 PRO9150 Front Housing Kit X X HLN9995 PRO5150 Label X HLN9996 PRO5350 Label X HLN9967 PRO5450 Label x Indicates one of each is required 8 2 PRO Series UHF 403 470 MHz UHF 403 470 MHz Model Description LAH25RDC9AA2 PRO5150 403 470 MHz 4W 4 Ch 4 Frequency LAH25RDC9AA3 PRO
15. FOR VEHICLES WITH AN AIR BAG WARNING Do not place a portable radio in the area over an air bag or in the air bag deployment area Air bags inflate with great force If a portable radio is placed in the air bag deployment area and the air bag inflates the radio may be propelled with great force and cause serious injury to occupants of the vehicle POTENTIALLY EXPLOSIVE ATMOSPHERES Turn off your radio prior to entering any area with a potentially explosive atmosphere unless it is a radio type especially qualified for use in such areas as Intrinsically Safe for example Factory Mutual CSA or UL Approved Do not remove install or charge batteries in such areas Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death Note The areas with potentially explosive atmospheres referred to above include fueling areas such as below decks on boats fuel or chemical transfer or storage facilities areas where the air contains chemicals or particles such as grain dust or metal powders and any other area where you would nor mally be advised to turn off your vehicle engine Areas with potentially explosive atmospheres are often but not always posted e BLASTING CAPS AND AREAS To avoid possible interference with blasting operations turn off your radio when you are near electrical blasting caps in a blasting area or in areas posted Turn off two way radio Obey all signs and ins
16. Hz 806 821 851 866 2 1 Chapter 2 Intrinsically Safe Radio Information 2 1 FMRC Approved Equipment Anyone intending to use a radio in a location where hazardous concentrations of flammable material exist hazardous atmosphere is advised to become familiar with the subject of intrinsic safety and with the National Electric Code NFPA 70 National Fire Protection Association Article 500 hazardous classified locations An Approval Guide issued by Factory Mutual Research Corporation FMRC lists manufacturers and the products approved by FMRC for use in such locations FMRC has also issued a voluntary approval standard for repair service Class Number 3605 FMRC Approval labels are attached to the radio to identify the unit as being FM Approved for specified hazardous atmospheres This label specifies the hazardous Class Division Group along with the part number of the battery that must be used Depending on the design of the portable unit this FM label can be found on the back of the radio housing or the bottom of the radio housing Their Approval mark is shown below WARNING Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualified e g FMRC Approved for such use An explosion or fire may result WARNING Do not operate the FMRC Approved Product in a hazardous atmosphere if it has been physically damaged e g cracked housing An explosion or fire may result
17. IEEE C95 1 1999 Edition e National Council on Radiation Protection and Measurements NCRP of the United States Report 86 1986 e International Commission on Non lonizing Radiation Protection ICNRP 1998 e National Radiological Protection Board of the United Kingdom 1995 e Ministry of Health Canada Safety Code 6 Limits of Human Exposure to Radio frequency Electromag netic Fields in the Frequency Range from 3 kHz to 300 GHz 1999 e Australian Communications Authority Radiocommunications Electromagnetic Radiation Human Expo sure Standard 1999 applicable to wireless phones only PORTABLE RADIO OPERATION AND EME EXPOSURE To assure optimal radio performance and make sure human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards always adhere to the following procedures Antenna Care Use only the supplied or an approved replacement antenna Unauthorized antennas modifications or attachments could damage the phone and may violate FCC regulations DO NOT hold the antenna when the two way radio is IN USE Holding the antenna affects call quality and may cause the radio to operate at a higher power level than needed Two Way Radio Operation When using your radio as a traditional two way radio hold the radio in a vertical position with the microphone one to two inches 2 5 to 5 cm away from the lips ii Safety Information Body Worn Operation To mai
18. MLN4216 PRO5150 Front Housing Kit X PMLN4199 PRO7150 Front Housing Kit X PMLN4218 PRO9150 Front Housing Kit X X HLN9995 PRO5150 Label X X X X _ PMAD4023 Antenna Whip 150 161 MHz X X X X PMAD4014 Antenna 136 155 MHz 14 cm X X X X PMAD4015 Antenna 155 174 MHz 14 cm X X 68P81089C96 PRO5150 User Guide X 68P81088C38 PRO7150 User Guide X 68P81089C99 PRO9150 User Guide x Indicates one of each is required 8 4 Low Band 29 7 42 35 50MHz PRO Series Lowband 29 7 42 35 50MHz LAH25BEC9AA3 PRO5150 29 7 42 MHz 6W 16 Ch LAH25CEC9AA3 PRO5150 35 50 MHz 6W 16 Ch Item Description X PMLB4002 PRO5150 Back Cover Kit 29 7 42 MHz X PMLB4010 PRO5150 Back Cover Kit 35 50 MHz X X PMLN4216 PRO5150 Front Housing Kit X X HLN9995 PRO5150 Label X X NAB6064 Antenna Molded Cut to Frequency X X 68P81089C96 PRO5150 User Manual x Indicates one of each is required 800 MHz 806 870 MHz 8 5 8 5 800 MHz 806 870 MHz PRO Series 806 870 MHz A Model Description O LAH25UCC6DU3 PRO5350 800MHz 2 5W LTR LAH25UCC6GB3 PRO5550 800 MHz 2 5W Non Display Privacy Plus LAH25UCC6GB3 PRO5650 800MHz 2 5W Non Display Privacy Plus w Roaming LAH25UCC6FC3 PRO5750 800MHz 3W Smart Zone LAH25UCH6DU6 PRO7350 800MHz 2 5W Display LTR LAH25UCH6GC6 PRO7550 800MHz 2 5W D
19. W MPT LAH25SDN9AA8 PRO9150 450 527 MHz 4W 160 Ch Item Description xX PMLE4172 PRO5150 Back Cover Kit 4 Frequency Xx PMLE4118 PRO5150 Back Cover Kit X PMLE4150 PRO5350 Back Cover Kit Xx PMLE4122 PRO5450 Back Cover Kit X PMLE4119 PRO7150 Back Cover Kit X PMLE4151 PRO7350 Back Cover Kit X PMLE4123 PRO7450 Back Cover Kit X PMLE4121 PRO9150 Back Cover Kit X X X x PMLN4216 PRO5X50 Series Radio Front Housing Kit X PMLN4199 PRO7150 Front Housing Kit X PMLN4365 PRO7350 Front Housing Kit X PMLN4304 PRO7450 Front Housing Kit X PMLN4218 PRO9150 Front Housing Kit X X HLN9995 PRO5150 Label X HLN9996 PRO5350 Label X HLN9967 PRO5450 Label X IX IX X X X X X NAE6483 Antenna Whip 403 520 MHz X X 68P81089C96 PRO5150 User Guide X 68P81088C40 PRO5350 User Guide X 68P81089C39 PRO5450 User Guide X 68P81088C38 PRO7150 User Guide X 68P81088C43 PRO7350 User Guide X 68P81093C15 PRO7450 User Guide X 68P81089C99 PRO9150 User Guide 8 4 VHF 136 174 MHz 8 3 VHF 136 174 MHz PRO Series VHF 136 174 MHz Model Description LAH25KDC9AA2 PRO5150 136 174 MHz 5W 4 Ch 4 Frequency LAH25KDC9AA3 PRO5150 136 174 MHz 5W 16 Ch LAH25KDH9AA6 PRO7150 136 174 MHz 5W 128 Ch LAH25KDN9AA8 PRO9150 136 174 MHz 5W 160 Ch Item Description X PMLD4159 PRO5150 Back Cover Kit 4 Frequency X PMLD4109 PRO5150 Back Cover Kit X PMLD4110 PRO7150 Back Cover Kit X PMLD4112 PRO9150 Back Cover Kit X X P
20. We recommend using the Motorola Static Protection Assembly part number 0180386A82 which includes a wrist strap two ground cords a table mat and a floor mat Wear a conductive wrist strap in series with a 100k resistor to ground Replacement wrist straps that connect to the bench top covering are Motorola part number RSX 4015 Do not wear nylon clothing while handling CMOS devices Do not insert or remove CMOS devices with power applied Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present When straightening CMOS pins provide ground straps for the apparatus used When soldering use a grounded soldering iron 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 lf so the reaction of a discharge to the case would cause the same damage as touching the leads Repair Procedures and Techniques General Parts Replacement and Substitution When damaged parts are replaced identical parts should be used If the identical replacement part is not locally available check the parts list for the proper Motorola part number and order the part from the nearest Motorola Communications parts center listed in Chapter 1 of this manual Rigid Circuit Boards This family of radios uses bonded multi l
21. a Brazil Motorola Do Brasil Rua Bandeira Paulista 580 04532 001 Sao Paulo SP Colombia Brazil Phone 571 615 5759 Phone 5511 821 9991 Puerto Rico Fax 5511 828 0157 Motorola de Puerto Rico A Street 21 Mario Julia Industrial Park Puerto Nuevo Puerto Rico 00922 Phone 787 273 2400 Fax 787 782 3685 Mexico Motorola De Mexico Huatabampo 50 COL Roma Sur Mexico D F 06700 Mexico Phone 525 574 1513 Fax 525 564 2188 1 3 Radio Model Information The model number and serial number are located on a label attached to the back of your radio You can determine the RF output power frequency band protocols and physical packages The example below shows one portable radio model number and its specific characteristics Table 1 1 Example LAH25KDC9AA3 Radio Model Number Radio Model Information Physical Channel Protocol Feature Model Model Packages Spacing Level Revision Package AA H 25 K C Cc 9 AA 2 A N or VHF 2 5W No Display Program Conventional 2F LA A 136 mable A 2 174MHz o 3 B 2 I 3 I sy 2 2 O Il lt q l 7 lt x lt R D D 6 DU 3 UHF1 4 5W Keypad 25kHz LTR 16F 403 470MHz S E H CK 5 UHF2 6W 1 Line Dis MPT 256F LTR 450 play 520MHz B N GB 6 Low 4 Line Dis Privacy Plus 128F Band R1 play 256F LTR 29 7 42 0MHz Cc GE 8 Low Privacy Plus 160F Band R2 Roaming 35 0 50 0MHz U 800M
22. at a minimum separation of 6 inches 15 cm be maintained between a handheld wireless radio and a pacemaker These recommendations are consistent with the independent research by and recommendations of Wireless Technology Research Persons with pacemakers should e ALWAYS keep the radio more than six inches 15 cm from their pacemaker when the radio is turned ON e not carry the radio in the breast pocket use the ear opposite the pacemaker to minimize the potential for interference turn the radio OFF immediately if you have any reason to suspect that interference is taking place Hearing Aids Some digital wireless radios may interfere with some hearing aids In the event of such interference you may want to consult your hearing aid manufacturer to discuss alternatives Other Medical Devices If you use any other personal medical device consult the manufacturer of your device to determine if it is adequately shielded from RF energy Your physician may be able to assist you in obtaining this information Safety Information iii SAFETY AND GENERAL e Use While Driving Check the laws and regulations on the use of radios in the area where you drive Always obey them When using your radio while driving please e Give full attention to driving and to the road e Use hands free operation if available e Pull off the road and park before making or answering a call if driving conditions so require OPERATIONAL WARNINGS e
23. ayer printed circuit boards Since the inner layers are not accessible some special considerations are required when soldering and unsoldering components The printed through holes may interconnect multiple layers of the printed circuit Therefore exercise care to avoid pulling the plated circuit out of the hole When soldering near the 20 pin and 40 pin connectors e Avoid accidentally getting solder in the connector Disassembling and Reassembling the Radio General 3 3 3 5 e Be careful not to form solder bridges between the connector pins e Examine your work closely for shorts due to solder bridges Flexible Circuits The flexible circuits are made from a different material than the rigid boards and require different soldering techniques Excessive prolonged heat on a flexible circuit can damage the material Therefore avoid excessive heat and excessive bending For parts replacement use the ST 1087 Temperature Controlled Solder Station with a 600 700 degree tip and use small diameter solder such as ST 633 The smaller size solder will melt faster and require less heat to be applied to the circuit To replace a component on a flexible circuit 1 Grasp with seizers hemostats the edge of the flexible circuit near the part to be removed 2 Pull gently 3 Apply the tip of the soldering iron to the component connections while pulling with the seizers NOTE Do not attempt to puddle out components Prolonged application of h
24. ccccnnnnn 8 10 Specifications PRO9150 PRO9450 Radios ooooooocncncccooooooncconononcnonononnnnnnnnnnnns 8 12 Specifications 800 MHZ Radio ccomcccccocnnccnnnnoncccncnnnnccnnnnnnccnnnnnnncconnnnnnnnnnos 8 14 Glossary of TOS de G 1 viii Notes Chapter 1 Introduction 1 1 1 2 1 2 1 1 2 2 Scope of Manual This manual is intended for use by service technicians familiar with similar types of equipment It contains service information required for the equipment described and is current as of the printing date Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions NOTE Before operating or testing these units please read the Safety Information Section in the front of this manual Warranty and Service Support Motorola offers support which includes full exchange and or repair of the product during the warranty period and service repair or spare parts support out of warranty Any return for exchange or return for repair to an authorized Motorola Dealer must be accompanied by a Warranty Claim Form Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer See section 1 2 4 on page 1 3 Warranty Period and Return Instructions The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or Reseller contract These conditions
25. crophone Nameplate PRO5450 MPT 20 5085962A02 _ Speaker d S5 800 MHz Only A 26 28 30 PT 8 Es i 27 29 PRO5X50 Exploded View and Parts List 3 16 3 9 PRO7X50 Radio Exploded Mechanical View and Parts List Motorola Part AN oat WP Number Please refer to section 7 1 on page 7 1 3680529201 3680530201 1380525201 3380644201 3280533Z01 6180527201 HLN9969A HLN9979A HLN9980A HHLN4155A HHLN4157A HHLN4159A 1586059A01 1386058A01 Description Antenna Knob Volume Knob Channel Selector Escutcheon Top Escutcheon Label Seal Control Top Litepipe Tx Nameplate PRO7150 Nameplate PRO7350 LTR Nameplate PRO7450 MPT Nameplate PRO7550 Extended Privacy Plus Nameplate PRO7650 Extended w Roaming Nameplate PRO7750 Smart Zone Dust Cover Universal Connector Escutcheon Universal Flex 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Motorola Part Number 1580666201 1580666202 Not Field Replaceable 7580532201 1380528201 7580620202 7580620Z05 7585680Z07 0104007J99 7580540Z01 5104949J05 7580637201 4280498201 3586057A01 1480577C01 5085962A02 5013920A04 8480549201 Description Front Cover with DTMF Front Cover without DTMF Escutcheon FM Keypad Side Control Bezel Side Control Keypad Full Keypad Full MPT Keypad Full Privacy Plus Keypad Board Assemb
26. d cause the liquid to collect in unwanted places After completing of the cleaning process use a soft absorbent lintless 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 and LDMOS Devices Complementary metal oxide semiconductor CMOS devices are used in this family of radios and are 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 first referring to the following CAUTION statement CAUTION This radio contains static sensitive devices Do not open the radio unless you are properly grounded Take the following precautions when working on this unit e Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert CMOS devices into conventional plastic snow trays used for storage and transportation of other semiconductor devices Ground the working surface of the service bench to protect the CMOS device
27. d in a hazardous location Unauthorized or incorrect modification of an FMRC Approved Product unit will negate the Approval rating of the product Repair of FMRC Approved Products REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF THE USER You should not repair or relabel any Motorola manufactured communication equipment bearing the FMRC Approval label FMRC Approved Product unless you are familiar with the current FMRC Approval standard for repairs and service Class Number 3605 You may want to consider using a repair facility that operates under 3605 repair service approval WARNING Incorrect repair or relabeling of any FMRC Approved Product unit could adversely affect the Approval rating of the unit WARNING Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in serious injury or death FMRC s Approval Standard Class Number 3605 is subject to change at any time without notice to you so you may want to obtain a current copy of 3605 from FMRC Per the December 1994 publication of 3605 some key definitions and service requirements are as follows Repair A repair constitutes something done internally to the unit that would bring it back to its original condition Approved by FMRC A repair should be done in an FMRC Approved facility Items not considered as repairs are those in which an action is performed on a unit which does not require the outer casing of the u
28. eat may damage the flexible circuit Disassembling and Reassembling the Radio General Since these radios may be disassembled and reassembled with the use of only four board to casting screws it is important to pay particular attention to the snaps and tabs and how parts align with each other The following tools are required for disassembling the radio e Chassis front cover disassembly tool e Penknife size screwdriver e TORX T6 screwdriver If a unit requires more complete testing or service than is customarily performed at the basic level send this unit to a Motorola Authorized Service Center See Chapter 1 for a list of authorized service centers 3 4 Radio Disassembly Detailed 3 6 Radio Disassembly Detailed The paragraph that follow describe how to disassemble the radio This includes the following major components e Front cover e Chassis e Keypad e Keypad option board e Display assembly e Speaker microphone universal flex connector e PTT assembly 3 6 1 Front Cover from Chassis Disassembly Turn off the radio Pull down on the two battery release buttons With the buttons pulled down the top of the battery will fall from the radio Nee Remove the battery completely from the radio Battery Release Buttons Battery Figure 3 1 Battery Removal Remove the antenna 6 Using the chassis and knob opener tool remove the volume and channel selector knobs off of th
29. eir shafts as shown in Figure 3 2 NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts 7 Separate the chassis from the internal electronics front cover assembly by inserting the chassis and knob opener tool in between the thin retaining wall and the chassis at the bottom of the radio as shown in Figure 3 3 Do not mar the housing O ring sealing area 8 Slowly pry the bottom of the chassis from the cover by pushing the chassis and knob opener tool back while rotating the handle of the tool over and behind the base of the radio This prying action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs Radio Disassembly Detailed 3 5 Chassis and Knob Opener J N gl S NIRO S Knobs Insert opener between knob and switch base then pry off knob Figure 3 2 Knob Removal Chassis and Knob Opener Radio Chassis Figure 3 3 Chassis Removal Marring the front cover O ring sealing area will prevent the radio from sealing properly 9 Lay the chassis down Rotate the front cover backward and slightly away from the chassis NOTE CAUTION Flexible ribbon circuits flexes connecting the front cover assembly and the chassis prevent you from completely separating the two units Display radios and radios with option boards have two flexes The PRO9150 will not lay flat with the two units separated 3 6 Radio Disassembly Detai
30. isplay Privacy Plus LAH25UCH6GB6 PRO7650 800MHz 2 5W Display Privacy Plus w Roaming LAH25UCH6FC6 PRO7750 806 870MHz 3W Smart Zone Item Description xX PMLF4012 PRO5350 Back Cover Kit xX X PMLF4016 PRO5550 PRO5650 Back Cover Kit X PMLF4020 PRO5750 Back Cover Kit X PMLF4013 PRO7350 Back Cover Kit X X PMLF4017 PRO7550 PRO7650 Back Cover Kit X PMLF4021 PRO7750 Back Cover Kit X IX X X PMLN4216 PRO5350 PRO5550 PR05650 PRO5750 Front Housing Kit X PMLN4199 PRO7350 Front Housing Kit X X X PMLN4373 PRO7550 PR0O7650 PRO7750 Front Housing Kit Xx HLN9996 PRO5350 Label X HHLN4154 PRO5550 Label Xx HHLN4156 PRO5650 Label Xx HHLN4158 PRO5750 Label X IX X X X X X X NAF5037 Antenna Whip X IX X X X X X IX NAF5042 Antenna Quarter Wave Stubby 806 870 MHz Xx 68P81088C40 PRO5350 User Guide xX X 68P81093C85 PRO5550 PRO5650 User Guide Xx 68P81093C87 PRO5750 User Guide X 68P81088C43 PRO7350 User Guide X X 68P81093C86 PRO7550 PRO7650 User Guide X 68P81093C88 PRO7750 User Guide x Indicates one of each is required MANUAL REVISION AA MOTOROLA Professional Radio 6881088C45 C PRO Series Basic Service Manual This revision outlines changes that have occurred since the printing of your manual Use this information to supplement your manual REVISION CHANGE On page 8 15 the first row of the Transmitter table in Section 8 14 Specifications 800MHz Radio should read as follo
31. led 10 Lift the latches on the main circuit board to release the flexes from their connectors as shown in Figure 3 4 Latches Flex Connectors Figure 3 4 Unlatching Flex Connectors NOTE At this point if necessary the DTMF Retrofit Kit Procedure can be performed See paragraph 3 7 7 3 6 2 Chassis Assembly Disassembly 1 If disassembly of the chassis or the main board is required then use a TORX screwdriver with a T6 head to remove the four screws holding the main board to the chassis 2 Lift the main board from the chassis as shown in Figure 3 5 e Screws 4 Compliant Ground y Contact y A Radio Retaining Features Figure 3 5 Main Board from Chassis Removal Radio Disassembly Detailed 3 7 CAUTION Refer to the CMOS CAUTION in paragraph 3 3 before removing the main board N Be sure to use ESD protection when handling circuit boards 3 Remove the small O ring retainers from their slots in the chassis Note the alignment of the retainers for reassembly Remove the O ring 5 VHF UHF and lowband only If required in disassembly slide off the ground contact from the top corner boss of the radio chassis 3 6 3 Keypad and Keypad Option Board Disassembly 1 If the disassembly of the keypad or the keypad printed circuit board is required lift the microphone flex circuit up and carefully remove the microphone and its boot from the front cover pocket as shown in Figure 3 6 2 Lay thi
32. ly Pad Display LCD Module Pad LCD Back Retainer Keypad PCB Felt Speaker Boot Microphone Speaker Microphone Flex Speaker Microphone 26 27 28 29 30 31 32 33 34 35 36 37 38 39a 39b 40 41 PRO7X50 Radio Exploded Mechanical View and Parts List Motorola Part Number 2113740A41 4280504201 1480503201 6062884G01 0304726J04 3980667201 See detailed manual 8480475Z02 1480652201 7580556201 3280534201 3280536201 3980698201 2780518Z01 2780518203 See section 7 5 on page 7 3 HLN9714 Description Capacitor 33pF Retainer Speaker Boot Backup Battery Backup Battery Screw Contact Finger Ctrl RF Board Assembly Flex Keypad Controller Insulator Antenna Pad Thermal Seal Contact Gasket O Ring Contact Ground Compliant Chassis Chassis Battery Beltclip PRO7X50 Exploded View and Parts List 3 11 Service Aids 3 11 Service Aids Table 3 1 lists service aids recommended for working on the PRO Series radios 3 19 NOTE 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 Motorola Part No Table 3 1 Description Service Aids Application RLN4460 Portable Test Set Enables connection to audio accessory jack Allows switching for
33. may change from time to time and the following subsections are for guidance purposes only In instances where the product is covered under a return for replacement or return for repair warranty a check of the product should be performed prior to shipping the unit back to Motorola This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty Prior to shipping any radio back to the appropriate Motorola warranty depot please contact Customer Resources Please see page 2 and page 3 in this chapter All returns must be accompanied by a Warranty Claim Form available from your Customer Resources representative Products should be shipped back in the original packaging or correctly packaged to ensure that no damage occurs in transit After Warranty Period After the Warranty period Motorola continues to support its products in two ways 1 Motorola s Radio Parts and Service Group CGISS offers repair service to users and dealers at competitive prices 2 RPSG supplies individual parts and modules that can be purchased by dealers who are capable of performing fault analysis and repair 1 2 Warranty and Service Support 1 2 3 Piece Parts Availability Some replacement parts spare parts and or product information can be ordered directly If a complete Motorola part number is assigned to the part and it is not identified as Depot ONLY it is available from
34. nd the retainer down to fit underneath the boss below the speaker If display keypad or keypad option board are not involved reinsert the microphone and boot into the pocket in the front cover 3 7 4 Keypad and Keypad Option Board Reassembly 1 If you are replacing the PRO7150 or PRO7350 display use a new double sided adhesive display pad item number 17 on the exploded view diagram in paragraph 3 8 Take care to avoid touching the display lens If you are replacing the PRO9150 display place the tabs at the bottom of the display into the reliefs in the front cover Gently snap the beam at the top of the display under the hooks in the front cover Take care to avoid touching the front of the display or the display lens Replace the keypad and the keypad option board Insert display module flex tail into connector on keypad option board Push down on latch closing it securely Display modules contain CMOS devices Be sure to use ESD protection i CAUTION Take care not to damage the display Do not cut bend or pinch the heat seal 4 For PRO7150 or PRO7350 insert the top hooks of the keypad retainer into the slots below the speaker above the display in the front cover For all models snap all four of the retainer arm tabs in place in the front cover NOTE If speaker and microphone not removed pull the speaker microphone flex circuit out of the way during reassembly Reinsert the microphone and boot into the pocket
35. nit to be opened in a manner which exposes the internal electrical circuits of the unit You do not have to be an FMRC Approved Repair Facility to perform these actions Relabeling The repair facility shall have a method by which the replacement of FMRC Approval labels are controlled to ensure that any relabeling is limited to units that were originally shipped from the Manufacturer with an FM Approval label in place FMRC Approval labels shall not be stocked by the repair facility An FMRC Approval label shall be ordered from the original manufacturer as needed to repair a specific unit Replacement labels may be obtained and applied by the repair facility providing satisfactory evidence that the unit being relabeled was originally an FMRC Approved unit Verification may include but is not limited to a unit with a damaged Approval label a unit with a defective housing displaying an Approval label or a customer invoice indicating the serial number of the unit and purchase of an FMRC Approved model Do Not Substitute Options or Accessories The Motorola communications equipment certified by Factory Mutual is tested as a system and consists of the FM Approved portable FM Approved battery and FM Approved accessories or options or both This Approved portable and battery combination must be strictly observed There must be no substitution of items even if the substitute has been previously Approved with a different Motorola communications equipment
36. ntain compliance with FCC RF exposure guidelines if you wear a radio on your body when transmitting always place the radio in a Motorola supplied or approved clip holder holster case or body harness Use of non Motorola approved accessories may exceed FCC RF exposure guidelines If you do not use a body worn accessory ensure the antenna is at least one inch 2 5 cm from your body when transmitting Data Operation When using any data feature of the radio with or without an accessory cable position the antenna of the radio at least one inch 2 5 cm from the body Approved Accessories For a list of approved Motorola accessories look in the accessory section of this manual ELECTROMAGNETIC INTERFERENCE COMPATIBILITY Note Nearly every electronic device is susceptible to electromagnetic interference EMI if inadequately shielded designed or otherwise configured for electromagnetic compatibility FACILITIES To avoid electromagnetic interference and or compatibility conflicts turn off your radio in any facility where posted notices instruct you to do so Hospitals or health care facilities may be using equipment that is sensitive to external RF energy AIRCRAFT When instructed to do so turn off your radio when on board an aircraft Any use of a radio must be in accordance with applicable regulations per airline crew instructions MEDICAL DEVICES Pacemakers The Health Industry Manufacturers Association recommends th
37. ooooonnccccnnnccccncccccccccnnnnnccccnnnncnnnananoss 3 12 3 7 6 Chassis and Front Cover Reassembly oooccccncccccccccccncccnccncoccnnnnnnnnnos 3 12 3 7 7 DTMF Retrofit Kit Procedure Optional Upgrade Procedure 3 13 3 7 8 Option Board Installati0N oooocnnnnnncccnncnnnnnnnnncccccnnncnnnannnnccncnnnnanannss 3 14 3 8 PRO5150 PRO5350 PRO5450 Radio Exploded Mechanical View and Parts Sacar A AAA 3 15 3 9 PRO7150 PRO7350 PRO7450 Radio Exploded Mechanical View and PASS a as 3 16 3 10 PRO9150 PRO9450 Radio Exploded Mechanical View and Parts List 3 17 S DOCE MOS diana 3 19 ato TOSPEQUIDIMEN a sa catadcait 3 21 3 13 Configuring and Wiring the Programming Test Cable ooooonnccccnnnnnnincccccncccnnnnns 3 22 Chapter 4 Transceiver Performance Testing Ad aaa RA matsp a N a a 4 1 42 TAE Test Mode iia E E et te 4 1 4 3 Test Frequencies for Display and Non Display Radios ccecceeeeeeeees 4 6 4 4 Receiver Performance TestS ccccccccccccccccnncccncnnnonannnnnnnn non nnnnnnnnnnnnnnnnnnnnnnnnnnnns 4 7 Chapter 5 Radio Tuning Programming Cloning and Lowband Antenna Cutting Procedure 5 1 INTOdUCUOM a ad arent et err erry tare 5 1 5 2 Global Radio Tuning Setup wai sa nae eee A Alda da Mae 5 1 5 2 1 Initial Test Equipment Setup ccononncccccnnncccnonncccnnnnnnoncnccncnnnnnnnancncnnnno 5 2 537 CPS Programming Setup secan a a coa 5 2 5 4 Cloning Conventional OY oa 5 3 5 4 1 Error Codes Di
38. osition Universal Connector Tail Microphone Boot Microphone Note PRO7150 radio shown Speaker Microphone as an example only Flex Circuit Assembly Figure 3 8 Speaker Microphone Removal 3 10 Radio Reassembly Detailed 3 6 6 PTT Disassembly If required the PTT bezel and the PTT seal assembly can be disassembled using a small screwdriver as follows 3 T Shaped Retainer Tab Tab Figure 3 9 PTT Removal Pry back the T tab found inside the front cover in between the four buttons on the PTT assembly Remove the PTT bezel by slightly bowing it until the top and bottom tabs are released from the slots in the front cover The PTT seal can be easily lifted from the bezel without the use of tools 3 6 7 Control Top Disassembly 1 2 To remove the control top assembly place a screwdriver next to the antenna boss then pry it against the control top escutcheon This lifts the control top escutcheon away from its double sided adhesive Grab the double sided adhesive near the volume potentiometer then lift it away Remove the integrated control top seal emergency button and remove the transmit light pipe 3 7 Radio Reassembly Detailed The paragraph that follow describe how to reassemble the radio This includes the following major components e Control top e Speaker microphone universal flex connector e Keypad option board e Chassis and front cover 3 7 1 Control Top Rea
39. ot pinched under the chassis 4 Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis 5 Do not over torque Torque limit is 3 inch lbs Chassis and Front Cover Reassembly Align the chassis assembly end to end with the front cover assembly Insert the tails of the flex circuits into their respective connectors at the bottom of the front cover Push down the latches on the connectors to hold the flex circuits to the main board E O Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover Push the chassis assembly completely into the top of the front cover until it settles in place Be sure the O ring is properly seated Snap the bottom of the chassis into the front cover ONO Reassemble the knobs dust cover antenna and battery Chassis Figure 3 11 Fastening the Chassis Radio Reassembly Detailed 3 13 3 7 7 DTMF Retrofit Kit Procedure Optional Upgrade Procedure If you are performing an upgrade from a PRO5150 or PRO5350 model with no keypad to a PRO5150 or PRO5350 DTMF model replace the existing front cover kit with kit number HLN9987 and follow the reassembly steps to reassemble the upgraded radio See paragraph 3 7 for details about reassembly To activate the retrofit using the radio software follow these steps 1 Start the Customer Programming Software CPS 2 Read the codeplug data by clicking on the READ icon in the
40. r Accessories oooooooccccccccccccccnncccninnnnnnnon 2 2 Chapter 3 Maintenance 3 1 NE FOCUCTION cartera laten 3 1 3 2 Preventivo Maintenance visitan eu alioli 3 1 32 1 A A al ate 3 1 3 2 2 Cleaning Procedures iaa 3 1 3 3 Safe Handling of CMOS and LDMOS Devices cccccccnccccccccccccnnnnncccncnincnnnannnnnos 3 2 3 4 Repair Procedures and Techniques General oooconnnnccccccncccnnnoncccnnnnncinannnonnns 3 2 3 5 Disassembling and Reassembling the Radio General oonnnnccccnnnncnnncccccccco 3 3 3 6 Radio Disassembly Detailed iii iii 3 4 3 6 1 Front Cover from Chassis Disassembly 0oooococccnnnnccccccnccccnccccccccccnnnnnnns 3 4 3 6 2 Chassis Assembly DisassemMbly ooooonninccnccccnnccinnncccccnoccnnnnnnnccnnnonannnns 3 6 3 6 3 Keypad and Keypad Option Board Disassembly cccccccccnnnnnnnnno 3 7 3 6 4 Display DiISass emba didas 3 8 3 6 5 Speaker Microphone and Universal Connector Flex Disassembly 3 8 3 6 6 PTT Disassembly aid 3 10 3 6 7 Control Top DISasSomblV everest ars 3 10 3 7 Radio Reassembly Detailed ooooocccnnnddininncicnnnnnnoccccccccccnnnnnnncccnnnnnnnnnncnnos 3 10 3 7 1 Control Top Reassembbly coccconocccncncnncnocccccccncncncnnnnccnnnnnnnnnncnnncnnnnnnnns 3 10 Se PTI MO isa rca 3 10 vi 3 7 3 Speaker Microphone and Universal Connector Flex Reassembly 3 11 3 7 4 Keypad and Keypad Option Board ReasseMbly ccoccnncnccccccccccccccccos 3 11 3 7 5 Chassis Assembly Reassembly co
41. radio testing HVN9027 Customer Programming Soft Programs customer option and channel data Tunes ware CPS CD ROM hardware parameters front end power deviation Includes images for high den etc Conventional and LTR products sity 1 4 Mbyte 3 5 floppy dis kettes HVN9030 Customer Programming Soft Same as above MPT protocol products ware CPS HVN9045 Customer Programming Soft Same as above 800 MHz LTR protocol products ware CPS HVN9065 Customer Programming Soft Same as above Privacy Plus Privacy Plus w Roam ware CPS ing protocol products HKVN4001 Customer Programming Soft Same as above Smart Zone protocol products ware CPS AARKN4075 Programming Cable Includes radio interface box RIB capability AARKN4074 Programming Cable Test Connects radio to RIB RLN4008B Cable AARKN4073 Radio to Radio Cloning Cable Allows radio to be duplicated from a master radio by transferring programmed data from the master radio to the other Only for Conventional and LTR models RLN4008 Radio Interface Box Enables communications between radio and com puter s serial communications adapter HLN9756 BNC Adaptor Adapts radio antenna port to BNC cabling of equip ment VHF and UHF B1 only 588031 3B69 SMA to BNC adapter Adapts radio antenna port to BNC cabling of equip ment 800 MHz radios HHLN4133A Rhombic tip adapter Yellow Adapts radio antenna port to BNC cabling of test equipment HHLN4134A Cylindrical tip adapter
42. row of keys and is used only for PRO9150 models For other PRO series models break off and discard the option board tab taking care not to damage the option board Trim any tab fragments that may remain on the option board Retainer Jumper Flex Keypad Note PRO7150 radio shown as an example only Figure 3 13 Changing Keypad Option Board Reassemble the option board to the front cover assembly Insert the display flex circuit into the connector on the option board Insert the jumper flex circuit into the connector on the option board Notice the orientation of the flex circuit Arrows on the jumper flex point to the correct way of inserting the flex into the connector For other PRO series models replace the retainer by placing the two top hooks into the slots below the speaker in the front cover then pivot the retainer into the front cover For all radio models ensure that all four tab arms snap correctly into the front cover With the speaker microphone keypad option board display and retainer correctly in place the front cover assembly can now be reassembled per paragraph 3 7 6
43. s flex circuit to one side 3 To remove the keypad retainer shield Insert the tip of a penknife size flat blade screwdriver in the opening at the end of the keypad retainer arm tab Pry the tab away from the side of the front cover until it moves past the ledges on the side wall Repeat this procedure for the four remaining retainer arm tabs Flat Blade Flex Circuit Tail Screwdriver Keypad Retainer Arm Tabs 4 ze Speaker Microphone Retainer Top Hooks Retainer Figure 3 6 Retainer Removal 4 Note that for the PRO series with the exception of the PRO9150 the two top hooks are still held underneath the front cover right below the speaker Lift the keypad retainer out of the front cover then lift and pivot the two hooks out of the front cover 5 Lift latch on connector located on the keypad board to release the display flex 6 The keypad option board and the keypad can be removed without the use of tools NOTE Atthis point the Option Board Installation Procedure should be performed if necessary See paragraph 3 7 8 3 8 Radio Disassembly Detailed Retainer Display Module 7 d eypa Figure 3 7 Keypad Retainer and Other Boards Removable 3 6 4 Display Disassembly 1 If disassembly involves the removal of the display module with the keypad retainer removed disconnect the display flex from the keypad option board connector by lifting the latch on the connector CAUTION
44. splay Radios Only ooooocccncnncccccccncccnoncccccccnnnnnnanancnnnnn 5 3 5 5 Lowband Molded Antenna Cut Chart cios oil 5 4 Chapter 6 Power Up Self Test 6 1 6 2 6 3 Error Codes Conventional RAdiOsS ccooocccnccnncccnnncnnnnnnnnacnnncnnnnnnnnncnnnncnonaninnns 6 1 ErrorCodes A cies 6 1 Operation Display Codes cove aia naa 6 2 vii Chapter 7 Accessories 7 1 ANtENNAS ula tte ladito ide ated rociado 7 1 7 2 Carrying ACCCSSONCS dido 7 1 7 3 Cary CSCS A es SNE eile RA Ee ost A ite oe 7 2 7 4 EN is 7 2 7 5 A a a a e de hao cate a 7 3 7 6 VOLET OIO Ee ta exes 7 3 7 7 Miscel NEoUS tal ed se haat hF 7 3 7 8 DEIS Ad a Ri Rise state rd 7 3 7 9 Audio Accessories pias told dido ida 7 4 710 Optim BOARS tec en uti ase ret 7 5 7 11 Remote Speaker Microphone 2 ccceeeeeeeeeceeeeeeeeeeeeneeeeeeeeeeeees 7 5 7 12 MANES asii ta 7 5 7 13 Retrofit Front Cover Sd Es 7 6 Chapter 8 Model Chart and Test Specifications 8 14 UHF 403 470 MZ A a a 8 1 UHF 450 527 MHZ oa 8 2 UHF 403 470 MHz MP Dis das 8 3 UHF 450 527 MHZ MP Ti ON 8 4 UHF 403 470 MHZ LTR rd 8 4 UHF 450 527 MHz ET enn 8 5 VEA Ae PUPIL ccs ccs EEEE EE EE EE E EEES 8 5 LowBand29 7 4285 00 HZ aia a 8 6 800 MHZ ETR A uy es a E a e erae aan aa ela ie be Be avarice 8 6 800 MHz Privacy Plus a 8 7 Specifications PRO5150 PRO5350 PRO5450 Radios cccccccccccccccccncnananano 8 7 Specifications PRO7150 PRO7350 PRO7450 Radios ooooccccccccnoccccccc
45. ssembly 1 2 Replace transmit light pipe and control top seal Peel off the liners from a new control top escutcheon and place it in the recess in the front cover Press the control top escutcheon firmly against the adhesive 3 7 2 PTT Reassembly 1 2 3 Put the PTT seal in the PTT bezel Place the bezel top tab in the top slot inside the front cover PTT opening Slightly bow the bezel so that the bottom tab can fall inside the bottom slot Press the PTT assembly against the front cover opening NOTE Look inside the front cover to make sure the T tab is fully engaged with the front cover If necessary press the T tab toward the top of the radio until it becomes fully engaged Radio Reassembly Detailed 3 11 3 7 3 Speaker Microphone and Universal Connector Flex Reassembly 1 Feed the universal connector tail of the speaker microphone flex assembly through the opening in the side wall of the front cover Peel off the adhesive liner on the back of the universal connector tail of the flex circuit Attach the flex tail to the front cover using the guide pins for correct alignment Replace the universal connector escutcheon Make sure that all the connector openings align with the gold pads on the flex circuit Align the notch in the speaker at the twelve o clock position with the tab on the front cover as shown in Figure 3 8 Place the speaker retainer bracket into the hole on the top of the front cover and be
46. the Accessories and Aftermarket Division AAD If no part number is assigned the part is not normally available from Motorola If the part number is appended with an asterisk the part is serviceable by a Motorola Depot only If a parts list is not included this generally means that no user serviceable parts are available for that kit or assembly To Order Parts in Latin America and the Caribbean 7 00 A M to 7 00 P M Central Standard Time Monday through Friday Chicago U S A 1 847 538 8023 Motorola Parts Accessories and Aftermarket Division Attention Order Processing 1313 E Algonquin Road Schaumburg IL 60196 Parts Identification 1 847 538 0021 Voice 1 847 538 8194 Fax Warranty and Service Support 1 3 1 2 4 Technical Support Technical support is available to assist the dealer distributor in resolving any malfunction which may be encountered Initial contact should be by telephone to Customer Resources wherever possible When contacting Motorola Technical Support be prepared to provide the product model number and the unit s serial number Latin America and Caribbean Depots Motorola Plantation Florida U S A 1 2 5 1 800 694 2161 1 954 723 3008 Warranty and Repairs For warranty and repairs contact Motorola Technical Support as listed below Be prepared to provide the product model number and the unit s serial number Colombia Motorola de Colombia Diagonal 127A 17 64 Santa Fe de Bogot
47. tructions OPERATIONAL CAUTIONS fi ANTENNAS Caution Do not use any portable radio that has a damaged antenna If a damaged antenna comes into contact with your skin a minor burn can result e BATTERIES All batteries can cause property damage and or bodily injury such as burns if a conductive material such as jewelry keys or beaded chains touch exposed terminals The conductive material may complete an electrical circuit short circuit and become quite hot Exercise care in handling any charged battery particularly when placing it inside a pocket purse or other container with metal objects This page intentionally left blank Safety Information Table of Contents Chapter 1 Introduction e Scope Ol IAIN a akc ie as Nee ee het 1 1 1 2 Warranty and Service SUppPOlt ooooococcnnncccnoccccccccnnonnncncnnnnnnnnanannnnnnnnnnnnnnnnncnnnnnnnnns 1 1 1 2 1 Warranty Period and Return Instructions ooconnnncnccccnnnnnnnncncccnnnnnn 1 1 1 2 2 Aller Warranty Poodle tia 1 1 1 2 3 Piece Parts Availability olores eii etica 1 2 1 2 4 Technical SUPP OM aia an 1 3 1 2 5 Warranty do An 1 3 Ls Radio Mod llnformation isis 1 4 Chapter 2 Intrinsically Safe Radio Information 2 1 FMRC Approved Equipment cccceeeeeeeneceeeeeeeeeeeeaeeeeeeeeeseeeeeeeeeeeeenaaaees 2 1 2 2 Repair of FMRC Approved Products sicsiiivesisciivcnerssecsincsaneisnanacunaretmedionscancaavtens 2 2 A A 2 2 222 Rola is 2 2 2 2 3 Do Not Substitute Options o
48. ws Specification 800 MHz RF Output Low High NiMH 7 5V 1W 2 5W O 806 824 MHz 2 0W 851 869 MHz O 2002 by Motorola Inc FMR 1978A 2 Commercial Government and Industrial Solutions Sector 8000 W Sunrise Blvd Ft Lauderdale FL 33322 2 20 02 Printed in U S A 2 02 All Rights Reserved SAFETY INFORMATION IMPORTANT INFORMATION ON SAFE AND EFFICIENT OPERATION READ THIS INFORMATION BEFORE USING YOUR TWO WAY RADIO The information provided in this document supersedes the general safety information contained in user guides published prior to July 2000 For information regarding radio use and hazardous atmosphere please refer to the Factory Mutual FM Approval Manual Supplement or Instruction Card which is included with radio models that offer this capability RF Operational Characteristics Your radio contains a transmitter and a receiver When it is ON it receives and transmits radio frequency RF energy Exposure To Radio Frequency Energy Your Motorola Two Way Radio is designed to comply with the following National and International Standards and Guidelines regarding exposure of human beings to radio frequency electromagnetic energy EME United States Federal Communications Commission Code of Federal Regulations 47 CFR part 2 sub part J e American National Standards Institute ANSI Institute of Electrical and Electronic Engineers IEEE C95 1 1992 e Institute of Electrical and Electronic Engineers
Download Pdf Manuals
Related Search