Motorola A8 Two Way Radio Manual
Motorola A8 Two Way Radio Manual
Radio Series
Basic Service Manual
6816101H01-A
Computer Software Copyrights
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, but not limited to, 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, reproduced, modified, reverse-engineered, or distributed in any manner without the express
written permission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to grant,
either directly or by implication, estoppel or otherwise, any license under the copyrights, patents or patent
applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in
the sale of a product.
i
DOCUMENT HISTORY
The following major changes have been implemented in this manual since the previous edition:
Notes
iii
Safety Information
Product Safety and RF Energy Exposure Booklet for Portable Two-Way
Radios
The information provided in this document supersedes the general safety information contained in
user guides published prior to February 2002.
BEFORE USING THIS RADIO, READ THE FOLLOWING INFORMATION WHICH CONTAINS
IMPORTANT OPERATING INSTRUCTIONS FOR SAFE USAGE AND RF ENERGY AWARENESS
AND CONTROL INFORMATION AND OPERATIONAL INSTRUCTIONS FOR COMPLIANCE WITH RF
ENERGY EXPOSURE LIMITS IN APPLICABLE NATIONAL AND INTERNATIONAL STAN-
DARDS. ALSO READ THE OPERATIONAL INSTRUCTIONS FOR SAFE USAGE. FOR RADIOS THAT
HAVE BEEN APPROVED AS INTRINSICALLY SAFE, READ THE INSTRUCTIONS AND
INFORMATION ON INTRINSIC SAFETY ON PAGE vii.
This two-way radio uses electromagnetic energy in the radio frequency (RF) spectrum to provide
communications between two or more users over a distance. It uses radio frequency (RF) energy or
radio waves to send and receive calls. RF energy is one form of electromagnetic energy. Other
forms include, but are not limited to, sunlight and x-rays. RF energy, however, should not be
confused with these other forms of electromagnetic energy, which when used improperly, can cause
biological damage. Very high levels of x-rays, for example, can damage tissues and genetic
material.
Experts in science, engineering, medicine, health, and industry work with organizations to develop
standards for safe exposure to RF energy. These standards provide recommended levels of RF
exposure for both workers and the general public. These recommended RF exposure levels include
substantial margins of protection.
All Motorola two-way radios are designed, manufactured, and tested to ensure they meet
government-established RF exposure levels. In addition, manufacturers also recommend specific
operating instructions to users of two-way radios. These instructions are important because they
inform users about RF energy exposure and provide simple procedures on how to control it.
Please refer to the following websites for more information on what RF energy exposure is and how
to control your exposure to assure compliance with established RF exposure limits:
http://www.fcc.gov/oet/rfsafety/rf-faqs.html
http://www.osha.gov/SLTC/radiofrequencyradiation/index.html
Exposure awareness can be facilitated by the use of a product label directing users to specific user
awareness information. Your Motorola two-way radio has a RF exposure product label. Also, your
Motorola user manual, or separate safety booklet includes information and operating instructions
required to control your RF exposure and to satisfy compliance requirements.
Your Motorola two-way radio is designed and tested to comply with a number of national and
International standards and guidelines (listed below) for human exposure to radio frequency
electromagnetic energy. This radio complies with the IEEE (FCC) and ICNIRP exposure limits for
occupational/controlled RF exposure environments at operating duty factors of up to 50% talk-50%
listen and is authorized by the FCC for occupational use only.
In terms of measuring RF energy for compliance with these exposure guidelines, your radio
generates measurable RF energy only while it is transmitting (during talking), not when it is receiving
(listening) or in standby mode.
NOTE: The approved batteries, supplied with this radio, are rated for a 5-5-90 duty factor (5% talk-
5% listen-90% standby) even though this radio complies with FCC occupational exposure
limits and may operate at duty factors of up to 50% talk.
Your Motorola two-way radio complies with the following RF energy exposure standards and
guidelines:
• United States Federal Communications Commission, Code of Federal Regulations; 47CFR part
2 sub-part J
• American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers
(IEEE) C95. 1-1992
• Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999 Edition
• International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998
• Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radiofrequency Elec-
tromagnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999
• Australian Communications Authority Radiocommunications (Electromagnetic Radiation -
Human Exposure) Standard, 2003
• ANATEL ANNEX to Resolution No. 303 of July 2, 2002 "Regulation of limitation of exposure to
electrical, magnetic and electromagnetic fields in the radio frequency range between 9 KHz and
300 GHz" and "Attachment to resolution # 303 from July 2, 2002"
"Additional Requirements for SMR, Cellular and PCS Product Certification"
Guidelines:
• Do not remove the RF Exposure Label from the device.
• User awareness instructions should accompany device when transferred to other users.
• Do not use this device if the operational requirements described herein are not met.
v
Operating Instructions
• Transmit no more than the rated duty factor of 50% of the time. To transmit (talk), push the Push-
To-Talk (PTT) button. To receive calls, release the PTT button. Transmitting 50% of the time, or
less, is important because this radio generates measurable RF energy exposure only when
transmitting (in terms of measuring for standards compliance).
• Hold the radio in a vertical position in front of the face with the microphone (and
other parts of the radio including the antenna) at least one inch (2.5 centimeters)
away from the nose or lips.
• Antenna should be kept away from the eye. Keeping the radio at a proper distance
is important since RF exposures decrease with increasing distance from the
antenna.
• When worn on the body, always place the radio in a Motorola-approved clip, holder, holster,
case, or body harness for this product. Using approved body-worn accessories is important
because the use of non-Motorola-approved accessories may result in exposure levels, which
exceed the FCC occupational/controlled environment RF exposure limits.
• If you are not using a body-worn accessory and are not using the radio in the intended use posi-
tion in front of the face, ensure the antenna and the radio are kept at least one inch (2.5 centime-
ters) from the body when transmitting. Keeping the radio at a proper distance is important
because RF exposures decrease with increasing distance from the antenna.
Approved Accessories
• Use only Motorola-approved supplied or replacement antennas, batteries, and accessories. Use
of Non-Motorola approved antennas, batteries, and accessories may exceed the FCC (IEEE)
and ICNIRP RF exposure guidelines.
• For a list of Motorola-approved accessories, visit the following website, which lists approved
accessories for your radio model: http://www.motorola.com/governmentandenterprise.
Additional Information
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 Advanced Medical Technology Association (AdvaMed) recommends that a minimum separation
of 6 inches (15 centimeters) be maintained between a handheld wireless radio and a pacemaker.
These recommendations are consistent with those of the U.S. Food and Drug Administration.
vi
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.
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.
Always check the laws and regulations on the use of radios in the areas where you drive.
Operational Warnings
For vehicle with air bags
Refer to vehicle manufacturer's manual prior to installation of electronic equipment to avoid
interference with air bag wiring.
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
(Explosive atmospheres refers to hazard classified locations that may contain hazardous gas,
vapors, or dusts.)
Turn off your radio prior to entering any area with a potentially explosive atmosphere unless it is
a portable radio type especially qualified for use in such areas as Intrinsically Safe (for example,
Factory Mutual, CSA, UL, or CENELEC).
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.
The areas with potentially explosive atmospheres referred to above include fuelin g areas such
as below decks on boats, fuel or chemical transfer or storage facilities, and areas where the
air contains chemicals or particles such as grain, dust or metal powders. Areas with potentially
explosive atmospheres are often, but not always, posted.
Blasting Caps And Blasting 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 instructions.
vii
Operational Cautions
Antennas
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.
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 touches 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.
Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and
the intrinsic safety approval labelling (FM, UL, CSA, CENELEC). Radios will not be upgraded to this
capability and labeled once they have been shipped to the field.
viii
A modification changes the unit's hardware from its original design configuration. Modifications can
only be made by the original product manufacturer.
Repair
REPAIRS FOR MOTOROLA PRODUCTS WITH INTRINSICALLY SAFE APPROVAL ARE THE
RESPONSIBILITY OF THE USER.
• Repairs to a Motorola FM approved radio product should only be done at a location that
has been FM audited under the FM 3605 repairs and service standard.
• Contact Motorola for assistance regarding repairs and service of Motorola intrinsically
safe equipment.
A repair constitutes something done internally to the unit that would bring it back to its original
condition.
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 unit to be opened in a manner that exposes the internal electrical circuits
of the unit.
The intrinsically safe Approval label affixed to radio refers to the intrinsically safe classification of that
radio product, and the approved batteries that can be used with that system.
The manual PN referenced on the intrinsically safe approval label identifies the approved
Accessories and or options that can be used with that portable radio unit.
Using a non Motorola intrinsically safe battery and or accessory with the Motorola approved radio unit
will void the intrinsically safe approval of that radio unit.
Table of Contents
Document History ................................................................................................. .i
Section 1 INTRODUCTION
1.0 Scope of Manual ... .................................................................................................. .1-1
2.0 Warranty and Service Support... .............................................................................. .1-1
2.1 Warranty Period and Return Instructions ... ...................................................... ..1-1
2.2 After Warranty Period ... ................................................................................... ..1-2
2.3 Piece Parts ...................................................................................................... ...1-2
2.4 Technical Support ... .......................................................................................... .1-2
2.5 Further Assistance From Motorola .................................................................. ...1-2
3.0 Radio Model Information... ....................................................................................... .1-3
4.0 Radio Features ... .................................................................................................. ..1-4
Section 2 MAINTENANCE
1.0 Introduction ... ........................................................................................................ ...2-1
2.0 Preventive Maintenance ... ...................................................................................... .2-1
2.1 Inspection ... ...................................................................................................... ..2-1
2.2 Cleaning Procedures ... ................................................................................... ...2-1
3.0 Safe Handling of CMOS and LDMOS Devices ... .................................................. ...2-2
4.0 Repair Procedures and Techniques — General ... .................................................. .2-3
5.0 Disassembling and Reassembling the Radio — General ... ................................... ..2-4
6.0 Radio Disassembly — Detailed ... .......................................................................... ..2-5
6.1 Front Cover from Chassis Disassembly ............................................................ .2-5
6.2 PC Board Disassembly ... ................................................................................. ..2-8
7.0 Radio Reassembly — Detailed ... .......................................................................... ...2-8
7.1 PC Board Reassembly .................................................................................... ...2-8
7.2 Chassis and Front Cover Reassembly ... ......................................................... ..2-9
8.0 Mechanical View and Parts List ... ....................................................................... ...2-12
8.1 Exploded View and Parts List... ..................................................................... ...2-12
9.0 Service Aids ... ..................................................................................................... ...2-16
10.0 Test Equipment... ................................................................................................... .2-17
11.0 Programming Cable (PMDN4043_R) ... .............................................................. ...2-17
12.0 Cloning Cable (PMDN4060_R) ............................................................................. .2-18
13.0 Test Box (PMDN4040_R) ... ................................................................................ ...2-18
Section 5 ACCESSORIES
1.0 Antennas... ............................................................................................................... .5-1
2.0 Carry Accessories ... ............................................................................................... ..5-1
3.0 Carry Cases ... ........................................................................................................ ..5-1
4.0 Chargers ... .............................................................................................................. .5-1
5.0 Batteries... ............................................................................................................... ..5-1
6.0 Audio Accessories ... ............................................................................................... .5-2
7.0 Publications ... ......................................................................................................... ..5-2
8.0 Service Kits ... ........................................................................................................ ...5-2
Section 1
INTRODUCTION
NOTE Before operating or testing these units, please read the Safety Information Section in the
front of this manual.
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 1-2). All returns must be accompanied by a Warranty Claim
Form, available from your Customer Services representative. Products should be shipped back in the
original packaging, or correctly packaged to ensure no damage occurs in transit.
1-2 Warranty and Service Support
After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola's Managed Technical Services (MTS) offers a repair service to both end users and
dealers at competitive prices.
2. MTS supplies individual parts and modules that can be purchased by dealers who are techni-
cally capable of performing fault analysis and repair.
Some replacement parts, spare parts, and/or product information can be ordered directly. If a
complete Motorola part number is assigned to the part, it is available from Motorola‟s Managed
Technical Services (MTS). 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 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.
All orders for parts/information should include the complete Motorola identification number. All part
orders should be directed to your local MTS office. Please refer to your latest price pages.
Technical support is available to assist the dealer/distributor in resolving any malfunction which may
be encountered. Initial contact should be by telephone wherever possible. When contacting
Motorola Technical Support, be prepared to provide the product model number and the unit‟s serial
number.
Type
Model
Series Freq. Band P ower Physical Channel Feature
of Protocol
Level Packages Spacing
Unit Level
LA H 84 J D C 8 AA 4
(136-150 MHz) 5W 16-Channel 12.5/25K Conventional A8
Black
K C
(150-174 MHz) 4W
Q
(403-425 MHz)
R
(450-470 MHz)
T
(490-512 MHz)
H = Portable
LA = Latin America Regional Prefix
1-4 Radio Features
Section 2
MAINTENANCE
1.0 Introduction
This chapter provides details about the following:
• Preventive Maintenance
• Safe Handling of CMOS and LDMOS Devices
• General Repair Procedures and Techniques
• Disassembling and Reassembling the Radio
2.1 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.
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: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Avoid
using aerosol sprays, tuner cleaners, and other chemicals.
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.
2-2 Safe Handling of CMOS and LDMOS Devices
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
since this could 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).
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:
• 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. 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. If so, the reaction of a
discharge to the case would cause the same damage as touching the leads.
Repair Procedures and Techniques — General 2-3
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 the Piece Parts section of this
manual.
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components. The
printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise care to
avoid pulling the plated circuit out of the hole.
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 F 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.
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 heat may damage the
flexible circuit.
Chip Components
Use either the RLN-4062 Hot-Air Repair Station or the Motorola 0180381B45 Repair Station for chip
component replacement. When using the 0180381B45 Repair Station, select the TJ-65 mini-
thermojet hand piece. On either unit, adjust the temperature control to 700 degrees F. (370 degrees
C), and adjust the airflow to a minimum setting. Airflow can vary due to component density.
• To remove a chip component, select a hot-air hand piece and position the nozzle of the hand
piece approximately 1/8” above the component to be removed. Begin applying the hot air.
Once the solder reflows, remove the component using a pair of tweezers. Using solder wick
and a soldering iron or a power desoldering station, remove the excess solder from the pads.
2-4 Disassembling and Reassembling the Radio — General
• To replace a chip component using a soldering iron, select the appropriate micro-tipped
soldering iron and apply fresh solder to one of the solder pads. Using a pair of tweezers,
position the new chip component in place while heating the fresh solder. Once solder wicks onto
the new component, remove the heat from the solder. Heat the remaining pad with the soldering
iron and apply solder until it wicks to the component. If necessary, touch up the first side. All solder
joints should be smooth and shiny.
• To replace a chip component using hot air, select the hot-air hand piece and reflow the solder
on the solder pads to smooth it. Apply a drop of solder paste flux to each pad. using a pair of
tweezers, position the new component in place. Position the hot-air hand piece approximately 1/8”
above the component and begin applying heat. Once the solder wicks to the component, remove
the heat and inspect the repair. All joints should be smooth and shiny.
• Phillips screwdriver
• Flat head screwdriver
• Chassis Opener
• Crab Eye Nut Opener
• Tweezers
If a unit requires more complete testing or service than is customarily performed at the basic level,
send this unit to a Motorola Authorized Service Center.
Radio Disassembly — Detailed 2-5
3
2a
2b
2a
Figure 2-1
3. Slide the battery downwards to remove the battery.
4. Remove the antenna by unscrewing it (see “Figure 2-2”).
5. Pull the On/Off Volume and Channel knobs out of their shafts using the Chassis Opener (see
“Figure 2-2”).
Figure 2-2
2-6 Radio Disassembly — Detailed
6. Insert the Chassis Opener at the bottom of the radio, between the chassis and housing (see
“Figure 2-2”). Lift the chassis gently. Be careful not to damage the housing or the O-ring
underneath.
7. Lift rear chassis away from the front cover. Be careful not to damage the speaker wire under-
neath.
Speaker Wire
Figure 2-3
8. Slide the rear chassis downwards, and away from the front cover.
9. Remove the speaker connector, which connects between the PC Board and the internal
speaker on front cover (see “Figure 2-4”).
Speaker
Connector
Figure 2-4
NOTE Proceed to perform steps 10, 11, and 12 only if there is a need to replace the latch.
12. Slide the battery latch shaft out from the latch.
Figure 2-5
NOTE Proceed to perform steps 13, 14, and 15 only if there is a need to replace the speaker,
speaker bracket or speaker felt.
13. Unscrew the speaker bracket from the housing (see “Figure 2-6”).
14. Remove the speaker from on top of the speaker felt with a flat head screwdriver.
15. Remove the speaker felt from the grille area.
Figure 2-6
2-8 Radio Reassembly — Detailed
Stickers for
Tuning Holes
Shield
Thermal Paste
PCB-Chassis Tape
POGO Pin Housing
Audio Jack Seal
Audio Bracket
PCB
Microphone Boot
1. Place the speaker felt onto the grille area (see “Figure 2-8”) .
2. Place the speaker on top of the felt.
Figure 2-8
3. Stick the speaker poron pad onto the back of speaker magnet.
4. Place the speaker bracket and screw the bracket to the housing.
NOTE Proceed to perform steps 5, 6, 7 and 8 only if there is a need to replace the latch.
5. Slot the battery latch shaft into the latch (see “Figure 2-9”).
Figure 2-9
6. Place the latch onto the housing, with the shaft protruding on the right side of the latch (see
“Figure 2-10”).
2-10 Radio Reassembly — Detailed
Figure 2-10
7. With the battery latch placed on the housing, push the shaft in the housing slot to the left (see
“Figure 2-11”).
Figure 2-11
8. Place the small latch pad onto the right slot space (see “Figure 2-11”).
Radio Reassembly — Detailed 2-11
9. Connect the internal speaker connector to the PC board (“see “Figure 2-12”).
Speaker
Connector
Figure 2-12
10. Place the diecast into the front housing (see “Figure 2-13”).
Figure 2-13
11. Snap the front housing cover firmly into place on the rear diecast .
12. Attach the battery.
13. Attach the On/Off Volume Knob, Channel Knob and Antenna.
2-12 Mechanical View and Parts List
48
49
19 20 30 52 45
18
17
29 50
13 15 10 42
11 41
14 16
43 34
22 9 33
23 8
12 32
7 21
28
37
38 31
5 46 51
39
6 47 36
35 53
44
2
27
24 40
25
26
4
1
Reference
Part No Part Name Qty
No
1 PMDN4001_R Front Housing 1
2 Lightpipe 1
4 PMDN4004_R A8 Nameplate 1
Reference
Part No Part Name Qty
No
6 PMDN4007_R PTT Rubber 1
23 Top Adhesive 1
Reference
Part No Part Name Qty
No
27 † 136 - 150 MHz 5W PC Board (EPP) 1
PMDD4000_R
29 Thermal Pad 1
37 Audio Bracket 1
38 PMDN4032_R Audio Jack Seal 1
39 PMDN4033_R Microphone 1
40 Microphone Boot 1
47 Pogo Pin 2
Mechanical View and Parts List 2-15
Reference
Part No Part Name Qty
No
48 PMAD4050_R Mag One™ 136-150MHz Antenna 1
52 PMDN4025_R O-Ring 1
Motorola Part
No. Description Application
PMDN4054_R Antenna Ground Plate To improve grounding while conducting tuning and
measurement.
PMDN4044_R T-Head Ceramic To tune the variable resistor for audio and sub-audio
Tuning Tool modulation adjustment; tuning points accessible via
battery-chassis area.
PMDN4026_R Flat Ceramic Tuning To tune the variable resistor for audio and sub-audio
Tool (1.8mm) modulation adjustment; requires disassembly of PCB
from chassis to get access to tuning point.
PMDN4053_R Flat Ceramic Tuning
Tool (0.9mm)
TT907A National Repairing Leadless Guide on how to successfully remove and replace
Service Technical Component surface mount devices.
Guide Assemblies
Test Equipment 2-17
Motorola
Description Characteristics Application
Part No.
R2600 Communication Frequency/deviation meter and signal
Analyzer generator for wide-range troubleshooting
and alignment
2.5pi e
2.5pie
8 ohm
1M ohm 1 0uF
AUDIO 1
2 4ohm
1 Mohm
AUDIO 1 S W1
1 0uF
3. 5pe
SW2
8 ohm
or 24 ohm
T X AU DI O
2 . 2Kohm
2 .5 p e
SW 3
Section 3
RADIO TUNING
1.0 Introduction
This chapter provides an overview of the hardware tuning for this Mag One™ Series radio. There is no
software tuning required.
In order to perform the manual tuning procedures, the radio needs to be disassembled to the PC
Board.
1. Transmitter Tuning
a. High Power Tuning
b. Low Power Tuning
c. Frequency Tuning
d. Modulation Balancing
e. Maximum Modulation
f. Subtone Modulation
2. Receiver Tuning
a. Wide Band Sinad Tuning
b. Narrow Band Sinad Tuning
3. PLL Synthesizer Tuning
a. Rx PLL Frequency Tuning
b. Tx PLL Frequency Tuning
For a list of Service Aids required, refer to Table 2-2 on page 2-16Parts ListParts List
3-2 Hardware Tuning Setup and Procedure
Transmitter 136.025
Receiver 136.025
VHF 136 - 150 MHz
Modulation Balance 136.025 (N band)
Transmitter 150.025
Receiver 150.025
VHF 150 - 174 MHz
Modulation Balance 150.025 (N band)
Transmitter 403.025
Receiver 403.025
UHF 403 - 425 MHz
Modulation Balance 424.975(N band)
Transmitter 450.025
Receiver 450.025
UHF 450 - 470 MHz
Modulation Balance 469.975(N band)
TEST BOX
Antenna Port
Acc 8 ohm 24 ohm
Jack
BNC BNC
Radio Tx Rx
N Type
TEST EQUIPMENT
BNC BNC
Input Hi Output
Lo
NOTE The radio may need to be disassembled to the PC board level to access certain tuning
ports. For disassembly, refer to "Radio Disassembly — Detailed" on page 2-5
4. Using the ceramic tool, adjust R425 to tune high power (refer to Figure 3-2).
R425
R426
R216
FL701
R215
3. Using the Audio Analyzer, inject a 0.3kHz tone to the radio through the test box.
4. Key up the radio.
Hardware Tuning Setup and Procedure 3-5
R159 TP1
R174
R172
5. Using the ceramic tool, adjust R174 (refer to Figure 3-3) to modulation balance as per Figure
3-4.
Figure 3-4
3. Using the Audio Analyzer, input a 1kHz tone + 67Hz subtone, 120mV to the radio through the
test box.
4. Key up the radio.
5. Using the ceramic tool, adjust R159 to tune maximum modulation between 2.4 ± 0.02KHz for
narrow band or under 5KHz for wide band (refer to Figure 3-3).
5. Using the ceramic tool, adjust R172 to tune subtone modulation to the configurations in Table
3-2.
5. Then adjust R216 counterclockwise at the point where the Audio Frequency signal appears.
1. Set the radio to the appropriate tuning frequency (refer Table 3-1).
2. Detect output voltage at test point TP1 (refer to Figure 3-3).
3. Using the ceramic tool, adjust C710 to tune the voltage to 5.0V +/-0.1V(refer to Figure 3-5).
R425
R426
C722 R216
C710
FL701 R215
1. Set the radio to the appropriate tuning frequency (refer Table 3-1).
2. Detect output voltage at test point TP1.
3. Using the ceramic tool, adjust C722 to tune the voltage below 5.0V +/-0.1V (refer to
Figure 3-5).
3-8
Notes
Introduction 4-1
Section 4
RADIO PROGRAMMING
1.0 Introduction
The radios can be programmed using the Customer Programming Software (CPS).
1. program your radio with all the necessary parameters, as required by your customers, and
then
2. clone these parameters over to all your customer‟s radios.
Cloning duplicates the contents of Radio 1 (master radio) into Radio 2 (slave radio).
Cloning duplicates the contents of your radio (master radio) into your customer‟s radio (slave radio).
Tuning and alignment information are not affected by cloning.
NOTE The LED will illuminate in RED and the radio will keep transmitting if the cloning cable is still
connected to the radio after cloning is completed. Please disconnect the cloning cable from
the radio
Radio
Programming Cable
PMDN4043_R
Comm
Port
Notes
Antennas 5-1
Section 5
ACCESSORIES
1.0 Antennas
PMAD4050_R Mag One™ 136-150MHz Antenna
4.0 Chargers
AZPMLN4685_R Mag One™ Mid-rate Charger Base
5.0 Batteries
PMNN4071_R Mag One™ NiMH Battery, 1200mAH
7.0 Publications
6815549H01 A8 User Guide (APAC English)
PMDN4041_R RF Adapter
PMDN4042_R Battery Eliminator
Section 6
MODEL CHART AND TEST SPECIFICATION
NOTE For specific models and options configuration, please refer to the Price Pages available on
Motorola Online at https://businessonline.motorola.com/ .
General UHF
Channel Spacing 12.5/25 kHz
UHF
Freq. Stability 0.00025%
Frequency: 403-425MHz (-30°C to +60°C)
Channel Capacity: 16 Spurs/Harmonics: -27 dBm
Power Supply: 7.5 Volts ±20% Audio Response: +1, -3 dB
Dimensions with 107mm x 58mm x 37mm (from 6 dB/oct. Pre-
Standard High Emphasis, 300 to
Capacity NiMH 3000Hz)
Battery: Audio Distortion: <5%
Weight: with 350g @ 1000 Hz, 60%
Standard High Rated Max. Dev.
Capacity NiMH FM Noise: 40dB
Battery:
Receiver
Sealing: Passes rain testing per
IPX4 (EN60529=1991) Hum and Noise 40 dB
Shock and Meets MIL STD 810C, D
Audio Distortion < 5%
Vibration: E and F
Conducted -57 dBm
Dust: Meets MIL STD 810C, D
Emission
E and F
Audio Output 500mW
Humidity: Meets MIL STD 810C, D @ <5% Distortion
E and F
All specifications are subject to change without notice.
UHF Band 2 Information (450 - 470MHz) 6-7
General UHF
Channel Spacing 12.5/25 kHz
UHF
Freq. Stability 0.00025%
Frequency: 450-470 MHz (-30°C to +60°C)
Channel Capacity: 16 Spurs/Harmonics: -27 dBm
Power Supply: 7.5 Volts ±20% Audio Response: +1, -3 dB
Dimensions with 107mm x 58mm x 37mm (from 6 dB/oct. Pre-
Standard High Emphasis, 300 to
Capacity NiMH 3000Hz)
Battery: Audio Distortion: <5%
Weight: with 350g @ 1000 Hz, 60%
Standard High Rated Max. Dev.
Capacity NiMH FM Noise: 40dB
Battery:
Receiver
Sealing: Passes rain testing per
IPX4 (EN60529=1991) Hum and Noise 40 dB
Shock and Meets MIL STD 810C, D
Audio Distortion < 5%
Vibration: E and F
Conducted -57 dBm
Dust: Meets MIL STD 810C, D
Emission
E and F
Audio Output 500mW
Humidity: Meets MIL STD 810C, D @ <5% Distortion
E and F
All specifications are subject to change without notice.
UHF Band 4 Information (490 - 512 MHz) 6-9
General UHF
Channel Spacing 12.5/25 kHz
UHF
Freq. Stability 0.00025%
Frequency: 490-512 MHz (-30°C to +60°C)
Channel Capacity: 16 Spurs/Harmonics: -27 dBm
Power Supply: 7.5 Volts ±20% Audio Response: +1, -3 dB
Dimensions with 107mm x 58mm x 37mm (from 6 dB/oct. Pre-
Standard High Emphasis, 300 to
Capacity NiMH 3000Hz)
Battery: Audio Distortion: <5%
Weight: with 350g @ 1000 Hz, 60%
Standard High Rated Max. Dev.
Capacity NiMH FM Noise: 40dB
Battery:
Receiver
Sealing: Passes rain testing per
IPX4 (EN60529=1991) Hum and Noise 40dB
Shock and Meets MIL STD 810C, D
Audio Distortion <5%
Vibration: E and F
Conducted -57 dBm
Dust: Meets MIL STD 810C, D
Emission
E and F
Audio Output 500mW
Humidity: Meets MIL STD 810C, D @ <5% Distortion
E and F
All specifications are subject to change without notice.
G-1
GLOSSARY OF TERMS
Term Definition
Busy Channel If BCLO is activated, the radio will check for channel activity before transmit-
Lockout (BCLO) ting. If activity is detected, transmission is prohibited. For carrier squelch mode,
radio will not transmit, if it is receiving carrier. For coded squelch mode, it will
not transmit, if it is receiving carrier with different PL/DPL code.
Carrier An electromagnetic signal that is transmitted on a selected frequency for the
purpose of carrying voice or data transmissions along with it. Carrier can then
be received by all radios listening on that frequency.
CD Compact Disk.
Channel A single path separated by frequency or time divisions used for transmitting
and/or receiving voice and/or data.
Codeplug A solid-state chip inside a radio where the radio‟s personality data is stored.
CPS Acronym for Customer Programming Software. Licensed Motorola software
used to program two-way radios with a unique set of features.
Frequency (a) The location of the center of a channel of operation in the radio spectrum.
Measured in Megahertz (MHz).
(b) A computer speed. Measured in Megahertz (MHz).
Model Number The model number identifies the type of radio. This information is stored in the
radio‟s codeplug.
Normal Scan For Normal Scan, the radio assigns equal priority to all members in the Scan
List selected for the current channel. When the radio is scanning a Scan List
(Active Scan), all scan list members (including the Home Channel) will be allocated
equal time to be scanned. For example, if the Home Channel is H1, and
the Scan List Members are Nn, then the scanning sequence is: N1, N2, N3, ...,
H1, N1, N2, ..., etc.
PLL Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a ref-
erence, usually after passing through a frequency divider.
Priority Scan For Priority Scan, the radio assigns the highest priority to the channel defined
in the CPS as Priority Channel. When the radio is scanning a Scan List (Active
Scan), 50% of the scans are targeted at the Priority Channel. For example, if
the Priority Channel is P1, and the non-priority Scan List Members are Nn, then
the scanning sequence is: P1, N1, P1, N2, P1, N3, P1, N4, P1, N5, etc.
Program The transfer of CPS information from the computer‟s temporary memory (RAM)
to the radio.
PTT Push-To-Talk: the switch located on the left side of the radio which, when
pressed, causes the radio to transmit.
RESET Reset line: an input to the microcontroller that restarts execution.
Reverse Burst / Causes a Tone Private Line (TPL) or Digital Private Line (DPL) code to be
Turn Off Code transmitted at the end of a transmission - once PTT is released, and while op-
erating on the current channel. This sub-audible tone causes the receiving ra-
dio to mute its speaker before loss of a carrier is detected. Muting the speaker
eliminates unwanted noise (squelch tail) during loss of carrier detection.
G-2
Term Definition
ROM Read Only Memory.
Scan List The Scan List determines which channels the radio scans, when operating in
the Scan Mode, on the current channel.
Scan List Member The Scan List allows you to select the grouping of channels that make up the
current Scan List Member channels. This grouping of Scan List Member channels
can then be scanned for transmission activity - one at a time, when the radio is in
Scan Mode. A Scan List can have a maximum of 16 Scan List
Members. Scan List Member scanning priority is definable.
Scan Mode When the radio is in one of the two Scan States: Active Scan and Landed Scan.
This mode is initiated when the programmable SCAN button is pressed.
Serial Number Each radio has its own unique serial number. This information is stored in the
radio‟s codeplug.
Software Computer programs, procedures, rules, documentation, and data pertaining to
the operation of a system.
Squelch Muting of audio circuits when received signal levels fall below a pre-determined
value.
Tone Private Line Transmitted when the receiving radio is to only receive calls from radios with
(TPL) specific TPL codes, this creates communications groups while operating in
Conventional Dispatch mode. TPL allows for more use and privacy on a fre-
quency. TPL is transmitted at a sub-audible (not able to be heard) frequency.
Also known as CTCSS.
Tx Frequency A designated frequency used when transmitting carrier for the current channel.
µC Microcontroller.
UHF Ultra High Frequency.
VHF Very High Frequency.
©2007 by Motorola, Inc. All rights reserved.
Mag One by Motorola is registered in the U.S. Patent and Trademark Office.
All other product or service names are the property of their respective
owners.
Motorola, Inc.
8000 West Sunrise Boulevard
Plantation, FL 33322
U.S.A.
March, 2007