ASTRO Digital SABER Portable Radios Basic Service Manual *68P81076C05*
FOREWORD The information contained in this manual relates to all ASTRO Digital SABER radios, unless otherwise specified. SAFETY INFORMATION The Federal Communications Commission (FCC), with its action in General Docket 79-144, March 13, 1985, has adopted a safety standard for human exposure to radio frequency (RF) electromagnetic energy emitted by FCC-regulated equipment. Motorola subscribes to the same safety standard for the use of its products.
TM ™ Digital SABER™ Portable Radios CONTENTS TITLE PAGE FOREWORD...................................................................................................................................................inside front cover LIST OF TABLES .....................................................................................................................................................................ii LIST OF ILLUSTRATIONS ........................................................................
CONTENTS (cont.) TITLE PAGE SECTION VII. BASIC THEORY OF OPERATION A. B. C. D. E. F. Introduction to This Section ..........................................................................................................................23 General Overview .........................................................................................................................................23 Analog Mode of Operation ........................................................................................
PORTABLE RADIO MODEL NUMBERING SYSTEM Typical Model Number: H Position: 1 0 2 4 3 U 4 C 5 F 6 Position 1 - Type of Unit H=Hand-Held Portable Positions 2 & 3 - Model Series 04=ASTRO Position 4 - Frequency Band A=Less than 29.7MHz P=336 to 410MHz B=29.7 to 35.99MHz Q=403 to 437MHz C=36 to 41.99MHz R=438 to 482MHz D=42 to 50MHz S=470 to 520MHz F=66 to 80MHz T=Product Specific G=74 to 90MHz U=806 to 870MHz H=Product Specific V=825 to 870MHz J=136 to162MHz W=896 to 941MHz K=146 to178MHz Y=1.0 to 1.
SPECIFICATIONS FOR VHF RADIOS All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted. GENERAL FCC Designation: Temperature Range: Operating: Storage: RECEIVER AZ489FT3770 Frequency Range: Bandwidth: –30°C to +60°C –40°C to +85°C Power Supply: Nickel-Cadmium Battery (NiCd) or Nickel-Metal-Hydride Battery (NiMH) Quieting Sensitivity (20dBQ): TRANSMITTER 136–178MHz 42MHz 0.5µV Max.
SPECIFICATIONS FOR UHF RADIOS All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted. GENERAL FCC Designation: Temperature Range: Operating: Storage: RECEIVER AZ489FT4783 –30°C to +60°C –40°C to +85°C TRANSMITTER Frequency Range: 403-520MHz Bandwidth: 70MHz Max. Quieting Sensitivity (20dBQ): Usable Sensitivity (12dB SINAD): Battery Voltage: Nominal: Range: Intermodulation: –70dB Selectivity (25kHz Adjacent Channel): –70dB 0.35µV Max.
SPECIFICATIONS FOR 800MHz RADIOS All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted. GENERAL FCC Designation: Temperature Range: Operating: Storage: RECEIVER AZ489FT5750 Frequency Range: Bandwidth: –30°C to +60°C –40°C to +85°C Power Supply: Nickel-Cadmium Battery (NiCd) or Nickel-Metal-Hydride Battery (NiMH) TRANSMITTER 851–870MHz 19MHz RF Power: Frequency Range: 3 Watts 806–825MHz 851–870MHz Quieting Sensitivity (20dBQ): 0.5µV Max.
SECTION I. INTRODUCTION A. General B. Radio Description This manual includes all the information necessary to maintain peak product performance and maximum working-time using the board-replacement service approach. This basic level of service (board-level) is typical of some local service centers, self-maintained customers, and some distributors.
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SECTION II. BASIC MAINTENANCE A. Introduction to This Section This section of the manual describes preventive maintenance, handling precautions, and some basic repair procedures and techniques. Each of these topics provides information vital to the successful operation and maintenance of your radio. B. Preventive Maintenance The ASTRO Digital SABER radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 1.
5. Use a static-safeguarded workstation, which can be accomplished through the use of an anti-static kit (Motorola part number 01-80386A82). This kit includes a wrist strap, two ground cords, a staticcontrol table mat and a static-control floor mat. For additional information, refer to Service and Repair Note SRN-F1052, “Static Control Equipment for Servicing ESD Sensitive Products,” available from Literature Distribution.
SECTION III. RECOMMENDED TEST EQUIPMENT, SERVICE AIDS, AND TOOLS A. Recommended Test Equipment The list of equipment contained in Table 2 includes all of the standard test equipment required for servicing two-way portable radios, as well as several unique items designed specifically for servicing this family of radios.
B. Service Aids and Recommended Tools Refer to the following tables, “Service Aids for Board-Level Troubleshooting” and “Recommended Test Tools for Board-Level Troubleshooting,” for a listing and description of the service aids and tools designed specifically for servicing this family of radios, as well as the more common tools required to disassemble and properly maintain the radio.
SECTION IV. PERFORMANCE CHECKS A. Introduction to This Section This section covers performance checks used to verify the radio meets published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule. b.
f. Press the top programmable button again; “3/1” appears, which indicates that the top programmable button is in the closed condition. • Press 4, “52/1” appears; release, “52/0” appears. • Press 5, “53/1” appears; release, “53/0” appears. g. Rotate the mode/zone selector switch; “4/0” through “4/15” appears, which indicates that the selector switch is in mode/zone position 1 through 15. • Press 6, “54/1” appears; release, “54/0” appears. • Press 7, “55/1” appears; release, “55/0” appears.
Table 8. Receiver Performance Checks Test Name System Analyzer Radio Test Set Comments Frequency error to be ≤ ±600Hz Reference Frequency Mode: PWR MON 4th channel test frequency❖ Monitor: Frequency error Input at RF In/Out TEST MODE, 4 CSQ output at antenna PTT to continuous (during the performance check) Rated Audio Mode: GEN Output level: 1.
Table 9. Transmitter Performance Checks Test Name System Analyzer Radio Test Set Comments Name Reference Frequency Mode: PWR MON 4th channel test frequency❖ Monitor: Frequency error Input at RF In/Out TEST MODE, 4 CSQ PTT to continuous (during the performance check). Frequency error to be ≤ ±600Hz. Power RF As above As above, 4 CSQ As above Refer to Maintenance Specifications page in front of manual.
SECTION V. RADIO ALIGNMENT PROCEDURE A. Introduction to This Section B. General This section describes both receiver and transmitter radio alignment procedures. An IBM personal computer (PC) and radio service software (RSS) are required to align the radio. Refer to the applicable RSS manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC, radio interface box (RIB), and a universal test set as shown in Figure 1.
All service and tuning procedures are performed from the SERVICE menu, which is selected by pressing F2 from the MAIN MENU. Figure 2 illustrates how the RSS alignment SERVICE screens are organized. The SERVICE screens introduce the concept of the “softpot,” an analog SOFTware controlled POTentiometer used for adjusting all transceiver alignment controls. Each SERVICE screen provides the capability to increase or decrease the ‘softpot’ value with the keyboard UP/DOWN arrow keys respectively.
Perform the following procedures in the sequence indicated. NOTE Some of the following screens may vary depending upon the radio under test and the version of radio service software you are using. Refer to your radio service software user’s guide. 3. Press Tab (or Enter or Return) to select a frequency field (starting with the highest frequency shown). Then, press F6 to key the radio. The screen will indicate that the radio is transmitting. 4. Measure the transmit frequency on your service monitor. 5.
D. Transmit Power Alignment 3. Press Tab (or Enter or Return) to select a frequency field (starting with the highest frequency shown). Then, press F6 to key the radio. The screen will indicate that the radio is transmitting. NOTE • All power measurements are to be made at the antenna port. • The transmitter power setting keeps the radiated power at or below the level specified in the exclusionary clause for low power devices of IEEE Standard C95.1-1991. 4.
E. Transmit Deviation Balance (Compensation) Alignment Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low-frequency port) lines. The compensation algorithm is critical to the operation of signalling schemes that have very-low-frequency components (for example, DPL) and could result in distorted waveforms if improperly adjusted. 1. From the SERVICE MENU, press F2 to select the TRANSMITTER ALIGNMENT MENU. 4. Press F4.
F. Transmit Deviation Limit Alignment IMPORTANT NOTE Put the radio in the RF test mode and scroll to the ASTRO test environment, indicated by “AST” on the display (refer to the "Performance Checks" section for details). All other deviation values are derived from the ASTRO test environment mode transmit deviation limit. 3. Press Tab (or Enter or Return) to select a frequency field (starting with the lowest frequency shown). 4. Press F6 to key the radio.
4. Set the RF test generator to the first receive frequency +150Hz. Set the RF level at the radio standard antenna port to 4.0µV with no modulation. G. Front-End Filter Alignment (VHF/UHF Only) NOTE This procedure is only required for tuning the frontend filter varactors in the VHF and UHF models. The 800MHz models utilize a fixed front-end filter. 1. From the SERVICE MENU, press F3 to select the RECEIVER ALIGNMENT MENU. 2. Press F2 to select the FRONT END FILTER ALIGNMENT screen.
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SECTION VI. DISASSEMBLY/REASSEMBLY PROCEDURES 3. CAUTION Before attempting any disassembly or reassembly of the radio, observe the handling precautions described in the “Basic Maintenance” section of this manual. Loosen the two slotted-spanner nuts on the bottom of the radio using the ROTO-TORQ adjustable torque screwdriver with bit No. 66-80370B89. When loosened, the slotted-spanner nuts are captive and will spin freely without separating from the baseplate. A.
5. Gently push the center bottom edge of the front shield assembly and lift it away from the bottom of the chassis. If necessary, use a small slotted screwdriver to disengage the two retaining clips near the bottom outer edges. Next, pull the front shield assembly out from under the plastic top panel. Be careful not to pull against the flexible circuits connecting to the controller board. 7.
8. Remove the center shield from the chassis by inserting a thin slotted screwdriver between each of five center-shield release clips and the corresponding chassis-retaining tabs. 2. Housing Assembly • The housing assembly includes many parts that are not replaceable or repairable. • The insulator on the universal connector can, and should, be replaced if the old insulator has been torn. When replacing the insulator take care to keep it out of the main-seal O-ring's seating area.
• When the knob is properly inserted, the arms of the switch bracket will snap into position (approximately 0.2 inches apart), the knob will not be loose in the switch bracket, and the bracket will hold the switch firmly against the inside of the top control panel. If this is not the case, replace the switch bracket. C. Reassembly 4. that when installed, the four controller shield screws are torqued per specifications; 5.
SECTION VII. BASIC THEORY OF OPERATION A. Introduction to This Section The following theory will help isolate the problem to a particular board. Using circuit board replacement as the basic service approach will maximize workingtime of the radio. B. General Overview The ASTRO Digital SABER radio is a wideband, synthesized, fixed-tuned radio available in the VHF, UHF, and 800MHz bands. All ASTRO Digital SABER radios are capable of both analog operation and ASTRO mode (digital) in 12.
active mixer coupled by transformers. Injection is provided by the VCO through an injection filter. See Table 14 for local oscillator (LO) and first IF information. The frequency generation function is performed by three ICs and associated circuitry. The reference oscillator provides a frequency standard to the synthesizer/prescaler IC, which controls the VCO IC. The VCO IC actually generates the first LO and transmit-injection signals and buffers them to the required power level.
SECTION VIII. BOARD-LEVEL TROUBLESHOOTING A. Introduction to This Section This section of the manual contains troubleshooting charts, error codes, a functional block diagram, interconnect diagrams, and flexible circuit information. This section will help you isolate a problem to the board level. Board-level troubleshooting does not attempt to isolate problems to the component level. Component-level service information can be found in the “ASTRO Digital SABER Portable Radios Detailed Service Manual.
D. Operational Error Codes During radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as error codes on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 16 to aid in understanding particular operational error codes. Table 16.
Table 18. Transmitter Troubleshooting Chart Symptom Possible Cause Correction or Test (Measurements Taken at Room Temperature) No RF Power Out 1. TX Power Level or Frequency Check TX power level and frequency programming (from RSS). 2. No PTT From Control Top With the PTT switch depressed (radio transmitting/keyed), check for INT PTT at P901 pin 6 of the control top/PTT flex; if not there, replace the control top/PTT flex. 3.
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