HT Series MTX Series PRO Series

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1 HT Series MTX Series PRO Series Professional Series Two-Way Portable Radios Detailed Service Manual

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3 Document History The following major changes have been implemented in this manual since the previous edition: Edition Description Date E46-E The Theory of Operation section has been divided into the following six sections: Distribution Keypad UHF Band 1 UHF Band 2 VHF Lowband, 800 MHz, PassPort, and 900 MHz Troubleshooting Flow Charts in the Maintenance section have updated. Added Z05 to UHF Band 1 Added Z14 to UHF Band 1 Added Z02 to UHF Band 1 Added Z03 to UHF Band 1 Added H01 to UHF Band 1 Added Z03 to UHF Band 2 Added Z01 to UHF Band 2 Added Z02 to UHF Band 2 Added H01 to UHF Band 2 Added B16 to VHF Added B17 to VHF Added B11 to VHF Added Z03 to VHF Added Z04 to VHF Added H01 to VHF July, 2005

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5 Title Page HT Series MTX Series PRO Series Professional Series Two-Way Portable Radio Detailed Service Manual Motorola, Inc West Sunrise Boulevard Fort Lauderdale, Florida C46-F

6 Foreword The information contained in this manual relates to all models of the Professional Series two-way portable radios, unless otherwise specified. This manual provides sufficient information to enable qualified service shop technicians to troubleshoot and repair portable radios to the component level. For details on the level 1 or 2 maintenance procedures, refer to the applicable manuals, which are available separately. A list of publications is provided in this manual in the section, "1.3 Related Documents" on page 1-2. Product Safety and RF Exposure Compliance! C a u t i o n Before using this product, read the operating instructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio. ATTENTION! This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements. Before using this product, read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number C98) to ensure compliance with RF energy exposure limits. For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which lists approved accessories: Manual Revisions Changes which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs provide complete replacement pages for all added, changed, and deleted items, including pertinent parts list data, schematics, and component layout diagrams. 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. Document Copyrights duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola. Disclaimer The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product or circuit described herein; nor does it cover any license under its patent rights nor the rights of others. Trademarks MOTOROLA and the Stylized M logo are registered in the US Patent & Trademark Office. All other products or service names are the property of their respective owners. Motorola, Inc

7 Table of Contents iii Table of Contents Foreword...ii Product Safety and RF Exposure Compliance...ii Manual Revisions...ii Computer Software Copyrights...ii Document Copyrights...ii Disclaimer...ii Trademarks...ii List of Figures...xi Intrinsically Safe Radio Information...xix FMRC Approved Equipment...xix Repair of FMRC Approved Products...xx Repair...xx Relabeling...xx Do t Substitute Options or Accessories...xxi Chapter 1 Introduction Scope of Manual Warranty and Service Support Warranty Period Return Instructions After Warranty Period Related Documents Technical Support Piece Parts Availability Radio Model Chart and Specifications Radio Model Information Chapter 2 Radio Power Distribution Chapter 3 Keypad Controller Board MCU Digital Real Time Clock Circuit Description MODB/VSTBY Supply Audio/Signaling

8 iv Table of Contents Chapter 4 UHF Band 1 Theory of Operation Transmitter General Power Amplifier Antenna Switch Harmonic Filter Antenna Matching Network Power Control Integrated Circuit (PCIC) Receiver Receiver Front-End Receiver Back-End Frequency Generation Circuitry Synthesizer Voltage-Controlled Oscillator (VCO) Chapter 5 UHF Band 2 Theory of Operation Transmitter General Power Amplifier Antenna Switch Harmonic Filter Antenna Matching Network Power Control Integrated Circuit (PCIC) Receiver Receiver Front-End Receiver Back-End Frequency Generation Circuitry Synthesizer Voltage-Controlled Oscillator (VCO) Chapter 6 VHF Theory of Operation Transmitter General Power Amplifier Antenna Switch Harmonic Filter Antenna Matching Network Power Control Integrated Circuit (PCIC) Receiver (for all models except those with PCB Z04) Receiver Front-End Receiver Back-End Automatic Gain Control Circuit Receiver (for models with PCB Z04) Receiver Front-End Receiver Back-End

9 Table of Contents v Automatic Gain Control Circuit Frequency Generation Circuitry Synthesizer Voltage-Controlled Oscillator (VCO) Chapter 7 Low Band, 800 MHz, PassPort & 900 MHz Theory of Operation Introduction Low Band Transmitter Power Amplifier (PA) Antenna Switch Harmonic Filter Antenna Matching Transformer Power Control Integrated Circuit (PCIC) Temperature Cut Back Circuit Electrostatic Discharge (ESD) Protection Circuit Low Band Receiver Receiver Front-End Receiver Back-End Automatic Gain Control (AGC) Frequency Generation Circuit Synthesizer Voltage Control Oscillators (VCO) Receive VCO Transmit VCO Buffer Diplexer/Output Filters Prescalar Feedback MHz Transmitter Power Amplifier Antenna Switch Harmonic Filter Power Control Integrated Circuit (PCIC) MHz Receiver Receiver Front-End Receiver Back-End Automatic Gain Control Circuit Frequency Generation Circuit Synthesizer Voltage Control Oscillator (VCO) Trunked Radio Systems Privacy Plus Trunked Systems LTR Trunked Systems MPT Trunked Systems PassPort Trunked Systems Power Supplies

10 vi Table of Contents Microcontroller (MCU) Low Speed Data Filter Keyboard Circuit BackLight Driver and LED's Voice Storage MHz Transmitter Power Amplifier Antenna Switch Harmonic Filter Power Control Integrated Circuit (PCIC) MHz Receiver Receiver Front-End Receiver Back-End Hear Clear IC Receive Path for Radios with Hear Clear Hear Clear Routing of Data/Signaling Automatic Gain Control Circuit Frequency Generation Circuitry MHz Synthesizer MHz Voltage Control Oscillator (VCO) Chapter 8 Maintenance Introduction Preventive Maintenance Inspection Cleaning Safe Handling of CMOS and LDMOS General Repair Procedures and Techniques Recommended Test Tools Replacing the Circuit Board Fuse Removing and Reinstalling the Circuit Board Power Up Self-Test Error Codes UHF Band 1 Troubleshooting Charts Troubleshooting Flow Chart for Controller for all models except PCB Z Troubleshooting Flow Chart for Controller for models with PCB Z Troubleshooting Flow Chart for Receiver for all models except PCB Z03 (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver for all models except PCB Z03 (Sheet 2 of 2) Troubleshooting Flow Chart for Receiver, for models with PCB Z03 (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver, for models with PCB Z03 (Sheet 2 of 2) Troubleshooting Flow Chart for Transmitter Troubleshooting Flow Chart for Synthesizer

11 Table of Contents vii Troubleshooting Flow Chart for VCO UHF Band 2 Troubleshooting Charts Troubleshooting Flow Chart for Controller for all models except those with PCB Z Troubleshooting Flow Chart for Controller for models with PCB Z Troubleshooting Flow Chart for Receiver, for all models except those with PCB Z02 (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver, for all models except those with PCB Z02 (Sheet 2 of 2) Troubleshooting Flow Chart for Receiver, for models with PCB Z02 (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver, for models with PCB Z02 (Sheet 2 of 2) Troubleshooting Flow Chart for Transmitter Troubleshooting Flow Chart for Synthesizer Troubleshooting Flow Chart for VCO VHF Troubleshooting Charts Troubleshooting Flow Chart for Controller for all models except those with PCB Z Troubleshooting Flow Chart for Controller for models with PCB Z Troubleshooting Flow Chart for Receiver, for all models except those with PCB Z04 (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver, for all models except those with PCB Z04 (Sheet 2 of 2) Troubleshooting Flow Chart for Receiver for models with PCB Z04 (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver for models with PCB Z04 (Sheet 2 of 2) Troubleshooting Flow Chart for Transmitter Troubleshooting Flow Chart for Synthesizer Troubleshooting Flow Chart for VCO Low Band Troubleshooting Charts Troubleshooting Flow Chart for Controller Troubleshooting Flow Chart for Receiver (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver (Sheet 2 of 2) Troubleshooting Flow Chart for Transmitter Troubleshooting Flow Chart for Synthesizer Troubleshooting Flow Chart for VCO MHz Troubleshooting Charts Troubleshooting Flow Chart for Controller Troubleshooting Flow Chart for Receiver (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver (Sheet 2 of 2) Troubleshooting Flow Chart for Transmitter Troubleshooting Flow Chart for Synthesizer Troubleshooting Flow Chart for VCO

12 viii Table of Contents 8.15 PassPort Trunking Troubleshooting Chart Keypad Troubleshooting Chart MHz Troubleshooting Charts Troubleshooting Flow Chart for Controller (Sheet 1 of 2) Troubleshooting Flow Chart for Controller (Sheet 2 of 2) Troubleshooting Flow Chart for Receiver (Sheet 1 of 2) Troubleshooting Flow Chart for Receiver (Sheet 2 of 2) Troubleshooting Flow Chart for Transmitter Troubleshooting Flow Chart for Synthesizer Troubleshooting Flow Chart for VCO Chapter 9 Schematic Diagrams, Overlays, and Parts Lists Introduction tes For All Schematics and Circuit Boards Flex Layout Keypad-Controller Interconnect Flex Schematic Keypad-Controller Interconnect Flex Parts List Universal Flex Connector Universal Connector Flex Schematic Universal Flex Connector Parts List Keypad Top and Bottom Overlays Keypad Circuit Board/Schematic Diagrams and Parts List Controller Circuit Board/Schematic Diagrams and Parts List UHF Band 1 Circuit Board/Schematic Diagrams and Parts List (PCB Z03) UHF Band 1 Circuit Board/Schematic Diagrams and Parts List (PCB Z13 / Z05) UHF Band 1 Circuit Board/Schematic Diagrams and Parts List (PCB Z14) UHF Band 1 Circuit Board/Schematic Diagrams and Parts List (PCB Z02) UHF Band 1 Circuit Board/Schematic Diagrams and Parts List (PCB Z03) UHF 1 Band Circuit Board/Schematic Diagrams and Parts List (PCB H01) UHF Band 1 Circuit Board/Schematic Diagrams and Parts List UHF Band 2 Circuit Board/Schematic Diagrams and Parts List (PCB Z02) UHF Band 2 Circuit Board/Schematic Diagrams and Parts List (PCB Z06 / Z03) UHF Band 2 Circuit Board/Schematic Diagrams and Parts List (PCB Z01) UHF Band 2 Circuit Board/Schematic Diagrams and Parts List (PCB Z02) UHF Band 2 Circuit Board/Schematic Diagrams and Parts List (PCB H01) UHF Band 2 Circuit Board/Schematic Diagrams and Parts List

13 Table of Contents ix 9.19 VHF Circuit Board/Schematic Diagrams and Parts List (PCB B09) VHF Circuit Board/Schematic Diagrams and Parts List (PCB B12) VHF Circuit Board/Schematic Diagrams and Parts List (PCB B16 / B17 / B11) VHF Circuit Board/Schematic Diagrams and Parts List (PCB Z03) VHF Circuit Board/Schematic Diagrams and Parts List (PCB Z04) VHF Circuit Board/Schematic Diagrams and Parts List (PCB H01) VHF Circuit Board/Schematic Diagrams and Parts List Low Band Circuit Board/Schematic Diagrams and Parts List MHz Circuit Board/Schematic Diagrams and Parts List (PCB Z02 / Z03 (Rev B) PassPort Circuit Board/Schematic Diagram MHz Circuit Board/Schematic Diagrams and Parts List (PCB Z01) Appendix A Replacement Parts Ordering... A-1 A.1 Basic Ordering Information...A-1 A.2 Transceiver Board and VOCON Board Ordering Information...A-1 A.3 Motorola Online...A-1 A.4 Mail Orders...A-1 A.5 Telephone Orders...A-2 A.6 Fax Orders...A-2 A.7 Parts Identification...A-2 A.8 Product Customer Service...A-2

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15 List of Figures List of Figures xi Figure 2-1. DC Power Distribution Block Diagram Figure 3-1. Keypad Block Diagram Figure 3-2. Controller Block Diagram Figure 3-3. RTC Circuit Figure 4-1. Transmitter Block Diagram Figure 4-2. UHF Receiver Block Diagram Figure 4-3. Frequency Generation Unit Block Diagram Figure 4-4. Synthesizer Block Diagram Figure 4-5. VCO Block Diagram Figure 5-1. Transmitter Block Diagram Figure 5-2. UHF Receiver Block Diagram Figure 5-3. Frequency Generation Unit Block Diagram Figure 5-4. Synthesizer Block Diagram Figure 5-5. VCO Block Diagram Figure 6-1. Transmitter Block Diagram Figure 6-2. VHF Receiver Block Diagram Figure 6-3. VHF Receiver Block Diagram Figure 6-4. Frequency Generation Unit Block Diagram Figure 6-5. Synthesizer Block Diagram Figure 6-6. VCO Block Diagram Figure 7-1. Low Band Transmitter Block Diagram Figure 7-2. Low Band Receiver Block Diagram Figure 7-3. Low Band Frequency Generation Unit Block Diagram Figure 7-4. Low Band Synthesizer Block Diagram Figure MHz Transmitter Block Diagram Figure MHz Receiver Block Diagram Figure MHz Frequency Generation Unit Block Diagram Figure MHz Synthesizer Block Diagram Figure MHz VCO Block Diagram Figure Transmitter Block Diagram Figure MHz Receiver Block Diagram Figure Frequency Generation Unit Block Diagram Figure Synthesizer Block Diagram Figure VCO Block Diagram Figure 8-1. UHF/VHF/Low Band/800 MHz/900 MHz Circuit Board Fuse Locations Figure 8-2. Circuit Board Removal and Reinstallation Figure 9-1. Keypad-Controller Interconnect Flex Figure 9-2. Keypad-Controller Interconnect Flex Schematic Diagram Figure 9-3. Universal Flex Connector Figure 9-4. Universal Flex Connector Schematic Diagram Figure 9-5. Keypad Top and Bottom Board Overlays Figure 9-6. Keypad Board (5000 and 7000 Series) Schematic Diagram Figure Series Keypad Top and Bottom Board Overlays Figure Series Keypad Board Schematic Diagram Figure 9-9. VHF/UHF Complete Controller Schematic Diagram Figure VHF/UHF Controller ASFIC/ON_OFF Schematic Diagram Figure VHF/UHF Controller ASFIC/ON_OFF Schematic Diagram Figure VHF/UHF Controller Microprocessor Schematic Diagram

16 xii List of Figures Figure VHF/UHF Controller Microprocessor Schematic Diagram Figure Controller Memory Schematic Diagram Figure Controller Audio Power Amplifier Schematic Diagram Figure Controller Interface Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls And Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Harmonic Filter Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) Complete Controller Schematic Diagram Figure UHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure UHF ( MHz) Controller Microprocessor Schematic Diagram Figure UHF ( MHz) Controller Memory Schematic Diagram Figure UHF ( MHz) Controller Audio Power Amplifier Schematic Diagram Figure UHF ( MHz) Controller Interface Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls And Switches Schematic Diagram Figure UHF ( MHz) Receiver Front-End Schematic Diagram Figure UHF ( MHz) Receiver Back-End Schematic Diagram

17 List of Figures xiii Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Harmonic Filter Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls And Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Harmonic Filter Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) Complete Controller Schematic Diagram Figure UHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure UHF ( MHz) Controller Microprocessor Schematic Diagram Figure UHF ( MHz) Controller Memory Schematic Diagram Figure UHF ( MHz) Controller Audio Power Amplifier Schematic Diagram Figure UHF ( MHz) Controller Interface Schematic Diagram Figure UHF ( MHz) Main Board Top Side PCB H Figure UHF ( MHz) Main Board Bottom Side PCB H Figure UHF Controls And Switches Schematic Diagram Figure UHF Receiver Front End Schematic Diagram Figure UHF Receiver Back End Schematic Diagram Figure UHF Synthesizer Schematic Diagram Figure UHF Voltage Controlled Oscillator Schematic Diagram Figure UHF Harmonic Filter Schematic Diagram Figure UHF Transmitter Schematic Diagram Figure Complete Controller Schematic Diagram Figure Controller ASFIC/ON_OFF Schematic Diagram Figure Controller Microprocessor Schematic Diagram Figure Controller Memory Schematic Diagram Figure Controller Audio Power Amplifier Schematic Diagram Figure Controller Interface Schematic Diagram Figure UHF ( MHz) 9000 Series Main Board Top Side PCB Figure UHF ( MHz) 9000 Series Main Board Bottom Side PCB Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram

18 xiv List of Figures Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Harmonic Filter Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure UHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure UHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure UHF ( MHz) Controls And Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Harmonic Filter Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) Complete Controller Schematic Diagram Figure UHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure UHF ( MHz) Controller Microprocessor Schematic Diagram Figure UHF ( MHz) Controller Memory Schematic Diagram Figure UHF ( MHz) Controller Audio Power Amplifier Schematic Diagram Figure UHF ( MHz) Controller Interface Schematic Diagram Figure UHF Band 2 ( MHz) Main Board Top Side PCB H Figure UHF Band 2 ( MHz) Main Board Bottom Side PCB H Figure UHF Band 2 Controls And Switches Schematic Diagram Figure UHF Band 2 Receiver Front End Schematic Diagram Figure UHF Band 2 Receiver Back End Schematic Diagram Figure UHF Band 2 Synthesizer Schematic Diagram

19 List of Figures xv Figure UHF Band 2 Voltage Controlled Oscillator Schematic Diagram Figure UHF Band 2 Harmonic Filter Schematic Diagram Figure UHF Band 2 Transmitter Schematic Diagram Figure Complete Controller Schematic Diagram Figure Controller ASFIC/ON_OFF Schematic Diagram Figure Controller Microprocessor Schematic Diagram Figure Controller Memory Schematic Diagram Figure Controller Audio Power Amplifier Schematic Diagram Figure Controller Interface Schematic Diagram Figure UHF ( MHz) 9000 Series Main Board Top Side PCB Figure UHF ( MHz) 9000 Series Main Board Bottom Side PCB Figure UHF ( MHz) Controls and Switches Schematic Diagram Figure UHF ( MHz) Receiver Front End Schematic Diagram Figure UHF ( MHz) Receiver Back End Schematic Diagram Figure UHF ( MHz) Synthesizer Schematic Diagram Figure UHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure UHF ( MHz) Transmitter Schematic Diagram Figure UHF ( MHz) Voice Storage Schematic Diagram Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB B Figure VHF ( MHz) Controls and Switches Schematic Diagram Figure VHF ( MHz) Receiver Front End Schematic Diagram Figure VHF ( MHz) Receiver Back End Schematic Diagram Figure VHF ( MHz) Synthesizer Schematic Diagram Figure VHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure VHF ( MHz) Transmitter Schematic Diagram Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB B Figure VHF ( MHz) Controls and Switches Schematic Diagram Figure VHF ( MHz) Receiver Front End Schematic Diagram Figure VHF ( MHz) Receiver Back End Schematic Diagram Figure VHF ( MHz) Synthesizer Schematic Diagram Figure VHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure VHF ( MHz) Transmitter Schematic Diagram Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB B Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB B Figure VHF ( MHz) Controls and Switches Schematic Diagram Figure VHF ( MHz) Receiver Front End Schematic Diagram Figure VHF ( MHz) Receiver Back End Schematic Diagram

20 xvi List of Figures Figure VHF ( MHz) Synthesizer Schematic Diagram Figure VHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure VHF ( MHz) Transmitter Schematic Diagram Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure VHF ( MHz) Controls And Switches Schematic Diagram Figure VHF ( MHz) Receiver Front-End Schematic Diagram Figure VHF ( MHz) Receiver Back-End Schematic Diagram Figure VHF ( MHz) Synthesizer Schematic Diagram Figure VHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure VHF ( MHz) Transmitter Schematic Diagram Figure VHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure VHF ( MHz) 5000/7000 Series Main Board Top Side PCB Z Figure VHF ( MHz) 5000/7000 Series Main Board Bottom Side PCB Z Figure VHF ( MHz) Controls And Switches Schematic Diagram Figure VHF ( MHz) Receiver Front End Schematic Diagram Figure VHF ( MHz) Receiver Back End Schematic Diagram Figure VHF ( MHz) Synthesizer Schematic Diagram Figure VHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure VHF ( MHz) Transmitter Schematic Diagram Figure VHF ( MHz) Complete Controller Schematic Diagram Figure VHF ( MHz) Controller ASFIC/ON_OFF Schematic Diagram Figure VHF ( MHz) Controller Microprocessor Schematic Diagram Figure VHF ( MHz) Controller Memory Schematic Diagram Figure VHF ( MHz) Controller Audio Power Amplifier Schematic Diagram Figure VHF ( MHz) Controller Interface Schematic Diagram Figure VHF ( MHz) Main Board Top Side PCB H Figure VHF ( MHz) Main Board Bottom Side PCB H Figure VHF Controls And Switches Schematic Diagram Figure VHF Receiver Front End Schematic Diagram Figure VHF Receiver Back End Schematic Diagram Figure VHF Synthesizer Schematic Diagram Figure VHF Voltage Controlled Oscillator Schematic Diagram Figure VHF Transmitter Schematic Diagram Figure Complete Controller Schematic Diagram Figure Controller ASFIC/ON_OFF Schematic Diagram Figure Controller Microprocessor Schematic Diagram Figure Controller Memory Schematic Diagram Figure Controller Audio Power Amplifier Schematic Diagram Figure Controller Interface Schematic Diagram Figure VHF ( MHz) 9000 Series Main Board Top Side PCB Figure VHF ( MHz) 9000 Series Main Board Bottom Side PCB Figure VHF ( MHz) Controls and Switches Schematic Diagram Figure VHF ( MHz) Receiver Front End Schematic Diagram Figure VHF ( MHz) Receiver Back End Schematic Diagram Figure VHF ( MHz) Synthesizer Schematic Diagram Figure VHF ( MHz) Voltage Controlled Oscillator Schematic Diagram Figure VHF ( MHz) Transmitter Schematic Diagram

21 List of Figures xvii Figure Low Band ( /35-50 MHz) Main Board Top Side PCB Figure Low Band ( /35-50 MHz) Main Board Bottom Side PCB Figure Low Band (30-50 MHz) Controls and Switches Diagram Figure Low Band ( /35-50 MHz) Controller Overall Schematic Diagram Figure Low Band ( /35-50 MHz) Controller Memory Schematic Diagram Figure Low Band ( /35-50 MHz) Controller AFSIC Schematic Diagram Figure Low Band ( /35-50 MHz) Controller Microprocessor Schematic Diagram Figure Low Band ( /35-50 MHz) Controller Audio PA Schematic Diagram Figure Low Band ( /35-50 MHz) Receiver Front End Schematic Diagram Figure Low Band ( /35-50 MHz) Receiver Back End Schematic Diagram Figure Low Band ( /35-50 MHz) Frequency Generation Unit Synthesizer Figure Low Band ( /35-50 MHz) Frequency Generation Unit VCO Diagram Figure Low Band ( /35-50 MHz) Transmitter Schematic Diagram Figure MHz ( MHz) Main Board Top Side PCB Z Figure MHz ( MHz) Main Board Bottom Side PCB Z Figure MHz Popular/Preferred ( MHz) Main Board Top Side PCB Z03 (Rev B) Figure MHz Popular/Preferred ( MHz) Main Board Bottom Side PCB Z03 (Rev B) Figure MHz Complete Controller Figure MHz Controller ASFIC/ON_OFF Figure MHz Controller Microprocessor Figure MHz Controller Memory Figure MHz Controller Audio Power Amplifier Figure MHz Controller Interface Figure MHz Controls and Switches Schematic Diagram Figure MHz Receiver Front End Schematic Diagram Figure MHz Receiver Back End Schematic Diagram Figure MHz Synthesizer Schematic Diagram Figure MHz Voltage Controlled Oscillator Schematic Diagram Figure MHz Transmitter Schematic Diagram (Rev A) Figure MHz Transmitter Schematic Diagram (Rev B) Figure PassPort Trunking Controller PCB Board Side 1 & Figure PassPort Controller Schematic Diagram Figure MHz ( MHz) Main Board Top Side PCB Z Figure MHz ( MHz) Main Board Bottom Side PCB Z Figure MHz Complete Controller Figure MHz Controller ASFIC/ON_OFF Figure MHz Controller Microprocessor Figure MHz Controller Memory Figure MHz Controller Audio Power Amplifier Figure MHz Controller Interface Figure MHz Controls and Switches Schematic Diagram Figure MHz Receiver Front End Schematic Diagram Figure MHz Receiver Back End Schematic Diagram Figure MHz Synthesizer Schematic Diagram Figure MHz Hear/Clear Schematic Diagram Figure MHz Voltage Controlled Oscillator Schematic Diagram Figure MHz Transmitter Schematic Diagram

22 xviii List of Figures

23 FMRC Approved Equipment xix Intrinsically Safe Radio Information FMRC Approved Equipment Anyone intending to use a radio in a location where hazardous concentrations of flammable materials 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 or the bottom of the radio housing. The FM Approval mark is shown below. FM APPROVED! W A R N I N G Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualified (for example, FMRC Approved) for such use. An explosion or fire may result. Do not operate an FMRC Approved Product in a hazardous atmosphere if it has been physically damaged (for example, cracked housing). An explosion or fire may result. 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. 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. Turn a radio off before removing or installing a battery or accessory. Do not disassemble an 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 Intrinsically Safe, hazardous atmosphere capability and FM Approval labeling. Radios will not be upgraded or converted to Intrinsically safe, and or labeled in the field, after it has been shipped from the manufacturing location. Modifications can only be made by the original product manufacturer (Motorola) at one of its FM audited manufacturing facilities.

24 xx Repair of FMRC Approved Products! W A R N I N G Failure to use an FMRC Approved portable radio unit with an FMRC Approved battery or FMRC Approved accessories specifically Agency approved for that product may result in the dangerously unsafe condition of an unapproved radio combination being used 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 PRODUCTS WITH FMRC APPROVAL 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 ). Repairs and service to be done FM audited locations.! W A R N I N G Incorrect repair or relabeling of any FMRC Approved Product unit could adversely affect the Approval rating of the unit. Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in serious injury or death. Repair Relabeling The following are key definitions, from the FMRC s Approval Standard Class Number 3605, 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 audited 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 unit to be opened in a manner which exposes the internal electrical. You do not have to be an FMRC audited Repair Facility to perform these actions. 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, provided there is 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.

25 Repair of FMRC Approved Products xxi Do t 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 FM 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 unit. Approved configurations are listed in the FM Approval Guide published by FMRC, or in the product FM product listing. This FM product listing is shipped from the manufacturer with the FM Approved radio and battery combination.

26 xxii Repair of FMRC Approved Products tes

27 1-1 Chapter 1 Introduction 1.1 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 that occur after the printing date are incorporated by a complete manual revision or alternatively, as additions. TE: Before operating or testing these units, please read the sections, "Product Safety and RF Exposure Compliance" on page ii and "Intrinsically Safe Radio Information" on page xix. 1.2 Warranty and Service Support Motorola offers long term support for its products. This support 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 by an authorized Motorola dealer must be accompanied by a warranty claim form. Warranty claim forms are obtained by contacting customer service Warranty Period The terms and conditions of warranty are defined fully in the Motorola dealer or distributor or reseller contract. These conditions may change from time to time and the following notes are for guidance purposes only Return Instructions 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 a Motorola warranty depot, please contact the appropriate customer service for instructions. 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 After Warranty Period After the Warranty period, Motorola continues to support its products in two ways: First, Motorola's Customer Care and Services Division offers a repair service to both end users and dealers at competitive prices. Second, Motorola s service department supplies individual parts and modules that can be purchased by dealers who are technically capable of performing fault analysis and repair.

28 1-2 Introduction: Related Documents 1.3 Related Documents The following documents are directly related to the use and maintainability of this product. Table 1-1. Related Documents Title Professional Radio Portable Level 1&2 Basic Service Manual- English (rth America) Professional Radio Portable Level 1&2 Basic Service Manual- English (Latin America) Professional Radio Portable Level 1&2 Basic Service Manual- Spanish Professional Radio Portable Level 1&2 Basic Service Manual- Portuguese Professional Radio Portable Service Manual Level 3 - English Professional Radio Portable Service Manual Level 3 - Spanish Professional Radio Portable Service Manual Level 3 - Portuguese Supplement to Professional Radio Portable Level 1&2 Basic Service Manual Part Number 68P80906Z54 68P81088C45 68P81088C47 68P81088C49 68P81088C46 68P81088C48 68P81088C50 68P81093C Technical Support Technical support is available to assist the dealer/distributor and self-maintained customers 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. The contact locations and telephone numbers are located in the applicable basic service manual listed in Table 1-1 above 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, the part is available from Motorola Customer Care and Services Division. 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.

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