Motorola Astro Digitalport Saber Basic 68p81076c05 Manual

							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 top-
ics 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; howev-
er, periodic visual inspection and cleaning is
recommended.
1. Inspection
Check that the external surfaces of the radio are
clean, and that all external controls and switches
are functional. A detailed inspection of the interior
electronic circuitry is not needed.
2. Cleaning
The following procedures describe the recom-
mended cleaning agents and the methods to be
used when cleaning the external and internal sur-
faces of the radio. External surfaces include the
front cover, housing assembly, and battery case.
These surfaces should be cleaned whenever a
periodic visual inspection reveals the presence of
smudges, grease, and/or grime. Internal surfaces
should be cleaned only when the radio is disas-
sembled for servicing or repair.
The only recommended agent for cleaning the
external radio surfaces is a 0.5% solution of a mild
dishwashing detergent, such as JOY
¨, in water.
The only factory recommended liquid for cleaning
the printed circuit boards and their components is
isopropyl alcohol (70% by volume).
a. Cleaning External Plastic Surfaces
(The detergent-water solution should be
applied sparingly with a stiff, non-metallic,
short-bristled brush to work all loose dirt away
from the radio. A soft, absorbent, lintless cloth
or tissue should be used to remove the solu-
tion and dry the radio. Make sure that no
water remains entrapped near the connectors,
cracks, or crevices.b. Cleaning Internal Circuit Boards and 
Components
Isopropyl alcohol 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.
Alcohol is a high-wetting liquid and can carry
contamination into unwanted places if an
excessive quantity is used. Make sure that
controls or tunable components are not
soaked with the liquid. Do not use high-pres-
sure air to hasten the drying process, since
this could cause the liquid to puddle and col-
lect in unwanted places.
Upon completion 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).
C. Handling Precautions
Complementary metal-oxide semiconductor
(CMOS) devices, and other high-technology devices,
are used in this family of radios. While the attributes of
these devices are many, their characteristics make
them susceptible to damage by electrostatic discharge
(ESD) or high-voltage charges. Damage can be latent,
resulting in failures occurring weeks or months later.
Therefore, special precautions must be taken to 
prevent device damage during disassembly, trou-
bleshooting, and repair. Handling precautions are
mandatory for this radio, and are especially important
in low-humidity conditions. DO NOT attempt to disas-
semble the radio without observing the following
handling precautions.
1. Eliminate static generators (plastics, Styrofoam,
etc.) in the work area.
2. Remove nylon or double-knit polyester jackets, roll
up long sleeves, and remove or tie back loose
hanging neckties.
3. Store and transport all static-sensitive devices in
ESD-protective containers.
4. Disconnect all power from the unit before ESD-
sensitive components are removed or inserted
unless otherwise noted.
3
SECTION II.  BASIC MAINTENANCE
CAUTION
The effects of certain chemicals and their
vapors can have harmful results on certain plas-
tics. Aerosol sprays, tuner cleaners, and other
chemicals should be avoided. 
						

							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 static-
control table mat and a static-control floor mat. For
additional information, refer to Service and Repair
Note SRN-F1052, ÒStatic Control Equipment for
Servicing ESD Sensitive Products,Ó available from
Literature Distribution.
Motorola
Literature Distribution
2290 Hammond Drive
Schaumburg, IL 60173
(708) 576-2826When these items are not readily available,
observing the following techniques will minimize
chance of damage.
¥ If a static-sensitive device is to be temporarily
set down, use a conductive surface for place-
ment of the device.
¥ Make skin contact with a conductive work sur-
face first and maintain this contact when the
device is set down or picked up.
6. Always wear a conductive wrist strap when servic-
ing this equipment. The Motorola part number for
a replacement wrist strap that connects to the
table mat is 42-80385A59.
4 
						

							A. Recommended Test Equipment
The list of equipment contained in Table 2 includes
all of the standard test equipment required for servic-
ing two-way portable radios, as well as several unique
items designed specifically for servicing this family ofradios. The ÒCharacteristicsÓ column is included so
that equivalent equipment may be substituted; howev-
er, when no information is provided in this column, the
specific Motorola model listed is either a unique item
or no substitution is recommended.
5
SECTION III. RECOMMENDED TEST EQUIPMENT, 
SERVICE AIDS, AND TOOLS 
Table 2.  Recommended Test Equipment
Motorola 
Model Number  Description  Characteristics Application
R2600   System Analyzer This monitor will substitute Frequency/deviation meter and signal
for items with an asterisk (*). generator for wide-range 
troubleshooting and alignment
R1049A* Digital Multimeter Recommended for ac/dc voltage
and current measurements
R1150C* Code Synthesizer Injection of audio and digital 
signalling codes
S1053D* AC Voltmeter 1mV to 300V, 10-Megohm
SKN6008A* Power Cable for Meter input impedance Audio voltage measurements
SKN6001A* Test Leads for Meter
R1094A Dual-Trace 20MHz bandwidth Waveform measurements
Oscilloscope 5mV to 5V/division
S1350C* Wattmeter 50-ohm, ±5% accuracy Transmitter power output
ST1213B (VHF)* Plug-In Element 10 watts, maximum measurements
ST1223B (UHF)* RF Dummy Load 0-1000MHz, 300W
R1065 Load Resistor 10-watt Broadband For use with wattmeter
S1339A RF Millivolt Meter 100µV to 3V RF RF-level measurements
10kHz to 1.2GHz
R1013A* SINAD Meter Receiver sensitivity
measurements
S1347D or DC Power Supply 0-20Vdc, 0-5 Amps Bench supply for 7.5Vdc
S1348D (programmable) current limited
* Any of the R2600 series system analyzers will substitute for items with an asterisk (*). 
						

							B. Service Aids and Recommended Tools
Refer to the following tables, ÒService Aids for
Board-Level TroubleshootingÓ and ÒRecommended
Test Tools for Board-Level Troubleshooting,Ó for a list-
ing 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 disas-
semble and properly maintain the radio. These kits
and/or parts are available from the Motorola Parts
Division offices listed in the ÒReplacement Parts
OrderingÓ section located on the inside back cover of
this manual.The following table lists service aids recommend-
ed for working on this family of radios. While all of
these items are available from Motorola, most are
standard shop equipment items, and any equivalent
item capable of the same performance may be substi-
tuted for the item listed.
C. Field Programming Equipment
This family of radios can be aligned and pro-
grammed in the field. This requires specific equipment
and special instructions. Refer to the applicable ÒRadio
Service Software Users GuideÓ for complete field
programming information.
6
RKN-4046A RIB/Radio/Test Set Cable Connects radio to RTX-4005B Test Box and RIB.
RTL-4224A Battery Eliminator Interconnects radio to power supply.
REX-4200A Housing Eliminator/ Provides for troubleshooting of the radio when the housing 
(contains REN-4014A Test Fixture is removed. If you have REN-4011A or the 
and REN-4011A) REX-4194A (SABER SI
TMHousing Eliminator), order REN-4014A only.
RTX-4005B or both Portable Test Set Enables connection to the universal connector.
RTX-4005A and RPX-4665A Allows switching for radio testing.
Field Modification Kit
RLN-4008B Radio Interface Box Enables communications between the radio and the
computers serial communications adapter.
01-80357A57 Wall-Mounted Power Supply Used to supply power to the RIB (120 Vac).
01-80358A56 Wall-Mounted Power Supply Used to supply power to the RIB (220 Vac).
30-80369B71 Computer Interface Cable Use B72 for the IBM PC AT. All other IBM models use B71.
or Connects the computers serial communications adaptor
30-80369B72 to the RIB.
RVN-4100A Radio Service Software Software on 3-1/2 in. and 5-1/4 in. floppy disks.
58-80348B33 SMA to BNC Adaptor Adapts radioÕs antenna port to BNC cabling of test equipment.
Motorola Part Number Description Application
Motorola Part Number Description Application
01-80386A82 Anti-Static Used during radio assembly and disassembly procedures.
Grounding Kit
RSX-4043A Roto-Torq Adjustable Used during radio assembly and disassembly procedures.
Torque Screwdriver
66-80370B89 Slotted-Spanner Used during radio assembly and disassembly procedures.
Nut Bit
66-80321B86 #0 Phillips Bit Used during radio assembly and disassembly procedures.
66-80321B79 #1 Phillips Bit Used during radio assembly and disassembly procedures.
66-80371B03 Spanner Nut Bit Used during radio assembly and disassembly procedures.
66-80371B34 Spanner Nut Bit Used during radio assembly and disassembly procedures.
Table 3.  Service Aids for Board-Level Troubleshooting
Table 4.  Recommended Tools for Board-Level Troubleshooting 
						

							SECTION IV.  PERFORMANCE CHECKS
7
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 manufactur-
ing equipment, with a few exceptions. Accuracy of the
equipment must be maintained in compliance with the
manufacturerÕs recommended calibration schedule.
B. Setup
Supply voltage can be connected from the battery
eliminator. The equipment required for alignment pro-
cedures is connected as shown in the ÒRadio
Alignment Test SetupÓ diagram.
Initial equipment control settings should be as
indicated in the following table, and should hold for all
alignment procedures except as noted in Table 5.
Table 5. Initial Equipment Control Settings
C. Test Mode
1. RF Test Mode
When the ASTRO Digital SABER radio is operat-
ing in its normal environment, the radios
microcomputer controls the RF channel selection,
transmitter key-up, and receiver muting. Howev-
er, when the unit is on the bench for testing,
alignment, or repair, it is removed from its normal
environment. It cannot receive commands from
its system and, therefore, the internal microcom-
puter will not key the transmitter nor unmute the
receiver. This prevents the use of normal tune-up
procedures. To solve this problem a special rou-
tine, called TEST MODE or Òair test,Ó has been
incorporated in the radio.
To enter the test mode:
a. Turn the radio on and adjust the volume for a
comfortable llistening level. The volume level
remains constant once in the test mode.b. Within 10 seconds after the ÒSelf TestÓ is
complete, press side button 3 five times in
succession.
c. After ÒRF TESTÓ appears, press the top pro-
grammable button (normally programmed as
the emergency button) once. Ò1 CSQÓ
appears, indicating: test frequency 1, carrier
squelch mode.
d. Each additional press of side button 3 will
advance to the next test channel. (Refer to
Table 7.)
e. Pressing side button 2 will scroll through 
and access test environments as shown in
Table 6.
NOTE
Transmit into a load when keying a radio
under test.
Table 6. Test Environments
2. Control Top and Keypad Test Mode
To check the display, the buttons, and the switch-
es, perform the following tests:
a. Turn the radio on and adjust the volume for a
comfortable llistening level. The volume level
remains constant once in the test mode.
b.
Within 10 seconds after the ÒSelf TestÓ is
complete, press 
side button 3 five times in
succession.
c. After ÒRF TESTÓ appears on the display,
press side button 1 once, ÒCH TESTÓ 
(14-character radio) appears on the display.
d. Next, press and hold the top programmable
button; all segments on the display will light,
and the LED on the control top will illuminate
a red color.
e. Release the top programmable button; Ò3/0Ó
appears, which indicates that the top pro-
grammable button  is in the open condition.
Monitor Mode: Pwr Mon Spkr set: A Voltage: 7.5Vdc
RF Attn: Ð70dB Spkr/load: DC on/standby:
Speaker Standby
AM, CW, FM: FM PTT: OFF Volt Range: 10Vdc
(center)
Oscope Source: Mod Current: 2.5Amps
Oscope Horiz: 10mSec/Div
Oscope Vert: 2.5kHz/Div
Oscope Trig: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: mid CW
Monitor Vol: 1/4 CWCSQ Carrier Squelch RX:unsquelch if carrier detected
TX: mic audio
TPL Tone  RX:unsquelch if carrier and tone
Private-Line (192.8 Hz) detected
TX: mic audio + tone (192.8 Hz)
AST ASTRO RX:none
TX: 1200Hz tone 
*
System Analyzer Test Set Power SupplyDisplay Description Function
*All deviation values are based on deviation tuning of this mode. 
						

							f. Press the top programmable button again;
Ò3/1Ó appears, which indicates that the 
top programmable button is in the closed 
condition.
g. Rotate the mode/zone selector switch; Ò4/0Ó
through Ò4/15Ó appears, which indicates that
the selector switch is in mode/zone position 
1 through 15.
h. Rotate the two-position (A/B) switch; Ò65/0Ó
and Ò65/1Ó appears.
i. Rotate the two-position programmable switch
(concentric with the top programmable but-
ton); Ò67/3Ó and Ò67/0Ó appear.
j. Rotate the volume control; Ò2/0Ó through
Ò2/255Ó appear.
k. Press side button 1, Ò96/1Ó appears; release,
Ò96/0Ó appears.
l. Press side button 2, Ò97/1Óappears; release,
Ò97/0Ó appears.
m. Press side button 3, Ò98/1Óappears; release,
Ò98/0Ó appears.
n. Press the PTT switch, Ò1/1Ó appears; release,
Ò1/0Ó appears.
Keypad Checks:
¥ Press 0, Ò48/1Ó appears; release, Ò48/0Ó
appears.
¥ Press 1, Ò49/1Ó appears; release, Ò49/0Ó
appears.
¥ Press 2, Ò50/1Ó appears; release, Ò50/0Ó
appears.
¥ Press 3, Ò51/1Ó appears; release, Ò51/0Ó
appears.¥ Press 4, Ò52/1Ó appears; release, Ò52/0Ó
appears.
¥ Press 5, Ò53/1Ó appears; release, Ò53/0Ó
appears.
¥ Press 6, Ò54/1Ó appears; release, Ò54/0Ó
appears.
¥ Press 7, Ò55/1Ó appears; release, Ò55/0Ó
appears.
¥ Press 8, Ò56/1Ó appears; release, Ò56/0Ó
appears.
¥ Press 9, Ò57/1Ó appears; release, Ò57/0Ó
appears.
¥ Press *, Ò58/1Ó appears; release, Ò58/0Ó
appears.
¥ Press #, Ò59/1Ó appears; release, Ò59/0Ó
appears.
¥ Press  , Ò128/1Ó appears; release,
Ò128/0Ó appears.
¥ Press HOME, Ò129/1Ó appears; release,
Ò129/0Ó appears.
¥ Press  , Ò130/1Ó appears; release, Ò130/0Ó
appears.
¥ Press the left-hand ¥ key on the top row of
keys, Ò131/1Ó appears; release, Ò131/0Ó
appears.
¥ Press the center ¥key, Ò132/1Ó appears;
release, Ò132/0Ó appears.
¥ Press the right-hand ¥key, Ò133/1Ó appears;
release, Ò133/0Ó appears.
8
TX #1 136.025 403.100 450.025 806.0125
RX #1 136.075 403.150 450.075 851.0625
TX #2 142.125 424.850 465.225 815.0125
RX #2 142.075 424.900 465.275 860.0625
TX #3 154.225 438.050 475.225 824.9875
RX #3 154.275 438.100 475.275 869.9375
TX #4 160.125 444.050 484.975 851.0125
RX #4 160.175 444.100 485.025 851.0625
TX #5 168.075 456.350 500.275 860.0125
RX #5 168.125 456.400 500.225 860.0625
TX #6 173.975 463.700 511.975 869.9875
RX #6 173.925 463.750 511.925 869.9375
TX #7 177.975 469.650 519.975 None
RX #7 177.925 469.700 519.925 None
Table 7. Test Frequencies
Test Channel VHF UHF Band 1 UHF Band 2 800MHz 
						

							9
Reference Mode: PWR MON TEST MODE, PTT to continuous Frequency error to be ²±600Hz
Frequency 4th channel test frequencyv4 CSQ (during the
Monitor: Frequency error output at performance check)
Input at RF In/Out antenna
Rated Audio Mode: GEN TEST MODE, PTT to OFF (center), Set volume control to
Output level: 1.0mV RF 4 CSQ meter selector to 3.74Vrms
4th channel test frequency
vAudio PA
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: ac Volts
Distortion As above, except to As above As above Distortion < 3.0%
distortion
Sensitivity As above, except SINAD, As above PTT to OFF (center) RF input to be < 0.35µV
(SINAD) lower the RF level for 12dB
SINAD
Noise Squelch RF level set to 1mV RF As above PTT to OFF (center), Set volume control to
Threshold meter selection to  3.74Vrms
(only radios with  Audio PA, spkr/load
conventional to speaker
system need
to be tested) As above, except change Out of TEST  As above Unsquelch to occur at < 0.25µV
frequency to a conventional MODE; select a 
system. Raise RF level from  conventional 
zero until radio unsquelches. system Preferred SINAD = 8-10dB
Table 8. Receiver Performance Checks
v(See Table 7.)
Test System
Name Analyzer Radio Test Set CommentsName 
						

							10
Reference Mode: PWR MON TEST MODE, PTT to continuous Frequency error to be ²±600Hz.
Frequency 4th channel test frequencyv4 CSQ (during the
Monitor: Frequency error performance check).
Input at RF In/Out
Power RF As above As above, 4 CSQ As above Refer to Maintenance Specifica-
tions page in front of manual.
Voice Mode: PWR MON As above, 4 CSQ As above, meter Deviation:
Modulation 4th channel test frequency
vselector to mic VHF, UHF, and 800MHz:
atten to Ð70, input to RF In/Out,³3.6kHz but ²5.0kHz
Monitor: DVM, ac Volts
Set 1kHz Mod Out level for
0.025Vrms at test set,
80mVrms at ac/dc test set jack
Voice Mode: PWR MON TEST MODE, Remove modulation Press PTT switch on radio.
Modulation 4th channel test frequency
v4 CSQ, input Say ÒfourÓ loudly into the
(internal) atten to Ð70, input to RF In/Out output at antenna radio mic. Measure deviation:
VHF, UHF, and 800MHz:
³3.8kHz but ²5.0kHz
PL  Change frequency to a  Conventional coded As above Deviation:
Modulation conventional transmit  squelch personality VHF, UHF, and 800MHz:
(radios with frequency, BW to narrow (clear mode³500Hz but ²1000Hz
conventional, operation)
clear mode, 4 TPL
coded squelch
operation only)
Talkaround Change frequency to conven- Conventional As above Deviation:
Modulation tional talk-around frequency. talk-around UHF and 800MHz: ³3.8kHz
(radios with Mode: PWR MON personality but ²5.0kHz
conventional, deviation, attenuation to Ð70, (clear mode
clear mode, input to RF In/Out operation)
talk-around Monitor: DVM, ac volts 1 CSQ
operation only) Set 1kHz Mod Out level for 
25mVrms at test set.
Talkaround Change frequency to conven- Conventional As above Deviation:
Modulation tional talk-around frequency. talk-around UHF and 800MHz: ³3.6kHz
(radios with Mode: PWR MON personality but ²4.4kHz
conventional, deviation, attenuation to Ð70, (secure mode
secure mode, input to RF In/Out operation)
talk-around Monitor: DVM, ac volts Load key into
operation only)  Mod: 1kHz out level for  radio
(**) 25mVrms at test set. 1 sec.
Table 9. Transmitter Performance Checks
* 800MHz radios only
** The secure mode, talkaround modulation test is only required for trac mode radios which do not have clear mode talkaround capability.
vSee Table 7.
Test System
Name Analyzer Radio Test Set CommentsName 
						

							A. Introduction to This Section
This section describes both receiver and transmit-
ter radio alignment procedures.B. General
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.
11
SECTION V.  RADIO ALIGNMENT PROCEDURE
BNC
RIB
RLN-4008B
RIB POWER SUPPLY
01-80357A57 (120V)COMPUTER INTERFACE
CABLE
30-80369B71
30-80369B72 (IBM AT ONLY)DATA
BUSY
GND COMPUTER AUDIO GENERATOR
SINAD METER
AC VOLTMETER TX
RX 30 dB PAD
30 dB PAD
RF GENERATORSYSTEM ANALYZER
OR COUNTER
WATTMETER
BATTERY
ELIMINATOR
RTL-4224A
TRANSMIT
RECEIVE
TEST SET
RTX-4005BRADIO
PROGRAM/TEST CABLE
RKN-4046A
AUDIO IN SET TO APPROX. 450mV FOR Tx
MEASURE 80mV FOR Tx
SMA-BNC
58-80348B33
Figure 1.  Radio Alignment Test Setup 
MAEPF-23413-O 
						

							All service and tuning procedures are performed
from the SERVICE menu, which is selected by press-
ing F2 from the MAIN MENU. Figure 2 illustrates how
the RSS alignment SERVICE screens are organized. 
Figure 2. RSS Service Menu Layout
All SERVICE screens read and program the radio
codeplug directly; you do NOT have to use the RSS
GET/SAVE functions to use the SERVICE menus.The SERVICE screens introduce the concept of
the Òsoftpot,Ó an analog SOFTware controlled POTen-
tiometer used for adjusting all transceiver alignment
controls.
Each SERVICE screen provides the capability to
increase or decrease the ÔsoftpotÕ value with the 
keyboard UP/DOWN arrow keys respectively. A
graphical scale is displayed indicating the minimum,
maximum, and proposed value of the softpot, as
shown in Figure 3.
Figure 3. Softpot Concept
Adjusting the softpot value sends information to
the radio to increase (or decrease) a dc voltage in the
corresponding circuit. For example, pressing the UP
arrow key at the Reference Oscillator screen instructs
the radioÕs microcomputer to increase the voltage
across a varactor in the reference oscillator, which
increases the frequency.
In ALL cases, the softpot value is just a relative
number corresponding to a digital-to-analog (D/A)
generated voltage in the radio.
12
REFERENCE OSCILLATOR ALIGNMENT
TRANSMIT POWER ALIGNMENT TRANSMITTER ALIGNMENT MENU
TRANSMIT DEVIATION BALANCE 
(COMPENSATION) ALIGNMENT
TRANSMIT DEVIATION LIMIT ALIGNMENT
F2 -
F2 -
F3 -
F4 -
F5 -
RECEIVER ALIGNMENT MENUF3 -
FRONT END BANDPASS FILTER ALIGNMENTF2 -
SERVICE
HELPF1 -
EXIT, RETURN TO SERVICE MENUF10 -
MAEPF-23414-O
CAUTION
Do NOT switch radios in the middle of any SER-
VICE procedure. Always use the EXIT key to
return to the MAIN menu screen before discon-
necting the radio. Improper exits from the
SERVICE screens may leave the radio in an
improperly configured state and result in seri-
ously degraded radio or system performance.
MAEPF 22858 O
Min.
ValueMax.
Value
015
MAEPF-22858-O