Motorola Astro Digitalport Saber Basic 68p81076c05 Manual
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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 userÕs guide. C. Reference Oscillator Alignment Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will result not only in poor operation, but also in a misaligned radio that will interfere with other users operating on adjacent channels. For this reason, the reference oscillator should be checked every time the radio is serviced. The frequency counter used for this proce- dure must have a stability of 0.1 ppm (or better). 1. From the SERVICE MENU, press F2to select the TRANSMITTER ALIGNMENT MENU. 2. Press F2again to select the REFERENCE OSCILLATOR alignment screen. See Figure 4.3. Press Tab(or Enteror Return) to select a fre- quency field (starting with the highest frequency shown). Then, press F6to key the radio. The screen will indicate that the radio is transmitting. 4. Measure the transmit frequency on your service monitor. 5. Use the UP/DOWN arrow keys to adjust the refer- ence oscillator softpot value. See Table 10. 6. Press F6again to dekey the radio. 7. Press F8to program the new softpot value. 8. Repeat steps 3-7 for the remaining frequencies. 9. Press F10once to return to the TRANSMITTER ALIGNMENT MENU, or press F10twice to return to the SERVICE MENU. 13 MOTOROLA Radio Service Software ASTRO Model: H04UCH9PW7AN MAIN:SERVICE:TX ALIGN:REF OSCUse UP/DOWN Arrows To Adjust Softpot. F1 HELPF2 F3 F4 F5 F6 TOGGLE PTTF7 F8PROGRAMVALUEF9 F10 EXIT REFERENCE OSCILLATOR FrequencyCurrent Value 869.9875 150 New Softpot Value ....................150 Transmitter ........On 0 Min255 Max Figure 4. Reference Oscillator Alignment Screen Band Target VHF ±150Hz UHF ±150Hz 800MHz ±150Hz Table 10. Reference Oscillator Alignment
D. Transmit Power Alignment NOTE ¥ All power measurements are to be made at the antenna port. ¥ The transmitter power setting keeps the radiat- ed power at or below the level specified in the exclusionary clause for low power devices of IEEE Standard C95.1-1991. 1. From the SERVICE MENU, pressF2to select the TRANSMITTER ALIGNMENT MENU. 2. Press F3to select the TRANSMIT POWER align- ment screen. The screen will indicate the transmit frequencies to be used. See Figure 5.3. Press Tab(or Enteror Return) to select a fre- quency field (starting with the highest frequency shown). Then, press F6to key the radio. The screen will indicate that the radio is transmitting. 4. Use the UP/DOWN arrow keys to adjust the trans- mit power per the values shown in Table 11. 5. Press F6to dekey the radio. 6. Press F8to program the value. 7. Repeat steps 3-6 for the remaining frequencies. 8. Press F10once to return to the TRANSMITTER ALIGNMENT MENU, or press F10twice to return to the SERVICE MENU. 14 TRANSMIT POWER Current Value New Softpot Value FrequencyHigh PwrLow PwrHigh PwrLow Pwr806.00000 35 35 10 23 815.00000 42 42 11 28 824.00000 50 50 20 33 851.00000 60 60 33 40 860.00000 70 70 43 45 869.00000 80 80 58 58 Transmitter..........On MOTOROLA Radio Service Software ASTRO Model: H04UCH9PW7AN MAIN:SERVICE:TX ALIGN:TX POWERUse UP/DOWN Arrows To Adjust Softpot. F1 HELPF2 F3 F4 F5 F6 TOGGLE PTTF7 F8PROGRAMVALUEF9 F10 EXIT 0 Min127 Max Figure 5. Transmit Power Alignment Screen Table 11. Transmit Power Setting Test Frequencies VHF Power Level 136-174MHz 174-178MHz 1W 1.2 -1.4 1.2 - 1.4 5W 5.2 - 5.4 4.2 - 4.4 1W 1.2 -1.4 1.2 - 1.4 4W 4.2 - 4.4 3.2 - 3.4 3W 3.2 -3.4 Test Frequencies UHF Power Level 450-512MHz 512-520MHz 800MHz Power Level All Test Frequencies
E. Transmit Deviation Balance (Compensation) Alignment Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (syn- thesizer 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 wave- forms if improperly adjusted. 1. From the SERVICE MENU, pressF2to select the TRANSMITTER ALIGNMENT MENU. 2. Press F4to select the TRANSMIT DEVIATION BALANCE (COMPENSATION) alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 6. 3. Press Tab(or Enteror Return) to select a fre- quency field (starting with the lowest frequency shown).4. Press F4. This will cause the radio to key and the radioÕs DSP IC to inject an 80Hz tone into the RF board. 5. Measure the deviation and record this value. 6. Press F4to dekey the radio. 7. Press F6. This will cause the radioÕs DSP IC to change the injection tone to 3kHz, 100mVrms. Use the UP/DOWN arrow keys to adjust the devia- tion to within ±2% of the value recorded in step 5. 8. Repeat steps 4-7 until the 3kHz tone deviation is within ±2% of the 80Hz tone deviation. 9. Press F6again to dekey the radio. 10. Press F8to program the new softpot value. 11. Repeat steps 3-10 for the remaining frequencies. 12. Press F10once to return to the TRANSMITTER ALIGNMENT MENU, or press F10twice to return to the SERVICE MENU. 15 MOTOROLA Radio Service Software ASTRO Model: H04UCH9PW7AN MAIN:SERVICE:TX ALIGN:BAL ATTNUse UP/DOWN Arrows To Adjust Softpot. F1 HELPF2 F3 F4TOGGLE LOW TONE PTTF5 F6TOGGLE HIGH TONE PTTF7 F8PROGRAMVALUEF9 F10 EXIT TRANSMIT DEVIATION BALANCE (COMPENSATION) Current Frequency ValueNew Softpot Value 450.62500 30 30 465.22500 30 30 475.22500 30 30 484.97500 45 45 500.27500 45 45 511.97500 45 45 Transmitter ..............Off 0 Min63 Max Figure 6. Transmit Deviation Balance (Compensation) Alignment Screen
F. Transmit Deviation Limit Alignment IMPORTANT NOTE Put the radio in the RF test mode and scroll to the ASTRO test environment, indicated by ÒASTÓ on the display (refer to the Performance Checks sec- tion for details). All other deviation values are derived from the ASTRO test environment mode transmit deviation limit. 1. From the SERVICE MENU, pressF2to select the TRANSMITTER ALIGNMENT MENU. 2. Press F5to select the TRANSMIT DEVIATION LIMIT alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 7.3. Press Tab(or Enteror Return) to select a fre- quency field (starting with the lowest frequency shown). 4. Press F6to key the radio. Then use the UP/DOWN arrow keys to adjust for a deviation per the values shown in Table 12. 5. Press F6again to dekey the radio. 6. Press F8to program the softpot value. 7. Repeat steps 3-6 for the remaining frequencies. 8. Press F10once to return to the TRANSMITTER ALIGNMENT MENU, or press F10twice to return to the SERVICE MENU. 16 MOTOROLA Radio Service Software ASTRO Model: H04UCH9PW7AN MAIN:SERVICE:TX ALIGN:VCO ATTNUse UP/DOWN Arrows To Adjust Softpot. TRANSMIT DEVIATION LIMIT Current FrequencyValueNewSoftpot Value 450.02500 175 175 465.22500 175 175 475.22500 180 180 484.97500 180 180 500.27500 180 180 511.97500 180 180 Transmitter ..............Off F1 HELPF2 F3 F4 F5 F6 TOGGLE PTTF7 F8PROGRAMVALUEF9 F10 EXIT 0 Min255 Min Figure 7. Transmit Deviation Limit Alignment Screen Table 12. Transmit Deviation Limit VHF 2785-2885 UHF 2785-2885 800MHz 2785-2885 Band Deviation (Hz)
G. Front-End Filter Alignment (VHF/UHF Only) NOTE This procedure is only required for tuning the front- end filter varactors in the VHF and UHF models. The 800MHz models utilize a fixed front-end filter. 1. From the SERVICE MENU, pressF3to select the RECEIVER ALIGNMENT MENU. 2. Press F2to select the FRONT END FILTER ALIGNMENT screen. The screen will indicate the receive frequencies at which the filter is to be aligned. See Figure 8. 3. Press Tab(or Enteror Return) to select a fre- quency field.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. 5. Adjust the UP/DOWN arrow keys to obtain a peak value in the RSSI (receive signal strength indica- tor) field. Note F4must be pressed to obtain each RSSI reading after adjustment. 6. Press F8to program the new softpot value. 7. Repeat steps 3-6 for the remaining frequencies. 8. Press F10once to return to the RECEIVER ALIGNMENT MENU, or press F10twice to return to the SERVICE MENU. 17 MOTOROLA Radio Service Software ASTRO Model: H04UCH9PW7AN MAIN:SERVICE:RX ALIGN:FE FLUse UP/DOWN Arrows To Adjust Softpot. FRONT END FILTER ALIGNMENT Current Frequency ValueNew Softpot ValueRSSI. . . .0 450.02500 0 0 465.22500 0 0 475.22500 0 0 484.97500 0 0 500.27500 0 0 511.97500 0 0 519.97500 0 0 F1 HELPF2 F3 F4 READ RSSIF5F6 F7 F8PROGRAMVALUEF9 F10 EXIT 0 Min255 Max Figure 8. Front-End Filter Alignment Screen
A. Disassembly (Refer to the following diagrams and the exploded view diagram located in the back of this manual.) 1.Turn off the radioby rotating the on/off/volume control fully counterclockwise until you hear a click. Remove the accessory connector cover or any accessory connected to the radio before beginning disassembly. 2. Remove the batteryfrom the baseplate on the bottom of the radio housing by pushing the spring- loaded battery latch toward the top of the radio, and sliding the battery away from the latch until it clears the baseplate. 3. Loosen the two slotted-spanner nutson the bottom of the radio using the ROTO-TORQ adjustable torque screwdriver with bit No. 66-80370B89. When loosened, the slotted-span- ner nuts are captive and will spin freely without separating from the baseplate. 4. Remove the chassis from the radio housing by grasping the antenna at its base and pulling it gently upward. Do not depress the PTT switch during removal and do not push on the slotted- spanner nuts to remove the chassis. 19 SECTION VI. DISASSEMBLY/REASSEMBLY PROCEDURES CAUTION Before attempting any disassembly or reassem- bly of the radio, observe the handling precautions described in the ÒBasic Mainte- nanceÓ section of this manual. AB ON/OFF/VOLUME CONTROL ILLUSTRATOR ENDATE LETTERINGREQUIRES EDITOR C HDATEEH 11/10/92 11/20/92 JWB MAEPF-23372-O BATTERY LATCHREMOVAL DIRECTION INSERTION DIRECTION BATTERY BASEPLATE MAEPF-20185-O 66-80370B89 SLOTTED-SPANNER NUT BIT SLOTTED-SPANNER NUTS RSX-4043A ROTO-TORQ ADJUSTABLE TORQUE SCREWDRIVER DESCRIPTION DRAWN: AISSLETTERING SIZE: REQUIRES:RE MA O SYSTEM ASTRO DIGITAL SABER UHF LOOSEN SPANNER NUTS MAEPF-23373-O MAEPF-23373-O created MAEPF-23373-O BASE OF ANTENNA LETTERING SIZ REQUIRES: MAEPF-23374-O
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 cir- cuits connecting to the controller board. 6. Disconnect the display flexible circuit (Models II and III only) and the speaker/microphone flexi- ble circuitfrom the controller board by pulling the respective connector plugs out and away from the controller board and shield assembly. The connec- tor plugs are covered with a protective rubberized pad. Also, disconnect thecontrol top/PTT flexi- ble circuit from the controller board by pulling up and rotating the flex connector plug out and away from the controller board and shield assembly. The connector plug is covered with a protective rubberized pad.7. Using a ROTO-TORQ adjustable screwdriver tool with a Phillips bit #0 point size (Motorola part num- ber 66-80321B86), remove the four controller shield screws. Next, gently pry the controller shieldup and out of the chassis by inserting the tip of a thin slotted screwdriver between the chas- sis and the controller shield at each of the three thin-walled chassis points (see diagram below). After the controller shield is freed, remove the controller board from the chassis by gently applying upward pressure on the black 15-pin connector. 20 CHASSIS ASSEMBLY TOP PANEL FRONT SHIELD ASSEMBLY MAEPF-23375-O DISPLAY FLEXIBLE CIRCUIT CONNECTOR PLUG (MODELS II AND III) SPEAKER/MICROPHONE FLEXIBLE CIRCUIT CONNECTOR PLUGCONTROL TOP/ PTT FLEXIBLE CIRCUIT CONNECTOR PLUG MAEPF-23376-O CAUTION To avoid damage to the control top/PTT flexible circuit, DO NOT insert the screwdriver tip near the flexible circuit connector or the dual-function switch. Insert the tip of the slotted screwdriver only at the thin-walled chassis points shown below. CHASSIS CASTING THIN WALL POINTS (3) CONTROLLER BOARD (UNDER SHIELD) DUAL-FUNCTION SWITCH HOUSING MAE CONTROLLER SHIELD SCREWS (4) CONTROLLER SHIELD 66-80321B86 PHILLIPS BIT 15-PIN CONNECTOR (THIS END) MAEPF-23377-O
8. Remove the center shieldfrom the chassis by inserting a thin slotted screwdriver between each of five center-shield release clips and the corre- sponding chassis-retaining tabs. Once freed from the chassis at the five release points, the center shield can be removed and the RF board can be removed from the chassis. B. Servicing Major Subassemblies Refer to the exploded view diagram at the back of this manual before attempting further disassembly or repair. 1. Baseplate ¥ All repairs to the baseplate assembly can, and should, be made with the radio chassis inside the radio. ¥ After the slotted-spanner nuts are loosened, the baseplate is held in place by the power contact screw. ¥ The retainers holding the slotted-spanner nuts in place are not reusable. Replacement of the retainers requires special insertion proce- dures; refer to the instruction sheet provided with the slotted-spanner nut kit. ¥ The O-ring portion of the elastomer seal must be fully seated on the threaded bushing before the baseplate is reassembled (the bushing is part of the housing assembly).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-rings seating area. ¥ The PTT lever can be replaced by prying out the old part with a soft plastic tool. The plastic housing around the lever may be damaged if a harder tool is used. 3. Control Top Panel The control top panel is fastened to the chassis by the on/off/volume control, mode/zone selector switch, programmable switch, and antenna switch; it should be removed from the chassis only if absolutely necessary. 4. Front Shield/Display Board Assembly The ASTRO Digital SABER radios display board can be replaced, but the comments and cautions in this manual must be strictly followed. To remove the display board from the front shield assembly: a. ensure that all static safeguards are in effect; b. turn the front shield/display board assembly face down; c. with slight upward pressure on the LCD bezel, bend back each of the two plastic tabs that hold the display board in place, and the bot- tom of the LCD will come loose; d. push the LCD from its secured position enough to grasp its edges, then pull firmly up and out on the front shield/display board assembly. 5. Chassis If you must lift or remove the control top/PTT flexi- ble circuit for any reason, do not re-adhere it to the chassis; the flexible circuit must be replaced. 6. Dual-Function Switch and Actuator Assembly ¥ Before removing the switch, remove the knob by gently separating the two arms of the switch bracket (located between the switch and the main O-ring seal) and pulling upward on the knob. ¥ Before re-inserting the knob, ensure that the slot in the switch is properly aligned with the blade on the knobs shaft. 21 CAUTION Use extreme caution to ensure that the release clips are only deflected enough to disengage the clip from the chassis. Too much pressure on the clips could permanently damage the retain- ing feature. CHASSIS WITH RF BOARD ASSEMBLYMAEPF-23378-O CENTER SHIELD RELEASE POINTS (5) CENTER SHIELD (UNDERNEATH) MAEPF-23378-O CAUTION The RF and ground contacts at the top of the RF board are exposed when the board is removed from the chassis. Special care must be taken to avoid accidental damage to these contacts. CAUTION Be very careful not to damage the keyswitch overlay which is adhesively attached to the LCD bezel.
¥ 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 Reassemble the radio in the reverse order of disassembly, referring to Servicing Major Subassem- blies (paragraph B) and making certain: 1. that the protruding block that functions as the PA heatsink (inside back casting), is coated with a thin film of thermal compound (Motorola part num- ber 11-10022A55), which helps provide maximum heat transfer; 2. that the RF board is properly seated in the chas- sis, and that when inserted, the five locking tabs on the center shield are engaged with the chassis; 3. that when the controller board is reinstalled over the center shield and mated to the RF board, the connector plug of the controller is pressed firmly into the connector jack of the RF board (the two boards should snap together);4. that when installed, the four controller shield screws are torqued per specifications; 5. that the control top/PTT flex plug, speaker/micro- phone flex plug, and display flex plug have all properly mated with their corresponding connector jacks; 6. that the keyswitch overlay is pressed firmly against the LCD metal bezel of the front shield assembly; 7. that there is no foreign material on the main O-ring or stud seals; 8. to properly orient the completed chassis assembly before inserting it into the radio housing; 9. that the PTT switch and monitor button are not depressed while the chassis is being inserted into the housing; 10. that the slotted-spanner nut closest to the battery latch is torqued first, then torque the other to the proper specification listed in Table 13. 22 CAUTION Inspect the chassis stud seals and the control top panel O-ring and replace if any damage exists. Table 13. Torque Specifications Application Torque Torque Torque (in -lbs) (N¥m) Bit Part No. RX/TX Switch Spanner Nut 20 2.27 66-80371B34 Frequency Switch Spanner Nut 8 0.91 66-80371B03 Power Contact Screws 2.5 0.28 66-80321B79 Slotted-Spanner Nut (Baseplate) 6 0.68 66-80370B89 Volume Pot Spanner Nut 8 0.91 66-80371B03 Controller Shield Screws 2.8 0.32 66-80321B86