Motorola EP450 Basic Service Manual
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Motorola EP450 Basic Service Manual

Vhf 146-174 mhz; uhf 403-440 mhz; uhf 438-470 mhz; uhf 465-495 mhz
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MOTOROLA, The Stylized M logo are trademarks of Motorola, Inc.
All other product or service names are the property of their respective owners.
© 2003 Motorola, Inc. All rights reserved. Printed in U.S.A.
HKLN4215A
HKLN4215A
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EP450
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Basic Service Manual

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  • Page 1 ™ Portable Radio Basic Service Manual MOTOROLA, The Stylized M logo are trademarks of Motorola, Inc. All other product or service names are the property of their respective owners. © 2003 Motorola, Inc. All rights reserved. Printed in U.S.A. HKLN4215A...
  • Page 2 EP450 Portable Radio Basic Service Manual VHF 146-174 MHz UHF 403-440 MHz UHF 438-470 MHz UHF 465-495 MHz Motorola, Inc. 1301 E. Algonquin Road HKLN4215A Schaumburg, IL 60196 More user manuals on ManualsBase.com...

  • Page 3: Product Safety And Rf Exposure Compliance

    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.

  • Page 4: Table Of Contents

    Table of Contents Table of Contents Foreword ..............................ii Product Safety and RF Exposure Compliance ....................ii Computer Software Copyrights ........................ii Document Copyrights ..........................ii Disclaimer..............................ii List of Figures ....................vi List of Tables ....................viii Chapter 1 Model Charts and Test Specifications ......1-1 Radio Model Information........................
  • Page 5 Chassis and Front Cover Re-assembly ............6-13 6.4.2.7 PTT Re-assembly .................... 6-15 Mechanical View and Parts List ....................6-16 6.5.1 EP450 Display Model Exploded View and Parts List ............6-16 Chapter 7 Non-Display Model Disassembly and Re-assembly ..7-1 Introduction ............................ 7-1 Preventive Maintenance ........................ 7-1 7.2.1...
  • Page 6 Chassis and Front Cover Re-assembly ............7-10 7.4.3.5 PTT Re-assembly .................... 7-11 Mechanical View and Parts List....................7-13 7.5.1 EP450 Non-Display Exploded View and Parts List............7-13 Chapter 8 Troubleshooting Tables ............. 8-1 Power-Up Error Codes ........................8-1 Operational Error Codes........................ 8-1 Troubleshooting Table for Receiver....................

  • Page 7: List Of Figures

    Figure 6-18. Microphone and Speaker Wires Re-assembly ............... 6-14 Figure 6-19. Keyboard Flex Cable Connection................... 6-14 Figure 6-20. Fastening the Chassis ....................6-15 Figure 6-21. PTT Re-assembly......................6-15 Figure 6-22. EP450 Full Keypad Radio Exploded View..............6-16 Figure 7-1. Battery Removal ....................... 7-3 Figure 7-2.
  • Page 8 Figure 7-12. Installation of Main Board onto Chassis ................. 7-10 Figure 7-13. Microphone and Speaker Wires Re-assembly ............... 7-11 Figure 7-14. Fastening the Chassis....................7-11 Figure 7-15. PTT Re-assembly......................7-12 Figure 7-16. EP450 Non-Display Radio Exploded View..............7-13 HKLN4215A December 3, 2003 More user manuals on...

  • Page 9: List Of Tables

    viii Table of Contents List of Tables Table 1-1. Radio Model Number (Example: LAH65KDC9AA2AN)............ 1-1 Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications..... 1-8 Table 3-1. Recommended Test Equipment ..................3-1 Table 3-2. Service Aids........................

  • Page 10: Chapter 1 Model Charts And Test Specifications

    Chapter 1 Model Charts and Test Specifications Radio Model Information The model number and serial number are located on a label attached to the back of your radio. You can determine the RF output power, frequency band, protocols, and physical packages. The example below shows one portable radio model number and its specific characteristics.

  • Page 11: Model Chart For Vhf 146-174 Mhz

    Model Charts and Test Specifications: Model Chart for VHF 146-174 MHz Model Chart for VHF 146-174 MHz EP450, VHF, 146-174 MHz Model Description LAH65KDC9AA2AN EP450, 146-174 MHz, 5 W, 16 Ch. Non-Display Model LAH65KDH9AA4AN EP450, 146-174 MHz, 5 W, 64 Ch. Display Model Item Description PMUD1857_ EP450, 146-174 MHz, 5 W, 16 Ch.
  • Page 12 VHF Test Specifications VHF Test Specifications General Transmitter RF Output High Channel Capacity: 16 or 64 Channels Li-Ion @ 7.5 V: 7.5 Volts ±20% Power Supply: Frequency: 146-174 MHz Dimensions (HxWxD) Channel Spacing: 12.5/20/25 kHz with Battery: 130.5mm x 62mm x 45mm High Capacity Li-Ion "...

  • Page 13: Model Chart For Uhf 403-440 Mhz

    Model Charts and Test Specifications: Model Chart for UHF 403-440 MHz Model Chart for UHF 403-440 MHz EP450, UHF, 403-440 MHz Model Description LAH65QDC9AA2AN EP450, 403-440 MHz, 4 W, 16 Ch. Non-Display Model LAH65QDH9AA4AN EP450, 403-440 MHz, 4 W, 64 Ch. Display Model Item Description PMUE1972_ EP450, 403-440 MHz, 4 W, 16 Ch.

  • Page 14: Model Chart For Uhf 438-470 Mhz

    Model Charts and Test Specifications: Model Chart for UHF 438-470 MHz Model Chart for UHF 438-470 MHz EP450, UHF, 438-470 MHz Model Description LAH65RDC9AA2AN EP450, 438-470 MHz, 4 W, 16 Ch. Non-Display Model LAH65RDH9AA4AN EP450, 438-470 MHz, 4 W, 64 Ch. Display Model Item Description PMUE1966_ EP450, 438-470 MHz, 4 W, 16 Ch.

  • Page 15: Model Chart For Uhf 465-495 Mhz

    Model Charts and Test Specifications: Model Chart for UHF 465-495 MHz Model Chart for UHF 465-495 MHz EP450, UHF, 465-495 MHz Model Description LAH65SDC9AA2AN EP450, 465-495 MHz, 4 W, 16 Ch. Non-Display Model LAH65SDH9AA4AN EP450, 465-495 MHz, 4 W, 64 Ch. Display Model Item Description PMUE1978_ EP450, 465-495 MHz, 4 W, 16 Ch.
  • Page 16 UHF Test Specifications UHF Test Specifications General Transmitter RF Output High Channel Capacity: 16 or 64 Channels Li-Ion @ 7.5 V: 7.5 Volts ±20% Power Supply: Frequency: 403-440 MHz Dimensions (HxWxD) 438-470 MHz with Battery: 130.5mm x 62mm x 45mm 465-495 MHz High Capacity Li-Ion "...

  • Page 17: Mil Standards

    Model Charts and Test Specifications: MIL Standards MIL Standards Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications (8.2 and 8.4) Military Standards 810 C, D, E, & F: Parameters/Methods/Procedures 810C 810D 810E 810F Applicable Methods...

  • Page 18: Chapter 2 Theory Of Operation

    Chapter 2 Theory Of Operation Introduction This chapter provides a basic theory of operation for the radio components. Major Assemblies • Transceiver Board – contains all transmit, receive, and audio circuitry. • Display (Display models only) – 8 characters (14 segments star burst) and 10 icons with back- lighting, liquid-crystal display (LCD).

  • Page 19: Transmitter

    Theory Of Operation: Major Assemblies The IFIC is a low-voltage monolithic FM IF system incorporating a mixer/oscillator, two limiting IF amplifiers, quadrature detector, logarithmic received signal strength indicator (RSSI), voltage regulator and audio, and RSSI Op Amps. The second LO frequency, 44.395 MHz, is determined by a crystal oscillator.

  • Page 20: Chapter 3 Test Equipment, Service Aids, And Service Tools

    Chapter 3 Test Equipment, Service Aids, and Service Tools Test Equipment Table 3-1 lists test equipment required to service the EP450 Radios. Table 3-1. Recommended Test Equipment Motorola Part No. Description Characteristics Application R2600 series System analyzer This item will substitute for...

  • Page 21: Service Aids

    Service Aids Table 3-2 lists service aids recommended for working on the EP450 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 substituted for the item listed.
  • Page 22 Test Equipment, Service Aids, and Service Tools: Service Aids Table 3-3. Recommended Service Tools (Continued) Motorola Part Description Application 0180386A78 Illuminated magnifying glass with lens attachment Illumination and magnification of components 0180302E51 Master lens system 0180386A82 Anti-static grounding kit Used during all radio assembly and disassembly pro-...

  • Page 23: Figure 3-1. Programming/Test Cable

    Test Equipment, Service Aids, and Service Tools: Service Aids Programming/Test Cable 25 POSITION 25 POSITION MALE CONNECTOR FEMALE CONNECTOR 36.0” CABLE 36.0” CABLE Figure 3-1. Programming/Test Cable 25 pin Male D Connector Components molded inside 2.5mm stereo and 3.5mm Orange 3.5mm Tip (Speaker +) Blue...

  • Page 24: Chapter 4 Performance Checks

    Chapter 4 Performance Checks General These radios meet published specifications through their manufacturing process by utilizing high- accuracy laboratory-quality test equipment. The recommended field service equipment is as accurate as the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 25: Rf Test Mode

    Monitor Vol: 1/4 CW RF Test Mode When the EP450 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer code plug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment using a special routine, called RF TEST MODE.

  • Page 26: Table 4-2. Test Environments

    Performance Checks: RF Test Mode To enter test mode: 1. Turn the radio on. Within ten seconds after the self test is complete (self test tone is heard), press SB2 (Side Button 2 in Figure 4-2) five times in succession. If the self test complete tone is not heard, see Error Codes information in Chapter 8.

  • Page 27: Table 4-4. Test Frequencies

    Performance Checks: RF Test Mode Table 4-4. Test Frequencies Channel Selector VHF R2 UHF R1 UHF R2 UHF R3 Test Channel Switch Position (MHz) (MHz) (MHz) (MHz) 1 Low Power TX#1 or #8 146.625 403.625 438.625 465.625 8 High Power RX#1 or #8 2 Low Power TX#2 or #9...

  • Page 28: Table 4-6. Transmitter Performance Checks

    Performance Checks: RF Test Mode Table 4-6. Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode: PWR MON TEST MODE, PTT to continu- Frequency error to be Frequency Test Channel 4 ous (during the ±200 Hz VHF 4th channel test frequency carrier squelch performance...
  • Page 29 Performance Checks: RF Test Mode Notes: December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...

  • Page 30: Chapter 5 Radio Alignment Procedures

    Chapter 5 Radio Alignment Procedures Introduction This chapter provides an overview of the Commercial Series Customer Programming Software (CPS) and the Global Tuner as designed for use in a Windows® 98/NT4/2000/ME/XP environment. Both cover all the functions of the traditional Radio Service Software (RSS) package. They are both available in the CPS Tuner (CD ROM) Kit (RVN4195).

  • Page 31: Radio Tuning Setup

    Radio Alignment Procedures: Radio Tuning Setup Radio Tuning Setup A Windows 98/NT4/2000/ME/XP PC (personal computer) and Global Tuner are required to tune the radio. To perform the tuning procedures, the radio must be connected to the PC, RIB (Radio Interface Box) and Universal Test Set as shown in Figure 5-2 below.

  • Page 32: Initial Test Equipment Control Settings

    Radio Alignment Procedures: Transmitter Alignment Options 5.3.1 Initial Test Equipment Control Settings The initial test equipment control settings are listed in Table 5-1. Table 5-1. Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode: Power Monitor Speaker set: A Voltage: 13.2 Vdc RF Attenuation: -70 Speaker/load:...

  • Page 33: Modulation Balance Attenuation

    Radio Alignment Procedures: Transmitter Alignment Options 1. Under Tx Align menu, select Reference Oscillator Warp (Figure 5-3). 2. There is only 1 frequency point shown which is always the last non-0 transmit frequency point, which will normally be F7. 3. Click on the slider thumb and press PTT Toggle to key up the radio at the corresponding fre- quency point.

  • Page 34: Transmit Power Tuning

    Radio Alignment Procedures: Transmitter Alignment Options 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 signaling schemes that have very low frequency components (Digital Private-Line) and could result in distorted waveforms if improperly adjusted.

  • Page 35: To Perform Transmit High Power Tuning, Do The Following

    Radio Alignment Procedures: Transmitter Alignment Options Table 5-3. Transmit High/Low Power Level RF Band (MHz) Model Number High Power(W) Low Power (W) 16 Channel VHF 146-174 H65KDC9AA2AN 5.2-5.5 1.1-1.3 64 Channel VHF 146-174 H65KDH9AA4AN 5.2-5.5 1.1-1.3 16 Channel UHF 1 403-440 H65QDC9AA2AN 4.2-4.5 1.1-1.3...

  • Page 36: Vco Attenuation

    Radio Alignment Procedures: Transmitter Alignment Options 5.4.4 VCO Attenuation Note: Modulation Balance Tuning must be done first. The Transmit Deviation Limit softpot sets the maximum deviation of the carrier. Tuning is performed for all (12.5 kHz, 20 kHz and 25 kHz) channel bandwidths. Tuning for 25 kHz channels must be done first for all frequency points.

  • Page 37: Vco Attenuation 12.5 Khz

    Radio Alignment Procedures: Transmitter Alignment Options 7. Program the softpot value by pressing the Program button. 8. Exit the VCO Attn. 25 kHz function. 5.4.4.2 VCO Attenuation 12.5 kHz Note: Tuning of Modulation Balance Attenuation and VCO Attenuation for 25 kHz channel bandwidth must be done first.

  • Page 38: Dtmf Deviation Tuning

    Radio Alignment Procedures: Transmitter Alignment Options 5.4.5 DTMF Deviation Tuning This tuning option controls the Dual Tone Multi-Frequency deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning the DTMF. Figure 5-7.

  • Page 39: Mdc-1200 Deviation Tuning

    5-10 Radio Alignment Procedures: Receiver Tuning 5.4.6 MDC-1200 Deviation Tuning This tuning option controls the MDC-1200 Signaling deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning this feature.

  • Page 40: Rated Volume Tuning

    Radio Alignment Procedures: Receiver Tuning 5-11 5.5.1 Rated Volume Tuning Note: When using test box RLN4460, the received audio output is taken from the AC/DC METER OUT terminals with the METER OUT rotary switch set to RX. The rated audio tuning procedure automatically configures the radio for 25 KHz.

  • Page 41: Squelch Tuning

    5-12 Radio Alignment Procedures: Receiver Tuning 5.5.2 Squelch Tuning Note: 1. Squelch tuning can only be accomplished after reference oscillator warping. 2. When using the test box RLN4460, the received audio output is taken from the AC/ DC METER OUT terminals with the METER OUT rotary switch set to RX. It is recom- mended that Rated Volume Tuning be performed so the correct 10 dB SINAD level can be obtained.

  • Page 42: Auto Tune

    Radio Alignment Procedures: Receiver Tuning 5-13 3. Set softpot to its maximum value to mute the radio. 4. Adjust the softpot value by using the slider, keying in the edit box or using the spin controls. Press ENTER to confirm the selection or use the spin controls. Do this until the radio is totally unmuted. Verify the squelch closing by inputting a signal level of 4 dB lower than that of the 10 dB SINAD level.

  • Page 43: Rssi Display Tuning

    5-14 Radio Alignment Procedures: Utilities 5. Adjust the input level to reflect the next soft spot value. Repeat steps 3 and 4 to tune the next value. 5.5.4 RSSI Display Tuning 1. Under the Rx Align menu, select RSSI Display Tuning. 2.

  • Page 44: Figure 5-12. Side Button Locations

    Radio Alignment Procedures: Radio-to-Radio Cloning 5-15 Procedure: 1. Turn source and target radios off. 2. Connect cloning cable (AAPMKN4003) to the side connector of both radios. 3. Turn on the destination radio. 4. Press and hold the two side buttons at the same time on the source radio and then power up the source radio (Figure 5-12).
  • Page 45 5-16 Radio Alignment Procedures: Radio-to-Radio Cloning Notes: December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...

  • Page 46: Chapter 6 Display Model Disassembly And Re-Assembly

    Chapter 6 Display Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 47: Safe Handling Of Cmos And Ldmos Devices

    • Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX- 4015.) • Do not wear nylon clothing while handling CMOS devices.

  • Page 48: Disassembling And Re-Assembling The Radio - General

    Scribe If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. See Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...

  • Page 49: Figure 6-2. Antenna And Knob Removal

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Remove the antenna. 4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis opener tool (Motorola part # 6686533Z01). (Figure 6-2.) Figure 6-2.

  • Page 50: Figure 6-4. Keyboard Flex Connection

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Note: The speaker wire assembly microphone wire assembly and keypad flex cable connector connecting the front housing assembly and the chassis prevent the two units from being completely separated 7.

  • Page 51: Dust Cover Disassembly

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.1.2 Dust Cover Disassembly 1. Gently pry the top of the dust cover away from the body of the radio. (See Figure 6-6). 2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed. 3.

  • Page 52: Keyboard Removal

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.1.4 Keyboard Removal 1. Carefully pry the four keypad retainer locking tabs free from the housing use a scribe. Note: Use care when removing the keypad retainer to prevent damage to the keyboard flex cable. 2.

  • Page 53: Chassis Disassembly

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Flat Blade Screwdriver Hooks PTT Seal Figure 6-9. PTT Removal 6.4.1.6 Chassis Disassembly CAUTION: Refer to the CMOS CAUTION paragraph (see 3.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

  • Page 54: Radio Re-Assembly - Detailed

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 4. Lift the main board from the chassis (Figure 6-10). 5. Remove the battery contact seal. 6.4.2 Radio Re-assembly - Detailed 6.4.2.1 Dust Cover Re-assembly 1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 6-11).

  • Page 55: Figure 6-12. Microphone Re-Assembly

    6-10 Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Microphone Boot Microphone Recess Microphone Position Figure 6-12. Microphone Re-assembly 4. Locate the speaker tab and align it with the tab opening in the front housing (Figure 6-13).

  • Page 56: Keypad And Lcd/Keyboard Re-Assembly

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-11 6.4.2.3 Keypad and LCD/Keyboard Re-assembly 1. Attach the flex cable from the LCD module to the keyboard, if not already attached (Figure 6-15). 2. Remove protective mylar from window and from keypad, if present. 3.

  • Page 57: Keyboard Retainer Re-Assembly

    6-12 Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6. Attach the flex cable into the connector on the keypad board, if not already connected. 7. Bend the flex cable as shown (Figure 6-15) 6.4.2.4 Keyboard Retainer Re-assembly 1.

  • Page 58: Chassis And Front Cover Re-Assembly

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-13 Audio Jack Shroud Frequency & (Replace after Plugging Volume Switches in Speaker and Mic) Main Board Interface Pad Flex Cable Connector Radio Chassis Battery Contact Seal O-Ring Figure 6-17.

  • Page 59: Figure 6-18. Microphone And Speaker Wires Re-Assembly

    6-14 Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Speaker Connector Microphone Connector Shroud Figure 6-18. Microphone and Speaker Wires Re-assembly 2. Position the radio (Figure 6-19), and reconnect the flex connector from the keyboard into the con- nector located on the bottom of the main board, pushing up the 2 end tabs.

  • Page 60: Ptt Re-Assembly

    Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-15 5. Snap chassis assembly completely into the top of the front cover (Figure 6-20) until it settles in place. Radio Chassis Figure 6-20. Fastening the Chassis 6. Make sure the 0-ring is properly seated. If the O-ring seal is pinched, separate the chassis from the housing using the knob removal/chassis opener and dress O-ring properly.

  • Page 61: Mechanical View And Parts List

    6-16 Display Model Disassembly and Re-assembly: Mechanical View and Parts List Mechanical View and Parts List 6.5.1 EP450 Display Exploded View and Parts List Figure 6-22. EP450 Display Radio Exploded View December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...
  • Page 62 Part Description Number Number See Section 6 Antenna NON-REFERENCED ITEMS 3386625Z01 Nameplate, Motorola 3680530Z02 Knob, Frequency Nameplate, EP450 1386440Z01 Escutcheon, Top; 4 Ch. 1386440Z02 Escutcheon, Top; 16 Ch. 5886627Z01 Antenna Adaptor/Seal (Optional) 1586391Z03 Housing, Full, with Lens 3586621Z01 Speaker, Felt...
  • Page 63 6-18 Display Model Disassembly and Re-assembly: Mechanical View and Parts List Notes: December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...

  • Page 64: Chapter 7 Non-Display Model Disassembly And Re-Assembly

    Chapter 7 Non-Display Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 65: Safe Handling Of Cmos And Ldmos Devices

    • Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX- 4015.) • Do not wear nylon clothing while handling CMOS devices.

  • Page 66: Disassembling And Re-Assembling The Radio - General

    TORX™ T6 screwdriver If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. See Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...

  • Page 67: Figure 7-2. Antenna And Knob Removal

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Remove the antenna. 4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis opener tool (Motorola part # 6686533Z01). (Figure 7-2) Figure 7-2.

  • Page 68: Dust Cover Disassembly

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6. Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case. (Figure 7-4). Rotate the chassis counterclockwise out of the housing and position next to the housing. Take care not to damage the speaker and microphone wires that are still connected to the chassis (Figure 7-4).

  • Page 69: Speaker And Microphone Disassembly

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.1.3 Speaker and Microphone Disassembly Note: The speaker is held in place with a retainer bracket. Be careful not to damage the speaker when removing the retainer bracket. 1.

  • Page 70: Chassis Disassembly

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Flat Blade Screwdriver Hooks PTT Seal Figure 7-7. PTT Removal 7.4.2 Chassis Disassembly CAUTION: Refer to the CMOS CAUTION paragraph (7.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

  • Page 71: Radio Re-Assembly - Detailed

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.3 Radio Re-assembly - Detailed 7.4.3.1 Dust Cover Re-assembly 1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 7-9).

  • Page 72: Chassis Assembly/Re-Assembly

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Note: Make sure the speaker and microphone wires are routed tightly between the speaker basket and the housing post 6. Insert one end of the speaker retainer into the slot in the front housing (See Figure 7-11)..

  • Page 73: Chassis And Front Cover Re-Assembly

    7-10 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Audio Jack Shroud Frequency & (Replace after Plugging Volume Switches in Speaker and Mic) Main Board Interface Pad Radio Chassis Battery Contact Seal O-ring Figure 7-12. Installation of Main Board onto Chassis 7.4.3.4 Chassis and Front Cover Re-assembly 8.

  • Page 74: Ptt Re-Assembly

    Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-11 Speaker Connector Microphone Connector Shroud Figure 7-13. Microphone and Speaker Wires Re-assembly Radio Chassis Figure 7-14. Fastening the Chassis 12. Snap chassis assembly completely into the top of the front cover (Figure 7-14) until it settles in place.

  • Page 75: Figure 7-15. Ptt Re-Assembly

    7-12 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Press the PTT assembly against the front cover opening (Figure 7-15b). a. Place bottom tab into bottom slot. b. Push down on PTT toward bottom Place top tab into top slot. of radio so hooks do not get crushed.

  • Page 76: Mechanical View And Parts List

    Non-Display Model Disassembly and Re-assembly: Mechanical View and Parts List 7-13 Mechanical View and Parts List 7.5.1 EP450 Non-Display Exploded View and Parts List Figure 7-16. EP450 Non-Display Radio Exploded View HKLN4215A December 3, 2003 More user manuals on ManualsBase.com...
  • Page 77 5586445Z02 Latch Assembly 4105944K01 Spring, Latch; 2 Used 3886441Z01 Cap, Dust 3286432Z01 Seal, Control Shaft 3386443Z01 Label, Escutcheon Seal 6186446Z02 Lightpipe 3680529Z01 Knob, Volume 0386434Z01 Screw, Speaker Retainer NON-REFERENCED ITEMS 3386625Z01 Nameplate, Motorola Nameplate, EP450 More user manuals on ManualsBase.com...

  • Page 78: Chapter 8 Troubleshooting Tables

    Chapter 8 Troubleshooting Tables Power-Up Error Codes During radio power-up, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as an error code 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.

  • Page 79: Troubleshooting Table For Receiver

    Troubleshooting Tables: Troubleshooting Table for Receiver Troubleshooting Table for Receiver Table Table 8-3 lists the possible causes of, and corrections for, receiver problems. Table 8-3. Receiver Troubleshooting Table Corrective or Test Symptom Possible Causes (Measurements at Room Temperature) Radio Dead; Display Does 1.

  • Page 80: Troubleshooting Table For Transmitter

    Troubleshooting Tables: Troubleshooting Table for Transmitter Troubleshooting Table for Transmitter Table Table 8-4 lists the possible causes of, and corrections for, transmitter problems. Table 8-4. Transmitter Troubleshooting Table Corrective or Test Symptom Possible Causes (Measurements at Room Temperature) No RF Power Out 1.
  • Page 81 Troubleshooting Tables: Troubleshooting Table for Transmitter Notes: December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...

  • Page 82: Appendix A Accessories

    Appendix A Accessories Antennas NAD6502_R VHF Heliflex Antenna 14cm (146-174 MHz) HAD9742 VHF Stubby Antenna, 9cm (146-162 MHz) HAD9743 VHF Stubby Antenna, 9cm (162-174 MHz) NAE6522_R UHF Heliflex Stubby Antenna 9cm (438-470 MHz) NAE6483_R Flexible Whip Antenna (403-520 MHz) 8505816K26 UHF Heliflex Stubby (470-520 MHz) Carrying Accessories RLN5498...
  • Page 83 Accessories Audio Accessories HMN9752 Earpiece with Volume Control, 1-Wire (plastic earloop) (Beige) HMN9727 Earpiece without Volume Control, 1-Wire (plastic earloop) (Beige) RLN4894 Earpiece without Volume Control, 1-Wire (plastic earloop) (Black) HMN9754 Earpiece with Microphone & PTT Combined, 2-Wire (Beige) RLN4895 Earpiece with Microphone &...
  • Page 84 Accessories BDN6647 Medium Weight Single Speaker Headset BDN6648 Heavy Duty Dual Muff Headset with Noise Canceling Microphone 5080371E66 Replacement Ear Pad for BDN6647 RMN5015 Heavy Duty Dual Muff Racing Headset (requires RKN4090 Headset Adapter Cable) REX4648 Ear Pad and Windscreen Kit RKN4090 Adapter Cable for use with RMN5015 Racing Headset RMN4051...
  • Page 85 Accessories December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...

  • Page 86: Appendix B Warranty, Service Support, And Replacement Parts

    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.

  • Page 87: Motorola Online

    Appendix B-2 Warranty, Service Support, and Replacement Parts: Replacement Parts Ordering 1.3.2 Motorola Online Motorola online users can access our on-line catalog at: https://businessonline.motorola.com 1.3.3 Mail Orders Send written orders to the following addresses: International Orders: Motorola, Inc. Customer Care and Services...

  • Page 88: Technical Support

    Technical Support Technical support is available to assist the dealer/distributor in resolving any malfunction which may be encountered. Initial contact should be by telephone wherever possible. When contacting Motorola Technical Support (“contact us” MOL at https://businessonline.motorola.com), be prepared to provide the product model number and the unit’s serial number.
  • Page 89 Appendix B-4 Warranty, Service Support, and Replacement Parts: Technical Support December 3, 2003 HKLN4215A More user manuals on ManualsBase.com...

  • Page 90: Glossary

    Micro Controller Unit MRTI Motorola Radio-Telephone Interconnect: a system that provides a repeater con- nection to the Public Switched Telephone Network (PSTN). The MRTI allows the radio to access the telephone network when the proper access code is received.
  • Page 91 Term Definition Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a refer- ence, usually after passing through a frequency divider. Push-To-Talk: the switch located on the left side of the radio; when pressed, causes the radio to transmit. Random Access Memory: the radio’s RAM is loaded with a copy of the EEPROM data.

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