98xx Series Mobile Service Manual - Repeater Builder

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SERVICEMANUALMOBILE984X SERIES (UHF)988X SERIES (800 MHZ)989X SERIES (900 MHZ)25 or 40 Watts (UHF); 15 or 30 Watts (800/900 MHz)13.6 VDCPart No. 242-98xx-xxxRemote-MountFirst PrintingJanuary 2001Supersedes: Part No. 001-9800-200, 9/99

98xx-SERIESFM TWO-WAY RADIOSERVICE MANUAL13.6 VDC25 or 40 Watts, UHF15 or 30 Watts, 800/900 MHzPart No. 242-984x-2xx (UHF)Part No. 242-988x-2xx (800 MHz)Part No. 242-989x-2xx (900 MHz)Copyright 2001 by the E.F. Johnson CompanyThe E.F. Johnson Company, which was founded in 1923, provides wireless communicationsystems solutions for public safety, government, and commercial customers. The companydesigns, manufactures, and markets conventional and trunked radio systems, mobile andportable subscriber radios, repeaters, and Project 25 digital radio products.Viking Head/EFJohnson logo, LTR , LTR-Net , Multi-Net , and Call Guard are trademarksof the E.F. Johnson Company. SMARTNET and SmartZone are trademarks of Motorola,Inc. All other company and/or product names used in this manual are trademarks and/or registered trademarks of their respective manufacturer.Information in this manual is subject to change without notice.

TABLE OF CONTENTSTABLE OF CONTENTS1GENERAL INFORMATION1.1SCOPE OF MANUAL . . . . . . . . . . . . . . . . . . . . 1-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1LTR , Low Tier, and Data Models . . . . . . . . . . 1-11.2TRANSCEIVER DESCRIPTION . . . . . . . . . . .1-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Available Frequency Bands . . . . . . . . . . . . . . . . 1-1Front and Remote Mounting . . . . . . . . . . . . . . . 1-2NPSPAC Models (800 MHz Only) . . . . . . . . . . 1-2Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Transceiver Alignment . . . . . . . . . . . . . . . . . . . . 1-21.3PART NUMBER BREAKDOWN . . . . . . . . . . .1-21.4TRANSCEIVER IDENTIFICATION . . . . . . . .1-31.5ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.6PRODUCT WARRANTY . . . . . . . . . . . . . . . . . 1-41.7FACTORY CUSTOMER SERVICE . . . . . . . .1-41.8FACTORY RETURNS . . . . . . . . . . . . . . . . . . .1-51.9REPLACEMENT PARTS . . . . . . . . . . . . . . . . . 1-51.10 INTERNET HOME PAGE . . . . . . . . . . . . . . . . . 1-53CIRCUIT DESCRIPTION3.1GENERAL TRANSCEIVER DESCRIPTION 3-1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Circuit Protection (Fuses) . . . . . . . . . . . . . . . . . . 3-1Synthesizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Audio/Logic Board . . . . . . . . . . . . . . . . . . . . . . . 3-1Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2POWER DISTRIBUTION AND SWITCHING 3-2Power Switching Control . . . . . . . . . . . . . . . . . . 3-2Supply Switching . . . . . . . . . . . . . . . . . . . . . . . . 3-2AUDIO/LOGIC BOARD DIGITAL CIRCUIT 3-4Microcontroller (U101) . . . . . . . . . . . . . . . . . . . . 3-4Memory and Latch Programming . . . . . . . . . . . . 3-6RECEIVE AUDIO/DATA PROCESSING . . . 3-7Amplifier (U301B) . . . . . . . . . . . . . . . . . . . . . . . 3-7Receive Audio Processing. . . . . . . . . . . . . . . . . . 3-7Receive Data Processing . . . . . . . . . . . . . . . . . . . 3-8Squelch Circuit (U304A, U304B) . . . . . . . . . . . . 3-9TRANSMIT AUDIO/DATA PROCESSING . 3-9Microphone Amplifier (U303B),High-Pass Filter (U303C) . . . . . . . . . . . . . . . . 3-9Summing Amplifier (U303D), Pre-Emphasis/Limiter (U303A) . . . . . . . . . . . . . . . . . . . . . . 3-10Splatter Filter (U302B, U302C) . . . . . . . . . . . . 3-10Transmit Data Circuit (U302D, U302A). . . . . . 3-10DISPLAY BOARD . . . . . . . . . . . . . . . . . . . . . 3-10SYNTHESIZER CIRCUIT DESCRIPTION(UHF MODELS) . . . . . . . . . . . . . . . . . . . . . . 3-11Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Voltage-Controlled Oscillator . . . . . . . . . . . . . . 3-11Active Filter (Q800), Buffer Amplifier (Q801) 3-12VCO and TCXO Modulation . . . . . . . . . . . . . . 3-14Synthesizer Integrated Circuit (U804) . . . . . . . 3-14Lock Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Shift Register (U800, U801) and DigitalPotentiometer (U802) Programming. . . . . . . 3-15RECEIVER CIRCUIT DESCRIPTION(UHF MODELS) . . . . . . . . . . . . . . . . . . . . . . 3-16Front End Filter . . . . . . . . . . . . . . . . . . . . . . . . . 3-16RF Amplifier (Q201). . . . . . . . . . . . . . . . . . . . . 3-17First Mixer (Q202), Injection Amplifier (Q204) 3-17Second Mixer/Detector (U201) . . . . . . . . . . . . . 3-17TRANSMITTER CIRCUIT DESCRIPTION(UHF MODELS) . . . . . . . . . . . . . . . . . . . . . . 3-19First and Second Amplifiers . . . . . . . . . . . . . . . 3-19Third Amp and Predriver . . . . . . . . . . . . . . . . . 3-19Driver (Q600), Final (Q601) . . . . . . . . . . . . . . . 3-20Antenna Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Directional Coupler, Low-Pass Filter . . . . . . . . 3-21Power Control (U500A/B, Q500-Q503) . . . . . . 3-213.23.33.43.52INSTALLATION2.1GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Scope of Instructions . . . . . . . . . . . . . . . . . . . . . 2-1Performance Tests . . . . . . . . . . . . . . . . . . . . . . . 2-1Transceiver Programming . . . . . . . . . . . . . . . . . 2-2Required Power Source . . . . . . . . . . . . . . . . . . . 2-2MOUNTING THE TRANSCEIVER . . . . . . . . . 2-2Selecting A Mounting Location . . . . . . . . . . . . . 2-2Installation Components . . . . . . . . . . . . . . . . . . . 2-2Attaching Mounting Bracket . . . . . . . . . . . . . . . 2-2POWER CABLE INSTALLATION . . . . . . . . . 2-3ACCESSORY CABLE INSTALLATION . . . . 2-4General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Accessory Pigtail Installation . . . . . . . . . . . . . . . 2-5Connecting Ignition Sense Wire. . . . . . . . . . . . . 2-5Connecting Horn Alert Wire . . . . . . . . . . . . . . . 2-6Other Accessory Cable Outputs . . . . . . . . . . . . . 2-6REMOTE CONTROL UNIT INSTALLATION 2-6General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Mounting Remote Control Unit . . . . . . . . . . . . . 2-6USING AN EXTERNAL SPEAKER . . . . . . . . 2-7DATA CABLE INSTALLATION . . . . . . . . . . . 2-7General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Data Cable Installation . . . . . . . . . . . . . . . . . . . . 2-8KEY CAP KITS . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Multi-Net and LTR-Net Models. . . . . . . . . . . . . 2-8SMARTNET/SmartZone Models. . . . . . . . . . . . 2-92.22.32.42.52.62.72.83.63.73.83.9iiFebruary 2001Part No. 001-9800-001

TABLE OF CONTENTSTABLE OF CONTENTS (CONT’D)53.10 SYNTHESIZER CIRCUIT DESCRIPTION(800/900 MHz MODELS). . . . . . . . . . . . . . . 3-22Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Voltage-Controlled Oscillator . . . . . . . . . . . . . 3-22VCO and TCXO Modulation . . . . . . . . . . . . . . 3-24Active Filter (Q800) . . . . . . . . . . . . . . . . . . . . . 3-25Buffer Amplifier (Q801), Tx/Tx Switch(CR801/CR802) . . . . . . . . . . . . . . . . . . . . . . 3-25Synthesizer Integrated Circuit (U804) . . . . . . . 3-26Lock Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Shift Register (U800, U801) and DigitalPotentiometer (U802) Programming . . . . . . 3-273.11 RECEIVER CIRCUIT DESCRIPTION(800/900 MHz MODELS). . . . . . . . . . . . . . . 3-27Front End Filter . . . . . . . . . . . . . . . . . . . . . . . . 3-27RF Amplifier (Q201) . . . . . . . . . . . . . . . . . . . . 3-27First Mixer (Q202), Crystal Filter (Z204) . . . . 3-28Second Mixer/Detector (U201) . . . . . . . . . . . . 3-283.12 TRANSMITTER CIRCUIT DESCRIPTION(800/900 MHz MODELS). . . . . . . . . . . . . . . 3-29Predriver (Q506), Driver (Q507) . . . . . . . . . . . 3-29Power Amplifier Module (U600), Final (Q651) 3-30Antenna Switch . . . . . . . . . . . . . . . . . . . . . . . . 3-30Directional Coupler, Low-Pass Filter. . . . . . . . 3-30Power Control (U500A/B, Q500-Q503) . . . . . 3-314SERVICING4.1GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Periodic Checks . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Schematic Diagrams and Component Layouts. . 4-1Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . 4-1Configuring Transceiver for Testing . . . . . . . . . 4-1SURFACE MOUNTED DEVICES (SMDs) . .4-1Servicing Techniques . . . . . . . . . . . . . . . . . . . . . 4-1Identifying SMD Resistors . . . . . . . . . . . . . . . . . 4-1SMD Capacitor Identification . . . . . . . . . . . . . . 4-2SMD Inductor Identification . . . . . . . . . . . . . . . 4-3Transistor/Diode Identification . . . . . . . . . . . . . 4-3SYNTHESIZER TROUBLESHOOTING . . . . 4-3Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Reference Oscillator (U806). . . . . . . . . . . . . . . . 4-4VCO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Synthesizer IC (U804) . . . . . . . . . . . . . . . . . . . . 4-4Determining Synthesizer Counter DivideNumbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5RECEIVER SERVICING . . . . . . . . . . . . . . . . . . 4-5TRANSMITTER SERVICING . . . . . . . . . . . . . 4-5AUDIO/LOGIC BOARD SERVICING . . . . . . . 4-5Digital Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Analog Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.24.34.44.54.6PARTS LISTFront Panel Assembly and Mechanical Parts . . . 5-1UHF RF and PA Boards . . . . . . . . . . . . . . . . . . . 5-3800/900 MHz RF and PA Boards . . . . . . . . . . . 5-18Audio/Logic Board . . . . . . . . . . . . . . . . . . . . . . 5-259800-Series Radio Mounting Kit . . . . . . . . . . . 5-309800-Series Remote Mounting Kit . . . . . . . . . . 5-30DC Power Cable and Hardware Kit . . . . . . . . . 5-30Accessory Wire Kit . . . . . . . . . . . . . . . . . . . . . . 5-30Amplified Dynamic Microphone . . . . . . . . . . . 5-3015 Watt, 4.7-Ohm Speaker (Black) . . . . . . . . . . 5-30Exploded ViewsFront Panel . . . . . . . . . . . . . . . . . . . . . . . . . .Front and Top . . . . . . . . . . . . . . . . . . . . . . . .Bottom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Control Unit. . . . . . . . . . . . . . . . . . .Remote Transceiver . . . . . . . . . . . . . . . . . . .65-315-325-325-335-33SCHEMATIC DIAGRAMS ANDCOMPONENT LAYOUTSAmplified Dynamic Microphone . . . . . . . . . . . . 6-2Transceiver Top Photo . . . . . . . . . . . . . . . . . . . . 6-3Transceiver Bottom Photo. . . . . . . . . . . . . . . . . . 6-3Interconnect Schematic. . . . . . . . . . . . . . . . . . . 6-4Interface Board Layout. . . . . . . . . . . . . . . . . . . 6-4Display BoardTop View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5RPI (P.N. 023-9800-000)Board Layout. . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Programming Cable (P.N. 597-2002-200) . . . 6-6Component Locator GuidesUHF RF Board . . . . . . . . . . . . . . . . . . . . . . . . 6-7800/900 MHz RF Board . . . . . . . . . . . . . . . . 6-10Audio/Logic Board . . . . . . . . . . . . . . . . . . . . 6-12430-470 MHz RFRF Board Schematic (Revised Board . . . . . .PA Board Schematic (25W) . . . . . . . . . . . . .RF Board Layout (Revised Board) . . . . . . . .VCO Board Layout . . . . . . . . . . . . . . . . . . . .PA Board Layout (25W) . . . . . . . . . . . . . . . .PA Board Schematic (40W) . . . . . . . . . . . . .PA Board Layout (40W) . . . . . . . . . . . . . . . .RF Board Schematic (Unrevised Board) . . .RF Board Layout (Unrevised Board) . . . . . .iii6-156-156-166-176-176-186-196-206-21February 2001Part No. 001-9800-001

TABLE OF CONTENTSTABLE OF CONTENTS (CONT’D)470-512 MHz RFRF Board Schematic. . . . . . . . . . . . . . . . . . .PA Board Schematic (25W). . . . . . . . . . . . .VCO Board Layout . . . . . . . . . . . . . . . . . . .PA Board Layout (25W) . . . . . . . . . . . . . . .PA Board Schematic (40W). . . . . . . . . . . . .PA Board Layout (40W) . . . . . . . . . . . . . . .6-226-236-246-246-256-26800/900 MHz RFRF Board Schematic (800/900 MHz). . . . . .PA Board Schematic (15W). . . . . . . . . . . . .RF Board Layout (800 MHz) . . . . . . . . . . . .RF Board Layout (900 MHz) . . . . . . . . . . . .VCO Board Layout . . . . . . . . . . . . . . . . . . .PA Board Layout (15W) . . . . . . . . . . . . . . .PA Board Schematic (30W). . . . . . . . . . . . .PA Board Layout (30W) . . . . . . . . . . . . . . .6-276-276-286-296-306-306-316-32LIST OF TABLES1-11-21-32-14-14-2Part Number Breakdown . . . . . . . . . . . . . . . . . .Identification Number Breakdown . . . . . . . . . . .98xx Accessories . . . . . . . . . . . . . . . . . . . . . . . .Data Cable Wire Chart . . . . . . . . . . . . . . . . . . . .Ceramic SMD Capacitor Identification . . . . . . .SMD Inductor Identification . . . . . . . . . . . . . . .1-21-31-32-84-24-3LIST OF 00/900 MHz Audio/Logic BoardSchematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33Board Layout . . . . . . . . . . . . . . . . . . . . . . . . 6-34ivFront Mount Installation Components . . . . . . . 2-1Remote Mount Installation Components. . . . . . 2-3Accessory Cable Installation . . . . . . . . . . . . . . . 2-4Accessory Cable Connector . . . . . . . . . . . . . . . 2-5R170 Location Diagram . . . . . . . . . . . . . . . . . . 2-5Data Cable Installation (-001 Cable Shown). . . 2-7Power Distribution and Switching . . . . . . . . . . 3-3Power On-Off Control Circuit. . . . . . . . . . . . . . 3-3Audio/Data Processing Circuitry Block Diagram 3-8RF Block Diagram (UHF Models) . . . . . . . . . 3-13Synthesizer Chip U804 Block Diagram . . . . . 3-16Limiter/Detector U201 Block Diagram. . . . . . 3-18RF Block Diagram (800/900 MHz Models) . . 3-23Simplified Synthesizer Block Diagram . . . . . . . 4-3February 2001Part No. 001-9800-001

GENERAL INFORMATIONSECTION 1 GENERAL INFORMATION1.1 SCOPE OF MANUALThe data version of the 98xx transceiver has afront panel that is blank except for the programmingjack. For servicing information on data models, referto the LTR manual just described.1.1.1 GENERALThis service manual contains installation andservice information for all current 9800 series mobiletransceivers. These include the UHF 984x, 800 MHz988x, and 900 MHz 989x models.The Multi-Net version of the 98xx transceiver hasa data interface that supports external data equipment.For information on this interface and the serial controlprotocol it uses, refer to the Multi-Net manualdescribed in the preceding section.This manual does not include operation, programming, or alignment information. This information iscovered by a separate operation/programming manual(addendum) for each operating protocol as follows:ProtocolNOTE: External data equipment is currently notsupported by the LTR-Net and SMARTNET/SmartZoneversions of this transceiver.Operation and ProgrammingManual98xx Multi-Net 98xx LTR-Net 98xx SMARTNET /SmartZone 1.2 TRANSCEIVER DESCRIPTION1.2.1 e 98xx-series transceivers combine the latesttwo-way radio features and technology into a ruggedand dependable package for the business, industrial,and public safety markets. These transceivers are digitally synthesized, microcomputer-controlled, and fieldprogrammable.Therefore, use this manual to install and service98xx transceivers, and use the above manual for operation, programming, and tuning information.NOTE: The above Multi-Net manual also includes98xx servicing information but has not been updatedwith the latest changes that are in this manual.1.2.2 AVAILABLE FREQUENCY BANDSUHF Models1.1.2 LTR , LOW TIER, AND DATA MODELSNOTE: LTR, low tier, and data versions of the 98xxtransceiver are no longer available.The LTR versions of the 98xx are covered byLTR 98xx Service Manual, Part No. 001-9800-200.This is a complete LTR manual that includes LTRoperation and programming information and 98xxhardware servicing information. There are also -201and -202 revisions that should accompany this manual. 430-470 MHz or 470-512 MHz models available. All currently available models are dual bandwidth(12.5/25 kHz). Therefore, they can be programmedto operate on both types of channels. High power (40W) or medium power (25W) modelsavailable.800 MHz ModelsThe LTR models of the 98xx mobile were available in both high and low tier versions, and the MultiNet, LTR-Net, and SMARTNET/SmartZone modelsare available in only the high tier version. Therefore,only high tier models are covered by this manual. Forservicing information on low tier models, refer to theLTR manual described in the preceding paragraph.1-1 Full band (806-824 MHz) operation. All currently available models are dual bandwidth(12.5/25 kHz). High power (30W) and medium power (15W)models available.February 2001Part No. 001-9800-001

GENERAL INFORMATIONprogramming software. Programming is described inseparate manuals as described in Section 1.1.1.900 MHz Models Full band (896-902 MHz) operation.1.2.6 TRANSCEIVER ALIGNMENT Only narrow band (12.5 kHz) models are availablebecause the 900 MHz band has always had a 12.5kHz channel spacing.Alignment is performed using the standardPersonality programming setup and special RadioTune software. There are only two or three adjustments that are made by physically adjusting a component on the PC board. All other adjustments are setdigitally. The desired setting is selected using thecomputer, and it is then automatically stored in thetransceiver memory. If the manual adjustments do notneed to be readjusted, transceiver alignment canusually be performed without removing the covers.Alignment is described in separate manuals asdescribed in Section 1.1.1.High power (30W) and medium power (15W)models available.1.2.3 FRONT AND REMOTE MOUNTINGHigh tier models are available in both front- andremote-mount versions, and low tier models wereavailable in a front mount version only. Remote mountversions are intended to be mounted in a remote location up to approximately 17 feet away from the controlunit such as the vehicle’s trunk. Front mount versionsare intended to be mounted within reach of theoperator.1.3 PART NUMBER BREAKDOWNThe breakdown of the part number used toidentify this transceiver is shown in Table 1-1. WithLTR-Net and Multi-Net models, digits 4-7 of thisnumber are displayed briefly at power up.The control unit connects to the remote pigtailcable coming from the back panel of the transceiver.This cable is standard with remote mount models andoptional with front mount models. The remote controlunit uses the high tier front panel assembly. A RemoteConversion Kit is available for converting a frontmount high tier model to remote mounting (see Table1-3). The transceiver does not have dual-control capability. Therefore, either the front panel or a remotecontrol unit can be used for control, but not both.Table 1-1 Part Number Breakdown242 - 9 8 x x -x x x xBand1 VHF*4 UHF8 800 MHz9 900 MHz1.2.4 NPSPAC MODELS (800 MHZ ONLY)Type1 Low tier, dual BW2 Mid tier, dual BW*3 High tier, dual BW4 Low tier, 12.5 kHz5 Mid tier, 12.5 kHz*6 High tier, 12.5 kHz8 High tier rem, dual BW0 High tier rem, 12.5 kHzAll 800 MHz 988x transceivers capable of operating on 25 kHz channels meet the stricter specifications established by NPSPAC (National Public SafetyPanel Advisory Committee) for public safety frequencies from 821-824 and 866-869 MHz. Since deviationis less on NPSPAC channels, an additional screen ismay be displayed b

The LTR models of the 98xx mobile were avail-able in both high and low tier versions, and the Multi-Net, LTR-Net, and SMARTNET/SmartZone models are available in only the high tier version. Therefore, only high tier models are covered by this manual. For servicing information on low tier models, refer to the LTR manual described in the preceding .

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