Motorola SABER R, Service Manual

Page 1: ...P81045C75 68P81063C30 68P81066C95 68P81067C10 68P81043C390 and 68P81043C95 Service Manual ety ON es i AA MOTOROLA SABER R SECURENET SABER R and SECURENET Systems SABER R Handietalkie Portable Radios H499 Ruggedized Option Supplement to Service Manuals 68P81045C70 68P81045C75 68P81063C30 68P81066C95 68P81067C10 68P81043C390 and 68P81043C95 Service Manual ety ON es i ...

Page 2: ... it this defeats the point of capturing this at high resolution If something is incorrect here or unreadable please reach out I likely have the original lossless compressed images In the final PDF that s color or grayscale will be JPEG 2000 format with highest quality selected B W images will be compressed using CCITT Group 4 This is quite close to the source material but there may be some artifac...

Page 3: ...l non exclusive royalty free license to use that arises by operation of law in the sale of a product COMPUTER SOFTWARE COPYRIGHTS The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer progra...

Page 4: ...se Bivd Ft Lauderdale FL 33322 Printed in U S A 5 92 All Rights Reserved Service Manual 68P81071C20 A A MOTOROLA INC SABER R SECURENET SABER R and SECURENET Systems SABER R Handie lalkie Portable Radios H499 Ruggedized Option Supplement to Service Manuals 68P81045C70 68P81045C75 68P81063C30 68P81066C95 68P81067C10 68P81043C90 and 68P81043C95 I INTRODUCTION The SABER R SECURENET SABER R and SECUREN...

Page 5: ...e Cable PC XT 3080369872 Computer Interface Cable PC AT TEST EQUIPMENT FIELD PROGRAMMING EQUIPMENT 2 SPECIALIZED TOOLS AND TEST EQUIPMENT SERVICE AIDS RPX 4665A Field Modification Kit RTX4005A RSX 4043A Rototorq Tool RTK 4203A Program Test Cable RTL 4208A RF Coaxial Probe RTL 4224A Battery Eliminator RTL 4225A Housing Eliminator RTL 4238A SABER RF Cable RTX 4005B Portable Products Test Set 0180370...

Page 6: ...INWARD ON BUTTONS MAEPF 21442 0 tip 073 KC ANTENNA BASE OF AAEPF 21444 0 PEN Me xc INSTAL a nenove 3 DISASSEMBLY REASSEMBLY PROCEDURES DISASSEMBLY A Turn off the radio by rotating the on off volume C Loosen the two slotted spanner nuts on the control knob fully counterclockwise until you hear a click bottom of the radio using Rototorq tool bit No Remove the universal connector cover or any accesso...

Page 7: ...d view diagrams at the back of this manual before attempting further disassembly or repair ASEMBLY 4 E With the speaker facing upward remove the speaker bracket assembly by inserting a thin screwdriver blade between the frame and the bottom of the speaker bracket and prying gently upward on the speaker bracket until it is disengaged from the frame FRONT SHIELD ASSEMBLY SPEAKER SPEAKER BRACKET MAEP...

Page 8: ...he top tab aligned with the 9 on the escutcheon A new frequency knob and insert must be used each time this change is made NOTE There are different detent washers for even or odd numbers of switch positions see the appropriate exploded view parts list D LCD Speaker Bracket Assembly The LCD assembly can be replaced on SABER II radio PC board assemblies but the instructions on the replacement kit s ...

Page 9: ... exists to properly orient the completed frame assembly before inserting it into the radio housing 6 When removing the main circuit board from the frame assembly do the following 1 Remove the back shield assembly 2 Unplug the PTT controls flexible circuit 3 Remove the two power amplifer module U202 screws from the frame 4 Remove module SECURENET US900 5 Remove the two main compression connector sc...

Page 10: ...isible when looking at the top side of the radio If the seal ts visible It ts improperly installed 7 ENSURING RADIO SUBMERSIBILITY INTRODUCTION SABER R radio models meet twice the stringent requirements of U S MIL STD 810C Method 512 1 Procedure MIL STD 810D Method 512 2 Procedure I and MIL STD 810E Method 512 3 Procedure 1 which require the radio to maintain watertight integrity when immersed in ...

Page 11: ...greater than 1 psig may push air around the main seal and may damage the grille area US OEve LERES 8 NOTE When seating the main seal o ring in the radio housing use hand pressure to press the radio into the housing Make sure that the baseplate slotted spanner nuts are properly aligned before tightening them V VACUUM TEST Refer to the exploded view diagrams and parts lists in this manual A General ...

Page 12: ... insert by inserting a screwdriver blade into the insert s slot then pull the insert off the shaft 9 8 Cc Steps 1 and 4 Maintain the pressure at 1 psig and submerse the radio into a water filled container 5 Watch for any continuous series of bubbles A stream of bubbles may occur emanating from the grille port hole refer to step V B 3 or the keypad area if applicable These phenomena are normal A st...

Page 13: ...ernal switch seal replace the switch s o ring e Before reassembling the radio inspect the light pipe seal and both switch seals for damage and foreign material Repair or clean as necessary f Reassemble the radio in reverse order of disassembly using new frequency switch and on off volume control knobs and inserts 5 RF Connector a d To replace the rf connector seal disassemble the radio until the m...

Page 14: ...80321B79 Top Panel to Frame Screws 0 23 6680321B79 Volume Pot Spanner Nut 0 91 6680370B88 8 6 2 8 11 8 Main Seal a Remove and discard the old main seal o ring around the control top panel Inspect the sealing surfaces on the housing and control top panel replacing faulty items and cleaning off any foreign material b Inspect the speaker bracket assembly to ensure that the two tabs protruding from th...

Page 15: ...NOTES 12 NOTES 12 ...

Page 16: ...37 0 1 80 20 C225 2113741A51 018 C226 2311049J26 10 16V C227 2113741A51 018 C228 Not Used 910 C64 43 SABER VHF Electrical Parts List TPLF 4077 0 For Clear SABER R Models Only NOTES For optimum performance order replacement diodes transistors and circuit modules by Motorola part number only SABER VHF ELECTRICAL PARTS LIST FOR CLEAR SABER R MODELS ONLY 13 C229 230 2113741A51 018 C231 Not Used C232 2...

Page 17: ...HH MH BAO 24 28 32 N C50 ft i 5 fazoe 3 4 6 433 H oer cay COO R433 os To 5 8 9 we e420 REMOTE i 5 uaoo GC O 402 09 2 14 6 19 23 251 C204 C50 10 C A Cala ANTENNA U i 4 Do TTS I CQ Y vee 3 230 C405 R4Q f c 9 3 ae 28 Rs C 58 55 53 SF 48 46 43 4 CEPF 2 263 0 L CEPF 2 263 0 U2 MOUNTED UNDER U4 L6 CEPF 2 264 0 L6 CEPF 2 264 0 OL CEPF 2 266 0 OL CEPF 21265 A SCHEMATIC AND CIRCUIT BOARD NOTES 6 LAYER C RC...

Page 18: ...S 15 M XER AMP 200 3 200 H R7 HD RB a 219 car 2 30 23 Je 3 3 9 R405 2 0 aj x 0 VHF SCHEMATIC DIAGRAM T TUN NG CLTAGE F LTERED 33 08 4 5 PETER C220 Tos REC 5V 09 RXRE oo cé c2 R5 C53 3 5 H F cs RS 56H 470 Ls c58 U 02 POWEP AMPL F ER PS 8 20 2 2a 2e 34 13536 3 RE 470 RE ON L20 STANDARD ANT 5v 92H RF REG 7 a La L203 6fe pase out 3 D RET ONAL C208 C238 C25 C202 PE R60 L LO 3 3300 D ésoT ee 3 50 820 H ...

Page 19: ...PY a 2 4 co ce 5 30 cat e503 826 mts a a arn __Jreez 8 700 502 Py 2 a a0 Jes 2 REMOTE O C2I6 aa a O 206 9 O F900 R2 R213 R 2 Q207 0208 Try sua PY PY rs PY 59 CZD SDE VIEWED FROM S DE x Pa t not no ma yp aced TO SPEAKER 405 é j e a fI CO O R417 10 9 L CEPF 2 267 0 L6 CEPF 2268 0 L CEPF 2 267 0 L6 CEPF 2268 0 OL CEPF 2269 0 OL CEPF 21270 A SCHEMATIC AND CIRCUIT BOARD NOTES OF EW NG 1 Unless otherw s...

Page 20: ...S R700 25 MITER OUT BAT 4 NTERFACE 78 7 BAS RES 2 4 PASE U200 8 SC2 R24 C703 3 DC TAL ANALOGL SC3 00k HS BYPASS 26 5 MOC REF 8 7 CONVERTER 6 3 6 2 2 20 69 823 NC U 03 C70 C233 2 sca 0 FREO COM VAGBYPASS 29 REGULATOR UB T33 6a ig SW TCH a r Nc NC TRUNK NG DATA N a C234 REG 4 00 NC e 8 C4 C48 R22 5 30 29 2 3 s 9 CS n OPT ONAL T680 o22 62 RAOS Rx ouT 0 AUD 0 SP XMT POWER ND SPKR SELECT 24 6 C24 1 C36...

Page 21: ...2113740A55 100pF 5 C235 2160521H41 0 22 80 20 C236 Not Used C237 2160521H41 0 22 80 20 C238 Not Used SABER UHF Electrical Parts List TPLF 4076 0 For Clear SABER R Models Only SWITCH 800 RPX4690A Kit On Of Volume includes R800 801 S804 4005221R01 Dua l Function Clear Code 804 Standard and Emergency S801 Optional 802 Not Used 803 RPX4694A Kit Contact Snapdome PTT 805 thru 807 RPX4694A Kit Contact Sn...

Page 22: ... O 2 56 23 58 E A Z 13 A 60 62 63 CEPF SABER R SYSTEMS SABER IR EXPLODED VIEW DIAGRAM AND PARTS LIST 19 TPLF 4003 A SABER Ri Systems SABER IR Exploded View Parts List 18 19 27 0305706001 SCREW Captive 4 reqd part of item 26 28 4205577Q01 CLIP Ground 1405343901 BOOT Oscillator SABER 1 RPX 4700A KIT PTT Controls Flex includes item 31 or RPX 4701A KIT PT Controls Flex Assembly includes items 2 3 31 3...

Page 23: ...5 56 1 22 58 26 27 a KAO 28 60 29 62 30 ge 3 5 41 42 iG CEPF 20 EXPLODED VIEW DIAGRAM AND PARTS LIST TPLF 4004 A SAGER IIR Exploded View Parts List SABER IIR 18 19 TEM MOTOROLA NO PART NO DESCRIPTION 31 RPX 4694A KIT Contact Snapdome 2 req d 4505315V01 part of item 30 LEVER PT part of item 43 4205292V01 SLIDE part of item 43 3805294101 BUTTON 2 req d part of item 43 3205082E84 O RING Battery part ...

Page 24: ...NOTES NOTES ...

Page 25: ...NOTES NOTES ...

Page 26: ...enfusing Size Adequate Size Too Small Not Covered in This Manual Disassembly Procedures Alignment Procedures Exploded Views Schematic Diagrams Circuit Board Details Electrical Parts Lists Exploded View Parts List 2 How would you rate the overall organization of this manual 0 excellent 21 very good OO good 0 fair poor 3 Did this Service manual provide you with the information necessary to service a...

Page 27: ...e Number Please include Area Code PLEASE USE TAPE TO SEAL POSTAL REGULATIONS PROHIBIT USE OF STAPLES NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 9040 FT LAUDERDALE FL City State Zip POSTAGE WILL BE PAID BY ADDRESSEE AA MOTOROLA Attention Technical Publications Room 2352 8000 W SUNRISE BOULEVARD FT LAUDERDALE FLORIDA 33322 FOLD Continued FOLD P...

Page 28: ...omer Response Center Sales and Service Assistance Call FAX 1 800 247 2346 1 800 232 9272 TEPF 9679 N REPLACEMENT PARTS ORDERING When ordering replacement parts or equipment information the complete identification number should be included This applies to all components kits and chassis If the component part number is not known the order should include the number of the chassis or kit of which it i...

Page 29: ...fee 68P81071C20 A Motorola 8000 West Sunrise Boulevard Fort Lauderdale Florida 33322 Pe W 0 aes ag ay fee Motorola 8000 West Sunrise Boulevard Fort Lauderdale Florida 33322 68P81071C20 A ...