GE MLSH041 User manual

LBI-38438A
Maintenance Manual
Service Section
MLS High-Band Two-Way
Mobile Radios
MLSH041

GENERAL INFORMATION
2LBI-38438A
NOTICE!
Repairs to this equipment should be made only by an authorized service technician or facility designated by the supplier. Any repairs,
alterations or substitution of recommended parts made by the user to this equipment not approved by the manufacturer could void the user's
authority to operate the equipment in addition to the manufacturer's warranty.
NOTICE!
The software contained in this device is copyrighted by Com-Net Ericsson Critical Radio Systems, Inc. Unpublished rights are
reserved under the copyright laws of the United States.
This manual is published by Com-Net Ericsson Critical Radio Systems, Inc., without any warranty. Improvements and
changes to this manual necessitated by typographical errors, inaccuracies of current information, or improvements to
programs and/or equipment, may be made by Com-Net Ericsson Critical Radio Systems, Inc., at any time and without
notice. Such changes will be incorporated into new editions of this manual. No part of this manual may be reproduced or
transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose,
without the express written permission of Com-Net Ericsson Critical Radio Systems, Inc.
.
Copyright ©1990-2000, Com-Net Ericsson Critical Radio Systems, Inc. All rights reserved.

TABLE OF CONTENTS
LBI-38438A 3
1 DESCRIPTION........................................................................................................................................4
2 INITIAL ADJUSTMENT........................................................................................................................4
2.1 TRANSMITTER ADJUSTMENT...............................................................................................4
2.2 RECEIVER ADJUSTMENT.......................................................................................................4
2.3 RE-INSTALLATION..................................................................................................................4
3 MAINTENANCE.....................................................................................................................................5
3.1 PREVENTIVE MAINTENANCE...............................................................................................5
3.1.1 Connections ...................................................................................................................5
3.1.2 Electrical System...........................................................................................................5
3.1.3 Mechanical Inspection...................................................................................................5
3.1.4 Antenna..........................................................................................................................5
3.1.5 Alignment......................................................................................................................5
3.1.6 Frequency Check ...........................................................................................................5
3.1.7 Disassembly...................................................................................................................5
3.2 PA TRANSISTOR REPLACEMENT.........................................................................................6
3.3 CHIP COMPONENT REPLACEMENT.....................................................................................7
3.3.1 To Remove Chip Components.......................................................................................7
3.3.2 To Replace Chip Components.......................................................................................7
4 DISASSEMBLY PROCEDURE.............................................................................................................8
4.1 TO REMOVE THE SYSTEM CONTROL/SYNTHESIZER BOARD.......................................8
4.2 TO REMOVE THE TRANSMITTER RECEIVER BOARD......................................................8
4.3 TO REMOVE THE FRONT PANEL/CONTROL UNIT............................................................8
5 ALIGNMENT AND TROUBLESHOOTING PROCEDURES...........................................................11
5.1 SYNTHESIZER...........................................................................................................................11
5.1.1 Test Equipment Required ..............................................................................................11
5.1.2 TX VCO & RX VCO Alignment...................................................................................12
5.1.3 Transmitter Frequency Adjustment ...............................................................................13
5.1.4 Receiver Frequency Adjustment....................................................................................13
5.1.5 Modulation Level Adjustment.......................................................................................13
5.1.6 Audio Check..................................................................................................................14
5.1.7 Audio Output Level Adjustment Procedure...................................................................15
5.2 TRANSMITTER..........................................................................................................................16
5.2.1 General Description of Adjustment ...............................................................................16
5.2.2 Measuring Instruments ..................................................................................................16
5.2.3 Adjustment System........................................................................................................17
5.2.4 Transmitter Adjustment Procedure................................................................................17
5.3 RECEIVER..................................................................................................................................20
5.3.1 Receiver Alignment.......................................................................................................20
5.3.2 Alignment Procedure.....................................................................................................21
5.3.3 Fixed Squelch Adjustment.............................................................................................21
5.3.4 Receiver Test Procedures...............................................................................................22
5.3.5 Test Procedure...............................................................................................................22

DESCRIPTION
4LBI-38438A
1 DESCRIPTION
The service section contains the information necessary for aligning and troubleshooting
the MLS two-way FM mobile radio. In addition, information is provided for removing
and replacing chip components, disassembly procedures and module replacement
procedures.
2 INITIAL ADJUSTMENT
After the radio has been installed as described in the Installation Manual, the following
adjustments should be made by a certified electronics technician.
2.1 TRANSMITTER ADJUSTMENT
The transmitter has been adjusted at the factory and should require no readjustment.
However, the antenna length should be adjusted for optimum VSWR, and the frequency
and modulation measured and recorded for future reference. For the complete transmitter
adjustment, refer to the Alignment Procedure (see Table of Contents).
2.2 RECEIVER ADJUSTMENT
No initial adjustments to the receiver are required. Refer to the Table of Contents for the
complete receiver alignment.
2.3 RE-INSTALLATION
The MLS series mobile radios are designed to operate in 12-Volt, negative ground
vehicles only. If the mobile radio is moved to a different vehicle, always check the
battery polarity of the new vehicle system.

MAINTENANCE
LBI-38438A 5
3 MAINTENANCE
3.1 PREVENTIVE MAINTENANCE
To insure high operating efficiency and to prevent mechanical and electrical failures from
interrupting system operations, routine checks should be made of all mechanical and
electrical parts at regular intervals. Preventive maintenance should include checks
detailed in the following sections.
3.1.1 Connections
Ground connections to the voltage source should be periodically checked for tightness.
Loose or poor connections to the power source will cause excessive voltage drops and
faulty operation. When ground connections are not made directly to the battery, the
connection from the battery to vehicle chassis must be checked for low impedance. A
high impedance may cause excessive voltage drops and alternator noise problems.
3.1.2 Electrical System
Check the voltage regulator and alternator or generator periodically to keep the electrical
system within safe and economical operating limits. Over-voltage is indicated when the
battery loses water rapidly. Usage of 1 or 2 ounces of water per cell per week is
acceptable for batteries in continuous operation. A weak battery will often cause
excessive noise or faulty operation.
3.1.3 Mechanical Inspection
Since mobile units are subject to constant shock and vibration, check for loose plugs,
nuts, screws and parts to make sure that nothing is working loose.
3.1.4 Antenna
The antenna, antenna base and all contacts should be kept clean and free from dirt or
corrosion. If the antenna or its base should become coated or poorly grounded, loss of
radiation and a weak signal will result.
3.1.5 Alignment
The transmitter and receiver meter readings should be checked periodically, and the
alignment “touched up” when necessary. Refer to applicable Alignment Procedure and
Troubleshooting sheet for typical voltage readings.
3.1.6 Frequency Check
Check transmitter frequency and deviation. Normally, these checks are made when the
unit is first put into operation, after the first six months and once a year thereafter.
3.1.7 Disassembly
To gain access to the transmitter, receiver, and the system control/synthesizer boards for
servicing, loosen the four screws securing the cover at the rear of the radio. Then pull the
cover out from under the edge of the front panel and lift the cover off.

MAINTENANCE
6LBI-38438A
WARNING
The PA transistor contains Beryllium Oxide, a TOXIC substance. If the ceramic or
other encapsulation is opened, crushed, broken or abraded, the escaping dust may be
hazardous if inhaled. Use care when replacing the module.
3.2 PA TRANSISTOR REPLACEMENT
1. Remove the two retaining screws securing PA transistors TR3 and TR4 to chassis
assembly.
2. Unsolder and remove capacitors. Use a de-soldering tool as necessary while lifting
the transistor leads with a small screwdriver or pick. Discard old capacitors.
3. Unsolder the emitter, base and collector leads of the transistor, and remove it from
the printed board.
4. Remove all excess solder from the board, and clean the holes to allow the new
transistor to be positioned properly and the capacitors to fit into proper locations.
Refer to Figure 1 and trim the new transistor leads (if required) to the lead length of
the removed transistor.
5. Apply silicon grease to back of the replacement transistor and place the transistor into
the mounting slot.
6. Replace the transistor mounting screws using a moderate torque of 5 inch-pounds.
7. Tack solder the four base leads to the printed board using minimum solder. Then
solder the emitter and collector leads.
8. Install the capacitors into their proper mounting areas, flush to the board.
9. Solder the capacitor bodies to the printed board by first soldering the outside edge.
Then, holding the iron to the outside edge, touch the solder to the inside edge of the
capacitor. Be careful not to create solder bridges at the front and back edges of the
capacitors.
10. Remove any flux left on board.
Figure 1- PA Transistor Lead Identification

MAINTENANCE
LBI-38438A 7
3.3 CHIP COMPONENT REPLACEMENT
Replacement of chip capacitors should always be done with a temperature controlled
soldering iron, using a controlled temperature of 700ºF (371º C). However, do NOT
touch black metal film of the resistors or the ceramic body of capacitors with the
soldering iron.
NOTE
The metallized end terminations of the parts may be touched with the soldering iron
without causing damage.
3.3.1 To Remove Chip Components
1. Using two soldering irons, heat each end of the chip at the same time until solder
flows, and then remove and discard the chip.
2. Remove excess solder with a vacuum solder extractor.
3. Carefully remove the epoxy adhesive and excess flux to prevent damage to the
printed board.
3.3.2 To Replace Chip Components
1. Using as little solder as possible, “tin” one end of the component and one of the pads
on the printed wiring board.
2. Place the “tinned” end of the component on the “tinned” pad on the board and
simultaneously touch the component and the pad with a well “tinned” soldering iron
while pressing the component down on the board.
3. Place the “tinned” soldering iron on the other end of the component and the pad
simultaneously. Apply solder to the top of the end of the component until the solder
starts to flow. Use as little solder as possible while getting a good joint.
4. After the component has cooled, remove all flux from the component and printed
wiring board area with alcohol.
The CMOS integrated circuit devices used in this equipment can be destroyed by static
discharges. Before handling of one of these devices, the serviceman should discharge
himself by touching the case of a bench test instrument that has a 3-prong power cord
connected to an outlet with a known good earth ground. When soldering or
desoldering a CMOS device, the soldering iron should also have a 3-prong power cord
connected to an outlet with a known good earth ground. A battery-operated soldering
iron may be used in place of the regular soldering iron.

DISASSEMBLY PROCEDURE
8LBI-38438A
4 DISASSEMBLY PROCEDURE
4.1 TO REMOVE THE SYSTEM CONTROL/SYNTHESIZER BOARD
1. Remove the two (2) screws (A) securing the top cover (refer to Figure 2). Remove
the top cover. Then disconnect the interconnecting cables.
2. Remove the eight (8) screws (B) securing the Synthesizer shield. Remove the shield.
3. Remove the three (3) screws (D) securing the board.
4. Remove the screws (C) securing regulator and carefully lift up and remove the board.
4.2 TO REMOVE THE TRANSMITTER RECEIVER BOARD
1. Remove the screws (E) securing the bottom cover (refer to Figure 3).
2. Disconnect the interconnecting cable. Remove the seven (7) screws (G), (H)
securing the receiver shield and the antenna shield.
3. Remove the two (2) screws (F) connecting the power supply cable to the board and
turn the cable stopper mounted on the rear of the frame assembly 90 degrees. Lift the
cable stopper up and remove the power supply cable.
4. Remove the two (2) screws (I) securing power module HC1. Remove the (I) screws
securing the power transistors, audio IC, and AVR IC.
5. Remove the two (2) screws (J) securing the board. Carefully lift up and remove the
board.
4.3 TO REMOVE THE FRONT PANEL/CONTROL UNIT
1. Remove the four (4) screws (N) securing the front panel to the frame assembly (refer
to Figure 4).
2. Carefully disconnect the speaker cable from the connector on the Control/Synthesizer
board.
3. Separate the front panel from the frame assembly.
4. Carefully disconnect the ribbon cable connecting the Front Panel/Control unit to the
Control/Synthesizer Board at (O).
5. Remove the two (2) screws located at (P).
6. While pushing the lock tabs at (Q) remove the Control Panel towards the front.

DISASSEMBLY PROCEDURES
LBI-38438A 9
Figure 2 – Disassembly Procedure (Top View)
Figure 3 – Disassembly Procedure (Bottom View)

DISASSEMBLY PROCEDURE
10 LBI-38438A
Figure 4 – Disassembly Procedure (Front Panel)

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
LBI-38438A 11
5 ALIGNMENT AND TROUBLESHOOTING PROCEDURES
Radio maintenance is facilitated by using the Troubleshooting Procedures and servicing
techniques unique to this radio. The Troubleshooting Procedures are designed to lead the
serviceman rapidly to the defective component or circuit.
Troubleshooting procedures are provided for most major problems that might arise in the
Transmitter, the Receiver, and the System Control/Synthesizer Board.
5.1 SYNTHESIZER
Alignment and Troubleshooting for Synthesizer Circuitry on System Control/Synthesizer
Board CMC-551A/B are detailed in the following subsections.
5.1.1 Test Equipment Required
1. Audio Oscillator
2. Deviation Monitor
3. Oscilloscope
4. Frequency Counter
5. RF Wattmeter (50 ohms, 100 W)
6. VTVM
7. Digital Voltmeter
8. Power Supply, 13.6 VDC regulated.

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
12 LBI-38438A
5.1.2 TX VCO & RX VCO Alignment
CMC-232A 29.7 - 42 MHz
STEP METERING POINT TUNING CONTROL METER READING PROCEDURE
1TP201
Control
Voltage
Monitor
L206 4.0 VDC
7.0 VDC
In case highest transmit frequency is
< 34.0 MHz. Select lowest frequency
transmit channel. With 50 ohm load on
the antenna connector J1, key the radio.
Monitor TP201 with digital voltmeter
and tune L206 for 4.0 VDC ±0.1 V.
Unkey the radio.
In case the highest transmit
frequency is > 34.0 MHz. Select
highest frequency transmit channel.
With 50 ohm load on the antenna
connector J1, key the radio. Monitor
TP201 with a digital voltmeter and tune
L206 for 7.0 VDC ±0.1 V. Unkey the
radio.
2 TP201 CV201 7.0 VDC Select the highest frequency receive
channel. Monitor TP201 with digital
voltmeter and tune CV201 for 7.0 VDC
±0.1 V.
3 TP201 3.5-7.5
VDC Select lowest frequency channel. Voltage should be between 3.5 – 7.5
VDC transmit and receive for lowest
and highest frequency channels.
4 J201 +1 to +8
dBm RX/EX injection level should be between +1 and +8 dBm.
NOTE: Refer to Figure 5 for location of tuning and adjustment controls.
Figure 5 – Synthesizer Tuning and Adjustment Controls
CMC-232B 42 – 50 MHz

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
LBI-38438A 13
STEP METERING POINT TUNING CONTROL METER READING PROCEDURE
1TP201
Control
Voltage
Monitor
L206 7.0 VDC Select highest frequency transmit
channel. With 50 ohm load on the
antenna connector J1, key the radio.
Monitor TP201 with digital voltmeter
and tune L206 for 7.0 VDC ±0.1 V.
Unkey the radio.
2 TP201 CV201 7.0 VDC Select the highest frequency receive
channel. Monitor TP201 with digital
voltmeter and tune CV201 for 7.0
VDC ±0.1 V.
3 TP201 3.5-7.5
VDC Select lowest frequency channel. Voltage should be between 3.5 – 7.5
VDC transmit and receive for lowest
and highest frequency channels.
4 J201 +1 to +8
dBm RX/EX injection level should be between +1 and +8 dBm.
5.1.3 Transmitter Frequency Adjustment
STEP METERING POINT TUNING CONTROL METER READING PROCEDURE
NOTE
This step assumes the frequency is
measured when the transmitter is first
keyed. If delayed, the rapidly rising
ambient temperature must be taken
into consideration. The oscillator
frequency should be set at 25°C
ambient temperature.
1 J201 (or J1) FREQ
TRIM
Control on
TCXO
(XU201)
Channel
Operating
Frequency
Press the PTT switch while monitoring
RX/EX injection frequency at J201.
Adjust FREQ TRIM Control on TCXO
(XU201) for the assigned channel
frequency ±0.5 PPM.
5.1.4 Receiver Frequency Adjustment
No receiver frequency adjustment is required.
With proper alignment of EX injection frequency, RX injection frequency will
automatically be correct.
5.1.5 Modulation Level Adjustment
Procedure for synthesizer Transmit Deviation
1. Select the highest frequency channel.
2. Rotate CG DEV ADJUST, RV202 fully counterclockwise.

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
14 LBI-38438A
3. Connect the audio oscillator and apply a 1 kHz tone at 850 mVrms to MIC HI, J701-
4. Connect the deviation monitor to the antenna connector, J1 through a 30 dB
decoupler. Key the radio. Set DEV ADJUST, RV201 for ±3.75 kHz deviation.
4. Set RV202 fully clockwise. Remove P602 from position 1-2 and set aside. Apply a
400 Hz tone to J602-2 and with the radio keyed, vary its amplitude until the
Deviation Monitor reads 2 kHz. Note the level.
5. Change the audio oscillator frequency for a 10 Hz tone at the same level and set
LOOP MOD ADJUST RV203 for a deviation of 2 kHz. Unkey the radio.
6. Disconnect the audio oscillator and replace P602 in position 1-2.
7. Select a frequency with Tone Channel Guard.
8. Key the radio and set CG DEVIATION ADJUST RV202 for a deviation reading of
±0.75 kHz.
NOTE
If Channel Guard is not used on any frequency channel, CG DEV ADJUST, RV201 may be set
for ± 4.5 kHz deviation instead of ±3.75 kHz.
5.1.6 Audio Check
5.1.6.1 Audio Sensitivity
1. Connect audio oscillator output to MIC HI, J701-4. Adjust output for 1 kHz at 1
Vrms.
2. Reduce oscillator output until deviation monitor indication falls to ±3.0 kHz for
radios without Channel Guard or to ±2.25 kHz for radios with Channel Guard.
Oscillator output voltage should be less than 120 millivolts.
.

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
LBI-38438A 15
5.1.7 Audio Output Level Adjustment Procedure
STEP METERING POINT TUNING CONTROL METER READING PROCEDURE
1 J701-1 RV601 See
Procedure
Set the signal generator to the receiver
frequency with ±3 kHz deviation and 1 kHz
modulation. Set the RF signal level to 1000
microvolts. Move P551 from J551-1, 2 to J551-
2, 3 on the Transmitter/Receiver Board.
Connect RF signal generator to J1.
Terminate J701-1, 6 with a 4 ohm, 6-watt
resistor, connect the audio level meter and the
distortion analyzer input across the resistor. Set
the volume to the maximum point. Press DOWN
button two times. Adjust RV601 for 4-watt
output (4 Vrms, using the distortion analyzer as
Volt Meter).
Return P551 to J551-1, 2.
Control Logic Troubleshooting

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
16 LBI-38438A
5.2 TRANSMITTER
Alignment and troubleshooting for Transmitter circuitry on the Transmitter/Receiver
board CMN-233A/B.
5.2.1 General Description Of Adjustment
This manual is prepared for adjustments and confirmations of the Exciter/PA section and
covers the following items.
5.2.2 Measuring Instruments
1. AVR (DC Power Supply DC 0-20V, 20A)
2. Power Meter (usable at the value above 80 W)
3. Directional Coupler
4. Signal Generator
5. Spectrum Analyzer
6. Attenuator (30 dB, above 80 W)
7. Tester

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
LBI-38438A 17
5.2.3 Adjustment System
5.2.4 Transmitter Adjustment Procedure
STEP ITEM TEST POINT TUNING CONTROL PROCEDURE
1 Initial
Setting Turn the volume on APC RV1, RV2 fully counterclockwise
(CCW).
2 Confirming
the voltage
TP4
Disconnect RF cable P101 from
connector J201.
Turn on the power.
Turn on the PTT (ground J701-2).
Confirm voltage of TR8 collector
is 9V at TP4 and that the relay K1
clicks at this time.
3Setting
APC off
power RV1
RV2
Connect RF cable P101 to J201.
Turn the control RV1 on APC
fully clockwise (CW).
Next, turn the volume RV2 slowly
CW and set an output of 70W
±2W at the highest frequency of
each band.
4 Confirming
minimum
power
RV1 Turn the volume RV1 on APC
fully CCW and confirm minimum
power of 30W or less.
5 Confirming
APC on
power
RV1 Turn volume RV1 on APC slowly
CW and set an output of 64W
±2W at the highest frequency of
each band. 60W or more for other
frequencies.

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
18 LBI-38438A
5.2.5 Transmitter Troubleshooting

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
LBI-38438A 19

ALIGNMENT AND TROUBLESHOOTING PROCEDURES
20 LBI-38438A
5.3 RECEIVER
Alignment and Troubleshooting for Receiver Circuitry on Transmitter/Receiver Board
CMN-233A/B.
5.3.1 Receiver Alignment
5.3.1.1 Equipment Required
1. RF Signal Generator (29 - 50 MHz)
2. DC Voltmeter
3. Frequency Counter (up to 100 MHz with 0.05 V sensitivity)
4. Audio Level Meter and Distortion Analyzer
5. 4 ohm, 6 Watt Resistor
5.3.1.2 Preliminary Adjustment
1. Connect 13.8 VDC to P2
2. Set MONITOR switch to “out” position
3. Select desired channel
4. Disable Channel Guard by connecting ground to J701-7
5. Connect RF Signal Generator to antenna jack J1
NOTE
Make sure the transmitter is properly aligned before aligning the receiver.