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radios in repeater or link service

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Contact Info:       Factory Repair Depot:
E. F. Johnson Co.
229 Johnson Ave.
Waseca MN 56093-0514 USA
Main Phone: 507-835-6367
Toll Free Phone: 800-368-4923
FAX: 507-835-6283
Web: www.efjohnson.com
Email: CustomerService /at/ efjohnson /dot/ com
E. F. Johnson Repair Depot
8050 Jetstar Drive, #175
Irving, TX 75063 USA
Phone: 800-328-3911 then press "4"



Anybody want to do an overview and programming article on the Low Band and High Band Johnson Challenger Line?
Supposedly the Challenger was designed as competition to the Motorola Maxtrac, and does everything it does but better.

Joel Huntley - WA1ZYX has a page on the Challenger that offers an intro on two UHF models: the 7184 and 7186 complete with photos, a link to downloadable RSS, the programming procedure, interfacing to a repeater controller, and more.   These radios program right up on the amateur UHF band.   (offsite link)
The Challenger 7171 Service Manual Part 1   3.1mb PDF file
The Challenger 7171 Service Manual Part 2   2.3mb PDF file

The PPL-6xxx was one of the last series of crystal-controlled radios, the PPL-6050 was the VHF version and the PPL-6060 was the UHF version.

PPL 6060 UHF repeater conversion       A conversion of the EFJ PPL 6060 to a GMRS repeater by Jim Sharp
PPL 6060 UHF Transmitter Tuning    Tuning instructions for the transmit section by Matt Krick  KC7GSA
PPL 6060 UHF Receiver Tuning    Tuning instructions for the receive section by Matt Krick  KC7GSA
PPL 6060 Service Manual    3.3mb PDF file donated by Eric Lemmon WB6FLY
Anybody have the 6050 service manual? (the VHF version)
Call-Guard tone table    "Call Guard" is Johnsons name for CTCSS tone squelch. This is a table explaining their tone numbering scheme.
CR-1010 Repeater Alignment     by Clay Brown KI4ONH
CR-1010 Repeater Service Manual    9mb PDF courtesy of Clay Brown KI4ONH
CR-1010 Indentifier PROM programming    120kb PDF courtesy of Clay Brown KI4ONH


Straight Info on EFJ radios and the Amateur 900 MHZ Band

The E.F. Johnson 900mhz mobile radios are a natural for the 900mhz amateur band, and the mod to put them there is simple. Since they are not as popular as the Motorola Spectra the radios are less in demand, therefore a lot less expensive. The programming software is readily available, doesn't have the computer speed limitation quirks that the Motorola software has and there are no software police to worry about. EFJ just doesn't care... you can download the software from a dozen web sites here in the USA.

There are two 900 MHz Discussion Lists and the first one listed below has 95% of the traffic. Note that these are 900mhz lists (any radio, not just Johnson) and do not take kindly to off-topic discussions. I'd subscribe to both.

http://groups.yahoo.com/group/AR902Mhz   From the description text: "This listserv is used to further experimentation and utilization of the 902-928Mhz amateur radio spectrum using voice and data communications. Please limit your posts to information relating to these subjects ONLY. Want and For-Sale ads allowed. Do not post EBAY links. Do NOT list non-900Mhz applicable items."

http://groups.yahoo.com/group/900mhz   From the description text: "For those interested in utilizing the 900 Mhz amateur radio band. This group is here to discuss modification of commercial radio gear to amateur radio use, repeater construction for 900 Mhz, and other related topics relating to the 900 Mhz amateur radio band."

The EFJ 8640 is a 10 ch. 15w 900mhz radio with full PL/DPL capabilities. The 8644 is a 4 ch. version of the same radio and exists only because the EFJ sales team needed a lower end radio than the 8640, so the EFJ programmers stripped the firmware from ten channels to four (that is the only difference between the two models). The 864x series can a talk only to a repeater, meaning it has no talkaround (simplex) circuit in the VCO. Since the replacement 900mhz firmware was based on the 8640, any converted 8644 will end up as an ten channel 8640.

The 8655 is a 5-30 watts (adjustable) radio, does both repeat and talk-around (simplex), and has either ten or sixteen banks of 10 channels each depending upon the vintage of the display board... therefor the "low end" 8655 has only 100 channels...

The factory mobile power cable has a 15a fuse in the positive lead and Anderson Powerpoles on the end that plugs into the back of the radio - yes, the radio has chassis mount powerpoles on the rear panel right from the factory - a nice touch. The only problem is that both are colored white(!) plus there is no marking on the back of the chassis. The top one is positive, the bottom one is negative, and the radio is negative gound only (the negative one is grounded to the chassis). I suggest a Sharpie pen for adding "+" and "-" marks next to the chassis mount Powerpoles.
The official factory mic for these radios was the 250-0740-300 "Amplified Dynamic" or the 250-0751-021 12-button DTMF or the 250-0742-010 Desk microphone.
Microphone pinout: (pin 1) Mic shield and PTT return, (2) Mic hot, (4) PTT

The "old" (ARRL endorsed) 900mhz amateur band plan was designed with no consideration to the fact that ham radio is secondary in the band, and no consideration to the available equipment. That plan specified -12mhz offsets and is used in very very few areas. The 900mhz band is shared with many other services, and they all tend to leave the bottom and top megahertz alone as guard bands. The 12mhz plan has the ham repeaters right in the middle of the commercial users (and they are primary in that allocation) and they do not take kindly to hams. Due to hostility from the primary users the ham repeaters have migrated to the outer megahertz at each end - 902 to 903 as repeater inputs, and 927 to 928 as repeater outputs. The N2MCI firmware was written for the modern 25mhz offset amateur environment and will NOT do the 12mhz offsets, or the commercial 900mhz frequencies.

Any of the above three models will go on the amateur 900mhz band by swapping the main microprocessor (it's socketed) and one SMD chip cap, and loading new frequencies into the radio! Pete Dziomba N2MCI developed the modification technique and sells complete kits.

The N2MCI kit consists of:
    a) one replacement microprocessor chip with new embedded firmware (available only from N2MCI).
    b) one surface mount capacitor, size 1206 (the value varies depending on if it's an 8640/8644 or an 8655 radio). You unsolder one cap on the RF board and replace it with the new one from the kit.

The kits cost US$8 each. Shipping is US$5 for any number of kits...
To purchase the conversion kit you will need to Pete an email first at n2mci //at// hvc //dot// rr //dot// com and then send a money order or a bank check.

Installation information and more details at http://home.hvc.rr.com/n2mci/efj864x.html.

Kyle Yoksh KØKN has a web page that has full modification information and procedures for the 8640, 8644 and 8655, complete with photos. In addition to the primary site he has an alternate location at qsl.net. His site also has info on converting the 800mhz model 8615 for use as a 902 MHz repeater receiver.

Here's the The 8640 / 8644 Service Manual   (9.9mb PDF).   It offers 5-12 watts (adjustable), 4 channels (8644) or 10 channels (8640), and is repeat only (no simplex/talkaround.
Here's the The 8655 Service Manual   (12.9mb PDF dated Dec 1987).   It offers 5-30 watts (adjustable), does both repeat and talk-around (simplex), and has either ten or sixteen banks of 10 channels each depending upon the vintage of the display board.

The microphone connector wiring is pretty EFJ-standard:       (courtesy of Steve KB3FSR)
Pin 1 : Ground = shield of pin 2
Pin 2 : Audio = White Wire
Pin 3 : Hang-up clip = Black Wire
Pin 4 : PTT = Red Wire
Pin 5 : 13.8v = Blue Wire
Pin 6 : Not connected


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Page created 27-December-2005 by Mike Morris WA6ILQ

This web page, this web site, the information presented in and on its pages and in these modifications and conversions is © Copyrighted 1995 and (date of last update) by multiple originating authors and Kevin Custer W3KKC.   All Rights are Reserved, including that of paper and web publication elsewhere.