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DP 340x MOTOTRBO Portable - Basic Service Manual

1. Item Description Part Number 23 Label Pot Seal 3371478L01 24 Seal Battery Contact 3215177H02 25 Battery Refer to separate Accessory List Leaf let 6866574D04 26 Belt Clip Refer to separate Accessory List Leaf let 6866574D04 5 9 3 Torque Chart Table 5 5 lists the various screws by part number and description followed by the torque values in different units of measure Torque all screws to the recommended value when assembling the radio Table 5 5 Torque Specifications for Screws Part Number Description Driver Socket 0386434202 Screw M1 91 x 0 79 x 5 8 mm T6 Torx 0316281H01 Screw M2 x 0 8 x 6 3 mm T6 Torx 0386104204 Screw M2 x 0 4 x 4 5 mm T6 Torx 0371981L01 Screw M2 x 0 4 x 5 0 mm T6 Torx Chapter 6 Basic Troubleshooting 6 1 6 2 Introduction This chapter contains error codes and board replacement procedures If the board does not pass all the performance checks in Chapter 3 or exhibits an error code listed below then the circuit board should be replaced If repair requires knowledge of details of component level troubleshooting please send radio to a Motorola Service Center listed in Appendix A NOTE To access the various connector pins use the housing eliminator test fixture along with the diagrams found in this section of the manual See the section Service Aids on page 2 2 for the appropriate Motorola service aids and tools parts number
2. Dust Cover Screw Figure 5 1 Dust Cover removal 5 6 Disassembly Reassembly Procedures Radio Disassembly Detailed 4 Remove the battery a Release the battery latch by moving it into the unlock position b With the latch released slide the battery downwards c Remove the battery from the radio Antenna Figure 5 2 Battery and Antenna removal 5 Remove the antenna by turning it counterclockwise 6 Remove the volume and channel selector knobs off from their shafts using the knob removal tool Figure 5 3 Knob removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts Disassembly Reassembly Procedures Radio Disassembly Detailed 5 7 7 Separate the chassis from the internal electronics front cover assembly as follows a b Unscrew the screws using the TORX T6 screwdriver Release the chassis slightly upward and disconnect the board to board connector between the option board and the keypad flex Remove the chassis from the front cover Chassis Figure 5 4 Chassis removal 5 8 Disassembly Reassembly Procedures Radio Disassembly Detailed 5 6 2 Chassis Disassembly 1 Display Module Disassembly a Release the display retainer catch and disconnect the board to board connector between the display flex and the transmission board subsequently remove the display module Display Retainer Catch Figure 5 5 LCD M
3. Electronic device that amplifies RF signals A receiver separates the audio signal from the RF carrier amplifies it and converts it back to the original sound waves Remote transmit receive facility that re transmits received signals in order to improve communications range and coverage conventional operation Radio Frequency The portion of the electromagnetic spectrum between audio sound and infrared light approximately 10 kHz to 10 GHz Receive An electrically transmitted electromagnetic wave Frequency range within which radiation has specific characteristics Muting of audio circuits when received signal levels fall below a pre determined value With carrier squelch all channel activity that exceeds the radio s preset squelch level can be heard Time out Timer A timer that limits the length of a transmission Tone Private Line Transmitter receiver A device that both transmits and receives analog or digital signals Also abbreviated as XCVR Electronic equipment that generates and amplifies an RF carrier signal modulates the signal and then radiates it into space Transmit Ultra High Frequency Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps Vehicle Interface Port HI MOTOROLA MOTOROLA and the Stylized M Logo are registered in the U S Patent and Trademark Office All other product or service names are the property of their respective owners 2007
4. 16 11 EXTERNAL MIC 20 9 EXTERNAL PTT 1 7 SPEAKER 4 1 GROUND Coax Connector aa slot for accessory GPO 0 connector hook RN e 1 Wire KNU N KZ Vbus Coaxial RF EN s Connector 1 A Figure 2 2 Pin Layout of Side Connector Chapter 3 Transceiver Performance Testing 3 1 3 2 General These radios meet published specifications through their manufacturing process by utilizing high accuracy laboratory quality test equipment The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions This accuracy must be maintained in compliance with the manufacturer s recommended calibration schedule Although these radios function in digital and analog modes all testing is done in analog mode Setup Supply voltage is provided using a 7 5 VDC power supply The equipment required for alignment procedures is connected as shown in the Radio Tuning Equipment Setup Diagram Figure 4 2 Do NOT use any form of connector e g wires crocodile clips and probes to supply voltage to the radio other WARNING than the Motorola approved battery eliminator Initial equipment control settings should be as indicated in Table 3 1 The remaining tables in this chapter contain the following related technical data Table Number Title 3 2 Front Panel Access Test Mode Displays 3 3 Test Environments 3 4 Test Frequencies 3 5 Transmitter Performance Checks
5. PUSH to TALK PTT Press to execute voice operations e g Group call and Private Call ANTENNA Provides the needed RF amplification when transmitting or receiving MICROPHONE Allows the voice to be sent when PTT or voice operations are activated UNIVERSAL CONNECTOR FOR ACCESSORIES Interface point for all accessories to be used with the radio It has twelve points to which specific accessories will connect to and be activated EMERGENCY BUTTON Turns on and off the Emergency Operations SPEAKER Outputs all tones and audio that are generated by the radio e g features like keypad tones and voice audio 1 4 Introduction Portable Radio Model Numbering Scheme 1 3 Portable Radio Model Numbering Scheme Model No Example AZ H 5 5 Q D H 9 L A 1 A N Position S 1 2 3 4 5 6 7 8 9 10 11 12 N Standard Package I AZ Asia Australia LA Latin America AA North America except Mexico Version Letter MD Europe Middle East Africa H Portable Feature Level 1 Standard 55 MOTOTRBO Portable Model Series Band Q 403 470MHz T 450 527 MHz J 136 174MHz Primary System Type A Conventional Power Level D 1 0 5 0 W LL Primary Operation Physical Packages J w o GPS C Non Display Model L w GPS H Display Model Channel Spacing 9 Variable Programmable Figure 1 3 Portable Radio Model Numbering Scheme Introduction Model Charts 1 5 1 4 Model Charts 1 4 1 VHF Model Chart DP Series V
6. Foreword This manual covers all models of the DP series Portable Radios unless otherwise specified It includes all the information necessary to maintain peak product performance and maximum working time using levels 1 and 2 maintenance procedures This level of service goes down to the board replacement level and is typical of some local service centers self maintained customers and distributors Product Safety and RF Exposure Compliance 1 Before using this product read the operating instructions for safe usage contained in the Product Safety and RF caution Exposure booklet enclosed with your radio ATTENTION This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements Before using this product read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio Motorola Publication part number 6864117B25 to ensure compliance with RF energy exposure limits For a list of Motorola approved antennas batteries and other accessories visit the following web site http www motorola com governmentandenterprise 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 programs including
7. Detailed ccccececcccceeeeeeceeeeeeseeceeeeeeeaaeeeeeneeaaeeeeesaeaaeeeenseeaaeeeeeneeaeeaeentes 5 5 5 6 1 Front Cover from Chassis Disassembly 5 5 5 6 2 Chassis DisassemblY ii 5 8 RE EE 5 11 5 7 Radio Reassembly Detailed i 5 12 57 1 Speaker E ul EE 5 12 5 7 2 Chassis Heassenmbiy i 5 14 5 7 3 Chassis and Front Cover Reassembly 5 17 5 8 Ensuring Radio Immersibility iana rea r e A E A A TT E 5 18 5 831 1 101 le A T AE E E E A al adr 5 18 5 8 2 Accidental Immersion iii 5 18 5 8 3 Specialized Test Equipment iissa niakoi ardue aan aa aa aaia aana Eea 5 19 5 8 4 Vacuum Pump Kit NENII eseun a EEATT E NTE 5 19 5 8 5 Pressure Pump Kit NTN4265 aia n i 5 19 5 8 6 Miscellaneous Hardware 5 19 5 8 7 Vacuum TeSt erai r ella ila 5 19 5 8 8 Pressure Testing echo lia 5 20 5 8 9 Troubleshooting Leak Areas iii 5 21 5 8 9 10 Front HOUSING ieee hee aan II INI a I IL 5 21 5 8 9 2 Chassis Main Seal O riN i 5 22 5 8 9 3 Battery Contact Gezai 5 22 5 8 9 4 Breathing Vent Membrane and Breathing Vent Label 5 23 5 8 10 Troubleshooting Charts 5 24 5 9 Radio Exploded Mechanical Views and Parts Lists 5 27 5 9 1 Display Model Exploded View and Parts List i 5 27 5 9 2 Non Display Model Exploded View and Parts List 5 30 5 992 Torque CGhar L
8. 1 Each short press of Side Button 2 changes the test environment CSQ gt TPL gt DIG gt USQ gt CSQ The radio beeps once when radio toggles to CSQ beeps twice for TPL beeps three times for DIG and beeps four times for USQ NOTE DIG is digital mode and other test environments are analog mode as described in Table 3 3 2 Each short press of Side Button 1 toggles the channel spacing between 25 KHz 12 5 KHz and 20 KHz as The radio beeps once when radio toggles to 20KHz beeps twice for 25KHz and beeps three times for 12 5KHz 3 Turning of the Channel Knob changes the test channel from 1 to 14 as described in Table 3 4 The radio beeps in each position LED Test Mode 1 Press and hold Side Button 1 in RF Test Mode The radio beeps once Upon any button key press the radio lights up the red LED Consequently upon any button key press the red LED is turned off and the radio turns on the green LED 4 Consequently upon any button key press the green LED is turned off the radio shall turn on both LEDs Speaker Tone Test Mode 1 Press and hold Side Button 1 after LED Test Mode The radio beeps once 2 The radio generates a 1 KHz tone with the internal speaker Transceiver Performance Testing Non Display Model Test Mode 3 11 3 4 5 3 4 6 3 4 7 3 4 8 Earpiece Tone Test Mode 1 2 Press and hold Side Button 1 after Soeaker Tone Test Mode The radio beeps once The radio generates a 1 KHz tone with the earpiec
9. 10 High Power RX 3 or 10 425 350 475 075 146 575 4 Low Power TX 4 or 11 436 500 486 525 155 575 11 High Power RX 4 or 11 436 500 486 525 155 575 5 Low Power TX 5 or 12 447 675 496 875 161 575 12 High Power RX 5 or 12 447 675 496 875 161 575 6 Low Power TX 6 or 13 458 850 504 875 167 575 13 High Power RX 6 or 13 458 850 504 875 167 575 7 Low Power TX 7 or 14 470 000 511 875 173 975 14 High Power RX 7 or 14 470 000 511 875 173 975 Transceiver Performance Testing Display Model Test Mode Table 3 5 Transmitter Performance Checks 3 5 Test Name EES Radio Test Set Comments Analyzer Reference Mode PWR MON TEST MODE PTT to Frequency error to be Frequency 4th channel test Test Channel 4 continuously 654 Hz for frequency carrier squelch transmit non GPS models Monitor Frequency during the UHF1 error performance 218 Hz for GPS Input at RF In Out check models UHF1 729 Hz for non GPS models UHF2 243 Hz for GPS models UHF2 233 Hz for non GPS models VHF 77 Hz for GPS models VHF Power RF As above As above As above Low Power 1 0 1 6W VHF UHF1 UHF2 High Power 4 0 4 8W UHF1 UHF2 5 0 6 0W VHF Voice Mode PWR MON As above As above meter Deviation Modulation 4th channel test selector to mic 4 0 kHz but lt 5 0 frequency kHz 25 kHz Ch Sp atten to 70 input to RF In Out Mon
10. 3 6 Receiver Performance Checks Table 3 1 Initial Equipment Control Settings Service Monitor Power Supply Test Set Monitor Mode Power Monitor Voltage 7 5Vdc Speaker set A RF Attn 70 DC on standby Speaker load Standby Speaker AM CW FM FM Volt Range 10V PTT OFF Transceiver Performance Testing Setup Table 3 1 Initial Equipment Control Settings Service Monitor Power Supply Oscilloscope Source Mod Current 2 5A Oscilloscope Horizontal 10mSec Div Oscilloscope Vertical 2 5kHz Div Oscilloscope Trigger Auto Monitor Image Hi Monitor Bandwidth Narrow Monitor Squelch Middle setting Monitor Vol 1 4 setting Transceiver Performance Testing Display Model Test Mode 3 3 3 3 Display Model Test Mode 3 3 1 Entering Display Radio Test Mode 1 Turn the radio on Within 10 seconds after Self Test is complete press Side Button 2 five times in succession The radio beeps and will show a series of displays that will give information regarding various version numbers and subscriber specific information The displays are described in Table 3 2 Table 3 2 Front Panel Access Test Mode Displays Name of Display Description Appears Service Mode The literal string indicates the radio has entered test mode Always Host Version The version of host firmware Always DSP Version The version of DSP firmware Always Model Number The radio s model number as programmed in
11. 5 2 Battery and Antenna removal i 5 6 Figure 5 3 Knob remMovali vas iaia air 5 6 ee IC Chassis e 5 7 Figure 5 5 LCD Module removal 5 8 Figure 5 6 LOD Retainer removal asirini iriiria ya aironi aent endast 5 8 Figure 5 7 Transmission and Interface Board removal i 5 9 Figure 5 8 Shield Glip femovalt par ito aah De aided dah eee lia dialed nett 5 9 Figure 5 9 O ring and Battery Contact Seal removal i 5 10 Figure 5 10 Speaker removal sii ies assesta arks nie se ili 5 11 Figure 5 11 Speaker reassembly Display MOdEl ns 5 12 Figure 5 12 Speaker reassembly Non Display Model 5 13 Figure 5 13 O ring and Battery Contact Seal reassembly rtr nnrtttrnnntnnn nanne nen nennen 5 14 Figure 5 14 Shield Clip reassemblY ii 5 15 Figure 5 15 Secondary O ring reassembly i 5 15 Figure 5 16 Transmission and Interface Board reassembly eee eter eee ae senna e eee a ae eteneeeee 5 16 Figure 5 17 LCD Retainer and LCD Module reassembly i 5 16 Figure 5 18 Back Cover Kit reassembly ii 5 17 Figure 5 19 Chassis to Front Cover reassembly cece eeeeere eens eeenee eee sees eeeeeaeeseeeeeeeeseaeeesaeeeeeeaees 5 18 Figure 5 20 Connector Fitting Fitting Seal Pump Connector 5 19 Figure 5 21 Display Model Exploded View 5 27 Figure 5 22 Non Display Model Exploded View 5 30 List of Tabl
12. 5 5 remove the chassis assembly from the radio 2 Refer to Section 5 6 2 Chassis Disassembly on page 5 8 remove the Main Board from chassis 3 Remove the main seal O ring Inspect the seal area around the chassis for foreign material that might prevent the main seal O ring from sealing properly 5 Assemble a new O ring discard the old O ring 6 For detailed O ring assembly sequence refer to clause 2 step i to step viii of Section 5 7 2 Chassis Reassembly on page 5 14 7 Reassemble the chassis assembly followed by installing into Front Cover Refer to Section 5 7 Radio Reassembly Detailed on page 5 12 8 Inspect the main seal O ring for proper seating Observe carefully to ensure that the main seal O ring is not pinched between the housing and the chassis NOTE When installing the assembled chassis to the Front Cover ensure the O ring at the top two corners are not dislodged from the chassis groove 5 8 9 3 Battery Contact Seal To replace the Battery Contact Seal 1 Refer to Section 5 6 Radio Disassembly Detailed on page 5 5 to remove the Battery Con tact Seal 2 Remove the Battery Contact Seal from the Chassis 3 Inspect the Battery Contact Seal Chassis and surrounding areas for foreign material that might prevent the Battery Contact Seal from sealing properly 4 Install a new Battery Contact Seal discard the old Seal 5 Replace a new main seal O ring discard the old O ring 6 Reass
13. Dealer must be accompanied by a Warranty Claim Form Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer A 1 1 Warranty Period and Return Instructions The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or Reseller contract These conditions may change from time to time and the following notes are for guidance purposes only 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 Prior to shipping any radio back to the appropriate Motorola warranty depot please contact Customer Resources Please see page A 3 All returns must be accompanied by a Warranty Claim Form available from your Customer Services representative Products should be shipped back in the original packaging or correctly packaged to ensure no damage occurs in transit A 1 2 After Warranty Period After the Warranty period Motorola continues to support its products in two ways 1 Motorola s Managed Technical Services MTS offers a repair service to both end users and dealers at competitive prices 2 MTS supplies individual parts and modules that can be purchased by dealers who are techni cally capable of performing fault analysi
14. SE MHz 4W MOTOTRBO Non Display Portable without Item Description X PMLE4371_ Back Cover Kit MOTOTRBO Display Portable with GPS PMLE4372_ Back Cover Kit MOTOTRBO Display Portable without GPS X PMLE4428_ Back Cover Kit MOTOTRBO Non Display Portable with GPS X IPMLE4429 Back Cover Kit MOTOTRBO Non Display Portable without GPS X PMLN4646_ Front Cover Kit with Display and Keypad X X IPMLN4922 Front Cover Kit without Display and Keypad X X PMLN4018_ UHF GPS Folded Monopole 403 433 MHz X X PMLN4024_ UHF GPS Folded Monopole 433 470 MHz X X PMAE4021_ UHF GPS Stubby Antenna 403 433 MHz X X PMAE4023_ UHF GPS Stubby Antenna 430 470 MHz X PMAE4022 UHF Whip Antenna 430 470 MHz X X 6866574D01 Quick Reference Guide X 6866574D02 Quick Reference Guide Introduction Model Charts 1 4 3 UHF2 Model Chart DP Series UHF2 450 512 MHz Model Description O _____ MDH55TDH9LA1 AN 450 512 MHz 4W MOTOTRBO Display Portable with GPS MDH55TDH9JA1 AN 450 512 MHz 4W MOTOTRBO Display Portable without GPS MDH55TDC9LA1 AN 450 512 MHz 4W MOTOTRBO Non Display Portable with GPS MDH55TDC9JA1AN Tr 2 MHz 4W MOTOTRBO Non Display Portable without Item Description X PMUE3088_ Back Cover Kit MOTOTRBO Display Portable with GPS PMUE3087_ Back Cover Kit MOTOTRBO Display Portable without GPS X PMUE3089_ Back Cover Kit MOTOTRBO Non Display Portable with GPS X PMUE3090_ Back Cove
15. a USB port for radio Alignment Cable programming testing and alignment PMNN4076_ 7 5V Universal Battery Eliminator Connects to radio via battery eliminator cable 5880348B33 DMR SMA to BNC RF Adaptor Adapts radio s antenna port to BNC cabling of test equipment PMHN4085_ Bench Test Housing Eliminator Interconnects radio to power supply Provides for troubleshooting of the radio when the housing is removed NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages NTN4265_ Pressure Pump Kit Allows servicer to locate leakages 5871134M01 Connector Fitting This connector allows the vacuum hose to be con nected to the radio chassis 3271133M01 Fitting Seal This seal secures the connector fitting to the radio chassis Test Equipment and Service Aids Programming Testing and Alignment Cable 2 3 Programming Testing and Alignment Cable 25 14 7 3 P 1 13 d Gi MOTOROLA KN Figure 2 1 Programming Testing and Alignment Cable 4 2 3 2 4 Test Equipment and Service Aids Programming Testing and Alignment Cable Table 2 3 Pin Configuration of Side Connector CONNECTION P3 Function 1 3 VCC 5V 3 4 DATA 2 5 DATA 16 6 GROUND 7 8 SPEAKER 17 10 EXTERNAL MIC
16. and assembled using environmentally preferred components and solder assembly techniques to comply with the European Union s Restriction of Hazardous Substances ROHS Directive 2002 95 EC and Waste Electrical and Electronic Equipment WEEE Directive 2002 96 EC To maintain product compliance and reliability use only the Motorola specified parts in this manual Iv intet 245 C Any rework or repair on Environmentally Preferred Products must be done using the appropriate lead free solder wire and lead free solder paste as stated in the following table Table 5 1 Lead Free Solder Wire Part Number List Motorola Flux Content Melting Supplier Part i Part Number Alley Flux Type by Weight ee 1088929Y01 95 5Sn 3 8Ag 0 7Cu RMA Version 2 7 3 2 217C 52171 0 015 1lb spool Table 5 2 Lead Free Solder Paste Part Number List Motorola Part Manufacturer Part Liquid oe visa 1085674C03 NC SMQ230 900 1000KCPs Type 3 95 5 Sn end 0 7 Cu 217 C Brookfield 5rpm 325 500 Parts Replacement and Substitution When damaged parts are replaced identical parts should be used If the identical replacement part is not locally available check the parts list for the proper Motorola part number and order the part Rigid Circuit Boards This family of radios uses bonded multi layer printed circuit boards Since the inner layers are not accessible some special considerations are required when soldering and unsoldering c
17. as shown in Figure 4 2 Battery E ae Service Monitor SC SMA to BNC or Counter PMNN4076 RF Adaptor Transmit Wattmeter RF Generator Receive HO 10 dB Pad 12VDC Ae Supply fon Tx Audio Generator T RLN4460 w RX Sinad Meter Programming Testing amp Alignment Cable AG Voltmeter PMKN4013 Figure 4 2 Radio Tuning Equipment Setup Chapter 5 Disassembly Reassembly Procedures 5 1 Introduction This chapter provides details about the following e Preventive maintenance inspection and cleaning e Safe handling of CMOS and LDMOS devices e Disassembly and reassembly of the radio e Repair procedures and techniques 5 2 Preventive Maintenance Periodic visual inspection and cleaning is recommended 5 2 1 Inspection Check that the external surfaces of the radio are clean and that all external controls and switches are functional It is not recommended to inspect the interior electronic circuitry 5 2 2 Cleaning Procedures The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the radio External surfaces include the front cover housing assembly and battery case These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges grease and or grime NOTE Internal surfaces should be cleaned only when the radio is disassembled for
18. the screen with vertical lines 1 line to the right of any existing line until the display is full 5 When the screen is filled up with the vertical lines any button key press clears the screen and displays the first 10 available icons on the screen Successive button key press displays the remaining 4 icons 3 3 4 LED Test Mode 3 3 5 3 3 6 3 3 7 3 3 8 1 Press and hold Side Button 1 after Display Test Mode The radio beeps once and displays LED Test Mode Upon any button key press the radio lights the red LED and displays Red LED On Consequently upon any button key press the red LED is turned off and the radio lights the green LED and displays Green LED On 4 Upon any successive button key press the green LED is turned off and the radio shall light both LEDs up while displaying Both LEDs On Since there is only one LED on the portable the LED color will be orange when the radio lights both LEDs Backlight Test Mode 1 Press and hold Side Button 1 after LED Test Mode The radio beeps once and displays Backlight Test Mode 2 The radio turns on both LCD and keypad backlight together Speaker Tone Test Mode 1 Press and hold Side Button 1 after Backlight Test Mode The radio beeps once and displays Speaker Tone Test Mode 2 The radio generates a 1 KHz tone with the internal speaker Earpiece Tone Test Mode 1 Press and hold Side Button 1 after Speaker Tone Test Mode
19. 0FXE Digital Vocoder Type AMBE 2 Digital Protocol ETSI TS102361 1 ETSI TS102361 2 ETSI TS102361 3 20 kHz channel spacing is not applicable for UHF2 Introduction Specifications RSC 1 11 VHF Self Quieter Frequencies 144 000 MHz 100k 147 320 MHz 5k 147 455 MHz 10k 151 200 MHz 5k 1 12 RSC Ee Introduction Specifications Introduction Specifications wae Display Non Display DP 3600 DP 3601 DP 3400 DP 3401 TTFF Time To First Fix Hot Start Accuracy specs are for long term tracking 95th percentile values gt 5 satellites visible at a nominal 130 dBm signal strength Military Standards Applicable MIL STD 810E 810F Methods Methods Procedures amme f do fe fr ons f rs fen fame fr TE OE o indies f re fem am m i m fto fase di fee di on fm lr fee fl 1 13 1 14 Introduction Specifications Environmental Specifications Operating temperature specification with Lilon battery is 10 C to 60 Operating temperature specification with NiMH battery is 20 C to 60 Conforms to MOTOTRBO Portable series radios meet FM Factory Mutual standards for intrinsic safety used in Class I Il III Division 1 Groups C D E F and G when properly equipped with a Motorola FM approved battery option They are also approved for nonincendive use in Class Division 2 Groups A B C and D For more details please refer to the Factory Mutual Approval Manual 687153
20. 1 Remove Battery 2 Remove Universal Connector Dustcover 3 Remove breathing vent label and membrane 1 Attach antenna firmly to the radio 2 Attach vacuum hose to vacuum pump 3 Ensure fitting seal is attached to hose to chassis pump connector 4 Screw pump connector into chas sis s tapped hole 5 Attach vacuum hose to pump connector 6 Place radio on flat surface 7 Operate pump gauge 6 in Hg Full equipment for pressure test procedure available Run Pressure Test 1 Replace Breath ing Vent label and Breathing Vent Membrane 2 Radio approved for immersibility End Troubleshooting Flow Chart for Vacuum Test Sheet 1 of 2 Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 25 End Send radio to Motorola Depot 1 Remove pump and connectors from radio 2 Remove antenna or 3 Separate front housing kit Motorola Service Center Changed back chassis kit Changed Changed main O ring front housing kit Examined main O ring fitting Examine and Replace front Replace main Replace new reassemble housing kit with O ring with chassis kit main O ring new unit new unit without PCBs lt Troubleshooting Flow Chart for Vacuum Test Sheet 2 of 2 5 26 End Disassembly Reassembly Procedures Ensuring Radio Immersibility 1 Remove vacuum hose from pump co
21. 20 V div Leader LS8050 www leaderusa com Tektronix TDS1001b www tektronix com or equivalent Waveform measurements Power Meter and Sensor 5 Accuracy 100 MHz to 500 MHz 50 Watts Bird 43 Thruline Watt Meter www bird electronic com or equivalent Transmitter power output measurements RF Millivolt 100 mV to 3 V RF Boonton 92EA RF level measurements Meter 10 kHz to 1 GHz www boonton com or equivalent Power Supply 0 V to 32 V B amp K Precision 1790 Voltage supply OAto20A www bkprecision com or equivalent 2 2 Test Equipment and Service Aids Service Aids 2 2 Service Aids Table 2 2 lists the service aids recommended for working on the radio While all of these items are available from Motorola most are standard workshop equipment items and any equivalent item capable of the same performance may be substituted for the item listed Table 2 2 Service Aids Motorola od ea Description Application Part No p PP RLN4460 Portable Test Set Enables connection to the audio accessory jack Allows switching for radio testing GMVN5141_ Customer Programming Allows servicer to program radio parameters tune Software on CD ROM and troubleshoot radios PMKN4012_ Portable Programming Cable This cable connects the radio to a USB port for radio programming and data applications PMKN4013_ Portable Programming Testing amp This cable connects the radio to
22. 2008 Motorola Inc All rights reserved August 2008 www motorola com mototrbo 6866574D29 E
23. 2L01 ETSI TS 102 361 Parts 1 2 amp 3 ETSI DMR Standard 1999 5 EC R amp TTE Radio and Telecommunications Terminal Equipment 2002 95 EC RohS Banned Substances 2002 96 EC WEEE Waste Electrical and Electronic Equipment 94 62 EC Packaging and Packaging Waste Radio meets applicable regulatory requirements Specifications subject to change without notice All specfications shown are typical Chapter 2 Test Equipment and Service Aids Generator 130 dBm to 10 dBm FM Modulation 0 kHz to 10 kHz Audio Frequency 100 Hz to 10 kHz www agilent com Ramsey RSG1000B www ramseyelectronics com or equivalent 2 1 Recommended Test Equipment The list of equipment contained in Table 2 1 includes most of the standard test equipment required for servicing Motorola portable radios Table 2 1 Recommended Test Equipment Equipment Characteristics Example Application Service Can be used as a substi Aeroflex 2975 Frequency deviation meter and Monitor tute for items marked with www aeroflex com signal generator for wide range an asterisk Motorola R2670 or equivalent troubleshooting and alignment Digital RMS 100 uV to 300 V Fluke 179 or equivalent AC DC voltage and Multimeter 5 Hz to 1 MHz www fluke com current measurements Audio 10 Mega Ohm Impedance voltage measurements RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements Oscilloscope 2 Channel 50 MHz Bandwidth 5 mV div to
24. 8 Radio RAM Test Failure Fatal Retest radio by turning it off and turning it on again If message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 01 90 General hardware test Fatal Retest radio by turning it off and turning it on or failure again If message reoccurs replace main FAIL 02 90 board or send radio to nearest Motorola Depot FAIL 02 81 DSP ROM Checksum is Fatal Reprogram FLASH Memory then retest If wrong message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 02 82 DSP RAMI test failure Fatal Retest radio by turning it off and turning it on again If message reoccurs replace main board or send radio to nearest Motorola Depot Basic Troubleshooting Power Up Error Codes Display Model only Table 6 1 Power Up Error Codes Continued 6 3 Error Code Description Error Type Corrective Action FAIL 02 84 DSP RAM2 test failure Fatal Retest radio by turning it off and turning it on again If message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 02 88 DSP RAM test failure Fatal Retest radio by turning it off and turning it on again If message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 02 C0 DSP ROM Checksum is Fatal Retest radio by turning it off and turning it on wrong again If message reoccurs replace main board or send radio to nearest Motorola Depo
25. HF 136 174 MHz Model gt Description o_____ MDH55JDH9LA1AN 136 174 MHz 5W MOTOTRBO Display Portable with GPS MDH55JDH9JA1AN 136 174 MHz 5W MOTOTRBO Display Portable without GPS MDH55JDC9LA1AN 136 174 MHz DW MOTOTRBO Non Display Portable with GPS MDH55JDC9JA1 AN Ge 74 MHz 5W MOTOTRBO Non Display Portable without Item Description x PMLD4308_ Back Cover Kit MOTOTRBO Display Portable with GPS X PMLD4309_ Back Cover Kit MOTOTRBO Display Portable without GPS x PMLD4326_ Back Cover Kit MOTOTRBO Non Display Portable with GPS X PMLD4327_ Back Cover Kit MOTOTRBO Non Display Portable without GPS X X PMLN4646 Front Cover Kit with Display and Keypad X X PMLN4922 Front Cover Kit without Display and Keypad X X X X PMAD4067 VHF GPS Helical Antenna 136 147MHz X X X X PMAD4068_ VHF GPS Helical Antenna 147 160MHz X X X X PMAD4069 __ VHF GPS Helical Antenna 160 174MHz X X 6866574D01 Quick Reference Guide X X 6866574D02 Quick Reference Guide 1 6 Introduction Model Charts 1 4 2 UHF1 Model Chart DP Series UHF1 403 470 MHz Model BPescripton O _______ MDH55QDH9LA1AN 403 470 MHz 4W MOTOTRBO Display Portable with GPS MDH55QDH9JA1AN 403 470 MHz 4W MOTOTRBO Display Portable without GPS MDH55QDC9LA1AN 403 470 MHz 4W MOTOTRBO Non Display Portable with GPS MDH55QDC9JA1AN
26. Press P1 160 1 appears amp radio beeps release 160 0 appears amp radio beeps Press P2 161 1 appears amp radio beeps release 161 0 appears amp radio beeps Transceiver Performance Testing Display Model Test Mode Press OK 85 1 appears amp radio beeps release 85 0 appears amp radio beeps Press MENU 139 1 appears amp radio beeps release 139 0 appears amp radio beeps Press BACK 129 1 appears amp radio beeps release 129 0 appears amp radio beeps Press d 128 1 appears amp radio beeps release 128 0 appears amp radio beeps Press P 130 1 appears amp radio beeps release 130 0 appears amp radio beeps 3 9 3 10 3 4 3 4 1 3 4 2 3 4 3 3 4 4 Transceiver Performance Testing Non Display Model Test Mode Non Display Model Test Mode Entering Non Display Radio Test Mode 1 Turn the radio on 2 Within 10 seconds after Self Test is complete press Side Button 2 five times in succession 3 The radio beeps RF Test Mode When the radio is operating in its normal environment the radio s microcontroller controls the RF channel selection transmitter key up and receiver muting according to the customer codeplug configuration However when the unit is on the bench for testing alignment or repair it must be removed from its normal environment via a special routine called TEST MODE or air test
27. The radio beeps once and displays Earpiece Tone Test Mode 2 The radio generates a 1 KHz tone with the earpiece Audio Loopback Earpiece Test Mode 1 Press and hold Side Button 1 after Earpiece Tone Test Mode The radio beeps once and displays Audio Loopback Earpiece Test Mode 2 The radio shall route any audio on the external mic to the earpiece 3 8 Transceiver Performance Testing Display Model Test Mode 3 3 9 Battery Check Test Mode 1 2 Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode The radio beeps once and momentarily displays Battery Check Test Mode The radio will display the following Capacity 88 Figure 3 1 Battery Check Test Mode Display 3 3 10 Button Knob PTT Test Mode 1 EON DAR E Press and hold Side Button 1 after Battery Check Test Mode The radio beeps once and displays Button Test line 1 The radio also displays the button knob PTT button command opcode BCO and state BCO state on the screen line 2 upon any button state changes Rotate the Volume Knob 2 0 through 2 255 appears The radio beeps at each position Rotate the Channel Knob 4 0 through 4 15 appears The radio beeps at each position Press Side Button 1 96 1 appears amp radio beeps release 96 0 appears amp radio beeps Press Side Button 2 97 1 appears amp radio beeps release 97 0 appears amp radio beeps Press S
28. This will help to eliminate unnecessary disassembly and reassembly of a radio with multiple leaks Troubleshoot only the faulty seal areas listed in Section 5 8 8 Pressure Test on page 5 20 and when multiple leaks exist in the order listed NOTE Before reassembling the radio always install a new Main seal O ring Battery Contact Seal in the defective area Front Housing Do one or both of the following 1 Ifa leak occurs at the Lens Display Models only Universal Connector chassis Housing interface PTT button area of the housing replace the housing Refer to Section 5 6 Radio Disassembly Detailed on page 5 5 a Remove the housing assembly from the radio b Discard the housing assembly and main seal O ring c Install a new main seal O ring around the chassis assembly according to Section 5 7 2 Chassis Reassembly on page 5 14 d Install a new housing assembly to the radio e Inspect the main seal for proper seating f Observe carefully to ensure that the main seal O ring is not pinched between the housing and the chassis interface 2 Ifthe leak occurs at the control top area remove the knobs in order to determine the leak location a Conduct the Pressure Test b Identify the leak location 5 22 Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 8 9 2 Chassis Main Seal O ring To replace the main seal O ring 1 Refer to Section 5 6 1 Front Cover from Chassis Disassembly on page
29. adio Observe the gauge for approximately 1 minute If the needle falls 0 5 in Hg or less one scale interval for example from 6 in Hg to 5 5 in Hg then the radio has passed the vacuum test and is approved for immersibility No additional testing will be required If the needle falls more than 0 5 in Hg one scale interval for example from 6 in Hg to less than 5 5 in Hg then the radio has failed the vacuum test and the radio might leak if immersed Additional troubleshooting of the radio will be required complete this procedure then go to Section 5 8 8 Pressure Test 7 Remove the vacuum hose and pump connector from the radio Pressure Test Pressure testing the radio is necessary only if the radio has failed the vacuum test Do not perform the pressure test until the vacuum test has been completed Pressure testing involves creating a positive pressure condition inside the radio immersing the radio in water and observing the radio for a stream of bubbles leak Since all areas of the radio are being checked observe the entire unit carefully for the possibility of multiple leaks before completing this test To conduct the pressure test 1 Screw the pump connector with fitting seal into the tapped hole in the chassis 2 Attach one end of the pressure hose to the pump connector and the other end to the pressure pump 3 Attach antenna firmly to the radio 4 Operate the pump until the gauge reads approximately 1 ps
30. arks Satire iena eo ei akk aay ii Document History 2 cascades Seege EeEEe alia iii Chapter 1 Introduction Lacie iaia 1 1 1 1 Notations Used in This Manual 1 1 1 2 Radio Descriptio eege ebe Eege latini araberne latin ius EE en 1 1 1 21 Display Modell ila Aa ode aiar 1 2 1 22 Non Display Model eet a ee EE karse ananas 1 3 1 3 Portable Radio Model Numbering Scheme ssessesesesseeeseeessiseiiesiisssirnssitnstrnnstnnnnnnntnnnsnnnnsnnns 1 4 1 4 Model Charts EE EE EE 1 5 L t VHF Model Gart onge d ses ccntnacasnve a a a a aa asias aani 1 5 1 42 Re len Ne RE EE 1 6 1 4 3 UHF2 Model Chart 1 7 1 5 Se IRR OOO OOO 1 8 Chapter 2 Test Equipment and Service Aids 2 1 2 1 Recommended Test Equipment rrrnnnnnvnnnnnnnnnnvvnnnnnnnnvnnnnnnnnvnnnnnnnnnnnnnsnnnnnnneeennnnnnnennnnnnnneennnnnnenee 2 1 2 2 Service AICS unni eder seres redd 2 2 2 3 Programming Testing and Alignment Cable i 2 3 Chapter3 Transceiver Performance Testing 3 1 3 1 EE 3 1 3 2 SEP uer 3 1 3 3 Display Model Test Mode usuniete edda ea cette 3 3 3 3 1 Entering Display Radio Test Mode 3 3 CD le EE 3 3 333 Display Test M0de usikrede hadet anden ude ea esa 3 7 3 3 4 LED Tost MOJO carn ki aee ene keratin erd 3 7 3 3 5 Backlight Test Mode iaia pet badekar spd ane Ak de 3 7 3 3 6 Speaker Tone Test Mode teleceesthiadi
31. asso TE 5 32 Table of Contents vii Chapter 6 Basic Troubleshooting wvrnnnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnenvnnnnnnnnr 6 1 6 1 Introduction arsen eie 6 1 6 2 Replacement Back Cover Kit Procedures i 6 1 6 3 Power Up Error Codes Display Model on 6 2 6 4 Operational Error Codes ne nane 6 4 Appendix A EMEA Regional Warranty Service and Technical Support A 1 A 1 Warranty and Service SUppott i A 1 A 1 1 Warranty Period and Return Instructions ssssssesseseeresserrssseirnsssinnsssrtinnsstennnnnrnnn A 1 A 1 2 After Warranty Period aaa A 1 A 2 European Radio Support Centre ERSC i A 2 A 3 Ne CEET A 2 A 4 gt Technical Support s ca e a aeaa ca Lams dane anette A 3 A 5 Further Assistance From Motorola GOSS BUY ve GE Glossary 1 viii List of Figures List of Figures Figure 1 1 Display Model ii Li i dende dl 1 2 Figure 1 2 Non Display Models ohio vali deretter eee 1 3 Figure 1 3 Portable Radio Model Numbering Gcheme i 1 4 Figure 2 1 Programming Testing and Alignment Cable ii 2 3 Figure 2 2 Pin Layout of Side Connector ii 2 4 Figure 3 1 Battery Check Test Mode Display 3 8 Figure 4 1 CPS Programming Setup 4 1 Figure 4 2 Radio Tuning Equipment Setup renn arrene nennnnrnnnrnnnnsrnrnennnnnenennee 4 2 Figure 5 1 Dust Cover removal a Ea E aE AEE A E aaa S 5 5 Figure
32. bsorbent lintless cloth to dry the area Do not brush or apply any isopropyl alcohol to the frame front cover or back cover NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material from previous usage Safe Handling of CMOS and LDMOS Devices Complementary metal oxide semiconductor CMOS devices are used in this family of radios and are susceptible to damage by electrostatic or high voltage charges Damage can be latent resulting in failures occurring weeks or months later Therefore special precautions must be taken to prevent device damage during disassembly troubleshooting and repair Handling precautions are mandatory for CMOS circuits and are especially important in low humidity conditions DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION paragraph in the Disassembly and Reassembly section of the manual Disassembly Reassembly Procedures Safe Handling of CMOS and LDMOS Devices DO NOT attempt to disassemble the radio without first referring to the following CAUTION statement AN Caution This radio contains static sensitive devices Do not open the radio unless you are properly grounded Take the following precautions when working on this unit Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert CMOS devices into conventional plastic snow trays used fo
33. but not limited to the exclusive right to copy or reproduce in any form the copyrighted computer program Accordingly any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied reproduced modified reverse engineered or distributed in any manner without the express written permission of 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 Document Copyrights No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola No part of this manual may be reproduced distributed or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Motorola Disclaimer The information in this document is carefully examined and is believed to be entirely reliable However no responsibility is assumed for inaccuracies Furthermore Motorola reserves the right to make changes to any products herein to improve readability function or design Motorola does not assume any liability arising out of the applications or use of any product or circuit described herein nor does it cover any lic
34. e Audio Loopback Earpiece Test Mode 1 2 Press and hold Side Button 1 after Earpiece Tone Test Mode The radio beeps once The radio shall route any audio on the external mic to the earpiece Battery Check Test Mode 1 Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode The radio beeps once The radio LED lights up accordingly green LED for High Battery Level orange LED for Mid Battery Level and blinking red LED for Low Battery Level Button Knob PTT Test Mode COD gt SOT Be GINS ve Press and hold Side Button 1 after Battery Check Test Mode The radio beeps once Rotate the Volume Knob the radio beeps at each position Rotate the Channel Knob the radio beeps at each position Press Side Button 1 the radio beeps release the radio beeps Press Side Button 2 the radio beeps release the radio beeps Press Side Button 3 the radio beeps release the radio beeps Press the PTT Switch the radio beeps release the radio beeps Press Top Button the radio beeps release the radio beeps 3 12 Transceiver Performance Testing Non Display Model Test Mode Notes Chapter 4 Radio Programming and Tuning 4 1 Introduction This chapter provides an overview of the MOTOTRBO Customer Programming Software CPS as well as the Tuner and AirTracer applications which are all designed for use in a Windows 2000 XP environment These programs are available in one kit as listed in Table 4 1 An Installatio
35. e test environment CSQ gt TPL gt DIG gt USQ gt CSQ The radio beeps once when radio toggles to CSQ beeps twice for TPL beeps three times for DIG and beeps four times for USQ NOTE DIG is digital mode and other test environments are analog mode as described in Table 3 3 3 4 Transceiver Performance Testing Display Model Test Mode Table 3 3 Test Environments No of sl Ge Description Function Beeps 1 Carrier Squelch RX if carrier detected CSQ TX mic audio 2 Tone Private Line RX unsquelch if carrier and tone detected TPL TX mic audio tone 3 Digital Mode RX if carrier detected DIG TX mic audio 4 Unsquelch RX constant unsquelch USQ TX mic audio 2 Each short press of Side Button 1 toggles the channel spacing between 25 kHz 12 5 kHz and 20 kHz as The radio beeps once when radio toggles to 20kHz beeps twice for 25 kHz and beeps three times for 12 5 kHz Turning of the Channel Knob changes the test channel from 1 to 14 as described in Table 3 4 The radio beeps in each position Table 3 4 Test Frequencies Channel Selector Test HF1 UHF2 VHF Switch Channel U U Position 1 Low Power TX 1 or 8 403 000 450 075 136 075 8 High Power RX 1 or 8 403 000 450 075 136 075 2 Low Power TX 2 or 9 414 150 464 075 142 575 9 High Power RX 2 or 9 414 150 464 075 142 575 3 Low Power TX 3 or 10 425 350 475 075 146 575
36. egedes DESEN rata illo 3 7 3 3 7 Earpiece Tone Test Mode ii 3 7 3 3 8 Audio Loopback Earpiece Test Mode A 3 7 3 3 9 Battery Check Test Mode ii 3 8 3 3 10 Button Knob PTT Test MOGE merei ieai ar eN E EAE EA R 3 8 3 4 Non Display Model Test Mode 3 10 3 4 1 Entering Non Display Radio Test Mode 3 10 vi Table of Contents 3 42 BRP Test Mode iano iii 3 10 3 4 3 LED Test Mode ea 3 10 3 4 4 Speaker Tone Test Mode 3 10 3 4 5 Earpiece Tone Test Mode 3 11 3 4 6 Audio Loopback Earpiece Test Mode 3 11 3 4 7 Battery Check Test Mode i 3 11 3 4 8 Button Knob PTT Test Mode 3 11 Chapter4 Radio Programming and Tuning 4 1 4 1 Introduction al set ieee cee ee ala A allea 4 1 4 2 Customer Programming Software Setup ccccccceeeeeeeeeeeeeeeaeeeeceeeesaaaeseeeeeeeeeaeeeeneeeeseeeseeeeeee 4 1 4 3 AirTracer Application Tool iaia ia 4 1 4 4 Radio NEE e EE 4 2 Chapter5 Disassembly Reassembly Procedures 5 1 5 1 Intr duetion aa aaret ei ii ila 5 1 5 2 Preventive Maintenance i 5 1 d d UASPOCON Assens hid lite leali 5 1 5 2 2 Cleaning Procedures i 5 1 5 3 Safe Handling of CMOS and LDMOS Devices nnt 5 2 5 4 Repair Procedures and Techniques General 5 4 5 5 Disassembling and Reassembling the Radio General 5 4 5 6 Radio Disassembly
37. emble the chassis assembly followed by installing into Front Cover Refer to Section 5 7 Radio Reassembly Detailed on page 5 12 7 Inspect the main seal O ring for proper seating Observe carefully to ensure that the main seal O ring is not pinched between the housing and the chassis IMPORTANT Both Breathing Vent Label 3371478L01 and Breathing Vent Membrane 3271570L01 need to be replaced after vacuum test pressure test or water leakage troubleshooting Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 23 5 8 9 4 Breathing Vent Membrane and Breathing Vent Label To replace the Breathing Vent Membrane and Breathing Vent Label 1 Remove the Breathing Vent Label that covers the Breathing Vent Membrane from the chas sis 2 Remove the Breathing Vent Membrane 3 Ensure that the chassis s surface at the Breathing Vent Label amp Breathing Vent Membrane recessed is clean no minimum scratches and free from any adhesive or other foreign mate rials 4 Install a new Breathing Vent Membrane covering the vent port hole in the small recessed area in the chassis Ensure that no oily substance come in contact with the seal 5 Install a new Breathing Vent Label over the Breathing Vent Membrane in the larger recessed area in the chassis Press down evenly over the label s surface to ensure good adhesion 5 24 Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 8 10 Troubleshooting Charts
38. ense under its patent rights nor the rights of others Trademarks MOTOROLA and the Stylized M logo are registered in the U S Patent and Trademark Office All other product or service names are the property of their respective owners 2007 and 2008 Motorola Inc All rights reserved Document History The following major changes have been implemented in this manual since the previous edition Updated Radio Exploded Mechanical Views and Parts Lists Edition Description Date 6866574D29 A Initial Release Feb 2007 6866574D29 B Added VHF band information June 2007 Updated UHF1 Model Chart Added leak test procedures 6866574D29 C Added pin layout diagram in Test Equipment and Oct 2007 Service Aids chapter Updated Troubleshooting Charts in Disassembly Reassembly chapter Added warning note in Transceiver Performance Testing chapter Updated front cover and diagrams of knobs Updated knob removal tool part number Updated Technical Support contact information in Appendix A 6866574D29 D Updated model charts and added 20kHz Jan 2008 specifications information in Introduction chapter 6866574D29 E Added UHF2 band information June 2008 Notes Table of Contents v Table of Contents Forewofd lell ll ilari ii Product Safety and RF Exposure Compliance i ii Computer Software ele le vunnet atte fatal iii ii Beste SETE EE ER ii Ne ln armatur ankeret ia li lea Roia ii Tradem
39. er Microphone User Manual nent 6871003L01 IMPRES Remote Speaker Microphone User Manual 6871004L01 Factory Mutual Approval Manual iiine onanera aA NNE aia ET KAE E EETAS AT ARARE EAA STERR 6871532L01 Chapter 1 Introduction 1 1 1 2 Notations Used in This Manual Throughout the text in this publication you will notice the use of note and caution notations These notations are used to emphasize that safety hazards exist and due care must be taken and observed NOTE An operational procedure practice or condition that is essential to emphasize A N CAUTION indicates a potentially hazardous situation which if not avoided might result in equipment damage Caution Radio Description The DP series portable radios are available in the following frequency ranges and power levels Table 1 1 Radio Frequency Ranges and Power Levels Frequency Band Bandwidth Power Level VHF 136 174 MHz 1 Watt or 5 Watt UHF Ri 403 470 MHz 1 Watt or 4 Watt UHF R2 450 512 MHz 1 Watt or 4 Watt These digital radios are among the most sophisticated two way radios available They have a robust design for radio users who need high performance quality and reliability in their daily communications This architecture provides the capability of supporting a multitude of legacy and advanced features resulting in a more cost effective two way radio communications solutio
40. es ix List of Tables Table 1 1 Radio Frequency Ranges and Power Levels 1 1 Table 2 1 Recommended Test Equipment 2 1 Table 2 27 Service Aids Ra abel deemed ech e ii 2 2 Table 2 3 Pin Configuration of Side Connector i 2 4 Table 3 1 Initial Equipment Control Settings essseeeeseeeeeeeeeesen eser reinttttntenistttnstsrnsstnnnstnnnsnnnnnnnnn nnen 3 1 Table 3 2 Front Panel Access Test Mode DisplayS 3 3 Table 3 3 Test Environments rta ees dee ER ieri EELER ten weve TEE ART E TAE 3 4 Table G Cl EE 3 4 Table 3 5 Transmitter Performance Checks 3 5 Table 3 6 Receiver Performance Checks ii 3 6 Table 4 1 Software Installation Kits Radio Tuning Setup 4 1 Table 5 1 Lead Free Solder Wire Part Number lei 5 4 Table 5 2 Lead Free Solder Paste Part Number LiSt 5 4 Table 5 3 Display Model Exploded View Parts LiSt 5 28 Table 5 4 Non Display Model Exploded View Parts Let 5 31 Table 5 5 Torque Specifications for SCrews i 5 32 Table 6 1 Power Up Error Codes i 6 2 Table 6 2 Operational Error Codes iii 6 4 x Related Publications Related Publications IMPRES Adaptive Single Unit Charger User Manual 6816787H01 IMPRES Adaptive Multi Unit Charger User Manual 6816789H01 IMPRES Adaptive Multi Unit Charger Service Manual 6871357L01 Remote Speak
41. g Vent Label and Breathing Vent Membrane Refer to Section 5 9 1 Display Model Exploded View and Parts List on page 5 27 or Section 5 9 2 Non Display Model Exploded View and Parts List on page 5 30 Vacuum Test The vacuum test uses a vacuum pump and gauge The pump creates a vacuum condition inside the radio and the gauge monitors the radio for a stable vacuum reading that is checking for a properly sealed watertight unit Before starting the vacuum test Remove the battery 5 8 8 Disassembly Reassembly Procedures Ensuring Radio Immersibility Remove the universal connector dustcover to expose the universal connector Remove the breathing vent label and breathing vent membrane To conduct the vacuum test 1 Attach antenna firmly to the radio 2 Attach the vacuum hose to the vacuum pump Check the pump and hose for leaks by block ing off the open end of the hose and operating the pump a few times The actual reading of the gauge at this point is not important it is important that the gauge pointer remained steady indicating no vacuum leaks in the pump 3 Ensure that the fitting seal is attached to the hose to chassis pump connector Screw the pump connector into the tapped hole in the chassis Attach the open end of the hose to the pointed end of the pump connector 5 Place the radio on a flat surface with the chassis facing upward 6 Operate the pump until the gauge indicates 6 in Hg of vacuum on the r
42. he integrity of the series radios To ensure that the radio is truly a watertight unit special testing test procedures and specialized test equipment are required The special testing involves a vacuum check of the radio and pressure testing troubleshooting for water leaks if the vacuum check fails The specialized test equipment instrument Table 2 2 on page 2 2 is authorized by Motorola and needed to perform the vacuum check and pressure testing if required Any equipment tools instruments not mentioned in the table must not be used to perform these test Vacuum Pump Kit NLN9839 The vacuum pump kit includes a vacuum pump with gauge and a vacuum hose A connector fitting part number 5871134M01 and fitting seal part number 3271133M01 pump connector which must be ordered separately connects the vacuum hose to the radio s chassis Fitting Seal part number 3271133M01 Connector Fitting part number 5871134M01 Figure 5 20 Connector Fitting Fitting Seal Pump Connector Pressure Pump Kit NTN4265 The pressure pump kit includes a pressure pump with gauge and a pressure hose As with the vacuum pump kit above the connector fitting fitting seal pair connects the pressure hose to the radio s chassis Miscellaneous Hardware Other items needed for testing the immersibility radio include e Large water container e Deionized Dl water e A supply of replacement parts Main seal O ring Battery Contact Seal Breathin
43. hes on the chassis vii Insert C into the chassis well and push to the bottom of the well to secure it viii Insert B2 into the bottom two catches on the chassis NOTE To maintain radio immersibility it is recommended that the main O ring be replaced although the existing one may appear undamaged Be sure to replace the battery contact seal also if necessary Secondary O ring 755 Battery Contact Seal Figure 5 13 O ring and Battery Contact Seal reassembly Disassembly Reassembly Procedures Radio Reassembly Detailed 5 15 3 Hook the shield clip on the top shield slot 4 Push against the clip towards the board until catch is securely in place Shield Clip Top Shield Transmission Board Figure 5 14 Shield Clip reassembly 5 Fit the secondary O ring onto the antenna nut securely Figure 5 15 Secondary O ring reassembly Disassembly Reassembly Procedures Radio Reassembly Detailed 6 Place the transmission board onto the chassis 7 Put on the interface board by connecting the board to board connectors between the inter face and transmission board 8 Fasten the screws using the TORX T6 screwdriver vw pe A T Main O ring Chassis Figure 5 16 Transmission and Interface Board reassembly 9 Place the display retainer 10 Fasten the screws using the TORX T6 screwdriver 11 Snap the display module onto the display retainer catch ai Di
44. ical Views and Parts Lists Table 5 3 Display Model Exploded View Parts List 1 Screw with Washer 0371981L01 2 Screw Speaker Retainer 0386434202 3 Retainer Speaker 4271352L02 4 Speaker 5085798F09 5 Assembly Front Housing PMLN4646_ 6 Nameplate for DP 3601 3371390L03 Nameplate for DP 3600 3371390L04 7 Cover Dust 1571477L01 8 Antenna Refer to separate Accessory List Leaf let 6866574D04 9 Knob Frequency 3615204H01 10 Knob Volume 3615205H01 11 Module Display 7215182H01 12 Screw 0386104Z04 13 Board Interface 0104022J35 14 Retainer Display 4215189H01 15 Clip Shield 4271320L01 16 Shield Can 2615156H01 17 Back Cover Kit See Section 1 4 Model Charts 18 Pad Thermal 7515526H01 19 O ring Chassis 3215181H01 20 Retainer O ring 4216293H01 21 Retainer O ring 4216292H01 22 Assembly Chassis Molded w MIP Shield 0104023J31 23 Seal Battery Contact 3215177H02 24 Screw 0316281H01 25 Seal Pot 3271570L01 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Item Description 26 Table 5 3 Display Model Exploded View Parts List Label Pot Seal Part Number 3371478L01 27 Battery Refer to separate Accessory List Leaf let 6866574D04 28 Belt Clip Refer to separate Accessory List Leaf let 6866574D04 5 29 5 30 Disassembly Reassembly Procedures Rad
45. ide Button 3 98 1 appears amp radio beeps release 98 0 appears amp radio beeps Press the PTT Switch 1 1 appears amp radio beeps release 1 0 appears amp radio beeps Press Top Button 148 1 appears amp radio beeps release 148 0 appears amp radio beeps Keypad Checks Press 0 48 1 appears amp radio beeps release 48 0 appears amp radio beeps Press 1 49 1 appears amp radio beeps release 49 0 appears amp radio beeps Press 2 50 1 appears amp radio beeps release 50 0 appears amp radio beeps Press 3 51 1 appears amp radio beeps release 51 0 appears amp radio beeps Press 4 52 1 appears amp radio beeps release 52 0 appears amp radio beeps Press 5 53 1 appears amp radio beeps release 53 0 appears amp radio beeps Press 6 54 1 appears amp radio beeps release 54 0 appears amp radio beeps Press 7 55 1 appears amp radio beeps release 55 0 appears amp radio beeps Press 8 56 1 appears amp radio beeps release 56 0 appears amp radio beeps Press 9 57 1 appears amp radio beeps release 57 0 appears amp radio beeps Press 58 1 appears amp radio beeps release 58 0 appears amp radio beeps Press 59 1 appears amp radio beeps release 59 0 appears amp radio beeps
46. ig CAUTION Pressure any greater than 1 psig might push air around the main seal 5 Maintain the pressure at 1 psig and immerse the radio into a water filled container 6 Watch for any continuous series of bubbles A stream of bubbles indicates a sign of leakage NOTE Some air entrapment may cause the accumulation of bubbles especially in the grille area but the bubbles should not be continuous Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 21 5 8 9 5 8 9 1 7 Note all of the seal areas that show signs of leakage Pinpoint the problem s to one or more of the following areas Front Housing e Chassis Main Seal O ring Battery Contact Seal 8 Remove the radio from the water container and dry the radio thoroughly Be especially care ful to dry the area around the main seal to prevent contamination of the internal electronics while the unit is open CAUTION Keep the area around the chassis s vacuum port dry by ensuring that there is no water around it 9 Remove the pump connector from the chassis 10 Radio after performing Pressure Test must undergo baking process in a temperature chamber for constant temperature soaking at 60 C for 1 hour This is to ensure no moisture is trapped inside the radio and prevent contamination of the internal electronics after reassembling the radio Troubleshooting Leak Areas Before repairing any leak first read all of the steps within the applicable section
47. io Exploded Mechanical Views and Parts Lists 5 9 2 Non Display Model Exploded View and Parts List Figure 5 22 Non Display Model Exploded View Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Item Description Table 5 4 Non Display Model Exploded View Parts List Part Number 1 Screw with Washer 0371981L01 2 Assembly Front Housing PMLN4922_ 3 Cover Dust 1571477L01 4 Nameplate for DP 3401 3371391L03 Nameplate for DP 3400 3371391L04 5 Antenna Refer to separate Accessory List Leaf let 6866574D04 6 Knob Frequency 3615204H01 7 Knob Volume 3615205H01 8 Speaker 5085798F09 9 Retainer Speaker 4271352L02 10 Screw Speaker Retainer 0386434202 11 Screw 0386104204 12 Board Interface 0104022J35 13 Clip Shield 4271320L01 14 Shield Can 2615156H01 15 Back Cover Kit See Section 1 4 Model Charts 16 Pad Thermal 7515526H01 17 O Ring 3215181H01 18 Retainer O Ring 4216293H01 19 Retainer O Ring 4216292H01 20 Assembly Chassis Molded w MIP Shield 0104023J31 21 Screw 0316281H01 22 Seal Pot 3271570L01 5 32 Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists Table 5 4 Non Display Model Exploded View Parts List
48. itor DVM AC Volts Set 1kHz Mod Out level for 0 025Vrms at test set 80mVrms at AC DC test set jack Voice Mode PWR MON TEST MODE Remove Press PTT switch on Modulation 4th channel test Test Channel 4 modulation input radio Say four internal frequency carrier squelch loudly into the radio atten to 70 input to RF output at mic Measure In Out antenna deviation 4 0 kHz but lt 5 0 kHz 25 kHz Ch Sp TPL As above TEST MODE As above Deviation Modulation 4th channel test Test Channel 4 gt 500Hz but lt 1000Hz frequency TPL 25 kHz Ch Sp BW to narrow 3 6 Transceiver Performance Testing Display Model Test Mode See Table 3 4 Table 3 6 Receiver Performance Checks Test Name Communicalotis Radio Test Set Comments Analyzer Reference Mode PWR MON TEST MODE PTT to Frequency error to be Frequency 4th channel test Test Channel 4 continuously 654 Hz for frequency carrier squelch transmit non GPS models Monitor Frequency error output at during the UHF1 Input at RF In Out antenna performance 218 Hz for GPS check models UHF 1 729 Hz for non GPS models UHF2 243 Hz for GPS models UHF2 233 Hz for non GPS models VHF 77 Hz for GPS models VHF Rated Audio Mode GEN TEST MODE PTT to OFF Set volume Output level 1 0mV RF Test Channel 4 center meter control to 2 83Vrms 4th channel test carrier squelch selector to Audio frequency PA Mod 1kHz tone at 3kHz deviation Monit
49. lete electromagnetic wave cycle occurs ina fixed unit of time usually one second General Purpose Input Output Pins whose function is programmable Global Positioning System Integrated Circuit An assembly of interconnected components on a small semiconductor chip usually made of silicon One chip can contain millions of microscopic components and perform many functions Intermediate Frequency kilohertz One thousand cycles per second Used especially as a radio frequency unit Liquid Crystal Display An LCD uses two sheets of polarizing material with a liquid crystal solution between them An electric current passed through the liquid causes the crystals to align so that light cannot pass through them Light Emitting Diode An electronic device that lights up when electricity is passed through it Glossary 2 Term MDC MHz Paging PC Board PL Programming Cable Receiver Repeater RF RX Signal Spectrum Squelch TOT TPL Transceiver Transmitter TX UHF USB VIP Definition Motorola Digital Communications Megahertz One million cycles per second Used especially as a radio frequency unit One way communication that alerts the receiver to retrieve a message Printed Circuit Board Also referred to as a PCB Private Line Tone Squelch A continuous sub audible tone that is transmitted along with the carrier A cable that allows the CPS to communicate directly with the radio using USB
50. lude hardware errors detected by the microprocessor and certain memory errors These memory errors include incorrect ROM checksum incorrect RAM checksum and incorrect checksums of codeplug Persistent Storage blocks that contain operating parameters If the codeplug block operating parameters are corrupted operation of the unit on the proper frequency system and group are in question Attempts to use this information could provide the user with a false sense of security that others are receiving his messages Corrupted codeplug blocks of call IDs or their associated aliases are considered non fatal errors While the user may be inconvenienced normal communication is still possible Table 6 1 Power Up Error Codes Error Code Description Error Type Corrective Action ERROR 01 02 Call ID or associated Non Fatal Normal communication is still possible but the aliases codeplug block user may be inconvenienced checksum is wrong Reprogram codeplug ERROR 01 22 Tuning Codeplug block Non Fatal Normal communication is still possible checksum is wrong FAIL 01 82 External Codeplug block Fatal Reprogram codeplug checksum is wrong FAIL 01 92 Secure Codeplug check Fatal Reprogram codeplug sum error FAIL 01 A2 Tuning Codeplug block Fatal Reprogram codeplug checksum is wrong FAIL 01 81 ROM Checksum is Fatal Reprogram FLASH Memory then retest If wrong message reoccurs replace main board or send radio to nearest Motorola Depot FAIL 01 8
51. m Motorola You can also contact the Customer Help Desk through the following web address http www motorola com governmentandenterprise contactus A 4 EMEA Regional Warranty Service and Technical Support Further Assistance From Motorola Notes Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to portable and mobile subscriber radio products All terms do not necessarily apply to all radios and some terms are merely generic in nature Term Analog Band CPS Default DP Digital DPL FCC Frequency GPIO GPS IC kHz LCD LED Definition Refers to a continuously variable signal or a circuit or device designed to handle such signals Frequencies allowed for a specific purpose Customer Programming Software Software with a graphical user interface containing the feature set of a radio A pre defined set of parameters Refers to Digital Professional Radio model names in the MOTOTRBO Professional Digital Two Way Radio System Refers to data that is stored or transmitted as a sequence of discrete symbols from a finite set most commonly this means binary data represented using electronic or electromagnetic signals Digital Private Line A type of digital communications that utilizes privacy call as well as memory channel and busy channel lock out to enhance communication efficiency Federal Communications Commission Number of times a comp
52. n 1 2 1 2 1 Introduction Radio Description Display Model On Off Volume Control Knob Push to Talk PTT Button Channel Selector Knob hy 2 Antenna 77 mx d LED Indicator sf Emergency Button s A Universal Connector for Accessories Side Button 1 Display Menu Navigation Keys Side Button 2 Side Button 3 Keypad Front Button P1 Microphone Front Button P2 Speaker Figure 1 1 Display Model ON OFF VOLUME KNOB Rotate clockwise until click is heard to turn on radio rotate counter clockwise until click is heard to turn off radio Rotate clockwise to increase volume level rotate counter clockwise to decrease volume level LED INDICATORS Red green and orange light emitting diodes indicate operating status LCD Liquid Crystal Display 132x34 full dot matrix display provides visual information about many radio features MENU NAVIGATION KEYS Five keys to provide menu navigation and selection interface KEYPAD Twelve keys that allows the user to input characters for various text based operations FRONT BUTTONS and SIDE BUTTONS These five buttons are field programmable using the CPS CHANNEL SELECTOR KNOB Rotate clockwise to increment and counter clockwise to decrement the channel PUSH to TALK PTT Press to execute voice operations e g Gr
53. n Guide is also included with the kit NOTE Refer to the appropriate program on line help files for the programming procedures Table 4 1 Software Installation Kits Radio Tuning Setup ee MOTOTRBO CPS Tuner and AirTracer Applications CD GMVN5141_ 4 2 Customer Programming Software Setup The CPS programming setup shown in Figure 4 1 is used to program the radio NOTE Refer to appropriate program on line help files for the programming procedures A N Computer USB ports can be sensitive to Electrostatic Discharge Do not touch 6 exposed contacts on cable when connected to a computer aution Programming Testing Battery amp Alignment Cable PMKN4012_ PMKN4013_ Figure 4 1 CPS Programming Setup 4 3 AirTracer Application Tool The MOTOTRBO AirTracer application tool has the ability to capture over the air digital radio traffic and save the captured data into a file The AirTracer application tool can also retrieve and save 4 2 4 4 Radio Programming and Tuning Radio Tuning Setup internal error logs from MOTOTRBO radios The saved files can be analyzed by trained Motorola personnel to suggest improvements in system configurations or to help isolate problems Radio Tuning Setup A personal computer PC Windows 2000 XP and a tuner program are required to tune the radio To perform the tuning procedures the radio must be connected to the PC radio interface box RIB and test equipment setup
54. nnector 2 Attach pressure hose to pump connector pressure 1 psig 1 Operate pressure pump 2 Immerse radio into a water 1 Remove Knobs filled container Series of bubbles NO 1 Dry the radio 2 Replace Breathing Vent label and Breathing Vent Membrane 3 Radio app for immersibility Continuou Bubbles from 1 Dry the radio Lens Univer 2 Replace Housing Main Bubbles from sal Connector Seal O Ring and repeat chassis steps in Troubleshooting Housing Inter Flow Chart for Vacuum Test face PTT Only for Display Model ER 1 Dry the radio 2 Replace Main Seal O ring Bubbles from and repeat steps in Chassis Troubleshooting Flow Chart for Vacuum Test 1 Dry the radio 2 Replace Battery Contact Seal Main Seal O Ring and repeat NO Bubbles from Battery Con steps in Troubleshooting Flow Chart for Vacuum Test Troubleshooting Flow Chart for Pressure Test amp Leakage Areas Disassembly Reassembly Procedures Radio Exploded Mechanical Views and Parts Lists 5 27 5 9 Radio Exploded Mechanical Views and Parts Lists 5 9 1 Display Model Exploded View and Parts List EST Figure 5 21 Display Model Exploded View Disassembly Reassembly Procedures Radio Exploded Mechan
55. odule removal b Remove the two screws using the TORX T6 screwdriver c Remove the display retainer Figure 5 6 LCD Retainer removal Disassembly Reassembly Procedures Radio Disassembly Detailed 5 9 2 Use the TORX T6 screwdriver to remove the four screws holding the transmission board and interface board 3 Lift up the interface and transmission board to remove DD R K E S crews Pa e Pa See T Interface Board Chassis Figure 5 7 Transmission and Interface Board removal 4 Release the catch from the reflow post by pushing away the shield clips 5 Remove the shield clip by releasing the hook from the slot at the top shield Shield Clip Reflow Post Figure 5 8 Shield Clip removal Disassembly Reassembly Procedures Radio Disassembly Detailed 6 Release all the tabs from the catches 7 Remove O ring and battery contact seal econdary O ring 5 oe Main O ring a te SC Notches Catches Notches Battery Contact Seal Figure 5 9 O ring and Battery Contact Seal removal Disassembly Reassembly Procedures Radio Disassembly Detailed 5 11 5 6 3 Speaker Disassembly 1 Remove the screws using the TORX T6 screwdriver 2 Remove the speaker retainer and subsequently the speaker Screws Figure 5 10 Speaker removal 5 12 Disassembly Reassembly Procedures Radio Reassembly Detailed 5 7 Radio Reassembly Detailed A Adhere
56. omponents The printed through holes may interconnect multiple layers of the printed circuit Therefore exercise care to avoid pulling the plated circuit out of the hole When soldering near a connector e Avoid accidentally getting solder in the connector Be careful not to form solder bridges between the connector pins e Examine your work closely for shorts due to solder bridges 5 5 Disassembling and Reassembling the Radio General When disassembling and reassembling the radio it is important to pay particular attention to the snaps and tabs and how parts align with each other Disassembly Reassembly Procedures Radio Disassembly Detailed 5 5 The following tools are required for disassembling the radio e TORX T6 screwdriver e Knob Removal Tool 6671789L02 The following item and tools are required for reassembling the radio e Grease 1185937A01 e TORX T6 screwdriver e Vacuum Pump Kit NLN9839 Radio Immersibility Test e Pressure Pump Kit NTN4265 Radio Immersibility Test e Connector Fitting 5871134M01 Radio Immersibility Test e Fitting Seal 3271133M01 Radio Immersibility Test If a unit requires further testing or service than is customarily performed at the basic level please send the radio to a Motorola Service Center 5 6 Radio Disassembly Detailed 5 6 1 Front Cover from Chassis Disassembly 1 Turn off the radio 2 Unscrew the fastener screw 3 Pull the dust cover upward to remove it
57. on or via Motorola Online at http emeaonline motorola com The Radio Products and Solutions Organization RPSO was formerly known as the Radio Products Services Division RPSD and or the Accessories and Aftermarket Division AAD EMEA Regional Warranty Service and Technical Support Technical Support A 3 A 4 A 5 Technical Support Motorola Product Services is available to assist the dealer distributors in resolving any malfunctions which may be encountered North Europe Stephen Woodrow Telephone 44 0 1256 488 082 Fax 44 01256 488 080 Email CSW066 motorola com Russia and Belarus Oleg Machnev Telephone 7 495 785 0150 Fax 7 495 785 0185 Email CSA002 email mot com Middle East and Africa Wayne Holmes Telephone 27 11 800 7922 Fax 27 11 800 7923 Email radiosupport za motorola com France Armand Roy Telephone 33 1 6935 7868 Fax 33 1 6935 7808 Email armand roy motorola com Central and East Europe Siggy Punzenberger Telephone 49 0 6128 70 2342 Fax 49 0 6128 95 1096 Email TFG003 email mot com Germany Customer Connect Team Telephone 49 0 30 6686 1539 Fax 49 0 30 6686 1916 Email cgiss emea europe mot com Italy Ugo Gentile Telephone 39 0 2822 0325 Fax 39 0 2822 0334 Email C13864 email mot com France Laurent Irrmann Telephone 33 1 6935 7866 Fax 33 1 6935 7808 Email laurent irrmann motorola com Further Assistance Fro
58. or DVM AC Volts Distortion As above except to As above As above Distortion lt 3 0 distortion Sensitivity As above except SINAD As above PTT to OFF RF input to be SINAD lower the RF level for center lt 0 35uV 12dB SINAD Noise RF level set to 1mV RF As above PTT to OFF Set volume Squelch center meter control to 2 83Vrms Threshold selection to only radios Audio PA with speaker load to conventional speaker system need to be tested As above except change Out of TEST As above Unsquelch to occur at frequency toa MODE select lt 0 25nV conventional system a conventional Preferred SINAD 9 Raise RF level from zero system 10dB until radio unsquelches See Table 3 4 Transceiver Performance Testing Display Model Test Mode 3 7 3 3 3 Display Test Mode 1 Press and hold Side Button 1 in RF Test Mode The radio beeps once and momentarily displays Display Test Mode 2 Upon entering Display Test Mode the radio displays a horizontal line on row 8 center row 3 With each button key press the radio fills the screen up with 2 horizontal lines from the center row 1 line each above and below the center row until the top and bottom of the screen row 7 0 and row 9 16 is completely full 4 When the screen is filled up with the horizontal lines any button key press clears the screen and displays vertical lines at column 0 6 12 18 24 30 36 42 48 54 60 Any button key press fills
59. oup call and Private Call ANTENNA Provides the needed RF amplification when transmitting or receiving MICROPHONE Allows the voice to be sent when PTT or voice operations are activated UNIVERSAL CONNECTOR FOR ACCESSORIES Interface point for all accessories to be used with the radio It has twelve points to which specific accessories will connect and be activated Introduction Radio Description 1 3 EMERGENCY BUTTON Turns on and off the Emergency Operations SPEAKER Outputs all tones and audio that are generated by the radio e g features like keypad tones and voice audio 1 2 2 Non Display Model On Off Volume Control Knob Push to Talk PTT Button A Channel Selector Knob Antenna Emergency Button LED Indicator Universal Connector for Accessories Side Button 1 Speaker D Microphone Q Side Button 2 Side Button 3 _ Figure 1 2 Non Display Model ON OFF VOLUME KNOB Rotate clockwise until click is heard to turn on radio rotate counter clockwise until click is heard to turn off radio Rotate clockwise to increase volume level rotate counter clockwise to decrease volume level LED INDICATORS Red green and orange light emitting diodes indicate operating status SIDE BUTTONS These 3 buttons are field programmable using the CPS CHANNEL SELECTOR KNOB Rotate clockwise to increment and counter clockwise to decrement the channel
60. r Kit MOTOTRBO Non Display Portable without GPS X PMLN4646_ Front Cover Kit with Display and Keypad X X PMLN4922 Front Cover Kit without Display and Keypad X X PMAE4050_ UHF2 GPS Folded Monopole 450 495 MHz X X PMAE4051_ UHF2 GPS Folded Monopole 495 527 MHz X X PMAE4052_ UHF2 GPS Stubby Antenna 450 495 MHz X X PMAE4048_ UHF2 GPS Stubby Antenna 495 527 MHz X IPMAE4049 UHF2 Whip Antenna 450 527 MHz X X 6866574D01 Quick Reference Guide X 6866574D02 Quick Reference Guide Introduction Specifications Specifications General Display Non Display DP 3600 DP 3601 DP 3400 DP 3401 Frequency VHF 136 174 MHz UHF1 403 470 MHz UHF2 450 512 MHz Dimensions HxWxT w NiMH battery 5 18 x 2 40 x 1 38 in 131 5 x 61 x 35 mm Weight with NiMH battery 15 2 oz 430 9 13 2 oz 375 g with Lilon FM battery 13 oz 370 g 11 1 oz 815 g with Lilon non FM battery 12 7 oz 360 g 10 75 oz 305 g with Lilon 2200 battery 12 7 oz 360 9 10 75 oz 305 g Power Supply 7 5V nominal Average battery life at 5 5 90 duty cycle with battery saver enabled in carrier squelch and transmitter in high power NiMH core battery Analog 8 hrs Digital 11 2 hrs IMPRES Lilon Slim Battery Standard Analog 9 3 hrs Digital 13 hrs IMPRES FM Lilon Analog 8 7 hrs Digital 12 1 hrs IMPRES Lilon 2200 Analog 13 5 hrs Digital 19 hrs Introduction Specifications Receiver Frequencies Channel Spacing Frequency S
61. r storage and transportation of other semiconductor devices Ground the working surface of the service bench to protect the CMOS device We recommend using the Motorola Static Protection Assembly part number 0180386A82 which includes a wrist strap two ground cords a table mat and a floor mat 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 4280385A59 Do not wear nylon clothing while handling CMOS devices Do not insert or remove CMOS devices with power applied Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present When straightening CMOS pins provide ground straps for the apparatus used When soldering use a grounded soldering iron If at all possible handle CMOS devices by the package and not by the leads Prior to touching the unit touch an electrical ground to remove any static charge that you may have accumulated The package and substrate may be electrically common If so the reaction of a discharge to the case would cause the same damage as touching the leads 5 3 5 4 Disassembly Reassembly Procedures Repair Procedures and Techniques General 5 4 Repair Procedures and Techniques General NOTE Environmentally Preferred Products EPP refer to the marking on the printed circuit boards examples shown below were developed
62. s Replacement Back Cover Kit Procedures Once a problem has been isolated to a specific board install the appropriate service kit See Model Charts from page 1 5 to page 1 6 which is orderable If a board is replaced it does not necessarily need to be retuned if it has been factory tuned It should however be checked for performance before being placed into service Of particular concern is the Bias DAC which will need to be set for the appropriate final device bias current prior to keying up the radio If the bias is not properly set it may be possible to cause damage to the transmitter CAUTION The Tuner Tool only allows the serial number of the blank board to be entered once Be very attentive during this procedure 6 2 Basic Troubleshooting Power Up Error Codes Display Model only 6 3 Power Up Error Codes Display Model only Upon powering up the radio performs certain tests to determine if its basic electronics and software are in working order Any error detected has an associated error code that is presented on the radio display These error codes are intended to be used by a service technician when the radio generates the Self Test Fail Tone If these tests are successfully completed the radio will generate the Self Test Tone There are two classes of detectable errors fatal and non fatal If it is considered as a fatal error then the normal radio operation will be inhibited Fatal errors inc
63. s and repair A 2 A 2 A 3 EMEA Regional Warranty Service and Technical Support European Radio Support Centre ERSC European Radio Support Centre ERSC The ERSC Customer Information Desk is available through the following service numbers Austria 08 00 29 75 41 Italy 80 08 77 387 Belgium 08 00 72 471 Luxemburg 08 00 23 27 Denmark 80 88 05 72 Netherlands 08 00 22 45 13 Finland 08 00 11 49 910 Norway 80 01 11 15 France 08 00 90 30 90 Portugal 08 00 84 95 70 Germany 08 00 18 75 240 Spain 90 09 84 902 Greece 00 80 04 91 29 020 Sweden 02 07 94 307 UK 08 00 96 90 95 Switzerland 08 00 55 30 82 Ireland 18 00 55 50 21 Iceland 80 08 147 Or dial the European Repair and Service Centre Tel 49 30 6686 1555 Please use these numbers for repair enquiries only Piece Parts Some replacement parts spare parts and or product information can be ordered directly If a complete Motorola part number is assigned to the part it is available from Motorola Radio Products and Solutions Organization RPSO If no part number is assigned the part is not normally available from Motorola If the part number is appended with an asterisk the part is serviceable by Motorola Depot only If a parts list is not included this generally means that no user serviceable parts are available for that kit or assembly Orders for replacement parts kits and assemblies should be placed directly on Motorola s local distribution dealer organisati
64. service or repair The only recommended agent for cleaning the external radio surfaces is a 0 5 solution of a mild dishwashing detergent in water The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol 100 by volume d The effects of certain chemicals and their vapors can have harmful results on certain plastics Avoid using aerosol sprays tuner cleaners and other Caution chemicals 5 2 5 3 Disassembly Reassembly Procedures Safe Handling of CMOS and LDMOS Devices Cleaning External Plastic Surfaces Apply the 0 5 detergent water solution sparingly with a stiff non metallic short bristled brush to work all loose dirt away from the radio Use a soft absorbent lintless cloth or tissue to remove the solution and dry the radio Make sure that no water remains entrapped near the connectors cracks or crevices Cleaning Internal Circuit Boards and Components Isopropyl alcohol 100 may be applied with a stiff non metallic short bristled brush to dislodge embedded or caked materials located in hard to reach areas The brush stroke should direct the dislodged material out and away from the inside of the radio Make sure that controls or tunable components are not soaked with alcohol Do not use high pressure air to hasten the drying process since this could cause the liquid to collect in unwanted places After completing of the cleaning process use a soft a
65. splay Retainer 2 Ddr Er Figure 5 17 LCD Retainer and LCD Module reassembly Disassembly Reassembly Procedures Radio Reassembly Detailed 5 17 5 7 3 Chassis and Front Cover Reassembly 1 Slide in the volume and channel shafts into the top slot 2 Connect the board to board connector between the keypad flex and the transmission board 3 Insert top chassis tabs into recesses on front cover and apply some force until tabs are fully inserted 4 Apply some grease at the bottom portion of the main O ring 5 Gently push the chassis onto the front cover NOTE Take necessary precautions while performing step 5 of See Section 5 7 3 Chassis and Front Cover Reassembly to prevent visible outward pinches of the main O ring Volume Shaft Channel Shaft Apply grease at the bottom portion of the O ring Figure 5 18 Back Cover Kit reassembly 5 18 Disassembly Reassembly Procedures Ensuring Radio Immersibility 6 A visual inspection into the two screw holes will reveal blockage by a pinched O ring in that area which requires the chassis to be re inserted into the front cover See Chassis and Front Cover Reassembly on page 5 17 Screw Holes Figure 5 19 Chassis to Front Cover reassembly 7 Fasten the screws using TORX T6 screwdriver 8 Reassemble knobs d If the antenna needs to be replaced ensure that only MOTOTRBO antennas are used Neglecting this would damage your radio Refer
66. strictly to ALL reassembly procedures to ensure radio immersibility Caution 5 7 1 Speaker Reassembly 1 Place the speaker onto the front cover with the orientation tab aligned with the orientation slot on the front cover 2 Place speaker retainer in the correct orientation 3 Fasten the screws using TORX T6 screwdriver d GF MED ING Speaker Retainer 3 Orientation Tab Screws Speaker Orientation Tab Speaker Retainer Speaker Orientation Slot Figure 5 11 Speaker reassembly Display Model Disassembly Reassembly Procedures Radio Reassembly Detailed Speaker Retainer A Orientation Tab Figure 5 12 Speaker reassembly Non Display Model 5 14 Disassembly Reassembly Procedures Radio Reassembly Detailed 5 7 2 Chassis Reassembly 1 Fit the battery contact seal onto the battery contact slot 2 Refer to Figure 5 13 to fit the main O ring onto the chassis in the following sequence i Ensure that the main O ring is not twisted and untangle it to its actual form if needed before performing reassembly ii Secure A1 into the top two notches on the chassis ii Fit the top section of the main O ring by inserting it into the grooves at the top two cor ners formed by the black retainers iv Insert B1 into the top two catches on the chassis v ER the bottom section of the main O ring around the bottom two corners of the chassis vi Secure A2 into the remaining four notc
67. t No Display Display module is not Fatal Check connection between main board and connected properly display module Display module is dam Replace with new display module aged NOTE A non display radio emits only the Self Test Fail Tone if it fails the self test 6 4 6 4 Basic Troubleshooting Operational Error Codes Operational Error Codes During radio operation the radio performs dynamic tests to determine if the radio is working properly Problems detected during these tests are presented as error codes on the radio s display The presence of an error code should prompt a user that a problem exists and that a Motorola Authorized MOTOTRBO dealer should be contacted Use Table 6 2 to aid in understanding particular operational error codes Table 6 2 Operational Error Codes Error Code Description Error Type Corrective Action FAIL 001 Synthesizer Out of Lock NON FATAL 1 Reprogram the codeplug 2 Refer to Detailed Service Manual FAIL 002 Personality checksum or NON FATAL Reprogram the codeplug system block error Appendix A EMEA Regional Warranty Service and Technical Support A 1 Warranty and Service Support Motorola offers long term support for its products This support includes full exchange and or repair of the product during the warranty period and service repair or spare parts support out of warranty Any return for exchange or return for repair by an authorized Motorola
68. tability 30 C to 60 C Analog Sensitivity Displa DP 3600 DP 3601 Non Display DP 3400 DP 3401 VHF 136 174 MHz UHF1 403 470 MHz UHF2 450 512 MHz 12 5 kHz 20 kHz 25 kHz m DP 3600 m DP 3601 1 5 ppm DP 3400 0 5 ppm DP 3401 35 uV 12dB SINAD typical 12dB SINAD typical 20dB SINAD Hum and Noise 40 dB 12 5 kHz 45 dB 20 kHz 25 kHz Audio Response 1 3 dBm Conducted Spurious Emission 57 dBm 20 kHz channel spacing is not applicable for UHF2 1 10 Frequencies Channel Spacing Frequency Stability 30 C to 60 C Power Output Low Power Power Output High Power Modulation Limiting FM Hum and Noise Introduction Specifications Display DP 3600 DP 3601 Non Display DP 3400 DP 3401 VHF 136 174 MHz UHF1 403 470 MHz UHF2 450 512 MHz 12 5 kHz 20kHz 25 kHz m DP 3600 m DP 3601 m DP 3400 m DP 3401 1W VHF 5 W UHF1 UHF2 4 W 2 5 kHz 12 5 kHz 4 0 kHz 20 kHz 5 0 kHz 25 kHz 40 dB 12 5 kHz 45 dB 20 kHz 25 kHz Conducted Radiated Emission 36 dBm lt 1 GHz 30 dBm gt 1 GHz 60 dB 12 5 kHz 70 dB 20 kHz 25 kHz Adjacent Channel Power Audio Audio Response GG 1 3 dBm Audio Distortion 3 typical FM Modulation 12 5 kHz 11KOF3E 20 kHz 14KOF3E 25 kHz 16KOF3E 4FSK Digital Modulation 12 5 kHz Data Only 7K60FXD 12 5 kHz Data amp Voice 7K6
69. the codeplug Always MSN The radio s serial number as programmed in the codeplug Always FLASHCODE The FLASH codes as programmed in the codeplug Always RF Band The radio s band Always NOTE The radio stops at each display for 2 seconds before moving to the next information display If the information cannot fit into 1 line the radio display scrolls automatically character by character after 1 second to view the whole information If the Left Navigation Key is pressed before the last information display the radio shall suspend the information display until the user presses Right Navigation Key gt to resume the information display The radio beeps for each button press After the last display RF Test Mode will be displayed 3 3 2 RF Test Mode When the radio is operating in its normal environment the radio s microcontroller controls the RF channel selection transmitter key up and receiver muting according to the customer codeplug configuration However when the unit is on the bench for testing alignment or repair it must be removed from its normal environment via a special routine called TEST MODE or air test In RF Test Mode the display upon the first line is RF Test together with the power level icon at the right end of the first line The display upon the second line is the test environment the channel number and channel spacing The default test environment is CSQ 1 Each short press of Side Button 2 changes th
70. to separate Accessory Caution List Leaflet 6866574D04 for a list of available antennas 5 8 Ensuring Radio Immersibility This section discusses radio immersibility concerns tests and disassembly and reassembly of the series radios 5 8 1 Servicing The series radios shipped from the Motorola factory have passed vacuum testing and should be capable of restoring the watertight integrity of the radio CAUTION It is strongly recommended that the maintenance of the radio be deferred to qualified ser vice personnel and service shops This is of paramount importance as irreparable damage to the radio can result from service by unauthorized persons If disassembly is necessary unauthorized attempts to repair the radio may void any existing warranties or extended performance agreements with Motorola It is also recommended that immersibility be checked annually by qualified service person nel workshop that is authorized by Motorola 5 8 2 Accidental Immersion If the radio is accidentally dropped in water shake the radio to remove the excess water from the speaker grille and microphone port area before operating otherwise the sound may be distorted until the water has evaporated or is dislodged from these areas Disassembly Reassembly Procedures Ensuring Radio Immersibility 5 8 3 5 8 4 5 8 5 5 8 6 5 8 7 5 19 Specialized Test Equipment This section summarizes the specialized test equipment necessary for testing t

DP 340x MOTOTRBO Portable - Basic Service Manual

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