Motorola motorrbo dm4400 Manuals

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Motorola motorrbo dm4400 Basic Service Manual

Motorola motorrbo dm4400 Basic Service Manual (116 pages)

XPR 5000 series  
Brand: Motorola | Category: Radio | Size: 14.79 MB
Table of contents
Product Safety And Rf Exposure Compliance3................................................................................................................................................................
Computer Software Copyrights3................................................................................................................................................................
Document Copyrights3................................................................................................................................................................
Disclaimer3................................................................................................................................................................
Trademarks3................................................................................................................................................................
Document History5................................................................................................................................................................
Table Of Contents7................................................................................................................................................................
Commercial Warranty13................................................................................................................................................................
Limited Warranty13................................................................................................................................................................
Motorola Communication Products13................................................................................................................................................................
What This Warranty Covers And For How Long13................................................................................................................................................................
Ii. General Provisions14................................................................................................................................................................
Iii. State Law Rights14................................................................................................................................................................
Iv. How To Get Warranty Service14................................................................................................................................................................
What This Warranty Does Not Cover14................................................................................................................................................................
Vi. Patent And Software Provisions15................................................................................................................................................................
Vii. Governing Law15................................................................................................................................................................
Chapter 1 Introduction17................................................................................................................................................................
Notations Used In This Manual17................................................................................................................................................................
Radio Description17................................................................................................................................................................
Table 1-1 Radio Frequency Ranges And Power Levels17................................................................................................................................................................
Control Head Description18................................................................................................................................................................
Control Head Controls (color Display Model)18................................................................................................................................................................
Figure 1-1 Radio Control Head (color Display Model)18................................................................................................................................................................
Control Head Controls (numeric Display Model)19................................................................................................................................................................
Figure 1-2 Radio Control Head (numeric Display Model)19................................................................................................................................................................
Mototrbo Mobile Radio Model Numbering Scheme20................................................................................................................................................................
Figure 1-3 Mobile Radio Model Numbering Scheme20................................................................................................................................................................
Vhf High Power (136-174 Mhz) Model Chart21................................................................................................................................................................
Vhf Low Power (136-174 Mhz) Model Chart22................................................................................................................................................................
Uhf1 High Power (403-470 Mhz) Model Chart23................................................................................................................................................................
Uhf1 Low Power (403-470 Mhz) Model Chart24................................................................................................................................................................
Uhf2 (450-512 Mhz) Model Chart25................................................................................................................................................................
1.10 Specifications26................................................................................................................................................................
Chapter 2 Test Equipment And Service Aids31................................................................................................................................................................
Recommended Test Equipment31................................................................................................................................................................
Table 2-1 Recommended Test Equipment31................................................................................................................................................................
Service Aids32................................................................................................................................................................
Table 2-2 Service Aids32................................................................................................................................................................
Programming Cables33................................................................................................................................................................
Figure 2-1 Mobile Front Programming Cable Hkn618433................................................................................................................................................................
Figure 2-2 Mobile & Repeater Rear Programming Cable Pmkn401033................................................................................................................................................................
Figure 2-3 Mobile & Repeater Rear Accessory Programming And Test Cable Pmkn401633................................................................................................................................................................
Chapter 3 Transceiver Performance Testing35................................................................................................................................................................
General35................................................................................................................................................................
Setup35................................................................................................................................................................
Table 3-1 Initial Equipment Control Settings35................................................................................................................................................................
Color Display Model Test Mode36................................................................................................................................................................
Entering Display Radio Test Mode36................................................................................................................................................................
Rf Test Mode36................................................................................................................................................................
Table 3-2 Front Panel Access Test Mode Displays36................................................................................................................................................................
Color Display Test Mode37................................................................................................................................................................
Led Test Mode37................................................................................................................................................................
Backlight Test Mode37................................................................................................................................................................
Speaker Tone Test Mode37................................................................................................................................................................
Earpiece Tone Test Mode37................................................................................................................................................................
Audio Loopback Test Mode38................................................................................................................................................................
Audio Loopback Earpiece Test Mode38................................................................................................................................................................
3.3.10 Button/knob/ptt Test Mode38................................................................................................................................................................
Numeric Display Model Test Mode38................................................................................................................................................................
Display Test Mode39................................................................................................................................................................
Button/knob/ptt Test Mode39................................................................................................................................................................
Table 3-3 Test Environments40................................................................................................................................................................
Table 3-4 Test Channel Spacing40................................................................................................................................................................
Table 3-5 Test Frequencies40................................................................................................................................................................
Table 3-6 Transmitter Performance Checks41................................................................................................................................................................
Table 3-7 Receiver Performance Checks42................................................................................................................................................................
Chapter 4 Radio Programming And Tuning43................................................................................................................................................................
Introduction43................................................................................................................................................................
Customer Programming Software Setup43................................................................................................................................................................
Figure 4-1 Customer Programming Software Setup From Front Connector43................................................................................................................................................................
Table 4-1 Radio Software Program Kit43................................................................................................................................................................
Airtracer Application Tool44................................................................................................................................................................
Figure 4-2 Customer Programming Software Setup From Rear Accessory Connector44................................................................................................................................................................
Figure 4-3 Customer Programming Software Setup With Test Box Connection44................................................................................................................................................................
Radio Tuning Setup45................................................................................................................................................................
Figure 4-4 Radio Tuning Equipment Setup45................................................................................................................................................................
Chapter 5 Disassembly/reassembly Procedures47................................................................................................................................................................
Preventive Maintenance47................................................................................................................................................................
Inspection47................................................................................................................................................................
Cleaning Procedures47................................................................................................................................................................
Safe Handling Of Cmos And Ldmos Devices48................................................................................................................................................................
Repair Procedures And Techniques - General50................................................................................................................................................................
Table 5-1 Lead Free Solder Wire Part Number List50................................................................................................................................................................
Table 5-2 Lead Free Solder Paste Part Number List50................................................................................................................................................................
Disassembling And Reassembling The Radio - General51................................................................................................................................................................
Radio Disassembly - Detailed51................................................................................................................................................................
Control Head Removal51................................................................................................................................................................
Figure 5-1 Typical Control Head Removal51................................................................................................................................................................
Top Cover Removal52................................................................................................................................................................
Figure 5-2 Flexible Connection Removal52................................................................................................................................................................
Figure 5-3 Top Cover Removal (image May Not Match Exact Product)52................................................................................................................................................................
Transceiver Board Removal53................................................................................................................................................................
Figure 5-4 Expansion Board And Flex Removal (image May Not Match Exact Product)53................................................................................................................................................................
Figure 5-5 Gps Nameplate Removal53................................................................................................................................................................
Figure 5-6 Gps Connector Nut Removal54................................................................................................................................................................
Figure 5-7 Gps Cable Removal54................................................................................................................................................................
Figure 5-8 Option Board Removal (image May Not Match Exact Product)55................................................................................................................................................................
Figure 5-9 Acoustic Plug Removal55................................................................................................................................................................
Figure 5-10 Die Cast Main Shield Removal56................................................................................................................................................................
Figure 5-11 Pa Screw Removal57................................................................................................................................................................
Figure 5-12 Accessory Connector Removal57................................................................................................................................................................
Figure 5-13 Dc Connector Retention Clip Removal58................................................................................................................................................................
Figure 5-14 Rf Connector Nut Removal58................................................................................................................................................................
Figure 5-15 Transceiver Board Removal59................................................................................................................................................................
Disassembly Of Color Display Control Head60................................................................................................................................................................
Figure 5-16 Control Head Flex Removal60................................................................................................................................................................
Figure 5-17 Volume/channel Knob Removal60................................................................................................................................................................
Figure 5-18 Control Head Screws And Speaker Removal61................................................................................................................................................................
Figure 5-19 Pcb Retainer Removal61................................................................................................................................................................
Figure 5-20 Control Head Board Removal62................................................................................................................................................................
Figure 5-21 Power Button Removal62................................................................................................................................................................
Figure 5-22 Keypad Removal63................................................................................................................................................................
Figure 5-23 Volume Encoder Seal And Mic Jack Seal Removal63................................................................................................................................................................
Figure 5-24 Display Pad Gasket Removal64................................................................................................................................................................
Figure 5-25 Color Display Removal From Pcb64................................................................................................................................................................
Disassembly Of Numeric Display Control Head65................................................................................................................................................................
Figure 5-26 Control Head Flex Removal65................................................................................................................................................................
Figure 5-27 Volume/channel Knob Removal65................................................................................................................................................................
Figure 5-28 Control Head Board Removal66................................................................................................................................................................
Figure 5-29 Power Button And Keypad Removal66................................................................................................................................................................
Figure 5-30 Speaker Removal (optional)67................................................................................................................................................................
Figure 5-31 Volume Encoder Seal And Mic Jack Seal Removal67................................................................................................................................................................
Radio Reassembly - Detailed68................................................................................................................................................................
Color Display Control Head68................................................................................................................................................................
Figure 5-32 Power Button Placement68................................................................................................................................................................
Figure 5-33 Keypad Assembly68................................................................................................................................................................
Figure 5-34 Assembly To Control Head Housing69................................................................................................................................................................
Figure 5-35 Assembling Color Display To Pcb69................................................................................................................................................................
Figure 5-36 Assembling Mic Jack Seal And Display Pad Gasket70................................................................................................................................................................
Figure 5-37 Assembling Control Head Board To Control Head Assembly70................................................................................................................................................................
Figure 5-38 Assembling Pcb Retainer71................................................................................................................................................................
Figure 5-39 Assembling Speaker71................................................................................................................................................................
Figure 5-40 Orientation Of Speaker72................................................................................................................................................................
Figure 5-41 Volume/channel Knob Assembly72................................................................................................................................................................
Numeric Display Control Head73................................................................................................................................................................
Figure 5-42 Power Button Placement73................................................................................................................................................................
Figure 5-43 Keypad Assembly73................................................................................................................................................................
Figure 5-44 Assembly To Control Head Housing74................................................................................................................................................................
Figure 5-45 Assembling Mic Jack Seal74................................................................................................................................................................
Figure 5-46 Assemble Speaker75................................................................................................................................................................
Figure 5-47 Speaker Retainer Assembly75................................................................................................................................................................
Figure 5-48 Assembling Control Head Board To Control Head Assembly76................................................................................................................................................................
Figure 5-49 Screw Sequence76................................................................................................................................................................
Figure 5-50 Volume/channel Knob Assembly77................................................................................................................................................................
Radio Assembly78................................................................................................................................................................
Figure 5-51 Thermal Pads And Shield Gasketing On Chassis And Die Cast Main Shield78................................................................................................................................................................
Figure 5-52 Chassis With Thermal Pads78................................................................................................................................................................
Thermal Pad Replacement Procedure79................................................................................................................................................................
Figure 5-53 Replacing Regulator Thermal Pads79................................................................................................................................................................
Figure 5-54 Replacing Audio Pa Thermal Pad80................................................................................................................................................................
Figure 5-55 Replacing Final Driver Thermal Pad80................................................................................................................................................................
Transceiver Board Reassembly81................................................................................................................................................................
Figure 5-56 Applying Thermal Grease81................................................................................................................................................................
Figure 5-57 Placing The Transceiver Board In The Chassis81................................................................................................................................................................
Figure 5-58 Inserting Dc Retention Clip82................................................................................................................................................................
Figure 5-59 Inserting Rf Lock Washer And Nut83................................................................................................................................................................
Figure 5-60 Screw Sequence To Compress Pcb83................................................................................................................................................................
Figure 5-61 Installing Pa Screws84................................................................................................................................................................
Figure 5-62 Inserting Accessory Connector84................................................................................................................................................................
Figure 5-63 Assembling Die Cast Main Shield Onto Chassis85................................................................................................................................................................
Figure 5-64 Screw Sequence To Tighten Die Cast Main Shield86................................................................................................................................................................
Figure 5-65 Rf Connector Nut Final Torque86................................................................................................................................................................
Figure 5-66 Acoustic Plug Installation87................................................................................................................................................................
Figure 5-67 Inspection Of Cover Assembly With Seal87................................................................................................................................................................
Figure 5-68 Assembling Cover Onto Chassis88................................................................................................................................................................
Figure 5-69 Gps Cable Installation89................................................................................................................................................................
Figure 5-70 Gps Cable Installation89................................................................................................................................................................
Figure 5-71 Flex Connection Connectors90................................................................................................................................................................
Figure 5-72 Expansion Board Assembly90................................................................................................................................................................
Figure 5-73 Gps Nameplate Assembly91................................................................................................................................................................
Figure 5-74 Gps Antenna Connector Assembly91................................................................................................................................................................
Figure 5-75 Orientation Of Option Board Flex To Option Board92................................................................................................................................................................
Figure 5-76 Assemble Option Board To Radio Chassis (image May Not Match Exact Product)92................................................................................................................................................................
Figure 5-77 Align Option Board To Mounting Holes93................................................................................................................................................................
Assemble Control Head To Radio Assembly94................................................................................................................................................................
Figure 5-78 Assemble O-ring To Chassis (image May Not Match Exact Product)94................................................................................................................................................................
Figure 5-79 Assemble Control Head To Chassis94................................................................................................................................................................
Figure 5-80 Flex Connection Connectors95................................................................................................................................................................
Exploded Mechanical Views And Parts Lists96................................................................................................................................................................
Radio Assembly Exploded View And Parts List96................................................................................................................................................................
Figure 5-81 Radio Assembly Exploded View96................................................................................................................................................................
Table 5-3 Radio Exploded View Parts List97................................................................................................................................................................
Control Head Exploded Views And Parts Lists98................................................................................................................................................................
Figure 5-82 Color Display Control Head Exploded View98................................................................................................................................................................
Table 5-4 Color Display Control Head (pmln5678_) Exploded View Parts List98................................................................................................................................................................
Figure 5-83 Numeric Display Control Head Exploded View99................................................................................................................................................................
Table 5-5 Numeric Display Control Head (pmln5677_) Exploded View Parts List99................................................................................................................................................................
Torque Chart100................................................................................................................................................................
Table 5-6 Torque Specifications For Nuts And Screws100................................................................................................................................................................
Chapter 6 Basic Troubleshooting101................................................................................................................................................................
High Power Rf Precaution101................................................................................................................................................................
Replacement Service Kit Procedures101................................................................................................................................................................
Power-up Error Codes102................................................................................................................................................................
Operational Error Codes102................................................................................................................................................................
Table 6-1 Power-up Error Codes102................................................................................................................................................................
Table 6-2 Operational Error Codes102................................................................................................................................................................
Chapter 7 Accessories103................................................................................................................................................................
Audio103................................................................................................................................................................
Speakers103................................................................................................................................................................
Desktop Accessories103................................................................................................................................................................
Mounting Kits104................................................................................................................................................................
Cables104................................................................................................................................................................
Antennas104................................................................................................................................................................
Bluetooth106................................................................................................................................................................
Miscellaneous Accessories106................................................................................................................................................................
Appendix A Replacement Parts Ordering107................................................................................................................................................................
Basic Ordering Information107................................................................................................................................................................
Motorola Online107................................................................................................................................................................
Mail Orders107................................................................................................................................................................
Telephone Orders107................................................................................................................................................................
Fax Orders107................................................................................................................................................................
Parts Identification108................................................................................................................................................................
Product Customer Service108................................................................................................................................................................
A.6 Parts Identification108................................................................................................................................................................
Appendix B Motorola Service Centers109................................................................................................................................................................
Servicing Information109................................................................................................................................................................
Motorola Service Center109................................................................................................................................................................
Motorola Federal Technical Center109................................................................................................................................................................
Motorola Canadian Technical Logistics Center109................................................................................................................................................................
B.1 Servicing Information109................................................................................................................................................................
Appendix C Limited Level 3 Servicing111................................................................................................................................................................
Maintenance111................................................................................................................................................................
Component Location And Parts List111................................................................................................................................................................
Figure C-1 Pcb Top Side View111................................................................................................................................................................
C.1 Maintenance111................................................................................................................................................................
Figure C-2 Pcb Bottom Side View112................................................................................................................................................................
Table C-1. Component Parts List112................................................................................................................................................................
Glossary113................................................................................................................................................................

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