Motorola_DM-4000_DM-4001_DM-4600_DM-4601_serv_2011.pdf

PROFESSIONAL DIGITAL TWO-WAY RADIO MOTOTRBO MOBILE BASIC SERVICE MANUAL DM4400 NUMERIC DISPLAY MOBILE DM4401 NUMERIC DISPLAY MOBILE (WITH BLUETOOTH nor does it cover any license under its patent rights nor the rights of others. Trademarks MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective owners. 2011 Motorola Solutions, Inc. All rights reserved. These servicing instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that contained in the Operating Instructions unless you are qualified to do so. Refer all servicing to qualified service personnel. Before using this product, read the operating instructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio. ! C a u t i o n ! C a u t i o n ii Notes iii Document History The following major changes have been implemented in this manual since the previous edition. EditionDescriptionDate 68012003037-AInitial Release.Dec. 2011 iv Notes Table of Contentsv Table of Contents Foreword.i Product Safety and RF Exposure Compliance.i Computer Software Copyrights .i Document Copyrights.i Disclaimer.i Trademarks .i Document History . iii Chapter 1Introduction. 1-1 1.1Notations Used in This Manual.1-1 1.2Radio Description .1-1 1.3Control Head Description.1-2 1.3.1Control Head Controls (Colour Display Model) .1-2 1.3.2Control Head Controls (Numeric Display Model).1-3 1.4MOTOTRBO Mobile Radio Model Numbering Scheme.1-4 1.5VHF High Power (136174 MHz) Model Chart .1-5 1.6VHF Low Power (136174 MHz) Model Chart .1-6 1.7UHF1 High Power (403470 MHz) Model Chart .1-7 1.8UHF1 Low Power (403470 MHz) Model Chart .1-8 1.9Specifications .1-9 Chapter 2Test Equipment and Service Aids. 2-1 2.1Recommended Test Equipment .2-1 2.2Service Aids.2-2 2.3Programming Cables.2-3 Chapter 3Transceiver Performance Testing. 3-1 3.1General.3-1 3.2Setup .3-1 3.3Colour Display Model Test Mode.3-2 3.3.1Entering Display Radio Test Mode.3-2 3.3.2RF Test Mode.3-2 3.3.3Colour Display Test Mode.3-3 3.3.4LED Test Mode.3-3 3.3.5Backlight Test Mode.3-3 3.3.6Speaker Tone Test Mode.3-3 3.3.7Earpiece Tone Test Mode.3-3 3.3.8Audio Loopback Test Mode.3-4 3.3.9Audio Loopback Earpiece Test Mode.3-4 3.3.10 Button/Knob/PTT Test Mode.3-4 viTable of Contents 3.4Numeric Display Model Test Mode.3-4 3.4.1Entering Display Radio Test Mode.3-4 3.4.2RF Test Mode.3-4 3.4.3Display Test Mode.3-5 3.4.4LED Test Mode.3-5 3.4.5Speaker Tone Test Mode.3-5 3.4.6Earpiece Tone Test Mode .3-5 3.4.7Audio Loopback Test Mode.3-5 3.4.8Audio Loopback Earpiece Test Mode.3-5 3.4.9Button/Knob/PTT Test Mode.3-5 Chapter 4Radio Programming and Tuning . 4-1 4.1Introduction .4-1 4.2Customer Programming Software Setup .4-1 4.3AirTracer Application Tool.4-2 4.4Radio Tuning Setup .4-3 Chapter 5Disassembly/Reassembly Procedures . 5-1 5.1Introduction .5-1 5.2Preventive Maintenance .5-1 5.2.1Inspection .5-1 5.2.2Cleaning Procedures.5-1 5.3Safe Handling of CMOS and LDMOS Devices.5-2 5.4Repair Procedures and Techniques General.5-4 5.5Disassembling and Reassembling the Radio General.5-5 5.6Radio Disassembly Detailed.5-5 5.6.1Control Head Removal .5-5 5.6.2Top Cover Removal.5-6 5.6.3Transceiver Board Removal.5-7 5.6.4GPS Antenna Connector Removal (For GPS Models Only).5-12 5.6.5Option Board Removal (For Option Board Models Only) .5-14 5.6.6Disassembly of Colour Display Control Head.5-15 5.6.7Disassembly of Numeric Display Control Head.5-20 5.7Radio Reassembly Detailed.5-23 5.7.1Colour Display Control Head.5-23 5.7.2Numeric Display Control Head .5-28 5.7.3Radio Assembly.5-33 5.7.4Thermal Pad Replacement Procedure .5-34 5.7.5Transceiver Board Reassembly.5-36 5.7.6GPS Plug or GPS Antenna Connector Reassembly .5-44 5.7.7Option Board Reassembly (For Option Board Models Only).5-49 5.7.8Assemble Control Head to Radio Assembly.5-51 5.8Exploded Mechanical Views and Parts Lists .5-53 5.8.1Radio Assembly Exploded View and Parts List .5-53 5.8.2Control Head Exploded Views and Parts Lists.5-55 5.9Torque Chart.5-57 Table of Contentsvii Chapter 6Basic Troubleshooting. 6-1 6.1Introduction.6-1 6.1.1High Power RF Precaution.6-1 6.2Replacement Service Kit Procedures.6-1 6.3Power-Up Error Codes .6-2 6.4Operational Error Codes.6-2 Appendix AEMEA Regional Warranty, Service and Support.A-1 A.1Warranty and Service Support.A-1 A.1.1Warranty Period and Return Instructions .A-1 A.1.2After Warranty Period.A-1 A.2European Radio Support Centre (ERSC).A-2 A.3Piece Parts .A-2 A.4Technical Support.A-3 A.5Further Assistance From Motorola .A-3 Appendix BLimited Level 3 Servicing.B-1 B.1Maintenance .B-1 B.2Component Location and Parts List.B-1 Glossary.Glossary-1 viiiList of Figures List of Figures Figure 1-1Radio Control Head (Colour Display Model).1-2 Figure 1-2Radio Control Head (Numeric Display Model) .1-3 Figure 1-3Mobile Radio Model Numbering Scheme.1-4 Figure 2-1Mobile Front Programming Cable HKN6184_.2-3 Figure 2-2Mobile rotate counterclockwise to decrease volume level. Push knob to activate channel function; rotate clockwise and counterclockwise to select channel. LED INDICATORS Red, yellow and green light-emitting diodes indicate operating status. LCD (Liquid Crystal Display) 160 x72 display provides visual information about many radio features. OK/MENU BUTTON One button to provide menu navigation and selection interface. PROGRAMMABLE BUTTONS Four buttons are field programmable using the CPS. SCROLL UP/DOWN BUTTONS Press buttons to scroll. RETURN/HOME BUTTON One button which quickly brings you to the home page. Scroll Up/Down LCD Screen Volume/Channe