PROFESSIONAL DIGITAL TWO-WAY RADIOS

MOTOTRBOTM
DEMTM 300 NUMERIC DISPLAY MOBILE
DEMTM 400 ALPHANUMERIC DISPLAY MOBILE

BASIC SERVICE
MANUAL

DEM 400
 i

Foreword
This manual covers all DEM™ 300/DEM™ 400 Mobiles, 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,
Motorola Authorized Dealers, self-maintained customers, and distributors.

These servicing instructions are for use by qualified personnel only. To

! reduce the risk of electric shock, do not perform any servicing other than
Caution that contained in the Operating Instructions unless you are qualified to do
so. Refer all servicing to qualified service personnel.

Product Safety and RF Exposure Compliance

ATTENTION!

Before using the mobile two-way product, DEM™ 300/DEM™ 400, read the RF Energy Exposure and
Safety guide that ships with the radio which contains important operating instructions for safe usage
and RF energy awareness and control for Compliance with applicable Standards and Regulations.

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, 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 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.
© 2013 Motorola Solutions, Inc. All rights reserved.
ii

Notes
 iii

Document History

The following major changes have been implemented in this manual since the previous edition.

Edition Description Date

68009626001-A Initial Release. June 2013

68009626001-B Changed warranty of DEM 300/DEM 400 mobile August 2013

radios to two (2) years.
iv

Notes
Table of Contents v

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

Commercial Warranty ...................................................................................xi

Limited Warranty ........................................................................................................................................xi
MOTOROLA COMMUNICATION PRODUCTS ..............................................................................xi
I. What This Warranty Covers And For How Long .....................................................................xi
II. General Provisions .................................................................................................................xi
III. State Law Rights (Applicable Only in U.S.A.)....................................................................... xii
IV. How To Get Warranty Service ............................................................................................. xii
V. What This Warranty Does Not Cover.................................................................................... xii
VI. Patent And Software Provisions ......................................................................................... xiii
VII. Governing Law................................................................................................................... xiii

Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.3 Control Head Description............................................................................................................. 1-2
1.3.1 Control Head Controls (Alphanumeric Display Model) .................................................... 1-2
1.3.2 Control Head Controls (Numeric Display Model)............................................................. 1-3
1.4 MOTOTRBO Mobile Radio Model Numbering Scheme............................................................... 1-4
1.5 VHF High Power (136–174 MHz) Model Chart ........................................................................... 1-5
1.6 VHF Low Power (136–174 MHz) Model Chart ........................................................................... 1-5
1.7 UHF1 High Power (403–470 MHz) Model Chart ........................................................................ 1-6
1.8 UHF1 Low Power (403–470 MHz) Model Chart ........................................................................ 1-6
1.9 Specifications .............................................................................................................................. 1-7

Chapter 2 Test Equipment and Service Aids ..................................... 2-1

2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids ................................................................................................................................. 2-2
2.3 Programming Cable ..................................................................................................................... 2-3
2.4 Test Cable ................................................................................................................................... 2-3
2.5 Accessory Cable .......................................................................................................................... 2-4
vi Table of Contents

Chapter 3 Transceiver Performance Testing ..................................... 3-1

3.1 General ........................................................................................................................................ 3-1
3.2 Setup............................................................................................................................................ 3-1
3.3 Alphanumeric Display Model Test Mode ..................................................................................... 3-2
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-2
3.3.2 RF Test Mode .................................................................................................................. 3-2
3.3.3 Alphanumeric Display Test Mode .................................................................................... 3-3
3.3.4 LED Test Mode................................................................................................................ 3-3
3.3.5 Backlight Test Mode ........................................................................................................ 3-3
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-3
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-3
3.3.8 Audio Loopback Test Mode ............................................................................................. 3-3
3.3.9 Audio Loopback Earpiece Test Mode.............................................................................. 3-4
3.3.10 Button Test Mode ............................................................................................................ 3-4
3.4 Numeric Display Model Test Mode .............................................................................................. 3-4
3.4.1 Entering Display Radio Test Mode .................................................................................. 3-4
3.4.2 RF Test Mode .................................................................................................................. 3-4
3.4.3 Display Test Mode ........................................................................................................... 3-4
3.4.4 LED Test Mode................................................................................................................ 3-5
3.4.5 Speaker Tone Test Mode ................................................................................................ 3-5
3.4.6 Earpiece Tone Test Mode ............................................................................................... 3-5
3.4.7 Audio Loopback Test Mode ............................................................................................. 3-5
3.4.8 Audio Loopback Earpiece Test Mode.............................................................................. 3-5
3.4.9 Button Test Mode ............................................................................................................ 3-5

Chapter 4 Radio Programming and Tuning ....................................... 4-1

4.1 Introduction .................................................................................................................................. 4-1
4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 AirTracer Application Tool............................................................................................................ 4-2
4.4 Radio Tuning Setup ..................................................................................................................... 4-2

Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1

5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
5.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
5.4 Repair Procedures and Techniques – General............................................................................ 5-4
5.5 Disassembling and Reassembling the Radio – General.............................................................. 5-5
5.6 Radio Disassembly – Detailed ..................................................................................................... 5-5
5.6.1 Control Head Removal .................................................................................................... 5-5
5.6.2 Top Cover Removal......................................................................................................... 5-6
5.6.3 Transceiver Board Removal ............................................................................................ 5-7
5.6.4 Disassembly of Alphanumeric Display Control Head .................................................... 5-11
5.6.5 Disassembly of Numeric Display Control Head ............................................................. 5-15
5.7 Radio Reassembly – Detailed.................................................................................................... 5-18
5.7.1 Reassembly of Alphanumeric Display Control Head ..................................................... 5-18
5.7.2 Reassembly of Numeric Display Control Head.............................................................. 5-22
5.7.3 Radio Assembly............................................................................................................. 5-26
Table of Contents vii

5.7.4 Thermal Pad Replacement Procedure .......................................................................... 5-27

5.7.5 Transceiver Board Reassembly .................................................................................... 5-31
5.7.6 Assemble Control Head to Radio Assembly.................................................................. 5-39
5.8 Exploded Mechanical Views and Parts Lists ............................................................................. 5-40
5.8.1 Radio Assembly Exploded View and Parts List ............................................................ 5-40
5.8.2 Control Head Exploded Views and Parts Lists .............................................................. 5-42
5.9 Torque Chart.............................................................................................................................. 5-44

Chapter 6 Basic Troubleshooting ....................................................... 6-1

6.1 Introduction .................................................................................................................................. 6-1
6.1.1 High Power RF Precaution .............................................................................................. 6-1
6.2 Replacement Service Kit Procedures .......................................................................................... 6-1
6.3 Power-Up Error Codes ................................................................................................................ 6-2

Chapter 7 Accessories ......................................................................... 7-1

7.1 Introduction .................................................................................................................................. 7-1
7.1.1 Antennas ......................................................................................................................... 7-1
7.1.2 Audio ............................................................................................................................... 7-2
7.1.3 Cables ............................................................................................................................. 7-2
7.1.4 Mounting Kits................................................................................................................... 7-2
7.1.5 Miscellaneous Accessories ............................................................................................. 7-3
7.1.6 Service Tools................................................................................................................... 7-3

Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information ..........................................................................................................A-1
A.2 Motorola Online ...........................................................................................................................A-1

Appendix B Motorola Service Centers...................................................B-1

B.1 Servicing Information ...................................................................................................................B-1
B.2 Motorola Solutions de México, S.A. .............................................................................................B-1
B.3 Motorola Solutions de Colombia, Ltda. ........................................................................................B-1

Appendix C Limited Level 3 Servicing ...................................................C-1

C.1 Maintenance ................................................................................................................................C-1
C.2 Component Location and Parts List.............................................................................................C-1

Glossary ......................................................................................... Glossary-1

viii List of Figures

List of Figures

Figure 1-1 Radio Control Head (Alphanumeric Display Model)............................................................. 1-2

Figure 1-2 Radio Control Head (Numeric Display Model) ..................................................................... 1-3
Figure 1-3 Mobile Radio Model Numbering Scheme............................................................................. 1-4
Figure 2-1 Front Telco MMP USB Programming Cable PMKN4147_ ................................................... 2-3
Figure 2-2 Back 20 Pin MAP Test Cable PMKN4150_ .......................................................................... 2-3
Figure 2-3 Back 16 Pin MAP Universal Cable PMKN4151_ ................................................................. 2-4
Figure 4-1 Customer Programming Software Setup from Front Connector .......................................... 4-1
Figure 4-2 Radio Tuning Equipment Setup ........................................................................................... 4-2
Figure 5-1 Typical Control Head Removal............................................................................................. 5-5
Figure 5-2 Flexible Connection Removal .............................................................................................. 5-6
Figure 5-3 Top Cover Removal (Image May Not Match Exact Product)................................................ 5-6
Figure 5-4 Die Cast Main Shield Removal ............................................................................................ 5-7
Figure 5-5 PA Screw Removal............................................................................................................... 5-8
Figure 5-6 Accessory Connector Removal ............................................................................................ 5-8
Figure 5-7 DC Cable Removal .............................................................................................................. 5-9
Figure 5-8 RF Connector Nut Removal ................................................................................................. 5-9
Figure 5-9 Transceiver Board Removal............................................................................................... 5-10
Figure 5-10 Control Head Flex Removal ............................................................................................... 5-11
Figure 5-11 Speaker Tape Removal ...................................................................................................... 5-11
Figure 5-12 Keypad Assembly Removal ............................................................................................... 5-12
Figure 5-13 Speaker Removal............................................................................................................... 5-12
Figure 5-14 PCB Removal..................................................................................................................... 5-13
Figure 5-15 Indicator Barrier Removal .................................................................................................. 5-13
Figure 5-16 LCD and LCD Flex Removal .............................................................................................. 5-14
Figure 5-17 Control Head Flex Removal ............................................................................................... 5-15
Figure 5-18 Speaker Tape Removal ...................................................................................................... 5-15
Figure 5-19 Keypad Assembly Removal ............................................................................................... 5-16
Figure 5-20 Speaker Removal............................................................................................................... 5-16
Figure 5-21 PCB Removal..................................................................................................................... 5-17
Figure 5-22 Indicator Barrier Removal .................................................................................................. 5-17
Figure 5-23 LCD Display Assembly....................................................................................................... 5-18
Figure 5-24 Indicator Barrier Assembly ................................................................................................. 5-18
Figure 5-25 Speaker Assembly ............................................................................................................. 5-19
Figure 5-26 Assembling PCB to Keypad ............................................................................................... 5-19
Figure 5-27 Speaker Connection ........................................................................................................... 5-20
Figure 5-28 Assembling Keypad to Control Head Housing ................................................................... 5-20
Figure 5-29 Assembling Speaker Tape to PCB ..................................................................................... 5-21
Figure 5-30 Assembling Control Head Flex to Control Head Board ...................................................... 5-21
Figure 5-31 Indicator Barrier Assembly ................................................................................................. 5-22
Figure 5-32 Assembling Speaker to Keypad ......................................................................................... 5-22
Figure 5-33 Assembling PCB to Keypad ............................................................................................... 5-23
Figure 5-34 Speaker Connection ........................................................................................................... 5-23
Figure 5-35 Assembling Keypad to Control Head Housing ................................................................... 5-24
Figure 5-36 Assembling Speaker Tape to PCB ..................................................................................... 5-24
Figure 5-37 Assembling Control Head Flex to Control Head Board ...................................................... 5-25
Figure 5-38 Thermal Pads and Shield Gasketing on Chassis and Die Cast Main Shield ..................... 5-26
Figure 5-39 Chassis with Thermal Pads................................................................................................ 5-26
Figure 5-40 Replacing Regulator Thermal Pads ................................................................................... 5-27
Figure 5-41 Replacing Audio PA Thermal Pad ...................................................................................... 5-28
Figure 5-42 Replacing Final Driver Thermal Pad .................................................................................. 5-29
List of Figures ix

Figure 5-43 Replacing PCB Thermal Pad ............................................................................................. 5-30

Figure 5-44 Applying Thermal Grease .................................................................................................. 5-31
Figure 5-45 Placing the Transceiver Board in the Chassis ................................................................... 5-31
Figure 5-46 Inserting RF Lock Washer and Nut .................................................................................... 5-32
Figure 5-47 Screw Sequence to Compress PCB .................................................................................. 5-32
Figure 5-48 Installing PA Screws........................................................................................................... 5-33
Figure 5-49 Screw Removal .................................................................................................................. 5-33
Figure 5-50 Inserting Accessory Connector .......................................................................................... 5-34
Figure 5-51 Assembling Die Cast Main Shield onto Chassis ................................................................ 5-34
Figure 5-52 Screw Sequence to Tighten Die Cast Main Shield ............................................................ 5-35
Figure 5-53 RF Connector Nut Final Torque ......................................................................................... 5-35
Figure 5-54 Installing DC Cable Assembly............................................................................................ 5-36
Figure 5-55 Inspection of Cover Assembly with Seal ............................................................................ 5-37
Figure 5-56 Assembling Cover onto Chassis ........................................................................................ 5-37
Figure 5-57 Rear Latch in Secure Position ........................................................................................... 5-38
Figure 5-58 MAP Connector Cover Installation ..................................................................................... 5-38
Figure 5-59 Assemble Control Head to Chassis ................................................................................... 5-39
Figure 5-60 Flex Connection Connector ............................................................................................... 5-39
Figure 5-61 Radio Assembly Exploded View ........................................................................................ 5-40
Figure 5-62 Alphanumeric Display Control Head Exploded View ......................................................... 5-42
Figure 5-63 Numeric Display Control Head Exploded View .................................................................. 5-43
Figure C-1 PCB Top Side View ..............................................................................................................C-1
x List of Tables

List of Tables

Table 1-1 Radio Frequency Ranges and Power Levels ....................................................................... 1-1
Table 2-1 Recommended Test Equipment ........................................................................................... 2-1
Table 2-2 Service Aids ......................................................................................................................... 2-2
Table 2-3 Wire Diagram for PMKN4150_ ............................................................................................ 2-3
Table 2-4 Wire Diagram for PMKN4151_ ............................................................................................ 2-4
Table 3-1 Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2 Front Panel Access Test Mode Displays .............................................................................. 3-2
Table 3-3 Test Environments................................................................................................................ 3-6
Table 3-4 Test Channel Spacing .......................................................................................................... 3-6
Table 3-5 Test Frequencies ................................................................................................................ 3-6
Table 3-6 Transmitter Performance Checks......................................................................................... 3-7
Table 3-7 Receiver Performance Checks ............................................................................................ 3-8
Table 4-1 Radio Software Program Kit................................................................................................. 4-1
Table 5-1 Lead Free Solder Wire Part Number List ............................................................................. 5-4
Table 5-2 Lead Free Solder Paste Part Number List ........................................................................... 5-4
Table 5-3 Radio Exploded View Parts List ......................................................................................... 5-41
Table 5-4 Alphanumeric Display Control Head (PMLN6320_) Exploded View Parts List .................. 5-42
Table 5-5 Numeric Display Control Head (PMLN6321_) Exploded View Parts List........................... 5-43
Table 5-6 Torque Specifications for Nuts and Screws ........................................................................ 5-44
Table 6-1 Power-Up Error Codes ......................................................................................................... 6-2
Table C-1. Component Parts List.......................................................................................................... C-1
Commercial Warranty xi

Commercial Warranty

Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

MOTOROLA SOLUTIONS, INC. (“MOTOROLA”) warrants the MOTOROLA manufactured
Communication Products listed below (“Product”) against defects in material and workmanship
under normal use and service for a period of time from the date of purchase as scheduled below:

DEM 300/DEM 400 Mobile Radios Two (2) Years

Product Accessories One (1) Year

Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.
This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.
MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.

II. General Provisions

This warranty sets forth the full extent of MOTOROLA's responsibilities regarding the Product.
Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive
remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR
DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE
DISCLAIMED BY LAW.
xii Commercial Warranty

III. State Law Rights (Applicable Only in U.S.A.)

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.
This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.

IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also open a
Contact Us case on Motorola Online (https://businessonline.motorolasolutions.com).

V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs
(including, without limitation, the addition to the Product of non-Motorola supplied equipment)
which adversely affect performance of the Product or interfere with Motorola's normal
warranty inspection and testing of the Product to verify any warranty claim.
F. Product which has had the serial number removed or made illegible.
G. Freight costs to the repair depot.
H. A Product which, due to illegal or unauthorized alteration of the software/firmware in the
Product, does not function in accordance with MOTOROLA’s published specifications or the
FCC type acceptance labeling in effect for the Product at the time the Product was initially
distributed from MOTOROLA.
I. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
J. Normal and customary wear and tear.
Commercial Warranty xiii

VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:
A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such
claim;
B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its
settlement or compromise; and
C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the
subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to
continue using the Product or parts or to replace or modify the same so that it becomes
noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and
accept its return. The depreciation will be an equal amount per year over the lifetime of the
Product or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.

VII. Governing Law

This Warranty is governed by the laws of the State of Illinois, USA.
xiv Commercial Warranty

Notes
Chapter 1 Introduction

1.1 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.

! CAUTION indicates a potentially hazardous situation which, if

not avoided, might result in equipment damage.
Caution

1.2 Radio Description

The DEM™ 300/DEM™ 400 mobile radios are available in the following frequency ranges and power
levels.

Table 1-1 Radio Frequency Ranges and Power Levels

Freq. Band Bandwidth Power Level

VHF 136–174 MHz 1–25 Watts

25–45 Watts

UHF B1 403–470 MHz 1–25 Watts

25–40 Watts

These 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 solution.
1-2 Introduction: Control Head Description

1.3 Control Head Description

The control head used with the radio has logic circuitry that operates the standard and optional
features built into the system.
The following illustrations show the typical radio control heads.

LED Channel Changing

Indicators Rocker

Power Button Volume Changing

Rocker

LCD Screen

OK/Menu Button Speaker

Programmable Buttons
Accessory Connector
Return/Home Button

Figure 1-1 Radio Control Head (Alphanumeric Display Model)

1.3.1 Control Head Controls (Alphanumeric Display Model)

• POWER BUTTON – Turns the radio on and off.
• VOLUME CHANGING ROCKER – Press top side to increment or bottom side to decrement the
volume.
• CHANNEL CHANGING ROCKER – Press top side to increment or bottom side to decrement
the channel.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LCD (Liquid Crystal Display) – 132x36 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.
• RETURN/HOME BUTTON – One button which quickly brings you to the home page.
Introduction: Control Head Description 1-3

LED
Indicators Channel Changing
Rocker
Power Button Volume Changing
Rocker
LED Display

Speaker
Accessory Connector
Programmable Buttons

Figure 1-2 Radio Control Head (Numeric Display Model)

1.3.2 Control Head Controls (Numeric Display Model)

• POWER BUTTON – Turns the radio on and off.
• VOLUME CHANGING ROCKER – Press top side to increment or bottom side to decrement the
volume.
• CHANNEL CHANGING ROCKER – Press top side to increment or bottom side to decrement
the channel.
• LED INDICATORS – Red, yellow and green light-emitting diodes indicate operating status.
• LED NUMERIC DISPLAY – Two digit numeric display.
• PROGRAMMABLE BUTTONS – Two buttons are field programmable using the CPS.
1-4 Introduction: MOTOTRBO Mobile Radio Model Numbering Scheme

1.4 MOTOTRBO Mobile Radio Model Numbering Scheme

Model No.Example : LA M 0 1 Q P H 9 J C 1 A N

Position : 1 2 3 4 5 6 7 8 9 10 11 12

Unique Variations
AZ: Asia N: Standard Package
LA: Latin America
AA: North America (except Mexico)
MD: Europe/Middle East/ Version Letter
Africa/Australia
Mobile
Feature Level
1: Mini-U (Mobile)
MOTOTRBO Mobile 2: BNC (Mobile)
DEM 300/400 : 01
Primary System Type
Band A: Conventional
J : 136–174 MHz B: Trunking
M : 217–222 MHz Power Level C: Analog Only
P : 300–400 MHz N: 1–25W
Q : 403–470 MHz P: 25–40W
T : 450–527 MHz Q: 25–45W Primary Operation
X : 450–520 MHz R: 1–40W J: Basic (No GPS, No Bluetooth)
U : 806–941 MHz M: 10–35W K: GPS and Bluetooth
V : 806–870 MHz L: GPS Only
Physical Packages M: Bluetooth Only
C: Low Tier (Numeric Display)
H: Mid Tier (Alphanumeric Display) Channel Information
9: Variable/Programmable
Channel Spacing

Figure 1-3 Mobile Radio Model Numbering Scheme

Introduction: VHF High Power (136–174 MHz) Model Chart 1-5

1.5 VHF High Power (136–174 MHz) Model Chart

VHF 136–174 MHz 25–45W, Mini-U
Model Description
LAM01JQC9JC1_N 136–174 MHz, 25–45W, MOTOTRBO DEM 300 Numeric Display Mobile
(Analog Only)
LAM01JQC9JA1_N 136–174 MHz, 25–45W, MOTOTRBO DEM 300 Numeric Display Mobile
LAM01JQH9JC1_N 136–174 MHz, 25–45W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile (Analog Only)
LAM01JQH9JA1_N 136–174 MHz, 25–45W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile
Item Description
X X X X PMUD3237_S *Service Kit, VHF, 25–45W
X X PMLN6321_ Numeric Display Model Control Head
X X PMLN6320_ Alphanumeric Display Model Control Head
X X X X 68009623001 Mobile Quick Reference Guide and Safety Booklet
X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1.6 VHF Low Power (136–174 MHz) Model Chart

VHF 136–174 MHz 1–25W, Mini-U
Model Description
LAM01JNC9JC1_N 136–174 MHz, 1–25W, MOTOTRBO DEM 300 Numeric Display Mobile
(Analog Only)
LAM01JNC9JA1_N 136–174 MHz, 1–25W, MOTOTRBO DEM 300 Numeric Display Mobile
LAM01JNH9JC1_N 136–174 MHz, 1–25W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile (Analog Only)
LAM01JNH9JA1_N 136–174 MHz, 1–25W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile
Item Description
X X X X PMUD3233_S *Service Kit, VHF, 1–25W
X X PMLN6321_ Numeric Display Model Control Head
X X PMLN6320_ Alphanumeric Display Model Control Head
X X X X 68009623001 Mobile Quick Reference Guide and Safety Booklet
X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
1-6 Introduction: UHF1 High Power (403–470 MHz) Model Chart

1.7 UHF1 High Power (403–470 MHz) Model Chart

UHF1 403–470 MHz 25–40W, Mini-U
Model Description
LAM01QPC9JC1_N 403–470 MHz, 25–40W, MOTOTRBO DEM 300 Numeric Display Mobile
(Analog Only)
LAM01QPC9JA1_N 403–470 MHz, 25–40W, MOTOTRBO DEM 300 Numeric Display Mobile
LAM01QPH9JC1_N 403–470 MHz, 25–40W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile (Analog Only)
LAM01QPH9JA1_N 403–470 MHz, 25–40W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile
Item Description
X X X X PMUE4156_S *Service Kit, UHF1, 25–40W
X X PMLN6321_ Numeric Display Model Control Head
X X PMLN6320_ Alphanumeric Display Model Control Head
X X X X 68009623001 Mobile Quick Reference Guide and Safety Booklet
X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

1.8 UHF1 Low Power (403–470 MHz) Model Chart

UHF1 403–470 MHz 1–25W, Mini-U
Model Description
LAM01QNC9JC1_N 403–470 MHz, 1–25W, MOTOTRBO DEM 300 Numeric Display Mobile
(Analog Only)
LAM01QNC9JA1_N 403–470 MHz, 1–25W, MOTOTRBO DEM 300 Numeric Display Mobile
LAM01QNH9JC1_N 403–470 MHz, 1–25W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile (Analog Only)
LAM01QNH9JA1_N 403–470 MHz, 1–25W, MOTOTRBO DEM 400 Alphanumeric Display
Mobile
Item Description
X X X X PMUE4160_S *Service Kit, UHF1, 1–25W
X X PMLN6321_ Numeric Display Model Control Head
X X PMLN6320_ Alphanumeric Display Model Control Head
X X X X 68009623001 Mobile Quick Reference Guide and Safety Booklet
X = Item Included
* = Service Kit is the main board only
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
Introduction: Specifications 1-7

1.9 Specifications
General

Specification VHF UHF1

Model: Numeric Alphanumeric Numeric Alphanumeric

Display Display Display Display

Channel Capacity: 16 64 16 64

Typical RF Output:
Low Power 1–25 W 1–25 W
High Power 25–45 W 25–40 W

Frequency Range: 136–174 MHz 403–470 MHz

Dimensions: (HxWxL) 1.7 x 6.7 x 5.3 in

(44 x 169 x 134 mm)

Weight: 2.9 lbs. (1.3 kg)

Current Drain:
Standby 0.81 A max
Rx @ rated audio 2 A max
Transmit 1–25 W: 11.0 A max
25–40 W: 14.5 A max
25–45 W: 14.5 A max

FCC Description: 1–25 W: 1–25 W:

ABZ99FT3090 ABZ99FT4092
25–45 W: 25–40 W:
ABZ99FT3091 ABZ99FT4093
1-8 Introduction: Specifications

Receiver

Specification VHF UHF1

Model: Numeric Alphanumeric Numeric Alphanumeric

Display Display Display Display

Frequencies: 136–174 MHz 403–470 MHz

Channel Spacing: 12.5 kHz/25 kHz

Frequency
Stability: ±0.5 ppm
(-30°C, +60°C, +25°C
Ref)

Analog Sensitivity 0.3 µV

(12 dB SINAD): 0.22 µV (typical)

Digital Sensitivity: 0.25 µV

(5% BER) 0.19 µV (typical)

Intermodulation
TIA603D: 75 dB 70 dB

Adjacent Channel
Selectivity
TIA603D: 50 dB @ 12.5 kHz, 50 dB @ 12.5 kHz,
75 dB @ 25 kHz 70 dB @ 25 kHz

Spurious
Rejection
TIA603D: 75 dB 70 dB

Rated Audio: 4 W (Internal)

7.5 W (External – 8 ohms)
13 W (External – 4 ohms)

Audio Distortion @ 3% (typical)

Rated Audio:

Hum and Noise: -40 dB @ 12.5 kHz

-45 dB @ 25 kHz

Audio Response: TIA603D

Conducted
Spurious Emission -57 dBm
(TIA603D):
Introduction: Specifications 1-9

Transmitter

Specification VHF UHF1

Model: Numeric Alphanumeric Numeric Alphanumeric

Display Display Display Display

Frequencies: 136–174 MHz 403–470 MHz

Channel Spacing: 12.5 kHz/25 kHz

Frequency
Stability: ±0.5 ppm
(-30°C, +60°C, +25°C
Ref)

Power Output:
Low Power 1–25 W 1–25 W
High Power 25–45 W 25–40 W

Modulation ±2.5 kHz @ 12.5 kHz

Limiting: ±5.0 kHz @ 25 kHz

FM Hum and Noise: -40 dB @ 12.5 kHz

-45 dB @ 25 kHz

Conducted/ -36 dBm <1 GHz

Radiated -30 dBm >1 GHz
Emission:

Adjacent 60 dB @ 12.5 kHz

Channel Power 70 dB @ 25 kHz
(TIA603D):

Audio Response: TIA603D

Audio Distortion: 3%

FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E

4FSK Digital 12.5 kHz Data: 7K60F1D & 7K60FXD

Modulation 12.5 kHz Voice: 7K60F1E & 7K60FXE
Combination of 12.5 kHz Voice & Data: 7K60F1W

Digital Vocoder Type: AMBE+2™

Digital Protocol: ETSI TS 102 361-1

ETSI TS 102 361-2
ETSI TS 102 361-3
1-10 Introduction: Specifications

Self-Quieter

VHF UHF1

153.6 MHz +/- 10 kHz 422.4 MHz

172.8 MHz +/- 10 kHz –

Military Standards 810C, D, E, F & G

MIL-STD 810C MIL-STD 810D MIL-STD 810E MIL-STD 810F MIL-STD 810G
Method Proc./Cat Method Proc./Cat Method Proc./Cat Method Proc./Cat Method Proc./Cat
Low 500.1 I 500.2 II 500.3 II 500.4 II 500.5 II
Pressure
High 501.1 I, II 501.2 I/A1, 501.3 I/A, 501.4 I/HOT, 501.5 I/AI, II
Temperature II/A1 II/AI II/HOT
Low 502.1 I 502.2 I/C3, 502.3 I/C3, 502.4 I/C3, 502.5 I/C3, II
Temperature II/C1 II/C1 II/C1
Temperature 503.1 – 503.2 I/A1/C3 503.3 I/AI/C3 503.4 I 503.5 I/C
Shock
Solar 505.1 II 505.2 I 505.3 I 505.4 I 505.5 I/A1
Radiation
Rain 506.1 I, II 506.2 I, II 506.3 I, II 506.4 I, III 506.5 I, III
Humidity 507.1 II 507.2 II 507.3 II 507.4 – 507.5 II - Aggra-
vated
Salt Fog 509.1 – 509.2 – 509.3 – 509.4 – 509.5 –
Dust 510.1 I 510.2 I 510.3 I 510.4 I 510.5 I
Vibration 514.2 VIII/F, 514.3 I/10, 514.4 I/10, 514.5 I/24 514.6 I/24
Curve-W II/3 II/3
Shock 516.2 I, II 516.3 I, IV 516.4 I, IV 516.5 I, IV 516.6 I, IV,
V, VI
Introduction: Specifications 1-11

Environmental Specifications

Operating Temperature -30°C / +60°C

Storage Temperature -40°C / +85°C
Thermal Shock Per MIL-STD
Humidity Per MIL-STD
ESD IEC 61000-4-2 Level 3
Dust and Water Intrusion IP54, MIL-STD*
Packaging Test Per MIL-STD

*Radio meets IP54 and MIL-STD rating with microphone sealing boot and rear accessory connector cover
properly installed.
Specifications subject to change without notice. All specifications shown are typical.
Radio meets applicable regulatory requirements. Version 1 05/13
1-12 Introduction: Specifications

Notes
Chapter 2 Test Equipment and Service Aids

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 mobile radios.

Table 2-1 Recommended Test Equipment

Equipment Characteristic Example Application

Service Monitor Can be used as a Aeroflex 3920 or equivalent Frequency/deviation meter and
substitute for items signal generator for wide-range
marked with an asterisk troubleshooting and alignment
(*)

Digital RMS 100 µV to 300 V Fluke 179 or equivalent AC/DC voltage and current
Multimeter* 5 Hz to 1 MHz (www.fluke.com) measurements. Audio voltage
10 Mega Ohm measurements.
Impedance

RF Signal 100 MHz to 1 GHz Agilent N5181 Receiver measurements

Generator* -130 dBM to +10 dBM (www.agilent.com) or equivalent
FM Modulation 0 kHz to
10 kHz

Oscilloscope* 2 Channels Tektronix TDS1001b Waveform measurements

50 MHz Bandwidth (www.tektronix.com) or
5 mV/div to 20 V/div equivalent

Power Meter and 5% Accuracy Bird 43 Thruline Watt Meter Transmitter power output
Sensor* 100 MHz to 500 MHz (www.bird-electronic.com) or measurements
50 Watts equivalent

RF Millivolt Meter 100 mV to 3 V RF Boonton 92EA RF level measurements

10 kHz to 1 GHz (www.boonton.com) or
equivalent

Power Supply 0 V to 32 V B&K Precision 1790 Voltage supply

0 A to 20 A (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
Description Application
Part Number

RLN4460_ Test Box Enables connection to audio/accessory jack. Allows

switching for radio testing.

Not Applicable *Customer Programming Allows servicer to program radio parameters, tune and
Software troubleshoot radios.

PMKN4147_ Front Telco MMP USB Connects the radio’s front connector to a USB port for
Programming Cable radio programming and data applications.

PMKN4150_ Back 20 Pin MAP Test Cable Connects the radio’s rear connector for testing. Must
use in conjunction with PMKN4147_ (Front Telco MMP
USB Programming Cable) for radio programming and
alignment.

PMKN4151_ Back 16 Pin MAP Universal Connects the radio’s rear connector to the center 16
Cable pins with unterminated connectors at the user end.

HPN4007_ Power Supply Provides the radio with power when bench testing.

PMEN4041_ Chassis Eliminator Kit Test Fixture used to bench test the radio PCB.

6686119B01 Control Head Dismantling Tool Assists in the removal of radio control head.

66012020001 RFIC (U0000) Repair Stencil Fixture to screen solder paste onto the IC leads for
replacement.

*This kit cannot be purchased. It can be downloaded from https://businessonline.motorolasolutions.com

Test Equipment and Service Aids: Programming Cable 2-3

2.3 Programming Cable

Figure 2-1 Front Telco MMP USB Programming Cable PMKN4147_

2.4 Test Cable

20 19

14

1
1
14
2 1

16 15

25

13

13
25
18 17

Figure 2-2 Back 20 Pin MAP Test Cable PMKN4150_

Table 2-3 Wire Diagram for PMKN4150_

WIRE DIAGRAM
20 PIN
ACCESSORY PORT CONNECTOR
WIRE COLOR DB25P

PIN
DESCRIPTION -- --
No.

1 SPEAKER - ORANGE 2&7

2 EXT MIC GREY 10 & 15

GPI_1
3 PINK 20
(EXT PTT)
5 FLAT TX YELLOW 18

7 GROUND BLACK 16

15 RSSI BROWN 19

16 SPEAKER + PURPLE 1&5

2-4 Test Equipment and Service Aids: Accessory Cable

2.5 Accessory Cable

PIN POSITION

2 1

16 15

Figure 2-3 Back 16 Pin MAP Universal Cable PMKN4151_

Table 2-4 Wire Diagram for PMKN4151_

WIRE DIAGRAM
16 PIN WIRE LEAD 16 PIN WIRE LEAD
WIRE COLOR WIRE COLOR
CONNECTOR SIDE CONNECTOR SIDE
1 BLACK NC 9 PURPLE NC
2 WHITE NC 10 GREY NC
3 GREEN NC 11 PINK NC
4* YELLOW / DRAIN WIRE NC * 12 WHT / BLK NC
5 ORANGE NC 13 WHT / BRN NC
6 BLUE NC 14 WHT / RED NC
7 BROWN NC 15 WHT / ORG NC
8 RED NC 16 WHT / GRN NC

(*) NOTE: CRIMP YELLOW WIRE AND DRAIN WIRE TO TERMINAL ON 26 PIN CONNECTOR.
TIN YELLOW WIRE AND DRAIN WIRE TOGETHER ON WIRE LEAD SIDE.
Chapter 3 Transceiver Performance Testing

3.1 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.

3.2 Setup
Supply voltage is provided using a 13.8 VDC power supply. (Note: applying 13.8 VDC at the DC
power cable will ensure a minimum of 13.2 VDC at the DC connector of the radio). The equipment
required for alignment procedures is shown in the Radio Tuning Equipment Setup Diagram,
Figure 4-2.

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 Channel Spacing
3-5 Test Frequencies
3-6 Transmitter Performance Checks
3-7 Receiver Performance Checks

Table 3-1 Initial Equipment Control Settings

Service Monitor Power Supply Test Set

Monitor Mode: Power Monitor Voltage: 13.8 VDC Speaker set: A

RF Attenuation: -70 DC On/Standby: Speaker/load:

Standby Speaker

AM, CW, FM: FM Volt Range: 20 V PTT: OFF

Oscilloscope Source: Mod Current: 20 A

Oscilloscope Horizontal: 10 mSec/Div
Oscilloscope Vertical: 2.5 kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor Bandwidth: Narrow
Monitor Squelch: middle setting
Monitor Vol: 1/4 setting
3-2 Transceiver Performance Testing: Alphanumeric Display Model Test Mode

3.3 Alphanumeric Display Model Test Mode

3.3.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within ten seconds after self test is complete, press button P2, five times in succession.
3. 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 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 Top Navigation Button () is
pressed before the last information display, the radio shall suspend the information display
until the user presses Bottom Navigation Button ( ) 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 (“CSQ CHXX SP25”). The default test environment is CSQ.
1. Each short press of button P2 changes the test environment
(CSQ->TPL->DIG->USQ->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 environment are analog mode as described in
Table 3-3.
2. Each short press of button P1 toggles the channel spacing between 20 kHz, 25 kHz and
12.5 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.
Transceiver Performance Testing: Alphanumeric Display Model Test Mode 3-3

3. Pressing of the Channel Changing Rocker changes the test channel from 1 to 14. Press the
top side to increase or bottom side to decrease the channel number. The radio beeps in each
position. The channel test frequencies are described in Table 3-5.

3.3.3 Alphanumeric Display Test Mode

1. Press and hold button P1 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 press, the radio fills up the screen 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 9–16) is completely filled.
4. When the screen is filled up with the horizontal lines, any button press clears the screen and
displays vertical lines at column 0, 6, 12, 18, 24, 30, 36, 42, 48, 54, 60. Any button press fills
the screen with vertical lines, (1 line to the right of all existing lines) until the display is filled.

3.3.4 LED Test Mode

1. Press and hold button P1 after Display Test Mode. The radio beeps once and displays
“LED Test Mode”.
2. Upon any button press, the radio lights on the red LED and displays “Red LED On”.
3. Consequently, upon any button press, the red LED is turned off and the radio lights on the
green LED and displays “Green LED On”.
4. Consequently, upon any button press, the green LED is turned off and the radio shall light on
the yellow LED and displays “Yellow LED On”.

3.3.5 Backlight Test Mode

1. Press and hold button P1 after LED Test Mode. The radio beeps once and displays
“Backlight Test Mode”.
2. The radio lights on both LCD and keypad backlight together.

3.3.6 Speaker Tone Test Mode

1. Press and hold button P1 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.

3.3.7 Earpiece Tone Test Mode

1. Press and hold button P1 after Speaker Tone Test Mode. The radio beeps once and displays
“Earpiece Tone Test Mode”.
2. The radio generates a 1 kHz tone with the earpiece.

3.3.8 Audio Loopback Test Mode

1. Press and hold button P1 after Earpiece Tone Test Mode. The radio beeps once and
displays “Audio Loopback Test Mode”.
2. The radio shall route any audio on the mic to the internal speaker.
3-4 Transceiver Performance Testing: Numeric Display Model Test Mode

3.3.9 Audio Loopback Earpiece Test Mode

1. Press and hold button P1 after Audio Loopback Test Mode. The radio beeps once and
displays “Audio Loopback Earpiece Test”.
2. The radio shall route any audio on the mic to the accessory earpiece.

3.3.10 Button Test Mode

1. Press and hold button P1 after Audio Loopback Earpiece Test Mode. The radio beeps once
and displays “Button Test” .
2. The radio also displays the Button Command Opcode (BCO) and state (BCO/state) on the
screen upon any button state changes.
3. The radio must be powered off to end Test Mode.

3.4 Numeric Display Model Test Mode

3.4.1 Entering Display Radio Test Mode
1. Turn the radio on.
2. Within ten seconds after self test is complete, press button P2, five times in succession.
3. The radio beeps.

3.4.2 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.
1. Each short press of button P2 changes the test environment
(CSQ->TPL->DIG->USQ->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 environment are analog mode as described in
Table 3-3.
2. Each short press of button P1 toggles the channel spacing between 20 kHz, 25 kHz and
12.5 kHz. The radio beeps once when radio toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.
3. Pressing of the Channel Changing Rocker changes the test channel from 1 to 14. Press the
top side to increase or bottom side to decrease the channel number. The radio beeps in each
position. The channel test frequencies are described in Table 3-5.

3.4.3 Display Test Mode

1. Press and hold button P1 in RF Test Mode. The radio beeps once and enters
‘Display Test Mode’.
2. Upon entering Display Test Mode, press any button to turn on the two character seven
segment display.
Transceiver Performance Testing: Numeric Display Model Test Mode 3-5

3.4.4 LED Test Mode

1. Press and hold button P1 after Display Test Mode. The radio beeps once.
2. Upon any button press, the radio lights on the red LED.
3. Consequently, upon any button press, the red LED is turned off and the radio lights on the
green LED.
4. Consequently, upon any button press, the green LED is turned off and the radio shall light on
the yellow LED.

3.4.5 Speaker Tone Test Mode

1. Press and hold button P1 after LED Test Mode. The radio beeps once.
2. The radio generates a 1 kHz tone with the internal speaker.

3.4.6 Earpiece Tone Test Mode

1. Press and hold button P1 after Speaker Tone Test Mode. The radio beeps once.
2. The radio generates a 1 kHz tone with the earpiece.

3.4.7 Audio Loopback Test Mode

1. Press and hold button P1 after Earpiece Tone Test Mode. The radio beeps once.
2. The radio shall route any audio on the mic to the earpiece.

3.4.8 Audio Loopback Earpiece Test Mode

1. Press and hold button P1 after Audio Loopback Test Mode. The radio beeps once.
2. The radio shall route any audio on the mic to the accessory earpiece.

3.4.9 Button Test Mode

1. Press and hold button P1 after Audio Loopback Earpiece Test Mode. The radio beeps once.
2. Rotate the volume knob, the radio beeps at each position.
3. Press any button, the radio beeps.
4. The radio must be powered off to end Test Mode.
3-6 Transceiver Performance Testing: Numeric Display Model Test Mode

Table 3-3 Test Environments

No. of
Description Function
Beeps

1 Carrier Squelch RX: unsquelch if carrier detected

(CSQ) TX: mic audio
2 Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detected
(TPL) TX: mic audio + tone (192.8 Hz)
3 Digital RX: unsquelch if carrier and digital code detected
(DIG) TX: mic audio
4 Unsquelch RX: constant unsquelch
(USQ) TX: mic audio

Table 3-4 Test Channel Spacing

Number of Beeps Channel Spacing

1 20 kHz

2 25 kHz

3 12.5 kHz

Table 3-5 Test Frequencies

Test Channel Test Channel VHF UHF1

Test Mode
Low Power High Power (MHz) (MHz)

TX 1 8 136.075 403.000

RX 1 8 136.075 403.000

TX 2 9 142.575 414.150

RX 2 9 142.575 414.150

TX 3 10 146.575 425.350

RX 3 10 146.575 425.350

TX 4 11 155.575 436.500

RX 4 11 155.575 436.500

TX 5 12 161.575 447.675

RX 5 12 161.575 447.675

TX 6 13 167.575 458.850

RX 6 13 167.575 458.850

TX 7 14 174.975 470.000

RX 7 14 174.975 470.000
Transceiver Performance Testing: Numeric Display Model Test Mode 3-7

Table 3-6 Transmitter Performance Checks

Communications
Test Name Radio Test Set Comment
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error:
Frequency 4th channel test frequency* Test Channel 4, continuously ±90 Hz (VHF)
(see Note Monitor: Frequency error carrier squelch transmit (during ±150 Hz (UHF)
below Input at RF In/Out the performance
Table 3-6) check)
Power RF As above TEST MODE As above Low Power Set:
Test Channel 4, 1.0–1.3 W: (VHF 1–25 W,
carrier squelch UHF1 1–25 W)
25–29 W: (VHF 25–45 W,
TEST MODE UHF1 25–40 W)
Test Channel 11,
carrier squelch High Power Set:
25–29 W: (VHF 1–25 W,
UHF1 1–25 W)
40–47 W: (UHF1 25–40 W)
45–53 W: (VHF 25–45 W)
Voice Mode: PWR MON TEST MODE As above, meter Deviation:
Modulation 4th channel test frequency* Test Channel 4, selector to mic 2.5 kHz Max.
atten to -70, input to RF In/ carrier squelch (12.5 kHz Ch. Sp.)
Out 4 kHz Max.
Monitor: DVM, AC Volts (20 kHz Ch. Sp.)
Set 1 kHz Mod Out level for 5 kHz Max.
800mVrms at test set, (25 kHz Ch. Sp.)
800mVrms at AC/DC test
set jack
Voice Mode: PWR MON TEST MODE, Remove Deviation:
Modulation 4th channel test frequency* Test Channel 4 modulation input 2.5 kHz Max.
(internal) atten to -70, input to RF In/ carrier squelch (12.5 kHz Ch. Sp.)
Out output at 4 kHz Max.
antenna (20 kHz Ch. Sp.)
5 kHz Max.
(25 kHz Ch. Sp.)
TPL As above TEST MODE, As above Deviation:
Modulation 4th channel test frequency* Test Channel 4 0.25–0.5 kHz
BW to narrow TPL (12.5 kHz Ch. Sp.)
0.4–0.8 kHz
(20 kHz Ch. Sp.)
0.5–1.0 kHz
(25 kHz Ch. Sp.)
3-8 Transceiver Performance Testing: Numeric Display Model Test Mode

Table 3-6 Transmitter Performance Checks (Continued)

Communications
Test Name Radio Test Set Comment
Analyzer
FSK Error DMR mode. FSK error TEST MODE, Key up radio Not Exceed 5%
Digital mode, with O.153 test
transmit with pattern
O.153 test modulation
pattern using Tuner
Magnitude DMR mode. Magnitude error As above As above Not Exceed 1%
Error
Symbol DMR mode. Symbol As above As above Symbol Deviation should
Deviation deviation be within 648Hz +/-10%
and 1944Hz +/-10%
Transmitter DMR mode As above As above Transmitter BER should be
BER 0%
* See Table 3-5
NOTE: It is recommended that the reference oscillator be recalibrated after two years to maintain
optimized Dual Capacity Direct Mode performance.

Table 3-7 Receiver Performance Checks

Communications
Test Name Radio Test Set Comment
Analyzer

Rated Audio Mode: GEN TEST MODE PTT to OFF Set volume control to
Output level: 1.0 mV RF Test Channel 4, (center), meter 7.5 Vrms
4th channel test frequency* 25 kHz channel selector to
Mod: 1 kHz tone at spacing, Audio PA
3 kHz deviation carrier squelch
Monitor: DVM: AC Volts

Distortion As above, except to As above As above Distortion <5.0%

distortion

Sensitivity As above, except SINAD, As above PTT to OFF RF input to be <0.3 µV

(SINAD) lower the RF level for 12 dB (center)
SINAD.

RF level set to 1 mV RF As above PTT to OFF Set volume control to

(center), meter 7.5 Vrms
Noise Squelch selection to
Threshold Audio PA, spkr/
(only radios load to speaker
with
conventional As above, except change out of TEST As above Unsquelch to occur at
system need frequency to a conventional MODE; select a <0.25 µV.
to be tested) system. Raise RF level from conventional Preferred SINAD =
zero until radio unsquelches. system 9–10 dB

Receiver BER IFR DMR mode. signal Test Mode, Read BER using RF level to be
generator with O.153 test Digital Mode, Tuner. Adjust <0.3 µV for 5% BER
pattern receive O.153 RF level to get
test pattern 5% BER

* See Table 3-5

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 on a Windows 8/7/Vista/
XP operating system. These programs are available as listed in Table 4-1. An Installation Guide is
also included with the kit.
NOTE: Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1 Radio Software Program Kit

Description

*MOTOTRBO CPS, Tuner and AirTracer Applications

*This kit cannot be purchased.

It can be downloaded from https://businessonline.motorolasolutions.com

4.2 Customer Programming Software Setup

The Customer Programming Software setups, shown in Figure 4-1 and Figure 4-2, are used to
program the radio.

NOTE: Refer to the appropriate program on-line help files for the programming procedures.

CAUTION: Computer USB ports can be sensitive to Electronic Discharge.

Do not touch exposed contacts on cable when connected to a computer.

Front Connector

ACC
R a d io

DC 13.8VDC
Power
RF Supply

Front Telco MMP USB

Programming Cable PMKN4147_ USB

Figure 4-1 Customer Programming Software Setup from Front Connector

4-2 Radio Programming and Tuning: AirTracer Application Tool

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
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.

4.4 Radio Tuning Setup

A personal computer (PC), Windows 8/7/Vista/XP and a tuner program (which is available as part of
the MOTOTRBO CPS kit) are required to tune the radio. To perform the tuning procedures, the
radio must be connected to the PC and test equipment setup as shown in Figure 4-2.

Front Telco MMP USB

Programming Cable PMKN4147_

USB

Back 20 Pin MAP Test Audio In Tx

Audio Generator
Cable PMKN4150_ Test Box
RLN4460_
Rx SINAD Meter

ACC 13. 8 V D C
Power AC Voltmeter
R a d io

DC Supply

RF 30 dB Pad
Tx
Service Monitor
Mini UHF Tx
to BNC Adaptor WATT meter
(if needed)

RF Generator

Figure 4-2 Radio Tuning Equipment Setup

Chapter 5 Disassembly/Reassembly Procedures

5.1 Introduction
This chapter provides details about the following:

• Preventive maintenance (inspection and cleaning).

• Safe handling of CMOS and LDMOS devices.
• Repair procedures and techniques.
• Disassembly and reassembly of the radio.

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 control
head and housing assembly. 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 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).

Use all chemicals as prescribed by the manufacturer. Be sure to follow all

! safety precautions as defined on the label or material safety data sheet.

Caution The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
chemicals.
5-2 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. Once the cleaning process is
complete, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, control head and housing assembly.

NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).

5.3 Safe Handling of CMOS and LDMOS Devices

Complementary Metal Oxide Semiconductor (CMOS) and Laterally Diffused Metal Oxide
Semiconductor (LDMOS) 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/LDMOS circuits and are especially important in low
humidity conditions.
Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices 5-3

DO NOT attempt to disassemble the radio without first referring to the following CAUTION
statement.

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:

Caution • Store and transport all CMOS/LDMOS devices in conductive

material so that all exposed leads are shorted together. Do not insert
CMOS/LDMOS devices into conventional plastic “snow” trays used
for storage and transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the
CMOS/LDMOS device. We recommend using a wrist strap, two
ground cords, a table mat, a floor mat, ESD shoes, and an ESD
chair.
• 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/LDMOS devices.
• Do not insert or remove CMOS/LDMOS devices with power applied.
Check all power supplies used for testing CMOS/LDMOS devices to
be certain that there are no voltage transients present.
• When straightening CMOS/LDMOS pins, provide ground straps for
the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS/LDMOS 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.
5-4 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 and assembled using environmentally
preferred components and solder assembly techniques to comply with the European
Union’s Restriction of Hazardous Substances (ROHS 2) Directive 2011/65/EU and
Waste Electrical and Electronic Equipment (WEEE) Directive 2012/19/EU. To
maintain product compliance and reliability, use only the Motorola specified parts in this
manual.

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

Alloy Flux Type Diameter Weight
Part Number by Weight Point number

1088929Y01 95.5Sn/3.8Ag/0.7Cu RMA Version 2.7–3.2% 217°C 52171 0.015” 1lb spool

Table 5-2 Lead Free Solder Paste Part Number List

Motorola Part Manufacturer Part Liquid

Viscosity Type Composition & Percent Metal
Number Number Temperature

1085674C03 NC-SMQ230 900–1000KCPs Type 3 (95.5%Sn-3.8%Ag-0.7%Cu) 217°C

Brookfield (5rpm) (-325/+500) 89.3%

Parts Replacement and Substitution

Check the parts list for the proper Motorola part number and order the part from the nearest Motorola
Radio Products and Solutions Organization.
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 components.
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:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges.
Disassembly/Reassembly Procedures: Disassembling and Reassembling the Radio – General 5-5

5.5 Disassembling and Reassembling the Radio – General

Since these radios may be disassembled and reassembled with the use of only eleven screws
(board to casting), it is important to pay particular attention to the snaps and tabs, and how parts
align with each other.
The following tools are required for disassembling and assembling the radio:
• Small Flat Blade Screwdriver
• Control Head Dismantling Tool (Motorola Part No. 6686119B01)
• Torque Driver (2–36 lbs-in or 0.2–4.0 N-m), (Motorola Part No. RSX4043A)
• TORX™ T10 Driver Bit (Motorola Part No. 6680387A74)
• TORX™ T8 Driver Bit (Motorola Part No. 6680387A72)
• 9/16” Deep Socket Driver (RF Connector Nut)
If a unit requires more complete testing or service than is customarily performed at the basic level,
please send radio to a Motorola Service Center listed in Appendix B.
The following disassembly procedures should be performed only if necessary.

5.6 Radio Disassembly – Detailed

The procedure to remove and replace the control head, top cover or transceiver board is similar for
all models. A typical procedure is therefore provided in this section followed by detailed disassembly
procedures for each specific control head model.

5.6.1 Control Head Removal

1. Insert the dismantling tool in the groove between the control head and the radio assembly as
shown in Figure 5-1.
2. Press the dismantling tool under the control head to release the snap features.

Dismantling
Tool

Figure 5-1 Typical Control Head Removal

5-6 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

3. Pull the control head away from the radio assembly as shown in Figure 5-2.
NOTE: During the control head disassembly, the control head PCB may snap out of position. The
control head PCB will need to be snapped back in place prior to reassembly.

Flex Cable

Figure 5-2 Flexible Connection Removal

4. Remove the flex cable from the socket on the radio assembly as shown in Figure 5-2.

5.6.2 Top Cover Removal

1. Insert the dismantling tool between the top cover and the chassis as shown in
Figure 5-3.
2. Press on the dismantling tool until one side wall of the top cover starts to clear the chassis
trunnion mounting features.
3. Repeat step 2 for the other side of the top cover.
4. A small flat screwdriver may be required to release the rear catch.
5. Lift the top cover from the chassis.
Trunnion Mounting
Feature

Dismantling
Tool

Figure 5-3 Top Cover Removal (Image May Not Match Exact Product)
Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-7

5.6.3 Transceiver Board Removal

1. Remove the eight screws from the die cast main shield, the one screw directly on the PCB
and the two screws from the DC Cable using the T10 TORX™ driver as shown in Figure 5-4.
2. Lift the die cast main shield from the chassis.

Die Cast
Main Shield

Screws (11)

Radio
Chassis

Figure 5-4 Die Cast Main Shield Removal

5-8 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

3. Remove the two screws from the PCB using the T8 TORX™ driver as shown in Figure 5-5.
NOTE: Do not remove the washers from the screws.

Screws (2)

Radio
Chassis

Figure 5-5 PA Screw Removal

4. Remove the accessory connector cap.

5. Remove the accessory connector from the radio assembly by pulling the connector straight
out of the Radio Chassis as shown in Figure 5-6.

! The accessory connector should never be removed when the die cast main
shield is still assembled to the radio.
Caution

Figure 5-6 Accessory Connector Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-9

6. Remove the DC Cable by gently pulling it away from the Radio Chassis as shown in
Figure 5-7.

Figure 5-7 DC Cable Removal

7. Remove the RF connector nut and lock washer using a 9/16” deep socket driver
(Figure 5-8).

RF Lock Washer and Nut

Figure 5-8 RF Connector Nut Removal

5-10 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

8. Remove the transceiver board by grabbing and lifting the SMT shields and lift the transceiver
board, as shown in Figure 5-9. Then, slide the transceiver board towards the front of the radio
to allow the RF connector to clear the chassis. Handle the transceiver board by the edges
only and store it in an antistatic bag.
NOTE: If the RF connector gasket remain in the chassis, remove it and place it back on the connector.
Every time the Transceiver Board is removed, the Final Driver Thermal Pad must be replaced.

!
The thermal pads can act as an adhesive and cause stress to critical
components on the transceiver board if the transceiver board is lifted too
Caution quickly.

Figure 5-9 Transceiver Board Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-11

5.6.4 Disassembly of Alphanumeric Display Control Head

1. Unplug the control head flex from the control head board by gently pulling the flex out of the
connector as shown in Figure 5-10.

Control Head Flex

Figure 5-10 Control Head Flex Removal

2. Remove the speaker tape from the PCB by using a tweezer as shown in Figure 5-11.
3. Disconnect the speaker connector from the control head board.

Speaker Tape

Speaker Connector

Figure 5-11 Speaker Tape Removal

5-12 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

4. Remove the keypad assembly from the control head housing by pushing on the keypad
buttons while disengaging the control head PCB by deflecting the control head housing side
walls. Once the keypad begins to separate from the control head housing, pull both
components apart. Refer to Figure 5-12.

Keypad Buttons
to Push Deflecting Direction

Keypad Buttons
to Push Deflecting Direction

Figure 5-12 Keypad Assembly Removal

5. Remove the speaker from the keypad assembly as shown in Figure 5-13.

Speaker

Figure 5-13 Speaker Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-13

6. Gently lift the keypad upwards to disengage the PCB tabs from the keypad openings.
Simultaneously, remove the keypad flaps around the PCB. Then remove the PCB from the
keypad. Refer to Figure 5-14.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

PCB Tab Protruding

Grounding
Through Keypad
Contact
Opening

Keypad Flaps
Constraining The
PCB On All 4 Sides

Figure 5-14 PCB Removal

7. Gently remove the indicator barrier from the keypad as shown in Figure 5-15.

Indicator Barrier

Figure 5-15 Indicator Barrier Removal

5-14 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

8. Gently push the LCD display latch and remove the LCD from the PCB. Refer to Figure 5-16.
9. Remove the LCD flex from the connector.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

LCD Latch

LCD Flex

Grounding Connector
Contacts

Figure 5-16 LCD and LCD Flex Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-15

5.6.5 Disassembly of Numeric Display Control Head

1. Unplug the control head flex from the control head board by gently pulling the flex out of the
connector as shown in Figure 5-17.

Control Head Flex

Figure 5-17 Control Head Flex Removal

2. Remove the speaker tape from the PCB by using a tweezer as shown in Figure 5-18.
3. Disconnect the speaker connector from the control head board.

Speaker Tape

Speaker Connector

Figure 5-18 Speaker Tape Removal

5-16 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

4. Remove the keypad assembly from the control head housing by pushing on the keypad
buttons while disengaging the control head PCB by deflecting the control head housing side
walls. Once the keypad begins to separate from the control head housing, pull both
components apart. Refer to Figure 5-19.

Keypad Buttons
to Push Deflecting Direction

Keypad Buttons
to Push Deflecting Direction

Figure 5-19 Keypad Assembly Removal

5. Remove the speaker from the keypad assembly as shown in Figure 5-20.

Speaker

Figure 5-20 Speaker Removal

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-17

6. Gently lift the keypad upwards to disengage the PCB tabs from the keypad openings.
Simultaneously, remove the keypad flaps around the PCB. Then remove the PCB from the
keypad. Refer to Figure 5-21.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

PCB Tab Protruding Grounding

Through Keypad Contact
Opening

Keypad Flaps
Constraining The
PCB On All 4 Sides

Figure 5-21 PCB Removal

7. Gently remove the indicator barrier from the keypad as shown in Figure 5-22.

Indicator Barrier

Figure 5-22 Indicator Barrier Removal

5-18 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7 Radio Reassembly – Detailed

5.7.1 Reassembly of Alphanumeric Display Control Head
1. Connect the display flex to the connector on the PCB.
2. Align the LCD alignment pins to the PCB holes.
3. Firmly press along the outer perimeter of the display until the LCD display latch is attached to
the PCB. Refer to Figure 5-23.
NOTE: Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

Grounding
Connector
Contacts

Figure 5-23 LCD Display Assembly

4. Gently assemble the indicator barrier to the keypad as shown in Figure 5-24.

Indicator Barrier

Figure 5-24 Indicator Barrier Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-19

5. Assemble the speaker to the keypad. Refer to Figure 5-25.

NOTE: Be sure to orient the speaker in the direction of the wire and connector towards the middle of
the control head.

Figure 5-25 Speaker Assembly

6. Assemble PCB assembly to the keypad as shown in Figure 5-26.

NOTE: Verify that the PCB is properly positioned to the keypad:
1) The four PCB tabs should protrude through the keypad openings.
2) The PCB should be seated to the keypad so the keypad flaps constrain the PCB.

Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.
PCB Tab Protruding
Through Keypad
Opening

Grounding
Contacts

Keypad Flaps
Constraining The
PCB On All 4 Sides
Figure 5-26 Assembling PCB to Keypad
5-20 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

7. Connect the speaker plug to its mating connector on the control head board as shown in
Figure 5-27.

Speaker Connector

Figure 5-27 Speaker Connection

8. Assemble the keypad with the PCB and speaker assembled to the control head housing.
Refer to Figure 5-28
NOTE: PCB needs to be snapped into the control head housing. Ensure entire keypad is fully seated
to the control head housing.

Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

Grounding
Contacts

Figure 5-28 Assembling Keypad to Control Head Housing

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-21

9. Assemble the speaker tape on the speaker wire and PCB. Press the speaker tape and make
sure it sticks firmly on the PCB. Refer to Figure 5-29.

Speaker Tape

Figure 5-29 Assembling Speaker Tape to PCB

10. Gently plug the control head flex to the control head board as shown in Figure 5-30.

Figure 5-30 Assembling Control Head Flex to Control Head Board

5-22 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.2 Reassembly of Numeric Display Control Head

1. Gently assemble the indicator barrier to the keypad as shown in Figure 5-31.

Indicator Barrier

Figure 5-31 Indicator Barrier Assembly

2. Assemble the speaker to the keypad. Refer to Figure 5-32.

NOTE: Be sure to orient the speaker in the direction of the wire and connector towards the middle of
the control head.

Figure 5-32 Assembling Speaker to Keypad

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-23

3. Assemble the PCB to the keypad as shown in Figure 5-33.

NOTE: Verify that the PCB is properly positioned to the keypad:
1) The four PCB tabs should protrude through the keypad openings.
2) The PCB should be seated to the keypad so the keypad flaps constrain the PCB.

Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.
PCB Tab Protruding
Through Keypad
Opening

Grounding
Contacts

Keypad Flaps
Constraining The
PCB On All 4 Sides

Figure 5-33 Assembling PCB to Keypad

4. Connect the speaker plug to its mating connector on the control head board as shown in
Figure 5-34.

Figure 5-34 Speaker Connection

5-24 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5. Assemble the keypad with the PCB and speaker to the control head housing. Refer to
Figure 5-35.
NOTE: PCB needs to be snapped into the control head housing. Ensure entire keypad is fully seated
to the control head housing.

Do not touch or contaminate the conductive contacts (especially the grounding contacts) on
the PCB.

Grounding
Contacts

Figure 5-35 Assembling Keypad to Control Head Housing

6. Assemble the speaker tape on the speaker wire and PCB. Press the speaker tape and make
sure it sticks firmly on the PCB. Refer to Figure 5-36.

Speaker Tape

Figure 5-36 Assembling Speaker Tape to PCB

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-25

7. Gently plug the control head flex to the control head board as shown in Figure 5-37.

Figure 5-37 Assembling Control Head Flex to Control Head Board

5-26 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

5.7.3 Radio Assembly

1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks,
cuts, etc.) or debris. Refer to the exploded view and bill of materials for the correct part
numbers and replace parts, as necessary. Replace all new seals on their respective parts.

For both the die cast main shield and the chassis, thoroughly inspect the shield gasketing for
damage and verify all thermal pads are in place and free from damage and debris. See
Section 5.7.4: Thermal Pad Replacement Procedure on page 5-27 to replace damaged pads.

Die Cast Main Shield

Chassis with Thermal Pads and Shield Gasketing
and Shield Gasketing

Figure 5-38 Thermal Pads and Shield Gasketing on Chassis and Die Cast Main Shield

2. Thoroughly inspect the chassis and verify all thermal pads are in place and free from
damage. See Section 5.7.4: Thermal Pad Replacement Procedure on page 5-27 to replace
damaged pads.
NOTE: Every time the Transceiver Board is removed, the Final Driver Thermal Pad must be
replaced.

Audio PA Thermal Pad

Regulator (75012059001)
Thermal
Pad Final Driver Thermal Pad
(75012018001) (75012058002)

Thermal Grease (1110022A55)

Figure 5-39 Chassis with Thermal Pads

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-27

5.7.4 Thermal Pad Replacement Procedure

Regulator Thermal Pad Replacement
1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place it
on the chassis as shown in Figure 5-40.

Regulator Thermal
Pad (75012018001)

Figure 5-40 Replacing Regulator Thermal Pads

5-28 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Audio PA Thermal Pad Replacement

1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
Care should be taken to minimize any cleaning-agent contact with the surrounding shield
gasket.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis as shown in Figure 5-41.

Audio PA Thermal Pad

(75012059001)

Figure 5-41 Replacing Audio PA Thermal Pad

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-29

Final Driver Thermal Pad Replacement

1. Use a plastic flat-edge tool to lift each pad from the transceiver board. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the chassis as shown in Figure 5-42.

Final Driver Thermal Pad

(75012058002)

Figure 5-42 Replacing Final Driver Thermal Pad

5-30 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

PCB Thermal Pad Replacement

1. Use a plastic flat-edge tool to lift the pad from the transceiver board. Discard the old pad.
2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary.
3. Once the surface is clean and dry, remove the new pad from the shipping liner, and place the
pad on to the transceiver board as shown in Figure 5-43.
NOTE: The PCB Thermal Pad is NOT placed for the UHF1 1–25W models. Placing the pad on a
UHF1 1–25W model may degrade radio performance.

Thermal Pad
(75012018001)

Figure 5-43 Replacing PCB Thermal Pad

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-31

5.7.5 Transceiver Board Reassembly

1. Apply thermal grease to the PA area. Refer to Figure 5-44.

Thermal Grease
(1110022A55)

Figure 5-44 Applying Thermal Grease

2. Insert the transceiver board into the chassis by tilting the transceiver board (approximately 45
degrees) and sliding it into place, taking care to line up the RF connector with the opening in
the back of the chassis.
NOTE: Prior to board installation verify that all thermal pads are present. Verify that a thermal pad is
present on the PCB.

Push the board down to fully seat it to the radio chassis.

Figure 5-45 Placing the Transceiver Board in the Chassis

5-32 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

3. Using a 9/16” deep socket driver install the lock washer and nut to an initial torque of 0.9 N-m
(8 lbs-in). Refer to Figure 5-46.

RF Lock Washer and Nut

Figure 5-46 Inserting RF Lock Washer and Nut

4. Using a T10 TORX™ driver insert three main shield thread forming screws (M3) at locations
3, 5 and 6 to compress the PCB. Tighten the screws to 1.0 N-m (9 lbs-in).
NOTE: This step is required; otherwise, damage could result to the final transmitter PA device.

Figure 5-47 Screw Sequence to Compress PCB

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-33

5. While the board is pressed down, align the PA holes on PCB to mounting holes on chassis
and insert two (M2.5) machine screws with washers (see Figure 5-48 for PA Screw
sequence). Using a T8 TORX™ tighten the screws to 0.45 N-m (4 lbs-in).

Install This Screw First

Install This Screw Second

Figure 5-48 Installing PA Screws

6. Using a T10 TORX™ driver remove the screws from locations 3, 5 and 6.

Figure 5-49 Screw Removal

5-34 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

7. Insert the accessory connector into the radio assembly and press into place until the
connector is flush with the chassis. Refer to Figure 5-50.

Accessory
Connector

Figure 5-50 Inserting Accessory Connector

8. Place the main shield on the transceiver board and lock in place the accessory connector by
aligning the main shield locking tabs to the pockets of the accessory connector.
9. Insert eight main shield thread forming screws (M3) through the shield and one thread
forming screw (M3) through the board.
10. Using a T10 TORX™ driver follow the sequence marked on the main shield and tighten all
nine screws to 1.47 N-m (13 lbs-in). Refer to Figure 5-51.
11. Retighten the eight screws on the main shield a second time.

Figure 5-51 Assembling Die Cast Main Shield onto Chassis

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-35

3
1 7
5

6 2
4
8

Figure 5-52 Screw Sequence to Tighten Die Cast Main Shield

12. Use a 9/16” deep socket driver to further tighten the nut to a final torque of 2.15 N-m
(19 lbs-in).

RF Connector Lock Washer and Nut

Figure 5-53 RF Connector Nut Final Torque

5-36 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Do not leave the transceiver board in the chassis for extended periods of time
! without the RF lock washer and nut assembled, or damage to the board
connectors may occur.
Caution

13. Install the DC Cable Assembly to the radio chassis slot. Ensure that it is seated correctly on
the chassis hook located below the DC Cable.
14. Insert two thread forming screws (M3).
15. Using a T10 TORX™ driver, tighten the screws to 1.47 N-m (13 lbs-in). Refer to Figure 5-54.

Figure 5-54 Installing DC Cable Assembly

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-37

16. Thoroughly inspect the cover assembly with seal attached. Ensure the seal is fully seated on
the cover and the locking tabs engaged at all six locations.

Locking Tab
(6 Places)

Figure 5-55 Inspection of Cover Assembly with Seal

17. Gently spread both sides of the cover.

18. Align the top cover to the chassis and snap the cover in place uniformly. Ensure the alignment
posts on the cover slide into the alignment slots on the chassis and that the rear latch is
secure.

Main Cover

Radio Chassis

Figure 5-56 Assembling Cover onto Chassis

5-38 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

NOTE: Ensure the DC Cable locking tabs fit in the designated slots on the connector overmold. Avoid
biting of locking tabs on the overmold.

DC Cable Locking Tabs

Figure 5-57 Rear Latch in Secure Position

19. Install the MAP Connector cover.

MAP Connector Cover

Figure 5-58 MAP Connector Cover Installation

Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-39

5.7.6 Assemble Control Head to Radio Assembly

1. Verify that the flex cable is fully seated in the connector on the control head assembly.

Make sure the main cover is assembled onto the radio chassis before

! assembling the control head onto the radio chassis.

Caution During the control head disassembly, the control head PCB may snap out of
position. The control head PCB will need to be snapped back in place prior to
reassembly.

Radio Chassis

Control Head

Figure 5-59 Assemble Control Head to Chassis

2. Assemble flex cable to the flex connector in the radio assembly, making sure it is fully seated.

Control Head Connector

Figure 5-60 Flex Connection Connector

3. Assemble the control head to the radio chassis by aligning one side of the control head
assembly tabs to one side of the radio chassis tabs and then rotate the control head
assembly until the other side engages.
5-40 Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5.8 Exploded Mechanical Views and Parts Lists

5.8.1 Radio Assembly Exploded View and Parts List

9
10
11
5 12

4 13

3 14

2 15

Figure 5-61 Radio Assembly Exploded View

Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists 5-41

Table 5-3 Radio Exploded View Parts List

Item No. Description Part Number

1 Chassis, Die Cast 0104056J09
2 Thermal Pad, Final Driver 75012058002
3 Thermal Pad, Regulator 75012018001
4 Thermal Pad, Audio PA 75012059001
See Section 1.5 to
5 PCB, Transceiver 1.8 to identify proper
board.
6 Main Shield, Die Cast 26012273001
7 Screw - M3x0.5x13mm 0310943J12
8 Main Cover and Gasket Assembly 15012229001
9 Screw - M2.5x0.45x12mm with Washer 03012037002
Thermal Pad, PA Output Match
10 VHF 25–45W, VHF 1–25W, UHF1 25–40W 75012018001
UHF1 1–25W NOT PLACED
11 Lock Washer, RF Connector 04012004001
12 Nut, RF Connector 02012015001
13 Accessory Connector Cover 3202607Y01
14 Accessory Connector 28012058001
15 DC Cable Assembly 28012059001
5-42 Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists

5.8.2 Control Head Exploded Views and Parts Lists

10
9

8
7

11

Figure 5-62 Alphanumeric Display Control Head Exploded View

Table 5-4 Alphanumeric Display Control Head (PMLN6320_) Exploded View Parts List
Item no Description Part No
1 Nameplate, DEM 400 33012051007
2 Label, Accessory Indicator 54012312001
3 Housing Front Assembly, Alphanumeric Control 0104056J26
Head
4 Nameplate, Motorola Logo 33012052001
5 Speaker 5015935H02
6 Keypad, Alphanumeric Control Head 75012194001
7 Light Guide Holder 07012052001
8 2 Line Monochrome Display Module 72012024001
9 PCB Assembly 0104054J38
10 Cable Flex, Control Head 30012065001
11 Speaker Tape 11012133001
Disassembly/Reassembly Procedures: Exploded Mechanical Views and Parts Lists 5-43

10
6

Figure 5-63 Numeric Display Control Head Exploded View

Table 5-5 Numeric Display Control Head (PMLN6321_) Exploded View Parts List

Item no Description Part No

1 Nameplate, DEM 300 33012051008
2 Label, Accessory Indicator 54012312001
3 Housing Front Assembly, Numeric Control Head 0104056J27
4 Nameplate, Motorola Logo 33012052001
5 Speaker 5015935H02
6 Keypad, Numeric Control Head 75012195001
7 Light Guide Holder 07012052001
8 PCB Assembly 0104054J37
9 Cable Flex, Control Head 30012065001
10 Speaker Tape 11012133001
5-44 Disassembly/Reassembly Procedures: Torque Chart

5.9 Torque Chart

Table 5-6 lists the various nuts and 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 5-6 Torque Specifications for Nuts and Screws

Part Torque
Description Driver/Socket
Number N-m lbs-in kg-cm
02012015001 Nut, RF Connector 9/16” deep socket 2.15 19 21.9
driver
03012037002 Screw, M2.5x0.45x12mm, Pan Head T8 Torx™ 0.45 4 4.6
0310943J12 Screw, M3x0.5x13mm, Pan Head T10 Torx™ 1.5 13 15
Chapter 6 Basic Troubleshooting

6.1 Introduction
This chapter contains error codes and board replacement procedures. This section can help you
isolate a problem to the board level. If the radio does not pass all the performance checks in
Chapter 3 or exhibits an error code listed below, then the circuit board should be replaced. Please
send the radio to a Motorola Service Center listed in Appendix B.
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 Section, "Service Aids" on page 2-2, for
the appropriate Motorola service aids and tools part numbers.)

6.1.1 High Power RF Precaution

The radio might transmit while the technician believes the radio is in receive

! mode under the following conditions: radio failure, digital affiliation, a

defective PTT button, or other unintentional activations.
Caution
To avoid possible equipment damage, when performing both transmit and
receive tests, a suitable attenuator rated at 100 W or more should always be
used with test equipment connected to the RF connector. The only
exception to this is when the equipment’s input power rating is higher than
the maximum output power of the radio.

6.2 Replacement Service Kit Procedures

Once a problem has been isolated to a specific board, install the appropriate service kit (see Model
Charts in section 1.5 on page 1-5 through section 1.8 on page 1-6), which is orderable from Motorola
Online. Refer to https://businessonline.motorolasolutions.com for further information.
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.

! The Tuner Tool only allows the serial number of a blank board to be entered
once. Be very attentive during this procedure.
Caution
6-2 Basic Troubleshooting: Power-Up Error Codes

6.3 Power-Up Error Codes

When the radio is turned on (powered-up), the radio performs cursory tests to determine if its basic
electronics and software are in working order. Problems detected during these tests are presented
as error codes on the radio’s display. The presence of an error should prompt the user that a
problem exists and that a service technician should be contacted.
Self-test errors are classified as either fatal or non-fatal. Fatal errors inhibit user operation; non-fatal
errors do not. Use the following tables to aid in understanding particular power-up error code
displays.

Table 6-1 Power-Up Error Codes

Error Code Description Error Type Corrective Action

ERROR 01/02 FLASH ROM Codeplug NON-FATAL Reprogram the codeplug.
Checksum
ERROR 01/22 Tuning Codeplug NON-FATAL Reprogram the tuning partition.
Checksum
FAIL 01/82 FLASH ROM Codeplug FATAL Reprogram the codeplug.
Checksum
FAIL 01/90 General Hardware Error FATAL Turn the radio off, then on. If
problem persists, send radio to
the nearest Motorola Solutions
Depot.
FAIL 01/92 Security Partition FATAL Reprogram the security partition.
Checksum
FAIL 01/93 FlashPORT AUTHENT FATAL Contact the depot.
CODE Failure
FAIL 01/A2 Tuning Codeplug FATAL Reprogram the tuning partition.
Checksum
FAIL 02/90 RF Hardware Error FATAL Send radio to the nearest
Motorola Solutions Depot.
Chapter 7 Accessories

7.1 Introduction
Motorola provides the following approved accessories to improve the productivity of your digital
mobile two-way radio.
For a list of Motorola-approved antennas, and other accessories, visit the following web site:
http://www.motorolasolutions.com

7.1.1 Antennas
Part No. Description
HAD4006_ VHF, 136–144 MHz, 1/4 Wave Roof Mount, Mini-U
HAD4007_ VHF, 144–150.8 MHz, 1/4 Wave Roof Mount, Mini-U
HAD4008_ VHF, 150.8–162 MHz, 1/4 Wave Roof Mount, Mini-U
HAD4009_ VHF, 162–174 MHz, 1/4 Wave Roof Mount, Mini-U
HAD4022_ VHF, 132–174 MHz, 3.0 dB Gain, Through-hole Mount, Mini-U
HAE4002_ UHF, 403–430 MHz, 1/4 Wave Roof Mount, Mini-U
HAE4003_ UHF, 450–470 MHz, 1/4 Wave Roof Mount, Mini-U
HAE4010_ UHF, 406–420 MHz, 3.5 dB Gain Roof Mount, Mini-U
HAE4011_ UHF, 450–470 MHz, 3.5 dB Gain Roof Mount, Mini-U
HAE6022_ UHF, 403–527 MHz, 2.0 dB Gain, Through-hole Mount, Mini-U
RAE4004_RB UHF, 445–470 MHz, 5.0 dB Gain Roof Mount, Mini-U
7-2 Accessories: Introduction

7.1.2 Audio
Part No. Description
GMMN4065_ Visor Microphone (Omni-Direction)
HLN9073_ Microphone Hang-up Clip (requires install)
HLN9414_ Microphone Hang-up Clip (Universal – no install required)
HSN8145_ External Speaker 7.5 W
PMLN6481_ Telephone Style Handset Kit (Includes Hang Up Cup)
PMMN4089_ Enhanced Keypad Microphone (for Alphanumeric Display models
only)
PMMN4090_ Compact Microphone with Clip
PMMN4091_ Heavy Duty Microphone
RSN4001_ External Speaker 13 W
PMLN6520_ Telephone Style Handset

7.1.3 Cables

Part No. Description

HKN4137_ Mobile Power Cable 10 FT., 14 AWG, 15 A
HKN4191_ Mobile Power Cable 10 FT., 12 AWG, 20 A
HKN4192_ Mobile Power Cable 20 FT., 10 AWG, 20 A
PMKN4147_ Front Telco MMP USB Programming Cable
HKN9327_R Ignition Switch Cable
PMKN4151_ Back 16 Pin MAP Universal Cable
GMKN4084_ Speaker Extension Cable

7.1.4 Mounting Kits

Part No. Description
FTN6083_ DIN Mount
RLN6466_ Low Profile Trunnion Kit
RLN6467_ High Profile Trunnion KIt
RLN6468_ Key Lock Trunnion Kit
03012045001 Trunnion Wing Screw M5x0.8x9.9 mm
Accessories: Introduction 7-3

7.1.5 Miscellaneous Accessories

Part No. Description
RLN4836_R External PTT with Emergency Footswitch
RLN4856_ Footswitch with Remote PTT
RLN4857_ Pushbutton with Remote PTT
HLN9457_ 16 Pin MAP Connector Kit
GMBN1021_ Rear Accessory Connector Seal with Connector and Pins
PMLN5620_ Connector Extender (20 pcs)

7.1.6 Service Tools

Part No. Description

GPN6145_ Mobile Radio Power Supply Unit
HPN4007_ Desktop Power Supply 1–60W
6686119B01 Control Head Removal Tool
66012020001 RFIC Repair Kit
PMEN4041_ Chassis Eliminator Kit
PMKN4150_ Back 20 Pin MAP Test Cable
RLN4460_ Radio Test Box
6680388A26 Mobile Crimping Tool
GKN6266_ Power Supply Cable (for GPN6145)(PWR CBL DC BASE RENA)
3085801L01 Argentina Line Cord
3060665A04 Power Cable (US Plug) (110V CHGR LINE CORD)
RSX4043_ Torque Driver
6680387A74 TORX™ T10 Driver Bit
6680387A72 TORX™ T8 Driver Bit
7-4 Accessories: Introduction

Notes
Appendix A Replacement Parts Ordering

A.1 Basic Ordering Information

Some replacement parts, spare parts, and/or product information can be ordered directly. While
parts may be assigned with a Motorola part number, this does not guarantee that they are available
from Motorola Radio Products and Solutions Organization (RPSO). Some parts may have become
obsolete and no longer available in the market due to cancelations by the supplier. If no Motorola
part number is assigned, the part is normally not available from Motorola, or is not a user-serviceable
part. Part numbers appended with an asterisk are serviceable by Motorola Depot only.

A.2 Motorola Online

Motorola Online users can access our online catalog at https://businessonline.motorolasolutions.com
To register for online access:
• Have your Motorola Customer number available.
• Please go to https://businessonline.motorolasolutions.com and click on “Sign Up Now.”
• Complete form and submit it.
• Contact your BDM to complete set-up and it will be done within 24 to 48 hours.
A-2 Replacement Parts Ordering: Motorola Online

Notes
Appendix B Motorola Service Centers

B.1 Servicing Information

If a unit requires further complete testing, knowledge and/or details of component level
troubleshooting or service than is customarily performed at the basic level, please send the radio to
a Motorola Service Center as listed below or your nearest Authorized Service Center.

B.2 Motorola Solutions de México, S.A.

Bosques de Alisos 125
Col. Bosques de las Lomas CP 05120
México D.F.
México
Tel: (5) 257-6700

B.3 Motorola Solutions de Colombia, Ltda.

Avenida Carrera 45 No. 108-27
Bogota - Colombia
Tel: (571) 6022111
B-2 Motorola Service Centers: Motorola Solutions de Colombia, Ltda.

Notes
Appendix C Limited Level 3 Servicing

C.1 Maintenance
For details on the following, please refer to Chapter 5 Disassembly/Reassembly Procedures –
Section 5.2 on page 5-1 to Section 5.4 on page 5-4.
• Preventive maintenance (inspection and cleaning).
• Safe handling of CMOS and LDMOS devices.
• Repair procedures and techniques.

C.2 Component Location and Parts List

1
J0700

R3110
C3051

18
2
20
C0846
C0824
C0809

TP4102
R0774
R0779

R0783

R0775
R0786
R0758

R0782

C3050 E4103
C0811
C0758
C0736

5
M3000

U3112

J4100

VR4110
C0766

R3150
C0722

3
4
3

E4101

E4100
2

2
3

TP4103
R0780
R0778
R0781
R0777
R0776
R0784
R0785

L0706
C

C0938

L0708
07

C0941 C3044 E4102

77

19

17
D0877
C0942 C3047 E3100
C0759

C0872
C0810
C0770
L0877

C0746
C0808

C0841
C0840
G2
G1

C3042
C3046

C3021

C0940
C3020
D0875

2
D0700

C0842

C0726 C0737
C
C0951

07

C0880 C0800
C

TP4101
63

C0755 C0721
08
C

06

R0956 C0952 C0751 C0730

07 02

R0807R0798 R0760
C

C3002
C3003
C0707
C0712
C0716

C0787 C0740
05 R0 12
73
08

C3112
R0791 R0763
C0867
C0932
08

C
9

R3175
C0785 C0875 C0748
80

L0952
09
R

R0808

TP3109
3

D0950 C0742
R0799 C0862 C0771C
06

C0870 C0865
C0874 C0863
R0792 C0869 C0805

C0786
39
2

L0885

09

C3152
C
R0804 R0810 8
0

07

C0850
30
R
R0803 R0811

C0733
08

28

R3001

R3002

R3003

R3004

C0816 C0795 C0723

R
L0875

C3111

6 10
C0756
U3109
C0864
C0868

C0779 C0757

10
C0845
R0958

R0957

C0847

C3102
C0950

R0950

C3129
C0876

R3107
C3106
5
C0768 R3106
R
08

E0703
2

C3225
3

E0701
D0876

R3101

L0710
R

02

R0793

R0800
08

L0857 R0790 R3102

R0736

R0797
01

R0796

U3204
4

R0794 R0789 R3005

08 2

C0933

R0770
C0934

R3261
C 79

R0795
2

3
C0791 C0873

R0772 R0788 R3132

07 04
0

R3006
C0821

R0787 R0773
C

C0818
C0714

5
74

Q3205

C0843 R0771 C0860

C0851

C0819
C0815
C0807
C0820

R3208 C3209

3
01

C0861
L0876

C0782 R3263
C

C0745

C3014
08

C0803

C0859
C0790
C0852

R0769

6
R0766
R0767
C

R0768
C0844

C0767

C0858 R3264 R3142

L0712 C0769
20

11
R3262 R3138
C0752
C0828

R3230

C0780 C0857

U3100
C0781 C0848 C3230 R3265 C3214
34
C0953

6
R0953

R3176
R3203
C3257

Q3201 C2004 C2012 R3287 R3290

R0952

C3222
R0951

R3231
Q3000

R3280
C3013

C2005
G1

C2011

L0711 R3256 C3221

C3219
R3015
D0951

6
4

C3226
C2010
2
3

C2008
6
2

34
L0951

C3224
3
L0950

C3228
Q0702

R1060
R3254
C2014

C0955 C2009 C3229 U3202 C3231

C0954

C0853
C3012
9

R3285 C3227 C3218

C2016
Q3209

C0788
C2013

C2015

E3202
7

C3223
2
8
R0955
R0954

C0822
R3200
2

R1052 R1036
R3204
C0701

C0718
L0727

R1044 R1035 C2020

C3204 C1032 C1029
C3124

C0706
C3171
C3151 C3153
R1033
E3111

C0928 R3108
C0731

R0700

R1049
L0852

C1060
C1047

C0710 R1040 R1011 R1050

R1051 C3248
E1004

R3119
E1002

R1069 R1064 C1014

C0902

C0957
R0962
R0961

6 10
U3108
R0704 C3150
R0960

C0814

C1013
C0812

R1010 R1062
C3122 R3147
8

C3173
R0735

R0727

R0725
R0734

R0738
R0732

TP0710 R1025 R1024

5
U3103
R0913

2 C0911
TP0900

C1006

R0720 R1031 R1030 C3123

C0855 C0929 E1001 E3113 R3146
C1041

C1025

R0723
4

5
R1026

C1007

R1028 R1027 C3144

R0718

C0776
C2007

C3118
Q3001

C2006
C1015
R0742

R0740

C0750
U0904

R1023
C0732
R0932 4 5

R1021
M0700

C0825 C0727 R1022 E1003 E3104

C0956 C0772 RT0900 C0823
G1

R0709 R1018
3

R0710
C0789
R1019

R0931 R0904 R1016 C3154

R0940 C1003
C1028

R0930 C0918
C1005

R0914 R0711
U1004

C1035 C1002
TP0708

C0854 C0764 C0754 R1014

C1008

TP0902
C1045

TP0903 R0939 R0743 R0741

9 6

R3141
R3181
C3180
R0746

C0919 R0933 R0744 R0915 C0761 C1017 C1020

R1012

C1001
C0916

R0929 C3116
Q1002

C0753 R0712
C1044
5

3
4
TP0904

R0920
R1046
R0928

R0923 C3175
U0902

2
R0737

Q0701

C1010
R3111
C0775
R0919

R0917 R0739
C1018

C1042

C0926 L0854
C1036

C1009
R3180

C1023
6

R0916
D3104
C3119
R0749

R0924 R1077
U1010

U3102
1

C1022

E3109
3
C1026

R0745
8

5 4
R0965

C1019

R0959 R0935 C1021

C0900
10
6
2

C3140
R1042
R0883

R0921 R1045
R3173

C0901 C3139
C0917
C0925

R0922

SH0700
3106

SH0900
4 3

U0903
120

R1001
921
934

R3116
37
38

76
0

Figure C-1 PCB Top Side View

Table C-1. Component Parts List

No. Circuit Ref. Motorola Part Number Description

1 J0700 09009348001 Mini-UHF Female RF Connector
2 U3204 51012450001 IC Audio Amplifier 1 Per Package
48012067002 (UHF1 1–25W/VHF 1–25W)
3 Q0702 RF MOSFET Power Transistor
48012022001 (UHF1 25–40W/VHF 25–45W)
C-2 Limited Level 3 Servicing: Component Location and Parts List

Notes
Glossary 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 Definition

Analog Refers to a continuously variable signal or a circuit or device designed to

handle such signals.

Band Frequencies allowed for a specific purpose.

CMOS Complementary Metal Oxide Semiconductor.

CPS Customer Programming Software: Software with a graphical user interface

containing the feature set of a radio.

Default A pre-defined set of parameters.

DEM Refers to Digital Professional Radio model names in the MOTOTRBO

Professional Digital Two-Way Radio System.

Digital 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.

DPL 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.

FCC Federal Communications Commission.

Frequency Number of times a complete electromagnetic-wave cycle occurs in a fixed unit

of time (usually one second).

GPIO General-Purpose Input/Output.

GPS Global Positioning System.

IC 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.

IF Intermediate Frequency.

kHz kilohertz: One thousand cycles per second. Used especially as a radio
frequency unit.

LCD 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.

LDMOS Laterally Diffused Metal Oxide Semiconductor.

LED Light Emitting Diode: An electronic device that lights up when electricity is
passed through it.
Glossary-2

Term Definition

MDC Motorola Digital Communications.

MHz Megahertz: One million cycles per second. Used especially as a radio
frequency unit.

Paging One-way communication that alerts the receiver to retrieve a message.

PC Board Printed Circuit Board. Also referred to as a PCB.

PL Private-Line Tone Squelch: A continuous sub-audible tone that is transmitted

along with the carrier.

Programming Cable A cable that allows the CPS to communicate directly with the radio using USB.

Receiver 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.

Repeater Remote transmit/receive facility that re-transmits received signals in order to

improve communications range and coverage (conventional operation).

RF Radio Frequency: The portion of the electromagnetic spectrum between audio

sound and infrared light (approximately 10 kHz to 10 GHz).

RX Receive.

Signal An electrically transmitted electromagnetic wave.

Spectrum Frequency range within which radiation has specific characteristics.

Squelch 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.

TOT Time-out Timer: A timer that limits the length of a transmission.

TPL Tone Private Line.

Transceiver Transmitter-receiver. A device that both transmits and receives analog or digital
signals. Also abbreviated as XCVR.

Transmitter Electronic equipment that generates and amplifies an RF carrier signal,

modulates the signal, and then radiates it into space.

TX Transmit.

UHF Ultra-High Frequency.

USB Universal Serial Bus: An external bus standard that supports data transfer rates
of 12 Mbps.

VHF Very High Frequency.

VIP Vehicle Interface Port.

Motorola Solutions, Inc.
1303 East Algonquin Road
Schaumburg, Illinois 60196 U.S.A.

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.
© 2013 Motorola Solutions, Inc. All rights reserved.
August 2013.

www.motorolasolutions.com/mototrbo

*68009626001*
68009626001-B