Motorola Dp3400 3401 3600 3601 Mototrbo Basic 6866574d29 E Manual

							Foreword
This manual covers all models of the  DP series Portable Radios, unless otherwise specified. It includes all the information 
necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance 
procedures. This level of service goes down to the board repl acement level and is typical of some local service centers, 
self-maintained customers, and distributors.
Product Safety and RF Exposure Compliance
ATTENTION!
This radio is restricted to occupational use only  to satisfy FCC RF energy exposure requirements. 
Before using this product, read the RF energy awareness information and operating instructions in the 
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 
6864117B25 ) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries,  and other accessories, visit the following web site: 
http://www.motorola.com/governmentandenterprise
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored in 
semiconductor memories or other media. Laws in the United  States and other countries preserve for Motorola certain 
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in 
any form the copyrighted computer progra m. 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-excl usive 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 porti on thereof shall take place without the express written permission 
of Motorola. No part of this manual may be reproduced, distribu ted, or transmitted in any form or by any means, electronic 
or mechanical, for any purp ose 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. Furthe rmore, 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 applic ations or use of any product 
or circuit described herein; nor does it cover any li cense under its patent rights nor the rights of others.
Trademarks
MOTOROLA and the Stylized M logo are registered in the U.S.  Patent and Trademark Office. All other product or service 
names are the property of  their respective owners.
© 2007 and 2008 Motorola, Inc.
All rights reserved.
Before using this product, read the operating instructions 
for safe usage contained in the Product Safety and RF 
Exposure booklet enclosed with your radio.
!
C a u t i o n 
						

							iii
Document History
The following major changes have been implemented in this manual since the previous edition:
EditionDescriptionDate
6866574D29-A Initial Release Feb. 2007
6866574D29-B Added VHF band information. Updated UHF1 Model Chart.
Added leak test procedures. June 2007
6866574D29-C Added pin layout diagram in Test Equipment and  Service Aids chapter.
Updated Troubleshooting Charts in Disassembly/
Reassembly chapter.
Added warning note in Transceiver Performance 
Testing chapter.
Updated front cover and diagrams of knobs.
Updated knob removal tool part number.
Updated Technical Support contact information in 
Appendix A. Oct. 2007
6866574D29-D Updated model charts and added 20kHz  specifications information in Introduction chapter. Jan. 2008
6866574D29-E Added UHF2 band information. Updated Radio Exploded Mechanical Views and 
Parts Lists. June 2008 
						

							iv
Notes 
						

							Table of Contentsv
Table of Contents
Foreword .........................................................................................................ii
Product Safety and RF Exposure Compliance ...................................................................................... ...... ii
Computer Software Copyrights ................................................................................................... ................ ii
Document Copyrights ............................................................................................................ ...................... ii
Disclaimer .................................................................................................................................................... ii
Trademarks ..................................................................................................................... ............................ ii
Document History ........................................................................................ iii
Chapter 1 Introduction ........... .............................................................. 1-1
1.1 Notations Used in This Manual ............................................................................................... ..... 1-1
1.2 Radio Description ........................................................................................................... ............. 1-1
1.2.1 Display Model ............................................................................................................. ..... 1-2
1.2.2 Non-Display Model ......................................................................................................... .1-3
1.3 Portable Radio Model Numbering Scheme ................................................................................. 1-4
1.4 Model Charts ................................................................................................................ ............... 1-5
1.4.1 VHF Model Chart ........................................................................................................... .. 1-5
1.4.2 UHF1 Model Chart.......................................................................................................... .1-6
1.4.3 UHF2 Model Chart.......................................................................................................... .1-7
1.5 Specifications............................................................................................................................... 1-8
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, Testing and Alignment Cable ........ ....................................................................... 2-3
Chapter 3 Transceiver Performance Testing ..................................... 3-1
3.1 General ..................................................................................................................... ................... 3-1
3.2 Setup ........................................................................................................................................... 3-1
3.3 Display Model Test Mode ..................................................................................................... ....... 3-3
3.3.1 Entering Display Radio Test Mode .................................................................................. 3-3
3.3.2 RF Test Mode .............................................................................................................. .... 3-3
3.3.3 Display Test Mode ......................................................................................................... .. 3-7
3.3.4 LED Test Mode............................................................................................................. ... 3-7
3.3.5 Backlight Test Mode ....................................................................................................... .3-7
3.3.6 Speaker Tone Test Mode ................................................................................................ 3-7
3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-7
3.3.8 Audio Loopback Earpiece Test Mode........... ................................................................... 3-7
3.3.9 Battery Check Test Mode ............................. ................................................................... 3-8
3.3.10 Button/Knob/PTT Test Mode ........................ ................................................................... 3-8
3.4 Non–Display Model Test Mode ................................................................................................. .3-10
3.4.1 Entering Non–Display Radio Test Mode ...... ................................................................. 3-10 
						

							viTable of Contents
3.4.2 RF Test Mode ................................................................................................................ 3-10
3.4.3 LED Test Mode ............................................................................................................. .3-10
3.4.4 Speaker Tone Test Mode .............................................................................................. 3-10
3.4.5 Earpiece Tone Test Mode ............................................................................................. 3-11
3.4.6 Audio Loopback Earpiece Test Mode ............................................................................ 3-11
3.4.7 Battery Check Test Mode .............................................................................................. 3-11
3.4.8 Button/Knob/PTT Test Mode ......................................................................................... 3-11
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.................................................................................................. .......... 4-1
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 Techniqu es – General............................................................................ 5-4
5.5 Disassembling and Reassembling the Radio — Gene ral ............................................................ 5-4
5.6 Radio Disassembly – Detailed ................................................................................................ ..... 5-5
5.6.1 Front Cover from Chassis Disassembly .......................................................................... 5-5
5.6.2 Chassis Disassembly....................................................................................................... 5-8
5.6.3 Speaker Disassembly .................................................................................................... 5-1 1
5.7 Radio Reassembly – Detailed................................................................................................. ... 5-12
5.7.1 Speaker Reassembly..................................................................................................... 5-1 2
5.7.2 Chassis Reassembly ..................................................................................................... 5-1 4
5.7.3 Chassis and Front Cover Reassembly ......... ................................................................. 5-17
5.8 Ensuring Radio Immersibility ................................................................................................ ..... 5-18
5.8.1 Servicing ................................................................................................................. ....... 5-18
5.8.2 Accidental Immersion .................................................................................................... 5- 18
5.8.3 Specialized Test Equipment .......................................................................................... 5-19
5.8.4 Vacuum Pump Kit NLN9839 .......................................................................................... 5-19
5.8.5 Pressure Pump Kit NTN4265 ........................................................................................ 5-19
5.8.6 Miscellaneous Hardware ............................................................................................... 5-19
5.8.7 Vacuum Test............................................................................................................... ... 5-19
5.8.8 Pressure Test ............................................................................................................. ... 5-20
5.8.9 Troubleshooting Leak Areas .......................................................................................... 5-21 5.8.9.1 Front Housing ................................................................................................. 5-21
5.8.9.2 Chassis (Main Seal O-ring)............................................................................. 5-22
5.8.9.3 Battery Contact Seal ....................................................................................... 5-22
5.8.9.4 Breathing  Vent Membrane and Brea thing Vent Label .................................... 5-23
5.8.10 Troubleshooting Charts ............................. .................................................................... 5-24
5.9 Radio Exploded Mechanical Views and Parts Lists ................................................................... 5-27 5.9.1 Display Model Exploded View and Parts Li st ................................................................ 5-27
5.9.2 Non-Display Model Exploded View and Parts List......................................................... 5-30
5.9.3 Torque Chart.............................................................................................................. .... 5-32 
						

							Table of Contentsvii
Chapter 6 Basic Troubleshooting ....................................................... 6-1
6.1 Introduction ................................................................................................................ .................. 6-1
6.2 Replacement Back Cover Kit Procedures ............ ....................................................................... 6-1
6.3 Power-Up Error Codes (Display Model only) ............................................................................... 6-2
6.4 Operational Error Codes .... ................................................................................................. ......... 6-4
Appendix A EMEA Regional Warranty, Service and Technical Support ..
A-1
A.1 Warranty and Service Support................................................................................................ ..... A-1
A.1.1 Warranty Period and Return  Instructions ........................................................................ A-1
A.1.2 After Warranty Period ..................................................................................................... .A-1
A.2 European Radio Support Centre (ERSC) .................................................................................... A-2
A.3 Piece Parts ................................................................................................................. ................. A-2
A.4 Technical Support ........................................................................................................... ............. A-3
A.5 Further Assistance From Motorola ............................................................................................ .. A-3
Glossary ........................................................................................ . Glossary-1 
						

							viiiList of Figures
List of Figures
Figure 1-1. Display Model....................................................................................................................... 1-2
Figure 1-2. Non-Display Model ................................................................................................... ............ 1-3
Figure 1-3. Portable Radio Model Nu mbering Scheme .......................................................................... 1-4
Figure 2-1. Programming, Testing an d Alignment Cable ........................................................................ 2-3
Figure 2-2. Pin Layout of Side Connector ........................................................................................ ...... 2-4
Figure 3-1. Battery Check Test Mode Display ..... ................................................................................... 3-8
Figure 4-1. CPS Programming Setu p ............................................................................................... ...... 4-1
Figure 4-2. Radio Tuning Equipment Setup ........... ................................................................................ 4-2
Figure 5-1. Dust Cover removal. ................................................................................................. ........... 5-5
Figure 5-2. Battery and Antenna removal............ ................................................................................... 5-6
Figure 5-3. Knob removal. ................................ ...................................................................................... 5-6
Figure 5-4. Chassis removal. .................................................................................................... .............. 5-7
Figure 5-5. LCD Module removal. ....................... ................................................................................... 5-8
Figure 5-6. LCD Retainer remova l. ............................................................................................... .......... 5-8
Figure 5-7. Transmission and Interface Board removal.......................................................................... 5- 9
Figure 5-8. Shield Clip remova l. ................................................................................................ ............. 5-9
Figure 5-9. O-ring and Battery Co ntact Seal removal........................................................................... 5- 10
Figure 5-10. Speaker removal. ................................................................................................... ............ 5-11
Figure 5-11. Speaker reassembly (D isplay Model)................................................................................. 5-12
Figure 5-12. Speaker reassembly (N on-Display Model). ........................................................................ 5-13
Figure 5-13. O-ring and Battery Cont act Seal reassembly. .................................................................... 5-14
Figure 5-14. Shield Clip reassembly. ............... ............................................................................. .......... 5-15
Figure 5-15. Secondary O-ring reassembly. ............. .............................................................................. 5-15
Figure 5-16. Transmission and Inte rface Board reassembly. ................................................................. 5-16
Figure 5-17. LCD Retainer and LCD  Module reassembly. ..................................................................... 5-16
Figure 5-18. Back Cover Kit rea ssembly. ......................................................................................... ...... 5-17
Figure 5-19. Chassis to Front Cover reassembly. .... ..............................................................................5-18
Figure 5-20. Connector Fitting - Fitting Seal Pump Connector ............... ................................................ 5-19
Figure 5-21. Display Model Exploded View ........... ................................................................................. 5-27
Figure 5-22. Non-Display Model Exploded View .................................................................................... 5-30 
						

							List of Tablesix
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. Pin Configuration of Side Connector .................................................................................. .. 2-4
Table 3-1. Initial Equipment Control Settings ................................................................................... ..... 3-1
Table 3-2. Front Panel Access Test Mode Displays . ............................................................................. 3-3
Table 3-3. Test Environments.................................................................................................... ............ 3-4
Table 3-4. Test Frequencies ..................................................................................................... ............. 3-4
Table 3-5. Transmitter Performance Checks ....................................................................................... .3-5
Table 3-6. Receiver Performance Checks .......................................................................................... .. 3-6
Table 4-1. Software Installation Kits Radio Tuning Se tup ..................................................................... 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. Display Model Exploded View Parts List ............................................................................ 5-28
Table 5-4. Non-Display Model Exploded View Parts Li st .................................................................... 5-31
Table 5-5. Torque Specifications for Screws ..................................................................................... .. 5-32
Table 6-1. Power-Up Error Codes ................................................................................................. ........ 6-2
Table 6-2. Operational Error Code s .............................................................................................. ........ 6-4 
						

							xRelated Publications
Related Publications
IMPRES Adaptive Single-Unit Charger User Manual ..................................................................6816787H01
IMPRES Adaptive Multi-Unit Charger User Manual.....................................................................6816789H01
IMPRES Adaptive Multi-Unit Charger Service Manual ................................................................ 6871357L01
Remote Speaker Microphone User Manual ................................................................................. 6871003L0 1
IMPRES Remote Speaker Microphone  User Manual .................................................................. 6871004L01
Factory Mutual Approval Manual ................................................................................................. 6871532L01