Motorola Pr400 Basic 6881096c24 A Manual

							MOTOROLA and The Stylized M logo are trademarks of Motorola, Inc.
All other product or service names are the property of their respective owners.
© 2004 Motorola, Inc. All rights reserved. Printed in U.S.A.*6881096C24*6881096C24-A
PR400
™
Commercial SeriesPortable Radio 
Basic Service Manual 
						

							PR400 Portable Radio
Basic Service Manual
VHF 136-162 MHz
VHF 146-174 MHz
UHF 403-440 MHz
UHF 438-470 MHz
UHF 465-495 MHz
Motorola, Inc.
1301 E. Algonquin Road
Schaumburg, IL 60196
6881096C24-A 
						

							ii
Foreword
This manual is intended for use by service technicians familiar with similar types of equipment. It contains 
service information required for the equipment described and is current as of the printing date. Changes which 
occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions.
Product Safety and RF Exposure Compliance
AT T E N T I O N !
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 
68P81095C98) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which 
lists approved accessories: http://www.motorola.com/cgiss/index.shtml.
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.
MOTOROLA and The Stylized M logo are trademarks of Motorola, Inc.
All other product or service names are the property of their respective owners.
© 2004 Motorola, Inc. All rights reserved. Printed in U.S.A. Note:
Before operating or testing these units, please read the Product Safety and RF Exposure
Compliance section.
Note:
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 
						

							Table of Contentsiii
6881096C24-AJuly, 2004
Table of Contents
Foreword............................................................................................................................................ ii
Product Safety and RF Exposure Compliance .................................................................................. ii
Computer Software Copyrights.......................................................................................................... ii
Document Copyrights ........................................................................................................................ ii
Disclaimer .......................................................................................................................................... ii
List of Figures ..............................................................................................vii
List of Tables ..................................................................................................x
Related Publications ......................................................................................x
Chapter 1 Model Charts and Test Specifications.............................. 1-1
1.1 Radio Model Information................................................................................................................ 1-1
1.2 Model Chart for VHF1 136-174 MHz .............................................................................................1-2
1.3 Model Chart for VHF2 146-174 MHz .............................................................................................1-3
1.4 VHF Specifications ........................................................................................................................ 1-4
1.5 Model Chart for UHF1 403-440 MHz .............................................................................................1-5
1.6 Model Chart for UHF2 438-470 MHz .............................................................................................1-6
1.7 Model Chart for UHF3 465-495 MHz .............................................................................................1-7
1.8 UHF Specifications ........................................................................................................................ 1-8
1.9 MIL Standards ............................................................................................................................... 1-9
Chapter 2 Theory Of Operation ........................................................... 2-1
2.1 Introduction .................................................................................................................................... 2-1
2.2 Major Assemblies .......................................................................................................................... 2-1
2.2.1 Receiver............................................................................................................................ 2-1
2.2.2 Transmitter........................................................................................................................ 2-2
Chapter 3 Test Equipment, Service Aids, and 
Service Tools ....................................................................... 3-1
3.1 Test Equipment.............................................................................................................................. 3-1
3.2 Service Aids ................................................................................................................................... 3-2
Chapter 4 Performance Checks .......................................................... 4-1
4.1 General .......................................................................................................................................... 4-1
4.2 Power-Up Self Test........................................................................................................................ 4-1
4.3 RF Test Mode ................................................................................................................................ 4-2
Chapter 5 Radio Alignment Procedures ............................................. 5-1
5.1 Introduction .................................................................................................................................... 5-1
5.2 CPS Programming Setup .............................................................................................................. 5-1 
						

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July, 20046881096C24-A
5.3 Radio Tuning Setup ....................................................................................................................... 5-2
5.3.1 Initial Test Equipment Control Settings ............................................................................. 5-3
5.4 Transmitter Alignment Options ...................................................................................................... 5-3
5.4.1 Reference Oscillator Warp ................................................................................................ 5-3
5.4.2 Modulation Balance Attenuation ....................................................................................... 5-4
5.4.3 Transmit Power Tuning .....................................................................................................5-5
5.4.3.1 To Perform Transmit High Power Tuning, do the following: .............................. 5-7
5.4.3.2 To Perform Transmit Low Power Tuning, do the following: - ............................. 5-7
5.4.4 VCO Attenuation ............................................................................................................... 5-8
5.4.4.1 VCO Attenuation 25 kHz .................................................................................... 5-8
5.4.4.2 VCO Attenuation 12.5 kHz ................................................................................. 5-9
5.4.4.3 VCO Attenuation 20 kHz .................................................................................... 5-9
5.4.5 DTMF Deviation Tuning .................................................................................................. 5-10
5.4.6 MDC1200 Deviation Tuning (MDC radios only) .............................................................. 5-11
5.5 Receiver Tuning ........................................................................................................................... 5-11
5.5.1 Rated Volume Tuning ..................................................................................................... 5-12
5.5.2 Squelch Tuning ............................................................................................................... 5-13
5.5.2.1 Manual Squelch Tuning ................................................................................... 5-13
5.5.2.2 Auto Tune ........................................................................................................ 5-14
5.5.3 RSSI System Level Tuning ............................................................................................. 5-14
5.5.4 RSSI Display Tuning .......................................................................................................5-15
5.6 Utilities ......................................................................................................................................... 5-15
5.6.1 Program Serial No. .........................................................................................................5-15
5.6.2 Temp Comp Data Read .................................................................................................. 5-15
5.6.3 Temp Comp Data Write .................................................................................................. 5-15
5.7 Radio-to-Radio Cloning................................................................................................................ 5-15
Chapter 6 Full Keypad Model Disassembly and
Re-assembly ........................................................................ 6-1
6.1 Introduction .................................................................................................................................... 6-1
6.2 Preventive Maintenance ................................................................................................................ 6-1
6.2.1 Inspection.......................................................................................................................... 6-1
6.2.2 Cleaning Procedures ........................................................................................................6-1
6.3 Safe Handling of CMOS and LDMOS Devices .............................................................................. 6-2
6.4 Disassembling and Re-assembling the Radio — General ............................................................. 6-3
6.4.1 Radio Disassembly — Detailed ........................................................................................ 6-3
6.4.1.1 Front Cover From Chassis Disassembly ........................................................... 6-3
6.4.1.2 Dust Cover Disassembly.................................................................................... 6-6
6.4.1.3 Speaker and Microphone Disassembly ............................................................. 6-6
6.4.1.4 Keyboard Removal ............................................................................................ 6-7
6.4.1.5 PTT Disassembly ............................................................................................... 6-7
6.4.1.6 Chassis Disassembly ......................................................................................... 6-8
6.4.2 Radio Re-assembly - Detailed .......................................................................................... 6-9
6.4.2.1 Dust Cover Re-assembly ................................................................................... 6-9
6.4.2.2 Microphone and Speaker Re-assembly ............................................................. 6-9
6.4.2.3 Keypad and LCD/Keyboard Re-assembly ....................................................... 6-11
6.4.2.4 Keyboard Retainer Re-assembly ..................................................................... 6-12
6.4.2.5 Chassis Assembly/Re-assembly...................................................................... 6-12
6.4.2.6 Chassis and Front Cover Re-assembly ........................................................... 6-13
6.4.2.7 PTT Re-assembly ............................................................................................ 6-15
6.5 Mechanical View and Parts List ................................................................................................... 6-16
6.5.1 PR400 Full-Keypad Exploded View and Parts List ......................................................... 6-16 
						

							Table of Contentsv
6881096C24-A July, 2004
Chapter 7 Limited Keypad Model Disassembly and
Re-assembly .......... .................................... .......................... 7-1
7.1 Introduction ................................................................................................................ .................... 7-1
7.2 Preventive Maintenance ...................................................................................................... .......... 7-1
7.2.1 Inspection ................................................................................................................ ......... 7-1
7.2.2 Cleaning Procedures ....................................................................................................... .7-1
7.3 Safe Handling of CMOS and LDMOS Devices ....... ....................................................................... 7-2
7.4 Disassembling and Re-assembling the Radio — Ge neral............................................................. 7-3
7.4.1 Radio Disassembly — Detailed ..................... ................................................................... 7-3
7.4.1.1 Front Cover from Chassis Disassembly ............................................................ 7-3
7.4.1.2 Dust Cover Disassembly ...................... ............................................................. 7-6
7.4.1.3 Speaker and Microphone  Disassembly ............................................................. 7-6
7.4.1.4 Keyboard Removal ............................................................................................ 7-7
7.4.1.5 PTT Disassembly............................................................................................... 7-8
7.4.2 Chassis Disassembly....................................................................................................... .7-8
7.4.3 Radio Re-assembly - Detailed .......................................................................................... 7-9 7.4.3.1 Dust Cover Re-assembly ...................... ............................................................. 7-9
7.4.3.2 Microphone and Speake r Re-assembly............................................................. 7-9
7.4.3.3 Keypad and LCD/Keyboa rd Re-assembly ....................................................... 7-11
7.4.3.4 Keyboard Retainer Re-assembly ..................................................................... 7-12
7.4.3.5 Chassis Assembly/Re-assembly ............. ........................................................ 7-12
7.4.3.6 Chassis and Front Cover Re-assembly ... ........................................................ 7-13
7.4.3.7 PTT Re-assembly ............................................................................................ 7-15
7.5 Mechanical View and Parts List .............................................................................................. ..... 7-16
7.5.1 PR400 Limited-Keypad Exploded View and Pa rts List ................................................... 7-16
Chapter 8 Non-Keypad Model Disassembly and
Re-assembly .......... .................................... .......................... 8-1
8.1 Introduction ................................................................................................................ .................... 8-1
8.2 Preventive Maintenance ...................................................................................................... .......... 8-1
8.2.1 Inspection ................................................................................................................ ......... 8-1
8.2.2 Cleaning Procedures ....................................................................................................... .8-1
8.3 Safe Handling of CMOS and LDMOS Devices ....... ....................................................................... 8-2
8.4 Disassembling and Re-assembling the Radio — Ge neral............................................................. 8-3
8.4.1 Radio Disassembly — Detailed ..................... ................................................................... 8-3
8.4.1.1 Front Cover From Chassis Disassembly ........................................................... 8-3
8.4.1.2 Dust Cover Disassembly ...................... ............................................................. 8-5
8.4.1.3 Speaker and Microphone  Disassembly ............................................................. 8-6
8.4.1.4 PTT Disassembly............................................................................................... 8-6
8.4.2 Chassis Disassembly....................................................................................................... .8-7
8.4.3 Radio Re-assembly - Detailed .......................................................................................... 8-8 8.4.3.1 Dust Cover Re-assembly ...................... ............................................................. 8-8
8.4.3.2 Microphone and Speake r Re-assembly............................................................. 8-8
8.4.3.3 Chassis Assembly/Re-assembly ............. .......................................................... 8-9
8.4.3.4 Chassis and Front Cover Re-assembly ... ........................................................ 8-10
8.4.3.5  PTT Re-assembly............................................................................................  8-12
8.5 Mechanical View and Parts List .............................................................................................. ..... 8-13
8.5.1 PR400 Non-Keypad Exploded View and Parts List ........................................................ 8-13 
						

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July, 20046881096C24-A
Chapter 9 Troubleshooting Tables ..................................................... 9-1
9.1 Power-Up Error Codes................................................................................................................... 9-1
9.2 Operational Error Codes ................................................................................................................ 9-1
9.3 Troubleshooting Table for Receiver ............................................................................................... 9-2
9.4 Troubleshooting Table for Transmitter ........................................................................................... 9-3
Appendix A Accessories ......................................................................... A-1
Appendix B Warranty, Service Support, and Replacement Parts ....... B-1
1.1 Scope of Manual ............................................................................................................................ 1-1
1.2 Warranty ........................................................................................................................................ 1-1
1.2.1 Warranty Period and Return Instructions .......................................................................... 1-1
1.2.2 After Warranty Period ....................................................................................................... 1-1
1.3 Replacement Parts Ordering ......................................................................................................... 1-1
1.3.1 Basic Ordering Information ............................................................................................... 1-1
1.3.2 Motorola Online................................................................................................................. 1-2
1.3.3 Mail Orders ....................................................................................................................... 1-2
1.3.4 Telephone Orders ............................................................................................................. 1-2
1.3.5 Fax Orders ........................................................................................................................ 1-2
1.3.6 Parts Identification ............................................................................................................ 1-2
1.3.7 Product Customer Service ................................................................................................ 1-3
1.4 Technical Support .......................................................................................................................... 1-3
Glossary ......................................................................................................G-1 
						

							Table of Contentsvii
6881096C24-AJuly, 2004
List of Figures
Figure 2-1. Major Assemblies Block Diagram..................................................................................... 2-1
Figure 2-2. Transceiver Block Diagram .............................................................................................. 2-2
Figure 3-1. Programming/Test Cable ................................................................................................. 3-4
Figure 3-2. Wiring of the Connectors .................................................................................................. 3-4
Figure 4-1. Radio Performance Checks Setup ................................................................................... 4-1
Figure 4-2. Side Button Locations ...................................................................................................... 4-2
Figure 5-1. CPS Programming Setup ................................................................................................. 5-1
Figure 5-2. Radio Tuning Setup.......................................................................................................... 5-2
Figure 5-3. Reference Oscillator Warp Window ................................................................................. 5-3
Figure 5-4. Modulation Balance Window ............................................................................................5-5
Figure 5-5. Transmit Power Window (High Power) ............................................................................ 5-6
Figure 5-6. VCO Attenuation Window (12.5 kHz) ............................................................................... 5-8
Figure 5-7. DTMF Deviation Tuning Window.................................................................................... 5-10
Figure 5-8. MDC1200 Deviation Tuning Window ............................................................................. 5-11
Figure 5-9. Rated Volume Tuning Window ....................................................................................... 5-12
Figure 5-10. Squelch Tuning Window................................................................................................. 5-13
Figure 5-11. RSSI Tuning ................................................................................................................... 5-14
Figure 5-12. Side Button Locations .................................................................................................... 5-16
Figure 6-1. Battery Removal ............................................................................................................... 6-3
Figure 6-2. Antenna and Knob Removal ............................................................................................6-4
Figure 6-3. Chassis Removal ............................................................................................................. 6-4
Figure 6-4. Keyboard Flex Connection ............................................................................................... 6-5
Figure 6-5. Microphone and Speaker Connections ............................................................................ 6-5
Figure 6-6. Dust Cover Disassembly .................................................................................................. 6-6
Figure 6-7. Removal Speaker-Microphone Assembly ........................................................................ 6-6
Figure 6-8. Keypad Removal .............................................................................................................. 6-7
Figure 6-10. Removal of Main Board from Chassis .............................................................................. 6-8
Figure 6-9. PTT Removal ................................................................................................................... 6-8
Figure 6-11. Dust Cap Re-assembly .................................................................................................... 6-9
Figure 6-13. Speaker Re-assembly .................................................................................................... 6-10
Figure 6-12. Microphone Re-assembly............................................................................................... 6-10
Figure 6-14. Keypad Re-assembly ..................................................................................................... 6-11
Figure 6-15. LCD/Keypad Board Re-assembly .................................................................................. 6-11
Figure 6-16. Keyboard Retainer Re-assembly ................................................................................... 6-12
Figure 6-17. Main Board onto Chassis Re-assembly ......................................................................... 6-13
Figure 6-19. Keyboard Flex Cable Connection................................................................................... 6-14
Figure 6-18. Microphone and Speaker Wires Re-assembly ............................................................... 6-14
Figure 6-20. Fastening the Chassis .................................................................................................... 6-15
Figure 6-21. PTT Re-assembly........................................................................................................... 6-15
Figure 6-22. PR400 Full Keypad Radio Exploded View ..................................................................... 6-16
Figure 7-1. Battery Removal ............................................................................................................... 7-3
Figure 7-2. Antenna and Knob Removal ............................................................................................7-4
Figure 7-3. Chassis Removal ............................................................................................................. 7-4
Figure 7-4. Keyboard Flex Connector................................................................................................. 7-5
Figure 7-5. Microphone and Speaker Connections ............................................................................ 7-5
Figure 7-6. Dust Cover Disassembly .................................................................................................. 7-6
Figure 7-7. Removal Speaker-Microphone Assembly ........................................................................ 7-6
Figure 7-8. Keypad Removal .............................................................................................................. 7-7
Figure 7-9. PTT Removal ................................................................................................................... 7-8
Figure 7-10. Removal of Main Board from Chassis .............................................................................. 7-9 
						

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July, 20046881096C24-A
Figure 7-11. Dust Cap Re-assembly..................................................................................................... 7-9
Figure 7-12. Microphone Re-assembly ............................................................................................... 7-10
Figure 7-13. Speaker Re-assembly .................................................................................................... 7-10
Figure 7-14. Keypad Re-assembly ..................................................................................................... 7-11
Figure 7-15. LCD/Keypad Board Re-assembly................................................................................... 7-11
Figure 7-16. Keyboard Retainer Re-assembly.................................................................................... 7-12
Figure 7-17. Installation of Main Board onto Chassis ......................................................................... 7-13
Figure 7-18. Microphone and Speaker Wires ..................................................................................... 7-14
Figure 7-19. Keyboard Flex Cable Connection ................................................................................... 7-14
Figure 7-20. Fastening the Chassis .................................................................................................... 7-15
Figure 7-21. PTT Re-assembly ........................................................................................................... 7-15
Figure 7-22. PR400 Limited Keypad Radio Exploded View................................................................ 7-16
Figure 8-1. Battery Removal ............................................................................................................... 8-3
Figure 8-2. Antenna and Knob Removal.............................................................................................8-4
Figure 8-3. Chassis Removal.............................................................................................................. 8-4
Figure 8-4. Microphone and Speaker Connections ............................................................................ 8-5
Figure 8-5. Dust Cover Disassembly .................................................................................................. 8-5
Figure 8-6. Removal Speaker-Microphone Assembly ........................................................................ 8-6
Figure 8-8. Removal of Main Board from Chassis .............................................................................. 8-7
Figure 8-7. PTT Removal.................................................................................................................... 8-7
Figure 8-9. Dust Cap Re-assembly..................................................................................................... 8-8
Figure 8-10. Microphone Re-assembly ................................................................................................. 8-8
Figure 8-11. Speaker Re-assembly ...................................................................................................... 8-9
Figure 8-12. Installation of Main Board onto Chassis ......................................................................... 8-10
Figure 8-13. Microphone and Speaker Wires Re-assembly ............................................................... 8-11
Figure 8-14. Fastening the Chassis .................................................................................................... 8-11
Figure 8-15. PTT Re-assembly ........................................................................................................... 8-12
Figure 8-16. PR400 Non-Keypad Radio Exploded View .................................................................... 8-13