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Motorola PR400 Basic Service Manual
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Motorola PR400 Basic Service Manual

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  • Page 1 PR400 ™ Commercial Series Portable Radio Basic Service Manual...

  • Page 3: C24-A

    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 6881096C24-A Schaumburg, IL 60196...

  • Page 4: Product Safety And Rf Exposure Compliance

    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.

  • Page 5: Table Of Contents

    Table of Contents 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 Radio Model Information........................
  • Page 6 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 Mechanical View and Parts List ....................6-16 6.5.1 PR400 Full-Keypad Exploded View and Parts List ............6-16 July, 2004 6881096C24-A...
  • Page 7 Chassis and Front Cover Re-assembly ............7-13 7.4.3.7 PTT Re-assembly .................... 7-15 Mechanical View and Parts List....................7-16 7.5.1 PR400 Limited-Keypad Exploded View and Parts List ........... 7-16 Chapter 8 Non-Keypad Model Disassembly and Re-assembly ................ 8-1 Introduction ............................ 8-1 Preventive Maintenance ........................
  • Page 8 Warranty Period and Return Instructions................1-1 1.2.2 After Warranty Period ....................... 1-1 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...

  • Page 9: List Of Figures

    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.
  • Page 10 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.

  • Page 11: List Of Tables

    Receiver Troubleshooting Table ..................9-2 Table 9-4. Transmitter Troubleshooting Table .................. 9-3 Related Publications PR400 Detailed Service Manual .................681096C25 PR400 Full-Keypad Model User Guide ...............681096C23 PR400 Limited-Keypad Model User Guide ............681096C26 PR400 Non-Display Model User Guide...............681096C27 PR400 User Guide CDROM.................HKLN4219 6881096C24-A...
  • Page 12 Table of Contents This Page Intentionally Left Blank July, 2004 6881096C24-A...

  • Page 13: Chapter 1 Model Charts And Test Specifications

    Chapter 1 Model Charts and Test Specifications Radio Model Information The model number and serial number are located on a label attached to the back of your radio. You can determine the RF output power, frequency band, protocols, and physical packages. The example below shows one portable radio model number and its specific characteristics.

  • Page 14: Model Chart For Vhf1 136-174 Mhz

    PR400, VHF1, 136-162 MHz Model Description AAH65JDC9AA2AN PR400, 136-162 MHz, 5 W, 16 Ch. Non-Display Model AAH65JDF9AA3AN PR400, 136-162 MHz, 5 W, 32 Ch. Limited Keypad Model AAH65JDH9AA4AN PR400, 136-162 MHz, 5 W, 64 Ch. Full Keypad Model Item Description PMUD1983_ PR400, 136-162 MHz, 5 W, 16 Ch.

  • Page 15: Model Chart For Vhf2 146-174 Mhz

    PR400, VHF2, 146-174 MHz Model Description AAH65KDC9AA2AN PR400, 146-174 MHz, 5 W, 16 Ch. Non-Display Model AAH65KDF9AA3AN PR400, 146-174 MHz, 5 W, 32 Ch. Limited Keypad Model AAH65KDH9AA4AN PR400, 146-174 MHz, 5 W, 64 Ch. Full Keypad Model Item Description PMUDxxxx_ PR400, 146-174 MHz, 5 W, 16 Ch.

  • Page 16: Vhf Specifications

    VHF Specifications VHF Specifications General Transmitter RF Output High Frequency: 136-162 MHz NiMH @ 7.5 V: 146-174 MHz Frequency: 136-162 MHz Channel Capacity: 16, 32, or 64 Channels 146-174 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/20/25 kHz Dimensions: Freq.

  • Page 17: Model Chart For Uhf1 403-440 Mhz

    PR400, UHF1, 403-440 MHz Model Description AAH65QDC9AA2AN PR400, 403-440 MHz, 4 W, 16 Ch. Non-Display Model AAH65QDF9AA3AN PR400, 403-440 MHz, 4 W, 32 Ch. Limited Keypad Model AAH65QDH9AA4AN PR400, 403-440 MHz, 4 W, 64 Ch. Full Keypad Model Item Description PMUExxxx_ PR400, 403-440 MHz, 4 W, 16 Ch.

  • Page 18: Model Chart For Uhf2 438-470 Mhz

    PR400, UHF2, 438-470 MHz Model Description AAH65RDC9AA2AN PR400, 438-470 MHz, 4 W, 16 Ch. Non-Display Model AAH65RDF9AA3AN PR400, 438-470 MHz, 4 W, 32 Ch. Limited Keypad Model AAH65RDH9AA4AN PR400, 438-470 MHz, 4 W, 64 Ch. Full Keypad Model Item Description PMUExxxx_ PR400, 438-470 MHz, 4 W, 16 Ch.

  • Page 19: Model Chart For Uhf3 465-495 Mhz

    PR400, UHF3, 465-495 MHz Model Description AAH65SDC9AA2AN PR400, 465-495 MHz, 4 W, 16 Ch. Non-Display Model AAH65SDF9AA3AN PR400, 465-495 MHz, 4 W, 32 Ch. Limited Keypad Model AAH65SDH9AA4AN PR400, 465-495 MHz, 4 W, 64 Ch. Full Keypad Model Item Description PMUExxxx_ PR400, 465-495 MHz, 4 W, 16 Ch.

  • Page 20: Uhf Specifications

    UHF Specifications UHF Specifications General Transmitter RF Output High Frequency: 403-440 MHz NiMH @ 7.5 V: 438-470 MHz 465-496 MHz Frequency: 403-440 MHz 438-470 MHz Channel Capacity: 16, 32, or 64 Channels 465-496 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/20/25 kHz Dimensions: Freq.

  • Page 21: Mil Standards

    Model Charts and Test Specifications: MIL Standards MIL Standards Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications (8.2 and 8.4) Military Standards 810 C, D, E, & F: Parameters/Methods/Procedures 810C 810D 810E 810F Applicable Methods...
  • Page 22 1-10 Model Charts and Test Specifications: MIL Standards This Page Intentionally Left Blank July, 2004 6881096C24-A...

  • Page 23: Chapter 2 Theory Of Operation

    Chapter 2 Theory Of Operation Introduction This chapter provides a basic theory of operation for the radio components. Major Assemblies • Transceiver Board – contains all transmit, receive, and audio circuitry. • Display (Limited and Full Keypad models only) – 8 characters (14 segments star burst) and 10 icons with backlighting, liquid-crystal display (LCD).

  • Page 24: Transmitter

    Theory Of Operation: Major Assemblies The IFIC is a low-voltage monolithic FM IF system incorporating a mixer/oscillator, two limiting IF amplifiers, quadrature detector, logarithmic received signal strength indicator (RSSI), voltage regulator and audio, and RSSI Op Amps. The second LO frequency, 44.395 MHz, is determined by a crystal oscillator.

  • Page 25: Chapter 3 Test Equipment, Service Aids, And Service Tools

    Chapter 3 Test Equipment, Service Aids, and Service Tools Test Equipment Table 3-1 lists test equipment required to service the PR400 Radios. Table 3-1. Recommended Test Equipment Motorola Part No. Description Characteristics Application R2600 series System analyzer This item will substitute for...

  • Page 26: Service Aids

    Service Aids Table 3-2 lists service aids recommended for working on the PR400 Radios. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.
  • Page 27 Test Equipment, Service Aids, and Service Tools: Service Aids Table 3-3. Recommended Service Tools (Continued) Motorola Part Description Application 0180386A78 Illuminated magnifying glass with lens attachment Illumination and magnification of components 0180302E51 Master lens system 0180386A82 Anti-static grounding kit Used during all radio assembly and disassembly pro-...

  • Page 28: Figure 3-1. Programming/Test Cable

    Test Equipment, Service Aids, and Service Tools: Service Aids Programming/Test Cable 25 POSITION 25 POSITION MALE CONNECTOR FEMALE CONNECTOR 36.0” CABLE 36.0” CABLE Figure 3-1. Programming/Test Cable 25 pin Male D Connector Components molded inside 2.5mm stereo and 3.5mm Orange 3.5mm Tip (Speaker +) Blue...

  • Page 29: Chapter 4 Performance Checks

    Chapter 4 Performance Checks General These radios meet published specifications through their manufacturing process by utilizing high- accuracy laboratory-quality test equipment. The recommended field service equipment is as accurate as the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 30: Rf Test Mode

    Monitor Vol: 1/4 CW RF Test Mode When the PR400 radio is operating in its normal environment, the radio's microcomputer 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 using a special routine, called RF TEST MODE.

  • Page 31: Table 4-2. Test Environments

    Performance Checks: RF Test Mode To enter test mode: 1. Turn the radio on. Within ten seconds after the self test is complete (self test tone is heard), press SB2 (Side Button 2 in Figure 4-2) five times in succession. If the self test complete tone is not heard, see Error Codes information in Chapter 9.

  • Page 32: Table 4-5. Receiver Performance Checks

    Performance Checks: RF Test Mode Table 4-4. Test Frequencies VHF1 VHF2 UHF1 UHF 2 UHF3 Channel Selector Test Channel (136-162 (146-174 (403-440 (438-470 (465-495 Switch Position MHz) MHz) MHz) MHz) MHz) 1 Low Power TX#1 or #8 146.625 403.625 438.625 465.625 8 High Power RX#1 or #8...

  • Page 33: Table 4-6. Transmitter Performance Checks

    Performance Checks: RF Test Mode * See Table 4-4 Table 4-6. Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode: PWR MON TEST MODE, PTT to continu- Frequency error to be Frequency Test Channel 4 ous (during the ???? Hz VHF1 4th channel test frequency carrier squelch...
  • Page 34 Performance Checks: RF Test Mode Notes: July, 2004 6881096C24-A...

  • Page 35: Chapter 5 Radio Alignment Procedures

    Chapter 5 Radio Alignment Procedures Introduction This chapter provides an overview of the Commercial Series Customer Programming Software (CPS) and the Global Tuner as designed for use in a Windows® 98/NT4/2000/ME/XP environment. Both cover all the functions of the traditional Radio Service Software (RSS) package. They are both available in the CPS and Global Tuner (CD ROM) Kit (RVN4191).

  • Page 36: Radio Tuning Setup

    Radio Alignment Procedures: Radio Tuning Setup Radio Tuning Setup A Windows 98/NT4/2000/ME/XP PC (personal computer) and Global Tuner are required to tune the radio. To perform the tuning procedures, the radio must be connected to the PC, RIB (Radio Interface Box) and Universal Test Set as shown in Figure 5-2 below.

  • Page 37: Initial Test Equipment Control Settings

    Radio Alignment Procedures: Transmitter Alignment Options 5.3.1 Initial Test Equipment Control Settings The initial test equipment control settings are listed in Table 5-1. Table 5-1. Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode: Power Monitor Speaker set: A Voltage: 13.2 Vdc RF Attenuation: -70 Speaker/load:...

  • Page 38: Modulation Balance Attenuation

    Radio Alignment Procedures: Transmitter Alignment Options 1. Under Tx Align menu, select Reference Oscillator Warp (Figure 5-3). 2. There is only 1 frequency point shown which is always the last non-0 transmit frequency point, which will normally be F7. 3. Click on the slider thumb and press PTT Toggle to key up the radio at the corresponding fre- quency point.

  • Page 39: Transmit Power Tuning

    Radio Alignment Procedures: Transmitter Alignment Options Figure 5-4. Modulation Balance Window Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low frequency port) lines. The compensation algorithm is critical to the operation of signaling schemes that have very low frequency components (Digital Private-Line) and could result in distorted waveforms if improperly adjusted.

  • Page 40: Figure 5-5. Transmit Power Window (High Power)

    Radio Alignment Procedures: Transmitter Alignment Options Note: When checking the RF power output of the radio with a test set, always use a pad of at least 30 dB attached to the radio end of the RF cable. This will avoid an RF mismatch and ensure a stable RF reading that will not change with varying lengths of connecting cable Figure 5-5.

  • Page 41: To Perform Transmit High Power Tuning, Do The Following

    Radio Alignment Procedures: Transmitter Alignment Options Table 5-3. Transmit High/Low Power Level RF Band (MHz) Model Number High Power(W) Low Power (W) 16 Channel VHF 136-162 MHz 32 Channel VHF 136-162 MHz 64 Channel VHF 136-162 MHz 16 Channel VHF 146-174 MHz H65KDC9AA2AN 5.2-5.5 1.1-1.3...

  • Page 42: Vco Attenuation

    Radio Alignment Procedures: Transmitter Alignment Options after typing in the softpot value). 4. Press PTT Toggle to dekey the radio, go to the next frequency point by selecting the slider, typing in the edit control box (press ENTER to confirm your selection) or toggling the softpot value using the spin control.

  • Page 43: Vco Attenuation 12.5 Khz

    Radio Alignment Procedures: Transmitter Alignment Options spin control can also be toggled via its up/down arrow buttons. The softpot value can also be typed into the edit control (press ENTER to confirm your selection/send a softpot value). 3. Inject 1 kHz at an appropriate level until 2.3 V rms is measured at the AC/DC METER (radio input) if using test box RLN4460.

  • Page 44: Dtmf Deviation Tuning

    5-10 Radio Alignment Procedures: Transmitter Alignment Options Table 5-4. Deviation Specifications Band Channel Spacing Deviation (kHz) UHF/VHF 25 kHz 4.40 - 4.60 UHF/VHF 12.5 kHz 2.20 - 2.30 UHF/VHF 20 kHz 3.40 - 3.60 5.4.5 DTMF Deviation Tuning This tuning option controls the Dual Tone MultiFrequency deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation.

  • Page 45: Mdc1200 Deviation Tuning (Mdc Radios Only)

    Radio Alignment Procedures: Receiver Tuning 5-11 5.4.6 MDC1200 Deviation Tuning (MDC radios only) This tuning option controls the MDC1200 Signaling deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning this feature.

  • Page 46: Rated Volume Tuning

    5-12 Radio Alignment Procedures: Receiver Tuning 5.5.1 Rated Volume Tuning Note: When using test box RLN4460, the received audio output is taken from the AC/DC METER OUT terminals with the METER OUT rotary switch set to RX. The rated audio tuning procedure automatically configures the radio for 25 KHz.

  • Page 47: Squelch Tuning

    Radio Alignment Procedures: Receiver Tuning 5-13 5.5.2 Squelch Tuning Note: 1. Squelch tuning can only be accomplished after reference oscillator warping. 2. When using the test box RLN4460, the received audio output is taken from the AC/ DC METER OUT terminals with the METER OUT rotary switch set to RX. It is recom- mended that Rated Volume Tuning be performed so the the correct 10 dB SINAD level can be obtained.

  • Page 48: Auto Tune

    5-14 Radio Alignment Procedures: Receiver Tuning 3. Set softpot to its maximum value to mute the radio. 4. Adjust the softpot value by using the slider, keying in the edit box or using the spin controls. Press ENTER to confirm the selection or use the spin controls. Do this until the radio is totally unmuted. Verify the squelch closing by inputting a signal level of 4 dB lower than that of the 10 dB SINAD level.

  • Page 49: Rssi Display Tuning

    Radio Alignment Procedures: Utilities 5-15 5. Adjust the input level to reflect the next softspot value. Repeat steps 3 and 4 to tune the next value. 5.5.4 RSSI Display Tuning 1. Under the Rx Align menu, select RSSI Display Tuning. 2.

  • Page 50: Figure 5-12. Side Button Locations

    5-16 Radio Alignment Procedures: Radio-to-Radio Cloning Procedure: 1. Turn source and target radios off. 2. Connect cloning cable (AAPMKN4003) to the side connector of both radios. 3. Turn on the destination radio. 4. Press and hold the two side buttons at the same time on the source radio and then power up the source radio (Figure 5-12).

  • Page 51: Chapter 6 Full Keypad Model Disassembly And Re-Assembly

    Chapter 6 Full Keypad Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 52: Safe Handling Of Cmos And Ldmos Devices

    • 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 RSX- 4015.) • Do not wear nylon clothing while handling CMOS devices.

  • Page 53: Disassembling And Re-Assembling The Radio - General

    Scribe If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. See Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...

  • Page 54: Figure 6-2. Antenna And Knob Removal

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Remove the antenna. 4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis opener tool (Motorola part # 6686533Z01). (Figure 6-2).

  • Page 55: Figure 6-4. Keyboard Flex Connection

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Note: The speaker wire assembly microphone wire assembly and keypad flex cable connector connecting the front housing assembly and the chassis prevent the two units from being completely separated 7.

  • Page 56: Dust Cover Disassembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.1.2 Dust Cover Disassembly 1. Gently pry the top of the dust cover away from the body of the radio. (See Figure 6-6). 2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed. 3.

  • Page 57: Keyboard Removal

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.1.4 Keyboard Removal 1. Carefully pry the four keypad retainer locking tabs free from the housing using a scribe. Note: Use care when removing the keypad retainer to prevent damage to the keyboard flex cable.

  • Page 58: Chassis Disassembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Flat Blade Screwdriver Hooks PTT Seal Figure 6-9. PTT Removal 6.4.1.6 Chassis Disassembly CAUTION: Refer to the CMOS CAUTION paragraph (see 3.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

  • Page 59: Radio Re-Assembly - Detailed

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 4. Lift the main board from the chassis (Figure 6-10). 5. Remove the battery contact seal. 6.4.2 Radio Re-assembly - Detailed 6.4.2.1 Dust Cover Re-assembly 1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 6-11).

  • Page 60: Figure 6-13. Speaker Re-Assembly

    6-10 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Microphone Boot Microphone Recess Microphone Position Figure 6-12. Microphone Re-assembly 4. Locate the speaker tab and align it with the tab opening in the front housing (Figure 6-13).

  • Page 61: Keypad And Lcd/Keyboard Re-Assembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-11 6.4.2.3 Keypad and LCD/Keyboard Re-assembly 1. Attach the flex cable from the LCD module to the keyboard, if not already attached (Figure 6-15). 2. Remove protective mylar from window and from keypad, if present. 3.

  • Page 62: Keyboard Retainer Re-Assembly

    6-12 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6. Attach the flex cable into the connector on the keypad board, if not already connected. 7. Bend the flex cable as shown (Figure 6-15). 6.4.2.4 Keyboard Retainer Re-assembly 1.

  • Page 63: Chassis And Front Cover Re-Assembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-13 Audio Jack Shroud Frequency & (Replace after Plugging Volume Switches in Speaker and Mic) Main Board Interface Pad Flex Cable Connector Radio Chassis Battery Contact Seal O-Ring Figure 6-17.

  • Page 64: Figure 6-19. Keyboard Flex Cable Connection

    6-14 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Speaker Connector Microphone Connector Shroud Figure 6-18. Microphone and Speaker Wires Re-assembly 2. Position the radio (Figure 6-19), and reconnect the flex connector from the keyboard into the con- nector located on the bottom of the main board, pushing up the 2 end tabs.

  • Page 65: Ptt Re-Assembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-15 5. Snap chassis assembly completely into the top of the front cover (Figure 6-20) until it settles in place. Radio Chassis Figure 6-20. Fastening the Chassis 6.

  • Page 66: Mechanical View And Parts List

    6-16 Full Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List Mechanical View and Parts List 6.5.1 PR400 Full-Keypad Exploded View and Parts List Figure 6-22. PR400 Full Keypad Radio Exploded View July, 2004 6881096C24-A...
  • Page 67 Motorola Item Part Description Item Part Description Number Number See Appendix Antenna NON-REFERENCED ITEMS 3386625Z01 Nameplate, Motorola 3680530Z02 Knob, Frequency 1386440Z03 Escutcheon, Top; 64 Ch. 5886627Z01 Antenna Adaptor/Seal (Optional) 1586391Z03 Housing, Full, with Lens 3586621Z01 Speaker, Felt 3886489Z01 PTT, Rubber...
  • Page 68 6-18 Full Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List This Page Intentionally Blank July, 2004 6881096C24-A...

  • Page 69: Re-Assembly

    Chapter 7 Limited Keypad Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 70: Safe Handling Of Cmos And Ldmos Devices

    • 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 RSX- 4015.) • Do not wear nylon clothing while handling CMOS devices.

  • Page 71: Figure 7-1. Battery Removal

    If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. See Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...

  • Page 72: Figure 7-2. Antenna And Knob Removal

    7-4 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 4. Pry off the volume and channel selector knobs from their shafts using the knob remover/chassis opener tool (Motorola part # 6686533Z01) (Figure 7-2). Figure 7-2. Antenna and Knob Removal Note: Both knobs slide on and off.

  • Page 73: Figure 7-4. Keyboard Flex Connector

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-5 6. Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case. (Figure 7-4).

  • Page 74: Figure 7-6. Dust Cover Disassembly

    7-6 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.1.2 Dust Cover Disassembly 1. Gently pry the top of the dust cover away from the body of the radio. (See Figure 7-6). 2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed. 3.

  • Page 75: Figure 7-8. Keypad Removal

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-7 7.4.1.4 Keyboard Removal 1. Carefully pry the four keypad retainer locking tabs free from the housing using a scribe. Note: Use care when removing the keypad retainer to prevent damage to the keyboard flex cable. 2.

  • Page 76: Figure 7-9. Ptt Removal

    7-8 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.1.5 PTT Disassembly 1. If required, the PTT (Figure 7-9) can be disassembly using a small screwdriver, as follows: Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab. Pry the PTT away from the radio housing.

  • Page 77: Figure 7-10. Removal Of Main Board From Chassis

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-9 Audio Jack Shroud Main Board Flex Cable Connector Radio Chassis O-Ring Figure 7-10. Removal of Main Board from Chassis 7.4.3 Radio Re-assembly - Detailed 7.4.3.1 Dust Cover Re-assembly 1.

  • Page 78: Figure 7-12. Microphone Re-Assembly

    7-10 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Insert the Boot and microphone sub-assembly into the microphone recess in the housing and route wires as shown in Figure 7-12. Microphone Boot Microphone Recess Microphone Position Figure 7-12.

  • Page 79: Keypad And Lcd/Keyboard Re-Assembly

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-11 7. Install the retainer screw using a T6 Torx screwdriver. Torque to 2.3 - 2.5 lb/in. 7.4.3.3 Keypad and LCD/Keyboard Re-assembly 1. Attach the flex cable connector from the LCD module to the keyboard, if not already attached (Figure 7-15).

  • Page 80: Keyboard Retainer Re-Assembly

    7-12 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6. Attach the flex cable connector into the connector on the keypad board, if not already connected. Make sure the microphone and speaker wires are not trapped under the LCD mod- CAUTION: ule.

  • Page 81: Chassis And Front Cover Re-Assembly

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-13 6. Check the top corner of the chassis by flipping the O-ring, if the O-ring came out easily, twist the O-ring and re-try until the O-ring is held properly by the chassis. Audio Jack Shroud Frequency &...

  • Page 82: Figure 7-18. Microphone And Speaker Wires

    7-14 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Connect the speaker wire assembly into the 2-pin connector on the main board and bend the wires at the board connector so the wires are positioned toward the top of the radio (Figure 7-18).

  • Page 83: Ptt Re-Assembly

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-15 4. Push the topside of the board chassis upward until it touches the housing end. Before snapping the board into the housing, perform the following checks: Open the dust cap and ensure the wires are not pinched between the shroud and housing.

  • Page 84: Mechanical View And Parts List

    7-16 Limited Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List Mechanical View and Parts List 7.5.1 PR400 Limited-Keypad Exploded View and Parts List Figure 7-22. PR400 Limited Keypad Radio Exploded View July, 2004 6881096C24-A...
  • Page 85 Part Description Item Part Description Number Number See Section 6 Antenna NON-REFERENCED ITEMS 3680530Z02 Knob, Frequency 3386625Z01 Nameplate, Motorola 1386440Z03 Escutcheon, Top; 32 Ch. 5886627Z01 Antenna Adaptor/Seal (Optional) 1586391Z02 Housing, Limited, with Lens 3586621Z01 Speaker, Felt 3886489Z01 PTT, Rubber 4586439Z01...
  • Page 86 7-18 Limited Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List This Page Intentionally Blank July, 2004 6881096C24-A...

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